ACC

Air Cooled Condensers &

The PAC SYSTEM®

GEA Heat Exchangers / GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Chuck Lenzie 1200 MW Combined Cycle (Nevada, USA)

• Air Cooled Condensers: 2 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Linden 614 MW Combined Cycle Cogen (New Jersey, USA)

• Air Cooled Condensers: 3 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Dry Fork 425 MW Coal Fired Plant (Wyoming, USA)

• Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

El Dorado 480 MW Combined Cycle (Nevada, USA)

• Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Millmerran 2x420 MW Coal Fired (Queensland, Australia)

• Air Cooled Condensers: 2 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Riyadh PP9 1200 MW Combined Cycle (Saudi Arabia)

• Air Cooled Condensers: 4 Units

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Bajio 500 MW Combined Cycle (Mexico)

• Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

GEA Power Cooling – Large ACC Experience

Coryton 750 MW Combined Cycle (United Kingdom)

• Air Cooled Condenser: 1 Unit

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

• 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

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

WINDWALL

FIN TUBE BUNDLES

STEAM DISTRIBUTION HEADER

COUNTERFLOW MODULE

PARALLEL FLOW MODULE

AIR MOVING SYSTEM

AIR REMOVAL SYSTEM

STEAM IN CONDENSATE TANK

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

ATM

K K D K
Bundle Bundle Bundle Bundle

Turbine

EQ Line
ATM

Vacuum
System

Motive
I/A Condenser
Steam
Return
Line
Condensate
Drain Tank Pumps
Line

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

Basic Design Relationship

Q / ITD ∝ ACC Capacity

ITD = Tsat. – Tair in

• Steam Parameters
• mass flow
• backpressure
• enthalpy/quality
• Ambient Conditions
• inlet air temperature
• barometric pressure or elevation

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

ACC Cost Evaluations

• 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

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers - Components

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

GEA Heat Exchangers/ GEA Power Cooling, Inc.

 Air Cooled Condensers

Sample Performance Curve – Fans Full Speed

300

250
Dry & Saturated Steam Flow - T/hr

200
FULL LOAD

150

100

50

0
20 25 30 35 40 45 50

Inlet Dry Bulb Temperature - C

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

ACC Performance – 100% Load

Steam Turbine Backpressure, mbar(a)

300

250

200

150

100

50

0
0 5 10 15 20 25 30 35 40 45 50

Ambient Temperature, deg. C

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

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

GEA Heat Exchangers/ GEA Power Cooling, Inc.

Air Cooled Condensers

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 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.

PAC SYSTEM®

Classifications of Cooling Systems

Enhanced Dry Plume Abated

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

What is a PAC SYSTEM®

DRY COOLING SYSTEM WET COOLING SYSTEM

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

SSC & ACC are condensing steam in parallel

Steam turbine steam

ACC

Cooling tower

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Cooling System Performance Comparison

Typical STG Backpressure Profile
7
Steam Turbine Backpressure, "HgA

6 DRY

5
PAC

WET
3

1
-10 0 10 20 30 40 50 60 70 80 90 100
o
Dry Bulb Temperature, F

GEA Heat Exchangers/ GEA Power Cooling, Inc.

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

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Example (Comanche)
• Location: Pueblo, Colorado
• Owner: Xcel Energy
• Plant type: Coal – Fired
• Output: 750 Mwe
• Heat rejection system water limit: 4x106 m³/yr
• GEA Scope:
• ACC (material supply)
• MDCT (material supply & erection)
• SSC (material supply)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Example (Comanche)

9 cell cooling tower + 45 cell ACC

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Example (Comanche): reduced BP in summer with PAC

10
9
8
BP (inch HgA)

7 ACC ONLY
6
5
4
3
2 PAC Reduced turbine BP results
1 in increased plant output
0
60 65 70 75 80 85 90 95 100
DBT (deg F)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Example (Comanche): dry cooling duty as function of DBT:

60%

50%
Dry Cooling Duty

40%

30%

20%

10%

0%
15 ⁰C 20 ⁰C 25 ⁰C 30 ⁰C 35 ⁰C 40 ⁰C 45 ⁰C 50 ⁰C
Dry Bulb Temperature

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Exeter Energy 30 MW Waste-to-Energy (NE USA)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Streeter 40 MW Power Station (Midwest USA)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Tucuman 450 MW Combined Cycle (Argentina)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Goldendale 248 MW Combined Cycle (Washington, USA)

GEA Heat Exchangers/ GEA Power Cooling, Inc.

PAC SYSTEM®

Benefits

• Reduced Capital Cost vs. 100% Dry System

• Improved Performance vs. 100% Dry System

100 % Wet 100 % Dry

Lower Capital Greater Capital

Expense Expense

GEA Heat Exchangers/ GEA Power Cooling, Inc.

 &
Questions and Answers

GEA Power Cooling, Inc.

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

GEA Heat Exchangers/ GEA Power Cooling, Inc.