Documente Academic
Documente Profesional
Documente Cultură
By
John Nesta
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Revision Log
TABLE OF CONTENTS
1.0 Introduction
1.1 Purpose
1.2 Scope
1.3 Application
1.4 How to use the Guidelines
1.5 Codes and Standards
2.0 Equipment Type (Forced versus Induced)
2.1 Selection
2.2 Induced Draft Limits
3.0 Design Optimization
3.1 Total Evaluated Cost
3.2 Design Methodology
4.0 General Design Guidelines
4.1 Bay Layout
4.2 Bundle Layout
4.3 Nozzles
4.4 Fouling
4.5 Pressure Drop
4.6 Liquid / Vapor Separation
4.7 Screens
5.0 Air Side Design
5.1 Fin Design
5.2 Fan Coverage
5.3 Power Requirements
5.4 Noise
5.5 Approach Velocity
5.6 Hot Air Recirculation
6.0 Tube Side Design
6.1 Tube Size
6.2 Velocity
7.0 Process Control and Winterization
7.1 General
7.2 Process Temperature
7.3 Tube Skin Temperature
7.4 Air Temperature Control
8.0 Special Applications
8.1 Total Steam Condenser
8.2 Partial Steam Condenser
8.3 Viscous Fluid Cooler
8.4 Condensers with water wash
Air Cooler Design Guidelines Page ii
Table of Contents July 2012
Rev 6
Appendices:
A Literature – Recommended Reading
Air Cooler Design Guidelines Page 1-2
Introduction July 2012
Rev 6
1.0 INTRODUCTION
1.1 Purpose
This practice establishes guidelines for thermal design and other parameters for the specification
of air-cooled heat exchangers used in the process industries.
1.2 Scope
The equipment types covered are flat bundle air coolers of either the forced or induced draft type.
A-frame vacuum steam condensers are beyond the scope of this practice.
This practice establishes the following:
• Thermal design guidelines
• Economic design and evaluation
• Other design parameters
1.3 Application
This practice is intended for use in designing air-cooled heat exchangers used in the process
industries.
1.4 How to Use the Guidelines
Many design parameters are merely based on user preference. It may be useful to prepare a
project checklist that can be used to identify these preferences at the start of a project. These
guidelines provide good engineering practice to determine those parameters that the client does
not specify. The guidelines and design preferences specified herein are to be used in the absence
of any client requirements.
The body of the text will provide various guidelines noted in normal text. Text shown in italics
provides some additional explanatory material, non-mandatory guidelines, or other background
information.
A full reading of the text, including the italicized text, is a good training exercise for new
engineers. A streamlined text without italics can be used as:
a) A design specification for projects. User preferences should be incorporated.
b) A design specification to maintain quality and design consistency for work sharing between
offices or for outsourcing designs.
1.5 Codes and Standards
It is assumed that the purchase specification will include, or be similar to, the following industry
standards:
• American Petroleum Institute (API) Specification 661 / International Standards Organization
(ISO) 13706
• The rating methods are assumed to be Heat Transfer Research Inc. (HTRI) and the XACE
program.
Air Cooler Design Guidelines Page 1-2
Introduction July 2012
Rev 6
overriding incentive to minimize field labor. This has been the recent case in Alberta where coolers have
been supplied either fully erected, or with a “shoe box” design that is has only two modules to be fitted
together.
The extent of shop assembly dictates the maximum bay size, and thus has a bearing on the thermal design.
3.2 Design Methodology
The heat transfer designer shall provide a design that satisfies the process requirements of the data sheet
in the most economical geometry that provides the lowest total evaluated cost.
The following discussion is based on finned tubes with 5/8 inch nominal fin height and 10 fins per inch.
Tube pitch is standard or wider than standard, typically an extra 1/8 inch. Compact designs with 11
fins/inch and/or pitch less than standard are not recommended as these arrangements tend to foul more
easily and are difficult to clean.
Tube outside diameter Standard tube pitch with 5/8 inch fin height
1” 2.5”
1.25” 2.75”
1.5” 3”
There will be many different solutions ranging from 4 to 8 rows, each with a range of different face
velocities. The number of rows has compensating effect on the total evaluated cost. On a unit area basis,
equipment cost decreases as the number of rows increase. However, it consumes much more power to
move the same amount of air across more rows with smaller face area. Thus, total mass air flow and
MTD decrease (and surface increases) as you add rows. Equipment cost is indeterminate until you work
out the designs. It depends on how much surface is added. For example, an 8 row design with more
surface area can be less expensive than a 4 row design with less surface area, due to the higher surface
area density with 8 rows. Designs with few rows tend to have the highest power cost compared to designs
with many rows.
The only way to be sure of the optimum design is to develop several and calculate the total evaluated
cost.
It is convenient to have a general idea of the optimum design before developing the detailed design in
XACE. Another option is to use the following tables to hone in on the number of rows and face
velocity. Then, complete the design in XACE. The tables were derived empirically from several cases.
An example follows at the end of this section.
Use the following steps to for an optimized air cooler design.
1) Calculate power cost.
2) Estimate relative equipment cost per Table 1.
3) Estimate power cost as a percent of equipment cost per Table 2.
4) Characterize the relative value of power cost per Table 3.
5) Estimate overall heat transfer coefficient (U) based on previous designs for similar service.
6) Pick the number or rows using Table 4. Note the comments following the table regarding MTD.
7) Develop a design within the face velocity range per Table 5.
8) Do a few designs that span the first guess. Calculate the total evaluated cost for each design to
confirm the design is optimized.
Air Cooler Design Guidelines Page 3-4
Design Optimization July 2012
Rev 6
The air side heat transfer accounts for 30-85% of the total resistance. When the tube side coefficient is
very high (e.g. condensing steam), the air side coefficient controls the design and it is desirable to use
fewer rows with high face velocity. When the tube side coefficient is very low, air flow is less important
and it pays to pile up the surface with many rows. This general guideline does not consider the MTD.
When the MTD varies sharply with a small change in air flow, it pays to limit the number of rows and use
a lot of air. So, even though you may have a U value that requires, say 6 rows, the optimum design may
be 4 or 5 rows if the MTD is sensitive to air flow. Unfortunately, this is not easily determined beforehand
without working out some designs. You can check this with XACE or a size estimate program. Calculate
surface for 4 and 8 rows at the mean face velocity of Table 5. If the surface area varies by more than
1.6, try one less tube row than Table 4 suggests.
The optimum design for liquids in transition flow may be determined by the geometry that provides the
highest tube side coefficient. Laminar flow should be avoided and this may be more easily accomplished
with fewer rows and less surface area. Thus, even though the tube side coefficient dominates, you may be
driven to a design with few rows.
And finally, certain service conditions may determine the row arrangement to the exclusion of economics.
For example, it is desirable to have one row per pass for a water-washed condenser with two phases at
the inlet. This may be more easily achieved with 4-5 rows due to pressure drop, even though economics
could dictate more rows.
Table 5. Optimum Face Velocity, SFM
Use the lower end of the face velocity range for tube diameters greater than 1 inch with the standard tube
pitch. Use the high end of the face velocity range for a wide tube pitch where it is desirable to use more
air. Wide pitch may be useful for designs controlled by the MTD.
EXAMPLE
Design Basis:
Number of years for power evaluation = 3
Operating hours per year = 50 * 24 * 7 = 8400
Electricity cost = $0.083/kW h
Plant location = Alberta, Canada
Service = quench water bottoms cooler
Control = 50% VFD
Air cooler cost factors: plug header, 304 SS material, 200 psig design pressure, extruded fins,
winterization type 3
Air Cooler Design Guidelines Page 3-6
Design Optimization July 2012
Rev 6
Calculations:
• Step 1
See paragraph 3.1.1 and the italicized discussion
Annual average power use factor = 0.6.
Power cost = 3 * 8400 * 0.083 * 0.6 * 0.746 / (0.92 * 0.83) = 1230 $/design HP.
• Step 2
Using a pricing program to determine relative cost, an air cooler with the cost factors noted above will
be ~2.1 times more expensive than the base cost as defined in Table 1. The relative equipment cost for
this item is midway between high and medium.
• Step 3
Interpolating from Table 2, optimized power cost will be in the rage of 15-20% of the equipment cost.
• Step 4
The value of power is characterized as low to medium per Table 3.
• Step 5
The overall coefficient is estimated at 120 (US units)
• Steps 6-8
Four rows look to be optimum from Table 4. The sensitivity of MTD is not considered since we are
already at 4 rows. It is a good idea to bracket the preliminary guess. I would try these designs in XACE:
4 rows with face velocity in the range of 600-650
5 rows with face velocity in the range of 560-610
END OF EXAMPLE
Air Cooler Design Guidelines Page 4-1
General Design Guidelines July 2012
Rev 6
4.1.7 The optimum tube length to eliminate a cross mounting beam for piperack mounted units is noted
below:
Equipment Type Tube Length
Forced draft up to 30 ft (9.1 m) tube length Piperack width + 2 ft (0.6 m) +/-
Forced >30 ft (9.1 m) tube length Piperack width + 2 ft (0.6 m) if the piperack is a
double bay construction with two piperacks side
by side. Not applicable if the piperack is a single
bay. The unit will likely have a third column at
the middle of the tube length and a horizontal
beam is required.
Induced draft 1.25 to 1.5 times the piperack width
4.2 Bundle Layout
4.2.1 Use the following table to determine header type:
Header Type Fouling, US (SI) Design Pressure, psig (kPa)
Plug up to 0.003 (0.000525) <3000 (20,700)
Plug >0.003 (0.000525) 350-3000 (2,400-20,700)
Cover plate >0.003 (0.000525) <350 (2,400)
For design pressure greater than 3,000 psig (10,300 kPa), consult a vendor. A manifold or other
special type of header may be required.
4.2.2 The minimum clearance between fin tips is 0.25 inch (6.35 mm). A tighter pitch may be
considered for plant revamps that have a limited plot space.
This is good engineering practice to avoid fouling and facilitate cleaning. You could squeeze in a few
more tubes with a tighter pitch, but it is rarely worth the effort.
4.2.3 The pitch shall be staggered.
4.2.4 The standard tube layout and starting point for most designs is:
Tube OD Fin OD Tube Pitch
1 inch 2.25 inch 2.5 inch
(25.4 mm) (57.15 mm) (63.5 mm)
4.2.5 The tube pitch for bare tubes shall be 1.5 times the tube OD.
4.2.6 The standard number of rows for finned tubes is 4 to 8. Three rows may be used when surface
area requirements are low. When using more than 6 rows, provide a conservative air side design
to assure that the required airflow can be achieved.
Fluor has used up to 10 finned rows with a standard tube pitch, but these are special cases where plot
was cramped. Note that, the greater the number of rows, the harder it is to clean the fins.
4.3 Nozzles
4.3.1 The minimum number of process nozzles is 2 each for inlet and outlet connections on bundles
exceeding 8 ft (2.44 m) in width.
As a rough rule of thumb, pressure drop in the nozzles shall not exceed 10% of the allowable pressure
drop. Air cooler nozzles greater than NPS 4” are fabricated with an oval transition piece that is ½ the
nozzle diameter. Nozzles not greater than NPS 8” are preferred to limit the header width to 4”. Nozzle
Air Cooler Design Guidelines Page 4-3
General Design Guidelines July 2012
Rev 6
size is usually limited to NPS 12”for a 6”header width. Increase the number of nozzles (within practical
limits) if required to limit the nozzle size to NPS 12”.
4.4 Fouling
Fouling factors are usually specified by the Process Engineer. Fouling is usually omitted on the
air side.
Some typical tube side fouling factors are shown in the Tubular Exchanger Manufacturer’s Association
(TEMA) Standards for Shell and Tube Exchangers, but these are not universally accepted.
Air side fouling is a serious problem in areas where insects or other matrial can collect on the fins. For
example, poplar tree fluff is a nuisance in Alberta. It is much better to eliminate the problem with lint
screens than to allow for fouling with an air side fouling factor.
4.5 Pressure Drop
4.5.1 Allowable pressure drop shall be for clean conditions. Allowance for increased pressure drop due
to fouling shall be made by the Process Engineer using appropriate safety factors for the overall
hydraulic loop calculations.
The fouled pressure drop is used in the hydraulic loop calculations, while the exchanger is designed and
guaranteed for clean pressure drop. Fouled pressure drop calculations are a guess at best. Three ways
to apply a fouling margin follow:
1) Calculate the clean condition and then multiply by a reasonable safety factor based on the service and
starting shear stress.
2) Same as (1) above with safety margin based on the fouling factor. One user’s criterion is noted in the
table:
Fouling resistance (US Customary Units) Multiplication Factor
<0.002 on tube side with alloy tubes or carbon 1.1
steel in non-corrosive service
<0.002 on tube side where some pitting and 1.2
corrosion is expected
0.002 – 0.005 1.3
>0.005 1.5
3) Size the pump for extra flow, say 125% of design plus a control allowance. This, in effect, allows for a
fouled pressure drop of 150% of clean pressure drop at design flow.
4.5.2 Use the smooth tube friction factor for tube side pressure drop. Use the commercial pipe friction
factor if the tube is made from pipe or for existing units where if tube is expected to be corroded
or pitted.
The friction factor for pipe and slightly corroded tubes results in a tube side pressure drop up to 20%
higher than the smooth tube value. As noted in 4.5.1, the Process Engineer should use an appropriate
factor to allow for fouling and/or corrosion in new designs.
Air Cooler Design Guidelines Page 4-4
General Design Guidelines July 2012
Rev 6
5.1.2 Consult the user for fin preference in corrosive air side environments such as damp ocean air.
Embedded fins have a galvanic cell at the fin base which is corrosive if salt laden moisture forms on the
tube. For this reason, some users prefer a fin selection that covers the tube with aluminum. Extruded fins
provide this protection. Footed fins, although covered with aluminum are not favored by some users
because the fin bond degrades with time.
This writer sees no need for special protection in damp ocean air if the cooler is operating more or less
continuously throughout the year. Salt laden condensate can not form on the tubes when the fans are
operating. Some users require special protection as noted above, while others have successful experience
with embedded and footed fins. When special protection is required, the tube ends not covered by
aluminum shall have a suitable coating.
5.1.3 The standard nominal fin height is 0.625 inch (15.875 mm), up to 1.75 inch (44.45 mm) tube OD,
and 0.75 inch (19.05 mm) for 2 inch (50.8 mm) tube OD. 0.5 inch (13 mm) fin height may be
used where desired.
0.5 inch fins are used in winterization applications for higher tube skin temperature, or where the high
tube side resistance controls the design to the extent that excessive finned surface is not useful.
5.1.4 Fin density ranges from 6 to 11 per inch (276 to 433 per m). The standard density is 10 / inch
(394 / m). The use of 11 fins per inch is discouraged as they are more prone to fouling and harder
to clean.
Lower fin densities or bare tubes are used for the same reasons as lower fin height noted above.
5.1.5 Use the XACE default values for L-footed fins to rate knurled, footed fins.
The knurled fins will likely have higher static pressure drop and heat transfer coefficient, but the affect on
the rating is not appreciable.
5.1.6 Model extruded fins by using a pseudo base thickness that results in a fin cross sectional area
equal to the actual extruded fin.
Extruded fins have a tapered profile. The XACE program only accepts a straight profile. Specify the
actual tip thickness and a pseudo base thickness that results in a sectional area equal to the actual
extruded fin with tapered profile. The pseudo base thickness can be calculated using extruded fin
dimensions provided by a vendor. Typical profiles from Hudson Products and pseudo base thickness are
shown on the Extruded Fin Dimensions spreadsheet. There are four choices based on collar thickness.
The collar is the aluminum muff or sleeve before extrusion. Some vendors call this collar the “tube”. If
the fin choice is not known, assume a collar thickness of 0.17 inches. Thicker fins are used for plant sites
with severe erosion (blowing sand) or external corrosion. Fins starting with a collar thickness of 0.16
inch would be the most economical, but the resultant fins are thin and not recommended.
5.1.7 Base your design on the most economical fin type with the acceptable design range:
1) Use tension wound, footed fins when the temperature allows.
2) Use embedded fins:
a) Where tension wound, footed fins are not allowed and the tube material is carbon steel.
b) With stainless steel tubes where the temperature does not allow extruded fins.
3) Use extruded fins:
a) Where tension wound, footed fins are not allowed and the tube material is stainless steel
or other hard to embed materials.
b) Consider using extruded fins for damp ocean air environment. Review with the user.
Air Cooler Design Guidelines Page 5-3
Air Side Design July 2012
Rev 6
4) Use knurled, footed fins as an economic alternative to extruded or embedded fins. The
vendor list must have vendors that make this fin.
The fin selection is usually left to the vendor to make the most economical choice within allowable design
limits. You do not have to know the actual fin type to create a design. There are compensating effects
and the type of fin does not change the optimum design. However, if embedded fins, are probable, then
make your design on this basis. These fins require thicker tubes, and this affects tube side pressure drop.
Footed fins are the most economical, followed by knurled footed, embedded and extruded.
The cost of extruded versus embedded is a function of the current cost of aluminum relative to the tube
material cost. Tubes with extruded fins are one gauge thinner than the tubes with embedded fins, but
extruded fins have more aluminum. This tradeoff usually favors embedded fins for carbon steel. The cost
differential shrinks for more expensive materials like stainless steel. Where you can use either extruded
or embedded fins, and the tubes are carbon steel, base the design on embedded fins. This will likely be
the most economical fin and will also have the highest tube side pressure drop. If extruded fins are more
economical, the vendor will quote it, and allowable pressure drop is not exceeded. The difference in
thermal performance is negligible, other than tube side pressure drop. Use extruded fins with stainless
steel tubes because the cost differential relative to embedded fins is probably small or it may favor
extruded fins, and you will get a better fin bond.
5.1.8 The performance of extruded, serrated fins may be estimated by adding the following multipliers
to the heat transfer and pressure drop calculated as if the fin were smooth.
a) 1.15 times air side heat transfer coefficient
b) 1.60 times static pressure drop
The recommendation is from a test on a serrated fin with 10 fins / in and 24 circumferential cuts.
5.2 Fan Coverage
5.2.1 The face area of the fans must be equal to at least 40% of the nominal face area of the bundle
(API requirement).
Fan coverage of at least 45% is desirable for forced draft fans, but not mandatory.
5.2.2 There shall be at least two fans per bay (API requirement). This is the standard arrangement.
5.3 Power Requirements
5.3.1 (API requirement) The power required at the motor output shaft is the greater of:
PDR = 1.05 PW / E M
or
PDR = 1.1 PD
Where:
PDR = Drive rated power.
PW = Fan brake power at the winter design temperature with the blade angle set for the
design temperature.
PD = Fan brake power at the design air temperature.
5.3.2 Use a total efficiency of 60% for input to the XACE program. The resulting motor size is the
minimum allowed for the rated air flow. Motor size may be increased if required by the vendor.
The HTRI default value is 65%. This is a system efficiency that includes the belt drive as well as the fan.
Fan efficiency for the blade in a wind tunnel can be upwards of 85%. The fan blade efficiency then has to
be corrected for system effects such as fan tip clearance, entrance loss, sealing at the hub, and air leaks.
System losses may be understated by the fan manufacturers. Vendors typically predict total efficiency in
the range of 65 to 75%. We have measured system efficiencies in shop tests as low as 40%. It is prudent
to be conservative here, and even 60% total fan efficiency may be too high. The motor size resulting with
60% efficiency should be the minimum size allowed, even though the vendor may think a smaller size is
adequate.
Note that total fan efficiency is based on static plus velocity pressure drop. This is the value used by
XACE. Static fan efficiency is based only on static pressure drop. The velocity pressure calculated by
XACE is based on an assumed hub size which is frequently too small. Thus, the calculated velocity
pressure is too low, and we have another reason to use conservative fan efficiency.
5.3.3 Specify the minimum motor size and the required airflow rate on the data sheet. Do not specify
the static pressure drop. Let the vendor calculate this.
5.3.4 The maximum motor sizes are:
Fan Diameter Maximum Motor Size
Up to 11ft (3.35 m) 30 HP (22 kW)
>11 ft (3.35 m) 60 HP (45 kW)
API 661 requires gears on motor sizes greater than 60 HP. Gears are expensive and are avoided for the
normal range of process industry applications. The 30 HP limit on fans less than or equal to 11 ft will
help to keep you out of trouble with respect to noise, or the ability to deliver the required airflow. This is
a soft guideline that can be exceeded if necessary to provide the required airflow. Check noise, and
provide a conservative fan/motor selection to insure delivery of the required air flow
5.3.5 API 661 requires Pw (see 5.3.1) to be evaluated at the minimum ambient temperature. For units
with enclosed warm air recirculation, you can, by agreement with the owner, use the minimum
plenum temperature, rather than the minimum ambient temperature.
There is little harm in operating the motors at greater than nameplate power for a short time at cold
startup. Using the minimum plenum temperature in lieu of the minimum ambient temperature typically
results in the motor being one standard size smaller for cold climates.
Air Cooler Design Guidelines Page 5-5
Air Side Design July 2012
Rev 6
5.4 Noise
The user shall specify the maximum noise level. If the noise level is not specified assume that the
maximum sound pressure level shall be 85 dBA, measured 3 feet (1 m) from the fan ring.
5.5 Approach Velocity
5.5.1 Air approach velocity not exceeding 800 SFM (4.1 m/s) is desireable. This is a rule-of-thumb for
good air-side distribution, and to mitigate air side fouling and summertime exhaust air
recirculation. A lower approach velocity, say 550 SFM (2.8 nominal m/s), may be in order with
blowing sand or other concerns that would dictate a low air velocity to the air cooler. The
minimum approach velocity requirement may be waived if the resultant column height makes
motor maintenance difficult (for example, for piperack mounted units with solid floors). Consult
the user. Fluor recommends providing the desirable face velocity, even if extended column
height is required.
5.5.2 The approach area for grade mounted units is the net free area for airflow at the periphery of the
air cooler bank from the side frame to grade. The approach area for piperack mounted units is the
net free area for airflow at the periphery of the air cooler bank from the side frame to the motor
maintenance platform elevation. The net free open area at the platform elevation may also be
included as long as it is nominally unobstructed for airflow.
The standard column height provides headroom under the fan ring (for forced draft), but should not be
too tall to provide easy access to the motors. Pipe rack mounted units with solid floors or units at grade
with long tube length and many bays in a bank will need extended column height to satisfy the minimum
approach velocity requirement. The approach velocity of piperack mounted units with open floors is
always very low and not a problem.
Inlet louver open area is ~80% of the gross louver area.
Extended column height at grade is not a problem. Something can be rigged to provide access to the
motors. However, pipe rack mounted units with extended columns may be more problematic. Consult the
user to determine the requirements.
Air coolers with external warm air recirculation are an example where solid floors are provided on the
pipe rack. Warm air recirculation may also be provided with louvers in the floors, or other arrangements
that provide increased airflow in the summer.
5.6 Hot Air Recirculation
5.6.1 See the article “Hot Air Recirculation …” in Appendix A for some guidelines on proper plot
arrangement to avoid hot air recirculation.
5.6.2 Where hot air recirculation is a concern use induced draft, or if using forced draft, increase the
design air temperature for critical services.
The amount of duty lost for each degree of air rise can be estimated as follows:
% duty loss for each ºF of air temperature rise = 55 / MTD
% duty loss for each ºC of air temperature rise = 31 / MTD
Forced draft units with a poor plot layout are susceptible to hot air recirculation
5.7 Static Pressure Drop
The static pressure drop shall not exceed 0.800 inches water pressure. A maximum of 0.700 is preferred.
This is a soft guideline that can be exceeded if necessary to provide the required airflow in special
circumstances, such as plant revamps, or new plants where power cost has no value. Check noise, and
provide a conservative fan/motor selection to insure delivery of the required air flow.
Air Cooler Design Guidelines Page 5-6
Air Side Design July 2012
Rev 6
Another desirable design feature is annular flow. This flow regime results in liquid coating the entire
surface. Try to do this for effluent coolers. However, it is impractical for the entire tube length of
overhead condensers, or for some turndown cases.
Air Cooler Design Guidelines Page A-1
Appendix A April 2012
Rev 6
APPENDIX A
Recommended Literature