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Berlin / Bochum / Cologne / Duisburg / Gelsenkirchen / Hamburg / Hoyerswerda / Munich / Salzgitter / Stuttgart
ZPP Ingenieure AG
Head officeLise-Meitner-Allee 1144801 Bochum
+49 234 9204-0
ZPP Group of companiesZPP Ingenieure AGZPP International GmbHLauPlan GmbHGERICON GmbHZPP Hennig GmbHBreddermann + Partner GmbBKuhfeld Schildberg Partnerschaft mbB
COOLING TOWER NEW BUILDINGNATURAL DRAFT-, HYBRID- AND CELL COOLING TOWERS
www.zpp.de/planning
> Höhler, S., Lehnen, D. (2013)Hybrid Cooling Towers - A new standard in urban areas. IASS Symposium Breslau, 23-27 September 2013
> Höhler, S., Vossen, T., Lehnen, D. (2012)Structural Calculation of Hybrid Cooling Towers. 6th International Symposium on Cooling Towers, ISCT, Cologne, 2012, 567-574
> Busch, D., Meyer, J., Ohlmann, U. (2012)The Quality Control during Construction of the Cooling Towers at the RWE Power Stations6th International Symposium on Cooling Towers, ISCT, Cologne, 2012, 349-356
> Lehnen, D., Meyer, J., Höhler S., Pfister T. (2011)Kühltürme - Schalentragwerke im Dienst der Energieerzeugung. Bauingenieur VDI-Bautechnik Jahresausgabe 2011/2012
> Niemann, H.-J., Harte, R., Meyer, J., Wörmann, R. (2011)Recent amendments to the VGB Guideline on the Design and Construction of Cooling Towers in Power Plants VGB PowerTech 9, 2011, 94-103
> Lehnen, D., Meyer, J., Bockhold, J., Pfister, T. (2010)Grundlagen des Lebensdauermanagements im Kühlturmbau. Innovationen im kostruktiven Ingenieurbau - Methoden - Materialien - Bauwerke. Ruhr-Universität Bochum, 2010
> Bockhold, J., Meyer, J., Klöker, T. (2006)Einsparpotentiale beim Bau von Kraftwerken am Beispiel von Windeinwirkungen auf KühltürmeBautechnik (WILEY-VCH Verlag) 83, Nr. 10, 2006, 669-680
PLANNING
+49 234 92 04-1262
Dr.-Ing. Sebastian Höhler
+49 234 92 04-1164
Dipl.-Ing. Martin Demmer
Natural Draft Cooling Towers
Worldwide, cooling tower structures are essential to dissipate process heat via the cooling cycle in power generators and industrial systems. However, the type of cooling tower needed is different depending on the prescribed requirements and boundary conditions. The most effective cooling tower technology is wet cooling, which includes natural draft cooling towers and fan-driven cooling towers. The hybrid cooling tower is a special form that combines the functions of wet and dry cooling. The new construction of cooling towers of any kind must be examined from the point of view of the thermal design basics, the static requirements and the economic aspects. The construction of large natural draft cooling towers of 200 meters height or more as well as sophisticated hybrid cooling towers are a challenge for every-one involved in their planning and construction due to the complex forces acting on them, the load bearing characteristics, and the dimensions. With decades of experience in the area of structural planning and verifying ZPP is the ideal partner for your cooling tower structure.
Natural draft cooling towers are, due to their impressive and highly visible appearance, symbols of power plants. Their height of up to 200 meters and thin-shell thickness make them complicated engineering structures. Their function is determined by the heat to be dissipated and, due to improvements in the flue gas cleaning systems in coal power plants, are being used more and more often as a replacement for a chimney. They are designed according to thermal as-pects, which need to be brought in line with the static requirements.
Running Operation
During running operation, the ZPP Cooling Tower Book keeps records on new circumstances and shows changes which may affect the structure.
Conservation of value and operational reliability: Recommendations of inspections within the scope of periodic
maintenance and inspection Timely identification and remedy of defects and damages
Database - Components In the database all documents are arranged and categorised in a clear direc-tory structure.
Grouping by such as: Construction component, Type, Status, Originator, etc. Detailed recording of contents such as: Date of creation, Author, Subject, File cabinet location of the originals, Document number with index, Approval, Linking of related documents, etc.
Cooling Tower Book References New building projects Datteln, Unit 4 Lünen Neurath, Units F + G Westfalen, Units D + E
Existing cooling tower projects Niederaußem, Unit K Neckarwestheim Staudinger, Unit 4 Reuter-West
Acting Forces The forces influencing cooling tower structures include its dead load, which in particular leads to pressure forces in the shell, and especially wind and tem-perature effects, but also unwanted sinking of the supports. The detection of forces specific to the site and knowledge of the conditions of the substrate as well as of load combinations conforming to the standards are decisive factors for the development of a statically and economically optimal support construction.
Standards / Regulations In Germany, natural draft cooling towers are designed according to the stand-ards for the forces acting on them as well as the standards for building materi-als. Furthermore, the VGB has developed the guideline R-610 for the construc-tion of cooling towers with the participation of ZPP. In this guideline, the as-sumed loads as well as constructive details are specified especially for cooling tower structures. The guideline has become the standard for many international projects and is applied all over the world.
Concrete pillars
Pure gas pipe
Cooling Tower internals
Cornice edge beam
Riser
Shell
Shell supporting struts
Ring foundation
Basin
Pedestal Pump house
Noise attenuating construction
ZPP Cooling Tower Book Always up-to-date!
Cooling Tower Book
The technical documentation is the key factor in the operation and maintenance of a cooling tower. This includes technical documents from the planning and construction phases as well as static calculations, execution drawings or con-struction supervision records, but also documentation from current inspections, construction projects or of irregularities after putting a cooling tower into opera-tion. This documentation is often incomplete, especially in the case of older cooling towers since valuable documents are misplaced or lost time and again after relocating or personnel changes. The building documentation according to DIN 1076 has been applied to bridge structures for a long time. This book contains a collection of data relevant to the structure. The VGB Guideline VGB R-613e "Code of Practice for Lifecycle Management of Reinforced Concrete Cooling Towers in Power Plants" contains similar ideas and specifies them in the context of cooling towers. These specifi-cations are consistently implemented and developed further in the ZPP Cooling Tower Book.
ZPP Cooling Tower Book Our long-time experience with the supervision and maintenance of cooling towers is the prerequisite for the development of the ZPP Cooling Tower Book. The ZPP Cooling Tower Book is prepared and maintained by experienced engineers within our own project information and management system ZPP INTERPROJECT. The actuality is assured at all times - and as part of the life cycle management, it supports the investment planning for the construction maintenance. All data is recorded centrally and drawn up in one file. The ZPP Cooling Tower Book is made available to the client both as a hardcopy and as a digital PDF file that can be accessed with the free Acrobat Reader. There is no need for special software and the handling is very easy. A survey key containing the most relevant geometric data and an informative visualisation by a stereoscopic model is included within the scope of service.
New Building Projects The documentation on new building projects includes:
Standing data Design and planning data Final documentation Structurally engineered conditions for the operation of the
cooling tower Documentation after the final documentation
Existing Cooling Towers The subsequent documentation for existing cooling towers includes:
Summary of existing documents Condition recording if necessary Evaluation of the object New circumstances
Numerical Simulation Calculations for cooling towers are performed by modelling them as a whole unit. The existing programme systems are based on finite element analyses at ZERNA (e.g. SOFiSTiK and ANSYS) and are the state-of-the-art for modelling complex support structures. It is possible to simulate all relevant geometries, materials, forces and construction states realistically and design the most im-portant components according to the standards. For modular cooling towers such as cell cooling towers, there are various framework programmes available for selection. There are two independent programming systems available for every application that allow you to validate your calculations. The following components are decisive for the modelling and calculation of a naturaldraft cooling tower:
Foundations with pile foundations, if present Shell supporting struts Cooling tower shell Cornice edge beam Cooling tower internals / fill support structure
The method of finite elements allows the analysis of the support structure when exposed to static and dynamic forces. We can look back on our special experi-ence in the area of dynamic testing. The forces from earthquakes can be deter-mined in accordance with the standards using various methods and the support structure can then be designed based on the results. In this case the calculation is performed depending on the requirements with the existing soil response spectrum or using an acceleration vs. time curve. Close cooperation with the expert soil surveyor allows us to model the local conditions optimally in a simulation. The evaluation of the responses is performed using the norm-conforming CQC method, ensuring calculations for a safe and perma-nent structure in regions subject to earthquakes.
Optimisation
The ability to model the entire support structure and the high performance of modern computers make it possible to examine the various design variations in advance. The results can then be used as a basis for deciding where to place the supports or how to arrange the pillars. Furthermore, it is also useful to optimise the shell geometry and shell thickness from an economical point of view in terms of optimal use of materials. We will of course work out the optimal solution for your support structure.
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Hybrid Cooling Towers
Interactive and Flexible Presentations!
Hybrid cooling towers combine the technology of a wet cooling tower with the advantages of dry cooling systems. Hybrid cooling towers are only half the height of comparable natural draft cooling towers, which is why they are not as prominent in the landscape and thus are accepted more readily. However, the natural draft effect is inadequate for precisely this reason and needs to be compensated for using mechanical aids, which in turn lead to higher costs. In a dry area, heat exchangers are used to direct heat in the air into the air flow to minimize the characteristic formation of vapour. Due to the political environment, less prominent structures are being required more and more in areas surrounding cities. The advantages of the lower height of hybrid cooling towers and their low level of vapour formation are being used more often as arguments in the approval planning process. The low percentage of hybrid cooling towers used to dissipate process heat in Germany will conse-quently increase. The geometric circumstances of a hybrid cooling tower do not allow application of all aspects of the current, valid standards and regulations for natural draft cooling towers. For this reason, new tests will need to be conducted in various areas and worked into the existing regulatory framework. ZPP was able to integrate its experience in the field of support characteristics and acting forces into different phases in the course of the construction and technical support of two hybrid cooling towers in Germany (Neckarwestheim, Moorburg).
Animations It is possible to produce animations from the 3D PDF file by navigating through the 3D objects with a camera and/or by expanding and separating the components and then putting them back in place again (exploded drawing). The 3D PDF files can be opened and viewed using the free Acrobat Reader. Additional information can be inserted retroactively. This increases the level of interactivity and flexibility of the file’s content.
"Hier doppelklicken, um Grafik einzufügen"
upper picture: PP Datteln - middle picture: PP Westfalen - bottom picture: PP Moorburg
We would like to offer you the benefits of our expe-rience in these areas with the following services
Consulting in the preliminary dimension-
ing of the support structure
Optimisation of the shell geometry
Preparation of structural analysis
Production of formwork and reinforce-ment drawings
Verification of statics documents in the framework of the SV-VO (regulation re-garding officially recognized experts ac-cording to the regional construction regulations) and quality assurance
Wind technology analysis and consulting service
3D Visualisation Cell Cooling Towers
Our 3D modelling allows you to realistically depict the geometry and properties of objects, components or entire power plants, both projected or already existing to simplify their analysis and presentation. Different scenes can be compliled through the application of a 3D model in which it is possible to define the position and point of view of a virtual observer as well as the geometry, materials and lighting. This allows the creation of static images as well as animations. After a three-dimensional model has been created, certain programmes allow you to generate views that can subsequently be edited in two-dimensional drawings. The 3D models are mainly supported by three different software solutions: AutoCAD, 3D Studio Max, and Adobe Acrobat. The 3D renderings can be easily exchanged and manipulated using the Adobe PDF format, enabling our client to view and edit the constructed, virtual object..
3D Handling After creating objects as a 2D and 3Dconstruction, it is possible to export them to Adobe Acrobat. Adobe Acrobat allows you to edit the CAD drawings in 3D while maintaining the scale and layer structure (referred to as the model hierarchy) existing in the CAD drawings.
The model can be rotated, zoomed or moved in the 3D document intuitively using the mouse. The observation of isolated construction components is possible without any limitation. By switching on individual layers, specific parts of the construction components can be examined more closely and conflicts between interfaces can be identified and considered in due time during the planning phase.
The use of cell cooling towers to dissipate process heat is not only limited to power generation plants. Cell cooling towers are also used in various production facilities. The modular design and the forced ventilation allow cell cooling towers to adapt flexibly to the requirements from the process technology and the ambi-ent conditions. Through the use of different materials (concrete, wood, steel, GFRP), it is possible to react to the different requirements. ZPP offers a wide range of services for cell cooling towers made of a wide variety of materials:
Detailed design (reinforced concrete, wood, steel, glass fibre rein-forced plastic GFRP)
Experts‘ reports Design verification according to SV-VO Dynamic design / vibration measurements
When using GFRP components in particular, it is necessary to pay special attention to the detailed design, because the used profiles are as filigreed as steel, but the material has different longitudinal and latitudinal strengths, just like wood. In many cases it is necessary to obtain a special approval (ZIE) and of course, ZPP will assist you as a consultant during this process.
Due to the use of ventilators to generate the airflow, vibrations reach into the construction. They are generated primarily by unavoidable residual imbalanc-es as well as aerodynamic excitations in the range of the blade passing fre-quencies - the sound of the rotor rotating. The vibrations resulting from this are not allowed to exceed specified limits. ZPP has a wide range of experi-ence from numerous successfully completed projects in the area of the plan-ning of dynamic design of the cooler construction. We can analyse existing vibration problems on-site using corresponding instruments and subsequently develop strategies to modify the dynamics accordingly to the results of the measurements.
Rendering Mode and Lighting There are versatile rendering mode options in 3D PDF files (e.g. filled, transparent, filled wire model, filled contour, shaded model, transparent boundary contours).They can be applied to the whole model or for each individual component of the model. It is possible to both define the background as well as the lighting of the model. A colour or a static image can be inserted as the background and it is also possible to apply one of several available lighting modes, e.g. daylight, bright lights, cube lighting, CAD optimized lighting or headlights.
Views and Section Drawings Having the 3D model in the PDF format allows you to look at the inside of the object. The different possibilities of alignment in the three-dimensional coordinate system (X, Y or Z axis and the observation from any given angle) offer a most comfortable manner of representation from every possible vantage point. Here, both views from different perspectives as well as sectional cuts can be created and managed. A 3D drawing can be inserted into an existing 3D PDF file to obtain a single sheet or to represent a completed comprehensive construction in a single file.
transparent
Cad water outlet
Wind Technology Concrete Technology
We combine research with practice!
Wind is one of the main forces acting on natural draft cooling towers, which is why the magnitudes of the wind forces have such a high economic importance. The exact identification of the wind climate conditions existing at the site and consideration of the ambient influences allow the economical design of the systems. The influences of structures in the immediate vicinity on the power plant grounds that lead to interference effects are not taken into account in most of the design rules. To obtain well-founded conclusions on the possible influences, tests are conducted on a theoretical basis and experimental model tests are conducted in a boundary layer wind tunnel in cooperation with the partners of ZPP. Precise testing of the effects of wind – usually in combination with non-linear calculations – has proven exceptionally beneficial for proving the stability of existing structures. In most cases, the resulting wind load can be significantly reduced, compared to the conservative standard values and we can therefore provide a valuable contribution to an economic, yet safe and reliable solution for our clients.
Wind Climate The peak velocity pressure, which depends on the wind zone and increases exponentially with height, is regulated by VGB 2010e in connection with DIN EN 1991-1-4. The increased stresses on a cooling tower arising due to the effect of gusts of wind, which is calculated according to theory of vibrations and is con-verted to equivalent static loads, are taken into account in BTR 2010 in the peak velocity pressure, which leads to resulting values that are slightly higher com-pared to DIN EN 1991-1-4.
Wind Tunnel Tests In spite of the specifications for the peak velocity pressure mentioned above, there is still great saving potential, for example by determining site-specific reference values and terrain categories. Tests in wind tunnels allow the loads arising to be determined realistically in advance while taking the neighbouring structures into account and can therefore provide a reliable prediction of forces acting on the cooling tower. This forms the basis for the optimal dimensioning of new cooling towers or the ability to proof the stability of existing cooling towers. The advancement of the cooling tower technology to hybrid cooling towers makes new tests to determine the wind loads necessary. ZPP played a decisive role in the early phases of wind tunnel tests for a hybrid cooling tower. The knowledge gained from the tests will make an important contribution to the adaptation of the existing design rules.
The development of construction material technology has made great progress over the last few years. This becomes apparent in the use of concrete for cool-ing tower shells where, in spite of chemical reactions due to acidic condensate, it is possible to work without the normally necessary coating. In connection with flue gas purification it is possible to forego a stack, thus releasing the flue gas through the cooling tower. Due to our comprehensive experience in the area of the variety of stresses placed on cooling tower structures, ZPP was a leading participant during the specification of development, testing and approval of the first concrete with "increased resistance against acid attacks“.
Quality Management Our many years of experience in the production of QM manuals and the moni-toring of QM distinguish ZPP as a competent partner for constructing new cooling towers.. In the past years, we have monitored and documented the production and application of the concrete for a variety of large cooling towers during their construction.
Cooling tower Niederaußem, Unit K Cooling tower Neurath, Units F + G Cooling tower Westfalen, Units D + E Cooling tower Lingen
Life Cycle Management / Monitoring There are many reasons for the owner to implement life cycle management and structural monitoring processes that meet the corresponding needs. The regular evaluations of the structures and the changes to the support structure lead to an early detection of problems and create a comprehensive knowledge of the history of the structure. The planning of the possible and necessary measurements (e.g. wind and temperature measurements, crack widths, settling, natural frequencies, concrete abrasion, chemical attacks) should be integrated in the overall planning process in advance. Our experience in the design and execution of life cycle manage-ment projects makes ZPP the ideal partner to accompany the structure through-out its useful life cycle.
Wind Technology Concrete Technology
We combine research with practice!
Wind is one of the main forces acting on natural draft cooling towers, which is why the magnitudes of the wind forces have such a high economic importance. The exact identification of the wind climate conditions existing at the site and consideration of the ambient influences allow the economical design of the systems. The influences of structures in the immediate vicinity on the power plant grounds that lead to interference effects are not taken into account in most of the design rules. To obtain well-founded conclusions on the possible influences, tests are conducted on a theoretical basis and experimental model tests are conducted in a boundary layer wind tunnel in cooperation with the partners of ZPP. Precise testing of the effects of wind – usually in combination with non-linear calculations – has proven exceptionally beneficial for proving the stability of existing structures. In most cases, the resulting wind load can be significantly reduced, compared to the conservative standard values and we can therefore provide a valuable contribution to an economic, yet safe and reliable solution for our clients.
Wind Climate The peak velocity pressure, which depends on the wind zone and increases exponentially with height, is regulated by VGB 2010e in connection with DIN EN 1991-1-4. The increased stresses on a cooling tower arising due to the effect of gusts of wind, which is calculated according to theory of vibrations and is con-verted to equivalent static loads, are taken into account in BTR 2010 in the peak velocity pressure, which leads to resulting values that are slightly higher com-pared to DIN EN 1991-1-4.
Wind Tunnel Tests In spite of the specifications for the peak velocity pressure mentioned above, there is still great saving potential, for example by determining site-specific reference values and terrain categories. Tests in wind tunnels allow the loads arising to be determined realistically in advance while taking the neighbouring structures into account and can therefore provide a reliable prediction of forces acting on the cooling tower. This forms the basis for the optimal dimensioning of new cooling towers or the ability to proof the stability of existing cooling towers. The advancement of the cooling tower technology to hybrid cooling towers makes new tests to determine the wind loads necessary. ZPP played a decisive role in the early phases of wind tunnel tests for a hybrid cooling tower. The knowledge gained from the tests will make an important contribution to the adaptation of the existing design rules.
The development of construction material technology has made great progress over the last few years. This becomes apparent in the use of concrete for cool-ing tower shells where, in spite of chemical reactions due to acidic condensate, it is possible to work without the normally necessary coating. In connection with flue gas purification it is possible to forego a stack, thus releasing the flue gas through the cooling tower. Due to our comprehensive experience in the area of the variety of stresses placed on cooling tower structures, ZPP was a leading participant during the specification of development, testing and approval of the first concrete with "increased resistance against acid attacks“.
Quality Management Our many years of experience in the production of QM manuals and the moni-toring of QM distinguish ZPP as a competent partner for constructing new cooling towers.. In the past years, we have monitored and documented the production and application of the concrete for a variety of large cooling towers during their construction.
Cooling tower Niederaußem, Unit K Cooling tower Neurath, Units F + G Cooling tower Westfalen, Units D + E Cooling tower Lingen
Life Cycle Management / Monitoring There are many reasons for the owner to implement life cycle management and structural monitoring processes that meet the corresponding needs. The regular evaluations of the structures and the changes to the support structure lead to an early detection of problems and create a comprehensive knowledge of the history of the structure. The planning of the possible and necessary measurements (e.g. wind and temperature measurements, crack widths, settling, natural frequencies, concrete abrasion, chemical attacks) should be integrated in the overall planning process in advance. Our experience in the design and execution of life cycle manage-ment projects makes ZPP the ideal partner to accompany the structure through-out its useful life cycle.
3D Visualisation Cell Cooling Towers
Our 3D modelling allows you to realistically depict the geometry and properties of objects, components or entire power plants, both projected or already existing to simplify their analysis and presentation. Different scenes can be compliled through the application of a 3D model in which it is possible to define the position and point of view of a virtual observer as well as the geometry, materials and lighting. This allows the creation of static images as well as animations. After a three-dimensional model has been created, certain programmes allow you to generate views that can subsequently be edited in two-dimensional drawings. The 3D models are mainly supported by three different software solutions: AutoCAD, 3D Studio Max, and Adobe Acrobat. The 3D renderings can be easily exchanged and manipulated using the Adobe PDF format, enabling our client to view and edit the constructed, virtual object.
3D Handling After creating objects as a 2D- and 3D-construction, it is possible to export them to Adobe Acrobat. Adobe Acrobat allows you to edit the CAD drawings in 3D while maintaining the scale and layer structure (referred to as the model hierarchy) existing in the CAD drawings.
The model can be rotated, zoomed or moved in the 3D document intuitively using the mouse. The observation of isolated construction components is possible without any limitation. By switching on individual layers, specific parts of the construction components can be examined more closely and conflicts between interfaces can be identified and considered in due time during the planning phase.
The use of cell cooling towers to dissipate process heat is not only limited to power generation plants. Cell cooling towers are also used in various production facilities. The modular design and the forced ventilation allow cell cooling towers to adapt flexibly to the requirements from the process technology and the ambi-ent conditions. Through the use of different materials (concrete, wood, steel, GFRP), it is possible to react to the different requirements. ZPP offers a wide range of services for cell cooling towers made of a wide variety of materials:
Detailed design (reinforced concrete, wood, steel, glass fibre rein-forced plastic GFRP)
Experts‘ reports Design verification according to SV-VO Dynamic design / vibration measurements
When using GFRP components in particular, it is necessary to pay special attention to the detailed design, because the used profiles are as filigreed as steel, but the material has different longitudinal and latitudinal strengths, just like wood. In many cases it is necessary to obtain a special approval (ZIE) and of course, ZPP will assist you as a consultant during this process.
Due to the use of ventilators to generate the airflow, vibrations reach into the construction. They are generated primarily by unavoidable residual imbalanc-es as well as aerodynamic excitations in the range of the blade passing fre-quencies - the sound of the rotor rotating. The vibrations resulting from this are not allowed to exceed specified limits. ZPP has a wide range of experi-ence from numerous successfully completed projects in the area of the plan-ning of dynamic design of the cooler construction. We can analyse existing vibration problems on-site using corresponding instruments and subsequently develop strategies to modify the dynamics accordingly to the results of the measurements.
Rendering Mode and Lighting There are versatile rendering mode options in 3D PDF files (e.g. filled, transparent, filled wire model, filled contour, shaded model, transparent boundary contours).They can be applied to the whole model or for each individual component of the model. It is possible to both define the background as well as the lighting of the model. A colour or a static image can be inserted as the background and it is also possible to apply one of several available lighting modes, e.g. daylight, bright lights, cube lighting, CAD optimized lighting or headlights.
Views and Section Drawings Having the 3D model in the PDF format allows you to look at the inside of the object. The different possibilities of alignment in the three-dimensional coordinate system (X, Y or Z axis and the observation from any given angle) offer a most comfortable manner of representation from every possible vantage point. Here, both views from different perspectives as well as sectional cuts can be created and managed. A 3D drawing can be inserted into an existing 3D PDF file to obtain a single sheet or to represent a completed comprehensive construction in a single file.
transparent
water outlet
Hybrid Cooling Towers
Interactive and Flexible Presentations!
Hybrid cooling towers combine the technology of a wet cooling tower with the advantages of dry cooling systems. Hybrid cooling towers are only half the height of comparable natural draft cooling towers, which is why they are not as prominent in the landscape and thus are accepted more readily. However, the natural draft effect is inadequate for precisely this reason and needs to be compensated for using mechanical aids, which in turn lead to higher costs. In a dry area, heat exchangers are used to direct heat in the air into the air flow to minimize the characteristic formation of vapour. Due to the political environment, less prominent structures are being required more and more in areas surrounding cities. The advantages of the lower height of hybrid cooling towers and their low level of vapour formation are being used more often as arguments in the approval planning process. The low percentage of hybrid cooling towers used to dissipate process heat in Germany will conse-quently increase. The geometric circumstances of a hybrid cooling tower do not allow application of all aspects of the current, valid standards and regulations for natural draft cooling towers. For this reason, new tests will need to be conducted in various areas and worked into the existing regulatory framework. ZPP was able to integrate its experience in the field of support characteristics and acting forces into different phases in the course of the construction and technical support of two hybrid cooling towers in Germany (Neckarwestheim, Moorburg).
Animations It is possible to produce animations from the 3D PDF file by navigating through the 3D objects with a camera and/or by expanding and separating the components and then putting them back in place again (exploded drawing). The 3D PDF files can be opened and viewed using the free Acrobat Reader. Additional information can be inserted retroactively. This increases the level of interactivity and flexibility of the file’s content.
"Hier doppelklicken, um Grafik einzufügen"
upper picture: PP Datteln - middle picture: PP Westfalen - bottom picture: PP Moorburg
We would like to offer you the benefits of our expe-rience in these areas with the following services
Consulting in the preliminary dimension-
ing of the support structure
Optimisation of the shell geometry
Preparation of structural analysis
Production of formwork and reinforce-ment drawings
Verification of statics documents in the framework of the SV-VO (regulation re-garding officially recognized experts ac-cording to the regional construction regulations) and quality assurance
Wind technology analysis and consulting service
Cooling Tower Book
The technical documentation is the key factor in the operation and maintenance of a cooling tower. This includes technical documents from the planning and construction phases as well as static calculations, execution drawings or con-struction supervision records, but also documentation from current inspections, construction projects or of irregularities after putting a cooling tower into opera-tion. This documentation is often incomplete, especially in the case of older cooling towers since valuable documents are misplaced or lost time and again after relocating or personnel changes. The building documentation according to DIN 1076 has been applied to bridge structures for a long time. This book contains a collection of data relevant to the structure. The VGB Guideline VGB R-613e "Code of Practice for Lifecycle Management of Reinforced Concrete Cooling Towers in Power Plants" contains similar ideas and specifies them in the context of cooling towers. These specifi-cations are consistently implemented and developed further in the ZPP Cooling Tower Book.
ZPP Cooling Tower Book Our long-time experience with the supervision and maintenance of cooling towers is the prerequisite for the development of the ZPP Cooling Tower Book. The ZPP Cooling Tower Book is prepared and maintained by experienced engineers within our own project information and management system ZPP INTERPROJECT. The actuality is assured at all times - and as part of the life cycle management, it supports the investment planning for the construction maintenance. All data is recorded centrally and drawn up in one file. The ZPP Cooling Tower Book is made available to the client both as a hardcopy and as a digital PDF file that can be accessed with the free Acrobat Reader. There is no need for special software and the handling is very easy. A survey key containing the most relevant geometric data and an informative visualisation by a stereoscopic model is included within the scope of service.
New Building Projects The documentation on new building projects includes:
Standing data Design and planning data Final documentation Structurally engineered conditions for the operation of the
cooling tower Documentation after the final documentation
Existing Cooling Towers The subsequent documentation for existing cooling towers includes:
Summary of existing documents Condition recording if necessary Evaluation of the object New circumstances
Numerical Simulation Calculations for cooling towers are performed by modelling them as a whole unit. The existing programme systems are based on finite element analyses at ZPP (e.g. SOFiSTiK and ANSYS) and are the state-of-the-art for modelling complex support structures. It is possible to simulate all relevant geometries, materials, forces and construction states realistically and design the most im-portant components according to the standards. For modular cooling towers such as cell cooling towers, there are various framework programmes available for selection. There are two independent programming systems available for every application that allow you to validate your calculations. The following components are decisive for the modelling and calculation of a naturaldraft cooling tower:
Foundations with pile foundations, if present Shell supporting struts Cooling tower shell Cornice edge beam Cooling tower internals / fill support structure
The method of finite elements allows the analysis of the support structure when exposed to static and dynamic forces. We can look back on our special experi-ence in the area of dynamic testing. The forces from earthquakes can be deter-mined in accordance with the standards using various methods and the support structure can then be designed based on the results. In this case the calculation is performed depending on the requirements with the existing soil response spectrum or using an acceleration vs. time curve. Close cooperation with the expert soil surveyor allows us to model the local conditions optimally in a simulation. The evaluation of the responses is performed using the norm-conforming CQC method, ensuring calculations for a safe and perma-nent structure in regions subject to earthquakes.
Optimisation
The ability to model the entire support structure and the high performance of modern computers make it possible to examine the various design variations in advance. The results can then be used as a basis for deciding where to place the supports or how to arrange the pillars. Furthermore, it is also useful to optimise the shell geometry and shell thickness from an economical point of view in terms of optimal use of materials. We will of course work out the optimal solution for your support structure.
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-0,02
0,00
0,02
0,04
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0,08
0,10
0,00E+00 2,00E+00 4,00E+00 6,00E+00 8,00E+00 1,00E+01 1,20E+01 1,40E+01 1,60E+01 1,80E+01
Natural Draft Cooling Towers
Worldwide, cooling tower structures are essential to dissipate process heat via the cooling cycle in power generators and industrial systems. However, the type of cooling tower needed is different depending on the prescribed requirements and boundary conditions. The most effective cooling tower technology is wet cooling, which includes natural draft cooling towers and fan-driven cooling towers. The hybrid cooling tower is a special form that combines the functions of wet and dry cooling. The new construction of cooling towers of any kind must be examined from the point of view of the thermal design basics, the static requirements and the economic aspects. The construction of large natural draft cooling towers of 200 meters height or more as well as sophisticated hybrid cooling towers are a challenge for every-one involved in their planning and construction due to the complex forces acting on them, the load bearing characteristics, and the dimensions. With decades of experience in the area of structural planning and verifying ZPP is the ideal partner for your cooling tower structure.
Natural draft cooling towers are, due to their impressive and highly visible appearance, symbols of power plants. Their height of up to 200 meters and thin-shell thickness make them complicated engineering structures. Their function is determined by the heat to be dissipated and, due to improvements in the flue gas cleaning systems in coal power plants, are being used more and more often as a replacement for a chimney. They are designed according to thermal as-pects, which need to be brought in line with the static requirements.
Running Operation
During running operation, the ZPP Cooling Tower Book keeps records on new circumstances and shows changes which may affect the structure.
Conservation of value and operational reliability: Recommendations of inspections within the scope of periodic
maintenance and inspection Timely identification and remedy of defects and damages
Database - Components In the database all documents are arranged and categorised in a clear direc-tory structure.
Grouping by such as: Construction component, Type, Status, Originator, etc. Detailed recording of contents such as: Date of creation, Author, Subject, File cabinet location of the originals, Document number with index, Approval, Linking of related documents, etc.
Cooling Tower Book References New building projects Datteln, Unit 4 Lünen Neurath, Units F + G Westfalen, Units D + E
Existing cooling tower projects Niederaußem, Unit K Neckarwestheim Staudinger, Unit 4 Reuter-West
Acting Forces The forces influencing cooling tower structures include its dead load, which in particular leads to pressure forces in the shell, and especially wind and tem-perature effects, but also unwanted sinking of the supports. The detection of forces specific to the site and knowledge of the conditions of the substrate as well as of load combinations conforming to the standards are decisive factors for the development of a statically and economically optimal support construction.
Standards / Regulations In Germany, natural draft cooling towers are designed according to the stand-ards for the forces acting on them as well as the standards for building materi-als. Furthermore, the VGB has developed the guideline R-610 for the construc-tion of cooling towers with the participation of ZPP. In this guideline, the as-sumed loads as well as constructive details are specified especially for cooling tower structures. The guideline has become the standard for many international projects and is applied all over the world.
Concrete pillars
Pure gas pipe
Cooling Tower internals
Cornice edge beam
Riser
Shell
Shell supporting struts
Ring foundation
Basin
Pedestal Pump house
Noise attenuating construction
ZPP Cooling Tower Book Always up-to-date!
CONTACT
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ZPP Ingenieure AG
Head officeLise-Meitner-Allee 1144801 Bochum
+49 234 9204-0
ZPP Group of companiesZPP Ingenieure AGZPP International GmbHLauPlan GmbHGERICON GmbHZPP Hennig GmbHBreddermann + Partner GmbBKuhfeld Schildberg Partnerschaft mbB
COOLING TOWER NEW BUILDINGNATURAL DRAFT-, HYBRID- AND CELL COOLING TOWERS
www.zpp.de/planning
> Höhler, S., Lehnen, D. (2013)Hybrid Cooling Towers - A new standard in urban areas. IASS Symposium Breslau, 23-27 September 2013
> Höhler, S., Vossen, T., Lehnen, D. (2012)Structural Calculation of Hybrid Cooling Towers. 6th International Symposium on Cooling Towers, ISCT, Cologne, 2012, 567-574
> Busch, D., Meyer, J., Ohlmann, U. (2012)The Quality Control during Construction of the Cooling Towers at the RWE Power Stations6th International Symposium on Cooling Towers, ISCT, Cologne, 2012, 349-356
> Lehnen, D., Meyer, J., Höhler S., Pfister T. (2011)Kühltürme - Schalentragwerke im Dienst der Energieerzeugung. Bauingenieur VDI-Bautechnik Jahresausgabe 2011/2012
> Niemann, H.-J., Harte, R., Meyer, J., Wörmann, R. (2011)Recent amendments to the VGB Guideline on the Design and Construction of Cooling Towers in Power Plants VGB PowerTech 9, 2011, 94-103
> Lehnen, D., Meyer, J., Bockhold, J., Pfister, T. (2010)Grundlagen des Lebensdauermanagements im Kühlturmbau. Innovationen im kostruktiven Ingenieurbau - Methoden - Materialien - Bauwerke. Ruhr-Universität Bochum, 2010
> Bockhold, J., Meyer, J., Klöker, T. (2006)Einsparpotentiale beim Bau von Kraftwerken am Beispiel von Windeinwirkungen auf KühltürmeBautechnik (WILEY-VCH Verlag) 83, Nr. 10, 2006, 669-680
PLANNING
+49 234 92 04-1262
Dr.-Ing. Sebastian Höhler
+49 234 92 04-1164
Dipl.-Ing. Martin Demmer
