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Chapter 6. HEATEXCHANGERS 349

Spira1 exchanger seen

from the outside (After
Alfa Laoal).

6.9 Air4ooled Exchangers

Air-cooled exchangers use atmospheric air a s a cooling fluid. After being
sucked in by fans, the air goes through the usually finned tube bundles where
a fluid circulating inside is to be cooled or condensed. The bundles can be hor-
izontal, vertical or inclined, with the air and fluid on the tube side circulating
in cross flow (Fig. 6.114). Bundles are horizontal in most air coolers employed
with petroleum products. They are termed induced draft (Fig. 6.1 15A) when
the fans are placed above the bundles and forced draft (Fig. 6.1 15B) when the
fans are located below.
For general refinery services, the American Petroleum Institute’s API
Standard 661 [ 191 defines the requirements for construction materials and
design, manufacture, inspection and testing rules. Air-cooled exchangers con-
sist of tube bundles, air ventilation systems, air plenum chambers between the
fans and the bundles as well a s structures.

6.9.1 The Tube Bundles

6.9.1.1 Component Parts
The bundles are composed of usually finned tubes, headers and a frame that
imparts rigidity to the assembly.
350 Chapler 6 HEATEXCHANGERS

A B

Horizontal Vertical Inclined

6.114 Air-cooled exchangers: bundle position [ZO].

A. Horizontal. B. Vertical. C. Inclined.

a . Finned Tubes and Configuration

Tube characteristics
The basic bare tubes are selected from standardized exchanger tubes (see
Appendix 6.3). The most commonly used nominal diameter is 1 in, with a min-
imum thickness defined by a BWG 14 gage for carbon steel and BWG 16 for
stainless steels. Larger diameters (1 1/4 in, 1 1/2 in, 2 in) can also be employed
to fit allocated pressure drop requirements. The gage is selected depending on
the working pressure. Usual lengths are 20,24 and 30 ft. With the huge scale of
some units, such as for natural gas liquefaction, lengths of 40 and 50 ft can be
supplied by some manufacturers.
Except for special cases of cooling viscous products or low pressure gases
which lead to low internal convection coefficients, the air-side resistance is
predominant. This justifies the use of extended surfaces in the form of trans-
verse fins mounted on the tubes. Fins provide an advantageous extra exchange
surface area on the air side. However, fins also constitute conduction resis-
tance that lessens the effect of the greater surface area. The overall effect is
measured by the fin efficiency, which depends on the geometry and construc-
tion material and is taken into account in thermal calculations.

Fin characteristics
The parameters determining the finned surface area are the fin size and
number per unit of length or the fin spacing. The fins are usually circular
(Fig. 6.1 16) and the standard height measured between the base and the top
 Chapter 6 HEATEXCHANGERS 351

\ '-

Figure
6.1 15 Air circulation in air coolers.
A. Induced draft. B. Forced draft (After Technip).
352 Chaoter 6. HEATEXCHANGERS

is 318 in, 112 in or 518 in. 518 in is the most widely used height and leads to a
diameter of 2 1/4 in for a 1 in tube. The height can be selected according to
the relative values of convection resistances inside the tubes and on the air
side.

The number of finslin can vary from 7 to 11. For common values of 10 and
11 finslin, the ratio between the total finned surface area and the bare tube sur-
face area are respectively 21.2 and 23.2. Possible fouling due t o the quality of
the ambient air is a limiting factor for fin size and density. Fins are generally
made of aluminum, an advantageous material because of its ductility for work-
ing and its thermal conductivity for heat transfer.

Characteristics of finned tubes

The fins are wrapped around the base tube in a spiral. The quality of the
mechanical connection between the fin and the tube is crucial and depends on
the operating temperature. Because of the differential expansion inherent t o
the differences in temperature and in expansion coefficients of materials, the
contact between the fin base and the tube may be inadequate. As a result, the
air-side thermal performance is affected. Various manufacturing methods are
employed to produce types of fins adapted to service conditions.

Type L footed fin (Fig. 6.1 17A)

The L shape is obtained by wrapping an aluminum strip under tension
around the tube surface, with part of the strip pressed against the tube and
constituting the base of the fin. The quality of the fin-tube contact leaves much
to be desired and maximum working temperature is 120°C.

Double L footed type fin (Fig. 6.11 7B)

The double L allows the fin base to be partially overlapped by the neigh-
boring fin, so the tube is better protected from atmospheric corrosion. The
maximum working temperature is in the 120-170°C range depending on user
rules. This type is more expensive and fairly infrequently used.
 Chapter 6 HEATEXCHANGERS 353

A B

I l I

C D

k z I I

Different types of fins. A. Type L. B. Double L-footed type. C. Knurled L-footed

type. D. Extruded fin. E. Embedded fin (After GEA Btt).
354 Chaoter 6 HEATEXCHANGERS

Knurled L footed type fin (Fig. 6.117C)

The construction technique is similar to that for the type L. The base of the
fin is knurled while it is being wrapped, which improves the fin-tube contact.
The maximum working temperature is in the 175-250°C range.

Extruded fin on bimetallic tube (Fig. 6.1 17D)

The fins are obtained by extrusion of an aluminum tube which is shrink fit-
ted onto the base tube. Good resistance to atmospheric corrosion is assured
and the maximum working temperature is around 250 to 300°C.

Embedded type G (Fig. 6.1 17E)

The aluminum fin is embedded in a spiral groove engraved on the base
tube. The embedding and tension exerted during wrapping provide a good
quality fin-tube contact. In contrast, no protection is afforded against atmo-
spheric corrosion.
The maximum working temperature is 400°C. Regarding minimum thick-
ness requirements, a s mentioned earlier during the discussion of tube charac-
teristics, the depth of the groove where the fin is embedded must be taken into
account in order to define the base tube thickness. Since the groove depth is
approximately 0.3 mm, this means selecting different gages from those used
for other manufacturing methods.

Tube layout
Tubes are laid out in a straight equilateral triangle pattern. For tubes with
a nominal diameter of 1 in provided with high fins of standard 2 1/4 in diame-
ter, the pitch is selected among the following values: 2 3/8 in, 2 112 in, 2 518 in
and 2 3/4 in. The pitch can be optimized by integrating the costs, however the
most commonly used are 2 1/2 in and 2 5/8 in.

b. Distribution headers or collectors

Headers or collectors introduce and distribute the hot fluid inside the tubes
and recover the cooled or condensed fluid at the outlet. Except for cylindrical
collectors, each header includes a tubesheet in which the tube ends are fixed
by expansion joints or by welding in special cases such a s high hydrogen par-
tial pressure. The fluid is distributed in one or more passes by welded pass
partition plates. The fluid inlet and outlet nozzles are welded on the headers
or collectors. Different types of headers or collectors can be adapted to ser-
vice conditions and maintenance requirements.

Plug headers or collectors (Fig. 6.1 18)

This is the most widely used type and its cost is moderate. It consists of a
welded parallelepiped-shaped box provided with one or more nozzles.
Holes are made in the front plate lined u p with the tubes fixed on the
tubesheet. They allow mechanical cleaning inside the tubes and certain main-
 Chapter 6. HEATEXCHANGERS 355

Plug Seal

Finned tube
Cleaning
hole

-
Figure
6.118 Plug header (After CEA BR>.

tenance operations such as temporary sealing of a leaky tube while waiting for
repairs. Threaded plugs are screwed into these holes, with the outside seal
assured by a washer ring (Fig. 6.119).
They can be used up to working pressures of approximately 200 bar.
Beyond this, cylindrical collectors are generally preferred, even though pre-
sent-day welding techniques and control allow parallelepiped boxes to be
employed at high pressures for certain applications.

Plug header bundles (Afier Creusot-Loire).

356 Chapter 6 HEATEXCHANGERS

Removable cover-plate headers or collectors

For fouling or corrosive fluids that require frequent periodic verification,
headers with each front face equipped with a removable cover-plate are more
convenient to use (Fig. 6.120). The seal is assured by a joint tightened by a
bolting system around the periphery of the cover.

4 I

-
Figure
6.120 Removable cover-plate header (AfterGEA Btt).

For high pressures, box thickness must be increased and bolting systems
enhanced, so this type of collector becomes expensive. Consequently, utiliza-
tion is limited to pressures of approximately 40 bar. For high pressure hydro-
gen services, such as in a hydrocracking unit, special covers provided with
welded joints can be installed.

Cylindrical headers (Fig. 6.12 1)

For high pressures of over 200 bar, cylindrical collectors of appropriate
thickness are generally used. The tube bundle consists of hairpin tubes with
finned straight sections and the inlet and outlet ends welded on bonnets inte-
gral with the headers (Fig. 6.121B).
The number of rows per collector is limited to a maximum of two. The
inside of the tubes can only be cleaned chemically. This type of collector is not
recommended for highly fouling services, unless it is acceptable for the hair-
pins to be cut and then rewelded after cleaning. Another more expensive solu-
tion is to fix each of the tubes to a sleeve welded on the collector (Fig. 121C).
A threaded hole in the sleeve coaxially to the tube affords access.

Bonnet headers (Fig. 6.122)

The collector consists of a semi-circular bonnet that can be welded or
bolted on the tubesheet. Welding is cost effective and has the advantage of
eliminating outward leakage risks. The use of this type is reserved for clean
 Chapter 6 HEATEXCHANGERS 357

Figure
6.121 Different types of cylindrical headers. A. Cylindrical header (After GEA B n ) .
B. Bundle with hairpins and a cylindrical header (After Creusot-Loire).
358 Chapter 6. HEATEXCHANGERS

A 6

-
Figure
6.122 Bonnet headers.
~- A. Welded bonnet (After CEA Btt). B. Removable bonnet.

services at low operating pressure or vacuum pressure. The removable bon-

net version requires piping to be dismounted in order to gain access to the
tubesheet.

Manifold headers (Fig. 6.123)

In the event that allowed pressure drop is low and particularly for conden-
sation services, a large diameter header is directly welded on the tubesheet.
Good vapor distribution is assured in each of the tubes in the bundle. This
type of header is often associated with vacuum steam condensers, with the
bundles installed overhead.
 Chapter 6 HEATEXCHANGERS 359

6.9.1.2 Tube Bundle Assemblies and Different Layouts

Bundles are obtained by assembling finned tubes, headers, tube supports to
prevent bending, and side frame providing rigidity to the assembly. Figure
6.124 illustrates the assembly of a plug header bundle with two passes on the
tube side. The return box guided in the frame is free to allow the bundle to
expand.

a. Number of Tubes in a Bundle

For easy mounting and handling, the maximum width of a bundle is limited to
3.2 to 3.5 m depending on the constructor. In a conventional solution with 1 in
-2 1/4 in finned tubes and 2 1/2 in spacing, a width of 3.5 m can accommodate
54 tubes comprising a layer. Additionally, the minimum recommended number
of layers or rows is 4 to obtain well established cross-flow circulation, since
the flow is not really transverse with a fewer number of rows. Though unfa-
vorable for transfer, bundles with 3 rows are sometimes specified in order to
decrease the pressure drop when air flow rates are high. This is because with
fewer rows, the cross-sectional area on the air side (face area) is larger, for a
given heat transfer area.
For a given bundle width, increasing the number of rows allows a larger
exchange surface area to be installed per bundle. If need be, increasing the
number of rows can also limit the number of bundles that have to be installed

Guided return
box free
to expand

frame

Fixed
/
distribution
box
Pass partition Rack
plate (support and separation
of tubes)

Figure
6.124
I Plug header bundle assembly.
360 Chapter 6 HEATEXCHANGERS

for a required service. This may be an advantage when floor space is a prob-
lem for layout design. The trade off is a reduction in air velocity, otherwise pro-
hibitive fan power will have t o be installed. Reduced air velocity leads to a
lower thermal transfer coefficient and a decreased mean temperature poten-
tial, which will then require a larger exchange surface area.
Choosing the number of rows is therefore crucial and must be optimized,
but it is common t o install 4 to 6 rows of tubes per bundle. For a width of 3.5 m
and tubes with a nominal diameter of 1 in and a triangular 2 112 in pitch, the
choice of 6 rows leads to 324 tubes and a bare tube surface area of 237 m2 for
a length of 30 It.

b. Distributing Passes and Tubes per Pass

The number of tube-side passes and the distribution of tubes on each of the
passes are used to adjust the flow velocity of the process fluid. It should be
remembered that this velocity has an impact on pressure drops and on the
internal transfer coefficient a s it determines the regimes, whether in single- or
two-phase flow. Passes and tubes per pass are distributed by partition plates
welded inside the headers. It is simple to have an equal whole number of rows
on each of the passes (Fig. 6.125). It is also possible to partition by differenti-
ating the number of tubes per pass in order to adjust the velocity and the flow
regime. The tubes in one row can be shared on several passes.

cPigure
6.125 Bundles with two tube-side passes and
four rows.

For a multi-pass bundle, differential expansion between two adjacent

passes must not be excessive in order to prevent mechanical damage to the
tubes and tubesheets. The API 661 Standard [ 191 limits the temperature dif-
ference between the fluid in two neighboring passes to 200°F (1 11°C). If this
condition is not fulfilled, two separate headers must be installed, independent
of each other and associated with two tubesheets, thereby avoiding the high
thermal gradient of a single tubesheet (Fig. 6.126).

c. Circulation Modes
For better efficiency, cross-flow circulation must be overall counter-current
(Fig. 6.127). With the air circulating from bottom to top, the inlet of the prod-
uct to be cooled or condensed is placed on the air outlet side. A set up with
 Chapter 6 HEATEXCHANGERS 361

1 Inlet

n/
box

box box

1 Figure
6.126 Two-pass bundle. Header with separate boxes.

Cross flow with overall

countercurrent.

overall cocurrent circulation performs less well from the standpoint of thermal
exchange. It can, however, be of interest in some special cases (see Section
6.9.6.1).

6.9.2 Ventilation Systems

Ventilation systems consist of fans driven by motors or engines and devices to
control the air flow rate.

6.9.2.1 Fans (Fig. 6.128)

Cool atmospheric air is distributed on the tube bundles by rotating helical fans
with a diameter of 6 to 18 ft. The rotor includes a hub mounted on the fan
shaft, blades mounted on the hub and in some cases a control mechanism. The
362 Chaoter 6 HEATEXCHANGERS

4 or 6 blades are made of aluminum, a lightweight alloy or glass fiber rein-

forced polyester resin.
The API 661 [ 191 stipulates that at least two fans must be installed length-
wise on a bundle or a bundle arrangement in order to provide minimum cool-
ing should one of the fans be stopped. However, for tube lengths of less than
15 ft, a single fan is acceptable.

Figure

blades.

In order to obtain proper air distribution on the whole face area of the bun-
dles, the surface area occupied by the fans must be at least equal to 40%of the
face area. In fact, a face area/fan projected area ratio of less than 2 is frequently
used. For very long tubes, approximately 50 ft, this consideration entails
installing three fans lengthwise along the bundles.

6.9.2.2 Air Flow Rate Control

a. Adjusting the Blade Angle
The angle can be adjusted when the fan is stationary by rotating the base of
the blade on the hub and fixing the position with a tightening system. It can
also be adjusted by a servomotor when the fan is in operation, if it features
self-adjusting blades (Fig. 6.129). Adjusting the air flow rate by the blade angle
controls the temperature of the outgoing cooled fluid. When several fans
assure the same service, one of them may have self-adjusting blades.

b. Adjusting the Rotation Speed

The rotation speed can be modified by using either two-speed motors or vari-
able speed motors when control is necessary. There are limits, however, on
rotation speeds. They must not result in fan tip speeds greater than
12000 ft/min (61 m/s), mainly in order to reduce the fan sound power level
(API 661 [ 191).
 Chapter 6 HEATEXCHANGERS 363

Air

Diaphragm
Figure
Fan with self-adjusf- 6.129
ing blades.

For operating rates at reduced process fluid flow rate or when the atmo-
spheric air temperature is much lower than the design temperature, the fan
with manually adjusted blades can be stopped. The relevant exchange surface
area is nevertheless cooled with air circulation by natural convection due to
the draft.

c. Adjusting with Louvers (or Shutters)

Louvers (straight shutters) are placed crosswise above the bundles
(Fig. 6.130). The opening can be varied, so the cross-sectional area for the exit-
ing air is occluded to a greater or lesser extent. This results in additional pres-
sure drop, which reduces the air mass flow rate with the same fan blade set-
ting and rotation speed. The louver opening can be adjusted manually or
automatically by a control system comparable to the one used for fans with
self-adjusting blades.

Figur
Air cooler with louvers. 6.13
L
364 Chapter 6 HEATEXCHANGERS

6.9.2.3 Drive and Transmission Systems

Motors or engines supply the power required by the fans in order to provide
the desired air flow rate. Fans can be driven by electric motors, or gas or gaso-
line engines, hydraulic systems or steam turbines. Electric motors are by far
the most common.
The power of the motor can be transmitted t o the fan:
directly: the fan shaft is connected directly to the motor,
indirectly, either by pulleys and belts or by gears (Fig. 6.131).
The API 661 Standard [19] states the rules concerning the type of trans-
mission to be used according to the rated power. Pulleys and belts are
employed up to 30 h p (22 kw), if the belts are serrated they can transmit
greater torque and up to 50 hp (37 kW). Above this value, gear transmission is
necessary though more expensive. Direct transmission is only applicable to
small diameter (5 ft) low power fans.

A B

Figure
Indirect transmission.
A. By pulleys and belts. B. By gears.

6.9.3 Plenum Chambers between Fans and Bundles

The air from the fans is distributed on the bundles (forced draft) or collected
at the bundle exit (induced draft) by means of a plenum chamber. The cham-
ber or hood (Figs. 6.132 and 6.133) can be a parallelepiped or a truncated cone-
pyramid t o provide better air distribution over the whole face area. A cylin-
drical element containing the fan is welded on the hood and constitutes the
fan ring.
The chamber must be high enough to allow fan dispersion angles of less
than 45 degrees for proper air distribution (Fig. 6.134). When two or more fans
are assigned to the same service, a separating plate must be installed between
 Chapter 6. HEATEXCHANGERS 365

Fan
,
,,
,,
-’ ring

Hood and fan ring.

Hood

Parallelepiped Truncated
shape cone-pyramid shape

Figure
Plenum chambers.
A. Forced draft. B. Induced draft.

two adjacent chambers. In the event one of the fans is stopped, this prevents
recirculation of hot air from the fans in operation.
The API Standard 661 [19] dictates a maximum radial clearance between
the fan blades and the fan ring: 0.5% of the blade length or 19 mm. Compliance
with this requirement is very important if the expected fan performance is to
be obtained. Some constructors use very small clearances by placing honey-
combs fixed inside the fan ring and compressed by blade rotation.
366 Chapter 6 HEATEXCHANGERS

Elevation Cross-section

Figure
6.134 Fan dispersion angle (After API 661) [191.

6.9.4 Structures
Structures are composed of a variety of frames, mechanical beams and gird-
ers. They provide support for the bundles, the motor and fan assemblies and
the walkways that afford access for handling and maintenance. They must be
calculated under static and dynamic conditions in order to withstand wind
load and seismic effects and avoid any vibration. The minimum free height
under the bundle in induced draft and under the fan ring in forced draft is
approximately 2.5 m.
When several air coolers are grouped together, special attention must be
given to the distance between the ground level and the bundles. The total lat-
eral surface area for air suction must be at least equal to the total face area of
the fan group in order to assure proper air distribution on all the bundles.

6.9.5 Air Cooled Exchanger Layout and Installation

6.9.5.1 ATr Cooled Exchanger Arrangements (Fig. 6.135)

The air cooled exchangers installed for a given service are termed a unit, con-
sisting of one or more bays (or sections) in parallel. Each bay is made up of
one or more bundles in parallel. Several units grouped together make up a
bank.
 Chapter 6. HEATEXCHANGERS367

1
Bay or section Bundle
I* -I I 4

Bundle

Bay with Unit Unit

2 different l- 4 1- *I
bundles
Bank
I- 4

___
Figure
6.135 Aircooled exchanger arrangements.

A specified service may require only a modest exchange surface area

which, given standard tube lengths, results in an excessively narrow bundle. In
this case, it can not be installed alone on a bay. It is recommended t o associ-
ate the service with one or more other larger bundles assigned to a different
service to form a group on a common bay and with common fans. Obviously,
control can not meet the requirements of both the services at the same time.

6.9.5.2 Layout
Layout studies for air cooled exchangers must take certain conditions in their
immediate environment into account: those that influence air supply and recir-
culation. Prevailing winds should be investigated, particularly if there are any
obstacles nearby: ground movement, buildings, control or machine rooms,
structures, furnaces, columns, etc. When adjacent units are planned, the bun-
dle elevation and type of draft must be identical so as to limit hot air recircu-
lation. Nearby sources of hot air such as furnaces should be avoided.
368 Chapter 6 HEATEXCHANGERS

6.9.5.3 Choosing between Induced Draft and

Forced Draft
It has been established that air is more effectively distributed through the
finned bundle of an induced draft air cooled exchanger. This is particularly
advantageous for a close temperature approach between the air and the pro-
cess fluid. The velocity of hot air at the fan ring outlet in induced draft is 2 to
2.5 times faster than at the bundle outlet in forced draft. This higher velocity
decreases the risks of recirculating hot air, especially in the presence of a side
wind. When fans are at a standstill, the chimney effect is more significant in an
induced draft system and allows better natural draft cooling. The position of
the hood and the fan above the bundle (Fig. 6.136) protects the tubes from
atmospheric precipitation and promotes good production unit stability. This
type of protection is provided in forced draft air coolers only if they are
equipped with louvers. In the induced draft system, the ground noise level is
lower, the free space below the bundles is greater and the first rows of tubes
that become the most severely fouled are accessible for cleaning without stop-
ping the fans. Preassembly and crane handling are also easier.

Figure
Bank of induced draft air cooled exchangers (After Creusot-
Loire).
 Chapter 6 HEATEXCHANGERS 369

However, since the fan drivers are located below the bundles, a long trans-
mission shaft is needed to provide the mechanical connection. It must go
through the bundle, thereby disabling several tubes or requiring clearance
between two bundles in the same bay. In addition, the fans and their compo-
nent parts are located in a hot air atmosphere. The air outlet temperature
must then be limited to 70°C for plastic blades and 90-100°C for aluminum
blades. At the same mass flow rate of delivered air, induced draft consumes
more power, since the volume flow rate is greater for hot air. Maintenance on
the fans is difficult even when they are at a standstill, due t o the natural draft
when the hot fluid is kept circulating. In conclusion, induced draft provides
numerous advantages from the standpoint of thermal performance, but forced
draft allows easier maintenance.

6.9.6 Special Devices

6.9.6.1 Overall Cocurrent Circulation (Fig. 6.137)
In order to avoid any problems of solidification or freezing when cooling pro-
cess fluids, it may be advantageous to use overall cocurrent circulation
instead of the usual overall counter-current. The inside wall temperature of
the tubes is situated between the air temperature and the process fluid tem-
perature and is higher than in overall counter-current circulation. There are
fewer risks a s a result, particularly in winter. Since the mean temperature
potential is lower, this solution obviously leads to installation of a larger
exchange surface area.

4I t t
Figure
Overall cocurrent 6.137
circulation.

6.9.6.2 Preheating the Air

With the same aim as mentioned in the preceding section, another cold
weather solution is to preheat the air enough for the wall temperature to
remain at an appropriate level. Steam coils are installed under the first row of
tubes in the bundle (Fig. 6.138). It is particularly advantageous to use them
during start up in cold weather, since the wall temperature is very low. A lou-
ver system is sometimes associated with the steam coils to limit the air flow
rate during start up.
370 Chapter 6. HEATEXCHANGERS

Bundles
\ Steam coils

Figure
6.138 Steam coils (After GEA Btt).

I\\\\\\\\
m 2 1

J- $.
4
--
00000000000000
0000000000000
00000000000000
,\\\\\
.
00 000 0 0 000 000

- - __
T 'I I
Figure
6.139 Air
--@
t ~
recirculation

\\
 Chapter 6. HEATEXCHANGERS 371

6.9.6.3 Recirculating the Air

When the two solutions mentioned above are inadequate, hot air recirculation
must be implemented, with the hot air mixed with cold air to obtain the appro-
priate temperature (Fig. 6.139). A recirculation chamber is installed surround-
ing the air cooled exchanger completely. It features a louver system with auto-
matic opening actuated by an air temperature control loop. Steam heating
coils still remain necessary for start up. The complete installation is reliable
but very expensive, with the cost being some 1.5 times that of the air cooled
exchanger alone.

6.9.6.4 Humidifying the Air

In hot dry climates, humidification systems are used on induced draft air
cooled exchangers to lower the air temperature. As an example, with air avail-
able at 40°C under different conditions of relative humidity, the following tem-
peratures can be obtained for humid air at saturation:

Relative humidity

Temperature obtained (“C)

Humidification chambers equipped with water sprayers are installed on

the inlet air circuit (Fig. 6.140). The air is saturated in water by causing the
phases to pass over plates to promote contact between them. Before reaching
the bundles, the moist air goes through a demister pad t o eliminate water
droplets. The non-evaporated water is recovered in a tank and mixed with the
make up water supplied to the spray nozzles.
The bundle tubes are generally bimetallic, with extruded fins to protect the
base carbon steel tube against corrosion. Anti-fouling and anti-corrosion treat-
ments are needed for the water. The complete installation, including the water
circuit, entails high investment, some 1.5 to 1.6 times the cost of the air cooled
exchanger alone. The additional operating costs (water consumption, pump-
ing and treatments) are also high.

6.9.6.5 RoofeType AirXooled Vacuum Steam Condensers

Air-cooled condensers associated with steam turbines are most frequently of
the roof type and consist of one-pass inclined bundles equipped with manifold
type headers (Fig. 6.141). The advantage lies in placing short inclined tubes in
parallel, allowing low pressure drops and good condensate drainage to the
final collector. Since the required exchange surfaces are generally large, the
roof configuration permits a 30 t o 40% saving on floor space in comparison
with a conventional horizontal air condenser.
372 Chapfer 6 HEATEXCHANGERS

t t

-
Figure
6.140 Humidifying the air.

1 1
Figure
6.141 Roof type air-cooled condenser (After GEA).

Non-condensables, which are inevitably present (vacuum system not com-

pletely air-tight, water treatment chemicals), must be discharged. Otherwise
poor local thermal performance may occur, along with condensate flow dis-
turbance, subcooling and possible freezing risks and corrosion. Special
arrangements or devices are implemented by the various constructors. For
example a pair of bundles can be mounted as a dephlegmator, with non-con-
densable extraction at the upper collector.
 Chapter 6 HEATEXCHANGERS 373

6.9.7 Estimating Costs

The method of estimating given below takes into account the base cost of a
common air cooled exchanger and provides corrections for certain different
characteristics. The unit cost c of the m2 of exchange surface area per bay is
given according to the surface area per bay for the following reference air
cooled exchanger:
1 bay consisting of 2 bundles and 2 fans (excluding control),
base tubes: d, = 1 in, BWG 14, 1 = 30 ft, carbon steel,
embedded fins: d, = 2 1/4 in, e = 0.4 mm, 11 fins/in, aluminum,
design pressure < 20 bar, design temperature < 300°C.

Bare tube surface arealbay (*)

Reference 1997 300 m2 500 m2

c (in F/m2)

I (*) Linear interpolation for any intermediate surface area. I

The cost also depends on the fin type, the tube length and construction
material, the design pressure and temperature, the fan type and the number of
bays in a unit.
These different factors influence the cost a s shown in the following for-
mula:
C = c x S X F, x Fl x F2 x F3 x F4 x Fi x F6 x F7
with:
C cost of the air cooled exchanger
C unit cost of the m2 of the reference air cooled exchanger
surface area
S exchange surface area in m2 of bare tubes
F,, Fl,... F7 corrective coefficients given in Table 6.4

6.9.8 Uses
The use of air cooled exchangers is often seen in terms of competition with
water cooled exchangers. Their downside is the unit cost of the m2 of bare
tube exchange surface area, practically double that of a shell-and-tube
exchanger, and the need to install a larger surface area for the same service.
The overall transfer coefficient is not a s good and the mean temperature
potential is lower, because on a given site the temperature of the available
water is lower than that of the atmospheric air. In contrast, water cooled
exchanger operating and maintenance costs are higher. Only an economic
study taking all investments and operating costs into account can be used to
choose between the two.
374 Chapter 6 HEATEXCHANGERS

Fin type Tube length (ft)

Extruded Type G Type

30 36 40
embedded knurled

Fn 1.02 1 0.99 Fl 1 0.90 0.86

Base tube Design pressure Design

construction material @@ temperature CQ

Carbon Stainless
steel steel = < 20 40 90 < 300 > 300

F3 1 1.50 F4 1 1.06 1.13 F5 1 1.03

, FG
Fan type

F7
Number of
identical bays

Corrective coefficients for calculating the cost o f uir cooled exchangers.

In particular, the water supply to coolers requires appropriate treatment

and a piping network, which is often very costly. However, it may be profitable
t o recover waste heat by producing hot water in the coolers.
Other criteria may also be considered, such as layout requirements, oper-
ating stability, etc. In this respect, air cooled exchangers are not at an advan-
tage. They require significant ground space and are very sensitive to sudden
changes in climatic conditions, despite the installation of elaborate control
systems.
In some cases an air- and a water-cooled exchanger can be associated to
cool a process fluid to a specified temperature. The exchange first takes place
with air with an approach of 10 to 15"C, and then with water with an approach
of 3 to 5°C in a trim cooler.
Air cooled exchangers are very widely used in the petroleum industry. For
large-capacity units the corresponding investment can amount to nearly 5%of
the total investment for the whole installation.
 Chaprer 6. HEATEXCHANGERS 375

6.10 Direct Contact Exchangers

As indicated previously in Section 6.2.2, direct contact exchangers do not use
an exchange surface and find an application only if the two fluids involved can
be readily separated. However, they are advantageous because of their high
thermal transfer coefficients, low fouling and pressure drops, and low cost
equipment. Besides cooling towers which are not covered in this volume, their
common applications are in condensation and gas cooling.

6.10.1 Gas Coolers

These exchangers consist of column-shaped vessels where the process gas
and a cold liquid circulate. Various devices are used to favor gas-liquid con-
tacts and heat exchanges.

6.10.1.1 Spray Columns (Fig. 6.142A)

The hot gas is introduced at the bottom of the column and circulates counter-
currently with a cold liquid sprayed by nozzles or perforated pipes. The most
homogeneous dispersion possible is implemented in order t o prevent gas
channeling. Cocurrent circulation is also possible.

Cold gas
A B outlet
T
Cold liquid-
inlet
Cold liquid-
inlet

Hotgas
inlet
- Hot gas -
inlet

-_ _
Figure
6.142 Exchange by direct contact.
A. Spray column. B. Baffle column.
376 Chapter 6 HEATEXCHANGERS

6.10.1.2 Baffle Columns (Fig. 6.142B)

Segmental baffles are placed inside the column, constituting blind plates
where the liquid flows from top to bottom. The gas is introduced in the bottom
of the column and circulates counter-currently with the liquid. The column
diameter is determined so that the gas circulation velocity is lower than the
velocity at which the vapor starts to entrain the liquid.

6.10.1.3 Sieve Plate Columns

The apparatus is the same a s in the preceding section, except that the plates
are perforated, allowing the gas to pass through the layers of liquid and
thereby favoring gas-liquid contacts and heat exchange (see Chapter 1: Sieve
plate columns).

6.10.1.4 Packed Columns

Packing increases the gas-liquid interfacial area and contact time, and also pro-
motes turbulence, all of which favor heat transfer. The packing may be random
or structured, with t h e second being more efficient but more costly (see
Chapter 2: Packed columns).

6.10.2 Condensers
This type of equipment is found in the applications discussed below.

6.10.2.1 Barometric Condensers (Fig. 6.143)

These condensers are associated with condensing turbines and fed by the
exhaust steam. They condense steam at reduced pressure in the presence of
non-condensables by a rain of cooling water. In counter-current circulation,
the cold water is distributed on a crown plate provided with a weir. The liquid
then flows on plates and contacts the rising stream of vapor to be condensed
which is introduced in the lower part of the vessel. The non-condensables and
the uncondensed steam are recovered at the top of the column and routed to
the vacuum system. At the bottom, the water is recovered and flows to a baro-
metric leg. The leg is at least 10 m high and partially immersed in a vessel to
form a hydraulic seal and maintain the vacuum. The cold water can also be
sprayed and circulation can be cocurrent. Here a circular baffle is incorpo-
rated to reduce the ascension of non-condensables and uncondensed steam.

6.10.2.2 Internal Condensers in Distillation Columns

This type of condenser is designed to generate the cold internal reflux in a col-
umn (Fig. 6.144). As a substitute for an external surface condenser, it prevents
pressure losses and therefore is particularly suited to vacuum distillation
columns.
 Chapter 6 HEATEXCHANGERS377

-
Figure
6.143 Barometric condensers 181

Vapor
-

Internal condensers.
Production

The top plate in the column is a draw-off plate, where the liquid is with-
drawn and then separated into two streams. One is the internal reflux of the
column and the other, after cooling, assures overhead production and the
recycle for sprinkling to partially condense the rising vapor by direct contact.
The condensed fraction and the sprayed liquid are mixed on the draw-off
plate. At the upper part of the column a demister grating or pad limits the
entrainment of liquid droplets by outgoing non-condensables and the uncon-
densed steam.
378 Chapter ti HEATEXCHANGERS

6.10.2.3 Air Dehumidifiers

Air can be dehumidified by condensing steam in direct contact exchangers
using chilled water as a cooling fluid. This operation is carried out in spray
columns and plate columns like those presented earlier.
In conclusion, although direct contact exchangers are relatively seldom
used in the petroleum industry, they still remain advantageous for certain spe-
cific applications. Their simplicity and relatively low cost with low mainte-
nance requirements are assets to be taken into consideration.

6.11 Conclusion
In this chapter, the presentation of the various heat exchangers has practically
been confined to those used in the petroleum industry, although some are
employed only marginally. This review does not claim to be exhaustive. Other
technological solutions have been deliberately ignored as they are related to
highly specific utilizations: cyclic or other air-flue gas exchangers associated
with furnaces or boilers, chillers in lube oil dewaxing units, graphite or Teflon
exchangers for corrosive services, flexible plastic sheath bundle exchangers,
etc.
In addition, the very wide variety of technologies implemented to achieve
heat exchanges can be noted. Conventional shell-and-tube exchangers are still
the great majority in a rather conservative industry, due to the huge invest-
ments and safety and environmental requirements. The same criteria, in
particular in the context of some gigantic natural gas treatment facilities and
offshore industry constraints, etc. have paradoxically promoted the develop-
ment of non-tubular exchangers, especially compacts. Real progress has been
made by constructors in obtaining a better match for demanding services and
better control of thermo-hydraulic calculation methods has also been
achieved, giving them a degree of credibility they have not always enjoyed.
As a last reminder, a heat exchanger is not chosen from a catalogue, but is
always “tailor-made” to fulfill a specified service. Close cooperation between
the future operators, design engineers and constructors is a must if the right
choice is to be made.
 Chapter 6. HEATEXCHANGERS 379

Appendixes
A6.1 Conversion Table
Units
Symbols

kcal Btu
Q Units W - -
Heat flow o r h h
Thermal power o r W 1 0.8601 3.41 18
Heating load o r
Duty kcal
- 1.1626 1 3.9683
h

Btu
- 0.2931 0.2520 1
h
Units m2 m2 ftZ
A
rn2 1 1 10.7639
E x c h a n g e s u r f a c e area
ft2 0.0929 0.0929 1
W
- kcal Btu
Units ~ ~

m2 h-m' h.ft'
W
-
m2 I' I 0.8601 I 0.3170

Heat f l u x kcal
~
1.1626 1 0.3687
h.m2
Btu
- 3.1549 2.7122 1
h.ft'

A0
Units I K I "C I "F
Temperature potential Kou"C I 1 I 1 I 1.8

"F I 0.5555 I 0.5555 I 1

mZ-K h.mZ."C h.ft'."F
Units -
W kcal Btu
m2.K
- 1 1.1626 5.6782
W
R
Heat t r a n s f e r r e s i s t a n c e h.m2."C
0.8601 1 1 4.8824
kcal
h-ft'-"F I 0,1761
I 0.2048

7
Units
Btu

0.860 1 0.1761
U
kcal
Heat t r a n s f e r coefficient 1.1626 1 0.2048
h.m2.-"C
Btu
5.6782 4.8824 1
h.ft'."F
W
Units

W
- 1 0.860 1 0.5784
h m.K
kcal
Thermal conductivity - 1.1626 1 0.6725
h.m."C

1.7288 1.4870
I'
 380 Chaorer 6 HEATEXCHANGERS

A6.2 27wwnaL ConductivSty of M a t e r i a l s

(According to TEMA Standards)

-
- - - WUI
-
. R. “F.-
- - - - -
Material
Carbon Steel
-
70

30.0
100

29.9
2M)

29.2
300

28.4
400

27.8
-
500

26.8
----
800

25.8
700

24.8
800

23.5
900
22.5
loo0 I1100

21.4 20.2
-
I200

19.0
---
1300

17.6
I400

18.2
1%

15.1
G I R Moly Steel 24.8 25.0 25.2 25.1 24.8 24.3 23.7 23.0 22.2 21.4 20.4 19.5 18.4 18.7 15.3 15.1
1 a-lR Mo & 1-114 0-1R Mo 21.3 21.5 21.9 22.0 21.9 21.7 21.3 20.8 20.2 19.7 19.1 18.5 17.7 18.5 15.0 14.1
2-1/4 a - 1 Mo 20.9 21.0 21.3 21.5 21.5 21.4 21. l 20.7 20.2 19.7 19.1 18.5 18.0 17.2 15.8 15.:
5 O - I R Mo 16.9 17.3 18.1 18.7 19.1 19.2 19.2 19.0 18.7 18.4 18.0 17.8 17.1 16.8 18.0 15.1
- - - - - - - - - -
1 G 1 R Mo 14.1 14.4 15.3 18.0 18.5 18.9 17.1 17.2 17.3 17.2 17.1 18.8 18.8 16.2 15.8 152
9 0 - 1 Mo 12.8 13.1 14.0 14.7 15.2 15.6 15.9 18.0 18.1 18.1 18.1 18.0 15.8 15.8 15.2 15.1
3-1R Nickel 22.9 23.2 23.8 24.1 23.9 23.4 22.9 22.3 21.8 20.9 20.1 19.2 18.2 16.9 15.5 15.:
13 Cr 15.2 15.3 15.5 15.6 15.8 15.8 15.9 15.9 15.9 15.9 15.8 15.6 15.3 15.1 15.0 15.1
15 0 14.2 14.2 14.4 14.5 14.8 14.7 14.7 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.1
- - - - - - - - - -
17 a 12.8 12.7 12.8 13.0 13.1 13.2 13.3 13.4 13.5 13.8 13.7 13.8 13.9 14.1 14.3 14.!
TP 304 Sln. SU. 8.8 8.7 9.3 9.8 10.4 10.9 11.3 11.8 12.2 12.7 13.2 13.8 14.0 14.5 14.9 15.:
TP 316 & 317 Sln. Sll. 7.7 7.9 8.4 9.0 9.5 10.0 10.5 11.o 11.5 12.0 12.4 12.9 13.3 13.8 14.2 14.1
TP 321 & 347 Sln. SII. 8.1 8.4 8.8 9.4 9.9 10.4 10.9 11.4 11.9 12.3 12.8 13.3 13.7 14.1 14.6 15.1
TP 310 Stn. Stl. 7.3 7.5 8.0 8.8 9.1 9.8 10.1 10.8 11.1 11.8 12.1 12.6 13.1 13.8 14.1 14.!
- - - - - - - - - -
Nickel 200 38.8 37.2 35.4 34.1 32.5 31.8 32.5 33.1 33.8
NiCv Alloy 400 12.6 12.9 13.9 15.0 18.1 17.0 17.9 18.9 19.8 20.9 22.0
NiQ-Fc Alloy 600 8.6 8.7 9.1 9.8 10.1 10.6 11.1 11.8 12.1 12.6 13.2 13.8 14.3 14.9 15.5 18.C
Ni-FcCr Alloy 800 8.7 8.8 7.4 8.0 8.8 9.1 9.8 10.1 10.8 11.1 11.8 12.1 12.7 13.2 13.8 14.!
Ni-Fc-Cr-Mo-Cu Alloy 825 7.1 7.6 8.1 8.8 9.1 9.8 10.0 10.4 10.9 11.4 11.8 12.4 12.9 13.1
- - - - - - - - - -
Ni-Mo Alloy B 8.1 8.4 8.7 7.0 7.4 7.7 8.2 8.7 9.3 10.0 10.7
Ni-MnCr Alloy C-216 5.9 8.4 7.0 7.5 8.1 8.7 9.2 9.8 10.4 11.0 11.5 12.1 13.2
Aluminum Alloy 3003 02.3 102.8 104.2 105.2 108.1
Aluminum Alloy 6061 96.1 96.9 99.0 100.8 101.9
Tilanium 12.7 12.5 12.0 11.7 11.5 119 11.2 11.1 11.2 11.3 11.4 11.8
- - - - - - - - - -
Admirally 70.0 75.0 79.0 84.0 89.0
Naval Bram 71.0 74.0 77.0 80.0 83.0
Copper 225.0 225.0 224.0 24.0 23.0
90-10 Ou-Ni 30.0 31.0 34.0 37.0 42.0 47.0 49.0 51.O 53.0
70-30 Cu-Ni 23.0 25.0 27.0 30.0 33.0 37.0
- - - - - - - - - -
Munb 71.O
Zinxmium 12.0
a - M o Alloy XM-27 11.3
e-Ni-Fc-Mn-Cu-C% (AUoy 2 0 8 ) 7.8
NiCr-Mo-Cb (Alloy 625) 5.87 5.83 8.25 7.25 8.17 9.08 0.08 11.0 12.0

- -
 Chapter 6. HEATEXCHANGERS 381

A 6 3 Characteristics of Exchanger Tubes

(According to TEMA Standards)
I - - - - -
TUbC lntcmd
Sq. R
%.
ExtcmiL% €3
IntCml Tube Moma TRRNW
O.D.
lnchcs
B.W.G.
G.gc
IhiCkllC
lnchca
Arcs
sq. Ineh PP
- - - ad
Surf.0
Fu
SUd.C
Pcr Fa
ID.
hchu
-
of Innl
Incha
0.D.
ID.
Murl Al
sq. w
1 I4 22 0.028 0.0286
L&*
ht?*
0.W
Lcngd
0.0501 0.068 0.194 o.cw1 0.0009 0.07Dl
-
1.289
-
0.0195
24
26
0.022
0.018
0.0333 o.my 0.063 0.054 0206 o.cw11 OXme 0.081c 1.214 0.0158
0.0380 0.06Y 0.05% 0.M 0214 0.0000 O.CQJ7 0.W 1.168
248
27
-
18
-
0.016
0.049
0.0373
__ - 0.005l 0.0571
- - __ 0.040 0218
-0.-
- 0.-
- 0.0BZ
-1.147
0.0131
0.01 18
0 . m 0.W 0.om 0.171 0277 OmOBl 0.- 0.116f 94
20 0.035 0.0731 0.098: 0.om 1.354 0.0m
22 0.028
0.127 0.m O.UlC5 0 . m 0.1208 114 1.m 0.M74
0.0799 0.m 0.0835 0.104 0.319 0.0a)ll 0.0325 0.1231
24 0.022 125 1.176 0.0305
-- - 0.0860 0.-
__0.0887 0.063
- - - 0.331 0 . W
- 0.0020
- 0.125c
-- 134 1.133
- 0.0244
112 16 0.065 0.1075 0.1m 0.0988 0.302 0.370 0.0021
18 0.049 0.1269 0.0086 0.1555 168 1.351 0.0888
0.1m 0.1052 0236 0.402 0.0018 0.0071 0.1604 190 1.244 0.0694
20 0.035 0.1452 0.1m 0.1128 0.174 0430 0.0014 0.0056 0.1M 227 1.163 0.051 1
Y8
22
__ - -
12
0.028
0.109
0.1w
- 0.1m
- 0.1162 0.141
- - 0.444 0.0012
- - 0 . W 0.1872
- - 241
- 1.128
-
0.0415
0.1301 0.1636 0.1068 0.601 0.407 0,0081 0.0197 0.1865 m 1.536
13 0.095 0.1488 0.1636 0.1138 0.177
0.538 OA35 0.0057 0.0183 0.1w 232 1.437 0.158
14 0.083 0.1655 0.1638 0.1202 0.481 oA59 0.- 0.01 70 0.1839
15 0.072 0.1817 0.1258 258 1.362 0.141
0.1636 0.m 041 0.0019 0.0156 0.1 972 283 1 .a 0.125
16 0.065 0.1924 0.1636 0.1298
17 0.054 0.m5 0.1638 0.1333
0.389
0.352
OA%
0.509
0.0015 0,0145 0.1993 m 1.263 0.1 14
18 0.019 0.W 0.0134 02015 317 1.228 0.103
0.2181 0.1638 0.1380 0302 0.527 0.0337 0.0119 02244 340
19 0.042 0.239 0.1838 0.1416 1.188 0.089
O m 0.541 0.- 0.0105 02067 359 1.155
244
20
-0.035
0.134
-0.2419
- 0.1838 0.1453
0221
- - 0.555
__ 0.0028
- o.om1 02090
- __.
377
- 1.126
0.077
0.065
10 0.1825 0.1963 0.1262 0.W 0.492 0.0128 0 . W 02229 285
~

0.120 0.2043 0.1963 0.1335 1.556 0.259

0.808 0.510 0.0122 0.0328 02267 319 1.471 0.238
12 0.109 0.m 0.1063 0.1383 0.747 0.532 0.01 16
13 0.095 0.2483 0.0309 02289 347 1.410 0.219
0.1963 0.14ea 0 . a 0.560 0.0107 0.0285 0- 384 1.339 0.195
15
14 0.083 0.2679 0.1963 0.1529 0.592 0.584 0.0098
0.072 0.2884 0.- 02376 418 1.284 0.174
0.1963 0.1587 0.522 0.606 0.maS 0.- 02411 450 1.238 0.153
16 0.065 0.3018 0.1063 O.le23 0.476 0.620 0.W 0.2433
17 0.058 0.3157 0.0221 471 1.210 0.140
0.1963 0.1m 0.m 0.634 0.0076 0.mM 02455 492 1.183 0.126
18 0.049 0.3339 0.1963 0.1~7 0.367 0.852 0.0087 0.0178 0.2484 521 1.150
718
~
20
-0.035 0.3032
- 0.1963 0.1780
- -
0268
-
0.680 0.m
- -
0.01% 0.2531
-- 587 1.103
-
0.108
0.079
10 0.134 0.2894 0.2291 0.1589 1 .og2 0.607 0.0221 0.0505 0 . m
11 0.120 0.3167 0.2291 0.1682 451 1.442 0.312
0.969 0.635 0.oZoB 0.0475 0.2703 494 1.378 0.285
12 0.109 0.3390 OPgl 0.1720 0.893 0.657 0.0196 02736
13 0.095 0.3665 0.0448 529 1.332 0.W
0.Pgl 0.1783 0.792 0.685 0.0180 0.0411 0.2778 575 1.277 0.23
14 0.083 0.3948 0.2291 0.1856 0.m 0.709 0.0164 0.0374 0.2815
15 0.072 0.4197 616 1 .r34 0.207
0.2291 0.1914 0.618 0.731 0.0148 0.0337 0.2850 655 1.197 0.182
16 0.065 0.4350 0.2291 0.1950 0.563 0.745 0.0137 0.0312 02873
18
17 0.058 0.4525 BBO 1.174 0.165
022Sl 0.1987 0.507 0.7759 0.0125 0.0285 02896 706 1.153 0.149
0.049 0.4742 0.2291 O m 0.433 0.m O.0lOg
20 0.035 0.0248 02925 740 1.126 0.127
1 8
-
0.165
0.5090
-
0.3526
0.Pgl
__
0.2818
02107
-
0.1754
0.314
- -
0.805 0.-
- -
0.0187 0.2872
- 794
- ~
1.087 0.W
-
1.473 0.670 0.0392 0.0784 0.3009 550 1.493 0.433
10 0.134 OAm 0.2618 0.1818 1241 0.7-32 0.0350 0.0700 0.3098
11 0.120 0.4536 0.2818 0.1m 656 1.366 0.365
0.109 1.129 0.780 0.0327 0.W 0.3140 708 1.316 0.332
12 0.4803 0.2618 0.W7 1 .om 0.782 0.0307 0.0615 0.3174 749
13 0.095 0.5153 oal8 0.2121 1.279 0.305
0.91 0 0.810 0.0280 0.0559 0.3217 804 1.235 0.270
14 0.083 0.5463 oal8 0.2183 0.814 0.834 0.0253 0.0507 0.3255
15 0.072 0.5755 0.2618 0.2241 852 1.199 0.239
0.065 0.714 0.856 0.0227 0.0455 0.3291 890 1.168 0.210
18 0.5945 0.2618 02278 0.650 0.870 0.0210 0.0419 0.3314 927
18 0.049 0.6390 0.2618 02361 1.149 0.191
0.490 0.902 0.0166 0.0332 0.3387 997 1.m 0.146
~
20
-
0.035 0.6793
- -
0.2818 02435
- 0.361
- 0.W 0.0124
- -
0.0247 0.3414
- - 1060
- 1.075 0.106
1-114 7 0.180 0.6221 0.3272 0 . m 2.m OSOD 1.0890 0.1425 0.3836 sm
~

8 0.165 0.6648 0.3272 02409 1.404 0.605

1.914 0920 1.0847 0.1355 0.3880 1037 1.359 0.562
10 0.134 0.7574 0.3272 02571 1.593 0982 1.0742 0.1187 0.3974 1182
11 0.120 0.8012 0.3272 0.-
1.273 0.470
1.450 1.010 1.m 0.1100 0.4018 1250 1.238 0.426
12 0.109 0.8365 0.3272 0.2702 1.330 1 .032 1.m2 0.1027 0 .W 1305
13 0.095 0.8825 0.3272 0.2775 1.211 0.391
0.083
1.173 1.080 1.0579 0.0826 0.4097 1 377 1.179 0.345
14 0.9229 0.3272 02838 1.038 1.084 1.0521 0.0833 0.4136 1440 1.153

t
16 0.065 0.9852 0.3272 0 . W 0.304
0.049 0.824 1.120 1.0426 0.0682 0.4196 1537 1.116 0.242
18 1.0423 0.3272 0.3016 0.629 1.152 1 .m 0.0534 0.4250 1626 1.085 0.185
1-112
0.035
__
0.134
1.0936
- -
0.3272 0.m9
- 0.455
- - 1.160 1.0247
- -
0.0395 0,4297
- -1708 1.059
- 0.134
__
1.1921 0.3927 0.3225 1.957 1232 1.1354 0.1808 0.4853 18M) 1.218 0.575
0.109 1.2908 0.3927 0.3356 1.621 1282 1.11759 0.1545 0.4933 2014
0.083 1.3977 0.3927 0,3492 1.170 0.476
1257 1334 1.0931 0.1241 0.5018 2180 1.124
2
-
0.065
0.120
1.4741
- -
0.3927 0.3587
- 0.897
- ~
1.370 1.0758
- -
0.1008 0.5079
- - 2300
~
1.095
~
0.369
0.293
2.4328 0.5238 04808 2.412 1.780 1.3144 0.3144 0.6660 3795
12 o.im 2.4941 0.5238 0.4685 2.204 1.782 12901 02904 0.6697 3891
1.136
1.122
0.708
0.648
13
-
0.095 2.5730 0.5238 0.4739 1.935 1.810
-
12586 02588 0.6744 4014 1.105 0.569
14 0.083

ow
2.6417 0.5238
carbon steel with a density of 0.28%
0.4801
-1.701
.lua m
- -
1.834 1
m O m 0.6784 4121 1.091 0.500
other m d r mu
D
I lY Lby lowing DIS:

Aluminum ..................... 0.35

__..___ Aluminum Bronze ...................... 1.04 Nickel ................................................ 1.13
Titanium .......................... 0.58 Aluminum Brass ........................ 1.06 Nickel-Copper ........................... 1.12
A.I.S.I. 400 Series S/Steels ......... 0.99 Nickel-Chrome-I
A.I.S.I. 300 Series S/Steels __ 1.02 Admiralty . _ _ _ _ . _ _ _ _

Ibs. Per Tube Hour

* * Liquid Velocity = in feet per sec. (Sp. Gr. of Water at 60°F = 1.0)
C x Sp. Gr. of Liquid
 302 Chapter 6 HEATEXCHANGERS

Usual Tube Diameters and Gages

TABLE RCB-2.21

O.D. Copper and Copper Alloys Carbon Steel, Aluminum Other Alloys
Inches and Aluminum Alloys
B.W.G. B.W.G. B.W.G.
1/4 27 27
24 24
22 22
3/8 22 22
20 20
18 18
1/2 20 20
18 18
5/8 20 18 20
18 16 18
16 14 16
3/4 I 20
18
16
14
18
16
I 16 14
7/ 8 I 18 I 14 I 16
16 I 12

lfi

16 I 14 I 14 I
1-1/2 16 14 14
14 12 12
2 14 14 14
12 12 12
 Chapter 6 HEATEXCHANGERS 383

A6.4 Heat Exchanger Types (According to TEMA Standards)

FRONT END REAR END

STATIONMY HEAD TYPES WEU TlpEI
HEAD rms

t3 AI_ *
CHANNEL:

AND REMOVABLE COVER

I
I
-
ONE PASS SHELL
-

-------______________
TWO PASS SHELL

WITH LONGITUDINAL BAFFLE

FIXED TUBESHEET
LIKE "A" STATIONARY HEAD

FIXED TUBESHEET
LIKE "B" STATIONARY HEAD

FIXED TUBESHEET
LIKE 'N" STATIONARY HEAD
BONNET (INTEGRAL COVER) SPLIT FLOW

JUTSIDE PACKED FLOATING HEAC

DOUBLE SPLIT FLOW

FLOATING HEAD
WITH BACKING DEVICE

DIVIDED FLOW

IL
CHANNEL INTEGRAL WITH TUBE.
SHEET AND REMOVABLE COVER

KETTLE TYPE REBOILER

U-TUBE BUNDLE

SPECIAL HIGH PRESSURE CLOSURE CROSS FLOW EXTERNALLY SEALED

FLOATING TUBESHEET
384 Chapter 6 HEATEXCHANGERS

Heat Exchanger Component Nomenclature

(Excerpted from TEMA Standards)

1. Stationary head - Channel 20. Slip-on backing flange

2. Stationary head - Bonnet 21. Floating head cover - External
3. Stationary head flange - Channel 22. Floating tubesheet skirt
or bonnet 23. Packing box
4. Channel cover 24. Packing
5. Stationary head nozzle 25. Packing gland
6. Stationary tubesheet 26. Lantern ring
7. Tubes 27. Tierods and spacers
8. Shell 28. Transverse baffles or support plates
9. Shell cover 29. Impingement plate
10. Shell flange - Stationary head end 30. Longitudinal baffle
11. Shell flange - Rear head end 31. Pass partition
12. Shell nozzle 32. Vent connection
13. Shell cover flange 33. Drain connection
14. Expansion joint 34. Instrument connection
15. Floating tubesheet 35. Support saddle
16. Floating head cover 36. Lifting lug
17. Floating head cover flange 37. Support bracket
18. Floating head backing device 38. Weir
19. Split shear ring 39. Liquid level connection

AES
 Chapter 6 HEATEXCHAMGERS 385

d d b b BEM d d
386 Chapter 6 HEATEXCHANGERS

AKT

AJW
 Chapter 6. HEATEXCHANGERS 387

References
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Services. American Petroleum Institute, Washington, USA.
388 Chaoter 6 HEATEXCHANGERS

20 Mukherjee R. (1997) Effectively design air-cooled heat exchangers.

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