空冷器Exchangers2(双语).doc

PRODUCTION TECHNICAL TRAINING 生生产产培培训训 PRESENTS 课程介绍课程介绍 MODULE Exchangers 2 模块 交换器模块 交换器 2 AIR COOLED HEAT EXCHANGERS 空冷器空冷器 DESIGNED FOR ENHANCING OPERATIONS KNOWLEDGE given a specific heat exchanger describe how to safely remove the exchanger from service and prepare it for maintenance according to the unit procedure 1 对于实地技术员而言 给定某一个热交换器 其应能够描述如何安全地将该热交换器拆下来 并根据本单元的程序对其进行维修 2 Explain the operations responsibilities involved in testing the exchanger after maintenance has completed their work and prior returning it to service 2 在完成维修之后但在重新将其投入使用之前 能够说明在测试该交换器的过程中所涉及到的操 作责任 3 Describe how to safely place the exchanger back in service according to the unit procedure 3 能够描述如何根据本单元的程序重新将该交换器复位 重新投入使用 File 655b01492f2aebbddf78c486439972b6 pdfPage 4Module Air Cooled Heat Exchangers LEARNING OBJECTIVES 培培训训目目标标 After completing the text of this module the trainee must with 100 accuracy 在完成此模块的课本学习之后 学员必须达到 100 的正确率 1 State the definition of a heat exchanger 1 陈述一种热交换器的定义 2 State the definition of an air cooled heat exchanger 2 陈述某一空冷器的定义 3 State the function of a plenum 3 说明一种空气调压室的功能 4 State the function of a header 4 说明集气总管的功能 5 State the temperature differential that is important to air cooled heat exchangers 5 说明对空冷器具有重要意义的温差 6 List two factors upon which heat transfer depends 6 列出两个决定传热的因素 7 State what is measured by heat transfer rate 7 说明传热率是用来测试什么 8 List two components of an air cooled heat exchanger aimed at enhancing heat transfer 8 列出一种空冷器中用于增强传热效果的的两个部件 9 List the two basic types of air cooled heat exchangers 9 列出空冷器的两个基本类型 10 List the three main parts of an air cooled heat exchanger system 10 列出一套空冷器系统的三个主要部件 11 State an advantage and two disadvantages of a V configuration tube bundle 11 说明 V 形管束的一个优点和两个缺点 12 List the three most common type of headers used on air cooled heat exchangers 12 列出空冷器上所使用的集气总管的三个最常见的型号 13 State why headers are equipped with plugs or plates File 655b01492f2aebbddf78c486439972b6 pdfPage 5Module Air Cooled Heat Exchangers LEARNING OBJECTIVES 培培训训目目标标 13 说明为什么集气总管装有塞子或盖板 14 State why fins are attached to tubes 14 说明为什么要将翅片连接到散热管上 15 State why serrations are sometimes cut in fins 15 说明为什么有时翅片会呈现锯齿状 16 List two ways that tubes are attached to headers on an air cooled heat exchanger 16 列出两种将散热管连接到空冷器的集气总管上的方法 17 State the main functions of the mechanical equipment on an air cooled heat exchanger 17 说明一台空冷器上机械设备的主要功能 18 List the components of the mechanical equipment on an air cooled heat exchanger 18 列出一台空冷器上机械设备的各部件 19 List the materials of which fans can be fabricated 19 列出风机可用哪种材料制作 20 List two ways of adjusting pitch on fan blades 20 列出调整风机叶片俯仰角的两种方法 21 List three types of fan drivers 21 列出三种类型风机传动装置 22 List the types of speed reducer used on air cooled heat exchangers 22 列出空冷器中使用的减速器的型号 23 State the purpose of the twist and taper of a fan blade 23 说明风机叶片的螺旋状和锥形的目的 24 State the function of vibration switches on air cooled heat exchanger systems 24 说明空冷器系统上的振动开关的功能 25 State why air cooled heat exchangers may overcool the process during fall and winter 25 说明为什么气冷式加热器在秋天和冬天会出现过度冷却 26 State the usual method of controlling process temperature in an air cooled heat exchanger 26 说明空冷器常用的控制工艺温度的方法 27 List the methods used to vary air flow in an air cooled heat exchanger 27 列出空冷器中改变气流的方法 File 655b01492f2aebbddf78c486439972b6 pdfPage 6Module Air Cooled Heat Exchangers LEARNING OBJECTIVES 培培训训目目标标 28 List the process or environmental conditions that can damage an air cooled heat exchanger 28 列出可能导致空冷器损坏的工艺条件或环境条件 29 List two methods of controlling air flow through an air cooled heat exchanger 29 列出两种控制通过空冷器中气流的方法 30 State why entering the plenum of a recently shutdown air cooled heat exchanger can be hazardous 30 说明为什么进入刚关闭的空冷器的空气调压室是危险的 File 655b01492f2aebbddf78c486439972b6 pdfPage 7Module Air Cooled Heat Exchangers TABLE OF CONTENTS 目目录录 If viewing this TOC on a computer you can move directly to a subject area by pointing at a title with your cursor and single clicking 如果是在计算机上阅读此如果是在计算机上阅读此 TOC 你可以将将光标直接指向标题单击 你可以将将光标直接指向标题单击 INTRODUCTION 1 简简介介 1 DEFINITIONS 1 定定义义 1 HEAT EXCHANGER 1 热热交交换换器器 1 AIR COOLED HEAT EXCHANGER 1 空空冷冷器器 1 AIR PLENUM 2 空空气气调调压压室室 2 HEADER 2 集集气气总总管管 2 THEORY OF OPERATION 2 操操作作原原理理 2 TEMPERATURE DIFFERENTIAL 2 温温差差 2 HEAT TRANSFER 3 传传热热 3 TYPES OF AIR COOLED HEAT EXCHANGERS 3 空空冷冷器器的的型型号号 3 FORCED DRAFT 强强迫迫通通风风式式 5 INDUCED DRAFT 诱诱导导通通风风式式 6 ACHX COMPONENTS 7 气气冷冷热热交交换换器器部部件件 7 File 655b01492f2aebbddf78c486439972b6 pdfPage 8Module Air Cooled Heat Exchangers TUBE BUNDLE 7 管管束束 7 Headers 9 集气总管 9 Fin Tubes 11 翅管 11 Fin Characteristics 12 翅片的特征 12 Tube Attachment and Support 16 散热管附件和支撑物 16 THE STRUCTURE 17 框框架架 17 Plenum 17 空气调压室 17 Mechanical Equipment Support 18 机械设备支撑物 18 Columns Braces and Supporting Steel 18 支柱 支架和支撑钢 18 Walkways 19 通道 19 MECHANICAL EQUIPMENT 19 机机械械设设备备 19 Fans 20 风机 20 Drivers 24 驱动器 24 Speed Reducers 25 减速器 25 PROTECTIVE DEVICES 28 保保护护装装置置 28 File 655b01492f2aebbddf78c486439972b6 pdfPage 9Module Air Cooled Heat Exchangers Vibration Switches 28 振动开关 28 Temperature Switches 28 温度开关 28 Overpressure Protection 28 过压保护 28 CONTROLS 29 控控制制器器 29 Local Manual Controls 29 局部 手动控制器 29 Automatic Controls 29 自动控制器 29 OPERATION 29 运运作作 29 NORMAL OPERATION 29 正正常常运运作作 29 SHUTDOWN 30 关关闭闭 30 STARTUP 30 启启动动 30 OPTIMIZING OPERATION ENERGY CONSERVATION 30 优优化化操操作作 能能源源节节约约 30 VARYING AIR FLOW 31 改改变变气气流流 31 EXTREME CASE CONTROLS 32 极极端端情情况况下下的的控控制制 32 Controlling Air Flow 33 控制气流 33 Moderating Air Temperature 33 适度的空气温度 33 File 655b01492f2aebbddf78c486439972b6 pdfPage 10Module Air Cooled Heat Exchangers Auxiliary Heating Coils 33 AIR COOLER EFFICIENCY 33 空空气气冷冷却却器器的的功功效效 33 Blade Angle 35 叶片角度 35 Belt Slippage 35 皮带打滑度 35 EXCHANGER ANALYSIS TABLE 37 MAINTENANCE 38 PREVENTIVE MAINTENANCE 38 预预防防性性维维护护 38 PREPARATION FOR MAINTENANCE INSPECTION 39 维维护护和和检检查查的的准准备备工工作作 39 Lubrication 39 添加润滑油 39 TECHNICIAN DUTIES 40 技技术术员员的的职职责责 40 TAKING EXCHANGERS OUT OF SERVICE 40 停停车车检检修修 40 ASSEMBLING AND TESTING EXCHANGERS 42 交交换换器器的的安安装装和和测测试试 42 PUTTING EXCHANGERS IN SERVICE 43 投投入入运运行行 43 REFERENCE 44 参参考考文文献献 44 TROUBLESHOOTING 45 故故障障检检修修 45 File 655b01492f2aebbddf78c486439972 b6 pdf Page 1Module Air Cooled Heat Exchangers INTRODUCTION 简介简介 This learning module is a description of air cooled heat exchangers and how they are used It describes the design and operation of this type heat exchanger and discusses the similarities and differences in the types of air cooled heat exchangers The module is designed to provide personnel with the knowledge to identify the equipment understand its use and supervise its usage If more in depth information is required please refer to the referenced information on page 0 of this module 本学习模块描述了空冷器 并对其如何使用进行了说明 此模块还说明了此种型号的 空冷器 的设计和操作 并讨论了空冷器不同型号之间的相似点和不同点 此模块目的在于向相关 人员提供识别设备的知识 理解其使用 并对其用法进行指导 如果要求更多深入的信 息 请参考此模块第0页的相关信息 DEFINITIONS 定义定义 HEAT EXCHANGER 热交换器热交换器 As defined in the chemical industry a heat exchanger is a device that transfers heat from one medium or system to another for example heat from hot fluid contained in a radiator dissipates when the metal walls of the device come in contact with cooler air 如在化工行业中所定义 热交换器是一种能够将热由一种媒介或系统转移到另一种媒介或 系统的装置 例如 当一个散热器的金属壁与较冷的空气接触时 热量就会从该散热器中 包含的较热流体向外散发 AIR COOLED HEAT EXCHANGER 空冷器空冷器 An air cooled heat exchanger is a device for removing heat from a process fluid by passing it through a bank of finned tubes that are cooled by blowing or drawing a stream of cooler air across the tube exteriors This is in contrast to rejecting heat to water and then rejecting it to air as with a shell and tube heat exchanger and a wet cooling tower system 空冷器是一种通过一组翅管将热量从某种过程流体带走的装置 其中该组翅管是通过从外 部吹进或抽进一股较冷的气流来冷却翅管外壁而实现的 这点与将热量传给水 然后由水 将热量传给空气是不一样的 例如管壳式热交换器与蒸发冷却塔系统 File 655b01492f2aebbddf78c486439972 b6 pdf Page 2Module Air Cooled Heat Exchangers AIR PLENUM 空气调压室空气调压室 The air plenum is an enclosure that provides for the smooth flow of air between the fan and bundle In this enclosure the interior air pressure is different than the exterior air pressure If the air is forced in the pressure is higher If air is pulled into this chamber the pressure is lower 空气调压室是一种壳状物体 它是用来确保风机和管束之间的空气的顺畅流动 在此装置 中 内部的空气压力和外部的空气压力不同 如果空气是被压进该调压室 则压力较高 若空气是被抽进此调压室内 则压力较低 HEADER 集气总管集气总管 A header is a conduit or pipe having many outlets or connected pipes that are usually parallel serving as a central point of distribution for the contents 集气总管是一种有很多的出口或连接管的导管或散热管 这些出口或连接管通常是相互平 行的 其作用是作为散热管的分散和汇集的中心 THEORY OF OPERATION 操作原理操作原理 TEMPERATURE DIFFERENTIAL 温差温差 The air cooled heat exchanger is a sensible heat transfer device It removes heat on the basis of the temperature differential between the ambient air and the process stream This heat transfer depends upon a number of factors 该空冷器是一个敏感的传热装置 它根据大气和过程流体的温差将热量带走 这种传热方 法取决于以下几个因素 Transfer rate from the process stream to the tube 过程流体与散热管之间的传送速率 Transfer rate from the outside tube surface to the air 散热管外表面与空气之间的传送速率 Temperature differential between the ambient air and the process stream 周围空气与过程流体之间的温差 The heat transfer rate measures the efficiency of heat transfer from one substance to another The heat transfer rate between the process stream inside the tube and the tube itself is usually much File 655b01492f2aebbddf78c486439972 b6 pdf Page 3Module Air Cooled Heat Exchangers higher than the rate from the outside of the tube to the air Overall heat transfer rates for air coolers are quite low compared to shell and tube exchangers 传热率衡量了热量从一种物质传送到另一种物质的效率 散热管内的过程流体与散热管本 身之间的传热率通常比从散热管外部到空气中的传热率高的多 与壳管式热交换器相比 空冷器的总体传热率较低 HEAT TRANSFER 传热传热 Two important components of an air cooled heat exchanger system are aimed at enhancing heat transfer between outside tube surfaces and the air stream fans and fins 空冷器系统的两个重要部件的目的是在于提高散热管外表面和空气气流之间的传热效率 这两个重要部件是 风机和翅片 Fans increase air velocity past the tubes increasing the outside surface heat transfer coefficient and reducing the surface area required for cooling 风机提高通过散热管的空气速率空气速率 提高外表面热交换的系数并减少流体冷却所需要的表面面积 Fins applied to the outside of the tube increase the tube surface area and consequently the amount of heat transferred from the tube to the air Fins vary by height and spacing and are selected on the basis of cost and system requirements Processes having very low heat transfer rates may need no fins 应用于散热管外部的翅片用于增加散热管的表面面积表面面积 因此增加了由散热管传到空气中的热量 翅管的安装高度和间距可不同 具体根据成本和系统的要求而选择 传热率非常低的工艺流程 可能不需要翅片 TYPES OF AIR COOLED HEAT EXCHANGERS 空冷器的型号空冷器的型号 The two basic types of air cooled heat exchangers are 1 forced draft and 2 induced draft Figure 1 shows both types and the major components associated with each Table 1 describes the two types of air coolers and lists the advantages and disadvantages of each type 空冷器的两个基本型号是 1 强迫通风式和 2 诱导通风式 图1是两个不同的型号及其主要的部件 表1描述了空气冷却器的两种型号 并列出了每个型号的优点和缺点 File 655b01492f2aebbddf78c486439972 b6 pdf Page 4Module Air Cooled Heat Exchangers 212 Forced draft 强迫通风式 Induced draft 诱导通风式 1 管束 2 集气总管 3 管口 4 支撑柱 5 空气调压室 6 风机 7 风机外套 8 风机平台 9 传动装置组件 Figure 1 Air Cooled Heat Exchanger Types 图图1 空冷器型号 空冷器型号 File 655b01492f2aebbddf78c486439972 b6 pdf Page 5Module Air Cooled Heat Exchangers TABLE 1 TYPES OF AIR COOLED HEAT EXCHANGERS 表表1 空冷器的型号 空冷器的型号 Type 型号型号 Description 说明说明 Advantages 优点优点 Disadvantages 缺点缺点 FORCED DRAFT 强迫通强迫通 风式风式 The fan and mechanical equipment are below the tube bundle 风机和机械设备位于管束之 下 Air is pushed up through the finned tubes 空气通过翅管上升 Tube bundle is exposed directly to the environment 管束直接暴露在环境中 This system is less expensive 1 5 系统较便宜 1 5 This system can handle higher operating fluid temperatures 系统可以处理较高的工作流 体温度 Maintenance is easier because no equipment is in the hot air stream 因为没有设备处在热气流 中 所以维修更容易进行 The system requires less horsepower 系统要求功率较低 Performance particularly of the exposed tube bundle which is affected by climate 性能 特别是暴露的管束容易受 气候影响 Less uniform distribution of air over the bundle 管束上的空气分布较不均匀 Low natural draft capability on fan failure 在风机出现故障时 自然通风能力 较差 The low velocity air exiting the heat exchanger is more easily recirculated 热交换器释放出来的较低速率的空 气更容易循环 File 655b01492f2aebbddf78c486439972 b6 pdf Page 6Module Air Cooled Heat Exchangers TABLE 1 TYPES OF AIR COOLED HEAT EXCHANGERS CONTINUED 表表1 空冷器的型号 接前 空冷器的型号 接前 Type 型号型号 Description 说明说明 Advantages 优点优点 Disadvantages 缺点缺点 INDUCED DRAFT 诱导通风诱导通风 式式 The fan is located above the tube bundle the motor and speed reducer are located below 风机位于管束上方 电 动机和减速器位于管束 下方 Air is pulled up across the tubes 空气穿过散热 管上升 Better distribution of air across the bundle 穿过管束的空气分布较均匀 Less possibility of hot effluent air recirculating into the intake The hot air is discharged upward at approximately 2 5 times the intake velocity or about 1 500 feet per minute 释放出来的热空气循环进入入口 的可能性较低 热空气的释放速 率是入口进气速率的2 5倍 或者 大约为1 500英尺 每分钟 Better process control and stability because the plenum covers 60 of the bundle face area 由于空气调压室覆盖管束表面的 60 面积 所以具有较好过程控 制性和稳定性 This system offers better temperature control 系统能提供更好的温度控制能 力 Operation is generally quieter because the fans are above personnel level 因为风机是位于人员位置上方 因此操作通常较安静 Increased capacity in the fan off or fan failure condition since the natural draft stack effect is much greater 由于具有较好的自然通风烟囱效 应 因此风机关闭或风机出现故 障时仍具有较好的通风能力 This system is limited by a maximum air temperature 200 F because the fan and fan shaft bearing must operate in the hot air stream 因为风机和风机轴承必须在热空气 流下进行操作 所以系统有一最高 工作温度 200 F Possibly higher horsepower requirements if the effluent air is very hot 如果释放出的空气非常热 则可能 要求更高的马力 Wider bays must accommodate fan shaft through the tube bundle 必须为穿过管束的风机轴提供较宽 的跨度 Greater chance for vibration problems equipment failures and misalignments because of longer fan shafts and exposure to hot air stream 因为风机轴较长时间暴露在热空气 中 所以更容易产生振动问题 设 备故障和失配 Fans are less accessible for maintenance and maintenance may have to be done in the hot air generated by natural convection 风机不便于维护 并且维护可能必 须在自然对流产生的热空气中进 行 Plenums must be removed to replace bundles 必须将空气调压室拆除 以便复位 管束 File 655b01492f2aebbddf78c486439972 b6 pdf Page 7Module Air Cooled Heat Exchangers Each type of exchanger performs satisfactorily if applied correctly Because the forced draft units are more versatile easier to maintain and less expensive they are more common 如果正确应用的话 每种交换器的型号都能令人满意地工作 由于强迫通风式装置功能更 全 便于维修 并且价格较低 因此使用更普遍 ACHX COMPONENTS 气冷热交换器部件气冷热交换器部件 The air cooled heat exchanger system is made up of three main parts tube bundle structure and mechanical equipment 气冷热交换器系统由三个主要部分构成 管束 整体框架和机械设备 TUBE BUNDLE 管束管束 The tube bundle Figure 2 is the heart of the heat exchanger A tube bundle is an assembly of tubes headers side frames and tube supports Usually the tube surface exposed to the passage of air has extended surface in the form of fins to compensate for the low heat transfer rate of air at atmospheric pressure and at a low enough velocity for reasonable fan power consumption 管束 图2 是热交换器中最重要的部件 管束由散热管 集气总管 侧面机架和管座组 成 通常暴露在气路中的散热管表面采用翅片的形式进行延伸 以补偿大气压力下以及为 确保合理的风机功耗所需采用最低风机转速时的较低空气传热率 File 655b01492f2aebbddf78c486439972 b6 pdf Page 8Module Air Cooled Heat Exchangers Plug header 塞式集气总管 Cover plate header 盖板集气总管 1 管板 2 塞盖 3 上部盖板和底部盖板 4 端板 5 散热管 6 气路隔板 7 加强肋 8 塞子 9 管口 10 侧面机架 11 散热管隔板 File 655b01492f2aebbddf78c486439972 b6 pdf Page 9Module Air Cooled Heat Exchangers 12 管座 13 散热管固定物 14 通风口 15 排气口 16 仪器连接口 17 盖板 18 垫圈 Figure 2 Tube Bundle 图图2 管束 管束 Bundles are usually arranged horizontally with the air entering below and discharging vertically Occasionally bundles are arranged vertically with the air passing across horizontally Bundles can also be arranged in an A or V configuration the principal advantage of this being a saving of plot area The disadvantages are higher horsepower requirements for a given capacity and decreased performance when winds on exposed sides inhibit air flow 管束通常是水平放置在进入空气的上方 而与 排放的空气垂直 有时 管束也可以垂直排 列 使空气水平穿过 管束也可以呈 A 或 V 结构排列 这种排列方法的优点是可以 节省一小块区域 缺点是在工作能力一定下时 其要求有更高的 功率 并且当在暴露在外 面一侧上的气流受到风抑制时其性能会降低 Within practical limits the longer the tubes and the greater the number of rows the less the heat transfer surface costs per square foot One or more bundles of the same or differing service may be combined in one unit bay with one set of fans All bundles combined in a single unit will have the same air side static pressure loss Consequently combined bundles having different numbers of rows must be designed for different face velocities 在实际应用时 散热管越长且排列的列数越多 每平方英尺所需的传热成本就越 低 相同 或不同的设备中的一个或多个管束可以组合在一个单元 跨度 内 并且配备一组风机 所有组合在一个单元内的管束具有相同的空气侧静态压力损失 因此 必须为排列列数不 同的组合管束设计出不同的表面速率 Headers 集气总管 Headers located on each end of the tube bundle distribute process fluid to the tubes They are generally built from carbon steel however nearly any material may be used For most jobs headers are designed to ASME Boiler and Pressure Vessel Code Section VIII Division 1 on pressure vessels The three most common types of tube bundle headers are 1 plug headers 2 removable cover plate headers and 3 pipe headers 集气总管位于管束的每个末端 它将过程流体分配给各个散热管 集气总管通常用碳钢制 成 但是 几乎任何材料都可以使用 对于大多数的工作而言 集气总管的设计应符合关 File 655b01492f2aebbddf78c486439972 b6 pdf Page 10Module Air Cooled Heat Exchangers 于压力容器的标准 ASME锅炉和压力容器规范 第一部分中的第8节规定 如今 最最普 遍使用到的三种管束为 1 塞式集气总管 2 活动盖板式集气总管 3 管式集气总 管 Plug Headers 塞式集气总管塞式集气总管 The most common headers are plug headers Figure 3 These type headers consist of a fabricated rectangular box with holes on one surface through which the tubes are inserted Each tube hole has a corresponding plug on the opposite side of the header to provide access to the inside of the tubes and headers for cleaning and inspection Such headers are designed for pressure up to and sometimes exceeding 2000 psig 最普遍使用的集气总管是塞式集气总管 图 3 此类集气 总管由一个预制矩形盒构成 矩形盒的一个面上有若干个 孔 散热管就通过个这些孔插入 每个散热管孔在集气总 管的对面都有一个相应的塞子 以便进行散热管和集气总 管的内部的清洁和检查 此集气总管的最高设计压力 有 时可以超过 2000 磅 平方英寸 Removable Cover Plate Headers 活动盖板式集气总管活动盖板式集气总管 Removable cover plate headers Figure 4 like plug headers consist of a fabricated rectangular box with holes on one surface through which the tubes are inserted A removable cover plate bolted to the header opposite the holes allows access to the tubes and headers for clean