produklinienbroschuere drycoolersandradiators view engl

7/27/2019 Produklinienbroschuere DryCoolersAndRadiators View Engl

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Top-level engineering solutions

GEA Cmact Radatrs Dry Clers

engineering for a better world GEA Heat Exchangers


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Operative excellence and customer proximity o GEA Heat Exchangers are based

on the perormance and experience o specialized Business Units. They are

organized according to product group technologies. The nned tube compact heat

exchanger systems oer natureriendly and costeective solutions to cool air

or liquids involved in rerigeration processes or industrial machines and engines.

One single technology or the worlds industriesThe use o air rather than water or cooling applications contributes to ground

water conserv ation and prevents su race water war ming. It also a llows the

installation o ecient cooling systems at sites where water resources are scarce.

GEA is a pioneer in industrial air coolers and a world market leader. With its heat

exchanger compact systems, GEA can oer, with just one single technology,

economic and sae optimum solutions, adapted to a large number o complex

enduser requirements.

Thanks to a worldwide commercial network able to promote these heat exchanger

compact systems, GEA can strengthen its technological leadership in products

and services with greater customer benets. GEA Heat Exchangers can also actively

design compact systems, involving expertise o our customers and suppliers

in uture technological developments. Primary advantages or compact systems

are high perormance density, minimum ootprints, and maximum eciency

with high saety standards. T his compact tech nology enab les customize d engineer

ing solutions even or niche market segments at a quite attractive price or quality

and value added proposition. Our wide range o approved compact nnedtube

systems, concepts, and designs is recognized throughout the world. In our research,

planning, and production centers, these elements are constantly adapted to latest

developments in technology and quality standards. This enables GEA to take

any known operational condition into consideration and to optimize components.

The internationally operating GEA Group ocuses on process technology and components or

sophisticated production processes in various end market applications. In each o its business

areas, GEA is recognized by its customers as market and technology leader as well as a top

innovator. GEA Heat Exchangers, which is the largest segment within the GEA Group, ocuses

on all heat exchanger activities and covers the most application areas, extending rom air

conditioning systems to cooling towers. As a result, GEA Heat Exchangers provides one o themost extensive i not the most extensive portolios o heat exchangers in the world.

GEA Heat Exchagers

Combined expertise and excellence in heat transfer

Compact nnedtubesystems, the product lines:

Closed circuit coolers

Charge air coolers

- Compact radiators / Dry coolers

Commercial air coolers

rerigeration

Customized air coolers

rerigeration

Air cooled condensers

rerigeration

Toplevel engineering solutionswith operative exce llence and de dicated project t eams

Our teams are multiskilled. Their knowledge o their customers businesses ensures that

they will nd the optimum solution or each project. They take ull responsibility or a

project, rom design to delivery, or support their customers in calculating the most suitable

solution as valueadding partners. At the same time, customers can rest assured that

the GEAs specialists understand their overall processes and, consequently, their critical

interaces by virtue o their combined expertise.

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GEA engineering solutions oer customers the benets o standardization and

modularity, lowmaintenance design, great energy eciency, and topquality service.

Our value proposition includes comprehensive quality management, ecient use

o resources, and ewer interaces. Our solutions are environmentally riendly: low

noise level as well as minimized water and electricity consumption. We design and

build using the most advanced computerized simulation tools available, assisted by

ullscale laboratory testing.

Available certications and applicable standardsAll the GEA production units as well as our listed suppliers and authorized

service workshops are DIN EN ISO 9 001 certied. Our integrated management

system is oriented towards saety, environment, sustainable development, and

consistent industrial quality at all manuacturing sites. Our installations are able

to meet numerous building and control regulations, whether country or industry

specic (such as CE markings, Eurovent certication, ASME U Stamp, and many

more), or can be executed according to GEA standards, or according to your own

requirements.

Quality management and consultingIn our oces and actories we cover all issues dealing with heat exchange: design,

thermodynamic calculations, construction, and manuacturing studies. We oer the

support o a worldwide company able to provide international monitoring o projects

right up to turnkey installations. Our specialists carry out physical measurements

and indepth analysis o your requirements on site, whenever necessary, to oer

improvements and reach set targets. Our aim is to ensure that you benet rom the

latest innovations also by providing improvements to already installed equipment.

Service and supportCustomers o GEA expect and benet rom outstanding service to ensure optimum

perormance o installations, 24 hours a day, seven days a week. Our goal is to

provide service on heat exchangers during operation and to extend their lie cycles.

The GEAs value proposition covers all aspects o its valueadded partnership and actors in the

entire lie cycle o investment in equipment and processes. As part o its process o liecycle

costing, all the relevant criteria such as planning, installation, eciency, and operating costs,

including maintenance, service, and upgrading are coordinated and optimized to maximize

benet or the customer.

Certied quality:

ISO 9000, 9001 and 14000

ASME UStamp

AD Facts Sheet

Codap

CE

Atex

Nuclear qualications (RCCM ...)

GOSTR

Other certicates

PED, H1 module

Center o Excellence

To promote innovative developments,

we ounded ou r Center o Excel lence

within GEA Compact Systems.

Experienced specialists work here

who are partic ularly wel l acquainted

with the prec ise enginee ring design

o the systems they support.

Makg the derece

Sustainability, certified quality, reliable service

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Heat exchangers operate under widely diverse conditions in various industrial engineering

processes. A broad range o nned tubes with customized materials and geometry represents

a signicant advantage or optimizing design, construction and, in turn, the reliability o

system operation. Copper, coppernickel, stainless and carbonsteel tubes with compact ns

in aluminum, marine aluminum, coated aluminum, copper, and stainless steel are available

to be adapted to the customers situation. GEA uses the highest class o epoxybased, anti

corrosion surace technology or the enclosures o dry compact coolers and or aluminum

ns with PoluAl coating rom our partner Blygold.

Customized compact radiatorsOur specic compact radiators can be adapted to meet all required demand,

technical specications, and main manuacturing codes. Each project is specically

designed on an individual basis, taking account o your requirements as well

as our large choice o heatexchange suraces and materials. Fans can be located

either above or below the equipment, in induced drat or orced drat mode.

Our customized compact radiators eature a design o fatbed and Vbank units

arranged in single and doublebank congurations. These compact radiators

enable the closest possible matching to a required specication, taking into con

sideration duty, noise level, size, and eciency (duty and motor input power).

Main applications: stationary dieselengine power plants, gas turbines, combined

cycle power plants.

Energy modular compact radiators (EMCR)

Our range o prespecied compact radiators enables us to be highly proactive withrespect to delivery deadlines and enables us to oer an optimized costbenet

ratio. This improved product range is dedicated to large diesel engine power plants

that oer high cooling capacity (> 2.5 MW). Our energy modular compact radiators

impress through a horizontal induceddrat design, with single or doublebank

conguration. They are available in an extensive selection o lengths, two widths,

and various bundle characteristics according to individual demands. Motors and

ans are ully dedicated to d iesel engine power plants. Low noise conguration is

possible. Beyond that the series is developed or low power consumption.

Main applications: large stationary dieselengine power plants.

Congured dry compact coolersLiterally thousands o models, created with modular design and a variety o an

sizes, oer an extensive choice to match your exact requirements. GEAcongured

modular dry compact coolers are most eective or power generation as well as

or a wide diversity o industrial processes with average to low cooling capacities.

Main applications: versatile power units using gas or diesel engines (gensets),

HVAC systems, industrial processes.

Transormer oil air compact coolers (TOACC)Transormer oil air compact coolers can be supplied in various mounting versions.

The standard oil air cooler version is designed or direct mounting on the trans

ormer tank. In addition, our range o products comprises reestanding transormer

oil air compact coolers designed to customer specications. Transormer oil air

compact coolers are available in various material versions.

Main applications: cooling o power transormer or transmission and distribution

o electricity. Oil pumps & fow meters can be supplied as optional items.

Compact bundles or HVAC and industrial processesThe compact bundles are a component o all compact radiators and dry compact

coolers, but can also be delivered separately. For specic applications, the draw

back o low heattransmission eciency can be compensated by a larger exchange

area the n ned surace. On the other hand, this produces the advantage o

greater process engineering fexibility thanks to variable tube d iameters, distances

between ns, turbulators, and product headers.

Main applications: chiller and antiicing compact coils or inlet air, HVAC systems,

industrial processes.

GEA Cmact Radatrs Dry clers

Finned-tube compact systems

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You will nd our solutions in stationary dieselengine power plants, in gas turbines, in combined

cycle power plants, in versatile power units, and in conventional or nuclear applications.

We design and manuacture compact radiators, dry compact coolers, compact bundles, and trans

ormer oil air compact coolers or power generation processes customized and sustainable.

GEA Compact Systems complies with all the standards required or energy operations: Codap,

ASME, AD, BS, GOST, as well as all other codes related to heat exchangers.

Versatile power units(gensets)

Engine generators are used to supply

electrical power to sites where mains

power is not available, or where

power is needed only temporarily,

or as a standby solution. For space

reasons, small and ecient heat

exchangers are usually installed.

Operational reliability is an impor

tant criterion or standby solutions

in hospitals or urban acilities with

essential social responsibilities.

Detailed inormation: page 15

Gas turbines and combinedcycle power plants

Water consumption by powerplant

condenser cooling is becoming

an issue o increasing importance.

Signicant reduction in plant water

consumption can be achieved by

the use o closedcycle dry cooling.

The eciency o combinedcycle

power plants can urthermore be

boosted by precooling combustion

air. This is eective or application

in hot climates and also oers the

benet o increasing power output.


Diesel engine stationarypower plants

Stateotheart heat transer pro

cesses and equipment are a key to

enhanced eciency o ossil uel

power generation. In many countries,

such plants provide most o the

electrical energy used. Fossilueled

power stations are greenhouse gas

emitters which makes it vital to

increase eciency.


Cogeneration power plants

Combined heat and power generation

(CHP), also known as cogeneration,

is the use o a power station to provide

both electric power and processes (or

district heat). Although such plants

emit heat at a temperature higher than

normal (to enable building heating

and increase overall plant eciency),

calculations show that cogeneration

is the cheapest method o reducing

carbon emissions.


Here we are

Compact systems for the energy industry

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Among the most outstanding projects is the power plant in

Mabruk, one o the largest oil elds in Libya. MAN 18V32/40

diesel motors with an output o MW each were installed

here. Induced drat compact radiators with AlMg ns are used

or cooling, especially designed or desert conditions and

highly resistant against abrasive and corrosive infuences.

Energy modular compact radiators (EMCR)EMCR, top quality products with competitive price and short delivery times, oer an

improved product range developed to match the technical requirements o the

main players in the large dieselengine market. With a basis o 40 years o success

ul applications, even moreadvanced technologies now ensure reliable perormance

in heat transer and ventilation, with eciency similar to that o customized

compact radiators.

The GEA product range uses horizontal induceddrat design, with single or

doublebank conguration (HT/LT). EMCR are modular compact products made o

prespecied components that are assembled according to analysis by design

sotware. They are completely assembled and tested in the GEA actory beore

delivery. All components are standard items, and outsourced repetition with a long

delivery time are put on stock to ensure adhoc availability. Only a limited range

o outsourced components (ans, motors, etc.) have been selected; they ensure,

however, priceworthiness based on ordering large quantities o similar components.

The high modularity o the product ensures sizing as close as possible to the

customers needs. Internal manuacturing allows a maximum o fexibility: a wide

variety o di mensions is available , with two w idths and over 6 0 dierent le ngths.

GEA sotware allows quotes, including 3D drawings, within two days.

Customized compact radiatorsCustomized compact radiators oer rugged and reliable design. They have been in

use at GEA or more than 40 years in all types o industrial applications. They

are suitable or diesel applications in which particular specications are applied.

Price and lead time are based on design specications. An innite variety o

subcontracted items can be ordered specically or each contract. Very large ans

driven by gear transmission or Vbelts and pulleys, with possibility o installation

in orceddrat conguration, are available to meet very quiet noise requirements

and to enable very low power consumption. Bay congurations are available;

Product eatures:Energy modular compactradiators

Improved product dedicated to

large dieselengine power plants

High cooling capacity (> 2.5 MW)

Range with predened

components, oering thousands

o models created with the aid

o modular compact design

Possibility o horizontal and

induceddrat congurations,

with single or d ouble bank s

Copper tubes and cylindrical

copperpipe headers

S32 ns, made o aluminum,

marine aluminum, or

copper; availability o epoxy

and PoluAl coating

4 and 6 eet diameter ans,

direct drive

Large selection o accessories

Product eatures:Customized compactradiators

Customized design to meet each

and every specic requirement

Suitable or nuclear applications

(emergency gensets), with

conormity to the applicable codes

Use o advanced specic

thermodynamic and mechanical

design programs

Copper tubes, 12 mm and

16 mm diameter

Al, AlMg, or copper (fat, rippled,

turbulated). poluAl coating

Cylindrical copper headers or

steel boxes type headers

Fan diameters rom 4 to 12 eet;

Vbelt or gearbox transmission

Various congurations

(orceddrat bays)

All required electrical and

mechanical accessories

they consist o two large bundles installed side by side, overlapped by two large

ans. Such congurations are regularly used in diesel engine power plants.

Any components available rom GEA or rom external suppliers can be installed.

GEA oers S32 and S40, with tube diameters o 12 or 16 mm and with the

materials copper, steel or stainless steel. Any design and manuacturing codes

can be applied such as ASME, Codap, AD, etc. also to meet all requirements,

including those o nuclear applications.

Accessories and equipmentAll necessary mechanical accessories are available rom GEA or this application,

such as steel structures, piping, valves, ladders and handrails or an access. We

can also provide all required electrical components or protection and control o

the system, i.e. control cabinets or starting and stopping ans either in stepped

mode or by requency inverters. Required instrumentation such as temperature

probes and vibration switches can also be supplied, as well as any other specic

instruments. Electric motors are Hclass insulation type, and may be equipped

with NT con densation heaters and epoxy paintin g i required b y site conditions.

Water spraying can be added to the dry cooling system to enhance cooling capacity

or peak temperatures, to eectively avoid oversizing the complete system or

only brie operation at high temperatures. Coating o the enclosure or EMCR or

customized types is available or highly corrosive conditions.

Fins coating is one o the main competitive advantages o GEA Compact Radiators.

We use the highly cu stomized paint PoluAl, which our partner Blygold developed

or this application. Without loss o thermal eciency, it provides highly eective

protection against corrosion risks in salty air and at industrial sites. Warranties

o ten years and beyond have already been granted or sites with highly severe

conditions. Other conventional coatings such as epoxy are also available, but they

provide much lower protection, with shorter lietime o the coolers.

Statary desel-ege wer lats

Solutions for smooth continous operation

Diesel power plant in Libya.

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Fin an compact coolersThis reliable design has been used at GEA or more than 40 years. Integrated systems

include many possible options (described on page 13), ully customized to individual

requirements and specications. Vbank design is also available. A virtually un

limited variety o subcontracted items can be ordered specically or each contract.

Mediumsized ans, directly driven or with gear transmission, are available or very

quiet requirements and or very low power consumption. Heat exchange technology

is based on S32 and S40 systems rom GEA with 12 and 16mm tubes made o

copper, steel, or stainless steel. PoluAl is used as coating on the aluminum ns to

prevent corrosion. The enclosures are made o thick carbon steel sheets, normally

protected by a specied painting system.

Auxiliary compact coolers (based on Forgo technology)Auxiliary compact coolers are available or gas turbines and combined cycles. These

very rugge d systems have be en used at GE A with a retu rn o experien ce and

fexibility to customers needs similar to n an coolers. Integrated systems include

many possible options (described on page 13), ully customized to individual require

ments and specications. Vtype and rootype design are also available. A virtually

unlimited selection o subcontracted items can be ordered specically or each

contract. Very large ans are available, driven by gear boxes or Vbelts and pulleys,

with possibility o installation in orced drat cong uration, or very quiet require

ments and or very low power consumption. Heat exchange technology is based on

Forgo technology rom GEA with diameters o 18 and 25 mm or tubes made o

aluminium, steel, or stainless steel. TiO2based coating is used on the aluminum ns

to prevent corrosion. Winterization is available or cooling at very low temperatures.

Dry/deluged compact solutions are also possible or cooling enhancement.

Compact bundlesNTicing and chiller coils or the inlet housing o gas turbinesDimensions are calculated specically or each project, according to design

parameters and site conditions. S32 or S40 technologies are employed with large

n pitch to keep pressure drop as low as possible. Fins are made o AlMg or coated

A 350 MW combinedcycle power plant operates in Esch sur

Alzette in Luxembourg. The customer, Alstom, uses GEA systems

or the cooling plant. Cooling water modules were delivered in

1999: a n an cooler plus expansion tank, piping, pump skid,

and instrumentation. The equipment included alu ns turbulated

type plus polual coating. The large ans (8 diameter) are drivenby means o transmissions (pulleys and Vbelts).

Product eatures:Customized n ancompact coolers

S32 and S40 ns

Closest possible match to a wide

range o specications and codes

Oil and water

Turbulators or oil cooling

Free conguration (horizontal,

in bays, Vbank, induced, orced)

No limitation in dimension

Availability o a great diversity

o headers, tubes, ns, ans,

casings, and accessories

Wide range o cooling capacity

Suitability or various applications:

e.g., gas turbines, combinedcycle

power plants, with specic design,

metallurgy, and numerous

industries

aluminum to ensure good mechanical resistance and anticorrosion eatures.

Water inlet and outlet as well as internal circuits must be designed according to

the conguration o the inlet housing o the gas turbine. Design compact

solutions take ull account o essential requirements such as equipment drainage.

For chiller coils, n spacing and positioning must take into consideration the

fow o n condensation due to temperature decrease. The condensate is collected

in a tray installed below the coils.


such as ladders and handrails or an access, steel structures, piping, valves,

pump skids, and expansion tanks (atmospheric or pressurized). We also provide

all required electrical components or protection and control o the system, i.e.

control cabinets or starting and stopping ans either in stepped mode or by

requency inverters. Required instrumentation such as temperature probes and

vibration switche s can also b e supplied, as wel l as any other sp ecic inst ruments.

Electric motors can be equipped with NTcondensation heaters and epoxy painting

i required by site conditions. Water spraying can be added to the dry compact

cooling system to enhance cooling capacity or peak temperatures, to eectively

avoid oversizing the complete system or only brie operation at high temperatures.

Fin coating is one o the main competitive advantages o GEA Compact Radiators.

For S32 and S40 ns, we use the highly customized paint PoluAl, which our

partner Blygold developed or this application. Without loss o thermal eciency,

it provides highly eective protection against corrosion risks in salty air and at

industrial sites. Warranties o ten years and beyond have already been granted or

sites with highly severe conditions. Other conventional coatings such as epoxy

are also available, but they provide much lower protection, with shorter lietime o

the coolers. TiO2based coating is used or the Forgo ns.

Gas turbines chiller coils in Adana, Turkey.

Product eatures:Auxiliary cooler typecompact radiators

Customized design to meet each

and every specic requirement

Based on Forgo technology rom

GEA with aluminum, steel, or

stainlesssteel tubes, with 18 and

25mm d iameters

ASME UStamp available

Various congurations (horizontal,

orceddrat, Vbank, roo type)

Winterization or very low temp.

(EGIs own design)

Dry/deluged solutions possible or

cooling enhancement (EGI own)

Internal turbulators or oil

Vbank and roo type

Bay design available

Large ans with gear transmissions

Forced drat

CCPP in Esch sur Alzette, Luxembourg.

Gas trbes ad cmbed-cycle wer lats

Customized compact solutions for each and every case

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Transormer oil air compact coolersCompact designs here are based on the specications o leading powertransormer

companies, to ensure a very long lietime (similar to the transormer itsel).

Application o the strictest standards assures eective cleaning o the inside o the

coolers and removal o any metallic particles that could result rom manuac

turing. Headers are removable to allow inspection o the inside part o the coolers

and to assure cleanliness. S32 n geometry is with copper or aluminum tubes

with 12 mm diameter (new!!

) and aluminum or AlMg ns, typically coated withPoluAl. Forgon geometry with aluminum tube diameter o mm is also available

(new!!). Each design corresponds to one type o transormer.

The coolers are then customized to the customers specic requirements:

Noise level: ans can be selected or each individual design

Internal and external protection by customized coatings

Supporting brackets to allow mounting in various positions

Dedicated lters to avoid ouling and clogging o the ns

Dedicated sotware used or individual components (bundles, ans, options, .)

Accessories and equipmentFlow meters as well as oil pumps rom Business Unit Shell&Tube are available. Air

lters which are used to avoid clogging o the ns are also applicable or transormer

oil air compact coolers.

Product eatures:Transormer oil aircompact coolers

No predened dimensions

required; wide range or each

transormer manuacturersspecications and codes

Possibility o horizontal, vertical,

and induceddrat congurations

S32 copper tubes, S32 and Forgo

aluminum tubes under

development; availability o

internal turbulators

Fins made o aluminum, marine

aluminum, or copper, with epoxy

and PoluAl coating available

Direct drive

Customized casing and coating

Availability o GEA oil pumps

Alternative products (single tube,

shellandtube) rom GEA HX

available

Dry compact coolersThis range o highquality congured products was developed to match the

technical requirements o the main players in the small to mediumsize diesel

and gasengine market (normally < 2.5 MW), with competitive prices and short

delivery times. The advanced technology o the nned tubes, used by GEA

or decades, ensures great system reliability. Doublebank conguration (HT/LT)

is available or our ranges. Fans able to operate under high temperatures are

used or this application. Modular compact products made o predenedcomponents are assembled according to analysis made by design sotware. The

compact products are completely assembled and tested in the GEA actory beore

delivery. All major congurations are available: fatbed (induced and orced

drat), Vbank, or vertical, or all individual cases. All components are standard,

and outsourced items with long delivery times are kept in stock to ensure prompt

delivery. Only a limited selection o outsourced components (ans, motors, etc.)

is used, to ensure avorable prices rom suppliers, based on large quantities o

similar components. Product fexibility ensures sizing as close as possible to the

customers requirements, with prompt availability owing to components manu

actured inhouse (many dimensions are available in our range). The reliability

o the compact cooler, also or highest ambient temperatures, ensures the operation

o the entire plant. Cogeneration power plants o modular design are or landll

gas and biogas extraction as well as or minegas extraction to generate electricity

and heat. Return cooling o the cooling water circuits o the gas engines is

perormed by standard dry coolers. The cooler is urnished with ventilators o

various noise le vels, which c omply with loca l emission regu lations.


such as ladders and handrails or an access, steel structures, piping and valves,

and expansion tanks. We can also provide all required electrical components or

protection and control o the system, i.e. control cabinets or starting and stopping

ans either in stepped mode or by requency inverters. Required instrumentation

such as temperature probes and vibration switches can also be supplied, as well

as any other specic instruments. Water spraying can be added to the dry cooling

system to enhance cooling capacity or peak temperatures, to eectively avoid

oversizing the complete system or only brie operation at high temperatures. Fin

coating is one o the main competitive advantages o GEA Compact Radiators.

We use the highly cu stomized paint PoluAl, which our partner Blygold developed

or this application. Without loss o thermal eciency, it provides highly eective

protection against corrosion risks in salty air and at industrial sites. Other con

ventional coat ings such as epox y are also ava ilable, but the y provide much lowe r

protection, with shorter lietime o the coolers.

Product eatures:Congured dry compactcoolers

Medium to low cooling capacity

Range with predened

components, with thousands

o models possible through

modular design

Possibility o horizontal, vertical,

Vbank, induceddrat, and

orceddrat congurations

Copper tubes and copper pipe

headers

Availability o S32 ns, made

o aluminum, marine aluminum,

or copper

Epoxy and PoluAl coating

available

Direct drive and VFD control

Large selection o accessories

Suitability or small diesel and

gas engines

Mobile genset rom Caterpillar.

Trasrmer l ar cmact clers

Efficient and flexible solutions for T & Ds

Versatle wer ts sg gas r desel eges

Space-saving solutions for compact gensets

14 | 15


9/15

Oce buildings withullaade glazing

Even though outstanding passive

building designs are now available,

modern glass aades represent

great challenges or climate control.

For example: it is not rare that

rooms on the building side toward

the sun must be cooled while heating

is necessary on the shady side.

Hotels and data centers

Feelgood climate and temperature

is highly individual, whether or

hotel occupants or or high tech in

computer centers. The design o the

air treatment plant must satisy all

demands. This also requires fexible

systems and easily congurable

components with top security against

ailure.

Parking garages

Wherever internal combustion

engines operate indoors, health

protection is critical. Respiratory

air quality is the crucial actor or

ventilation and e xhaust. In parking

garages, ventilation systems must

also be able to cope with rapid

load fuctuation and high peak

perormance levels.

Museums and libraries

For their archiving requirements,

museums and libraries require

absolutely stable indoor climate

conditions. Fluctuations in room

humidity endanger works o art

and books. Eective air treatment

thereore requires ar more than

mere temperature control.

Where heating, cooling, purication, humidication, and dehumidication o air are required,

HVAC Systems makes its contribution to progress. GEA specialists can exploit prepared and

globally accessible knowledge within the GEA Heat Exchangers Segment and can early in the

planning stage successully create an airtreatment system optimized or energy consumption

and cost eectiveness.

Here we are

Compact systems for HVAC processes

16 | 17


10/15

GEA in the heart o Paris: The client Trane decided on using

our innovative systems or air conditioning a building o France

Telecom. The dry compact coolers are a component o chillers

type RTHD and operate with cooling kits with a capacity

o 1,200 kW per chiller. A total o seven were delivered in 2002.

Dry compact coolersThis range o highquality congured compact products has been developed to

match all technical requirements (dimensions, noise level, etc.) with competitive

prices and short delivery times. The critical technology used in the nned tubes,

used by GEA or decades, ensures great reliability o the system, including

availability o Euroventcertied units. EC ans or auto control o output at low

temperatures with very quiet operation, and or minimum power consumption,

are used or this application.

These are modular compact products made o prespecied components that are

assembled according to analysis by design sotware. They are completely assembled

and tested in the GEA actory beore delivery. All major congurations are available:

fatbed (induced and orceddrat), Vbank, or vertical, or all individual cases.

All components are standard items, and outsourced items with a long delivery time

are put on stock to ensure prompt availability. Only a limited range o outsourced

components (ans, motors, etc.) have been selected; they ensure, however, price

worthiness ba sed on ordering large quantit ies o similar compone nts. Product fe xi

bility ensures sizing as close as possible to the customers requirements, with prompt

availability owing to components manuactured inhouse (many dimensions are

available in our range). Integrated quotation sotware allows quotes with drawings

within just a ew days.

HVAC dry compact coolers in Paris.

Product eatures:Dry compact coolers

Modular design

Copper tubes with 12mm

diameter

Aluminum ns, rippled

or turbulated Cylindrical copper headers

Availability o Vbank

Fan diameters rom 760 mm

to 900 mm

AC or EC ans

Lowspeed motors

Eurovent certication

PoluAl or epoxy coating on ns

Compact bundlesFor air handling units, compact bundles are used or heat transer between the

dierent media (water/steam/power). According to the number o tubes o a bundle,

the heat transer area between the media is larger or smaller to ensure that heat

transer (hot or cold) takes place with various degrees o eectiveness. The range

includes bundles mounted either into the air handling unit or inside the pipes,

depending on the application. Water or environmentally riendly CFC fuids can be

used as cooling media. We oer a wide range o possibilities with Co/Al coils,

and with c ylindrical copper headers always equipped with draining devices.

Depending on the application, ns are made o aluminum or copper, and can be

epoxycoated.


such as steel structures, piping, valves, and ladders and handrails or an access.

We can also provide all required electrical components or protection and control

o the system, i.e. control cabinets or starting and stopping ans either in stepped

mode or by requency inverters. Required instrumentation such as temperature

probes can also be supplied, as well as any other specic instruments.

HP (100 bar) and LP (3 bar) water spraying can be added to the dry cooling system

to enhance cooling capacity or peak temperatures, to eectively avoid oversizing

the complete system or only brie operation at high temperatures. Water treatment

is also available to prevent sanitary risk o contamination by bacteria such as

legionella. Coating o the enclosure is available or highly corrosive conditions.

Fin coating is one o the main competitive advantages o GEA Compact Radiators.

We use the highly customized paint PoluAl, which our partner Blygold developed or

this application. Without loss o thermal eciency, it provides highly eective

protection against corrosion risks in salty air and at industrial sites. Warranties

o ten years and beyond have already been granted or sites with extreme conditions.

Other conventional coatings such as epoxy are also available, but they provide

much lower protection, with shorter lietime o the coolers.

Product eatures:Compact bundles or HVAC

Suitability or various

industrial processes as well as

HVAC systems

Complete duty range

Low pressure drop

Modular design

Flexible dimensions to t all

types o airhandling units and

ventilation pipes

Copper tubes 12-mm diameter

Aluminum or copper ns, rippled

or turbulated

PoluAl or epoxy coating available

or corrosive conditions

HVAC systems ad rcesses

We ensure feel-good climate in buildings

18 | 19


11/15

Food and pharmaceuticalprocessing

Any equipment used in these indus

tries must comply with demanding

environmental, health, and saety

regulations. Manuactured in

stainless steel, heat exchangers by

GEA oer outstanding liecycle

characteristics, with extraordinary

reliability in thermal perormance.

Their perectly sealed liquid circuits

are absolutely essential.

Other industries

Hardly any industrial process is imag

inable without heat transer. Drying

or powder production, control o air

humidity, processwater cooling, and

air preheating thermal transer

between materials fows always plays

a key role.

Automotive industry

The manuacture o motor vehicles

involves numerous work steps that

require cooling: pressing, welding,

the use o robots and compressors,

and painting. Costconscious solutions

are likewise in demand, as well as

intelligent utilization o waste heat.

Wood, pulp, and paper

Paper machines, elt drying, presses,

and any process requiring cooling

water and consider able energy:

control o heat exchange enables this

industry to better manage costs

while improving product qua lity.

Energy and gas compressionstations

Since most gasliqueaction plants

are installed in dry regions or in

areas where acceptable coolingwater

quality is not available, air cooling

has become the preerred method or

the initial section o the gascascade

cooling process.

Waste incineration plants

Pressurized steam air condensers or

turbines, primary air heaters, equip

ment to recover smoke and gases, and

air coolers or condensation water: all

this is essential in waste incineration

plants.

We work or all the worlds industries. Look in almost any industrial process, and you will nd

GEA solutions. They are customized and eature dedicated designs or every individual case.

GEA specialists are amiliar with all typical process requirements: they will be more than glad

to nd the optimal solution or your special application.

Iron and steel industry

Very high temperatures, a corrosive

environment, and air pollution are the

challenges in the metalworking and

steel industries. Our thick AlMg ns,

or example, are extremely robust and

support airprocessing temperatures

up to 200 C and at relatively high

pressure. This GEA technology is

suitable or dusty environments and

can be cleaned by highpressure water

jet devices, providing a lietime o ull

perormance or over 20 years.

Here we are

Compact systems for an extensive range

of industries

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Gas compression stationsI the distance between a natural gas

source and the consumer is greater than

1,300 km, a potential alternative to the

pipeline is the liqueaction o gas or the

purpose o transportation and storage.

Liqueed Natural Gas (LNG) only takes

up a raction o the volume. Natural

gas could be considered the most

environmentally riendly ossil uel,

because it has the lowest CO2 emissions

per unit o energy and because it is

suitable or use in higheciency com

binedcycle power stations. While gas

liqueaction already consumes approx.

10 to 25 percent o the gass own energy

content, reconstitution o the gaseous

state (heating rom 161 to + 5 degrees

Celsius at a pressure o 90 bar) also

requires signicant quantities o energy

and/or sea water. Cooling o requency

converters (demin water) and com

pressors are applications served by GEA

Compact Systems in gas compression

stations.

Pulp and paperPaper and cellulose production is a

highly energyintensive process.

Constantly increasing energy prices

orce up production costs. The best

way to gain a compet itive edge in t he

paper industry is to reduce energy

requirements using higheciency

system components. GEA provides the

optimum compact solution with its ull

range o compact radiators and dry

compact coolers. Our equipment helps

to achieve lasting reductions in energy

costs and to optimize the energy con

sumption in manuacturing processes

such as cellulose production, heat

recovery, and waste water treatment.

The systems are installed as machinery

cooler, engine cooler, and in water

process cooling. Renowned cu stomers

such as SonocoCascades, Arjowiggens,

Ahlstrom, Norske Skog, Egger, and

Tembec already prot rom this peror

mance portolio.

Waste incineration plantsWaste incineration plants also belong

to the innovative business sectors o

GEA cooling technology. The system

ullls the highest demands or e

ciency and sustainability. Application

areas include the condensation o

the steam at the outlet o the steam

turbine with pressurized steam

condensers, as well as cooling o the

ST lube oil or bearing and generator

thanks to a dry compact cooler.

This advanced compact technology is

already successully in operation by

clients such as CNIM, Von Roll Inova

and Vinci.

Automotive industryFiltered as well as heated, humidied,

or airconditioned supply o air is

necessary or the operation o a painting

booth. It must be conditioned to 24 C

and 65 % relative humidity. The required

cooling capacity is so high that the

operation would be uneconomical. An

air recirculation system is employed or

energy conservation which cleans, lters,

and airconditions the paintspraying

booth exhaust air to a high quality and

employs this treated exhaust air as

spraying booth supply air. Even though

this represents an enormous energy

conservation, high cooling and heating

output must still be provided. GEA

equipped dierent sites, e.g. Renault

and PSA in France.

Iron and steel industryFor metallurgy, iron, and steel, GEA

uses AlMg thick ns, which have low air

resistance and are highly resistant to

corrosion. They are extremely robust,

supporting airprocessing temperatures

o over 200 C.

Cooling of furnaces: Customized

compact radiators with Co tubes and

AIMg ns, cylindrical copper tubes

Cooling of galvanization lines:

Compact coolers/compact bundles with

CuNi or SS tubes and Al ns, cylindrical

copper tubes

Cooling of electrolyzing bath for

production of aluminium (demin

water): Customized compact radiators

with SS tu bes and alu ns

Pharmaceutical and oodprocessing sectorOur compact coolers comply with

European standards or pressurized

equipment and with health regu

lations covering ood processing and

pharmacy. Milk powder, starch powder,

yeast powder, medic al powder .. . the

heat exchangers developed by GEA have

applications in both drying processes

and atmospheric processes used to cool

the air carrying the powders. Manu

actured in stainless steel, the heat

exchangers have an excellent lie span

and their thermal perormance is

particular reliable: temperatures are

regulated with great accuracy. In addi

tion, we provide our clients with

perectly sealed circuits, thus avoiding

any buildup o powder in the piping.

Use in various processes to dry and

transform food products: Compact

bundles with dierent metallurgies

involved

Cooling of service water: Standard and

customized dry compact coolers

Drying and humidity control: Heating

and cooling bundles

These customized compact heat

exchangers are also used in the textile,

plaster, cement, and chemistry industry

to cool service water and dry products.

May ad vars dstres ad rcesses

Customized solutions with specific design

22 | 23


13/15

With more than 80 years o experience and knowhow in

the design and construction o heat exchangers, GEA has devel

oped countless types o compact ntube systems to meet all

specic requirements involving media temperature, pressure,

noise levels, reduced ootprint, vibration, and protective coatings.

FinsFrom the wide GEA nnedtube range, the ollowing three are most commonly

used due to their technical fexibility and costeective advantages: turbulated,

rippled, and fat. GEA turbulated ns provide the best ratio eciency/pressure

drop o the market today, and are not sensitive to clogging risks thanks to its high

tech turbulator acting as a guide o the cold air behind the tube and not as an

obstacle to generate turbulances. In compact systems, the ns are punched by

highprecision machines. The shape o the turbulators and the sophisticated tube

n connection, achieved by expansion o the tube diameter, enable the top

perormance o the system. The choice o material used or the ns depends on

environmental constraints. For example, highresistance AlMg alloys enable

highpressure jet cleaning without damage.

Pumps skid, maniold, and interconnection piping:Design and manuacturing to the customers requirements with suction and dis

charge interconnection pipes, valves, lters, and required instrumentation

such as pressure sensors. The pumping skid normally has two circulating water

pumps (one in service, the other in standby) sized to meet the designed pressure

drop o the complete loop (heat exchanger, piping, and customers equipment)

and fow requirement o the application.

Expansion tanksAtmospheric or pressurized types made o either galvanized or painted carbon steel.

Its unction is to allow the expansion o the fuid to be absorbed during rises in

temperature in the circuit. It is made o steel, with internal and external treatment

against corrosion. In most cases, the atmospheric type is preerred, and tted on

top o the unit. Its position should always be above the highest point o the circuit,

so as to avoid overfows and air pockets. Vent and charging holes connected to

the input and output headers by fexible pipes permit continuous venting o the

installation. Equipped with level detectors and alarms. The pressurized type will

contain a bladder blown by air inside, and can be xed on ground level.

Fins type vs site conditions.

Adiabatic dry compact cool er with HP

misting system.

Coating with a unique corrosion protective systemIn partnership with Blygold, GEA has designed and developed a unique automated

process to apply a perectly graduated coating. It protects the compact nned

coils against harsh environmental conditions such as erosion by sand or salt. It

provides a barrier and avoids the risk o electrolytic reactions between the

two metals involved. The coating contains aluminum to maintain the thermal

perormance o the compact coil, resulting in extension o the lietime, maximum

cooling capacity, and reduction o energy costs. Moreover, in the event o any

incident or shock to the exchange surace, the ns and the lm can be repaired

on site without changing or even moving the dry cooler or radiator.

Adiabatic dry compact coolers with HP misting system andbacteria control in the waterMost installations are sized according to maximum temperatures occurring

only rarely during the year. This situation is worsened by increased heatwave

phenomena o recent years, which has resulted in oversizing and a larger

ootprint, higher noise levels, and greater investment in terms o nonproductive

exchange suraces. Adiabatic dry compact coolers retain the advantages o a dry

air cooler. GEAs exclusive process involves a very high pressure misting system

(> 100 bars) as well as hydrodynamic cavitation and UV rays to destroy biolm

and kill all pathogens bacteria including Legionella allowing to reach the

highest cooling perormance in ully sae conditions, and conorm to ACOP L and

NSF55 Class A regulations. Water consumption remains limited because spraying

operates only at the hottest times o the year. This concept avoids oversizing o

dry compact coolers, and thereore reduces the dimensions o the exchanger,

lowers the amount o power used by the ans, and dampens the noise level o the

installation. GEA also oers another type o adiabatic cooling system consisting

o induced drat dry/deluged coolers with horizontal cooling deltas. A continuous

water lm on the fat ns enha nces cool ing perormanc e. The delug ing system

operates on ly in hot summer hours and dramatically reduce s cooler size.

Acetic salt spra y test.

Brazer at GES.

S32 turbulated aluminum fns.

IR thermography.

Pumps skid.

Expansion tank.

Detals techlgy ad ctaltes

Energy-efficient compact solutions and corrosion

protection

24 | 25


14/15

Expect onestop solutions

By concentrating various perormance elds into a single, onestop solution, GEA especially

enables more eective control o the complex processes in heat transer. It also speeds up

order execution and simplies preventive and remedial maintenance o heat transer

acilities. In this way, GEA creates clear and personally addressable responsibility or the

entire process o project implementation. In a global, tightly meshed network, our highly

qualied sta provides all key processes industrial production and air treatment.

GEA has set a new standard or eciency, reliability, and availability in heat exchange.

With production and service locations around the world, GEA Compact Systems as part o

GEA Heat Exchangers oers, based on a singlesource technology, a unique industrial

network to provide excellence in engineering and expertise in local services and compre

hensive support o our customers in a wide range o dedicated applications.

EuRopE

Center of Excellence

GEA Erg-Spirale et

Soramat SAS2,

rue de lElectrolyse

62410 Wingles, France

Phone: +33 3 21 69 89 00

Email: [email protected]

GEA NEMAWrmetauscher GmbH

Friedensstrae 3a

08491 Netzschkau, Germany

Phone: +49 3765 492-0


GEA Maschinenkhltechnik

GmbH

Sdstrae 48

44625 Herne, Germany

Phone: +49 2325 468-801


GEA Searle Ltd.

20 Davis Way, Newgate Lane,

Fareham, Hampshire,

PO14 1AR United Kingdom

Phone: +44 1329 823344

Email: ino.searle.uk@

geagroup.com

GEA Polska Spolka Z O.O.

Ul. Sikorskiego 38

58-160 Swiebodzice, Poland

Phone: +48 74 8500 800

Email: ino.polska.pl@

geagroup.com

GEA EGI Contracting/

Engineering Co. Ltd.

4-20. Irinyi J. Str.,

Science Park, Building B

H1117 Budapest, Hungary

Phone: +36 1 225-6100


AfRiCA

GEA Erg-Spirale et

Soramat SAS

2, rue de lElectrolyse

62410 Wingles, France

Phone: +33 3 21 69 89 00


ASiA

GEA IHE Systems (China) Co. Ltd.

No. 8 Yangtian Road, Jiujiang

Economic Development Area,

241007 Wuhu Anhui, China

Phone: +86 553-5951222-0

Email: inoihechina@

geagroup.com

GEA IHE Systems IndiaF602, SAI ANSH,

Opp. Jui Nagar Station(W),

Plot no. 7, Sector 11, Sanpada,

Navi Mumbai 400705, India

Phone: +91 98204 53979

Email: jayakumar.nair@

geagroup.com

EGI Cooling System Trading Ltd.

Unit 716, Tower 2, Landmark Towers,

No. 8 Dongsanhuan Beilu,

100004 Beijing, China

Phone: +86 10-6590-7558


oCEAniA

GEA IHE Systems (China) Co. Ltd.

No. 8 Yangtian Road, Jiujiang

Economic Development Area,

241007 Wuhu Anhui, China

Phone: +86 553-5951222-0


noRTH AMERiCA

GEA Rainey Corp.5202 West Channel Road,

Catoosa OK 74015-3017, USA

Phone: +1 918 266 3060


SouTH AMERiCA

GEA do Brasil

Intercambiadores Ltda.

Estrada SP 354 km 43,5 Serra

dos Cristais Franco da Rocha

SP CEP 07803-970, Brazil

Phone: +55 11 4447-8800


Sales / Distribution

Production / Manufacturing

Yr GEA exerts r radatrs / dry clers wrldwde

Reachable always and everywhere

26 | 27


15/15

Excellence Passion Integrity Responsibility GEA-versity

GEA Group is a global mechanical 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.

G

EAHeatExchangers.

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12/2011.www.papp.cc

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