7 EG-3 Approved Dec 03

Air-Cooled Heat Exchangers

Engineering Guides and General Specifications

7 EG-3
Air Cooled Heat Exchangers
Table of Contents

1. General.......................................... 2 4.5 Additional Process Control

1.1 Scope.................................................. 2 Considerations..................................10
1.2 References ......................................... 2 4.6 Arrangement .....................................11
4.7 Viscous Oil Coolers ..........................11
2. Process Specification and 4.8 Coolers with Mixed Phase Inlet Flow
Design Considerations ................ 2 when at least One Phase is
Corrosive...........................................13
3. Thermal Design Methods ............ 5 4.9 Design Pressure And Temperature ..14
4.10 Tubes ................................................17
4. Mechanical Design 4.11 Headers ............................................18
Considerations ............................. 5 4.12 Steam Coils.......................................20
4.1 General ............................................... 5 4.13 Fan Considerations...........................20
4.2 Special ................................................ 6 4.14 Structures And Platforms..................21
4.3 Type, Induced or Forced Draft, with 4.15 Materials ...........................................22
Horizontal Tube Bundle ...................... 7 4.16 Pre-Assembly....................................22
4.4 Control of Process Conditions Using 4.17 Preparation for Shipment..................23
Air Flow Variation ............................... 8

Drawings
7/8D4 Detail of Two-Part Plug with Gasket Compressor
7/8D5 Two Phase Flow Regimes in Horizontal Tubes

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1. General

1.1 Scope

1.1.1 This guide is intended to aid the specifier and purchaser of air-cooled heat
exchangers in the selection of features and design requirements appropriate
to the service and selected design class.
1.1.2 This guide and General Specification 7 GS-5 are written specifically for dry
surface air coolers using ambient air. Wet surface and humidified air
designs have generally different, and specialized, applications and are not
covered although many of the requirements are similar.

1.2 References

1.2.1 Shell General Specification 2 GS-30, Supplementary Requirements for SA-

516 Steel Plate in Wet Hydrogen Sulfide Service
1.2.2 Shell General Specification 7 GS-5, Air-Cooled Heat Exchangers
1.2.3 Shell General Specification 8 GS-10, Requirements for Steel Pressure
Equipment in Wet Hydrogen Sulfide Service
1.2.4 Shell General Specification 24 GS-8, Environmental Protection - General
Equipment Noise Data
1.2.5 Shell Engineering Guide 2 EG-1, Materials Selection
1.2.6 Shell Engineering Guide 24 EG-7, Environmental Protection - Noise
1.2.7 Shell General Specification 15GSSMT001, AC Squirrel Cage Induction
Motors up to 600 Volts for the Shell-Siemens Alliance
1.2.8 ISO 13706 Petroleum and natural gas industries Air-cooled heat
exchangers, First edition, April 2000

2. Process Specification and Design Considerations

2.1 Properties and data must be provided in the manner specified in the following
paragraphs to allow design and analysis using Shell's preferred methods.
2.2 For single phase cooling, transport properties (viscosity, density, thermal
conductivity, specific heat) shall be provided at the inlet and exit conditions. The
pour point temperature shall be specified for liquids with pour points greater than
20F (11C) below the minimum ambient temperature for the location in which the
air cooler will be installed.
2.3 For condensing streams, transport properties shall be provided for each phase at the
inlet, mid and outlet conditions. The transport properties shall be based on the total
composition of each phase including water, air and/or steam when these components

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are part of a homogeneous phase. Additionally, plots of percent heat duty, percent
(by weight) vapor, percent (by weight) of the second liquid phase (if present) and
vapor molecular weight vs. temperature at inlet pressure and the inlet pressure minus
the allowable pressure drop shall be provided. The above information shall be
calculated under the assumption of thermodynamic equilibrium.
2.4 If condensate has immiscible components liquid properties are to be specified
separately and completely for each liquid phase, and in addition to the other curves,
the percent (weight) of one liquid phase plotted against temperature should be
provided.
2.5 Data sheets and curve-specified data must represent the actual design conditions.
2.6 All expected operating conditions are to be identified by separate data sheets.
Predictable upset conditions and full range of flows (turn-down) should also be
indicated.
2.7 Liquid properties at the dew point and vapor properties at the bubble point should be
included when such points occur within the air cooler.
2.8 If liquid disengages from vapor in an amount sufficient to alter vapor-liquid
equilibrium implicit in clause 2.3 above, differential condensation plots of percent
(weight) vapor and vapor molecular weight should be provided.
2.9 The heat exchange (duty) specified should be consistent with the flow and
temperatures specified. If excess flow or heat exchanger capability is required the
resulting temperatures, flow and heat load should be specified.
2.10 Air coolers should not be specified with "excess surface". Instead abnormal flows
and/or temperature conditions that are expected to impose additional duty
requirements should be specified. In the case of heavy fouling expectations, define
the condition by a fouling factor.
2.11 Tubeside fouling factors should be based on experience in a specific service. When
no other data or experience is available, TEMA recommended values for the most
similar fluid may be used.
2.12 External fouling factors are not normally applied. These should be identified only
when there is concern about a particularly dirty environment (dust, seeds, cooling
tower drift, etc.). Fouling of the external surface usually affects the resistance to air
flow with little effect on heat transfer coefficient. The performance of the cooler
suffers due primarily to reduced air flow and temperature difference so imposition of
a thermal resistance (fouling factor) is not realistic. An allowance on air flow should
be considered in such cases.
2.13 The air dry bulb temperature is determined by geographical location and localized
plant influences. Base data, by geographical location, is obtained at urban centers
and military installations. This information should then be modified (usually an
increase) to reflect any local variations, due largely to plant operations. It is good
practice to obtain ambient dry bulb temperature readings at the proposed site and
compare them to simultaneous readings taken at the nearest source of base weather
data. The difference between the readings will indicate the appropriate correction for
plant influences. The correlation is best when the base data and cooler site locations
experience similar weather conditions, usually requiring relatively close proximity.

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Base dry bulb temperature data, by geographical location, is available in various

publications. Two of these are "Evaluated Weather Data for Cooling Equipment
Design" published by Fluor Products Company in 1958 and "Engineering Weather
Data" published by the Marley Company. Each includes information on dry bulb
temperature which is equaled or exceeded a stated percentage of the time during the
four hottest months of the year.
Air-cooled exchangers designed for a high likelihood of meeting or exceeding the
process duty requirements will usually base the inlet design air temperature on the
ambient dry bulb temperature that is equaled or exceeded five percent of the time
during the four hottest months. To this base should be added an allowance for
surroundings and recirculation. For FW-2 Class 1 plants the allowance should
be 2F (1C). For Class 2 plants the allowance should be 5F (3C). For Class 3
plants the allowance should be 7F (4C).
Exchangers in rundown service may use the ambient dry bulb air temperature
determined as above less 5F (3C) to take advantage of the normal diurnal
temperature variation.
Exchangers in cooling-sensitive services such as refrigeration and compressor
interstage cooling may require larger air temperature additives than above to assure
proper operation.
2.14 Provide the design minimum ambient air temperature as this may be important in the
selection of the temperature control method to avoid freeze point or dew point (if
corrosive) and in mechanical construction. The latter is a factor if duty is allowed to
vary with ambient temperature. In such a case the process temperature range can
become large and require split header construction to handle the thermal expansion
differential between passes.
2.15 It is generally less costly, on an evaluated basis, to maintain all of a cooling duty in
one type of equipment, e.g., air-cooled or water-cooled exchanger, rather than
dividing the duty between air and water cooled units when cold end approach
temperatures are 20F (-7C) or more. Pressure drop, extra first cost, process
requirements, additional maintenance, piping, and plot area considerations all affect
this evaluation. Although air-cooled exchangers have been designed with a 5F
(-15) cold end approach this is unusual. When the cold end approach drops below
20F (-7C) the cost of the unit rises rapidly and the option of applying a downstream
water-cooled exchanger to handle part of the duty should be evaluated. For such an
arrangement studies based on 95F (35C) design air and 90F (32C) design cold
water temperatures have shown that the optimum process temperature for the
transition between types of cooler is about 130F (54C). This temperature optimum
may rise for short life units where the cooling water cost could reflect the short usage
period because the water capacity could be utilized elsewhere after unit shutdown.
2.16 The vendor should be required to predict the natural draft performance with design
ambient air temperature when necessary to determine relief valve requirements. Such
will typically become important during power failure conditions when cooling
capability is reduced due to fan outage and high pressure relieving flows are likely to
occur. The cooling due to natural draft may reduce relief system design loads.

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2.17 Conditions of shock loading or higher than normal inlet temperature, as a result of a
power failure or unit upset, should be specified when predictable.
2.18 Units that may be subject to continued high temperature flow during a power failure
(loss of fans) should be so indicated to the vendor.

3. Thermal Design Methods

The thermal design for air cooled exchangers is normally performed by the vendor. During
the evaluation of the vendors' bids the contractor and/or Shell should check rate the vendors'
thermal designs. The vendors' design should be adjusted as required by the calculations.
HTRI methods must be used in the check rating calculations.

4. Mechanical Design Considerations

4.1 General

4.1.1 Air-cooled heat exchangers are generally attractive for services with large
duty, services at elevated temperatures which would cause excessive
scaling if water coolers were used, and where water use for cooling is
restricted.
4.1.2 Air-cooled exchangers are typically located on structural frames either near
grade or over pipe racks. The latter choice allows more compact plant
designs and may reduce piping costs but at the expense of added access and
maintenance walkways. Either location is technically acceptable from the
exchanger viewpoint as long as vibration is minimized and air inflow to the
fan or tube bundle is not restricted.
4.1.3 An adequate unobstructed flow area for incoming cooling air is required so
as to avoid flow maldistribution to the bundle, inadequate air flow to fans
leading to unstable operation, and excessive air velocities which may
increase recirculation of warm discharge air to the bundle inlet. A common
rule-of-thumb to allow adequate inlet air flow area is to locate the fan
(forced draft type) or the tube bundle (induced draft type) so that the
approach velocity of the entering air does not exceed 800 ft/min
(244M/min) (nominal).
A different rule, applicable only to forced draft fans, is that the approach
velocity should not exceed fifty percent of the fan discharge velocity. The
approach velocity is based on the area of a cylinder of diameter equal to the
fan ring and projected normally to the nearest obstruction. Usually the
more conservative of these rules should be applied, to assure adequate air
flow.

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4.1.4 Recirculation of warm discharge air to the inlet air stream reduces heat
transfer because the temperature difference is lessened. Air recirculation
problems may be minimized by the following.
1. Maintain low inlet air approach velocity.
2. Maximize warm exit air discharge velocity.
3. Avoid placing air-cooled exchangers at different elevations near each
other.
4. Refer to section 4.6 for additional guidance.
4.1.5 Tube bundles for condensing services should have full width (not partial
width) tube passes so that temperature differences and performance are
readily predictable, unless the design analysis is shown to properly account
for the unequal air temperatures leaving any row.
4.1.6 Tube bundle designs with partial rows per pass at the inlet (hot) end of
the process fluid flow path should be evaluated to determine the need
for split headers or other methods of restraint relief. Lack of
appropriate restraint relief can result in bowed tubes, roll leaks, and
air flow restriction due to unequal thermal expansion of tube rows.
4.1.7 Where four or more fans are applied in systems designed for long life and
minimum maintenance the use of automatic central greasing systems for
lubrication of fans, actuators, and drivers should be evaluated. Significant
increases in bearing life are attributed to use of these systems.
4.1.8 The motors specified in General Specification 7 GS-5 conform to General
Specification 15GSSMT001. Only the appropriate specification and Motor
Design Data Sheet are to be supplied with the inquiry.
4.1.9 If a specific model of vibration switch is desired it should be so stated in
the inquiry.
4.1.10 Use of ISO 13706 checklist is useful in preparing data sheets and selecting
design options.
4.1.11 An equipment noise data sheet is to be supplied in the inquiry for each
item. For normal noise limitation requirements use the data sheet 24G8S1
from General Specification 24 GS-8. Where a particularly noisy operating
area or restrictive fence line noise limits occur the allowable equipment
sound pressure levels are to be developed per Engineering Guide 24 EG-7.
The noise data sheet to be used is then 24E7S1 Engineering Guide 24 EG-7
with the allowable levels noted in Column A.

4.2 Special

4.2.1 The Material Selection Report should be consulted for special requirements
such as postweld heat treatment or hardness.
4.2.2 If a carbon steel exchanger will be in wet H2S service, clause 4.6. in
2 EG-1 should be consulted. It will usually require the use of 2 GS-30 and
8 GS-10 in addition to the regular General Specification (7 GS-5) for the

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exchanger. 2 GS-30 spells out the supplementary requirements for SA-516

steel plate in wet H2S service. 8 GS- 10 spells out the additional
fabrication and nondestructive testing requirements for carbon steel
pressure equipment in wet H2S service.
The additional requirements of 8 GS-10 are set by specifying whether the
exchanger will be per category 1 or category 2. These categories are set by
mutual agreement between the Shell Material and Pressure Equipment
Specialists. The severity of service category of the exchanger, 2 GS-30,
8 GS-10 and the basic General Specification (7 GS-5), should all be
specified on the exchanger data sheet.
1. The welding and inspection requirements in 8 GS-10 will prohibit the
use of plug box headers and welded return bends. Removable cover
plate or bonnet headers will be required (See clause 3.10.2. and
3.10.3.). Where economically attractive, alloy plug box headers may be
used in lieu of carbon steel removable cover plate or bonnet headers. At
pressures greater than 400 psig (2,760 kPag), alloy plug box headers
shall be used. The Shell materials specialist should be consulted
regarding acceptable alloy materials.
2. When construction per 8 GS-10 is required, the minimum nozzle size is
2 in. Long weld-neck type nozzles are required for 4 in and smaller
nozzles.

4.3 Type, Induced or Forced Draft, with Horizontal Tube Bundle

4.3.1 Normally the type should be specified as forced draft, except as indicated
below, to facilitate retubing and for ease of access to fans, fan bearings, and
AV hubs as well as to minimize the exposure of the rotating parts to high
temperature.
4.3.2 Condensers with process inlet temperature less than 300F (149C) and
other services with process inlet temperature less than 300F (149C)
where rain on the cooler may upset the process system control should
normally be specified as induced draft. The hood over the tubes of an
induced draft unit provides protection against the thermal impact of rain on
the tubes. If outlet air temperature can exceed the limits for fan, bearings,
grease, and appurtenances a forced draft design should be applied.
4.3.3 Induced draft is preferred for services with process inlet temperature less
than 300F (149C) and a cold end and/or hot end temperature approach of
20F (-7C) or less so as to facilitate the uniform air distribution desirable
to assure a close temperature approach. If outlet air temperature can exceed
the limits for fan, bearings, grease, and appurtenances a forced draft design
should be applied.
4.3.4 Units with a process inlet temperature higher than 300F (149C) and a
cold end approach of 20F (-7C) or less may be specified as forced draft at
the hot end and induced draft at the cold end where the size requirement is
for more than one bay, where the routing of the process fluid in series is

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acceptable, and if warm air recirculation from the forced draft to the
induced draft unit can be avoided. Otherwise they should be specified as
forced draft only.
4.3.5 The use of other types such as A-frame, natural draft, vertical fan and/or
bundle, wetted surface should be considered where economically and
technically feasible but should be specifically approved.

4.4 Control of Process Conditions Using Air Flow Variation

4.4.1 Air flow variation is a common technique used in air-cooled exchangers to

control process conditions. Auto variable pitch (AV) fans, wherein the fan
blade pitch varies continuously thus modulating the fan's pumping
capability, are most commonly applied for air flow control. AV fan hubs
may be specified to conserve fan power, when economical, in addition to
providing close process temperature control.
The evaluation when considered for power savings alone must include the
increased installation and maintenance costs over the standard manually
adjustable pitch hub design, which requires shutdown to manually change
blade pitch. The greater reliability of the adjustable pitch hub will
generally be preferred unless evaluation shows a great advantage in power
savings for the AV fan.
4.4.2 AV hubs applied for process control may employ a valve positioner with
mechanical feedback and a single passage rotary union. Dual air passage
rotary unions are not acceptable due to poor reliability and the impact of
union failure on other fans in the same control system. Hysteresis should be
specified as a maximum of 1 percent of full stroke to provide precise
process control. For critical control applications and/or services where an
AV hub failure may damage the tube bundle (freeze-up or corrosion) and
maximum reliability is required, a hub employing a detached actuator
serviceable from the maintenance platform may be considered. Such an
alternative arrangement is shown in drawing 7/8D3.
4.4.3 In lieu of a valve positioner amplifying bias relays may be used where
hysteresis of 1 in blade position, and the implied reduced accuracy of
process control, is acceptable. These relays amplify the control signal so as
to provide greater force on the hub actuator diaphragm or piston.
4.4.4 AV hubs employed only for power conservation should be specified
without valve positioners. The maximum allowable fan hysteresis should be
specified as 1. Amplifying bias relays should be employed on each AV
hub when necessary to reduce the hysteresis to within 1 to assure the
planned power savings.
4.4.5 Isolating 1:1 relays should be installed for each AV hub on installations of
multiple AV hub fans actuated by a single controlling instrument directing
signal air to the actuator diaphragm or piston. They are not required when
valve positioners or individual amplifying bias relays are used. These
relays prevent a hub failure from affecting other fans controlled by the

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same instrument, but may be eliminated for minimum cost equipment

where higher maintenance and reduced stream factor are acceptable.
4.4.6 Normally AV fans should be specified to go to full pitch on air failure. A
lock-in-position feature should be specified for supply air failure only for
critical services where maximum air flow may damage the tube bundle.
The lock- in-position feature does not function in the event of a signal air,
rotary union or hub diaphragm or piston failure.
4.4.7 Avoid combining AV and manually adjustable pitch fans in the same
service. Such fans typically do not have equal capacities so conditions
occur where the air flow from one is too little and from the other is too
great to maintain control, e.g., the fans "hunt" or cycle causing poor
control..
Another problem with combining AV and manually adjustable pitch fans
occurs in hot services on forced draft units. Control of the process with the
adjustable pitch fan on may require that the AV hub reverse blade pitch and
air flow. This could cause overheating and failure of the AV hub.
If AV hubs are to be used for control specify all fans in the service as
having autovariable pitch hubs.
4.4.8 Variable frequency AC controllers are normally preferred in lieu of AV
hubs. While the first cost is usually higher for the variable frequency
controllers, maintenance/reliability issues normally make the variable
frequency controllers attractive especially in Class IV plants. For units
with multiple bays the number of controllers specified should reflect a
balance between required reliability and first cost. A Shell electrical
specialist should be consulted regarding use of these items. Critical speeds
of the fan should be identified so that the variable frequency controller can
be programmed to avoid operation at these speeds.
4.4.9 In evaluating AV hubs versus speed variation consider the range of control
desired. AV hubs can reverse the fan blade pitch so as to eliminate net air
flow, even that due to natural convection, and provide a zero cooling mode.
Speed variation control would require reversal of rotation to accomplish
zero cooling. Reverse rotation is undesirable due to the potential for
structural damage of the fan blades.
4.4.10 Process control via air flow variation becomes less accurate below a bundle
face velocity of about 100 ft/min (30M/min). Below this point louvers
should be considered if close control is important. Evaluation of the impact
of this limitation should consider likely process flow variations and the
superimposed impact of low ambient air temperature.
4.4.11 Automatic louvers should normally not be used for process control except
in recirculation units, to control an individual bundle in a bay with bundles
in other services, or for a service with large turndown requirement.
Louvers require significantly increased fan power, even when open, and
represent more costly operation than fan blade pitch or speed variation for
control. Louvers are generally installed above the tube bundle in the
discharge air stream.

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4.4.12 Units specified with steam coils should normally have louvers for heat-up
purposes. Louvers are closed to allow rapid warming of the bundle for
start-up or melt-out. Such louvers can be provided with either a manual or
pneumatic actuator, the choice to depend on design classification and
frequency of operation.
4.4.13 Louvers should normally go to the full open position or remain in last
position on control air failure, if fitted with an actuator.
4.4.14 The cost of operation with fully open louvers can be approximated by
adding one velocity head of air flowing through the louvers to the fan
delivered pressure and determining the resulting increase in power
requirement.
4.4.15 Louvers may be provided in either opposed blade or parallel blade
configurations. The latter are less expensive, have less complex linkage,
and close more tightly. The parallel blade louvers do deflect the exiting
warm air and may promote recirculation or high ambient temperatures in an
adjacent elevated operating area if poorly oriented. If the prevailing wind
blows toward the parallel louver opening the fan performance will suffer.
Opposed blade louvers maintain a linear percent opening versus blade angle
(or control signal) characteristic over a greater range of angle than parallel
blade designs. This is advantageous for wider control ranges.
Normally parallel blade louvers will be applied unless problems with this
design are identified or the vendor requires an opposed blade system to
provide the required control.

4.5 Additional Process Control Considerations

4.5.1 Process temperature control can also be achieved by bypassing fluid around
the air cooler. Turndown for this method is limited unless control valves
are provided for both the cooler flow and bypass flow. If the process fluid
can freeze or become highly viscous this option should be avoided since the
bypass flow increases as the air temperature drops and the intube
temperature may rapidly fall to the critical level.
4.5.2 Viscous fluid coolers with multiple coils or bundles in parallel should be
provided with controls to equalize flows through the active paths.
Otherwise a slight change in conditions, caused for example by uneven
cooling, will increase the pressure drop in one path shifting flow and duty
to the other path(s). The cooler thermal performance will deteriorate, the
pressure drop will increase, and some portions may become plugged.
4.5.3 Viscous or freezing fluid services with a large temperature range are
sometimes cooled in two bays in series, with the hot bay arranged counter
currently (air versus fluid) and the cold bay arranged concurrently. For
such cases the outlet temperature of each bay should be individually
controlled to avoid overcooling and potential flow problems in the hot bay.

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4.6 Arrangement

4.6.1 The vendor should be advised of the prevailing summer wind direction and
the proposed arrangement of the units relative to each other, to existing air
coolers, to other heat generating equipment and to any objects in close
proximity that may affect air recirculation. Air flow obstructions either
upwind or downwind promote recirculation if near the air-cooled exchanger
and should be avoided. (Refer also to clause 3.1.3).
4.6.2 The proposed arrangement should be reviewed with the vendor; the
purpose being to optimize the arrangement if possible or to determine the
need for stacks or skirts to mitigate recirculation and sustain design
performance.
4.6.3 Place air-cooled exchangers with close temperature approaches upwind of
other (particularly forced draft) air coolers.
4.6.4 Forced draft units should be grouped together, where practical, to minimize
air circulation to induced draft units and to minimize header walkway
elevation changes. Minimize mixing of forced and induced draft designs in
a single air cooler bank for the same reasons.
4.6.5 Locate air cooled exchangers so that steam vents, process vapor vents,
combustion products, and cooling water tower vapors and drift do not enter
the bundles to avoid the additional cooling load, fouling, and/or corrosion
that would result.
4.6.6 Tube bundles for smaller duties are sometimes combined so that they can
be served by a single set of fans. Process control via regulation of air flow
should not be applied to such combined arrangements because the
controlled cooling of one bundle or service will cause unwanted duty
cycling in the other service(s) in the bay.

4.7 Viscous Oil Coolers

4.7.1 The design of viscous oil coolers and other units with a critical process
temperature is reviewed in detail in ISO 13706 (see clause 1.2.6 of this
Guide).
4.7.2 Where tubewall temperature restrictions apply some degree of
"winterization" design is usually appropriate. For the most difficult
applications a hot air recirculation design or an indirect cooling system
should be considered.
4.7.3 An indirect system cools the viscous oil or other critical temperature
process fluid in a conventional tubular exchanger using light oil,
condensate, or ethylene glycol-water solution as the coolant. The coolant is
in turn cooled in an exchanger of relatively simple design. This system is
usually preferred in viscous or high pour point fluid applications due to
easy operability, lower operating costs, and usually less expensive
installation. The controlled variables are the flows of process and coolant
fluids and the coolant temperature leaving the air cooler.

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4.7.4 The alternative to an indirect system in difficult applications is the hot air
recirculation design. In this type the temperature of the air entering the
cooler bundle is maintained above the critical tubewall temperature by
mixing hot exit air with incoming ambient air. Of the several recirculation
designs available only the external recirculation type should be used in
difficult services since it is minimally affected by wind and other
environmental factors.
Recirculation designs require coordinated movement of several different
louvers. This coordination deteriorates with time and temperature control
suffers accordingly.
4.7.5 Viscous oil coolers of either type should be designed with ample process
fluid pressure drop so as to promote good distribution and stable flow
within the exchanger.
4.7.6 Application of thermal insulation to the headers of a recirculation unit
in viscous, high pour point, or freezing fluid service should be
considered. Chilling of the headers may cause plugging or
solidification, with loss of flow and possible equipment damage. An
alternative is to use "over-the-end" recirculation air ducts (rather than
"over-the- side") to shield the headers.
4.7.7 Good mixing of incoming ambient and recirculated hot air prior to entry
into the fan is important for proper operation of any air recirculation design.
For an external recirculation unit the ambient air louvers should be high in
the wall of the recirculation duct so as to maximize mixing time. A
restriction between the recirculation duct and the fan inlet plenum will
promote mixing of the two air streams and overcome the tendency for air
stratification.
If stratification occurs it will not be corrected by mixing in the fans. Fans
are poor mixers; they rotate the incoming air flow but don't stir it greatly.
Cold air entering at one quadrant will largely retain its entering temperature
on discharge but will be rotated. This cold air can cause local low tubewall
temperatures and intube plugging.
4.7.8 Mechanical and instrument parts in recirculation units are exposed to hot
air, particularly during warm-up operation with a steam coil. The
temperature limits of these parts should be identified and means to provide
cooling or modify the exposure investigated if necessary.
If the control system requires air flow variation adjustable frequency
AC controllers should be used to control fan speed. Alternatively,
consider a control scheme that modulates total and recirculation air
flows via louver manipulation only, while fans operate at constant
speed and pitch.
4.7.9 Refer to Section 4.4 for system control considerations.
4.7.10 All tube-to-tubesheet joints should be roller expanded and strength
welded to minimize potential for tube to tubesheet joint leaks caused
by differential thermal expansion.

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4.8 Coolers with Mixed Phase Inlet Flow when at least One Phase is
Corrosive

4.8.1 These units require special consideration relative to materials, header

design, tube arrangement, velocity, flow regime, and wash water flow rate,
determined by the concentration of corrosives in the process stream. Refer
to Shell Global Solutions Basic Practice and Guideline MAT-20
Water Washing in Hydrotreaters and Hydrocrackers for details.
Hydrocracker and hydrotreater effluent coolers are the most prominent
example of such units.
4.8.2 For the more severe conditions the design should incorporate the
following:
1. Not more than one row per pass to avoid gross phase separation in the
header.
2. A minimum of one inlet and one outlet nozzle per 3.5 ft (1 M)of header
length to facilitate equal phase distribution to all tubes. Greater nozzle
density is preferred.
3. Minimum header width to promote turbulence and phase mixing
throughout the length of the header.
4. A velocity sufficient to maintain annular flow to completely wet the
tube wall at the inlet and over the full length of the tubes. This criteria
is satisfied by conditions above or to the right of the heavy dashed line
on the flow regime chart in drawing 7/8D5. In addition, the liquid
velocity in the tubes should not exceed 20 ft/sec (6.1 M/sec) to avoid
erosion corrosion.
5. Heavier than normal corrosion allowance especially where carbon steel
is employed. Header and tube corrosion allowance will be specified
by Shell. Carbon steel tubes should be seamless.
6. For hydrocrackers include pipe manifolds that effect equal distribution
of the water, liquid hydrocarbon and vapor to the air cooler header
nozzles. Internal baffling of the supply line and pipe headers will be
needed to assure equal phase splits and a stratified flow regime in the
pipe header.
4.8.3 When swaged or transition nozzles are applied, to satisfy clause 4.8.2.2 and
3. above, guide vanes or deflector bars should be provided in the nozzles to
equalize phase distribution across the opening to the header. Such vanes or
bars shall not be credited as stays in the pressure rating of the nozzles or
nozzle-to-header connections.
4.8.4 Clauses 4.8.2.2, 4.8.2.3, and 4.8.3 describe good practice for any air-cooled
exchanger with a gas-liquid mixture inlet fluid.

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7 EG-3 Approved Dec 03
Air-Cooled Heat Exchangers

4.9 Design Pressure And Temperature

4.9.1 The specification of design pressure should provide adequate differential

between maximum operating pressure and design pressure to prevent
leakage of the relief devices during normal operation and to allow reseating
of relief valves following overpressure incidents without requiring
extraordinary procedures, such as reducing operating pressure or closing of
block valves under relief valves.

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7 EG-3 Approved Dec 03
Air-Cooled Heat Exchangers

Air cooled heat exchangers should be designed for an internal pressure

(design pressure) that exceeds the maximum operating pressure as follows:
Maximum Minimum Differential With:
Operating Pressure Relief Valves Rupture Disks
15 psi (104 kPa) to 25 psi (173 kPa) 25 psi (173 kPa)
250 psi (1,725 kPa)

251 psi (1,730 kPa) to 10 percent 10 percent

500 psi (3,450 kPa)

501 psi (3,457 kPa) to 50 psi 10 percent

1000 psi (6,900 kPa)

Over 1000 psi 7 percent 7 percent

(6,900 kPa)

The differential pressure should not be less than the blowdown of the relief
valve.
Conditions may warrant wider or in some cases narrower differentials. The
following factors should be considered:
Wider differential should be considered when:
Hard-to-seal fluids are present such as superheated steam or hydrogen.
Flammable vapors will be released to the atmosphere.
Process conditions are expected to change appreciably during the run
for reasons such as fouling.
Processes where liquids released to the flare would require cleaning of
the flare header system following a release, (for example, a polymer).
Narrower differential may be considered when:
Economics of exchanger fabrication warrant such.
Pilot operated relief valves are employed.
4.9.2 Fabricated box headers should normally be specified for a design pressure
of no less than 75 psig (518 kPag) at the design temperature and for full
vacuum at 300F (149C).
4.9.3 The design temperature should normally be determined as follows:
1. The maximum design metal temperatures for air cooled exchangers will
normally be the maximum operating temperature of the fluid in the
exchanger coincident with design pressure. Because of varying
operational conditions such as pressure (e.g., vacuum, steam-out,
regeneration conditions, etc.), it may be necessary to specify multiple
design temperatures coincident with the various pressure conditions to
establish the proper design.

Engineering Guides and General Specifications Page 15 of 23

7 EG-3 Approved Dec 03
Air-Cooled Heat Exchangers

2. The effect of the following is to increase the design temperature to the

highest level without incurring additional first cost.
3. The design temperature is selected at or above the maximum operating
temperature at the level at which all of the following restrictions are
satisfied.
a. The maximum temperature at which flange rating and header
thickness is not increased, i.e., where the Code allowable stress
decreases.
b. The maximum temperature permitted by the fin attachment type per
General Specification 7 GS-5.
c. The maximum temperature permitted by the expansion constraints
of the tube bundle.
4.9.4 A minimum design metal temperature (MDMT) must be specified. ASME
Section VIII, Division 1, paragraph UG-20 (b) spells out the requirements
for setting the MDMT.
Consideration shall include the lowest operating temperature, operational
upsets, auto-refrigeration, atmospheric temperature and any other sources
of cooling when determining the MDMT.
The MDMT shall be taken as the lowest temperature when considering the
following:
1. The lowest temperature with normal operating pressure that can occur
during normal operation, operational upsets, auto-refrigeration or any
other cooling source. This information shall be obtained from the
process specialist.
2. The minimum temperature that can be reached under the influence of
atmospheric temperature is determined from the lowest one-day mean
ambient temperature (LODMAT) for the location. The information on
the LODMAT for each Shell location has been obtained from
LODMAT charts in API-650 and is as follows:
Convent, LA 15F Mobile, AL 15F
Deer Park, TX 15F Norco, LA 15F
Geismar, LA 15F Port Arthur, TX 15F
Los Angeles, CA 35F Puget Sound, WA 15F
Martinez, CA 30F Yabucoa, PR 65F

If process requirements do not dictate the MDMT then the temperature

listed above should be shown as the MDMT in the appropriate block on
the data sheet.
Temperatures that may exist only during auxiliary operations (e.g.,
start-up, shutdown, depressuring, etc.) while the pressure is being
controlled to a value less than the design pressure need not be

Engineering Guides and General Specifications Page 16 of 23

7 EG-3 Approved Dec 03
Air-Cooled Heat Exchangers

considered in establishing the MDMT, provided that Figure UCS-66.1

of ASME Section VIII, Div. 1 is used for calculating the minimum
temperature and that the equipment can be operated below the MDMT
with the reduced pressure during auxiliary operation.
For guidance in selecting materials for air cooled exchangers with a
MDMT less than -20F (-29C) see 2 EG-1.
4.9.5 The operating temperature, the maximum design temperature and the
minimum design metal temperature are to be shown on the heat exchanger
data sheet.

4.10 Tubes

4.10.1 Maximizing the tube length, within plot limitations, generally provides the
lowest cost unit. Fan size and coverage of the bundle and the supporting
structure dimensions must be considered when selecting tube length. The
usual maximum tube length for air-cooled exchangers is 48 ft (15 M). The
maximum allowable length is specified on the data sheet and the vendor is
usually free to optimize within this limitation.
4.10.2 Tube size is normally selected as the best compromise between heat
transfer and pressure drop requirements. At times the size may be selected
on the basis of a required flow regime. Normally the size is specified as
1in O.D. but the vendor should be encouraged to offer alternate sizes that
are optimized basis thermal and hydraulic performance. It is the
purchaser's responsibility to verify flow regime if it is critical. Two-phase
flow regimes may be studied using drawing 7/8D5.
Tube sizes should be limited to those that are usually available from major
tube supplier stocks for the particular material. This is usually 1 in, 1 in,
1 in, and 2 in for carbon steel with 1 in outside diameter the most
common and the minimum acceptable size.
4.10.3 Pipe sizes and schedules used in serpentine coil units should also be limited
to those that are usually available from major supplier stocks for the
particular material. Vendor offerings should be reviewed to verify
appropriate sizes.
4.10.4 In Gulf Coast facilities and other areas where atmospheric corrosion is
severe, the following paragraphs should be included in the project
specifications for FW-2 Design Class 3 units.
1. The lower 2 rows of tubes, in units cooling to below 125F (52C) at
design air temperature, should normally be specified with extruded fins
tubes. The exposed ends of carbon and low chrome steel tubes should
be "metallized" with aluminum or zinc. The minimum fin tip thickness
should be specified as 0.011 in (0.28 mm).
2. Diversion coolers and/or other units that are in intermittent service
should be specified with extruded fin tubes with a minimum fin tip

Engineering Guides and General Specifications Page 17 of 23

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Air-Cooled Heat Exchangers

thickness of 0.011 in (0.28 mm), as above, in the area of the bundle

where the tube wall temperature permits.
a. The exposed ends of carbon and low chrome steel tubes with
extruded fins should be "metallized" with aluminum or zinc.
b. The total length of bare carbon or low chrome steel tubes
should be grit blasted per SSPC- SP6 to NACE3 cleanliness and
coated with inorganic zinc primer to a 3 mil (0.08 mm).
minimum dry film thickness.
c. Embedded fin tubes used in the upper rows that have metal
temperature too hot for extruded tubes should be specified with
1/16 in (1.6 mm) minimum corrosion allowance but not less
than 12 BWG minimum tube wall thickness.
4.10.5 For process fluid inlet temperature less than 550F (288C) austenitic
stainless tubes should be specified with only the extruded fins. For
process fluid inlet temperature above 550F (288C), a Shell heat
transfer specialist should be consulted.
4.10.6 Extruded serrated fins are normally acceptable where the smooth extruded
fin is permitted. Do not apply serrated fins where air particulate loading
may be high (dust, seeds, pollen, etc.).
4.10.7 High frequency continuously welded edge wound fins may be used on units
using pipe coils or on units with temperature too high for embedded
aluminum fins.
4.10.8 Tube wall thickness should be calculated for the design conditions. The
specified tube wall should not be less than as required by General
Specification 7 GS-5 and ISO 13706. The Shell materials specialist should
determine the appropriate corrosion allowance.
4.10.9 The following condensers should be specified with tubes sloped a minimum
of 1/16 in/ft (5.3 mm/M) in the direction of flow to overcome normal sags
between supports and provide adequate tube drainage.
1. Single tube pass condensers.
2. All condensers on columns employing a material balance control
system whereby the bundle is partially flooded. When multipass, all
passes should slope in the direction of flow, including a subcooling
pass if provided.
3. Each pass of condensers operating in vacuum service.

4.11 Headers

4.11.1 Normally a box header with shoulder plugs, the least costly standard
arrangement, should be specified at both ends of the tubes. Clad plate is
normally not used in plug type box headers due to fabrication difficulties.

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7 EG-3 Approved Dec 03
Air-Cooled Heat Exchangers

4.11.2 Removable flat plate cover type headers should be specified only for design
pressure less than 350 psig (2,415 kPag) and design process inlet
temperature less than 400F (203C), where extreme fouling or frequent
tube inspection and maintenance are anticipated. Through-bolted designs
are acceptable. Cover plate units at higher pressures and temperatures
often have leakage problems.
4.11.3 Bonnet type headers are acceptable for low pressure gas or condensing
service where a large header is required for low pressure drop. They may
also be used as an "expendable" carbon steel header, with a large corrosion
allowance or protective coating, in conjunction with high alloy tubes and
tube sheet. Bonnet headers have the disadvantage that removal for tube
access requires that piping be disconnected. Also reconnecting the piping
may cause header warpage, making it difficult to tightly seal the header- to-
tubesheet joint. The "through bolted" type design is preferred for bonnet
headers to avoid very thick tubesheets.
4.11.4 For high pressure (over 5000 psig) (34,500 kPag), relatively clean,
noncorrosive service, where access to the tubes is required, welded 180
return bends may be used at one end, with billet type headers at the other.
4.11.5 For high pressure (over 5000 psig) (34,500 kPag) service that is
noncorrosive and nonfouling and where access to the tubes for cleaning or
inspection is not required, welded manifolds may be used at the inlet and
outlet with welded 180 return bends as required.
4.11.6 All welded, serpentine type units with pipe size coils may be used for
services where a minimum number of parallel flow paths is a requirement,
such as viscous oil coolers with high pour point.
4.11.7 Corrosion allowances will normally be specified by the Shell materials
specialist in the Materials Selection Report. If such report has not been
issued consult with the materials specialist. Guidance as to typical
allowances is given in Engineering Guide 2 EG-1.
4.11.8 For FW-2 Design Class 1 units consider a reduction in plug and tubesheet
minimum thicknesses to in (20 mm) per ISO 13706. Screwed vent,
drain, and instrument connections should also be considered, using
couplings per ISO 13706, for minimum design class units.
4.11.9 Pass partition plates and stiffeners in headers should be of the same
material as the remainder of the header to avoid failures due to differential
thermal expansion.
4.11.10 Headers with thick plug sheets may require special plug design to avoid
crevices that could promote corrosion or erosion or "blind" areas that
cannot be adequately purged to a safe condition. One plug design choice is
shown in drawing 7/8D4; proposals for other designs should be
encouraged.

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Air-Cooled Heat Exchangers

4.12 Steam Coils

4.12.1 Steam coils should be specified for services that require preheating of the
tube bundle to prevent freeze-up when starting the unit. They normally
should be used in conjunction with louvers and only on start-up.
4.12.2 When steam coils are applied special attention should be paid to the
selection of steam traps and of valving arrangements. Leaking inlet valves
and non-functional traps have caused freezing and damage of heating coils.
Trap and piping systems should be completely drainable or otherwise
freeze-protected when not in service.

4.13 Fan Considerations

4.13.1 The efficiencies of fans installed in air-cooled exchangers are less than as
shown on the typical fan performance curve. This is largely due to
variations between test and field installations, with the standardized test
facility being more ideal with regard to flow patterns and pressure
recovery. Therefore, in evaluations the reported (curve) efficiencies should
be discounted; actual total efficiencies seldom exceed 75 percent.
4.13.2 Quoted air delivery (ACFM) should also be discounted in critical or long-
lived service units, primarily due to inaccuracies in the static pressure drop
prediction. In practice, airside pressure drop exceeds predictions due to
unequal flow distribution, dirty tubes, air flow leakage effects, and
resistance of appurtenances located in the air flow path. The increased
pressure drop causes lower air flow, lower temperature difference, and
lower heat transfer coefficient. Critical services should be evaluated at an
airside pressure drop ten percent greater than stated by the vendor; this
implies increased fan horsepower requirement.
4.13.3 Fan performance can be improved by reducing tip clearance, providing
tapered or eased inlet fan ring, increasing fan ring depth, and providing a
fan hub seal disk to prevent flow reversal. Proposals should be reviewed for
these features, particularly when high fan efficiencies are claimed. These
can also be a means of improving cooler performance.
4.13.4 The velocity profile of air discharged by an axial flow or propeller fan is
not equal along the blade length. Rather, it approaches zero near the blade
hub and tip and typically is a maximum at about 2/3 of the distance
between hub and tip. This profile has a marked effect on the cooling
performance if the fan on a forced draft unit is too close to the tube bundle.
High localized cooling air flows may cause flow stoppage of viscous fluids
or corrosion if local condensation occurs. No net air flow may occur over
the hub and inner sections of the blades. As the fan gets closer to the bundle
air distribution becomes more uneven and cooling performance
deteriorates.
Three criteria are applied to minimize this problem without uneconomic
design.
1. Fan dispersion angle is limited per ISO 13706.

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Air-Cooled Heat Exchangers

2. Fan plane is at least one-half fan diameter removed from the bottom
tube row of the bundle.
3. The static pressure loss across the bundle is at least 3 times the velocity
head loss of the fan (General Specification 7 GS-5).
4.13.5 On induced draft units the exposure temperature may limit the choice of fan
blade materials. Usually the reported or calculated air temperature is taken
as the average temperature leaving the bundle. On a single tube pass unit
use of the average value may severely understate the exposure temperature
of the fan nearest the process inlet end of the exchanger; this should be
checked on single pass induced draft designs.
4.13.6 On induced draft units of short anticipated life and where high maintenance
costs are acceptable to reduce first cost top-mounted motors and belt drives
may be considered instead of the bottom- mounted design per General
Specification 7 GS-5. The exposure temperatures of the equipment and
equipment accessibility must be considered.
4.13.7 The number of fans per service should be such that the loss of one fan
does not cause the process unit to be shut down. Evaluation to
determine the minimum number of fans should be based on design
fouling factor and design inlet air temperature.

4.14 Structures and Platforms

4.14.1 The need for platforms should be reviewed for each case. Generally units
mounted at or near grade require no platforms. Elevated units should
always have platforms for access to the mechanical equipment. The extent
of ladders and stairs to access these platforms should be reviewed
considering safety, inspection needs, and equipment design class.
Particularly for large banks of air coolers it is difficult to define desired
platform, walkway, stair, and ladder arrangements in text. Consideration
should be given in such cases to providing a drawing to define such details.
4.14.2 Header level walkways are generally applied for long life, low maintenance
cost coolers elevated well above grade. For nonfouling, noncorrosive
services and units of lesser design class consider specifying no header
walkways or permanent scaffold supports.
4.14.3 Plenums and fan decks of short life, high maintenance design class units
may be of minimum metal thickness per ISO 13706 rather than per General
Specification 7 GS-5. Also, for such units consider electro-galvanized or
painted plenum components.
4.14.4 Velocity recovery stacks may be attractive on induced draft units with
adjustable pitch fans where electric power costs exceed $0.03 per kwh,
particularly where maximum natural draft duty to limit flare losses during
power failures is desired. Also recovery stacks are expected to be attractive
where the fan velocity pressure exceeds 0.3 in (7.6 mm) w.g. If either of
the above conditions apply the vendors should be asked to quote the
additional (installed) cost of the stacks and the horsepower required with

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Air-Cooled Heat Exchangers

and without velocity recovery. At times use of the stacks may allow lower
installed horsepower motors. Velocity recovery stacks should normally not
be credited with pressure recovery greater than 67 percent of theoretical
recovery.

4.15 Materials

4.15.1 Materials of construction will normally be specified by the Shell materials

specialist in the Materials Selection Report. If such a report has not been
issued consult with the materials specialist.
4.15.2 Plug headers of austenitic stainless steels are susceptible to damage due to
galling between header, plugs, and plug gaskets. Two options are available
to minimize galling in this situation.
1. For 304SS headers provide plugs of 17-4 PH material unless otherwise
specified by the materials specialist. If in sulfidic service the hardness
of the 17-4 PH should be controlled to HRC 33 maximum. For 316SS
headers provide plugs of Nitronic 50 unless otherwise specified by the
materials specialist. If in sulfidic service the hardness of the Nitronic
50 should be controlled to HRC 35 maximum. Hardness is controlled
to minimize plug cracking.
2. Use soft iron gaskets coated with the thread lubricant specified in
7 GS-5.
The installation of plugs in this situation should be specified as by hand,
not with high speed impact wrench, to avoid galling damage to header box.
4.15.3 Where atmospheres may contain chlorides, such as some industrial
locations and coastal exposures, the aluminum fin material should be
specified as containing no copper alloying constituents in order to minimize
fin corrosion.

4.16 Pre-Assembly

4.16.1 Bays should be specified pre-assembled to the maximum extent possible

consistent with the method of shipment to reduce field labor requirements
and fitup problems.
4.16.2 Bays that are to be shipped with the fans assembled should be specified to
have the fan blades set at the predicted pitch angle for the service and the
fan tip clearance checked.
4.16.3 When it is anticipated that a pre-assembled bay will be commissioned
within 10 weeks after arrival at the job site, the motors should be specified
to be assembled to the bay by the vendor and the rotating equipment given
a "run- in" check. The "run-in" check should, as a minimum, consist of a
vibration test and a motor load test. The "run-in" check can be deleted for
units with lesser design class requirements.

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Air-Cooled Heat Exchangers

4.16.4 When the bays are not to be commissioned within 10 weeks of shipment
the "run-in" check should be waived and the motors specified to be shipped
separately and stored out of the weather according to the motor
manufacturer's instructions.

4.17 Preparation for Shipment

1. Tubes for overseas shipment or for projects requiring pre-commissioning storage

outside for over 6 months should be given special consideration. The extruded
fin type tubes with metalized tube ends and back side of the tube sheet coated
per Shell specifications should normally be specified for these situations in
order to minimize deterioration due to atmospheric corrosion.
2. Internal protection should be specified in the inquiry as follows:
a. Pressure with dry Nitrogen or Argon to 15 psig (104 kPag) and depressure
twice. Repressure to 15 psig (104 kPag) with dry Nitrogen or Argon.
b. Stencil the following at a location visible to the sealed connection; "Contents
Under Nitrogen or Argon Pressure; Do Not Open Without Purchasers
Approval".

Engineering Guides and General Specifications Page 23 of 23

 7/8D4
DETAIL OF TWO-PART PLUG WITH
GASKET COMPRESSOR
SHEET 1 OF 1
DEC 91

GASKET COMPRESSOR

GASKET

PLUG

VENT HOLES

THREADED HOLE
 7/8D5
TWO-PHASE FLOW REGIMES IN
HORIZONTAL TUBES
SHEET 1 OF 1
JUL 89

10

SLUG ANNULAR

STRATIFIED
SLUG

ANNULAR

INLET SLUG
ANNULAR
AT INLET

(ft/sec/in) INTERMITTENT
PARTIALLY
DRY WALL

0.1 (SMOOTH) (STRATIFIED) SEMI- MIST

STRATIFIED WAVE ANNULAR (ANNULAR)
WALL FILM WASHES TOP

UNIFORM WALL FILM

ATOMIZATION
STARTS

0.01
0.01 0.1 1 10

= SUPERFICIAL LIQUID VELOCITY, FT/SEC

= SUPERFICIAL GAS OR VAPOR VELOCITY, FT/SEC
= FROUDE NUMBER, DIMENSIONLESS
D = TUBE INSIDE DIAMETER, INCHES OR FEET
= VAPOR OR GAS DENSITY, LB/(CU.FT.)
= LIQUID DENSITY, LB/(CU.FT.)

g = GRAVITATIONAL CONSTANT, 32.17 FT/SEC/SEC