Protect your air-cooled condenser from efficiency losses: a reflection from the ACCUG Conference

In this blog, we share insights from the Air-Cooled Condensers (ACC) Users Group Conference and discover how wind screens for ACCs can prevent efficiency losses.

By Jamie Wilde, commercial director and cooling solutions team leader

I was privileged to represent Galebreaker as a headline sponsor at the 2024 Air-Cooled Condenser (ACC) Users Group Conference, an event which brings together power plant managers, engineers, and industry experts from around the world to share insights and wind protection strategies for these essential cooling systems.

Wind-related efficiency losses were a major theme throughout the conference. As climate patterns shift and unpredictable weather increases, air-cooled condensers (ACCs) face rising challenges from high winds.

These issues can lead to significant performance losses. For example, an increase in windspeed from 3-5 m/s can lead to a 30% reduction in airflow, while a A 20% airflow reduction can lead to a 33% increase in back pressure. Such operational inefficiencies can have a commercial knock-on effect, potentially reducing a power plant’s output.

Why ACCs are growing in popularity and need weather protection

Air cooled condensers are an increasingly popular cooling system in power plants due to their flexibility and environmental benefits.

Unlike water-cooled systems, ACCs use air to condense turbine exhaust steam, reducing the need for water—a critical advantage in drier regions where natural resources are scarce.

They can also help lower ongoing costs as they don’t require significant infrastructure investment, as can be the case with cooling towers or water treatment facilities.

However, ACCs are particularly vulnerable to environmental factors like wind, which can disrupt their efficiency and lead to costly operational downtime, where power generation is temporarily halted to protect equipment.

As these systems gain traction at power stations worldwide, addressing wind-related issues is becoming more and more essential for reliable and sustainable electricity generation.

How does adverse weather affect power plant efficiency?

High winds can interfere with ACC systems in three main ways:

1. Wind shear: Disrupts airflow, reducing cooling efficiency
2. Mechanical vibrations: High winds can cause dynamic fan blade loading, leading to increased vibration and mechanical stress, fan blade damage and eventual component failure
3. Hot air re-circulation: When wind pushes hot exhaust air back into the system, it reduces cooling effectiveness

See our infographic: effects of wind on air cooled condensers

When these issues occur, plants may need to ‘derate’ (lower) their power output. This loss of capacity can result in missed production targets and financial penalties.  

Effective wind mitigation is possible with Galebreaker’s wind screens, which help stabilise airflow, ensuring ACCs operate reliably and avoid these costly inefficiencies.

At the ACC Users Group Conference, we heard from a range of delegates from all over the world who had used wind screens to counter environmental challenges at their plants.  

Addressing desert winds at Fadhili Combined Heat and Power Plant , Saudi Arabia

One standout presentation at this ACC Users Group Conference was from Muhammad Asim Ghafoor, Lead Performance and Reliability Engineer at the Fadhili Combined Heat and Power Plant (FCHP) in Saudi Arabia.

A joint venture between ENGIE, Saudi Aramco, and Saudi Electricity Company, the Fadhili plant generates 1,507MW of electricity while supplying vital steam and feedwater to the adjacent gas plant. Located in the desert, its ACC setup faces extreme winds of up to 15 meters per second.

These extreme winds caused high vacuum levels triggering  frequent plant de-rating during peak summer demand. This led to  gas flaring – a costly exercise where excess gas had to be burned off due to capacity issues.

To counter these challenges, Fadhili installed 20 custom Galebreaker wind screens. This intervention stabilised ACC performance, eliminating gas flaring and achieving a payback on the screens within three months. While Fadhili’s situation is unique, it highlights the potential for rapid returns from targeted wind mitigation.

Read our case study on Fadhili Combined Heat and Power Plant: Wind protection screens in Saudi Arabia

Download Muhammad’s  ACC Users Group Conference presentation

Long-term benefits of wind screens at Coryton Power Station

Closer to home, the Coryton Power Station in the UK has relied on Galebreaker wind screens for nearly 20 years. Situated on the River Thames, this 800MW natural gas-fired power plant supplies power to approximately 800,000 homes annually.

Coryton’s ACC, a 40-cell air-cooled condenser allows the plant to use approximately 95% less water than a typical thermal power plant, and has been pivotal in achieving sustainable operations.

After nearly two decades of reliable performance, Coryton’s original Galebreaker wind screens were replaced and updated with a new, optimised design developed using the latest CFD modelling techniques.

The new arrangement of 26 perimeter and cruciform screens has further improved airflow performance, reduced back pressure, and enhanced steam turbine output.

Attendees at the ACC Users Group Conference had the chance to tour Coryton’s facility, witnessing firsthand how the new wind screens are continuing to enhance operational stability and efficiency.

Read our case study and watch the video of our installation at Coryton Power Station.

Looking Ahead

Reflecting on the ACC Users Group Conference, it’s clear that power plants worldwide are prioritising wind mitigation to safeguard operational efficiency and meet demand.

Presentations and insights from the conference are available on our website, providing valuable information on strategies for optimising ACC performance in various environment.

Technical Case Studies & Published Articles – Galebreaker

As climate change forces us to grapple with more unpredictable weather patterns, it is more vital than ever to invest in effective wind protection. Ensuring reliable ACC performance is not just about operational efficiency—it’s also about supporting sustainable energy production, ensuring we meet growing demand.

Investing in wind screens today ensures more reliable power generation tomorrow – contributing to a more resilient and sustainable energy future.

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