Dynamic ACC Solutions

Debottlenecking Air Cooled Coolers

Hans van Essen

Bahrain – October, 2014

Index

• Introduction Bronswerk

• Whizz-wheel®

• Case 1: Debottlenecking –Litoral-A offshore platform.

• Case 2: Debottlenecking – Bayernoil

• Additional solutions

History:

1940

1988 – Privately owned

2014

What we do:

• Process design

• Thermal design

• Mechanical design

• Manufacturing

• Supply

• Installation & Commissioning

• After market

Heat to atmoshpere (Air Cooled Cooling):

• “closed” systems, called Air Cooled Coolers (ACC)

• “open” systems, called Cooling towers

This presentation covers the bottlenecks and other lack

of duty in ACC, and particularly how to overcome this

lack.

Reasons for lack of duty:

• Original design was (too) small

• Fouling of the cooler

• Influence of wind

• Higher cooling air temperature, because:

– Global warming

– Local warming

– Hot air recirculation

Whizz-wheel®

:

Develop ultra low noise fans to meet the stricter client

requirements.

Conventional :

Whizz-wheel®

:

Main features

•Rim

•Small hub

•Blades are fully curved

Whizz-wheel®

:

Developed for low noise: 6 – 20 dB lower noise

Benefits:

• 45 - 60% lower absorbed power

• Up to 40% more cooling air flow with same absorbed power

• Or a combination

• Minimal vibrations

• Rigid construction

• Less sensitive to wind

CASE 1: Debottlenecking

2 new gas compression modules – Mexico

Litoral-A

Case description :

Plant

• Existing platform

• Two new gas compression trains (modules)

Challenges:

1. Plot space

2. Maximal absorbed power

3. Maximum noise level

Solutions :

Conventional Whizz-wheel®

Plot space area 582m2 412m2

Installed motor power 390 kW 308 kW

Sound pressure level 90 dB(a) @ 1m <85 dB(a) @ 1m

Total height 7,6m 7m

Total weight of units 141 ton 126 ton

Results:

• 40% reduced plot space

• 24% lower absorbed power

• 8% reduced height

• 12% less weight

• No noise issues

Quote PM: “without the whizz-wheel we could not have

executed this project.”

CASE 2: Debottlenecking

BAYERNOIL– Germany

Case description:

Plant

• 120.000 barrels/day

• Located in a populated area

• More then 60 fans

• Different services

Challenge:

• Reduce high noise

emissions

Solutions :

Option 1: Standard low noise fans

• Noise level of 72 dB(a)

• 12,6 kW absorbed power

Option 2: Whizz-wheel ® system

• noise level of 66 dB(a)

• 5,6 kW absorbed power

Results:

• 20 dB(A) proven lower noise

• 56% lower absorbed power

• 5% more airflow

• Installation during operation

Air side Fouling

• Prevention (screens)

• High pressure water cleaning

• Dry cleaning

Hot Air Recirculation & Wind

• Wind screens

Fogging

• Decrease ambient air temperature

Site Survey

What is your specific challenge?

• Intensification of your plant

• Increased ambient air temperature

• Wind

• Hot Air Recirculation

• Air side fouling

• Vibrations

• damaged fans

• ..

With a Site Survey the problem can be identified and a

solution is within reach!

Thank you for your attention.

Questions?

How to contact us:

Hans van Essen

Essen@bronswerk.com

+31-33-24-72-562

www.bronswerk.com