50 Using this Manual

Abstract
This section summarizes the contents and explains the organization of the Heat
Exchanger and Cooling Tower Manual. This manual is divided into two volumes.
Volume 1 contains the engineering guidelines with accompanying appendices.
Volume 2 contains specifications, industry codes and standards, and standard draw-
ings and forms. Both volumes have a table of contents and a complete index to aid
you in finding specific subjects.

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Scope And Application

The Heat Exchanger and Cooling Tower Manual provides guidelines and specifica-
tions pertaining to heat exchangers (Part I) and cooling towers (Part II). These
guidelines include general information, design background and procedures, sample
calculations, service and materials considerations, and inspection, testing and main-
tenance procedures. The model specifications include comments that explain their
provisions and clarify interpretations based on Company experience.
This manual is written for entry-level engineers and nonspecialists regardless of
experience. This manual should not be used as a substitute for sound engineering
judgment, nor should it take precedence over the judgment of an experienced heat
exchanger or cooling tower specialist.
The intent of this manual is to provide practical, useful information and theory
based on Company experience and established practices. Forms are provided in the
front of the manual for your convenience in suggesting changes. Your knowledge
and experience are important for improving subsequent printings and keeping this
manual up-to-date.

Organization
The colored tabs in the manual will help you find information quickly.
• White tabs are for table of contents, introduction, appendices, PC disks, index,
and general purpose topics.
• Blue tabs denote engineering guidelines.
• Gray tabs are for model specifications, industry standards, and standard draw-
ings.
• Red tab marks a place to keep documents developed at your facility.

Engineering Guidelines
The Heat Exchanger and Cooling Tower Manual covers a variety of topics relating
to heat exchangers and cooling towers. Part I is devoted to heat exchangers and
includes: general background and design information; service considerations; shell
and tube exchanger design and selection and component design; air cooled and plate
and frame exchangers; materials; inspection, testing, and maintenance; and perfor-
mance monitoring. Part II discusses cooling towers and contains: general informa-
tion and design guidelines; rating and retrofitting; the design of water treatment and
chemical injection systems; cooling tower operations and troubleshooting; and
inspection and maintenance. A summary of each section of the manual with perti-
nent specifications is given below.

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Part I—Heat Exchangers

Section 100 General Information
This section gives an overview of typical heat exchanger applications, available
industry technology and standards, and the Company’s normal degree of involve-
ment in heat exchanger design and selection. A brief comparison is made between
water-cooled shell and tube exchangers and air cooled exchangers with an accompa-
nying discussion of the standards and technology developed by Heat Transfer
Research Inc. (HTRI), the American Society of Mechanical Engineers (ASME),
Tubular Exchanger Manufacturers Association (TEMA), the American Petroleum
Institute (API), and Chevron. References are given to other sections of the manual
for specific topics.

Section 200 Design Background

This section presents introductory information and general design guidelines. Heat
transfer and fluid flow correlations and rigorous analysis methods are referenced.
Topics discussed include: (1) equations for the rate of heat transfer and mean
temperature difference (MTD); heat transfer coefficients; single-phase convective
heat transfer; sensible heat transfer in two-phase hydroprocessing feed effluent heat
exchangers; and boiling and condensation heat transfer; (2) economic pressure drop
and velocity; (3) flow splitting; (4) fouling, including particulate, salt precipitation,
chemical reaction, filming amine, biological, and corrosion fouling; (5) overdesign;
(6) tube vibration, including design criteria to prevent failure; (7) enhanced
surfaces; and (8) abstracts of heat exchanger simulation computer programs.
Also included are four appendices relating to this section: Appendix A, “Mean
Temperature Difference Charts,” Appendix B, “Single-Phase Heat Transfer Coeffi-
cients,” Appendix C, “Two-Phase Heat Exchangers,” and Appendix D, “Shell Side
Hydrocarbon Boiling Correlations.”

Section 300 Service Considerations

This section provides design and operating guidelines that apply to specific service
classes, including treated cooling water, untreated sea water, closed loop water
cooling, moderate temperature process steam generators, high temperature waste
heat steam generators, reboilers, condensers, crude unit heat exchangers, and FCC
flue gas coolers.
Topics discussed under these headings include: heat transfer resistance and thermal
stability limits of corrosion inhibitors; measures to avoid or control inorganic and
biological fouling; conventional and kettle steam generators with mass velocity
criteria; the components of high temperature steam generators and field modifica-
tions to increase dryout heat flux; vertical tube side and horizontal shell side
reboilers; shell side reboiler sizing; and control of fouling in crude unit heat
exchangers.
Appendix E, “Analysis of Horizontal Shell Side Steam Generators With Very High
Temperature Process Gas,” supplements the discussion of this section.

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Section 400 Shell and Tube Exchanger Design and Selection

This section contains information on TEMA nomenclature, selecting the most
economic exchanger configuration for a defined service, allocating the streams to
shell or tube side, setting economic design criteria, specifying appropriate mechan-
ical components, defining baffle layout, deciding if a small predesigned exchanger
is appropriate, and estimating the size and cost of shell and tube exchangers.
Typical shell and tube exchanger geometry is discussed along with bundle and tube
arrangements. The cost estimating methods include a step by step procedure and
equations for calculating surface area, tube count and number of tube passes, shell
diameter, and exchanger investment cost.

Section 500 Shell and Tube Exchanger Component Design Considerations

This section discusses the mechanical design of shell and tube heat exchangers and
their components. Topics discussed in this section include: (1) design pressure and
temperature, with a discussion of pressure relief and thermal relief valves, and tube
rupture surge pressure; (2) bundle design, including tubesheet design, tube-to-
tubesheet connection, longitudinal shell baffles, impingement devices, and retrofit-
ting floating head bundles with U-tubes; (3) channel and shell design, including
body flanges, high pressure closures, and connections; (4) gaskets, including
composition-asbestos, double-jacketed, spiral-wound, and solid-metal gaskets; and
(5) insulation.
Appendix F, “Flow Rates and Shock Pressures Through Tube Ruptures,” includes
methods to calculate tube rupture flow rates and shock pressures for shell and tube
exchangers containing gases, two-phase mixtures, and liquids.
Appendix G, “Flange Reference Information,” contains criteria for bolt loads and
flange thickness for leak tightness in service.
Specifications and industry standards that pertain to this section are:
EXH-MS-2583, Shell and Tube Heat Exchangers for Routine Service;
EXH-MS-4764, Heat Exchangers Using Special Materials or Thick Wall Construc-
tion; EXH-MS-4766, Double Pipe and Hairpin Heat Exchanger for Chemical and
General Services; and API Standard 660, Shell-and-Tube Heat Exchangers for
General Refinery Services. These model specifications and industry standard are
included in Volume 2 of this manual. Section 3100, Specifying and Purchasing
Procedure, which contains a Model Quotation Request or Purchase Order for shell
and tube and air cooled exchangers, is also pertinent for this section.

Section 600 Air Cooled Heat Exchangers

This section provides general design guidelines for air cooled exchangers (also
called air coolers). General design topics discussed in this section are: design air
temperature, tube side design, viscosity plugging, draft, fans, fins, and winteriza-
tion. The specification relating to this section is EXH-MS-1826, Air Cooled Heat
Exchangers, and its accompanying data sheet, EXH-DS-1826. API Standard 661,
giving air cooler nomenclature and illustrations for mechanical design require-
ments, is also included in Volume 2 of the manual.

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Section 700 Plate and Frame Exchangers

This section briefly describes the advantages and disadvantages of plate and frame
exchangers. Model Specification EXH-MS-4870, Plate and Frame Heat Exchanger,
is also included in Volume 2.

Section 800 Materials Considerations

This section provides general background on exchanger materials. It summarizes
major factors that must be considered in selection of materials for exchanger
components and in the exchanger design. Major component materials and applica-
tions are discussed for tubes, tubesheets, baffles, and shells, along with a brief
consideration of minimum pressurizing temperature, cathodic protection, and insu-
lation, with references to other manuals for more detailed information.

Section 900 Inspection and Testing

This section covers both shop inspection of new equipment and inspection of
existing units during maintenance turnarounds. The section on shop inspection
covers information on shop testing and inspection to verify that the new unit is built
to specifications and with good workmanship.
Heat exchanger failures cause many plant shutdowns and slowdowns. The cost of
these failures is high due to lost production and replacement of the exchangers.
Inspection’s responsibilities are to: (1) inspect existing exchangers when they are
taken out of service to determine extent of repairs and remaining life; (2) verify that
repairs are completed to the tolerances specified; and (3) maintain accurate long
term records that facilitate accurate forecasting.
This section covers inspection and testing requirements for new and existing shell
and tube and air cooled heat exchangers. The type of damage found in exchangers is
discussed, along with the primary inspection and testing techniques used to deter-
mine the condition of an exchanger. Detailed shutdown inspection checklists are
included. Acceptable dimensional tolerances are discussed, and guidance on Safety
Instruction Sheets (SIS) for shell and tube exchangers and air cooled heat
exchangers is provided. Safety Instruction Sheets are included in Volume 2.

Section 1000 Maintenance

This section discusses the major maintenance requirements for heat exchangers.
This includes repairing and replacing the body flanges, body flange gasketing and
torquing considerations, bundle replacement and repair, tube leak repairs, shell
repairs, and online leak repairs. Methods for determining the causes of leaks are
presented, and a bundle repair worksheet is included, along with a typical leak
sealing service checklist and procedures for sealing flange leaks.

Section 1100 Performance Monitoring

This section discusses performance monitoring of operating heat exchangers.
Reasons for monitoring are presented along with methods of measuring perfor-
mance that include heat transfer efficiency based on monitoring the overall heat
transfer coefficient. This section also includes a sample calculation for evaluating
the performance of a heat exchanger.

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Part II—Cooling Towers

Section 2100 General Information
This section discusses types of cooling water systems, types of cooling towers and
cooling tower components, and provides a list of contacts and references for more
information on cooling water systems. A comparison is made between cooling
water towers and air cooling, with a discussion of the different types and compo-
nents, including splash and film fill and drift eliminators.
The Cooling Tower Institute (CTI) has developed the industry standards for cooling
towers. The commonly used standards are referenced in Specification EXH-MS-
1317, Induced Draft Cooling Towers, included in this manual, with its accompa-
nying data sheet guide and (CTI) data sheet.

Section 2200 Cooling Tower Design Guidelines

This section discusses cooling tower design parameters, electrical facility installa-
tion, environment/safety/fire protection considerations, and forebay design. The key
design parameters discussed are: heat load (duty), circulating water rate, wet bulb
temperature, optimizing cooling tower costs, makeup water, and blowdown. The
discussion of electrical installations and environmental, safety, and fire protection
include: area classification, materials, installation, effluent quality, air quality, and
safety and fire protection measures and procedures. Forebay design covers guide-
lines for horizontal and vertical pumps, forebay dimensions and capacity, and
hydraulic model testing. A list of references is also provided.
Standard Drawing GB-Q99594, Piping and Screen Details—Suction Pit for Cooling
Tower Basin, is included in the manual.

Section 2300 Ratings/Retrofits

This section discusses rating and retrofitting a cooling tower, and includes a simpli-
fied method for evaluating a cooling tower, with sample calculations, and ways to
retrofit existing towers to improve performance and efficiency. Also included is a
list of independent sources for performance testing, new construction, or upgrading
a cooling tower, with a discussion of Company participation. The simplified method
of evaluating a cooling tower relies upon Cooling Tower Institute (CTI) perfor-
mance curves. The discussion of retrofits to existing cooling towers focuses upon
ways to change L/G and to increase KaV/L, and how to improve mixing and distri-
bution of air-water.

Section 2400 Water Treatment System Design

Treating recirculating cooling water is necessary to protect the plant and minimize
operating costs. This section, in conjunction with Appendix B, “Single-Phase Heat
Transfer Coefficients,” and Appendix I, “Cooling-Water Treatment for Control of
Scaling, Fouling, Corrosion,” discusses the mechanisms of fouling and corrosion in
a cooling water system, the water treatment methods, and the sources of makeup
water. Each system must be individually evaluated to establish specific water treat-
ment requirements, type of controls and supporting equipment, and operating costs.
System effluent quality resulting from chemical treatment must be in accordance

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with the local governmental regulations. For any cooling tower evaluation, the costs
should include the cooling tower itself, any incremental makeup water treating
equipment, and cooling tower blowdown costs.
Particular topics discussed in this section include the following: (1) scale control, by
controlling pH, blowdown, and using antiscalant; (2) the causes and control of
fouling and the use of antifoulants and dispersants; (3) the causes of microbiolog-
ical growth and its control by chlorine injection and nonoxidizing biocide; (5) moni-
toring corrosion and fouling, including automatic control systems; (6) sources of
reused water for makeup to cooling towers; and (7) how to choose a water treat-
ment system supplier.

Section 2500 Chemical Injection System Design

This section discusses the process control and design of a chemical injection system
for a cooling tower. Included are discussions of automatic controls; design consider-
ations; types of containers for feeders and storage; location of facilities; chlorine
injection facilities, with sizing, piping, and location; system commissioning; and
safety requirements.
Also included are the following drawings of typical systems that relate to this
section: D-253080, Bulk Tank Facilities for Chemicals; D-603001, Standard 150-lb
Chlorine Containers for C.H.T.’s; B-603002, Standard One Ton Chlorine Facility for
Cooling Towers; B-603003, Semi-Bulk Facilities, Chemical Injection; and B-
603005, Chemical Injection from Barrels.

Section 2600 Cooling Tower Operations/ Troubleshooting

This section briefly discusses cooling tower commissioning and gives some sugges-
tions for cooling tower prestartup plans. Figure 2600-1 is a troubleshooting table for
mechanical/electrical components.

Section 2700 Inspection and Maintenance

This section briefly discusses cooling tower inspections and maintenance and
includes a Cooling Tower Institute (CTI) checklist for inspection and a list of main-
tenance activities for key tower components.

Specifications Drawings and Forms (Volume 2)

Volume 2 contains (1) a specifying and purchasing procedure for ordering heat
exchanger equipment (Section 3100) that includes a Model Quotation Request and
Requisition; (2) Company specifications in commented form; (3) Company stan-
dard drawings and forms that pertain to the areas discussed in the guidelines; (4)
industry standards that are pertinent to the guidelines; and (5) Safety Instruction
Sheets for shell and tube exchangers and air coolers.

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Other Company Manuals

The text sometimes refers to documents in other Company manuals. These docu-
ments carry the prefix of that manual. The prefixes and their referents are:
Prefix Company Manual
CIV Civil and Structural
CMP Compressor
COM Coatings
CPM Corrosion Prevention
DRI Driver
ELC Electrical
EXH Heat Exchanger and Cooling Tower
FFM Fluid Flow
FPM Fire Protection Manual
HTR Fired Heaters and Waste Heat Recovery
ICM Instrumentation and Control
IRM Insulation and Refractory
MAC General Machinery
NCM Noise Control
PIM Piping
PMP Pumps
PPL Pipeline
PVM Pressure Vessels
TAM Tanks
UTL Utilities
WEM Welding

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