Third Edition

ALPEMA 2010

THE STANDARDS OF THE BRAZED

ALUMINIUM PLATE-FIN HEAT
EXCHANGER MANUFACTURERS'
ASSOCIATION

A1LJPJE}''I1[A

Published by:

The Brazed
Aluminium Plate·
Fin Heat Exchanger
No part of this publication may be included in another publication, including publications in electronic Manufacturers'
media, without prior permission from ALPEMA.
Association
Cl
Copyright 2010 by the Brazed Aluminium Plate-Fin Heat Exchanger Manufacturers' Association.
(AlPEMA)
All rights reserved.

PrOVided by IHS under license with AlPEMA www.alpema.org

 MEMBERSHIP LIST 2010
BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER
MANUFACTURERS' ASSOCIATION

Chart Energy and Chemicals , Inc ---------------------------------------------- ---------------- 2191 Ward Avenue ,
La Crosse, Wisconsin 54601 ,
USA.
Tel: +1 6087873333
Fax: +1 6087872141
Email: bahx@chartindustries.com
http: //www.chartindustdes.com

Kobe Steel, Ltd -----------------------------------------------------.----------------------------- Mach inery Business,

Energy Systems Center,
2-3-1 Shinhama, Arai-cho,
Takasago-Shi , Hyogo-Ken ,
676-8670, Japan.
Tel : +81 794457144
Fax: +81 794457239
Email: alex@kobelco.com
http://www.kobelco .co.jp/english/machinery/products/ecmachin ery/alexf

Linde AG ------------------------------------------------------------------------------------------ Enginee ri ng Divis ion,

Schalchen Plant,
0 -83342 Tacherting ,
Germany.
Tel: +49 8621 856294
Fax: +49 8621 856622
Email: plantcomponents@linde-le.com
http://INWW.linde-plantcomponents.com

Fives Cryo ----------------------------------------------------------------------------------------------- 25 bis, rue du fort

BP87,
88194 Golbey Cedex,
France.
Tel : +33 (0)3 29 68 0000
Fax: +33 (0)3 29312218
Email: fivescryogenie-exchangers@fivesgroup.com
http://www.fivesgroup.comlFivesCryogenie

Sumitomo Precision Products Co Limited ----------Thermal Energy Systems Engineering Department,

1-10 Fuso-cho, Amagasaki,
Hyogo Pref. ,
660-0891 , Japan.
Tel : +81 664895867
Fax: +81 664895879
Email: cryogen@spp.co.jp
http://INWW.spp.co.jp
 PREFACE

This is the Third Edition of the Standards of the Brazed Aluminium Plate-Fin Heat Exchanger
Manufacturers' Association (ALPEMA). It is the result of the work by a technical committee of all the
Members to meet the objective of the Association to promote the quality and safe use of this type of
heat exchanger. The Standards contain all relevant information for the specification, procurement, and
use of Brazed Aluminium Plate-Fin Heat Exchangers.

The First Ed ition, published in 1994, was extremely successful and popular and the Second edition
was published in 2000. The ALPEMA Members review the Standards every year to consider whether
updates are required and what these should be. Two amendments to the Second Edition were issued
as a result of these reviews. Changes in the industry, experience with using the Standards and
feedback from Users has indicated that the time is right for the Third Edition . The addit ions and
amendments that have been made are summarised here.

1. A new Chapter 9 has been added to cover cold boxes and block-in-shell heat exchangers.
2. Photographs of typical plate-fin designs have been added, and some figures have been redrawn
for clarity.
3. Information is provided on two-phase distributors.
4. Guidance on flange design and transition joints is included.
5. Guidance on acceptable mercury levels is given.
6. New information on proper storage of Brazed Aluminium Plate-Fin Heat Exchangers, manifold
assemblies, and the Manufacturer's scope of supply has been added.
7. Many small changes have been made to improve clarity.

Comments by Users of the Standards are welcomed.

NO WARRANTY EXPRESSED OR IMPLIED

The Standards herein are recommended by The Brazed Aluminium Plate-Fin Heat Exchanger
Manufacturers' Association to assist Users, engineers and designers who specify, design and install
Brazed Aluminium Plate-Fin Heat Exchangers. These Standards are based upon sound engineering
principles , research and field experience in the manufacture, design, installation and use of these
exchangers. These Standards may be subject to revision as further investigation or experience may
show is necessary or desirable. Nothing herein shall constitute a warranty of any kind, expressed or
implied, and warranty responsibility of any kind is expressly denied.

PLEDGE

ALPEMA members will conduct themselves fairly and honestly, always practicing within legal and
legislative boundaries.

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 Table of Contents

LIST OF FIGURES vii

LIST OF TABLES vii

1 GENERAL DESCRIPTION AND NOMENCLATURE 1

1.1 GENERAL DESCRIPTION 1
1.1.1 Background 1
1.1.2 Introduction 1
1.1.3 Successful Applications for Brazed Aluminium Plate-Fin Heat
Exchangers 1
1.1.4 Limits of Use - Maximum Working Temperature and Pressure 3
1.1 .5 Acceptable Fluids 3
1.2 NOMENCLATURE OF THE COMPONENTS 5
1.2.1 Components of an Exchanger 5
1.2.2 Components of Manifolded Exchangers 6
1.2.3 Module Construction 6
1.2.4 Connection Options 6
1.2.5 Header/Nozzle Configurations 7
12.6 Fin~~_oos 9
1.2.7 Distributors 10
1.2.8 Two-Phase Distributors 12
1.2.9 Flow Arrangements 14

2 TOLERANCES 15

3 GENERAL DESIGN, FABRICATION AND CONTRACTUAL INFORMATION 18

3.1 SHOP OPERATION 18
3.2 DESIGN CODE 18
3.3 INSPECTION 18
3.3.1 Third Party Inspection 18
3.3.2 Manufacturer's Inspection 18
3.3.3 Purchaser's Inspection 18
3.4 NAMEPLATE 18
3.4.1 Manufacturer's Nameplate 18
3.4.2 Purchaser's Nameplate 19
3.5 DRAWINGS AND CODE DATA REPORTS 19
3.5.1 Drawings Information 19
3.5.2 Drawings Approval and Change 20
3.5.3 Drawings for Record 20
3.5.4 Proprietary Rights to Drawings 20
3.5.5 Code Data Reports 20
3.6 GUARANTEES 20
3.6.1 Thermal , Hydraulic and Mechanical Guarantees 20
3.6.2 Consequential Damage 21
3.6.3 Corrosion 21
3.7 PREPARATION OF BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGERS
FOR SHIPMENT 21
3.7.1 General 21
3.7.2 Cleaning 21
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 3.7.3 Drying 21
3.7.4 Flange Protection 21
3.7.5 Dummy Passages/Inactive Areas 21
3.7.6 Pressurising 21
3.8 SCOPE OF SUPPLY 22
3.9 GENERAL CONSTRUCTION FEATURES 22
3.9.1 Supports 22
3.9 .2 lifting Devices 22
3.10 NONCONFORMITY RECTIFICATION 23
3.10.1 Introduction 23
3.10 .2 Procedures and Documentation 23
3.10.3 Side-Bar-to-Sheet Joint Leak Rectification 23
3.10 .4 Blocking of layers 23
3.10 .5 Other Rectification Work 23

4 INSTALLATION, OPERATION AND MAINTENANCE 24

4.1 GENERAL 24
4.2 LIFTING AND HANDLING 24
4.3 SUPPORT BEAMS 24
4.3.1 Support Insulation 25
4.4 SLIDING GUIDE FRAME 25
4.5 FIXING (MOUNTING) BOLTS 28
4.6 VENTING OF DUMMY/INACTIVE AREAS 30
4.7 FIELD TESTING 30
4.7 .1 Non-Destructive Testing 30
4.7.2 Proof Pressure Testing 31
4.8 INSULATION 31
4.9 OPERATION 32
4.9.1 Start-up 32
4.9.2 Normal Operation 33
4.9.3 Shut-down 33
4.9.4 Warming Up 33
4.10 MAINTENANCE 33
4.11 LEAK DETECTION 34
4.11 .1 Introduction 34
4.11.2 Site leak Detection Pressure Test 34
4.11 .3 Site Helium Leak Detection Test 35
4.12 REPAIR OF LEAKS 35
4.12.1 Repair of Leaks to the Brazed Aluminium Plate-Fin Heat Exchanger 35
4.13 STORAGE 36

5 MECHANICAL STANDARDS 37
5.1 SCOPE 37
5.2 DEFINITION OF A BRA2ED ALUMINIUM PLATE-FIN HEAT EXCHANGER 37
5.3 CODES FOR CONSTRUCTION 37
5.4 TYPICAL MATERIALS OF CONSTRUCTION 37
5.5 DESIGN PRESSURES 38

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 5.6 TESTING 38
5.6.1 Pressure Test 38
5.6.2 Leak Test 38
5.7 METAL TEMPERATURE LIMITATIONS 39
5.7.1 Metal Temperature Limitations 39
5.7.2 Design Temperature 39
5.8 PERMISSIBLE TEMPERATURE OIFFERENCES BETWEEN ADJACENT
STREAMS 39
5.9 CORROSION ALLOWANCES 40
5.10 SERVICE LIMITATIONS 40
5.11 TYPICAL RANGE OF SIZES 40
5.11 .1 Parting Sheets 40
5.11.2 Cap Sheets 40
5.11 .3 Side Bars 40
5.11.4 Fins 40
5.12 HEADERS AND NOZZLES 41
5.12.1 Headers 41
5.12.2 Nozzles 41
5.12.3 Aluminium Flanged Connections 42
5.13 EFFECT OF PRODUCTION PROCESS ON MATERIALS 43
5.14 ARRANGEMENT OF LAYERS 43
5.15 BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER AS A PRESSURE
VESSEL 43
5.15 .1 Fins 43
5.15.2 Parting Sheets 44
5.15.3 Side Bars 44
5.15.4 Cap Sheets 44
5.15 .5 Headers and Nozzles 44
5.16 SPECIAL FEATURES 44

6 MATERIALS 45
6.1 TYPICAL MATERIALS OF CONSTRUCTION 45

7 THERMAL AND HYDRAULIC DESIGN 47

7.1 INTRODUCTION 47
7.2 FEATURES OF A BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER 47
7.2.1 Primary and Secondary Heat Transfer Surfaces and Thermal Length 47
7.2.2 Single and Multiple Banking 48
7.2.3 Multi -stream Brazed Aluminium Plate-fin Heat Exchangers 48
7.3 THERMAL DESIGN PROCEDURE 48
7.4 THERMAL RELATIONS 49
7.4 .1 Basic Heat Transfer Relation 49
7.4.2 MTD and UA, 52
7.4.3 Overall Effective Heat Transfer Surface of Exchanger 53
7.4.4 Effective Heat Transfer Coefficient of Each Stream 53
7.4.5 Heat Transfer Surface of Each Passage 54
7.4.6 Rough Estimation of the Core Volume and Weight 55
7.5 HYDRAULIC RELATIONS 55
7.5.1 Components of Pressure Loss 55
7.5.2 Single-Phase Pressure Loss 56
7.5.3 Two-Phase Pressure Loss 57
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 7.6 GENERAL CONSIDERATIONS IN THE THERMAL AND HYDRAULIC DESIGN 57
7.6.1 Choice of Fin Geometry 57
7.6.2 Layer Stacking Arrangement 58
7.6.3 Two-Phase Distribution 58
7.6.4 Thermosyphon 58
7.6.5 Manifold Assemblies 58

8 RECOMMENDED GOOD PRACTICE 59

8.1 THERMAL STRESSES WITHIN BRAZED ALUMINIUM PLATE-FIN HEAT
EXCHANGERS 59
8.1.1 Introduction 59
8.1.2 Failure Mechanism 59
8.1 .3 Recommendations 60
8.1.4 Summary 60
8.2 FOULING AND PLUGGING OF BRAZED ALUMINIUM PLATE-FIN HEAT
EXCHANGERS 60
8.2.1 Fouling 60
8.2.2 Plugging 61
8.3 CORROSION 62
8.3.1 Process Environments Containing Water 62
8.3.2 Process Environments Containing Mercury 63
8.3.3 Atmospheric or Environmental Corrosion 64
8.3.4 Other Services 65

9 SPECIAL APPLICATIONS AND EXCHANGER PERIPHERALS 66

9.1 BLOCK-IN-SHELL HEAT EXCHANGERS 66
9.1.1 General 66
9.1.2 Features/Advantages 66
9.1.3 Arrangement/Construction 66
9.1.4 Thermal and Hydraulic Design 67
9.1.5 Mechanical DesignlTesting 67
9.1.6 Typical Applications 68
9.2 COLD BOXES 68
9.2.1 General 69
9.2.2 Advantages 69
9.2.3 Structure 69
9.2.4 Therma l Insulation 69
9.2.5 Nitrogen Purge 69
9.2.6 Wall Penetrations 70
9.2.7 Attachments 70
9.2.8 Safety Devices 70
9.2.9 Temporary Bracings 70
9.2.1 0 Fire Protection 70
9.2.11 Flanged Connections 70
9.2.12 Shipping , Handli ng a nd Installation 70

Notation 71

References 72

Index 73
 LIST OF FIGURES

Figure 1-2: Components of a Brazed Aluminium Plate-Fin Heat Exchanger ..... .......... ..... .................... 5
Figure 1-3: Typical Assembly of Three Brazed Aluminium Plate-Fin Heat Exchangers in Parallel ........ 6
Figu re 1-4: Typical Header Configurations ........................ .................................................................... 8
Figure 1-5: Typical Header/Nozzle Configurations .................. ................................. ............. ................ 8
Figure 1-6: Principal Types of Fin ......................................................................................................... 9
Figure 1-7: Definition of Fin Dimensions ............................................................................................. 10
Figure 1-8: Examples of the Principal Distributor Types ... ................ ...................... ............. ................ 11
Figure 1-9a: Perforated Tube or Bar Distributor ........... .................. ..................................................... 12
Figure 1-9b: Slotted Parting Sheet. Split Passages Type ....... ................. ......... .... ........ ....................... 13
Figure 1-9c: Slotted Parting Sheet, Adjacent Passages Type ......................................... .................... 13
Figure 1-10: Structure of an Individual Layer ........................ ..................................... ......................... 14
Figure 1-11: Flow Arrangements ......................................................................................................... 14
Figure 2-1: Important External Dimensions of One Core using the Core Centre Line .......................... 15
Figure 2-2: Important Externa l Dimensions of One Core using the Support Base Line .......... ............. 16
Figure 2-3: Important Externa l Dimensions of a Manifolded Assembly of Two Cores: General
Flange Details ..................................................................................................................................... 17
Figure 4-1: Typical Sliding Guide Frame ............................................................................................. 25
Figure 4-2: Typical Heat Exchanger Assembly of Three Cores Showing Shear Plate Supports ........ .. 26
Figure 4-3: Typical Heat Exchanger Assembly of Three Cores Showing Angle Bracket Supports ...... 27
Figure 4-4: Coefficient of Thermal Expansion of Aluminium ..... .................................. ......................... 29
Figure 4-5: Typical Shear Plate Bolt Assembly ................................................................................... 29
Figure 4-6: Recommended Minimum Insulation Thickness (mm )................................... ......... ............ 32
Figure 5-1: Positions of the Three Reference Axes .................................................................... ......... 42
Figure 7- 1: Cross Sectional View of Fin and Parting Sheet.. ............................................................... 47
Figure 7-2: Single and Double Banking .................................. ............ ......................... ........ ................ 48
Figure 7-3: Typical Specification Sheet ............................................................................................... 50
Figure 7-4: Typical Specification Sheet ................................................... .................... .. ............ .......... 51
Figu re 7-5: Example Composite Curve ............................................................................................... 52
Figure 7-6: Pressure Loss Components .................................................................... ....... ................... 56
Figure 7-7: Manifold Assemblies ..................................................... .......................... ...... .... ............... 58
Figure 9-1: Block-In-Shell Heat Exchanger ......................................................................................... 67
Figure 9-2: Cold Box ............................................................................. ................. ...... ....................... 68

LIST OF TABLES

Table 1-1: Plant Types and Applications ......... ................. .... ... ................................... ........................... 4
Table 5-1: Typical Resultant Forces and Moments Allowable at Nozzle-to-Header Intersection ......... 42
Table 6- 1: Typical Materials Used in the Construction of Brazed Aluminium Plate- Fin Heat
Exchangers and their Maximum Applicable Design Temperature (Celsius) ...................... 45
Table 6-2: Typical Materials Used in the Construction of Brazed Aluminium Plate-Fin Heat
Exchangers and their Maximum Applicable Design Temperature (Fahrenheit) ................. 46
Table 7-1: Common Applications for each Type of Fin ........................................................................ 57

(vi)
 CHAPTER 1
General Description and Nomenclature

1 GENERAL DESCRIPTION AND NOMENCLATURE

1.1 GENERAL DESCRI PTI ON

1.1.1 Backgro und

Brazed aluminium plate·fin exchangers are the most compact and energy efficient heat
exchangers for handling a wide range of services, noted particularly for their relative
high thermal efficiency, compactness , low weight and low maintenance. They provide
low capital , installation and operating costs over a wide range of cryogenic and non-
c~ogenic applications. Typically, these units have a total surface area of 1000-1500
m 1m3 of volume; this compares , for instance, with a shell-and-tube unit where the
surface area per unit volume is of the order of 40 to 70 m2/m3 . Plate-fin heat
exchangers with surface areas of 2000 m2;m 3 are sometimes employed in the process
industry. For these reasons plate-fin heat exchangers find applications in aircraft,
automobiles, rail transport, offshore platforms, etc. The main applications are in
industrial gas processing, natural gas processing and LNG, refining of petrochemicals
and refrigeration services. Their ability to carry multiple streams, occasionally up to 12
or more, allows process integration in certain industrial processes, establishing them
firmly in air separation processes and other cryogenic systems. The very large surface
area per unit volume is particularly advantageous when low temperature differences
apply. Such applications are typically found in cryogenic systems and hydrocarbon
dewpoint control systems where temperature difference is linked to compressor power.
While plate-fin heat exchangers are available in various materials, this Standard refers
solely to brazed aluminium plate-fin heat exchangers.
Where it is feasible to use a brazed aluminium plate-fin heat exchanger, it is nearly
always the most cost effective solution, otten by a significant margin.

1.1.2 Introducti on
A brazed aluminium plate-fin heat exchanger consists of a block (core) of alternating
layers (passages) of corrugated fins . The layers are separated from each other by
parting sheets and sealed along the edges by means of side bars, and are provided
with inlet and outlet ports for the streams. The block is bounded by cap sheets at the
top and bottom .
An illustration of a multi-stream plate-fin heat exchanger is shown in Figure 1- 1.
The stacked assembly is brazed in a vacuum furnace to become a rigid core. To
complete the heat exchanger, headers with nozzles are welded to the side bars and
parting sheets adjacent to the ports.
The size of a brazed aluminium plate-fin heat exchanger shall be specified by width W,
stacking height H and length L of the rectangular block. (Figure 1-2).
The three dimensions shall be given always in the same sequence as W x H x L,
e.g. 900 x 1180 x 6100 mm.

1.1.3 Su ccessful Applications for Brazed Alumi nium Plate-Fin Heat Exchangers

1.1.3. 1 Typic al servi ces

Most brazed aluminium plate-fin heat exchangers have been installed in
process plants used to separate a feed gas into its constituents , for example
by the partial liquefaction of the feed and subsequent distillation and
separation. The products and wa ste streams are then re-warmed against the
feed streams. Condensers and reboilers are associated with distillation
columns. Often chillers using standard refrigerants are used. Brazed
aluminium plate-fin heat exchangers are well suited for these and many other
services. A partial listing includes:
STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION •
CHAPTER 1
General Description and Nomenclature

Name Service
Main exchanger To cool inlet feed streams against return product and
residue streams
Reversing Air separation application to cool air and remove
exchanQer atmospheric water and CO, bv reversina flow
Subcooler To subcoolliauidproducts or other liquid streams
Reboiler To reboil column bottoms or vaporise tray liquids.
Often this exchanger is installed inside a column
Overhead condenser To condense column overheads, usually against a
refrigerant stream
Chiller To cool a process stream with a vaporising
refriaerant
Liquefiers To liquefy the feed gas in a closed loop
Oephlegmators , To condense overheads w ith vapour and liquid in
reflux condensers countercurrent flow and perform simultaneous heat
and mass transfer
Aftercooler To cool vapour comino from a compressor discharge
Block-in-sh ell Type of reboiler with horizonta l block inside a shell.
exchangers Operates as a kettle reboiler (See Chapter 9-).

Stream 2
Stream 1

Nozzle (stub pipe)

Header

ili"f.JJ!:'.... Stream 3
"4-- Wear plate

Distributor fin

Heat transfer fin

Support plate

Side bar

Parting sheet

Cap sheet

Figure 1-1: Ill ustration of a Typica l Mu lti-Stream Brazed Aluminium Plate-Fin Heat Exc hanger
2 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION
 CHAPTER 1
General Description and Nomenclature
1.1.3.2 Pl ant types
Brazed aluminium plate-fin heat exchangers have been successfully used in
the above services in a variety of applications. The major applications have
been in the cryogenic separation and liquefaction of air (ASU ); Natural Gas
Processing (NGP) and liquefaction (LNG); the production of petrochemica ls
and treatment of offgases; large refrigeration systems. Table 1-1 gives some
typical applications where brazed alum inium plate-fin heat exchangers are
used extensively and have proven reliable over many years of service.

1.1.4 Limits of Use - Maximum Working Temperature and Pressure

The maximum working pressure for brazed aluminium plate-fin heat exchangers can be
over 100 bar g while also having a natural ability to accommodate a full vacuum design
condition. Manufacturer dim ension al constrains and thicker components are required at
high pressures , however. It is possible to have over twelve process streams, at various
pressures from minimum to maximu m, in a single heat exchang er.
The maximum temperature rating is typically specified at 65°C. An upper limit of 65 °C
is suitable for most application s, and it allows manufacturers to use 5083 aluminium
alloy piping which is more econom ical. However, designs are available for up to
+204°C at lower pressures. The minimum design temperature is -269°C. See
Chapter 6 for a full material listing.

1.1.5 Acceptable Fluids

Brazed aluminium plate-fin heat exchangers are capable of hand li ng a wide variety of
fluids in many different types of applications. In general, fluids need to be clean , dry,
and non-corrosive to alumi nium. Trace impurities of H 2S, NH 3 , CO2 , S02, N02 , CO, CI
and other acid-forming gases do not create a corrosion problem in streams with water
dewpoint temperatures lower than the cold-end temperature of the brazed aluminium
plate-fi n heat exchanger.
Under specific conditions , mercury can corrode aluminium and therefore caution must
be used when handling mercury-containing fluids . However, there are many instances
where brazed aluminium plate-fin heat exchangers have been successfully used with
fluids containing mercury provided that the proper equipment design and operating
procedures are impl emented . In all cases, it is particularly recommended that th e heat
exchanger manufacturer is consulted about specific conditions.
Further information on corrosion guid elines is given in Section 8.3.
Proper filters (usually mesh filters) must be installed upstream of the heat exchanger
system and maintained according to the filter manufacturers' recomm endations to
prevent plugging from particulates such as pipe scale or molecular sieve dust. If a
brazed aluminium plate-fin heat exchanger is accidentally plugged, proven clean ing
procedures are avail able. Further information on this subject is given in Section 8.2.
Fluids conta ining compressor lube oils , and other heavy hydrocarbons, are acceptable
pro vided these contaminants do not precipitate out on the fin surface. In the event of
heavy fouling, chemical solvent cleaning of the exchanger is a proven method of
clean ing.

STANDARDS OF THE BRAZED ALUM INIUM PLATE·FIN HEAT EXC HANGER MANUFAC TURER'S ASSOCIATION • 3
CHAPTER 1
General Description and Nomenclature

Table 1-1: Plant Types and Applications

Industrial Gas Production Oxygen

• Air Separation Nitrogen
- Liquefaction Argon
- Nitrogen Production Rare Gases
il

- Expander Type Ethane

- Nitrogen Rejection Unit (NRU) Propane
- Liquefied Petroleum Gas (LPG) Butane
- Helium Recovery Pentane
Nitrogen
Helium
Hydrogen
Hexane
Carbon Dioxide
I
Load
- Peakshaver i
- Floating LNG Nitrogen Refrigerant
- Boil-off gas reliquefaction (80G)

- Ethylene Propylene
- Ammonia Ethane
- Refinery Off-Gas Purification Propane
- HYCO Plant Ammonia
Carbon Monoxide

Refrigeration Systems Helium to -269 45

- Cascade Cooling Freon
- Liquefaction Ethylene
Propane
Propylene
Nitrogen
Hydrogen
Multi-Component

Iii as i i
to-Liquids (GTL) - Air ' Oxygen necessary in GTUCTL plants) and natural
gas processing plants

4 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 1
General Description and Nomenclature

1.2 NOMENCLATURE OF THE COMPONENTS

Section 1.2 describes the components which are part of a brazed aluminium plate-fin heat
exchanger. Typical geometrical dimensions are included in Chapter 5 of these Standards.
Other items are described in the relevant chapters (e.g. supports are illustrated in Chapter 4 of
these Standards).

1.2.1 Components of an Exchanger

For the purpose of establishing standard terminology, Figure 1-2 illustrates the
components of an exchanger.

Block (core)

Distributor
fins

Parting sheet

Length, L
AHeaders
Heat transfer _-!l>k- . ....,
fins
/
Side bars £.::::':"'I---~~~I
! !
Cap sheet --~--

Width,

Figure 1-2: Components of a Brazed Aluminium Pl ate -Fin Heat Exchanger

STANDARDS OF THE BRAZED ALUM INIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 5
CHAPTER 1
General Description and Nomenclature
1.2.2 Components of Manifolded Exchange rs
Multiple brazed aluminium plate-fin exchangers may be connected in parallel, in series ,
or in parallel-series combination, to form one assembly.
Figure 1-3 illustrates an assembly of three brazed alum inium plate-fin heat exchangers
connected in parallel. For this case, each individual stream enters the assembly
through a manifold, is distributed to the inlet nozzles on each of the three heat
exchangers, flows through the heat exchanger and leaves the assembly through the
outlet manifold .

Figure 1-3: Typi cal Assembly of Three Brazed Aluminium Plate-Fin Heat Exchangers in Parallel

1.2.3 Module Construction

Two or more individually brazed alum inium plate-fin exchanger blocks may be welded
together in parallel to form one composite block. In this way the stacking height of the
exchanger can be increased above a dimension limited by the manufacturing process
or other restrictions.

1.2.4 Connection Options

Several options are available for connecting a brazed aluminium plate-fin heat
exchanger to plant piping.

• • STAN DARDS OF THE BRAZED ALUMINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER·S ASSOCIATION
 CHAPTER 1
General Description and Nomenclature
1.2.4.1 Alumin ium Stub Ends
This option is selected if the exchanger nozzles are to be directly (butt-)
welded to the connecting aluminium pipes.

1.2.4.2 Flanges
This option is available if the heat exchanger is to be connected to steel
piping or if installation of the heat exchanger without welding is desired.
Under this option, the manufacturer normally provides the heat exchanger
with aluminium flanges welded on the nozzles to fit with mating (normally
steel) flanges on the piping. Details on the adequacy and design of such
flanged connections are given in Chapter 5, Section 5.12.3. As an option,
the manufacturer can weld transition joints on the aluminium nozzles and
steel flanges on the end of the installed transition joints to provide steel
flange connections to fit the mating flanges in the plant piping. Details of
transition joints are described in Chapter 5, Section 5.12.3.

1.2.4.3 Steel Stub Ends

This alternative to flanges is available if the heat exchanger is to be directly
(butt-) welded to steel piping. Under this option, the manufacturer provides
the heat exchanger with transition joints welded to the nozzles. The
transition joints are to be directly (butt-) welded to the connecting steel piping.

1.2.5 Header/N ozzle Configurations

Streams to and from the heat exchanger enter and leave by means of various
header/nozzle configurations.
The head ers are normally made from half cylinders with flat and/or mitred ends or
mitred dome headers. Typical variants are shown in Figure 1-4.
The nozzles may be radial , tangential or inclined to the header and can also be
equipped with flanges or transition jOints. There are many different acceptable
variations of header/nozzl e configurations in use and some typical variations are shown
in Figure 1-5.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 7

CHAPTER 1
General Description and Nomenclature

Standard header with flat ends Header with inclined ends

Header with mitred ends Dome header with mitred ends

Figure 1-4: Typical Header Configurations

Radial nozzle Inclined nozzle Tangential nozzle

Figure 1-5: Typical Header/Nozzle Configurations

, • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 1
General Description and Nomenclature
1.2.6 Fin Corrugations
Various shapes of corrugated fins are available.

1.2.6.1 Principal types of fin

The principal types are plain, serrated and herringbone as illustrated in
Figure 1-6. Plain and herringbone fins may also be perforated as illustrated.
For the thermal and hydraulic behaviour of each fin-type refer to Chapter 7 of
these Standards.

Plain fins Plain-perforated fins

Serrated fins Herringbone or wavy fins

Figure 1-6: Principal Types of Fin

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 9

CHAPTER 1
General Description and Nomenclature
1.2.6.2 Dimensions offins
Each type of fin is characterised by its height. h, thickness , t, and pitch , p , or
by the number of fins per inch (FPI) or by the number of fins per meter as
shown in Figure 1-7. Additionally, specification is required for the percentage
perforation of perforated fins (e.g. 5% of corrugated area), for th e length of
the serration of serrated fin s Is, and for the distance between crests on
herringbone fins.

t p
L p

Plain fin Herringbone fin

h
/

t
L L P
Serrated fin

Figure 1-7: Definition of Fin Dimensions

1.2.7 Distributors
There are various distributor types available for streams entering or leaving a block.
The principal distributor types a re:
sid e distributor (mitred or diagonal)
e nd distributor (left, right or central)
intermediate distributor (special)
Some typical examples are shown in Figure 1-8. Manufacturers may offer other
designs.
Special designs of distributor are offered for two-phase streams entering a block (see
Section 1.2.8).
10 • STANDARDS OF THE BRAZED ALU MINIUM PLATE-FI N HEAT EXCHANGER MA NUFACTURER'S ASSOCIATION
 CHAPTER 1
General Description and Nomenclature

Side distributors End distributors Intermed iate distributors

Diagonal 'A' Left Diagonal

Diagonal 'S' Centre Split flow entry/exit

Diagonal 'C' Open end Re-entrant 'A' with one or more

separator bars

Diagonal with double entry/exit Double entry/exit Re-entrant 'S' with one or more
separator bars
Figu re 1-8: Examples of the Prin cipal Distributor Types

STANDA RDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXC HANG ER MANUFACTU RER'S ASSOCIATION • 11
CHAPTER 1
General Description and Nomenclature
1.2.8 Two·Phase Distributors
Single-phase distributor types shown in Figure 1-8 can also be used when two-phase
streams enter a block. In addition , there are special distributors for two-phase streams
entering the block. In these designs, the liquid and the vapour are separated in a
vessel upstream of the plate-fin heat exchanger and then introduced through separate
distributors. Some examples are
• Perforated tube or bar distributor (Figure 1-9a)
• Slotted parting sheet: Split passages type (Fig. 1-9b)
• Slotted parting sheet: Adjacent passages type (Fig. 1-9c)
Manufacturers may offer other designs.

- -- --. ----,-- '"'<0"""--_.""'-- . ---"~- - -""

Exploded
part view
of heat
exchanger

.Jl_____ p.~c'raled lube

or bar

Parting sheets

Stream 2 passage Stream 1 passage

Figure 1-9a: Perforated Tube or Bar Distributor

12 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 1
General Description and Nomenclature

out out

~'I--/ Second
stream

Second

Liquid feed
Vapour feed
Partition sheet omitted
Section through liquid entry for clarity
Section through vapour entry
(stream 1) (stream 1)

Fig ure 1-9b: Slotted Parting Sheet, Split Pass ages Type

out
Second
stream
out

- l- :Sea,lii"9 ba r
(shown cut
away)

Ii

Second

~~~~l;~~::,~~:
Liquid ;c (Streamfeed
1)
Liquid in
(Stream 1)
in (Stream 1)
(Stream 1)

Section throug h liquid entry Section through vapou r entry

(stream 1 and stream 2) (stream 1)

Figure 1-9c: Slotted Parting Sheet, Adjacent Passages Type

STAN DARDS OF THE BRAZED ALUMI NIU M PLATE-FI N HEAT EXCHANG ER MAN UFACTURER'S ASSOCIATION • 13
CHAPTER 1
General Description and Nomenclature
1.2.9 Flow Arrangements
Figure 1-10a illustrates the structure of an individual layer. Internal distributor fins (1)
conduct the stream from the narrow entry port across the full width of the layer to the
heat transfer fins (2). Distribution fins (3) then conduct the stream to the exit port
Figure 1-10b illustrates the fin arrangement of a layer with an intermediate port (see
also Figure 1-8). Various arrangements of the layers for each of the streams provide
various possible flow arrangements, as shown in Figure 1-11. Manufacturers may offer
further arrangements.

' " Intermediate

port

(a) (b)

Figure 1-10: Structure of an Individual Layer

A B t c
t

B is in counterflow to A
C is in cross-counterflow to A
o is in co-current flow to 8
E is in crossflow to 0
D t E

Figure 1·11: Flow Arrangements

14 • STANDARDS OF THE BRAZED ALUMINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 2
Tolerances

2 TOLERANCES
Standard tolerances for the external dimensions of brazed aluminium plate-fin heat
exchangers are shown in Figure 2-1 and Figure 2-2. The core centre line (Figure 2-1 ) and the
base line of supports (Figure 2-2) are used here as datum lines to illustrate these dimensions.
However, manufacturers may use other reference datum lines. The Purchaser and
Manufacturer may adopt other tolerance values upon agreement.
Figure 2-3 shows the tolerances for a manifolded assembly of two cores. Here, the base line of
the supports may also be used as a datum line as shown in Figure 2-2. Detai ls for flanges are
also shown in Figure 2-3.
For spa re and replacement exchangers these tolerances shall also be applied .

I. B
-T

-.

N Q-dia
._._+ _._-
Core bolt hole
centre line

. ...L

J K
"j ·1

Items Tolerances Items Tolerances

A, B, C, ± 6 mm for Dim :s; 1000 mm G ±3°

D, E, F, ± 8 mm for 1000 mm < Dim:S: 2000 mm NO P t3mm
H, I,J, K ± 10 mm for Dim> 2000 rnm Q ±1mm

Figure 2-1: Important External Dimensions of One COfe using the Core Centre Line

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FI N HEAT EXCHANGER MAN UFACTURER'S ASSOCIATION o 15
CHAPTER 2
Tolerances

I'
D
Support
base line ~
I ~--,£'J
~ Q-d ia
._j- bolt hole

I
F
I
I
I

GL-',..-"'"
?'1~Ic+J
I ""-~ _ ..L

I
0I,- -J- ,I

Items Tolerances Items Tolerances

A, B,C, ± 6 mm for Dim!'> 1000 mm G ± 3"

D, E, F, ±S mm for 1000mm < Dim S 2000mm O, P ±3mm
H, I, J, K ± 10 mm for Dim> 2000 mm a ± 1 mm

Figure 2-2: Important External Dimensions of One Core using the Support Base Line

,. " STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATIO N
 CHAPTER 2
Tolerances

C A
lr' ---"-----.,'11-
I II - -I _ ._+---
.
I II I I
I II I
I II I

sl_i HI
+- .- - f-
I
D
I
F
I

,, ,,

I, E G J .1
--1 M

-. -.-
~
Items To lerances Items Tolerances
A, B, C. ± 6 mm for Dim $ 1000 mm H ±3mm
D. E, F, ± 8 mm for 1000 mm < Dim s; 2000 mm L ± 1°; max 5 mm at f1anQe oeriphery
G,I, J, K ± 10 mm for Dim> 2000 mm M ± 1°; max 5 mm at bolt circle

Figure 2-3: Important External Dimensions of a

Manifolded Assembly of Two Cores: General Flange Details

STANDARDS OF THE BRAZED ALUMINIU M PLATE-FI N HEAT EXCHANGER MAN UFACTURER'S ASSOCIATION • 17
CHAPTER 3
General Fabrication Contractual Information

3 GENERAL DESIGN, FABRICATION AND CONTRACTUAL

INFORMATION

3.1 SHOP OPERA nON

The detailed methods of shop operation are left to the discretion of the Manufacturer in
conformity with these Standards.

3.2 DESIGN CODE

The design of the equipment shall be performed by the Manufacturer in complete compliance
with the agreed Code. As a minimum, the latest mandatory edition of the Code in effect at the
date of purchase order shall apply. For more information refer to Chapter 5 of these Standards.

3.3 INSPECTI ON

3.3.1 Third Party Inspecti on

Generally all brazed aluminium plate-fin heat exchangers are subject to an inspection
by an independent third party inspection authority. The authority shall carry out the
inspections and witness tests required by the agreed applicable Code, and certify that
the heat exchanger is in accordance with Code mandatory requirements.

3.3.2 Manufactu rer's Inspectio n

In some circumstances, in agreement with the Purchaser, the Manufacturer may carry
out the inspection and testing of the heat exchanger in the absence of being witnessed
by the Code certifying authority. Acceptance criteria shall not be less than that required
when performed by a third party inspection authority in accordance with the
Manufacturer's Code registration terms of reference (i.e. Code quality control manual
requirements) .

3.3.3 Purcha ser's Inspecti on

The Purchaser shall have the right to participate in any inspection and to witness any
test that has been contractually agreed . However, Purchaser's inspections and
witnesses shall be restricted to non-proprietary operations unless mutual agreement
has been made to the contrary. Advance notification of inspections and tests shall be
given as agreed upon between the Manufacturer and the Purchaser. Inspection by the
Purchaser shall not relieve the Manufacturer of the Manufacturers responsibilities for
compliance with the Code and these Standards.

3.4 NAM EPLATE

3.4.1 Manufacturer's Nameplate

A suitable Manufacturers nameplate shaU be permanently attached to each individual
brazed aluminium plate-fin heat exchanger. The location of the nameplate shall allow
easy access after installation of the heat exchanger in the plant.
The nameplate shall be of corrosion resistant material, which may be an aluminium
alloy or austenitic stainless steel. When specified by the Purchaser, the nameplate
shall be attached to a bracket welded to the heat exchanger. If the heat exchanger is to
be installed in a permanent enclosure, (e.g. a cold box or vessel), a second identical
(duplicate) nameplate shall be fitted to the supplied enclosure by the Manufacturer in a
visibl e location mutually agreed with the Purchaser. Where the enclosure is not
provided by the Manufacturer, the duplicate nameplate shall be supplied loose for
attachment onto the enclosure by others.

18 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFAC TURER'S ASSOCIATION
 CHAPTER 3
General Fabrication Contractual Information

3.4.1.1 Nameplate structure

Because brazed aluminium plate-fin heat exchangers are capable of
accommodating more than two streams, i.e. containing more than two
independent pressure chambers , it is common practice that nameplates used
by Manufacturers are able to specify data for several streams. Alternatively,
several nameplates can be used.

3.4.1.2 Nameplate data

The nameplate shall , as a minimum, include all data required by the Code.
The following data are typical for each stream: the maximum allowable
working pressure and the maximum and minimum allowable working
temperatures or design metal temperature. Other nameplate information
norm ally given will be the Manufacturer's name and address, the heat
exchanger serial number and the year built. In the case of a cold box, a name
plate should also be attached outside of the cold box, Nameplates shall be
readable from an accessible area.

3.4.1.3 Supplementary Information

The Manufacturer may supply supplementary information pertinent to the
identification, operation, or testing of the heat exchanger. This may include
information about different design and test pressure conditions or other
restrictive conditions applicable to the design and/or operation of the heat
exchanger. Such information can be noted on the nameplate or on a
supplementary plate attached to the heat exchanger, close to the nameplate
location.

3.4.2 Purchaser's Nameplate

Purchaser's nameplate, when used, is to be supplied by the Purchaser and
supplement, rather than replace, the Manufacturer's nameplate. The Purchaser shall
supply information about size and material of supplementary nameplates to the
Manufacturer at the date of order.

3.5 DRAWINGS AND CODE DATA REPORTS

A general drawings package shall be prepared and submitted by the Manufacturer to the
Purchaser and the appointed third party inspection authority.

3.5.1 Drawings Information

The Manufacturer's drawings package shall contain all the necessary information for
approval, and may include the following:
overall dimensions and material thicknesses,
supports and weights,
specification and identification of materials, and if required by the Code, type of
material certificates ,
types of fins used ,
nozzlelflange location, identification numbering, and connection details, - type of
fluid for each stream if required by Purchaser or the Code,
fabrication and test data, extent and location of non-destructive examinations,
extent of leak testing , test pressures and appropriate weld identification as required
by the relevant Code,
tolerance information,
centre of gravity for erection.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 19

CHAPTER 3
General Fabrication Contractual Information

3. 5.2 Draw ings Approval and Change

The Manufacturer shall submit the outline drawings for the Purchaser's review and
approval. An agreed number of prints of an outline drawing shall be submitted. Other
drawings or documents may be furnished as agreed upon by the Purchaser and the
Manufacturer.
Review and/or approval of drawings and documents shall be carried out by the
Purchaser within a reasonable agreed period.
The Purchaser's approval of drawings shall not release the Manufacturer from his
liability and responsibility for compliance with these Standards and applicable Code
requirements.

3.5.3 Draw ings for Record

After approval of drawings, the Manufacturer shall furni sh an agreed number of prints
of all approved drawings.

3.5.4 Proprietary Rights to Draw ings

The drawings and the design indicated by them are to be considered the property of
the Manufacturer and are not to be used or reproduced without his permission , except
by the Purchaser for his own internal use.

3. 5.5 Code Data Reports

After completion of fabrication and inspection of the exchanger(s), the Manufacturer
shall furnish an agreed number of copies of the Manufacturer's Data Report.

3.6 GUARANTEES
Manufacturers are prepared to grant a thermal and hydraulic performance guarantee, and a
mechanical guarantee. Details sh all be agreed upon by the Purchaser and the Manufacturer.
The following sections give an indication of terms of guarantees which may be expected from
the Manufacturer.

3.6.1 Thermal , Hydrauli c and Mechani c al Guarantees

The Manufacturer will typically warrant to the Purchaser for a period of twelve (12)
months from date of equipment startup, but not to exceed eighteen (18) months from
date of shipment, whichever occurs first, that the equipment provided is (1) free from
defects in material and workmanship, and (2) will meet the thermal and hydraulic
performance set forth in the Manufacturer's heat exchanger specifications, provided
th at no warranty is made against corrosion, erosion, or deterioration. If any
performance deviations are to be applied in respect to the thermal and hydraulic
performance guarantee, the acceptance criteria shall be by agreement between the
Purchaser and Manufacturer. The Manufacturer will not warrant heat exchanger
performance and/or mechanical design if the operating process conditions of flows,
temperatures, pressures, fluid composition and turndown conditions are more severe
than those specified on the Manufacturer's specification sheets, or for pressures or
temperatures outside the design range specified on the heat exchanger nameplate, or
for damage due to improper installation, operation or storage, or due to external forces
applied to the heat exchanger from the connecting piping or support system, which
exceed the Manufacturer's specified allowable load s.
The Manufacturer's obligation and liability, at the option of the Manufacturer, is limited
to the repair , modification, or replacement of the Manufacturer's equipment if found not
to be in compliance with the stated warranty. The Manufacturer's obligations and
liabilities are limited to furnishing replacement equipment, ex works, not conforming to
this warranty.

20 • STANDARDS OF THE BRAZED ALU MINIUM PLATE-FIN HEAT EXCHANGER MANUFAC TURER'S ASSOCIATION
 CHAPTER 3
General Fabrication Contractual Information

3.6.2 Consequential Damage

In no event shall the Manufacturer be held liable for any costs for gaining access ,
installing, lost product , lost production , lost profits or any incidental or consequential
damages of any nature.

3.6.3 Corrosion
After delivery the Manufacturer assumes no responsibility for any defect of the
equipment due to corrosion, except wh ere the Manufacturer has expressively accepted
the conditions and/or substances which have caused such corrosion.

3.7 PREPARATION OF BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGERS FOR

SHIPMENT

3.7.1 General
Brazed aluminium plate· fin heat exchangers will be suitably protected to prevent
damage during shipment If there are no special instructions from the Purchaser, the
following terms shall apply.

3.7.2 Cleaning
Internal and external surfaces will be free from oil and grease and free from any loose
scale or other foreign material.

3.7.3 Drying
The Manufacturer will ensure that all pressure chambers are sufficiently dry before
shipment.

3.7.4 Flange Protection

All exposed machined contact surfaces will be protected against mechanical damage
by suitable covers.

3.7.5 Dummy Passages/Inactive Areas

Openings in dummy passages or inactive heat exchanger areas will be suitably
protected to avoid ingress of water and dust.
Reference should be made to Chapter 4 of these Standards.

3.7.6 Pressurising
To avoid ingress of any moisture or dust during transport, brazed aluminium plate-fin
heat exchangers will be shipped with flanges and nozzles hermetically sealed and all
pressure chambers pressurised with dry, oil-free nitrogen gas or air to bet'oNeen 0.2 and
1.2 bar g.
All connections must carry warning labels stating that the heat exchanger is under
pressure.
WA RNING: REMOVAL OF END CLOSURES IS ONLY ALLOWED AFTER
REDUCING THE PRESSURE TO ATMOSPHERIC IN THE RELEVAN T CHAMBER
BY THE INSTALLED GAUGENALVE.
The Purchaser and Manufacturer may agree that pressurising the heat exchanger for
transport is not necessary. In that case it may be considered necessary to sh ip the heat
exchanger packed in a plastic fo il with a humidity-absorb ing agent inserted.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 21

CHAPTER 3
Genera l Fabrication Contractual Information

3.8 SCO PE OF SUPPLY

Unless express ively agreed otherwise between the Purchaser and the Manufacturer, the
scope of the Manufacturer's supply is as follow s:
(1) Heat exchanger core(s) complete with headers and nozzles , and , jf applicable, manifolded
to form an assembly.
(2) For stub pipe connections:
Nozzles are normally sea l welded with closures for transport. The Manufacturer will
provide sufficient length of stub pipes to allow easy connection to the plant piping after
cutting the closures.
(3) For flanged connections :
The Manufacturer's scope of supply wi ll end with the face of the flanges , which are
normally covered by blind flanges for transport. These blind flanges with pertinent bolts
and gaskets are on ly included to protect the flange faces and to allow moderate
pressurising of the individual chambers for transport.
Other options can be agreed between Purchaser and Manufacturer, such as the following:
(1) Insulation material, which is not normally included in the Manufacturer's scope of supply.
(2) Normally there are no spare parts necessary for the equipment covered by these
Standards, other than flange bo ltings and gaskets where applicable.
(3) Steel counterflanges, bolts and gaskets suitable for plant operation are normally not in the
Manufacturer's scope of supply but may be specified by the Purchaser.
(4) The Manufacturer can supply su itable supports and lifting lugs/devices as described in
Sections 3.9.1 and 3.9.2 below.

3.9 GENERAL CO NSTRUCTION FEATURES

3.9.1 Supports
Generally all brazed alum inium plate-fin heat exchangers are provided with supports.
Any exceptions are to be agreed upon between Purchaser and Manufacturer,
The supports are designed to accommodate the we ight of the heat exchanger and its
contents , during both operating and test cond itions.
For purposes of support design, Manufacturers provi de a design margin for external
loads from piping, wind and seismic events. This margin is provided by, or is available
upon request from the Manufacturer. As an alternative, the Purchaser may supply the
Manufacturer with the external loadings for th e Manufacturer's support design.
Wind and seism ic loads will not be assumed to occur simultaneously.
Support details are described in Chapter 4 of these Standards.

3. 9,2 Lifting Devices

lifting lugs/devices shall be designed using one of the following methods:
(1) The Purchaser shall inform the Manufacturer of the way in which he plans to lift and
move the heat exchanger,
(2) The Manufacturer shall ad vise the Purchaser of the approved method for lifting and
moving the heat exchanger and provide drawings showing the centre-of-gravi ty.
If appli cable, the Manufacturer can design a suitable device , or provide lifting lugs or
equivalent on the heat exchanger, to safely lift and transport the heat exchanger into its
installed position.

22 • STAN DARDS OF THE BRAZED ALU MINI UM PLATE-FIN HEAT EXCHANGER MAN UFACTU RER'S ASSOCIATION
 CHAPTER 3
General Fabrication Cont ractual Information

The Manufacturer shall advise the Purchaser of the proper use of the lifting device and
lugs. If these do not exist, it is possible , with prior approval from the Manufacturer, to lift
the heat exchanger with belts or ropes , if attention is fully paid to suitable protection of
the heat exchanger corners.

3.10 NONCONFORMITY REC TIFI CATIO N

3. 10.1 Introduction
Rectification work on a brazed plate·fin heat exchanger block is necessary if a
nonconformity occurs during the manufacturing process. This section describes
procedures and Purchaser notifications to resolve a nonconformity.
The Manufacturer judges the severity of the nonconformity and reviews contractual
requirements in determining the involvement of the Purchaser in deciding disposition.
Unless there are contractual requirements to the contrary, the following procedures are
followed in performing nonconformity rectification.

3.10.2 Procedures and Docum entation

All rectification work shall be carried out according to approved procedures based on
sound engineering principles. All rectification must conform to Code requirements ,
assure leak integrity and not affect the structural integrity of the heat exchanger. The
Manufacturer will fully maintain the agreed mechanical guarantee.
A nonconformity record document shall be completed by the Manufacturer and be
available for review by the Purchaser, on request.

3.10.3 Side-Bar-t o-S heet Joint Leak Re ctif icati o n

A brazed aluminium plate-fin heat exchanger typically contains more than 1600 linear
meters of brazed, side-bar joints. Based on a very controlled brazing process the
overall structural and leak integrity of the side-bar to parting sheet joint is excellent.
However, due to the large number of potential leak sites, small leaks in the side-bar-to-
sheet joint can sometimes occur.
Rectification is by seal welding using a proven procedure developed for this purpose.
External leaks at the brazed connection between side bars and parting sheets may be
seal welded without notification of the Purchaser.

3.10.4 Bloc king of Lay ers

A typical brazed aluminium plate-fin heat exchanger contains more than a half million
linear meters of braze jOints between fins and parting sheets , produced by the brazing
process in excellent quality. However, due to manufacturing variations over the large
number of fin-to-sheet braze sites , a small area of unacceptable brazing may
occasionally occur within a layer and is detected by the pressure test.
Rectification is typically to block the layer using a proven procedure developed for this
purpose. Blocking of an active layer requires notification of the Purchaser.
The Manufacturer shall perform calculations to estimate the influence of the blocked
layer(s) on thermal performance and pressure drop for any exchanger designed by the
Manufacturer.

3. 10.5 Other Re ctification Wo rk

The Purchaser will be notified and involved in any disposition decision if the
rectification has impact on the performance guarantee or installation of the unit.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXC HANG ER MANU FAC TURER'S ASSOCIATION • 23
CHAPTER 4
Install ation , Operation and Maintenance

4 INSTALLATION, OPERATION AND MAINTENANCE

4.1 GENERAL
It is normal for brazed aluminium plate-fin heat exchangers to be installed in the vertical
orientation, warm end up. There are, however, some exceptions to this such as reversing heat
exchangers for air separation or cross flow sub-coolers. Heat exchangers are normally
supplied with all the necessary supports to facilitate site installation.
Generally, mounting supports are, if possible, positioned in the warm half of the block. This
reduces movement at the juncture of the bracket to the support beam during start-up and shut-
down cycles.
In addition to the main supports, there may be a need for an additional sliding guide to restrict
movement from the vertical plane. Several aspects need to be considered to determine if such
a device is necessary, for example:
Physical dimensions of the heat exchanger
Weight of the heat exchanger
Site conditions (earthquake, wind , pipe load etc. )
Relative position of the main support plane to the centre of gravity of the heat exchanger.
Upon request, the Manufacturer will provide values for the allowable forces and moments
which may be applied at the junctions of the header tank to nozzle of the heat exchanger. The
Purchaser should then ensure that these values are not exceeded for all connecting pipe runs
(refer to Section 5.12.2.4 and Table 5-1 for typical values).
If the connecting pipe joints between the heat exchanger and the Purchaser's pipework are to
be made by means of welding , then this must be done using the relevant qualified weld
procedures and welders. The weld filler materials used must be those approved for welding the
materials to be joined. Details of the nozzle material are normally marked on the heat
exchanger nozzles as well as being stated on the relevant drawing. The Manufacturer should
be asked if the installer has any doubts on this matter.

4.2 LlFnNG AND HANDLI NG

Extreme care should be taken in the lifting and handling of brazed aluminium plate-fin heat
exchangers. The Manufacturer will ensure that a heat exchanger is provided with the means of
lifting, e.g. lifting lugs, lifting attachments, specified nozzles, etc. The Manufacturer will provide
detailed instructions for lifting and handling; these instructions will be specific to each heat
exchanger and must be strictly followed. If there are any doubts about lifting and handling of
any heat exchanger, the Manufacturer should be consulted.
WARNI NG: FAILURE TO FOLLOW THE MANUFACTURER'S LIFTING AND HANDLING
INSTRUCTIONS FOR A SPECIFIC HEAT EXCHANGER COULD SERIOUSLY DAMAGE
THE EXCHANGER.

4.3 SUPPORT BEAMS

The beams onto which the heat exchanger is to be mounted, unless within the scope of
supply, are the responsibility of the Purchaser. In the selection of these beams, in addition to
the dead weight imposed by the heat exchanger, loads generated by applied external forces
and mom ents should also be consid ered. 1t is a common practice in this evaluation to assume
that the allowable forces and moments given in the Manufacturer's design documents are not
applied simultaneously. The mating faces of the support beam should be flat and be aligned so
that, when installed, th e deviation of the unit to the true vertical is a maximum of %" or 15 mm
measured over the block length. T he alignment may be achi eved with the aid of metal shims,
but this is not preferred. For light applications the support beams may be manufactured from
aluminium, however, it is normal for the beams to be made from the appropriate steel alloy.

24 • STAN DARDS OF THE BRAZED ALUMINIUM PLATE-FI N HEAT EXCHANGER MANUFAC TU RER'S ASSOCIATION
 CHAPTER 4
Installation, Operation and Maintenance
4.3.1 Support Insulation
To prevent heat leakage, thermal insulation is required between the mating faces of the
supports. The heat-break insulating material (for example Micarta") must be capable of
load bearing and allow movement on the support. The thickness of heat-break should
be selected by the Manufacturer depending on the operating conditions. If the heat
exchanger is mounted in a cold box, a proportion of the required total thickness of heat-
break may be fitted at the junction of the support beam and cold box, in addition to the
mating face between the heat exchanger support and the support beam.

4.4 SLIDING GUIDE FRAME

For applications where externally applied forces due to wind, earthquake and pipeloads are
large enough to cause lateral movement, it is necessary to limit horizontal movement of the
heat exchanger.
The function of the sliding guide is to limit the horizontal movement. Details of typ ical support
systems and guides are shown in Figure 4-1 , Figure 4-2 and Figure 4-3. The guide frame
should be separated from the heat exchanger with layers of heat·break material. To
compensate for core contraction in service, the break must be tightly packed and fixed to the
guide frame with stainless steel screws to prevent it from becom ing detached. An additional
wear plate (scuff plate) may be fitted to the heat exchanger for protection. The interface
members of the frame should be made from the appropriate steel alloy and braced back to the
main structural members of the cold box or support frame to give stability.

OpcJooaI
wear pate

SI;,jing !Pde
"me

Heat break fixed

to glide frame

Figure 4-1: Typical Sliding Guide Frame

Trade name
STANDARDS OF THE BRAZED ALUMINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 25
CHAPTER 4
Installation, Operation and Maintenance
Figure 4-2 shows a typical assembly of three heat exchangers with a Shear Plate Support
Arrangement The heat exchangers are supported at the upper warm end and guided at the
lower cold end.

Support angle

Support
beams

8radng
(when required )

Guide frame to
prevent the
----+--1\:/'
exdlanger from
Bracing (when required)
rotating on
supports

Figure 4-2: Typical Heat Exchanger Assembly of Three Cores Showing Shear Plate Supports

26 • STANDARDS OF THE B RAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANU FACTURER'S ASSOCIATION
 CHAPTER 4
Installation, Operation and Maintenance
Figure 443 shows a typica l assembly of three heat exchangers with an Angle Bracket Support
Arrangement. The heat exchangers are supported from angle brackets welded onto the side-
bar faces.

o
Support
bracket

Support
beams

Bracing
(when required)

Guide frame to - -- -1-- -1\:/

prevent the
exdlanger from
Bracing (when required)
rotating on
supports

Figure 4-3: Typical Heat Exchanger Assembly of Three Cores Showing Angle Bracket Supports

STANDARDS OF THE BRAZED ALUM INIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 27
CHAPTER 4
Installation, Operation and Maintenance
4.5 FI XING (MOUNTING) BOLTS
There are several methods employed for locating heat exchangers on supports; a mounting
bolt system is typical.
The object of the mounting bolt is to keep the heat exchanger in contact with the support
beam , It is NOT to fix the heat exchanger rigidly , because a rigid attachment will lead to very
high moments and forces being applied at the supports when the heat exchanger contracts or
expands during start-up and shut-down.
Manufacturers recommend a mounting assembly that allows differential contraction of the
supports on the heat exchanger and the support beams.
A typical method of using mounting bolts is shown in Figure 4-5. With this method a stainless
steel tube some 0.5 mm longer than the combined thickness of the support components is
used to prevent rigid locking when the mounting bolt nut is tightened .
Alternatively, the mounting bolt nuts can be installed "finger-tight" to prevent rigid locking and
the stainless steel sleeve omitted. However, the bolts should be installed "head-up" to avoid
detachment should the nuts work loose and it is recommended that lock nuts or thread locks
be used,
Typically, four mounting bolts per heat exchanger are employed, one at each corner. These
should be manufactured from stainless steel, although for light applications an appropriate
aluminium alloy may be used.
During start-up, the heat exchanger will contract or expand on the mounting beam in both
horizontal directions.
WARNING: THE NECESSARY AMOUNT OF CLEARANCE MUST BE ALLOWED
BETWEEN THE INSERT TUBE (OR BOL T ONLY WHEN USED) AN D THE SUPPORT
COMPONENTS.
The necessary clearance to take account of the expected thermal movement may be
calculated from the following expression for both horizontal directions:
X =a t 6.TR s
Where:
X : Required clearance (mm)
a t : Coefficient of linear expans ion at the average temperature between ambient and
operating temperatures (m/m K) (from Figure 4-4)
ilTR : Temperature range at support = difference between operating temperature and
ambient temperature (K)
s : Distance between the extreme bolts in a given plane (mm).

28 • STANDARDS OF TH E BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 4
Installation, Operation and Maintenance
Average temperature, gc
20
- 200 -100 o 100 200 300 400 500 36.0

"""-
-cu
u:
•
16
I I
~
~ --- ---
,
I
•
-
(j

28.8 ;;
c
.~ .2
w
c
I
[~ 12
.. -
~ x ./ ------ 21 .6 0
m~
x .0

..•
_
x
"- (j
E• I : / E •
••
;; "0. 8
-c
0
I ;
--•
14.4 " "~
~

0
C
.~
IE
4 I I 7.2 .~

u
•
0 I I IE
~
(j
)
0-400 -200 o 200 400 600 800 1000
Average temperature, OF
Figure 4-4: Coefficient of Thermal Expansion of Aluminium

For estimated clearances of up to 4 mm , the clearance may be achieved by drilling the

mounting hole in the support bracket with an oversize . For larger clearances , the support
bracket must be slotted in the direction of the movement. For larger two-d irectional
movements, the clearance is maintained by slotting both the support bracket and the support
beam , with the slots being positioned at 90 to each other. 0

Cores
She... plates

Customer's
suppott bOOm

Heat-bmak

Figure 4·5 : Typical Shear Plate Bolt Assembly

STANDARDS Of THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 29

CHAPTER 4
Installation, Operation and Maintenance
4.6 VENTING OF DUM MY/INACnVE AREAS
Many brazed aluminium plate-fin heat exchangers contain void or inactive areas.
Typical examples of these inactive areas are:
1) Inactive or dummy layers on the top or bottom of the heat exchanger stack.
2) The space formed between two streams in the same layer having adjacent side headers.
3) The dead corner of an end distributor employing the slant bar drainability feature.
4) The modular space formed by welding together two heat exchanger blocks.
5) Other special features.
The presence of inactive areas is indicated by a note on the drawing; the positioning of open
areas requires that they are drainable.
Manufacturers take precautions to dry and seal the inactive areas prior to shipment.
WARNING: FOLLOWING INSTALLATION AND PRIOR TO SITE TESTING AND
OPERATION, THE SHIPPING SEALS COVERING THE INACTI VE AREAS MUST BE
RE MOVED AND REPLACED WITH EITHER A VENT PLUG OR MONITORING VENT LI NE,
ETC., AS INSTRUCTED BY THE MANUFACTURER.

4.7 FIELD TESTING

4.7.1 Non-Destructive Testing

Manufacturers recommend the following non-destructive testing of the connecting
pipework welds to be canied out to maintain an acceptable quality level.
1. A vi sual inspection of all connecting pipework root welds.
2. A liquid penetrant examination of all connecting pipework and cap welds.
3. A radiographic examination of a minimum of 10% of all closing butt welds ,
Representative samples of each welder's work should be examined.
The test procedures and acceptance criteria shall be in accordance with the governing
construction Code.
Note: Dye penetration examination of the brazed surfaces should not be performed as
this type of testing is not appropriate, not required and the results will be misleading.
This is due to:
1. The configuration of the side bar and parting sheet surface and
2. The braze engagement length (bar width) which greatly exceeds the
minimum braze engagement length required by the governing construction
Codes.
For Clarification Purposes : Due to the geometry of the side bar and parting sheet
surface, false indications of braze defects will occur when subjected to liquid
penetration examination. Due to the width of the bars used, the braze engagement
length far exceeds the minimum requ ired by the construction Codes and thus the
adequacy of the brazed joint does not depend on the brazed joint extending fully to the
outside surface of the plate fin heat exchanger.

30 • STANDARDS OF THE BRAZED ALUMINIU M PLATE-FIN HEAT EXCHANGER MANU FACTURER'S ASSOCIATION
 CHAPTER 4
Installation, Operation and Maintenance
4. 7.2 Proof Pressure Testing
Most governing jurisdictions require a pressure test of the piping system after a heat
exchanger is installed. The test shall meet the requirements of the relevant Code
authority with the following additional considerations fully taken into account
It is highly recommended that a pressure test is NOT conducted with water as the test
medium. Water removal after the heat exchanger is installed is difficult and residual
water trapped within the heat exchanger can freeze during unit operation causing
serious damage and lead to premature failure of th e heat exchanger.
W ARNING: SPECI AL PREC AUTIONS MUST BE TAKEN IF THE HE AT
EXCHANGER IS TO BE PNEU MATIC ALLY TESTED. PNEU MATIC TESTING CAN
BE HIGHLY DANGEROUS IF NOT CARRIED OUT BY FOLLOWING THE
RELEVANT LOCALLY APPROVED PROCEDURES.
Each stream of the heat exchanger system must be tested individually, with the other
streams not pressurised. Oxygen-free nitrogen of dewpoint -40"C or better should be
used as the test medium.
WARNI NG : THE TEST PRESSURE MUST BE IN ACCORDANC E WITH THE LOCAL
CODE REGULATIONS BUT SHOULD NOT UNDER ANY CIRCU MSTANC ES
EXCEED THE PROOF TEST PRESSURE OF THE HEAT EXCHA NGER.
On completion of the proof test for the heat exchangers tested at values above the
design pressure, each stream is firstly to be de-pressurised down to its design or
operating pressure and a soap bubble leak test carried out on all pipe weld
connections. For heat exchangers proof tested at the design pressure or less, the leak
test is to be carried out at the operating pressure.
The evaluation of the proof pressure test must take into account any variation in
ambient temperature from commencement of the pressure hold period to its
completion. For the test pressure to have been sati sfactorily held over this period , the
final pressure can be calculated from:
. . .. . Final Ambient Absolute Temperature
Final Pressure Reading ="mllal Pressure Reading x
Initial Ambient Absolute Temperature

The pressures used in this calculation are absolute, not gauge.

4.8 INSULATION
On completion of all field testing the heat exchanger will require to be insulated.
For heat exchangers mounted within a cold box th e minimum insulated distance, in mm ,
between the heat exchanger and cold box wall is taken from Figure 4-6. The void space
between the heat exchanger and wall must be packed with insulant. This may be either
expanded perlite or rockwool. For perlite a density in the range of 50 to 70 kg/m 3 is normally
used. When packing with rockwool care must be taken to avoid damage to the heat
exchanger's connections. Prior to start-up, a continuous dry oxygen-free nitrogen purge is to
be connected to the cold box.
For stanchion (pedestal) or frame mounted heat exchangers, the minimum thickness of
insulation is also to be taken from Figure 4-6. The insulation used for this type of heat
exchanger is usually of the spray-on polyurethane foam type. After appl ication of the insulant,
the heat exchanger must be sealed with a weatherproof jacket.

STANDARDS OF TH E BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 31

-
CHAPTER 4
Installation, Operation and Maintenance
40
\
o \
\
-40
\
\
-,90
Exchanger minimum \
temperature , °C
-120 \
\
-160 \
,\
- 200 \
I \
-240 \
\
o 100 200 300 400 500mm

Figure 4-6: Recommended Minimum Insulation Thickness (mm).

4.9 OPERATION

4.9.1 Start-up
WARNING: TO ENSURE SAFE OPERATION EACH STREAM OF THE HEAT
EXCHANGER MUST BE PROTECTED WITH A PRESSURE RELIEF DEVICE. IT IS
THE RESPONSIBILITY OF THE USER TO PROVIDE AND ENSURE PROPER
INSTALLATION OF THE PRESSURE RELIEF DEVICES. THE RELIEF
PRESSURES SHALL BE SET NO HIGHER THA N THE MAXIMUM ALLOWA BLE
WORKING PRESSURE OF THE STREAMS, CONSIDERING BOTH THE HEAT
EXCHANGER AND THE CONNECTING PIPI NG.
Prior to start-up , internals of the connecting pipework and vessels system must be
thoroughly cleansed of all particulate matter such as rust, scale, grit or sand. The
system should then be purged using oxygen-free nitrogen or other suitable purge gas
(dewpoint of ·40°C or less). The objective of this purge is to remove any res idual
moisture, the presence of which could result in freeze damage to the heat exchanger
during operation. Duration of the purge should range from 4 hours to several days
depending on size, complexity and physical state of the heat exchanger system. The
purge exit should be monitored until consistent readings of dewpoint (approaching that
of the inlet purge gas dewpoint) are obtained.
Cool-down of the heat exchanger is only permitted using gas (i.e. no liquid phase
present). Cool-down should be carefully controlled to avoid thermal shocking of the
heat exchanger and pipework. A rate of 2°C per minute maximum is normally
recommended to allow for gradual dimensional adjustments but the Manufacturer
should be consulted if this rate is likely to be exceeded. With the agreement of the
Manufacturer, rates in excess of 2°C have been approved for certain heat exchanger
appl ications. Furthermore, th e cool-down rate shall not exceed 60°C in an hour. The
COOling gas should be introduced to all streams simultaneously to prevent local thermal
stresses developin g. The gas when introduced to the system should not have a
temperature difference greater than 30°C relative to the local metal temperature.

32 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 4
Installation, Operation and Maintenance
A record of all relevant data should be kept for each individual start-up. This will be
required in the event of problems developing later in the life of the heat exchanger.
Temperature monitoring devices can be added when requested by the customer.
WA RNING : THE MAXIMUM OPERATI NG PRESSURE FOR THE DESIGN OR
WO RKI NG TEMPERATURE SHOWN ON THE HEA T EXC HANGER'S NAM EPLATE
AND THE MANUFACTURER'S DRAWINGS MUST NOT BE EXC EEDED.

4.9.2 Normal Operation

If all the recommended procedures have been followed, then the heat exchanger will
give many years of trouble-free service.
Some industrial pollutants , notably mercury, sulphur dioxide, chlorine , nitrogen oxides ,
etc. , can be extremely harmful and corrosive to aluminium. It is therefore advisable that
reference be made to Chapter 8 on Recommended Good Practice on operation with
potentially corrosive streams.
To prevent particulate matter from entering the heat exchanger, the heat exchanger
system must be operated with mesh filters at the stream inlets. A valved bypass
system should be considered to permit cleaning of filters without having to shut down.
As a minimum , filtration should remove particles larger than 177 microns (80 Mesh
Tyler Standard).
All process fluids entering the heat exchanger should be in steady flow state. Pulsing or
surging from pumps or compressors must be avoided , and the Manufacturer should be
consulted about permissible limits.
To prevent over-pressurisation, it is the User's responsibility to install sufficient and
suitable pressure-relieving devices into each stream. The relief setting of the devices
must not be greater than the stated maximum allowable working pressure. Relief
settings and relief capacities must comply with the relevant governing Code and there
is no need to account for inter-stream leakage due to the nature of the construction of
plate-fin heat exchangers.

4.9 .3 Shut-d own

The cautions applicable to start-up in Section 4.9.1 also apply to shut-down. In
particular, to prevent thermal shocking , warm -up should be accomplished slowly at no
more than the recommended rate of 20 C per minute measured at a suitable location on
the heat exchanger. As with start-up the Manufacturer should be consulted if this rate
is likely to be exceeded.

4.9 .4 W arming Up
Warming up shall be performed with gas and only after all liquid has been drained from
the heat exchanger.
On attainment of ambient temperature the heat exchanger is to be purged with oxygen
free nitrogen of dewpoint -40°C or less. When a sterile internal atmosphere has been
achieved then the heat exchanger should be blanked off using blind flanges. If the
shut-down is to continue for any length of time, the streams should be pressurised with
dry nitrogen to a pressure of 0.2 to 1.2 bar g.

4.10 MAINTENANCE
Other than the directives and recommendations outlined , no routine maintenance should be
required. A log of all plant operational events which might affect the heat exchanger should be
kept. The log should record details of all start-ups, shut-downs and any plant malfunctions
together with any available routine operational data.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURE R'S ASSOCIATION • 33
CHAPTER 4
Installation, Operation and Maintenance
Problems with brazed aluminium plate-fin heat exchangers are rare. However, if problems
develop, advice should be sought from the Manufacturer. Rectification of problems should not
be attempted without prior consultation with the Manufacturer.
Extra care is required when investigating problems associated with heat exchangers installed
in cold boxes:
The nitrogen purge for the cold box must be disconnected.
WARNING: PERSONNEL MU ST NOT BE ALLOWED INTO THE COLD BOX UNTIL THE
UNIFORM LEVEL OF OXYGEN IN THE BOX ATMOSPHERE HAS REACHED A MINIMUM
OF 19% BY VO LUME.
A continuous alarm type monitor of the oxygen level in the cold box should be kept. The
monitor should be checked at regular intervals of one hour by a second monitor. All monitoring
should be at face level of working personnel.
If only part of the box insulation is to be removed to effect access to the heat exchanger, the
working cavity so formed must be secured with scaffolding and planking to prevent the residual
insulant from collapsing. If welding is to take place, the cavity should be lined with polyethylene
sheeting or similar material.
WARNING: FOR PERSONNEL SAFETY, COLD BOXES INSULATED WITH PERLITE
SHOULD BE COMPLETELY EMPTIED PRIOR TO PERMITTING PERSONNEL ACCESS
INTO THE COLD BOX.
WARNING: COLD NITROGEN GAS CAN ACCUMULATE AT GROUND LEVEL AND HAVE
FATAL RESULTS THROUGH ASPHYXIATIO N.

4.11 LEAK DETECTION

4.11.1 Introduction
External leaks will be evident by the appearance of localised freeze spots or vapour
clouds on the outer casing of the insulation. In the case of heat exchangers installed in
a cold box, an increase in or contamination of the purge gas flowing out of the cold box
purge valve will be evident. The smell or sound of the escaping fluid may also be
discernible.
Internal leaks can manifest themselves in the reduction of product purity and, if the leak
is of sufficient magnitude, a redistribution of flow levels will occur between affected
streams.
When a leak is suspected, it should be investigated fully and immediately and the
Manufacturer's repair procedure be put in action as soon as practicable. In the case of
leakage where harmful substances are present, immediate action is necessary.
WARNING: FAILURE TO RECTIFY LEAKING UNITS MAY RESULT IN
PERSONN EL INJURY AND/OR SERIOUS DAMAGE TO THE UNIT AND
COMPROMISE THE SAFETY OF THE PLANT.
To establish the existence of a leak the following procedures may be applied.

4.11 .2 Site Leak Detection Pressure Test

Prior to any site work taking place, all streams must be purged with either dry nitrogen
or dry air. A gas analysis should be performed to ensure that any harmful gas residues
are completely removed from the system. In the case of work being carried out within
a cold box, the oxygen concentration within the cold box has to be controlled
continually with good venting of the box maintained through openings on the top and
bottom.
Each of the unit streams is isolated using blind blanking flanges fitted with suitable
pressure gauges. In turn and on an individual basis, each stream is pressurised;
initially the test pressure should be set at a maximum of, say, 5 bar 9 since the majority
of leaks will be detected at low pressure. Further tests at higher pressures may be
34 • STANDARDS OF THE BRAZED A LU MINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION
 CHAPTER 4
Installation, Operation and Maintenance
necessary depending on the type of leak but the test pressure should not exceed the
operating pressure of the stream being tested. The test should be carried out with
either dry nitrogen or dry air. The pressure is held for a period of ten to twelve hours.
If after this time the pressure level has decayed, and the amount of the decay was not
caused by temperature changes , the presence of a leak has been established. The
holding time will depend on the sensitivity of the pressure gauges and the volume of
the streams on test A coinciding rise in pressure of any of the isolated streams is
indicative of an internal inter-stream leak. All streams must be fitted with pressure relief
systems to prevent over-pressurisation.
A check is to be carried out to ensure that no mechanical joints are leaking.
If no subsequent rise in adjacent stream pressure is evident then the leak is to the
external.
Throughout this procedure the safety aspects covered in the Proof Pressure testing
section 4.7. 2 of this standard MUST be rigidly adhered to.
WARNING: PRECAUTIONS MUST BE TAKEN TO ENSURE THAT LEAKS HAVE
NOT CREATED A COMBUSTIBLE SITUATION OR DISPLACED OXYGEN IN
ENCLOSED SPACES.
WARNING: SPECIAL PRECAUTIONS MUST BE TAKEN IF THE HEAT
EXCHANGER IS TO BE PNEUMATICALLY TESTED. PNEUMATIC TESTING CAN
BE HIGHLY DANGEROUS IF NOT CARRIED OUT BY FOLLOWING THE
RELEVANT LOCALLY APPROVED PROCEDURES.
All pressures recorded must be adjusted in accordance with the method described in
the above proof testing section 4.7.2, to compensate for ambient temperature
differences over the duration of the test.
To locate external leaks the soap bubble lest described in the proof pressure testing
section 4.7.2 of this standard is repeated .

4.1 1.3 Site Helium Leak Detection Test

The helium leak test may be used to locate the harder to find leaks , both internal and
external. However, whilst helium leak testing is a valid testing procedure, especially
when dealing with high purity applications , carrying out such tests and interpreting the
results on site can be impractical. Only highly trained personnel using specialised
equipment must therefore carry out such helium tests.

4.12 REPAIR OF LEAKS

Detected external leaks , such as cracked pipe welds, etc., may be repaired by re-welding
using an approved weld procedure and by a qualified aluminium alloy welder.

4.12.1 Repair of Leaks to the Brazed Aluminium Plate-Fin Heat Exchanger

Should the need arise to locate and repair a leak associated with the brazed aluminium
plate-fin heat exchanger then this should be discussed with the Manufacturer.
Dependent on the type of leak, the location of the leak, accessibility in the plant,
together with other criteria, such as climatic cond itions at site, a recommendation will
be given by the Manufacturer on how, where and when a repair should be carried out.
The repair of internal and external leaks involving work on the brazed structure of the
heat exchanger requires specialised knowledge and repair techniques . These repairs
should not be attempted without prior consultation with the Manufacturer. It is strongly
recommended that any such repairs be carried out only by the Manufacturer or a
recognised specialist repair team who have at their disposal all necessary backup and
equipment to effect such repairs.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S AssoclAnoN • 35

)
CHAPTER 4
installation, Operation and Maintenance
As previously detailed under section 3.10, repair or rectification can be carried out
during the manufacture of the heat exchanger; this is recognised to be a normal and
acceptable practise in the industry. These same repair-welding techniques can be
employed to repair a heat exchanger in the field, and when carried out by an approved
specialist repair team the mechanical integrity of the heat exchanger should not be
affected. Within the contractual mechanical guarantee period any repair or modification
of the plate-fin heat exchanger not authorized by the original Manufacturer will typically
lead the mechanical guarantee to become immediately void .

4.13 STORAGE

The following are general recommendations for interim and long term storage of brazed
aluminium heat exchangers. The Purchaser shall refer to the Manufacturer's Installation,
Operation and Maintenance (10M) manual for specific instructions.
An indoor storage area away from any main work area is recommended. Indoor storage is
required for exchangers having open layers or nozzles not covered with welded or bolted
covers. Any ingress of moisture into these open layers should be avoided. In all storage
areas, the following additional recommendations should be followed .
The heat exchangers are shipped in protective crates, wooden boxes, or on wood or steel
skids and should be stored in the original shipping package. Stacking of exchangers is not
advised without prior approval from the Manufacturer.
The storage area should provide level , uniform support with good drainage. When the heat
exchanger is removed from its crate or packaging, it should be laid on wooden sleepers in a
horizontal position on the outside cap sheet face of the exchanger.
The storage area should not be located where the heat exchanger is subjected to fluids or
atmospheres which are corrosive to aluminium, or subjected to vibration .
Avoid a location where other work activity or falling objects will be in the vicinity of the stored
heat exchanger. External denting of the heat exchanger can damage the internal structure of
the heat exchanger and cause leakage,
Avoid a location which is subj ect to large fluctuations in temperature , especially below aoe
(32°F), or high humidity when the exchanger is not sealed and weather·proofed, as this can
cause condensed water to accumulate in the exchang er and freeze when the exchanger is
placed in storage or operation. Water freezing inside the heat exchanger can damage its
internal structure.
Heat exchangers must be properly covered and sealed in such a manner that dirt, sand, water,
or foreign materials cannot enter open nozzles, ports, or through any other access into the
heat exchanger. Periodically, the heat exchanger should be checked to ensure that the
transport pressure is maintained as per Section 3.7.6.
For heat exchangers which are not shipped with transport pressure and do not have welded
shipping covers on the nozzles, all nozzle openings on the heat exchanger should be covered
and sealed while the unit is in a dry condition.

36 • STANDARDS OF THE BRAZED ALUMINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 5
Mechanical Standards

5 MECHANICAL STANDARDS

5.1 SCOPE
These Standards apply to all vacuum -brazed aluminium plate-fin heat exchang ers.
In theory , there is no limit to the size of a brazed aluminium plate-fin heat exchanger core since
the internal pressure forces are resisted by the internal structure (fins, sheets). Thus,
effectively the size of a single brazed core is limited by the size of the vacuum furnace of the
Manufacturer.
However, the wall-thickness and diameter of the headers, nozzles and piping connections for a
given internal pressure will limit the practical size of the heat exchanger core .

5.2 DEFINITION OF A BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER

A brazed aluminium plate-fin heat exchanger is an arrangement of a succession of layers,
each being designed for heat exchange duties, flow characteristics and pressure, specific to
given process conditions.
All the layers carrying the same stream are connected together by headers (inlet, outlet,
intermediate) directly attached by welding onto the brazed core, as illustrated in Figure 1-2 of
Chapter 1. Certain layers may be open to the surrounding space within a vessel , i.e. without
any headers attached to the core (typical arrangement for condensers I reboilers , or see
Section 9.1 ).

5.3 CODES FOR CONSTRUCTION

The design, construction and testing of brazed aluminium plate-fin heat exchangers are
governed by the existing national rules applying to pressure vessels.
The design of a heat exchanger is the result of the mechanical strength analysis of:
the plate-fin structure under pressure
the influence of headers on the plate-fin structure
the header/nozzle assembly
Specific details regarding the design of the individual components are given in Section 5.15.
Brazed aluminium plate-fin heat exchangers are commonly designed under the provisions of
the existing Codes, typically:
ASME VIII , Div. 1
European PED and related Codes (e.g. AD 2000, CODAP,
Dutch Pressure Vessel Code, Swedish Pressure Vessel Code,
Raccolta, etc.)
Japanese HPGS Law
AS 1210.

5.4 TYPICAL MATERIALS OF CONSTRUCTION

Typical materials for use on the construction of brazed aluminium plate-fin heat exchangers
are:
Core matrix (fins, plates, side bars) 3003 aluminium alloy
Headers/nozzles 5083 aluminium alloy
For a more comprehensive set of materials refer to Chapter 6.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTU RER'S ASSOCIATION • 37
CHAPTER 5
Mechanical Standards
5. 5 DESIGN PRESSU RES
A brazed aluminium plate-fin heat exchanger is a pressure vessel consisting of more than one
independent pressure chamber, operating at the same or different pressures, It shall be
designed to withstand the most severe condition of coincident pressures expected in service.
Design pressures for each individual stream shall be specified by the Purchaser. Pressure
parts shall be designed for full vacuum jf specified by the Purchaser.
The Purchaser shall also indicate the design pressure of the environment around the heat
exchanger, in case it is to be installed inside a pressure vessel. In this case, the heat
exchanger shall be designed to withstand the internal pressure forces independently from the
external compression forces.
The Purchaser shall also state if the heat exchanger is to be vacuum insulated (i.e. installed in
a vacuum vessel) and the Purchaser shall determine the design pressures of streams
accordingly.

5.6 TESTING

5.6.1 Pressure Test

The brazed aluminium plate-fin heat exchanger must be pressure tested in accordance
with the applicabl e design Code. This may be carried out by either of the following
methods:

5.6.1.1 Hydrostatic test

The heat exchanger is hydrostatically tested with water. Each individual
chamber is to be pressurised up to its test pressure with water.
The minimum hydrostatic test pressure at room temperature shall be 1.3
times the design pressure, except where Code or Purchaser requirements
rule otherwise.

5.6.1.2 Pneumatic test

The heat exchanger is subjected to a pneumatic test, where each individual
chamber is pressurised up to its test pressure.
WA RNING: A PNEU MATIC TEST MAY ONLY BE PERFORMED
PROVIDED THE RULES OF SAFETY FOR SUCH PNEU MATIC TESTI NG
ARE ADHERED TO.
The pneumatic test pressure shall be in accordance with Code and
Purchaser requirements.

5.6.2 Leak Test

In order to ascertain the absence of a leak from one chamber towards any other
chamber or into the atmosphere, a leak test is necessary. The extent-of-Ieak testing as
well as the allowable leakage rates have to be agreed upon between Purchaser and
Manufacturer.
The leak test may be carried out by either, or a combination, of the methods listed
below.

5.6.2.1 Air test

All chambers shall be tested for external and interstream (chamber to
chamber) leakage. The test pressure, applied to one chamber only, is
typically the design pressure for each individual chamber.

38 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 5
Mechanical Standards
WARNING : AN AIR TEST MAY ONLY BE PERFORMED AFTER AN D IF
THE PRESSURE TEST DESCRIBED UNDER SECTION 5.6.1 HAS BEEN
CARRIED OUT.

5.6.2.2 Heli um test

The following test methods may be used:
External leak test: helium vacuum test under non-metallic cover for
checking the leak-tightness of the exchanger to the atmosphere.
All chambers of the heat exchanger are evacuated and directly
connected with the gas detector. The heat exchanger is sealed within a
non-metallic cover and the space between cover and exchanger is filled
with helium.
Standard allowable leak rate is 1 x 10-3 mbar litre/s (at pressure
difference = 1 bar).
Interstream leak test: helium test for checking the leak-tightness between
those chambers selected by the Purchaser and the Manufacturer.
Helium is successively admitted to the test chamber. The other chambers
are evacuated and connected to the gas detector. Starting with the
chamber with the highest operating pressure each chamber is tested for
leaks into the other chambers .
The standard allowable leak rate is 1 x 10-2 mbar litrel s (at pressure
difference = design pressure) or 1 x 10-3 mbar litre/s (at pressure
difference = 1 bar).
A helium test may only be performed after and if the pressure test
described under section 5.6.1 has been carried out.

5.7 METAL TE MPERATURE LI MITATIONS

5.7.1 Metal Temperature Limitations

The metal temperature limitations for the typical materials used are those prescribed by
the Codes.
Alloy ASME AD2000-MerkblatterN dTOV
3003 -269 / +204°C -270 I +65°C
5083 -269 / +65°C -270 I +80°C
Refer to Chapter 6 for further information.

5.7.2 Design Temperature

All aluminium alloys have advantageous behaviour at low temperatures , i.e. the values
of rupture strength and yield strength increase as temperature decreases. Therefore ,
only the maximum design temperatures are of importance for aluminium alloys.
Higher temperatures may be allowed for short periods and reduced pressures (e.g. for
deriming purposes); Manufacturers should be consulted for details.
Temperature monitoring devices can be added when requested by the customer.

5.8 PER MI SSIBLE TE MPERATURE DIFFERENCES BETWEEN ADJACENT STREAMS

Due to the nature of aluminium plate-fin heat exchangers which are produced by brazing, all
internal components are metallurgically bonded to each other. The simultaneous presence of
streams at different temperatures will produce contraction/expansion of the parts subjected to
temperature , leading to thermal internal stresses.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANG ER MANUFAC TURER·S ASSOCIATION • 39
CHAPTER 5
Mechanical Standards
The thermal stresses developed must remain within the acceptable limits for the material used.
It is generally accepted that, for a typical geometry of a brazed aluminium plate· fin heat
exchanger under steady state conditions, the maximum permissible temperature difference
between streams is approximately 50"C.
However in more severe cases such as two-phase flows, transient and/or cyclic conditions ,
this temperature difference should be lower, typically 20 - 30"C.
For details, reference should be made to Chapter 8, Section 8.1, regarding thermal shock!
temperature differences.
There are two methods for reducing the temperature difference:
either modify the process conditions (modifying the flow rate, installing a by-pass line, etc.)
to reduce the imposed temperature difference to acceptable limits, or,
when applicable , design the heat exchanger to reduce the stresses, generally by absorbing
the imposed temperature difference in a modified structure.

5.9 CORROSION ALLOWANCES

Brazed aluminium plate-fin heat exchangers are designed for operation with non-corrosive
fluids.
There is no allowance for corrosion.

5.10 SERVICE LIMITATIONS

The service limitations of brazed aluminium plate-fin heat exchangers are described in Chapter
1, Section 1.1.3.

5.11 TYPICAL RANGE OF SIZES

5.11.1 Parting Sheets

Standard parting sheet thicknesses typically vary between 0.8 mm and 2.0 mm and are
selected by the Manufacturer mainly according to the design pressures.
Parting sheets are normally clad on both sides with a brazing alloy. However, unclad
parting sheets are available , where brazing is performed using brazing foils.

5.11.2 Cap Sheets

Standard cap sheet thicknesses are typically 5 and 6 mm. However, thicknesses from
2 mm to 10 mm are also used for special applications.

5.11.3 Side Bars

Side-bar heights are the same as the fin heights.
Side-bar width is selected by the Manufacturer according to the design pressure and
typically varies between 10 mm and 25 mm. Manufacturers use different shapes of side
bars for manufacturing reasons.

5.11.4 Fins
Typically, fin height, thickness and density, vary within the following range:
Fin height 2.0 mm to 12 mm
Fin thickness 0.15 mm to 0.7 mm
Fin pitch 1.0 mm to 4.5 mm (25 fpi to 6 fpi)
Not every Manufacturer will use the whole range of these dimensions. In addition, as a
result of the restrictions of manufacturing tools, not every combination of fin dimensions
can be produced, e.g. large thickness with many fins per inch (fpi) may be excluded.

40 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 5
Mechanical Standards
5.12 HEADERS AND NOZZLES

5.12.1 Headers
Headers are fabricated from half cylinders with welded end caps. Some typical
configurations are shown in Chapter 1, Figure 1-4. Headers are usually made either
from standard pipe sizes or formed from plates.
At elevated design pressures, the resulting required wall thickness of large diameter
headers may exceed a reasonable or producible value. In that case, the use of multiple
headers of smaller diameter is common practice.
The use of reinforcing pads around nozzles, common on conventional cylindrical
pressure vessels, has limited application to headers as a result of the restricted
distance from the block surface to the nozzle.

5.12.2 Nozzles

5.12.2.1 Nozzle construction

Nozzles are normally welded into the cylindrical part of the headers. Radial
nozzles are considered as standard; other installations may be used (see
Chapter 1, Figure 1·5).
Generally nozzles are selected from commercial seamless standard pipes.
Large and special sized nozzles may be made from welded pipes or formed
plates.
If the nozzle diameter is to be limited and acceptable flow velocities are to be
maintained, several nozzles may be wel ded into one common header.

5.12.2.2 Flow velocities in nozzles

Nozzle sizes are determined primarily on the basis of pressure drop and flow
distribution.

5.12.2.3 Nozzle installation

Nozzles shall be installed to ensure venting and draining of the individual
pressure chambers, as far as possible.
Additional vent or drain connections to the header or connecting pipe (min.
¥." NPS) may be required.

5.12.2.4 Nozzle loadings

The associated piping can impose forces and moments on the heat
exchanger nozzles. Resultant forces and moments are usually calculated by
resolving the forces and moments along and about the three reference axes
shown in Figure 5-1. These resultant forces, F" and moments, Mr , are
defined by:

I 2 2 2
M r= vM.t +My +M:

F,. =JF./ -<-F,/+ F/

Some typical maximum allowable values of moments (M....,) and forces (F-.J
can be taken from Table 5-1.
Manufacturers will specify maximum allowable forces and moments. Where
simultaneous application of forces and moments occurs, the following rule
can be applied as a guideline, where M",,,, and Ii"... are those in
Table 5·1 :
(1vI/ 1vI_,) + (F/ F_ ) < 1.
STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 41
CHAPTER 5
Mechanical Standards

Figure 5-1: Positions of the Three Reference Axes

Table 5-1: Typical Resultant Forces and Moments Allowable at Nozzle-ta-Header Intersection
Nozzle size M~ (Nm) F_ (N)
Inches Resultant Moment Resultant Force
M, F,
2 120 810
3 330 1500
4 660 2660
6 1530 3600
8 2160 5540
10 2700 6740
12 3300 9000
14 3900 10800
16 4640 12900
18 5400 15000
20 6000 16500
24 7200 20600

5.12.3 Aluminium Flanged Connections

5.12.3.1 Principles
Generally , weld-neck type flanges with raised-face (R F) sealing surfaces are
selected. Other types and facings can be provided. For compatibility with
the mating flanges, dim ensions, drilling details and facings shall comply with
the applicable flange standards , e.g . ASME 816.5 for NPS <; DN600 (24"),
ASME 816.47, series A or 8 , for NPS > DN600 (24"), or DIN/EN, IMth the
possible exception of the flange ring thickness which may have to be
increased depending on the service cond itions. When non-standard flange
ring thicknesses are required, the ring thickness will be specified to allow
procurement of suitable studs.
Bolt holes shall straddle natural centre lines.
The Manufacturer will provide recommended bolt torque values on request.

42 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FI N HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 5
Mechanical Standards
5.12.3.2 Design
Aluminium flanges wi ll be provided in accordance with ASM E 831.3
Appendix L to 816.5 geometry or, alternatively, the Manufacturer will
determine the geometry by designing the flanges accord ing to the provi sions
of the applicable pressure vessel Code, eg ASME VIII/1, App 2, or AD
Merkblatter B7/B8. Flange design is dependent on the bolting and gasket.
The Purchaser shall specify type and material properties of bolts and gaskets
that will be used in service. If such information is not available, the
Manufacturer wi ll advi se of the assumptions made in the flange design
(all owable stress, number and diameter of bolts, deformation stress and
seating factor of gasket). [t is the Purchaser's responsibility to verify that
these assumptions meet all operating conditions .

5.12.3.3 Transition Joints

Bi-metallic transition joints are available from several suppliers, using
different design and manufacturing techniques (e.g. hot pressing , explosion
bonding, cold-pressure welding , friction-stir welding). Qualification of
transition joints shall be supported by adequate re liabi lity tests such as leak
tests, therma l shock tests , etc. Strength design for transition joints shall meet
applicable piping Cod e regulations, e.g. ASM E B31.3. Manufacturers wi ll
consider th e maximum allowable external loads provided by the supplier of
the transition joints.
Temperature limits have normally to be considered during welding to avoid
impacting the bonded aluminium-steel connection. Care should also be
taken to stay within these limits during installation.
Temperature limits have also to be considered when the heat exchanger is
dried after hydrostatic testing. When a value of temperature limit is lower
than the drying temperature, transition joints shall be installed on nozzles
after hydrostatic testing and drying are complete .

5.1 3 EFFECT OF PRODUCTION PROCESS ON MATERIALS

As a result of the manufacturing process of brazing, the core of the heat exchangers will be in
the fully annealed cond ition , referred to as the '0' temper.

5.14 ARRA NGEMENT OF LAYERS

In principle there are no limitations or restrictions on permissible layer arrangements.
Usually the ratio of "warm" to "cold" passages varies between 1:1 (sing le banking) and 1:2
(double banking) or vice versa . Details are described in Chapter 7, Section 7.2.2.

5.15 BRAZED ALU MINIU M PLATE-FIN HEAT EXCHANGER AS A PRESSURE VESSEL

Brazed alum inium plate-fin heat exchangers are vesse ls, for which the mechanical design
procedure is governed by a pressure vessel Code. However, as a result of unique construction
features , certa in items need specific attention.

5.15.1 Fins
As well as the ir therma l performance, fins have to be selected by the Manufacturer for
their ability to resist the pressure loadings as structural members.
These loads essentia lly produce tensile stresses in the fins . The maximum allowable
design pressure for the indivi dual fins sha ll be determined either by calcu lation or by
burst-test methods. The same fin corrugation may be acceptable up to different design
pressures, depending on the requ irements of the appli cable Codes.

STANDA RDS OF THE BRAZED ALU MINIU M PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCI ATI ON • 43
CHAPTER 5
Mechanical Standards
5.1 5.1.1 Calculation procedure
Pressure vessel Codes generally do not contain formulae for the fins in
brazed aluminium plate-fin heat exchangers.
The ca lculation methods used by Manufacturers have been approved by the
applicable Code Authority . The stresses thus calculated are compared with
the maximum allowable stress of the Code.

5.15.1.2 Burst test method

A representative brazed sample is pressurised up to bursting. By applying a
safety factor to the measured burst pressure, the allowable maximum design
pressure for the particular fin type is deri ved depending on the applicable
Code , including adjustm ents for tolerances in material properties.

5.15.2 Parting Sheets

The parting sheet thickness must be sufficient to resist the tensi le stresses from the
pressure forces acting on the side bars. These stresses depend on pressure loadings
on the adjacent sides of th e parting sheet and on the height of the adjacent side bars.

5.15.3 Side Bars

The side-bar height is the same as the fin height. Side-bar width is chosen to take
account of pressure loading from the header attachment and all ow a reasonable mass
for welding.

5.15.4 Ca p Sheets
Due to their th ickness, cap sheets are lightly stressed structural members of the heat
exchanger. Their main task is to protect the core against phys ical damage and provide
a base to allow welding of supports and other attachments.

5.15.5 Headers and Nozzles

It is common practice to determine wall thicknesses and reinforcement of openings
from the requ irements of the applicable Code.
Manufacturers give consideration to th e weld efficiency factors for the attachment of
headers to the core, as required by the applicable Code.

5.16 SPECI AL FEATURES

The Purchaser should indicate within the specification of the equ ipment any special conditions
which may include vibration, seismic loading, therma l cycling , pressure cycling or vacuum or
external pressure conditions or layers where there will be a "no flow" condition during some
operating modes. The Manufacturer will then take into account these effects in his design.

44 • STANDARDS Of THE BRAZED ALUMINIUM PLATE-fi N HEAT EXCHANGER MAN UfACTURER'S ASSOCIATION
 CHAPTER 6
Materials

6 MATERIALS

6.1 TYPICAL MATERIALS OF CONSTRUCTION

The heat exchangers covered by these Standards are constructed from aluminium alloys.
Materials are selected for their braze·ability , weld-ab ility and other characteri stics. Typical
materials used for construction and their maxim um applicable design temperatures , are shown
in Table 6-1 and Table 6-2. Fi gure 1-2 details the components.

Table 6-1 : Typical Materials Used in the Construction of Brazed Aluminium

Plate-Fin Heat Exchangers and their Maximum Applicable Oesign Temperature (Celsius)

COMPONENTS Alloy No Alloy No. .,

204' C EN-AW -JOO3 200'C

EN-AW-J003
""'·C

3003 204' C A3003P """ C

5052 204' C EN-AW-5754 150'0 A5052P 200'C
5083 65'0 EN-AW-5063 8O'C A5083P 65'0
5454 204' C A5454P 200'C

204' C A3003TlD&TE A3003P 200'C

5052 204' C EN-AW-5754 150°C A5052Tl Q&T E A5052 P 200'C
5083 65'0 EN-AW-5083 8O'C A5083TIO&TE A5083P 65' C
5086 65'0 A5086P 65' C
5454 204"C A5454T E A5454P 200'C
6061 204' C A6061 TO&TE A6061P 200'C
58-2218.58-241 A6063TlD&TE 200'C
6063 204' C

5083 65' C EN-AW-5083 8O'C A5083 FO 65'0

6061 204' C A&l6 1FO 200'C

204' C EN-AW-5754 150'C 200'C

5083 65'0 EN-AW-50S3 8O'C A5083P 65'0
6061 204' C A6061P 200'C
6063 204' C

Re mar1<.s ' l Maximum applicable temperature is as per ASME Sec, V1l1 , Di v.1, where the official unit is British (degree F).
'2 Ma ximum applicable temperature is as per AD2CXXl-Merk blatlerNd-TOV, whe re the official urtit is Metric (deg ree C),
·3 Maximum applicable temperature is as per Japanese High Pressure Gas Sa fety Law, where the offiCial unit is Metric
(degree C).
·4 They may be typically clad With brazing materia l
·5 The ma Xi mum applicable design tempe ratlSe may be higher for special matetlal certification.

STANDA RDS OF THE BRAZED ALU MINI UM PLATE-FIN HEAT EXC HANGER MANUFACTURER'S ASSOCI ATION , 45

J
CHAPTER 6
Materials

Table 6-2 : Typical Materials Used in the Construction of Brazed Aluminium

Plate-Fin Heat Exchangers and their Maximum Applicable Design Temperature (Fahrenheit)

I I
M" I I
COMPONENTS I M" """" AI\Qy No. M"""j,"
Alloy No.
"""" Alloy No.

I ~~o"o, S~ 150°F'~ H'=~ 392"F

~~. 392°F
I
"" ''':
~: :::;~
EN-AW-3003 150°F"' 392°F
392'F
I""~' '~,oo3 «JO"F 150'F' M';~3S 392'F
Ic,m" ""

~ H'~:3P
«JO"F 150'" 392'F
eort". SO,"
«JO"F 150'F" 392'F
I
«JO"F 150'F" 392'F

M'"'' ''': :,w.'" «JO"F 1~3P 392'F

«JO"F EN-AW-5754 302'F A5052P 392'F
5083 150°F EN-AW-5083 176-F A5083P 15O"F

I Noul,
~
4OO'F
4OO'F :; 392'F
392'F

I'i""""5063
5066
4OO'F
4OO'F
15O"F
15O"F
EN-AW-5754
EN-AW-5083
302'F
t76'F
H4~~~~E
A5052TIO&TE
A5083TID&TE
,
A3003P
A5052P
A5083P
A5086P
392"F
392'F
15O"F
150°F
5454 «JO"F A5454TE A5454P 392°F
6001 «JO"F A6061 TO/HE A&l61P 392°F
56-221 & 56-241 A6063TD&TE 392°F
«JO"F

'''"'' I 5083 15O"F EN-AW-5083 176°F ~~FD 15O"F

6001 «JO"F A6061FD 392°F
302'F
I'"PP'" I"st;;;; "" «JO"F EN-AW-5754 302'F H~2P 392'F
5063 15O"F EN-AW-5083 176°F A5063P 15O"F
6001 4OO'F A6061P 392'F
6003 4OO'F 266°F
, , 'WA

Remarks '1 Maximum appl icable temperature is as per ASME Sec. VIII, Div.1, where the official unrt is British (degree F).
'2 Maximum applicable temperature is as per AD2OCO-MerkblatierNd-TOV, where the official unit is Metric (degree C).
'3 Maximum applicable temperature is as per Japanese High Pressure Gas Safety Law, where the official unit is Metric
(degree C).
'4 They may be typ ically clad with brazing material.
'5 The maximum applicable design temperature may be higher for special material certification.

46 • STANDARDS OF THE BRAZED A LU MINIUM PLATE-FI N HEAT EXCHANGER MAN UFACTURER'S ASSOCIATION
 CHAPTER 7
Thermal and Hydraulic Design

7 THERMAL AND HYDRAULIC DESIGN

7.1 INTRODUCTION
The bra zed aluminium plate-fin heat exchanger has special features and advantages which
make it quite different from other types of heat exchangers:
1. A very large heat transfer surface area can be made available per unit volume of heat
exchanger. This surface area is composed of primary and secondary (finned) surfaces.
Even taking into account the fin efficiency of the secondary surface, the effective surface
area per unit volume can be typically five times greater than that of a shell-and-tube heat
exchanger.
2. A rang e of fin types is available. The fin type is selected to suit the characteristics of a
stream. For example, serrated, wavy and perforated fins (Chapter 1, Figure 1-6) are
particul arly suitable for gas streams.
3. One heat exchanger can incorporate several streams and heat can be exchanged
simultaneously amongst several streams in a multi-stream heat exchanger. Suitable
headers and distributors also permit streams to enter and leave the heat exchanger at
intermediate points along its length as well as at the end s.

7.2 FEATURES OF A BRAZED ALU MINIU M PLATE·FIN HEAT EXCHANGER

7.2.1 Primary and Secondary Heat Transfer Surfaces and Thermal Length
Heat is transferred from or into a stream within a finned passage. The primary heat
transfer surface within the heat exchanger consists of the bare parting sheet and the fin
base directly brazed to the parting sheet (Figure 7-1 ).

\ \.-.
Primary heat
transfer surface
'\ :---.. Secondary heal
transfer surface

Figure 7-1: Cross Sectio nal View of Fin an d Parting Sheet

The secondary heat transfer surface is provided by the fins . The effectiveness of the
secondary surface to transfer heat is given by the fin efficiency.
Per unit area of each layer:
the primary surface is given by : 2( I - 111),
th e secondary surface is given by : 211(1/ - /)
where 1/ is the fin density (m"l), i.e. number of fins per unit length,
/ is the fin thickness (m),
h is the fin height (m).
The thermal length of a singl e pass of a brazed aluminium plate-fin heat exchanger is
typically defined as the effective length of the finned region between, but not including,
the distributors.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANG ER MANU FACTURER'S ASSOCIATION • 47
CHAPTER 7
Thermal and Hydraulic Design
7.2. 2 Single and Multiple Banki ng
There are two types of layer arrangement for a stream: single banking and multiple
banking , (typically double banking , as in Figure 7-2).

c JI lUI ILJ
c
W
Heat Heat

c n
+
Heat
W
-t
Heat

CWCWCWC
(Single banking)
C II Inl rn
CWWCWWCWWC
W Warm stream layer (Double banking)
C Cold stream layer

Fig ure 7-2 : Sin gl e and Doub le Banking

Single banking is the simplest arrangement where each warm stream layer (W) is
adjacent to a cold stream layer (C). The thermal efficiency of this fin arrangement is
given in Section 7.4.5.
Double banking is also illustrated in Figure 7-2. Here, two layers of equal height are
provided for a warm stream with a large flow rate within the allowable pressure drop.
More than two layers can also be used. The thermal efficiency of double banking is
also given in Section 7.4.5.
In double banking, the parting sheet between the two layers becomes a secondary
surface and the fin efficiency is reduced because of the increased length of the heat
path along the fins.

7.2.3 Multi -stream Brazed Al uminium Plate-fin Heat Exc hangers

The brazed aluminium plate-fin heat exchanger is capable of accommodating many
streams within its structure and heat can be exchanged among several streams
simultaneously.
A multi-stream brazed aluminium plate-fin heat exchanger, with streams also entering
and leaving at intermediate positions between its ends, can accommodate over twelve
different streams. The selection and design of the layer arrangement, the fins of the
layer and the effective length of each stream is of crucial importance.

7.3 THER MAL DESIGN PROCEDURE

The design procedure for a brazed aluminium plate-fin heat exchanger is different, in many
respects, from a traditional tw~ream exchanger such as a shell and tube. The main
differences are: -1' ~l).;
1. In most cases, more~ two streams must be handled.
2. The secondary surface area provided by the fins is a large portion of the total heat-transfer
area.

48 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTU RER'S ASSOCIATION
 CHAPTER 7
Thermal and Hydraulic Design
3. There are a variety of fin types available for giving the best heat transfer and pressure drop
characteristics for each individual stream (see Section 7.6.1).
4. An efficient sequence of layers is required where each layer is the flow channel for a given
stream with the appropriate choice of fin. This is known as the layer stacking arrangement
and is discussed in Section 7.6.2.
5. There is a strong inter-relationship between the mechanical and thermal-hydraulic design
because key elements in the thermal design, such as fin density, height and thickness, are
governed by the mechanical design.
6. Optimising a design involves working with a large number of variables , and this is best
handled using a specially developed software combined with expert knowledge from an
experienced designer.
7. The designer requires much more information to cover the many streams and the greater
detail often required for each stream. Figure 7-3 and Figure 7-4 give examples of
specification sheets which allow for this extra information.
The calculation method given in Section 7.4 is a simple one that effectively converts a multi-
stream heat transfer process into a two-stream one. The first step is to generate the
temperature-enthalpy plot (T - Q curve) for all the cold streams and all the warm streams.
Plotting these curves on the same chart is very revealing in showing where close temperature
approaches (temperature pinches) arise, which require special care in design. An overall heat
transfer coefficient is also calculated which combines the individual heat transfer coefficients
for all the streams.
It is stressed that this calculation method is an approximation which can provide good solutions
for simpler heat transfer processes. More rigorous calculation methods are available , which
take into account the detailed variations from stream to stream , including the temperature
differences between individual parting sheets. An experienced designer should therefore be
consulted at an early stage in detailed design.

7.4 THER MAL RELATIONS

7.4.1 Basic Heat Transfer Rel ation

The required surface area of a brazed aluminium plate-fin heat exchanger can be
obtained from:

VA ~ Q (1)
• MTD

where
u : Overall heat transfer coefficient between streams (Wlm' K)
A, Required overall effective heat transfer surface (m' )
Q Heat to be transferred 0N)
M7 D : Mean temperature difference between composite or combined streams (K)

STANDARDS OF THE BRAZED ALUMINIU M PLATE-FIN HEAT EXC HANGER MANUFACTURER'S ASSOCIATION • 49
 -iCl
", PLA', ,·FIN t~AT mON ::T::c
• ~~
3 "tJ
~ IBT ~
., --I
-m
., ;0
l- -I- :::>
I I I I I I c, ....
::c
;- i '-
I
; '<
.,c:
C,

11
; -; - ; -I- ; ; -
~

', - ; ; ; -; -,
0
0
-; ; ; ; i ; ~
CD
II>
cO'
-, :::>
Io/Oel I I I I
~

1-- , I-- , I- , , -

:".:~"'" OW".
.-~;;;,uf.;
I '" . i
,~, "':;

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, , I I ,
-; ~ - ; ; ; -;
J -L

.
"'z~ 1 I , n. ,c-rl" HEAT ""UN
0
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;~
2
'0" .0'" ~
I M~I=
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"'0 c
~
~
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4 III f--
I
-< ~ T,mp, H,,"o,d ; , ; ;
"m !>: 5
,, q~::~ MW ! D,,,"V H"t- , Thermal MW I D'"'"Y HOof ;
<D
'~" -<
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en 8
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-< ~
15
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0, •0' 16 10 c- - I-
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en 18

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m ~ 20
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Z
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23
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m
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~
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25 19 --i
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l>
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C
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CHAPTER 7
Thermal and Hydraulic Design
7.4.2 M TD and UA,
The MTD can be obtained by calculating the logarithmic mean temperature difference
(LMTD) in each section where both warm and cold composite T - Q curves are linear.
An example composite curve is shown in Figure 7-5.

50
- - Hot composite
.- Cold composite H-7-
. -'--+-
o

-50
+ + +

Temperature (oG)
+ + +
+
-100
L
-125
-150 1---/-7"''--+---+--1
-130 /
11000 12000
j
13000
-200 +----+----f---'~=F====!===='4
o 10000 20000 30000 40000 50000
Enthalp y (kW)

Figure 7-5: Examp le Composite Curve

Equation (1) becomes :

VA
,
=2: LMfD,
Q, (2)

where

LMTD , = .6.T,+! -ilT, _ (3)

In (>.T,., 6.T,_

while 6.T, and 6T, +! are the temperature differences between warm and cold streams at
each end of section i (K).
This LMJD can be used for counter-flow or parallel-flow.
For cross-flow and cross-caunter-f1ow, however, the LNfTD must be corrected , Details
are given in Reference (1).
For a multi-stream brazed aluminium plate-fin heat eXChanger, the M7D must be
obtained from the two composite temperature-enthalpy curves for the combined warm
and combined cold streams. Further information can be found in References (1) to (4).

52 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 7
Thermal and Hydraulic Desig n
7.4.3 Ove rall Effect ive Heat Tra nsfer Surface of Exchan ger
The overall effective heat transfer surface can be estimated from Equation (4). The
thermal resistance of the parting sheet between the two streams can usually be
ignored primarily because it is made from thin aluminium sheet.

(4)

where
eto : Effective heat transfer coefficient of a stream (W/mzK)
A : Effective heat transfer surface of a passage or layers of a stream (m 2)
Ad : Designed (or estimated) overall effective heat transfer surface (m 2)
suffix wi , ci : Warm or cold stream i

7.4.4 Effective Heat Tran sfer Coefficient of Each St ream

The heat transfer coefficient of each stream can be estimated from Equation (5).
a = jG",Cr (5)
Pre 3

where
a : Heat transfer coefficient of a stream (W/m' K)
j : Colburn factor for a finned passage (- )
Gm : Mass flux of a stream (kg/m' s)
Cp : Specific heat capacity of a stream at constant pressure (J /kg K)
Pr : Prandtl number of a stream (CplJ/k) (- )
k : thermal conductivity of a stream (W/mK)
~ : dynamic viscosity of a stream (Ns/m')

The effective heat transfer coefficient of each stream , ao, can be estimated from
Equation (6) which takes the fouling resistance into account.
1 1 (6 )
-=-+ r
ao a

where
,. Fouling resistance of a stream (m' K/W)
Equation (5) can be used for single phase streams, i.e. all vapour or all liquid flow. For
twcrphase condensing or vaporising flows , various equations are available for
predicting the two-phase heat transfer coefficient; given for example in Reference (4).
A Manufacturer, however, will use calculation methods based on experience with two-
phase streams.
The Colburn factor, j, is highly dependent on the type of fin , its nominal geometry and
details of manufacture, as well as the Reynolds Number of the stream. Information
about the Colburn factor j can also be obtained from Reference (2).
Heat transfer coefficients of each stream must be calculated locally where the
thermodynamic and/or physical properties of the stream change rapidly, for example, at
a phase-change or in the super-critical state. For these conditions, a step-by-step
calculation along the stream will be necessary.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • S3

CHAPTER 7
Thermal and Hydraulic Design
7.4.5 Heat Transfer Surface of Each Passage
The effective heat transfer surface area for a passage, A , is obtained from the following
expression
A = A, +1/,¢4, (7)

where 111 can be estimated from the following expression for single banking:

~, =tanh e 2: (8)
P2
Instead for double banking , the area A is obtained from the following expressions :

(9)

1
~,= ( p +y
XB-I] B+I
(10)

w here

P=h(2U o
) '·' (11 )
A ,.,f

y=JlJ .!._I] (12)

2h l n

B =(: :J~ ( 13)

Primary heat transfer surface of a stream (Figure 7·1 ) (m')

Secondary heat transfer surface of a stream (Figure 7·1 ) (m')
Passage fin efficiency for sing le ban king (-)
Passage fin efficiency for double banking ( -)
Passage fin height (m)
t Passage fin thickness (m)
/I Passage fin density (m-' )
u, Effective heat transfer coefficient of a stream (W/m' K)
Unpertorated fraction [1 - (percentage pertoration)/ 100] (- )
Thermal conducti vity of fin material (aluminium) (W/m K)

54 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 7
Thermal and Hydraulic Design
7.4.6 Rough Estimation of the Core Volume and Weight
To obtain a quick indication of the heat exchanger volume required for a certain duty,
the following simple relation may be used:

(14)

where
V Required volume of heat exchanger or heat exchangers (without headers) (m 3)
Q Overall heat duty (W)
M7D Mean temperature difference between streams (K)
C Coefficient; 100,000 for hydrocarbon application (W/m 3 K)
50,000 for air separation application
The values of 100,000 and 50,000 reRresent the product, UA d , assuming an overall
heat transfer coefficient of 200 W/m K and 100 W/m 3 K respectively , and a mean
geometric heat transfer surface density of 500 m2/m3 .
The weight of a complete heat exchanger may be assumed to be 1000 kg per unit core
volume (m\ This value varies in practice between 650 and 1500 kg/m3 .

7.5 HYDRAULIC RELATIO NS

The Purchaser usually specifies the allowable pressure loss for each stream , within the
Manufacturer's scope of supply.
In the hydraulic design of the heat exchanger, the fin type and passages are chosen to meet
this pressure loss requirement. In order to ensure uniform flow distribution of a stream among
its passages , the components of the pressure drop are evaluated. Uniform distribution of a
stream over the width of a layer is provided by good design of the distributors.

7.5.1 Components of Pressure Loss

The individual pressure losses within a heat exchanger typically consist of
(See Figure 7-6):
1. Expansion loss into the inlet header
2. Contraction loss at th e entry to the core
3. Loss across the inlet distributor
4. Loss across the heat transfer length
5. Loss across the outlet distributor
6. Expans ion loss into the outlet header
7. Contraction loss into the outlet nozzle
8. Gravitational loss (or gain).

Additional pressure losses in piping andl or manifolding outside the Manufacturer's

scope of supply are to be accounted for by the Purchaser. The Purchaser usually
specifies the allowable nozzle to nozzle pressure drop.
General methods for predicting these pressure losses are given in Reference (4).
Manufacturers make use of their experience to select the most appropriate method of
estimating the losses given in Items 1 to 7 above.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANU FACTURER'S ASSOCIATION • 55
CHAPTER 7
Thermal and Hydraulic Design

FlJid in +

l Fluid out

Figure 7-6 : Pressure Loss Components

7.5.2 Single-Phase Pressure Loss

The frictional pressure loss across a plate-fin passage and at any associated entry , exit
and turning losses, can be expressed by:

M' = 4f (~ YG.')+ K(G

d A2p
.')
2p
(15)
h

where

f Fanning friction factor (- )

Passage length (m)
Hydraulic diameter of passage (m)
Mass velocity (mass flux) of stream (kg/m' s)
Density of a stream (kg/m3)
Expansion, contractio n or turning loss coefficient (-)
Overall pressu re drop (Pa)
Note: By convention , the upstream mass flux is used for estimating expa nsion losses
and the downstream for contractions.

56 • STANDARDS OF THE BRAZED ALU MINIUM PLATE-FI N HEAT EXCHANGER MANUFAC TURER'S ASSOCIATI ON
 CHAPTER 7
Thermal and Hydraulic Design
7.5.3 Two·Phase Pressure Loss
In brazed aluminium plate·fin heat exchangers with two·phase streams where fluid
quality and physical properties are changing , it is necessary to divide the heat
exchanger into suitable increments of length in order to assess the overall pressure
gradient simultaneously with the thermal design calculations.
The pressure gradient in a two-phase flow can be divided into three components:
The frictional component,
The static head component,
The accelerational compon ent.
Each Manufacturer uses suitable design correlations for estimating these components
from experience. General estimating methods are given in Reference (4) .

7.6 GENERAL CONSIDERA TIONS IN THE THER MAL AND HYDRAULIC DESIGN

7.6.1 Choice of Fin Geomet ry

Each fin must conduct the required amount of heat and also withstand the design
pressure at the design temperature as a structural component.
Fin geometry is therefore selected to meet both requirements. Details of the required
structural performance are given in Chapter 5. Details of the fin's required thermal
performance are given earlier in Section 7.4.4.
The choice of fin will also influence the most economical design of an exchanger for a
specific application. Table 7· 1 provides general information on common applications for
each type of fin (see Figure 1·6, Chapter 1).

Table 7·1 : Comm on A pplications f o r Each Type of Fin

Corrugation Description Application Features

Relative pressure Relative heat

drop transfer

Plain Straight For general use lowest lowest

Peliorated Straight with small Most frequently used low low

holes for any purpose .
Sometimes used for
the "hardway" finning

Serrated Straight , offset half a Frequently used , highest highest

pitch - usually about especially for low
every 3-4 mm pressure gas
streams in air
separation plants

Herringbone or Smooth but in wa ves Often used for gas high high
long-lanced of about 10 mm pitch streams with low
serrated (can be perforated), allowable pressu re
or serrated with long drop
serration pitch

STANDARDS OF T HE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 57

CHAPTER 7
Thermal and Hydraulic Design
7.6.2 Layer Stacking Arrangement
With multi-stream heat exchangers, the choice of the stacking sequence or layer-
pattern must take into account the local heat balance among streams and any local
non-linearity of the Enthalpy-Temperature Curves of each stream. A thermally well-
balanced stacking arrangement would result in a nearly uniform metal temperature at
any cross section of the heat exchanger, thus allowing the detailed design to proceed
with the assumption of a common wall temperature .
The deviations from a uniform metal temperature can be evaluated by using a more
detailed (Iayer-by-Iayer) analysis, taking into account heat being transferred by metal
conduction between non-adjacent layers.

7.6.3 Two-Phase Distribution

When a stream at the exchanger inlet is made up of a mixture of vapour and liquid, it
can be necessary to separate the two phases first and then to distribute them in
separate distribution systems that mix the two phases in a controlled way within the
exchanger. Re-mixing of the two phases can be done in the header or in the passages
depending on the distribution system being used. Details of typical systems are shown
in Section 1.2.8.

7.6.4 Thermosyphon
A thermosyphon design is available based on design information from the Purchaser.

7.6.5 Manifold Assemblies

For multiple core assemblies, so-called U-piping configuration is preferred to Z-piping
for improved flow distribution. Figure 7-7 illustrates this pOint.

• •

U-piping Z-piping

Figure 7-7: Manifold Assemblies

58 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 8
Recommended Good Practice

8 RECOMMENDED GOOD PRACTICE

8.1 THER MAL STRESSES WITHIN BRAZED AL UMIN IU M PLATE-FI N HEAT EXC HANG ER S

8.1.1 Introdu ctio n

As with any pressurised heat exchanger, stresses in each component of a brazed
aluminium plate-fin heat exchanger must be maintained within allowable limits.
Pressure loads, externally applied loads (e.g. piping forces and moments), and
thermally induced loads produce stresses which must be maintained within permissible
limits to prevent component damage or failure.
Manufacturers design each brazed aluminium plate-fin heat exchanger for the intended
design pre ssure loads; Users are provided with details of allowable external loads that
may be exerted on the exchanger. A margin above the stresses created by these loads
is made available by the Manufacturer for thermally-induced loads which may occur in
service. In this section the mechanism by which thermal stresses are induced is
explained.
Recommendations are given for the measures to be taken in the operation of brazed
aluminium plate-fin heat exchangers so that the overall combined stresses remain
within allowable limits during standard and non-standard operating conditions.

8.1.2 Failure Mechanism

The components of a brazed aluminium plate-fin heat exchanger are relatively close
and rigidly connected in all directions to each other. As a result, conditions which
generate large local metal temperature differences in and between the components of
its structure will cause significant thermal stress in these components.
Local metal temperature differences result from the components, or portions of the
components, warming or cooling at different rates in response to a thermal input
(change). These differences produce a transient differential expansion or contraction
within or between the components; mechanical restraint to these thermally-induced
structural movements results in thermal stress in the components. If the local metal
temperature differences are large, the combined thermally-induced stresses and other
stresses from imposed loads can exceed the yield stress and possibly the ultimate
stress of the material.
Temperature differences between adjacent parts of a heat exchanger, having the
potential to produce significant thermal stresses, can arise from:
1. Continuously unsteady operating conditions: for example, larg e flow fluctuations;
unstable flow in boiling channels; inadequate plant control systems.
2. Transient operating conditions: for example, start-up; shut·down; plant upsets;
deriming; cool-down and warm-up; etc.
An example of the creation of thermal stress is illustrated by the quick opening of a
valve. If this action allows a significant quantity of cold fluid with a high thermal capacity
to enter a warm heat exchanger, then those parts of the heat exchanger which can lose
heat rapidly will contract quickest. The fins in the region of the inlet port would thus
contract more quickly than the side bars on either side of the port; tensile thermal
stress would be created within the fins and compressive stress in the side bars. These
stresses will diminish as temperature differences decrease and thermal equilibrium is
restored. Thermally-induced failures can also occur in other components of a heat
exchanger apart from the fins. The next most susceptible component is the parting
sheet.
Continuously unsteady operating conditions , as described above, can generate cyclic
stresses exceeding the yield strength, and failure by fatigue may result.

STANDARDS OF TH E BRAZED ALUM INI UM PLATE·FIN HEAT EXC HANGER MAN UFACTURER·S ASSOCIATION • 59
CHAPTER 8
Recommended Good Practice
During transient operating conditions, if the combined stresses exceed the ultimate
tensile strength of the material, components may fail.

8.1.3 Recommendations
To reduce the possibility of component damage or failure during the operational
conditions described above, the following recommendations are made:
1. Limit the pressure and external load s to those allowed (stated) by the
Manufacturer.
2. As with any heat exchanger, bring the brazed aluminium plate-fin exchanger to or
from operating or derime conditions slowly to avoid excessive thermal stress. This
is of particular importance when introducing a liquid or two-phase stream due to
the heat capacity of the stream and its ability to transfer heat rapid ly to or from the
components. Recommended rates for start-up and shut-down, cool-down, warm-
up, deriming, etc. are presented in Chapter 4.
3. Limit the temperature differences between adjacent streams at any point in the
heat exchanger to those recommended in Chapter 5 or by the Manufacturer.
Temperature differences recommended in Chapter 5 are general to all brazed
aluminium plate-fin heat exchangers. Other recommendations may be provided by
the Manufacturer when supplying a heat exchanger for a particular application.
4. Exercise particular care in applications where a liquid is totally vaporised within the
heat exchanger. Boiling to total dryness can produce large temperature
differences and also induce flow instabilities. The Manufacturer's recommended
allowable temperature differences for these applications must be strictly adhered
to . Also , the design of the process plant must ensure that stable flow occurs.
5. Design and operate the plant equipment and piping connected to the heat
exchanger to prevent flow excursion and instabilities (for example, intermittent
slugging of liquid to the exchanger). This is particularly important with boiling
streams.
6. Limit cyclic or frequently repeated temperature fluctuations of any stream to ±1 °C
per minute.

8.1 .4 Summary
Brazed aluminium plate-fin heat exchangers are robust exchangers which are very
tolerant of large steady-state stream-to-stream temperature differences. Being
relatively compact and rigid structures, brazed aluminium plate-fin heat exchangers are
susceptible to damage if subjected to transient or continuously unsteady operating
conditions which produce excessive thermal stressing. Excessive thermal stressing can
be avoided by following the precautions (recommendations) outlined above, thus
helping to ensure long life of the heat exchanger.

8.2 FOULING AND PLUGGING OF BRAZED ALU MINIU M PLATE-FIN HEAT EXCHANGERS

8.2.1 Fouling
Fouling is generally not encountered for processes in which brazed aluminium plate-fin
heat exchangers are traditionally used: air separation: hydrocarbon separation and
liquefaction of gases.
In the case where a degradation of thermal performance is observed with little or no
change in pressure drop of the product, fouling may be suspected.
Recommended actions are as follows :

6. • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFAC TURER'S ASSOCIATlON
 CHAPTER 8
Recommended Good Practice
8.2. 1.1 Prevention
Before deciding on the use of brazed aluminium plate-fin heat exchangers,
the fluid conditions have to be examined for the presence of solids, foreign
particles forming deposits during operation of the heat exchanger, especially
in low temperature regions.
It is important also to consider fouling that may arise from contaminants in
the process fluids. A typical example is the use of seal oil with refrigerant
streams, which could deposit as a solid film on the fin surfaces and reduce
the thermal performance of the heat exchanger.
WA RNING : GASES CONTAINING TRA CES OF NO. MUST NOT BE
USED: NO. WILL ACCU MULATE IN THE CRYOGENIC PORn ON OF THE
EQUIPMENT. EXPERIENCE HA S SHOWN THAT SU CH PRO DUCTS
CANN OT BE RE MOVED FRO M THE INTERIOR OF THE EQUIPMENT
AND MAY SUDDENLY EXPLODE DURING WA RMING UP OF THE
PLANT.

8.2.1. 2 Remed ial action

If the liquid/solid transformation of the fouling agent is reversible with
temperature , changing the operating conditions of the heat exchanger and
thus warming up the fouled zone may be sufficient to eliminate the deposits.
In cases where this techn ique is not effective, solvent cleaning may be used.
Brazed aluminium plate·fin heat exchangers can be modified or designed to
incorporate a solvent injection system, thus allowing flushing of the
contaminated surfaces.

8.2.2 Pl ugging
Plugging is defined as the obstruction of fin channels inside a brazed aluminium plate·
fin heat exchanger as a result of solid particles having entered the unit.
The effect of plugging on a brazed aluminium plate·fin heat exchanger may be very
serious on its thermal performance since, generally, the plugging medium will not be
distributed evenly to all passages, or uniformly within the width of the passages and will
thus cause severe maldistribution. Simultaneously, the pressure drop of the plugged
stream will increase significantly. Uneven plugging may lead also to induced thermal
stresses.
Accumulation of rime in the flow channels is a form of plugging. Importantly, the
structure of rime (soft) is different from ice (hard). H20 and CO 2 are typical rime
components , for example in air separation units. Plugging in oxygen service is a
particularly severe hazard.
WA RNING: IN THE CASE OF EXTREMELY SEVERE PLUGGI NG, THE SAFETY
A SPECTS OF THE PLAN T MUST BE CO NSIDERED.

8.2.2.1 Prevention
Plugging of brazed aluminium plate·fin heat exchangers can be prevented by
following these recommended actions:
The Purchaser should develop and implement procedures that maintain
the cleanliness I dryness of the cores during storage and installation
on site.
The end closures of brazed aluminium plate·fin heat exchangers should
always be maintained in place until the connection of nozzles or flanges
to the plant pipework.
The cleanliness of the connecting pipes should be checked to make sure
that rust, debris, dust, etc. can not enter the heat exchanger.
STANDARDS OF THE BRAZED ALUM INIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 61
CHAPTER 8
Recommended Good Practice
Filters on the feed streams must be installed at any location where there is a
possibility of contaminating the process fluid. Recommendations are provided
by Manufacturers as to the mesh size. A mesh size of 177 microns (80
Tyler) is capable of covering most applications.
Filter manufacturers should be consulted for recommendations on filter types,
etc. , and on maintenance considerations.

8.2.2.2 Remedial action

Should the heat exchanger be significantly plugged for any reason (absence
of filter, wrong cleaning procedure of plant pipework, failure of filtering
equipment, etc.), the consequences on both the thermal and pressure drop
performance will be obvious.
The plugged stream can generally be identified quickly and corrective action
be planned to be taken during a shut-down of the plant. This should not be
done without the advice of the Manufacturer.
Deriming refers to the method for getting rime out of a plate-fin heat
exchanger. It is typically performed by blowing a comparatively warm , low
pressure gas through the channels when the fluid stream shows an adverse
increase in pressure drop.
The mechanical methods to remove plugging from a brazed aluminium plate-
fin heat exchanger require the use of an air or nitrogen gas discharge from
the exchanger:
Either back-blow the plugged stream, having installed a bursting disc at
the inlet and pressurising up to the rupture of the disc. (This operation
has to be repeated until no particles are observed being discharged);
or install a special "deplugger" at the outlet of the heat exchanger, made
of a volume of air under pressure and a quick-opening valve, to produce
a shock wave inside the heat exchanger core.
In the case of severe plugging, a deplugging action may be undertaken on
every passage, having connected the "de plugger" successively to each
individual passage.
The use of a solvent and gas bubbling uses the bubbles generated inside the
liquid which fills the structure, and these provide the mechanical energy to
dislodge the particles.

8.3 CORROSION
Brazed aluminium plate-fin heat exchangers are satisfactorily used in many processes without
experiencing corrosion problems. However, as with any heat exchanger, when corrosion is
possible, caution must be exercised both on the choice of process fluids and the en vironment
to which the brazed aluminium plate-fin heat exchanger is exposed. Purchasers/operators
should contact the Manufacturer to determine the best course of action to avoid corrosion
problems.
WARNING: CAUTION MUST BE EXC ERCISED BOTH IN THE CHOICE OF PROCESS
FLUIDS AND THE ENVIRONM ENT TO WHICH HEAT EXCHANG ERS ARE EXPOSED
WHEN CORROSION IS POSSIBLE.

8.3.1 Process Environments Containing Water

The corrosion processes due primarily to water or which involve water as one of the
contributors will stop or be unable to start in those portions of the brazed aluminium
plate-fin heat exchangers which are operating below the freezing point of water. This
may not be DOC due to water purity variations and supercooling phenomena. Above
the freezing point, for example during de-riming, consideration must be given to other
factors. Water service can be grouped into 3 categories:
62 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION
 CHAPTER 8
Recommended Good Practice
8.3.1.1 Water service in neutra l environments
Brazed aluminium plate-fin heat exchangers can be used extensively in the
processing of many materials containing water provided the water is and
remains relatively neutral in character while within the exchanger (pH of 6 to
8) even in the presence of halides. The compatibility of the aluminium heat
exchanger with a process stream containing neutral water can be affected by
factors such as the degree of heavy metals contained within the process
stream and deposit formation.
For example, aluminium heat exchangers used together with copper and its
alloys , or with other heavy metals such as iron, nickel and lead, should be
avoided unless an inhibitor is used to protect the alum inium heat exchanger
components. The pitting corrosion resulting from the use of process streams
containing heavy metals is usually less severe when the soluble ions of these
heavy metals are decreased. Consequently , the presence of heavy metals in
acidic or neutral water service process streams in conjunction with aluminium
plate-fin heat exchangers will be more detrimental than in alkaline process
streams. Austenitic stainless steels are very acceptable for use in
combination with aluminium plate-fin heat exchangers in neutral water
service process streams.

8.3.1.2 Water se rvice in acidic environments

Aluminium alloys commonly used in heat exchangers are resistant to acidic
process streams or local acidic conditions in the 4.5 to 6.0 pH range.
However, an inhibitor should be used in this pH range if heavy metals or
halides are present in the process stream . Below a pH of 4.5, corrosion can
initiate by breakdown of the protective oxide film and by galvanic coupling
between components or areas of the aluminium heat exchanger and other
more noble metal s in the process equipment. Structurally significant
corrosion can result from direct chemical conversion of the exposed nascent
aluminium after the protective oxide has broken down. As is the case with
neutral environments, the formation of deposits can change both the
environmental conditions at which corrosion begins and the severity of the
attack once the corrosion begins.

8.3.1. 3 Water serv ice i n alkaline en vironments

Aluminium heat exchanger alloys have excellent corrosion resistance in
mildly alkaline environments (pH of 8 to 9). An alkaline process stream may
discolour the surface of the aluminium components, but this darkening of the
surface is only superficial and will not affect the structural or operational
integrity of the heat exchanger. The use of aluminium plate-fin heat
exchangers in more severe alkaline environments (pH> 9) should be done
only after a very careful analysis and consideration of the chemical process
streams involved. Other factors such as process and impurity concentrations
and temperatures within the operating environment to which the equipment
will be subjected also need to be given some consideration .
To summarise, the pH value should remain between 4.5 and 8.5 and the presence of
halides and heavy metal ions should be avoided.

8.3.2 Pro cess Envi ronments Containing Mercu ry

In general, mercury will not react with aluminium unless it is allowed to exist in contact
with the heat exchanger in its liquid state and there is water present. If these
conditions exist within a heat exchanger, then mercury contamination can result in
problems. This attack is most severe when coupled with another corrosion process.

STANDARDS OF THE BRAZED ALUMINIUM PLATE -FI N HEAT EXCHANG ER MANUFACT URER'S ASSOCIATION • 63
CHAPTER 8
Recommended Good Practice
Another possible problem resulting from mercury in the process stream affects
aluminium alloys that contain a high level of magnesium. A rapid reaction of mercury
with a magnesium-based secondary phase within the aluminium can take place in th e
absence of water. If features are not designed into the equipment to address this
problem and conditions are conducive, mercury corrosion cracking can occur and
propagate at substantially lower levels of stress than that required if mercury were not
present.
Many brazed aluminium plate-fin heat exchang ers are able to operate successfully with
fluids containing mercury by using precautions that are available. Purchasers can
remove mercury from the feed gas with commercially available systems. Operators
may also use special shutdown procedures (nitrogen blanketing) to restrict moisture
and avoiding , for metallurgical reasons, elevating temperatures above 100°C for long
periods , for example during de-riming operations.
Manufacturers can offer several options when mercury service is specified. Design
features can eliminate the build up or pocketing of mercury. Often it is possible to
avoid th e us e of susceptible alloys. When those choices are not possible, precautions
are available either to isolate or protect the high-magnesium containing alloys from
mercury attack.
In summary:
• Brazed aluminium plate-fin heat exchangers should not be operated in
environments where mercury concentrations are greater than 0.1 Ilg/Nm 3 .
Above this limit, mercury guard beds should be installed and mercury tolerant
features should be considered in the design of the exchanger.
• Below 0.1 ).lg/Nm 3 , Purchasers should consider using exchangers with mercury
tolerant features and mercury guard beds because the same gas field can
sometimes contain large variations in mercury levels over time.

8.3.3 Atm ospheric or En vi ronmental Corrosion

Aluminium plate-fin heat exchangers will generally not suffer to any structurally
appreciable extent from atmospheric corrosion to the external surfaces of the core,
considering the internal process streams to be sealed/protected from the
atmospheric/environmental conditions. Slight cosmetic corrosion may result if the
exchangers are left outside in a humid environment with temperature changes that
result in condensation of the humidity on the aluminium surfaces.
Extra precautions should be taken if the exchangers are exposed to an environment
containing appreciable quantities of salt spray or salt air, for example, during extended
open storage at site locations in coastal areas or during ocean transport. In the case of
ocean freight without seaworthy packing ; e.g. transport of exchanger batteries, it is
recommended that, immediately after arrival on site , all surfaces be washed with water
with a chlorine content < 25 ppm. Manufacturers should be contacted regarding the
detailed procedures to be used to wash the core. After external washing, all surfaces
need to be dried thoroughly.
Since it is difficult to ensure the leak tightness of any heat exchanger insulation system
it is important that safety systems which use water to control fire hazards do not
expose the heat exchangers to sea , brackish or other forms of salt water. This water
could become trapped between the heat exchanger insulation and the heat exchanger
metal surfaces resulting in corrosion of the exposed surfaces , Even tap water can
result in corrosion under these conditions , and Manufacturers should be contacted
regarding procedures to be used to dry the cores.

6. • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 CHAPTER 8
Recommended Good Pract ice
8.3.4 Other Services
There are many possible service environments for satisfactory operation of brazed
aluminium plate·fin heat exchangers. Not all corrosion risks are addressed in this
guideline. If there is uncertainty about the fluid and/or process conditions, contact the
Manufacturer for specific advice.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 65

,
CHAPTER 9
Special Applications and Exchanger Peripherals

9 SPECIAL APPLICATIONS AND EXCHANGER PERIPHERALS

9.1 BLOCK-iN-SHELL HEAT EXCHANGERS

9.1.1 General
The term block-in-shell is used to describe a heat exchanger system of one or more
aluminium plate-fin heat exchanger blocks installed in a shell made either of aluminium
or steel (see Figure 9-1). Enclosing the block in a larger shell is sometimes
advantageous because it avoids the need to have a separate knock-out drum.
The arrangement is similar to a tubular exchanger known as a kettle reOOHer. Hence
these are sometimes also known as block-in-shell exchangers. The block-in-shell
exchanger offers several advantages over the tubular kettle reboiler as is described
below.

9.1.2 Features/Advantages
Advantages of a block-in-shell exchanger include extreme compactness, operating
efficiency, reliability and smooth operation. In comparison with the tubular kettle
reboiler, the block-in-shell type has the advantages of:
• Reduced temperature approach and consequent energy saving.
• Up to ten times greater heat transfer surface per unit volume.
• Multistream capability in a single unit when required.
• Elimination of leak-prone mechanical joints.
• Smaller overall size, weight and footprint.
• Lower installation costs.
• Reduced liquid inventory.

9.1.3 Arrangement/Con struct ion

Most block-in-shell exchangers only involve two streams and are th erefore of a
comparatively simple deSign. This design is shown in figure 9-1. Here, stream A is a
condensing stream and B is a boiling stream operating in a natural circulation mode.
Headers and nozzles attached to the block are only required for the condensing
stream. All passages occupied by the boiling passages in the block are directly open to
the fluid in which the block is immersed. The internal piping, especially in the case of
multiple cores in a single vessel , may have a substantial effect on the overall shell
tangent to tangent distance.
When the shell is made of steel, material transitions (so called "transition joints") are
needed between the aluminium heat exchanger block and the steel kettle.
Manholes, nozzles for level indication and support saddles can be provided by the
Manufacturer.

66 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FI N HEAT EXCHANGER MAN UFACTURER'S ASSOCIATION
 CHAPTER 9
Special Applications and Exchanger Peripherals

® CONDENSIN G FLUID

®
®
BOILIN G FLUID

GAS OUT ®
GASIN
•
® • POSS IBL E LOCATIO N FOR
TRANSITION JOINT (IF ANYI

2.PHASE IN

1L-_ _ SHELl

POS SIBLE LOCAT'O -i",", --':

FOR TRANS ITI ON JI
(I F ANY)

• UOUIDOUT
DRAI N
LEVEl
®
®
Figure 9·1 : Bl ock-in-She rr Heat Exc hanger

9.1.4 Therma l and Hydrauli c Design

The boiling stream is arranged in vertical up-flow with the condensing stream usually in
horizontal flow, giving a cross-flow layout. Circulation of the evaporating stream arises
because the density of this two-phase stream within the block is lower than the density
of the liquid surrounding the block. This static pressure imbalance gives a drivin g force
to create the up-flow in the boiling channels , Le. a thermosyphon effect. The actua l
flow rate achieved is determined by the balance between the driving head and the
combined frictional losses and fluid acceleration in the channels. Proprietary software
is available for calculating the flow rates and inter-related heat transfer rates in these
units.
Sufficient space is allowed above the block to allow the liquid to disengage from the
vapour so that a very small amount of liquid is entrained in the outlet vapour leaving the
shell. The maximum allowable li quid entrainment from the block-in-shell heat
exchanger shall be specifi ed by the Purchaser.

9.1.5 Mechanical Design/Testing

The block is mechanically designed for both internal and external pressure. Prior to
installation into the shell , the passages of the condens ing stream block are tested in
the normal way , and in accordance with applicable Codes , for pressure containment
and leaks. Following installation of the block in the shell, the block is tested under
external pressure.

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 67

CHAPTER 9
Special Applications and Exchanger Peripherals
9. 1.6 Typi cal Applications
These include
• LNG plants (liquefaction of natural gas against a refrigerant vaporizing in
natural circulation)
• Ethylene plants

9. 2 COLD BOXES

Figure 9-2 : Cold Box

68 • STANDARDS OF THE BRAZED ALU MINIUM PLATE-FI N HEAT EXCHANGER MANUFAC TU RER'S ASSOCIATION
 CHAPTER 9
Special Applications and Exchanger Peripherals
9.2.1 General
The term col d box is used to describe a carbon steel casing which houses cryogenic
equipment (see Figure 9-2) . The cold box may have a rectangular or circular footprint.
The cold box provides stru ctural support , insulation containment, and protection for the
internal equipment. A cold box may contain any type of cryogenic equipment, such as
plate-fin heat exchangers, rectification columns , knock-out drums, interconnecting
piping , valves, and instrumentation.

9.2.2 Advantages
Some of the advantages of installing cryogen ic equipment into a cold box are:
• It arrives on site nearly "ready to operate" (that is, insulation is normally added
on site), reducing cost and the time associated with on site construction.
• All interconnecting piping between the various components is already complete
inside the cold box, thus eliminating flange pairs, piping and the expense of
insulating interconnecting piping.
• No additional support structures are necessary.
• Thermal insulation (perl ite) can normally be removed or added more eas ily
than other methods of insulation .
• It provides excellent protection of equipment and insu lation against external
influences like rain, snow, wind , etc.
• The design facilitates ease of hydrocarbon leak detection through analysis of
the exiting purge gas.

9.2.3 Structure
A cold box is designed as a welded and self-supporting carbon steel structure with
welded carbon steel sheeting. All internal equ ipment is supported by the carbon steel
structure of the cold box . Beams directly supporting the internal cryogenic equipment
are typicall y stainless steel. For warm appli cations carbon steel may be used.

9.2.4 Thermal Insulation

T he space between the various cold box components is normally filled with expanded
perlite for thermal insulation. Raw Perlite is a type of volcanic stone containing some
water. When heated above 1000°C the entrapped steam creates "expanded perlite", a
sponge type material with a very low density of on ly 50-70 kglm 3 and very low therma l
conductivity, and thus it is perfectly suited for therma l insulation .
Adequate perl ite fill and drain connections are included in the cold box casing.
Manways can often be used for the same purpose.

9.2.5 Nitrogen Purge

In order to maintain th e original properties of the insulation material and to ensure the
cold box atmosphere is free of oxygen , hydrocarbons and humidity , each cold box is
equipped with a nitrogen purge system . Dry nitrogen is typically fed into the cold box
near the base through perforated tubes which distribute the purge gas equally over the
cross section of the cold box. Depend ing on the height of the cold box, other distributor
tubes may be installed at higher elevations . The purge gas norma lly leaves the cold
box at the roof. The nitrogen purge system is externa ll y controlled by val ves and
instrumentation , such as pressure gauges and flow indicators . Manufacturers can
provide recommendations or can supply the complete system.

STANDARDS OF THE BRAZED ALUMINI UM PLATE-FIN HEAT EXCHANG ER MANU FACTURER'S ASSOCIATION . 6'
CHAPTER 9
Special Applications and Exchanger Peripherals
9.2.6 Wall Penetrations
All pipes entering and leaving the cold box need to pen etrate the cold box sheeting.
This can be done either with fixed or flexible wall penetrations. Generally, flexible wall
penetrations utilising seal boots (e.g. rubber boots) are used. These penetrations keep
the cold box air tight while allowing certain movements of the piping in relation to the
cold box wall. Fixed penetrations can be provided on pipe penetrations where there is
adequate flexibility within the cold box, but are generally limited to smaller lines.

9.2.7 Attachments
Cold boxes can be equipped with the following extemal attachments:
• Roof railings.
• Ladders or stairs .
• PlatfoOTls .
• Top davits .
• Pipe supports.

9.2.8 Safety Devices

Cold boxes are desi gned for positive internal pressure of nitrogen purge
(e.g. 10 mbar·g). In case of leakage from the internal process equipment, the cold box
must be protected against pressurisation over the design limit. Manufacturers provide
protection by breather valves, emergency flaps , rupture disks, or a combination of
these devices. It is important to understand that in an unlikely emergency case, a large
volume of expanded perlite can escape through such safety devices with consequent
dang er of suffocation for people beside the cold box. Operators need to take this into
account in their plant layout.

9.2.9 Temporary Bracings

In many cases cold boxes are fabricated and transported in a horizontal position. Often
temporary bracing is installed to support internal equipm ent during shipm ent. After final
cold box erection, and prior to any site pressure testing , the temporary bracing must be
removed. Temporary bracing shoul d be colour coded to ensure the correct parts will be
removed once the cold box is erected.

9.2.10 Fire Protection

The cold box steel casing should not be considered as fire protection.

9.2.11 Flanged Connections

Flanged connections to nozzles, valves, etc. should not be made within the cold box
casing .

9.2.12 Shipping, Handling and Instaliation

The Manufacturer will provide the deta ils necessary for shipping , handling and
installation of the cold box.

70 • STANDARD S OF TH E BRAZED ALU MINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION

 Notation

Notation
51 IMPERIAL
A Effective heat transfer surface of a passage or layer m' ft'
Ad Designed or estimated overall effective heat transfer surface m' ft'
A, Required overall effective heat transfer surface m' ft'
Al Primary heat transfer surface of a stream m' ft'
A, Secondary heat transfer surface of a stream m' ft'
B Defined by Equation (13) , Chapter 7
C Coefficient, defined by Equation (1 4), Chapter 7 W/m'K Btum' F
Cp Specific heat J/kg K Btull b F
(h Hydraulic diameter of passage m ft
f Fanning friction factor
F Force N Ib
Gm Mass flux/velocity of a stream kg/m 2s Ibm' hr
in
"
j
H
Fin height
Stacking height of a core
Colburn factor for a finned passage
mm
mm in

K Expansion/contraction/turning loss coefficient

r, Passage length mm
Serration length or distance between crests on herringbone fins mm
in
in
L Core length mm in
LMID Logarithmic mean temperature difference K F
M Moment Nm Ib ft
M71J Mean temperature difference K F
/I Fin density m-I in- 1
p Fin pitch mm in
Pr Prandtl num be r
Q Overall heat duty; heat to be transferred W Btu
/' Fouling resistance m'K/W ft'F hr/ Btu
5 Distance beween the extreme bolts in a given plane mm in
I Fin thickness mm in
U Overall heat transfer coefficient between streams W/m'K Btu/hr ft'F
V Volume of heat exchanger or exchangers m' ft'
IV Width of core mm in
X Required clearance distance mm in
Gree k
a, Coefficient of linear expan sion at average temperature m/m K ftlft F
a, Effective heat transfer coefficient of a stream W/m2K Btu/hr ft' F
a Heat transfer coefficient of a stream W/m2K Btu/hr ft' F
~ Defined by Equation (11 ), Chapter 7
y Defined by Equation (12) , Chapter 7
t:,P Overall pressure drop N/m' (Pa) Ib/in2
M Local temperature difference between warm and cold streams K F
t;TR Temperature range at support K F
'1, Passag e fin efficiency for single banking
'1, Passage fin efficiency for double banking
I,m Therma l conductivity of fin material W/mK Btu/hr ft F
P Density of stream kglm ' Ibltt3
$ Un perforated fraction of fin
Subs c ript s
c Cold stream IV Warm stream
Section x,y,z Direction

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 71

-.
References

References
(1) ESOU, "Design and performance evaluation of heat exchangers: the effectiveness-NTU method.
Parts 1 - 5", ESDU 98003 - 98007, IHS (Global) Ltd, UK. 2007.
(2) Kays , W.M. and London , A.L., "Compact Heat Exchangers", McGraw Hill , New York, Third
Edition, 1984.
(3) Taborek , J. and Spalding, o.B., "Heat Exchanger Design Handbook", Hemisphere Publishing
Corporation, 1983.
(4) Taylor, M.A. , "Plate-Fin Heat Exchangers - Guide to Their Specification and Use", HTFS, 392 .7
Harwell , Oxon, OX11 ORA, UK. 1987.
(5) ESDU , "Selection and costing of heat exchangers. Plate-fin type" , ESDU 97006, IHS (Global) Ltd,
UK. 2003.
(6) ISO 15547-2, Petroleum , petrochemical and natural gas industries - Part 2 : brazed aluminium
plate-fin heat exchangers .

72 • STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXC HANGER MANUFACTURER'S ASSOCIATION
 Index

Index
Acceptable Fluids .................. ... . ....... 3 Damage . .. ........ 20, 21 , 24, 31 , 32, 34 , 36
Air Separation Unit(ASU) ............. ... 3 Definition. . ........... .... ............ . ................... 37
Air test ........ ........... ..... .............................. .. 38 Deplugging ............ .. ........... .62
Ammonia ........................... . ....... . 3, 4 Description
Angle Bracket Support Arrangement ........... 27 General ......................... . .. ... 1
Argon ............................................................ 4 DESIGN
AS 1210 ....................................................... 37 HYDRAULIC ....................................... 47-58
ASME VIII, Div. 1 ................................... 37 TH ERMA L ...... .................................... 47- 58
Asphyxiation .......... ..... ..... . .. 34 Design Code ................ .................... ....... .... 18
Atmospheric Corrosion . ......... ..... . 64 Design Pressures .... ........ ............................ 38
Banking Design Temperature ..... ............ ...... .. ... 39
Multiple ................................................. .48 Distributor
Single .... ................ ... 48 End ......................................................... 10
Beams Intermediate .................. ........ 10
Support ............................ .. ........ 24 Side....... ................. ........... ... 10
Blocking of Layers ....................................... 23 Special ..................................................... 10
Boil-off Gas Reliquifaction .............................. 4 Drawings ....................................................... 19
Burst test method. ... .................... ....... 44 Approval and Change ................. .. ..... 20
Butane ......................................................... 4 for Record ... ... ..... ....... ... 20
Cap Sheets.. .. ........... 36,40, 44, 45 Information ....... ............ .. . .... 19
Carbon Dioxide....... ........... ..... . .. 3 , 4 Proprietary Rights ...... ..................... 20
Carbon Monoxide ............................... 3, 4 Drying ...... .................. ............ 21
Cascade Cooling .................. ... 4 Dummy Passages ..................... .................. 21
Chillers ........ .... .................... . ....... 1, 2 Dutch Pressure Vessel Code .... . ..... 37
Chlorine .............................................. 3, 33, 64 Enhanced Oil Recovery (EaR) .. ............ .4
Choice of Fin Geometry .............................. 57 Ethane ........................................................... 4
Cleaning ... .. ......................... 3, 21 , 33, 61 Ethylene ....................................................... .4
Solvent... ............................................... 3, 61 European PE D ............ ....... ..... .. 37
Coal-to-liquids (CTL) ................ .. .... 4 Exchanger
CODAP .................. ........ .......... .. ....... 37 block (core) ............................ ........... 1
Code Data Reports . .................. ........ 20 cap sheets ..... ..... ......... ............ . ....... 1
Codes for Construction . ... . .................... 37 inlet ports. ........... . ...................... 1
Coefficient of Thermal Expansion .. . ...... 29 layers (passages) .. ......... .. .... .. 1
Colburn Factor ........................................... 53 multi-stream ............... ... ......... . .............. 1
COLD BOXES .......................... 25, 31 , 34, 68 outlet ports .............................. . ............ 1
Components parting sheets . ...................... . ............. . 1
of an Exchanger .. .................... ... 5 side bars ... ................................................ 1
of Manifolded Exchangers ........... .... 6 size ........... ....... .................. . ...... ......... 1
Condensers .............. ..................... ...... 1, 2, 37 FABRICATION .. .. ...... 17- 23
Connection Options Failure Mechanism . .................... 59
Flanges ............. 7, 15, 17, 19,22,42, 70 Field Testing. ............................ 30
Stub Ends ................... ...... .. ......... 7 Filters .... ................ .. ........ 3, 33, 62
CONTRACTUAL INFORMATION ......... 18 Fin Corrugations. ...... ....... . ......... 9
Cool·down ... ........... ..... ......... . ....... 32 , 59 Fin Dimensions ... . ................................ 10
Core Volume Definition ............................... . ............ 10
Estimation ...................... . 54 Fins Per Inch (FPI) .................................. 10
Corrosion ..... . 62 Percentage Perforation ............................. 10
Acidic Environments ...... .................. 63 Fin Geometry
Alkal ine Environments ...... ..... 63 Choice of. .. ..... ... ....... ..... . .... 57
Atmospheric or Environmental ............ ...... 64 Fin Types ............ ......................... ........... 9
Enviro nments containing Mercury . ..... 63 Fins ........................... ............. .................. ... 43
Water .......... . ............................. 62 H~~~M .................................. 9
Corrosion Allowances ............................... .. . 40 Perforated .... .............. . ........... 9
STANDARDS OF THE BRAZED ALUMINIUM PLATE-FI N HEAT EXCHANGER MANUFACTURER'S ASSOCIATION • 73
Index
Plain...... .... .... ....................... . .. 9 Leak Rate .. .................................................. 39
Serrated ...................... . .. 9 Leak Test ......... H. ,........... . ........ 38
W avy ......... ........... ............. 9 Air ... ......... ........... . ................ 38
Fixing Bolts ...... .. ..... ... .. .... ..... ........ ....... .. 28 Helium ... ". ......... ....... .. 39
Flange Protection ........ ..... .. ........... ... 21 Length ... . ..... ... ..... ...... ...... . ....... ... 5
Flow Arrangements ................. .... ... ........ ..... 14 Lifting .... .. ... ..... .............. .... ... ................ 24
Flow Fluctuations. ... . ..... 59 Lifting Devices ... ..... .......... .22
Flow Velocities in Nozzles ........................... 41 Lifting Lugs ................................. ............... 22
Fluids limits of Use
Acceptable .................................................. 3 Max imum working pressure ....... ................ 3
Fou li ng .................................................. 3, 60 Maximum working temperature .................. 3
Fouling Resistance .............. . .... 53 Minimum design temperature .............. 3
Freeze Spots .. .. ..... .. ................................. 34 liquefaction .. " ................ ... ... ...... ....... ........... 4
Freon .... ..................... ..... ...... ..... 4 Liquefied Natural Gas ..... "'''" ... . , ......... 4
Gas- ta-Liq uids (G TL) ....... ........ .......... ... 4 Liquefied Natural Gas (LN G) ...... ... .... ............ 4
General Description . . ................ ........ 1 Liquefied Petroleum Gas (LPG) . ..... .............. 4
GENERAL D ESCRIPTION . 7- 14 Liqu ified Natural Gas (LNG ).. ...... . ...... 3, 4
GOOD PRACTICE ................................. 5S-71 Logarithmic Mean Temperature Difference ... 52
Guarantees ................................................... 20 Maintenance ................................................. 3 3
Co nsequential Damage ............................. 21 MAINTENA NCE ...................................... 23-36
Corrosion ............................ ......... 21 Manifo ld A ssemblies .............. . ............. 58
Therm al and Mechanical..... . .... ...... 20 MATERIA LS .......................................... 45-46
Gu ide Frame Materials of Construction ............ ............ 37 , 45
Sliding .......... ........ ............ .......... ......... .. . 25 Mean Temperature Difference ... ............ ....... 49
Hand ling ............... ..... ... .... 24 MECHANICAL STANDARDS ... ............. 36-44
Header Mercury ....................................... ........ 3, 33, 63
Dome .. .... ............ ........... . .... 8 Metal Temperature limitations ........ .............. 39
Inclined Ends ................................... ......... 8 Methane .......................................................... 4
Mitred Ends ................................................ 8 Module Construction ...................... ................. 6
Sta nda rd ......... ......................... . ......... 8 Mounting Bolts ............................................ 28
Header/Nozzle Configurations . ....... . ..... 7 Multi· Component Refrigerants ........................ 4
Headers ........ ..... ............................... 7, 41 , 44 Multiple Banking ..... ..... ......... .48
Heat Transfer Coefficient of a Stream .. .. .. ... . 53 Multi·Stream ........................... ............. ........ 48
Heat Transfer Surface .. . ... ...... . 49 Nameplate .. ................ ........ 18
H~~ ... 5 Data .... ..................... .... ......... ......... .. 19
Stacking ....... .................. .. 1 Manufacturer's ............... . ............ 18
Heliu m .......................................................... 4 Purchaser' s ............................ .................. 19
Heliu m Leak Test .............................. . .... 35 Structure .................................... .............. 19
Helium Recovery .................................. .......... 4 Supplementary Informatio n ....................... 19
He lium test ... ....................................... ......... 39 Natu ral G as Processing (NGP) .... ........ ....... 3, 4
H~M ................................ ........ 4 Nitrogen ....................... ........... ....... .... 4
HYCO Plant ..... .... ....... . ... .. ..4 Nitrogen Dioxide ........................... ................. 3
HY DRAULIC D ESIGN ........................ . 47- 58 Nitrogen Oxides ...... ...................................... 33
Hydrogen ..... ..... .. ........................... .... .......... 4 Nitrogen Rejection Unit (NRU) ........ .. ... .... 4
Hydrogen Sulph ide ....................................... 3 NOME NCLAT URE ............ .......... ........ 7- 14
Inactive Areas. ... .............. ....... 21 Nomenclature of the Com ponents .... .............. 5
Injury ........................................................... 34 Nonconformity Rectification ... . ................ 23
In spection .................................................... 18 Non· Destructive Testing ............................... 30
Ma nufacturer's .............................. .......... 18 Nozzle
Purchaser' s . ............. .... ........ 18 Incli ned. ............ .................. ................... 8
Third Party ... ..... .................... ............. .. 18 Radial ................................. ....... ...... ......... 8
I NSTALLAT ION .... ..... ........ ...... .. 23-36 ~~~~ ..................... .. .. ..... ... ............ 8
Insulation .... ...... ..... . .... ... 31 Nozzle loadings ........ .......... ..... ............... .... 41
Japanese HPGS Law ...... 37 Nozzle Type ....................... ..... ............ .. ........ 7
Layer Arra ngements ... . ... 43 Nozzles ......................... 7, 41 , 44
Leak Detection ............... . ................ . ... 34 Flow Velocities in .......... .............. 41

74 • STAN DARDS OF THE BRAZED ALUMINIUM PLATE·FIN HEAT EXCHANGER MANUFACTURER'S ASSOCIATION
 Index
Loadings .... .... ...................................... ..... 41 Sliding Guide Frame ...... ....................... ....... 25
Operation. ...... .......................... .... 32 Solvent Injection Syste m .... . ..... ......... 61
OP ERATION . .. . ...................... ... 23-36 Spare parts ...................................... .. .... ....... 22
Overall Heat Transfer ............ . ...49 Special Features ...... ....... .... ............. . ... ...... 44
Oxygen ............................................. ......... ... 4 Specification Sheets .. .. ..... ..... . .... ..49--51
Particulate Matter. .. .. ..... .... .. "' .. ... .......... 32 Stacking Arrangement. . .... . .. 58
Parting Sheets ... ..................... .... ... ... . 44 Stacking height .. .. .. .. ......... .. .. ............ .... ... .. . 1
Pentane ....... ....... .... ................................ .. .... 4 Standard Sizes . .... .. ......... .40
Petrochemical Production ...... . .. . 4 Cap Sheets ..40
Piping ........................ . ............................ 6 Fins ........ .... .......... ........... . ... 40
Plant Upsets .............. . ........................ .. 59 Parting Sheets ............................ ...... ......... 40
Plugging .................. . ..................... 60 , 61 Side Bars ................................................... 40
from dust .............. .................. ... 3 STANDA RDS
from molecu lar sieve dust .. ... 3 MECHA NICAL .............................. .. .. 36-44
from particulates .. 3 Start-up ... ..... ............ ...................... ........ ..... 32
Pressure Loss ............ .. ... . ......... .... ...... 55 Storage ...... .. ............... ... .. ........... .... 36
Single-P hase ............ ... . ... ... 56 Sulphur Dioxide ...... ... ........ ............ . . .. 3
Two-Pha se ...... .. . ... ... .. 57 Supply
Pressure Relief Devi ce . ... .. ........... . .. .. 32 Scope of .. .................. .. ... 22
Pressure Relieving Devices .......................... 33 Support Arrangement
Pressure Te st ........... .................. 34, 38 Ang le Bracket ................................... 27
Hydrostatic .... .. ..................... . 38 Shear Plate ............ . ................... ......... 26
Pneumatic ............. ............ . .... 38 Support Beams ... .......................................... 24
Pressure Testing ....................... .... 30 Support Insulation ...... . ......... .............. ..... 25
Pressure Vessel ...... ....... .. ................. ........ 43 Supports ...... ........... ......................... ... ........ 22
Pressurising .. . .... ...... . . ....... .... 21 Surface Area ............ ............ .... . 49
Primary Heat Transfer Surface .... .... ..... 47 Surging ....... .. ................... ..... ............. 33
Production Process . .......... ......... . ..... .... 43 Swedish Pressure Vessel Code ...... ............. 37
Proof Pressure T esting ............... . ..... 30 Temperature
Propane .............. ......................... ........ 4 Design ........................... ... 39
Propylene ..................................... .... .... 4 Tempe rature Differences
Pulsing ........ ................. ............... . ..... 33 Perm issible .... ................. . .. 39
Raccolta ........... ....... ..... ...... ........ . ..... 37 Temperature Lim itations ..... . ........ ........ 39
Rare Gases ........................................... ...... 4 Testing ....................................... ................ 38
Reboilers .... ..... .... .... ... .. ... . ......... ... 1, 37 Field .. ......... .............................. .......... ...... 30
Rectification Non-Destructive ............. ... ............ .... 30
Leak ........... .... ........ .. ........ ..... . 23 Pressure .......................... .......... .. ....... 30
Nonconformity ................ . .... ...... 23 TH ERMA L DESIGN ...................... 47- 58
Rectification of Leaks .............................. ..... 23 Thermal Expansion ...................................... 28
Refrigeration Systems ............... ......... 4 Therma l Length ........................................... .47
Repair of Leaks ........................................... 35 Thermal Movement .......................... ............ 28
Safety..... ......... ........ .................. .. .. ..... 34 Thermal Shocking ...... ........... . ...... 33
Scope of Supply . .... ................. .. ..... 22 Therma l Stresses ............... .40, 59
Secondary Heat Transfer Surface ..... .. 47 TOLERA NCES .. .. .. .... ..................... .... .. 1&--17
Services ........ ....... ... .................... . ... ... .. 1 Transient Operating Conditions ..... ............ ... 59
Shear Plate Support Arrangement . . .... 26 Two- Phase Pressure Loss ........ .................. . 57
Shipment ...................... .. .. . 21 Unsteady Operating Cond itions . .... ......... 59
Shop Operation ...... .................... . 18 Vapour Cloud ...... .............. .. .... 34
Shut-down .................................... .... .. 33 Venting Of Dummy/Inactive Areas ... ............ 30
Side bars .. ................................... ...... 44 W arm· up .................................................... 33
Sing le Banking ............................................ 48 W eight of a Complete Heat Exchanger ......... 55
Sing le- Phase Pressure Loss .......... 56 Wi dth .............................. ... 5
Site leak Detection ........................ .. .. 34

STANDARDS OF THE BRAZED ALUMINIUM PLATE-FIN HEAT EXC HANGER MANUFACTURER'S ASSOCIATlON • 75
 THE STANDARDS
OF THE BRAZED
ALUMINIUM PLATE-
FIN HEAT
EXCHANGER
MANUFACTURERS'
ASSOCIATION

Third Edition
2010

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Copyright 2010 by the Brazed Aluminium Plate-Fin Heat Exchanger Manufacturers' Association.
All rights reserved.

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