Ge Air Cooled Heat Exchangers Brochure

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Air cooled heat exchangers

Robust and reliable for all loads and applications

GE Oil & Gas

What it is

Air cooled heat exchangers are commonly used in industrial applications

where a reliable source of water is not available as a cooling medium. Air cooled

steam condensers are a special type of heat exchanger employed to condense

steam at the exhaust end of a steam turbine for both power generation and

mechanical drive applications.

How it works

The hot process fluid to be cooled flows through finned tubes while the cooling

air flows across the outer surface to remove heat. The cooling air is propelled by

fans in either a forced draft or induced draft configuration.

Worldwide presence

GE’s Oil & Gas business has more than 100 years of industry

experience and 5,500 employees worldwide. Our Air Cooled Heat

Exchanger team is centered in Vibo Valentia, Italy, and is an

integral part of the larger Oil & Gas organization headquartered in

Florence. Together, we provide complete solutions to all industry

segments – with a broad and expanding portfolio of advanced

technologies, plant equipment and services.

We are a global company with a local touch. Our highly

experienced personnel offer comprehensive customer support

backed by immediate access to all of GE’s broad resources. Our

people understand the local customs and regulations, and can

help you identify and track growth opportunities.

Experience makes the difference

We have been a global leader in the fabrication of air cooled heat

exchangers and steam condensers since the late 1960s. The first

high tech pipe and bend air cooled heat exchanger we supplied in

the early 1970s was for sweet gas with pressure slightly over 300 bar.

Our latest applications are for more than 650 bar with H2S content

as high as 18%. We have supplied more than 10,000 bundles

for applications throughout the industry from upstream to

hydrocarbon processing. Our investment in technology continues

in an effort to meet even more extreme conditions.

The quality of our exchangers is a result of advanced design

techniques employing the latest software, world-class fabrication

facilities and capabilities, Six-Sigma quality methodology and

extensive experience in both manufacturing and in-field service.

All our manufacturing processes are implemented in strict

accordance with GE’s world-class Six-Sigma quality system,

which conforms to all major international quality assurance

standards including ISO9001, BS5750 and UNI EN 29001.

Compliance of the QA system with these standards is

certified by LLRR.

Focused on

quality

Gas

re-injection

Gas

compression

& gathering

gas lift

Liquefied

natural gas

Gas pipelines &

storage Gas-to-liquids Refineries &

petrochemicals

Machinery lube

oil cooling

Header configuration

Pipe & bend

Plug box

Cover plate

Finning type

Extruded/Embedded

L-footed

A complete range of products

Advanced technology in gas cooling

Gas type and pressure are the two key considerations behind

proper design and materials selection to ensure the performance

on which our customers rely over the long term.

Materials

The level of H2S and CO2 contained in the gas will significantly

affect machine durability and performance relative to corrosion.

We therefore choose special, heavy-duty materials for sour gas

applications – not only for the air cooled heat exchanger, but

for the whole plant. Advanced corrosion-resistant alloys such

as Incoloy 825 require specialized welding techniques and we

have the expertise to ensure high quality construction with these

materials.

Welding

Very high pressures require special considerations in material

type and thickness, design and manufacturing – particularly

welding – all carefully adapted to the specific characteristics

of the gas. Welding of complex parts and various thicknesses

involves extreme heat and, therefore, demands expert care to

ensure uniform cooling and to avoid material stresses. We analyze

and relieve stress levels with local heat treatment (tube-to-header

welds) and our specialized furnace (headers and flanges).

Our commitment to R&D

Since the late 1960s GE Oil & Gas has been a global market

leader in the design and fabrication of air cooled heat exchangers

and steam condensers. We are continuously advancing our

technologies to meet our customers’ requirements. Leveraging

synergies across the entire GE network, we create solutions so

that challenges on the horizon can be transformed into real

opportunities.

Providing service to the industry

GE Oil & Gas offers a complete portfolio of after-sales services to

keep heat exchanger and condenser equipment operating at peak

performance for many years, or to upgrade them to meet more

stringent regulations or new operating requirements. Beyond

parts and bundle replacements, our services include:

Optimization

The performance of air coolers is checked and diagnosed by

collecting data on air flow, tube flow, fan power and the overall

status of the equipment, and processing it directly in the field. We

provide a detailed action plan to optimize air cooler performance.

Upgrades and modification

It is also possible to upgrade any installed air cooler and increase

the machine capacity. The performance assessment can provide

useful information on what upgrades are feasible for the current

equipment and the GE experts are able to perform any kind of

modifications including re-qualification to provide performance

guarantees.

Air cooled

heat exchangers

Design flexibility and manufacturing

quality to meet all pressure and

temperature requirements

Cover plate configuration

These exchangers are generally used for dirty fluids with

low operating pressures in applications such as cooling of

machinery oil and heavy hydrocarbons in refineries.

Cover plate heat exchangers are designed for ease of

maintenance. A flanged, removable cover allows complete

access to the inside of the header for cleaning – since this

feature substantially limits the design pressure, this type

of heat exchanger is not recommended for critical service

applications. Operating conditions are typically up to 35 bar

(507 psi) and processed fluids can be very viscous.

Plug box configuration

These exchangers are suitable for a wide range of

applications and services involving cooling and condensing

of hydrocarbons and gases over a broad range of process

conditions in any size plant.

The distributor (header) of this model is a completely

welded box with holes in front of each finned tube to allow

cleaning and inspection. The design effectively meets

competing needs such as low cost and high versatility. This

configuration can cover most common applications with

operating conditions typically up to 220 bar (3,192 psi).

GE Oil & Gas

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Pipe & bend configuration

This equipment uses a header made of forged pipe and is

designed to withstand very high pressures.

It is recommended for use with clean fluids since no

inspection openings are provided. Its fully welded design is

especially suitable for critical and hazardous applications.

Designs can handle extremely demanding pressure – over

650 bar (9,427 psi) – temperature and material conditions.

Finning

Together with header features, finning of the tubes is key to

air cooled heat exchanger performance. GE produces three

types of finning.

Extruded

High efficiency fins for higher temperature applications

(typically up to 300°C). These fins provide the base tube

with complete and permanent corrosion protection against

atmospheric contaminants.

Embedded or grooved

High efficiency finning for high operating temperatures

(even up to 400°C).

L-footed

Standard fin for low temperature applications (typically

up to 170°C) where some degree of tube wall protection is

required.

Header configuration Finning type

Pipe & bend Plug box Cover plate Extruded/

Embedded L-footed

Gas re-injection • •

Liquefied natural gas • •

Gas pipelines & storage • • • •

Gas-to-liquids • •

Refineries & petrochemicals ••••

Machinery lube oil cooling ••••

Applications

GE imagination at work

GE Oil & Gas provides the industry-unique capability to optimize plant

performance with a condenser-turbine package that is fully matched

through the entire design process. The turbine, condenser and pump

are all manufactured by GE Oil & Gas, while the boiler is supplied by our

verified supplier to exact GE specifications and quality standards

Condenser Boiler

Turbine

Pump

Air cooled

steam condensers

Thermodynamic design to meet all

unique project specifications

Advanced, single-source solutions

Air cooled condensers are preferred to water cooled

condensers when there are special environmental or water-

shortage conditions. The steam condenser is a vacuum-tight,

air cooled heat exchanger, usually with bundles sloped at

approximately 30° to reduce the footprint and with 100%

fully welded connections.

Our system is a full package consisting of the core unit

and all auxiliary equipment needed for operation of the

condensation steam plant. With over 60 years of extensive

experience in this area and advanced thermodynamic design

capabilities, we fine-tune the critical connection between the

condenser and steam turbine for optimized performance in

any steam cycle. Our designs also ensure uniform operating

conditions within the heat exchanger to avoid the formation

of air pockets.

The breadth of our experience also gives customers a single

point of responsibility for an entire project – which is highly

beneficial to overall system efficiency and reliability, speed of

problem solving, and reduced project management costs.

GE Oil & Gas

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Installed fleet capabilities

Fin technology Embedded and extruded•

Non-porous aluminum•

Operating temperature -25°C to 50°C

Max. finning tube length 15 m

Turbine exhaust pressure Min. 0.05 barA

Inlet flange temperature Min. 33°C

Package supply

Vacuum system•

Finned tube bundles•

Pumps•

Hot well•

Steam duct •

Piping•

Site assembly•

Power generation

Thermal solar, CSP•

Waste to energy•

Cogeneration•

Combined cycle•

Mechanical drive

Refinery•

Ammonia and urea•

Methanol•

Ethylene•

Applications

GE imagination at work

Investing in local partnerships to

maximize process, skill and technology

transfer across the region

Local partnership

In October 2009, a 50-year relationship was reinforced by

combining the TAMIMI Group’s local engineering strength with

GE’s global technology leadership. Our latest joint venture is

dedicated to serving Saudi Arabian, Middle East and North

Africa customers with localized manufacturing and testing

capabilities, as well as rigorous supply chain logistics and

transportation resources. The partnership also promotes

Middle East growth through technology transfer and the

development of skills for the local workforce.

© 2011 General Electric Company. All rights reserved.

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ge.com/oilandgas

Technologies & support

Heat exchangers and condensers for all high pressure,

process plant and low pressure applications. Expert field

service and life cycle support for installation, maintenance,

upgrades and modifications to ensure optimized long-term

performance.

GE Oil & Gas

Global Headquarters

Via Felice Matteucci, 2

50127 Florence, Italy

T +39 055 423 211

F +39 055 423 2800

customer.service.center@ge.com

Nuovo Pignone S.p.A.

Nuovo Pignone S.r.l.

Air Cooler and

Steam Condenser Facility

Contrada Le Marinate

88019 Vibo Valentia, Italy

T +39 0963 5691

F +39 0963 567 528

For complete contact information,

please refer to our website.

ge.com/oilandgas

The information contained herein is general in nature

and is not intended for specific construction, installation

or application purposes. GE reserves the right to make

changes in specifications or add improvements at any

time without notice or obligation.

GE, the GE Monogram, and imagination at work are

registered trademarks of the General Electric Company.

©2011 General Electric Company

All Rights Reserved

GE_ACHE_110811

GE imagination at work