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Scatter graph, before and after windscreen installation at Ferrybridge 1. Orange plots represent ACC vacuum pre Galebreaker windscreen installation. Blue plots represent vacuum post installation
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F1 vacuum F2 vacuum
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After Galebreaker Before Galebreaker
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is an integral part of the Saudi Aramco Fadhili gas plant as the plant is fully dependent on FCHPP for its 1447 tons per hour (TPH) process steam and 768 TPH feedwater supply.
Fadhili’s desert location poses severe challenges for its ACC system, explains Muhammad Asim Ghafoor, the plant’s lead performance and reliability engineer. “In the design, wind speeds up to 3 meters per second were assumed, but in reality we face gusts of up to 15 meters per second.
“The stronger-than-expected winds caused high vacuum levels, which led to de-loading during peak summer demand – resulting in financial penalties. Reduced load triggered gas flaring, as the plant couldn’t consume natural gas from the 40–50 km pipelines supplying it fast enough”. The plant considered adiabatic cooling, but the high cost and lack of water made this solution unviable. “Adiabatic cooling was ruled out because it didn’t address the wind problem and required water, which is scarce in our region,” Muhammad notes. Instead, they opted for windscreens. “The windscreens were lightweight and manufactured to fit the existing steel frames of our ACC, which was a key factor in our decision.”
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Scatter graph comparing Ferrybridge 1 and 2. Ferrybridge 1, blue plot, has the Galebreaker windscreens installed. Ferrybridge 2, green plot, currently doesn’t have windscreens
Measurable improvements
Since the installation of the windscreens, Ferrybridge 1 has seen a marked improvement in performance. “The digital twin was pretty accurate in predicting the outcome,” Lee reflects. “Ferrybridge 1 is now consistently outperforming Ferrybridge 2, with a better backpressure rate. The windscreens have also helped reduce the strain on our fan motors and gearboxes, improving overall mechanical stability.” “We also no longer have to adjust our boiler throughput rate or risk tripping the turbine due to high backpressure, something that happened in 2022, but hasn’t been an issue since,” he adds.
Looking ahead: wind and climate change Lee predicts rising ambient temperatures, due to climate change, will make ACC performance more challenging, increasing the need for wind mitigation. “From autumn to spring, we’re seeing 80 to 100 MWh per day more generation at Ferrybridge compared to the summer,” he notes. “If you consider that at £100 per MWh, you’re looking at about £9000 per
day loss potential because of higher ambient temperatures.”
With windscreens proving their worth, plans are now underway to install them at four sister sites, including the company’s new location at Skelton Grange. “It’s crucial plant managers monitor their ACC performance closely and address any deviations. Engaging with a specialist and using CFD modelling gives peace of mind that the investment will deliver a return in a short period.”
Fadhili combined heat and power plant – addressing ACC challenges in the desert The Fadhili combined heat and power plant (FCHPP) is a 1507 MW gas-fired facility in Saudi Arabia’s Eastern Province. Co-owned by Engie Energy Services, Saudi Aramco, and Saudi Electricity Company, it plays a critical role in meeting the country’s growing energy demand. FCHPP, commissioned in 2020, is located next to Saudi Aramco’s Fadhili gas plant, the first gas plant to treat non-associated gas from both onshore and offshore fields, with a processing capacity of 2.5 billion standard cubic feet per day (BSCFD). FCHPP
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To ensure optimal windscreen placement, Galebreaker used CFD modelling, which gave the necessary assurances to the plant’s investors and shareholders. “The CFD analysis confirmed the screens’ effectiveness and allowed us to secure investment with confidence,” says Muhammad. Since the installation of the windscreens in 2023, Fadhili has experienced dramatic improvements. The plant saw a rapid return on investment, achieving payback within just three months. “In 2022, we were frequently reducing load almost on daily basis, but last summer, we only reduced load twice - and that was during the two hottest days of the year,” says Muhammad. “Moreover, gas flaring has been eliminated, reducing environmental impact and financial penalties.”
With water scarcity driving more plants in Saudi Arabia to adopt air-cooled condensers, Muhammad anticipates increased demand for windscreens. “We’re seeing more plants moving inland, away from coastal areas where they could rely on seawater cooling. As more plants transition to air-cooled condensers, wind mitigation will become a critical factor for stable plant operations,” he concludes.
Future developments As climate conditions become more unpredictable, future demands will likely call for more advanced strategies.
Galebreaker is already exploring ways to enhance windscreen technology, including the potential integration of bespoke wetting systems to offer an alternative to traditional adiabatic cooling, addressing both temperature and wind issues.
Galebreaker presentations from the 2024 Air-Cooled Condenser Users Group conference are available at
Galebreaker.com
www.modernpowersystems.com | October 2024 | 31
ACC vacuum ACC vacuum
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