Exchanger Piping PDF

BECHTEL CORPORATION
ENGINEERING – PLANT DESIGN

DESIGN GUIDE
EXCHANGER PIPING
3DG-P22-00004, Revision 002, 2002 July 23
Reason for Issue: Issued for Use
Prepared by: B. Tarr
Checked by: P.R.Wood
Approved by: R. Fox
INTRODUCTION
This Engineering Design Guide explains the different types of heat exchangers that are most
commonly used in facilities.
It addresses locations, elevation requirements, nozzle locations, exchanger supporting, associated

piping supports, maintenance and operation access.
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to the electronic documents in BecRef for current revisions.
Bechtel Confidential
© Bechtel Corporation 2002. Contains confidential and/or proprietary information to Bechtel and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission. All rights reserved.
3DG-P22-00004-002 Page 1 of 52
TABLE OF CONTENTS
INTRODUCTION ...................................................................................................................... 1
LIST OF FIGURES ................................................................................................................... 5
1.0 PURPOSE ....................................................................................................................... 7
2.0 EXCLUSIONS.................................................................................................................. 7
3.0 DISCUSSION................................................................................................................... 7
3.1 SAFETY........................................................................................................................... 7
3.2 OPERATION.................................................................................................................... 7
3.3 MAINTENANCE............................................................................................................... 7
4.0 TERMINOLOGY .............................................................................................................. 7
5.0 BASICS OF HEAT TRANSFER ...................................................................................... 9
6.0 TYPES OF EXCHANGERS ........................................................................................... 10
6.1 SHELL & TUBE............................................................................................................. 10
6.2 DOUBLE PIPE EXCHANGERS..................................................................................... 18
6.3 AIR COOLERS ............................................................................................................. 18
6.4 OTHER EXCHANGER TYPES..................................................................................... 20
7.0 EXCHANGER PLOT LOCATION AND ELEVATION OF EXCHANGERS.................... 24
7.1 SHELL & TUBE ARRANGEMENTS ............................................................................. 24
7.2 LOCATION BY ASSOCIATION..................................................................................... 24
7.3 EXCHANGER BATTERY ARRANGEMENTS............................................................... 27
7.4 ELBOW NOZZLES TO REDUCE SHELL ELEVATION................................................ 28
7.5 EXCHANGERS WITH CONDENSATE POTS ............................................................... 28
7.6 REBOILERS WITH CONDENSATE POTS ................................................................... 30

Bechtel Confidential © Bechtel Corporation 1995, 2002. All rights reserved.
Engineering Design Guide – Exchanger Piping
3DG-P22-00004-002 Page 2 of 52
7.7 DOUBLE PIPE EXCHANGERS..................................................................................... 30
7.8 RACK MOUNTED AIR COOLERS................................................................................ 30
8.0 SHELL AND TUBE NOZZLE LOCATION & NOZZLE TYPE ....................................... 33
8.1 SHELL & TUBE NOZZLE LOCATION OPTIONS......................................................... 33
8.2 SHELL & TUBE NOZZLE ORIENTATION OPTIONS................................................... 34
8.3 NOZZLE LOCATION WITH RESPECT TO FLOW ....................................................... 35
8.4 AIR COOLERS .............................................................................................................. 35
9.0 SUPPORTS ................................................................................................................... 37
9.1 SHELL & TUBE............................................................................................................. 37
9.2 SPACE FRAMES OR SPACERS .................................................................................. 38
9.3 SADDLE / FOUNDATION CLEARANCES.................................................................... 39
9.4 SHELL & TUBE PIPE SUPPORT LOCATIONS ........................................................... 40
9.5 VERTICAL REBOILER SUPPORTS ............................................................................. 41
9.6 AIR COOLER SUPPORTS............................................................................................ 42
10.0 MAINTENANCE AND OPERATIONAL ACCESS ......................................................... 43
10.1 SHELL & TUBE............................................................................................................. 43
10.2 BUNDLE EXTRACTOR................................................................................................. 46
10.3 CLEARANCES .............................................................................................................. 47
10.4 STACKED EXCHANGERS............................................................................................ 47
10.5 CRANE ACCESS........................................................................................................... 47
10.6 AIR COOLERS .............................................................................................................. 47
10.7 AIR COOLER HEADER BOX ACCESS ........................................................................ 48
10.8 PLATFORM OPTIONS FOR AIR COOLER MOTOR ACCESS .................................... 49
11.0 PIPE STRESS............................................................................................................. 50

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11.1 EXCHANGER ANCHOR LOCATION ............................................................................ 50
11.2 SHELL & TUBE NOZZLE LOADS ................................................................................ 51
11.3 AIR COOLER NOZZLE LOADS.................................................................................... 51
12.0 REFERENCES............................................................................................................ 52
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LIST OF FIGURES
Figure 1 Standard Counterflow Patterns for Shell & Tube ................................................. 9

Figure 2 Exchanger Nomenclature................................................................................... 12
Figure 3 Shell & Tube Fabrication Tolerances................................................................. 14
Figure 4 Shell & Tube Fabrication Tolerances................................................................. 15
Figure 5 Vertical Vessel Mounted Reboilers .................................................................... 16
Figure 6 Condensate Pot Effect on Tower ....................................................................... 17
Figure 7 Vertical Direct Mount Condenser ....................................................................... 17
Figure 8 Double Pipe Exchanger Components ................................................................ 18
Figure 9 Air Cooler Header Box Types ............................................................................ 19
Figure 10 Air Cooler Components...................................................................................... 20
Figure 11 Stab-in Reboiler ................................................................................................. 21
Figure 12 Spiral Exchanger................................................................................................ 21
Figure 13 Plate Exchanger................................................................................................. 22
Figure 14 Aluminum Core Exchanger ................................................................................ 23
Figure 15 Core Exchanger Insulation................................................................................. 23
Figure 16 Standard Piping Arrangements for Shell & Tube Exchangers ........................... 24
Figure 17 Exchanger Placement ........................................................................................ 27
Figure 18 Arrangement of Exchanger Batteries ................................................................. 28
Figure 19 Elbow Nozzles ................................................................................................... 28
Figure 20 Alternative to Vertical Condensate Pot .............................................................. 29
Figure 21 Condensate Pot Piping Arrangement ................................................................ 29
Figure 22 Double Pipe Exchanger – Method of Support.................................................... 30
Figure 23 Conventional Platform Design for Air Coolers ................................................... 31
Figure 24 Air Cooler Supports ........................................................................................... 32
Figure 25 Nozzle Adjustments to Standard Exchangers .................................................... 33
Figure 26 Possible Nozzle Arrangements for Shell & Tubes ............................................. 34
Figure 27 Change Nozzles to Improve Routing ................................................................. 35
Figure 28 Change Flow to Improve Routing ...................................................................... 35
Figure 29 Odd or Even Pass Air Coolers ........................................................................... 36
Figure 30 Standard Air Cooler Piping Arrangements......................................................... 36
Figure 31 Inserts for Air Coolers ........................................................................................ 37
Figure 32 Shell & Tubes at Grade with Same U/G Cooling Water Supply ........................ 38
Figure 33 Shell & Tubes on Elevated Platform .................................................................. 38
Figure 34 Space Framing................................................................................................... 39
Figure 35 Clearances for Shell & Tube Exchangers .......................................................... 40
Figure 36 Support Design for Piping at Shell & Tube ........................................................ 41
Figure 37 Vertical Reboilers............................................................................................... 42
Figure 38 Air Cooler Supports ........................................................................................... 43
Figure 39 Shell & Tube Exchanger Access........................................................................ 44
Figure 40 Tube Pulling Requirements ............................................................................... 45
Figure 41 Tube Bundle Extractor ....................................................................................... 46
Figure 42 Crane Access..................................................................................................... 47
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Figure 43 Plugged Header Box.......................................................................................... 48
LIST OF FIGURES (contd.)
Figure 44 Air Cooler Platforming Alternatives.................................................................... 50

Figure 45 Slotted Holes for Shell & Tubes......................................................................... 51
Figure 46 Lateral Stresses on Air Cooler Nozzles ............................................................. 52
Figure 47 Spring Supports for Air Coolers ......................................................................... 52
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1.0 PURPOSE
To provide the layout designer with guidelines for the development of piping design for non-
fired heat transfer exchangers.
2.0 EXCLUSIONS
All or part of this guide may be superseded by client mandatory standards or by the codes and
regulations imposed by governmental jurisdictions covering the location where the piping is
installed.
3.0 DISCUSSION
3.1 SAFETY
Proper consideration for personnel safety around exchangers requires arranging piping and
valves in a manner that does not obstruct access for operation, maintenance or egress.
3.2 OPERATION
Exchangers normally require minimal attention during operation. Valves however, must be located
for easy access. Where valves cannot be operated from grade, chain operators shall be used. If
chain operators are not allowed per client specifications, platform access to valves shall be
considered.
3.3 MAINTENANCE
Piping shall be arranged in a manner to allow adequate access to removable channel covers
without requiring excessive dismantling of the piping system. The bolting connecting the channel
cover to the shell must be easily accessed in order to pull the tube bundle. Consideration shall be
given for clearances in all directions for the use of bundle extractors (10.2).
4.0 TERMINOLOGY
Baffles: Partial interior walls set within the shell of an exchanger to redirect the flow in the
exchanger to maximize contact time and thereby increase heat transfer (Fig. 1).
Bundle: A group of tubes connected to common inlet and outlet head/heads. Bundles are usually
associated with shell and tube type exchangers (Fig. 1), though at times they may be used
independent of a shell (as in the case of stab-in heaters) (Fig. 11).
Cell: A grouping of tubes connected to common inlet and outlet manifold boxes. Cells are
usually associated with air coolers.
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Conduction: The ability of an object to pass (conduct) heat through its molecular structure; the
distribution or transfer of heat (energy) from one end of an object or from one object to another
through physical contact.
Convection: The mixing action that occurs in any heated fluid (heated fluid rises displacing
cool fluid which falls replacing heated fluid); the transfer of heat within a fluid or from one fluid to
another by means of the thermal mixing action.
Fins: Appendages affixed to the outer skin of tubes to augment their surface area to increase
contact time and thereby heat transfer.
Forced draft: A method of tube cooling in which fan driven air is blown directly through a tube cell
(Fig. 10).
Induced draft: A method of tube cooling in which fan drawn air is pulled (induced) through a
tube cell (Fig. 10).
Parallel: A method of interconnection of exchangers in which the flow stream is split between
two or more exchangers capable of operating independently either simultaneously or in back-up
of each other. Exchangers in parallel usually can be isolated from the flow stream to allow for
maintenance or for temperature or output control (Fig. 16).
Series: A method of interconnection of exchangers in which the flow stream must past through
each exchanger in sequence. Exchangers operating in series are treated as one system
component and usually cannot be isolated without shutdown of the system (Fig. 16).
Shell: Closed conduit used to convey a medium around a set of tubes for the purpose of heat
transfer between that medium and one being conveyed by the tubes (Fig. 1).
TEMA: The Tubular Exchanger Manufacturers Association, an industrial association which has
published standards for the design and manufacture of tubular exchangers (Fig. 2).
Thermosiphon: A method of circulation based on a heated fluid's tendency to rise. This method
of circulation is used most often in boiler and reboiler systems.
Tubes: Closed conduit for a single heating/cooling media most often used in conjunction with a
sealed outer conduit (shell), but may also be used in open contact with atmospheric
cooling/heating media. They are also often referred to as channels (Fig. 1).
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5.0 BASICS OF HEAT TRANSFER
The most common method of heat transfer from one fluid to another in a process environment
is by the use of exchangers. Exchangers, while varying greatly in design, all operate on the
same principle. The principle that heat (energy) tends to equalize by dissipation. That is that
heated objects try to equalize their temperature by transmitting their heat to surrounding
cooler objects. This is similar to a liquid seeking its own level. Hot objects try to transmit their
heat to any cooler objects around them, which in turn tend to absorb that heat. All exchangers
employ this principle by using one or more of three heat transfer methods; conduction,
convection and radiation.
The tendency of the heated portions of a fluid to rise dictates the most common pattern of flow in
exchanger piping. That pattern is for the fluid receiving heat to flow up through the exchanger and
the fluid expending heat to flow down (Fig. 1).
Figure 1 Standard Counterflow Patterns for Shell & Tube
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6.0 TYPES OF EXCHANGERS
While often referred to by their design and construction characteristics, exchangers are most
frequently identified by their process function. The following is a listing of process names often
assigned exchangers relative to their function:
Exchanger: Heats one stream while cooling another (Very efficient in that there is no waste heat
loss).
Cooler: Cools liquids or gases without condensation.
Subcooler: Condenses vapor and further cools the condensate using water as a cooling medium.
Condenser: Cools a vapor to its dew point in order to extract condensate from it.
Chiller: Uses refrigerants to cool a stream below the standard temperature of available cooling
water streams.
Heater: Heats process stream (generally to its boiling point) with no appreciable vaporization
(often uses steam as heating medium).
Reboiler: Reboils (vaporizes) the bottom stream of a fractionating tower prior to its return to the
tower. Often employs thermosiphon phenomenon rather than any mechanical flow enhancement.
Waste Heat Boiler: Uses waste heat (i.e., gas-turbine exhaust) as a heating medium.
Steam Generator: Uses process liquids or gases to produce steam (usually from boiler feed
water).
Vaporizer: Vaporizes part of a process stream (also called an evaporator).
6.1 SHELL & TUBE
The most common heat exchanger encountered in any process or power plant is the shell and
tube exchanger. These exchangers, because of their reliability, low maintenance, and durability,
generally offer the most economical method of heat control and transfer, while their "no moving
parts" simple means of operation can be very efficient.
They operate by conducting one fluid stream through the channel (tube) head of the exchanger
into a set of tubes (the bundle) that is encased within the exchanger shell. A second fluid is
simultaneously directed through the shell (usually in the opposite direction) while maintaining
contact with the tubes. The heat transfer is effected through the tube walls without the fluids
coming in direct contact with each other.
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6.1.1 Conventional TEMA Exchangers
Of shell and tube exchangers the most common are those designed to meet TEMA standards of
design and construction (Fig. 2).
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Figure 2 Exchanger Nomenclature
TEMA exchangers offer the following:
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Economy: they can be varied in size in accordance with the heat transfer required thereby utilizing
the minimal material for the maximum result; they can handle large flow rates with a large range of
pressure ratings; they can often reduce waste heat by heating one flow stream while cooling
another.
Maintenance: standardization allows standardized maintenance procedures with more readily

obtainable parts; few parts subject to failure; minimal assembly/disassembly requirements.
Efficiency: by “multiple pass series flow” these exchangers offer an almost unlimited range of
transfer rates.
Reliability and Consistency: design is made simpler and reliability increased by the
standardization of design and construction tolerances set by TEMA.
6.1.2 Fabrication Tolerances

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Figure 3
Sh
ell & Tube Fabrication Tolerances
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Figure 4 Shell & Tube Fabrication Tolerances
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6.1.3 Reboilers
A variation of the conventional shell and tube, still incorporating TEMA standardized components,
is the reboiler (Figs. 5 and 6).
Figure 5 Vertical Vessel Mounted Reboilers
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Figure 6 Condensate Pot Effect on Tower
6.1.4 Direct Mount Condensers
Occasionally condensers associated with separators, knockout drums, or accumulators are

mounted directly on the vessel. Such configuration can be very cost effective in that they eliminate
some of the components required for a stand alone condenser, the interconnecting piping between
the equipment as well as the supports for said piping. (Fig. 7)
Figure 7 Vertical Direct Mount Condenser

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6.2 DOUBLE PIPE EXCHANGERS
Double pipe are probably the most economical exchangers available. They consist of a single
tube enclosed within another. As with conventional shell and tube exchangers, double pipes rely
on the cross flow of two fluid streams to affect a heat transfer.
In an effort to increase the contact time of fluids in double pipe exchangers, most manufactures
attach fins to the inner tube. This practice has resulted in this type of exchanger being referred to
as fin-tubes or G-fins. (Fig. 8)
Figure 8 Double Pipe Exchanger Components
6.3 AIR COOLERS
Air coolers make up the second largest family of process and power plant exchangers. While not
as efficient, compact or precise as shell and tubes, air coolers are often the answer when supplies
of cooling fluids (cooling water, refrigerant, cool process fluids...) are limited. Their purchase cost
is often lower than that of shell and tubes, which can also make them preferable for services where
precise temperature control is less of a concern.
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Air coolers operate by flowing a fluid through a set of tubes (cell) while air is passed through the
cell around the tubes. The passing air absorbs and carries away the heat.
Header boxes for air coolers may be specified plugged or with cover plate. Plugged boxes
allow the maintenance of damaged tubes without the disassembly of the box but are generally
heavier and more prone to leakage. (Fig. 9)
Figure 9 Air Cooler Header Box Types
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6.3.1 Forced Draft
Forced draft coolers operate by pushing air through the tube cells from fans mounted below them.
This method of fan and motor mounting make them easily accessible from below the exchanger.
These coolers are more efficient than induced draft because the cool air they move is denser
(more air is moved), however, because the fans tend to channel the air, distribution may be
uneven. This may result in the formation of hot spots in the cells and cause uneven tube wear.
The cells of these coolers are exposed to the elements, also contributing to wear (Fig. 10).
6.3.2 Induced Draft
Induced draft coolers draw air up through the tube cells with fans mounted above them. This
arrangement reduces the formation of hot spots by flowing air more evenly across the tubes and
do protect the cells from the elements by covering them with the fan cowlings. The air they move,
however, is warm and less dense (having already passed through the cells), reducing their
efficiency. The over head fan and motor mounting make these coolers more difficult to maintain
(Fig. 10).
Figure 10 Air Cooler Components

6.4 OTHER EXCHANGER TYPES
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6.4.1 Stab-In Exchangers
Also referred to as bayonet exchangers, they are often used where pressure loss through piping,
space limitations or other circumstances preclude the use of more conventional exchangers. They
are usually constructed of a TEMA standardized head and tube bundle. Often used as heating
elements for tanks and occasionally in lieu of reboilers for fractionating towers.
These exchangers, because of the way they are integrally connected to the equipment they
service, usually cannot be worked on without shut down of that equipment. This limits their
maintainability and often makes them a last choice method of heat control (Fig. 11)
Figure 11 Stab-in Reboiler
6.4.2 Spiral Exchangers
These consist of a tube or set of tubes, twisted into a helical coil, contained in a barrel like
shell or casing. The casing is usually split (most often vertically) and can be opened for
maintenance. One fluid enters and exits the tubes through nozzles penetrating one side of the
casing while the second fluid passes through the casing from nozzles on either end (Fig. 12).
Figure 12 Spiral Exchanger
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6.4.3 Plate Exchangers
While not having true tubes, the plate exchanger operates on the same mechanical principles as
the shell and tube. Instead of tubes the plate exchanger uses sets of tightly arranged thin, flat,
hollow plates. The fluids flows through alternate contacting opposite walls of each plate,
transferring their heat in the process. These exchangers can be very efficient in their ability to
transfer heat attaining as low as a 2% heat differential between exiting fluids. Plates can also be
added or removed to vary the performance or for maintenance and repair (Fig. 13).
Figure 13 Plate Exchanger
6.4.4 Core Exchanger
Core exchangers (or core chillers) are a unique variation of plate exchangers. These exchangers
use plates alternately set within a shell through which the flow media pass, as do plate
exchangers. The plates in a core, however, are sealed together, in a process called brazing, to
create a single monolithic unit. Materials used in these types of exchangers are often aluminum or
aluminum alloys, which are great for heat transfer, but notoriously bad in terms of tinsel strength
and stress durability. For that reason cores are used for low temperature or chilling services
exclusively. Piping serving these exchangers is usually S.S., requiring a transition piece between
the piping and exchanger. These are often supplied by a third party vendor specializing in such
items. (Fig. 14 & 15)
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Figure 14 Aluminum Core Exchanger
Figure 15 Core Exchanger Insulation
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7.0 EXCHANGER PLOT LOCATION AND ELEVATION OF EXCHANGERS
7.1 SHELL & TUBE ARRANGEMENTS
With exchanger piping, as with most piping systems, the less piping required, the better the
design. The designer shall investigate strategies such as stacking and banking exchangers in
like service to minimize the piping required (Fig. 16)
Figure 16 Standard Piping Arrangements for Shell & Tube Exchangers
7.2 LOCATION BY ASSOCIATION
In setting locations for exchangers, attention shall be paid to the placement of associated
equipment. (Fig. 17) Locations will be chosen with a view toward reducing the amount of
3DG-P22-00004-002 Page 24 of 52
piping required to connect the system. The overall system flow will be reviewed and studies
done to determine the optimal placement for exchangers.
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3DG-P22-00004-002 Page 26 of 52
POOR
LOCATION
PREFERED
LOCATION
Example 1
PREFERED POOR
LOCATION LOCATION
Example 2
EXCHANGER PLACEMENT
Fig. 17
Figure 17 Exchanger Placement
7.3 EXCHANGER BATTERY ARRANGEMENTS
Exchanger battery arrangements for maintenance and operational access and also serve as
unobstructed escape routes from the area in case of emergency (Fig. 18).
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Figure 18 Arrangement of Exchanger Batteries
7.4 ELBOW NOZZLES TO REDUCE SHELL ELEVATION
The elevation of exchangers is frequently set by the requirements of the process they are trying to
maintain. The designer shall be aware, however, of the opportunities for reducing piping runs that
lowering or raising some exchangers may present (Fig. 19). It should be noted that elbow nozzles
will, to a certain extent, “fix” the pipe routing local to the exchanger due to nozzle orientations. The
customer shall be consulted prior to any decision to use elbow nozzles.
Figure 19 Elbow Nozzles

7.5 EXCHANGERS WITH CONDENSATE POTS
The elevation of exchangers operating on steam is often set by the resident time of the
downstream condensate pot, i.e. the time the condensate must remain in the pot prior to being
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returned to the condensate header, and is critical to maintaining upstream and downstream
pressure and temperature. If process conditions allow, use of a horizontal pot rather than a
vertical one, it can significantly lower the elevation requirements of the exchanger (Figs.20 & 21).
Figure 20 Alternative to Vertical Condensate Pot
Figure 21 Condensate Pot Piping Arrangement
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7.6 REBOILERS WITH CONDENSATE POTS
With vertical reboilers the condensate pot is commonly at grade and once again backpressure is
critical to maintaining temperature in the reboiler. The pot elevation in this case is often set by the
pump or downstream condensate system requirements. Every effort must be made to keep the
elevation of this pot as low as possible. The higher the pot has to be, the higher the reboiler must
be and consequently the higher the tower liquid level must be. As the tower goes up so do all
costs associated with it (additional skirt steel, additional piping, stronger foundation...) (Fig. 6).
7.7 DOUBLE PIPE EXCHANGERS
These exchangers are usually stacked in large banks and operated in series because of their
relatively low heat transfer rates. Occasionally, when only one double pipe is required, it is good
to keep in mind that there are options on mounting the exchanger that can result in significant cost
savings. The standard method of support for such items is an independent two-pier foundation,
but the light weight of the double pipe lends it to mounting on piers for other required equipment
(such as drums) or even nearby structural columns by side bolting (Fig. 22). Such mounting
eliminates the need for the foundation.
Figure 22 Double Pipe Exchanger – Method of Support
7.8 RACK MOUNTED AIR COOLERS
Air cooler elevations (whether at grade or elevated on racks or structures) are generally set by
their air drawing capabilities, therefore a certain amount of clear space must be maintained to
ensure the performance of the cooler. It is necessary to provide maintenance platforming for
access to the motors and header boxes (Fig. 23 & 24). Note that this platforming, because of
its relative elevation when air coolers are rack mounted, makes a good place for locating relief
valves.
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Area can be used for
equipment relief valves to flare
HEADER BOXES PLATFORMS

MOTORS
PLATFORMING
HEADER LEVEL MOTOR / FAN LEVEL
CONVENTIONAL PLATFORM DESIGN FOR AIR COOLERS

Fig. 23
Figure 23 Conventional Platform Design for Air Coolers
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PLAN
WHEN ENGINEERING CONTRACTOR
PROVIDES SUPPORTING STEEL,
INTERMEDIATE PIPE SUPPORTS CAN
BE LOCATED MORE EASILY
ELEVATION
ACCESS ACCESS
WAY WAY
BY VENDOR
BY ENG. CONTRACTOR
BY VENDOR
BY ENG. CONTRACTOR
AT GRADE OR
ON RACK
AIR COOLER SUPPORTS Fig. 24
Figure 24 Air Cooler Supports
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8.0 SHELL AND TUBE NOZZLE LOCATION & NOZZLE TYPE
8.1 SHELL & TUBE NOZZLE LOCATION OPTIONS
The designer shall be aware of the allowable variations to shell and tube exchanger nozzle
locations (Fig. 25).
Figure 25 Nozzle Adjustments to Standard Exchangers
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8.2 SHELL & TUBE NOZZLE ORIENTATION OPTIONS
A rearrangement of nozzles, can in some cases, reduce the required piping for a system.
While such relocation is something that must be discussed with and approved by the
Responsible Engineer (RE), significant cost savings can be attained by such rearrangement.
(Fig. 26 and 27)
Figure 26 Possible Nozzle Arrangements for Shell & Tubes
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Figure 27 Change Nozzles to Improve Routing
8.3 NOZZLE LOCATION WITH RESPECT TO FLOW
As with relocation of nozzles, a change in the flow direction of an exchanger can at times
result in an improved design (Fig. 28). As with nozzle relocation, any changes in the flow
direction must be discussed with and approved by the RE prior to implementation in the
design.
Figure 28 Change Flow to Improve Routing

8.4 AIR COOLERS
8.4.1 Nozzle Locations
The locations of nozzles are based on the number of tube bundle cells manifolded together and
the number of passes the tubes make between the inlet and outlet manifold boxes. An even
number of passes place the inlet and outlet nozzles on the same side of the cooler, while an odd
number of passes results in the nozzles being on opposite sides. This can be particularly
important when the coolers are rack mounted. If the upstream and downstream equipment are on
the same side of the rack an even pass arrangement is preferable, while if they are on opposite
sides of the rack an odd number of passes could reduce piping runs (Fig. 29).
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Figure 29 Odd or Even Pass Air Coolers
8.4.2 Air Cooler Piping Arrangements
The piping arrangements called for at air coolers can also greatly affect their placement and
elevation. In cases where true symmetrical (cascaded) piping is required to stabilize two-phase
flow, the required elevations of supports for the piping can become prohibitive. In such cases the
use of header box inserts may reduce the need for symmetry to the point that a rake style
arrangement may be used (Fig. 30 and 31). The RE shall be consulted about such possibilities.
Figure 30 Standard Air Cooler Piping Arrangements
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Figure 31 Inserts for Air Coolers
9.0 SUPPORTS
9.1 SHELL & TUBE
Shell & Tube exchangers at grade operating off of the same underground cooling water
supply line shall be aligned by the channel head nozzle (Fig. 32). The offset of the supports
will have little cost effect at grade. Exchangers in upper levels of structures, however, shall be
aligned by supports to minimize the requirement for structural steel (Fig. 33).
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Figure 32 Shell & Tubes at Grade with Same U/G Cooling Water Supply
Figure 33 Shell & Tubes on Elevated Platform
9.2 SPACE FRAMES OR SPACERS
As a standard, shell and tube exchangers come with saddle supports. When ordered for a
stacked application, the lower exchanger is generally ordered with opposed top and bottom
saddles to support the upper exchanger. However, there are occasions when it is desirable to
set the upper exchanger at a greater height than normally achievable with saddles (i.e.,
exchangers in different services that are stacked to save plot space or expansion of an
3DG-P22-00004-002 Page 38 of 52
existing unit requiring the placement of a new exchanger on an existing one). In these cases,
space frames (or spacers) will be required (Fig. 34).
Figure 34 Space Framing
9.3 SADDLE / FOUNDATION CLEARANCES
Clearances for piping, valves, insulation, maintenance equipment and instrumentation shall
always be checked (Fig. 35).
3DG-P22-00004-002 Page 39 of 52
Figure 35 Clearances for Shell & Tube Exchangers
9.4 SHELL & TUBE PIPE SUPPORT LOCATIONS
Often pipe supports at shell and tube exchangers can be incorporated with the exchangers
support foundations or can be set upon the same foundation. This can save the expense of
3DG-P22-00004-002 Page 40 of 52
separate support foundations (Fig. 36). Anchors set on such supports allow the pipe to grow
with the exchanger instead of against it.
Figure 36 Support Design for Piping at Shell & Tube
9.5 VERTICAL REBOILER SUPPORTS
3DG-P22-00004-002 Page 41 of 52
In setting vertical reboilers, a number of options for method of support are possible. The best
choice for any given application will depend on the process requirements as well as the availability
of space, type and weight of the equipment being used. The maintenance requirements for these
reboilers shall also be reviewed in deciding how best to support them in that bundle pulling for a
vertical exchanger can require some unconventional clearances (Figs. 5, 37 & 40)
Figure 37 Vertical Reboilers
9.6 AIR COOLER SUPPORTS
3DG-P22-00004-002 Page 42 of 52
Air coolers can be ordered with two different types of supporting structures, with or without
legs provided (Fig. 38). The latter of these two options can help reduce costs and increase
flexibility of the exchanger's supports especially when the coolers are to set above a pipe
rack. Coolers provided with legs can reduce costs for grade mounted air coolers and can also
be mounted with air controlling louvers or walls to protect against freezing or reduce motor
noise levels. The types of supporting structures for these coolers can affect the piping runs
serving them.
Figure 38 Air Cooler Supports
10.0 MAINTENANCE AND OPERATIONAL ACCESS
10.1 SHELL & TUBE

3DG-P22-00004-002 Page 43 of 52
Exchangers shall be piped with a view toward maximizing access to the tube bundle and other
maintainable components (Figs. 39 & 40). Break out flanges at the channel end, however, are
often an unnecessary added expense. Even at exchangers with fixed tube bundles (where
bundle pulling is not a concern), sufficient room shall be allowed at the heads to allow rodding
out of tubes. Usually an area equal to the length of the tubes will do.
Clear accessways should be provided to allow operator access to valves. If chain operators
are used for elevated valves, care should be taken to avoid chains obstructing the walkways.
HEAD + 30" (750mm)

9" (230mm) min. (ALL BODY FLANGES)
OPERATING VALVES
(SUGGESTED LOCATIONS)
WALKWAY 30" (750mm) min.

HEAD REMOVAL AREA
18" (450mm) MIN. BETWEEN

FLANGES OR INSULATION
18" (450mm) min. TUBE LENGTH + 30" (750mm)

(TYPICAL)
HEAD SWING (IF

FITTED WITH A DAVIT)
SHELL AND TUBE EXCHANGER ACCESS

FIG. 39
Figure 39 Shell & Tube Exchanger Access
3DG-P22-00004-002 Page 44 of 52
Figure 40 Tube Pulling Requirements
3DG-P22-00004-002 Page 45 of 52
10.2 BUNDLE EXTRACTOR
Most tube bundle pulling equipment can operate with a minimum of space allowance (Fig. 41).
Check the client's clearance requirements for his particular bundle extractor.
Figure 41 Tube Bundle Extractor
3DG-P22-00004-002 Page 46 of 52
10.3 CLEARANCES
Clearances for maintenance, such as wrench clearance at flanges shall be provided in all cases.
Often 12" (300mm) from bottom of pipe to grade is an adequate elevation for piping, however if a
drain is provided in the line, a minimum of 4" (100mm) below the plug shall be provided for the
removal of that plug. Knuckle clearance shall also be provided around spectacle blinds (where
provided) (Fig. 36).
As stated earlier, access ways shall be provided for the maintenance of all exchangers requiring
maintenance. These access ways shall provide a minimum of 2’-6" (750mm) of unobstructed
walkway with a minimum of 7’-0" (2200mm) headroom. The designer shall review the
arrangement of exchangers and the placement of access ways as an overall scheme instead of in
terms of individual components. Each access can be used to service more than one set of
exchangers, optimizing the space allocated to their placement (Figs. 39, 40 & 42).
10.4 STACKED EXCHANGERS
Shell & Tube exchangers may be stacked up to a maximum of three shells high if approved by the
customer.
10.5 CRANE ACCESS
For exchangers requiring the movement of large heavy components for maintenance, road and
heavy equipment access must be a consideration. Clear unobstructed lift and laydown areas, and
carry-out routes must be designated and kept clear of equipment, platforming and structures. A
single crane lift area can service several pieces of equipment if properly located (Fig. 42).
Figure 42 Crane Access
10.6 AIR COOLERS
As well as platforming for header box maintenance, most air coolers (especially those mounted on
racks) require platforming for motor access (Fig. 44). If the cooler is at grade and the motors are
within the reach of and are accessible by mobile equipment, the platforms might be eliminated.
3DG-P22-00004-002 Page 47 of 52
10.7 AIR COOLER HEADER BOX ACCESS
Platform access at air cooler header boxes is often required. Such platforming shall provide
enough access to allow the blinding of cells or the plugging of damaged tubes without interfering
with the support and routing of manifold piping (Fig. 43)
Figure 43 Plugged Header Box
3DG-P22-00004-002 Page 48 of 52
10.8 PLATFORM OPTIONS FOR AIR COOLER MOTOR ACCESS
In cases where large platforms are needed to service several bays of coolers, use a solid pattern
for platforming. Reducing the details required for design, and simplified construction, outweigh the
savings in material (Fig. 44).
Finger style platforming shall be used only after consulting with Civil/Structural engineer.
3DG-P22-00004-002 Page 49 of 52
FO R LONG A IR CO O LERS
CO NV E NTIONA L A P PRO ACH TO FA N MOTO R MA INT. P LA TFO RM
FAN MOTO RS
CO NV E NTIONA L A P PRO ACH P RO VIDE S
MO RE P LA TFO RMING , W HILE HA VING
LITTLE CO ST IMPA CT V S. ALTE RNATE
A LTERNA TE AP PRO A CH
FAN MOTO RS
AIR COOLER P LATFORMING ALTERNATIVES

FIG. 44
Fi
gure 44 Air Cooler Platforming Alternatives
11.0 PIPE STRESS
11.1 EXCHANGER ANCHOR LOCATION
Anchors play a large role in determining the piping configurations for exchangers. In many cases
the location of anchors can be adjusted to accommodate a better piping design. This is applicable
3DG-P22-00004-002 Page 50 of 52
to both pipe anchors and exchanger support anchors. With shell and tubes, anchors are generally
placed to allow the piping to grow parallel to the growth of the exchanger. This minimizes the
stress loads on the nozzles (Fig. 36).
Anchor points of the exchangers themselves can often be manipulated to provide the best design.
Slots can be cut into the exchanger support bolt holes to allow movement in a desired direction
(Fig. 45). If friction forces created by the weight of the exchanger are excessive, slide plates can
be introduced to allow greater ease of movement.
Figure 45 Slotted Holes for Shell & Tubes
11.2 SHELL & TUBE NOZZLE LOADS
The allowable loads at nozzles for shell & tube exchangers are not usually a problem. However,
when exchangers in like service are banked, it shall be kept in mind that tight fitting-to-fitting
configurations for the piping may generate unacceptable loads. Changes to the piping
configuration or the addition of springs to piping supports can be used to reduce these loads.
Adding springs to piping supports can also aid in vertical thermal load reduction when exchanger
locations require lengthy vertical piping runs.
11.3 AIR COOLER NOZZLE LOADS
Air cooler piping anchors shall be placed close to the exchanger to minimize the growth toward the
nozzles. Anchors on distribution headers shall be centered to equalize, as much as possible, the
lateral growth parallel to the header boxes.
Air coolers are notorious for the low limits of allowable stress at the points of piping connection.
The header boxes for these exchangers are usually made of gage steel and configured in a
fashion that affords little if any structural strength. When these conditions are applied to even
moderately hot services the result is often stress loads at the nozzles that far exceed acceptable.
Lengthening the piping riser between the piping header and the manifold box can help to reduce
3DG-P22-00004-002 Page 51 of 52
the lateral stresses (Fig. 46) and the addition of spring supports can reduce the load forces in the
vertical (Fig. 47)
Figure 46 Lateral Stresses on Air Cooler Nozzles
Figure 47 Spring Supports for Air Coolers
12.0 REFERENCES
Tubular Exchanger Manufacturers Association Standards (8th Edition)

3DI-P21-00001 ISBL Equipment Layout
3GS-P34-00002 Piping Design and Layout
3DG-P22-00004-002 Page 52 of 52

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BECHTEL CORPORATION

ENGINEERING – PLANT DESIGN

It addresses locations, elevation requirements, nozzle locations, exchanger supporting, associated

LIST OF FIGURES ................................................................................................................... 5

1.0 PURPOSE ....................................................................................................................... 7

4.0 TERMINOLOGY .............................................................................................................. 7

5.0 BASICS OF HEAT TRANSFER ...................................................................................... 9

6.0 TYPES OF EXCHANGERS ........................................................................................... 10

6.1 SHELL & TUBE............................................................................................................. 10

6.2 DOUBLE PIPE EXCHANGERS..................................................................................... 18

6.3 AIR COOLERS ............................................................................................................. 18

6.4 OTHER EXCHANGER TYPES..................................................................................... 20

7.0 EXCHANGER PLOT LOCATION AND ELEVATION OF EXCHANGERS.................... 24

7.1 SHELL & TUBE ARRANGEMENTS ............................................................................. 24

7.2 LOCATION BY ASSOCIATION..................................................................................... 24

7.3 EXCHANGER BATTERY ARRANGEMENTS............................................................... 27

7.4 ELBOW NOZZLES TO REDUCE SHELL ELEVATION................................................ 28

7.5 EXCHANGERS WITH CONDENSATE POTS ............................................................... 28

7.6 REBOILERS WITH CONDENSATE POTS ................................................................... 30

7.8 RACK MOUNTED AIR COOLERS................................................................................ 30

8.1 SHELL & TUBE NOZZLE LOCATION OPTIONS......................................................... 33

8.2 SHELL & TUBE NOZZLE ORIENTATION OPTIONS................................................... 34

8.3 NOZZLE LOCATION WITH RESPECT TO FLOW ....................................................... 35

8.4 AIR COOLERS .............................................................................................................. 35

9.0 SUPPORTS ................................................................................................................... 37

9.1 SHELL & TUBE............................................................................................................. 37

9.2 SPACE FRAMES OR SPACERS .................................................................................. 38

9.3 SADDLE / FOUNDATION CLEARANCES.................................................................... 39

9.4 SHELL & TUBE PIPE SUPPORT LOCATIONS ........................................................... 40

9.5 VERTICAL REBOILER SUPPORTS ............................................................................. 41

9.6 AIR COOLER SUPPORTS............................................................................................ 42

10.0 MAINTENANCE AND OPERATIONAL ACCESS ......................................................... 43

10.1 SHELL & TUBE............................................................................................................. 43

10.2 BUNDLE EXTRACTOR................................................................................................. 46

10.3 CLEARANCES .............................................................................................................. 47

10.4 STACKED EXCHANGERS............................................................................................ 47

10.5 CRANE ACCESS........................................................................................................... 47

10.6 AIR COOLERS .............................................................................................................. 47

10.7 AIR COOLER HEADER BOX ACCESS ........................................................................ 48

10.8 PLATFORM OPTIONS FOR AIR COOLER MOTOR ACCESS .................................... 49

11.0 PIPE STRESS............................................................................................................. 50

11.2 SHELL & TUBE NOZZLE LOADS ................................................................................ 51

11.3 AIR COOLER NOZZLE LOADS.................................................................................... 51

Figure 1 Standard Counterflow Patterns for Shell & Tube ................................................. 9

LIST OF FIGURES (contd.)

Figure 44 Air Cooler Platforming Alternatives.................................................................... 50

Figure 1 Standard Counterflow Patterns for Shell & Tube

Cooler: Cools liquids or gases without condensation.

Vaporizer: Vaporizes part of a process stream (also called an evaporator).

6.1 SHELL & TUBE

TEMA exchangers offer the following:

Maintenance: standardization allows standardized maintenance procedures with more readily

6.1.2 Fabrication Tolerances

Figure 5 Vertical Vessel Mounted Reboilers

Occasionally condensers associated with separators, knockout drums, or accumulators are

Figure 7 Vertical Direct Mount Condenser

Figure 8 Double Pipe Exchanger Components

6.3 AIR COOLERS

Figure 9 Air Cooler Header Box Types

6.3.2 Induced Draft

Figure 10 Air Cooler Components

Figure 11 Stab-in Reboiler

6.4.2 Spiral Exchangers