Btt - Batignolles

technologies thermiques
Energy Technology
Division

Aircooled Heat Exchangers

‘we just give a bit more energy to the air’
 Summary
GEA Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.3

GEA Btt at a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.4

GEA Btt’s products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.8

- Air Fin Coolers
- Air Cooled Condensers
- Finned tubes

Your partner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.12

- to define your project
- to execute your project

Field Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.22

Products and markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p.25

- Oil
- Petrochemical
- Gas
- Energy and other fields

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GEA Group The Energy Technology Division of GEA is by tradition a world-
wide player in the heat transfer industry. We serve our clients
in the power generation business and all traditional areas of
Customized Process Process Plant the process industries such as chemical and petrochemical
Systems Equipment Engineering Engineering plants as well as refineries. Our product portfolio
includes products and systems for :
- Direct Dry Cooling ( Air Fin Coolers )
Process Energy Lurgi - Direct Condensing ( Air Cooled Condensers )
Air Treatment Oil, Gas,
Equipment Technology Chemicals - Wet Cooling ( Natural Draft Cooling Towers, Cell Cooling
Towers, Hybrid Cooling Towers )
Lurgi Lentjes
Refrigeration
Mechanical Process
Environmental - Indirect Dry Cooling ( mainly Heller® Systems )
Separation Engineering Engineering - Special Applications ( Surface Condensers, Desublimators,
Post Reactors, Shell & Tube Heat Exchangers, BoP
Dairy Farm Zimmer
Polymers, Fibers
Engineering )
Systems
- Services.
E-Division
Gas Cleaning
GEA Energy Technology

The GEA Group is a leading global technology group with

more than 250 companies operating in approximately 50 Industrial
Power Process Heller
countries. GEA stands for Global Engineering Alliance. Our Products
core competences are specialty mechanical engineering and Batignolles Technologies
GEA Power Cooling EGI Engineering/ Polacel b.v
plant engineering. In 90 percent of our businesses we rank Inc. (GPC)
Thermiques Contracting Ltd.(EGI) (PCL)
S.A.S. (BTT)
among the worldwide market and technology leaders.
GEA Energietechnik GEA Rainey 2H Kunststoff
GmbH (GET) Corporation (GRC) GmbH (ZHK)
In 2005 more than 17,500 employees generated Group sales
of 4.5 billion Euros. The GEA Group is listed in the MDAX. Beijing GEA GEA Iberica S.A.
Energietechnik Co. (GIB)

GEA Scambiatori GEA Luftkühler GmbH

di Calore S.r.l. (GSC) (GLK)

GEA Aircooled
Systems (Pty.)
Ltd.(GAS) 3
 GEA Btt at a glance
1958: the start of the design and manufacturing of the first
API aircooler in France under the name of ‘Creusot Loire’.

GEA Rainey
USA
HOUSTON

1985: GEA takes over Btt

and supports Btt to become the world leader in the API 661 Aircooled Heat
Exchangers market, including Aircooled Steam Condensers for oil and gas
applications.
Through the Process Business Unit of
GEA’s Energy Technology Division
2006: Btt is a worldwide leader for process aircooled heat exchangers market with GEA is also serving this market with
over 150 Mo euros yearly sales and the lead unit of the Process Business Unit of GEA the following operations:
Technology Division. - GEA Rainey Corp in the USA for the
American market,
- GEA Iberica in Spain for the Spanish
market,
-GEA Aircooled Systems in South
Africa for the South African market.
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A worldwide presence since 1958 in oil, gas, energy and petrochemical sectors

PARIS
GEA Bochum
GEA Btt Nantes Germany
BEIJING

France GEA Iberica

Spain
MADRID

Btt Changshu
SHANGHAI China
Btt DOHA
RIYAD Qatar To respond to the increasing demand
of the Middle East and Asian markets,
Btt is operating 2 workshops in Qatar
and China.
These new facilities are operating
based upon Btt’s technology and
quality and are 100% Btt’s subsidiary.

GEA Btt has partnership agreements in

South Korea, Indonesia and Australia.
For specific projects, local partnerships
may be developed to provide a local
content.

GEA Aircooled Systems

South Africa

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 Large facilities to serve a growing world demand

in China in France

China capacity:
- 30 km/week of extruded finned tubes
- 25 km/week of L and G finned tubes
- 500 tube bundles per year

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 in Qatar

Qatar capacity:
- 30 km/week of extruded finned tubes
- 25 km/week of L and G finned tubes
- 500 tube bundles per year

France capacity:
- 75 header boxes per week
- 55 km/week extruded finned tubes
- 50 km/week L and G finned tubes
- 1200 tube bundles per year
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 GEA Btt’s products

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Air Fin Coolers and Air Cooled Condensers
Products manufactured by GEA Btt respect the environment.

Air Fin Coolers (AFC) use the ambient air to cool industrial fluids.

Individual solutions for

refineries, gas treatment
stations, petrochemical
plants and some industrial
plants.

Air Cooled Condensers (ACC) use the ambient air to condensate turbine exhaust steam under vacuum.

Complete system including

vacuum units, condensate tanks,
pumps, control devices installed
behind generator or compressor
driven steam turbines in oil and
gas industries and other auxiliary
plants.

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 Finned tubes

Bimetallic extruded G (embedded) L (wrap-on) Knurled L Double LL

Maximum working
300°C/750°F 400°C/750°F 120°C/250°F 250°C/480°F 120°C/250°F
temperature

Atmospheric corrosion Excellent Poor Acceptable Medium Medium

resistance
Mechanical resistance Excellent Acceptable Poor Acceptable Poor
Price index 125 105 100 102 105

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Headers
The plug header is the most commonly used up to
250 bar working pressure

The cover plate header is used for fluids with high

fouling factors up to 30 bars when a frequent
mechanical cleaning is necessary.

The pipe header is used for working pressure over

200 bars when no inner access is necessary.

The welded bonnet header is used for ammonia

condensers and aircooled steam condensers. The
advantage is the full welded constructions,
suitable for vacuum applications.

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 GEA Btt is your partner to define your project
Thermal Design

A dedicated team deals with customer technical requirements:

- Heat duty
- Maximum tubeside pressure drop
- Maximum noise level
- Plot plan restriction
- Electrical power consumption
- Extreme environmental conditions
- Any specific request

and on the other hand with the associated costing in order to

provide customer with the most optimized solution.

Tools
- In-house design and costing software
- International recognized thermal software
(Xace® from HTRI)
- Fan suppliers’ sizing softwares
- Computational Fluid Dynamics software

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Research and Development

As part of a global organization specializing in heat

exchangers, GEA Btt is involved in development programs
aiming at increasing efficiency and performance through
collaboration with experts.
- Member of HTRI communication Committee
- Member of ISO Technical Committee
- Member of ASME Committee for testing procedure validation
(PTC 30)

Tests are regularly performed in close partnership with our

customers and our suppliers to test and validate new designs
or new equipment.

CFD software has been used and further developed to study

Testing facilities have been specifically developed :
- Tube tester - Hot air recirculation
- Bundle tester - Multiphase distribution inside the exchanger
- Tubeside flow and heat transfer

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 TOTING Design of Headers Design of
TOTING is an in-house developed
software which can generate
■ In-house developed finite element
preliminary engineering at an
early stage of the project. calculation methods certified by
ASME authorised inspection agencies
are used for header design as per
ASME VIII div.1 App. 13.

■ Arrangement drawings and ■ Finite Element specific softwares

loading data can be submitted and models are used for nozzle
to the customer during the pre- stress analysis under piping
engineering phase to optimize loads.
the plant cost.

■ Bill of materials allows us to

optimize our cost calculation.

■ The detail engineering phase can

be launched immediately after
order placement.

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steel structure for AFC and ACC Design of the auxiliaries for ACC
■ From the GAD issued by TOTING we
are able to generate a 3 D model in
order to perform the calculation of
the structural steel using STAAD pro®
software. This model is then exported
to X-steel® software to issue 3 D dra-
wings and shop drawings.

■ This integrated design process will

ensure the manufacturing of the steel
structure and will allow us to produce
calculation data when requested.

■ Basic and detailed engineering for auxiliary

equipments are carried out under one
roof by a dedicated team of specialists
using the latest state of the art.

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 GEA Btt is your partner to execute your project

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t
Manufacturing facilities
All GEA Btt’s facilities include all the required machinery and know how to insure that the complete bundles are manufactured to
a quality standard and to schedule.

Headers manufacturing has been substantially improved

over the years with the use of modern manufacturing
techniques, CNC equipment and bar coding systems.

GEA Btt is highly experienced in special design

using exotic materials (such as Titanium, Monel,
Incolloy...) for special services (very toxic, lethal...).
Tubes manufacturing is performed with in-house
improved machinery for extruded fins and latest
available technology for wrap-on fins.

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 Quality Control
Before being delivered to the customer, the products go through extensive tests:

Pressure parts

Complete bundle

X-Ray, Ultrasonic, Liquid Penetrant tests …

hydrotest

AFC and ACC testing

PMI examination

Shop run-in test may include vibration, air flow, power consumption
and noise level measurement
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 Certifications
Design and manufacturing activities at GEA Btt comply at all locations with the latest certifications, European
directives and with some specific National regulations.

ISO 9001 version 2000 for the quality of the whole process
(design, manufacture, tests, installations) with regular
audit from the Authorized agencies.

ASME (American) U, U2, for pressure vessels

Local authority’s approval:

ISO 9001 for

Btt China shop

China Poland Belarus

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 Packing Module assembly
A large storage area is available in GEA Btt’s workshops for the preparation GEA Btt may also use local yard facilities for
of shipments where packing lists, packing, marking and customer storage and modular erection.
requirements are controlled.

A specific packing has been developed for sea transportation.

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Transport
GEA-Btt is committed to on-time delivery.

... by air

... by road

... by sea 21
 Field Activities
Erection, commissioning and services

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Once the product is delivered, GEA Btt is also present on site for:

■ the erection of Air Fin Coolers or Air Cooled Condensers

supervision only or full turnkey service.

■ commissioning

■ performance tests

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 Services - Components
A full range of after sale services is at your disposal :

GEA Btt supplies spare parts and services to all

aircooled heat exchangers, including 3rd party design.

GEA Btt proposes identical or interchangeable spare parts, designed

and manufactured in compliance with the most recent standards and
international codes. GEA Btt can also propose an expedited delivery
concept (less than 72 hours) on requests for components in stock.

GEA Airflow Services GEA Btt Spare Parts & Components Dept
GEA Btt has created a subsidiary company “GEA Airflow Bundles
Services” fully dedicated to after sales field services such as: • We design and deliver spare bundles certified interchangea-
ble with original supply (header boxes / fintubes / frame).
• Aircooled heat exchangers assessments Fans
• Performance improvement by up grading fans and drivers • We supply spare parts for fans from stock: blades, hubs,
• Debotllenecking analysis bushings…
• Maintenance programs Components
• Cleaning verification and consultancy • We supply bearings, pulleys, belts, gear reducers, shafts,
• Cleaning hardware plugs, gaskets, bolting…

One e-mail: info@airflow-services.com One e-mail: spares@btt-nantes.com

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Products and markets
OIL

Refineries
Project: Leuna 2000 Project: Melaka PSR2
Country: Germany Country: Malaysia
Products: Air Fin Coolers Products: Air Fin Coolers
(induced draft) (forced draft)

Oil fields
Project: Irving Oil Project: Hassi Messaoud
Country: Canada Country: Algeria
Products: Air Fin Coolers Products: Humidified
with external Aircooler
recirculation

Project: Nanjing
Country: China
PETROCHEMICAL Products: Air Fin Coolers and
Air Cooled Condensers

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 GAS
LNG (Liquid Natural Gas)
Project: Bonny Island Project : Woodside
Country : Nigeria Country : Australia
Products : Air Fin Coolers Products : Air Fin Coolers
(induced draft) (induced draft)

Gas To Liquid (GTL)

Project : Oryx Project : Bintulu SMDS
Country : Qatar Country : Malaysia
Products : A-frame Products : A-frame
Air Cooled Condensers Air Cooled Condensers

FPSO Offshore platforms

Project : Sanha LPG

Country : Angola
Project : Bongkot Project : Tunu
Products : Air Fin Coolers
Country : Thailand Country : Indonesia
(Forced draft)
Products : Air Fin Coolers Products : Air Fin Coolers

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ENERGY…
Steam Condensers

Project: Le Havre Project: Kulim

Country: France Country: Malaysia
Products: Vacuum Steam Products: Vacuum Steam Condenser
Condenser for for Combined Cycle
Incineration Plant

Turbine Cooling
Fuel Gas Heater
(TCA/FGH)
Project: Power Plant
Country: Taïwan
Products: Air Fin Coolers … AND OTHER FIELDS

Project: Chillers for Eurotunnel

Country: England/ France
Products: Air Fin Coolers
(induced draft)

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 Btt - Batignolles
technologies thermiques
Energy Technology
Division

A company of GEA Group

GEA Batignolles technologies thermiques S.A.S. - 25, rue du Ranzai - 44300 Nantes - France - Phone : +33 2 40 68 24 24 - Fax : +33 2 40 68 29 91 - www.btt-nantes.com - E-mail : bttntes@btt-nantes.com