Temperature Gradient Impact on Heat Exchanger Leaks Using CFD Analysis

– Heat exchanger leaks are common failures in gas and oil industry. However, the root causes of failure are not always obvious to identify. Therefore, utilizing advanced analysis tools such as computational fluid dynamics and finite element analysis are vital to better understand the problem. Here, we discuss a real case of a heat exchanger facing repeated leaks in an oil and gas industry. Detailed computational fluid dynamics analysis is used to determine the impact of temperature gradient on displacement of the heater flanges and gaskets. The simulated conditions include 5 steady-state and transient operating conditions. The analysis results show that thermal expansion cause loss of bolt load and further reduces gasket contact pressure. Maximum gasket scuffing due to differential radial thermal expansion could result in gasket damage over repeated thermal cycles. This finding is the most likely root cause of the repeated heater leaks. The results discuss additional potential root causes of the leaks mainly related to gasket damage due to thermal expansion behavior. The results of this work will be used for future work utilizing finite element analysis tools.