Forced Draft Air Coolers In Oil Refinery, API 661 and ASME SEC VIII Div-1

Forced Draft Air Coolers are widely used in industries like oil refineries, petrochemical plants, and power generation , gas station due to their efficiency and ease of maintenance. Below is a detailed explanation of their application, internal structure, and inspection practices.

Applications of Forced Draft Air Coolers:

1. Oil Refineries:
- Cooling of process fluids (e.g., crude oil, lube oil, and hydrocarbon gases).
- Condensation of vapors in distillation units.
- Cooling of compressor discharge gases.

2. Petrochemical Plants:
- Cooling of reactor effluents.
- Temperature control in polymerization processes.

3. Power Plants:
- Cooling of turbine lube oil and other auxiliary systems.

4. Gas Processing:
- Cooling of natural gas and other hydrocarbon streams.

5. General Industrial Applications:
- Cooling of hydraulic fluids, water, and other process liquids.

Internal Structure of Forced Draft Air Coolers:

1. Finned Tubes:
- Tubes are typically made of carbon steel, stainless steel, or other alloys depending on the process fluid.
- Fins are attached to the tubes to increase the surface area for heat transfer. Fins are often made of aluminum for high thermal conductivity.

2. Tube Bundle:
- A collection of finned tubes arranged in rows or banks.
- The tube bundle is housed in a plenum or casing to direct airflow.

3. Fans:
- Located at the bottom of the cooler, fans force ambient air upward through the tube bundle.
- Fans are usually driven by electric motors and may have variable frequency drives (VFDs) for speed control.

4. Plenum Chamber:
- A chamber that distributes air evenly across the tube bundle.
- Ensures efficient heat transfer by minimizing air bypass.

5. Headers:
- Inlet and outlet headers distribute the process fluid into the tubes and collect it after cooling.
- Headers are typically made of the same material as the tubes.

6. Support Structure:
- A robust frame supports the tube bundle, fans, and motors.
- Designed to withstand operational loads and environmental conditions.

7. Louvres or Dampers:
- Optional components to control airflow and temperature.

QUALITY DOCUMENTATION.
The Contractor will deliver to the Client the Quality documentation concerning of delivery of Goods under the contract within the scope, including but not limited to:
1: Inspection & Test Plan
2: Material Test Certificates
3: WPS, PQR for Welding
4: NDT & Hydrotest Procedures
5: Sandblasting & Painting Procedure
6: As Built Drawings
7: All Inspection Reports.