AIR COOLER DESIGN GUIDELINES

By

John Nesta
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 Revision Log

Air Cooled Exchanger Design Guidelines

Revision 4, March 2008

All pages revised.

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Air Cooler Design Guidelines Page 1
Table of Contents Mar 2008

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
Air Cooler Design Guidelines Page 2
Table of Contents Mar 2008

8.2 Partial Steam Condenser

8.3 Viscous Cooler
Appendices:
A Literature – Recommended Reading
Air Cooler Design Guidelines Page 1-1
Introduction Mar 2008

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
● 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.
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Air Cooler Design Guidelines Page 2-1
Introduction Mar 2008

2.0 EQUIPMENT TYPE (FORCED VS. INDUCED)

2.1 Selection
The standard type of air cooler shall be forced draft. Induced draft may be considered
when the detrimental effect of hot air recirculation or other factors make it an optimum
choice. If possible, all adjacent bays on the same piperack shall be the same type.
The type of air cooler is usually specified by the client. Each type has advantages over the
other. Forced draft air coolers will be the optimum choice, on balance, for most users and
climates.
The advantages of each type are noted below:
Forced Draft
● Capital cost is less by 1-5%.
● Power consumption is less, in the range of 5-10%.
● Easier to maintain fans.
● Easier to remove bundles, if necessary.
● Required for severe winterization requirements.
● Not limited by discharge air temperature as the fan and motor are outside the exhaust air
stream.
Induced Draft
● The discharge air velocity is much higher and, therefore, hot air recirculation to the inlet air
is limited. Induced draft should be considered for low MTD applications where a small
increase in ambient air temperature (due to hot air recirculation) has a large effect on the
resultant duty.
● The plenum chamber provides protection against sudden surges in performance caused by
rain or hail.
● The plenum reduces heat gain from solar radiation. This can be in the range of 5% of the
heat duty in a hot climate. Induced draft coolers are commonly used in the Middle East.
● The plenum chamber acts as a chimney, which provides a higher heat rejection in the case of
fan failures.
● Possibly better air side flow distribution.
● Less susceptible to picking up sand or other contaminants.
● Easier to mount on piperacks.
● Design of supporting substructure is less complicated.
Air Cooler Design Guidelines Page 2-2
Introduction Mar 2008

2.2 Induced Draft Limits

The temperature limits below are approximate. Consult the vendor for exact values. When the
airflow is controlled, consider low airflow cases to determine maximum outlet temperature.
Item Maximum Temperature
Aluminum fan with standard bushing 230º F (110º C)
Aluminum fan with high temp bushing 300º F (149º C)
Fiberglass fan 230º F (100º C)
Autovariable pitch hub 230º F (100º C)
Air Cooler Design Guidelines Page 3-1
Design Optimization Mar 2008

3.0 DESIGN OPTIMIZATION

3.1 Total Evaluated Costs
3.1.1 The total evaluated air cooler cost shall be the sum of the following costs:
1. Equipment cost
2. Ancillary equipment cost (such as motor starters and cable)
3. Shipping cost
4. Erection cost
5. Structural and foundation cost (plot)
6. Operating cost
Erection cost is a function of the extent of shop assembly and the number of bays. Given the
same amount of shop assembly, the erection cost is then directly proportional to the number of
bays. The cost can be obtained from the Estimating Department or Construction Manager. A
rough estimate is noted below:
Degree of Shop Assembly Ext. Air Recirculation Hours for Field Assembly per Bay
Shoe box No 50
Shop pre-assembly per 3.1.4.b No 250 – 400
Knocked down No 350 – 600
Shoe box Yes 50
Shop pre-assembly per 3.1.4.b Yes 400 – 600
Knocked down Yes 500 – 800
The range of erection hours is dependent on extent of lint screens, heating coil, louvers, and
walkways.
The cost for motor starters and cable is proportional to the number of motors and motor size.
The cost can be obtained from the Electrical Engineer.
The cost of plot is not so easily obtained and frequently ignored. If coolers are piperack
mounted, there will be a certain length of piperack available at no extra cost to the project.
However, if the air coolers require additional piperack length, structure, or plot at grade; there
will be an incremental cost associated with the air cooler plot requirements. This should be
evaluated on a case-by-case basis with the Structural Engineer.
Air cooler fan drives are electric motors (the usual case) or steam turbines (rarely). To
calculate the operating cost you need the cost of electric power or steam, the evaluation period
and the time value of money. A typical evaluation period for users in the process industries is 2
to 4 years on a straight-line basis. The power industry (when regulated) usually uses a longer
evaluation period, from 15 to 30 years, but with a present worth analysis.
Air Cooler Design Guidelines Page 3-2
Design Optimization Mar 2008

3.1.2 In general, a design with the lowest equipment cost will satisfy as many of
the following points as possible:
● Lowest bare tube surface area
● Fewest number of bays
● Most compact plot (most tube rows)
● Most compact header (longest tube length and smallest tube diameter)
● Fewest number of fans
3.1.3 Use the average yearly operating case to evaluate operating cost, not the design case.
Consider the type of process control, if any. The average power usage is then:

Where: = Average power usage at motor input throughout the year

= Power at the motor output shaft at maximum design air temperature

(the power calculated by XACE)
= Factor to account for average power

= Motor efficiency
= Motor power factor
Consider the control scheme (VFD motors, AV pitch fans, shutting motors off, etc.) and develop
a cost factor (F) for the average operating case throughout the year. You do not have to be too
scientific about this. Just develop some factors that directionally give credit for the control
scheme and average annual climate. Calculate the operating requirements for a few cases at the
mean average ambient temperature throughout the year and develop an appropriate factor to
multiply times the design power. Here are some values that were calculated assuming:
a) Coolers in cold climate without recirculation have louvers, and they are partially closed at
50% motor speed.
b) The plenum temperature is 50 ºF for coolers with recirculation
Climate 100% VFD 50% VFD Fans On / Off
Hot 1 1 1
Temperate 0.4 0.7 0.9
Cold with warm air recirculation 0.2 0.6 N/A
Cold without warm air recirculation 0.2 0.6 0.8
Surprisingly, there was little difference between coolers with or without recirculation. The
values are rounded to the nearest 0.1 %. The reason for this is that below 30-50 ºF ambient
temperature, louvers are partially closed to stabilize control.
Air Cooler Design Guidelines Page 3-3
Design Optimization Mar 2008

For total power input to the motor, you need to also consider the appropriate motor efficiency
and power factor. Motor efficiency and power factor are a function of motor size and loading.
As a rough guess use 85% for power factor and 90% for efficiency.
3.1.4 As a general rule of thumb, the extent of shop assembly that optimizes
erection and shipping cost is as follows:
a) Provide air coolers knocked down for field erection where ocean shipment is
required.
b) Provide shop assembly of the bundle, plenum, fan ring, fan and motor support when
only truck freight is required. Additional assembly may be provided if feasible.
It is much more cost and time effective to have air coolers preassembled in the vendor’s shop
compared to the field. However, the shop assembled piece adds shipping volume that increases
ocean freight cost. In some cases, erection cost and schedule may control to the extent that shop
assembly is preferred, even with ocean shipment. Full assembly including support steel is more
difficult but feasible if there is an 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
3.2.1 The heat transfer designer shall provide a design that will satisfy the
process requirements of the data sheet in the most economical geometry
that provides the lowest total evaluated cost. For most cases, this will be a
design that has the lowest equipment capital cost.
Many air cooler sizes work. It just depends on how much air you blow across the bundle! In
general, reducing surface area reduces costs 1 to 5 noted in Section 3.1, but increases operating
cost. The optimum design will have the lowest total evaluated cost.
A short evaluation period minimizes the importance of operating cost unless power cost is
unusually high. Thus, for most of our projects in the process industries, power cost can be
ignored and the designer can strive for a design with the lowest equipment cost. Noise and other
guidelines for good engineering practice will then essentially limit the design. Air cooler
equipment cost can be estimated using the Fluor cost program.
When power cost has some value, the designer must develop a few alternate low power designs
in addition to a base design with the lowest equipment cost; then evaluate the designs for lowest
total evaluated cost.
Air Cooler Design Guidelines Page 3-4
Design Optimization Mar 2008

3.2.2 The design procedure is a series of trial and error check ratings. The designer assumes a
geometry, maximizes tube side heat transfer while observing pressure drop limits, and
calculates the airflow required to solve the design equation. If the airflow is too high,
such that noise or power limits are exceeded, add more surface or increase face area. If
the airflow and resultant power is very low, you can reduce surface or face area. And so
on, until a solution is reached. An acceptable design satisfies the process requirements of
the data sheet, does not have excessive noise, and does not have airflow exceeding good
engineering practice.
Air cooler size estimate program available from Hudson Products facilitates the first guess.
ACE also has a design mode.
The following table gives a fair estimate for the number of rows and air side face velocity that
might be used for a given overall coefficient.
Bare Tube U RowsFace Velocity, SFM
20-60 7-8 450
60-80 6 500
80-100 5 540
>100 4 575
The number of rows should also be limited when there is a low MTD. The crux of all this is that
when there is a good tube side heat transfer coefficient or low MTD, the design is limited by
airside flow; so fewer rows are used to allow as much airflow as possible. Increasing tube pitch
is an alternative to limiting the number of rows. For items with U <20 expect to use bare tubes
or a combination of bare tube and extended surface.
This will give an initial size estimate for air cooler size. Now check the design with XACE.
● Input geometry
● Try 1 inch (25.4 mm) tubes, 2.25 inch (15.88 mm) fin OD, fin density of 10 / inch (394 / m)
and a staggered tube pitch of 2.5 inches (63.5 mm). Do not use 11 fins per inch (433 / m) or
a fin tip clearance less than 0.25 inches (6.35 mm). In-line pitch is almost never used.
● Optimize the number of passes that maximizes tube side pressure drop and heat transfer. If
the design is limited by tube side pressure drop, increase tube diameter, increase number of
tubes, or reduce tube length.
● Calculate required airflow. Revise area as required to use the maximum airflow that does
not exceed noise or power limitations. If the power requirements are very low initially, use
less surface by reducing the bundle width, number of rows or tube length. If the power
requirements are too high initially, add surface and / or increase face area.
● If the tube side heat transfer coefficient is low, try an alternate design with less extended
surface. Use a lower fin height or fin density.
Air Cooler Design Guidelines Page 4-1
General Design Guidelines Mar 2008

4.0 GENERAL DESIGN GUIDELINES

4.1 Bay Layout
4.1.1 The maximum bundle width for plug headers is 14 ft (4.27 m).
In many locations, 14 ft (4.27 m) is the maximum width allowed for truck transportation without
incurring prohibitive shipping cost. In some locations up to 16 ft (4.88 m) is allowed. Consider
a smaller maximum width for cover plate headers for ease of handling the cover plate and
seating the gasket. Consult the user and fabricator for local shipping constraints, and
preferences regarding maximum cover plate width.
4.1.2 When air coolers are provided with shop preassembly, the maximum bay
width is 14 ft (4.27 m). Larger bay widths are acceptable when air coolers
are shipped knocked down.
Shop assembled bays are limited by shipping constraints. Bay sizes larger than 14 ft (4.27 m)
are possible by combining two or more bundles per bay and shipping the pieces knocked down.
Large bays for induced draft coolers are also possible with partial shop assembly by building
the bays in half sections consisting of the bundle, plenum and fan ring. The fan and motor
support are shipped knocked down. The total width including recirculation ducts must be
considered for fully erected or “shoe box” shop assembly.
4.1.3 Acceptable bay aspect ratios (width x length) are a function of the required
fan coverage and number of fans. The minimum number of fans is 2 (API
661 requirement) and this is the standard arrangement. Where tube
bundles are long and skinny, 3 fans must be used to provide the required
coverage. Avoid 3 fans per bay except for special cases with tube lengths
greater than 40 ft (12.2 m). Limit fan size to 16 ft (4.88 m) as larger fans
are likely to require gears, which increase air cooler cost.
4.1.4 When the required surface is too small to be provided in a standalone bay,
it may be combined with another service in a common bay.
4.1.5 Any tube length that is permitted by the plant plot plan is acceptable.
4.1.6 Where coolers are grouped together on a piperack, it is convenient (but not
mandatory) to use the same tube length for all, so that header walkways
are aligned.
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 32 ft (9.75 m) tube length Piperack width + 2 ft (0.6 m) +/-
Forced >32 ft (9.75 m) tube length Not applicable. 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
Air Cooler Design Guidelines Page 4-2
General Design Guidelines Mar 2008

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).
This is good engineering practice. You could squeeze in a few more tubes with a tighter pitch,
but it is rarely worth the effort as power requirements increase as well. Also, fins are more
easily fouled.
4.2.3 The pitch shall be staggered.
In-line pitch may be used for special cases to reduce air side pressure drop, but this should be
avoided as in-line pitch has been rarely used or tested with air coolers.
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. A maximum of six rows
is preferred. 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. 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.
4.3.2 As a rough rule of thumb, pressure drop in the nozzles shall not exceed 10
to 15% of the allowable pressure drop.
4.4 Fouling
Fouling factors are usually specified by the Process Engineer. Fouling is usually omitted
on the air side.
Air Cooler Design Guidelines Page 4-3
General Design Guidelines Mar 2008

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 tree fluff 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 HTRI program allows input of a fouling layer thickness in order to calculate fouled pressure
drop. The fouling layer thickness can be estimated from the fouling factor and fouling thermal
conductivity. Some values are given in the HTRI computer manual. But the fouling factor is in
most cases is not accurate (see the discussion in the Shell and Tube Design Guidelines) and the
thermal conductivity of many fouling layers is not known. Thus, fouled pressure drop
calculations are a guess at best. If fouled pressure drop is required, it is preferable to calculate
the clean condition and then multiply by a reasonable safety factor based on the service. The
fouled pressure drop is used in the hydraulic loop calculations, while the exchanger is designed
and guaranteed for clean pressure drop. One user’s criterion based on extent of fouling follows:
Fouling resistance (US Customary Units) Multiplication Factor
<0.002 on tube side with alloy tubes or 1.1
carbon steel in non-corrosive service
<0.002 on tube side where some pitting 1.2
and corrosion is expected
0.002 – 0.005 1.3
>0.005 1.5
Another approach is to size the pump for 125% of design flow 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.
4.6 Liquid / Vapor Separation
When 2 phase flow exists in a header, provide the following details:
● One row per pass is preferred, especially for the first pass with a 2-phase inlet. Where
multiple rows are used, use the XACE phase separation model.
● Each tube pass shall extend of the entire width of the header.
Air Cooler Design Guidelines Page 4-4
General Design Guidelines Mar 2008

Phase separation in air coolers is usually ignored, but this is what could happen: two phase
flow may separate in the header box, especially at the inlet. The liquid will flow to the bottom
tube rows and vapor to the top rows. The top rows will cool or condense the vapor, while the
bottom rows cool the liquid. The phases will then remix in the return or outlet header. The net
result is always less heat transfer than if the phases did not separate. An additional problem in
condensing service is that you will get a new heat curve for the next tube pass after the phases
separate (the curve is less conservative), and the heat curve changes for each pass. XACE has
an option to model the headers with phase separation. At this time, the writer has not
investigated how XACE does this in the absence of the heat curves noted above. However, it is
probably better, and certainly more conservative, to use the phase separation model, rather than
ignoring phase separation.
If the tube pass extends the entire width of the header, some liquid may be entrained into the top
row of the return headers. However, two phases at the inlet header are almost certain to have
phase separation. Where you have a 2-phase inlet, use one row for the first pass in critical
applications such as water wash.
4.7 Screens
4.7.1 Where required, protective screens for insects and lint shall be provided at
the periphery of the air cooler.
Exchanger Type Screen Location
Induced At the bundle inlet
Forced At the periphery of the bay at the vertical columns
and under the motor maintenance walkway
Screens should not be placed in a small box around the fan ring of forced draft units. Screens
will plug quickly and the resultant air side pressure drop will be high.
4.7.2 Fan and motor selection shall have an allowance for pressure drop across the screens.

A suggested value is 1.5 velocity heads based on the net free area through the
screens. This allows for some fouling of the screen. This has not been tested, so it is a soft
guideline at this time.
Air Cooler Design Guidelines Page 5-1
Air Side Design Mar 2008

5.0 AIR SIDE DESIGN

5.1 Fin Design
Fins are made of aluminum. Four types of fin attachment are commonly provided.
● Tension wound, footed (L-footed) fins have a shoulder at the base and are in the shape on an
“L”. They are attached to the tube by winding under tension and secured at the tube end by
a zinc collar or stainless steel staple. The zinc collar provides a better attachment, but it is
rarely used anymore because of environment concerns with the casting process. Footed fins
can be used with process fluid temperature up to 275 to 350º F (135 to 177º C). The
maximum allowable temperature varies between users. Fluor uses the lower limit for
conservatism. The footed fin attachment is the least effective in maintaining the fin-to-tube
bond over time. Also, with the use of staples rather than zinc collars, they are subject to
unravelling due to temperature excursions. There is another type of wrapped fin called
overlapped footed, where the base shoulder of one fin rests on the foot of the adjacent fin,
making it sort of “double wrapped”. Supposedly, the corrosion resistance and bond is
improved. However, we are skeptical about the improvement in the bond, and see no use for
this fin considering the increased cost.
● Embedded fins are wrapped and peened into a spiral groove cut into the tube. Tubes need to
be one gauge thicker than the minimum allowed thickness to account for the groove depth.
Maximum allowable process temperature is 750º F (399º C) and the fin-to-tube bond is
good. Embedded fins are not suitable for a damp ocean air environment, because the tube is
not entirely covered by aluminum. The fin-to-tube connection at the groove represents a
possible site for galvanic corrosion when the bundle is out of service or when fans are off.
Embedded fins are not always effectively attached to stainless steel or other materials of
similar hardness, although vendors will generally claim that this is not a problem. A pull
test should be required when fins are embedded into stainless steel or other hard-to-embed
materials.
● Extruded fins are extruded onto the tube to form a continuous mechanical bond. Maximum
allowable process temperature is 550º F (288º C). The fin bond is good. The fin type is also
known as bi-metallic. Extruded, serrated fins are a special variation with a cut and twist to
the fin. The serrated fin increases turbulence and air side heat transfer coefficient.
However, the increased heat transfer rate is not an efficient return for the increased static
pressure drop. Serrated fins are rarely used by Fluor, unless the air side coefficient
dominates the design, and you have low power cost.
● Knurled footed is a hybrid footed fin. The fin is footed and attached via knurling to the tube.
It is offered by European and Australian vendors, but to date, no one in North America
makes this fin.
Air Cooler Design Guidelines Page 5-2
Air Side Design Mar 2008

5.1.1 Fin types are allowed up to the maximum process fluid inlet temperature
noted below. Unless specified otherwise, assume that the design
temperature noted on the data sheet is the maximum process fluid inlet
temperature.
Fin Type Maximum Temperature
Tension wound, footed 275º F (135º C)
Knurled, footed 350º F (177º C)
Extruded 550º F (288º C)
Embedded 750º F (399º C)
For temperature greater than 750º F (399º C), use bare tubes or a welded type of fin.
5.1.2 Use extruded or knurled, footed fins in corrosive air side environments
such as damp ocean air.
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.
05 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).
A density of 11 per inch is discouraged as the fins are hard to clean and the additional surface
area is rarely worth the cost or additional static pressure drop. 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, 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 thicknesses 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 a little thin.
Air Cooler Design Guidelines Page 5-3
Air Side Design Mar 2008

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.
Embedded fins have a galvanic cell at the fin base which is corrosive if slat 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.
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 final fin type to create a design. The air
side performance does not vary that much between fin types. 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 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.
Air Cooler Design Guidelines Page 5-4
Air Side Design Mar 2008

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
At this time, I am not confident in the HTRI predicted performance. 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).
For forced draft fans a minimum fan coverage of 45% is desirable, but not mandatory.
5.2.2 The minimum number of fans per bay is two (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:

or

Where:

= Drive rated power.

= Fan brake power at the winter design temperature with the blade angle set for
the design temperature.

= Fan brake power at the design air temperature.

= Mechanical efficiency of the power transmission.

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.
Air Cooler Design Guidelines Page 5-5
Air Side Design Mar 2008

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.
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
11 ft (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 than 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 to be evaluated at the minimum ambient temperature. For units with
enclosed warm air recirculation, you can, by agreement, use a less conservative plenum
temperature, rather than the minimum ambient temperature.
There is little harm in operating the motors at the minimum ambient for a short time at cold
startup.
Air Cooler Design Guidelines Page 5-6
Air Side Design Mar 2008

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 total open area between columns.
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
Air Cooler Design Guidelines Page 5-7
Air Side Design Mar 2008

% 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.
As in 5.4.3 above, this is a soft guideline than can be exceeded if necessary to provide the
required airflow in special circumstances, such as plant revamps. Check noise, and provide a
conservative fan/motor selection to insure delivery of the required air flow.
Air Cooler Design Guidelines Page 6-1
Tube Side Design Mar 2008

6.0 TUBE SIDE DESIGN

6.1 Tube Size
6.1.1 The minimum tube diameter per API 661 is 1 inch (25.4 mm).
6.1.2 The tube thickness shall be adequate for design pressure, or the minimum
required by API 661. If the tube corrosion allowance is not specified,
assume the following values:
Material Corrosion Allowance, in (mm)

Carbon steel and low alloys 0.03 (0.76)

Copper, copper alloy, stainless steel 0.015 (0.38)
and other high alloys
Titanium 0.005 (0.13)

The minimum API thickness is:

Material Thickness, in (mm)
Carbon steel and low alloys 0.083 min. (2.11 min.)
Copper, copper alloy 0.065 min. (1.65 min.)
High alloy steel and other 0.065 min. (1.65 min.)
non-ferrous material
Titanium 0.049 min. (1.24 min.)
6.1.3 When calculating the thickness of U-tubes, account for the thinning in the
U-bend per API 661 (same as TEMA).
6.1.4 When using a minimum wall gauge with carbon steel or ferrous alloys
input the thickness for thermal design as the minimum wall thickness plus
10%. Input the wall thickness for copper and copper alloys same as the
minimum thickness.
The thickness of the purchased tube for carbon steel and ferrous alloys will typically be 5 to 7%
more than the minimum wall thickness. Carbon steel and ferrous alloy seamless tubes will be in
the order of 10% thicker than the minimum wall thickness. Copper and copper alloys will be
smooth drawn and the average thickness is close to the minimum wall thickness.
6.1.5 Tube thickness for embedded shall account for the groove depth. The
purchased tube for these fin types is one gauge thicker than the minimum
required by 6.1.2 above.
6.2 Velocity
6.2.1 The maximum velocity for liquids is 6,000 lb / ft sec2 (8,900 kg / m sec2).
6.2.2 The maximum velocity for vapor and 2 phase flow 5,000 lb / ft sc2 (7,400
kg / m sec2).
Air Cooler Design Guidelines Page 6-2
Tube Side Design Mar 2008

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Air Cooler Design Guidelines Page 7-1
Process Control and Winterization Mar 2008

7.0 PROCESS CONTROL AND WINTERIZATION

7.1 General
Winterization shall be in accordance with API 661, Annex C. Some requirements are
repeated in the following sections.
7.2 Process Temperature
Air coolers are designed for a maximum ambient temperature. In some cases this temperature
may be reached for only a few days in the summer. When the air temperature is lower than the
design air temperature, additional cooling will result.
7.2.1 The process outlet temperature may be controlled using one, or a
combination of, the following methods:
a) Regulate the airflow
b) Fluid bypass
c) Flooded bundle for condensers
Unless specified otherwise by the user or Process Engineer, assume that the method of
control is to regulate the airflow.
7.2.2 Airflow shall be controlled by the use of motors with variable frequency
drive (VFD). The design requirements are noted in Table 7.5.1, based on
the desired degree of process control.
The standard method of controlling airflow is to use motors with VFD. However, there are
many ways as summarized below:
● Autovariable pitch (AV) fans have a diaphragm hub that feathers the fan pitch. They are
economical and power usage is lower at air temperature below design. However, AV pitch
fans have come into disfavor recently due to concerns over reliability.
● Variable frequency drive (VFD) motors vary the motor speed and resultant airflow. VFD
drives have come into favor recently in lieu of AV pitch fans, because they are very reliable.
● Two speed motors provide step rather than continuous control. If there are many bays this
can, in effect, provide continuous control. For example, 6 bays with 6 one-speed and 6 two-
speed motors will have 30 control steps. However, step control that produces different
cooling rates in adjacent bays is not suitable where flow maldistribution is not desirable.
When this is the case, the motors must be operated in unison, i.e. all on, all at ½ speed, etc.
● Turning fans off will provide three steps of control per bay.
● Louvers are reliable but expensive and they do not save power. Louvers by themselves do
not provide stable airflow in the lower range of control. However, louvers are often used in
combination with other methods in cold climates where very low airflow is required. AV
pitch fans do not deliver stable airflow at low blade pitch. VFD motors have a bit longer
range and deliver stable airflow down to ~10% of design. Partially closed louvers help to
stabilize the airflow at very low flow by making the fans operate at increased pitch (for AV
fans) or motors at higher frequency (for VFD).
Air Cooler Design Guidelines Page 7-2
Process Control and Winterization Mar 2008

7.2.3 Louvers shall be provided in combination with VFD when airflow

requirements of the VFD fan are less than 20% of design for any operating
case.
7.2.4 When not required for control reasons, VFD motors may be considered if
justified by power cost savings.
Motor power is a function of motor speed to the third power. The following table illustrates the
power savings obtained by increased extent of VFD.
Motor Power as a Fraction of Design
Airflow, Control Mode
% of Design Fans On / Off 50% VFD 100% VFD
100%
1 1.0 1.0
75% Not controlled
0.51 0.42
50%
0.5 0.5 0.125
25% Not controlled
0.125 0.02

7.3 Tube Skin Temperature

The process fluid may have a freeze point, pour point, salt precipitation temperature, or other
danger point that needs to be considered in the air cooler design. This is called the
winterization critical temperature.
7.3.1 When the process fluid critical temperature is greater than the minimum
ambient temperature, it shall be noted on the data sheet.
7.3.2 The air cooler shall be designed to have the tube wall temperature safely
above the critical temperature for the range of operating conditions noted
on the data sheet. The clean, turndown case shall be considered. The cold
startup case is considered, but does not control the design.
7.3.3 The tube wall temperature safety margin shall be at least those noted in
API 661, Winterization Annex.
7.3.4 The tube wall temperature may be controlled by one, or a combination of,
the following methods:
1) Airflow control
2) Bare tubes
3) Low fin density
4) Co-current flow
5) Air temperature control via warm air recirculation
Air Cooler Design Guidelines Page 7-3
Process Control and Winterization Mar 2008

Air temperature control is used when the tube wall temperature cannot be controlled by
methods 1 - 4, or when the resultant design using these methods is uneconomical. When
the air cooler can be economically designed to control the tube wall temperature for all
but startup or shutdown cases, louvers and heating coil may be provided in lieu of warm
air recirculation. Design requirements are noted in Table 7.5.2.
If airflow control is used for the purpose of controlling the tube wall temperature, it shall
be 100% VFD, and the airflow requirements shall not be less than 15% of the design
airflow for any operating case.
Tube wall temperature control can also be achieved by varying the active heat transfer
surface via valves that isolate bundles. This is useful for turndown cases, but is not a
practical operating procedure for most users.
7.4 Air Temperature Control
7.4.1 Air temperature control shall normally be provided by forced draft,
external, over-the-side warm air recirculation. Internal recirculation is
discouraged. If internal recirculation is used, check the full range of
operating conditions to insure that full duty is performed while also
controlling the skin temperature.
Internal recirculation is more economical than external recirculation, but control is less
reliable. With internal recirculation, it is not unusual to have someplace in the range of
operation where it is impossible to provide full duty while also control the skin temperature.
There may be successful installations using internal recirculation, but the Fluor standard is to
use external recirculation when air temperature control is required. When internal recirculation
is used, check the entire range of operating conditions to preclude the problem noted above.
The standard arrangement for external recirculation is over-the-side because it allows optimum
use of the plot for long tube lengths. Over-the-end is more reliable for one-pass designs in
severe service. Over-both-ends can be used for severe multi-pass services.
7.4.2 Air recirculation shall be over both sides where bay width exceeds 14 ft or
where the tube wall temperature control is critical (example: viscous oil
coolers with high pour point).
7.4.3 The air velocity in the recirculation duct shall not exceed 1,000 ft / min
(305 m / min). The duct size shall be based on the amount of air required
to maintain a plenum temperature at least 9º F (5º C) above the critical
point. For problematical designs, such as vacuum steam condensers, base
the amount of recirculated air on a plenum temperature at least 14º F (8º
C) above the critical point.
A very important requirement!
Air Cooler Design Guidelines Page 7-4
Process Control and Winterization Mar 2008

7.4.4 A separate plenum temperature indicator shall be provided for each fan
when control is by 50% VFD. The plenum temperature shall be set by the
lowest temperature from either indicator. The temperature indicator shall
be an averaging device such as capillary bulb or resistance temperature
device (RTD). A single device over the entire length of the bundle is
acceptable with 100% VFD, but separate indicators are preferred.
7.4.5 When over the side air recirculation is provided with multi-bay units, provide an isolation
wall above the bypass louver. An isolation wall below the louver is not required unless
recommended by the vendor.
7.5 Winterization Type and Control Category
Design requirements to control process temperature of tube skin temperature shall be in
accordance with the following tables:
Air Cooler Design Guidelines Page 7-5
Process Control and Winterization Mar 2008

Table 7.5.1 Control Category

Control Degree of Control Design
Category Requirement
C 1) For +/- 2 C control of process outlet temperature 100% VFD
2) For recirculation systems with open floors
3) For type 2 where one fan on full speed results in
unacceptable tube skin temperature
B For +/- 5 C control of process outlet temperature 50% VFD
A Close control not required None: fans
on/off
Table 7.5.2 Winterization Type
Winterization Description Design Criteria
Type
1 No louvers or heating Winterization critical temperature is less than the
coil minimum ambient temperature.
2A Louvers Same as Type 1, but louvers are added where the
minimum airflow of the VFD fan is less than
20% of design (Control Cases C and B)
2B Louver plus heating Winterization critical temperature is greater than
coil or equal to the minimum ambient temperature
(Note 4)
3 Warm air recirculation 1) Where tube skin temperature using only air
(usually external over flow control results in airflow less than 15%
the side) of the design airflow.
(Note 5) 2) For control mode C where minimum airflow
is less than 15% of the total design airflow.
Notes:
1. Tube skin temperature shall be calculated for the clean, turndown condition at minimum
ambient air temperature.
2. Minimum air flow shall be calculated for the clean, turndown condition at minimum ambient
air temperature.
3. Tube skin temperature safety margin shall be in accordance with API 661, winterization
Annex.
4. The heating coil shall be directly under the bundle. Remote auxiliary heaters such as Ruff
Neck heaters are not allowed unless the area under the bundle is enclosed.
5. A heating coil or auxiliary heater is required with warm air recirculation.
Air Cooler Design Guidelines Page 8-1
Special Applications Mar 2008

8.0 SPECIAL APPLICATIONS

8.1 Total Steam Condensers
The first row that sees the coldest air condenses the most steam. The next row that sees
preheated air from first row condenses less steam, and so on for the remaining rows. When the
outlet pass has multiple rows, the top rows only partially condense the steam while the bottom
rows do some subcooling. Steam from the top rows may backflow to the colder rows. This may
result in corrosion due to water hammer, freezing of the condensate, or loss of duty due to
accumulation of non-condensable gas (e.g. air in vacuum service). The condition is more severe
with turndown or low ambient air temperature where the air flow is tempered to control the
duty.
Backflow is particularly prominent at operating pressure less than 40 psia (275 kPa(a)).
8.1.1 The design shall be evaluated for backflow throughout the range of
operating conditions. Subcooling in the cold rows must be eliminated, or
at least lessened, to avoid backflow. Design options include:
a) Minimize the number of rows for the outlet pass.
b) The tube length shall not be greater than 360 times the tube outside diameter.
c) Vary the fin height, and/or fin density, with lower height or density for the cold rows.
d) Vary the tube diameter, with larger diameter for the cold rows.
e) Provide orifice restrictions such that more steam is forced into the cold rows.
f) Provide a two-stage condenser. The first stage partial condenses the steam (say 80-
90%). The second stage is arranged in such a way as to avoid subcooling, for example
an inclined tube with steam entering at the bottom.
Check the XACE tubeside monitor. Backflow is possible where there is a negative pressure drop
and increasing pressure somewhere along the length of the tube. This is likely in the cold
rows just prior to subcooling.
8.1.2 A design with two passes and not more than one row for the outlet pass is
preferred. If this arrangement is not feasible, one or a combination of the
options noted in 8.1.1 shall be considered.
8.1.3 Special vendor proprietary designs are typically used for vacuum steam
condensers.
8.1.4 Where warm air recirculation is required, consider over-the-end ducting
for single pass condensers.
8.1.5 Any required subcooling shall be handled in a dedicated section.
Generally, this would be one row with one or more passes that provide a
high condensate velocity
8.2 Partial Steam Condensers
When the outlet quantity of vapor is low, partial condensers may be subject to the same
problems as noted above for total condensers. Check the design to insure that subcooling
and backflow is not present in the cold rows.
Air Cooler Design Guidelines Page 8-2
Special Applications Mar 2008

8.3 Viscous Coolers

Viscous coolers can have a phenomenon called unstable flow, which causes severe flow
maldistribution. This results in loss of performance and / or winterization problems. The design
should be safely above the laminar regime, say Re > 3000, including turndown.
8.3.1 Laminar flow in air coolers is not allowed unless the cooler is a one tube
(or pipe) serpentine coil. Alternate design options include:
a) Increase allowable pressure drop to the extent required for turbulent or transition
flow.
b) Use indirect cooling. The viscous fluid is cooled on the shell side of a shell and tube
exchanger with a cooling medium that is, in turn, cooled by the air cooler.
8.3.2 If is preferable that laminar flow also be avoided for the turndown case. If
this is not feasible, the ratio of wall viscosity to bulk viscosity shall not
exceed 3:1. In addition, the use of U-tubes should be considered to
preclude mechanical damage due to different cooling rates in adjacent
tubes.
Air Cooler Design Guidelines Page A-1
Appendix A Mar 2008

APPENDIX A

Recommended Literature

1 Hot Air Recirculation by Air Coolers

By A.Y. Gunter and K.V. Shipes
Twelfth National Heat Transfer Conference
A.I.Ch.E. – A.S.M.E.
Tulsa, Oklahoma 15-18, 1971

2 Air Cooled Exchangers in Cold Climates

By K.V. Shipes
Chemical Engineering Progress
July, 1974
Air Cooler Design Guidelines Page A-2
Appendix A Mar 2008

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