High-grade process cooler (HGPC)
A01
Tailor-made coolers for a wide range of applications
For those projects with the most stringent
requirements and extreme conditions,
customers around the world depend on
Luvata for tailor-made cooling solutions.
At Luvata we understand the industry’s strict
and demanding standards that must be upheld
and know that mistakes or performance failures
are not tolerated.
To meet the latest regulatory, performance and
customisation requirements, Luvata is proud to
present the High-Grade Process Cooler (HGPC).
The HGPC offers a wide range of uses.
Applications include land based power plants
(gas, diesel or nuclear), emergency and
standby generating sets for offshore platforms,
reactor and thyristor valve cooling plants for
power transmission lines and many more.
The HGPC is a high-end quality product that
offers flexibility in material choices and endless
ways for customisation. When developing this
product, flexibility, price, quality and available
accessories were the primary focus areas.
With Luvata your cooling process is in
good hands.
02
WWW.LUVATA.COM
HGPC is the result of Luvata’s many years of
experience that brings together the know how
to deliver the top of the line cooler that meets
the industry’s most demanding requirements.
With its superior performance, the HGPC
delivers the highest safety, reliability and
durability on the market today.
Luvata´s management system is certified
according to ISO 9001:2008, ISO 14001:2004
and ISO 3834-2.
”
Luvata’s global footprint makes it possible to supply and work
close to our customers. With more than 70 years of experience,
Luvata continues to provide the world with inventive solutions
and engineering support. Delivering quality products and
dependability with every installation, Luvata is excited to present
the High-Grade Process Cooler with exceptional design flexibility
and superior performance.
”
Patric Jonsson
Global Product Manager – Industrial
WWW.LUVATA.COM
03
High-Grade Process Cooler (HGPC)
Background
In 1941, Luvata Söderköping in Sweden
began manufacturing heat exchangers and
coolers. And every year since, it has further
refined the design to deliver air blast coolers,
also called dry coolers, for a wide variety of
different applications.
To meet the latest requirements of a rapidly
changing global market, Luvata has developed the HGPC where the name “HighGrade Process Cooler” means best in class
for overall performance.
04
WWW.LUVATA.COM
Application
The Luvata HGPC is developed specifically
for projects where site ambient conditions
are harsh, material choice matters and
quality and reliability must come first.
Typical applications are cooling of thyristor
valves in HVDC power converter stations
and cooling of large diesel or gas engines.
Benefits
The HGPC allows project-based design:
The cooler size is calculated using our own
proprietary software COILS that has been
verified to ensure we deliver on customers’
exact specifications. The cooler and its
components are pre-designed for a large
number of combinations, delivering an
optimal total design on each project.
Via the extensive product ordering code,
we can also specify the appropriate options
for every cooler.
The cooler can be made with a heat
exchanger up to a maximum of 14 x 2.8
meter in size. With the number of available
tube rows and fin pitches we can match the
specific cooling requirement exactly.
For export projects the coolers can be sized
to fit perfectly in a standard container.
We also offer a design for different working
pressures (on the liquid side) and with
different flanges and nozzles available.
Materials
Luvata offers a wide variety of material
choices for both air side (outside) and liquid
side (inside), depending on the required
performance and application. Available tube
and pipe materials include stainless steel,
aluminium, copper-nickel and titanium,
or copper for more normal conditions.
Typical fin materials include aluminium
(also available with epoxy coating), AlMg
alloy or copper. The cooler casing and legs
are made of galvanized steel, or stainless
steel is also available.
With our metallurgical expertise and heat
transfer knowledge, we can select the specific
material best suited for the corresponding
environment and application.
Corrosion protection
When selecting the right cooler, corrosion
protection is an important consideration.
The actual site conditions (outside), liquid
conditions (inside), the general operating
conditions and operational lifetime requirements will help to determine the correct
corrosivity category required.
The standard cooler design fulfills the
corrosivity category C3 requirements
(ISO 12944/ISO 12944:5), but can easily
be extended up to category C4 or C5.
To achieve the correct protection level,
consideration is given to material choice and
corresponding coating application system
that fulfill the specified requirement for the
fan and motor as well as other components.
WWW.LUVATA.COM
05
CODE KEY
HGPC - when quality comes in first place
HGPC-aabbcc-deeff-gg-hhh-i-jjjj-kllm-nop-qrst-u
aa = Module length
bb = Module width
cc = Number of modules
Cooler size: From 1,0 x 1,0 to 14 x 2,8 meter
Fan size: From 450 to 1800 mm in diameter
Max working pressure: 0,6; 1,0 or 1,2 MPa (higher on request)
Max working temperature: 99°C (higher on request)
d = Number of tube rows
Min working temperature: -20°C (lower on request)
ee = Fin pitch
Material in tubes & manifolds: Aluminium,
stainless steel or acid proof stainless steel.
ff = No of liquid passes
gg = Number of fans per module
hhh = Fan type, motor type
i = Motor control
jjjj = Fan speed
Internal cleanliness of cooler
suited to the highest of
requirements.
k = Material in tubes and manifolds
ll = Fin material and fin thickness
m = Flange connection size
n = Coil type
o = Type of installation
p = Corrosion category protection class
q = Design revision
r = Safety switch/circuit breaker to motor
s = Electrical wiring
t = Draining and venting valves
u = Pressure class
Robust design with bolted header.
Coolers in compliance with
ATEX, Eex requirements available.
Options & accessories
• Supporting structure
• Railing and ladder
• Maintenance platform
• Individual fan marking in stainless steel
With over 200 available fan and motor solutions we are
able to tailor-make coolers acc. to customers needs.
• Esthetic painting of complete cooler
• Painting C4, C5 for extra corrosion protection
• Fin materials for several environmental demands
Flat roof for easy access for service
personell and to avoid trapped water.
• Screw joints in stainless steel, A2 and A4
• Counter flanges
• Venting and draining valves
The HGPC is built with a strong casing
and is designed to handle thermal
expansion of the heat exchanger.
• Common terminal box for motors
• Cabling in conduits
• Frequency controlled or STEP controlled motors
• Special fan motors (ATEX classified, NEMA, etc.)
•
•
Motors equipped with many different accessories:
- Anti-condensation heating elements
- PTO
- PTC
- Etc.
Expansion tanks
Supporting structures.
Railing, ladder and
maintenance platform.
Cooler available in any
corrosivity category C3-C5 M,I.
Integrated cable tray.
Cooler with railing.
Common terminal box for motors.
Modern solutions with the best efficiency
Fan and motor
The HGPC can be equipped with one,
or up to 56 fans, depending on cooler size.
The choice of available fans and motors is
vast and dependent on customer specifications. Factors to take into account include
power supply voltage, frequency variations,
sound level, power consumption, thermo
contact, space heater, corrosion protection
and method of speed regulation, which
could be by frequency control (with EMC
designed cooler) or by using EC motors.
Luvata works together with the major fan
and motor manufacturers to provide modern
solutions with the best efficiency, and in
accordance with the latest ErP directive.
08
WWW.LUVATA.COM
Popular designs offer low noise external
rotor motor fans, and often include a foot
mounted motor and separate impeller for big
fan units when NEMA standard is required.
Electric cabling
The fan motor on a standard HGPC is delivered wired and connected to a safety switch
located on each fan outlet. Also available
is complete cabling, including terminals,
to a common connection box mounted on
the cooler.
Verification
The pressure vessel is designed in compliance with the European pressure equipment
directive PED/97/23/EC. ASME Section 8
Division I compliance can be certified upon
customer request. Advanced Finite Element
Method (FEM) analysis is used for structural
verification and risk assessment.
Other options & accessories
HGPC is available with a number of
customized accessories including different
cabling options and terminal connection
boxes, prepared for EMC or without, and
with or without a frequency control unit.
The liquid headers are available with
mounted drain and air vent valves.
Appropriate leg support for single or group
installation, where the required height is
dependent on the number of coolers.
Different types of wooden packing,
depending on mode of shipment.
Coolers come with stainless steel nameplates
with tag numbers, along with customer
approved dimensional drawings and other
related documentation.
Computer selection software COILS
w!
Ne
COILS generates a print-out of the selected cooler.
HGPC is available in a wide range of configurations. Luvata’s computer software COILS
is used to select and size the correct cooler
for any installation. The software is reliable
and flexible and generates a print-out of the
technical data and a dimensional drawing of
the selected cooler.
One new feature of the COILS software is
the slider that can be found on the lower left
side of the screen. The speed of the fans
can easily be adjusted to optimize the
selected coolers even further. After reviewing
the calculations, select the preferred cooler
from the list. Then highlight the relevant
characteristic to be optimized: fixed ambient
temperature or fixed cooling capacity.
By moving the slider, the data will change
in accordance with changed fan speed.
Some variables to be considered
while sizing and selecting include:
•
•
•
•
•
•
•
Cooling capacity
Ambient temperature
Fan motor power supply
Environmental conditions
Sound level
Cooler size
Number of fans, tube rows, etc.
Contact the sales office in Söderköping
to obtain the COILS software.
WWW.LUVATA.COM
09
About Luvata
Luvata is a world leader in metal solutions manufacturing and related engineering services. Luvata’s solutions are used in industries such as
renewable energy, power generation, automotive, medicine, air-conditioning, industrial refrigeration, and consumer products. The company’s
continued success is attributed to its longevity, technological excellence and strategy of building partnerships beyond metals. Employing over
6,500 staff in 17 countries, Luvata works in partnership with customers such as Siemens, Toyota, CERN and DWD International.
Luvata Söderköping AB. 14-05. Subject to alteration.
Luvata Söderköping AB
Söderköping, Sweden
Tel +46 121 191 00
luvata.soderkoping@luvata.com
www.luvata.com
Luvata Italy Srl
Pocenia (UD), Italy
Luvata Guadalajara S.A.
Guadalajara, Spain
Copyright © 2014 Luvata