MASTERY IN PROCESS COOLING

AIR FIN COOLERS

BGR ENERGY SYSTEMS LIMITED

AIR FIN COOLER DIVISION
 MASTERY IN PROCESS COOLING

AIR FIN COOLERS

FIN-TUBE BUNDLES FAN
FAN RING

PLENUM CHAMBER

LOUVERS

STEAM COIL

MACHINERY MOUNT HEADER

WALKWAY

ELECTRIC MOTOR
SUPPORTING STRUCTURE BELT PULLEY

l Based on the know-how of GEA-Btt, France

l Member of Heat Transfer Research Inc (HTRI), USA
l ISO 9001 Certified and Holder of ASME U, U2 & R stamps
l Computer aided thermal and mechanical design
l Design and manufacture of air cooled heat exchangers as per ASME and API specifications.
Coolers complying to PED of European Union - CE marking
l Turnkey ability to design, engineer, manufacture, supply, erect and commission up to
950 tube bundles per annum
l Approved by Bechtel, Lurgi, SNC Lavalin, Technip, Mitsui, Toyo, Stork, Aker Kvaerner,
Chemtex, Petrofac, EIL, Jacobs H&G, UHDE, TAKREER, QP, PDO, EGPC, ENPPI, CTCI,
KBR, KNPC, SABIC, GASCO, SONATRACH, STIR, Axsia Howmar, etc
l Executed contracts under third party inspection of BVIS, DNV, EIL, Velosi, Lloyds, etc
l Finning on state-of-the art finning machines, 6 nos. G, L, KL and 1 no. extruded finning
machine, total finning capacity of 2100 kms per annum
l Expertise in carbon steel, low alloy steel, stainless steel, duplex steel, incolloy, titanium and
clad materials to ASME, NACE and other international codes and standards
l Experience in supplies to refineries, petrochemical, fertilizer, steel and power plants,
oil & gas and other process plants

PRODUCT RANGE
l Process Coolers l Tube Bundles
l Radiator and Compressor Coolers l Finned Tubes

AIR FIN COOLER SELECTION
FORCED DRAFT UNIT
Air is pushed across the finned tube surface and
fan is below tube bundle. The forced draft unit
allows easy access to fans and bundles. Fans
remain in cold ambient condition.
INDUCED DRAFT UNIT
Air is pulled across the finned tube surface and
fan is located above the tube bundles. Steady and
durable performance due to protection of
finned surface. Better air distribution and less
hot air circulation, less fouling and low noise
levels at grade.
AIR COOLER VACUUM
STEAM CONDENSER
Exhaust steam flows from the steam turbine
through large ducts to steam distribution
manifold. This manifold in turn feeds an array of
fin tube heat exchangers. While steam flows
inside the core tubes, cooling air is drawn
through the fins by large fans. Air takes the heat
from steam and converts it into condensate.
MASTERY IN PROCESS COOLING
FIN TUBE SELECTION
G EMBEDDED FINS
Max working temp: 400oC/750oF
Atm. corrosion resistance: Poor
Mechanical resistance: Acceptable
Fin consists of an aluminium strip
whose foot edge is tension wrapped
and embedded into the primary tube
wall.
L WRAP ON FINS
Max working temp: 120oC/250oF
Atm. corrosion resistance: Acceptable
Mechanical resistance: Poor
The aluminium strip foot section is
first formed in to an L shape and then
tension wrapped on to the base tube
and wound fin base sections are close
to each other so as to ensure a
continuous cover over the primary
tube surface. Finally, the fin strip is
fastened at ends to prevent
loosening.
KNURLED L FINS
Max working temp: 250oC/480oF
Atm. corrosion resistance: Medium
Mechanical resistance: Acceptable
An aluminium strip is folded to form
an L Shape and then wound around
the base tube. The feet of the fins are
joined together and covers the whole
of the tube surface. The root of the fin
is simultaneously knurled with the
inner tube ensuring tight contact
between fins and tube.
BIMETALLIC
EXTRUDED FINS
Max working temp: 300oC/570oF
Atm. corrosion resistance: Excellent
Mechanical resistance: Excellent
A core tube, or liner is fitted into an
aluminium primary tube. This
tube-in-tube assembly is then fed into
the finning machine equipped with
three spindles. The gang discs which
are stepped in profile and diameter will
first extrude and shape the fin properly
and then shrink fit the primary tube on
its liner.
 MASTERY IN PROCESS COOLING

TYPES OF HEADERS
PLUG HEADER
Plug header is the most commonly used up to 350 bar
working pressure. The plug holes opposite each tube
allows expansion of the tube in the tube sheet,
mechanical cleaning and plugging in case of leakage.
Seal welding or strength welding can be provided for
high partial hydrogen pressure resulting in a less
expensive solution than pipe header. Generally used for
over 200 bar pressure.

COVER PLATE HEADER

Cover plate is used for fluids with high fouling factors
and upto 40 bar maximum when frequent mechanical
cleaning is needed. It is also used for very corrosive
process fluids so as to periodically check corrosion
allowance.

Special cover plate headers using welded gaskets are

provided for hydrogen service in hydrocracking plants.

WELDED BONNET HEADER

Welded bonnet type is used in some special services
such as Ammonia condensers, Freon condensers and
Vacuum Steam condensers.

One advantage of this design is the fully welded

construction which provides perfect sealing required for
such applications.

MANIFOLD HEADER
A large circular manifold is used in some cases where
the allowable pressure drop is very low.

This large manifold ensures an equal distribution of

fluid flow in the tubes. The tube sheets are directly
welded to the Manifold. This type is used for vacuum
steam condensers and refrigeration units.

PIPE HEADER
Pipe headers are used for working pressures over 200
bar. The U bend tubes are welded to weldolets on the
pipe. The welds are heat treated and X-ray tested.
 MASTERY IN PROCESS COOLING

FANS DRIVES AND AIRFLOW CONTROL

Air fin coolers generally employ
axial flow fans which develop large
air volumes, at low static
pressure.
Salient Features
l Aluminium or FRP fans
TRANSMISSION
The fans of Air fin coolers are
usually driven by electric motors
either directly or through
V/HTD/PGGT belts or gear boxes.
Direct Drive : Low speed upto
15 HP
l Manual or automatic
controlled louvers
l Dual speed electric motors
l Variable speed drive with
control system
Automatic variable pitch fans
l

Belt Drive : V/HTD/PGGT Belt

l Manual adjustable pitch or
upto 60 HP with dynamically
auto variable pitch fans
balanced pulleys
l Dynamically balanced
Gear Drives : Above 60 HP.

SPARES AND FIELD ENGINEERING SERVICES

BGR Energy has highly trained

and experienced team of Field
engineering personnel who can:
l Supervise/undertake total
responsibility for erection,
commissioning and trial run of
the air fin coolers
l Undertake retubing of air fin
cooler bundles
BGR Energy can supply spares
like fan blades, plugs and gaskets,
etc. for running maintenance of the
air fin coolers.

Indian Petrochemicals Corporation Ltd., Gandhar - SS Bundles - 1997