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Optimisation of Air Cooled Heat Exchanger Performance
Technical Assistance
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Marie-Andre SENEGAS (AET)

Olivier BERNAERT (AET)
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1) Tip Clearance according to API-661 specifications: installation of Tip seals
2) Air recirculation at the centre of the fan : installation of Seal disk
3) Pitch angle setting : adjustment rules
4) Fan blade positioning inside fan ring.
5) External cleaning of tube bundle: water + detergent, foam de-scaling ,
6) Fan blade static efficiency : airfoil of fan blade
7) Belt efficiency
8) Improvement of inlet conditions: installation of Inlet bells .
9) Improvement on airtightness : air seals
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1) TIP CLEARANCE
Tip Clearances are critical to the efficiency of a fan system. If there is too much distance
at the tip of the blade, this will cause air recirculation problems. This recirculation will
directly affect the duty exchanged by the air cooler due to a loss in airflow going through
the tube bundle.
Too big of a tip clearance can lead to a loss of 5% to 10% in airflow (depending on how
bad the tip clearance is to start with).
Tip Clearance
Tip Clearance is to be set within API661 specifications.
Fan diameter
Tip Clearance
Meters
Feet
Minimum
Maximum
1 and 3
3 and 9
6 mm (1/4 inch)
13 mm (1/2 inch)
> 3 and 3.5
> 9 and 11
6 mm (1/4 inch)
16 mm (5/8 inch)
> 3.5
> 11
6 mm (1/4 inch)
19 mm (3/4 inch)
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Optimisation of Air Cooled Heat

Exchanger Performance
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TIP CLEARANCE
tip seal
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Aim : If properly installed, a tip seal will re-create a tip clearance in line with API 661 (3/8"
3/4") regardless of fan ring irregularities, such as ovalness or eccentricity.
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Cost : Approximately US$350 per tip seal (non installed) and US$ 200 per tip seal roller

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TIP CLEARANCE
Effect of tip clearance on fan efficiency for different sizes of fans
Reference : AIRPOWER HUDSON Products Corporation

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TIP CLEARANCE
Tip Seal: Installation procedure
Step 1
Remove all fan blades (except one).

Mark a line showing where to install the tip seal.
Step 3
Adjust tip seal roller to set desired tip clearance :

Step 4 install it where the last section of tip seal has not
been installed yet. Push fan blade with roller so as to crush
the tip seal until proper depth is reached.
Step 2 -
Install all pieces (except one) aligned to the

upper edge drawn in step 1. For installation use
self-tapping, auto perforating screws.
Install last section and push roller over

last section.
Remove roller!
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2) AIR RECIRCULATION AT THE CENTRE OF THE FAN
Air Recirculation is often observed at the centre of the fan

High velocities will typically be located at the second half of the fan
blade (outer end), becoming increasingly lower (even negative) at the
centre of the fan.
Local Velocity,
ft/mn
Negative velocities imply a recirculation of hot air, thus a decrease in

fan efficiency.
Percentage of Fan Radius from Hub
Please note that the handkerchief

is pointing down instead of up, indicating
negative airflow.
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AIR RECIRCULATION AT THE CENTRE OF THE FAN

INSTALLATION OF SEAL DISK ON FAN HUB
The value of the Seal Disk (made out of FRP) lies in that it bounces
the hot air back up into the airflow and helps to prevent air
recirculation at the centre of the fan.
Therefore, the Seal Disk will increase the amount of air going
through the bundle.
Expected increase in airflow by using Seal Disk: up to 5%.

Average cost of Seal Disk (non-installed)= US$ 250
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3) SETTING OF PITCH ANGLE
Optimal blade pitch setting will result in maximum airflow

The point at which the pitch angle is measured differs from manufacturer to manufacturer (at
1" of the tip of the blade, at 2/3 of the fan blade). When a fan manufacturer specifies a pitch
angle, he is required to indicate the location at which the pitch angle will be measured.
As a general rule: in order to ensure the smooth functioning of the fan and thereby avoiding
extraneous air impulses, It is of crucial importance that the angle of a given blade should be
exactly the same for the remaining blades.
Supplier must select a fan in such a way, that at a specified speed, it should be feasible (by
blade pitch angle modification) to gain 10% more airflow, taking the corresponding static
pressure increase into consideration. This measure is required by API 661 to avoid "stalling" a
fan, which is generally associated with a drastic loss in fan efficiency.
An increase of 10% of the blade pitch angle leads to :

16% absorbed power
5% airflow
11% static pressure
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BLADE PITCH ANGLE SETTING
The following formulas illustrate the relationship between blade pitch angle variations and other variables. These formulas are valuable for
blade pitch variations of 5 :
absorbed power at fan:
tan 2
BHP2 = BHP1 * 1.06 *

tan 1
BHP = Brake Horse Power

= Power absorbed at fan shaft (expressed in HPs)
= Blade pitch angle (expressed in degrees)

Fans airflow:
1
tan 2 3
CFM 2 = CFM 1 * (1.06) *

tan 1
CFM = Cubic Feet per Minute @ T and P
= airflow volume
1
3
Fans static pressure:
Ps
2
3
tan 2
Ps2 = PS1 * (1.06) *

tan 1
= Static Pressure ("H2O) (all pressure drops through the tubes bundle)
2
3
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2/3
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To maximise the air flow of a fan, it is important to set the correct pitch angle.
In practice, this setting is adjust to verify that the increasing in static pressure
(manometric measurement) increases like the angles tangent :
2/3
Ps
tan( 1 + )
= (1.06 )
Ps1
tan 1
If the static pressure does not increase as much as calculated, it is because the fan is in stall
conditions.
It is important to never increase the intensity of the electrical engine over the nominal
conditions.
Ps + 18%
Theoretical increasing in
electrical engine intensity
I + 28%
Ps + 14 %
The variations of intensity and static pressure for an increasing of 2 of blades angles
could be estimated as following.
Started pitch
angle
10 ( 20 %)
I + 21 %
Ps + 11 %
Increasing in static pressure
15 ( 13 %)
I + 18 %
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20 ( 10 %)

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- Particular case Conditions of fan stall
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The Fan stall phenomenon is a lot like a cavitating pump. At fan stall, the boundary layer
of air at the leading edge is changed from laminar to turbulent flow. The effect of a fan in
stall is a horsepower increase but the net fan work actually decreases.
Air
This phenomenon can often be seen on air coolers affected by an increase in static pressure as
a result of external fouling; a low RPM; or in case the blade pitch angle is too high. In practice
however, it is usually a combination of the three scenarios described above.
high absorbed power ( nominal power)

negative airflow on a large portion of fan blade
Air
Air
high blade pitch angle setting (compared to supplier recommended pitch angle)
fouled finned tube bundle
Air
In the field, A fan suspected of being in stall will show the following characteristics :
-
A simple remedy to cure the problem is to decrease the blade pitch angle. If decreasing the
pitch angle does not result in the static pressure behaving according to the following rule (i.e. it
stays constant), this demonstrates that the fan was in stall:
2
3
tan
2
Ps2 = PS 1 * (1.06)3 *
tan 1
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Please note that a fan in stall not only decreases the airflow therefore duty - it can also lead to
vibration problems.

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Fan Blade Pitch adjustment to avoid Stall
Fan in early stage of stall
Air flow
Air flow
Air flow
Air flow
As blade pitch is increased, air flow may stall and start to reverse. This may be evidenced using smoke or filament strips.
Fan in later stage of stall
Air flow
Air flow
Air flow
Air flow
Propagation direction of stall when blades pitch is further increased
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SETTING OF BLADE PITCH ANGLE
Stall phenomenon
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Pitch angle
(in degrees)
100
73
Measured airflow
(m3/s)
0.9
0.9
Static pressure
(mm H2O)
44
63
Power measured
at substation
(kW)
Fan in stall
Case of fan in stall encountered at the Flanders Refinery on an A-frame condenser of the
steam turbine carrying the cracked gas compressor of the FCC
20
Blade tip
Hub
A decrease of 7 in blade pitch angle generated an increase in airflow of 35% with an absorbed
power decrease of 30%. Please note that the static pressure has remained constant
Hub
Reversed airflow
on a large portion
of the blade
Blade tip
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Another solution to solve the stall problem could be to decrease the pitch angle and increase
the RPM of the fan (by replacing the existing gearbox). This solution has the advantage that
the engine can be fully loaded (due to the increase in RPM), thereby increasing the airflow.

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4) Fan blade positioning inside fan ring
An incorrect positioning inside the fan ring can considerably affect static fan efficiency due to air recirculation at the tip of the blade.
Wrong positioning
Correct positoning
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5) EXTERNAL CLEANING OF TUBE BUNDLE
EXAMPLE OF HEAVILY
FOULED TUBE BUNDLE DUE
TO EXCESSIVE SCALING
External cleaning of tube bundle must be carried out regularly, especially on units considered as critical. These cleaning projects
must be scheduled before the hot seasons.
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EXTERNAL CLEANING OF TUBE BUNDLE

Description of different cleaning methods
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1- "Hydro-jets" or high pressure water sprays

In essence, this method has proven to be a very easy one to use. The
disadvantage associated with this method is the fact that since a high-pressure jet
of water is used to clean the tube bundle, the risk of fins being damaged is great.
2- Low pressure water sprays with detergent method
This method is definitely the preferred choice and most used option amongst our
refineries.
Large amounts of water (20 m3/h) are sprayed at low-pressure levels
(4-5 bars) in combination with a detergent.
Advantages of low pressure water sprays and detergent method:
- the detergent dissolves fat / greasy deposits
-low pressure water sprays minimise the risk of damaging the fins.
- the water used for washing - non-toxic and free of oils goes down the
drainpipe.
3- Chemical cleaning with foam
Can be considered an option in the case of specific dirt deposits (scale deposit
after the spraying of a bundle).
Although the chemical cleaning with foam method is an efficient one, it is still not
widely recognised nor used. The foam ensures that the fins are kept in contact
with the active chemical element. This cleaning method necessitates abundant
rinsing afterwards. In addition, careful planning should be made as to the final
destination of the water used for washing (please make provisions for a
neutralisation process).
4- Inverting the polarity of engines
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This method basically unsticks deposits that are loosely attached to the surface of
the tube bundle. Although this method is very easy to use, it is also only seldom
used in our refineries.

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CLEANING OF THE BUNDLE
Air Cooled Heat Exchanger with forced draft
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Start cleaning the tubes of the lower layers engines on (only if the engines are
located above the bundle).
Proceed by cleaning the tubes of the upper layers engines off.
Finish the job by cleaning the tubes of the lower layers engines off.
Air Cooled Heat Exchanger with induced draft
Recommended cleaning procedure

Low pressure water sprays + detergent method
Exact same procedure as in the case of the Air Cooled Heat Exchanger with
induced draft.
Extra precaution: stop the engines and protect these, together with the belts.
Note :
To be efficient, an average cleaning session for a dirt-ridden piece of

equipment will last 4 hours per fan.
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Before the upper layers of the tube bundles are cleaned, protection
will be secured (this to avoid crushing the fins). This type of
procedure is a standard maintained for all maintenance operations in
particular on Air Cooled Heat Exchangers with induced draft.
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CLEANING OF THE BUNDLE
CASE HISTORY
Water wash procedure of the airside of fin fan air coolers
RN - Reforming unit (Cr6) - E13
Water wash procedure
(2)
Water wash efficiency - Airflow measurements and Duty
improvement
BEFORE
water wash
AFTER
water wash
Air flow (Nm3/h)
150 000
195 000
Duty (MM kcal)
3.8
4.2
(1)
Forced draft
Use of important flow rate (20m3/h) and low pressure

Use of a detergent/surfactant mixture added in water
For a forced draft, the fan is stopped during the washing
2 STEPS
(1) 3 hours below the fin tubes to wash
INCREASE OF 30 % of airflow
INCREASE OF 10% of duty
Overall cost estimation of the water wash operation
300 US$ / fan
(2) 1 hour above the fin tubes to rinse
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6) STATIC EFFICIENCY OF FAN BLADES
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The efficiency of a fan depends on the shape of the blade (airfoil). In effect, a highly efficient fan
requires a minimum of power for a maximum volume of airflow.
CFM * Ps
The power required by a fan (BHP) for a given amount of airflow (CFM) and static pressure (P
through the bundle) is inversely proportional to the efficiency of the fan.
BHP
statique
TEST PERFORMED AT NORMANDY REFINERY / HUILES 3
(%)
43 %
static
80
m3/s
73
Airflow
34
Energy
consumption
kW
35
22
mm H2O
19
static Pressure
58 %
A blade replacement test was performed at the Normandy Refinery on the unit called huiles 3
(E807-A3). Aluminium blades were replaced with synthetic resin blades. Airflow measurements
were performed before and after the replacement of blades.
Aluminium
Blades
Synthetic resin
Blades
HUDSON
Using more efficient fan blades generated an airflow increase of 10% while simultaneously
using the same amount of electricity.
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Using more efficient fan blades increases the volume of airflow going through a tube
bundle - thus the duty exchanged by the cooler - utilising the same electrical engine for
the powering of the fan (thus implying a reduction in costs). A reduction in power can
occasionally be observed, and in some cases it is possible to augment the level of speed
(transmission change), and thus the airflow.

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COMPARATIVE EFFICIENCY TEST BETWEEN FAN BLADES

Normandy Refinery Unit Huile 3 : Air cooled Heat Exchanger E807 A3
HUDSON TUFLITE II Blade
MOORE Blade
A
i
r
Tip seal
s
p
e
e
d
Blade efficiency
Average air speed, HUDSON = 8.5 m/s

Average air speed, MOORE = 7.5 m/s
(m/s)
Seal disk
Blade Tip
Hub
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INSTALLATION OF NEW MORE EFFICIENT BLADES

CASE HISTORY
Provence Refinery - ALKYLATION UNIT - overhead deisobutaniser (E301)
MODIFICATIONS ON AIR SIDE :
- Installation of new blades : HUDSON blades with more static efficiency.
- Increase of RPM from 200 to 280 rotation per minute. New belt and pullet.
Installation of seal disk, inlet bell and tip seals.
These modifications had taken four nights of work - cost - 250kFF installed.
AIR SIDE IMPROVEMENT :
Before
Number of blades
Rotation speed (RPM)
Static pressure
Electrical (KW)
Static efficiency
Average Air Flowrate
6
200
7.2 mmH20
10 (design = 15)
51%
63 m3/s
After
(HUDSON blades)
4
278
9.2 mmH20
14
58%
80m3/s
=> Gain of air flowrate of 30 % (15% due to increase of electrical consumption and 15% due to blades efficiency, belts,....)
PROCESS SIDE IMPROVEMENT :
Gain of 4% on the total overhead duty (air condensers and trim cooler). In consequence, increase of an average of 15T/j of
production of alkylate due to these modifications. Pay out time, for 3 months summer and 80$/T alkylate, is approximately POT 2.5
months.
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COMPARATIVE EFFICIENCY TEST BETWEEN FAN BLADES

Provence refinery Alkylation unit : Air cooled Heat Exchanger E301
Pale Hudson Tuflite TUFLITE II

A
i
r
s
p
e
e
d
m
/
s
Pale Howden Stork
Tip seal and inlet bell
Blade efficiency
Average air speed, HUDSON = 5,7 m/s

Average air speed , Stork= 4,5 m/s
Inlet bell +
Tip seal
Seal disk
Hub
Blade Tip
Position of point of measurement from blade tip (cm)
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7) EFFICIENCY OF BELTS
The following list provides an overview of the type of belts most frequently used by refineries:
- V-belt
- HTD belts
- Banded V-belt (HUTCHINSON POLY V)
Efficiency varies depending on the type of belt and on the craftsmanship of its installation. For instance, HTD belts are widely recognised,
particularly as to their transmission efficiency.
We have observed on site that the slipping of belts can reduce the rotation speed of a fan by 10%, thus a 10% reduction in airflow.
TYPE OF BELTS
USE IN REFINERIES
INTRINSIC
EFFICIENCY
DISADVANTAGE(S)
V-Belts
WIDELY USED
AVERAGE 80%
RE-TIGHTEN ON REGULAR BASIS
HTD Belts
USED ON NEW MACHINERY
VERY GOOD 100 %
TENDENCY TO SLIP VERTICALLY

LESS ABLE TO COPE WITH THE START UP
SHOCKS
Banded V-Belts
NOT WELL KNOWN
GOOD 98%
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EFFICIENCY OF BELTS
DIFFERENT TYPES OF BELTS
V-Belts
HTD-Belts
Banded Belts
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EFFICIENCY OF BELTS
EXAMPLE OF THE INSTALLATION OF AN HTD-BELT
CORRECT INSTALLATION
INCORRECT INSTALLATION
BELT IS FITTED TOO
TIGHTLY
INCORRECT INSTALLATION
BELT IS FITTED TOO
LOOSELY
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8) INLET BELL INSTALLATION

The inlet conditions for air are particularly important for Air Cooled Heat Exchangers with a forced draft configuration, and the same is true
be it at a lesser extent for Air Cooled Heat Exchangers with induced draft configurations.
The installation of an Inlet Bell will limit the level of turbulence in the entrance area of the fan ring.
Air recirculation
Air Flow
without inlet bell
Air Flow
with inlet bell
In the case of a straight air entry, turbulences emerge as a result of the brutality with which air enters the fan ring
(vena contracta ). The effective surface for air is reduced substantially.
Therefore, a smoother shape of the fans entrance will decrease the effect in question
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Example:
For a fan with a diameter of 10 producing an airflow of 60m3/s under a static pressure of 13mmH2O, a straight entry will
generate, approximately, a P of 2mmH2O. Concretely, the implication is that the useable potential of the static pressure
is factually only utilised by as much as 11 mmH2O, instead of the 13 mmH2O that could have been achieved had the
appropriate Inlet Bell been installed.
The loss incurred amounts to a 15% decrease in static pressure, which itself translates into a 7% loss in airflow
through the bundle.
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INSTALLATION OF INLET BELL

Material cost without installation: US$ 300 per fan 12 (non installed).
Discounted airflow gain + 5 % - for the replacement of a straight entrance of the ventilation ring by a progressive entrance (photograph
below).
INLET BELL
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9) AIR SEAL INSTALLATION

The function of air seals is to eliminate all air leaks that may exist between the bundle and the plenum chamber. In other words, air seals are
simply metal plates fixed with screws.
As a rule of thumb, air leaks occur rarely with new equipment.
On the other hand, older equipments tend to suffer from cavities in the plenum - due to corrosion - and missing airseals lost over time.
Although accurately estimating the actual loss in airflow caused by missing air seals is hardly possible, replacing these air seals is an
economical operation and it is certain to increase the airflow.
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OPTIMIZING AIR COOLED HEAT EXCHANGER PERFORMANCE

SUMMARY OF TOTALFINA TRIALS
MODIFICATION
1 INSTALLATION OF TIP SEAL
DECREASE OF TIP CLEARANCE FROM 30 mm to 6mm
2 INSTALLATION OF SEAL DISK
INCREASE IN
AIRFLOW
+10 to +15%
+ 5%
3 OPTIMIZATION OF FAN PITCH ANGLE

GETTING FAN OUT OF STALL
4 CLEANING OF BUNDLE
+ 5 to + 20%
5 MORE EFFICIENT UTILISATION OF HYDRODYNAMIC BLADES
+ 10 to + 20%
6 OPTIMIZATION OR REPLACEMENT OF BELTS TO AVOID

SLIPPAGE
7 INSTALLATION OF INLET BELL
CONVERSION OF STRAIGHT ENTRANCE TO SMOOTH
ENTRANCE
8 INSTALLATION OF AIR SEAL
+ 5 to + 15%
+10 to 30%
+ 5 to +10%
AUDIT RESULTS
RN HUILES 3
RF FCC/HDT/CDU
RP DEPROPANIZER
RP - ALKYLATION
RP - ALKYLATION
RN HUILES 3
RF FCC/HDT/CDU
RF FCC
RN REFORMER
RF FPP
RN FCC
RP - VDU
RN HUILES 3
RP - ALKYLATION
RP DGO3
RP - FPP
RP - ALKYLATION
+ 5%
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Annex 1
Comparison between PUMPS and FANS
PUMP
FAN
A pump is a piece of equipment that transmits energy to a non- A fan is a piece of equipment that transmits energy to air via
compressible fluid via the intermediary of one or more wheels. the intermediary of blades.
When expressed in inches of water, reference is made to the When expressed in inches of water, the energy is referred to
elevation (H).
as the static pressure (Ps).
The manufacturer will provide a number of characteristic
curves. One such curve provides the elevation (H) for a given
pump running at a given speed taking the flow volume (Q) into
account.
The manufacturer will provide a number of characteristic

curves. One such curve provides the static pressure (Ps) of
a given fan at a given speed taking the airflow volume
(CFM) into account.
The power absorbed by the pump is illustrated using the The power absorbed by the fan is illustrated using the
following formula : Parbre Q * H * d *
pompe
The operating point of a pump within a circuit is the point that

is situated at the intersection between the characteristic curve
of the pump H=f(Q) and the characteristic curve of the circuit
P = f(Q)
following formula : BHP CFM * PT *
vent .
The operating point of a fan through the bundle is the point

that is situated at the intersection between the characteristic
curve of the fan Ps=f(CFM) and the characteristic curve of
the circuit P = f(CFM).
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Inefficient configuration
Improved configuration
Undersized
Seal disk
Air recirculation can reduce

fan performance up to 40 %
Inlet bell
Seal disk
Honey comb tip seal
New blades
Air leakage
air seal
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Appendix 3
AIR COOLERS - Influence of speed rotation and blade angle
on a clean system
Induced draft
Forced draft
Ps
Ps
CFM
CFM
For an increase of 10% of the rotation speed

*
*
*
*
+ 10% of the airflow rate (CFM)

Increase of 21% of the static pressure (Ps)
Increase of 33% of the horse power developed by the fan (BHP)
4% of duty
For an increase of 10% of blades angle (max. = +5 compare to design)

*
*
*
*
+ 5% of air flowrate
Increase of 11% of the static pressure
Increase of 17% of the horse power of the fan
+ 1.5% of duty
Page 36 sur 36

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Optimisation of Air Cooled Heat Exchanger Performance

Marie-Andre SENEGAS (AET)

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Optimisation of Air Cooled Heat Exchanger Performance

Optimisation of Air Cooled Heat Exchanger Performance

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Optimisation of Air Cooled Heat Exchanger Performance

Tip Clearance is to be set within API661 specifications.

> 3 and 3.5

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Optimisation of Air Cooled Heat

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Optimisation of Air Cooled Heat

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Optimisation of Air Cooled Heat Exchanger Performance

Remove all fan blades (except one).

Adjust tip seal roller to set desired tip clearance :

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Install all pieces (except one) aligned to the

Install last section and push roller over

Optimisation of Air Cooled Heat Exchanger Performance

Air Recirculation is often observed at the centre of the fan

Negative velocities imply a recirculation of hot air, thus a decrease in

Percentage of Fan Radius from Hub

Please note that the handkerchief

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Optimisation of Air Cooled Heat Exchanger Performance

AIR RECIRCULATION AT THE CENTRE OF THE FAN

Expected increase in airflow by using Seal Disk: up to 5%.

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Optimisation of Air Cooled Heat Exchanger Performance

Optimal blade pitch setting will result in maximum airflow

An increase of 10% of the blade pitch angle leads to :

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Optimisation of Air Cooled Heat Exchanger Performance

BHP2 = BHP1 * 1.06 *

BHP = Brake Horse Power

= Blade pitch angle (expressed in degrees)

CFM 2 = CFM 1 * (1.06) *

Fans static pressure:

Ps2 = PS1 * (1.06) *

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Optimisation of Air Cooled Heat

BLADE PITCH ANGLE SETTING

Increasing in static pressure

G:\Assistance Technique\FICHES TECHNIQUES\FICHIER format PDF\MATERIELS\Arorefrigerant\toolboxlastversion.doc

Optimisation of Air Cooled Heat

BLADE PITCH ANGLE SETTING

high absorbed power ( nominal power)

G:\Assistance Technique\FICHES TECHNIQUES\FICHIER format PDF\MATERIELS\Arorefrigerant\toolboxlastversion.doc

Optimisation of Air Cooled Heat Exchanger Performance

Fan in early stage of stall

Fan in later stage of stall

Propagation direction of stall when blades pitch is further increased

G:\Assistance Technique\FICHES TECHNIQUES\FICHIER format PDF\MATERIELS\Arorefrigerant\toolboxlastversion.doc

Optimisation of Air Cooled Heat

G:\Assistance Technique\FICHES TECHNIQUES\FICHIER format PDF\MATERIELS\Arorefrigerant\toolboxlastversion.doc

Optimisation of Air Cooled Heat Exchanger Performance

G:\Assistance Technique\FICHES TECHNIQUES\FICHIER format PDF\MATERIELS\Arorefrigerant\toolboxlastversion.doc