Dry Cooling Systems-Service

Maintenance & Technical Solutions

Dry Cooling Systems

Delivering Excellence since 1936

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delivering excellence since 1936

Air Cooled Condensers

To meet different customer requirements SPIG offers design, engineering, manufacture and installation of ACC Dry Cooling Systems suitable for Power Plants, Waste to Energy Plants, Chemical and Petrochemical Industry, Oil Refineries, etc. SPIG high efficiency design Air Cooled Condensers are flexible and customized A-frame, V-frame or D-frame configuration, low fan power consumption, resistant to corrosion and freezing conditions, requiring very low maintenance and guaranteeing long life operation and cost effective solutions.

Air Fin Coolers

Air Fin Coolers are a cost effective solution using air to cool process fluids, typically used in various process industries such as Oil & Gas, Petrochemical, Refineries, Power Plants, Waste to Energy Plants, Chemical, Petrochemical Industry, Solar etc. SPIG qualified and experienced thermal engineers use advanced technologies to provide the most cost-effective designs to meet the required thermal performances and to ensure the best efficiency in thermal and mechanical design of pressure parts (ASME code), in steel structure and in noise management.

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Certificates & Industry Association

SPIG considers Quality and Safety as the main drivers to reach excellence in every project.

In 2000, SPIG certified according to ISO 9001 international standard, covering all the Company activities from the design to installation and service.

Since 2004 all the installations, revamping, maintenance and Global Service activities has been executed according to safety SCC 2008 international standard.

Moreover, SPIG is a proud member of HTRI, HEI, ACC Users Group etc.

Air Pre-Heater (APH)

APH, Air Pre-Heater, is a general term used to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. Steam or other source may be used as air heating media. Economizer (ECO) An economizer is a mechanical device which is used as a heat exchanger by preheating a fluid to reduce energy consumption. In a steam boiler, it is a heat ex-changer device that heats up fluids or recovers residual heat from the combustion product i.e. flue gases in thermal power plant before being released through the chimney or flue gas treatment system.

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Ducted Bundles Tube bundles ducted type are commonly used of heat recuperation, HVAC, district net or flue gas heating for treatment system or Denox. Customer care To meet customer requirement SPIG is committed to being a reliable and flexible partner for plant owners and operators. SPIG Service solutions offers a vast array of options ranging from basic technical assistance, field service and support to a completelong term service agreement, as well as installation, commissioning and start-up, performance test and review optimization, including upgrades and conversions. In order to maintain plants at the highest level of efficiency,SPIG Global Service is the best solution for operation and maintenance staff with site training academy and technical information. EQUIPMENT LIFE TIME SPIG Service

The SPIG comprehensive after-sales service portfolio includes inspections, maintenance programs, structural and thermal repairs, upgrades, refurbishment, addition of new cells and spare parts supply.

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Service Engineering

P & I Diagrams & Process Schematics System Plant Layout Equipment specification & evaluation Cycle optimization studies Piping mechanical design & stress analysis pipeline & yard piping Foundation load design Structural design & analysis Plant instrumentation & control logics Noise abatement study

Stress analysis Ducting and piping are subject to severe operating conditions, therefore subject to special accuracy during the design. SPIG has gained adequate experience that allows the management and design with the most advanced software available in the market (SPIG, CAESAR II licensee). SPIG has developed a dedicate mechanical engineering department for ducting and piping stress analysis in order to fulfil all the customer specifications and codes. Structural calculation Since the last decade, SPIG has constantly studied and developed and a new concept of the steel structure, in full compliance with theinternational standard regulations (ASCE, EC and any local normative). This specific asset has been designed for highly demanding site conditions and customers benefit.

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Service Activities

Project Management Seasonal testing, data record, trends and

correction solutions report Procurement, delivery and installation of original

spare parts Heat exchangers reconditioning Inner surface and extended surface cleaning Maintenance program execution & check list Vibration measurement and analysis Field Noise testing Checking and cleaning heat transfer surface Checking air flow rate and fans reconditioning Infrared camera scanning NDT Eddy current tube test Data gathering by customer DCS or SPIG UNICO

online monitoring system

Vibration analysis SPIGs best practice assures the highest reliability in design method for rotating equipments vibration analysis and reduction. Equipments are installed and commissioned according to the international standard guidelines and SPIG Standard Procedures Guide. Field service analysis and SPIGs scheduled plan inspection guarantee outstanding efficiency and long life operation. Noise evaluation With over 75 years of proven experience, SPIG has developed an in depth noise reduction expertise. Our dedicated team of technicians is committed to study the superior solutions aimed at noise reduction in ACC. By using the most advanced software SPIG is able to achieve the highest results for customers benefit, at lower cost impact.

Noise reduction trend

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NDT tube testing SPIG has developed a wide knowledge to deliver cutting edge NDT tube testing. Eddy current testing (ECT) is commonly used to inspect non-ferromagnetic materials; Remote Field Testing (RFT) or Magnetic Flux Leakage (MFL) is used for carbon steel and other ferromagnetic materials; ultrasound Ultrasonic Testing of Tube may be used for accurate thickness measurements of either non-ferromagnetic or ferromagnetic materials. Infrared Scanning SPIGs infrared scanning is a preventive maintenance solution to spot leaks in tube bundles, piping, flanges and connections in power and Petrochemical operations. The infrared camera can rapidly scan large areas and pinpoint leaks in real time. It is suitable for monitoring plants difficult to reach with contact measurement tools. Spigs predictive maintenance (PdM) programs use thermography to monitor the apparent temperatures of operational equipment, using the heat values to detect and avoid equipment loss. CFD analysis Computational Fluid Dynamics is a methodology that allows engineers to predict or evaluate negative impact on Air Coolers performance. CFD is a powerful system enabling SPIG efficient design to assure the best improvement solutions for outstanding plant performance.

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UNICOTM

In order to extend Cooling Systems life time and optimize their performance it is mandatory to constantly monitor their conditions. Air Cooled Heat Exchangers may face fouling of the heat exchangers surface, leakages, corrosion due to lack of a proper maintenance program, checking and alarms. As a consequence Cooling Systems may then incur in failures and unscheduled, costly shut-down affecting the plant productivity. SPIG software, allows to monitor, collect, analyse, and deliver critical information about customers plants, enabling them to make better, data-driven decisions. UNICO is suitable to monitor a large and steadily expanding variety of industries, including power, petrochemical, oil and gas etc.

Cleaning system SPIG has the expertise to return the Heat Exchanger to high performance, when efficiency is affected by any type of dust deposits, solid particulate or corrosion. Our trained technicians are able to provide state-of-the-art Semi-automatic high pressure demi-water jet cleaning system and infrasonic soot.

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Performance improvement

Project Management EPC for Plant Expansion & Modifications Projects Detailed Engineering & Procurement Fabrication and Erection of heat exchanger , piping

& Steel Structure Pre-Assembly and installation of non-pressure

parts (fans, stack, duct & structure) Pre-Assembly and installation of pressure parts

(heat exchanger, vessel, duct & structure) Fabrication, pre-assembly, installation, testing &

commissioning of new equipment Equipment Installation, Pre-commissioning &

commissioning De-commissioning, preservation and reconditioning

of existing equipment Cycle optimization study and sensitive analysis

Performance improvement Overview

New boundaryrestriction

Obsolete system

UpgradesExistingfootprintsystem

Increasefans

efficiency

Providenew

improvedfans group

Bundlesriconditioning

Heattransfer surface

cleaning

New bundles

asexisting

New bundlestechnology

Fogging or spryhumidification

air intake

Plantextension

Increasecells

number

New improved

technologyheat

exchanger

hybridsystem (HCS)

Process efficiency reduction

Others plants detrimental

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EXISTING FOOTPRINT

Fans group

Blade angle pitch optimization and speed rotation Change blade material with higher efficiency profile Provide better low resistance fans ring and guard Automatic grease bearing system installation Provide long life axial shaft Improve rotating speed for maximum air flow rate

purpose Sealing system improved for air leakage removal

Tube bundles

Provide new tube bundles Increase performance with better fin tube type

technology and material Complete bundles reconditioning and revamping New process obtimization of product passes vs

product pressure drop Provide better piping/ducting routing for pressure

drop reduction

Typical performance improvement with SRC tube

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Extra cooling system and winterization

Proactive Fogging or Humidification system Chillers system and water assistance Anti freezing with ACC Full dephlagmator system Anti freezing with roof or cell sectioning and

louvers natural draft control

Proactive fogging system upgrade

Auxiliary systems

Vacuum system riconditioning and capacity enangment (SJE, LRVP and Hybrid system)

Drain and Condensate extraction pump system Instrumentation review and new proved derivative

logic Control logic optimization for start-up, operation

and shut down Cycle optimization and energy recovery (preheater,

flue gas heat recover, condensate subcooling reduction etc.)

Old vacuum system New vacuum system

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PLANT EXTENSION

Cooling system upgrade, by adding additional exchanger modulessimilar to the existing or an improved type technology

Hybrid Cooling Solution (SPIG HCS system), using both air and water in order to mitigate the reduction of production during hot periods. This option can be used in sites where some water is present for supplemental cooling, though not enough for a fully wet-cooled system.

Global Service

SPIG has earned a strong worldwide reputation as a reliable and top quality service provider, guaranteeing and enhancing the thermal performance of the plant according to customers requirements. The SPIG team of after sales engineers and technicians are fully dedicated to Maintenance Activities that guarantee long service life of the plant. SPIG offers a planned Global Service activity on a multi-year basis which is most suitable for plants operating since a long time in critical conditions where the client aims to avoid costly shutdowns and repairs.SPIG Global Service activities range from but are not limited to

UNICO Unique Online Continuous Monitoring Field and Online Technical Assistance Seasonal tests Design review Reporting Activity & improving solutions Enhancement of plant reliability and consultant

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Global Reach

Headquarters

Piazza San Graziano 31, 28041 Arona (NO) ITALY Ph. +39 0322 245401 - Fax +39 0322 245499 E-mail: [email protected]

BranchOffices

USA RUSSIA SPIG USA INC. SPIG VOSTOK 9988 Hibert Street, Suite 102 BolshayaPochtovaya 26V, Build 2, office 400 San Diego, CA 92131 107076 Moscow Ph. +1 877 955 7744 Ph. +7 495 545-43-76 Fax +1 858 260 2104 Fax +7 495 545-43-76

BRAZIL GERMANY SPIG-TORRES DE RESFRIAMENTO SPIG KHLTURMTECHNOLOGIEN GmbH Rodovia Alkindar Monteiro Junqueira S/N Km 5,5 ImLipperfeld 25 SP63 Bairro: Ponte Nova D-46047 Oberhausen Itatiba SP Cep:13252-810(S.P.) Brazil Ph. +49 (0)208 94 1884-0 Ph. +55 11 4594 9988 Fax +49 (0)208 94 1884-10 Fax +55 11 4594 9988

TURKEY U.A.E. SPIG MIDDLE EAST SPIG SOGUTMA SISTEMLERI TIC.LTD.STI. Lob 7 - Office No: 7F09 - Opp. Post Office Sair Esref Bulv. No : 22/812 Jebel Ali Free Zone 35230 Izmir Dubai - U.A.E. Ph. +90 232 441 08 46/47 Ph. +971 4881 7202 Fax +90 232 48 373 20 Fax +971 4881 7223

INDIA CHINA SPIG COOLING TOWERS INDIA PVT. LTD. SPIG SHANXI COOLING SYSTEMS Co. Ltd 608, Palmspring Dongcun Industrial Park Link Road, Malad (W) Dingxiang, Xinzhou Shanxi Mumbai 400064 Shanxi Ph. +91 (22) 40 890 500 Ph. +86 35 03 323 223 Fax +91 (22) 40 890 599 Fax + 86 35 03 323 208

KOREA

SPIG SEOUL 702, 7th Floor Kangnam-officetel, 40 Seocho-Daero, 73-Gil, Seocho-gu Seoul, 137-857, Korea Ph. +82 1032486489

www.spig-int.com

Dry Cooling Systems-Service

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