Products

Air Cooled Heat Exchanger

Since 1980 we have meet the needs of the Oil, Chemical, Petrochemical and Power Industries A.C.H.E. requirements, through a state of the art technology and advance manufacture processes. Caltuca’s Heat Transfer equipment are designed to comply with a wide variety of process that goes from a Water cooler to a complex condenser or two phase flow cooler, considering always the most economical and effective design that meets client’s thermal requirements. Also our detailed mechanical design considers the best relationship performance against final unit weight in order to offer a good solution to the site installation design consideration. When you combine those experiences in design and manufacture it is easy to see why Caltuca builds successful equipments.

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The manufacturing process considers 3 stages:

1. Pressure parts Manufacture.
2. Structural parts Manufacture.
3. Tube Bundle, Final Assembly and Test.

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Pressure parts Manufacture.

a.- Nozzles Manufacture

– Nozzles preparation.
– Nozzle welding.
– Dimensional checking and NDE performance.

b.- Pressure Headers boxes Manufacture.

– Plate preparation.
– Plate holes pre-drilling.
– Header boxes preassembly and fit-up.
– Header Boxes Welding.
– Header Boxes Dimensional checking and NDE performance.
– Header Boxes Nozzles hole cutting.
– Nozzles welding to Header Boxes.
– Nozzle to Header Boxes Dimensional checking and NDE performance.
– Post Weld Heat treatment performance.
– Header Boxes holes machining (Tapping and grooving).
– Header Boxes Sandblasting and Pre-Painting.
– Header Boxes Final inspection.

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Structural parts Manufacture.

a.- Side Frame Manufacture.

– Structural Plate and Shape preparation.
– Structural parts welding.
– Side Frame parts pre-assembly.
– Dimensional checking.
– Side Frame parts Disassembly.
– Side Frames parts hot deep galvanizing.
– Side Frames parts final assembly.
– Side Frames final checking and release.

b.- Wind Box and Drive POD Manufacture.

– Wind Box Structural Plate and Shape preparation.
– Wind Box Structural parts welding.
– Drive POD Structural Plate and Shape preparation.
– Drive POD Structural parts welding.
– Wind Box and Drive POD parts pre-assembly.
– Dimensional checking.
– Wind Box and Drive POD parts Disassembly.
– Wind Box and Drive POD parts hot deep galvanizing.
– Wind Box and Drive POD parts final assembly.
– Wind Box and Drive POD final checking and release.

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Tube Bundle, Final Assembly and Test.

a.- Tube Bundle Assembly.

– Tube Finning.
– Header Boxes preassembly in Side Frames.
– Dimensional checking.
– Finned tube installation.
– Finned tube expansion and Welding (if applies).
– Final bundle assembly.
– Plugs Installation.
– Final dimensional checking.

b.- Final Assembly and Test.

– Motor installation.
– Fan Installation.
– Dimensional Checking.
– Sprocket or Pulleys Installation.
– Belts installation.
– Driver POD tightening.
– Dimensional checking.
– Vibration Switches installation.
– Tube Bundle Hydro test.
– Tube Bundle and Wind Box assembly.
– Dimensional Checking.
– Run-in Test.
– Tube Bundle and Wind Box disassembly.
– Equipment Final release for delivery.

Finned Tubes

The Finning machine is fed with the tube material specified by the client, which depends on type, metallurgy composition, quality, thickness, diameter and length according to the type of fluid to be cooled (water, gas, crude oil, etc. ) and the process design. The machine is fed also with an aluminum band of a width, thickness and quantity specified by the process design.

The Finning Machines rolls and push forward the tube while is dragging the aluminum band wrap it in spiral to the tube. This way the tube is completely covered with the aluminum band and looks like the cooling tubes in a car radiator, but in bigger scale.  We produce two types of Finning processes depending on client’s specifications.

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Type L “Footed”

Tube Diameter: 5/8”, ¾”, 1”, 1-1/4”, 1-1/2”
Fin Height: 7/16”, ½”, 5/8”
FPS (Fins per inch.): 7, 8, 9, 10, 11
Fin Thickness: 0.016”
Fin Material: A-1100 Aluminum.
Tube Lengths: from 3 ft to 60 ft.
Service Temperature: up to 300°F (149°C)

The aluminum band is performed in “L” shape previous to its adherence (with tension).

This Finning type gives good stability and heat transmission at moderate temperature.

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Type G “EMBEDDED”

Tube Diameter: 5/8”, ¾”, 1”, 1-1/4”, 1-1/2”

Fin Height: 7/16”, ½”, 5/8”
FPS (Fins per inch.): 7, 8, 9, 10, 11
Fin Thickness: 0.016”
Fin Material: A-1100 Aluminum.
Tube Lengths: from 3 ft to 60 ft.
Service Temperature: up to 750°F (399°C)

The machine cut a groove on the tube just where the aluminum band inlays on its edge by rotational tension and then the machine trap the aluminum band on the tube.This Finning type gives good stability and heat transmission at higher temperature.

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ASME Specification for common Finning tubes.

SA-214, SA-179 Carbon Steel.
SA-249, SA-213 (TP 304, TP 316, TP 304L, TP 316L) Stainless Steel.
SB-111 (Admiralty, 90-10CuNi, 70-30CuNi) CuNi Alloys.
SB-423 S08825 Incolloy 825.
SB-338 Titanium.

Accesories

Aluminum finned tubes (L “Footed”, G “Embedded”).
Aluminum Manual and Automatic Axial Flow Fans, Blades & Parts.
Electric Motors.
Reduction Gears.
Sprocket, Sheaves and Pulleys.
V belts, Cogged Belts and Timing Belts.
Manual & Automatic Louvers.
Vibration Switches & Vibration Monitoring Elements.
Flange Type bearing.
Drivers Couplings.
Automatic Lubrication Systems parts.
Steam Coils.
Fan rotation control devices.

Raw Materials

Plates: SA-516-70/60 (N/HIC), SA-240 TP304/304L/316/316L, SB-424 S08825, Etc.
Tubes: SA-214, SA-179, SA-249 TP304/304L/316/316L, SA-213 TP304/304L/316/316L, SB-423 S08825, Etc.
Plugs: SA-105, SA-182 F304/304L/316/316L, SB-564 S08825, Etc.
Gaskets: Soft Iron, SS-303, SS-304, SS-316, SB-424 S08825, etc.
Swages: SA-234 WPB, SA-403 TP304/304L/316/316L, SB-366 S08825, Etc.
Pipe: SA-106B, SA-312 TP304/304L/316/316L, SB-423 S08825, Etc.
Flanges: SA-105, SA-182 F304/304L/316/316L, SB-564 S08825, Etc.
Threaded Couplings: SA-105, SA-182 F304/304L/316/316L, SB-564 S08825, Etc.
Structural Steel Shapes: PS-25, A-36
Structural Plates: A-36.
Gratings: PS-25
Bolts and Nuts: Carbon Steel.

Field & Post-Sale Service and Repair

We understand our service does not end when material leaves our facility. This is why Caltuca offers several options to meet your specific needs.
Replacement Parts. We provide replacement parts for any Air Cooled Heat Exchanger, regardless of the original manufacturer. Plugs, Gaskets, Finned Tubes, Tube Bundles, Fans, Motors, Drive POD, Belts are just a few examples.

Specialized Service

We understand our service does not end when material leaves our facility. This is why Caltuca offers several options to meet your specific needs. Replacement Parts. We provide replacement parts for any Air Cooled Heat Exchanger, regardless of the original manufacturer. Plugs, Gaskets, Finned Tubes, Tube Bundles, Fans, Motors, Drive POD, Belts are just a few examples.

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