How Oil Cooler Work and Common Problems?

In a stock setup, transmission fluid is cooled as its collected heat transfers to the colder engine coolant that surrounds it. Coolers usually work best when mounted in front of a stock radiator since this is where it can often get the most unobstructed source of cool air. This, in turn, allows much cooler fluid to return back to the transmission case.

While a majority of cars are not manufactured with proprietary engine oil coolers, there is a large aftermarket for them in many places, and they are common accessories in vehicles involved in towing and other heavy-duty applications. People can buy oil cooling kits to upgrade their vehicles themselves, though this usually requires a bit of expertise. Many professional shops will also install these for people looking for ways to make their machines more efficient.

Common Problems

The optimum temperature for oil is usually between 180° and 200°F (82° and 93°C). Failures start to occur when oil cannot dissipate its collected heat fast enough and rises past this threshold, which can begin to degrade the oil. Oil loses its lubricating, as well as its cooling, properties when it starts to break down, and this can lead to a number of serious engine and transmission problems. Coolers should usually be inspected fairly regularly to keep them in good working order, and owners should take care to regularly inspect and service them to avoid major failures.

Oil Cooler System 

•  To prevent the unconstrained heating of the oil, most high-performance hydraulic systems include a hydraulic oil cooler, a device placed in line with the system to allow heat to dissipate from the oil.

• As the mixture grows steadily cooler, other compounds condense, until it hits the top of the column.

Oil Cooler Radiator 

• An oil cooler is essentially any device or machine intended to cool oil, but in most instances people talk about it in the context of cars, trucks, and sometimes airplanes.
• The cooling medium absorbs heat from the oil and carries it away from the cooler, where it is typically shed into the atmosphere. Common hydraulicoil cooler designs include radiator, shell and tube, or plate and frame types.

Large Oil Cooler 

• While a majority of cars are not manufactured with proprietary engine oil coolers, there is a large aftermarket for them in many places, and they are common accessories in vehicles involved in towing and other heavy-duty applications.
• The lubricating oil in automobile engines also serves as a coolant, thereby absorbing heat from the combustion area and shedding it through a separate oil cooler or the reserve oil in the engine sump. Large industrial gearboxes and drive trains also utilize combined oil lubrication and cooling.

Industrial Oil Cooler

• An oil cooler is essentially any device or machine intended to cool oil, but in most instances people talk about it in the context of cars, trucks, and sometimes airplanes.
• The lubricating oil in automobile engines also serves as a coolant, thereby absorbing heat from the combustion area and shedding it through a separate oil cooler or the reserve oil in the engine sump. Large industrial gearboxes and drive trains also utilize combined oil lubrication and cooling.

 

What Is an Oil Cooler and its Main Purpose

 

An oil cooler is essentially any device or machine intended to cool oil, but in most instances people talk about it in the context of cars, trucks, and sometimes airplanes. In these settings the cooler basically acts as a small radiator that helps keep an engine cool by keeping the oil supply at a consistent temperature. Cooled oil helps keep the engine running smoothly, particularly during gear changes in very hot weather or on long-haul trips when things might otherwise have a tendency to overheat and break down. Not all cars and trucks use oil as a coolant, but those that do really depend on a working cooler in order to get good efficiency and performance.

Main Purpose

Automotive engines tend to be somewhat complex, and usually depend on a series of different combustions, heat sources, and temperature regulators in order to function properly. Oil coolers are most common in heavy-duty machinery that has a more industrial-grade engine. Trucks used to haul freight and large vehicles designed for off-roading are two common examples; some recreational vehicles (RVs) and airplanes have them, too, and they may even be found in certain motorcycle models. Race car drivers sometimes add them to sports cars to make them more efficient, too, and to improve their fuel combustion times.

A transmission oil cooler is often considered essential in high-strain situations because a transmission's lubricating fluid heats up with each gear change. While not crucial for highway driving when vehicles more or less stay within a few gears, transmission coolers can markedly improve the performance and longevity of transmissions that are subjected to a great deal of stress. Overheated transmission oil can lead to slower gear shifts, worn seals, lower mileage, and, ultimately, premature failure.

Even though the main job is to cool and lubricate the engine, this part can also act as an important coolant for a number of other parts. A motor's bottom end, which includes parts such as the crankshaft, bearings, camshaft, rods, and pistons, is also cooled only by engine oil, for instance, and this cooling can impact overall performance just as much as it could in the engine itself.

Types

Engine oil cooler design can generally be split into two types. Tube and fin models are the first, and are designed so that oil circulates through cooler lines that surround the engine. As the oil moves away from the heat of the central engine, its temperature drops and excess heat is funneled out by fin-like vents attached to the tops or sides. Stacked-plate designs, by contrast, force oil through a series of metal plates. Heat dissipates as air moves across the plates, and the oil cools faster when it has greater surface area and is shallower, too.

Plated models are often slightly less effective at cooling oil than their tube and fin counterparts since they’re more passive, basically waiting for cooling to happen on its own. A lot of this depends on the application, though. In some settings, stacked plate coolers make more sense.

Pipe Marking

Anyone that has ever planned or completed a home improvement project will know that organization is one of the most important parts of the process. If the person undertaking the do it yourself project has not properly labeled and arranged all of the items that they will need ahead of time, they will find themselves struggling to finish the project while constantly trying to find supplies and equipment to do the job. This is why items such as pipe markings are so popular, because trying to undertake a home improvement project with unmarked pipes is almost always a disaster.

There are many places available where a do it yourselfer can purchase pipe markings. Many regional and national home improvement stores will carry a wide variety of these items to give their customers the biggest selection available. Almost anywhere that carries pipes will have pipe markings located
nearby so that the customer will not have to search for them.



The prices for pipe marking can vary from retailer to retailer and from region to region. Some individuals consider the cost to be too insignificant to worry about while some others are always looking for the best deal for their money. If consumers are interested in finding the best prices, they may want to compare price and quality between several different stores and make the decision based on which store provides the best value.

There are several different types of pipe markings available at most of the retailers that carry this type of product. The type used will vary according to the conditions of the home improvement project being undertaken. Some individuals that have worked with pipes before may have a preference for one type or another, so that may be a factor in the type of pipe markings they choose.

Most brands of pipe markings are pretty similar in quality so different brands of the same item will have most of the same qualities. Some brands may be made of a slightly superior material or last longer under certain conditions, so it is important to choose the one that is right for the customer's needs. The differences between the brands will be listed on the outside of the package to give the consumer the information at a glance.

If the person is interested in purchasing pipe markings in bulk quantities, there are a number of different manufacturers that will ship the items to the customer directly. These companies generally sell much of their merchandise in stores, but will ship products directly to the customers that prefer their brands. The customer will generally pay a reduced rate for purchasing the items in bulk, but will have to pay a shipping charge to have the items delivered to their home or business.

Many of the companies that will sell pipe markings directly to the customer can be found on the internet with many of them having websites that display their products and gives a small amount of information about their company. It is important to ensure that the company on the internet is actually a legitimate business and not a scam set up to separate honest individuals from their money. In many cases, it is best to first find a brand that is preferred in the stores and then use the company's website to continue obtaining the product and find out about new products the company is developing that they may like.

There may also be interesting reviews of the different types of pipe markings found on different websites on the internet. There are certain websites on the internet that allow average consumers to rate the products that they purchase and some of these websites focus exclusively on pipes and pipe accessories. The reviews on these websites are the consumer's actual opinion about the product that they purchased.

It is important not to base the choice of which type of pipe markings to use on a single bad review because many people can be dissatisfied with different product for different reasons. Some individuals do not follow the directions properly while other individuals may use the items in situations that they are not recommended for. It is best to read several different reviews for each brand to be able to make an objective decision as to which one provides the best value for the money.

Tenova Pyromet Plate Cooler design successfully installed on six-in-line furnace for Northam Platinum

Electric furnaces and associated plant equipment specialist, Tenova Pyromet, has successfully completed an engineering contract for the design of a complete furnace cooling system. The contract was signed with Northam Platinum Limited in July 2013. The client, Northam Platinum Limited (Northam), is an independent, mid-tier, integrated platinum group metals producer listed on the JSE Limited. Tenova Pyromet is part of the global Tenova Mining & Minerals Group.

The plate cooler project was fast-tracked by Northam Platinum to minimize the plant shutdown period. Construction drawings were issued by Tenova Pyromet a mere two months after project commencement and after installation and cold-commissioning, the furnace was switched on in October 2013. Northam Platinum has been satisfied with the furnace operation since restart.

The project followed a pre-feasibility study awarded to Tenova Pyromet by Northam Platinum in 2010 to up-rate their six-in-line furnace from 15 MW to 25 MW. In the study report, Tenova Pyromet recommended that plate coolers be fitted on the furnace side-wall, to operate safely at 25 MW. During an inspection in 2013, Northam Platinum identified that the refractory lining on its 15 MW furnace had eroded prematurely.  As a remedy, Northam Platinum decided to implement the recommended plate cooler solution and to install a new refractory lining. Thermal calculations indicated that the refractory life at 15 MW operation would be extended by cooling the side-wall. The adoption of plate coolers prompted installation of an additional water supply system, which included cooling towers, a pump station, piping, electrical and instrumentation.

A key advantage of Tenova Pyromet Plate Coolers is their configurability, noting that the arrangement and number of plate coolers can be tailored to provide various degrees of cooling. The Tenova Pyromet Plate Cooler has been used to cool side-walls in slag and tidal zones of base metal furnaces. The plate coolers are fabricated from high grade copper which is Oxygen Free and provides High Conductivity. The simple shape allows the water cooled passages to be drilled, ensuring effective and safe cooling.  A steel shell lining is not mandatory when plate coolers are installed; a bare plate cooler front surface makes both maintenance and inspection easier.

“Tenova Pyromet’s track record with copper cooler technologies is reassuring to furnace operators. Our references are underpinned by 18 years of R&D, our commitment to excellence and our customer focus” says Andre Esterhuizen, Tenova Pyromet General Manager Sales and Marketing.  “Tenova Pyromet commends Northam Platinum for its swift and effective action taken to realize this project” he adds.

Tenova Pyromet is a leading company in design and supply of high capacity AC and DC furnaces and complete smelting plants for production of ferroalloys, base metals, slag cleaning and refining. Tenova Pyromet also designs and supplies equipment for material handling and pre-treatment, alloy conversion and refining, granulation of metal, matte and slag, furnace off-gas fume collection and treatment, and treatment of hazardous dusts and waste. Tenova Pyromet has several technologies to reduce operating costs and increase production power consumption.

Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling and minerals beneficiation and processing sectors, offering innovative technological solutions and full process and commodity knowledge across the mining & minerals industry value chain.

About Air Cooled Heat Exchangers (Fin Fan Coolers, Air Fin Coolers)

Air cooled heat exchangers, also called Fin Fan Cooler, Air Fin Coolers, are used to reject heat from a fluid, directly to ambient air. Generally they consist of finned tube bundles and one or more fans.  As the working fluid passes through the finned tubes, the fan blows ambient air across the tubes to cool the working fluid.  The simplest (and smallest) example of an air cooled heat exchanger would be an automobile radiator, however on industrial plants these heat exchangers can be up to 90ft wide by 180 feet long.  Some key components of an Air Cooled Heat Exchanger are explained as follows:

Tube Bundle:  These are normally finned to increase the heat exchange area and efficiency.
Air moving device: Generally a fan or blower (forced or induced draft).  In some cases natural draft is possible.  If an air moving device is used it will require some type of driver.

Support structure: Suitably sized to allow sufficient air flow to/from the entry/exit from the cooler.
Air Cooled Heat Exchangers are commonly used in the oil and gas, petrochemical and power industries. For Oil and Gas and Petrochemical Applications, air cooled heat exchangers are designed and built to API 661 (which provides recommendations for the design, materials, fabrication, inspection, testing, and preparation for shipment of air-cooled heat exchangers for use in the petroleum, petrochemical, and natural gas industries).  EngineeringCircle has assessed major air cooled heat exchanger manufacturers from across the globe and brings our users the worlds best suppliers.

When designing and purchasing air cooled heat exchangers, purchasers will need to consider the following factors, which are usually expressed in the form of a technical data sheet (available upon request from EngineeringCircle.com):

Design code (API 661, ASME BPVC Sec VIII)
Forced Draft or Induced draft fan
Type of finned tubes:
Grooved Type,
L Type,
Extruded Type,
Embedded type,
Knurled Type,
Wrap on Type,
Header Type:
Plug Header
Cover Plate Header
Pipe Header
Welded Bonnet Header
Manifold Header
Design conditions, including the working fluid and ambient air design conditions

Inherent features of the ideal oil coolers for Harley Davidson

When a bike owner realizes the true value of coolers for Harley Davidson, he is impatient to introduce this worthy addition with immediate effect. Though it is of utmost importance to introduce coolers for Harley, the bike owner should pick the best variety that offers good value for the money spent on the oil cooler. In essence, an enthusiast should expend efforts to handpick the best one from among the great variety of coolers for Harley to gain good mileage out of this component. The motorbike owner should look into the inherent features of the best coolers for Harley and take an informed decision in the process. What are the inherent features of the best Harley.
Davidson oil coolers?

Superior technology
In the first place, the prime feature that differentiates the best cooler from the ordinary ones is the superior technology with which this premium oil coolder is built. The best oil coolers for Harley arise out of groundbreaking technology, where the source that has built this Harley cooler consider various aspects before introducing the cooler for Harley Davidson bike. Most importantly, reputed Harley coolers strike a good balance between flow and performance, owing to the superior technology which the coolers are built.

Alluring features
Another significant aspect pertaining to the best coolers for Harley Davidson is the alluring features that come along with the Harley coolers. The alluring features can take several forms, as the features can take the form of a unique oil distribution system or unique air fins that are designed to dissipate heat in an efficient manner. When the enthusiast gleans details about the alluring features of the best coolers for Harley Davidson he is sure to understand the uniqueness of the features, which allow the oil cooler to stand apart from the ordinary ones.

Worthy contribution
Most importantly, one of the inherent features of the best coolers for Harley is the worthy contribution afforded by the best coolers. Taking a closer look at the components pertaining to the Harley oil cooler kit an enthusiast can fathom the power of the components, and the contribution of the components to pave the way for an effective cooler system.

Scores over competition
Another significant feature of the best coolers for Harley is the ability of the oil coolers to stand apart from the competition. The best Harley Davidson coolers come with the best design, groundbreaking technology, and alluring features to pave the way for desired results. The efficient performance of the best oil coolders for Harley is better than the ordinary ones, helping the best oil cooler to score over competitor brands.

Value for money
While the bike owner is keen to buy the best coolers for Harley Davidson, there is another significant feature that speaks volumes of the best cooler kit. The best Harley oil coolers offer good value for the money spent on coolers, and the many benefits offered by the best coolers for Harley Davidson work to the advantage of the bike owner.

While an ardent bike owner is keen to identify best oil coolers for Harley Davidson, he should look into the inherent features of the best coolers to make an informed decision.

Heat Exchangers for the HVAC Industry

HVAC refers to the terms Heating, Ventilation and Air conditioning. HVAC is the name of technology which refers to indoor or self-propelled outdoor environmental ease. Refrigerators and air conditioners manufacturing industries come into the category of heating-coil industry. HVAC is important in the design of standard of huge industries and their office buildings because healthy working conditions are required there. These conditions are optimal temperature and humidity which are controlled by heating-cooling technologies and devices, such as central air conditioning of a large volume of the whole building.

The products manufactured by HVAC industries such as refrigerators and air conditioners work on the principle of heat exchanging. The heat plates exchanging takes place through heat and cool exchangers that are the sub devices used in refrigerators and air conditioners. Heat exchangers are also called as thermal transfer exchangers.

There are two types of HVAC exchangers which are used in cooling and heating industries, depending upon the liquid used in heat exchanger or a gas. Usually, gas type plate exchangers are used in house hold HVAC devices such as refrigerators and air conditioners. It is also used in case of large volumes such as in big refrigerator systems, for the cold storage stores of vegetables.

The principle behind the refrigeration and air conditioning is based on newton's law of cooling. According to this, heat is removed from a body and its temperature is lowered down. For this process, coil exchangers are used. Heat exchangers are a gift to the mankind by the mechanical engineers. The pressure and volume relation to temperature proves this theorem of cooling.

In Brazetek exchangers, some tubes like structures or pipes are present that contain the liquid heat exchangers or gas depending upon the type of cooling machine. So, these units are fundamental and the most basic requirement for HVAC industries.

Brazetek exchangers are made up of materials like alloys of aluminum. And in these, tubes are joined by the process of brazing. These exchangers are of many types like tube and shell, plate, pillow plate, plate fin, and fluid heat transfer and exchange plates.

Water to air heat exchangers are also called as coils or air coils. The coils are made up of tubes of alloy of aluminum. The coils act as a perfect exchanger of heat. Example of liquids used in HVAC coils are water glycols solution, water steam or any other coolant substance. There are two types of coils present. One is cooling coil and the other is heating-coil. In cooling coils, heat transferring process takes place like refrigeration and air conditioning, where as in heating-coil, a boiler comes which does the job of transferring the heat.

In different situations like freezing weather in winter seasons, when the coils are exposed to atmosphere, they can face problems like freezing of exchanging liquid which can block the heat exchange tubes. And tubes can also get cracks because liquid expands on cooling. So, if the liquid present in tubes will freeze, it can damage the tubes.

What Are Pressure Vessels

Pressure Vessels are closed lid containers which have been designed to hold liquids or gases at pressures substantially different from the ambient pressure. (The pressure outside of the container)

During the history of their development many fatal accidents have occurred due to the dangerous differential pressure, and consequently their design, operation and manufacture have to be regulated by rules and regulations which are backed up by law.

The definition of a pressure vessel changes from country to country, however it still involves parameters such as the maximum safe operating temperature and maximum pressure.

They are used and seen in many different industries and some of their uses and applications are:

o Diving cylinders

o Nuclear reactor vessel

o Road vehicle airbrake reservoir

o Hydraulic reservoir

o Storage tanks for butane, ammonia, propane and chlorine gases and liquids

They can take practically any shape depending upon its application, however the most commonly used shapes are cones, cylinders and spheres. A very popular design for them is a cylindrical shape with a hemispherical end cap.

In theory a sphere is the best shape for a pressure vessel; however a spherical shape is quite difficult and expensive to manufacture so cylindrical shapes are more commonly employed. Small vessels can be manufactured from a pipe and two end covers.

Most are made of steel, but they can be manufactured from any material which has good tensile properties, and is chemically stable for the desired application. Other materials such as carbon fibre which are held in place with a polymer can also be used due to its high tensile strength, it is much lighter than steel but more difficult to manufacture. Some composite materials may be wrapped around a metal liner forming a composite overwrapped vessel.

They can be lined with other types of various metals, ceramics or polymers to help prevent leaking, and also to help protect the vessels structure from the contained fluid or gases.

Pressure vessels are designed to work safely at specific temperatures and pressures. Any vessel that is not designed by the desired code or codes represents a significant safety hazard.

Design Techniques Behind Shell And Tube Heat Exchange Designs

High-pressure applications need shell and tube heat exchangers that are robust and are able to withstand the needs of numerous operating settings. A shell and tube exchanger's structure has a huge role in their capability to keep going throughout excessively challenging and difficult situations.
Shell and tube heat exchangers are manufactured from a series of tubes, which commonly be constructed from sturdy material such as fluoropolymers. Fluoropolymers are highly sturdy plastics. Fluoropolymers, like heat exchangers, have a place in a range of industries such as the automotive, medical, and aeronautical.

In the shell of the exchanger, heated or cooled fluid flows throughout one set of tubes. There is a second set of tubes which hold liquid, which directs the heating and cooling of the primary tube set. A range of shapes are employed for a tube set, depending upon the particular application. The fluid in and around the tubes usually flow in opposite directions which is referred to as counter current flow. This facilitates a greater degree of heat exchange within the system. These systems are utilized in a range of industries. Chemical industries and refineries are two of the prime users of these units.
Multiple aspects of construction must be kept in mind by engineers of tube and shell exchangers. An example of this is that a reduced tube diameter are able to result in problems with malfunctioning and cleaning, even though it allows the shell and tube exchanger to be compact and cost effective. Tubing of a larger size eliminates problems related to cleaning and proper flow. When resulting in a heat exchanger, the engineer must give consideration to cost, space, and the tendency for liquids to break down.

Tube thickness is crucial to make sure there is room for corrosion; vibration existing in the product has resistance; and, the shell and tube exchanger can hold up against pressure coming from both in and outside of its internal tubes.
Exchanger performance is increased by folding or wrinkling the inner tubes, enhancing the flow of liquid and therefore heat transfer.

Placement of inner tubing is of concern to those who engineer these devices. You have a number of different configuration choices for the tubes. Internal designs are often unique for different jobs and perform by stopping wasteful liquid buildup and maximizing heat exchange.

Baffle aspects are also included in tube and shell heat exchange units. Baffles serve several purposes such as holding the tube bundle in place; making sure tubes do not sag or vibrate; and, facilitating fluid flow.

The Key Features of Heat Exchanger Retubing For Shell and Tube Heat Exchangers

In the category Heat Exchanger, there is one most popular type of exchanger is Shell & Tube Exchanger. There are found in various industries to control wide range of pressures and temperatures because of flexibility and compact.

As the name proposes, this type is combined of two types of tube or tube bundle. These exchangers are normally used for the transfer of heat in various industrial process applications. These are also available in a variety of lengths and diameters. It is designed and developed using the most advanced technology accessible and is specifically engineered for a wide range of applications.

Shell and Tube Heat Exchangers are used widely throughout various industrial process and as such a basic need of their design, construction and action is important to keep them maintained. So that, when required heat exchanger retubing is also important. These are intended for cooling or heating process fluids, they are for instance appropriate for closed circuit cooling of electrical equipment using decriminalized water and for cooling water soluble oil solutions in quenching tanks.

There are various types of common features specified regarding type of industry exchanger. The shell and tube exchanger includes of a number of inside tubes mounted a cylindrical shell. There are two ways in which the fluid exchange the heat, one fluid flows over the outside of the tubes whilst the second fluid flows do arrangement through the tubes. The process fluids can be of two or single phase and can flow in a cross/counter or parallel a flow arrangement. The set inside is filled with the liquid that needs to be either cooled down or heated up. The outside set runs just next to the first one and either cools this system or heats it up. The shell is the subdivision that environs the tube bundles. Mostly, these exchangers are used in high-temperature and high-pressure operations. Applications includes steam engine locomotives and power plants.

Heat exchangers are a fastener in today's industrial devices. They are not only present in small industries in the simplest of devices; heat exchangers have also found their use in big scale industries and machinery in the world presently. They are basically devices found in some machines that enable it to transportation heat from one medium to another. They make possible the efficient transfer of heat from one object to another. But for their long run you also need to keep in mind the Heat Exchange Plugging is also important.

Counter Top Water Filters and Air Coolers

Counter top water filtering systems as the simple and fast way to clean your water. You can even take it with you when you travel.


If you are going on vacation, or renting a place for a while, you may want to make sure that your water is just as clean and pure as your home water supply. The perfect solution for this kind of situation is to bring along a counter top water filtering system. Many people also use this type of system if they are unable to install an under the sink system because of space restrictions or your landlord won't allow alterations such as this. A simple counter to systems needs no plumbing yet it offers more filtering power than the small faucet additions that many people use.

A counter top system can be installed by anyone; no plumber is needed since it is simply a matter of using a diverter valve to attach the system to any faucet you like. Using a diverter valve such as this, you can shut it on or off, depending on whether you need the water to be filtered. You filtered water will be cleaner and better tasting, and it does not require a great deal of space on your kitchen counter, Of course, the more compels the filtering system, the larger the unit will have to be. The models also come in a range of finishes and styles the will fit in with the style of your kitchen. Another convenient feature is a decanter you can fill from the filtering system so that you can keep cool, filtered water in the firdge at all times.

A counter top filtering system will remove many unpleasant particles from your drinking water such as calcium, potassium, magnesium, lead, chlorine and other chemicals you prefer not to drink. You may not realize it, but there may be particles of pesticides, herbicides and dirty sediment in your water; a water filtering system, even a fairly simple one such as counter top system, will remove a great deal of these. Just as an air cooler removes impurities from the air, these will remove impurities from the water. If your drinking water tastes orsmalls funny, a water filter system will improve the taste and smell as well. This solution is a great alternative to bottled water, since it only costs about 10 cents a gallon to produce.

Make sure that your system keeps doing its job properly by changing the systems filter according to the manufacturer's instructions, usually twice a year, or after a certain number of gallons have been purified. It is simple enough to change the filter-just open the compartment, remove the old one and slip in a new filter. It is a good idea to run some water through the new filter before you start draining it.

If you want to make sure that you your family drink safe, clean water, a counter top filtering system is the ideal solution.

The Importance of Heavy Machining and Applications of Pressure Vessels in Industrial Sectors

One cannot compromise on precision and quality when it is about machining critical components of large dimensions and sizes. The equipments that are used to fabricate large components need to be equally large in size too. This is precisely why heavy component machining firms have an army of precision cutting tools and equipments that are all capable of being used on elements that measure several feet, and can also handle parts weighing several tons.

How is Heavy Machining Defined in Industrial Sectors?

It is a process in which large and heavy pieces of hard-core, raw materials are accurately machine-cut to get a desired shape or component. These components are further circulated and utilized in different industrial domains for fulfilling multifarious roles and operations. The overall process of machining mainly consists of elimination of unwanted parts from the actual forms of raw materials in order to gain a precise, desired shape of the material. Although this type of precision machining method is mostly used on industrial metal pieces, it can also be carried on other forms of raw materials such as ceramics, plastics, wood and/or other composites.

For instance, a simple component like a plain shaft or a rod can be turned into a threaded rod by imparting grooves or threads using milling and turning techniques. However, this is just one illustration. Similarly, one can easily create other types of parts and components using specialized heavy machines such as bores, lathes, drills, and milling machines to achieve precision machined elements. Nonetheless, today almost all machining is carried out using advanced methods such as CNC software.

Use of Heavy Duty Equipments for Producing Precision Parts

Heavy machining and precision machined components have created a major impact in industrial livelihood in several ways. For instance, the fuel we fill in our vehicles was probably once contained in large pressure vessels before being transported to individual gas stations. Such pressure containers are also created using heavy duty machining techniques. While these are basic elementary instances, there are many other industries that have to deal with sensitive materials and mediums such as storing strong liquids and gases at high pressures. In such cases, sturdy, strong-walled containers come very handy. Besides being addressed as pressure vessels, such containers are also called as autoclaves. They are highly capable of carrying fluids or gases at very high pressures.

Heavy machining services does not only create new components or parts, but it also deals with maintaining and repairing heavy objects that could weigh several tons. Large machining in many industries is carried out on various grades of steel and other non-ferrous materials like copper, aluminum, and other exotic materials. Irrespective of the size, dimensions, and fabricating materials, when large components are being created it is necessary to maintain their precision and high-tolerance specifications to the highest degree.

Click here to know more about pressure vessel.

Air Cooled Heat Exchangers

Air cooled heat exchangers are only one of various kinds of heat exchanger. Heat exchangers are gadgets which are specially designed for aiding the transfer of heat from one fluid towards the other. For us to better understand, typical samples of devices that use heat exchangers include the air conditioners, refrigerators as well as space heaters.

But let us not dwell a lot of over the general heat exchanger rather let's now take a look at air cooled heat exchangers or ACHEs for short. It rejects heat from a hot fluid directly to fan-blowing ambient air. ACHEs are commonly utilized each time a procedure or set up creates heat that has to be removed and regrettably lacks local use. Your car's radiator is actually an example of ACHE device. The engine must be cooled to prevent overheating due to friction and combustion functions by the engine. The excess heat is taken away by the water or glycol coolant mix. Majority of the heat should be taken away, and the best way is as simple as supplying ambient air.

There are more functions for air cooled heat exchanger, including the upstream production, refineries and petrochemical facilities. It can also be used on conditions with high temperature, high pressure, corrosive fluids and environments. Moreover, air coolers is usually equipped and used in gas and oil refineries; compressor stations for oil pipelines; subsurface gas storage facilities; plants producing polychlorvinyl, polyethylene, glass fiber, biplastic; caustic soda plants; by-product coke plants and ammonia transportation and handling plants.

Besides learning the actual functions of ACHEs, we should have a view upon how it operates inside and its elements. Usually, air coolers for process application are composed of a finned-tube bundle with rectangular container headers on both ends of the tubes. Headers are boxers that dispense the fluid from the piping to the tubes. The other parts include one or more fans that give cooling air. The fans are generally powered by electric motors and are also accompanied by speed reduction devices. The fan drive assemblage is sustained by the metal mechanical drive support system. Generally, the air flows up-wards all the way through a horizontal tube bundle. The fans could be either forced or induced draft, dependant upon whether the air is pushed or pulled through the tube bundle. Forced draft unit enables a simple access for maintenance for the fans and the bundles. Furthermore, the fans stay in the cold ambient air. Whilst the induced draft unit provides a stable as well as strong thermal performance because of the protection of the finned surface against wind, rain, hail and snow by the plenum chamber. The induced draft also guarantees an improved air distribution, much less hot air recirculation, much less air-side fouling and lower noise levels at grade. Space in between the fans and the tube bundle is encircled by a plenum chamber, that directs the air. The full assembly is usually installed on legs or perhaps a pipe rack.

Understanding and knowing the inside and out of ACHEs is fairly difficult, especially for those who have no background in mechanical matters. And for this reason, let us once again move our attention on another subject matter, which is the "why" question. With regards to economy, air coolers are preferred due to the lower maintenance expenses. Some other benefits offered by air coolers are as follows: lack of the need for cooling water or other cooling media, no issue shall arise with regards to the thermal as well as chemical pollution of cooling fluids, and it quite fast to install by bolted assembly.

ACHEs are regarded as a "green" alternative because no chemical treatment methods are required to the water or fluid used by the assembly. And temperature is the only parameter that has to be considered whenever getting rid of the water used. Without a appropriate heat exchanger equipment, overheating will ruin your equipments and appliances, specially the parts subjected to heat. Out of all of the things that have been pointed out, if we are to consider the trend that the world is going, air cooled heat exchangers are the ideal choice for industrial plants and other plants if the environment is to be considered.

Pressure Vessel Testing Through Non Destructive Methods

Pressure vessels play a key role in many industrial businesses, from chemical, petrochemical, oil & gas, refining, pulp and paper, plastics, pharmaceutical, refrigeration, natural gas processing amongst many more.

Pressure vessels are not to be confused with storage tanks, which are often performing a similar role, however, they're not storing liquid or gas at a pressure far enough removed from the local pressure to be considered a pressure vessel.

The definition of what constitutes a pressure vessel varies across the globe, depending on what different institutes consider "far enough removed". Typical pressures range from 0.5-1 bar before a vessel is considered a pressure vessel.

Pressure vessels can be constructed from a variety of materials, and in a variety of different shapes. They're usually cylindrical in shape, with end caps called "Heads". This is because more complex geometries are much more difficult to assess for safety, as well as usually more difficult and expensive to manufacture.

Many vessels are made of steel or concrete, due to concretes brittle nature steel cabling is used to reinforce it, so it can withstand the tensile stresses placed upon it. The same method can be employed for other materials which are weak in tension.

Technically any material with good tensile properties could be used, however due to the potential hazards involved standards, codes and regulations are used to govern the manufacture as well as operation of pressure vessels, so as to avoid accidents, and potential loss of life.

Maintenance is especially critical when the production rate, price or pressures involved are high. Because a short shutdown or accident could mean thousands or hundreds of thousands in lost opportunity, it's important to keep equipment in good condition and running within reliable tolerances.

To this end non-destructive testing, can be used, sometimes whilst equipment is in operation to inspect areas, and determine possible defects, and levels of degradation. The important feature of NDT is its ability to gather intelligence on a piece without having to damage it or break into it in anyway. Technologies such as ultrasound, eddy currents and magnetism can be used to inspect from afar, through the limits of physical boundaries.

Typically LFET (Low Frequency Electromagnetic Technique) can be used for the wall plates, and eddy current inspection can be used for welds. Other technologies can be used as well however, depending on client requirements and thoroughness required. Technologies such as magnetic particle, ultrasonic and dye penetrant can also be used.

How to Find Industrial Grade Pressure Vessels

Pressure vessels are used to store and utilize high volume liquids and gases in industrial applications. The range of products includes oxygen, oil and gas, compressed air, and high grade chemicals. It safely store these gases and liquids for use in high pressure applications.

Clearly, its work is highly important. Hence, it is also critical that they meet stringent quality requirements of industries and customers worldwide. However, how can a customer know that the what he is planning to purchase is a quality manufactured product? This question can be answered by keeping a few important points in mind.

Quality Features for Finding and Selecting

There are certain features and qualifications that must be met to purchase.

ASME BPVC Code: The American Society of Mechanical Engineers (ASME) created the Boiler and Pressure Vessel Code (BPVC) in 1914. This Code is the standard with which all aspects of pressure vessel manufacturing are performed. Depending on the vessel's design and use, every ASME pressure vessel will come with a certification mark such as UV, U, UM. This will guarantee that the vessel has met all the regulations of the BPVC, and can be safely installed and used in an industrial application.

High Grade Materials: The ASME BPVC basically defines all aspects of pressure vessel manufacturing. This includes materials that are used in the manufacturing process. Its manufacturers can or rather only use high grade materials within the criteria of the BPVC. These include stainless steel, carbon steel, aluminum, low and high alloy steels, copper, austenitic stainless steel, and nickel, to name a few. The completed vessel should be able to provide optimum performance even in harsh environmental conditions consisting of extreme weather, corrosion, natural or manmade tremors, etc.

Welding: When all the necessary components have been created, they are welded together to form the final product. The welding process is also a precise and intricate one. Only professional ASME certified welders are allowed to perform this task. The reason for this is that ASME welders have complete knowledge of the safety regulations in Section 9 of the BPVC. This section specifically provides information about welding.

Autofrettage, Testing, and Inspection: Autofrettage is a process where the vessel is subjected to high pressures to create internal compressive stresses within the vessel. This makes it more durable to withstand any environmental hazards. After assembly, one of the final processes is testing. Various types of NDE examinations such as radiography, magnetic particle tests, and ultrasonic testing are performed to ensure that there are no defects in the product.

Before the pressure vessel is provided to the customer, it must be inspected by an ASME qualified inspector. His examination includes:

• Washing of the vessel
• Removal and inspection of all plates, plugs, and water connections
• Examination of the vessel welds, headers, furnace, lugs and other supports
• Removal and testing of pressure gauges
• Inspections of the feed valves, drain valves, non-return and stem top valves, and the steam generation unit.

It is only when the inspection has been completed and all these factors have been met that the inspector provides a certification for the pressure vessel.

This may seem like a lot of information for any customer to process. However, every pressure vessel manufacturer is obligated to provide you with this information. By having a basic understanding of all the above points beforehand, it will be easy for you to find a quality pressure vessel.

As a specialist in custom metal fabrication and machining industry I am passionate about helping businesses succeed by sharing my knowledge and experience. ASME Pressure vessels are used to store and utilize high volume liquids and gases in industrial applications. Know certain features and qualifications that must be met to purchase pressure vessels.

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ASME Pressure Vessel Protection Since 1907

Pressure vessels have a profound impact on our lives on a daily basis. Hot water storage tanks, refrigerant vessels, gas storage tanks, hydro pneumatic tanks and autoclaves are just a few of the uses for them. They are defined as a sealed container designed to hold gases or liquids at a set pressure which is different from the ambient pressure. Pressure vessels are created to work at a specified pressure and temperature. They are specifically designed for pressures greater than 15 psi and an overall volume higher than 5 cubic feet. These technical terms are often described as design temperature or design pressure.

Although harmless looking, they can propose a serious danger if not maintained or built correctly. The pressure differential within them is dangerous and throughout history many accidents, sometimes fatal have occurred while developing and operating pressure vessels. These accidental explosions caused shrapnel to be sent into the air or exposed hazardous content which leaked from the vessels. As a result of these accidents, pressure vessel operations are regulated by engineering authorities to ensure safety.

These engineering authorities include the ASME Boiler and Pressure Vessel Code in North America, the Pressure Equipment Directive of the EU (PED), Japanese Industrial Standard (JIS), and the CSA B51 in Canada to name a few. The ASME Boiler and Pressure Vessel Code is recognized as an American Society of Mechanical Engineers standard that sets guidelines for design, fabrication and the inspections of pressure vessels. The committee is made up entirely of volunteers who are nominated based on their knowledge and expertise in the areas pertaining to pressure vessels as well as boilers. The American Society of Mechanical Engineers is also the accreditation body which entitles independent third parties to complete such tasks as verification, testing and allows certification agencies to inspect and ensure that all of the vessels and boilers meet compliance to the BPVC.

The origin of these committees dates back many years. The ASME which was originally formed in 1880 created the Board of Boiler Rules. This was before it became the ASME Boiler Code Committee which came about in 1911. This would be the committee that would eventually setup the ASME Boiler Code - Rules for the Construction of Stationary Boilers and for the Allowable Working Pressures. This first edition was published in 1915. All of this was initially started by the public outcry after several serious explosions that took place in Massachusetts during the early 1900's. These boiler explosions lead the state of Massachusetts to enact the initial legal code on boiler construction, which was based on ASME's steam boiler construction guidelines.

Making Safety Pressure Vessels For Industrial Systems

Have you ever attended a children's party where the balloons started to burst when they were pricked? Sometimes, balloons begin to burst even while they are being filled up. They created a loud noise don't they? And the remains of the balloon simply flew away in any direction.

But balloons contain only low pressure air or gas. How about those huge pressure vessels we see in the factories and other industrial plants? How can we be sure that they will not burst like balloons?

Industrial processes often use pressure vessels at much higher pressures. In compressed air systems, air reservoirs are utilized to store compressed air in large enough volumes so that the pressures in the system do not fluctuate rapidly as the air is consumed. Industrial gases are often stored in gas cylinders at extremely high pressures.

It would be a disaster if any one of these cylinders were to burst or explode. Injury or loss of life may result from such an accident. It is such a safety concern that many government agencies insist that such pressure vessels be inspected regularly. This is because the environment in which the pressure vessel is operated can play a major part in the deterioration in strength of the vessel. Corrosion is a main culprit for the weakening of material of the pressurized vessel.

In order to ensure that pressure vessels are safe for use in the intended service, design engineers usually add a factor of safety for deterioration in their design. The intended service may include parameters like working temperatures, working pressures, type of fluid, weather, vibration and environment. However, they will also have to look at various other aspects like the material used, the welding preparation, and the additional strengthening arrangements in the weak points like openings, the presence of drainage for condensed water, and other structural strength support for the weights. Usually, they will be following some engineering codes and standards like ASME, JIS, BS, etc.

When the vessel is ready to be fabricated, it goes through a sequential series of checks.

Firstly, the steel plates are identified. The steel plates from the steel manufacturers are usually tested for various chemical composition and mechanical strengths. Each steel plate will be identified by their markings and accompanied by their mill certificates.

Once they have been identified, the plates are cut to the sizes required and formed by rolling. The edges of the plates are also prepared for welding by grinding to the required angle.

The welding process will also need to be standardized. Usually, the manufacturer of these pressure vessels will have done tests for the welding positions, electrodes, welding procedure qualifications, welding performance qualifications, welding procedure specifications in their quality control system. Various mechanical tests like tensile and charpy tests should be done during these standardizations.

Non-destructive examinations are carried out on various welding joints to determine the quality of the welds. Some to the methods used are radiography, ultrasonic, magnetic particles, and dye penetrant. In addition, visual examinations are also carried out.

The final test to determine whether the vessel can withstand the required pressure is called the hydrostatic test. This test is conducted by filling the vessel completely with water and pressurizing it to usually 1.3 or 1.5 times the maximum allowable working pressure and holding it for at least 1 hour. This is a destructive test. If the vessel cannot withstand this pressure, it will break. But because water does not reduce its volume appreciably under pressure, it does not expand much too when it leaks out. The failed vessel does not burst out with a destructive force like a balloon.

If the vessel can withstand the hydrostatic test, it is considered to have fulfilled the final manufacturing requirement. The water is then drained off, the vessel dried up and several protective paint coatings can be applied to its surfaces both internally and externally.

The pressure vessel is then shipped out to the buyer who can rest assured that the pressure vessel will not burst like a balloon provided it is used according to the designed conditions.