11th December 2024
Boost Air-Cooled Condenser efficiency with CFD modelling
At Galebreaker, our custom wind screens are designed to offer optimum protection against the elements, guided by advanced computational fluid dynamics (CFD) modelling.
Wind screens for air-cooled condensers are crucial for addressing wind-related issues that can disrupt airflow and impact performance. But how do we ensure our wind screens are precisely configured to maintain steady energy output and protect plant efficiency?
Our CFD modelling approach enables us to tailor wind screens to each site, providing a cost-effective alternative to expensive structural upgrades. In this blog, we lift the lid on our process.
Configuring power plant windscreens: How CFD modelling creates value for your plant
Our CFD modelling process is the first step in the customer journey to optimising power plant performance with wind screens.
The process begins by creating a ‘digital twin’ of your plant, enabling us to simulate how wind speed and airflow interacts with the plant’s key structural surfaces. This analysis helps us pinpoint the optimal wind screen placement to stabilise airflow around the ACC.
Here’s how we use CFD modelling to assess your plant’s performance:
- Digitise the fan curve
We create a digital model of your plant’s ACC fans for the simulation - Simulate wind conditions
The CFD programme mimics real-world wind speeds and environmental factors - Measure pressure and performance
We assess static pressure changes and fan performance to pinpoint cooling inefficiencies - Analyse airflow and thermal impacts
The CFD model shows zones of low or negative airflow velocity – helping us to spot disruptions and predict the impact of cooling efficiency changes - Compare with and without screens
We simulate plant performance with and without wind screens to quantify improvements.
Optimising wind screens with CFD modelling
Gary Dicker, Galebreaker’s UK and European cooling specialist, highlights the benefits of CFD:
“CFD modelling doesn’t just help optimise airflow; it lets us analyse how wind affects fan performance and thermal efficiency. This means plant managers can see exactly what return on investment to expect before installation”.
By using CFD, operations managers can better-understand and mitigate key issues like:
- Wind shear: Crosswinds can accelerate beneath the ACC, disrupting airflow and changing the fan static pressure – leading to cooling inefficiencies.
- Dynamic fan blade loading: Uneven wind pressure can cause mechanical stress, increasing wear on the fan’s mechanism.
- Recirculation: Hot air re-entering the ACC, reducing cooling effectiveness
- Fan blade damage: A single fan replacement can cost over £40,000 and take up to 20 weeks to install
“The digital twin provides an incredibly detailed way of translating airflow improvements into actual performance gains,” Gary continues. “It’s not just about showing airflow; by simulating real-world operating conditions, it gives power plants the tools to calculate annual savings in megawatts or revenue, making the case for investment crystal clear.”
“CFD modelling lets us test different windscreen configurations or even alternative solutions before installation,” says Gary. “By digitising the fan curves and applying variable conditions, we can predict exactly how a plant’s performance will change with or without screens.”
Real-world success stories: Coryton Power Plant and beyond
Our CFD modelling has been used to optimise the placement of windscreens and delivered measurable results at power plants across the world.
- Coryton Power Station (UK): CFD modelling enabled the redesign of 20-year-old wind screens to further enhance airflow , leading to increased steam turbine output and significantly reduced back pressure – improving overall plant efficiency.
- Rio Bravo Energy Center (Mexico): Wind screens improved vacuum pressure by 20mbar and boosted output by 1.68 MW during high winds on hot days. Read the full case study
- Fadhili Combined Heat and Power Plant (Saudi Arabia): Custom wind screens improved thermal performance, preventing plant de-loading during high desert winds, and helped mitigate gas flaring. CFD modelling ensured accurate wind data upfront, securing stakeholder confidence prior to windscreen investment. Read the full case study.
See all wind protection case studies
Wind screens for air cooled condensers – a sustainable investment
CFD modelling has shown that power plant wind screens are not just a protective measure—they are a long-term investment in operational reliability and sustainability. By stabilising airflow and reducing mechanical stress, plants can avoid expensive turbine trips and minimise maintenance costs.
Our wind screens are lightweight, durable, and tailored to each facility’s unique needs. The partnership between Galebreaker and leading CFD experts, Ergon Research, ensures that every installation is backed by scientific analysis.
Gary Dicker explains: “Many operators don’t realise the hidden cost of wind-related inefficiencies. CFD helps us quantify those losses and offer tailored solutions that deliver rapid payback, often within six to 12 months.”
This makes Galebreaker’s wind screens an ideal solution for power plants dealing with volatile weather conditions. With over 100 installations worldwide, our experience speaks for itself.
Why choose Galebreaker?
- Expertise in CFD-led design ensures solutions are tailored to your site.
- Proven results in diverse climates, from the UK to Saudi Arabia.
- Durable, low-maintenance fabric windscreens designed for longevity and easy installation
- See the return on investment before installation
Our solutions are not just about stopping performance loss—they’re about future-proofing operations. By using CFD modelling to create bespoke wind screen solutions means plants can avoid the risk of plant de-rating and safeguard against the unpredictability of shifting weather patterns, a growing concern in today’s climate-conscious world.
See the benefits
Watch our 2-minute video to see Galebreaker’s wind protection solutions in action.
Ready to find a solution that will help optimise your plant?
Speak to our experts and start your consultation.
