Siljan Allards www.siljanallards.com

Shell & Tube Heat Exchangers in Carbon and Stainless Steels Reference List

Dec 2007

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Siljan Allards is one of Sweden's largest manufacturers of stainless process equipment. The combination of • Ca 35 years of experience with stainless steel manufacturing • Large, ca 10.000 sqm, and adequate work shops • Very experienced and skilled personnel • Productive machinery • One of Scandinavia's largest pickling plant for surface treatment • Large capacity for thermal and mechanical design • Very high knowledge of the microstructure and properties of stainless steels, includ-

ing welding metallurgy, plate forming, corrosion and mechanical properties. makes us very efficient as well as secures a high quality.

One of our main products is shell & tube heat exchangers in carbon steel, stainless steel and nickel base alloys and in different executions, both as conventional heat exchangers with round tubes and as the twisted tube heat exchanger AlfaTwist. We have a complete organization for thermal and mechanical design, manufacturing and testing of shell & tube heat exchangers. We also have resources to support and solve thermal and mechanical problems in existing shell & tube heat exchangers, to perform retubing as well as controlling if existing heat exchangers are leak proof, do tube plugging work and repair work. In this brochure we give a number of examples of heat exchangers which we have de-signed and manufactured the last years

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Reference list-shell & tube heat exchangers The reference list exemplifies shell & tube heat exchangers which we have manufactured, mainly during the years 2004-2007, divided into applications. 1. Power plants Page 4 2. Pulp- & paper industry Page 9 3. Chemical industry Page 16 4. Pharmaceutical and food industry Page 20 5. Steel– and metal industry Page 21 6. Others Page 23

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1. Power plants

1a. Carbon steel shell & tube heat exchanger for a power plant in southern Sweden

1b. Condenser for a power plant in the northern part of Sweden. In carbon steel.

1c. A twisted tube heat exchanger, AlfaTwist, supplied to Vattenfalls power plant in Uppsa-la, Sweden, in 2005. The twisted tube bundle below. ”It sounds like a spinning cat” the chief engineer said, when this heat exchanger was taken into ser-vice. In the same power plant there is a twis-ted tube heat exchanger installed in 1983, still performing in an excellent way and in 1983 solving vibration problems in a conventional shell & tube heat exchanger.

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1d. Twisted tube heat ex-changer manufactured and delivered to a large power plant in northern Sweden. The twisted tube bundle in the second picture.

1e. Twisted tube heat exchanger for a power plant in central Sweden. Rebuilt to decrease the pressure loss. Shell in carbon steel, tubes in the stainless steel 1.4301/304. With such a design of a shell & tube heat exchanger, the following problems are eliminated:

• General corrosion of carbon steel tubes. • Vibration damages of tubes at baffle plates • Vibration damages of tubes at tube sheet

In general, a twisted tube heat exchanger has a lower weight and smaller dimensions.

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1f. The twisted tube heat exchanger AlfaTwist installed as a condenser in a power plant in central Sweden. Significantly more efficient than a con-ventional shell & tube heat exchanger, needs less space and the risk for damages of tubes due to corrosion is eliminated. The support construction was also manufactured by Siljan Allards.

1g. Rebuilding of a twisted tube heat exchanger AlfaTwist for a power plant in central Sweden. The steam inlet was modified for increased capacity. The twisted tube bundle in carbon steel was switched to a tube bundle in stainless steel, 1.4301/304. Below the tube bundle with stainless steel tubes. To the left: The heat exchanger installed and ready for its duty during the winter season. This heat exchanger represents the most efficient and reliable on the market: • The geometry of the twisted tube improves the thermal

efficiency and decreases the size of the heat exchanger. • Possible vibration damages of tubes are eliminated

since the twisted tubes support each other along the whole tube length.

• The selection of stainless steel tubes eliminates the cor-rosion of carbon steel tubes.

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1h. The twisted tube heat exchanger Alfa-Twist, with stainless steel tubes, for a po-wer plant in central Sweden Tube bundle above, the complete heat ex-changer below. .

1i. Reconditioning of a heat exchanger installed in a power plant at the west coast of Sweden. Retubed in the work shop, pressure tested and the heat exchanger is as new again.

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1j. Vacuum condenser delivered to a large power plant in southern Sweden. 3421 tubes, Product weight empty: 24 tonnes. At the thermal design, the risk for leakage of air at valves etc was considered. To the left a condensate vessel to be placed below the condenser.

1k. A twisted tube heat exchanger delivered to a power plant in central Sweden.

1l. A shell & tube heat exchanger for a power plant in central Sweden, sent to us for inspec-tion and control.. We performed the control, pressure tested both sides, checked the flange surfaces and the tube bundle. This heat exchanger was in good shape. Our control work was documented, documentation sent to customer.

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2a. Turpentine condenser for a pulp & paper plant in central Sweden. Material: 1.4436/316 high Mo

2b. Shell & tube heat exchanger for a paper mill in northern Swe-den; Material: 1.4435/316L High Mo. 8 passes on the tube side. Co-vers on both sides can be opened, if needed, for cleaning. Davits on both covers.

2c. Shell & tube heat exchanger in 1.4432/316L High Mo, for use as a fil-trate cooler in a paper mill in Chile. The covers at both ends can be opened.

The supports are designed to resist an earthquake.

2. Pulp- & paper industry

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2d. Two shell & tube heat exchangers for cooling of filtrate in a paper mill in norhern Sweden. Multipass design, tubes in the duplex stainless steel 1.4462/S31803, shell and flanges in 1.4432/316L High Mo; The covers can be opened, are equipped with davits. Tube sheets, tube weld-ments and end pieces are polished to avoid fibers sticking to the surfaces.

2e. Floating Head heat exchanger for a paper mill in central Sweden. Tube bundle below. Material: 1.4432/316L high Mo This type of heat exchanger has advantages if the fluid on the shell side is dirty.The tube bundle can easily be drawn out of the shell for cleaning.; The tube side is also easy accessab-le for cleaning.

Below: The floating head heat exchanger with the tube bundle installed inside, pickled surfa-ces, controlled and approved by the notified body, ready for shipment.

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2f. The twisted tube heat ex-changer AlfaTwist, manufac-tured in the stainless steel 1.4432/316L high Mo for the cooling of black liquor; The customer, a paper mill in northern Sweden, has since many years three heat ex-changers of this type, is very satisfied, needed an increasd cooling capacity and ordered one more of the same type. When twisted tubes are used, the fouling is reduced as compared to round tubes. If cleaning still becomes ne-cessary, the covers at both ends are removable and the tubes can be cleaned using a high pressure probe.

2g. Shell & tube heat exchanger for a paper mill in Por-tugal. Manufactu-red in 1.4301/304, diameter 1200 mm. Vertical installa-tion, davit with a special design.

2h. Shell & Tube heat exchanger in 1.4404/316L for a paper mill in Tjeck-ien. Vertical installa-tion, davit with a special design.

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2i. Calorisator after some 20 years of service in a paper mill in southern Sweden.The tu-bes, tube sheets and expansion bellow in 1.4301/304, the shell and baffle plates in carbon steel.

Heavy thinning (general corrosion) and cracks (stress corrosion cracking)) in tubes in the lower part of the heat ex-changer. Also the baffle plate at the bottom end heavily corroded.

A new double expansion bel-low was designed, including calculation of the fatigue life. Siljan Allards has its own manufacturing of bellows, which makes it easier to fit to an existing shell.as well as it decreases the delivery time.

Manufacturing of a new tube bundle in EN 1.4462/S31803 (duplex stainless steel) which has an improved resistance to corrosion. Installation of the tube bundle in the existing shell and tube sheets

After control by a Notified Body, including pressure and X-ray testing, the heat ex-changer is ready for delivery. In a better shape than the original, will function another 20 years!

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2j. Repair of a shell- & tube heat exchanger made in brass; Heavy thinning of tubes after a number of years in service in a paper mill in central Sweden. Some of the documentation was missing. The brass grade of the tubes was determined by electron microscopy. Retubing, tube expanding, pressure testing, Notified Body inspection, documentation and delivery, as new.

2k. Design and manufacturing of a shell & tube heat exchanger for a paper mill in central Sweden. Tube and tube sheets in 1.4404/316L, shell in carbon steel.

2l. Two shell & tube heat exchangers for the heating of white liquor in a paper mill in southern Sweden. Two passes on the tube side. The tube side was manufactured in the stainless steel 1.4307/304L, and the shell side in 1.4436/316 2.5 Mo.

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2m. Reflux and final condenser for a paper mill in northern Swe-den. Manufactured in the stainless steel 1.4404/316L

2n. Repaired hair pin heat ex-changer which had been in service in a paper mill for 20 years. Material: 16Mo3, which is a low alloyed creep resistant steel. After inspection and agreement with the customer, the tubes, one tube sheet and one nozzle were replaced. After inspection by Notified Body, and complete documenta-tion, shipping to customer.

2o. Turpentine cooler for a paper mill in cen-tral Sweden. Manufactured in 1.4404/316L

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2p. Shell & tube heat exchang-er for a paper mill in central Sweden.. Material: Stainless steel, 1.4301/304

2q. Steam reformer/reboiler supplied to a paper mill in northern Sweden. Material: 1.4404/316L

2r. U-tube bundle made in 1.4404/316L for a paper mill in central Sweden.

2s. Twisted tube heat exchanger, AlfaTwist, in 1.4404/316L, during installation in a paper mill in central Sweden.

2t. Condensor made in carbon steel, delivered to a paper mill in northern Sweden. Will be used for heat recovery for central heating in the community.

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3a. Two out of three floa-ting head heat exchangers with tubes in the duplex stainless steel 1.4462/ S31803, other parts in 1.4436/316 2.5 % Mo, for a petrochemical plant on the west coast of Sweden.

Detail of a floating head heat exchanger.

3b. Shell & tube heat ex-changer in 1.4436/316 2.5 % Mo, for a petrochemical plant on the west coast of Sweden.

3c. Two reboilers for the concentra-tion of nitric acid in a chemical plant in central Sweden. The material is 1.4307/304L with a low content of impurities, to resist the corrosivity of this process fluid. Equipped with expansion bellows to handle the thermal expansion.

3. Chemical Industry

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3d. Shell & tube heat exchanger which had been in service for many years in a petrochemical plant on the west coast of Swe-den. Heavy thinning (general corro-sion) of tubes in 1.4404/316L. Retubing with the stainless steel 1.4571/316Ti.

3e. Shell & tube heat exchanger which had been in service for many years in a petrochemical plant on the west coast of Sweden. Heavy thinning (general corrosion) of tubes in 1.4404/316L. Retubing with the high alloyed stainless steel 1.4539/N08904 (20Cr25Ni4.5Mo1.5Cu).

3f. Manufacturing of a u-tube bundle with tubes in the high alloyed stainless steel 1.4539/N08904 (20Cr25Ni4.5Mo1.5Cu) and tube she-et in 1.4404./316L. Replaces an existing tube bundle in a petro-chemical plant on the west coast of Sweden.

3g. Shell & tube heat exchang-er for a petrochemical plant on the west coast of Sweden. Made in the stainless steel 1.4404/316L. Replaces an exchanger which failed due to thermal fatigue. This heat exchanger has been designed to resist thermal ex-pansion in a better way than the old heat exchanger.. The welding procedures were changed to give the welded joints of the shell maximum strength. The shell was also equipped with a double expan-sion bellow.

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3h. Shell & tube heat exchanger manufactured in the stainless steel 1.4404/316L This is a reboiler to be con-nected to a 40 meter high column, also manufactured by Siljan Allards.

3i. U-tube heat exchanger for a chemical plant in northern Sweden. That plant refines by-products from the paper industry.

3j. U-tube heat exchanger made in carbon steel for a chemical plant in southern Sweden.

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3k. U-tube heat exchanger in 1.4404/316L for a petrochemical plant on the west coast of Sweden.

3l. U-tube bundle in 1.4404/316L for two dumping condensers, to be instal-led in a petrochemical plant on the west coast of Sweden.

3m. Twisted tube heat exchanger in 1.4404/316L for a chemical plant in central Sweden.

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4a. Shell & tube heat exchanger in 1.4404/316L for a phar-maceutical plant in cen-tral Sweden.The tubes are electropolished on the inside.

Double tube sheets make the heat exchanger more leak proof.

4b. Twisted tube heat exchanger with tubes in the super duplex stain-less steel 1.4410/S32750 to be installed in a corrosive environment in a food manufacturing plant in southern Sweden.

4. Pharmaceutical and Food Industries

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5a. A tube & shell heat ex-changer with 1.4547/S31254 on the tube side, carbon steel on the shell side, to be used for the concentration of a process fluid containing fluo-rides and chlorides. Installed in vehicle manufacturing plant in southern Sweden.

5b. Tube bundle in the duplex stainless steel 1.4462/S31803 for installation in a steel work in northern Swe-den.

5c. Two shell & tube heat exchangers for a steel mill in central Sweden. Manufactured, inspected, insulated and ready for shipping.

5d. Two u-tube heat exchangers, 200 bars pressure on the shell side. Manufactured in carbon steel.

5. Steel– and metal industry

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5e. Shell & tube heat ex-changer for a casting company in central Sweden. . The whole heat exchanger is manufactured in 1.4404/316L and 1.4432/316L 2.5 % Mo.

5f. U-tube bundle in carbon steel for installation in a steel mill in central Swe-den.

5g. One out of four recuperators for heat recovery in a direct re-duction plant in Malaysia. Tubes in 1.4876/N08810 och 1.4835/S30815, bent to accomo-date thermal expansion. Tube sheets and end pieces in 1.4835/S30815. Delivered in 1995, excellent per-formance.

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6a. Small, compact heat exchanger in 1.4301/304, for a mobile equipment within the transport industry.

6b. Similar application as for 6a.

6. Other applications

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Examples of manufacturing steps

TIG-orbit tube-to-tube sheet welding; Efficient, highest quality.

Weldments after TIG-orbit wel-ding.; highest quality.

Expansion of tubes into tube sheet. Close control of expan-sion force. Measurements of the expansion using special instru-ments.

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You are welcome to contact us for more information.

Siljan Allards AB Brändavägen, SE-79532 Rättvik, Sweden; Tel: +46 248 12535; Fax: +46 248 13785 E-mail: info@siljanallards.com Web site: www.siljanallards.com

Short about quality and technique Quality assurance: We apply the quality system, ISO 9001-2000, for welding EN 729-2. Thermal design: We use the design pro-gram HTFS /Aspentech, which regularly is updated. Vibration control is always made. Mechanical design: We use the Visual Ves-sel Design program, regularly updated. We can perform calculations according to ; PED 97/23/EC-EN 13445, PD5500:2000 and ASME. Welding: We have welding procedures for about 550 combinations of materials, di-mensions, geometries, welding methods and standards. Welding methods: GTAW, MAW, GMAW, PAW and UP welding. Mechanized welding is performed to a large extent. Welding qualifications according to EN 288-3 EN 288-6 PD 5500 ASME Norsok M 601 och 602 NACE AD Merkblatt HP 2/1 Materials: Carbon steel, low alloyed steel, stainless standard and special steels, nickel base alloys and high temperature materials.