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

HEADER
WALKWAY

MACHINERY MOUNT
SUPPORTING STRUCTURE

ELECTRIC MOTOR

BELT

PULLEY

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

Member of Heat Transfer Research Inc (HTRI), USA

ISO 9001 Certified and Holder of ASME U, U2 & R stamps

Computer aided thermal and mechanical design

Design and manufacture of air cooled heat exchangers as per ASME and API specifications.
Coolers complying to PED of European Union - CE marking

Turnkey ability to design, engineer, manufacture, supply, erect and commission up to

950 tube bundles per annum

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

Executed contracts under third party inspection of BVIS, DNV, EIL, Velosi, Lloyds, etc

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

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

Experience in supplies to
refineries, petrochemical, fertilizer, steel and power plants,
oil & gas and other process plants

PRODUCT RANGE
l

Process Coolers

Tube Bundles

Radiator and Compressor Coolers

Finned Tubes

MASTERY IN PROCESS COOLING

AIR FIN COOLER SELECTION

FORCED DRAFT UNIT

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.

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

L WR AP ON FI NS

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
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

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
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.

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
TRANSMISSION

AIRFLOW CONTROL

Air fin coolers generally employ

axial flow fans which develop large
air volumes, at low static
pressure.

The fans of Air fin coolers are

usually driven by electric motors
either directly or through
V/HTD/PGGT belts or gear boxes.

Manual or automatic
controlled louvers

Dual speed electric motors

Salient Features

Direct Drive : Low speed upto

15 HP

Variable speed drive with

control system

Automatic variable pitch fans

Aluminium or FRP fans

Manual adjustable pitch or

auto variable pitch fans

Dynamically balanced

Belt Drive : V/HTD/PGGT Belt

upto 60 HP with dynamically
balanced pulleys
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

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

RELIABLE PARTNER
FOR COMPLETE OIL & GAS, POWER PLANT SOLUTIONS

FOCUS ON OIL

& GAS

 Primary equipment for Separation of Liquid &

Gas (Two Phase) or Oil, Water & Gas (Three
Phase) from Oil Well Stream
Designed & Manufacture as per API 12J
Internal Inlet Impingement Baffles, Wave
Baffles, Flow Straightening Baffles, Weirs, Mist
Eliminators & Vortex Breakers for
effective
Separations
Equipment adequately designed to allow
sufficient retention period
Controls & Instrumentation provided to
accurately measure the Gas, Oil & Water Flow
rates, Regulate the Pressure and
Monitor
the levels of Oil, Water in the
Separator
Automated Liquid (Oil & Water) removal
system provided
Large Size / Pressure Range
Compact, Skid Mounted System can also be
provided

Gas Fired Indirect Water Bath Heaters

designed in full compliance to API 12K
specifications
Natural Draft Burners, directly
mounted on Fire Tube. Forced Draft
Burners also provided as per requirement
Precise temperature control of Water Bath
Removable Single or Twin Fire Tube Design
Removable Heating Coil for case of
maintenance
Burners System complete with Pilot, Main
Burner, Gas Train, Spark Igniter with
Transformer provided
Flame Arrestors at Burners Air Intake and
Stack Top provided
Large Heating capacity upto 5 Million
K.Cal/Hr

Ensures supply of Dry and Dust Free Gas

Generally it comprises of a 1 100%
Knockout Drum & 2 100% Filter
Separators together with Indirect Water
Bath Heater (as per service requirement)
complete with Interconnecting Piping,
Valves, Instrumentations, Electrical and
PLC based Control Panels for unattended
& smooth operation
Separation and Removal of Liquid from
the Gas Stream
Compact, well engineered skid mounted
layout to facilitate easy access to all
Valves, Instruments & Filter Elements
Condensate Tanks & Vent Stack also
provided
Stainless Steel piping used downstream of
Filter Separation System to ensure the
pure gas

GAS CONDITIONING, REGULATING & METERING SYSTEMS

&

proven

equipment

like

as well as in Flow Measurement

High accuracy in Pressure Regulation

Flow Meter & Flow Totalizers used

Pressure Regulator, Slam Shut Valves,

Reliable

Mounted or in Cabinet

Metering Stations, either Skid

Compact, well engineered Gas

separately.
The key features are:

as a part of the Gas Conditioning System or

Regulating and Metering System are provided

As per the client's requirements, Pressure

GAS CONDITIONING, REGULATING & METERING SYSTEMS

Used for Solid / Liquid Separation

from Gas Stream

Provision for Automated Liquid Level

Monitoring & Liquid Removal

Large Size Range

Large Collection Volumes

Low Pressure Drops

Prevents re-entertainment of
separated particles

VANE / MESH / Multi-cyclone design

Removes Solid and Liquid Particle

sizes greater than 10 Microns with
100% efficiency

KNOCKOUT DRUMS / SCRUBBERS

For Removal of Liquid / Solid Particles down

to 1 Micron with 99.9% efficiency
Horizontal / Vertical Design
High
Performance,
Proven
Make,
Coalescing Type Glass Fiber Elements used in
Primary Section
Secondary Section provided with efficient
Impingement Separators or Mist Eliminators to
remove Coalesced
Liquid
In horizontal Filter Separator down comers
from Primary and Secondary Sections pass
liquid
to
sump
to
prevent
re-entrainments
Large Liquid Collection Volumes
Equipment provided with Quick Opening
Closures for quick access to Filter Elements
Provision
for
Automated
Liquid
Level
Monitoring & Liquid Removal

FILTER SEPARATORS / DRY GAS FILTERS

 Supply of Scrapper (Pig) Traps with

Quick
Opening
Closures
of
reputed international
make
Quick Opening Closures provided
with
Pressure warning device
and Mechanical interlock system
Traps capable of handling specific
type
and no. of pigs
Material of Construction is Carbon
steel or Stainless steel as required
including NACE specification
Flow Tees, Barred Tees, Anti-spark Pig
Receiving Trays
Pig Handling System with Jib crane,
etc.,
Pig Signalers - Intrusive / Non-intrusive

PIG LAUNCHING / RECEIVING TRAPS

GLYCOL DEHYDRATION UNIT (AMR)

DESALTER PACKAGE (AMR)

THREE PHASE SEPARATOR FOR OIL INDIA DULAIJAN

MOBILE TEST SEPARATOR FOR AKAS & ALMANSURIA PROJECT - IRAQ

INDIRECT WATER BATH HEATER FOR CLP (GPEC) INDIA

ARRAY OF PIG LAUNCHER & RECEIVER SKID WITH JIB CRANE CAIRN ENERGY

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