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Experimental testing of two-phase maldistribution in air-cooler headers can lead to more effective header design

April 03, 2024

Salem Bouhairie, Group Lead, Research Air-cooled heat exchangers (ACHEs) in the oil, gas, and power industries often process two-phase fluids, and their performance is usually limited by the airside thermal transfer resistance. However, flow on the tube side can undergo phase change, such as by vapor condensation or liquid vaporization, producing...
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• AIR COOLED
• MULTIPURPOSE VISUALIZATION UNIT
• MALDISTRIBUTION
• XACE
• AIR-COOLED HEAT EXCHANGER

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Getting Started: Building Your First Case in Xace

July 20, 2022

Are you ready to build your first case in Xace®? This webinar provides an overview of the program's user interface and basic functionality then demonstrates the specification of an exchanger design in Xace using the information in an API 661 Spec Sheet. View this webinar for a step-by-step specification of a new Xace case including process...
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• XACE
• GETTING STARTED

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Collecting Measurements Using a Motorized Traverse System

October 11, 2021

Our research technicians built a motorized traverse to acquire more data in a shorter amount of time. This video shows a traverse with two bridges, suspended above the finned tube bundle and moving synchronously across the outlet face of an air-cooler. Each bridge has six clusters of instruments that record data...
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• AIR COOLER
• XACE

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Two-phase flow in air-cooled heat exchangers

June 10, 2020

Brandon White, Test Engineer Air-cooled heat exchangers are one of the most widely used types of heat exchangers. At times, they can experience two-phase flow separation and flow maldistribution inside their header boxes, potentially reducing process heat transfer. At HTRI’s Research & Technology Center, we are currently working on a project...
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• AIR-COOLED HEAT EXCHANGER
• XACE
• TWO-PHASE FLOW

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Simulating air-cooler header and fan performance informs physical testing plans

June 05, 2019

Salem A. Bouhairie, Senior Project Engineer, Research Both tubeside and airside behavior affect the overall performance of an air cooler. Two concerns with air-cooled heat exchanger (ACHE) operation are two-phase process-side maldistribution in headers and misrated airside fan performance. At HTRI’s Research & Technology Center (RTC), we are developing plans to...
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• AIR-COOLED HEAT EXCHANGER
• AIR-COOLED UNIT
• XACE
• CFD

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TT-27 Modeling air-cooled heat exchangers with redundant fans

April 14, 2019

Component: Xace Applicable to: All supported versions (versions 7.3 and 8) Date posted: 15 April 2019   Air-cooled heat exchangers are typically designed for operation with all fans on. A bay with two, three, or four operating fans is commonly identified as 2×50%, 3×33%, or 4×25% fans, indicating that each operating...
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• AIR COOLED
• HEAT EXCHANGER DESIGN
• TECHTIP
• XACE

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Research Update: Shellside Vacuum Condensation with Mixtures

June 07, 2018

Condensation data were recently collected in the Low Pressure Condensation Unit (LPCU) using hydrocarbon mixtures. This recent set of data wraps up a multiyear research project to study shellside condensation under vacuum conditions. This webinar will focus on the latest results collected with hydrocarbon mixtures. High-speed videos are shown along with...
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• CONDENSATION
• LPCU
• RESEARCH
• XACE

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CS-20-TR Condensation of Immiscible Fluids Outside Plain Tubes

April 30, 2018

HTRI investigated condensation of a water/octane mixture outside a plain tube bundle. Tests were conducted in the Low Pressure Condensation Unit (LPCU) at three different vacuum pressures and five different vapor inlet flow rates. Almost all of the measured compositions varied from the azeotrope composition. High-speed videos for each case show a...
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• CONDENSATION
• LPCU
• XACE

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TT-3 Model fan-off operation in Xace

January 26, 2017

Component: Xace Applicable to: All supported versions (7.3 and 8) Date posted: 4 March 2008 Last updated: 25 March 2019   Air-cooled heat exchangers are typically designed for operation with all fans on. For a bay with two, three, or four operating fans, this operation is commonly indicated as 2×50%, 3×33%...
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• XACE
• TECHTIP
• AIR COOLED

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TT-2 Learn how driver power is calculated

January 26, 2017

Component: Xace Applicable to: All supported versions (versions 7.3 and 8) Date posted: 15 January 2008 Last updated: 22 January 2021 The Xace Output Summary includes the calculated driver power (or the power consumed by each fan motor) on line 41. But how does Xace calculate this value? The basic definition for...
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• XACE
• TECHTIP

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Model Plugged Tubes in Xace

January 16, 2017

For many exchanger designs, having plugged tubes in the bundle is necessary. This tutorial will demonstrate to users how to model plugged tubes in Xace®....
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• AIR COOLED
• XACE

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Identify Current Software Version and Save in a Different Version of Xchanger Suite

January 16, 2017

Did you know that you can save a case in a different version of Xchanger Suite®? This tutorial shows how to identify which version you are working in and how to save and open in a different version....
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• AIR COOLED
• XACE

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Research Update: CFD Simulations of Forced Draft Air Coolers with Air Maldistribution

January 16, 2017

API-compliant air coolers are modeled in two- and three-dimensional computational fluid dynamics (CFD) simulations to see what improvements are needed in Xace® with regard to the airside maldistribution. We validated the CFD model using Xace base cases. We then used CFD to simulate non-ideal airside flow situations that can potentially affect...
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• CFD
• RESEARCH
• XACE

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Is My Design OK? Modeling Air-Cooled Condensers with Subcooling

January 16, 2017

Subcooling is often required for air-cooled condensers. This webinar will address common technical support questions such as – how many tubes and passes are needed to subcool sufficiently? how is phase separation modeled? what are the best modeling guidelines for Xace®? – and provide HTRI's recommendations. Attending this webinar will help...
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• AIR COOLED
• CONDENSERS
• DESIGN
• SUBCOOLING
• XACE

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Is My Design OK? Applying API 661 Annex C to Air-Cooled Heat Exchanger Designs with Viscous and High Pour Point Fluids

January 16, 2017

Winterization in accordance with API 661 Annex C may need to be considered by designers when air-cooled heat exchangers are operating in climatic extremes. In order to prevent operating problems in-situ, a temperature safety margin should be added to the critical process temperature to determine the specified minimum tubewall temperature. For...
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• AIR COOLED
• API 661
• DESIGN
• VISCOUS
• XACE

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TechTip: Applying the HTRI Parametric Study Tool

January 16, 2017

In this session, we walk through applying the HTRI Parametric Study Tool to a real case. We first model a one-fan-off Xace® case and then work towards running a parametric study on air-cooler winterization. This webinar does not include any background information on the basics of the HTRI Parametric Study Tool....
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• PARAMETRIC STUDY TOOL
• TECHTIP
• XACE

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TechTip: Modeling DX Evaporators

January 16, 2017

This webinar provides an overview of DX evaporators and how to model them in Xist® and Xace®, including what has changed in Xchanger Suite® 7....
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• DX EVAPORATOR
• TECHTIP
• XACE
• XCHANGER SUITE
• XIST

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Is My Design OK? Selecting Finned-Tube Bundles

January 16, 2017

Are you using Xchanger Suite® to model finned-tube bundles? This webinar provides an overview of finned tubes and the various types of finned tubes that Xchanger Suite models. In addition to guidance on when to select each type, the session highlights important, high-level mechanical design aspects of finned tubes....
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• DESIGN
• FINNED TUBES
• XACE
• XIST

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TechTip: Modeling A-Frame Condensers

January 16, 2017

A-frame condensers can be modeled in Xace® 6 by using the workarounds outlined in this webinar. After viewing this webinar, you will be able to describe A-frame geometry and analysis methods. The webinar includes a demonstration of Xace input options and works through two sample cases – a rating without reflux and a...
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• A-FRAME CONDENSER
• TECHTIP
• XACE

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Q14-3 Modeling Fans-Off Operation in Xace

January 16, 2017

During winter or in turndown conditions when full design duty is not required, air-cooled heat exchangers commonly run with one or more fans off. Xace® models this operation by allowing users to specify an inlet flow maldistribution. This article provides guidelines for modeling fans-off operation in Xace and describes a computational...
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• XACE
• CFD
• AIR COOLED

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