News of 2023-05-23
Dry cooler for cooling diathermic oil with ambient temperature air
A German customer has requested the design and construction of a Dry Cooler for cooling diathermic oil at 160°C with ambient temperature air.
Cos.Ter decides to create a machine composed of an air heater (TX) combined with an inspectable battery (BTI).
At these temperatures, further cooling the diathermic oil (which is typically used as a heat transfer fluid) involves dealing with a very dense oil, resulting in increased fluid-side pressure drops and therefore requiring more accurate internal circuit design to contain and minimize pressure losses. For this reason, the German company turned to Cos.Ter to develop a specific sizing and design for this application.
Cos.Ter interprets the customer's request by thoroughly examining all the technical aspects together with them, designing and proposing the most suitable solutions for the field of application. The chosen solution and materials for this specific case, including the use of AISI 316L material, are determined in collaboration with the customer.
The customer informs us that the installation area for the product is an ATEX zone, thus requiring an ATEX-compliant fan (the only moving part). ATEX is the conventional name that encompasses two European Union directives:
Directive 2014/34/EU regulates equipment for use in potentially explosive atmospheres, targeting manufacturers of equipment intended for use in areas with potentially explosive atmospheres and requiring certification for these products.
Cos.Ter promptly develops and defines the project, including the specific ATEX requirements, and proceeds with dimensional and construction drawings, obtaining official approval from the customer. Upon customer approval, Cos.Ter begins developing all the manufacturing details and commences the construction of the Dry Cooler.
The Dry Cooler (cooling air cooler) is entirely built in AISI 316L and consists of a radiant coil with finned tubes fully welded to the tube plates using a qualified TIG welding procedure, carried out by a qualified specialized operator for TIG welding. All our welding procedures and specialized operators are certified by an external authorized body.
TECHNICAL SOLUTION
Due to the characteristics of the oil, which make it denser than the average of other oils, the Cos.Ter air cooler has been designed and manufactured with two appropriately diaphragm-distributed and completely removable distribution headers to facilitate potential tube cleaning.
To ensure a tight seal between the headers and tube plates, a single-piece Teflon gasket is used.
The design pressure of the air cooler is 5 bar, while the test pressure is 8 bar.
The air cooler is tested in a water tank with dry air at 8 bar inside the tube bundle for a duration of 60 minutes, yielding positive results. The test report and certificate are then issued.
The finishing process includes pickling all the plates and welds, followed by the restoration of the film and passivation layer of AISI 316L.
The assembly of the ventilating base, consisting of the air distribution plenum and the corresponding ATEX axial fan, is then completed.
CUSTOMER FEEDBACK
The customer company installs and tests the air cooler, which immediately meets its expectations in terms of performance and practicality during regular maintenance, with ease and simplicity in dismantling and reassembling the two oil distribution headers. The customer also finds the various drain sleeves on both distribution headers to be very practical.
Cos.Ter decides to create a machine composed of an air heater (TX) combined with an inspectable battery (BTI).
At these temperatures, further cooling the diathermic oil (which is typically used as a heat transfer fluid) involves dealing with a very dense oil, resulting in increased fluid-side pressure drops and therefore requiring more accurate internal circuit design to contain and minimize pressure losses. For this reason, the German company turned to Cos.Ter to develop a specific sizing and design for this application.
Cos.Ter interprets the customer's request by thoroughly examining all the technical aspects together with them, designing and proposing the most suitable solutions for the field of application. The chosen solution and materials for this specific case, including the use of AISI 316L material, are determined in collaboration with the customer.
The customer informs us that the installation area for the product is an ATEX zone, thus requiring an ATEX-compliant fan (the only moving part). ATEX is the conventional name that encompasses two European Union directives:
Directive 2014/34/EU regulates equipment for use in potentially explosive atmospheres, targeting manufacturers of equipment intended for use in areas with potentially explosive atmospheres and requiring certification for these products.
Cos.Ter promptly develops and defines the project, including the specific ATEX requirements, and proceeds with dimensional and construction drawings, obtaining official approval from the customer. Upon customer approval, Cos.Ter begins developing all the manufacturing details and commences the construction of the Dry Cooler.
The Dry Cooler (cooling air cooler) is entirely built in AISI 316L and consists of a radiant coil with finned tubes fully welded to the tube plates using a qualified TIG welding procedure, carried out by a qualified specialized operator for TIG welding. All our welding procedures and specialized operators are certified by an external authorized body.
TECHNICAL SOLUTION
Due to the characteristics of the oil, which make it denser than the average of other oils, the Cos.Ter air cooler has been designed and manufactured with two appropriately diaphragm-distributed and completely removable distribution headers to facilitate potential tube cleaning.
To ensure a tight seal between the headers and tube plates, a single-piece Teflon gasket is used.
The design pressure of the air cooler is 5 bar, while the test pressure is 8 bar.
The air cooler is tested in a water tank with dry air at 8 bar inside the tube bundle for a duration of 60 minutes, yielding positive results. The test report and certificate are then issued.
The finishing process includes pickling all the plates and welds, followed by the restoration of the film and passivation layer of AISI 316L.
The assembly of the ventilating base, consisting of the air distribution plenum and the corresponding ATEX axial fan, is then completed.
CUSTOMER FEEDBACK
The customer company installs and tests the air cooler, which immediately meets its expectations in terms of performance and practicality during regular maintenance, with ease and simplicity in dismantling and reassembling the two oil distribution headers. The customer also finds the various drain sleeves on both distribution headers to be very practical.