GEA Power Cooling Systems Air Cooled CondensersGe Unparclleled the feld of dry cooling GEA instanton fst contains over 400 oir cooled conchersers worldwide, including the words Jarges at the 4,000 MW Aono ‘Seton (righ) and one of Noch ‘America’s lrges ot the 614 MW {inden Cogeneration Focily (oppeste poge) Dry cooling is becoming more and more prevalent in the power industry as en- vironmental regulations become increasingly re- stricive and water avail- ty becomes inereas- ingly uncertain. GEA hos unparalleled experience in the field of dry cooling, hving supplied the worlds first air cooled, vacuum steam condenser in 1939. Since then, GEA has cap: tured over 90% of this market worldwide During its more than fifty years of experience, GEA has provided air cooled condensers for a wide vor riety of design criteria, from ‘extremely cold to extremely hot climates, from severely space limited sites, to sites with highly restrictive noise limitations. GEA has con- tinued fo evolve the basic technology of dry cooling, striving for maximum eff- ciency, aveilability ond economy of scale. GEA has, in its long history, de- finod the state ofthe ort in dry cooling. ‘The air cooled condenser The GEA air cooled con- denser is comprised of fin tube bundles grouped to- gether into modules and mounted in an A-frame configuration on a steel support structure, as shown ct right, Vertical and hori- zontal configurations ore also available, GEA employs a two stage, single pressure condensing processto achieve efficient cond reliable condensation. In this process, the steam is first ducted from the steam turbine to the air cooled condenser where it enters parallel flow fin tube bundles from the top. The steam is only portly con- dented in the parallel flow modules and the remaining steam is ducted in a lower header to counterflow fin tube bundles. The steam enters from the bottom ond rises in the fin tubes to point where condensation is completed. Non- condensibles are drawn off bore this point by ejection equipment. The condensate drains by gravity to a con- densote tank and is then sent back to the feedwater system to be recycledWINDWALL \ \— PARALLEL FLOW MODULE FORCED DRAFT FAN STEAM IN "\ in aewovat system 7 . EAS we ge single pres cooled condenser “CONDENSATE TANK ‘Mou Elec’: Moaloea Combined Cycle Pant uilises the vertical cneenser configuration (le) Cogen Technol Linn Cogeneration Fi employs an Acrome condense: igh)ign features that moa dteee GEA second genera fr tbe ‘it tigen lrger eros ‘ecionolarec provides perc. perfomance over the waar hbo aly ot oe teperatres There are two features which distinguish the GEA cir cooled condenser — 0 highiy efficient ond durable fin ube and the single pres- sure, two skage condensing process The GEA fin tube — designed to last Fin tubes comprise the heat transfer surface of an air cooled condenser, making them the most vital element of the entire condensing system, GEA recognized from the outset that avail able standard fin tubes were not suitable for vacuum steam condensing service ond that a custom fin tube design was re- quired. GEA found the so- lution in an elliptically shoped steel core tube onto which flanged rectangular steal fins incorporating in- tegralturbulctors are tightly filed. Voriabe in pitch is employed in each of mul- tiple fin tube rows. The os- sembly is then het dip gol- vanized. This combination of fectures which sets the stendard in cir cooled vacuum steam condensers ters the following odvan- tages: High fin efficiency Virtually the entire fia tube is active in efficient heat transfer. High heat tronsfer coefficient Due to the streamlined shape of the elliptical core tube, porasitic air side pros- sure losses ore low. Incor- porating turbulotors on the fins to induce air side tur- bulence significantly in- creases the overall heat transfer coefficient 1 Uniform condensing rates As the oir traverses across multiple fin tube rows, its temperature steadily in- creases, In order to main- tain uniform condensing rates in each tube row, the fin pitch is reduced in suc- ceeding rows. Durability In the galvanizing process, uniform thickness coating of zinc is applied over the entire exterior surface of the fin tube providing long term aaihodic prokacion agerat corrosion. The zinc alse fills the interspace between the fin flange and the core tube creating 0 soldered con- nection that is mechanically strong, as well as creating athigh conductivity connec tion between fin and tube. ‘1 Efficient steam side performance GEA’: elliptcally shoped core tube has a larger ross sectional area than most ‘other fin tubes. This larger ore minimizes sieam side pressure losses — on im portant factor in achieving efficient heat transfer. 1 Cleanabilty The rectangular fins are orranged into a fin tube bundle with no internal voids. This compact at- rangement reduces the ‘omount of debris allowed to lodge between the fin tubes, a problem with most conventional condensers.Go For maximum perfor- mance, air cooled condens ers require periodic cleon- ing of the fin tubes with high pressure water. GEA’s rugged all steel fin tubes withstand sproy pressures of up to 6000 psi, in con: trast to most other types of fin tubes that will deform ‘ond bend a high pressures. This ability to thoroughly clean the fin tubes ollows operators of GEA cir cooled condensers to main- tin their equipment at full capobility over the long haul The two row design GEAS current fin tube is a second generation design. GEA had previously em- ployedia smaller bein & eee toa icoatigurations However, as the size of EAS installations grew, the need for a larger tube Leoame apparent: The ar rent tube has over twice the internal cross section of the tube previously used. This lorger tube is configured in ato cow design which provides greoter heat rans: fer capobiliies ond greater freeze protection as dem: onstrated in numerous low ‘cnipetahire Sppleaionk Unsurpassed performance at very low temperatures Mini subcooling in the condens- ing process is a crucial re= quirement in order to aveidl ing condensate corrosion and the potential fer froeze damage the fin tubes. To satisfy this re- quirement, GEA developed and introduced the Iwo stage, single pressure con- densing process over 50 yeors ago and hes used it ever since, Thistime proven process maintains conden: sole in contact with steam ot all fimes precluding the formation of socalled dead zones where only conden: sote and non-condensibles are present. This process wai amily Weak proof condenser. GEA design also incorpo- roles other proven freeze protection features including: 1 Ellipticel tube Withstands multiple freeze thaw cycles. Air flow control with two speed fans or VFD's Permits adjustment of con- denser capacity. mWindwall Prevents winds from over- powering fans. Self draining design Prevents pockets of conden- sole from forming Al ofthese features in com- bination add up to a con- denser that will continue operating in the horshes of conditions for the life of the plont. GEA air cooled condensers ore sir eaze proof” thle to design innovesins hot make this technology perfect for cold weather projects such asthe 365 MW Wyedek Power lant in Gilet, Wyoming, where ferpperotures have reached weesThe GEA difference — GEA’s high standards of is commitment excellence extend beyond just building @ better cir cooled condenser. As im- portant os its technical ex- pertise and experience is GEA's commitment to its customers. In order to en- sure that all of its custom- A portoble semi-automatic fin tube cleaning syste keeps condensers operoing af peak perfermonce lee yeorreurd, ers’ needs are met, GEA holds Owner/Operotor conferences, These confer ences provide GEA's clients with o forum for the exchange of ideas and information on ‘operating experience. It also gives GEA the oppor tunity to make technical im provements that directly correspond fo customers! needs. One of these im provements was the recent development of the semi- automatic fin tube cleaning system, This portable sys tem provides an efficien method of cleaning the heat transfer surfaces ofthe con- denser, enabling peak per- formance of the equipment year round. GEA believes in lifetime customer satisfaction and stands behind every piece of equipment it supplies for the life of that equipment. This commitment to its cus- tomers is what hos made GEA the world leader in heat rejection technology for the las fifty yearsGEA Power Cooling Sys- fems is a member of the Germany based GEA Group, word leader in heat rejection technology whose commitment to qual- ity ond customer safsfac- tion has sot the indusiry standard for excellence. In cedditon to providing direct Ge dry cooling in the form of cir cooled condensers, GEA Power Cooling Sys: ide cooling towers, combine- tion systems forboth plume abatement and water sav- ing, the indirect dry Heller Systems ond thermal up- grodes tems is also oble to pr Background GEA insoled 0 wetersoving poralel condersing system a he Enetor Energy Resource Recovery Foclty in String, Connecticut A hos provided numerous i cooled corral tele evangy fociesinchting Hi ne atthe Spolane Resource Renny Fecily fo} Woshington.cA 7 610 West Ash Street 17th Floor San Diego, California 92101 Tel: (619) 232-7200 Fax: (619) 232-7177 www.geapcs.com