AIR-COOLED CONDENSERS

Chemistry, corrosion,
performance, O&M
dominate annual
user-group program
By Steven C Stultz, Consulting Editor

T
he eighth annual meeting know that both the depth and breadth chemistry and ACC internal corrosion.
of the Air Cooled Condenser of ACC experience are expanding This launched the first tutorial.
(ACC) Users Group, held Oct quickly. We will stay at the forefront Meeting participants listened care-
3-6, 2016 in Dallas, offered and provide both education and dis- fully as Dooley, a member of the ACC
a tailored agenda based on previous cussion for both repeat and first-time Users Group steering committee and
participant feedback. The content participants.” executive secretary for the Interna-
recognized the seasoned combined- One point stressed repeatedly was tional Association for the Properties
cycle professional, but also addressed based on a good understanding of the of Water and Steam (IAPWS), traced
those perhaps newer to the industry fundamentals, but equally (if not more) operating experience and research
attending to absorb fundamentals importantly on in-depth awareness history through specific sites in South
along with up-to-date experiences and of ongoing and expanding operating Africa, the US, and Australia.
achievements. experience. That point: Chemistry South Africa is where researchers
Day One in Dallas began with three of the ACC controls chemistry of the began to quantify chemistry impact on
tutorials capturing the essence of the generating unit. specific areas (tube entry, for example).
overall program: This helped identify specific issues
n Chemistry and corrosion.
n Design and performance. Day One beyond just knowing that this was a
two-phase environment. Cross-mem-
n Operation and maintenance. bers were reviewed which increased
Interestingly, many of the funda-
mentals attracted insightful comments
Chemistry, corrosion understanding (liquid-droplet con-
tingent).
and discussion threads by even the Dr Barry Dooley was first at the As the amount of data collected
most seasoned veterans. podium. Recognized internationally for increased, a plant in Queensland
“We make every effort, each year, to his expertise and commitment to cycle showed that “some OEMs do not com-
adjust to the industry [and its people],” chemistry, with a particular emphasis municate on cycle chemistry needs.
said ACC Steering Committee Chair- on flow-accelerated corrosion (FAC), Within short operation at this plant,
man Dr Andrew Howell, senior sys- the senior associate at Structural high levels of damage began to appear.
tems chemist, Xcel Energy. “We know Integrity Associates Inc, presented a We learned specifically that pH levels
the industry is in transition, and we comprehensive review of steam-cycle impact iron throughout the cycle,”
Dooley said.
1. Dooley/Asp- Dooley’s experience gave full cre-
140 den relationship, dence to meaningful summary state-
important to ACC ments, such as these:
120 operation, graphs the n ACC chemistry and corrosion issues
relationship between are the same worldwide, regard-
100 pH and total iron. less of unit manufacture, size. and
Note that ammonia chemistry.
Iron, ppb

80 Curve based on the solubility was used exclusively n Focused research began about 2007,
of magnetite at 120F for pH control in this but uncertainty was high and we
60 case; iron levels were knew it.
measured at the con- n We know now that compound turbu-
40 densate-pump dis- lence is the main concern for ACC
charge. Data for iron tube entry areas.
20 solubility are attrib- For tube entry inspection, color
uted to Piero Sturla is important and can be confusing,
0 of ENEL’s Piacenza but clearly indicates the two-phase
8.8 9.0 9.2 9.4 9.6 9.8 10.0 Laboratory (1973) activity.
pH n Internal inspection is critical
56 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016
 AIR-COOLED CONDENSERS

Water/steam flow
flow, but will also increase fan shaft
power, decrease pressure margin, and
Turbulence increase stall risk. “It will reduce fan
created by efficiency, increase noise, and influ-
geometry ence mechanical dynamics that should
be discussed with the fan manufac-
turer,” he noted.
Speed was then discussed through
fan scaling laws (scaling of air volume
flow rate) and the effect on shaft power.
Protective An interesting summary point: stalling
porous
magnetite issues cannot be solved by reducing
fan speed.
Then came the practical versus
the theoretical: Some common operat-
ing variables are fouling, air stream
Carbon obstacles, and wind. The effect of wind
steel
received the most attention.
As would be covered further dur-
2. Two-phase FAC (steam and water) is a consequence of a flow-accelerated ing the meeting, the primary effects
increase in mass transfer of dissolving and reacting species at a high-flow or of wind are the following:
highly turbulent location n Additional pressure loss.
• Increased resistance.
because tubes rarely are removed tom line: Damage takes time (months n Non-uniform inlet conditions.
for laboratory inspection. or years) to repair. The best operating • Loss in fan performance.
The ACC “controls” unit cycle target is less than 5 ppb iron and pH • Increased loading on fan blades.
chemistry, the speaker continued. A great than 9.8. n Recirculation (hot exhaust back into
decade ago, international guidance He followed with an update (status) fan inlet).
was not available on this. Work since on film-forming products, and some • Reduced thermal performance.
undertaken by IAPWS, in particular initial trials to use these products to Illustrations showed the impact of
its publication of technical guidance repair FAC damage. This is a long- various wind speeds. Non-uniformity
documents, has provided plants much term topic from last year’s meeting, was shown through air velocity mea-
needed advice (sidebar, p 65). and will be ongoing. One specific surements at various points within
Dooley next explained the develop- technology was presented during the the ACC. Use of windscreens was then
ment of the Dooley/Aspden relation- meeting and is reported below in the discussed, concluding that they have
ship for pH control of the ACC. In section on film-forming agents. a positive effect on the expected life
summary, they found that total iron “We are still looking for answers,” of the fan but noting that windscreen
versus pH was consistent worldwide said Dooley. “The only source of com- studies are ongoing. For a detailed
(Fig 1). plete knowledge is experience.” Spe- discussion on ACC windscreens, see
Further characterization became cific international guidelines were then “Windscreens improve performance,
available with the Dooley Howell ACC discussed for ACCs and two-phase flow reduce O&M cost of ACCs,” CCJ
Corrosion Index (DHACI), allowing with reference to the IAPWS technical 2Q/2016, p 60.
standardized investigation and track- guidance documents. Participant questions and discus-
ing for both tube inlets and lower ducts sions followed, focusing on dynamic
(details in CCJ 1Q/2015, p 110). More Air flow management blade loading.
specifically, the index evaluates and
describes concerns in both the upper Sander Venema, Howden Netherlands, Performance
and lower sections of the condenser. It followed Dooley with a presentation
is now is used globally to identify and on air flow management. It reviewed enhancements
monitor ACC condition, and allows for fundamental definitions and fan laws: The morning sessions ended with a
comparisons worldwide. system resistance (pressure drop); fan performance-improvement review by
The essence of damage, according performance definitions (aerodynamic Chairman Howell.
to Dooley, is the dissolution rate and power, air volume rate, fan pressure “Basically,” he said, “ACC perfor-
impact on the directly related inner rise); and both total and static effi- mance is limited by ambient tempera-
ferrous hydroxide (Fig 2). “But did ciency. ture and tube fouling, parasitic load
we understand the environment, the Fan performance details covered demand, and potentially by non-opti-
mechanisms, and the proper preven- system and fan curves, operating mal ACC design.” The outcome of these
tion?” The answer: No, and still not yet. points, stability, and stall points. For limitations, the chemist continued, is
Studies continue as various solutions a refresher, access Venema’s slides increased cost of generating electric-
are applied. at www.acc-usersgroup.org (click the ity, largely attributed to increased fuel
As Dooley explained, “the key is “Presentations” button). Application use. “Highly significant,” said Howell,
understanding phase-transition-zone basics included fan diameter, type, “is high ambient temperature, which
environments. The low-pressure tur- number of blades, pitch angle, and can reduce power generation by 10%
bine environment is thoroughly char- operating speed. “The most easily to 15%.”
acterized, and this is the starting point adjusted parameters,” said Venema, ACC design factors therefore
for the ACC environment.” “are pitch angle and speed.” include ambient conditions (wind
The solution, says Dooley, is depen- Pitch angle was covered in detail, and temperature), anticipated load
dent on removing the saturation of comparing static pressure to flow and demand (both internal and external),
iron oxide Fe3O4 at the surface and stall. One summary: increasing the the steam distribution system, tube
precipitating it adjacently. The bot- blade angle will increase air volume design including number of rows, and
COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016 59
 604.607.7781
1.800.749.2201

WeatherSolve Structures is a specialist

designer / manufacturer of suspended
fabric structures. What does this mean?
Ÿ 100% custom product
Ÿ Large array of wind and dust fencing
Ÿ Cladding options
Ÿ 35+ years of experience
Ÿ Aerodynamically engineered and tested
Ÿ Heights over 30m Top: Wind deflection screen
Bottom: Wind and dust control fence
Ÿ Many km long showing integration of a doorway and conveyor

Ÿ Pole spacings 30m apart

Ÿ Special cladding systems
Ÿ Work around conveyors or moving parts
Ÿ Doorways and gates

www.weathersolve.com
Productive Environments for All Weathers

Turbine Air-cooled condenser

Wet cooling tower Mechanical-draft

Air-cooled wet tower
To boiler condenser

3. Hybrid cooling (wet and dry) is illustrated conceptu-

ally at the left, in service at right

the fans. Performance can be optimized Howell then explained the system there is no water source to even con-
by numerous design, operation, and in detail, including the complete steam sider hybrid cooling, another option
upgrade options. cycle and condensate/cooling system. is to increase air flow through the fan
Standard operational improve- The example given uses a two-cell wet system.
ments include external tube cleaning, system to supplement the ACC at a In this example, motors were
air flow management (previous sec- combined-cycle plant in Mexico. increased from 100 to 200 hp which
tion), spray enhancement (fogging), A second retrofit example described also meant replacing electrical switch-
and air in-leakage control. All topics adding a third street of cells to an exist- gear, cabling, motors, gearboxes and
were covered further at the meeting. ing ACC at a nominal 80-MW coal-fired fans, while completing detailed struc-
Some retrofits can be complex. In facility in Wyoming. After this third tural analyses for load-bearing and
one example, Howell offered a good street with five larger fans was added, resonance issues. For this 100-MW
economic option for large plants in at 97F ambient, the plant measured plant, 15 new motors, gearboxes and
hot weather, especially those with 7 MW of additional output. However, fans were selected, leading to these
high power replacement costs and power production decreased in cold results:
adequate water supply. Although not weather (less than 32F) due in part n Improved ACC performance under
generally used during cooler ambient to more conservative unit operation. adverse ambient conditions.
temperatures, hybrid cooling (Fig 3) Howell then addressed fan and n No additional water required.
is achieved by adding a parallel wet motor upgrades, which would also n Increasing the number of blades to
cooling system to the ACC. be highlighted during the meeting. If nine from four minimized vibration
60 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016
 AIR-COOLED CONDENSERS
and resonance issues. 9. Action items with dates. n Sealing media falling out of posi-
n Air flow increased from 542 m3/s to 10.Individual division of responsibili- tion between tube bundles and cell
730, static pressure from 71 Pa to ties. walls.
125. Specific to ACCs, Rettke offered n Door hinges failing.
n Parasitic load increased from 1.12 examples from Higgins. Some of the n Lights not working.
to 2.24 MW because of the larger CBM discoveries were: n Structure bolting missing or loose.
fan drive system. n Safer gear-reducer change-out n Decking and grating not properly
Significant performance results using a fixture that bolts directly fastened.
included: to the reducer. n Various weld repair requirements.
n Removal of backpressure limitation n A way to remotely monitor gear n Repair needs for expansion joints
(sustained improvement at 3.5 in. reducer and motor vibration and from steam turbine to ACC.
Hg abs). oil pressure. He then declared, “An ACC is a
n Increase in power output (could n A fixture to secure the hub with live structure. It moves. Things come
increase condenser load; steam flow blades attached during gear-reduc- undone.” This statement reinforced the
through the turbine). er change-outs. value of consistent and comprehensive
n Improvement in heat rate (lower Some direct benefits of CBM at observation.
condenser pressure/backpressure Higgins include: Rettke followed with a review of
on the steamer—so-called “free n All oil changes are determined by specific procedures and tools developed
power”). oil sampling, prior to filtering. at Higgins, ending with a review of
Howell then highlighted the pre- n Oil changes are based on sampling, root cause analysis. He is both RCA
sentation conclusions: not hours. administrator and RCA participant,
1. ACC performance is critical to low- n Gear-reducer lube is filtered bian- and noted “Sometimes you need to do
cost unit operation. nually. an RCA on the RCA.” He then added:
2. Initial ACC design is critical to n Blade angle and condition are “Please remember that RCAs also have
achieving suitable unit-specific checked annually and precisely value when you do something right!”
baseline performance. recorded. Rettke clearly captured the post-
3. Careful and consistent operating n Weekly walkdowns are performed lunch participants—a difficult assign-
practices can optimize unit perfor- for the entire ACC system by ment. Lengthy discussion followed on
mance. mechanical staff and include equip- inspection and maintenance methods,
4. Retrofit options can improve perfor- ment and structure inspections. experiences, and specific safety issues
mance and reduce plant operating Rettke stressed that these walk- and techniques.
costs. downs (144 steps up and 144 steps
Ensuing discussions covered ACC down) – “have caught many significant Tube-bundle cleaning
permitting, design temperature selec- issues over time.” He followed with
tion, wind speed as a factor in thermal specific examples, including: The term tube-bundle “fouling” had
design, and a conclusion that retro- n Loose turnbuckles. been used earlier in the day, and Huub
fit projects tend to offer immediate Hubregtse, ACC Team Technology,
results. offered specific examples and clean-
ing methods.
Gearbox maintenance “Fouling,” he explained, “consists of
fibers, dust, pollen, and other materi-
David Rettke, maintenance specialist, als on ACC bundles restricting air flow,
NV Energy, expanded his assigned reducing heat transfer, and increasing
topic of gearbox maintenance to backpressure at the turbine exhaust.”
include, and stress, condition-based Such fouling normally has a fairly
maintenance (CBM). His talk was weak bond (Fig 4) and often can be
filled with examples of how CBM, removed by spraying high-pressure
if applied correctly, also allows fine 4. Fouling (fibers, dust, pollen, etc) of water.
tuning for long-term plans, improv- ACC bundles restricts air flow, limits Scaling is more difficult. A layer
ing long-term performance and value. heat transfer. Deposits shown have a can be deposited on the fins by fumes,
Rettke highlighted, and exemplified, fairly weak bond, but 50% closure of spraying water with high dissolved
continuous active involvement in plant heat-transfer surface solids on the bundles, or gearbox oil
operations and maintenance. leakage. This layer cannot be removed
At the Walter M Higgins Gener- by water spray alone (Fig 5).
ating Station, Rettke is intimately Some types of scale foulants have a
involved in ACC maintenance. He strong bond from limestone deposits,
champions the plant’s programs for oil contamination, or chemical fumes
continuous performance improvement, mixed with the cooling air. This must
root cause analysis (RCA), vibration be dissolved in water or with chemi-
monitoring, and CBM. cals.
The effective CBM meeting, he After the use of chemicals, solvents
noted, should have a 10-item agenda: and/or blasting with sodium bicar-
1. Maintenance history. bonate, the residual deposit must be
2. Operator interviews and surveys. removed by high-pressure cleaning. If
3. Safety issues. 5. Some types of fouling have a strong residue remains, it can become baked
4. Operational issues. bond to the fin. Such deposits may onto the finned tubes, forming a hard
5. Maintenance issues. require pretreatment with solvents or layer.
6. Predictive tools data and results. chemicals, and/or blasting with sodium Cleaning is normally required when
7. Root cause analysis results. bicarbonate, to achieve desired results the internal static pressure rises to a
8. Possible continuous improvements. with high-pressure cleaning certain level because of restrictions in
COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016 61
 CCGT / HRSG Chemistry Experts

+ Cycle Chemistry Audits

+ New Project Specifications
+ FAC Management
+ Chemistry Investigations
+ Cycle Chemistry Training
6. Cleaning equipment is lightweight for ease of handling,
and automated

www.thermalchemistry.com
+64 21 843 762
[email protected]
NEW ZEALAND 7. These tubes had been frozen and damaged by debris
trapped behind support beams

the spaces between fins, normally detected by high con-

denser backpressure. Levels are site-specific.
For normal fouling, most cleaning equipment is light-
HRSG weight and easy to handle, as with the washing system
shown in Fig 6. Hubregtse concluded with examples of
maintenance automatic cleaning systems, noting that most of the setup
costs are in the rails. These systems, he said, are relatively
planning, simple and moderately priced. Automation, setup time, and
cost discussions followed.
inspection, Willis Shook, Conco Systems, continued with three
detailed case studies on water-wash tube cleaning, empha-
and analysis sizing that it is not unusual for an ACC project to encounter
the unexpected.
by ALS Consulting LLC, The Yellowstone Power Plant ACC experienced
Amy Sieben, PE, principal severely leaking tubes. Ambient temperatures covered
an extremely wide range, and local industries contrib-
Sieben, a frequent speaker at user
meetings with three decades of uted to fouling.
boiler/power-industry experience, also The 65-MW facility is equipped with two pet-coke-fired
represents Chanute Manufacturing in the fluidized-bed boilers, one steamer, and one ACC. The last
HRSG aftermarket for pressure-part design, has 10 modules consisting of eight condensing cells and
www.alsconsultingllc.com
upgrades, and in-kind replacements. two reflux cells. Each module contains one fan and six
finned-tube bundles. Each bundle has 211 coated carbon
HRSG services include: Additional capabilities: steel oval tubes in a three-tube arrangement.
■ Inspections (online and ■ Boiler-water chemistry Fans are 26 ft in diameter, have 10 blades, and two-
offline) ■ Expense and capital speed motor drivers that can be reversed in severe weather.
■ Performance evaluation budgeting Some tubes had been frozen and damaged by debris
■ Specs for new units, retrofit ■ Owner’s engineer trapped behind support beams, as shown in Fig 7.
projects ■ Plant-acquisition planning Holes had also developed in the top of the tube connec-
■ Bid evaluation and due diligence tions to the steam header, and at the lower condensate
■ Cycling studies ■ Expert-witness testimony header connections (reflux cells)—caused by corrosion from
■ Low-load studies ■ Operator training washing with poor quality water.
■ RCA and problem Yellowstone solutions included the following:
resolution Call Amy for n Use of underground cable shrink wrap and aluminum
■ Long-term maintenance all your tube duct tape to patch major leaks in tubes.
strategy and harp needs.
n Use of sleeve inserts and outer sleeves to fix tube-to-
Amy Sieben, PE • [email protected] • 651-785-8516 header connection leaks.
n Sandblasting and pressure washing of tubes to remove
62 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016
 debris from finned areas.
n Use of epoxy paints to help preserve and close pin-hole
leaks in steam header and condensate header connec-
tions.
n Wind fence.
n Upper wind wall.
Outer tubes were removed for access to inner-row tube Acid is troublesome.
leaks. Tube sleeve inserts and outer couplers (Fig 8) were
installed. Condensate holes were repaired and coated with Varnish is complicated.
epoxy paint for added protection.
Another example plant burns coker gas from a nearby
refinery. Steam is then sent back to the refinery. A harsh
winter partially froze the coker gas line, creating a block-
Removing them is easy.
age backed by high pressure. When the blockage broke
free, pressurized oil leaked through the loop-seal stack.
Oil covered the outside surface of the ACC and the sur-
rounding area.
Then another unexpected event. A truck carrying flyash
overturned near the plant in winter, and the ash was sucked

Original Tube coupler

Sleeve tube

8. Tube sleeve inserts and outer couplers are one way to

eliminate leaks (above)

into the ACC fans. The undersides of the tubes were coated
with oil and ash, with the oil acting like a glue.
Attempts to clean using the installed high-pressure
water system failed. An adjustable and higher pressure
system was brought to the plant. Bundles were presoaked
with biodegradable degreaser, then the unit was cleaned
with the higher pressure ACC cleaning system.

Air in-leakage testing

FSJL
Conoco Systems’ Andy Leavitt, followed Shook, covering
leak detection equipment and set-up, air in-leakage indi-
cators, and testing challenges specific to ACCs. Standard
in-leakage indicators are high backpressure, dissolved
oxygen, and continuous hogger use.
His message of caution: The leak is not always in the Complete Jet Lube
ACC. It could be in the hogger or hogger exhaust, the
gland-seal drain/trap, the crossover bellows, or base weld Conditioning Systems
leaks in retrofit projects. “But even more frightening,” he
said, “is finding leaks in new units.” » Remove water, acid, particulate,
Discussions followed on the best media. “Helium is the gels, and dissolved metals
best tracer gas,” he concluded.
This presentation offered large variety of leak locations » Eliminate expensive unit trips & fail-to-starts
and detection examples. Day One ended with, in Leavitt’s » Lower ISO Codes + extend fluid life
words: “ACCs present lots of possibilities.”
» Protect servo valves and critical components
Day Two
A key feature of ACC User Group annual meetings is to learn more, visit
interaction.
Barry Dooley led off Day Two by listing and reviewing hyprofiltration.com/FSJL
the long list of questions he had been asked during the
Day One breaks, the evening gathering, and breakfast.
FAC mechanisms (and color indications) topped the list.
Related questions centered on the speed of change (dam-
age), determining iron levels, elevated ammonia levels in
summer, optimum makeup, pH balance and maintenance,
and clarity of compound turbulence indicators.
An understanding of pH impact seemed critical. Said
Dooley, “Two-phase FAC is very sensitive. For example,
COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016 63
 Cooling Fan technology
Maximising efficiency, minimising noise

Howden is the preferred cooling fan supplier for top tier

quality, unparalleled proven efficiency, and lowest
guaranteed sound levels. We offer cooling fans with
reliable duty and sound performance. Howden can
assist in selecting lower noise, higher efficiency fans, or
a balance between the two this is key in optimizing your
cooling system requirements.

For more information please get in touch:

Howden Netherlands
P.O. Box 975, Lansinkesweg 4
7550 AZ, Hengelo
The Netherlands
t: + 31 74 255 6000
f: + 31 74 255 6060
e: [email protected]

www.howdencoolingfans.com © Howden Group Ltd. All rights reserved. 2016

a system pH of 9.6 can start the FAC Visuals then clarified the process screen protection design based on CFD
process. A pH of 9.8 can stop and stages: analysis.”
reverse it.” n Stage 1. Anodamine permeation As reported in CCJ 2Q/2016, p 60,
He then offered a brief presenta- through oxide to virgin base metal. wind impacts both the ACC and plant
tion on aluminum cooling towers and n Stage 2. Partial epitactic hydropho- performance (power output) through
jet condensers (indirect dry cooling). bicity; base metal protection. degraded fan performance and recircu-
Operations and investigations (indus- n Stage 3. Complete oxide hydrophobic- lation of hot air into the downwind fan
try education) are following a path ity. Protection achieved with continu- inlets. This presentation estimated a
similar to ACCs (discussed in Day ous 1000 to 1500 ppb equilibrium nominal 10% power reduction for every
One). This time, however, “IAPWS is residual. Dosage then can be reduced 10 m/s (22 mph) of wind.
working on it up front and is, as one to maintain 800 to 1000 ppb. Also, as reported previously in this
example, monitoring aluminum and Anodamine was contrasted with periodical, the economic breakeven
iron levels.” IAPWS is currently study- conventional film-forming amines point remains uncertain for wind-
ing supercritical units with Heller (FFAs). Although research contin- screen design and installation. Some
Towers and jet condensers. ues, some FFAs show various limita- gains are difficult to estimate, but
“We now know,” Dooley continued, tions—including trapping of inorganic performance improvements are being
“that for these units we need a pH level contaminants and base-metal attack reported and analyzed.
of 8 or lower under oxidized conditions, through under-deposit corrosion. Bianchini’s presentation gave
so this is the opposite of ACCs. And Specifics for Anodamine included details on the 3D computational meth-
we have to realize that the corrosion reduced corrosion-products transport od; sub-models for fans, tube bundles,
products (for monitoring) are soluble, during cyclic operation, improved unit and screens; and expected outputs.
not particulate.” startups, and reduced operating costs. Case studies followed for compari-
Ongoing work will be discussed at Case studies and economic examples son of various windscreen designs and
future meetings of the group. were presented. configurations. Key elements are screen
Discussion questions included rela- porosity and positioning. Also signifi-
Film-forming agents tionships to FAC mechanisms (ongoing cant are any surrounding tanks, build-
study), collaboration with IAPWS, and ings, and geographic characteristics.
Paul Hattingh, Anodamine Inc, fol- a statement of no known impact on Conclusions drawn by Bianchini
lowed with the topic “Application of system pH control. were that “3D CFD modeling of plant
a film-forming agent and corrosion layout and components provides a rea-
reduction in ACCs.” Subtopic was Windscreen analysis sonable and detailed estimate of the
non-toxic, OEM-compliant metal pro- wind field around the ACC. It is now
tection: A surface-active metal pas- Reinforcing ongoing studies on the possible to verify several windscreen
sivation technology for low-, medium-, impact of winds, Cosimo Bianchini, configurations to determine the most
and high-pressure boilers.” Ergon Research, presented “Wind- effective solution.”
64 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016
 AIR-COOLED CONDENSERS

How IAPWS helps ACC owner/operators

Technical guidance documents in preventing steam turbine failure/ tions (September 2013) offers
(TGDs) have been developed by damage. guidance for a wide range of tur-
the International Association for the n Instrumentation for monitoring and bines (fossil, nuclear, industrial,
Properties of Water and Steam to control of cycle chemistry for the geothermal, etc) and failure mech-
provide advice on cycle chemistry to steam/water circuits of fossil-fired anisms. It includes customizations
users responsible for fossil and com- and combined-cycle powerplants for plants using amines.
bined-cycle plants. The documents, (September 2015) includes a table n Corrosion product sampling and
available at no cost on the organiza- that can be used to determine the analysis (May 2014) covers the opti-
tion’s website at www.iapws.org, rep- minimum level of instrumentation mum procedures and techniques
resent the accumulated experience required for any fossil or com- for monitoring iron and copper. A
of members of the IAPWS working bined-cycle/HRSG plant. table of achievable iron levels for
group on power cycle chemistry from n Volatile treatments for the steam/ plants with ACCs is included.
24 countries. water circuits of fossil and com- n HRSG HP evaporator sampling
n Monitoring and analyzing total bined-cycle/HRSG powerplants for internal deposit identification
iron in fossil and combined cycle (July 2015) includes the basis for (September 2016) includes the
plants (May 2014). Document AVT and OT for all plants, with locations where to take samples
details represent the consensus of customization for plants with ACC from HRSGs, how to analyze the
24 countries. and using ammonia and amines. samples, and a new IAPWS map
n Film-forming products (Septem- Recently added guidance is to assist in determining whether
ber 2016) received final review offered for fast start and frequently the HRSG HP evaporator requires
and approval from the two-dozen started HRSGs. chemical cleaning.
countries represented in IAPWS. n Phosphate and NaOH treatments n Application of film-forming amines
Reviews included most of the for the steam/water circuits of in fossil, combined-cycle, and
chemical supply companies and fossil and combined-cycle/HRSG biomass plants (September 2016)
most of the steam turbine, boiler, powerplants (October 2015) covers covers optimum application guid-
and HRSG manufacturers. the basis for selecting the optimum ance for FFA/FFA products in
n Procedures for the measurement boiler/HRSG evaporator water all-ferrous plants. It includes cus-
of carryover of boiler water and treatment (phosphate and NaOH) tomizations for shutdown/layup,
steam (September 2008) includes for all drum plants, including cus- multiple pressures, mixed-metal-
a technique for measuring car- tomization for plants with ACC. lurgy feedwater systems, conden-
ryover from drum boilers to assist n Steam purity for turbine opera- sate polishing, and air cooling.

Direct-drive motors Weinandy began with a quick

review of direct-drive technology,
Pratt began with the basics: Pre-
pare a specification that leads to an
At the 2014 ACC Users Group meeting introduced to the cooling-tower mar- ACC that meets all codes, achieves
in San Diego, Tom Weinandy, Baldor ket in 2008 with shaft-up configura- optimal thermal performance, meets
Electric/ABB, presented “Design con- tion. Baldor launched its shaft-down, all permitting and environmen-
siderations for a direct-drive motor direct-drive ACC design in 2013, based tal restrictions, epitomizes quality
retrofit on an ACC.” He returned in in part on discussions at the 2012 ACC throughout, and is easy to maintain.
2016 with updates, discussing the Users Group meeting in Gillette. And all at the right price—of course.
prototype installations at Basin Elec- Considerations included more He called it a balance of “infinite wants
tric Power Co-op’s Dry Fork Station horsepower and torque, less noise, within a finite budget and schedule.”
in Gillette, Wyo. and a robust mechanical strategy to “Homework is absolutely critical,”
The basis of this multi-year work address wind issues. Weinandy pro- said Pratt, and we can’t forget two some-
is an agreement between Baldor and vided full details, including the drive times overlooked but critical details:
Basin to supply two direct-drive ACC motor controls. 1. Cycle chemistry must be part of the
motors for an 18-month evaluation peri- Retrofit installation challenges homework, how the ACC fits into
od (April installations 2015 and 2016). discussed included a drive-motor the cycle as a whole, and. . .
Dry Fork is a nominal 400-MW weight of 7679 lb but an existing trol- 2. You must consider ACC require-
coal-fired unit that came online in ley system rated below 5000 lb, and ments for the current (and foreseen)
November 2011. The design includes a an increase in motor size. generation of flexible and fast-start
45-cell ACC. Initial operations showed Based on successful installation combined-cycle plants.
some significant issues: and operation of these prototypes to Pratt’s credibility? He is a seasoned
n Motor bearing failures attributed date, Weinandy stated that “it is their design engineer who communicates
to shaft-down orientation. intention to replace the balance of the directly and frequently with plant
n System operations during peak fan units with direct-drive technology.” owner/operators and site personnel.
season required 15% to 20% more Timing is not yet determined. Pratt quickly drew a distinction
air than could be provided with between ACCs and surface condensers.
existing motors. OEM ACC specifications First, ACCs are more complex, with
n Half of the gearboxes were leaking more technical scope. Second, there is
oil. Many questions about OEM specifi- less history with ACCs, and industry
n Local wind gusts of up to 80 mph cations were raised and discussed at standards have not fully caught up
caused equipment concerns. the 2015 meeting in Gettysburg, and with the operating experience. As an
Dry Fork wanted a 250-hp (at 104 Gary Pratt, engineering manager at example, surface condenser standards
rpm) direct-drive design with a carrier Advisian/WorleyParsons, brought both from the Heat Exchanger Institute
bearing for added protection against pinpoint suggestions and good common are in their eleventh edition. HEI
side loading. sense rules to Dallas. standards for ACCs are in their first.
COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016 65
AIR-COOLED CONDENSERS
Therefore, when drawing up a 2. “Stay connected with the industry. performance during high ambient
specification, more responsibility is Lessons learned prevent repetition temperatures.
placed on both the engineer and the of errors.” Some methods include wetting the
end user to properly specify and estab- During comments and questions, heat-transfer surface (more common
lish all relevant design criteria. At its Dooley suggested including IAPWS in Europe) but this can also cause
highest level, the ACC specification information with similar items (ASME corrosion of the tube bundles, damage
must also cover requirements for the Performance Test Codes). Interesting to motors and gearboxes, algae on the
overall project. discussions followed on codes and other structure and equipment, and lime-
Expanding, he listed the common requirements that can vary by state. stone fouling when using hard water.
sources of specification input: Fogging is often preferred. A fogging
n Design engineer knowledge and Gear standard update mist is released into the air flowing
experience. through the fans and tube bundles.
n Operating experience. The Cooling Technology Institute The mist evaporates quickly, cooling
n Industry standards. outlined its proposed ACC gearbox the air. The only requirement is a rela-
n User-group interaction and reports. standard, and requested input. CTI tive humidity of around 50% to 60%
n Industry subject matter experts. intends to complete a new standard (allowing evaporation to take place).
n Equipment manufacturers and sup- that will offer reliability and minimal The maximum quantity of water used
pliers. maintenance through: is that needed to achieve 95% to 100%
n Construction and commissioning n Robust product design specifically relative humidity.
lessons learned. for ACCs. Hubregtse presented a practical
He carefully reinforced the example using a four-cell
requirements of listing pre- ACC, ambient temperature of
cise project communication 86F, and relative humidity of
and coordination methods, 50%, referencing the Mollier
a rigid division of responsi- diagram. Results included a
bilities, a fully loaded sched- boost of 2.21 MWh per day.
ule, and logistics including Also for this example,
inspection points, quality evaporation required water
assurance, field testing, and droplets of between 25 and
guarantees. 40 microns, calling for either
He added specifics on an atomizing or a high-pres-
terminal points, submittal sure spray nozzle system.
schedules, drawing quality The latter, with its large
standards, approval cycles, number of nozzles, is con-
and records retention. sidered the most efficient.
On the product (OEM) side, He then reviewed, in
Pratt also emphasized two detail, specifics on nozzles,
general categories of require- sensors and controls, and
ments: Those that meet estab- water quality. Soft water
lished codes and standards must be used.
(building code, for example), 9. Plumes from fog nozzles, installed to improve thermal Hubregtse also stressed
and those more difficult to performance, are visible for only a few feet before evapora- the impact on the gas tur-
define: What the owner/opera- tion bine. “If the backpressure at
tor is thinking about for best the turbine exhaust reaches
value, and the technology target that n Proper sizing and selection. the trip point during high ambient
moves as user experience expands (per- n Proper installation. temperatures, fogging can lower the
haps during the contract period). n Best practices in operation and vacuum enough to prevent this.”
On the overall project side, Pratt maintenance. In the discussions, Hubregtse con-
pointed out several key elements— Initial meetings were held at the firmed that evaporation takes place
including full meteorological and topo- CTI Summer Workshop in July 2016. before entry through the tube bundles
graphical site data, and wind data for Attendees included three gear manu- (Fig 9), so there is no fouling impact.
all seasons. Equipment location should facturers, several ACC designers, EPC
be based on numerous factors—includ- firms, fan manufacturers, but only one External inspection guide
ing wind, adjacent structures, space owner/operator.
and height limits, and noise. Key issues addressed included In 2015, the ACC Users Group pub-
He ended with a list of current gear ratings and service factors, wind lished the first draft of an internal
(and perhaps more difficult) topics, effects on design, oil containment and ACC inspection guide (ACC.01),
concerns, and ongoing developments, filtration, and condition monitoring. currently available at www.acc-
including: The update ended with an appeal usersgroup.org/reports. Dave Rettke
n Motor selection: single speed, dual for input from owner/operators. The brought 2016 participants up to date
speed, and VFD. committee chair is Craig Burriss of on the document.
n Windscreens. Amarillo Gear Co. Anticipated publica- His presentation discussed the
n Fan and bridge vibration. tion is in the first half of 2017. guide’s organization and depth. If this
n Tube and fin materials (and cladded goes “too far down into the weeds,”
versus coated). Fogging enhances dry said Rettke, “to valves, for example,
n Fans and gearboxes. that is going too far. Valves vary by
And for base awareness, he stressed cooling plant, and they have their own manu-
two important items: Huub Hubregtse returned to the als. The best foundation is perhaps
1. “Achieve clarity. If it’s not written podium and presented a case study on any external inspections discussed in
down you’re not going to get it.” spray-enhanced cooling to help ACC OEM manuals.”
66 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016
 AIR-COOLED CONDENSERS
Energy (ARPA-E), explained the
goals of this US government initia-
tive to help improve efficiency, reduce
energy imports, and reduce energy-
related emissions. Efficiency related
to decreasing water availability was
the topic in Dallas.
Three overriding facts were pre-
sented to support the theme of “Energy
as a water problem”:
1. 41% of freshwater drawn in the US
is for thermoelectric power plant
cooling.
2. 3% of cooling-tower water load is
evaporated and dissipated.
3. Energy and agriculture are com-
peting for the same fresh water
resource.
Referencing studies that included
EPRI and DOE, Stark gave these
statistics for the US powerplant infra-
10. Low-profile lifting devices are used to remove fan motor drivers and gearboxes structure (2008):
n Water cooling, 99% (cooling tower
Areas of initial concentration are motor-trip problems, all causing 42%, once through 43%, cooling
decking, steam ducting, and expan- concerns.” Motorized screens were pond 14%).
sion joints. Other headings being installed, and the fans were changed n Dry cooling, 1%. Direct air-cooled
considered are piping and hangers, from six blades to nine. condenser dominates. Indirect dry
tubesheets, tube washing systems, The conclusions to date, said Mir- cooling and hybrid cooling are mini-
structural members, fans, and motors. sky, are the following with the screens mal.
The goal of ACC.01 is to improve normally at 50% deployment: Stark also stated that “more strin-
both safety and performance. Photos 1. Differences in back- versus front- gent EPA regulations on water intake
and a checklist will be included in the cell air velocities are normalized. and thermal discharge will render once-
final document. A progress report will 2. Dynamic blade loading is reduced through cooling obsolete” in the future.
be presented at the 2017 meeting. considerably. He then addressed air versus water
3. Longer fan blade life is projected. cooling and introduced the Advanced
Windscreens at 4. Measured static pressure differ- Research in Dry Cooling (ARID) pro-
ences are reduced. gram launched in 2015, with 14 proj-
Caithness 5. Average static pressure is reduced ects, including air-cooled heat exchang-
The windscreens at Caithness have indicating air flow increases. ers. Project teams design kilowatt-scale
been reported in CCJ, most recently in The update gave an interesting per- testing prototypes to ensure the tech-
the 2Q/2017 Outage Handbook issue. spective on what is both an expanding nologies can scale up to the megawatt-
Gary Mirsky, Galebreaker Indus- and analysis-driven technology. cooling capacities of real systems with-
trial, reviewed the overall project out significant performance loss.
and offered detailed literature ref- Dry cooling research Discussion points included a
erences on this long-term program. reminder from ACC owner/operators
“There was never a specific perfor- A research summary presentation that good theoretical developments can
mance problem,” he explained. “It by Addison Stark, program director, cause real problems and require some
was amperage, fans, vibrations, and Advanced Research Project Agency— degree of caution.

12. Fogging system installed at Midlothian to demon-

11. Placement of ground-level screens was based on strate performance improvement increased steam-turbine
results of CFD modeling output by 5.8 MW at 100F and 30% relative humidity
COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016 67
 Ninth Annual
n Preventive maintenance summary.
Reviewing maintenance, he noted
issues with the motors and gearboxes,
caused largely by water ingress.

Conference
Staying with maintenance (and
preventive maintenance) Hiefner
highlighted schedule details. One
significant item was a walkdown each
(and every) shift.
October 2 - 5, 2017 Instrumentation specifics include
retrofit gearbox oil-pressure trans-
Westin Las Vegas mitters tied to plant DCS (for
improved monitoring), and fan cell
Agenda at www.acc-usersgroup.org temperature RTDs to trend fogging
performance and monitor any fan
stalls attributed to wind velocity or
direction.
Windscreens have improved unit
performance (output) and are remov-
able for maintenance access and out-
Users Group age laydown. Ground-level screens
(Fig 11) were placed based on CFD
modeling.
Midlothian’s multi-year fogging
project began in 2012 when a 12-stage
system, rated 600 gpm of demineral-
ized water at 1500 psig, was installed
on Unit 6 as a proof of concept (Fig 12).
The 12 levels, located below the
ACC, contain nearly 18,000 nozzles in
sum (1200 per fan). Variable results
average a unit increase of 5.8 MW at
100F and 30% RH (ambient).
Air Cooled Condenser Users Group Systems were installed on Units
Technical conference. The 2017 meeting will feature prepared 3 and 5 in 2013, with similar perfor-
presentations, open technical forums, and a plant tour. Receptions mance results.
Midlothian next investigated the
and meals allow for informal discussions with colleagues. This user
placement of nozzles immediately
group welcomes the participation of qualified consultants and below and above the fans, and in 2014
vendors in the information exchange. The technical agenda focuses converted Unit 5 to a mixed system,
on the following subject areas: relocating half of the nozzles immedi-
■ Operation and maintenance. ately below the fans and a separate
lower-pressure arrangement (500 psig)
■ Chemistry and corrosion. above the fans.
■ Design and performance. Expectations were a 6-MW boost in
output, 3 MW from fogging below the
ACC Users’ online forum, hosted at www.acc-usersgroup.org, fan, 3 MW from fogging above the fan.
enables member owner/operators, consultants, and Actual results with nozzles below and
equipment/services suppliers to communicate 24/7 to share experi- above the fan in operation: 4.5 MW
ences, get advice/referrals, locate parts and specialty tooling, etc. below and 1.5 MW above. The hybrid
The forum, managed by Chairman Andy Howell system improved unit performance at
([email protected]), has hundreds of registered partici- 100F and provided “significant cooling”
pants worldwide. of 20 deg F.
In 2015, the below-fan nozzle design
was implemented on all remaining
units. The overall fogging program now
Midlothian Power instrumentation, windscreens, a multi-
year and multi-unit fogging project, includes 90 ACC fans, 180 pumps, and
Terry Hiefner, engineering super- and near-term plans for direct drives 67,500 nozzles (750 per fan).
visor, Midlothian Energy Facility, and fan conversions. The next significant ACC program
Engie NA, followed with an overview He began with the motor/gearbox/ at Midlothian will be a direct-drive/
of the plant the attendees would tour bearing assembly details, describing Hudson fan conversion by Industrial
the next morning, and its activi- maintenance activities as: Cooling Solutions (ICS). Attend the
ties. Midlothian, located just south n Component rigging improvements. 2017 meeting for a progress report.
of Dallas/Ft Worth, consists of six • Trolley-beam south wall exten- Meeting participants visited the
single-shaft, F-class combined cycles, sions. plant the next morning. As recapped by
the first of which began commercial • Motor and gearbox low profile Andrew Howell, “Plant Manager Mike
operation in 2001. Total rated output: lifting devices (Fig 10). Knisley and his team went all-out to
1495 MW. • Grating rigging access for fan inlet describe and show their ACCs, includ-
Hiefner concentrated on the ACCs— screen. ing operation of the spray-misting sys-
including maintenance activities, n Equipment failure history. tem, for our observation.” ccj
68 COMBINED CYCLE JOURNAL, Number 51, Fourth Quarter 2016