O N E C O M P A N Y, O N E S P E C I A L T Y... HEAT TRANSFER INDIVIDUAL SOLUTIONS - LEADING TECHNOLOGIES
2 Fluid Dynamics Pty Ltd HEAT EXCHANGERS SINCE 1981 25 Star Crescent Hallam, Melbourne Vic 3803 Australia T: +61 3 9796 5988 F: +61 3 9796 5777 E: mail@fluiddynamics.com.au W: www.fluiddynamics.com.au
3 INDEX Shell & Tube FluidEX Off the Shelf 4 Marine 5 Fail Safe 6 Hybrid 7 Corrugated Multitube Industrial 8 Multitube Hygienic 8 Annular Space 8 Tube in Tube 8 Exhaust Gas 8 Custom Build 10 Scraped Surface Heat Exchangers 9 Piston Pumps 9 Special Projects 11 FD-Plate Gasket 12 Gasket - Fail Safe 12 Brazed 13 Brazed - Fail Safe 13 Fully Welded 14 Fin Tube 15 Coil Condensers 15 Dry Air Coolers 16 Adiabatic Coolers 16 Air Cooled Condensers & Evaporators 17 FluidAIR Bar & Plate 18 FT Range On Road / Off Road 19 Ultrasonic Cleaning 20 Our Facilities 21 Defence Recognised Supplier 22 Some Customers 23 Aftermarket 24
4 Shell & Tube Off the Shelf FluidEX Shell and Tube heat exchangers provide ideal cooling solutions for a wide variety of applications. FluidEX Shell & Tube heat exchangers are manufactured using floating tube stacks that prevent premature failure as a result of thermal expansion fatigue and allow for easy cleaning. For over 30 years our highly efficient heat exchangers have been giving superb service throughout Australia and beyond. FluidEX robust and lightweight auto transmission oil coolers, incorporating high density tube stacks specially designed by Fluid Dynamics, are used in the incredibly reliable and rugged Bushmaster armoured vehicles. FluidEX coolers can also be found on engines, gen sets, compressors, transmissions and pumps in mines, factories and ships throughout Australia and abroad including the Australian Navy s Armidale Class Patrol Boats and Anzac Class Frigates. Features: Cast iron headers for industry Gun metal headers for marine or heavily polluted water Aluminium headers for On Road & Off Road applications 90/10 copper/nickel tubes standard 70/30 copper/nickel tubes for heavily polluted environments Naval brass tube plates standard Also available in stainless steel & titanium Ex-stock for standard product range Can be customised to suit almost any application Assembled and thoroughly leak tested in our factory before delivery
5 S h e l l & Tu b e Marine The design of FluidEX standard in marine shell & tube range includes raw water/fresh water heat exchangers, exhaust manifolds and charge air coolers. The removable headers and floating tube stack allow easy maintenance supported by the availability of replacement bundles and service kits. The design of FluidEX marine tubestacks is versatile and can be adapted to fit into the bespoke housings of marine equipment manufacturers. FluidEX marine heat exchangers undergo 100% pressure testing in our factory and can be supplied with full material certification. Accredited third party inspection and certification by internationally recognised independent classification societies such as Lloyds Register, Bureau Veritas, ABS, DNV & NKK is also available. The reliability of the FluidEX range has resulted in a well-earned reputation with the Australian Navy and established companies including manufacturers of marine engines, deck handling equipment & winches, marine hydraulic power packs, generators and gear boxes.
6 S h e l l & Tu b e Fail Safe Fluid Dynamics understands the dangers of heat exchanger failure causing contamination of one fluid with another. If you are concerned about cross contamination causing damage to your equipment or allowing oil to get into water causing environmental damage and embarrassment then you will find your solution here. Fluid Dynamics now brings to you the latest in heat exchanger technology - the new Fail Safe Shell & Tube heat exchangers that can handle heat loads up to 1,000 kw using double tubes, a special sealing fluid and a sensor based on a pre-charged diaphragm accumulator. The new Fail Safe Shell & Tube heat exchanger removes the risk of leaking by means of a double tube design with the space between the two tubes filled with a special sealing liquid. This liquid enables optimum heat transfer. A pre-charged diaphragm accumulator compensates the thermal change in the volume of the sealing liquid and keeps the liquid pressure almost constant. A leak in any of the tubes is detected immediately the pressure alters and activates an alarm. The sealing liquid is frost-resistant up to -30 C and, at the same time, safe with food-stuffs. Other liquids are available on request. Standard Units Tube in tube technology with sealing liquid Water side: optimized durability Electronic security On-tank cooler Heat dissipation up to 800 kw Flow rates up to 1800 l/min Cu/CuNi/SS tubes guarantee an independent operating pressure for both mediums.
7 S h e l l & Tu b e Hybrid The Hybrid series is a logical further development of a tube-bank heat exchanger for a wide range of industrial applications. This unit combines the advantages of both shell & tube and plate. It provides the robustness and ease of cleaning of a shell & tube cooler and the compact size and effectiveness of a plate cooler. This range is particularly effective due to the additional cooling area of the fins, and offers a heat exchange performance of up to1000 kw. This outstanding performance is produced by aluminium fins which are pushed over the bank of tubes with metal-to-metal contact. The Hybrid range of heat exchangers has a cooling surface from 0.43 m2 to 56 m2 Features: Aluminium fins ensure larger levels of heat exchange Heat dissipation up to 1000 kw Oil flow rates of up to 1500 l/min Removable end caps for easy cleaning of the tubes Max. pressure: oil 35 bar / water10 bar Option Sea water version Certifications for marine applications Compressed-air application Water-Water application Stainless steel version or chemically Nickel plated Flanges allow the heat exchanger to be turned through 90 Optionally available with internal bypass check valve (patented)
8 S h e l l & Tu b e Corrugated Corrugated tubes increase turbulation and heat transfer rates making a corrugated tube heat exchanger much more efficient than normal smooth tube heat exchangers. M u l t i t u b e I n d u s t r i a l K The FluidEX K series heat exchanger is an all stainless steel shell and tube heat exchanger for industrial use & is ideal for steam to water applications such as CIP heating. M u l t i t u b e H y g i e n i c MI The FluidEX MI series is an all stainless steel shell and tube heat exchanger for the food industry and is ideal for pasteurisation applications. A n n u l a r S p a c e AS The FluidEX AS annular space heat exchanger consists of three concentric tubes for heat transfer with viscous fluids. Product flows through the annulus and the media fluid flows in the other two channels heating and cooling the product from both sides. Tu b e i n Tu b e DTI The FluidEX DTI type heat exchanger is a double tube heat exchanger. The inner tube is corrugated and the product flows through the inner tube and the service fluid through the outer tube. Because of its geometry, the DTI heat exchanger is a true counter current heat exchanger. An expansion joint in the shell allows for differential expansion of the tubes during operation. E x h a u s t Gas G The FluidEX G series heat exchanger is specially designed for thermal energy recovery from exhaust gases. The corrugated inner tubes keep pressure drops to a minimum & an expansion joint allows differential expansion of the tubes during operation.
9 Scraped Surface Heat Exchanger U n i c u s The Unicus is a tubular heat exchanger with scraper bars in each tube that move in a back and forth manner. Ideal for highly sensitive fluids, such as food industry products, with whole particles. The gentle scraper movement provides efficient heat transfer without damaging the product s integrity for all hygienic and industrial applications. Highly scalable with heat transfer areas ranging from 0.7 to 120 m² in one heat exchanger makes the Unicus ideal for very large applications, such as evaporation of environmental waste for highly fouling fluids. R o tex The Rotex has been developed for applications where higher levels of product mixing are required due to high viscosities. It is a rotary scraped surface heat exchanger with scraping velocities up to 300 rpm. Unlike other rotary scraped surface heat exchangers the Rotex can be fitted with several heat transfer tubes in one single shell. This means more heat transfer area per module with significant capital and operational cost Piston Pumps Pumping without destroying product integrity is as important as the heat exchanger that comes after the pump. Our piston pumps can handle very delicate and viscous food stuffs and can pump up to very high pressure without damaging the food particles. It can also be applied very successfully in heavy duty applications for industries other than the food industry. Does not break the product. Delivers high flow rates (up to 20 m3/hr). Allows high pressure drop (20 bar). Can work under vacuum. Is self priming. Can work empty (without product). Requires few spare parts. Has no seals in contact with the product. Hygienic. Can work at high temperatures (100 C) Few number of valves per volume unit.
10 S h e l l & Tu b e Custom Build One of the key features of Fluid Dynamics is its ability to design, re-engineer, manufacture, test and repair Shell & Tube heat exchangers of all sizes and applications. Manufactured to the highest standards using the best quality materials. Whether from drawings or from reengineering an existing unit, we can deliver a beautifully constructed tubestack that will fit perfectly into an existing shell or we can manufacture an entire shell & tube heat exchanger. Many of our faithful customers are some of the largest power stations in Australia. They not only require us to manufacture replacement heat exchangers on time to meet their demanding timeframes, but each unit has to be made to exacting standards from the best materials to ensure trouble free cooling over extended periods. And Fluid Dynamics delivers time and again.
11 Special Projects Thrust Bearing Oil Coolers Manufacture of 6 units Diameter 2.4 metres 30mm seamless drawn copper tubes Tubes roller expanded into annular grooves Stainless steel tube sheets & headers Hydrogen Cooler Length 3.6 metres Seamless drawn copper tubes Tubes roller expanded into annular grooves Copper fins Rolled naval brass tube sheets Thrust Bearing Oil Coolers Rolled naval brass tube sheets Stainless steel headers Seamless drawn 90/10 copper nickel tubes Tubes roller expanded into annular grooves Generator Air Coolers Manufacture of 48 units Length 2.8 metres Height 1.2 metres 20 mm thick rolled naval brass tube sheets Seamless drawn copper tubes Aluminium fins Cooling Coils Length 3.5 metres Seamless drawn copper tubes Copper fins Copper headers Hand brazed joints Coil cote protection
12 FD-Plate Gasket Not only can Fluid Dynamics supply its own high quality FD-Plate it also can supply plates and gaskets to suit almost any brand of Gasket Plate heat exchanger including Alfa Laval, APV, GEA & Sondex. FD Plate Heat Exchangers provide: High thermal efficiency Effective heat transfer High performance Versatile & compact design Low installation cost Easy dismantling and cleaning Environmental efficiency FD-Plate Gasket Fail Safe To the convenience and efficiency of Plate Coolers we have added our Fail Safe system which effectively removes the risk of contamination between fluids in plate heat exchangers. We have combined the high-efficiency of conventional plate heat exchangers with Fluid Dynamics double plate design providing a barrier between the fluids. A failure in one plate enables timely detection of leaks before any damage is done. DOUBLE WALL GASKET THERMAL PLATE AIR SPACE TO ATMOSPHERE LEAK LEAK
13 FD-Plate Brazed Cost Effective Compact Easy to Install Our Brazed Plate Heat Exchangers are extremely compact giving you all the advantages of gasketed plate heat exchangers but condensed in size within a brazed body. If you have space limitations our Brazed Plate coolers are ideal. No carrying bars or bolts make our brazed plate heat exchangers easy to install. FD-Plate Brazed Fail Safe Brazed Plate Heat Exchangers are well regarded for their light weight & efficient heat transfer capabilities and their ability to withstand high temperatures and pressures. BRAZING MATERIAL DOUBLE WALL THERMAL PLATE LEAK Combine this with Fluid Dynamics Fail Safe system and you add years to the durability of the unit and remove concerns of detecting leaks before it is too late. LEAK FD-Plate Brazed Plates are sealed using either copper or nickel brazing depending on the application. AIR SPACE
14 FD-Plate Fully Welded Our Fully Welded Plate Heat Exchangers combine a significant range of technological advantages into one compact unit. The all-welded design removes the need for any gaskets between plates allowing them to operate with a wide range of aggressive fluids at high temperatures and pressures. The corrugated plate patterns generate high turbulence & provide heat transfer coefficients 3 to 5 times greater than standard shell & tube heat exchangers. Fouling is reduced & the use of corrosion-resistant exotic metals becomes financially viable. Perfect for handling aggressive, high-temperature fluids of all kinds in corrosive operating environments. These heat exchangers are compact and can be installed virtually anywhere in a wide range of heat exchanger applications including as a condenser on reactors or as a condenser or reboiler for distillation and stripping columns.
Fluid I N T E G R I T Y F in Tub e Superbly manufactured ensuring precise mechanical bond between fins and tubes producing the most efficient heat exchange available. Our Fin Pac Heat Exchangers can be manufactured using tubes of almost any thickness and material including copper, copper/nickel, aluminium or stainless steel. The fins can also be made from almost any metal including copper, stainless steel or aluminium with rolled naval brass tube sheets to ensure a high quality robust unit suitable for the most demanding environments. Co il Cond ens e rs Fluid Dynamics uses only the highest quality coil units and can supply condensers from fractional to 60 horsepower. We provide a huge range of products in hermetic, scroll, digital scroll and semi-hermetic. From our fully-housed condensing units to custom build the Fluid Dynamics has the flexibility to match your needs. Chilled fluid Hot water Steam systems Refrigeration Air conditioning Process Comfort conditioning Dehumidification Drying 15
16 Dry Air Coolers Dry air cooling is a highly effective alternative to evaporative cooling. For efficient cooling of liquids or condensate gases in closed circuits through intelligent heat transfer with high-density finned coil to air at ambient dry bulb temperature. Reduces water usage Eliminates water treatment Eliminates plumes Reduces maintenance Eliminates Legionella risks Ideal for compact or restricted areas. Adiabatic Coolers Adiabatic describes a thermodynamic process that happens without loss or gain of heat. Adiabatic coolers are either air-cooled or are condensers with adiabatic pre-coolers. Before the fan draws the ambient air through the finned coil the air is pre-cooled adiabatically as it passes over the coil face evaporating the water in the air boosting its cooling capacity. Low process temperatures Increases capacity up to 40% compared to dry cooling Reduces energy consumption Safe operation No water recirculation No stagnant water No aerosol generation No water carry-over Saves more than 80% on water usage compared to cooling towers.
17 Air Cooled Condensers & Evaporators Air-cooled and evaporative cooled chillers are intended for outdoor installation and operation. Air-cooled units are directly cooled by ambient air being mechanically circulated directly through the machine's condenser coil to expel heat to the atmosphere. Evaporative cooled machines are similar, except they implement a mist of water over the condenser coil to aid in condenser cooling, making the machine more efficient than a traditional aircooled machine. No remote cooling tower is normally required with either of these types of packaged air-cooled or evaporative cooled chillers. Fluid Dynamics can design and manufacture Condensers and Evaporators using a range of materials including finned tube or coils.
Fluid I N T E G R I T 18 Y Bar & Plate Custom Build FluidAIR aluminium & copper core heat exchangers provide ideal cooling solutions for a wide variety of applications where air is the cooling medium. Built to last, FluidAIR bar & plate heat exchangers are manufactured in Australia using the highest quality core and manufacturing techniques. For over 30 years our Heat Exchangers have been giving outstanding service to industry throughout Australia and beyond. You can choose from our off-the-shelf range or have a unit custom made to suit your exact needs. We can manufacture rugged aluminium core heat exchangers from 20cm to over 2 metres. Copper core units also available. Fluid Dynamics offers a prompt after market service that can provide high quality heat exchangers for almost any application and equipment at the right price. We are the exclusive Australian dealer for AKG Gruppe, Germany s leading manufacturer of aluminium core since 1919. Our partnership with AKG ensures access to the world s leading heat exchange engineers, manufacturers & designers. OEMs too can benefit from our expert service. We supply many OEMs with JIT service for heat exchangers that are custom built for their valuable machinery. Our FluidAIR range can be manufactured with or without fans -12V, 24V, AC, DC, 3 phase, electric or hydraulic, with a range of options including pumps, temperature switches, stone guards and 1 pass & 2 pass designs. GEN SETS HYDRAULICS AUTO TRANSMISSIONS PUMPS COMPRESSORS SUPER CHARGERS WIND TURBINES
Fluid I N T E G R I T Y FT Range On-Road / Off Road Air-Oil Coolers Proudly Australian Made and Owned. Fluid Dynamics has developed a range of robust and highly efficient aluminium core coolers specifically for the Australian heavy automotive market. We call it our FT range and it is built and individually tested in our well equipped factory to our highest standards. These coolers are made to last. Not only do we hold stock of our FT Range, we are happy to adjust them to suit our customers exact needs: Short lead times Full range of socket sizes no need to add adapters Full range of fans 12v or 24v Optional stone guards, temperature switches and custom fit hoses 19
20 The magic of Ultrasonics Fluid Dynamics has probably the largest Ultrasonic tank in Australia available to all industries. Equipped with over 300 transducers, a variety of environmentally safe & effective chemicals plus the ability to heat the tank to 90C, our Ultrasonic Cleaning System can safely clean an amazing range of equipment and machinery including: Heat exchangers - plate, finned, tube, plate & bar etc. Radiators Fuel tanks Catalytic Converters Filters Pumps Compressor rotors Engine parts Transmissions Valves etc. etc.
Fluid I N T E G R I T 21 Y O ur Facilit ie s In over 30 years of operation Fluid Dynamics has built an enviable reputation for being able to design, reengineer, refurbish, clean and test a huge range of heat exchangers in its fully equipped facility. We carry a large range of stock and have the right equipment for even the most complex jobs D es i gn Using our inhouse computer design programmes and a network of experts we can design almost any heat exchanger and build it. Our friendly staff is always willing to discuss your heat exchanger problems and provide a cost effective and high quality solution. Re- En g ine e ring We are experts at manufacturing all types of heat exchangers and are repeatedly called upon to re-engineer and fabricate heat exchangers of all sizes and types whether they are shell & tube coolers, finned tube, coils or plate. Many of our important customers such as power stations, mining companies, heavy equipment operators, demand the highest quality of workmanship and materials. Our thriving aftermarket business allows customers to avoid OEM prices by having us fabricate a unit that will fit exactly and often out perform the original. Refu rb ishme nt A significant part of our operation is the complete refurbishment of dirty and damaged heat exchangers. We have the expertise to professionally assess, clean and test heat exchangers. If they can be repaired we will carry out repairs promptly and add years to the unit s useful life. If the unit is beyond repair we have the ability to expertly rebuild a replacement.
22 Fluid Dynamics has had a long and distinguished relationship with Australia s Department of Defence and continues to supply it with many types of heat exchangers. Our marine shell & tube coolers are found on Navy craft such as the ANZAC Class Frigates, Armadale Class Patrol Boats and the Landing Craft Heavy (LCH) vessels. We designed and supply a special range of our FD oil coolers for the transmission oil and an aluminium core cooler to cool the transfer case oil for the famous Bushmaster armoured vehicle. We also ultrasonically clean and service armoured tank cooling packs including intercoolers, charge air coolers and radiators and intercoolers for Naval frigates.
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24 Fluid Dynamics - a company you can trust. Aftermarket Whether your equipment has been made in Japan, Germany, USA or elsewhere you will find the ideal heat exchanger at Fluid Dynamics You won t have to pay exorbitant prices and You won't have to adapt your equipment to suit our units Let us build your next aftermarket heat exchanger to fit your equipment - at the right price Contact Fluid Dynamics for high quality heat exchangers designed and manufactured in Australia For NATIONWIDE prompt and expert advice and assistance with Selection Sizing Performance call our friendly staff at Fluid Dynamics Since 1981 Fluid Dynamics has been designing, custom building and supplying heat exchangers of exceptional quality to industry throughout Australasia and the Pacific. Fluid Dynamics is a fully certified ISO 9001:2008 company and is proud to be the first company in Australia to sign up for the rigorous Twenty First Century Supply Chains (SC21) programme. SC21 is an initiative of the Australian Government developed to ensure Australian Defence and other industries are served by suppliers who are committed to the continuous improvement of their products and services to ensure the needs of all customers are met properly and promptly. Fluid Dynamics Pty Ltd HEAT EXCHANGERS SINCE 1981 25 Star Crescent Hallam, Melbourne Vic 3803 Australia T: +61 3 9796 5988 F: +61 3 9796 5777 E: mail@fluiddynamics.com.au W: www.fluiddynamics.com.au