100 General Information

Abstract
This section provides an overview of typical heat exchanger applications, available
industry technology and standards, and the Company’s normal degree of involve-
ment in heat exchanger design and selection.

Contents Page

110 Types of Exchangers and Applications 100-2

120 Industry Codes and Practices 100-2
130 Company Practice 100-3

Chevron Corporation 100-1 December 1989

100 General Information Heat Exchanger and Cooling Tower Manual

110 Types of Exchangers and Applications

The type of exchanger used for a given service depends on process, safety and oper-
ating requirements, and economics. Selection of the most economical heat
exchanger in a given service includes the initial cost of the exchanger, installation
costs, maintenance costs, incremental pumping and compression costs, and where
applicable, utility system investment and energy requirements.
As an example, the initial cost of a water-cooled shell and tube heat exchanger will
be much less than an air-cooled heat exchanger for the same service. However, the
cost of the cooling water supply, including makeup water, chemical treatment, blow-
down disposal, the cooling tower and fans, water circulation pumps, and piping to
and from the water-cooled exchanger, often more than offset the lower first cost of
the water-cooled exchanger. Operating and maintenance costs for water coolers are
also more than for air coolers.
Air cooling is usually more economical than water cooling when the required
process fluid outlet temperature is 20°F or more over the design ambient air temper-
ature. Specific air cooler types, and their applications and limitations, are discussed
in Section 600.
In most cases, a custom designed shell and tube heat exchanger will be the econom-
ical choice. Specific varieties of shell and tube exchangers, and their applications
and limitations, are discussed in Section 400.
Pre-engineered double pipe or small multitube hairpin heat exchangers compete
with custom designed shell and tube exchangers and are usually economical when
the required heat transfer surface area is less than about 1000 square feet. Informa-
tion on small pre-engineered exchangers is given in Section 400.
Plate and frame heat exchangers may be economical where weight and space are
highly valued, alloy material is required, pressures and temperatures are moderate
(less than 200 psig and 250°F), and fluids are compatible with rubber gaskets. Tita-
nium plate and frame exchangers on offshore platforms in sea water/fresh water
service are appropriate applications.

120 Industry Codes and Practices

The Company uses Heat Transfer Research Inc. (HTRI) technology, supplemented
by Company experience, for design and evaluation of thermal and hydraulic perfor-
mance of heat exchangers. HTRI conducts large scale tests of heat exchangers and
incorporates the results into reports and computer programs. HTRI has tested exten-
sively shell and tube exchangers in boiling, condensing and single phase service,
and completed limited testing of air coolers and plate and frame exchangers. HTRI
information is contract confidential and should not be disclosed outside of the
Company.
Mechanical design of exchangers is based on standards developed by the American
Society of Mechanical Engineers (ASME), Tubular Exchanger Manufacturers Asso-
ciation (TEMA), American Petroleum Institute (API), and Chevron.

December 1989 100-2 Chevron Corporation

Heat Exchanger and Cooling Tower Manual 100 General Information

ASME covers mechanical design of pressure vessel components (shells, channels,

tubesheets, headers and some aspects of large flanges), and imposes restrictions on
piping, instrumentation and inspection of steam boilers.
TEMA addresses shell and tube heat exchangers only, and covers nomenclature,
fabrication tolerances, standard tube sizes, standard clearances, minimum plate
thickness, and minimum tie rod requirements. TEMA also provides tubesheet
design rules that differ from ASME tubesheet design rules.
TEMA tubesheet rules are used for most shell and tube exchangers. ASME
tubesheet rules are used for stayed fixed tubesheet steam boilers, and air cooler
headers. API standards address mechanical design criteria of shell and tube
exchangers, and air-cooled exchangers.
There are no industry standards for double pipe, multitube hairpin or plate and
frame heat exchangers.
Fouling, corrosion, tube vibration, leak tightness of flanges, and safe design for
tube rupture pressure transients are also discussed in this manual because the
subjects are beyond the scope of industry standards. (See Sections 200, 300 and
500.)

130 Company Practice

Company practices vary. Some locations normally specify all geometric parameters
that affect thermal and hydraulic performance of shell and tube exchangers, with
due consideration for fouling, corrosion, tube vibration, and maintainability.
Mechanical design is then left to the manufacturer, subject to the Company’s speci-
fied criteria and standards. Other locations only specify the fluid streams, flow
rates, and desired thermal performance. They rely on Vendors to do the mechanical
and thermal design, and have reported satisfactory results.
Experience with shell and tube exchanger manufacturers also varies. Some facilities
have experienced problems with manufacturers’ designs for controlling tube vibra-
tion, fouling, corrosion, and thermal and hydraulic performance, whereas other loca-
tions routinely leave these design considerations to the manufacturer and
experience no problems.
Thermal, hydraulic, and mechanical design of air coolers are usually completed by
the manufacturer, subject to the Company’s specified criteria and standards. Air
coolers are used to condense and cool low viscosity fluids. Vendors have adequate
expertise in these services, and in air side design, including fan design, hub seals,
tip seals, auto-variable blade control, etc. If fouling is a potential problem, the
Company must take responsibility for it and advise the Vendor how to control it.
Tube vibration is not a problem in air coolers.
Double pipe and small multitube hairpin exchangers are pre-engineered and have
proprietary components. They are preferred for small duty, low viscosity, single
phase services. The Company normally selects specific models from catalog infor-
mation.

Chevron Corporation 100-3 December 1989