leading designer and manufacturer of heat exchangers ... · inspection and test. shell and tube. we...

Leading Designer and Manufacturer of Heat Exchangers , Finned Tubeand Associated Spares

Designed and Manufactured in the U.K.

AIR COOLED HEAT EXCHANGERS

Spiro-Gills Thermal Products Limited became part of the Diesel Marine International Group inSeptember 2016.

Our corporate aim, building on Spiro-Gill’s many years of experience, is to continue the very highquality manufacture of Air Cooler products, repairs, re-tubing and upgrading.

Spiro-Gills , with more than 50 years experience (encompassing GEA Spiro-Gills, GEA AirExchangers Ltd, APV Spiro-Gills Ltd & Stafford Fabrications Ltd) in the design and fabrication of allmajor process cooling components, including finned tubing, headers, plenum chambers, fan rings,bundle frames and structure, are able to offer customers an unparalleled guarantee on thethermal and mechanical performance of our equipment and supplied finned tubes.

The DMI Group consists of Spiro-Gills Thermal Products Ltd, AMI Exchangers Ltd,Landons Engineering Ltd , DMI Young and Cunningham Ltd, DMI Netherlands (Zwolle),DMI Drechsler (Hamburg) , DMI Automotive (Detroit), Applied Cooling Technology (Florida)

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It is always our ambition to exceed your expectations.

DMI Drechsler

GROUP INTRODUCTION

Spiro-Gills Thermal Products LtdHas a wealth of experience in designing andmanufacturing air cooled heat exchangers fora multitude of cooling applications.

Our extensive experience includes, but is notlimited to, Process Coolers, Power GenerationCooling, Transformers, Condensers, Evaporatorsand many more.

AIR COOLED SYSTEMS

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We employ a dedicated team of thermal engineers with extensive experience in solving the kindof problems likely to arise in this area of operations.

Rigorous Testing We ensure all tube bundles are subject to thorough hydraulic tests.Every fan supplied as an integral part of our equipment is tested to ensure there are no inherentvibration problems and it complies with the appropriate specifications. In addition, noise levelscan be measured if required. Comprehensive certification is issued covering all stages ofinspection and test.

Shell and Tube We also offer ourShell and Tube Heat Exchangers forLubricating Oil Circuits and TransformerCooling . All designed and manufacturedto same high quality standards and testing.

Our coolers are designed to meet the mostonerous worldwide environments on sitesfrom the Arctic to the Equator. Design andconstruction incorporate materials thatensure long and trouble-free service with aminimum of maintenance. The heat transfersurfaces are selected from Spiro-Gills’extensive range of finned tube systems andare optimised to suit the application in themost cost-effective manner.

DESIGNING AIR COOLERS

Typical Components of an Air-Cooled Heat Exchanger

Induced Draft

Forced Draft

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Spiro-Gills Thermal Products Limited in-house design team use leading-edgetechnology, including the latest Computer Aided Design systems, to ensuremaximum efficiency in:

• Thermal design• Mechanical design of headers and steel structure• Noise level predictions• Preparation of the specification sheet• Preparation of the general outline drawings• Preparation of proposals• Price estimation

HEADERS

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Plug Header

The plug header is the most commonly usedheader type for working pressures up to 350bar.

The plug hole opposite each tube allows thetube to be expanded into the tube sheet. Italso facilitates mechanical cleaning andplugging in case of leakage.

Seal welded or strength welded tube totubeplate joints can be provided for hydrogenservice at high pressure etc.

This is less expensive than using pipe headersthat are generally employed for a servicepressure above 200 bar.

Cover Plate Header

The cover plate header is used for fluids withhigh fouling factors up to 40 bar maximumwhere frequent mechanical cleaning is needed.

It is also used for highly corrosive process fluidsto allow periodic checking of the corrosionallowance.

Talk to our Design Engineers

Tel +44 (0)1785 254 554

FINNED TUBES

Spiro-Gills Thermal Products Limited is the only UK company to manufacture Welded andApplied Finned Tubes. Extruded Finned Tubes can also be supplied , although historically there isa lesser demand for extruded. Spiro-Gills has the ability to manufacture high-specification finnedtube from 25mm to 219mm diameter and 22 meters in length for use in Process / Engine Coolers,Boilers and Furnaces.

We Promise :- Using Spiro-Gills to manufacture your finned tubes, will guarantee that youreceive a high-quality product, delivered on time at a highly-competitive price.

Extruded Finning machineApplied Finning MachineWelded Finning Machine

FINNED TUBES

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CHOOSING THE CORRECT FINNED TUBE --- WELDED

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We supply two types of welded finned tubes, Solid and Serrated. Fin height, thickness andnumber of fins per unit length will depend on the requirements of the application and standardsrequested by the client.

Solid Serrated

WELD QUALITY.The welding of fins to tubes is now faster thanks to the use of the high-frequency resistancewelding process. However, operator skill and knowhow are still vital to produce consistentlysuperior welds in the many different materials required by the power, chemical and petroleumindustries.

HIGH FREQUENCY WELDED FINNED TUBES.Spiro-Gills Thermal Products Ltd are the only UK manufacturer of HF Welded Finned Tubes foruse in oil refineries, petrochemical plants, power generating stations, fertilizer and gasproduction plants throughout the world.

We are the UK's largest manufacturer of extended surface tubing and our HF Welded FinnedTubes are found all over the world in a wide range of applications. The major uses for HighFrequency Welded Finned Tubes are associated with heat recovery in boilers, gas turbines andin furnace applications in the petrochemical industry.

We have vast expertise and over 50 years experience in field of Helical High Frequency WeldedTube finning and over 70 years experience in the manufacture of finned tubes.

• Tube diameters of 19.05mm – 219mm. Tubes materials – Carbon steel & exotic materials.• Fin heights of 6mm to 31.8mm. Fin thicknesses of 1mm – 2.6mm.• Fins per inch – 1 FPI – 7 FPI Fin materials – Carbon steel & exotic materials.

CHOOSING THE CORRECT FINNED TUBE APPLIED

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SG-G Fin(Embedded Fin)Application: High-efficiencyfin for high operatingtemperatures

Upper limiting temperature:400°C

Manufacture: A helicalgroove is formed in basetube displacing of materialand fin is wound into thegroove under tensionfollowed by backfilling ofthe displaced material to lock the fin root into thetube

Fin materials: AluminiumBase tube materials:Any readily machinablematerial

SG-L Fin(Wrapped Fin)Application: Standard fin forlow-temperature applicationwhere some degree of tubewall protection is required


Manufacture: Fin foot ispre-formed into L shape andapplied to base tube undertension. The adjacent finsabut one another giving adegree of base tubeprotection for lessaggressive environments

Fin materials: AluminiumBase tube materials:Any metallic material

SG-LL Fin(Overlapped L Fin)Application: Standard fin forlow-temperature applicationsgiving increased atmosphericcorrosion protection of thebase tube


Manufacture: Fin foot ispre-formed into an LL shape(overlapped LL) and appliedto base tube under tension.However, foot is pre-shapedto give overlap of one footonto another therebyimproving the base tubeprotection and the thermalcontact area


We supply four types of applied finned tubes, as well as the higher specification extruded tube used for more demanding applications. Fin height, thickness and number per unit length will depend on the requirements of the application and standards needed by the client.

APPLIED FIN

CHOOSING THE CORRECT FINNED TUBE EXTRUDED

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SG-K Fin(Knurled L Fin)Application: Standard finfor medium-temperatureapplications, giving increasedatmospheric corrosionprotection to the outer surfaceof the base tube


Manufacture: Fin foot is pre-formed intoan L shape and applied to base tube undertension. Knurling tools both precede andfollow the laying down of the fin foot sothat the fin material is locked into thepre-knurled tube. This gives up to 50%greater thermal contact area than standardL fin and also ensures an airtight fin totube bond, resulting in greater tubeprotection .


SG-Extruded Fin(Bi-metallic Fin)Application: High-efficiency fins for highertemperature applications giving completeand permanent atmospheric corrosionprotection of the base tube. Using over 40%more aluminum than the equivalent appliedfin the extended fin is very robust andresistant to mechanical damage, allowing thefinned tubes to be cleaned without damageusing either steam or high-pressure water


Manufacture: A carefully degreased core tubeis fitted into an aluminium primary tube. Thisassembly is then fed into the triple-spindlefinning head of the fin-extruding machine.Three special multi-disc packs extrude thealuminium tube into helical high fins whilereducing the inner diameter to give firmpressure contact with the core tube

Fin materials: AluminumBase tube materials:Any metallic material

APPLIED FINS EXTRUDED FINS

CHOOSING FANS, DRIVERS AND TRANSMISSIONS

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Fan blades are made of either aluminium or G.R.P.The number of blades and tip speed depend on airflowand noise limitations. Fans are balanced according tocode requirements.

Belt and pulley transmissions are used for up to 37kW.Pulleys are dynamically balanced. Belt types are:• V belt• Toothed belt (HTD)• Chevron Belts

Gear drives are generally preferred for over 37kW and are:• Parallel shaft• Right-angle drive

Electric motors are generally used as drivers, being selected to satisfy clients specific hazardous area requirements when required. Hydraulic motors may also be used, as well as low-speed direct-drive electric motors.

Airflow can be controlled in one of the following ways:

• Variable-speed electric motors (variable frequency)• Louvres (manual or automatic)• Two-speed electric motors• Automatic variable pitch fan

Many repairs – including the complete re-tubing of tube bundles are offered. Our preference is tore-tube/refurbish in our own workshop where the work can be carried out under factory conditions.Where this is not possible, in-situ repairs can be arranged with our highly skilled site engineers.

We have dedicated site engineers for outside repairs. Maximum notice from Clients is desirable to ensure the team is available and ready to deploy with all the necessary tooling .

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REFURBISHMENT/ RE-TUBING

Spiro-Gills Thermal Products Limited offers valuable expertise to operators who areconsidering an upgrade. This can often be the solution when process demands have outstrippedthe original specification and the space or funds are not available for a wholly new installation.

Our thermal and mechanical assessment will establish the best and most cost-effective upgradewithin the limitations of your budget – our vast experience with fans, drives and other aspects ofair-cooled heat exchanger technology can make this a surprisingly successful option.

Existing fans are often old, noisy or obsolete. By applying the correct engineering solution andusing an uprated drive with increased power electric motors an outdated cooler can be modified tocope with a higher heat load while still meeting the ever more stringent industry standards fornoise and vibration levels.

UPGRADING

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QUALITY CONTROL AND SPARES PARTS

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KEEP YOUR EQUIPMENT RUNNING EFFICIENTLY AND SAFELY .

Spiro-Gills have an extensive range of spares available at short notice. We can offer header plugs, gaskets, fan blades, tube supports and much more. Our dedicated spares sales team isready to answer your queries. We have extensive archives to ensure you receive the correct response to your enquiries. Rely on the original manufacturer to supply you the most suitable cost effective spare parts!

QUALITY CONTROL

Spiro-Gills are proud to have achieved fullaccreditation to ISO 9001:2015 in all stages ofdesign and manufacture.

We are also able to manufacture to ASME U stampstandard.

All tube bundles are subject to thorough hydraulictests appropriate to the cooling medium employed.

We also have individual test rigs for flushing,filtration, flow and pressure loss measurement.

Air Flow, Noise and Vibration tests are available andcan be witnessed if required.

Comprehensive certification is issued coveringmaterials, inspection and testing if required.

Talk to our Spares Dept.

Tel +44 (0)1785 254 554

WORLDWIDE

DELIVERING EXCELLENCE

Spiro-GillsThermal Products LimitedSt Albans Road Stafford ST16 3DREngland

T: +44 (0)1785 254554

F: +44 (0)1785 259501

www.spiro-gills.com

T: +44 (0)1785 254554

F: +44 (0)1785 259501

www.spiro-gills.com

Spiro-Gills Thermal Products LimitedSt Albans Road Stafford ST16 3DREngland

leading designer and manufacturer of heat exchangers ... · inspection and test. shell and tube. we...

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