Acc GEA Information

ACC/Heller BU
Air Cooled Condensers &

The PAC SYSTEM
GEA Heat Exchangers / GEA Power Cooling, Inc.
Topics of Discussion
Introduction to GEA Group

GEA Power Cooling
Air Cooled Condensers
Constructability
PAC SYSTEM
GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling
Constructability
PAC SYSTEM
Introduction to GEA Group Overview
GEA Group is 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
requirements and allows access to
manufacturing facilities located throughout
the world.
In 2008 the GEA Group employed over

21,000 people and generated sales of
EUR 5.2 billion.
http://www.geagroup.com
Introduction to GEA Group Summary

GEA Group is a driver of innovation in
its markets; up to 70% of products are
less than five years old.
The key markets are the energy and

petrochemicals industries, as well as
food and dairy.
GEA Group is a leading international

technology group with operating companies
in more than 50 countries.
The GEA Group Aktiengesellschaft is listed on MDAX stock index
WKN: 660 200, ISIN: DE0006602006
Introduction to GEA Group HX Segment
GEA Heat Exchangers

The Heat Exchanger Segment of GEA is by tradition a worldwide
player in the heat transfer industry. Our history goes back to the year
1920, when GEA was founded. The corporate culture is rooted in the
principles of decentralization and entrepreneurship.
Our clients are in the power generation business and all traditional
areas of the process industries such as chemical and petrochemical
plants as well as refineries.
The GEA Heat Exchangers Business Units

Heat exchangers can be found in almost every industrial plant. The
HX Segment of GEA particularly focus on the markets of the food and
energy industry as well as the markets for climate and environmental
technology.
Products supplied by the GEA HX Segment are:

Finned tube heat exchangers
Shell-and-tube heat exchangers
Plate heat exchangers
Wet and dry cooling systems
Systems for air conditioning and treatment in buildings
HX Segment Company Locations

Europe
Middle East / Africa
GEA Batignolles Technologies Thermiques S.A.S.

GEA EGI Contracting/Engineering Co. Ltd.
GEA Energietechnik GmbH
GEA Energietechnik Ltd. U.K.
GEA Ibrica S.A.
GEA Scambiatori di Calore S.r.l.
OOO GEA Energietechnik
GEA Aircooled Systems (Pty) Ltd.

GEA Energietechnik GmbH KSA Branch Office
Asia Pacific
Bejing GEA Energietechnik Co., Ltd.

EGI Cooling Systems Trading (Beijing) Co.
GEA Batignolles Technologies Thermiques
(Changshu) Co. Ltd.
North America
GEA Power Cooling Technology (China) Ltd.
GEA Power Cooling de Mexico S. de R.L. de C.V. GEA Shanxi Thermal Equipment Company Ltd.
GEA Power Cooling, Inc.
ACC Technology
First Air Cooled Steam Condenser Installed in 1939

650+ Air Cooled Condensers in Operation Worldwide
75% of Installed Dry-Cooling Capacity Worldwide
Worlds Largest ACC Installed on 4,700 MW Plant
Typical Service Life of 30 Years or Longer
Reliable Operating Experience in Extreme Climates
Flexible Design Solutions are Available
Low Operating Costs (no costly water treatment)

GEA Power Cooling
Constructability
PAC SYSTEM
GEA Power Cooling ACC Experience
Dry Cooling Systems
Over 100 Air Cooled Condensers since 1979

Over 20 Air Cooled Condensers supplied on a turn key basis
Wet/Dry PAC SYSTEMS
8 systems supplied since 1990

All existing parallel condensing systems supplied by GEA
GEA Power Cooling Large ACC Experience

Project (Location) Plant Size/Type
Riyadh (Saudi Arabia)
1200 MW C/C
Tucuman (Argentina)
450 MW C/C
El Dorado (USA) 480 MW C/C
Coryton (UK) 750 MW C/C
Millmerran (Australia) 2 x 420 MW Coal
Bajio (Mexico)
500 MW C/C
Gelugor (Malaysia) 380 MW C/C
Front Range (USA) 500 MW C/C
Athens (USA)3 x 360 MW C/C
Chuck Lenzie (USA)
2 x 600 MW C/C
Choctaw (USA)
890 MW C/C
Hunterstown (USA)890 MW C/C
Otay Mesa (USA) 510 MW C/C
Spalding (UK)
750 MW C/C
Current Creek (USA)
500 MW C/C
Comanche (USA)
750 MW Coal
AFAM VI (Nigeria) 600 MW C/C
Immingham (UK) 400 MW C/C
Caithness (USA) 280 MW C/C
Dry Fork (USA)
425 MW Coal
San Lorenzo (Mexico)
400 MW C/C
Astoria II (USA)
550 MW C/C
Successfully Completed All

Projects (~100)
Many New Projects Are
Repeat Customers
Lead Technology Center for
Air Cooled Condensers and
Wet/Dry Systems Worldwide
Lead Technology Center for
Dry Cooling in Combined
Cycle Power Stations
Worldwide
Financially Strong &
Diversified Company
Air Cooled Condensers - Experience
Millmerran 2x420 MW Coal Fired (Queensland, Australia)
Air Cooled Condensers: 2 Units
Chuck Lenzie 1200 MW Combined Cycle (Nevada, USA)
Riyadh PP9 1200 MW Combined Cycle (Saudi Arabia)
Coryton 750 MW Combined Cycle (United Kingdom)
Air Cooled Condenser: 1 Unit
Spalding 750 MW Combined Cycle (United Kingdom)
Samalayuca II 630 MW Combined Cycle (Mexico)
Linden 614 MW Combined Cycle Cogen (New Jersey, USA)
Bajio 500 MW Combined Cycle (Mexico)
El Dorado 480 MW Combined Cycle (Nevada, USA)
Dry Fork 425 MW Coal Fired Plant (Wyoming, USA)
GEA Power Cooling Project Execution
Project Structure and PM Support
Professional and Experienced Project Managers

PMP Certified
Customer focused
Strong in knowledge of Project Controls
Introduction of Project Engineer Role

Support PM in expediting day-to-day tasks/activities
Project Controls and Procedures in place

Primavera
Master Schedule Templates
Design and Engineering Processes Streamlined

Use of external engineering resources as necessary
Customer
Steering
Committee
Quality
Sales
Field/Comm
Services
Subcontractors
Safety
Project
Manager
Construction
Services
Finance
Supply
Chain Mgt
Vendors/
Suppliers
Scheduling
Contract
Admin
Design/
Engineering
In-house
Fabrication
Engineering
Services
Master Schedule Prepared Upon Project Commencement
Hiring of Project Controls

Professional
Certified in Primavera P3 and P6
Experienced in EPC Contract
Execution
Baseline Template Created

Contains all project related activities
(engineering design reviews,
customer approvals, procurement,
QA/QC, delivery & construction
milestones, etc.)
Baseline is Customized for

Project Specific Requirements
GPC Sales Philosophy
Strict Bid / No-Bid Process

Selective of Project and Customer
Detailed Input from Project Execution Group at Bid Stage
To ensure resources are available to meet schedule requirements
To ensure compliance with contract requirements
To ensure commitments to customer are met
Project Execution Hi-Lights

Fully-Integrated Project Execution Company
Conceptual Design, Detailed Design, Global Procurement, In-house Fabrication,
Erection Services, Operator Training, Commissioning
Collocation of Project Team

All Engineering, Procurement, QA/QC and Project Management Performed in
Lakewood, CO Office
Strong Project Controls

Project Execution Managed and Monitored according to Detailed Scheduling Program
(design/fabrication/inspection/delivery/construction)
Detailed Design/Engineering Accomplished using Integrated 3-D Modeling

Software
Equipment/Materials Sourcing Available through GEAs Global Procurement
Network
Manufacturing of Key Components within GEA Manufacturing Chain
GEA Power Cooling Engineering/Design
Efficient Engineering and Design
Integrated 3-D Design Capabilities & Software

Comprehensive Structural and Hydraulic System Interfacing
Automated Reporting and Generating of Supplemental Documents
(BOM, Component Data & Lists)
Innovative Design Solutions for Project Specific Requirements
Integrated 3-D Modeling
3-D Modeling program incorporates all of the major ACC subsystems

(structures, steam ducting, interconnecting piping, bundles, etc.)
Structural & Hydraulic System Interfacing
Avoidance, during engineering stage, of potential interference of GEA

& Customer supplied equipment eliminates costly field modifications.
Automated Production of Key Engineering Documents

TeklaStructures
-------------------------------------------------------------------------MATERIAL LIST FOR CONTRACT No:
Page: 1
TITLE:
PHASE:
Date: 09/30/2009
-------------------------------------------------------------------------Size
Grade
Qty.
Length
Area (in.2) Weight(pounds)
-------------------------------------------------------------------------PIPE_20"DIA_STD_ A53
1
1'-4 3/4"
1074.9
109.4
PIPE_20"DIA_STD_ A53
1
1'-8"
1278.6
130.6
1
3'-0 13/16"
2335.2
240.5
1
3'-3 13/16"
2522.6
260
1
4'-2"
3161.8
326.5
1
4'-2 15/16"
3220.1
332.6
1
4'-9"
3602.9
372.4
1
6'-10 1/16"
5176
536
1
14'-7 3/8"
11032.7
1145.3
1
36'-6"
27515.5
2860.1
1
39'-0"
29398.6
3056
---------------------------------------------------------------------119'-6 13/16" 90318.8
9369.2
Efficient and accurate generation of detailed engineering data and

documents such as Bill of Materials, component weights and
dimensions, and engineering data.
Innovative Engineering Solutions
Modular Construction Options

Innovative Engineering Solutions
Lightweight Structural and Ducting Design Concepts

GEA Power Cooling
Fully-integrated
Project
Management
Global
execution capabilities
Proven
track record of project
management and execution

GEA Power Cooling
Constructability
PAC SYSTEM

Direct Cooling
(Condensing)
Ambient Air as Medium

Complete System
Closed Circuit
No Water Usage
No Emissions
No Visible Plume
Dry Bulb Sensitive
Air Cooled Condenser
WINDWALL
FIN TUBE BUNDLES
STEAM DISTRIBUTION HEADER
D
COUNTERFLOW MODULE
PARALLEL FLOW MODULE

AIR MOVING SYSTEM
AIR REMOVAL SYSTEM
STEAM IN
CONDENSATE TANK

ATM
K
Bundle
K
Bundle
D
Bundle
K
Bundle
Turbine
EQ Line
ATM
Vacuum
System
I/A Condenser
Return
Line
Drain
Line
Condensate
Tank
Motive
Steam
Pumps
Basic Design Relationship

Q / ITD ACC Capacity
ITD = Tsat. Tair in
Steam Parameters
mass flow
backpressure
enthalpy/quality
K=
Q/I
TD
Ambient Conditions
inlet air temperature
barometric pressure or elevation
ACC System Typical Evaluation Criteria
Capital Equipment Cost

Installation Cost
Other EPC Cost (Civil Work & Electrical, etc.)
Operating Costs (Power Consumption, Maintenance, etc.)
Far Field Noise Requirements
Hot Weather Performance
Cold Weather Performance
Air Cooled Condensers - Components
ACC Fin Tubes
A-Tube (Hot-dip Galvanized)

ALEX (Single Row)
ACC Fin Tubes

A-Tube: 2 Row, Elliptical, HDG Carbon Steel
COOLING AIR
Rugged, HDG steel tube and fin

Economical for higher noise applications
ACC Fin Tubes

ALEX : Single Row, Carbon Steel Tube, AL Fins
Composite Tube Bundle Fabrication
(Self-Supporting)
Lightweight Heat Exchanger with High
Structural Rigidity
Compact Design w/ High Extended
Surface Ratio (~ 117:1)
Manufactured in North America,
Germany and China
ACC Substructure, Platform, Columns, and Fan Deck Plate
Fan Guards
Fan Bridges
Monorail Beam and A-Frames for Internal Partitions
A-Frames for support of siding only. HX bundles are self supporting

Monorail beam travels length of roof
Windwall Structure & Siding
Galvanized or painted structure & siding implemented

Wind wall extends to the height of the Hx bundles
Transition Piece
Orientation dependant on turbine manufacturer

Occasionally supplied whole to reduce on site welding
Main Steam Duct & Manifold Steam Duct
Large diameter to maintain low steam side velocities

Supplied circumferentially whole when practical to reduce field
welding
Main Steam Duct & Manifold Steam Duct Sample Plan View
Axial STG Configuration
Steam Duct Supports
Steam Duct Risers & Expansion Joints
Tied universal EJ on vertical riser duct

Hinged EJ on horizontal steam header
Steam Duct Risers & Expansion Joints Elevation View
Steam Duct Headers
Condensate Tank & Pumps

Typical design includes:
Sizing for 10 minute flow
Normal operating level at 50%
Pumps provided 2x100% or 3x50%
Fan Rings
Mechanical Equipment
Fan
Motor
Gearbox
Vacuum Equipment
Steam Jet Air Ejectors (SJAE)
2 x 100% Holding
1 x 100% Hogging
Motive Steam Supply Requirements
Vacuum Equipment
Liquid Ring vacuum Pumps (LRVP)
2 x 100 % (both pumps for Start-up/Hogging)
3 x 50% Option
Additional aux load
Vacuum Equipment
Hybrid Systems
LRVP for Start-up/Hogging
SJAE for Normal/Continuous Operation
Rupture Disk
Supplied by GEA for protection of over-pressurization

Set pressure is slightly less than ACC design pressure
Fin Tube Cleaning System Option

Semi Automatic Module
Requires manual movement
traversing each ACC valley
Motor operated spray manifold
travels from valley to peak
Recommended cleaning
approximately once per year
(depending on ambient conditions)
Approximate water usage per
cleaning 2,800 gallons/cell
Sectionalizing Valves Option
The need for sectionalizing valves

is evaluated based on the low
load /low temperature design case
Isolate entire rows of ACC
Utilize valve motor operators
Bypass Spargers Option
When introduced into steam path

additional pressure losses are
created, therefore steam duct
diameter must be increased
Steam entering duct must be less
than 250F and 1164 Btu/lb
Provided by others or by GEA as
an option
Noise Abatement Option
Low noise fans

Gearbox enclosures
Sound walls at site boundary
Sound baffles enclosing entire
ACC
Wind Screen Option
High winds can reduce ACC

performance
ACC test codes allow wind
speeds up to 3 m/s (6.7 mph)
Wind screens help channel air
flow to fans
Sample Combined Cycle Site Plan
Sample Arrangement 15 Cell ACC
Sample P&ID Main Steam Duct
A
C
C
Sample P&ID 15 Cell ACC
Sample P&ID Air Removal System & Condensate Tank
Sample Input / Output List 15 Cell ACC
Air Inlet Height Determined by Air Speeds

Air Outlet Velocity = 4.2 m/s
Air Inlet Velocity = 4.0 m/s
Sample Foundation Load Diagram
Sample Foundation Details
Sample Performance Curve Fans Full Speed
Dry & Saturated Steam Flow - T/hr
300
250
FULL LOAD
200
150
100
50
0
20
25
30
35
40
45
50
Inlet Dry Bulb Temperature - C

Sample Steam-side Pressure Losses

Condensate Out
(139 F)
Design @
6HgA, 141F
T = 2 F
Pressure, "HgA
Main Steam
Duct
Design @
2HgA, 101F
138.5
F
2
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1
Distribution
Duct
K - Bundles
D - Bundles
Air Removal
Piping
T = 14 F
Condensate Out
(87 F)
82 F
Sample Airside Pressure Losses
Fan
Bridge
Plenum
Losses
Fan
Inlet
Acc.
Inlet
Direction
Change
Bundle
Losses
Outlet
Direction
Change
Natural
Draft
Dump
Loss
Fan
Guard
Sample Auxiliary Fan Power Consumption

Motor ff = 95%
Gear ff = 98%
Motor Input Power

Motor Output Power
Fan Shaft Power
Fan Shaft Power = 103 kW

Motor Output Power = 106 kW
(@98% - 1% margin)
Motor Input Power = 113 kW
(@95% - 1% margin)
15 x 113 kW = 1695 kW
Guarantee = 1700 kW
(1660 kW expected)
Process Control of ACC Fans

Fan Motor Options
Single speed motors
High efficiency
Inverter Duty Available
Two-speed motors
Variable Frequency Drives
Cost impacts (ACC and Plant Equipment)
Performance impacts/opportunities
Steam Turbine Backpressure, mbar(a)
ACC Performance 100% Load

300
250
200
150
100
50
0
0
10
15
20
25
30
35
40
45
50
Ambient Temperature, deg. C

Factors Affecting ACC Design & Price
Heat Rejection Capacity (Q)

Level of Specified Performance (ITD)
Steam Turbine Backpressure vs. Cooling Air Temp.
Noise Emission Levels (Far Field)
Unusual Project Specific Guarantees
Excess Capacity (redundancy)
Fan Power Consumption Limits
Over-design for High Wind Speed (> 3 m/s)
Geometric Considerations
ITD Trends
110
100
90
80
70
ITD F
60
50
40
30
ITD = Tsat - Tamb
20
1980
1985
1990
1995
2000
2005
2010
Air Cooled Condensers Noise Abatement
Low Noise Trends
dB(A) @ 400
ft.
Sayreville, NJ
16/30 diameter
Bellingham, MA
16/30 diameter
65
Linden, NJ
60/30 diameter
Union County, NJ
9/30 diameter
60
Onondaga County, NY 10/30 diameter
55
North Bay, Ontario
8/30 diameter
Kapuskasing, Ontario
8/30 diameter
50
Arbor Hills, MI
3/24 diameter
Pine Bend, MN
3/18 diameter
45
Mallard Lake, IL
3/26 diameter
Barry, United Kingdom
12/32 diameter
40
Dighton, MA
16/28 diameter
Coryton, United Kingdom 40/32 diameter
35
Tiverton, RI
16/32 diameter
30
Rumford, ME
16/32 diameter
1990
1991
1992
1993
1994
1995
Bajio, Mexico
35/34 diameter
Athens, NY
3 x 18/34 diameter
Hunterstown, PA
50/32 diameter
53 dB(A) @ 400 1989

53 dB(A) @ 400 1989
54 dB(A) @ 1000
45 dB(A) @ 750
50 dB(A) @ 200 1992
52 dB(A) @ 100m
52 dB(A) @ 100m
62.5 dB(A) @ 50
62.5 dB(A) @ 50
38 dB(A) @ 400
50 dB(A) @ 122m
50 dB(A) @ 250
51 dB(A) @ 300m
60 dB(A) @ 320
60 dB(A) @ 320
1996
1997
1998
58 dB(A) @ 100m
52 dB(A) @ 400 2000
51 dB(A) @ 400 2001
1990
1991
1994
1994
1995
1995
1996
1998
1998
1999
1999
1999
1999
1999
2000
Noise Reduction Options

1.3
ACC Price Multiplier
1.25
1.2
1.15
1.1
1.05
1
0
10
15
20
25
Noise Reduction, dB
Fan Options
Low Noise Fans
Standard Noise Fans
Ultra Low Noise Fans

Acoustical Treatment
Unusual Project Specific Guarantees
Excess Capacity (Redundancy)

Fouling Factors
Standby Fans (1 or 2 fans off)
Additional Surface (+10%, etc.)
Fan Power Consumption Limits

Over-design for Increased Wind Speed
< 5 m/s (11.2 mph)
< 7 m/s (15.7 mph)
Air Cooled Condensers High Wind

Solutions
Performance Modeling

Solutions
Effect of wind on ACCs
The effect of wind on ACC performance has become a topic of high
interest in the power industry.
Plant operators are becoming familiar with ACC limitations
Low noise fans are highly sensitive to wind
Aggressive ITDs cause small changes in wind to largely effect overall
plant output. There is even potential of a STG trip.

Solutions
Two Distinct Impacts Same Result
Increased air inlet temperature (RECIRCULATION):

Part of the warm outlet air is mixed with the ambient air and leads
to an increased air inlet temperature, thereby reducing the ACC
performance (increased ST back pressure)
Increased fan static pressure (FAN PERFORMANCE):

Due to the increase in static pressure at high wind velocities, the
fan capacity (air flow rate) is reduced, thereby reducing the ACC
performance (increased ST back pressure)
RESULT: Increased back pressure reduced output (kW = $$$)

Solutions
GEAs Wind History
GEA validates computer model on two ACCs located in the US:

Neil Simpson II (Wyoming)
El Dorado (Nevada)
GEAs recommendations implemented
Preliminary results are VERY POSITIVE

Solutions
Wind Effects Case Studies
Neil Simpson II
El Dorado Energy

Solutions
El Dorado Prior to Wind Mitigation Modification
Plant DCS Data Sept. 6, 2001
25 30% ACC Performance

loss at 30 mph (13.4 m/s)
ACC Degradation vs. Wind Speed
105%
100%
95%
90%
85%
80%
75%
70%
65%
60%
0
10
20
30
40

Solutions
Permanent Wind Mitigation Modification II
Plant DCS Data Sept. 15, 2002
Current observations indicate > 90% ACC

performance available up to 30 mph
104%
102%
100%
98%
96%
94%
92%
90%
88%
0
10
20
30

Solutions
El Dorado Wind Mitigation Summary

Solutions
Typical Wind Screen Installation

Solutions
Site Geometric Restrictions
Inadequate Plot Area Available

unorthodox ACC arrangements
small A-frame angles
unique steam duct solutions
Height Restrictions
large A-frame angles
greater recirculation risks
Obstructions
tanks, buildings, etc.
Dighton 170 MW Combined Cycle (NE USA)
Typical Performance Guarantees
Thermal Performance (subject to LDs)

turbine exhaust pressure
auxiliary fan power (motor input)
Operational Performance (make good)

dissolved oxygen level in condensate
near and far field noise emission
Others
start-up time
minimum specific performance (if applicable)
Start-up / Commissioning
Field Pressure Decay Verification (leak test)

Must meet acceptable pressure decay rate
Pre-requisite to start-up
Trial Run of Fan Motors and other Equipment

Check of fan motor power usage
Fan blade pitch adjustment as needed
Hot-commissioning Activities
Steam Blows (by others)
Discharge of rust and steam (bypass)
Condensate filters/strainers
Typical Maintenance
Daily/weekly walk-by inspection through the fan cells checking only

for excessive noise or vibration (access to ACC fan motor assemblies
is done on-line and does not require fan motor shut down)
Annual oil change to gearboxes

Annual (or bi-annual) external fin washing to maintain 100% thermal
performance capability (washing is performed on-line, no more than a
single fan is shut down).
Routine inspections during planned plant outages

GEA Power Cooling
Constructability
PAC SYSTEM
Constructability
A-Frameless Design
Shop-Installed Integral Condensate Header
ACC Fan Deck Design
ACC Fan Ring Design
Steam Distribution Header
Constructability
A-Frameless Design
COMPOSITE BUNDLE
FABRICATION RESULTS IN A
LIGHT WEIGHT HEAT
EXCHANGER WITH HIGH
STRUCTURAL RIGIDITY
BUNDLES ARE COMPLETELY

SELF-SUPPORTING FROM THE
FAN DECK
A-FRAMES ARE ONLY

REQUIRED FOR CELL
PARTITION WALLS AND
MONORAIL SUPPORT
Constructability
Shop Installed Integral Condensate Header
FACTORY INSTALLED CONDENSATE HEADER
CONDENSATE HEADER ALSO FUNCTIONS AS BUNDLE BASE

SUPPORT
THERMAL EXPANSION ACCOMODATED BY SLIDE RAILS AND

TEFLON PADS
Constructability
Fan Deck Above Deck Welding

3/16 STICH WELD X 3LONG
EVERY 12,TYP.
B-B
SECTION A-A
A-A
CONTINUOUS BUTT
WELD, TYP.
(30 FAN BAY, TYP.)
3 DECK PLATES
PER QUADRANT
EXTERIOR WALKWAY
3/16FILLET WELD ALL

AROUND A 1 DIA HOLE,
TYP.
SECTION B-B
TOTAL WELDS PER BAY: ABOVE DECK 181-2

BELOW DECK NONE
Constructability
Fan Ring Installation

DURING
ASSEMBLY
ASSEMBLED
CAPTURED NUT
BOLTS & WASHERS INSTALLED FROM ABOVE DECK

NO INSTALLATION REQUIRED UNDERNEATH DECK
Constructability
Steam Distribution Header New Design
3 LONGITUDINAL WELDS
ALL WELDS DOWNHAND
OPTION TO WELD FROM INSIDE OR

OUTSIDE HEADER
Constructability
Modularization Options
Fan Deck Ground Assembly
Constructability
Fan Deck, Ring, & Guard Ground Assembly
Constructability
Fan Deck, Ring, Guard & Air Moving System Ground Assembly
Constructability
Complete Fan Module Preassembly
Constructability
Complete Fan Module Preassembly

Extreme Site Constraints
Site Conditions
Restricted lay down area
Limited Construction window
Tailored Solutions
Complete modular erection concept.
Off site construction of modules (~270
Ton Single lifts).
Barge assembled modules to site.
Minimum on site erection activities.
Constructability
ACC Substructure Array
Constructability
Air Moving Assembly Lift
Constructability
Tube Bundle Rigging
Constructability
Tube Bundle Rigging
Constructability
Tube Bundle Rigging
Constructability
Tube Bundle Lifting Assembly
Constructability
Tube Bundle Placement
Constructability
Tube Bundle Installation with Scaffolding
Constructability
Upper Steam Header Section Hoist
Constructability
Main Steam Duct Manifold & Risers
Constructability
Completed Cell Interior
Constructability
Construction Plan / Sequencing (Completed ACC)

GEA Power Cooling
Constructability
PAC SYSTEM
PAC SYSTEM
Classifications of Cooling Systems
Enhanced Dry
Plume Abated
PAC SYSTEM
What is a PAC SYSTEM
DRYCOOLINGSYSTEM
WETCOOLINGSYSTEM
A synergy of established cooling technologies

PAC SYSTEM
SSC & ACC are condensing steam in parallel

Steamturbine
steam
ACC
Coolingtower
The result: PAC SYSTEM

PAC SYSTEM
Cooling System Performance Comparison

Typical STG Backpressure Profile
Steam Turbine Backpressure, "HgA
DRY
6
5
PAC
WET
3
2
1
-10
10
20
30
40
50
60
70
80
90
100
Dry Bulb Temperature, F

PAC SYSTEM
Design data required for the thermal sizing of a PAC SYSTEM
Total steam turbine exhaust Steam Flow

Steam Enthalpy or steam quality
Steam Turbine Exhaust Pressure
Plant Site Elevation (or atmospheric pressure)
Design Inlet Air Dry Bulb and Wet Bulb Temperatures
Annual or instantaneous Makeup Water Usage Limitations
Auxiliary cooling duty (& flow) to be handled by cooling tower
PAC SYSTEM
Example (Comanche)
Location: Pueblo, Colorado

Owner: Xcel Energy
Plant type: Coal Fired
Output: 750 Mwe
Heat rejection system water limit: 4x106 m/yr
GEA Scope:
ACC (material supply)
MDCT (material supply & erection)
SSC (material supply)
PAC SYSTEM
Example (Comanche)
9 cell cooling
tower
45 cell
ACC
PAC SYSTEM
Example (Comanche): reduced BP in summer with PAC
Reduced turbine BP
results in increased plant
output
PAC SYSTEM
Example (Comanche): dry cooling duty as function of DBT:

60%
50%
Dry Cooling Duty
40%
30%
20%
10%
0%
15 C
20 C
25 C
30 C
35 C
40 C
45 C
50 C
Dry Bulb Temperature

PAC SYSTEM
Example (Comanche): Cooling Tower
Circulating water flow rate: 171,000 gpm or 38,838 m3/h

In-line arrangement with 9 counter-flow cells
Cell dimensions: 54 ft x 54 ft
Motor nameplate rating: 250 hp
PAC SYSTEM
Example (Comanche): Steam Surface Condenser
Surface area = 13,000 m2

1 inch Sea Cure 24 BWG tubes 2 passes
L x W x H = 18.2 m x 8.5 m x 7.3 m
PAC SYSTEM
Example (Comanche): Air Cooled Condenser
Surface Area: 134,068 s.f.

9x5 Arrangement
Overall Dimensions: 213 L x 405 W x 120 H
Motor nameplate rating: 250 hp
PAC SYSTEM
Example (Comanche): ACC Main Steam Duct
9.144 m
OD
PAC SYSTEM
Exeter Energy 30 MW Waste-to-Energy (NE USA)
PAC SYSTEM
Streeter 40 MW Power Station (Midwest USA)
PAC SYSTEM
Tucuman 450 MW Combined Cycle (Argentina)
PAC SYSTEM
Goldendale 248 MW Combined Cycle (Washington, USA)
PAC SYSTEM
Benefits
Reduced Capital Cost vs. 100% Dry System

Improved Performance vs. 100% Dry System
100 % Wet
Lower Capital
Expense
100 % Dry
Greater Capital
Expense
&
QA
Questions and Answers
GEA Power Cooling, Inc.

143 Union Blvd., Suite 400 Lakewood, CO 80228
(303) 987-0123 www.geapowercooling.com

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ACC/Heller BU

Air Cooled Condensers &

Introduction to GEA Group

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group Overview

GEA Group is the worlds largest heat

This provides us the technological and

In 2008 the GEA Group employed over

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group Summary

The key markets are the energy and

GEA Group is a leading international

Introduction to GEA Group HX Segment

GEA Heat Exchangers

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group HX Segment

The GEA Heat Exchangers Business Units

Products supplied by the GEA HX Segment are:

Introduction to GEA Group HX Segment

HX Segment Company Locations

Middle East / Africa

GEA Batignolles Technologies Thermiques S.A.S.

GEA Aircooled Systems (Pty) Ltd.

Bejing GEA Energietechnik Co., Ltd.

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group

First Air Cooled Steam Condenser Installed in 1939

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Introduction to GEA Group

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling ACC Experience

Dry Cooling Systems

Over 100 Air Cooled Condensers since 1979

8 systems supplied since 1990

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling Large ACC Experience

Successfully Completed All

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Millmerran 2x420 MW Coal Fired (Queensland, Australia)

Air Cooled Condensers: 2 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Chuck Lenzie 1200 MW Combined Cycle (Nevada, USA)

Air Cooled Condensers: 2 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Riyadh PP9 1200 MW Combined Cycle (Saudi Arabia)

Air Cooled Condensers: 4 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Coryton 750 MW Combined Cycle (United Kingdom)

Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Spalding 750 MW Combined Cycle (United Kingdom)

Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Experience

Samalayuca II 630 MW Combined Cycle (Mexico)

Air Cooled Condensers: 3 Units