GEA Air-cooled Heat Exchangers - GEA Batignolles Technologies ...

GEA Air-cooled Heat ExchangersHeat Transfer is our Passion.GEA Heat Exchangers / GEA Batignolles Technologies Thermiques

[Background ]GEA GroupSummaryGEA Group 3GEA Group Aktiengesellschaft is one of the largest systemproviders for food and energy processes.As an internationally operating technology group, the companyfocuses on process technology and components for demandingproduction processes in various end markets. The groupgenerates about 70 percent of its revenue from the long-termgrowing food and energy industries. The GEA Group Aktiengesellschaftis currently present in more than 50 countriesworldwide, and is active in all growth regions.The benefits of GEA:The innovative strength of a stronggroupSynergies within all GEA segmentsDifferent technologies and productsto serve different marketsGEA BTT at a glance 4Product Range 8Air Fin CoolersAir-cooled CondensersFinned tubesHeadersYour partner 12for designing your projectsfor manufacturing your projectsThe GEA Group provides GEA Batignolles Technologies Thermiques(GEA BTT) with a solid foundation and, through partnershipwith other Group members, allows a greater scope ofsupply. These close relationships with organisations that arethemselves leaders in their fields provide GEA BTT with inspirationto stimulate its own development and maintain itsmarket leading technology.GEA Batignolles Technologies Thermiques ispart of the GEA Heat Exchangers segment of theGEA Group and specialises in heat exchangersfor the global heat exchange market.Field Activities 21ServicingSpare partsPerformance assessmentProducts and markets 23OilPetrochemicalGasEnergy and other sectorsGeothermal and solar plantCarbon capture and storage applicationsGEA Batignolles Technologies Thermiques 2 3 GEA Batignolles Technologies Thermiques

A worldwide presence since 1958 in the oil, gas, energyand petrochemical sectors[ History]GEA Batignolles TechnologiesThermiques at a glance1958The design and manufacturing of the first API Air-cooler in Francebegins under the name of ‘Creusot Loire’.GEA BatignollesTechnologies ThermiquesNantes, FranceGEA LuftkühlerHerne, Germany1985Batignolles Technologies Thermiques is acquired by GEA GroupAktiengesellschaft. Under the new ownership, GEA BTT isdeveloped to become a world leader in the market for API 661 Aircooledheat exchangers.2010GEA BTT is a worldwide market leader for process air-cooled heatexchangers and part of the GEA Heat Exchangers segment.GEA Rainey CorporationCatoosa, USADue to the strong cooperation within theGEA Heat Exchangers segment GEA BTT issupported by the following companies:GEA Scambiatori di CaloreMonvalle VA, ItalyGEA do Brasil IntercambiadoresFranco da Rocha / SP - BrasilGEA BatignollesTechnologies ThermiquesDoha, QatarGEA Batignolles TechnologiesThermiques (Changshu)Changshu, ChinaTo respond to the increasing demand of theMiddle East and Asian markets, GEA BTToperates two workshops in Qatar and China.These new facilities are 100% GEA BTTsubsidiaries and operate to GEA BTT’stechnology and quality standards.GEA Rainey Corp in the USAGEA Aircooled Systems in South AfricaGEA Luftkühler in GermanyGEA do Brasil Intercambiadores in BrazilGEA Scambiatori di Calore in ItalyGEA BTT in ChinaGEA BTT in QatarGEA Aircooled SystemsGermiston, South AfricaGEA BTT has experience to developlocal partnerships for national contentrequirements.GEA Batignolles Technologies Thermiques 4 5 GEA Batignolles Technologies Thermiques

[ Worldwide]Large facilities to serve a growingworld demandThe world markets are going through rapid changeglobally.New processing capacity has been built in the Middle East andAsia to follow the increasing demand. At the same time existingplants in Europe and North America need upgraded extensions.With its global manufacturing network GEA BTT is able to fulfilcustomers’ global needs locally.FranceManufacturing capacity in France75 header boxes per week55 km/week of extruded finned tubes50 km/week L and G finned tubes1200 tube bundles per yearGEA - 105The benefits of GEALocal service from globalmanufacturing network.Extensive engineering know how inheat transfer since 1920.The ability to handle huge, complexprojects by networking betweenmanufacturing sites.ChinaManufacturing capacity in China30 headers per week30 km/month of extruded finned tubes25 km/month of L and G finned tubes700 tube bundles per yearQatarManufacturing capacity in Qatar30 km/month of extruded finned tubes25 km/month L and G finned tubes500 tube bundles per yearGEA Batignolles Technologies Thermiques 6 7 GEA Batignolles Technologies Thermiques

GEA Batignolles TechnologiesThermiques ProductsAir Fin Coolers (AFC)Process air-cooled heat exchangers are designed to condenseand cool fluids in a lot of industries. Air Fin Coolers are used inpetrochemical industries, geothermal and solar plant or incarbon capture and storage applications. The heat exchangesurface is made of round finned tubes fed by inlet and outletheader boxes. Finned tube bundles are installed flat on astructure and sometimes sloped in an A-frame structure aswell and are blown by fans.Air Cooled Condensers (ACC)Air Cooled Vacuum Steam Condensers (ACC) are designed tocondense exhaust steam from turbines. The heat exchangesurface is an assembly of finned tubes, fed by an inlet steamduct and manifold. Condensates are drained down into bonnetheader boxes. The finned tube bundles are sloped in an ‘A’frame structure and blown by fans and drivers. GEA BTT isexperienced to handle and deliver complete packages includingvacuum units, condensate tanks, pumps, control devices.GEA Batignolles Technologies Thermiques 8 9 GEA Batignolles Technologies Thermiques

Finned tubesThe cost efficiency of air-cooled heat exchangers depends amongothers on the heat transfer capabilities of the finned tubes used.Important factors to increase the heat transfer are: the quality ofthe finning, the quality of the contact between the fin and theinnertube, the fin profile.HeadersBimetallic extrudedMaximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformanceA range of header designs have been developed for differentapplications and requirements. Standard header configurationsare listed below.300 °C560 °FExcellent Excellent Very goodPlug headerG (embedded)The plug header is the most commonly used forworking pressures up to 250 bar.Maximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformance400 °C750 °FLow Very good Very goodCover plate headerL (wrap-on)The cover plate header is used for fluids withhigh fouling factors, when frequent mechanicalMaximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformancecleaning is necessary, at pressures up to 30 bar.120 °C250 °FAverage Low AveragePipe headerKnurled LThe pipe header is used for working pressuresover 250 bar when no inner access is necessary.Maximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformance250 °C480 °FGood Acceptable AverageD type headerDouble LLMaximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformanceThis lage manifold ensures an equal distributionof fluid flow in the tubes. This type is uses forvacuum steam condensers and refrigaerationunits.120 °C250 °FGood Low AverageWelded bonnet headerThe welded bonnet header is used for ammoniaGROOVY ©Maximum workingtemperatureAtmosphericcorrosionresistanceMechanicalstrenghtThermalperformancecondensers and air-cooled steam condensers.It benefits from a full-welded construction thatis suitable for vacuum applications.400 °C750 °FLow Excellent ExcellentGEA Batignolles Technologies Thermiques 10 11 GEA Batignolles Technologies Thermiques

Finned tube testGEA BTT - your partner fordesigning your projectsThermal DesignResearch and DevelopmentA dedicated team deals with customers‘ technical requirements:Heat dutyMaximum tubeside pressure dropMaximum noise levelPlot plan restrictionElectrical power consumptionExtreme environmental conditionsAny specific requestSystems are designed with cost and efficiency in mind to providethe most appropriate plant for each customer’s requirements, atthe right price.ToolsHigh qualified team for developing, improving and optimizingthe products through continuous research and development activitiesLong and short term researchCollaboration with research institutesDevelopment of testing facilitiesDevelopment of new innovative productsPatents (3 new patents every year)Use of Computational Fluid Dynamics, experiments,prototyping for validation of new ideasSome of our current projects:Newly designed and patented finned tubeReduction of noise level by innovative designEnvironmental friendly system for regasification plantIn-house thermal rating and costing softwareInternationally-recognised thermal software(Xace ® from HTRI)Fan suppliers’ sizing softwaresComputational Fluid Dynamics softwareGEA Batignolles Technologies Thermiques 12 13 GEA Batignolles Technologies Thermiques

Design of steel structure for AFC and ACCTotal support from FEED stagewith TOTINGFrom the GAD produced by TOTING GEA BTT will generatea 3-D model to perform the calculation of the structuralsteel using STAAD pro ® software. This model is thenexported to X-steel ® software to produce 3-D drawingsand shop drawings.TOTING is a software developed in-house which can generatefrom the thermal design preliminary engineering drawings atan early stage of the project.Arrangement drawings and loading data canbe submitted to the customer during thepre-engineering phase to optimise the plant cost.Bill of materials allows cost calculations to be optimised.The detail engineering phase can be launchedimmediately after order placement.This integrated design process ensures themanufacturing of the steel structureand allows the production ofcalculation data when required.Design of the auxiliaries for ACCGEA BTT carries out basic and detailed engineeringfor auxiliary equipment using the latest design technology.Design of HeadersFinite element calculation methods, developed in-houseand certified by ASME authorised inspection agencies,are used for header design as per ASME VIII div.1 App. 13.Finite element specific software and models areused for nozzle stress analysis under piping loads.GEA Batignolles Technologies Thermiques 14 15 GEA Batignolles Technologies Thermiques

CertificationsGEA BTT – your partner formanufacturing your projectsDesign and manufacturing activities at GEA BTT comply withthe latest certifications, European directives and with somespecific national regulations.Manufacturing facilitiesAll GEA BTT’s facilities have the necessary equipment andexpertise to ensure the manufacture of complete bundleson time and to the approved quality standard.The manufacturing of headers has been substantially improvedover the years with the use of modern manufacturing techniques,CNC equipment and bar coding systems.Complete bundleHydrotest, PMI examinationISO 9001ISO 9001 for thequality of thewhole process(design, manufacture,tests,installation)with regularaudit from theauthorisedagencies.GEA BTT is highly experienced in special design using exoticmaterials (such as Titanium, Monel, Incolloy, etc.) for special/stringent services (very toxic, lethal, etc.) and using the mostmodern welding technology such as electron bean welding.Tube manufacturing is performed with machinery developedin-house by GEA BTT for extruded fins and the latest availabletechnology for wrap-on fins.ASME(American)S, U, U2 forpressure vesselsand pressureboiler.The benefits of GEAModern manufacturing facilitiesExperience with different kinds ofmaterials and alloysProduction machinery has beenadapted by GEA for the special needsof the heat exchanger industryASME(American)NB and RQuality ControlProducts go through extensive testing before delivery to thecustomer.AFC and ACC testingShop run-in tests may include vibration, airflow, power consumption and noise levelmeasurement.AD 2000Code HP 0Pressure partsX-Ray, Ultrasonic, Liquid PenetrantGEA Batignolles Technologies Thermiques 16 17 GEA Batignolles Technologies Thermiques

TransportGEA-BTT is committed to on-time delivery.PackingA large storage area is available in GEABTT’s workshops for the preparation ofshipments where packing lists, packing,marking and customer requirements arecontrolled. A specific packing area hasbeen developed for ocean freight.Ocean freightAir freightRoad transportModule assemblyGEA BTT uses either local yard facilities forstorage and modular erection or erection facilitiesin the different workshop location.GEA Batignolles Technologies Thermiques 18 19 GEA Batignolles Technologies Thermiques

Field ActivitiesErection, commissioning andservicesOnce equipment is delivered, GEA BTT ison site for:the erection of Air Fin Coolers or AircooledCondensers with a ‘supervisiononly’ or ‘full turnkey’ serviceCommissioningPerformance testsGEA Batignolles Technologies Thermiques 20 21 GEA Batignolles Technologies Thermiques

Products and markets: A specific offer for each customerA range of aircoolers for different applications in different markets.Spares and After-Sales-ServiceOil / RefineriesOil fieldsPetrochemicalGEA BTT provides a full range of After-Sales-Services includingspare parts and services for all air-cooled heat exchangers,including 3rd party design.GEA BTT recommends identical or interchangeable spare parts,designed and manufactured in compliance with the most recentstandards and international codes. Fast-track delivery (under72 hours) is available on request for all stock components.Air Fin Coolers (induced draft)Leuna 2000, GermanyHumidified AircoolerKhursaniyah, K.S.A.Air Fin Coolers and Air Cooled CondensersNanjing, ChinaGEA BTT Spare Parts & Components DeptGas / Liquid Natural Gas (LNG)Gas / FPSOGas / Offshore platformsBundlesSpare bundles certified interchangeable withoriginal supply (header boxes / fintubes / frame),designed and delivered.FansSpare parts for fans from stock: blades, hubs, bushingsComponentsBearings, pulleys, belts, gear reducers, shafts,plugs, gaskets and boltingAir Fin Coolers (induced draft)Bonny Island, NigeriaAir Fin Coolers (Forced draft)Sanha LPG, AngolaAir Fin CoolersTunu, IndonesiaEmail:bttspares@geagroup.comEnergy / Steam CondensersEnergy / Steam CondensersEnergy / Turbine Cooling-Fuel Gas Heater (TCA/FGH)GEA Airflow ServicesGEA BTT has created a subsidiary company, GEA Airflow Services,fully dedicated to after-sales field services such as:Air-cooled heat exchangers assessmentsPerformance improvement by up grading fans and driversDe-bottlenecking analysisMaintenance programsCleaning verification and consultancyCleaning hardwareVacuum Steam Condenser forCombined Cycle; Kulim, MalaysiaA-frame Air Cooled CondenserBintulu SMDS, MalaysiaAir Fin CoolersPower Plant, Taiwan... and other fieldsWebsite:Email:http://www.airflow-services.comairflow@geagroup.comGEA Batignolles Technologies Thermiques 22 23 GEA Batignolles Technologies Thermiques Air Fin Coolers (induced draft)Chillers for Eurotunnel, England/France

Date printed 01-2011GEA Heat ExchangersGEA Batignolles Technologies Thermiques S.A.S25, rue de Ranzai · 44315 Nantes Cedex 3 · FrancePhone +33 2 40 68 24 24 · Telefax +33 2 40 49 34 39www.btt-nantes.com · btt@geagroup.comGEA Heat ExchangersGEA Batignolles Technologies Thermiques (Changshu) Co. Ltd.Southeast Development Zone Changshu · No. 66 Xin An Jiang Road215504 Changshu Province · ChinaPhone +86 0512-52306120 · Telefax +86 0512-52306116www.gea-btt.com.cn · info@gea-btt.com.cnGEA Heat ExchangersGEA Airflow Services25, rue de Ranzai · 44315 Nantes Cedex 3 · FrancePhone +33 2 72 74 00 93 · Telefax +33 2 40 50 61 53www.airflow-services.com · airflow@geagroup.comGEA Heat ExchangersGEA Batignolles Technologies Thermiques Qatar L.L.C.Road L, New Salwa Industrial AreaDoha QATARPhone +974 44 11 49 84 · Telefax +974 44 11 49 82GEA Batignolles Technologies Thermiques 24Phone (mobil) +974 55 80 02 75 · gerard.leport@geagroup.com