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AIR COOLED HEAT EXCHANGER STRUCTURE

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MOQ : 1 Metric Ton

AIR COOLED HEAT EXCHANGER STRUCTURE Specification

Max. Capacity
Up to 20 MW thermal (or as requested)

Temperature
Design temperature up to 200C or more

Diameter
Tube OD: 19 mm to 51 mm (customizable)

Air Volume
50,000 to 500,000 m3/h (per unit)

Max Pressure
Up to 35 bar

Thickness
Tube wall thickness 2.5 mm to 5 mm

Number of Pipe
Custom as per process (typically 100s of tubes per bundle)

Condition
New

Structure
Heavy-duty welded steel frame with galvanized/corrosion protection

Liquid Flow Rate
100 to 10,000 m3/h (as per process requirements)

Working Presssure
Up to 35 bar (as required by application)

Voltage
380V / 415V / 440V, 3 phase, 50/60 Hz

Power
Depends on fan motors (commonly 5-50 kW per fan drive)

Weight
Varies as per design (typically several tonnes)

Dimensions
Custom engineered (Length: 5-30 m, Width: 3-10 m, Height: 3-12 m)

Mounting
Horizontal/vertical/sloped mounting

Control System
PLC/SCADA-based automation with temperature and vibration monitoring

Vibration Dampers
Installed for fan and structural protection

Surface Treatment
Galvanized, epoxy coated, or painted

Inspection Openings
Provided for ease of maintenance

Tube Material
Carbon steel, stainless steel, or alloy steel

Installation Type
Modular for field assembly or skid mounted

Fan Type
Axial or centrifugal with adjustable pitch

Fan Drive
Electric or gear drive with VFD option

Ambient Operation
-20C to +55C standard design

Application
Oil & gas, petrochemical, power plants, refineries

Fin Type
Extruded finned, embedded finned, or G-type fin

Noise Level
As per site regulation, typically <85 dB(A) at 1m

About AIR COOLED HEAT EXCHANGER STRUCTURE

Product Overview:
We specialize in the high-precision fabrication of structural components for Air-Cooled Heat Exchangers (ACHE), also known as Fin-Fan Coolers. Our fabrication services cover the entire external assembly, including heavy-duty support structures, air-directing plenums (casings), and safe-access maintenance platforms. Designed for extreme industrial environments such as Oil & Gas refineries, power plants, and chemical processing units, our structures ensure mechanical stability and optimal airflow efficiency.

Key Components & Features:

Support Structure: Fabricated from high-grade structural steel (MS/SS) to support heavy tube bundles and mechanical drive systems. Available in both Forced Draft and Induced Draft configurations.
Plenum Chamber (Casing): Engineered for uniform air distribution across the tube bundle. We offer both box-type and slope-sided plenum designs to minimize air bypass and maximize cooling efficiency.
Maintenance Platforms: Cantilevered or independent walkways featuring anti-skid steel gratings, safety handrails, and access ladders (OSHA/IS compliant).
Fan Rings & Stacks: Precision-rolled fan cylinders designed to maintain tight blade clearances for reduced noise and improved static pressure

Technical Specifications:

Material of Construction (MOC): Carbon Steel (ASTM A36, IS 2062), Stainless Steel (304/316), or Galvanized Iron.
Surface Treatment: Hot-Dip Galvanizing (for superior corrosion resistance) or multi-coat industrial epoxy painting.
Welding Standards: All welding is performed by certified welders as per ASME Section IX standards.
Design Standards: Fabricated in strict accordance with API 661 and ASME Section VIII requirements.
Load Capacity: Custom-designed to withstand seismic loads, high wind speeds, and vibration from large axial fans.

Tailored Engineering for Demanding Industries

Each Air Cooled Heat Exchanger is meticulously constructed to address heavy-duty industrial requirements, including oil & gas, petrochemical, and power generation plants. By offering customizable dimensions, tube materials, and mounting options, these units ensure seamless integration and optimal performance in diverse regulatory and environmental settings across India.

Advanced Control and Monitoring Features

With PLC/SCADA-based automation and temperature and vibration monitoring, these heat exchangers enhance process reliability and safety. Integrated vibration dampers, inspection openings, and modular/skid-mounted designs make maintenance straightforward and operational uptime a priority.

Superior Performance and Durability

Utilizing galvanized, epoxy-coated, or painted surfaces, and engineered with tube wall thickness up to 5 mm, the system safeguards against corrosion and withstands pressures up to 35 bar and temperatures over 200C. Robust fans, efficient finned tubes, and VFD fan drives further improve heat transfer efficiency and energy savings.

FAQ's of AIR COOLED HEAT EXCHANGER STRUCTURE:

Q: How does an air cooled heat exchanger function within industrial processes?

A: An air cooled heat exchanger dissipates process heat by transferring it from hot process fluids inside finned tubes to ambient air. Axial or centrifugal fans draw air over the finned tubes, efficiently cooling the fluid before it returns to the system. This method eliminates the need for cooling water, making it ideal for industries with limited water resources.

Q: What materials and surface treatments are used to enhance durability and corrosion resistance?

A: Tube materials include carbon steel, stainless steel, or alloy steel, chosen based on medium and process requirements. Galvanized, epoxy coated, or painted finishes are applied to the structure and key components, protecting against harsh climates, industrial emissions, and corrosive environments, which is crucial for reliability and longevity in India's diverse industries.

Q: When is modular or skid-mounted installation recommended for these exchangers?

A: Modular field-assembled units are best for sites with access or transport limitations, enabling easy on-site assembly. Skid-mounted designs are suited for rapid, plug-and-play installation in projects where minimizing downtime is critical. Both types support swift deployment across new and existing facilities.

Q: What controls and automation features are included, and how do they benefit operation?

A: These exchangers come with PLC/SCADA-based automation for precise process control, including temperature and vibration monitoring, fault indication, and integrated alarms. Variable Frequency Drives (VFD) and adjustable fan pitch optimize airflow and energy consumption, ensuring both safety and operational efficiency.

Q: Where are inspection and maintenance features incorporated into the design?

A: Inspection openings are strategically placed to allow safe and convenient access for routine maintenance and inspections. The use of vibration dampers and a robust frame protects fans and tubes, further simplifying servicing and reducing the risk of unexpected downtime.

Q: What applications in India typically use these heavy-duty air cooled heat exchangers?

A: Their modular and rugged design makes them popular in oil & gas fields, refineries, petrochemical complexes, and power plants throughout India. They're engineered to handle large thermal loads, aggressive ambient conditions (-20C to +55C), and varying installation sites.

Q: What are the major performance benefits and maximum operating conditions of these units?

A: These exchangers achieve up to 20 MW thermal capacity, handle working pressures up to 35 bar, and process flow rates from 100 to 10,000 m3/h. Air volume per unit ranges between 50,000 and 500,000 m3/h, supporting customized industrial application needs and ensuring reliable, water-free operation.

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