Shell & Tube Heat Exchangers

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 1 of 9

Shell & Tube

Heat Exchangers

Installation, Operation and Maintenance

Manual

thermex Ltd

Merse Road, North Moons Moat, Redditch, Worcestershire. B98 9HL. United

Kingdom

T +44(0)1527 62210 F +44(0)1527 60138

E sales@thermex.co.uk W www.thermex.co.uk

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 2 of 9

Contents

1. INSTALLATION 3

2. OPERATING CONDITIONS 4

3. DISMANTLING 4

4. SERVICING 5

5. INSPECTION 6

6. REASSEMBLY 7

7. UNIT CONSTRUCTION & FLOW DETAILS 8

8. AFTER SALES SERVICE 9

8.1. Ordering parts

8.2. Modifications to the heat exchanger

8.3. Contacts

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 3 of 9

1. INSTALLATION

The coolers may be mounted either horizontally or vertically but the pipe

work should always be designed such that the water inlet is adjacent to the

oil outlet, i.e. with flow of water and oil in opposite directions (counter flow).

When mounting horizontally, venting is assisted if the water outlet positioned

facing upwards.

Long lengths of unsupported pipe work should be avoided and if the

installation is subject to severe vibration, flexible hoses should be used or

alternatively a flexible compensator flange (also available from Thermex Ltd).

The cooler should ideally be installed in the return line to the tank, however

where large fluctuations in flow or pressure are likely, we recommend that

the cooler is mounted off-line with a separate re-circulating pump.

In cold weather, a check valve to bypass oil around the cooler is

recommended for oils with a high viscosity. Care should be taken to prevent

the cooling water from freezing if the cooler is exposed to harsh winter

conditions.

If cooling with seawater, we strongly recommend that the specified water

flow rates are observed. Both too little and too much seawater flow can cause

erosion within the cooler. In addition, we recommend that the sea water is

filter to 2.0mm to prolong the life of the exchanger.

If fitting a temperature control valve, make sure it is installed on the water

side and on the inlet to the cooler.

Provision is made for mounting the cooler using the following bolt sizes:

2300 Series = M6

2500 Series = M8

2700 & 2800 series = M12.

Double seals and witness rings are provided on all 2700 & 2800 series units,

and as an optional fitment on other products, with a small leak detection

hole in the witness ring so that, in the unlikely event of a seal failure, the

second seal will protect from cross contamination whilst the small leak from

the detection hole will alert the user to conduct repairs.

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 4 of 9

2. OPERATING CONDITIONS

Maximum operating pressure:

Through Tubes (Water) = 10 Bar

Over Tubes (Oil) 2300 & 2500 Series = 30 Bar

2700 & 2800 Series = 20 bar

Maximum operation temperatures: 100°C (Nitrile seals)

120°C (Viton seals)

3. DISMANTLING

 Prior to dismantling, ensure that the new replacement seals are

available for re-assembly.

 Isolate, drain and remove any pipe work connected to the header

boxes.

 Wipe clean the exterior of the unit.

 Note the position and orientation of the headers.

 Remove the cap screws securing both of the header boxes to the

body.

 Carefully remove both of the header boxes (and witness rings where

fitted).

 Remove the O-ring seals from both ends of the unit and discard.

 Note the orientation of the stack in the shell.

 The tube stack should now be free to be removed from the shell.

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 5 of 9

 Care should be taken to support the stack as it is removed to prevent

damage to the baffles, tube plates and tubes.

o Should the stack no be free due to fouling etc then a blow from

a soft faced hammer should break the bond and allow the stack

to be removed.

o The face of the tube plate must be protected if the above action

is taken.

 Refer to the ‘Servicing’ and ‘Inspection’ sections of this manual.

4. SERVICING

Tube stack

 The tubestack should first be degreased using a suitable solvent.

 Any heavy contamination on the oil side can be removed using a high

pressure water wash.

o On no account should nay sharp object be used for removing

contamination due to danger of piercing the tubes.

o Any contamination inside the tubes can also be removed with a

high pressure water wash or for more stubborn deposits by

using a special cleaning rod (available from Thermex Ltd.).

Shell & header boxes

 Conventional cleaning methods should be applied to the boxes and

shell

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 6 of 9

5. INSPECTION

It is recommended that heat exchangers be inspected as part of the routine

maintenance program of the system into which they are installed. However, it

is suggested that heat exchangers operating within their design conditions

are inspected on an annual basis as a minimum. Any loss of performance

related to the heat exchanger should also be investigated and the unit, where

necessary, dismantled and serviced.

General overview

 The heat exchanger should be visually inspected for leaks and damage

on a daily basis and witness rings, where fitted, should be checked for

any evidence of seal failure.

Tubestack

 Check for signs of erosion and/or corrosion on the face of the tube

plates.

o Any evidence of either of the above conditions would indicate

poor conditioning of the tube side fluid.

 Check for any fouling across the face of the tube plate and in the bore

of the tubes.

o This must be removed.

 Check for signs of erosion and/or corrosion on the periphery of the

tube plates.

o Any evidence of either of the above condition require

replacement of the tube stack.

 Check for any fouling on the periphery of the tube plate.

o This must be carefully removed as this peripheral face forms

the sealing face.

 Check the condition of the baffles.

o Slightly bent baffles can be carefully straightened; otherwise the

complete stack must be discarded and replaced.

Shell/housing

 Check for signs of erosion and/or corrosion in the bore of the shell.

o Any evidence of either of the above conditions would indicate

poor conditioning of the shell side fluid.

 Check for cleanliness and condition of the O-ring sealing chamfer.

o This must be clean and free from damage.

 General checks for cleanliness & good integrity.

Header boxes.

 General checks for cleanliness & good integrity.

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 7 of 9

6. REASSEMBLY

Tube stack

 The tube stack should be inserted into the body with the arrow on the

face of the tube plate aligned with the arrow on the end of the body.

o This ensures that the baffles are correctly positioned relative to

the ports.

Seals

 New seals, including header bypass seals on multi-pass units, should

be fitted throughout.

 Before fitting new O-rings they should be lubricated with a lubricant

that is compatible with both the O-ring material and the working

process/fluids.

 Fit the O-rings over the tube plate and gently push into the

corresponding chamfer.

Headers (and witness rings where applicable)

The cap screws should be fully tightened in sequence to avoid distortion.

Plastic Headers:

M6 = 7Nm M8 = TBA Nm M10=TBA Nm

Metallic Headers:

M6 = 10Nm M8 = 25Nm M10=55Nm

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 8 of 9

7. UNIT CONSTRUCTION & FLOW DETAILS

2300 & 2500 Series

2700 & 2800 Series

1. Tubestack

2. Body

3. Seal

4. Witness ring (where applicable

5. Seal (where applicable)

6. Header

TTS007 – Thermex Shell & Tube Heat Exchangers

Installation, Operation & Maintenance Manual

Updated: 03 MAR 16 Page 9 of 9

8 AFTER SALES SERVICE

8.1 Ordering parts

When ordering parts it is important that the correct details are

given. At least the following should be quoted:

 Unit serial number

 Exchanger series type

 Required parts

8.2 Modifications to the heat exchanger

The heat exchanger is built up to a specific design and therefore is not

flexible with respect to enlargements or reductions. If the operating

conditions of the unit change we would be pleased to advise you as to the

continued suitability of the heat exchanger, or recommend an alternative

unit where applicable.

8.3 Contacts

You can contact the factory as follows:

thermex Ltd

Merse Road,

North Moons Moat,

Redditch,

Worcestershire. B98 9HL

United Kingdom

Telephone +44(0)1527 62210

Fax +44(0)1527 60138

E-mail [email protected]o.uk

International customers can also locate a local distributor via our website at