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Guide to Tube Bundle Replacement for Shell and Tube Heat Exchangers

Guide to Tube Bundle Replacement for Shell and Tube Heat Exchangers

by | Aug 14, 2024 | Heat Exchangers

In the world of industrial and commercial applications, shell and tube heat exchangers are indispensable for heat transfer. However, like all mechanical systems, they require regular maintenance and occasional repairs to stay in top working condition. One of the most critical components subject to wear and tear is the tube bundle. In this blog post, we’ll explore the ins and outs of tube bundle replacement, providing facility managers and mechanical contractors with the knowledge they need to keep their systems running smoothly.

What is a Tube Bundle?shell and tube bundle process

The tube bundle is the heart of a shell and tube heat exchanger. It consists of a series of tubes, typically made of copper, stainless steel, or other materials, arranged in a cylindrical shape within the outer shell. These tubes are responsible for carrying fluid through the exchanger.

Why Tube Bundles Need Replacement

Tube bundles are susceptible to corrosion, fouling, and mechanical damage over time. Here’s why tube bundle replacement is often necessary:

  • Corrosion: Constant exposure to water and steam can cause the tubes to corrode, weakening the metal and leading to potential leaks.
  • Fouling: The buildup of biological matter, scale, or dirt can reduce the efficiency of heat transfer, increasing operational costs.
  • Mechanical Damage: Cracks or pinhole leaks can develop, compromising the integrity of the entire system.

Benefits of Timely Tube Bundle Replacement

Replacing tube bundles at the right time can offer several benefits:

  • Enhanced Efficiency: Fresh, clean tubes ensure optimal heat transfer, reducing energy consumption.
  • Extended Lifespan: Regular maintenance and timely replacements can extend the life of your heat exchanger.
  • Safety: Preventing leaks and contamination protects both the equipment and the workers.

Key Maintenance and Repair Strategies

To keep your shell and tube heat exchangers in top shape, regular maintenance is crucial. Here are some key strategies:

1. Regular Inspections

  • Exterior Inspection: Look for signs of damage like cracks or leaks.
  • Tube Bundle Inspection: Check for corrosion or fouling. If you notice any buildup, it’s time for a cleaning or replacement.

2. Cleaning

  • Chemical Cleaning: Suitable for light fouling, this method uses chemicals to dissolve and flush out deposits.
  • Mechanical Cleaning: For heavier fouling, use brushes or water jets to physically remove buildup.

3. Corrosion Prevention

  • Use corrosion-resistant materials like stainless steel.
  • Conduct regular testing and inspections to catch early signs of corrosion.

4. Handling Damaged Tubes

  • Tube Plugging: Insert a plug into the cracked section to prevent fluid leaks.
  • Tube Replacement: If the damage is extensive, replacing the entire tube bundle may be necessary. Contact a professional to properly measure and build a drop-in replacement bundle.

How to Measure a Heat Exchanger for Replacement

In most cases, the model number alone can help our team duplicate your tube bundle. However, sometimes more detailed measurements are needed. Our team will:

  • Take pictures and note the dimensions of the bundle, including the number of passes and the nominal width and length.
  • Record steam and water pressure as well as type of the fluid to determine the appropriate materials.

Common Brands We Replace

We frequently replace tube bundles from the following brands:

  • Armstrong
  • Bell & Gossett
  • Cemline
  • Dunham-Bush
  • Old Dominion
  • Patterson-Kelley
  • Reco
  • Taco
  • Thrush

Conclusion

Tube bundle replacement is a critical aspect of maintaining shell and tube heat exchangers. By following regular maintenance and inspection protocols, you can ensure your system operates efficiently and safely. If you’re unsure about the condition of your tube bundles, don’t hesitate to call in a professional for assistance.

At Cooney Coil & Energy, we specialize in tube bundle replacement. Contact us today to keep your heat exchangers running at their best.

Uncover Your Facility’s Hot Water Needs

Uncover Your Facility’s Hot Water Needs

by | Jul 3, 2023 | Heat Exchangers

Importance of a Properly Designed Domestic Hot Water Return & Distribution System

Hot water is a basic necessity in commercial facilities, like college dormitories and hospitals. However, waiting for minutes for hot water to reach the point of use when a hot water tap is turned on can be frustrating and wasteful. This is where a properly designed hot water return and distribution system is key. It ensures on-demand point-of-use domestic hot water in a facility.

Maximizing Efficiency with an Instantaneous Steam to Hot Water Heat Exchanger

Cooney Thermo-Pack is an instantaneous steam-to-hot water generator that uses the entire hot water distribution system with the hot water return system to maintain a constant flow of hot water as needed. It does not heat unnecessary amounts of storage tank water. The V Ball steam control valve technology and counter cross-flow sub-cooling system design ensure significant steam savings for generating the same heat load in a vertical, space-saving footprint. The Cooney Thermo-pack provides the consistent and reliable hot water needs of any application.

In existing large hot water storage tanks in commercial facilities that have hot water return systems installed, hot water on-demand is solved, but it may be wasteful in keeping the contents of that entire storage tank hot, as well as the entire domestic hot water system. The Cooney Thermo-Pack, on the other hand, provides a solution that is more efficient and effective.

Do you know how much hot water your facility actually needs?

Engineers often oversize domestic water heaters, resulting in an inefficient generation of hot water. This is because the system is generally sized for a peak demand that may not be seen very often. To get an accurate representation of a facility’s actual hot water consumption needs, we offer a free flow-rate analysis with non-invasive water meters for Cooney Thermo-Pack quotes. This data can be used to properly size a heat exchanger that is more appropriately sized for their actual hot water consumption, resulting in increased efficiency and cost savings.

Contact Cooney for Your Free Flow-Rate Analysis Today!

In conclusion, a properly designed hot water return and distribution system is essential for any facility that requires on-demand hot water. Waiting for hot water to reach the point of use when a hot water tap is turned on can be frustrating and inefficient.  It usually results in significant amounts of stratified cooler water wasted down the drain, waiting for the user to get their desired water temperature from the tap. The Thermo-Pack provides an efficient and effective solution for high domestic hot water consumption needs in commercial facilities.

Contact us today for your free flow-rate analysis and see how a Cooney Thermo-Pack can help to reduce your bottom line. Contact us today to learn more at 610-783-1136 or [email protected]. We look forward to helping you get the reliable hot water your facility needs!

Heat Exchangers 101: What Facility Managers Should Know

Heat Exchangers 101: What Facility Managers Should Know

by | Jan 16, 2023 | Heat Exchangers

Heat exchangers are an essential component in facilities and systems that require the transfer of heat from one medium to another. In most cases, that means transferring heat from a hot medium (such as steam) to a cold fluid (like water).

But how does it work? And more importantly, which type of heat exchanger is best suited for your facility? Let’s break down some of the basics.

Types of Heat Exchangers

Heat exchangers come in many shapes and sizes, each designed to handle different levels of pressure, temperature, and flow rate There are four main types of heat exchangers: Hot Water Storage Tanks with Steam or Hot Water Immersion bundles, Plate & Frame, Shell & Tube, and Shell & Coil. Let’s take a look at the key differences between these types of heat exchangers:

Hot Water Generator Storage Tanks with Steam or Hot Water Immersion Bundles

These hot water generator / storage tanks have been popular with facilities for many, many years. They have been typically used for generating domestic hot water for the facility using either a steam immersion bundle or 180F heating hot water bundle in a large vertical or horizontal storage tank. Circulation pumps are used to assist in the recovery rate of the hot water and also maintaining the proper hot water set temperature throughout the system. They provide a large buffer amount of available hot water.

These storage tanks take up a large footprint and energy efficiency suffers by keeping the large volume of water (1500 gallons or more) at the desired temperature even at times of minimal actual usage. Unheated, stratified potable water in this system may be susceptible to Legionella concerns, especially in healthcare facilities. Leaking immersion bundles require rapid attention to prevent possible water contamination or flooded condensate systems.

Plate and Frame Heat Exchangers

Plate and frame heat exchangers are a common type of heat exchanger used in industrial applications. This type of heat exchanger consists of several metal plates sandwiched together with gaskets between each plate. The plates create separate channels for each fluid to flow through; as one fluid passes over the plates it absorbs the heat from the other fluid. Plate and frame heat exchangers can be used for both heating and cooling processes for facilities that need to maintain steady temperatures year-round. Be careful using these with steam applications as the gaskets often get worn out due to the high temperatures and can cause leaking. If used with improperly filtered water, the tight fluid pathways in the plates may clog and decrease heat transfer dramatically.

 

Shell & Tube Heat Exchangers

Shell and tube heat exchangers are another type of commonly used industrial and commercial grade heat exchanger. These consist of a tube bundle contained within an outer shell; one fluid flows through the tubes while another medium (typically steam) flows around them in the shell space.

Shell and tube heat exchangers are fairly efficient; they can handle large volumes of both hot and cold fluids simultaneously while providing very good temperature control. This makes them ideal for applications where precise temperature control is needed. A disadvantage to shell & tube heat exchangers is their large footprint which can make maintenance difficult if repairs are needed to the tube bundle. Other concerns may be, pull space for bundle replacement and flash steam in the condensate system.

Shell & Coil Heat Exchangers

Shell & coil heat exchangers are similar to shell & tube units but with several distinct advantages — they offer more compact designs, improved portability, higher levels of thermal efficiency, faster response times, lower pressure drops across the unit, quieter operation, easier maintenance access, and increased durability due to fewer components than traditional designs have.

While fully-welded stainless steel shell & coil units may not be as widely used as hot water generator or storage tanks, plate & frame or shell & tube units yet, these advantages make them well worth considering if you need a reliable yet highly efficient source of thermal energy transfer in your facility.

 Heat exchange is an important part of any facility manager’s job because it can help increase efficiency while lowering costs associated with energy usage. These four main types of heat exchangers each offer their own unique set of advantages depending on your application needs. By understanding which type best suits your needs, you can ensure that you get maximum performance out of your thermal energy transfer equipment while reducing operational costs over time.   It pays to do some research on which type would work best in your situation so you can maximize its potential benefits for your facility’s operations!

Need help selecting a heat exchanger? Give our team a call today at (610) 783-1136!

Looking for a New Heat Exchanger?

At Cooney Coil & Energy, we offer a variety of heat exchangers for all types of applications.

Unsure of what you need? Give our team a call at (610) 783-1136 to schedule a site visit and consultation today.

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How to Select the Best Heat Exchanger For Your Brewery

How to Select the Best Heat Exchanger For Your Brewery

by | Jul 30, 2019 | Heat Exchangers

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With the current boom of craft breweries in the United States, there has never been more variety in the marketplace. You can find anything from a simple light lager to an IPA that tastes like your favorite childhood marshmallow cereal. This wide variety of beer and various sizes of breweries means cooling equipment must be tailor-made to meet individual brewery needs.

Advancement in Heat Exchange Technology

Did you know that the craft of brewing beer is over 1000 years old and dates back to the Egyptians? Before modern-day heat exchangers or wort chillers existed wort was cooled in a coolship or a large shallow vessel that must be stirred throughout a whole night. Advancements in technology have cut cooling time significantly. A high-end heat exchanger can cool the wort down in less than 45 minutes. Heat exchangers can also do a lot to improve quality, production, and efficiency at your brewery.

Maintaining Tight Temperature Control

temperature control

Brewing can be complex and requires tight temperature control throughout the process. If the wort is not cooled quickly, dimethyl sulfide (DMS) can continue to produce, resulting in a tainted flavor. The formation of bacteria is another concern when it comes to flavoring and sanitation of the beer. With an effective heat exchanger, rapid heating and cooling will reduce bacteria and contaminants preventing alteration of the brews one-of-a-kind taste.

The quick cooling of wort not only helps to produce a better tasting product but helps increase production. When a heat exchanger is properly sized, the wort can be ready for fermentation in less than 45 minutes. Quicker cooling, faster brew, and increased production potential.

The key to an efficient brewery is recovering the water used in the brewing process. After cooling takes place hot water exits the heat exchanger. If this water is recovered it can be reused to heat cool water entering the building which can increase energy and water savings.

What Type of Heat Exchanger is Best For My Brewery?

With so many benefits, upgrading your brewery’s heat exchanger can pay for itself in less than a year. So where should you begin when selecting a heat exchanger? First, there are a few types to consider:

//Plate & Frame

  • Utilizes metal plates to transfer heat between two fluids
  • Suitable for fluid

//Shell & Coil

  • Tube bundle consists of closely pact layers of helically corrugated tubes layered in a crisscross pattern
  • Fluid flows through the tubes while another fluid flows through the shell and the heat exchange occurs through the tube walls
  • Suitable for steam or fluid

//Shell & Tube

  • Commonly known as “counterflow”
  • Consist of a shell with a bundle of tubes inside
  • Fluid flows through the tubes while another fluid flows through the shell and the heat exchange occurs through the tube walls
  • Suitable for steam or fluid

Heat Exchangers - Breweries JAD A-Line Cobrex

The A-Line plate & frame systems from AIC offer a reliable cost-effective way of attaining heat transfer. Double-walled options are available to avoid cross-contamination in the case of a failure. The A-Line units can also be disassembled to adjust plates and clean. Note that these units do require floor space and that should be considered when selecting a heat exchanger.

Shell & Coil, more specifically JAD systems are constructed of welded 316L stainless steel which makes them durable and ideal for sanitary applications. The shell & coil’s tube design allows for a high heat transfer area in a small space. The vertical design and angled connections are perfect for breweries needing heat exchange in tight spaces. These units are easy to clean in place and offer the benefit of less maintenance because the larger gaps are less prone to fouling and there are no gaskets.

If your process requires copper equipment for specialized brew taste, the Cobrex shell & tube heat exchanger is for you. Doubled walled copper construction avoids cross-contamination. These units are also easy to clean in place and resistant to fouling. The Cobrex, like the JAD, features a vertical design for a small footprint.

From Nano-Breweries to Commercial Brewhouses Cooney Coil can Help!

Every project and each brew remain unique. If you’re a small single-batch brewery or a large commercial facility, we can help! Having a dedicated Cooney Coil specialist that can outline equipment capabilities will help you achieve the best performance and efficiency as possible. If you aren’t sure what model is best for you, we’d love to come to perform a site visit where we will evaluate energy consumption, process bottlenecks, and space-saving opportunities.

Contact us at 610-783-1136 to schedule a site visit or request a quote below!

 

HVAC Tube Bundle Maintenance

HVAC Tube Bundle Maintenance

by | Jun 25, 2019 | Heat Exchangers

Tube bundles are an essential part of the HVAC and hydronic system of a commercial facility. They are the heating elements that exchange and transfer energy in the form of heat into the water that is then typically used for either building heat or domestic hot water requirements. Without this critical component, the system wouldn’t work at all—which is why it’s such a big problem if it fails.

It’s important to make sure that your tube bundles are in good working condition if you want to keep the system functioning at optimal levels. If the HVAC tube bundle ruptures or springs a leak, hard water may enter your condensate return system and damage your boiler, or steam could migrate into your hydronic system and create a dangerous environment to the domestic and/or heating systems. Here are a few things to look for if you’re unsure about how to check your tube bundles for damage.

Signs of Deterioration in Your Tube Bundles

It’s a good idea to schedule regular maintenance for your heat exchangers. If you’re not comfortable inspecting the tube bundle yourself, get a proffessional to help you out. Otherwise, we recommend looking for these signs which indicate that you may need some repairs:
Tube Bundle

  • Corrosion on the tubes: Most tube bundles are made from conductive metals, such as copper. On these metals, corrosion usually appears as a slimy or flaky green/brown tint. Over time, your tubes will likely corrode a small amount as they are exposed to the water/steam moving through the system. A little corrosion is nothing to worry about. However, corrosion weakens the metal and can eventually cause it to break or release tiny particles of oxidized metal into the fluid running through your tube. So, if you see a lot of corrosion, call a professional.
  • Air and dirt in the system: No matter how well-crafted a tube bundle is, it will experience wear and tear that may degrade it. These contaminants can be hard to spot because they are behind the opaque surface of the tube. Look for dirt buildup at the base of the tubes where they meet with the tube sheets and baffles. If there is significant dirt buildup there, especially if it is slimy or pitted, call a professional. Leaking tube bundles can cause additional problems for your domestic water and heating system.
  • Pinhole leaks: Sometimes, a leak in your system won’t be visible to the naked eye. If you see the hard water showing up in your condensate return to your boiler, you may have a leak. Isolate the suspect heat exchanger from the steam supply and then open the water valve while also opening the condensate wye strainer drain. If the water begins to flow out of the strainer, you know you’ve got a failed tube bundle. This problem can be disastrous if left unattended. Allowing failed tube bundles to leak into your system can be very dangerous, especially if hard water makes it back to your boiler and is left unaddressed for a prolonged period of time.

You don’t have to shoulder the burden of checking your tube bundles for leaks alone. Call the professionals at Cooney Coil & Energy if you need assistance with diagnosing the problem and finding the right parts for repair or replacement tube bundles.

Get a Quote on a Replacement Tube Bundle

Need to replace a tube bundle? Cooney Coil  & Energy has several tube bundles in stock for same-day replacement delivery in the greater Philadelphia, PA, NJ, &  DE area. Give us a call at 610-783-1136 or place a quote online.

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The Heat Exchanger Perfect-Fit Guarantee

The Heat Exchanger Perfect-Fit Guarantee

by | May 11, 2018 | Heat Exchangers

A heat exchanger is one of the most important parts of your hydronic system. They’re the device that transfers heat between two fluids, allowing heat to be taken out or put into your system. That means the heat exchanger in your HVAC is responsible for the temperature of your water, and it also means that if yours is broken, your fluid temperature is probably out of control.

So what if one does break, or needs to be replaced for some other reason? Luckily, Cooney Coil & Energy can find a replacement for you, and we can guarantee, based on our exact measurements, that it will fit. Why is that so important? Well, it’s tougher than it seems, because not every heat exchanger is created equal. When we say that we guarantee a perfect fit, here’s what we really mean.

How Can We Guarantee a Perfect Heat Exchanger?

For some companies, “guarantee” can be a scary word. It’s tough to claim responsibility for something entirely, especially when you’re claiming that one of the most finicky pieces of equipment in common use will work correctly. But Cooney Coil & Energy believes in the knowledge, skill, and competency of its technicians, and we know that we can make this guarantee with confidence.

We Know This Because…

Our technicians are specially trained to be experts in finding you replacement components for your heat exchangers. When we send someone to your site to take a look at your unit, they are bringing years of experience and expertise. After taking a few careful measurements, they’ll ask you a few questions about what you need. After all, there are a lot of different kinds of ways to exchange heat, and not all of them will work perfectly for what you need.

When they’ve gathered enough information, Cooney Coil & Energy will secure the exact product or part with the exact specifications that you need. Based on the measurements and the information our team gathers, we will be able to build a drop-in replacement. If we still feel like we need to make adjustments to get it down to the last few millimeters of a perfect fit, our team can return to the site with state-of-the-art measuring tools.

This process allows us to be very confident in our guarantee that a new heat exchanger will fit and work perfectly when we install it. We don’t worry about the guarantee, and you shouldn’t have to worry either. If you have any questions about our guarantee policy, heat exchangers, or anything else, don’t hesitate to get in touch. You can give us a call at (610)783-1136, or receive a quote online. We look forward to hearing from you.