GEA Aircooled Systems

engineering for a better world

GEA Heat Exchangers

The HX-Factor, your additional value: combined expertise and excellence in heat transfer
Efficiency and sustainability are standards. But GEA Heat Exchangers (abbreviated HX, which stands for heat exchange) offer you more. Because we have the HX-Factor. At HX, we all have it. Every team. Every colleague. It can be found in all products and services. It makes the difference. It assures you of added value in heat exchange. By engineering services based on market experience and expertise. By a sensitivity that leads to the right decision, even in the most complex projects. By reliability in all situations. By the enjoyment of difficult challenges. By commitment, far-sightedness, and precision. All that is our HX-Factor. Experience it. Use it.

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GEA Aircooled Systems

The GEA parent company was founded by Mr. Otto Happel senior at Bochum, Germany. Initially the company specialised in the manufacture of dust removal systems. Its name: Gesellschaft fur Entstaubungs-Anlagen (company for dust-removal-plants), from which the abbreviation GEA was derived. Over the years the companys activities expanded into fields of thermal and energy technologies, food and process engineering, air-treatment, refrigeration and environmental technology. GEA developed and pioneered the direct air-cooled steam condensation system and became the world leader in this field, as well as in the design and manufacture of finned tube heat transfer equipment. To supplement and complete this specialised engineering and product range, an evaporative cooling tower division was established. In 1971, GEA founded its South African company, GEA Aircooled Systems. Initially, GEA Aircooled Systems functioned as an engineering and sales office for the groups products and services, which were essentially imported from the parent company. Large contracts for the power industry were awarded to GEA Aircooled Systems in the early 1970s, and further contracts for the petro-chemical industry, resulting in a rapid expansion of the South African operation. This necessitated the acquisition and subsequent extension of local manufacturing facilities. A total technology transfer from the parent company to GEA Aircooled Systems has been effected and successfully implemented, rendering GEA Aircooled Systems largely independent. GEA Aircooled Systems has become an integral part of GEA Heat Exchangers, with substantial thermodynamic and mechanical design expertise, as well as engineering, manufacturing and contract management capabilities. Nonetheless, GEA Aircooled Systems has access to all the resources and know-how of the GEA Group. GEA Aircooled Systems service department evolved into a separate company, GEA Nilenca, which specialises in refurbishment of heat transfer equipment, site erection work, cleaning of heat exchangers, etc.
GEA Group headquarters, Dsseldorf, Germany

GEA Aircooled Systems, Roodekop, South Africa

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Engineering and Quality

GEA Aircooled Systems is well acquainted and experienced in the design and manufacturing of the following codes and guidelines: The Quality Management System of GEA Aircooled Systems has been assessed and complies with the requirements of BS EN ISO-9001 for design, manufacturing, supply, delivery, erection and commissioning of heat exchanger plant and equipment. GEA Aircooled Systems relies on the most advanced computer equipment and software for: Thermal design Mechanical design Preparation of the general outline drawings / fan selection and noise level prediction Cost price estimation Computational Fluid Dynamics (CFD) modelling Finite Element Analysis (FEA) Vibration analysis for shell-and-tube heat exchangers The following thermal and mechanical engineering design software is available in-house and is constantly upgraded:

ASME VIII PD 5500 AD-2000 (AD Merkbltter) TEMA API 660 API 661

Thermal design software:

HTRI, Heat Transfer Research Inc. (USA), for the thermal design of all types of shell-andtube heat exchangers as well as air-cooled heat exchangers. GEAs in-house heat exchanger and cooling tower design software.

Mechanical design software:

OPTIVESSEL ASME VIII + PD5500 (SA) COMPRESS ASME VIII (USA) FINGLOW ASME VIII + PD5500 (UK) Our in-house drawing office facilities employ state-of-the-art computer technologies, using the latest AutoCAD and Autodesk Inventor draughting software.

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Research and Development

GEA is committed to ongoing research activities and programmes to provide its clients with state-of-the-art products. In a competitive market where emphasis is placed on environmental aspects and management of resources, continuous research is required to ensure technically and economically optimised engineering solutions. GEA has an in-house research and development department at its headquarters in Germany, dedicated to the technological development of heat exchanger products offered by the GEA group of companies. Research techniques applied by GEA include theoretical analysis, experimental investigations and Computational Fluid Dynamics (CFD). Model tests in wind tunnels and CFD modelling are used to determine the operating characteristics of cooling systems in the vicinity of buildings and structures, as well as the effect of wind on the cooling systems performance. Examples include thermal and fluid-dynamic analysis of column-top air-cooled condensers for petro-chemical plants, evaporative cooling systems and dry cooling systems for power stations. Investigations into the performance of axial flow fans and the air-flow distribution in cooling systems assist us in the accurate prediction of their performance. Where possible, full scale models are constructed. Fans of up to 10 m in diameter can be installed in a test rig to investigate the air-flow through the heat exchanger configuration. In South Africa, GEA co-operates with universities and engineering consultants to investigate and improve the performance of our product range. This enables us to offer customised cooling systems on request. Such investigations not only constitute advances for GEA but also assist our clients in gaining a better understanding of the products being procured.
Droplet impact on a T-shaped slat at 5 millisecond intervals

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BEE
GEA Aircooled Systems is a proud contributor to South Africas BBBEE (Broad Based Black Economic Empowerment) program. The current shareholders of GEA Aircooled Systems are GEA TE, Nozala Investments, Tanguliza Services, Komec Investments and an employee share scheme (ESOP). GEA Aircooled Systems currently qualifies as a DTI Level 3 contributor and has qualified as a BEE (Black Economic Empowerment) supplier in line with the requirements of ESKADAAT 6 Revision 4.

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In-house facilities
The GEA Aircooled Systems manufacturing operation is split into two distinct areas of manufacture. The Standard Products shop caters for the manufacture, repair and reconditioning of shell-and-tube heat exchangers as well as air-cooled heat exchangers, pressure vessels and distillation columns for the petro-chemical, mining and power industries. These products are manufactured in carbon steel, stainless steel and various exotic materials. A designated clean area for the manufacture of feedwater heaters using the latest technology for internal bore welding of tubes to tubesheets is in place.
Plate rolling machine

The second manufacturing area is used to manufacture specialised galvanised air-cooled condenser bundles for direct steam condensing systems for the local and export markets. Undercover manufacturing area 14863 m2 Total plot area 21518 m2 Maximum crane capacity 70 t Hydraulic plate rolls with capacities up to 110 mm thick x 3 000 mm wide CNC profile cutting up to 250 mm thick CNC plasma profile cutting up to 160 mm thick 2 x Quickmill CNC drilling machines 3 m x 6 m Kiheung CNC milling machine 1.5 m x 4 m Niles Vernon boring mill 2.8 m diameter 3 x McElroy finning machines for spirally wound and embedded finned tubing 6 x Edelhoff finning machines for hot dip galvanized finned tubing 2 x DEMAG overhead cranes Capacity: 35 t each, total 70 t 7 x DEMAG overhead cranes Capacity: 8 t to 12.5 t each 1 x overhead crane double hoist Capacity: 2 x 6.3 t (galvanising plant) 1 x DEMAG overhead crane Capacity: 25 t
Numerically controlled drilling

McElroy finning machine

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Products and services

GEA offers customised solutions quality products and services especially tailored to meet your specific needs in the following categories: Air-cooled heat exchangers for any application Finned tube heat exchangers such as oxygen coolers and compressor intercoolers A large variety of finned tubes Direct air-cooled condensers for steam turbines Indirect condensing systems for steam turbines Shell-and-tube heat exchangers including recuperators, waste-heat boilers, feedwater heaters and surface condensers Distillation columns Pressure vessels Cooling towers (mechanical and natural draft) Bulk air coolers Performance testing of heat exchangers and cooling towers In-house engineering and design including optimisation and lifecycle costing Site services, installation, commissioning and shut-down services Refurbishment of heat exchangers and cooling towers Our products are backed by the following commitment: High quality standards and products Design and engineering innovation On-time manufacturing Excellence in customer service Professionalism and ethical business practice Proficient management

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Finned tubes
GEA manufacture various types of aluminium, copper, stainless steel and galvanized carbon steel finned tubes, according to the customer specifications for working temperatures, ambient temperatures, corrosive atmospheres, etc.

Finned tubes

FINNED TUBE TYPES AND THEIR APPLICATION Bi-metallic extruded Maximum working temperature Maximum working temperature according to API 661 6th Edition 2006 Atmospheric corrosion resistance Mechanical resistance Fin material Embedded G Wrap-on L Wrap-on double L Hot-dip galvanised

350C

400C

130C

130C

400C

300C Excellent Excellent Aluminium

400C Poor Poor Aluminium / Copper / Stainless steel Any readily machinable material

130C Acceptable Acceptable Copper / Aluminium Any metallic material

130C Medium Medium Copper / Aluminium Any metallic material

360C Excellent Excellent Steel

Tube material

Any metallic material

Steel

Image

Application

High efficiency fin with complete protection of base tube against corrosion

High efficiency fin for high temperature application

Standard fin for low temperature with some corrosion protection of base tube

As for L fin with better corrosion protection for base tube

Excellent thermal performance with complete corrosion resistance

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Air-cooled heat exchangers

GEA offers a range of different air-cooled heat exchanger configurations in order to meet the specific requirements of both the process and the site location. Whatever the configuration, one of the most important design criteria is to ensure that air is allowed to freely enter and leave the system, ensuring maximised heat transfer.

Induced draft air-cooled heat exchanger

Forced draft layout

Better access for maintenance to fans and fan drive systems. Fans operate in a cold ambient air stream.

Induced draft layout

Protection of finned surface against wind, hail, snow and rain. Fan/ plenum chamber configuration ensures better air distribution and less hot air recirculation.

Plug type header box

D-type header

Plug type header

Removable cover plate header

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Fan blades are generally made of either aluminium or Glass Reinforced Plastic (GRP). Fan drive systems include conventional v-belts, integral v-belts, toothed High Torque Drive (HTD) belts and gear drives linked to electric motors. Air-flow control can be realised using variable pitch fans, variable louvres or Variable Speed Electric Drives (VSD).

Pressure distribution on the blades of a fan in an air-cooled heat exchanger

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Shell-and-tube heat exchangers

As technologies of the various process industries advance, they tend to use larger, more sophisticated heat exchangers with improved performance. The combination of technical advances in the fields of welding, heat treatment, and non-destructive testing with highly flexible manufacturing capabilities allows GEA to fully meet clients requirements, at the same time offering optimised solutions.

Shell-and-tube heat exchangers

GEA has the in-house capability to design and manufacture shell-and-tube heat exchangers for the petrochemical, mining and power generation industries.
Large shell-and-tube heat exchanger with removable bundle

HP and LP feedwater heaters

GEA Aircooled Systems has collaboration agreements with TEI (USA) and EON (Germany) for the design and manufacture of feedwater heaters. Tubesheet type feedwater heaters are offered. Tube to tubesheet attachments could be by conventional welding, internal bore welding, explosion welding, etc.

Surface condensers
A surface condenser is the commonly used term for a water-cooled shell- and-tube heat exchanger, installed on the exhaust steam side of a steam turbine. GEA supplies surface condensers for vacuum condensing applications.

HP heater

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SHELL-AND-TUBE HEAT EXCHANGER TYPES

Front end Stationary Head Types
A
Channel and removable cover

Shell types

Rear end head types

L
Fixed tubesheet like A stationary head

E
One pass shell

F
Two pass shell with longitudinal baffle

M
Fixed tubesheet like B stationary head

B
Bonnet integral covers

G
Split flow

N
Fixed tubesheet like N stationary head

P C
Channel integral with tubesheet and removable cover (removable tube cover only)

H
Double split flow

Outside packed floating head

Surface condenser for vacuum steam condensation

S J
Divided flow Floating head with backing device

N
Channel integral with tubesheet and removable cover

T K
Kettle type reboiler Pull through floating head

U
U-tube bundle

D
Special high pressure closure

X
Cross flow

W
Externally sealed floating tubesheet

Waste heat boiler for a petrochemical plant

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Air cooled condensers (ACC)

The GEA air-cooled condenser consists of finned tube bundles grouped together into fan modules and mounted in an A-frame configuration on a concrete or steel support structure. Fans mounted below the A-frames draw in air from below and force it through the finned tube bundles.
Matimba ACC during construction

The steam side of an air cooled condenser operates as follows: steam from the steam turbine enters the finned tube bundles from the top of the A-frames. The largest fraction of the steam is condensed in the parallel flow modules (condenser) and the remaining steam is ducted to the lower headers of the counterflow finned tube bundles (dephlegmator).

The steam enters the counterflow finned tube bundles from below and rises in the finned tubes to a point where the condensation is complete. Non-condensable gasses are drawn off above this point by vacuum equipment. The condensate drains to a condensate tank by gravity and is then piped back to the feedwater system.
Elgen power station at BHP Billitons Samancor plant

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Windwall

Majuba ACC

Counterflow module

Parallel flow module Forced draft fan Steam in Air removal system Condensate tank
Medupi ACC during construction (Feb 2012) with Matimba Power Station in the background

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Other heat exchangers & pressure vessels

Plate and frame heat exchangers
GEA offers its clients the following diverse range of plate heat exchanger systems:

Gasketed plate heat exchangers: A whole range of different plate types are used for cooling and heating liquids and for condensing vapours. Special designs are also available for evaporators and for liquids containing a high proportion of undissolved solid matter.

Brazed plate heat exchangers: These compact units consist of profiled stainless steel plates, which are brazed together in a high vacuum furnace. Used in high pressure and/or high
Plate and frame heat exchangers

temperature applications, or where gaskets are prone to chemical attack.

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Plate and shell heat exchangers

GEA also offer plate and shell heat exchangers. These heat exchangers employ a welded plate pack inside a shell. This type of design offers the high heat transfer rate of plate and frame heat exchangers without the pressure limitations of the plate and frame heat exchanger designs.

Inter/After coolers
All types of finned tubes for compressor inter- and after-coolers are produced at GEA Aircooled Systems factory in Roodekop, Germiston.
Plate and shell heat exchanger

The inter- / after-coolers are typically manufactured using Cu-Ni tubes with Cu fins and Cu-Ni tubesheets because of the water vapour condensing on the air side of these devices.

Oxygen coolers
GEA Aircooled Systems has been granted a provisional patent for the manufacturing process of copper finned tubes suitable for 100% oxygen duty.

Pressure vessels and columns

GEA has the in-house capabilities to design and manufacture pressure vessels as well as distillation columns. The petrochemical industry is a major client for this type of equipment.
Oxygen cooler

Typical column in the workshop

Operating principle

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Cooling towers and BACs

Cooling systems utilising water evaporation are usually the most cost effective heat rejection systems. In a cooling tower, hot water from a plant is brought into contact with ambient air. Energy is transferred from the water to the air by evaporation (mass transfer) and convection (heat transfer). The cooled water is then returned to the plant. Evaporative cooling systems can achieve lower re-cooled water temperatures than dry cooling systems.
On-line refurbishment of natural draught cooling tower

Evaporation rates are approximately 1.5 to 2 m3/hr per MW of heat rejection or 1% to 2% of the circulating water flow rate. In a natural draught cooling tower, the natural buoyancy of the hot air moves the air upwards through the tower, drawing in fresh cool air through the air inlet at ground level. Therefore no fan is required. The tower shell is usually constructed in reinforced concrete and can be as high as 200 m. Mechanical draught cooling towers on the other hand, make use of fans to generate the air flow through the tower. Depending on the cooling load, multiple cells, each with its own fan, can be employed. Fan diameters of up to 10 m and more are commonly used. The relative flow direction of the water and the air streams can be arranged in either cross or counterflow.

Belle Vue Power Station mechanical draught cooling towers

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Bulk Air Coolers (BACs) are often employed to provide large quantities of cold air in mines. A BAC is functionally an inverted cooling tower, in which cold water from a refrigeration unit is used to cool the incoming air and to provide a stream of cold air into the mine.

Typical bulk air cooler

MAXIMUM COOLING WATER TSS (Total Suspended Solids) Cross fluted film fill Max TSS (continuous), ppm Max TSS (short term, <10 hrs), ppm 70 100 Vertical fluted film fill 120 200 Trickle type fill 300 500

Splash fill No limitation No limitation

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Excellence

Passion

Integrity

Responsibility

GEA-versity

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.

GEA Heat Exchangers

GEA Aircooled Systems (Pty) Ltd
Aberdein St, Roodekop, Germiston, South Africa Phone: +27 (0)11 861 1500, Fax: +27 (0)11 865 2200 gas@gea.com, www.gea.co.za

GEA Nilenca (Pty) Ltd

Aberdein St, Roodekop, Germiston, South Africa Phone: +27 (0)11 866 4000, Fax: +27 (0)11 866 4040 gnl@gea.com, www.geanilenca.co.za

GEA Heat Exchangers. All rights reserved.