GEA Rainey

Corporation
Energy Technology
Division

Air Cooled Heat Exchangers for Process

and Power Industries

Adapting Global Technologies for Individual Solutions

GEA - The Leader in the Air Cooled Heat Exchanger Industry

GEA Rainey
Corporations mis-
sion is to provide
quality products
and services with
honesty, integrity
and commitment to
our customers,
employees, share-
holders and the
global community.

We have been and

continue to be a
global leader in the
design and manu-
facture of air cooled
heat exchanger
equipment. For
approximately 40
years we have met
the needs of the
chemical, petro-
chemical and power GEA Rainey Corporation located at Tulsa, Oklahomas Port of Catoosa
industries cooler
requirements, through engineering and
construction firms or directly with end
users.

GEA Rainey is a subsidiary of GEA AG, the

worlds largest heat transfer equipment
technology group specializing in energy
and thermal technology, as well as process,
refrigeration and air treatment industries.
This provides us the technological and
financial resources to meet any require-
ments and allows access to manufacturing
facilities located throughout the world.
When you combine this experience it is
easy to see why we build successful de-
signs for every continent.
Custom Engineering - Designing Specifically for Your Needs
No two process or power
plants are alike. Space
limitations, operating con-
ditions, climate, environ-
mental and
community
consider- We are ALWAYS
ations all
affect the
and different
design of
each air cooled heat ex-
change system.
This is why our first step in
developing a design is to
begin with an analysis of
the customers needs. An
experienced Sales Engineer
reviews your specifications
and requirements then
utilizes proprietary rating
software and the latest
commercial programs to
provide the most economi-
cal and efficient solution.
GEA Rainey
Corporation
routinely
designs
both simple
and com-
plex coolers.
We have
created
solutions
for air
cooled heat
exchangers
required to
operate in -60 to 140 degree
Fahrenheit ambient condi-
tions, earthquake zones and
at ultra high pressure.
looking for new
ways toIMPROVE
Operating pressures from
full vacuum to over 12,000
psig do not present a chal-
lenge.
Upon order placement, our
Sales Department initiates
the order process by enter-
ing all job specific informa- dance with specifications.
tion into a database shared
by all internal departments.
Customer requirements,
material tracking, auto-
mated generation of draw-
ings are just a few examples
of GEA technology.
To further reduce the
potential for lost data, no
transition exists between
the proposal Sales Engineer
and order Project Manager.
The individual responsible
for selling the order is also
the individual responsible
for leading your order to
completion. This ensures
promised reliability.
Once the order is entered
into our database, it is the
responsibility of the Design
Engineering Department to
create all drawings for
customer approval. The
Design Engineer first re-
views your
specifica-
tions and
. require-
ments thus
verifying all
as-sold requirements. Then
utilizing a proprietary
software called Calqlys, the
Design Engineer automati-
cally generates all appropri-
ate approval drawing tem-
plates, which are then
modified in exact accor-
Following customer drawing approval,
GEA Rainey begins purchasing and fabrica-
tion of critical path items such as header
material, and initiates the Detail Engineer-
ing Department to finalize all structural
designs utilizing Calqlys, AutoCad and
STAAD.Pro.

GEA Raineys fabrication facilities are lo-

cated at the Port of Catoosa, near Tulsa,
Oklahoma. Our four manufacturing facili-
ties contain over 200,000 square feet of
work space which are equipped with the
latest computerized milling systems, weld-
ing equipment, finning machines, 40 ton
break press, as well as typical metal work-
ing machinery.

From inquiry to delivery, GEA Rainey will

meet or exceed your expectations.

Over 200,000 ft2

available manufacturing
facility
 Cooler Design - Configurations for All Situations

AIR FLOW Forced Draft - The most

common style of air cooled
heat exchanger, a forced
draft design positions the
fans beneath the process
bundle allowing easy access
to all mechanical compo-
nents. The design also
allows simplified future
plant expansions with
direct access to the bundle.
Structural disassembly is
not required.

AIR FLOW AIR FLOW

Induced Draft - Offering
greater control of the pro-
cess fluid through more
efficient airflow distribu-
tion, the induced draft
design also provides pro-
tection to the pressure
vessel by positioning the
plenum chamber above the
bundle. Other benefits
include reduced potential
for hot air recirculation and
lower noise levels at grade.

Installations in extreme cold locations require different cooler styles. GEA Rainey Corpo-
ration offers two main styles to meet these harsh conditions.

Recirculation - This style completely encases a forced draft cooler inside a structural
building. Intake and exhaust louvers modulate the transfer of outside air while louvers
located in the recirculation duct provide further control. Winter temperatures of -50 de-
grees Fahrenheit present no challenge with this design.

Shoe-Box Recirculation - For installations requiring recirculation units but have installa-
tion restrictions, the shoe-box design is a pre-assembled cooler divided into an upper and
lower section. Installation is as straight forward as bolting both sections together.
Pressure Vessel - The Components
The center of an air cooled
heat exchanger is the
bundle. This pressure
vessel consists of three
main sections; headers,
finned tubes and support-
ing structure.
The headers serve as a
transition between the
customers manifolds and
the finned tubes, evenly
distributing the process
fluid.
Inlet / Outlet
Header
Tube Keeper
Flange
Air Seal
Air passing across the
finned tubes then cools or
heats the process fluid,
depending on required
design scenarios.
The supporting steel struc-
ture encases the tubes and
headers in order to both
maintain design integrity
and to allow for thermal
expansion. Lateral move-
ments caused by customer
piping can be absorbed
within each bundle. In
Tube Support
Lifting Lug
Tube Spacers
addition, piping thrust is
controlled via header sup-
port and slide pad systems
which further restrict or
enhance allowable move-
ments.
GEA Rainey can and has
built vertical, horizontal
and angled bundles to meet
whatever your process
dictates.
Rear Header
Sideframe
Finned Tubes
Header Support
 Header Configurations

Plug Header
The most common
air cooled heat
exchanger header
style, this general
purpose design
allows cleaning of
individual plugs
and is used for most
refinery and power
processes with low
to moderately high
pressures.

Cover Plate Header

Either removable
cover or bonnet, a
cover plate header
is typically used in
chemical applica-
tions or services
with severe fouling
conditions. This
design is available
for low to medium
pressure (<300 psi)
installations.

Pipe Manifold or
Billet Header
Pipe manifold
headers are com-
mon for all pres-
sures, including full
vacuum. Billet
headers, machined
from a solid piece
of material, are
used in extremely
high pressure
(>10,000 psig) appli-
cations.
Finned Tube - The Heat Exchangers Core

L Fin Overlap L Fin Extruded Fin Embedded Fin

Commonly referred The overlap L fin Primarily used in This design consists
to as wrap on, the is formed by creat- corrosive atmo- of an aluminum
L fin is created by ing a standard L sphere and high strip placed into a
forming an alumi- fin but tension temperature condi- toleranced groove
num strip into an L- wrapped closer tions, the extruded on the primary
shape which is then together, resulting fin is manufactured tube, tension
tension wound onto in an overlap of the by compressing an wound on edge and
the primary tube. fins base. This aluminum bloom, finally caulked in
The fin sections are design offers in- or sleeve, onto a place by the groove
positioned against creased corrosion parent tube. High lip. This fins pri-
each other to ensure protection and a compression re- mary applications
complete tube wider operating forms the alumi- are high tempera-
coverage. temperature range. num into the final ture or cyclic
fin profile. services.

L OVERLAP L EXTRUDED EMBEDDED

Maximum Maximum Maximum Maximum
Temperature Temperature Temperature Temperature
300F 350F 550F 750F
Tube Diameters Tube Diameters Tube Diameters Tube Diameters
5/8", 3/4", 1", 1 1/4", 5/8", 3/4", 1", 1 1/4",
1", 1 1/4", 1 1/2", 2" 1", 1 1/4", 1 1/2"
1 1/2", 2" 1 1/2", 2"
Fin Heights Fin Heights Fin Heights Fin Heights
7/16", 1/2", 5/8" 7/16", 1/2", 5/8" 1/2", 5/8" 1/2", 5/8"
Fins per Inch Fins per Inch Fins per Inch Fins per Inch
7, 8, 9, 10, 11 7, 8, 9, 10, 11 8, 9, 10, 11 7, 8, 9, 10, 11
 Quality - A Foundation for Business

At GEA Rainey Corpora- our quality standards.

tion, we understand that
quality is how we maintain
a successful business. We
have never had a thermal
performance warranty
failure. We always try to
meet or exceed our
customers requirements.
We understand that in-
creasing efficiency does not
mean cutting corners.
Our Quality Assurance
Department reports directly
to the President, ensuring
the full authority to enforce
Combined with our com-
pany-wide philosophy and
practice of continuous
improvement, Total Quality
Management (TQM) and
ISO 9001 certification, GEA
Rainey also coordinates
with authorized National
Board inspectors for the
supervision of our ASME
U-stamped pressure ves-
sels. We also routinely
comply with requirements
and recommendations
listed in API 661 and 614,
AWS, CRN, CISC, AISC
and TEMA codes.

In an industry where 10 to 15 years is

the typical lifespan of fintube
bundles, GEA Rainey products are
known to last over 25 years.
Research and Development

As part of a global organization specializ- mathematical modeling techniques are

ing in heat exchangers, GEA Rainey Corpo- validated by wind tunnel measurements
ration is involved in development pro- and visual airflow characteristics. This
grams aimed at increasing efficiency and ensures our fin profiles maintain optimum
performance through collaboration of efficiency and that large scale installations
experts. will perform as designed with minimal
chance of air recirculation.
From an operational standpoint, GEA
Rainey has developed an internal software
package, named Calqlys, capable of de-
signing and generating both customer
approval and detail structural shop draw-
ings. Initial input is based on the data
sheet approved at time of order. Calqlys
reads the data sheet and builds base design
drawings. It then allows the necessary
flexibility to tailor each drawing to the
customers exact specifications.

Because our coolers performance is based

on air, GEA performs extensive research on Calqlys program, implemented in 2002.
different fin profiles and cooler orientations
to maximize heat transfer. The latest
Wind tunnel simulation for large installation

We understand our service
does not end when material
leaves our facility. For this
reason GEA Rainey offers
several options to meet
your specific needs.
Replacement Parts
We can provide replace-
ment parts for any air
cooled heat exchanger,
regardless of original
manufacturer. Bundles, fin
tubes, plugs, gaskets, mo-
tors and belts are just a few
examples.
Specialized Service
Our service organization
specializes in air cooled
heat exchanger mainte-
nance. Regardless of brand
or model, our specialists
understand the require-
ments for proper operation.
Customer Support and Field Service
Building on global technol-
ogy, we give customers a
guarantee of receiving the
best possible cooler perfor-
mance unmatched by any
other service organization.
Capacity Measurement
Even when cooler perfor-
mance remains acceptable,
a coolers capacity can drop
below a critical level. Addi-
tional equipment, changes
in production or other
factors play significant roles
in performance. Our mo-
bile research team has the
appropriate measuring
devices to gather informa-
tion to predict performance.
Periodic Inspections
Routine maintenance is the
key for assuring optimal
performance. We offer two
service models; inspection
or maintenance. For an
inspection contract, our
experts check the air cool-
ers, record findings and
make maintenance recom-
mendations as applicable.
The maintenance contract
simply extends our inspec-
tion requirements to in-
clude normal cooler main-
tenance. This comprehen-
sive solution is customized
to work with your internal
programs as required.
Noise Reduction
Noise is an increasingly
important environmental
concern. Our engineers
will analyze your condi-
tions and make the appro-
priate recommendations
from blade balancing to
total fan replacement.
 GEA Rainey
Corporation
Energy Technology
Division

A company of mg technologies group

Power Sales Office: 8050 North FR 189 Fair Grove MO 65648 USA
Phone: (417) 833-5155 Fax: (503) 214-9641 E-mail: info@gearainey.com Web: www.gearainey.com