EXH-DU-5142-B.

HEAT EXCHANGER DESIGN

APPLICATION: ONSHORE, TOPSIDES

This document is the confidential property of Chevron U.S.A. Inc. and its
affiliates. When made available to any contractor providing services to
Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this document
shall be governed by the confidentiality provisions of the applicable
contract or bid package. Without limiting the foregoing, neither the whole
nor any part of this document may be disclosed by the contractor to any
third party, other than an affiliate of the contractor that requires this
information for purposes of the contract with the Chevron entity, without
the prior written consent of the Chevron entity that has disclosed this
document to the contractor. When requested by Chevron U.S.A. Inc. or its
disclosing affiliate, the contractor must return all copies of this document
to the Chevron entity requesting such return and delete any electronic
copies from the contractor’s systems.

Any and all modifications (changes, amendments, etc.) to this document

must follow approved Chevron Engineering Standards governance
processes.

Rev Date Description Author Sponsor

A 06/08 General revision. RPHO RPHO
B 08/11 General revision. RPHO RPHO
B.1 09/15 Technical modification: Replaced references to R.P. Hohmann B. Whitsitt
EXH-SU-9.06 with EXH-SU-4870; replaced
references to EXH-SU-9.02 with EXH-SU-1826.
— 12/15 (E) Errata change: Title changes for EXH-SU-5110 n/a n/a
and EXH-SU-4766. No technical content
change.

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Heat Exchanger Design EXH-DU-5142-B.1

CONTENTS

1.0 Scope ..........................................................................................................................3

2.0 References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3
3.0 Acronyms ....................................................................................................................4
4.0 Process Definition and Considerations ...................................................................4
5.0 Stream Data ................................................................................................................6
6.0 Materials of Construction ..........................................................................................7
7.0 Thermal Design ..........................................................................................................8
8.0 Stream-Specific Considerations ...............................................................................9
9.0 Service-Specific Considerations ............................................................................10
9.1 ......Shell and Tube Exchangers with Single-Phase Streams ...............................10
9.2 ......Shell and Tube Exchangers with Two-Phase Streams ..................................11
9.3 ......Shell and Tube Reboilers ...............................................................................11
9.4 ......Shell and Tube Condensers ...........................................................................12
9.5 ......Air Coolers for Single-Phase Streams ............................................................13
9.6 ......Air Coolers for Two-Phase Streams ...............................................................14
9.7 ......Air-Cooled Condensers ..................................................................................14
9.8 ......Water-Cooled Surface Condensers ...............................................................15
9.9 ......Plate Exchangers ...........................................................................................16
9.10 ....Small Heat Exchangers ..................................................................................16
10.0 Mechanical Considerations .....................................................................................16
11.0 Deliverables ..............................................................................................................18

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Heat Exchanger Design EXH-DU-5142-B.1

1.0 SCOPE
1. This document identifies the design requirements to be followed for shell and tube exchangers,
air coolers, multi-tube hairpins, double pipes, water cooled-surface condensers, and plate heat
exchangers.
2. Use this specification in conjunction with the appropriate documents referenced in
Sections 2.1 and 2.2. Materials specifications are selected based on the exchanger type
(e.g., shell and tube, air cooled) and for the particular type of facility (onshore, offshore
platform, or floating).
3. This specification identifies information that Purchaser (or designated process licensor) shall
provide to the Exchanger Designer to allow for complete process and thermal design, partial
mechanical design, cost estimates, and troubleshooting of existing heat exchangers.

2.0 REFERENCES
1. The following documents are referenced herein and are to be considered part of this
specification.
2. Unless otherwise specified in Section 2.1 or 2.2, use the latest edition of the referenced
documents.

2.1 Purchaser Documents

EXH-SU-9.00 Shell and Tube Heat Exchangers – Exception to API 660, 2007
EXH-SU-1826 Air-Cooled Heat Exchangers – Exception to API 661, 2013
EXH-SU-2583 Shell and Tube Heat Exchangers for General Refinery Service – Exception
to API 660, 2007
EXH-SU-4764 Shell-and-Tube Heat Exchangers Using Special Materials or Thick Wall
Construction – Exception to API 660, 2007
EXH-SU-4766 Double Pipe and Multi-Tube Hairpin Heat Exchangers - Exception to API
663, 2014
EXH-SU-4870 Plate-and-Frame Heat Exchangers – Exception to API 662, Part 1; 2006
EXH-SU-5110 Brazed Aluminum Heat Exchangers for General Cryogenic Service –
Exception to ALPEMA, 2010 with Amendments May 2012
EXH-SU-5162 Core-in-Shell Heat Exchangers
[EXH] GC-E1048 Allowable Unsupported Tube Lengths in Shell and Tube Heat Exchangers
[PVM] GF-C13950 Baffle Arrangement for Columns with Reboilers

2.2 Industry Codes and Standards

American Petroleum Institute (API)
Std 662 Plate Heat Exchangers for General Refinery Services
Part 1—Plate-and-Frame Heat Exchangers
Part 2—Brazed Aluminum Plate-fin Heat Exchangers
Heat Exchange Institute (HEI)
Standards for Steam Surface Condensers, 10th Edition
Tubular Exchanger Manufacturers Association, Inc. (TEMA)

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Heat Exchanger Design EXH-DU-5142-B.1

Ninth Edition of the Standards of the Tubular Exchanger Manufacturers Association

3.0 ACRONYMS
BEDD—Basic Engineering Design Data
BWG—Birmingham Wire Gauge
CCR—Continuous Catalytic Reformer
CGG—Corrugated Gasket, Graphite-covered
CMG—Corrugated Metal Gasket
CW—Cooling Water
FPSO—Floating, Production, Storage, and Offloading
HTRI—Heat Transfer Research, Inc.
ID—Inside Diameter
MAWP—Maximum Allowable Working Pressure
MDMT—Minimum Design Metal Temperature
MPMT—Minimum Pressurizing Metal Temperature
NPSH—Net Positive Suction Head
NTIW— No Tube in Window
OD—Outside Diameter
PO—Purchase Order
QA/QC—Quality Assurance/Quality Control
SIS—Safety Information Sheet

4.0 PROCESS DEFINITION AND CONSIDERATIONS

1. Purchaser shall specify the type of exchanger. Examples include the following:
a. Shell and tube
b. Multi-tube hairpin
c. Double pipe
d. Air cooler
e. Water-cooled surface condenser
f. Plate
g. Brazed aluminum (plate fin)
2. Purchaser shall define the range of operating conditions.
3. Exchanger Designer shall provide design case simulations to Purchaser prior to finalizing
exchanger geometry.
4. Purchaser shall define any additional operating cases that require rigorous simulation (for
example, air cooler performance with fans off [power lost] or fan power draw at winter
conditions).

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Heat Exchanger Design EXH-DU-5142-B.1

5. Purchaser shall identify and describe any potential fouling mechanisms that could constrain
design.
6. Exchanger Designer shall prepare the design as directed, offering alternatives that reduce
equipment cost or improve reliability.
7. Novel heat transfer technologies (e.g., tube inserts, coatings, finning, twisted tubes, helical
baffles, triple segmental baffles, plate, spiral plate, or other enhancements) shall not be used
unless reviewed and accepted by Purchaser.
8. Shell and tube exchangers shall have removable bundles unless specifically waived in writing
by Purchaser.
9. Air coolers shall be forced-draft type unless overcooling during rain storms is a problem or
design relief loads would be significantly reduced by using induced-draft type (superior
performance with fans off).
Note Column overhead condensers and refrigerant condensers are frequently
induced-draft type. Induced-draft air coolers are generally specified for LNG plants.
10. Purchaser shall designate the case with the largest shellside volumetric flowrate as “for
vibration analysis.”
11. Baffling and tube support in shell and tube exchangers shall comply with GC-E1048.
12. Exchanger Designer shall place streams as specified in Table 1 for shell and tube exchangers.
a. Stream routing shall be based on total (equipment, installation, operating, and
maintenance) cost considerations.
b. Exceptions to recommendations in Table 1 shall be reviewed and accepted by Purchaser.

Table 1: Allocating Streams for Shell and Tube Heat Exchangers (1 of 2)

In Order of Decreasing Priority
Stream Property Compared to Route Stream
Reason for This Choice
Other Stream Shell Tube
Match coefficients and pumping power - - Minimizes cost.
Lower film coefficient expected X Enhance (fin) outside surface to raise
(hshell / htube <0.3) limiting side coefficient (single-phase gas
only).
Condensing - - Determined by coolant.
Treated cooling tower water X Corrosion inhibitors effective tubeside;
otherwise, alloy tubes shall be used.
Viscosity above 5 cP X Staggered tube layout induces good heat
transfer at low Reynolds number.
Alloy required for corrosion X Allows less costly shellside components.
Very low system pressure or P X Switching from E to J or X (TEMA) shell
available style shortens flow path and reduces
pressure drop.
High system pressure X Reduces shell thickness; however, tube
rupture design sometimes controls.
High T across one bundle X Excessive T in stationary tubesheet if
(> 200°F [110°C]) placed on tubeside.

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Heat Exchanger Design EXH-DU-5142-B.1

Table 1: Allocating Streams for Shell and Tube Heat Exchangers (2 of 2)

In Order of Decreasing Priority
Stream Property Compared to Route Stream
Reason for This Choice
Other Stream Shell Tube
Normal fouling - - Does not matter (hydroblasting effective
both sides).
Deposits too hard to hydroblast (rare) X Uses floating rear head for straight tubes.
Complete tube plugging (rare) X Uses floating rear head for straight tubes.

13. Purchaser shall provide the following information for design consideration:
a. Process constraints, including the following:
1) Available pressure drop.
2) Minimum return pressure, e.g., limited by steam condensate header or downstream
pump net positive suction head (NPSH).
3) Minimum or maximum rundown temperatures.
b. Hydraulic requirements, particularly for treated cooling water (CW) and hot oil services.
(Exchanger Designer shall calculate CW and hot oil consumption to determine flow rate
of the utility stream.)
c. Process control scheme, including how duty shall be controlled (e.g., by flow bypass, by
throttling inlet of a condensing heating medium, or by backing up a stagnant pool of liquid
into the exchanger).
14. Exchangers in parallel shall not be used unless they are used to meet one or more of the
following criteria:
a. Conform to weight, size, and diameter limitations.
b. Accommodate wide operating range.
c. Meet online cleaning requirements.
15. Exchanger Designer shall identify the requirements for liquid subcooling and determine
whether a separate subcooler designed for higher velocity is economical.
16. Exchanger Designer shall use two separate exchangers to vaporize and then superheat streams.

5.0 STREAM DATA

1. Purchaser shall provide physical and thermal properties for both streams over the entire
operating range of the exchanger.
2. If stream is multi-phased, properties shall be provided for each phase present—vapor, liquid,
or solid.
3. Purchaser shall define composition of each stream as pure component, multi-component,
hydrocarbon, aqueous, etc. This shall include water and noncondensible gas content.
4. For multiphase (two-phase, boiling, and condensing) streams, Purchaser shall provide the
following additional information:
a. Weight fraction/percent vapor curve
b. Vapor molecular weight curve
c. Total stream enthalpy curve

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Heat Exchanger Design EXH-DU-5142-B.1

d. Latent heat of vaporization (boiling only)

e. True (not pseudo) critical pressure and temperature (boiling only)
f. Surface tension (enhanced heat transfer surface or boiling)
5. Properties normally shall not be provided for air and single-component streams (such as pure
water liquid or steam) unless requested by Exchanger Designer.
6. Purchaser shall identify presence of mercury, hydrogen sulfide, acids, chlorides, etc., and
potential for hydrates formation.
7. Purchaser shall identify presence of any surface active agents, such as corrosion inhibitors,
filming amines, antifoulants, oxygen scavengers, or antifoams.

6.0 MATERIALS OF CONSTRUCTION

1. Materials selection shall be consistent with both normal and periodic operating conditions.
2. If not specified, materials requirements for the following items shall be selected by Exchanger
Designer, and shall be reviewed and accepted by Purchaser:
a. Tubes
b. Fins
c. Shell
d. Shell cover
e. Channel components
f. Floating head
g. Tubesheets
h. Baffles
i. Bundle components (tie rods, seal strips, flexible seals)
j. Impingement device
3. Tube gauge (minimum Birmingham Wire Gauge [BWG] for carbon steel and average BWG
for alloys) shall be specified by Exchanger Designer.
a. Corrosion allowance shall not be applied for tube thickness calculations.
b. Minimum tube thickness for 3/4-inch (19-mm) outside diameter (OD) tubes shall be
14 BWG (min) for carbon steel and 16 BWG (average) for alloy. Thinner tubes
(particularly if titanium) may be used only if reviewed and accepted by Purchaser.
c. Minimum tube thickness for 1-inch (25.4-mm) OD carbon steel tubes shall be 12 BWG
(min).
4. Corrugated metal gaskets (CMGs), also known as corrugated gasket, graphite-covered (CGG)
metal gaskets, shall be specified for each of the following joints and connections (exceptions
shall be reviewed and accepted by Purchaser):
a. Channel cover to channel
b. Channel to stationary tubesheet
c. Shell to stationary tubesheet
d. Shell cover
e. Floating head

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Heat Exchanger Design EXH-DU-5142-B.1

5. Corrosion allowance shall be indicated for components.

a. Zero corrosion allowance shall be used for tubes, alloys, alloy lining, overlay, and clad.
b. A 1/8-inch (3.2-mm) minimum corrosion allowance shall be applied to components made
of carbon and low alloy steels.
c. Purchaser shall request any other allowances in writing.

7.0 THERMAL DESIGN

1. An exchanger shall be designed based on excess area or capacity requirements set by
Purchaser.
a. Excess area (usually a percent) shall be defined as the ratio of clean to service overall heat
transfer coefficients with 1.0 subtracted (multiplied by 100 for percent).
b. For reboilers, duty required to flood the distillation tower shall be specified as the capacity
requirement.
c. For designs, the resulting fouling allowance shall be back-calculated.
d. Service or stream fouling factor tables shall not be used.
2. Thermal requirements shall also include fouling factors for known asymptotic fouling streams
(i.e., treated cooling water, streams contaminated with filming amines) and for linear fouling
streams (i.e., untreated seawater, river water, brackish water). Exchanger Designer shall
contact Purchaser for guidance on choosing the appropriate fouling factors or rates.
3. Heat exchangers shall be designed and simulated with the appropriate Heat Transfer
Research, Inc. (HTRI) software.
a. Exchanger Designer shall generate data for design cases, turndown cases, and other cases
that provide information to properly assess any special control or operating requirements.
b. Exceptions to using HTRI shall be reviewed and accepted by Purchaser. Typical
exceptions follow:
1) For brazed aluminum (plate fin) exchangers, the Aspen Technology MUSE software
or Honeywell software shall be used.
2) For high-pressure hydrogen/hydrocarbon liquid mixtures (two-phase streams),
Purchaser’s proprietary methods shall be used.
4. Tube size for shell and tube exchangers shall be 3/4 inch (19 mm) OD.
a. Larger diameter tubes shall be acceptable and appropriate to manage pressure drop or
increase natural circulation.
b. Tubes smaller than 3/4 inch (19 mm) OD shall not be used unless accepted by Purchaser.
5. Rotated square (45-degree) layout angle shall be used for liquids and two-phase streams.
6. Square (90-degree) layout angle shall be used for condensing, boiling, and single-phase gas
streams.
7. Triangular pitch shall not be used for shell and tube exchangers unless reviewed and accepted
by Purchaser.
8. Tube pitch for shell and tube exchangers shall provide a minimum 1/4-inch (6.3-mm) gap
between tubes to allow for hydroblasting and inspection.
9. Tube size for air coolers shall be 1 inch (25.4 mm) OD.
a. Smaller tubes may be used for very clean services like lube oil coolers.

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Heat Exchanger Design EXH-DU-5142-B.1

b. Larger diameter tubes are infrequently used, but may be necessary to keep below the
allowable pressure drop.
Note Typical tube for air coolers is finned at 10 fins per inch (390 fins per meter) with high
fins 5/8 inch (16 mm) in height.
10. Double-pipe and multi-tube hairpin configurations shall be used when stream volumetric rates
are small.

8.0 STREAM-SPECIFIC CONSIDERATIONS

1. Streams shall be treated as potentially corrosive and containing foulants unless Purchaser
specifies otherwise.
2. Exchanger Designer shall confirm that shear stress is sufficient to prevent particulate
settling/fouling, even at turndown conditions. For liquid shellside or tubeside, shear stress
shall exceed 0.0006 psi (4 Pa) over entire operating range.
Note For flow inside tubes, shear stress is calculated as pressure drop divided by flow path
length times the inside diameter (ID) divided by 4 (in consistent units). For other
geometries, ID is replaced with hydraulic diameter.
3. Local site requirements (basic engineering design data [BEDD] documents) shall be consulted
for the following:
a. Treated cooling water summer and winter design temperature and available pressure drop
at the exchanger.
Note Cooling water distribution and flow are based on system hydraulics; Purchaser
specifies the actual available or design pressure drop (not flow rate).
b. Ambient air summer and winter design temperature and humidity for air cooler design and
motor sizing.
c. Available steam and condensate return header pressures at the exchanger.
4. Treated cooling tower water shall be allocated tubeside.
a. Calculated (actual) pressure drop shall be equal to available pressure drop.
b. CW rate shall be determined by hydraulics and shall not be directly controlled.
c. Maximum tubewall temperature shall be below 160°F (70°C) or colder if recommended
by treatment system provider.
5. Process streams shall not be cooled to within 5°F (3°C) of water coolant when using shell and
tube coolers unless reviewed and accepted by Purchaser.
6. Process streams shall not be cooled to within 20°F (10°C) of design ambient air temperature
when using air coolers unless reviewed and accepted by Purchaser.
7. Closed loop cooling systems shall be charged with distilled water or condensate so that no
fouling factor is required. Water source requirement shall be specified in the design data sheet.
8. Seawater or river water shall be sterilized with hypochlorite, chlorine, or equivalent so that no
fouling factor is required.
a. Water sterilization shall be specified in the design data sheet.
b. Exchanger Designer shall confirm that metallurgy of water-wetted components is resistant
to oxygen attack.

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Heat Exchanger Design EXH-DU-5142-B.1

c. Carbon steel shall not be used unless reviewed and accepted by Purchaser.
9. When using steam for heating, the following requirements shall apply:
a. Inlet steam shall be throttled for process control.
b. Condensate line shall provide free draining of condensate to a receiver (condensate pot);
this shall be specified in the design data sheet.
c. Turndown operation shall be evaluated; minimum steam operating pressure shall be
specified in the design data sheet.
d. High side vent connection shall be required and so specified in the design data sheet.
10. Hydrogen service shall be specified in the design data sheet if normal operating conditions are
at or above 100 psia (700 kPaa) hydrogen partial pressure.
11. Wet hydrogen sulfide (H2S) service shall be specified in the design data sheet if normal
operating conditions include free liquid water phase and any of the following:
a. Vapor phase H2S partial pressure of 0.25 psia (1.7 kPaa) or more.
b. Water phase containing 50 ppm (or more) by weight H2S.
c. Liquid hydrocarbon phase containing 250 ppm (or more) by weight H2S.
12. When water is injected into a process hydrocarbon stream for corrosion or fouling control, the
design data sheet shall specify that liquid properties are for hydrocarbon liquid only. Accurate
mixed stream enthalpy and weight fraction vapor curves shall be used.
13. Purchaser shall alert Exchanger Designer to special considerations (such as risk hydrate
formation, auto-refrigeration during stream depressurization, mercury contamination, or
velocity limit to avoid corrosion/erosion) that may influence mechanical design or materials
selection.

9.0 SERVICE-SPECIFIC CONSIDERATIONS

9.1 Shell and Tube Exchangers with Single-Phase Streams

1. A horizontal TEMA AEU configuration shall be used unless otherwise reviewed and accepted
by Purchaser. (TEMA floating head type [S or T] shall be specified if straight tubes are
preferred per local site requirements [BEDD documents].)
2. Viscous fluid (viscosity above 5 cP) shall be placed shellside to enhance heat transfer.
3. Tube count and tube passes shall be configured to achieve economic velocity of
6 to 9 ft/s (2 to 3 m/s) for liquids routed tubeside.
4. Central baffle type and spacing shall be configured to achieve economic cross-flow velocity of
2 to 3 ft/s (0.7 to 1 m/s) for liquids routed shellside.
5. Tube length shall be limited to 20 feet (6.1 m) maximum unless reviewed and accepted by
Purchaser.
a. Shorter tubes shall be acceptable, but shall be standard TEMA lengths.
b. Exchangers shall be used in series to meet velocity targets while providing appropriate
surface area for heat transfer.
6. Potential fouling mechanisms shall be prevented over the entire operating range. (TEMA
standards describe various fouling mechanisms.)

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Heat Exchanger Design EXH-DU-5142-B.1

7. Shell and tube heat exchangers in general refinery service shall comply with EXH-SU-2583,
and EXH-SU-4764 shall apply for high-pressure conditions.
8. Shell and tube heat exchangers in offshore and floating, production, storage, and offloading
(FPSO) service shall comply with EXH-SU-9.00.

9.2 Shell and Tube Exchangers with Two-Phase Streams

Note Two-phase streams are mixtures of gas and liquid with little phase change; examples are
feed/effluent exchangers in reformer, hydroprocessing, and lube oil units.
1. Exchanger style (shell and tube or plate), orientation (horizontal or vertical), and TEMA type
shall be determined in collaboration with Purchaser.
2. U-tubes shall be preferred for horizontal units, especially when high pressure closures are
necessary.
3. Requirements in Section 9.9 shall apply if plate style is selected.
Note Start by trying E shells in series to provide effective temperature driving force. For
hydroprocessing and continuous catalytic reformer (CCR) services, which have relatively
clean streams, TEMA F shells are economical and acceptable. For a CCR, the combined
feed/effluent is typically a vertical PACKINOX plate exchanger.
4. Viscous fluid (viscosity above 5 cP) shall be placed shellside to enhance heat transfer.
5. Tube count and tube passes shall be configured to achieve shear controlled flow regime
(HTRI Cg below 0.3) over entire operating range for tubeside fluid.
6. Baffling shall be configured to achieve shear controlled flow regime (HTRI Cg below 0.3)
over entire operating range for shellside fluid.
7. Tube length for horizontal units shall be limited to 20 feet (6.1 m) and for vertical units shall
be limited to 80 feet (24.4 m) maximum unless reviewed and accepted by Purchaser.
a. Shorter tubes shall be acceptable, but shall be standard TEMA lengths when
20 feet (6.1 m) or less.
b. Exchangers in series shall be used to meet flow regime requirements while providing
appropriate surface area for heat transfer.
8. Potential fouling mechanisms shall be prevented over entire operating range. (TEMA
standards describe various fouling mechanisms.)
9. Shell and tube heat exchangers in general refinery service shall comply with EXH-SU-2583,
and EXH-SU-4764 shall apply for high-pressure conditions.
10. Shell and tube heat exchangers in offshore and FPSO service shall comply with
EXH-SU-9.00.

9.3 Shell and Tube Reboilers

1. The style of reboiler shall be determined in collaboration with Purchaser (e.g., kettle, forced
flow, once-through or circulating thermosiphon, horizontal or vertical orientation).
Note Reboiler style depends on boiling range, operating pressure, reduced pressure, and
local preference.
2. TEMA configuration shall be selected based on style.

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Heat Exchanger Design EXH-DU-5142-B.1

3. TEMA T-type heads shall be used for vertical in-tube reboilers.

4. Floating tubesheets for vertical in-tube reboilers shall be positioned as follows:
a. For condensing heating media, floating tubesheets shall be well down into the shell head.
b. For sensible-heating media, floating tubesheets shall be adjacent to the shellside inlet
nozzle.
5. Boiling shall always be in nucleate or flow boiling regime.
6. Geometry shall be configured to achieve economic velocity (see Section 9.1 item 3 and
item 4) and for single-phase liquid heating medium.
7. The control scheme shall be evaluated over specified operating range.
a. The following requirements apply to steam-heated services:
1) Steam inlet shall be throttled to control pressure (produces corresponding change in
condensing temperature).
2) Condensate shall freely drain to receiver/condensate pot.
3) Condensate pot shall be on level control with pump if needed.
4) Turndown condition requirements shall be checked.
b. The following requirements apply to sensible-heating media:
1) Turndown operation shall be checked.
2) Hot stream shall be routed co-current with boiling fluid unless otherwise accepted by
Purchaser.
8. Potential fouling mechanisms shall be prevented over entire operating range. (TEMA
standards describe various fouling mechanisms.)
9. Inlet and outlet lines and layout piping shall be sized by Exchanger Designer for both
thermosiphons with bottom re-circulation and head driven once through reboilers.
10. Line sizing and layout shall not be required from Exchanger Designer for kettle and
forced-flow styles.
11. Distillation column bottom compartment shall comply with GF-C13950 when a recirculating
thermosiphon reboiler (vertical or horizontal) is specified.
12. Shell and tube heat exchangers in general refinery service shall comply with EXH-SU-2583,
and EXH-SU-4764 shall apply for high-pressure conditions.
13. Shell and tube heat exchangers in offshore and FPSO service shall comply with
EXH-SU-9.00.

9.4 Shell and Tube Condensers

1. Streams shall be allocated depending on coolant (see Table 1).
2. If condensing shellside, Exchanger Designer shall progress from TEMA E to J to X-type shells
in order to meet pressure drop restrictions.
3. Likewise, for baffling, Exchanger Designer shall try single, then double segmental, then no
tube in window (NTIW).
4. If condensing tubeside, horizontal or vertical orientation shall be selected based on installed
cost.

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Heat Exchanger Design EXH-DU-5142-B.1

5. Geometry shall be configured to achieve economic velocity (see Section 9.1 item 3 and
item 4) for sensible (single-phase) cooling medium.
6. Condenser design shall be consistent with control scheme.
a. Sufficient area shall be allowed for subcooling if a backup condenser is used.
b. Process outlet shall be sized for free drainage (and open channel flow if noncondensibles
escape through single outlet).
7. Vent for noncondensibles opposite liquid outlet for horizontal condensers shall be specified in
the design data sheet.
8. Exchanger Designer shall confirm that potential fouling mechanisms are prevented over entire
operating range. (TEMA standards describe various fouling mechanisms.)
9. Shell and tube heat exchangers in general refinery service shall comply with EXH-SU-2583,
and EXH-SU-4764 shall apply for high-pressure conditions.
10. Shell and tube heat exchangers in offshore and FPSO service shall comply with
EXH-SU-9.00.

9.5 Air Coolers for Single-Phase Streams

1. Forced-draft units shall be used to reduce installed and maintenance cost.
2. Local site requirements (BEDD documents) shall be consulted for design summer and winter
air temperatures.
3. A different exchanger type shall be considered if cooling a viscous fluid (viscosity
above 5 cP).
4. Tube count and tube passes shall be configured to achieve economic velocity of
6 to 9 feet (2 to 3 m) for liquids.
5. Fin type shall be selected in collaboration with Purchaser.
a. Fins shall be smooth integral (extruded) or embedded unless otherwise accepted by
Purchaser.
b. Spiral wound (L-footed, overlapped, or knurled) and serrated (or enhanced) fins shall not
be used unless accepted by Purchaser.
6. Winterization shall be specified in the design data sheet where indicated by local site
requirements (BEDD documents).
7. For high pour point fluids (pour point above ambient temperature), Exchanger Designer shall
specify steam coil to be installed to warm inlet air.
8. Drives shall be variable speed (or frequency) for fans unless otherwise accepted by Purchaser.
9. Exchanger Designer shall confirm that potential fouling mechanisms are prevented over entire
operating range. (TEMA standards describe various fouling mechanisms.)
10. Air coolers for general refinery and FPSO service shall comply with EXH-SU-1826.

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9.6 Air Coolers for Two-Phase Streams

Note Two-phase streams are mixtures of gas and liquid with little phase change. Effluent
coolers are an example.
1. Induced draft shall be used to reduce impact of a rainstorm on control and provide significant
cooling in the event of a power outage, unless otherwise accepted by Purchaser.
2. Local site requirements (BEDD documents) shall be consulted for design summer and winter
air temperatures.
3. A different exchanger type shall be considered if cooling a viscous fluid (viscosity
above 5 cP).
4. Tube count and tube passes shall be configured to achieve shear controlled flow regime
(HTRI Cg below 0.3) over entire operating range.
5. Piping to and from multiple bays shall be symmetrical to ensure equal flow distribution.
6. If requested by Purchaser, connections for aqueous stream injection shall be specified in the
design data sheet.
7. Purchaser shall determine potential for fouling or corrosion, and shall identify location of
injection points likely to be installed on piping.
8. Fin type shall be selected in collaboration with Purchaser.
a. Fins shall be smooth integral (extruded) or embedded unless otherwise accepted by
Purchaser.
b. Spiral wound (L-footed, overlapped, or knurled) and serrated (or enhanced) fins shall not
be used unless accepted by Purchaser.
9. Winterization shall be specified in the design data sheet where indicated by local site
requirements (BEDD documents).
10. For high pour point fluids (pour point above ambient temperature), Exchanger Designer shall
specify steam coil to be installed to warm inlet air.
11. Drives shall be variable speed (or frequency) for fans unless otherwise accepted by Purchaser.
12. Exchanger Designer shall confirm that potential fouling and corrosion mechanisms are
prevented over entire operating range. (TEMA standards describe various fouling
mechanisms.)
13. Air coolers for two-phase flow in refinery and FPSO service shall comply with
EXH-SU-1826.

9.7 Air-Cooled Condensers

1. Induced draft shall be used to reduce impact of a rainstorm on control and provide significant
cooling in the event of a power outage, unless otherwise accepted by Purchaser.
2. Consult local site requirements (BEDD documents) for design summer and winter air
temperatures.
3. A different exchanger type shall be considered if condensing generates a viscous liquid phase
(viscosity above 5 cP).

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Heat Exchanger Design EXH-DU-5142-B.1

4. Tube count and tube passes shall be configured to achieve effective heat transfer.
Note The number of tubes per pass usually varies for wide condensing-temperature-range
fluids (especially when subcooling condensate). Allowing higher pressure drop
reduces size and cost.
5. If requested by Purchaser, connections for aqueous stream injection shall be specified in the
design data sheet.
6. Winterization shall be specified in the design data sheet where indicated by local site
requirements (BEDD documents).
7. For high pour point fluids (pour point above ambient temperature), Exchanger Designer shall
specify steam coil to be installed to warm inlet air.
8. Purchaser shall determine potential for fouling or corrosion, and shall identify location of
injection points (likely to be installed on piping).
9. Fin type shall be selected in collaboration with Purchaser.
a. Fins shall be smooth integral (extruded) or embedded unless alternatives are reviewed and
accepted by Purchaser.
b. Spiral wound (L-footed, overlapped, or knurled) and serrated (or enhanced) fins shall not
be used unless reviewed and accepted by Purchaser.
10. Drives shall be variable speed (or frequency) for fans unless alternative is reviewed and
accepted by Purchaser.
11. Exchanger Designer shall confirm that potential fouling and corrosion mechanisms are
prevented over entire operating range. (TEMA standards describe various fouling
mechanisms.)
12. Air coolers for general refinery and FPSO service shall comply with EXH-SU-1826.

9.8 Water-Cooled Surface Condensers

1. Coolant (treated cooling water, seawater, etc.) shall be allocated tubeside.
2. Exchanger Designer shall confirm that the number of tube passes and calculated velocity are
consistent with system hydraulics.
3. TEMA X shellside arrangement or a modification shall be used to improve steam condensing
efficiency. Arrangement shall be reviewed and accepted by Purchaser.
4. Removable bundle (rather than fixed tubesheet) shall be specified, unless otherwise accepted
by Purchaser.
5. Purchaser shall identify applicable design standards per local site requirements.
Note Typically, appropriate Owner shell and tube exchanger specification is imposed.
Occasionally, the Heat Exchanger Institute (HEI) Standards for Steam Surface
Condensers are substituted to reduce equipment cost, but complicate maintenance
and repair.
6. Selected standard shall be documented in the design data sheet by Exchanger Designer.
7. Exchanger Designer shall identify whether external vessels or auxiliary equipment is
necessary and shall submit requirements in writing to Purchaser.
8. Purchaser’s standard criteria for avoiding tube vibration shall be met (refer to GC-E1048).

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Heat Exchanger Design EXH-DU-5142-B.1

9. Backflushing connections for cooling water shall be provided as directed by Purchaser.

10. Purchaser shall determine the location of extra connections on surface condenser. Valves and
piping shall be added for backflushing.
Note Split headers are occasionally used to reduce impact on process during backflush.

9.9 Plate Exchangers

1. Exchanger style shall be identified (e.g., plate and frame, PACKINOX, Compabloc, brazed
aluminum [plate fin], core in shell, printed circuit, hybrid).
2. Plate geometry and count shall be configured to achieve (or exceed) minimum shear stress
required by API 662.
3. Plate geometry and count shall be configured to achieve minimum shear stress of
0.003 psi (20 Pa) for liquids at turndown conditions.
Note For flat parallel plates, shear stress is pressure drop divided by flow path length
times the spacing between the plates (gap) divided by 2 (in consistent units).
4. Impact of potential transients in operation shall be considered, including temperature gradient,
reduced flow, stream composition, and impurities.
5. Exchanger Designer shall confirm that potential fouling mechanisms are prevented over entire
operating range. (TEMA standards describe various fouling mechanisms.)
6. Plate and frame exchangers for general refinery, offshore, and FPSO service shall comply with
EXH-SU-4870.
7. Brazed aluminum plate fin exchangers shall comply with EXH-SU-5110.
8. Core in shell heat exchangers shall comply with EXH-SU-5162.

9.10 Small Heat Exchangers

1. Exchanger Designer shall propose use of double pipe or multi-tube hairpin geometry when
economical compared to shell and tube exchangers. Selection shall be reviewed and accepted
by Purchaser.
2. Small heat exchangers shall comply with EXH-SU-4766.

10.0 MECHANICAL CONSIDERATIONS

1. Exchanger Designer shall specify maximum expected internal operating pressure in the design
data sheet.
2. Purchaser shall confirm that the internal operating pressure is consistent with normal, startup,
and shutdown conditions, as well as with equipment shut-in pressure and pressure relief
system.
3. Transient conditions due to possible tube rupture in shell and tube exchangers shall be
evaluated when setting the design pressure for the low-pressure side.
4. Maximum allowable working pressure (MAWP) shall be determined based on maximum
expected operating pressure as given in Table 2.
5. Maximum operating temperature for a “hot service” shall be determined.
a. Service is a “hot service” if all stream temperatures are -20°F (-29°C) or above.

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Heat Exchanger Design EXH-DU-5142-B.1

Table 2: Setting MAWP

Maximum Expected Operating Pressure Minimum Amount by Which MAWP Exceeds
psig (kPag) Maximum Expected Operating Pressure
0–170 (0–1200) 25 psi (170 kPa)
170–300 (1200–2100) 15% of maximum operating pressure
300–450 (2100–3100) 45 psi (310 kPa)
450–1000 (3100–6900) 10% of maximum operating pressure
1000+ (6900+) Not less than 8% of maximum operating pressure

b. Design temperature shall be set at least 25°F (14°C) above maximum operating
temperature.
Note This design temperature is different from the nameplate maximum design temperature
(usually the highest temperature at which the specific material maintains its
maximum allowable stress) found in the ASME Code.
6. Minimum operating temperature for a “cold service” shall be determined.
a. Service is a “cold service” if any stream temperature falls below -20°F (-29°C).
b. Design temperature shall be set at least 5°F (3°C) below minimum operating temperature.
c. Minimum design metal temperature stamped on the nameplate shall be at or below this
temperature.
7. Minimum design metal temperature (MDMT) and minimum pressurizing metal temperature
(MPMT) shall be established based on local site requirements (BEDD documents).
8. Fixed tubesheets or longitudinal baffles (TEMA F, G, and H shells) shall not be used for shell
and tube exchangers unless reviewed and accepted by Purchaser.
9. TEMA A-type channels shall be used for shell and tube exchangers unless alternative is
reviewed and accepted by Purchaser.
10. If a TEMA B-type bonnet is used, a full diameter tubesheet shall be specified.
11. Exchanger Designer shall confirm that air cooler fan and components for induced-draft units
are rated for elevated hot air discharge temperature when fans are off. Different blade material
or forced-draft units shall be used if necessary.
12. Air cooler fans and motor drives shall operate without overload.
a. For forced-draft units, Exchanger Designer shall use minimum design winter temperature
and humidity conditions.
b. For induced-draft units, Exchanger Designer shall use minimum temperature air with no
process flow through tubes.
13. Tube-to-tubesheet joints shall be strength-welded for shell and tube exchangers, multi-tube
hairpins, or air coolers when the following conditions apply:
a. Differential pressure is greater than 750 psi (5200 kPa).
b. Hydrogen service is designated (see Section 8.0 item 10).
c. Wet hydrogen sulfide (H2S) service is designated (see Section 8.0 item 11).
d. Lethal service is designated.
e. Intermixing of shell and tube fluids is detrimental to the process or environment.

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Heat Exchanger Design EXH-DU-5142-B.1

f. Leak from air cooler is detrimental to environment.

14. Purchaser shall define plot restrictions and fit-up requirements with existing piping systems or
structural elements, providing sketches and drawings as appropriate.
Note Common restrictions are maximum tube length or bundle weight. Structural elements
may include supports, unit stacking, holding up or interference with other equipment,
and expansion and contraction allowances.
15. Structural and fit-up specifications for replacing or modifying existing equipment shall
comply with Purchaser requirements and shall be confirmed by Exchanger Designer.
16. When specified by Purchaser, nozzles shall be matched to line sizes. Otherwise, Exchanger
Designer shall specify nozzle size and schedule.
17. Exchanger Designer shall specify auxiliary nozzles, connections, and inspection ports.
18. Seismic and wind design information shall comply with local site requirements (BEDD
documents).
19. Purchaser shall specify the location of the exchanger (e.g., at grade, above piperack, top of
structure, slung off-side of column).
20. Exchanger Designer shall ensure that replacement components are compatible with the
existing exchanger and reused components.
21. If evaluating or replacing an existing exchanger, Purchaser shall provide a full set of
mechanical drawings and any available maintenance/inspection reports and recommendations.
22. Exchanger Designer shall confirm that weight for any exchanger components, bundles, and
exchangers does not exceed limits set by local site requirements (BEDD documents).

11.0 DELIVERABLES
1. Exchanger Designer or Supplier shall provide the following work products (deliverables) as
directed by Purchaser.
a. Specification sheet (from API) or design data sheet provided by Purchaser.
b. Safety information sheet (SIS) to meet local site requirements (BEDD documents).
c. Supporting calculations, including HTRI simulations for hydraulics and thermal
performance, and tube vibration criteria. (Executable HTRI files are always preferred.)
d. Drawings or sketches to guide Supplier in preparation of final construction drawings.
e. Written reports describing exchanger design and operating considerations.
f. Price and fabrication schedule for exchanger (if appropriate).
g. Invoice for engineering services (if appropriate).
2. Work products (deliverables) shall be negotiated and agreed upon prior to placing the purchase
order (PO).
3. Inspection plan for procurement and fabrication shall be formulated to meet local site
requirements (BEDD documents) for quality assurance/quality control (QA/QC).

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