BULLETIN 1800

MODULAIR BY COLMAC
AUGUST 20, 1999

MODULAIR BY COLMAC COIL

FLUID COOLERS
8 Models Capacities to 3,000 MBtu/h

Colmac coils are rated in accordance with standard industry practice.

SPECIFY COLMAC QUALITY

Table of Contents

Standard Features, Options ............................................................................................................. 3 Nomenclature ................................................................................................................................... 3 Selection Procedure ......................................................................................................................... 4 Modulair Cooler Selection Charts .................................................................................................... 5-8 Specifications, Connection Sizes ..................................................................................................... 9 Sound Levels ................................................................................................................................... 9 Dimensions ...................................................................................................................................... 10,11

NOMENCLATURE:
MOD - BT - 10 - D - L - D MOD Modulair Fluid Cooler Air Flow: DT-Draw through BT -Blow through Number of fans: Width: D Double Width S Single Width Coil Type: L Low Capacity H High Capacity Voltage Code: B 208-230/60/3 D 460/60/3 E 575/60/3 F 380/60/3 H 200/50/3 I 400/50/3

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STANDARD FEATURES:
Modulair air cooled fluid coolers are designed to provide cooling of Water, Ethylene Glycol/ Water and Propylene Glycol /Water solutions in a variety of closed loop applications. The compact plate fin heat transfer surface provides a compact and efficient air cooler suitable for many power generation cooling applications. Modulair air cooled fluid coolers are available in a series of standard modules for either forced or induced draft to simplify selection. Any cooling load can be accommodated by connecting the required number of standard modules in parallel to a common pump skid.

Wide range of sizes and fin spacing to match any cooling load and temperature. Seamless 5/8 inch copper tubes with high efficiency aluminum plate fins with self spacing collars. Copper headers designed for 150 psig @ 200 F with carbon steel 150# ANSI RF flanges. Independent fan compartments to prevent short circuiting of air during sequential fan operation. Corrosion resistant construction, 14-gauge galvanized steel cabinets, powder coated steel OSHA fan guards, galvanized steel fan blades. Heavy duty rigid foot mounted direct drive totally enclosed fan motors with moisture protected rainshields (slingers). Motor insulation is Class F rated for 154 F (67 C). Motors are 710 RPM for 50 HZ and 850 RPM for 60 HZ operation. Weatherproof NEMA 4 electrical enclosures located at the end of each cooling module provide single point field wiring for each cooling module. Built in lifting connections and easy to install legs simplify lifting and installation.

OPTIONS:
Polycoat aluminum fins for added corrosion protection. Copper fins with copper tubes. Tin coated copper tubes with marine grade aluminum fins for severe corrosion service. Stainless steel cabinet, side frame, fan blades and hardware. Factory wired fused disconnect switch for each fan motor. Factory wired starters for each fan motor with overload protection and alarm contact. Coil block built in accordance with the requirements of the ASME Boiler and Pressure Vessel Code.

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SELECTION PROCEDURE:
The selection procedure for eight standard Modulair cooler sizes is provided. Cooling capacity charts are shown in Figures 1 to 8 based on the flow rate of 50% ethylene glycol-water and the approach temperature oF with forced draft air flow (blow through). The approach temperature is the difference between the leaving fluid temperature and the inlet air temperature. The pressure drop for 50% ethylene glycol- water is shown in Figure 9 and the pressure drop correction for water instead of 50% ethylene glycol-water is shown in Figure 10 . Figures 11 to 13 provide rating factors for other conditions that are applied to the cooling capacities from Figures 1 to 8. The rating reduction factor for induced draft (draw through) air flow is shown in Figure 11. Figure 12 shows the rating increase to apply when water is used instead of 50% ethylene glycol-water. The cooling capacity charts are based on 1000 feet elevation (305 meters) and rating capacity factors for elevations above 1000 feet are shown in Figure 13. Figures 14 and 15 are the rating reduction factors to apply to the nominal cooling capacity when excess surface is required. Figures 16 and 17 provide the equivalent percentage excess surface conversion for inside fouling factors (hr.ft2.oF/Btu). For operating conditions that are markedly different than the conditions used for the cooling capacity charts please contact your Modulair representative or factory staff to check a standard Modulair selection or to prepare a custom design selection. EXAMPLE: A gas turbine installation has a design cooling load of 3,800,000 Btu/h to cool 1600 gpm of 50% ethylene glycol-water to 120 oF with 95 0F ambient air at 2,000 feet elevation. The specification calls for 15% excess surface and induced draft (draw through) fan arrangement. The approach temperature is 120 - 95 = 25 oF . The rating factor for induced draft for this approach temperature is 0.94 from Figure 11 and the rating factor for 2,000 feet elevation is 0.97 from Figure 13. As the rating charts are in MBtu/h divide the given cooling duty by 1,000. If the cooling conditions are given in kW and l/min multiply kW by 3.412 to convert to MBtu/h and divide l/min by 3.785 to obtain gpm. Next review the rating charts to estimate the number of cooling modules required. Select either two or three of the larger units and calculate the flow per unit for a trial run. Trial number of coolers Ethylene glycol-water flow per cooler Nominal cooling capacity required Trial coolers selected Cooling capacity from chart Design cooling capacity Excess surface rating factor Design cooling capacity 2 1600/2 = 800 3800/2 = 1900 BT-10-D-H (Figure1) 2270 .94x.97x2270= 2070 .95 (Figure 14) .95 x 2070 = 1966 3 1600/3 = 533 3800/3 = 1267 BT-8-D-L (Figure 4) 1650 .94x.97x1650 = 1504 .923 (Figure 15) .923 x 1504 = 1388

gpm MBtu/h MBtu/h MBtu/h MBtu/h

Both trial selections will provide adequate cooling but the two larger coolers will be a more economical selection. The pressure drop from Figure 9 is 15 feet (4.57 m) liquid head. The selection is two MOD-DT-10-D-H Modulair air cooled fluid coolers 10 fan double width . Note the second term is the letters DT to designate draw through fan arrangement. From Table 2 for 800 gpm each cooler will have 2-6 inlets and 2-6 outlet connections with 150# ANSI flanges. The overall dimensions and footing dimensions are shown in Figure 19. The two coolers may be arranged end to end with the pump skid at the center or side by side with the pump skid at the connection end.

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MODULAIR COOLER SELECTION CHARTS

FIGURE 1 MODULAR RATING CURVE MOD - BT - 10 - D - H FIGURE 3 MODULAR RATING CURVE MOD - BT - 10 - D - L
3200 2800
3000

MODULAIR RATING CURVE MOD BT 10 D H

2600

2400 2000 1600 1200 800 200

2200

Mbtu/hr.

1800

1400

1000

300

400

500

600

600

FLOW GPM 50% glyco

200

FLOW GPM 50% glyco

FIGURE 2 MODULAR RATING CURVE MOD - BT - 8 - D - H 2400

FIGURE 4 MODULAR RATING CURVE MOD - BT - 8 - D - L 2300

2100
2000 1600 1200 800 400 300

1900 1700 1500 1300 1100 900 700

400 500 600 700 800 900

500 200

300

400

500

600

FLOW GPM 50% glyco

FLOW GPM 50% glyco

g
30 F approach 20 F approach 10 F approach 25 F approach 15 F approach 5 F approach

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MODULAIR COOLER SELECTION CHARTS

MODULAR RATING CURVE MOD - BT - 6 - D - H

1600 1400 1200 1000 800 600 400 200 200

MODULAR RATING CURVE MOD - BT - 4 - S - L

1100 1000 900 800 700 600 500 400 300 200 150

300

400

500

600

200

250

300

350

FLOW GPM 50% glyco Figure 5

FLOW GPM 50% glyco Figure 7

MODULAR RATING CURVE MOD -B 5 -S - S - L MODULAIR RATING CURVE MOD BT 5 L

1500 1300 1100 900 700 500 300 150

MODULAR RATING CURVE MOD - BT - 3 - S - L

750 700 650 600 550 500 450 400 350 300 250 200 150

200

250

300 l

350

200

250

300

350

FLOW GPM 50% glyco Figure 6

FLOW GPM 50% l

FLOW GPM 50% glyco Figure 8

30 F approach 20 F approach 10 F approach

25 F approach 15 F approach

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MODULAIR COOLER SELECTION CHARTS

PRESSURE DROP FEET OF LIQUID

20

PRESSURE DROP CORRECTION FOR WATER

0.80 0.78

15

0.76
10

0.74 0.72

0.70 150

300

450

600

750

900

0 100

200 300

400

500 600

700 800

900

FLOW GPM Water @ 110F Figure 10

FLOW GPM 50% glyco @ 110F Figure 9

10-D-H 8-D-L 3-S-L 8-D-H 6-D-L 10-D-L 5-S-L

D-L

D-H

S-L

1.000 0.980 0.960

WATER RATING FACTOR
1.16 1.12 1.08 1.04

INDUCED DRAFT RATING FACTOR based on 90 F inlet air based on 90 oF inlet air

0.940 0.920 10 15 20 25 30
APPROACH TEMPERATURE F Figure 11

MODULAIR ELEVATION RATING FACTOR

1 100 200 300 400 500 600 700 800 900

FLOW GPM WATER @ 110F Figure 12

D-L D-H S-L

1.00 0.98 0.96 0.94 0.92 0.90 0.88 0.86 1000 2000 3000 4000 Elevation feet Figure 13 5000

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MODULAIR COOLER SELECTION CHARTS

1.000

EXCESS SURFACE RATING FACTORS D-H COOLERS

1.000 0.950 0.900 0.850 0.800 0.750 100

EXCESS SURFACE RATING FACTORS S-L and D-L COOLERS

RATING FACTOR

0.950 0.900 0.850 0.800 0.750 300

400

500

600

700

800

900

200

FLOW GPM 50% glycol Figure 14 5% 25% 10% 30% 15% 35% 20%
5% 25%

300 400 500 FLOW GPM 50% glycol Figure 15 10% 30% 15% 35% 20%

600

Percent Excess Surface for Cooler Size D- H as equivalent to fouling factors in hr.ft2.F/btu 40%

Percent Excess Surface for Cooler Sizes D- L and S- L as equivalent to fouling factors in hr.ft2.F/btu 40%

30% 20%

30%

20%

10%
10%

0% 300

400 500 600 700 800 FLOW GPM 50% glycol @ 120 F Figure 16 0.0005 0.001 0.0015 0.002

900

0% 200

300

400

500

600

FLOW GPM 50% glycol @ 120 F Figure 17

0.0005 0.0015

0.001 0.002

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TABLE 1: PHYSICAL SPECIFICATIONS Model BT-3-S-L BT-4-S-L BT-5-S-L BT-6-D-L BT-8-D-L BT-8-D-H BT-10-D-L BT-10-D-H No. of Fans 3 4 5 6 8 8 10 10 Overall Dimn. Width Length 49 5/8 49 5/8 49 5/8 95 95 95 95 95 Wt. of Dry Wt. 50% glycol lbs. 196 261 326 391 522 783 654 977 1358 1728 2165 2607 3351 3970 4756 5532

TABLE 2: COOLER CONNECTION SIZES GPM per Cooler Single Width Inlet Outlet Double Width Inlet Outlet

174 inches 228 282 174 228 228 282 282

under 230 1- 4 1- 4 230 460 2-4 2-4 2- 4 Over 460 NA NA 2- 6 Connection sizes shown are inches

2- 4 2- 6

Standard Flanges are C. Steel ANSI 150# RF

Note: Dry weights in lbs. are based on 5/8 x .025 copper. Dimensions are in inches

SOUND LEVELS:
Sound levels are free field dbA (A weighted) values with no reflecting surfaces near the cooler. Sound levels are the average of readings at five foot intervals five feet from the perimeter of the cooler and five feet above grade. Installed coolers may vary by + or - 2 dB. TABLE 3: APPROX. SOUND LEVELS, dBA Number of fans 3 4 5 6 60 Hz 870 rpm 80 81 82 83 50 Hz 710 rpm 78 79 80 81

8 84 82

10 85 83

TYPICAL COOLER SPECIFICATION:

Fluid coolers shall be air cooled dry surface coolers of standard modules with single speed direct drive multiple fans and vertical air discharge. Coolers shall be compact fin construction utilizing plate fin heat transfer surface with spacing collars. Tube shall be seamless copper 5/8 inch diameter minimum .025 inches thick with brazed end bends. Headers shall be copper with carbon steel ANSI 150# flanged nozzle connections. Fan motors shall be heavy duty rigid foot mount totally enclosed with vertical shaft and moisture rain shield. Each fan motor shall be factory wired to a common weatherproof electrical enclosure located at the connection end of each cooler. Fan guards shall be of carbon steel construction powder coated or hot dip galvanized and meet OSHA standards. Fan cabinets shall be 14 gauge galvanized sheet steel with independent fan compartments to prevent short circuiting of air. Hardware shall be Grade 5 plated steel minimum. Coolers shall be designed for 150 psig at 200 oF and pressure tested at 225 psig. Cooler support legs shall be galvanized carbon steel with two electrical grounding locations per cooler. Coolers shall be designed to withstand 100 mph winds and seismic load of 0.1 g horizontal or vertical. Supplier shall provide approval drawings showing dimensions and electrical power requirements. I.O.M. instructions shall be provided as required.

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FIGURE 18 DIMENSIONS - SINGLE WIDTH COOLERS

[ 1227 ] 48.3 G1 G2 ELECTRICAL ENCLOSURE INLET J1 J2 B

LIFTING EYE, (K) PLACES

[ 942 ] 37.1

OUTLET H1 H2 0.75 HOLE, (L) PLACES [ 1143 ] 45

[ 94 ] 3.7, TYP. [ 1181 ] 46.5

[ 94 ] 3.7, TYP. D E

TYPE DT - DRAW THRU (INDUCED DRAFT)

[ 2370 ] 93.3 G1 G2 [ 838 ] 33 [ 838 ] 33 J1 INLET J2 B LIFTING EYE, (K) PLACES ELECTRICAL ENCLOSURE

OUTLET

[ 942 ] 37.137.075

H1 H2 [ 1143 ] 4545 0.75 HOLE, (L) PLACES

[ 2324 ] 91.5

[ 94 ] 3.7, TYP.

[ 94 ] 3.7, TYP. D E

TYPE BT - BLOW THRU (FORCED DRAFT)

Single Width Models Blow Draw B-5-S D-5-S B-4-S D-4-S B-3-S D-3-S No. of Fans 5 4 3 Footing Dimensions - In. (mm) A B C 273.3 (6942) 162 (4115) 44.3 (1125) 219.3 (5570) 108 (2743) 44.3 (1125) 165.3 (4199) 164.8 (4186) 44.3 (1125) D 109.5 (2781) 109.5 (2781) 109.5 (2781) E 54 (1372) 54 (1372) F 108 (2743) 108 (2743) K L 4 16 4 12 4 12

Air Flow Blow Draw

Connection Dimensions - In. (mm) G1 G2 H1 40.5 (1029) 7.5 (190) 79.2 (2012) 40.5 (1029) 7.5 (190) 53.1 (1349)

H2 59 (1499) 32.9 (836)

J1 20 (508) 20 (508)

J2 7 (178) 7 (178)

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FIGURE 19 DIMENSIONS - DOUGLE WIDTH COOLERS

C
ENG00002625

[ 2370 ] 93.3 G1 G2 [ 838 ] 33 [ 838 ] 33 J1 ELECTRICAL ENCLOSURE J2 B

LIFTING EYE, (K) PLACES

INLET

[ 942 ] 37.1

OUTLET H1 H2 0.75 HOLE, (L) PLACES [ 1143 ] 45

[ 2324 ] 91.5

[ 94 ] 3.7, TYP.

[ 94 ] 3.7, TYP. D E

TYPE DT - DRAW THRU (INDUCED DRAFT)

ENG00002685

[ 1227 ] 48.3 G1 G2 INLET OUTLET

J1 J2

B LIFTING EYE, (K) PLACES ELECTRICAL ENCLOSURE

[ 942 ] 37.137.075

H1 H2 [ 1143 ] 4545

[ 94 ] 3.7, TYP. [ 1181 ] 46.5

[ 94 ] 3.7, TYP. D E

0.75 HOLE, (L) PLACES F

TYPE BT - BLOW THRU (FORCED DRAFT)

Double Width Models Blow Draw B-10-D D-10-D B-8-D D-8-D B-6-D D-6-D No. of Fans A 273.3 (6942) 219.3 (5570) 165.3 (4199) Footing Dimensions - In. (mm) B C D 162 (4115) 89.3 (2268) 109.5 (2781) 108 (2743) 89.3 (2268) 109.5 (2781) 164.8 (4186) 89.3 (2268) 109.5 (2781) E 54 (1372) 54 (1372) F 108 (2743) 108 (2743) K L 4 16 4 12 4 12

10 8 6

Air Flow Blow Draw

Connection Dimensions - In. (mm) G1 G2 H1 40.5 (1029) 7.5 (190) 79.2 (2012) 40.5 (1029) 7.5 (190) 53.1 (1349)

H2 59 (1499) 32.9 (836)

J1 20 (508) 20 (508)

J2 7 (178) 7 (178)

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Colmac

Colmac
Co lma

Colmac Colmac Colmac Colmac

Colmac

Colmac

A Tradition of Quality
Colmac Coil was founded in 1971 and has been distinguished for its commitment to quality in the new and replacement coil markets with listings, certifications, and code markings such as ARI, ASME, UL, CSA, and CRN. Located in the Northwest USA, Colmac has grown to prominence as a trusted coil manufacturer with commercial/industrial heating & cooling, HVAC and refrigeration customers worldwide. Colmac has a network of over 250 factory representatives in over 80 sales offices around the world.

QUALITY COLMAC PRODUCTS

HEAT TRANSFER PRODUCTS
HVAC/Industrial/OEM Heating and Cooling Coils Fluid Coolers Heat Pipe Coils

HEAT PUMP WATER HEATERS

Commercial/Industrial Air-Source Heat Pump Water Heaters with Air Conditioning Benefit

REFRIGERATION PRODUCTS Evaporators - Air Coolers Air-Cooled Condensers Blast Freezers

Local Representative
Industrial/Commercial Tube Bundles Hydro Coolers Bunker Coils

COLMAC COIL MFG., INC. 370 North Lincoln P.O. Box 571 Colville, WA 99114-0571 Phone: 509-684-2595 Fax: 509-684-8331 e-mail: mail@colmaccoil.com Website: www.colmaccoil.com