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Finned Tube Bundle for Air-Cooled Heat Exchangers (ACHE) TEMA / ASME VIII-1 / API 661 / ISO 13706
Finned Tube Bundle for Air-Cooled Heat Exchangers (ACHE) | Design Temp -40°C to +450°C | Design Pressure Up to 10.0 MPa | Per TEMA / ASME VIII-1 / API 661 / ISO 13706
Overview - Finned Tube Bundle in Air-Cooled Heat Exchangers
An air-cooled heat exchanger (ACHE) uses ambient air as the cooling medium, passing across a finned tube bundle to remove heat from process fluid flowing inside the tubes. The finned tube bundle is the core heat transfer element of the ACHE. Fins are applied to the outside of the tubes to compensate for the low convective heat transfer coefficient of air (typically 10-60 W/m²*K) compared to liquid or condensing fluids inside the tubes.
This product is designed and manufactured per TEMA Class C/B/R, ASME Section VIII Division 1, API 661 (Air-Cooled Heat Exchangers for General Refinery Service), and ISO 13706 (Petroleum, Petrochemical and Natural Gas Industries - Air-Cooled Heat Exchangers). All parameter selections below are based on applicable design standards and process conditions.
ACHE Configuration Overview
The finned tube bundle in an ACHE consists of multiple finned tubes arranged in horizontal rows (typically 2 to 8 rows deep), supported by tube sheets and intermediate supports, with headers or inlet/outlet manifolds at each end. Ambient air is forced or induced across the bundle by fans.
A typical ACHE finned tube bundle includes:
Finned tubes (straight, with fins applied to external surface over the entire active length between tube sheets)
Tube sheets (front and rear) with drilled holes to accept tubes
Side frames and support structure
Header boxes (inlet and outlet) with flanged connections
Pass partitions (for multi-pass arrangement)
Optional: Louvers for air flow control, plenum chamber, fan ring, and wind wall
Air-Side Heat Transfer Parameters - Design Basis
The following parameters are used in thermal sizing of air-cooled finned tube bundles per API 661 and ISO 13706:
Parameter
Typical Range
Notes
Air face velocity (approach to bundle)
1.5 - 4.0 m/s
Selected based on fan power limit and bundle geometry. Lower velocity for low-noise design.
Air mass velocity (through bundle)
2 - 6 kg/m²*s
Based on bundle free area (gaps between tubes and fins).
Air-side convective HTC (bare tube equivalent)
30 - 120 W/m²*K
Depends on fin geometry, air velocity, and fin material thermal conductivity.
Fin efficiency
40% - 90%
Calculated per Kern or ESDU method. Dependent on fin height, thickness, material, and fin-to-tube bond.
Overall HTC (air-to-tube side, referenced to bare tube area)
15 - 60 W/m²*K
Typical for ACHE finned bundles in process service.
Air-side pressure drop (across bundle)
100 - 300 Pa
Per API 661 design limit. Higher values require increased fan power.
Design ambient temperature range
-40°C to +55°C
Based on site meteorological data (summer maximum and winter minimum for fan start-up/stall consideration).
Bundle face area
10 - 200 m² per bay
Larger bundles with multiple bays in parallel.
Fin Types - ACHE-Specific Selection Criteria
The following fin attachment types are commonly used in ACHE service. Selection is determined by service temperature, corrosion environment, and thermal cycling duty.
L-Foot Tension-Wound Fin (Wrap-On)
Fin strip formed with L-shaped foot, helically wound around tube under tension
Fin foot contacts tube outer surface
Maximum continuous operating temperature (fin tip / tube metal): ≤ 150°C per HTRI ESG-11
Fin materials: Aluminum 1100 (most common), Copper C1100
Tube materials: Carbon steel, 304/316L, copper
ACHE application: Low-temperature gas cooling, compressor intercoolers, hydrocarbon condensers (air-cooled) where tube-side temperature ≤ 120°C
Limitation: Thermal cycling > 100 cycles at > 120°C will degrade mechanical bond, requiring additional fin area per HTRI bond resistance correction.
KL-Foot (Knurled L-Foot)
Base tube knurled before winding; fin foot mechanically interlocked into knurled surface
Maximum continuous operating temperature: ≤ 320°C
Fin materials: Aluminum 1100
Tube materials: Carbon steel, stainless steel
ACHE application: Medium-temperature process gas cooling, compressor aftercoolers (tube-side temperature 120°C to 280°C), refinery overhead condensers
Bond characteristic: Improved bond vs. standard L-foot; retains 80% of initial thermal contact at 250°C after 1,000 thermal cycles per manufacturer test data.
LL-Foot (Overlapped L-Foot)
Fin foot overlapped to fully enclose tube circumference
Provides full tube surface coverage for corrosion protection
Maximum continuous operating temperature: ≤ 177°C
Fin materials: Aluminum 1100, Copper C1100
Tube materials: Carbon steel, 304/316L
ACHE application: Marine environment air coolers, coastal process cooling, atmospheric corrosive environment where tube OD corrosion protection is required. Alternative to more expensive extruded fin.
Extruded Finned Tube (Bimetallic)
Formed from bimetallic tube (aluminum outer sleeve on inner base tube). Fins extruded from outer sleeve by rolling.
Integral fin-to-tube bond - no mechanical gap, no bond resistance.
Maximum continuous operating temperature: ≤ 230°C (aluminum outer) - ASME/API 661 design limit for extruded fins.
ACHE application: Corrosive atmospheric environments, marine and offshore air coolers, chemical plant finned bundles, coastal refineries. Provides cathodic protection of base tube in saline environment (aluminum corrodes preferentially).
High-Frequency Welded Finned Tube
Fin strip continuously welded to tube outer surface by high-frequency resistance welding - metallurgical bond.
Fin materials: Carbon steel (hot-dip galvanized or painted), 304/316L
ACHE application: High-temperature gas cooling, waste heat recovery, fired heater convection sections, steam superheater air coolers, process gas coolers with tube-side temperature > 280°C
Serrated (slit) fin option: Provides 10-15% higher air-side HTC compared to solid fin at same fin density, with slightly increased air-side pressure drop.
Fin Geometry - ACHE Standard Ranges (API 661 / ISO 13706)
Parameter
L-Foot / KL / LL
Extruded
High-Frequency Welded
Base tube OD
19.05mm (3/4") - 38.1mm (1.5")
15.88mm - 50.8mm
19.05mm - 50.8mm
Tube wall thickness
1.65mm - 3.4mm
1.65mm - 3.4mm
1.65mm - 5.0mm
Fin height (from tube OD)
8mm - 16mm
8mm - 16mm
8mm - 19mm
Fin pitch (FPI - fins per inch)
7 - 11.5
7 - 11
2 - 7 (for high-temp, soot-prone service)
Fin thickness
0.25mm - 0.5mm
Integral (0.4mm - 0.8mm equivalent)
0.8mm - 3.2mm
Fin-to-tube surface area ratio (extended / bare)
10 - 23 (depending on height and pitch)
10 - 20
6 - 15
Max operating temp (fin tip)
150°C (L) / 320°C (KL) / 177°C (LL)
230°C
450°C
ACHE Bundle Mechanical Construction
Tube Bundle Arrangement (Common Configurations)
Tube rows: 2, 3, 4, 6, or 8 rows (API 661 typical). The number of rows is determined by required air-side heat transfer area and allowable fan power.
Tube pitch (transverse): Typically 1.5* to 2.5* tube OD (center-to-center across air flow direction)
Tube pitch (longitudinal): Typically 1.5* to 2.5* tube OD (along air flow direction)
Bundle face area: Determined by total air flow required and face velocity (1.5-4.0 m/s). Larger bundles are split into multiple bays.
Tube-to-Tubesheet Joint Types (ACHE)
Expanded joint: Hydraulic expansion at 160-220 MPa. Pull-out strength ≥ 20 MPa (per TEMA RCB-4.3 for carbon steel tubes). Suitable for non-toxic, non-hazardous service.
Welded joint: Seal weld (fillet leg 1.5-2.0mm) + full penetration for toxic or high-pressure service. Weld procedure per ASME Section IX.
Combined (weld + expand): Recommended for thermal cycling service (> 500 cycles/year) and tube-side pressure > 5.0 MPa.
Headers and Manifolds (Tube-side distribution)
Inlet/outlet headers: Rectangular or round, with flanged connections per ASME B16.5 or B16.47.
Pass partitions (baffle plates inside headers): Used to configure tube-side flow path as single-pass, two-pass, or four-pass depending on tube-side allowable pressure drop and required heat transfer coefficient.
Header design pressure: Matched to tube-side design pressure (typical 0.1 to 10.0 MPa). Per ASME VIII-1.
Air-Side Structural Elements
Side frames and support members: Steel channel or I-beam construction to support bundle weight and handle fan-induced vibration.
Wind walls: Optional vertical panels around bundle perimeter to prevent air recirculation and ensure uniform air flow distribution.
Louvers: Manually or automatically adjustable to control air flow during cold weather start-up or turndown.
Material Selection - ACHE Finned Tube Bundles
The following material combinations are standard per API 661 for refinery and process plant services. Selection is based on tube-side fluid corrosivity, operating temperature, and atmospheric corrosion severity.
Tube Materials
Material
Applicable Tube-Side Fluids
Temperature Range
Chloride Limit
ASTM / BS Spec
Carbon steel SA-179 / 106 Gr.B / 20#
Water, oil, non-corrosive gases, steam
-20°C to +425°C
N/A (no pitting risk)
ASTM A179 / A106 / GB 8163
Stainless 304 / 304L
Clean process gas, deionized water, mild hydrocarbons
-196°C to +600°C (derated above 425°C per ASME II-D)
≤ 200ppm
ASTM A213 TP304L
Stainless 316 / 316L
Chloride-containing process fluids, organic acids, sour service (≤ 200ppm Cl⁻)
-196°C to +500°C
≤ 200ppm (316L)
ASTM A213 TP316L
Titanium Gr.2 / TA2
Seawater, brine, high-chloride cooling water
-40°C to +230°C
Up to 20,000ppm
ASTM B338 / GB/T 3625
Copper-nickel C70600
Marine cooling, brackish water
-40°C to +200°C
< 500ppm (CN develops passivation layer)
ASTM B111
Fin Materials
Fin Material
Fin Attachment Type
Temp Limit
Thermal Conductivity (at 20°C)
Corrosion Resistance Notes
Aluminum 1100 / 1050
L-foot, KL, LL, extruded
150-320°C (type-dependent)
~220 W/m*K
Good atmospheric corrosion; forms protective oxide. Sacrificial to steel in coastal marine exposure (protective).
Copper C1100 / C1220
L-foot, LL-foot
≤ 200°C
~390 W/m*K
High thermal conductivity; used where maximum heat transfer required at low temp; susceptible to ammonia.
Carbon steel (galvanized / painted)
High-frequency welded
≤ 450°C
~50 W/m*K
For high-temp service; requires coating for corrosion resistance in humid environments (hot-dip galvanizing per ASTM A153 or epoxy paint).
Stainless 304 / 316L
High-frequency welded
≤ 400°C
~16 W/m*K
For high-temp corrosive service (e.g., sour gas, H₂S); no additional coating required.
