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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution

SPECIFICATION EXH-MS-1826-H
AIR COOLED HEAT EXCHANGERS

NOTE: This document is the "Commented" version of Specification EXH-EG-1826-H.

The comments, based on Company experience, provide background for the
requirements stated in the Specification. These comments are for Company use only, not
for distribution to Vendors/Contractors.
Copies of the EG Specification (without comment) are available in both hard copy
(paper) and electronic (MS Word for Windows) format. To order, contact CRTC
Technical Standards at either (510) 242-7232 or -7241. Copies of the MS Specification
are available only electronically. To order, contact CRTC Technical Standards at (510)
242-7241.

December 1989

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution
CONTENTS
1.0

GENERAL............................................................................................................................3

2.0

PROPOSALS........................................................................................................................3

3.0

DOCUMENTATION............................................................................................................3

4.0

GUARANTEE (EXCEPTION) .............................................................................................4

5.0

DESIGN ...............................................................................................................................4

6.0

MATERIALS........................................................................................................................8

7.0

FABRICATION..................................................................................................................10

8.0

INSPECTION, EXAMINATION, AND TEST ...................................................................10

9.0

PREPARATION FOR SHIPMENT....................................................................................12

11.0

COMPANY REFERENCE DOCUMENTS (ADDITION) ..................................................13

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution

1.0

GENERAL
1.1 Scope
(Addition) This specification supplements the requirements of the latest edition of API
Standard 661 (referred to hereafter as API 661) and its Appendices. An accompanying data
sheet for each unit describes further requirements for performance and construction.
1.1.1

Nomenclature.

An exception, as noted, to an API paragraph deletes the entire API paragraph.

An addition, as noted, to an API paragraph expands the requirements or selects
options.
If an API 661 paragraph is not discussed, then its contents are accepted.

1.6 Conflicting Requirements

1.6.1

(Exception) In order of precedence, the unit shall conform to the following

documents:

2.0

3.0

Purchase Order/List Sheets

Air Cooled Exchanger Data Sheet (EXH-DS-1826)
This Specification
Referenced Specifications
Referenced Standard Drawings
API 661, Air Cooled Heat Exchangers for General Refinery Services

PROPOSALS
2.2.1

(Exception) The Vendor's proposal shall include a completed data sheet,

EXH-DS-1826 for each unit.

2.2.8

(Exception)

The proposal shall include a completed noise data sheet, NCM-EF-594.

DOCUMENTATION
3.1 Approval Information
3.1.1

December 1989

(Addition) In addition to the items listed in Paragraph 3.1.1 of API 661, Vendor
shall include the following information on the outline drawings.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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14.

Cross-section drawings of all major components and tube bundle details

sufficiently complete so that Company can fabricate and assemble a
replacement bundle.

3.1.2

(Addition) Vendor shall not start fabrication until Company has approved
preliminary or final shop drawings submitted in accordance with Paragraph 3.1.1.

3.1.4

(Addition) All proposed welding procedures and qualifications shall be submitted

for approval prior to start of fabrication.

3.2 Final Records

3.2.1

Information Required Prior to Shipment

2.

(Addition) Report separately in the manufacturer's data report any thickness

of steel in the header that is in excess of required minimum thickness, plus
specified corrosion allowance.
Comment 3.2.1, No. 2 Thicker materials have a greater tendency to be
brittle at low temperatures. The purpose here is to alert the Company to the
need to review Minimum Pressurizing Temperatures if the Vendor increases
the metal thickness.

4.0

9.

(Addition) A characteristic performance curve for the fans shall be

furnished.

12.

(Addition) Copies of certified test reports or certificates of compliance

covering pressure-containing material (except as excluded by Code Paragraph
UG-11) and any low and high alloy material used for internals.

GUARANTEE (EXCEPTION)
Vendor shall guarantee each unit in accordance with GAM-EG-3042.

5.0

DESIGN
5.1.6

Headers - Removal Cover Plate and Removable Bonnet Type

5.1.6.7 (Addition) Stud closures in lieu of through-bolting are not permitted.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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5.1.9

Gaskets
5.1.9.2 (Addition) Where compressed asbestos gaskets are used or where gaskets
are not confined, 450F shall be given as maximum allowable temperature.
Comment 5.1.9.2 This is consistent with Company piping standards.

5.1.10 Nozzles and Other Connections

5.1.10.1 (Addition)

Inlet/Outlet nozzles shall be flanged 2-inch NPS or larger.

Comment 5.1.10.1 Most Company locations require 2-inch minimum

nozzles for added strength.
5.1.10.4 (Addition) Cast transition nozzles are acceptable only when specifically
approved by Company.
Comment 5.1.10.4 Castings can have poor properties and poor quality.
Their use should be limited to noncritical and nonhazardous services, and
then only when a significant incentive (availability, cost, etc.) exists.
5.1.10.8 and 5.1.10.9 (Addition) Nozzles of each unit shall be equipped with a
temperature and pressure connection.
Comment 5.1.10.8 and 5.1.10.9 Even if these connections have no
immediate need, they generally are used by process engineers for checking
process conditions.
5.1.12.7 (Addition) The fin types listed in Paragraph 5.1.12.7 of API 661 shall have
the following temperature limits:

Type of Fin
1.
2.
3.
4.

December 1989

Maximum Inlet
Fluid Temperature

Embedded
Integral
Overlapped Footed
Footed

750F
550F
250F
250F

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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5.2 Air-Side Design
5.2.2

Noise Control
5.2.2.1 (Exception) The Vendor's base proposal shall include his standard sound
level control features, if any. Unless otherwise specified, maximum sound
pressure levels at any location 3 feet from any air cooler surface shall not
exceed 85 dBA.
For the basic offering, the Vendor shall furnish the guaranteed A-weighted
sound pressure level at 3 feet from the unit. If the sound pressure level of the
basic offering exceeds 85 dBA, the Vendor shall separately quote special
designs and/or acoustic treatment that would be required for the Vendor to
guarantee 85 dBA. Details of specific designs and/or acoustic treatment shall
be furnished with the proposal.
Comment 5.2.2.1 The noise level for several identical fans operating in
parallel is only slightly greater than the noise of one fan operating at the
same tip speed. The extensive use of air coolers contributes significantly to
plant noise level. Reduction of fan speed is the principal means of reducing
decibel level.

5.2.3

Fans and Fan Hubs

5.2.3.5 (Exception)

5.2.5

Fan tip speed shall not exceed 10,000 fpm.

Lubrication Facilities
5.2.5.1 (Addition) Length of lines supplying grease to bearings shall be held to the
minimum consistent with good accessibility.
5.2.5.2 (Addition) Gear box oil level shall be capable of being checked and oil
added if necessary without hazardous exposure of the operator or shutdown
of the equipment.

5.2.8

Electric Motor Drivers (Exception) Electric Motors shall be furnished in

accordance with Specification DRI-EG-1824.

5.2.11 Belt Drives

5.2.11.1

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(Exception) Belt drives shall be Uniroyal High Torque Drive (HTD)

synchronous belts and pulleys or Company-approved equivalent.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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5.2.11.9

(Exception) HTD synchronous belts shall have a minimum service

factor of 2.2 for fixed speed drivers and a minimum service factor of 2.4
for two speed drivers, based on driver-rated brake horsepower.

5.2.12 Gear Drives (Addition)

review and approval.

All gear selection is subject to the Company's specific

5.2.14 Vibration Cutout Switches

5.2.14.1 (Addition) Units shall be furnished with vibration shutdown devices
(Robertshaw Vibraswitch or equal approved by Company) suitable for
Class 1, Division 2 location. The placement and orientation of the sensor
shall be determined by the Vendor and shall be a point which is known to
the Vendor to vibrate with sufficient amplitude to activate the shutdown
whenever the machine becomes unbalanced.
5.3 Structural Design
5.3.2

Structural Design Loads and Forces

4.

(Addition) Air cooled heat exchangers must be structurally and thermally

designed to accept maximum fluid inlet temperature throughout the cooling
coils during power failure conditions without warping or pulling of tubes or
any other mechanical damage or any leakage of the fluid in the tubes.
Comment 5.3.2, No 4 When a power failure occurs, the entire tube bundle
will heat up quickly to the inlet temperature. Because this temperature
increase can be large, the tubes may experience significant expansion.
Section 6.1.8.3 of this specification lists other operating conditions that can
cause significant structural load changes.

5.3.4

Access Facilities
Comment 5.3.4 For designs where the air cooler sits above a pipeway or
structure, the engineering contractor will be responsible for platforms to access the
unit. When the platform is required from the Vendor, the Vendor should design the
platform, ladders, etc., to Company standards. Be especially aware of support
cross members interfering with access to the fans and fan drivers.
5.3.4.1 (Addition) Full platform access to fan motors, gears, vibration shutdown
switches, and piping flanges is required. Where plug access is the only
maintenance requirement, permanent supports for temporary scaffolding are
acceptable.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution
5.3.4.3 (Addition)

Grating is acceptable material for use as floor plates.

5.3.4.5 (Addition) Ladders, cages, and guards shall be designed in accordance with
Standard Drawings GD-M13909, GF-M88575, and GF-M99645.

6.0

MATERIALS
6.1 General Requirements (Addition)
Sheet EXH-DS-1826.
6.1.1

(Addition)

Materials shall comply with requirements of Data

Tube material shall be specified as follows:

Carbon Steel
Low-Alloy Steel
Austenitic Stainless Steel
Ferritic Stainless Steel

SA-179 or SA-192
SA-209 or SA-213
SA-213
SA-268

6.1.1.1 Tubes shall be seamless.

Comment 6.1.1.1 Seamless tubes are preferred for air coolers because
tubes are pressure containing parts and seamless tubes are more reliable.
This provision could be deleted in noncritical or nonhazardous services
such as water.
6.1.8

(Addition) Fan materials, construction, and maximum diameter shall be as follows:

Acceptable Materials and Construction

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Maximum
Fan Diameter

a. One piece cast aluminum blades.

Marley is an acceptable supplier.

12 feet

b. Aluminum blades, extruded or fabricated

from sheet metal, with either cast,
wrought, or fabricated shanks. Chittom
Equipment Co. and The Moore Co. are
acceptable suppliers.

18 feet

c. Chrome-nickel stainless steel, Type 304

18 feet

d. Reinforced Plastic. Hudson Products Co.

is an acceptable supplier.

18 feet

December 1989

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution
6.1.8.1 (Addition) Copper content of aluminum blades shall not exceed 0.4% to
exclude aluminum alloys with poor corrosion resistance.
Comment 6.1.8.1 Some aluminum alloys contain copper deliberately added
to make them stronger or easier to coat. However, it causes serious
degradation of corrosion resistance especially in a coastal or marine
atmosphere.
6.1.8.3 (Addition) All components of the fan assembly including the nonmetallic
parts such as plastic fan blades, blade mounting bushings, variable pitch
controls shall meet the following conditions:
1.

Fans in induced draft service may be shut down for extended periods,
and will then be subjected to the inlet temperature of the fluid being
cooled. They shall be suitable to be re-started from this condition.

2.

During turnaround, the cooling coils will be subject to steam flow at

a temperature specified by the Company. The fans will not be
operated during or immediately following this period. Fans and other
components above the bundle in induced draft services will be
subjected to the saturation temperature of the steam.

3.

For air cooled heat exchangers with provisions for air recirculation,
due consideration shall be given to the temperature to which the fans
may be subjected during abnormal operation.

Comment 6.1.8.3 Plastic fan blades are especially sensitive to

temperature. or example, a common type of blade construction uses a
fiberglass shell with a plastic foam filling. The Company has experienced
failure of these fans under the conditions described above. Accidental
overheating caused the plastic foam to expand, splitting the fiberglass outer
shell. It is very important for the engineer to allow for these situations. For
instance, a power outage can lead to a situation similar to #1.

December 1989

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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7.0

FABRICATION
7.1 Welding
7.1.1

General
7.1.1.5 (Addition) Weld rod or wire shall be selected to ensure that the deposited
weld metal in the finished header will not exceed 100,000 psi tensile strength.
This shall be verified by hardness testing in accordance with Section 8.2.13.
Comment 7.1.1.5 Weld metal stronger than 100,000 psi tensile strength
will be susceptible to sulfide cracking in sour service. Cracking can occur
quickly. It may result from normal H2S levels in the process fluid, or from
short term exposure during transient conditions (i.e., upsets, startups,
shutdowns).

7.2 Postweld Heat Treatment

7.2.1

(Addition) Carbon steel shall receive a postweld heat treatment when required by
Code or when specified by the Company.
Preheat and postweld heat treatment requirements for carbon steel shall be as follows:

8.0

Thickness and Minimum

Preheat Temperature

Postweld Heat Treatment

Temperature
Holding Time

To 1-1/2 in.:
70F
Over 1-1/2 in.: 250F

1100-1200F

Per Code

INSPECTION, EXAMINATION, AND TEST

8.2 Quality Control
8.2.2.1 (Addition) Fine grain, high definition, high contrast film (Kodak Type AA or
equivalent brands) shall be used. Fluorescent intensifying screens shall not
be used.
Comment 8.2.2.1 Using this type of film enables the viewer to see more
fine detail.
8.2.3

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(Addition) Company shall be notified sufficiently in advance so that it may

designate the locations at which the spot radiographs shall be taken.
December 1989

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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8.2.13 Hardness Examination

Comment 8.2.13 Weld metals which are harder than the limits specified herein
may fail in service from sulfide stress cracking. If exposed to conditions which
promote cracking, failure can occur quickly. Because the incidence of sulfide
cracking in the industry is high and cracking-resistant (i.e., soft) weld metal is easily
obtained, these precautions are justified as a general requirement.
The following are additions or exceptions to the items listed in Paragraph 8.2.13 of
API 661.
1.

(Addition) Hardness readings need not be taken on a carbon steel header if

demonstrated to Company that it is welded with a brand of rod or wire which
has been proven to have an acceptable maximum hardness.

2.

(Addition)
tester.

3.

(Addition) Tests shall be made after any required postweld heat treatment
and before hydrostatic testing.

4.

(Exception) Any carbon steel joint with a hardness over 200 Brinell or lowalloy joint with a hardness over 215 Brinell shall be rejected.

5.

(Exception) Hardness shall be verified by one spot hardness test of weld

metal on each circumferential and each longitudinal joint.

6.

(Addition) Proposed corrections to lower hardness of rejected joints shall

be submitted in writing to Company for approval.

Tests shall be made with a Telebrineller or Bitzen hardness

8.3 Pressure Tests

8.3.1

(Addition) The tube side shall be hydrostatic tested to 1-1/2 times the maximum
allowable pressure at the test temperature calculated for the nominal thickness as
constructed in accordance with Code Paragraph UG-99(b).

8.3.3

(Addition) The minimum fluid temperature for hydrostatic testing shall be higher
than the Minimum Pressurizing Temperature listed on the Data Sheet EXH-DS-1826.
Comment 8.3.3 The exchanger materials are selected to avoid brittle fracture
down to the Minimum Pressurizing Temperature. If hydrotested at lower
temperatures than this, brittle fracture could occur during the hydrotest.

8.3.7
December 1989

(Addition)

Normal service gaskets shall be used for all hydrostatic tests.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

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Comment 8.3.7 The ability of a gasket joint to pass a pressure test depends on the
gasket used. This paragraph prevents the Vendor from using something other than
the normal service gasket to make it easier to pass the hydrotest.
8.3.8

(Addition) The purchaser's inspector shall witness the final required tests as
described above.

8.4 (Addition) Shop Run In

A shop run of the completely assembled exchanger is required. The Purchaser's inspector
shall witness this test.
Comment 8.4 This shop run verifies that everything fits and vibration levels are
acceptable.
8.5 Nameplate
8.5.3

(Addition) In addition to the data required by the Code and API 661, the nameplate
shall give the following information:
a.
b.
c.
d.

9.0

Maximum allowable working pressure

Maximum allowable temperature
Company's order number
Stamp of Company's inspector

PREPARATION FOR SHIPMENT

9.1 General
9.1.4

(Exception) Company will specify coating system to be used and surface

preparation requirements. Vendor may submit alternate coating proposals for
Company review and approval.
Comment 9.1.4 On major construction projects, use the project painting
specification if one exists. Otherwise, select the appropriate coating system from
the Coatings Manual, use the table in Drawing COM-EF-68A or 68B (Section 210)
to select the proper coating system. Then refer to the data sheet for that specific
coating system, which can be found in Section 1120. It will give the exchanger
manufacturer the information he needs to coat the exchanger the way you want.
Also, give the exchanger manufacturer a list of acceptable coatings; these can be
found in COM-EF-872A or B of the Coatings Manual.

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Specification EXH-MS-1826-H

AIR COOLED HEAT EXCHANGERS

Commented Copy Not for Vendor/Contractor Distribution
For example, in an inland location, Section 210 (COM-EF-68A) will tell you to use
Coating System 2.3 for uninsulated surfaces which are below 300F and/or must
withstand steamout. In Section 1120, you will find the data sheet for System 2.3,
which tells you what surface preparation and film thickness are required. It also
gives you a Chevron code number for the coating (in this case P9). The acceptable
brands list COM-EF-872-A or B in Section 1100 tells you what P9 really is and who
makes brands that have a good performance record.
Vendor's standard coating systems will generally not perform as well as the ones
the Coatings Manual recommends. However, they can be used and will save money
when the environment where the exchanger is to be used is only mildly corrosive.
Vendor's standard is also a useful option when a coating is not needed for the
service conditions, but only to protect the exchanger from rust which might occur
before it is placed in service.
In severe environments (i.e., offshore), the header tubesheets may require painting.
In this case, the tubesheet face must be painted prior to tubing the unit using care
not to paint welds or other parts of the header. The reason for this is that the
tubesheet is impossible to clean and paint after the tubes are installed. The
remainder of the header is painted after the hydrostatic test.
9.1.5

(Addition) Connections equipped with permanent blind flanges or covers shall be

bolted up with specified gaskets in place, ready for service. All other flange faces
shall be protected by applying a stiff grease and bolting on wooden or steel covers
with at least four bolts.
Threaded connections on outside of heat exchanger shall be protected from damage
by installing carbon steel bar stock plugs.
Tell-tale holes in reinforcing pads shall be plugged with stiff grease only.

11.0 COMPANY REFERENCE DOCUMENTS (ADDITION)

The following drawings and specifications are referenced in and are part of this Specification:

EXH-DS-1826
DRI-EG-404
DRI-EG-1824
GAM-EG-3042
NCM-EF-594
GD-M13909
GF-M88575
GF-M99645

December 1989

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