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Safety heat exchanger
Type VEV / VEV-L Safety Heat Exchangers with Double Tubes (U-tube heat exchangers, straight-tube heat exchangers, available in vertical and horizontal configurations, removable or fully welded)
Our safety heat exchangers are frequently used in the chemical and pharmaceutical industries, the food industry, as well as in shipbuilding and power generation. They are particularly common in areas where safety heat exchangers are required for chemical processes or for gas supply. Risks such as potential contamination of cooling or process water are avoided, and damage caused by mixing of the media is prevented.
This is ensured by a double-pipe system featuring a monitored safety chamber. The use of VEV-DRsafety heat exchanger models in semiconductor manufacturing ensures safe operation even under extreme conditions.
A typical application for Thielmann’s safety heat exchangers is in working environments with high pressures and extreme temperatures, such as those found in gas preheating or in safety heat exchangers for critical applications. In the event of a tube failure, the medium enters the interstitial space. This allows leaks to be detected early and prevents unwanted mixing of media.
This is ensured by a double-pipe system featuring a monitored safety chamber. The use of VEV-DRsafety heat exchanger models in semiconductor manufacturing ensures safe operation even under extreme conditions.
A typical application for Thielmann’s safety heat exchangers is in working environments with high pressures and extreme temperatures, such as those found in gas preheating or in safety heat exchangers for critical applications. In the event of a tube failure, the medium enters the interstitial space. This allows leaks to be detected early and prevents unwanted mixing of media.
Features of Safety Heat Exchangers
- Optimal load case design
- Flow-optimized design
- Vibration-optimized design
- Type VEV / VEV-L
- U-tube heat exchanger design
- Straight-tube heat exchanger
- Vertical and horizontal configurations
- Pull-out or fully welded
E-1000 Thielmann Energietechnik GmbH
Features of Our Safety Heat Exchangers
- Customized design for other regulations (ASME, EN 13445, SVTI, AS1210, PD5500 etc.)
- Design according to TEMA
- Customer-specific approvals
- Customer-specific tests
- Application for sour gas (NACE)
- Design for low temperatures down to -50 °C
- Design pressure up to 300 bar
- Customized nozzle arrangement
Safety Heat Exchangers: General Information
How Our Safety Heat Exchangers Work
Unlike standard VEV/VEV-L shell-and-tube heat exchangers with a single-tube design, the tubes in our double-tube safety heat exchangers, VEV-DR safety heat exchanger or VEV-L-DR safety heat exchanger, have a double tube wall consisting of an inner and an outer tube. In addition, there are two tube sheets on each side.
If the inner tube is damaged, the containment medium flows through the leakage channels between the double tubes into the leakage chamber between the two tube sheets and triggers an alarm in the leakage sensor due to a pressure differential.
The GTS differential pressure gauge can also display this pressure difference and help ensure clear leak detection. Since the second tube wall is undamaged, the two media remain separate in the media-separated heat exchanger.
This prevents contamination of the processes and associated equipment, allowing the plant operator to keep the shell-and-tube heat exchanger with a safety chamber in operation until the next maintenance. This avoids costly, unplanned downtime.
If the inner tube is damaged, the containment medium flows through the leakage channels between the double tubes into the leakage chamber between the two tube sheets and triggers an alarm in the leakage sensor due to a pressure differential.
The GTS differential pressure gauge can also display this pressure difference and help ensure clear leak detection. Since the second tube wall is undamaged, the two media remain separate in the media-separated heat exchanger.
This prevents contamination of the processes and associated equipment, allowing the plant operator to keep the shell-and-tube heat exchanger with a safety chamber in operation until the next maintenance. This avoids costly, unplanned downtime.
E-1000 Thielmann Energietechnik GmbH
Quality management
- DIN EN ISO 9001 certified manufacturer
- Our appliances are tested in accordance with AD 2000 regulations and CE-certified in accordance with EC/PED 2014/68/EU. Testing is carried out by approved experts (TÜV, Lloyd's Register etc.).
- Test and material certificates are issued by the experts in accordance with the design regulations.
Accessories for Our Safety Heat Exchangers
on request
- Water SAV safety shut-off valve (water jacket pressure-resistant)
- Water SBV safety blow-off valve (water jacket not pressure-resistant)
- Rupture disk, water side (water jacket not pressure-resistant)
Your contact persons
Distribution / Sales
Safety heat exchangers for media-separated heat transfer in industrial processes
Certified safety heat exchangers for industrial use are essential components in industrial processes that require reliable heat exchange of gaseous or liquid media. As industrial heat exchangers with safety features—in particular, safety double-pipe heat exchangers and heat exchangers with leak detection—they ensure the safe and efficient transfer of thermal energy between different material streams and offer the highest level of operational safety, especially in sensitive applications.
Safety heat exchangers are designed for all gaseous and liquid media, including natural gas, biogas, hydrogen, process gas, LNG, nitrogen, air, water, as well as glycol and glycol mixtures. These industrial safety heat exchangers are used in a wide variety of industrial sectors, including the chemical, petrochemical, and polymer industries; natural gas production; the food industry; shipbuilding; and maritime and industrial applications. Thanks to their robust construction and high corrosion resistance, they are also suitable for special applications where the highest level of process safety is required.
Depending on process requirements, safety heat exchangers for gas enable the heating, superheating, or cooling of media, thereby contributing to the optimal control of thermal processes. Their special double-wall tube design prevents unintended mixing of media and ensures maximum operational safety. Thanks to innovative technologies and high-quality materials, they offer a durable solution for demanding thermodynamic tasks across a wide range of industries.
Safety heat exchangers are designed for all gaseous and liquid media, including natural gas, biogas, hydrogen, process gas, LNG, nitrogen, air, water, as well as glycol and glycol mixtures. These industrial safety heat exchangers are used in a wide variety of industrial sectors, including the chemical, petrochemical, and polymer industries; natural gas production; the food industry; shipbuilding; and maritime and industrial applications. Thanks to their robust construction and high corrosion resistance, they are also suitable for special applications where the highest level of process safety is required.
Depending on process requirements, safety heat exchangers for gas enable the heating, superheating, or cooling of media, thereby contributing to the optimal control of thermal processes. Their special double-wall tube design prevents unintended mixing of media and ensures maximum operational safety. Thanks to innovative technologies and high-quality materials, they offer a durable solution for demanding thermodynamic tasks across a wide range of industries.
Applications of Safety Heat Exchangers in Industry and Process Engineering
1. Chemical and Petrochemical Industry
2. Oil and Gas Industry
3. Power Plants
4. Food and Beverage Industry
5. Marine and shipping industry
6. HVAC and Air Conditioning / District Heating and Cooling / Refrigeration Technology for Distribution Warehouses / Distribution Centers
7. Metal and steel industry
- Reactor cooling: Shell-and-tube safety heat exchangers are used for temperature control in chemical processes to maintain reactors at an optimal temperature.
- Heat recovery: Utilization of waste heat from chemical processes to preheat other process media.
- Distillation: They are used in distillation columns as safety heat exchangers for condensing vapors or heating mixtures.
2. Oil and Gas Industry
- Condensation of steam in refineries: In refineries, they condense water vapor or other process gases.
- Cooling of lubricating oils: RBWTs help control the operating temperature of machinery by cooling oils within the tube bundle.
- Natural gas processing: Heat exchangers for safety applications are used as safety heat exchangers for gas preheating to heat or cool the gas before it is further processed.
3. Power Plants
- Steam-water cycles: Safety heat exchangers for power plants are used for heat recovery from exhaust gases or for heating feedwater.
- Condensers for steam turbines: They condense the steam exiting the turbine on either the shell side or the tube side.
- District heating transmission: In district heating networks, they function as media-separated heat exchangers to facilitate heat exchange between primary and secondary circuits.
4. Food and Beverage Industry
- Pasteurization of milk and juices: Heating and cooling of liquids using double-wall tube heat exchangers for preservation.
- Heating of process water: Used in breweries and dairies for temperature control with double-walled heat exchangers.
- Cooling of production equipment: Shell-and-tube heat exchangers help maintain a stable operating temperature for machinery.
5. Marine and shipping industry
- Cooling of marine engines: Shell-and-tube heat exchangers are used to cool engines, generators, and lubricants in steel-welded structures.
- Seawater cooling systems: Seawater is used as a cooling medium to regulate the operating temperature of equipment on ships via a double-pipe system.
6. HVAC and Air Conditioning / District Heating and Cooling / Refrigeration Technology for Distribution Warehouses / Distribution Centers
- Building cooling and heating: They are used as safety heat exchangers for heat recovery in ventilation systems or air conditioning systems.
- Industrial cooling systems: Shell-and-tube heat exchangers help operate large cooling circuits efficiently as counterflow shell-and-tube heat exchangers.
7. Metal and steel industry
- Cooling of furnaces and rolling mills: Shell-and-tube heat exchangers are used to efficiently remove process heat.
- Heating of metal solutions: In electroplating or in chemical baths with a safety chamber and leakage channels for temperature control.
Industries That Use Safety Heat Exchangers
Safety heat exchangers are essential components in thermal processes and are used in a wide range of industries. They enable safe and efficient heat exchange in systems where the highest level of operational safety is required. Thanks to their robust construction and application-specific designs, they are particularly well-suited for demanding industries where thermal processes must be reliably controlled.
Machinery and Plant Engineering
Inmachinery and plant engineering, safety heat exchangers play a central role in temperature control across a wide variety of systems. They ensure the precise heating, cooling, or superheating of process media and contribute significantly to the efficiency and longevity of machines and production facilities. Thanks to their high resistance to thermal and mechanical stresses, they guarantee long-term operational reliability.
Chemical, Petrochemical, and Polymer Industries
Safety heat exchangers are indispensable in the chemical industry, the petrochemical industry, and polymer plants. They are used for the thermal treatment of process gases and liquids to precisely control chemical reactions. These applications often involve aggressive media and high temperatures, which is why safety heat exchangers are manufactured from corrosion-resistant materials. In petrochemical plants, they also support the processing of crude oil and the production of petrochemical products by efficiently regulating the temperature of process streams.
Natural gas production
In natural gas production, as well as in the further processing and distribution of natural gas, safety heat exchangers are used to control the temperature of gas streams. Since natural gas processing often takes place under extreme environmental conditions, the heat exchangers must withstand high pressures and temperature fluctuations. For example, they are used in the dehumidification and conditioning of natural gas as safety heat exchangers for gas preheating to enable safe further processing.
Food Industry
In the food industry, precise temperature control is essential for product quality and safety. Safety heat exchangers are used here for the heat treatment of liquids and process media, for example in pasteurization systems or for maintaining the temperature of raw materials. Hygiene standards are particularly high in this industry, which is why the heat exchangers are often made of food-grade, corrosion-resistant materials and meet strict cleanliness requirements.
Shipbuilding and Maritime Applications
Shipbuilding places high demands on the operational safety and efficiency of technical systems. Safety heat exchangers are used in maritime applications to ensure heat transfer in cooling and propulsion systems. They are used, for example, in engine cooling, in air conditioning systems, or for waste heat recovery from ship propulsion systems. Their resistance to saltwater and harsh environmental conditions is a crucial factor in ensuring a long service life.
Industrial and Special Applications
In industry, safety heat exchangers are used in virtually all areas where thermal energy must be transferred efficiently. They are used in heating and cooling systems, in production processes, and in power generation as media-separated heat exchangers. Depending on the application, they are designed for high pressure and temperature ranges and are manufactured from special materials to meet the respective operating conditions.
In addition, there are numerous specialized applications in which safety heat exchangers play a key role. These include, for example, applications in the semiconductor industry, pharmaceutical production, or high-temperature processes. Here, customized solutions are required that meet the highest standards for safety and performance.
Process Industry
In the process industry, safety heat exchangers are an integral part of many production facilities. They enable precise temperature control and thus contribute to process stability and product quality. Since requirements in the process industry vary greatly depending on the sector, there are a wide variety of heat exchanger types, including double-pipe heat exchangers and safety heat exchangers, which are specifically adapted to the respective operating conditions.
Machinery and Plant Engineering
Inmachinery and plant engineering, safety heat exchangers play a central role in temperature control across a wide variety of systems. They ensure the precise heating, cooling, or superheating of process media and contribute significantly to the efficiency and longevity of machines and production facilities. Thanks to their high resistance to thermal and mechanical stresses, they guarantee long-term operational reliability.
Chemical, Petrochemical, and Polymer Industries
Safety heat exchangers are indispensable in the chemical industry, the petrochemical industry, and polymer plants. They are used for the thermal treatment of process gases and liquids to precisely control chemical reactions. These applications often involve aggressive media and high temperatures, which is why safety heat exchangers are manufactured from corrosion-resistant materials. In petrochemical plants, they also support the processing of crude oil and the production of petrochemical products by efficiently regulating the temperature of process streams.
Natural gas production
In natural gas production, as well as in the further processing and distribution of natural gas, safety heat exchangers are used to control the temperature of gas streams. Since natural gas processing often takes place under extreme environmental conditions, the heat exchangers must withstand high pressures and temperature fluctuations. For example, they are used in the dehumidification and conditioning of natural gas as safety heat exchangers for gas preheating to enable safe further processing.
Food Industry
In the food industry, precise temperature control is essential for product quality and safety. Safety heat exchangers are used here for the heat treatment of liquids and process media, for example in pasteurization systems or for maintaining the temperature of raw materials. Hygiene standards are particularly high in this industry, which is why the heat exchangers are often made of food-grade, corrosion-resistant materials and meet strict cleanliness requirements.
Shipbuilding and Maritime Applications
Shipbuilding places high demands on the operational safety and efficiency of technical systems. Safety heat exchangers are used in maritime applications to ensure heat transfer in cooling and propulsion systems. They are used, for example, in engine cooling, in air conditioning systems, or for waste heat recovery from ship propulsion systems. Their resistance to saltwater and harsh environmental conditions is a crucial factor in ensuring a long service life.
Industrial and Special Applications
In industry, safety heat exchangers are used in virtually all areas where thermal energy must be transferred efficiently. They are used in heating and cooling systems, in production processes, and in power generation as media-separated heat exchangers. Depending on the application, they are designed for high pressure and temperature ranges and are manufactured from special materials to meet the respective operating conditions.
In addition, there are numerous specialized applications in which safety heat exchangers play a key role. These include, for example, applications in the semiconductor industry, pharmaceutical production, or high-temperature processes. Here, customized solutions are required that meet the highest standards for safety and performance.
Process Industry
In the process industry, safety heat exchangers are an integral part of many production facilities. They enable precise temperature control and thus contribute to process stability and product quality. Since requirements in the process industry vary greatly depending on the sector, there are a wide variety of heat exchanger types, including double-pipe heat exchangers and safety heat exchangers, which are specifically adapted to the respective operating conditions.
Technical Requirements and Standards for Safety Heat Exchangers
Safety heat exchangers must meet the highest technical requirements and function reliably in a wide range of industrial applications. Specific regulations, approvals, and tests, as well as design and operational parameters in the double-pipe system , play a central role in this regard. To meet the individual requirements of various industries and markets, designs are tailored to each customer while taking all relevant norms and standards into account.
Standards and International Regulations
Safety heat exchangers must comply with the requirements of various national and international regulations. Depending on the application and market requirements, the following standards may apply:
These regulations ensure that the safety heat exchangers meet the highest safety and quality requirements and can be used worldwide in various industries.
Customer-specific approvals and inspections
Many industries require customized acceptance and testing by independent testing organizations or companies with specific requirements. Safety heat exchangers can be manufactured and tested in accordance with the specifications of renowned customers and institutions, including:
These tests ensure that the heat exchangers operate reliably even under the most demanding operating conditions and meet the highest safety requirements.
Use in Special Operating Environments
Safety heat exchangers often have to withstand extreme conditions. Therefore, the design and material selection are tailored to the specific operating requirements:
High-pressure and high-temperature ranges:
Custom design and connection configuration
Depending on the application, safety heat exchangers can be manufactured with a customer-specific nozzle arrangement on both the shell side and the tube side. This enables flexible integration into existing systems and ensures optimal adaptation to specific process requirements. A shell side designed to withstand inlet pressure can also be incorporated to meet specific system requirements.
Standards and International Regulations
Safety heat exchangers must comply with the requirements of various national and international regulations. Depending on the application and market requirements, the following standards may apply:
- ASME (with or without a U-stamp) for the international market, particularly for the U.S. and North America
- EN 13445 for the European market, as the authoritative standard for unheated pressure vessels
- SVTI for Switzerland, with specific requirements for pressure equipment and safety devices
- AS 1210 for Australia, as the standard for pressure vessels in the industrial sector
- PD 5500 for the British market, with specific calculation and design requirements
These regulations ensure that the safety heat exchangers meet the highest safety and quality requirements and can be used worldwide in various industries.
Customer-specific approvals and inspections
Many industries require customized acceptance and testing by independent testing organizations or companies with specific requirements. Safety heat exchangers can be manufactured and tested in accordance with the specifications of renowned customers and institutions, including:
- BASF, OGE, Gascade, Sasol, INGL, ERI, Dolphin, Saudi Aramco, Gasco, MAN, Jenbacher, MAPNA, Siemens, DONG, TEMA, and many more.
These tests ensure that the heat exchangers operate reliably even under the most demanding operating conditions and meet the highest safety requirements.
Use in Special Operating Environments
Safety heat exchangers often have to withstand extreme conditions. Therefore, the design and material selection are tailored to the specific operating requirements:
- Sulfur-containing gas applications (NACE): Heat exchangers operated in environments containing hydrogen sulfide (H₂S) must meet specific requirements of the NACE standards to prevent corrosion damage and material failure.
- Low-temperature applications: Designed for low operating temperatures down to -50 °C, for example, for processing liquefied gases such as LNG or cryogenic applications.
High-pressure and high-temperature ranges:
- Design pressure up to 300 bar, ideal for high-pressure safety heat exchangers in the process and gas industries.
- Design temperature up to 250 °C to ensure efficient heat transfer even at high process temperatures.
Custom design and connection configuration
Depending on the application, safety heat exchangers can be manufactured with a customer-specific nozzle arrangement on both the shell side and the tube side. This enables flexible integration into existing systems and ensures optimal adaptation to specific process requirements. A shell side designed to withstand inlet pressure can also be incorporated to meet specific system requirements.
Materials Used in Our Safety Heat Exchangers
Safety heat exchangers can be manufactured from various materials to meet the specific requirements of each application. A wide variety of materials makes it possible to optimally adapt the heat exchangers to operating conditions and ensure high resistance to mechanical, thermal, and chemical influences. As a supplier of safety heat exchangers, we offer a wide range of solutions manufactured from various materials to meet the specific requirements of each application in a double-pipe system.
Carbon steel is frequently used when high mechanical strength and pressure resistance are required. This material offers good thermal conductivity and is particularly cost-effective to manufacture. It is especially suitable for applications that do not require high corrosion resistance.
Stainless steel, on the other hand, is used in environments where aggressive media, moisture, or high hygiene standards play a decisive role. In safety heat exchangers for gas preheating, it is characterized by excellent corrosion resistance and high temperature resistance, making it suitable for demanding industrial processes. Stainless steel also ensures a long service life for the heat exchanger and reduces the risk of deposits or material failure.
In some cases, safety heat exchangers are manufactured from a combination of carbon steel and stainless steel. This combines the mechanical advantages of carbon steel with the corrosion resistance of stainless steel. These hybrid solutions offer a cost-effective yet high-performance alternative by combining the structural stability of carbon steel with the durability of stainless steel in areas in contact with the medium, such as the inner and outer tubes.
Choosing the right material is crucial for the operational safety and service life of a safety heat exchanger. Depending on the requirements, materials are specifically selected to ensure optimal performance and resistance to thermal, chemical, and mechanical stresses in safety double-pipe heat exchangers.
Carbon steel is frequently used when high mechanical strength and pressure resistance are required. This material offers good thermal conductivity and is particularly cost-effective to manufacture. It is especially suitable for applications that do not require high corrosion resistance.
Stainless steel, on the other hand, is used in environments where aggressive media, moisture, or high hygiene standards play a decisive role. In safety heat exchangers for gas preheating, it is characterized by excellent corrosion resistance and high temperature resistance, making it suitable for demanding industrial processes. Stainless steel also ensures a long service life for the heat exchanger and reduces the risk of deposits or material failure.
In some cases, safety heat exchangers are manufactured from a combination of carbon steel and stainless steel. This combines the mechanical advantages of carbon steel with the corrosion resistance of stainless steel. These hybrid solutions offer a cost-effective yet high-performance alternative by combining the structural stability of carbon steel with the durability of stainless steel in areas in contact with the medium, such as the inner and outer tubes.
Choosing the right material is crucial for the operational safety and service life of a safety heat exchanger. Depending on the requirements, materials are specifically selected to ensure optimal performance and resistance to thermal, chemical, and mechanical stresses in safety double-pipe heat exchangers.
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