Professional Documents
Culture Documents
Capabilities
AXH air-coolers’ offers an unparalleled level of experience and technical expertise throughout
the entire organization with nearly 400 employees. AXH’s (2) plants, which total 249,000 sq ft ,
are located on 25 acres outside of Tulsa adjacent to Route 66 in Claremore, Oklahoma, in which
AXH Plant 1 is the largest single manufacturing facility in the air -cooled industry.
Reliability
We have manufactured tens of thousands of air-coolers for the natural gas compression and
process industries and have an established reputation for meeting delivery commitments.
Foremost we are committed to quality assurance and on time shipment.
Integrity
AXH air-coolers’ objective and commitment is to consistently provide our customers with the
highest quality air-coolers and support at a competitive price.
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AXH air-coolers
AXH Plant 1
186,000 Sq Ft with
over 300 Employees
AXH Plant 2
59,000 Sq Ft located on
13 acres
Slide 3
AXH air-coolers
Facilities
Bay #1 – Large Cooler Final Assembly - Paint Room #1
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AXH air-coolers
Facilities
Bay #2 – Assembly Area, Paint Room #2, Structure Dept
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AXH air-coolers
Facilities
Finning Area in 750 foot long Bay #1 5,000 Sq Ft Parts Warehouse
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AXH air-coolers
AXH Plant No. 2 – Bay 1
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AXH air-coolers
Equipment
Bay #3 – Dual High Definition 105’ Plasma Table
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AXH air-coolers
Equipment
Bay #3 – 5-Axis C&C Pipe Beveler - 20” ID Max
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AXH air-coolers
Equipment
Bay #3 – Larger of Two Horizontal Bridge Mills
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AXH air-coolers
Basics
of
Air-Cooled Heat
Exchangers
Slide 11
AXH air-coolers
Overview
I. Cooler Component Parts and Their III. Basic Heat Transfer Fundamentals
Functions
• Sections (Headers and Fin Tubes – IV. Primary Design and Sizing Criteria
coils or Bundles)
• Factors Affecting Cooler Size and Cost
• Structure
– Ambient Temperature
• Mechanical Components (Fans,
Bearings, Motors and Drives) – Approach Temperature
• Accessories (Louvers, Bug – Allowable Pressure Drop
Screens, Hail Guards and Auto – Gas SPGR
Controls) – Noise Limitations
– Gas Composition – Sweet-vs-Sour
II. Categories and Types of Coolers
• Categories V. Basic Fan Laws (Cooler Noise and
– Forced Draft Attenuation)
– Induced Draft • Effect of Tip Speed on Noise and Size
• Types and Models • Fan Noise Projection
– Vertical Sections and Fans • Sound Basic Fan Performance
– Horizontal Sections and Fans • Deterioration
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AXH air-coolers
I. Cooler Component Parts and Their Functions
ACCELERATOR ROD
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AXH air-coolers
Cooler Nameplate
Section Nameplate
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AXH air-coolers
Finned Tubes
L-Foot Fin
Slide 19
AXH air-coolers
High Efficiency Fin Design
Inherent advantages include a reduction in overall size and heat transfer surface requirements for a specific cooling duty.
Conversely, a similar sized cooling section using the high performance fin will require either less air flow thereby reducing
power costs or will provide increased cooling capacity. This is an important factor when replacing older tube bundles or
sections.
The High Performance Fin design can offer up to 25% greater heat transfer than the conventional plain fin design. A spiral,
L-foot or shoulder-type fin with radial openings achieves superiority over the plain smooth fin by substantially reducing
required heat transfer surface while incorporating the strength and non-clogging characteristics of a smooth fin.
When any fluid passes over a surface, a stagnant fluid layer or film builds up adjacent to the surface. The greater the contact
area and/or longer contact length the greater the stagnant layer becomes. In similar fashion, air passing over a plain or
smooth fin surface forms a thin but stagnant air film that reduces thermal conduction and lowers the rate of heat transfer to
the atmosphere. The High Performance Fin's interrupted surface through its radial openings, prevents this stagnant film of air
from reaching its maximum thickness thus increasing the outside film transfer coefficient. Importantly, it does not increase the
turbulence of the air passing over the fins and the result is an increase in overall heat transfer rate without an increase in
static pressure or fan horsepower.
Slide 20
AXH air-coolers
Tube & Plug Sheets
Ring Grooves
Slide 21
AXH air-coolers
Fabricated Box Header
Section (Tube Bundle Assembly)
Fin Tubes
Top Tube
Plug Sheet Support
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AXH air-coolers
Rectangular Tube Header
(non-code)
Combined Header
Divider Plate
End Block
Water Header
Pipe
Flange
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AXH air-coolers
Slab Header Patented Obround Header
Slide 24
AXH air-coolers
Structures
Induced Draft Type VI
Forced Draft Type EF
WATER FLOW
POSITIVE HEAD
STATIC
HEAD
Slide 26
AXH air-coolers
Mechanical Components, Drives, & Guards
Internal EF Motor & V-belt Drive Engine Drive - V-belt Drive and Slide Idler
• Accessories
– Louvers
– Auto Controls
– Discharge Guard
– Bug Screens
– Hail Guards
– Vibration Switch
Slide 28
AXH air-coolers
Fan Guard / Bug Screen Guard
3/16” Galvanized Woven Wire Guard Material
Slide 29
AXH air-coolers
Inlet Louvers on Induced
Draft Type VI
Slide 30
AXH air-coolers
Aluminum Shutters and Discharge Coil Guard
Slide 31
AXH air-coolers
II. CATEGORIES AND VARIOUS TYPES OF COOLERS
AXH Air-Coolers Models and Configurations
The nomenclature used by AXH Air-coolers to define various models and sizes consists of a combination of numbers and
letters. The numbers reflect the fan size and the number of fans while the letters signify the type of cooler. The first group of
numbers indicates the fan size in inches, the next group of numbers following a hyphen (-) represents the number of fans,
and the last group of letters reflects the type of cooler. Examples are: (108EF, 42VV, 132-2ZF.
Type EF – Vertical discharge, forced draft with sloped sections is the most widely used and recognized packaged engine and
compressor cooler in the history of the industry.
Type E – Similar to Type EF, forced draft, vertical discharge, with sections “rotated” 90° with tubes running vertically
resulting in a narrower overall width.
Advantages
•Inherently more efficient Forced draft design
•Ideally suited for multiple services including engine utility cooling along with oil and multi-stages of gas
compression
•High vertical discharge air velocity results in the cooler being less affected by wind direction or adjacent
equipment
•Sloped sections result in greater cooling capacity in a smaller footprint or plot area
•Elimination of “top-heaviness” means greater safety, stability, and ease of handling
•Superior air-flow minimizes hot air recirculation
•Improved safety with excellent visual inspection and access to critical moving parts
Type FF – Multiple fans, lower profile, forced draft with narrower width designed for larger horsepower engine
driven applications.
Advantages
•Also offers multiple cooling services in a single multiple fan unit
•Forced draft design is inherently more efficient
•Narrow width and lower profile
•Section design facilitates piping
•Single, fan-shaft drive
•Improved safety with excellent visual inspection and access to critical moving parts
Slide 32
AXH air-coolers
II. CATEGORIES AND VARIOUS TYPES OF COOLERS
AXH Air-Coolers Models and Configurations
Type VI – Single fan, induced draft, vertical discharge, primarily for engine driven applications.
Advantages
•Offers multiple cooling services in a single unit
•High vertical discharge air velocity results in the cooler being less affected by wind direction or adjacent equipment
•Greater accessibility to sections
•Potentially superior air-flow control improves process operation
Type VV– Horizontal airflow, either forced or induced draft, (F-forced, I-induced) can be either engine driven or electric
motor driven. Generally used for smaller horsepower applications where engine cooling is not involved and economics are a
prime consideration.
Advantages
•Can accommodate multiple cooling services in a single fan unit
•Available as either a Forced or Induced draft design with horizontal air flow
•Round tube, box header construction with ASME code designs
•Small installation footprint
•Easy access to sections
•Excellent visual inspection and access to moving parts
Type ZF – Horizontal, forced draft, typically remote mounted, normally electric motor driven with suspended drives,
generally bolted galvanized construction with individual column legs (otherwise similar to the Type HF) in plan area.
Type HF - Horizontal, forced draft, single or multiple fans, normally electric motor driven, incorporates integral substructure
base, leg extensions and can accommodate various type drives, including internal plenum drive components like the type
ZF.
Slide 33
AXH air-coolers
II. CATEGORIES AND VARIOUS TYPES OF COOLERS
AXH Air-Coolers Models and Configurations
Advantages
•The horizontal Type ZF and HF coolers offer flexibility that can accommodate multiple cooling services in a common
horizontal cooler
•Self-contained design eliminates field assembly and reduces transportation costs and field installation time
•Available with single or multiple fans
• Forced or Induced draft configurations
•Accommodates various type drive options
•Excellent access to component parts and inspection
Type ZI – Horizontal, induced draft, otherwise, similar to Type HF or ZF, ideally suited for pipe rack mounting or congested
areas where higher discharge air velocities are desirable.
All structural designs, except Type VV, provide for the (vertical) upward discharge of heated air, reducing the deterioration
of performance due to wind direction and the effects of hot air recirculation.
Slide 34
AXH air-coolers
II. Types of Coolers
1. Forced Draft - Fan handles cooler more dense ambient air forcing
air over the tube bundles.
2. Induced Draft - Fan handles hot air after it has been drawn or
induced over the tube bundles.
Slide 35
AXH air-coolers
Forced Draft / Induced Draft
Basic Advantages
Much better suited for warm air recirculation system Slightly quieter (1-2 dBA) in Vertical VI design
Protected interior coils with EF
Inherently safer positive static head between fan and
coils
Better suited for bug screens
Requires less skid space with EF
CG near physical center of unit with EF
Slide 36
AXH air-coolers
II. Categories and Various Types of Coolers
Type EF –
• Forced draft
• Vertical discharge
• t
• Sloped sections
• Most widely used and recognized packaged engine and
compressor cooler in the history of the industry.
Advantages
• Inherently more efficient
• High vertical discharge air velocity results in the cooler being less
affected by wind direction or adjacent equipment
• Sloped sections result in greater cooling capacity in a smaller footprint or plot area
• Improved safety with excellent visual inspection and access to critical moving parts
Slide 37
AXH air-coolers
Type EF
Slide 38
AXH air-coolers
Type EF - Air Flow
AIR
AIR
AIR
Slide 40
AXH air-coolers
II. Categories and Various Types of Coolers
Type VI –
• Induced draft
• Single fan
• Vertical discharge
• Primarily for engine driven applications
Advantages
• Multiple cooling services in a single unit
• High vertical discharge air velocity results in the cooler being less affected by wind direction
or adjacent equipment
Slide 41
AXH air-coolers
Type VI
Slide 42
AXH air-coolers
II. Categories and Various Types of Coolers
Type VV –
• Horizontal airflow
• Forced or Induced draft, (F-forced, I-induced)
• Can be either engine driven or electric motor driven
• Generally used for smaller horsepower applications
where engine cooling is not involved
• Economical
Slide 43
AXH air-coolers
II. Categories and Various Types of Coolers
Type ZF –
• Horizontal
• Forced draft
• Typically remote
• Normally electric motor driven with suspended drives
• Generally bolted construction with individual column legs
Slide 44
AXH air-coolers
Special Designs
Model 48-2ZF
with Evaporative
Inlet Coolers
Type ZF
(3) Two Fan with
Winterization
Slide 45
AXH air-coolers
ZF Structure Assembly
Slide 46
AXH air-coolers
II. Categories and Various Types of Coolers
Type HF –
• Horizontal
• Forced draft
• Single or multiple fans
• Normally electric motor driven
• Incorporates integral substructure base
• Suitable for recirculation systems
• Leg extensions and can accommodate various type drives
Slide 47
AXH air-coolers
Induced Draft Model 120ZI
Slide 48
AXH air-coolers
Warm Air Recirculation Systems
Slide 49
AXH air-coolers
Warm Air Recirculation
Pneumatic Actuated
Shutters Warm Air
Recirculation
System
Type EF Recirculation
Assembly
Slide 50
AXH air-coolers
Type ZF – Galvanized Model 138-2ZFR
INTERNAL DRIVES WITH OVER THE END WARM AIR RECIRCULATION SYSTEM
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AXH air-coolers
Basic Cooler Design
Slide 52
AXH air-coolers
III. Basic Heat Transfer Fundamentals
S = Q (BTU/HR)
U x LMTD
Where:
S= Bare Tube Surface Area (SQ FT)
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AXH air-coolers
Tube Surface
Tube size Bare Tube Surface Extended Tube Surface
Slide 54
AXH air-coolers
”Q”- Heat Load or Duty
Calculation of Q in equation btu/hr:
• Fluid Properties
• Fin Type
• Tube Fouling (internal)
• Film Thickness (air and fluid sides)
• Tube Side Velocity
(pressure drop, tube size & length, pass arrangement)
• Air Side Velocity – Fan HP
Slide 56
AXH air-coolers
“LMTD” - Log Mean Temperature Difference
Slide 57
AXH air-coolers
Air Temp Rise oF(ATR) = Heat Load / (SCFM x 1.085)
Hot Discharge Air Flow
Slide 58
AXH air-coolers
IV. Primary Design and Sizing Considerations
Site Conditions:
Mechanical:
Slide 59
AXH air-coolers
IV. Primary Design and Sizing Considerations
Process:
Slide 60
AXH air-coolers
Ambient -vs- Size (Cost)
105
133%
100
122%
110 95 111%
AMBIENT TEMPERATURE
90 100%
105 86 91%
95
Type EF Cooler
90 1200 Horsepower
Two-Stage
85 * 90 F Ambient Base Design
80
800 900 1000 1100 1200
OPTIMUM TUBE SURFACE - SQ. FT.
Slide 61
AXH air-coolers
Approach vs Surface (Size)
220
210 40 (130°) 79%
190
180
170
GAS
160
150
140
130
120 .2%
.5%
110 1%
100 2%
∆Ρ
90
0 50 100 150 200 250
SURFACE AREA - SQ. FT.
Slide 64
AXH air-coolers
Minimum Surface vs SPGR (Mass Flow - #/HR)
& Heat Load
450
BTU/HR
400 SURFACE-SF
350
300
250
SQ. FT.
200
150
100
50
0
SPGR .60 .65 .70 .75 .80 .85
Static Pressure
- Varies as the Square of the change in air flow.
Fan Horsepower
- Varies as the Cube of change in fan speed.
AIR FLOW
AIR FLOW
Slide 67
AXH air-coolers
ALTITUDE I TEMPERATURE
FT. DENSITY RATIO °F
8000 300
1.90
.90
SEA LEVEL 0
Slide 68
AXH air-coolers
Aerovent 6-blade, 96” @ 13,000 fpm
1.8 40.0
1.6 30.0
24°
1.4 22° 20.0
.8
.6
.4
.2
0
0 20 40 60 80 100 120 140 160
CFM - 1000
Slide 69
AXH air-coolers
Blade Angle –vs- Stall Condition
Slide 70
AXH air-coolers
Noise Level Vs Tip Speed
100 1800
90 6,000 fpm
7,000 fpm
8,000 fpm
80 9,000 fpm
10,000 fpm 1350
11.000 fpm 69.5
70
SURFACE (FT2)
dBA @ 50 FEET
67.3 12,000 fpm
60 64.8
62.1
59.0
50 51.5
55.5 900
40 dBA Level
30
450
20 Model 120EF / 840HP Engine Driven Screw
Constant Pitch & Number of Blades
10
0 0
6 7 8 9 10 11 12
TIP SPEED - 1000 fpm
900
450
0
6 7 8 9 10 11 12
PERCENT FAN
HORSEPOWER
80 75 HP 80
HORSEPOWER
AMBIENT - -FF
PERCENT FAN
70 AMBIENT
AIR FLOW 70
FAN HORSEPOWER
AMBIENT
60 60
50 50
40 40
30 30
20 20
10 10
0 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 100
PERCENT SCFM
Slide 72
AXH air-coolers
Fan Noise Projection
Refer to Sound Deterioration Curve
EF
Slide 73
AXH air-coolers
Sound Deterioration
M FT
0
150 -500
300 -1000
460 -1500
615 -2000
750 -2500
925 -3000
-3500
1080
0 5 10 15 20 25 30 35 40
DISTANCE DBA REDUCTION
(Free Field Conditions)
Slide 74
AXH air-coolers
AXH Air-Coolers Design Advantages
• Use of Dodge taper roller bearings on fans and idlers which offer 10 times the life expectancy of ball bearings and are two
grade levels above spherical bearings
• Improved idler locations which provide better v-belt “wrap” and more effective adjustment on engine driven cooler models
• Formed alum channel tube supports which lock and maintain positive tube spacing as opposed to attempting to “wrap”
individual tubes with fin stock
• Heavy galvanized fan and discharge guards using 2x2 – 3/16” woven wire material, expanded metal or welded wire
• Grooved tube sheets are used on all water and oil sections to provide a superior tube seal corresponding to the double
grooving used on high pressure ASME code sections
• Additional plenum depth in both inlet and discharge chambers to achieve better air distribution with lower static resistance
on vertical discharge type coolers (EF & VI)
• Additional structural supports, both vertically and horizontally, to support additional customer mounted equipment, i.e.
mufflers and surge tanks on top, piping runs along the sides (EF & VI)
• Centering of fans vertically on all vertical discharge coolers (EF & VI) which results in improved air flow distribution,
especially to the upper sections which are normally the more critical water services
• Providing “swivel” mounts on all louver actuators to prevent potential linkage binding
• Woven, vinyl coated, polyester “soft” bug screens which provide 64% open area with at least twice the inlet area of the fan
(nylon will deteriorate in UV, sun light) which attach with Velcro with positive studs at the corner of each panel
• All coolers receive both prime and finish coats of paint during the various manufacturing steps or are galvanized
• Complete electronic documentation supplied on all orders via direct electronic access or in a CD format
Slide 75
AXH air-coolers
Slide 76
AXH air-coolers