IDEAS ENGINEERED
DRY COOLING
CONTENTS
1.
CAPABILITY
2.
CAPACITY
3.
MODULAR SUPPLY
4.
REFERENCES
5
ECOLOGIC
6. TECHNICAL
CAPABILITY
Capability Jord International has been designing and supplying custom built air-cooled heat exchanger and condenser systems since its inception in 1972. A large percentage of the Group’s $200 million of annual revenues is generated from this technology. Jord’s forty odd years of references cover the full spectrum of applications; pressures up to 450 bar, temperatures from -60°c to 450°c, toxic, lethal & hydrogen services, and viscous high pour point services. Jord is experienced with most of the exotic metals, including inconel 625, incoloy 825, duplex and super-duplex grades. The longevity of our installations, many of which have been operating for decades, bears testament to the robustness of our designs. Jord is formally registered as an approved supplier to most of the oil, gas, petrochemical and power generation majors. Such customers include for example, Shell, ExxonMobil, Aramco, SABIC, BP, Chevron, Conoco-Phillips and Dow Chemical. Jord holds IMS accreditation to ISO9001, 14001 and 18001. Our wholly owned Malaysian workshop holds ASME U, U2, R and NB certification, as does our Korean joint venture wor kshop, and our various other manufacturing alliances around the world. All technical design work is carried out in-house. Software includes HYSIS (for process simulations), HTRI & HTFS (thermal design), Strand 7 (finite element analysis), Staad Pro (structural design) and Inventor (3D design). Project execution is undertaken using Jord’s proprietary Lotus Notes based “Horizon’s” system. This provides real-time access for all project details to Jord staff, suppliers and customers, wherever they may be in the world.
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VACUUM STEAM CONDENSER, SAUDI ARABIA Condensing steam turbine exhaust in the Sahara Petrochemical PDH plant, built by Daelim
CAPACITY
Capacity With a manufacturing capacity of 1,200 tube bundles per year, Jord has a demonstrable record of successfully delivering world scale projects. The bulk of capacity lies in the company’s wholly owned Malaysian workshop, which is exclusively dedicated to Dr y Cooling manufacture, and in our Korea n joint venture workshop. A number of other Asian and Middle Eastern fabrication alliances supplement this capacity. Extensive finned tube production capacity is available in-house across most fin types. Reasonable inventories are maintained to cater for emergency deliveries. All workshops have substantial hard-stand outside areas for lay-down, trial assembly and factory acceptance testing (“FAT”). This leaves workshop bays free for production-line style tube bundle and fan drive assembly production. Jord has embraced both “Six Sigma” and “Lean” process improvement programs. A team of Black Belt and Green Belt qualified staff are regularly challenged to identify and realise opportunities for Jord to improve quality, eliminate waste and/or increase productivity.
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JORD KOREA In par tnership with KC Cottrell, Jord’s Korean fabrication workshop near Pyeongtaek Port, has a capacity of 800 bundles per year
MODULAR SUPPLY
Modular Supply Jord International’s Dry Cooling systems have been delivered to more than 50 countries throughout the wor ld. Modular design is incor porated wherever possible, to minimise site erection time and cost, and to maximise the ability to test each un it as much as practical in the workshop prior to shipment.
Air coolers supply
ACC supply
PAGE 5
MODULAR SUPPLY Air cooler bays are shipped in modular form wherever possible, resting on their machinery mounts, as shown for this 6.6m wide unit
REFERENCES
PAGE 7
Incoloy 625 Materials PSN / Exxon Mobil, Australia 10 bays of offshore gas compression coolers, incoloy 625 pressure components, 240 bar pressure, strength weld tube to tube sheet joints.
Toxic Ser vices Bechtel / Foster Wheeler / Thai Oil 66 new bays & replacement bundles / drive arrangements and a vacuum steam condenser for a complex Aromatics plant revamp project. Toxic, hydrogen and low temperature service applications compliant to Shell DEP specifications.
LNG Train Kellogg JV / Woodside 71 bays, covering a plotspace of 230m x 40m comprehensively shop tested for airflow, vibration and hemi-spher ical noise analysis.
Natural Gas Processing Plant Chiyoda / Petrochina, Indonesia 51 air cooler bays handling 20 different process ser vices, fully delivered in 9 months.
Vacuum Steam Condenser Samsung / NPPC, Saudi Arabia Two units with a capacity of 260 tons/hour for a polypropylene plant.
Natural Draft OMV & SUI Gas, Pakistan Multiple natural draft gas compressor cooler stations using duplex pressure components. Remote locations in the Sindh desert necessitated the use of motorless “natural draft” designs.
FACTORY ACCEPTANCE TESTING VSD driven, super-duplex SAF2507 air coolers, bound for PDO Oman, being comprehensively tested in the Korean workshop prior to shipment
ECOLOGIC
A clean solution for an Algerian project Even in hot climates, most cooling and condensing applications for industrial plants should be at least par tially under taken using air instead of water. Such as these condensers at the back of an Algerian industrial plant. By avoiding seawater cooling, harbour marine life was saved from the harmful effects of an increased water temperature . By avoiding freshwater cooling, the substantial water loss associated with conventional evaporative cooling was saved. In both instances, the capital and operating costs of water treatment facilities were eliminated. By using Jord's air-cooled technology, the plant owner selected the only tr uly ECOLOGIC™ solution.
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ECOLOGIC A bank of Jord induced draft air coolers on the Algerian coastline
TECHNICAL
Components of an air cooler
1 4
3
2
1
1
3 1 2
6 7 4
5
3
2
Tube bundle (one or more per bay) 1 Header box
Structure for a single bay 1 Plenum chamber
Fan drive system 1 Fan (fixed or auto-variable pitch)
2 Finned tube
2 Header walkway
2 Motor (single, dual or variable speed)
3 Bundle frame
3 Support structure
3 Machinery mount
4 Louvres (optional)
4 Vibration switch 5 Drive pulley 6 Driven pulley 7 HTD belt
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JORD MALAYSIA Jord's wholly ow ned wor kshop, dedicated exclusive ly to air coolers and condensers, has a capa city of 4 00 bundles pe r yea r
TECHNICAL
Header Types
Diagram
Comments
For design pressures up to 450 bar. The most versatile and common header type. A plug hole opposite each tube allows access for expansion, seal weld or strength weld of the tube into the tube sheet.
Plug
For design pressures up to 25 bar. It is used for high fouling fluids where frequent internal access for cleaning is necessary. May be flanged or stud type.
Cover Plate
Welded Bonnet
For design pressures up to 300 bar. Suitable for vacuum applications, such as steam condensers, or other applica tions where an external leak to atmosphere can not be tolerated.
Manifold
For high design pressures where internal access is not necessary. U-bend tubes are often used with this header type.
Fin Tube Types
Extruded fin
Embedded (G) fin
Diagram
Comments Suitable for services below a design temperature of 250°c. A robust fin with excellent corrosion and mechanical properties. Formed by extruding an aluminium sleeve over a base tube. An alternative is produced with serrated fins to increase the heat transfer. However, serrated fins are more prone to fouling and are not commonly specified. Suitable for high temperature services up to 450°c. A helical groove is cut into the tube (0.25mm +/- 0.05mm) and the fin material is tension-wound into the groove. Fins are predominantly aluminium, although copper or steel fins can be produced for some applications.
The most cost effective and common fin type. Suitable for moderate services up to a maximum design tempera-
L & KL fin
LL fin
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ture of 150°c for L and 250°c for KL.The fin is formed into an L-shape and tension wound over the base tube, providing additional corrosion protection of the base tube. A more robust alternative involves knurling of the foot onto the tube (KL type). Produced the same way as L fin however with a wider fin base and successive overlap of the fins. The base is completely protected from atmospheric corrosion, except for tube ends that can be painted. A cost effective alternative to services that would otherwise require extruded fins.
WELDED BONNET HEADERS, EGYPT Each bay shown has two finned tube bundles that were fabricated with welded bonnet type headers
IDEAS ENGINEERED
IDEAS ENGINEERED
Jord International Pty Ltd Sydney Head Office 38 Oxley Street St Leonards NSW 2065 Sydney, Australia
[email protected] T + 61 2 8425 1500 F + 61 2 8425 1555 www.jord.com.au
Details of office locations can be found on our website at www.jord.com.au
Jord is an ISO 9001, 14001 & 18001 accredited company
