Shell and tube heat exchangers are special type of unit operation which is needed for high-pressure applications; they are durable products, which can withstand the demands of many working environments. Their design plays a large part in ashell and tube exchanger’s ability to endure exceedingly-challenging situations. The gaskets are normally spiral wound gaskets made of stainless steel.

Shell and tube heat exchangers are made from a series of tubes, which can be made of durable material such as fluoropolymers. Fluoropolymers are highly-durable plastics such as PTFE, FEP, and PFA. Fluoropolymers, like heat exchangers, have a place in a variety of industries such as the automotive, medical, and aeronautical.

In a heat exchanger’s shell, one set of tubes contains fluid, which is either heated or cooled. Another set of tubes also contains liquid, which facilitates the heating or cooling of the primary set of tubes. A tube set is referred to as the tube bundle and can take on a variety of shapes depending on what is most conducive for the intended job.

Engineers of shell and tube heat exchangers need to consider several components of construction, among them are:

• A smaller tube diameter enables the shell and tube exchanger to be economical and compact, yet a tiny diameter can facilitate malfunction and difficulty of cleaning. Larger tubing can be instituted to eradicate potential flow and cleaning problems. Engineers must factor cost, space, and the propensity of liquids to foul when constructing a heat exchanger.
• Tube thickness is important to make sure there is room for corrosion; vibration existing in the product has resistance; and, the shell and tube exchanger can withstand pressure coming from both in and outside of its internal tubes.
• Folding or wrinkling the inner tubes increases the flow of the liquid, which facilitates the transfer of heat, producing better performance from the exchanger.
• Designers also consider the layout of the inner tubes. Tubes can be fashioned in a triangular, square, rotated square, or rotated triangular fashion. Particular, internal designs are conducive to specific jobs and the elimination of potential problems such as fouling of the liquid.
• Shell and tube heat exchangers also host baffle components. Baffles serve several purposes such as holding the tube bundles in place; making sure tubes do not sag or vibrate; and, facilitating fluid flow.

More information regarding this report:Power Boiler and Heat Exchanger Manufacturing Industry in the U.S. and its International Trade

http://www.reportlinker.com/p0206939/Power-Boiler-and-Heat-Exchanger-Manufacturing-Industry-in-the-U-S-and-its-International-Trade.html#utm_source=LivePR&utm_medium=pr&utm_campaign=LivePR

This June edition of Power Boiler and Heat Exchanger Manufacturing Industry report is the comprehensive market research guide for the industry. It publishes the latest information on the industry’s key financial data, competitive landscape, cost and pricing, and trends during the current economic environment.

In 2009, the value of imported products within this industry into the U.S. has been relatively high, at approximately 40% of U.S. production. Because of this reliance on imports, the report covers the foreign trade statistics including the top 25 countries the U.S. imports from and their respective import values. This industry exhibits a high amount of trade activity, because in 2009, the value of exported products within this industry into the U.S. has also been relatively high, at approximately 30% of U.S. production. This reliance on exports is also covered in the report’s foreign trade statistics.

At 162 pages with over 150 charts and tables, the report’s extensive coverage includes topics such as current macroeconomic trends, granular product data, global trade, channel mix, government demand, and labor structure. It relies on over a decade of historical data and enhanced forecasting to project industry trends through 2014 on the domestic market, global market and overseas growth opportunities. This current report contains shipment data, inventory levels, international trade volume, and industry specific price indices through April 2010. Industry analysts and Fortune 500 customers rely on this quarterly report to make accurate forecasts and planning in today’s uncertain economy.

In this report, you will find industry data on the following major categories:

Executive Summary

• Quick Industry Statistics: 2-page overview for the CEO on the run
• Supply & Demand with Capacity Utilization
• 2010-2014 Forecast

Industry Income Statement

• All relevant financial data including: Revenue, Cost of Materials, Labor Costs, Gross Profit, SG&A, Net Income, etc.
• 4-year Financials Comparison and Trends

Industry Balance Sheet

• Traditional key elements of Assets, Liabilities, and Equity
• Inventory fabrication stages
• Calculated balance sheet ratios

Capital Expenditure

• Plant additions and expansions
• Computer and IT investments
• Machinery and Equipment for production and material handling

Industry Cost Analysis

• Upstream Industries and the cost allocations towards producer, wholesale, retail, and freight
• Materials and their percentage share of total material costs

Industry Pricing Analysis

• Producer Pricing Indices at industry, wholesale, and retail levels for comparison and trend forecasting
• Pricing Distribution among Downstream Industries differentiated at producer, wholesale, retail, and freight categories

Industry Foreign Trade

• Detailed Import/Export Data by commodities and by countries
• Mode of Shipment and insurance and freight costs

Industry Structure

• Labor and Compensation Structure: productivity indices, hourly wages, production hours, output index, HR structure
• Establishments: Trends, Employee Statistics, State by State numbers
• Valued added statistics: industry GDP contribution

Competitive Landscape

• Industry Concentration: HHI, number of companies, size distributions, market shares
• Major Players: company profiles and market size ranges

__________________________________________

Definition & Classification

This industry comprises establishments primarily engaged in manufacturing power boilers and heat exchangers. Establishments in this industry may perform installation in addition to manufacturing power boilers and heat exchangers. This 6-digit NAICS industry (332410) is under the hierarchy of Boiler, Tank, and Shipping Container Manufacturing Industry Group (3324), Fabricated Metal Product Manufacturing Subsector (332), and the Manufacturing Sector (31-33). Its SIC equivalent codes are: 3443 – Fabricated Plate Work (Boiler Shops) (power boilers and heat exchangers); and 3559 – Special Industry Machinery, NEC (nuclear control rod drive mechanisms).

Revenue, Profitability & Foreign Trade Preview

The industry’s revenue for the year 2009 was approximately $4.8 billion USD, with an estimated gross profit of 27.65%. Import was valued at $2.0 billion USD from 64 countries. The industry also exported $1.3 billion USD worth of merchandise to 141 countries. Adding import value to and subtracting export value from the industry’s shipment value, the total domestic demand for the industry in 2009 was $5.5 billion USD.

Report Summary

This industry report contains 162 pages of in-depth market research with over 150 charts and tables. Current and forecasted industry sales and shipment data within the U.S. and its international trade are presented. For financial analysis, the report presents industry level income statements, balance sheets, and capital expenditure figures. In the cost analysis section, 48 upstream industries are analyzed to offer insight into the supply chain cost structure. For the channel and pricing structure, 63 downstream industries are analyzed. The competitive landscape section provides the number of companies and their respective revenue share, the market concentration, and a list of major players. Furthermore, products within the industry are listed with their respective market sizes and import and export data. The appendices contain relevant resources to additional trade statistics, U.S. State statistics, and industry trade associations.

Our clients include Fortune 500 companies, manufacturers, international top consulting firms, major retailers and wholesalers, professional trade associations, financial corporations, universities, governmental entities, start-ups and individuals. We are committed to providing the highest level of quality to all our clients and assure your satisfaction in the report delivering as promised.
(rlk1-2010-07-24) plp

• Preface
• Introduction
  • Definition
  • Related Industries
  • Comparison to U.S. Manufacturing Sector
  • Scope
  • History
• Executive Summary
  • Quick Statistics
  • Supply, Demand and Capacity Utilization
  • 2010-2014 Forecast
    • Shipments
• Industry Income Statement
  • Revenue (Value of Shipments, Net Sales)
  • Compensation (Payroll and Fringe Benefits)
    • Salaries
    • Wages
    • Fringe Benefits
    • Compensation Distribution
  • Cost of Materials
    • Materials Cost Excluding Fuel and Energy
    • Electricity Cost
    • Fuel Costs
    • Materials Consumption Breakdown
  • Gross Profit
  • Other Costs
    • Administrative, Sales and Marketing Expenses
    • Current and Deferred Taxes
  • Net Income
    • Income (or Loss) From Operations (EBIT)
    • Other Non-Operating Income
    • Income (or Loss) Before Income Taxes (NIBT)
    • Income (or Loss) After Income Taxes
    • Earnings before Interest, Depreciation and Taxes (EBIDT)
• Industry Balance Sheet
  • Assets
    • Cash and Government Securities
    • Accounts Receivable
    • Inventories
    • Inventories Stage of Fabrication Ratios
    • Total Current Assets
    • Current Assets Distribution Chart
    • Property and Other Non-Current Assets
  • Liabilities
    • Current Liabilities
    • Total Liabilities
  • Equity
    • Stockholders’ Equity
    • Profit on Stockholders’ Equity before Income Tax
    • Profit on Total Assets before Income Tax
    • Total Current Assets to Total Current Liabilities
    • Total Cash and Government Securities to Total Current Liabilities
• Capital Expenditures
  • Building and Structure
  • Machine and Equipment Expenditures (including Automobile and Computers)
  • Computers
  • Automobile and Highway
  • Other Machine and Equipment
• Product Market Sizes
• Cost Analysis
  • Upstream Industries
• Pricing Analysis
  • Producer Price Indices
    • Industry-Level Producer Price Indices
    • Manufacturing Sector PPI
    • Producer Price Index – Wholesale Sector
    • Producer Price Index – Retail Sector
    • Consumer Price Index – All Items
    • Consumer Price Index – Durable Goods
    • Consumer Price Index – Non-Durable Goods
    • Consumer Price Index – Electricity
    • Consumer Price Index – Gasoline
  • Pricing Distribution
  • Downstream Industries
• Industry Foreign Trade
  • Import
    • Import Process
    • Harmonized Tariff Schedule
    • Top Import Commodities Analysis
    • Ranking – Countries US Imported From
    • Top 5 Countries US Imported From
    • Top 25 Countries US Imported From
    • Importing Insurance and Freight Cost Index by Country
    • Import Total Value from 2000 to 2012
    • Import Total Quantity from 2000 to 2012
    • Import Export Total Value Comparison from 2000 to 2012
    • Import Export Total Quantity Comparison from 2000 to 2012
    • Import Price Indices from 2000 to 2012
    • Comparison of Import and Export Price Indices from 2000 to 2012
  • Export
    • Domestic Exports
    • Foreign Exports (Re-exports)
    • Export Statistics Summary
    • Top Export Commodities Analysis
    • Ranking – Countries US Exported To
    • Top 5 Countries US Exported To
    • Top 25 Countries US Exported To
    • Export Total Value from 2000 to 2012
    • Export Total Quantity from 2000 to 2012
    • Export Price Indices from 2000 to 2012
• Industry Structure
  • Labor and Compensation
    • Trend
    • Production Workers
    • Production Workers to Total Employees Ratio
    • Hourly Wages
    • Production Hours Trend
    • Contribution (Revenue) per Production Worker
    • Annual Wage per Production Worker
    • Production Worker Contribution (Revenue) Ratio
    • Revenue to Number of Workers
    • Labor Productivity (output per hour)
    • Labor Input Index (total labor hours)
    • Output Index
    • Unit Labor Cost Index
    • Labor Compensation Index
    • Output per Worker Index
    • All Worker Index
    • Human Resources – Occupations
  • Establishments
    • Trend
    • Average Number of Employees per Establishment
    • Contribution (Revenue) per Establishment
    • Establishment Sizes by Number of Employees
    • Establishments by U.S. States
  • Value-Added
  • Sustainability
• Competitive Landscape
  • Industry Concentration
  • Industry Aggregate
  • Major Players
• Appendix A – Additional Foreign Trade Statistics
  • Trading Countries’ Rank
  • Top 5 US Trading Countries and Other
  • Top 25 US Trading Countries
• Appendix B – Industry U.S. States’ Statistics
  • Production Workers Ratio
  • Average Hourly Wage
  • Average Annual Salary
  • Cost of Materials Ratio
  • Capital Expenditure Ratio
  • Industry Shipment Ratios
  • Electricity Consumption and Environmental Impact
  • Fuel Consumption and Environmental Impact
• Appendix C – Additional Links
  • Trade Associations
  • Trade Publications
  • Trade Shows
  • Industry Standards
  • Legislation, Regulation, Tax and Environmental Related Issues
    • Industry Specific Regulatory Agencies
    • Non-Industry Specific Regulatory Agencies
• Appendix D – Industry’s 4-Year Financial Statement
• Appendix E – Report Methodology

Source: http://www.live-pr.com/en/power-boiler-and-heat-exchanger-manufacturing-r1048523622.htm

Tube Tech International proved that previous industry standards for cleaning such equipment with U bends were inadequate and, for the first time on this unit, Tube Tech gave not only the straight legs, but also the U sections a complete internal clean.

PHex is an easy to use tool which domonstrates the thermal calculations of Gasketed Plate Heat Exchangers, The plate dimensions and materials can be entered, this includes the size of plate heat exchanger and chevron angle (25 to 65 degrees).

List of main features:

1- User friendly and easy to use with ability to save/load data.

2- Estimate the Physical properties of more than 1450 components; the database has the ability to estimate Thermal Conductivity, Density, Heat Capacity and Viscosity. The database also included critical properties, boiling and melting points.

3- Estimate mixture properties.

4- Create you own database of Plates and Components. You can add your fluid physical properties and load the data to your project with a click of a button and more…

5- Chose between S.I. or English U.S. units of measurements.

6- Temperature and Flow rate estimation in the event of insufficient data.

7- Heat load required (clean or fouled) calculations.

8- Duty clean / dirty calculations.

9- Total effective area calculation.

10- Surface area calculation.

11- Number of plates calculations.

12- Overall Coefficient (clean / dirty) calculations.

13- Pressure drop Channel/Port/Total for Hot side and Cold side Calculations.

14- Plate heat exchanger dimension calculations.

15- Velocity through ports, Mass velocity through channel/ports calculations.

16- Reynolds and Nusselt numbers calculations.

17- Heat transfer coefficient calculations.

18- Summary of results with image to help in understanding.

This is without doubt a must have software for heat exchanger designers. This superb software cost only $69.99 per computer (1 license). You can also add on additional license with some extra cost if you are interested. For more information, click the following link:

>>> Get PHex Gasketed Plate Heat Exchanger Design Software

Four different types of steel used for high-temperature service:

• Carbon steels – for most usage up to 750 degrees F (400 degrees C). Carbon steels are cheaper, very strong, with highest thermal conductivity. Above 750 degrees F, their creep increases; above 950 degrees F (510 degrees C) they get oxidized too.
• Chromium-molybdenum steels – resist oxidation up to 1200 degrees F (650 degrees C). But their thermal conductivity is lower; and chromium-molybdenum steels are more expensive than carbon steels.
• Ferritic stainless steels – can be used up to 1500 degrees F (820 degrees C).  Ferritic stainless steels have higher thermal conductivity, lower thermal expansion coefficient, and less expensive than other materials for the same service. Ferritic stainless steels can resist oxidation as well as attack from sulfur- and carbon-containing flue gases. Coefficient of thermal expansion of ferritic stainless steels is lower than for austenitic stainless steels. Loose strength after a very long usage at high temperatures.
• Austenitic stainless steels – the strongest among steels for use at high temperatures and do not loose strength after very long usage at high temperatures. Austenitic stainless steels resist oxidation at high temperatures and are widely used in boilers, super-heaters, refinery services, etc., where chlorine is not present.

These are part of the steels that can be used for the manufacturing of various heat exchanger including shell and tubes, spiral heat exchanger and plate heat exchanger.

This information is credited to http://brazedplateheatexchangers.wordpress.com/2010/07/01/which-types-of-steel-can-be-used-for-high-temperature-service/

SGS Korea (www.kr.sgs.com/home_kr_v2.htm?selen=1) was awarded a contract to provide Leak Testing of a heat exchanger tube and tube-tube sheet in a refinery in Ulsan, Korea on March 16, 2010. This Non-Destructive Testing (NDT) method was used for the very first time on a heat exchanger.

The SGS team of four experts successfully performed Leak Testing (link to: www.kr.sgs.com/srs/special_leak_test_srs/helium_leak_test_srs.ht ..) of a heatexchanger tube and tube-tube sheet using helium gas during the two days of testing. The gas was introduced into the internal space of the heat exchanger and over pressurized. Consequently, the gas flew through welding flaws, cracks or pin holes and was sucked into a sniper attached to a helium mass spectrometer. Following the ionization of the gas in the ion chamber by an electronic beam, the helium ion collector gathered the helium ions and sent an amplified signal to the indicator. The leakage could be measured by the signal strength.

Due to SGS’s extensive experience in Non-Destructive Testing (www.ndt.sgs.com/) the leakage in the welding area of the heat exchanger was successfully identified and reported to the client. The successful completion of the project resulted in SGS receiving further contracts for NDT services from this client.

For the very first time, SGS applied Leak Testing, which had been limited to LNG carriers until now, to a completely new field. As Leak Testing of a heat exchanger tube and tube-tube sheet proved to be successful, SGS will expand its NDT technologies to new industrial fields.

In addition to Leak Testing of heat exchangers, SGS provides Heat Exchanger Life Assessment System (HELAS) (www.sgs.com/ndt-heat-exchanger-life-assessment-system?serviceId= ..), which is based on the measurement of ultrasonic immersion length, converted into the corrosion depth inside cooling water or air fin type tubes.

About SGS Industrial Services

As the world’s leading inspection, verification, testing and certification company, SGS offers a complete package of inspection in and around heat exchangers, in order to create a full set of data which is easy accessible and ready for follow-up. Several inspection and testing technologies and tools can be applied depending on your preferences and technical requirements.

The SGS Group is the global leader and innovator in inspection, verification, testing and certification services. Founded in 1878, SGS is recognized as the global benchmark in quality and integrity. With more than 56,000 employees, SGS operates a network of over 1,000 offices and laboratories around the world.

The article is taken from the following press release:

Leak testing of heat exchanger provided by SGS.

Press Release.

1.  Is there a phase change involved in my system?

2.  How many “zones” are involved in my system?

3.  What are the flowrates and operating pressures involved in my system?

4.  What are the physical properties of the streams involved?

5.  What are the allowable pressure drops and velocities in the exchanger?

6.  What is the heat duty of the system?

7.  What is the estimated area of the exchanger?

8.  What geometric configuration is right for my exchanger?

9.  Now that I have a geometry in mind, what is the actual overall heat transfer coefficient?

10.  What is the actual area of the exchanger using the ‘actual’ heat transfer coefficient?

11. What are the materials of Construction, ease of maintenance, cost of exchanger and overall heat integration

Think of the questions…

We’ll provide answers for it in latter posts.

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http://rapidshare.com/files/97496005/HTRI_5.part2.rar.html

http://rapidshare.com/files/97659439/HTRI_5.part3.rar.html

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