The document provides a comprehensive analysis of various heat exchangers, including radiator type, plate type, and shell and tube types, discussing their applications, maintenance practices, and operational principles. It emphasizes the importance of efficient heat exchange, maintenance to prevent issues such as fouling and leaks, and different types of heat exchangers used in specific plant locations. Additionally, it outlines contingency plans for potential failures and vendor contact information for support.

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

2. Types of heat exchanger
Parallel flow
Diagonal flow
Acc. To
fluid flow
Counter flow
Cross flow

3. Counter flow
Cross flow
Diagonal flow

5. RadiatOR tyPe HX’s (RHe)
 AIR to WATER heat
exchanger.
 Uses fans to circulate air
and cool the fluid inside
tubes of HX’s.
 Cooling medium is
“AIR”.
 Radiator is made via
Al alloy.
Working of a radiator type HX

6. HOw tO MaiNtaiN RHe’s
 Feed the oil from inlet only.
 Flush clean the radiator with
pressurized air once in a week, to
maintain proper air flow.
 Don’t keep any obstacle in front of
radiator which may obstruct the air
flow.

7. DAIKIN 90507; TRACTOR PLANT( M/C SHOP)
DAIKIN 80017; TRACTOR PLANT( M/C
SHOP)

8. DSL 50; AXLE PLANT(STEERING KNUCKLE LINE)
HH5C-PLC; AXLE PLANT( STEERING KNUCKLE L

9. #50604 HELLER MCH300; BKW HX; TRACTOR PLANT( M/C

10. 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 ensures
superior heat transfer properties

11. Cooling towers
 Heat withdrawn from water via contact between
the 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.

12. Cooling tower, utility area

13. Plate type HX’s (PHE)
 Constitutes of 2 plates – fix frame plate and
pressure 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.

15. Principle of PHE
 Channels are formed b/w the plates & corner ports are
arranged 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.

16. CHESSISE PHE; AM 10 FM1; TRACTOR PLANT (PAINT SH

17. defects
Leakage in plate heat exchanger

18. CALCIUM SULPHATE SCALING
IRON FOULING

19. HOw tO MaiNtaiN PHe’s
 Back flush the PHE once a week.
 check the PHE for leaks, especially during intense running
periods.
 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.

20.  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.

21. Types of PHE
Gasketed PHE
Semi-welded PHE
Welded PHE

22. 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

23. 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.

24. limitations
 Extreme temperature difference b/w 2 fluids-it’s
generally 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 high
fluid temperatures, by the temperature limitations of
the gasket.

26. BHE
 BHE is a compact variation of PHE but does not have
carbon 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.

27. WORKING OF BHE
EXPLODED VIEW OF BH

28. GEA MAKE BHE;AXLE PLANT
Top view of BHE; GEA MAKE; AXLE PLA

29. OPERATING PRINCIPLE
 Based on the plate and nozzle orientation, each fluid passes
through 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.

30. TYPES OF BHE
 TPL SERIES- In case of media with average viscosity and high
viscosity. 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.

31. TPL SERIES
GPL SERIES

32. CB-COPPER BRAZED HX
 These heat exchangers from the smallest unit CB14, to the
largest 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.

33. CB- COPPER BRAZED HX

34. Fusion bonded PHE
 AlfaNova, the world’s first 100% stainless steel AND
fusion 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.

35. ALFANOVA- FUSION BONDED PHE

36. ADVANTAGES OF BHE
 High corrosion resistant- All plates uses SUS316 material.
 High pressure resistant
 High thermal efficiency
 High working temperature- Brazed Plate Heat Exchanger's
SUS316 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.

37. HOw tO MaiNtaiN BHe’s
 For heavier fouling use chemicals such as formic
acid, 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).

38. sHeLL & tuBe tyPe HX’s
 Water to water heat exchanger
 consists of a shell (a large pressure vessel) with a
bundle 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.

39.  Tube pitch- The shortest distance between centers of two
adjacent 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.

40. Exploded view of shell and tube heat exchanger

41. Yantra make HX ; shell and tube type; TRACTOR PLANT( ENGINE SHO

42. Shell and tube type HX in diesel generators; utility area

43. How to Maintain shell & tube HX
 At regular intervals , an examination should be made of internal
as 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.

44. 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.

45. Analysis of HX’s used in
CNH(Case New Holland)
4 types of HX’s are being
used in CNH
RHE
PHE
Shell &
Tube
type
BHE

46. MACHINE
SHOP
RADIATOR type
HX’s
PAINT SHOP
PLATE type
HX’s
ENGINE SHOP
SHELL & TUBE
type
NEW DRIVE
LINE (NDL)
BRAZED HX’s
MACHINE
SHOP
BRAZED HX’s
TRACTOR
PLANT
CNH
DIFFERENTIAL
LINE
AXLE PLANT
STEERING
KNUCKLE
LINE
PLANET
CARRIER LINE
RADIATOR
type HX’s

47. 4%
RHE
9%
PHE
BHE
7%
SHELL & TUBE
COOLING TOWER
12%
68%
PIE CHART SHOWING HX DISTRIBUTION

48. 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

49. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
RHE
TRACTOR
MACHINE
#533
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#682
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#615
MAKINO
A81
DAIKIN
RHE
TRACTOR
MACHINE
#534
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#683
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
# 195
MAKINO
A81
DAIKIN
TRACTOR
MACHINE
#50437
HELLER
BKW
MODEL/TY
PE OF HX’s
90507
40807

50. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
RHE
TRACTOR
MACHINE
#441
MAKINO
A81
DAIKIN
RHE
TRACTOR
MACHINE
#352
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#685
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#485
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#351
MAKINO
A81
DAIKIN
RHE
TRACTOR
MACHINE
#456
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#533
MAKINO
DAIKIN
MODEL/TY
PE OF HX’s
80017

51. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
RHE
TRACTOR
MACHINE
#440
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#485
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#634
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#684
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#456
MAKINO
A77
DAIKIN
RHE
TRACTOR
MACHINE
#607
MAKINO
A81
DAIKIN
RHE
TRACTOR
MACHINE
#352
MAKINO
DAIKIN
MODEL/TY
PE OF HX’s

52. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
MODEL/TY
PE OF HX’s
SHELL AND
TUBE TYPE
TRACTOR
ENGINE
SHOP
ENGINE
YANTRA
ASSEMBLY
TEST CELL 4
RHE
TRACTOR
MACHINE
SHOP
#50604
HELLER
MCH 300
BKW
WRK10/2R2
8-CH2
RHE
TRACTOR
MACHINE
SHOP
#50603
HELLER
MCH 300
BKW
WRK10/2R28
-CH2
RHE
TRACTOR
MACHINE
SHOP
#50437
HELLER
MCH 300
BKW
WRK10/2R28
-CH2
RHE
TRACTOR
MACHINE
SHOP
#50239
HELLER
MCH 300
BKW
WRK10/2R28
-CH2
RHE
TRACTOR
MACHINE
SHOP
#50240
HELLER
MCH 300
BKW
WRK10/2R28
-CH2

53. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
MODEL/TY
PE OF HX’s
PHE
TRACTOR
PAINT SHOP
CHESSISE
PHE
Alfa laval
AM 10 FM1
PHE
TRACTOR
PAINT SHOP
PRE
DEGREASIN
G TANK
NO.1
Alfa laval
P2FL1 (OLD)
PHE
TRACTOR
PAINT SHOP
DEGREASIN
G-1 TANK
NO. 2
Alfa laval
P2FL1
PHE
TRACTOR
PAINT SHOP
DEGREASIN
G-2 TANK
NO. 3
Alfa laval
P2FL1
PHE
TRACTOR
PAINT SHOP
PHOSPHATE
TANK NO. 7
Alfa laval
P2FL1 (OLD)
PHE
TRACTOR
PAINT SHOP
PHOSPHATE
TANK NO. 7
Alfa laval
M6-MFG
(NEW)
PHE
TRACTOR
PAINT SHOP
CED BATH
Alfa laval
TANK NO. 11
P2FL1
PHE
TRACTOR
PAINT SHOP
PRE
M6-mfg
Alfa laval

54. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
BRAZED
HX’s
TRACTOR
NDL (NEW
DRIVE
LINE)
NDL M/C 1
FUNKE
BRAZED
HX’s
RHE
TRACTOR
NDL (NEW
NDL M/C 2
DRIVE
DIFFERENT BEMCO
LINE)
IAL LINE
FUNKE
RHE
AXLE
DIFFERENTI HIND
GK ENGG.
AL LINE
HH473-11797
HH5C-PLC
RHE
AXLE
STEERING
KNUCKLE
LINE
BEMCO
20Ton
WARKIN
DSL 50
RHE
AXLE
STEERING
KNUCKLE
LINE
HIND 5Ton
GK ENGG.
HH5C-PLC
RHE
AXLE
STEERING
KNUCKLE
LINE
BEMCO
20Ton
WARKIN
DSL 50
RHE
AXLE
STEERING
KNUCKLE
LINE
BEMCO
20Ton
WARKIN
DSL 50
AXLE
MODEL/TY
PE OF HX’s
WARKIN

55. TYPE OF
HX’s
PLANT
LINE/SHOP
M/C NAME
MAKE OF
HX’s
MODEL/TY
PE OF HX’s
RHE
AXLE
PLANET
CARRIER
LINE
BEMCO
40Ton
WARKIN
DKL 307
RHE
AXLE
PLANET
CARRIER
LINE
BEMCO
40Ton
WARKIN
DKL 307
RHE
AXLE
MACHINE
SHOP
MAC 6290
MAKINO
A100E
YUKEN
RHE
AXLE
MACHINE
SHOP
MAC 11173
MAKINO
A100E
YUKEN
RHE
AXLE
MACHINE
SHOP
MAC 6291
MAKINO
A100E
YUKEN
RHE
AXLE
MACHINE
SHOP
MAKINO
A81
YUKEN
RHE
AXLE
MACHINE
SHOP
MAKINO
A81
YUKEN

56. TYPE OF
HX
PLANT
SHOP
RHE
TRACTOR
RHE
MACHINE
NAME
MAKE
MODEL
DRIVE LINE #50525
HELLER
MCH 300
BKW
WRK10/2R2
8-CH2
TRACTOR
DRIVE LINE #50237
HELLER
MCH 300
BKW
WRK10/2R2
8-CH2
RHE
TRACTOR
DRIVE LINE #51276
HELLER
MCH 300
BKW
WRK10/2R2
8-CH2
BHE
AXLE
M/C SHOP
FAMAR
ERGO 500
GEA
WP 1-24E
BHE
AXLE
M/C SHOP
FAMAR
ERGO 500
GEA
WP1-24E
BHE
AXLE
M/C SHOP
FAMAR
ERGO 500
GEA
WP 1-24E

57. Contingency plans
Radiator 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.

58. Radiator type HX

61. BRAHMASTRA FOR PHE
 When the level of problem is at a level where above
written precautions don’t work then use “
BRAHMASTRA” that is contact the vendor. And here
it’s “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

63. 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 it’s
”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

64. 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

65. Knowing
danger
Ways to
eliminate
danger
Safety

66. Universal

67. HAZARDS INVOLVED
PHE
• 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

68. SHELL & TUB

69. THANK YOU