Quality Heat Exchangers

Transcription

1 Quality Heat Exchangers 1

2 Overview FUNKE is your specialist for the development and fabrication of heat exchangers with a heat transfer area from 0,04 m² of up to 2500 m². FUNKE heat-exchangers are used in applications where heating, cooling, ventilation or air-conditioning is required. FUNKE calculates, designs and fabricates the most common types of heat exchangers and as such offers superior expertise between a variety of solutions. Shell-and-Tube Heat Exchangers Oil-Air Coolers Brazed Plate Heat Exchangers Plate-and-Frame Heat Exchangers 2

3 Overview FUNKE Products apply to: HEATING COOLING VAPORIZING CONDENSING of Liquids and Gases 3

4 Fields of Application Mechanical engineering Compressors Chemistry Food/Pharmaceutics Petrochemistry Paper Industry Hydraulic systems Lubricating oil systems Shipbuilding Heating/Ventilation/Air-conditioning Power plants 4

5 Overview Shell-and-Tube Heat exchangers with pressure ratings of up to 600 bar, 600 C and a diameter of 2 mt. Plate and Frame heat exchangers with Heattransfer areas of 2500m², flowrates of 4,500m³/h and 34 mw (120 C to 30 C, 10 C to 100 C,dp 4bar, 4100m³) Brazed Heat Exchangers upto 4 connections Aluminium Oil/Air Coolers with a front area of 1,5 m² and 15 hp Motors. 5

6 Overview FUNKE products are applied in most critical processes: Double Oil-Cooler at John Crane Ltd. Double Oil-Cooler for Brazilian Oil-Rig Hydraulic Oil Cooler for the Liebherr Concrete-Mixer Truck Double Oil-Cooler for Baric Pumps Ltd Methanol Cooler for DOW Chemicals (ANGUS) 6

7 Overview Process Water Cooling at Masterfoods Double oil cooler at a Siemens Power Plant Power Plant of 5x12 MW at Volkswagen FUNKE Heat-Exchangers are installed where it matters 7

8 Our 3 productlines all contribute considerably to our revenue: 10% SIP S&T PHE 56% 34% 8

9 The quality and reliability of our products and performance results in a steady growth. FUNKE Germany Employees Turnover (Mio. ) Subsidiaries 0 9 with Employees International Sales Partners Employees in the Group ca. 140 ca

10 Growing of Headquarters

11 The FUNKE-Group on the global key-markets in 2009 Supported by a global net of approx. 30 sales and manufacturing partners. 11

12 A selection of our customers 12

13 Core Competence Design and calculation strictly adapted to the customers' requirements: Process engineering, thermodynamics, stress analyses, vibration analyses. 13

14 Core Competencies World-wide standards / design codes: EU-97/23/EG (Pressure vessels) AD-data sheet (D) TEMA (International) ASME, U-Stamp (USA) API (American Petr.Industry (USA) British Standard (GB) Stoomwezen (NL) Swedish Pressure Vessel Code TTK (FIN) Australian Standard 1210 OEWBV (A) Codes SNCT (F) ARAB (B) Raccolta (I) ABS (USA) ISCIR (Rumänien) USSR-Register of Shipping GOST (GUS) Lloyd`s Register Bureau Veritas Det Norske Veritas Germanischer Lloyd 14

15 Core Competencies We have supplied in accordance with the following customer specific specifications: Engineering companies: - Badger - C.J.Brown - Fluor-Daniel - Edeleanu - Fluor - Linde - Lummus - Lurgi - R.M. Parsson - Petronas - Davy Powergas - SNAM Progetti - Technimont - Technip - Uhde - Foster Wheeler Oil companies: - Agip - BP - Esso - Exxon - Shell - Statoil 15

16 Funke is holder of following certificates - AD Merkblatt HP 0 acc. DIN EN ASME U Code Stamp - Bureau Veritas (BV) - Det Norske Veritas (DNV) - DIN EN ISO 9001:2000, BS EN ISO 9001: Germanischer Lloyd (GL) - GOST (Russia) - TÜV Nord, CE RTN (Russia) - SELO (China- Stamp, SQL) 16

17 Quality is recognized world-wide certifications 17

18 Core Competencies Design, manufacturing and supply to world-wide Standards - American Petroleum Institute (API Standard) - ATEX RL 94/9/EG - BASF Standards - Bayer Standard - Heatexchanger Institut (HEI) Standard - Linde Standard - NACE Standard - Shell Dep s - Krupp Uhde Standards 18

19 Funke supplies to customized specifications - Aerzener Maschinenfabrik (D) - Andritz AG (D / A) - Atlas Copco Energas GmbH (D) - Burckhardt Compression (CH) - Caloric Anlagenbau (D) - Chemieanlagenbau Cemnitz (D) - Coperion Werner & Pfleiderer (D) - Coperion Waeschle (D) - Cryostar France S.A. (F) - Dresser Rand GmbH (D) - Gardner Denver Nash (D) - Hermetic Pumpen GmbH (D) - Hydac Technology GmbH (D) - Ingersoll Rand (I) 19

20 Funke supplies to customized specifications II - Leobersdorfer Maschinenfabrik (A) - Linde AG (D) - Lefa GmbH (D) - MAN Turbo (D / CH) - Neuman & Esser (D) - OMV (A) - Peter Brotherhood, Ltd (GB) - Siemens AG (D) - Thomassen Compress. Syst. (NL) - Uhde Inventa Fischer (D) - Voith Turbo (D) - Voith Paper (D) - Zeppelin GmbH (D) 20

21 And specifications of engineering companies ABB Lummus Global B. V. ADNOC (Abu Dhabi National Oil Company) * Aker Kvaerner Inc.* Air Liquide Engineering * Air Products Armstron Engineering BASF * BASELL Bayer * Bechtel Corporation Borealis * BP * Celanese Ltd. * Conoco Phillips * Daewoo Engineering Company Davy Process Technology Limited * Dow Chemicals Company * ENPPI (Engineering Petroleum & Process Industries)* Eastman Chemical Company Edeleanu * Exxon Mobil Research and Engineering Company * Flour * Foster Wheeler Energy Limited * Hyundai Engineering Co., Ltd. Hitachi Ltd. Jacobs Engineering Group Inc.* Kellogg Brown & Roots, Inc. Linde AG * Lurgi AG (*registrated as supplier with document or delivered) Mitsubishi Chemical Corperation Mitsui Engineering & Shipbuilding Co., Ltd. MOBIL OIL * OMV * PARS * Parsons Infrastructure and Technology Group Inc. PETROBRAS Petroleo Brasileiro S. A. * Petronas Malaysia * Reliance Engineering Associates (P) Limited Repsol S. A.* SABIC * Samsung Engineering Co., Ltd. Sasol * SAUDI ARAMCO (Saudi Arabian Oil Co.) Sazeh * SembCorp Engineers & Contstructors Pte Ltd. Siemens AG * Simon Carves Sinopec Engineering Incorperation Snamprogetti S. p. A. Stone & Webster Inc. Technicas Reunidas S. A. Terbodin B.V., Consultants & Engineers Technimont S.p.A. * Technip * Total * TOYO Engineering Corporation * Uhde GmbH * 21

22 Calculation with HTRI-Software 22

23 Manufacturing equipment at Gronau Machinery and Plants: Testing procedure: - laser-plasma cutting equipment - machine tools CNC and conventional - large automatic presses (max tons) - vacuum soldering installation - shot blasting equipment - pickling bath - paint shop - rolling equipment for tubesheets - equipment for hydraulic tests - with automatic pressurising up to 200 bar - manual pressurising up to 600 bar - radiographic test - magnetic particle test - ultrasonic test - spectroscopic analysis - high tension test - penetration test - helium test - layer thickness test 23

24 Shell-and-Tube Heat Exchangers 24

25 Shell-and-Tube Heat Exchangers Used materials carbon steel, stainless steel, titanium, aluminium alloys, copper, copper-nickel, brass, plated steel (more on request) Linings plastic coatings linings rubber metallic linings Performance 1 KW - 30 MW Transfer Surface 0,11 m m 2 Shell Diameter 60 mm mm Operating Temperature -20 C C Operating Pressure max. 600 bar Max. dimensions diameter: 2000 mm length: 10 m weight: 20 t 25

26 Shell-and-Tube Heat Exchangers Standard units Customized solutions TDW, BCF, CCF, SSCF, CCFA CP, A 100, C 100 C 500, WRA 200 Preselected geometries enable: - Short delivery times - Attractive price performance ratio - Guaranty of years of approved series Strict application of customers requirements: - Company specifications - Standards of engineering companies - International design standards 26

27 Customised solution C300 (BEU) with operating pressure 200bar 27

28 Customised solution C300 with operating pressure 200bar 28

29 Shell-and-Tube Heat Exchangers fabrication examples 29

30 Shell-and-Tube Heat Exchangers fabrication examples 30

31 Tube to tube sheet (two layers) welding by hand 31

32 Plate Heat Exchangers 32

33 Plate-and-Frame Heat Exchangers, introduction FUNKE heat transfer plates were developed to create high heat transfer coefficients. This results in a superior economical and technical adaption to the respective application requirements. Single-pass and multi-pass plate heat exchangers - heat exchange surfaces/plate 0,04 3,00 m² - max. design pressure 25 bar - max. design temperature 195 C Also available as safety plate heat exchangers 33

34 Plate and Frame Heat Exchangers, introduction Standard features Our plates are provided with double gaskets at the inlet and outlet which prevent mixing of the two media. If designed as safety heat exchanger, double plates are provided with a special sealing system Plate material standard: stainless steel /AISI /AISI 316 (L) optionally: , 254 SMO, titanium, NI200 Gasket materials NBR (nitrile-rubber), EPDM (ethylene-propylene-rubber) Viton (fluorine-rubber) -other materials on request. 34

35 Plate and Frame Heat Exchangers, introduction 35

36 Plate and Frame Heat Exchangers, technology 1. fixed plate 2. pressure plate 3. support 4. carying beam 5. guiding bar 6. carrier roller 7. tightening bolt 8. fixing screws 9. rubber liner 10. gaskets 11. heat transfer plates 36

37 Plate and Frame Heat Exchangers, technology Single-pass Two-pass Position of single-pass und multi-pass connections Three-pass 37

38 Plate and Frame Heat Exchangers, technology FUNKE-Offset-Wave standard Sinus-Wave The Funke specific Off-set wave and conventional wave 38

39 Plate and Frame Heat Exchangers, technology Semi welded PHE FPG series Advantages: - compact, low weight - easy maintenance - minor fouling - rapid and cost effective assembly - high heat transfer rate - high corrosion resistance 39

40 Final PHE-assembly 40

41 Funke Instrumentation for PHE 5 Presses for plate manufacturing 10,000 m², assembly and warehouse In situ hydronic testing Automated frame blast and paint line High speed multihead CNC Qualified approved welding 41

42 Plate Heat Exchangers Embossing of quality plates with 6000 tons clamping force Production unit for the new developed plate program, comprising 14 sizes and four different corrugations, enabling nine special flow gaps. 42

43 Plate Heat Exchangers Fully automated press line with a clamping force of tons 43

44 Production hall for large PHE units with 5 cranes and automated sand blasting line. Sand Blasting Line 44

45 Fully automated coating and curing line coating curing complete line 45

46 Plate Heat Exchangers Final assembly hall small and medium sized units 46

47 Large versus small 47

48 Brazed Plate Heat Exchangers 48

49 Brazed Plate Heat Exchangers Type GPLK 49

50 Brazed Plate Heat Exchangers Type GPLK - Design GPLK are made of corrugated stainless steel plates. The plates are assembled in a 180 angle to each other. Depending on the requirements of the application, the plates are vacuum brazed using either copper or nickel (NPLK). This results in separate flow gaps with counter-flow of the media involved in the heat exchange (standard 50

51 Application conditions Operating pressure and operating temperature The BPHE GPLK is designed for a working pressure up to 30 bar / 435 psi at max. 200 C / 392 F. In special designs, GPLK can work with up to 45 bar / 653 psi at 150 C / 302 F. The NPLK (nickel brazed) can be operated at 10 bar / 145 psi at 150 C / 302 F. In special designs, NPLK can be operated at up to 30 bar / 435 psi at 150 C / 302 F. Material: For the plates stainless steel AINSI 316 / is used. Performance: 2.0 to kw / 6824 Btu to 20.5 MBtu 51

52 Applications For universal applications with media of low viscosity GPLK has a well balanced ratio of high heat transfer rates with low pressure losses. The thermodynamic optimized corrugation of the embossed plates allows for high turbulent flow even at low volumetric flow rates. This allows for efficient use of the heat exchange area available and leads to a perfectly optimized heat transfer. The high turbulent flow also results in an efficient self-cleaning effect, which greatly reduces maintenance and time-out. GPLK have a compact design and are used for high pressures and temperatures. 52

53 Applications Typical applications for brazed plate heat exchangers GPLK are heating, cooling, condensing System separation Heat extraction and heat recovery in domestic and process technology Refrigeration engineering Mechanical engineering Oil cooling Hot water/process water Heating engineering (solar thermal systems, central heating, floor heating) Evaporation / Condensing in cooling systems Air drying Hydraulic oil cooling Cooling of machines and motors Mold machine temperature control Economizing 53

54 Media Copper brazed plate heat exchangers GPLK are mainly used for media such as Oil and oil containing fluids Glycol mixtures Alcohols Refrigerants Gas/Air Water many more (according to media properties and its viscosity) 54

55 Information Copper brazed plate heat exchangers GPLK should not be used for the following media: Seawater Ammonia Deionates Silicone oils high chloride media For applications with Ammonia Deionates Silicone oils the nickel brazed plate heat exchangers NPLK are recommended. 55

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57 Brazed PHE s type TPL With special turbo-plates in the flow gaps, especially developed for the requirements in plant and mechanical engineering. Application Hydraulic- and Motor-oil-Cooling Air cooling universally applicable with diverse media 57

58 Plattenwärmeaustauscher Brazed PHE s type TPL Technical Data heat transfer surface / plate 0,035 0,286 m² max. operating pressure 30 bar max. operating temperature -100 C bis +200 C Material plates / AISI 316 solder copper 99,9 % Small design sizes are possible due to high heat transfer rates at higher viscosities. This compact design means it needs lesss space compared to conventional brazed PHE. This system only is available from FUNKE! 58

59 Vacuumovens (brazed PHEs) 59

60 SIP Standard Industry Products 60

61 Oil/Air Cooling Units Electrical Oil Pre-heaters 61

62 Oil/Air Cooling Units Standards 13 sizes with cooling capacity up to 2,5 kw/k Application Cooling of oil, emulsions and fluids (of low flammability) with air especially for plant- and mechanical engineering as well as for mobile hydraulic systems. Technical Data frontal area of core 0,05 1,50 m² max. operating pressure 16 bar max. operating temperatures oil/emulsion 120 / 90 C Fan drive Three-phase motor, direct-current motor, or hydraulic motor; power related controlled 62

63 Oil/Air Cooling Units Standards New series Okan III Innovative construction raises customer s benefit Thermodynamically optimised: - oil/air-lamellae - oil in- and outlet channels - depth of cooler block reduced to 64 mm - optimised, selfsupporting fan bonnet 63

64 Oil/Air Cooling Units Standards The new series Okan III Less Euro per kw cooling capacity! Up to 18% more cooling capacity! (with the same inflow area as before) Therefore especially suited for mobile hydraulics and compact mechanical engineering Fa. Putzmeister, concrete mix facility Fa. Raster Zeulenroda, producer of presses Fa. Liebherr, concrete mixer 64

65 Applications for mechanical engineering and mobile hydraulics 65

66 Electrical Oil Pre-heaters Available in 11 sizes for use in- and outdoors Application Heating of oil, emulsions and fluids (of low flammability) using electric current. Especially for machines and plants outdoors. 66

67 Electrical Oil Pre-heaters Technical Data Heat transfer rate kw max. operating pressure < 6kW / > 9kW 25 / 16 bar max. final temperature 80 C Design/Material Heating element: with bent heating rods (like a U-tube bundle) shell: steel, standard thermostat 67

68 Thank you for your attention! 68