air cooled heat exchangers - gea brochure

GEA Luftkühler GmbH

Energy TechnologyDivision

Air-CooledHeat Exchangers

“cool engineering”

GLK-PROZESSLUFT-E-2607-Q 17.09.2002 14:57 Uhr Seite 1

AAir for CoolingAir cooling is a process of choice in many applications. Modern utility facilities are, ofcourse, among the installations that are usually air cooled.

Air is hardly corrosive, does not cost a price, is an unlimited resource, is a clean coolingfluid, does not need to be treated and is not subject to strict disposal standards.

The size of air cooling systems is essentially a function of the maximum air inlet temper-ature and the desired product outlet temperature of the heat exchanger. For this reason,the surplus capacity of an air cooler is substantial when the outdoor temperature is low.The reduction of air flow under these conditions optimizes cooler performance, lowersenergy consumption and reduces noise levels.

Wherever water is costly, but product temperatures must be very low, GEA Luftkühler offers evaporative coolers which can be changed over from wet to dry operation.

GEA Luftkühler supplies customized coolers designed to GEA standards, recognized international standards and codes of practice and all applicable rules and regulations.Coolers and heat exchangers made by GEA Luftkühler feature a wide range of differentfin shapes and headers in any material or combination of materials desired.

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Air-Cooled Heat Exchangers

Horizontal type air cooler at Shell Per+, Rotterdam / The Netherlands


SSectors and Applications ServedGEALuftkühler’s air-cooled heat exchang-ers serve a wide range of sectors and appli-cations including refineries, the chemical in-dustry, the petrochemical industry, oil andgas production operations, pipeline com-pressor stations, steel mills, mining, powerstations, water recooling systems and largeair-conditioning plants.

GEA Luftkühler offers a complete range ofservices including:

❚ feasibility and viability studies,❚ conceptual design,❚ basic engineering design, ❚ detailed engineering design,❚ procurement and production, ❚ assembly and installation and❚ commissioning including operator

training.

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Air-cooled condenser in a chemical plant

Central water chilling plant


LL TubesApplications: The Ltube is a finned tube for low temperature applicationswhere a certain degree of protection of the tube wall against corrosion isrequired. The broad contact surface between the tube and the finning en-hances heat transfer.

Manufacture: The foot of the fin is shaped first and the fin is then tension-wound around the tube. Each fin is in contact with an adjacent fin and pro-vides a certain degree of protection in atmospheres which are not highlycorrosive. The manufacturing technology allows the use of relatively thin-walled tubes.

XXE TubesApplications: XE tubes are mainly used for high pressure applications wherespace is limited. The tube combines the excellent properties of galvanizedsteel tubes featuring steal finning with the geometry of round tubes. The de-sign (two tubes with one fin) minimizes the size of the exchanger. As the finsare very stiff, they can be cleaned easily by high-pressure water without dam-age to the finning.

Manufacture: The process for the manufacture of the XE tube is similar tothe FE tube production process.

FFE TubeApplications: The FE tube is a finned tube with an optimized shape whichfeatures excellent thermodynamic properties. The airside pressure dropacross an elliptical finned tube is lower than the pressure loss in a round-tube exchanger, as less downstream turbulence is developed. Turbulatorson the finning which have a negligible impact on pressure loss achieve ex-cellent heat transfer rates. Rectangular fins keep the face area limited andallow a compact design.

Galvanization and the wide fin collar enhance heat transfer between thetube and the fin and make the finned tube insensitive to thermal and mech-anical stress. The fin collar and the metal-to-metal joint strengthen the tube.Complete external galvanization provides outstanding protection againstcorrosion. Cleaning by high-pressure water lancing presents no risk.

Manufacture: Fins are punched and then lined up on the tube by an auto-matic process. The galvanization that follows achieves excellent heattransfer and corrosion resistance properties.

Fin material: SteelTube material: Steel/stainless steelWorking temperature: 360°C

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Finned Tube Details


Fin material: SteelTube material: Steel/stainless steelWorking temperature: 360°C

Fin material: AluminumTube material: Any metalWorking temperature: 130°C

The cost efficiency of air-cooled heat exchangers depends essentially on the heat transfercapabilities of the finned tube used. Important factors to be considered include the heattransfer rate, the size of the heat exchanger and the airside pressure drop.


BBimetal Finned TubesApplications: Bimetal finned tubes are designed for increased tempera-ture service and protect the tube fully against atmospheric corrosion. Theextruded fins feature 40 % more aluminum than comparable fins. Theyare very sturdy and resistant to mechanical stress and can therefore becleaned easily by steam or water. The tube material can be adapted to thefluid handled. The tube is for this reason fit for nearly all aggressive chem-icals.

Manufacture: The fins are extruded from a sleeve around the tube. In thisprocess, the inside diameter of the sleeve is reduced and the sleeve ispressed on the tube. The process produces a strong joint with excellentheat transfer capabilities.

GG-Fin TubeApplications: The G-fin tube was designed for high thermal or mechan-ical stress.

Manufacture: The finning is tension-wound into a helical tube groove andembedded in the groove by high-pressure expansion. The material dis-placed is then pressed against the fin sides.

KK TubeApplications: The K tube was developed from the L tube for increasedtemperature levels and provides enhanced corrosion protection to the out-side wall of the tube.

Manufacture: The foot of the fin is shaped first and the fin is then tension-wound around the tube. Knurling tools both precede and follow the finand lock the fin material in the pre-knurled tube. The process increasesthe area available for heat transfer. The joint between the fin and the tubeis air tight and improves corrosion protection.

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Fin material: AluminumTube material: Any metalWorking temperature: 250°C

Fin material: AluminumTube material: Any metal suitable foreasy mechanical processingWorking temperature: 400°C

Fin material: Aluminum.Tube material: Any metalWorking temperature: 220°C


SStudded Header with CoverThe studded header features top or bottom nozzles to allow cover removalwithout disassembly of the piping. Nozzles may alternatively be integratedin the cover.

The header is fit for a maximum pressure of 60 bar depending on fluid tem-perature and the type of sealing. Anon-standard header design is requiredfor higher pressures.

Tubes may be weld connected or expanded.

SScrew-Bolted Header with CoverThe screw-bolted header features a removable cover for easy inspectionand tube cleaning. It is normally sufficient to remove a pipe bend forinspection, since the removal of the bend allows the examination of partof the tube array.

Tubes may be weld connected or expanded.

WWelded HeaderThe low-cost welded header is mainly used for clean products or vacuumpressure conditions. The tubes are welded into tube sheets to which thebonnet-type header with the necessary nozzles is welded.

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Tube-to-header joints are either welded or expanded depending on header design. A range of header designs has beendeveloped for different applications and requirements. Standard header configurations are presented below.

Header Details


PPlug-Type HeaderTubing is usually connected to plug-type headers by expansion, but mayalso be weld-connected to the tube sheet. A threaded plug with a soft irongasket is provided opposite each tube and may be removed for furthertube expansion or tube cleaning. As nozzles are top or bottom mounted, pip-ing does not need to be disassembled for inspection or cleaning.

The plug-type header is normally used for high-pressure applications.

H

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H

High-Pressure Headerwith Plugged ReversingSegmentsAthreaded plug with a softiron gasket is located oppo-site each tube. The plug maybe removed for further tubeexpansion or for tube clean-ing.

High-Pressure Headerwith Welded ReversingBendsThe two high-pressureheaders are ideal for hightemperature differences,since each tube can expandand contract indepen-dently.


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Configurations

GEA offers a range of air-cooled heat exchanger configu-rations to accommodate different process and site require-ments. Unrestricted air access and discharge is vital for eachof these configurations: Roof-mounted structures are oftenselected where space is limited.

vertical configuration

roof-mounted configuration in-line configuration

horizontal configuration

induced draft

forced draft

forced draft induced draft


FFan, motor and reduction gearing selectionFan blading is manufactured from aluminum or fiber-re-inforced plastic. The air flow rate and noise emission speci-fications determine the number of blades, the blade shapeand the fan speed. All fans are balanced in accordance withapplicable standards and codes.

Belts and pulleys are normally used for all motor ratings.Dynamic balancing is provided for pulleys. V-belt, toothedbelt and power band drives are available. Gear drives arelimited to large motors.

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Fan Details

increased noise emission requirements

v: 40-45 m/s n:>6 blades d/D:=0.30

The following systems are employed to control air flow,either single or in combination:

• louvers (manual or automatic)• pole reversing motors• automatically adjustable fan blades• frequency converters

standard noise emission requirements

v: 50-60 m/s n:>4 blades d/D:=0.23

model currently used to satisfy strictestnoise emission requirements

strict noise emission requirements

v: 28-32 m/s n:>8 blades d/D:=0.37


GGeared DriveThe motor shaft is coupled directly to theinput shaft of the gearing.

IInduced-Draft Belt DriveIf the discharge air temperature is low, themotor may alternatively be mounted abovethe heat exchanger.

FForced-Draft Belt DriveThe speed of the motor is reduced to the de-sired fan speed by means of pulleys.

DDirect Drive The fan is mounted directly on the motorshaft. The fan and the motor operate at thesame speed.

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Fan Drive Details


FFinned-Tube BundleThe finned-tube bundle consists of the finned tubing (or unfinned tubes in certain cases), the headers (manifolds)and a frame.

AAir Cooler BankThe air cooler bank consists essentially of finned-tube bundles, fan rings, axial-flow fans with their motors, a supportstructure as well as any maintenance platforms, louvers and other equipment required by the client.

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Luftkühler’s Design Details

heating coil

louver

finned-tube bundlefan

fan ringair plenum

support structure

belt

pulley

motor

vent/drain

inlet header

outletheader

tube sheet (floating side)

guide bolt

cover

gasket

tube sheet(fixed side)

bracket

finned tubes

lug

side wall

cover plate


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Quality Management System and Quality Assurance


GEA Luftkühler’s quality management system has beencertified to ISO 9001 since 1992.

The quality management manual contains written in-structions for each single operation of a project from de-sign to delivery to assure that each product fully satisfiesall requirements of the customer specification or the rele-vant standards and codes.

Qualified staff such as design engineers, welding engineers,non-destructive test examiners and quality inspectors re-sponsible for receiving inspections, interim tests and finaltests ensure compliance with all engineering design, pro-duction and test quality standards.

Pressure vessels can be designed, manufactured, tested andmarked in accordance with all relevant international codesincluding AD-M 2000, Stoomwezen requirements, Britishstandards, ASME codes and standards, API 661 or theEuropean Pressure Equipment Directive 97/23/EC.

Advanced computer-aided quality and weld scheduling to eliminate interface risks and tooptimize quality

Quality Management System and Other Certifications❚ ISO 9001❚ AD Merkblatt HP0❚ EN 729-2❚ ASME Pressure Vessel Code, Sec. VIII, Div. 1 and 2❚ Lloyd’s Register, class 2/2❚ Ö-NORM 7812-1❚ UDT Poland requirements

Notified Bodies for the Verification ofDesigns and Tests❚ Supervising organizations of the chemical and

petrochemical industries❚ RWTÜV❚ Stoomwezen ❚ Lloyd’s Register❚ Bureau Veritasand others


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GEA test bench for fans

Research and Development

Flow simulation using the PHOENICS CFD software Wind tunnel model testing / R&D centre in Bochum / Germany

The headquarters Research and Development Center ofGEA Luftkühler develops new and improved productswith a highly customer-focused approach.

Both advanced mathematical modeling techniques andwind tunnel tests visualizing air flows are used. These re-sources allow GEA Luftkühler to optimize large-scale fa-cilities for local site conditions during the design phase.

Finned tubes for air-cooled heat exchangers are also im-proved continuously using a wind tunnel built specifical-ly for this purpose.

Fan design is a function of the fan performance requiredand applicable noise emission standards. GEA Luftkühleroperates its own fan test bay to test the efficiency and thenoise emissions of full-scale fans nearly under field condi-tions and to optimize fan units.


Refineries

Facility Customer1. Lingen, Germany Lurgi2. Nanking, China Lurgi3. Shell Cressier, Switzerland Comprimo4. Shell Per+, The Netherlands Fluor/Lummus/Comprimo 5. Samara, Russia Salzgitter Anlagenbau6. PCK Schwedt, Germany Edeleanu Leipzig7. Slovnaft, Slovakia Raytheon Engineers8. Kaucuk, Czech Republic ABB, Lummus Global9. MSPO-2, Moerdijk, The Netherlands ABB/Shell

10. DEA Heide, Germany Lurgi11. DEA Wesseling, Germany Edeleanu Alzenau12. Tar

Petrochemical Plants

Facility Customer1. Methanol plant, Sabameth, Malaysia Lurgi2. Styrene plant, BASF, Germany Krupp Koppers3. Urethane plant, China Hanyang Chemical4. Methanol plant, Trinidad Ferrostaal5. Propylen glycol and ether plant, The Netherlands John Brown6. Styrene expansion project, Antwerp, Belgium BASF Antwerpen N.V.7. Cracker, EC, Dormagen, Germany Bayer8. Methanol plant, Khag Island, Iran Centrigrade, Shiraz9. EOA plant, BASF, The Netherlands Kraftanlagen Energie- und

Umwelttechnik GmbH

Steel Mills

Facility Customer1. Kursk steel mill, Russia DSD, Düsseldorf2. Posco steel mill, Korea Mannesmann Demag3. ICDAS steel mill, Turkey ICDAS, Istanbul4. Water recooler, Germany Dillinger Hütte5. Water recooler, Germany Stahlwerke Bremen6. Water recooler, Russia VAI, Linz7. Evaporative air cooler, Germany Salzgitter Anlagenbau8. Water recooler, Belgium Sidmar, Belgien

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Major Reference Plants


Gas Facilities and Compressor Stations

Facility Customer1. Orenburg pipeline, Russia Mannesmann Anlagenbau2. Yamal pipeline, Russia AEG Kanis3. Gas coolers, Germany PLE/Ruhrgas4. Berlin gas plant, Germany Babcock Borsig5. Grijpskerk II, The Netherlands NAM B.V.6. Gas coolers, Czech Republic CKD, Prag7. Gas coolers, TAG II OMV, Wien8. Gas coolers, ARAK, Iran PLE, Essen

Other Installations

Facility Customer1. Cabora Bassa, Apollo, Mozambique AEG, Frankfurt2. Aramco gas program, Saudi Arabia Aramco, Dhahran3. Sasolburg coal gasification plant, South Africa Lurgi/Linde/Fluor4. Medina air conditioning plant, Saudi Arabia York Int’l, USA5. Condenser, Saudi Arabia ABB/SADAF6. Evaporative cooler, Schwarzheide, Germany BASF Schwarzheide7. Condenser, Al-Jubail, Saudi Arabia ABB Lummus B.V.

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Erection of an air-cooled heat exchanger High-Pressure, plug type, alloy steel header

Roof type condensers, BASF Antwerp / Belgium Air cooler, LGN plant Woodside / Australia


GEA Luftkühler GmbH · Dorstener Strasse 18-29 · D-44651 Herne, Germany · Tel. ++49/234/980-0 · Fax ++49/234/980-1974

www.gea-luftkuehler.com

Energy Technology Division

GEA LuftkühlerGmbH

A company of mg technologies group

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air cooled heat exchangers - gea brochure

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