AIR COOLERS

PROCESS CONSIDERATIONS
Fluid to

be cooled flows through the tubes, either finned or bare, and air is blown from outside to take away the heat Economic selection when
Temperature difference : 15-25 degC Heat loads > 2.52 Mkcal / hr

SELECTION
Required

cooling water not available Make up water is expensive Space permits installation of of such big unit.

CONSTRUCTION
Horizontal and

vertical units are in use Horizontal units are preferred for ease of installation Vertical units are used for maximum draining Angled sections in condensing services and positive draining. Typical angle 30 deg

HEADR DESIGN
PLUG

HEADER

HEADER DESIGN
COVER

PLATE HEADER

TUBESHEET JOINTS
EXPANSION &

GROOVE WELDING SEAL WELDING STRENGTH WELDING

DETAILS
Fan Bays: 2

are most commonly used Tubes: Length 6-50 feet; Width: 4-30 feet Fins: inch, 5/8 inch

TYPES OF AIR COOLER

TYPES OF AIR COOLER

FORCED DRAFT Consumes less power Equipment is located at lower temperature zone, hence less maintenance Lower exit velocities (3-4 m/sec), hence poor distribution and chances of back-mixing and sensitive to cross currents Offers less pressure drop INDUCED DRAFT Consumes high power Equipment is located at higher temperature zone, hence prone for maintenance Higher exit velocities (10-15 m/sec), hence better distribution and no chances of back-mixing and less sensitive to cross currents Offers high pressure drop

Cheaper Option

Expensive Cannot be used for temp > 350 degC

TEMPERATURE CONTROL
2

speed motor speed Variable speed drive Inlet / Outlet louvers Variable pitch fans Warm air circulation

WARM AIR CIRCULATION

For

extreme variation in air temperature, which might cause freezing of process fluid, certain warm air is circulated back to inlet of the unit.

WARM AIR CIRCULATION

LOCATION
Should

be located away from building Forced draft coolers are preferably located high above ground, above pipe racks to avoid backmixing Avoid placing 2 coolers close to each other. Avoid placing downwind of heat generating device.

SAMPLE CALCULATION PROCEDURE

INPUTS Data of hot fluid Physical properties, Heat load, Inlet / outlet temperature Allowable pressure drop Data of air Ambient temperature Elevation

SAMPLE CALCULATION PROCEDURE

CALCULATIONS

STEPS Assume overall HTC from chart Calculate temperature rise and CMTD Calculate Area Calculate no of tubes and tube-side pressure drop Calculate tube side heat transfer coefficient Calculate air side heat transfer coefficient based on charts available (function of air face mass velocity) Calculate overall HTC. Shall be less than assumed.

SAMPLE CALCULATION PROCEDURE

FAN

CALCULATIONS Number of fans (Fanned section length / bay width <= 1.8) Fan Area:
Face area: Projected area of fan / Face of section covered by fan; 0.40 FAPF = (0.40) x Fa / No of Fans

SAMPLE CALCULATION PROCEDURE

Fan static pressure drop

(Fp) (N) / (Dr) Fp: Pressure drop factor (function of air face velocity) N: No of tube rows Dr: Avg air density

Fan

dynamic pressure loss

(flow rate / area)2 x (Dr)

Fan Power