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TPo is the process side outlet temperature TAi is the air side inlet temperature TAo is the air side outlet temperature A correction factor is then added to the MTD to account for different row/pass configurations.
k = tube wall conductivity factor U = 1/R The effective outside film coefficient, in terms of tube surface, is the true air film coefficient multiplied by the ratio of total surface to tube surface and by fin efficiency. The inside film coefficient is depends on tube size, velocity of the liquid or gas in the tubes and various physical properties of the fluid, such as the viscosity. The inside fouling factor is dependent on the dirt or scale characteristics of the liquid or gas in the tubes. The outside fouling factor, based on tube surface, must be divided by the surface ratio, (bare to finned) which results in a very small figure, negligible in most cases. The thickness of the tube is normally small enough with sufficiently high conductivity that this factor is almost negligible.
1. Lower horsepower requirements due 1. Better distribution of air across the to lower inlet air temperatures. bundle. 2. Better accessibility of fans and bearings. 2. Less possibility of hot air recirculation. 3. Better accessibility of bundles for re3. Better process control since plenum placement. covers 60% of bundle face area, blocking it from sun and rain. 4. Accommodates higher process inlet 4. Increased capacity with fan off due to temperatures. natural draft stack effect. Disadvantages Disadvantages
1. Less uniform distribution of air over 1. Higher horsepower since fan is in outlet the bundle. air stream. 2. Increased possibility of air recirculation. 2. Mechanical equipment subjected to higher temperatures. 3. Low natural draft capability on fan 3. Fans are less accessible for maintenance. failure. 4. Exposure of coils to sun, rain, etc. 4. Plenums must be removed to replace bundles.
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Extruded For applications where atmospheric corrosion is critical, the extruded fin tube provides the best protection. The extruded fin is produced by inserting the tube into an aluminum sleeve and then extruding the fins from the aluminum sleeve. Since the tube is totally covered by the aluminum sleeve, the tube wall is protected from outside corrosion, and the bond between the fin and the tube remains tight. The extruded fin tube is good for tube wall temperature up to 650 degrees F. This is the most expensive fin tube to produce.
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Knurled L-footed fin: Again, this process is very similar to the L-footed tension wound fin, but utilizes knurling wheels that actually knurl the fin foot into the tube. This allows for a tighter bond between the tube and the fin, and reduces the likelihood of a corrosion film between the two. L-footed fins with slits cut into the fin: By cutting a slit into the fin, more air turbulence can be created, due to the interruption of the air boundary layer. This in turn increases the airside heat transfer coefficient with a modest increase in the airside pressure drop and the fan horsepower.
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Tapered or Eased Rings The tapered inlet and eased rings both allow for a more uniform exit of the air from the fan ring. Most fan design programs will indicate slightly less horsepower required for this configuration. In addition, these fan rings allow for better air dispersion since the air is directed when it leaves the ring. In most air-cooled heat exchangers, the cost of producing this configuration outweighs the increased savings in horsepower, or in airflow efficiency. Straight, Flanged Inlet or Channel Rings These are the most common fan rings utilized by manufacturers. This ring is easily produced, and provides good air movement if close tip clearance between the ring and the fan are maintained. The depth of this ring will vary with the fan selected.
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In the initial design of the equipment, it is possible to reduce noise in the air cooler and to have an impact on the overall plant noise. Generally, the following are general rules to use in the design of a noise efficient air cooler: Fans should be run at slow tip speeds, utilizing wide chord with blades to achieve adequate airflow. Normally this will require reducing the static pressure through the coils, due to the fact that most fans will not overcome high static pressures at low tips speed. V-belts, not cog belts should be used to drive the air cooler. Normally v-belts will add very little noise to the overall air cooler package. The use of newer cog type belts, including HTD belts will add a significant factor to the noise level. Premium efficiency motors are generally quieter than a standard efficiency motors. The motor is very seldom responsible for noise problems, however in the case of extreme noise level requirement, the motor may play a factor.
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General Air Cooler design practices 1. 2. Static pressures through the coils should be limited to a reasonable number. Normally, this would range from .4 to .7 static pressure. A general rule of thumb for the airside face velocity through the coils is as follows: 3 row coil 800 to 850 FPM 4 row coil 500 to 700 FPM 5 row coil 450 to 600 FPM 6 row coil 350 to 500 FPM On new construction, good design practice would normally restrict the number of tube rows to four. This allows for some modification, if need later, to allow for higher heat load applications. Normally, on gas compressor applications, the air is at such a high temperature after the four rows, that additional cooling from additional rows in minimal. A minimum fan to coil face area of forty percent. Air dispersion angle of forty five percent should not be exceeded, without compensating for this in the design. Fans should be operated in the mid range of the fan performance, this should be applied to tip speed, ability to handle the static pressure, and blade angle. More surface area is always better than more airflow.
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Amercool Manufacturing Inc. is a full service provider of air-cooled heat exchangers for Gas Compressors, Gas Transmission, Power Generation and General Industrial requirements. Amercool has been producing air cooled heat exchangers for these markets since its inception in 1987. The information contained in this booklet is derived from the combined experience of many years in operation, shop and field testing, and joint studies undertaken with fan manufacturers and industry groups.
Amercool Manufacturing Inc. P.O. Box 9310 Tulsa, Oklahoma 74157 Phone 918.446.4406 Fax 918.445.2857 www.amercool.com