1.Analysis of Heat exchangers Efficient heat exchange comes in various formsAkshay Kr Mishra Sharda University MECH , 4 YR.

2. Types of heat exchangerParallel flowDiagonal flow Acc. To fluid flowCounter flowCross flow 3. Counter flowCross flowDiagonal flow 4. RadiatOR tyPe HXs (RHe) AIR to WATER heatexchanger. Uses fans to circulate air and cool the fluid inside tubes of HXs. Cooling medium is AIR. Radiator is made via Al alloy. Working of a radiator type HX 5. HOw tO MaiNtaiN RHes Feed the oil from inlet only. Flush clean the radiator withpressurized air once in a week, to maintain proper air flow. Dont keep any obstacle in front ofradiator which may obstruct the air flow. 6. DAIKIN 90507; TRACTOR PLANT( M/C SHOP)DAIKIN 80017; TRACTOR PLANT( M/C SHOP) 7. DSL 50; AXLE PLANT(STEERING KNUCKLE LINE)HH5C-PLC; AXLE PLANT( STEERING KNUCKLE L 8. #50604 HELLER MCH300; BKW HX; TRACTOR PLANT( M/C 9. Applications of RHE Forced air heating & cooling Indoor & outdoor wood furnaces/stoves/boilers Heat pumps Chilled water cooling Permanent aluminum fin to copper coil bond ensuressuperior heat transfer properties 10. Cooling towers Heat withdrawn from water via contact betweenthe water and the air. Heat exchange is b/w air and water and through the evaporation of a small part of the water that needs to be cooled. It allows to cool down to a temperature lower than the ambient temperature, which is an important advantage compared to dry coolers. A regular maintenance will also minimize the risk of legionella. 11. Cooling tower, utility area 12. Plate type HXs (PHE) Constitutes of 2 plates fix frame plate andpressure plate(movable). Pack of corrugated metal plates with portholes for passage of 2 fluids b/w which Heat transfer takes place. These plates are fitted with gasket which seals the inter plate channel and directs the fluids into alt. channels. 13. Principle of PHE Channels are formed b/w the plates & corner ports arearranged so that the media flows through alt. channels. Heat transferred via plate b/w channels & complete concurrent flow is made for highest possible efficiency. Corrugation of plates provides passage b/w plates, support each plate against adjacent one and enhances the turbulence, resulting in efficient heat transfer. 14. CHESSISE PHE; AM 10 FM1; TRACTOR PLANT (PAINT SH 15. defects Leakage in plate heat exchanger 16. CALCIUM SULPHATE SCALINGIRON FOULING 17. HOw tO MaiNtaiN PHes Back flush the PHE once a week. check the PHE for leaks, especially during intense runningperiods. Check Regularly the gaskets as soon as possible for softness & elasticity, as brittle gaskets are no good. Install a water cleaning system. It will soften the water & will prevent hard scaling and fouling from coating the plates. Even chlorination should be proper. 18. Effective Heat Transfer- Large surface areas and corrugated plates allow Plate heat exchangers to transfer heat very efficiently. Easy Maintenance Compact Design Cost-efficient- PHE are smaller and use less material to produce. Materials- PHE are available in a wide variety of materials. Plates are available in: Stainless Steel, Titanium, Titanium-Palladium, Nickel etc. as per our requirement. 19. Types of PHEGasketed PHESemi-welded PHE Welded PHE 20. 1.Gasketed PHE -use high quality gaskets and design to seal plates together and protect against leaks. Plates can easily be removed for cleaning. expansion, or replacing purposes, drastically reducing maintenance costs. Applications include - Chemical, HVAC etc.2.Welded PHE - Here plates are welded together. Extremely durable, ideal for transferring fluids with high temperatures or corrosive materials. Mechanical cleaning of plates is not an option as with PHE due to welding. Applications include- Hazardous liquids , oil cooling 21. 3.Semi-welded PHE A mixture of welded and gasketed plates. Contains pairs of two plates welded together which are then gasketed to other pairs Easy to service on one side and able to transfer more intense fluids on the other. They are perfect for transferring expensive materials since they have a very low risk of fluid loss. 22. limitations Extreme temperature difference b/w 2 fluids-itsgenerally more cost efficient to use a Shell & Tube heat exchanger . As in a Plate heat exchanger, there can be a high pressure loss due to the large amount of turbulence created by the narrow flow channels. Gasketed Plate Heat Exchangers are limited in highfluid temperatures, by the temperature limitations of the gasket. 23. BHE BHE is a compact variation of PHE but does not havecarbon steel frame, gaskets or tightening bolts. It simply has AISI 316 stainless steel corrugated channel plates and the heat exchangers are brazed in a vacuum furnace and helium pressure tested to ensure leak-free performance. No pressure retaining parts such as shell of a shell and tube type etc. This combination with maximum heat transfer and high efficiency make it the most efficient HX. 24. WORKING OF BHEEXPLODED VIEW OF BH 25. GEA MAKE BHE;AXLE PLANTTop view of BHE; GEA MAKE; AXLE PLA 26. OPERATING PRINCIPLE Based on the plate and nozzle orientation, each fluid passesthrough alternative channels within the heat exchanger. All plate material and nozzles are of Stainless Steel 316. An extremely high heat transfer coefficient is attained due to the flow characteristics in each channel. A specially designed and tested chevron pattern causes a turbulent flow of the fluid resulting in higher heat transfer. 27. TYPES OF BHE TPL SERIES- In case of media with average viscosity and highviscosity. The TPL unit has special turbulators placed between the flow of gaps and by diagonal media flow together with large diameter connections very high heat exchangers rates are reached. GPL SERIES- Heat transfer plates with V-corrugation for universal application in case of media with low velocity. GPL series has thermally optimized plate corrugation which produces highly turbulent flow even in case of low mass flow. 28. TPL SERIESGPL SERIES 29. CB-COPPER BRAZED HX These heat exchangers from the smallest unit CB14, to thelargest unit CB300, are brazed with 99.9 % copper. This forms a self-contained unit that can handle both high pressures and high temperatures. The exceptional heat transfer efficiency makes all CB units very compact. As a result, they can tackle large-capacity duties even though there is only limited installation space available. 30. CB- COPPER BRAZED HX 31. Fusion bonded PHE AlfaNova, the worlds first 100% stainless steel ANDfusion brazed plate heat exchanger, Extreme temperature and pressure fatigue conditions that would destroy a conventional brazed heat exchanger are no match for the rugged AlfaNova. compact, high-performance AlfaNova offers levels of hygiene and corrosion-resistance unmatched by any other BHE or any HX. 32. ALFANOVA- FUSION BONDED PHE 33. ADVANTAGES OF BHE High corrosion resistant- All plates uses SUS316 material. High pressure resistant High thermal efficiency High working temperature- Brazed Plate Heat Exchanger'sSUS316 material structure offers higher working temperature range up to 200. Compactness Low maintenance- The corrugated plates are designed to achieve turbulence flow at a low flow rate, thus decreasing the need for frequent maintenance. 34. HOw tO MaiNtaiN BHes For heavier fouling use chemicals such as formicacid, citric acid in concentration compatible with copper. Use CIP(cleaning in place) systems to chemically remove calcium deposits and other forms of scaling from different plate surfaces. Do not leave the unit on standby after cleaning. Do not use liquids that are corrosive to stainless steel or brazing material(Cu or Ni). 35. sHeLL & tuBe tyPe HXs Water to water heat exchanger consists of a shell (a large pressure vessel) with abundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. 36. Tube pitch- The shortest distance between centers of twoadjacent tubes is called the tube pitch, should not be less than 1.25 times the tube diameter. Baffles- Responsible for obstructing and redirecting the flow of fluid in the shell side of an exchanger. Situated normal to the walls of the shell and force the liquid to flow at right angles to the axis of the tubes Thus increasing turbulence resulting in greater heat transfer. 37. Exploded view of shell and tube heat exchanger 38. Yantra make HX ; shell and tube type; TRACTOR PLANT( ENGINE SHO 39. Shell and tube type HX in diesel generators; utility area 40. How to Maintain shell & tube HX At regular intervals , an examination should be made of internalas well as external of HX. Intervals b/w cleaning should not inc. because difficulty of cleaning will inc., as scaling or deposits on tubes will inc. Before disassembly, make sure that unit has been depressurized, vented and drained of all hazardous materials purged. Circulate hot wash oil and hot water with high vel. to remove sludge and salt deposits from tubes. 41. Forced draft ventilation Controls indoor air quality. Excess humidity, odors &contaminants controlled via dilution or replacement with outside air. Ventilation includes both the exchange of air to the outside as well as circulation of air within the building. 42. Analysis of HXs used in CNH(Case New Holland) 4 types of HXs are being used in CNH RHEPHEShell & Tube typeBHE 43. MACHINE SHOPRADIATOR type HXsPAINT SHOPPLATE type HXsENGINE SHOPSHELL & TUBE typeNEW DRIVE LINE (NDL)BRAZED HXsMACHINE SHOPBRAZED HXsTRACTOR PLANTCNHDIFFERENTIAL LINE AXLE PLANT STEERING KNUCKLE LINE PLANET CARRIER LINERADIATOR type HXs 44. 4%RHE9%PHE BHE7%SHELL & TUBE COOLING TOWER12%68%PIE CHART SHOWING HX DISTRIBUTION 45. TOTAL NO. OF HEAT EXCHANGERS IN CNH- 71 NO. OF RADIATOR TYPE HX - 46 TRACTOR PLANT -27 AXLE PLANT 16 UTILITY AREA- 3 NO. OF PLATE TYPE HX- 8 COOLANT TOWER- 6 NO. OF BRAZED TYPE HX- 5 NO. OF SHELL &TUBE TYPE HX- 6 TRACTOR PLANT- 2 UTILITY AREA - 4 46. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsRHETRACTORMACHINE#533 MAKINO A77DAIKINRHETRACTORMACHINE#682 MAKINO A77DAIKINRHETRACTORMACHINE#615 MAKINO A81DAIKINRHETRACTORMACHINE#534 MAKINO A77DAIKINRHETRACTORMACHINE#683 MAKINO A77DAIKINRHETRACTORMACHINE# 195 MAKINO A81DAIKINTRACTORMACHINE#50437 HELLERBKWMODEL/TY PE OF HXs9050740807 47. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsRHETRACTORMACHINE#441 MAKINO A81DAIKINRHETRACTORMACHINE#352 MAKINO A77DAIKINRHETRACTORMACHINE#685 MAKINO A77DAIKINRHETRACTORMACHINE#485 MAKINO A77DAIKINRHETRACTORMACHINE#351 MAKINO A81DAIKINRHETRACTORMACHINE#456 MAKINO A77DAIKINRHETRACTORMACHINE#533 MAKINODAIKINMODEL/TY PE OF HXs80017 48. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsRHETRACTORMACHINE#440 MAKINO A77DAIKINRHETRACTORMACHINE#485 MAKINO A77DAIKINRHETRACTORMACHINE#634 MAKINO A77DAIKINRHETRACTORMACHINE#684 MAKINO A77DAIKINRHETRACTORMACHINE#456 MAKINO A77DAIKINRHETRACTORMACHINE#607 MAKINO A81DAIKINRHETRACTORMACHINE#352 MAKINODAIKINMODEL/TY PE OF HXs 49. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TY PE OF HXsSHELL AND TUBE TYPETRACTORENGINE SHOPENGINE YANTRA ASSEMBLY TEST CELL 4RHETRACTORMACHINE SHOP#50604 HELLER MCH 300BKWWRK10/2R2 8-CH2RHETRACTORMACHINE SHOP#50603 HELLER MCH 300BKWWRK10/2R28 -CH2RHETRACTORMACHINE SHOP#50437 HELLER MCH 300BKWWRK10/2R28 -CH2RHETRACTORMACHINE SHOP#50239 HELLER MCH 300BKWWRK10/2R28 -CH2RHETRACTORMACHINE SHOP#50240 HELLER MCH 300BKWWRK10/2R28 -CH2 50. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TY PE OF HXsPHETRACTORPAINT SHOPCHESSISE PHEAlfa lavalAM 10 FM1PHETRACTORPAINT SHOPPRE DEGREASIN G TANK NO.1Alfa lavalP2FL1 (OLD)PHETRACTORPAINT SHOPDEGREASIN G-1 TANK NO. 2Alfa lavalP2FL1PHETRACTORPAINT SHOPDEGREASIN G-2 TANK NO. 3Alfa lavalP2FL1PHETRACTORPAINT SHOPPHOSPHATE TANK NO. 7Alfa lavalP2FL1 (OLD)PHETRACTORPAINT SHOPPHOSPHATE TANK NO. 7Alfa lavalM6-MFG (NEW)PHETRACTORPAINT SHOPCED BATH Alfa laval TANK NO. 11P2FL1PHETRACTORPAINT SHOPPREM6-mfgAlfa laval 51. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsBRAZED HXsTRACTORNDL (NEW DRIVE LINE)NDL M/C 1FUNKEBRAZED HXs RHETRACTORNDL (NEW NDL M/C 2 DRIVE DIFFERENT BEMCO LINE) IAL LINEFUNKERHEAXLEDIFFERENTI HIND GK ENGG. AL LINE HH473-11797HH5C-PLCRHEAXLESTEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50RHEAXLESTEERING KNUCKLE LINEHIND 5TonGK ENGG.HH5C-PLCRHEAXLESTEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50RHEAXLESTEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50AXLEMODEL/TY PE OF HXsWARKIN 52. TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TY PE OF HXsRHEAXLEPLANET CARRIER LINEBEMCO 40TonWARKINDKL 307RHEAXLEPLANET CARRIER LINEBEMCO 40TonWARKINDKL 307RHEAXLEMACHINE SHOPMAC 6290 MAKINO A100EYUKENRHEAXLEMACHINE SHOPMAC 11173 MAKINO A100EYUKENRHEAXLEMACHINE SHOPMAC 6291 MAKINO A100EYUKENRHEAXLEMACHINE SHOPMAKINO A81YUKENRHEAXLEMACHINE SHOPMAKINO A81YUKEN 53. TYPE OF HXPLANTSHOPRHETRACTORRHEMACHINE NAMEMAKEMODELDRIVE LINE #50525 HELLER MCH 300BKWWRK10/2R2 8-CH2TRACTORDRIVE LINE #50237 HELLER MCH 300BKWWRK10/2R2 8-CH2RHETRACTORDRIVE LINE #51276 HELLER MCH 300BKWWRK10/2R2 8-CH2BHEAXLEM/C SHOPFAMAR ERGO 500GEAWP 1-24EBHEAXLEM/C SHOPFAMAR ERGO 500GEAWP1-24EBHEAXLEM/C SHOPFAMAR ERGO 500GEAWP 1-24E 54. Contingency plansRadiator type HX MODES OF FAILURE 1. Radiator gets choked/jammed 2. Fan of RHE stops working.CONSEQUENCES 1.No proper air flow , oil will take time to get cooled, leading to accumulation of heat & eventually m/c will go down.PRECAUTIONS 1. Make sure that radiator is cleaned once in 2-3 months. 2. Keep the fan as a spare part with you. 55. Radiator type HX 56. BRAHMASTRA FOR PHE When the level of problem is at a level where abovewritten precautions dont work then use BRAHMASTRA that is contact the vendor. And here its ALFA LAVAL.NAME: ALFA LAVAL INDIA LTD. ADDRESS: 704-705,Ansal bhavan,16, Kasturbha Gandhi Marg , Delhi PHONE NO: 01141293300 EMAIL ID: india.info@alfalaval.com 57. Brahamastra for BHE well it does not have any modes of failure except that it stops working, so in that case is contact the vendor. And here its FUNKE and GEA. NAME: Funke heat exchangers India pvt ltd. ADDRESS:14, Hadapsar Industrial estate, Hadapsar, Opposite Kwality bakery,Pune. CONTACT PERSON: Ashish B Kale PHONE NO:02066047894,9403961354 EMAIL ID: info@funke.co.in 58. NAME: GEA Ecoflex India Pvt Ltd. ADDRESS: R-493, MIDC, TTC Industrial Area, Rabale 400701 Navi Mumbai India CONTACT PERSON: Virendra Jhamb FAX: +91 22 27693797 EMAIL ID: virendra.jhamb@geagroup.com 59. Knowing dangerWays to eliminate dangerSafety 60. Universal 61. HAZARDS INVOLVEDPHE While cleaning the plates; scaled or fouled deposits may come flying right into ones eyes. Hot gases may leak while cleaning which forms CO when mixes with surroundings.PREVENTIVE METHODS Use Goggles Use protective masks 62. SHELL & TUB 63. THANK YOU