Air Cooled Condensers – Innovative Wind Mitigation

1 2009 SPX COOLING TECHNOLOGIES, INFRASTRUCTURE X PROCESS EQUIPMENT XDIAGNOSTIC TOOLSF ebruary 1, 20111 Air Cooled Condensers Innovative wind MitigationSPX Cooling Technologies, Inc. - Dry Cooling 2009 SPX COOLING TECHNOLOGIES, 1, 20112 Agenda Air Cooled Condensers Innovative wind Mitigation Introduction .. 3 Air Cooled Condensing Process .. 7 General Considerations .. 10 wind Mitigation Options .. 19 SPX wind Mitigation Innovation .. 23 Conclusions ..27 2009 SPX COOLING TECHNOLOGIES, 1, 20113 Introduction SPX is a leader in Dry Cooling, with over 350 Air Cooled Condensers (ACCs) installed worldwide over the past 30+ years. The typical ACC is the forced draft A-Frame configuration. ACCs serve power plants of various sizes and types, from 20 MWBiomass Plants to > 600MW Coal Plants ACCs range in size from two(2) modules to over one-hundred(100)modules 2009 SPX COOLING TECHNOLOGIES, 1, 20114 Introduction Small three (3) module ACC 2009 SPX COOLING TECHNOLOGIES, 1, 20115 Introduction Medium thirty-five (35) module ACC 2009 SPX COOLING TECHNOLOGIES, 1, 20116 Introduction THE FOCUS OF THIS PRESENTATION IS TO.

2 Illustrate the operational challenges that wind poses to ACCs and Power Plant operations Recognize previous efforts to illustrate the effects of wind Quantify the effects of wind on ACC performance Review existing solutions to mitigate the effects of wind on ACC performance Promote new, Innovative solutions to mitigate the effects of wind on ACC performance 2009 SPX COOLING TECHNOLOGIES, 1, 20117 Condensing Process ACC Module 2009 SPX COOLING TECHNOLOGIES, 1, 20118 Condensing Process Two Stage Condensing Process- Mitigate Sub-Cooling- Effective Extraction of Non-CondensiblesPrimary Heat ExchangerSecondary Heat ExchangerSteam & Non Condensable FlowAir Takeoffto Vacuum System 2009 SPX COOLING TECHNOLOGIES, 1, 20119 Condensing Process BASIC THERMODYNAMIC PRINCIPLESQ condensation= Q airm (h turbine exhaust hf) U A (T sat. steam T air)Therefore .. If T air.

3 Then Tsat. steam (Backpressure )If U (Overall HTC) .. then Tsat. steam (Backpressure ) If Backpressure .. MWe , $ Revenue (Herein the Rub ) 2009 SPX COOLING TECHNOLOGIES, 1, 201110 General Considerations ACC PERFORMANCE DERATE Given the preceding equation, for a given ACC with a constantsteam flow condition, ambient air temperature and fan state, theleading factors that could contribute to an instantaneous backpressure increase are: Instantaneous Change in Cooling Air Temperature Instantaneous Change in Heat Transfer Coefficient 2009 SPX COOLING TECHNOLOGIES, 1, 201111 General Considerations ACC PERFORMANCE DERATE Instantaneous Change in Cooling Air Temperature An instantaneous change in inlet air temperature is generallycaused by hot air recirculation. A typical ACC, with perimeter siding (discharge), for the mostpart, hot air recirculation is predominantly mitigated.

4 ACCs without perimeter siding (few and far between) areprone to recirculation related performance issues. ACCs with unique site arrangement may also be at risk torecirculation. Generally speaking, however, recirculation is not the drivingACC performance issue. 2009 SPX COOLING TECHNOLOGIES, 1, 201112 General Considerations ACC PERFORMANCE DERATE Instantaneous Change in Heat Transfer Coefficient (U) An instantaneous change in heat transfer coefficient is almostexclusively caused by wind effect on fan (airflow) performance ACC fans are typically operate at a High Volume / LowStatic Pressure working point Seemingly small increases in static pressure lead to notabledecreases in volumetric cooling air flow Notable decrease in ACC air flow leads to reduced U resultinginanincreaseinSTBackpressureand adecreaseinST Generator MWeoutput 2009 SPX COOLING TECHNOLOGIES, 1, 201113 General Considerations ACC PERFORMANCE TEST CODES As wind effects have been recognized by Owners, Operators,EPCs, Academicians, Testing Companies and OEMs, ACCperformance test codes have followed suit with their wind speeddesign standard: VDEW WD-0285-1965 Max.

5 Velocity m/s VGB-R 131 M e -1997 Ave. Velocity m/s Max. Velocity m/s ASME PTC Ave. Velocity m/sMax. Velocity m/s CTI ATC107 Pending Ave. Velocity m/sMax. Velocity m/s 2009 SPX COOLING TECHNOLOGIES, 1, 201114 General Considerations MARKET DEMAND Mitigate the recognized effects of wind on ACC performance Reasonable initial cost / High lifetime operational value Easily integrated into new ACCs Capability to retrofit of existing ACCs No wind direction dependency Reduced ACC fan power electrical consumption Improved ACC Performance / ST Backpressure More consistent backpressure / power generation 2009 SPX COOLING TECHNOLOGIES, 1, 201115 General Considerations TECHNICAL PAPERS & PRESENTATIONS Investigations of wind effects have beencommissioned byOwners, Academicians and Technical Organizations depictingspecific wind induced issues with individual ACCs.

6 Adrian Melhuish BSc & Simon Melhuish - Installation ofGalebreaker Windshield at Kings Lynn Power Station, 2006 Chuck McGowin & Kent Zammit EPRI, John Maulbetsch(Maulbetsch Consulting) - Field Testing of wind EffectsPresentation, EPRI, June 2008 van Rooyen, Universityof Stellenbosch - PerformanceTrends of an Air- Cooled Steam Condenser Under WindyConditions, J. Eng. Gas Turbines Power - March 2008 2009 SPX COOLING TECHNOLOGIES, 1, 201116 General Considerations TECHNICAL PAPERS & PRESENTATIONS These various investigations, as well as SPX s own experience inrecent years, yields the following general indications: Foranincreaseinwindfrom3m/sto4m/s,anincr easeinsteam turbine backpressure of Hg to Hg can beexpected Foranincreaseinwindfrom3m/sto9m/s,anincr easeinsteam turbine backpressure of Hg to Hg can beexpected Very Important.

7 wind effect on ACC performance is uniqueto each and every ACC, due to site arrangement, ACCarrangement, thermal design conditions, equipment selectionand other factors. 2009 SPX COOLING TECHNOLOGIES, 1, 201117 General Considerations ACC LIMITING STEAM TURBINE GENERATOR OUTPUT Mainly, curtailment of capacity due to increased backpressure isonly a concern when the ambient temperature and wind speed areat increased levels All ACC fans already at full speed No Reserve Capacity Incremental increase in backpressure causes a notabledecrease in STG MWeoutput or .. ST Alarm/Trip! At reduced air temperatures, all ACC fans may not be at full speedand/or backpressure is reduced. Backpressure excursions due to wind are typically automaticallyhandled by the inconspicuous increase of the ACC fan(s). 2009 SPX COOLING TECHNOLOGIES, 1, 201118 General ConsiderationsST Exhaust Pressure vs.

8 Generationfor a nom inal 260 MW ST Back pre s sure , in. HgAST Genererator Output, MW-25-20-15-10-505 Change In ST Generator Output, MWACC Design Point ACC LIMITING STEAM TURBINE GENERATOR OUTPUT Hg Backpressure ~ 5 MWe 2009 SPX COOLING TECHNOLOGIES, 1, 201119 wind Mitigation Options HORIZONTAL EXTENSIONS Improves flow attachment at perimeter fans Effective w/ >10 m extensions Becomes less effective as wind speed increases 2009 SPX COOLING TECHNOLOGIES, 1, 201120 VERTICAL PERIMETER SIDING EXTENSIONS Little effect with 5 m extension Negligible effect on fan inlet conditionsWind Mitigation Options 2009 SPX COOLING TECHNOLOGIES, 1, 201121 PERFORATED WALL Increased ACC height and/or fan power Negligible effect on fan inlet conditions wind direction dependentWind Mitigation Options 2009 SPX COOLING TECHNOLOGIES, 1, 201122 MIXER PLATES / BAFFLES Inlet Air Flow Stabilization wind direction dependentWind Mitigation Options 2009 SPX COOLING TECHNOLOGIES, 1, 201123 SPX s Innovative wind Mitigation Developed over the past years, coupling intuitive design process and detailed CFD modelling CFD models demonstrate improved/increased airflow at design wind conditions, without increase in fan power CFD models demonstrates significantly reduced airflow degradation at wind speeds up to 9 m/s (20 mph)

9 Details regarding the physical attributes remain confidential until further physical testing is complete as to validate CFD predictions Validation testing currently in progressInnovative Solution 2009 SPX COOLING TECHNOLOGIES, 1, 201124 Innovative Solution CFD RESULTS Mitigation Features Improve Airflow at 3 m/s to 0 m/s wind 2% to 7% Increase in Airflow to Hg Backpressure Decrease 1 to 3 MWe STG Improvement $ Generation IncreaseWith wind MitigationWithout wind Mitigation 2009 SPX COOLING TECHNOLOGIES, 1, 201125 Innovative Solution CFD SIMULATION RESULTS Without wind Mitigation Features / 9m/s Quartering wind 15% to 20% Reduction in Airflow to Hg Backpressure Increase 5 to 7 MWe STG Reduction $ Notable Generation Loss 2009 SPX COOLING TECHNOLOGIES, 1, 201126 Innovative Solution CFD SIMULATION RESULTS WithSPX s wind Mitigation Features / 9m/s Quartering wind Only a 4% to 9% Reduction in Airflow to Hg Backpressure Increase 2 to 4 MWe STG Reduction $ Reduced Generation Loss 2009 SPX COOLING TECHNOLOGIES, 1, 201127 Conclusions The mal-effect of wind on ACC performance has been recognized forsome time.

10 ACC Performance Test Codes have evolved to account for increasedwind speeds, however, they still need account for wind conditions thatare reasonable to provide for a mutually acceptable, verifiable ACCperformance level. Over the years, various solutions have been studied and orimplemented by various parties with varying degrees of success. All ACCs and sites are different. Thorough CFD analysis for eachunique is required to provide for the optimal wind Mitigation result. By coupling its ACC experience and R&D expertise and resources,SPX strives to respond to the market s expressed needs and toprovide defined solutions to improve ACC performance under windconditions. 2009 SPX COOLING TECHNOLOGIES, 1, 201128 ConclusionsThank you for your attention and participation.