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Condenser Presentation
Condenser Presentation
SURFACE CONDENSERS
Topics of Discussion
Condenser Basics Design of Condensers
GENERAL DESCRIPTION OF
SURFACE CONDENSER
It is a shell-and-tube heat exchanger in which steam is
condensed on the shell-side while cooling water flows
through the tubes. The condensate and cooling water
leave the system separately
They are heat exchangers which convert steam from
its gaseous to its liquid state at a pressure below
atmospheric pressure
CONDENSER
Primary Functions:
Provide minimum temperature heat sink in the plant.
The rejected heat is carried away by the circulating
water. Extracts latent heat from steam.
Condense steam at turbine exhaust and feed the
condensate to Condensate extraction Pump. Pumping
the liquid condensate into the cycle back is
economical as compared to pumping the low
temperature steam.
This enables the steam condensate to be re-used.
Primary Functions:
The difference between the heat of steam per unit
mass at the inlet to the turbine and the heat of steam
per unit mass at the outlet to the turbine represents the
heat which is converted to mechanical power.
Maintaining a vacuum in the steam condenser, the
efficiency of the steam-power plant can be increased
as greater the vacuum in the system, greater will be the
enthalpy drop of steam. Therefore, more work will be
available per kg of steam condensing.
Secondary Functions:
Deaeration of condensate / make-up water
Removal of non-condensable. The non-condensate
(air) can be removed from the condensate-steam
circuit by pulling and maintaining a vacuum in the
steam side. Therefore, the condensate can be used as
boiler feed.
Provide storage capacity of condensate
Act as receiver of system drains
Surface Condenser
SURFACE CONDENSER
DESIGN
Important Definitions
Condenser Back Pressure: The absolute static pressure
maintained within the condenser shell at locations not
greater than one foot from the first tube.
Cleanliness Factor: Ratio of condenser Heat Transfer
Coefficient to the clean Heat Transfer Coefficient.
Condensate Depression/Condensate Sub-cooling: The
difference between condensing steam temperature and
temperature of the condensate in the hotwell.
Effective surface: The total surface measured on the
outside of the tubes between the T/s inside surfaces
and includes the air cooler surfaces.
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Important Definitions
Effective Tube length: Distance between the inside
surfaces of T/s.
Hotwell capacity: Condensate storage volume of
hotwell.
Initial Temperature Difference (ITD): Difference
between the condensing steam temperature and the
inlet CW temperature.
Temperature rise: Difference between the outlet and
inlet CW temperatures
Important Definitions
Terminal Temperature Difference/Approach temp.
(TTD): Difference between the condensing steam
temperature and the outlet CW temperature.
Condenser Duty: The net heat transferred to the CW
water
Design Codes:
ASME SEC. VIII Div.1
HEI for Steam Surface Condensers
TEMA
Mechanical Design:
As per 1. HEI for Steam Surface Condensers
2. ASME Section VIII Div.1
3. TEMA
Lowe Exhaust Neck, Tubesheets & waterboxes for rectangular
condensers are analysed using FEM techniques.
Strength Expansion
Mechanical / Hydraulic Expanders
Strength of joint can be enhanced by providing grooves
in tube holes
Welded joints - Titanium, SS Clad Tubesheets
Allowable joint load can be arrived at by using
guidelines of Appendix - A of ASME code
MATERIAL OF CONSTRUCTION
MATERIAL OF CONSTRUCTION
SELECTION CRITERIA
¾ Turbine Configuration
¾ Size Limitations
¾ Cost
¾ Condenser Features
High Pressure Shell
Low Pressure Shell
Equalized Hotwell
Equalized Hotwell
¾ Condenser Features
Two Single Pressure Shells
Equalized Exhaust Neck
Equalized Hotwell
SURFACE CONDENSER
PERFORMANCE
SURFACE CONDENSER
CONSTRUCTION
CONDENSER CONSTRUCTION
Condenser Sections
Main Shell
Waterboxes
Hotwell
Exhaust Neck
Internals
CONDENSER CONSTRUCTION
Condenser Sections
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CONDENSER CONSTRUCTION
CONDENSER CONSTRUCTION
Condenser Shell
Section where condensation of steam over tubes takes
place
Consist of Tube Bundle, Tubesheets, Support Plates,
Air Removal Section
CONDENSER CONSTRUCTION
Rectangular Condenser Shell
CONDENSER CONSTRUCTION
Rectangular Condenser Shell
CONDENSER CONSTRUCTION
CONDENSER CONSTRUCTION
Tube - Bundle
CONDENSER CONSTRUCTION
Tubesheets
Hold tubes firmly
Separate shell from waterboxes
Tubesheets
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CONDENSER CONSTRUCTION
Air-removal Section
Removes accumulated air & non-condensable gases
Isolation of section of tubes
CONDENSER CONSTRUCTION
Air-removal Section
CONDENSER CONSTRUCTION
Air-removal Section
CONDENSER CONSTRUCTION
Support Plates
Provides supporting structure to tubes
Minimises tube vibration
Provides additional stiffening to shell from inside
CONDENSER CONSTRUCTION
Support Plates
CONDENSER CONSTRUCTION
Condenser Waterboxes
Receives & delivers cooling water to Circulating water
system
Inlet Waterbox: Receives cooling water from
circulating water system in the plant & passes the
water to the tubes
Outlet Waterbox: Receives water from the tubes &
delivers to the circulating water system
Return Waterbox: Acts as transition piece between two
passes in case of multi-pass condensers
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CONDENSER CONSTRUCTION
Waterboxes
CONDENSER CONSTRUCTION
Waterboxes
CONDENSER CONSTRUCTION
Waterboxes
CONDENSER CONSTRUCTION
Condenser Hotwell
Receives & Stores the condensate falling down from
the tubes
CONDENSER CONSTRUCTION
Exhaust Neck
Transition piece between condenser & turbine
CONDENSER CONSTRUCTION
Exhaust Neck
CONDENSER CONSTRUCTION
Exhaust Neck
CONDENSER CONSTRUCTION
Condenser Support
Circular condensers are supported on saddles
Rectangular condensers are directly mounted on
hotwell bottom plate
CONDENSER MANUFACTURING
MANUFACTURING STAGES
Waterbox Fabrication
Waterbox Fabrication
LEN Fabrication
LEN Fabrication
TUBE INSERTION
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VACUUM TESTING
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WELDING DETAIL
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CONDENSER
PAINTING, COATING & CORROSION
PROTECTION
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DISPATCH ARRANGEMENT
OF
SURFACE CONDENSER
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CONDENSER Dispatch
Single Piece
Multiple Sections
• Completely Knocked Down Condition
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CONDENSER Dispatch
• Single Piece
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CONDENSER Dispatch
• Multiple Sections
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CONDENSER Dispatch
• Completely Knocked Down Condition
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Final Assembly & Dispatch
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L&T CONDENSERS
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CRITICAL FEATURES
Tubesheet layout with proper steam distribution path
Maintain Straight Effective Tube Length (SETL).
Reduce bowing effect of tubesheet to minimum
Gasket face of Tubesheet must be flat to have proper sealing
of waterbox
Condenser being a vacuum service equipment, it is very
important to achieve proper sealing i.e soundness of weld
joints & leak proof flanged joints in the equipment
Tube side fouling OR blockage of tubes must be avoided
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L&T CONDENSERS
ALGIERS REFINERY
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L&T CONDENSERS
L&T CONDENSERS
L&T CONDENSERS
L&T CONDENSERS
L&T CONDENSERS
L&T CONDENSERS
SNM Algeria
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L&T CONDENSERS
CONDENSER
OPERATION & MAINTENANCE
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CONDENSER OPERATION
• Start-up
• Normal Operating Mode
• Abnormal Operating Mode
• Shut Down
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Condenser Shut-Down
• All flows to condenser stopped
• Shut down Air Evacuation System
• Condenser vacuum to be broken using vacuum
breaker
• After shell side is cooled down, shut down circulating
water pump.
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CONDENSER MAINTENANCE
• Periodic Inspection of Condenser
• Accumulation of Debris, Scale Deposit inside
Waterbox & Tubes
) Mechanical Cleaning
) On-Line Tube cleaning System
• Cathodic Protection Anode Check
• Waterbox painting check
• Gasket replacement
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Air Ingress
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Tube Cleaning/Debris in W/B
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• Tube Failure
) Plugging of Tubes
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CONDENSER
TROUBLE SHOOTING
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APPENDIXG
TROUBLESHOOTING GUIDE
This troubleshooting guide has been prepared to as~ist operators of steam surface condensers. The guide
provides general guidance, and operators are advised to consult with the manufacturer when necessary for spe-
cific instructions regarding their equipment. Many of the items listed below are not in the scope of the condenser
manufacturer; however, these items do affect operation and must be considered by operators.
HEI has produced a computer rating program to assist operators in evaluating the performance of their con-
denser. Contact lIEI at hei@heatexchange.org, or visit the IIEI website at www.heatexchange.org for further details.
Leaks from incoming vents and drains Check all valves on vent and drain lines
No pigtail on steam line pressure Install pigtail siphon and replace gauge if
gauges heat damage has occurred
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APPENDIXG
TROUBLESHOOTING GUIDE
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APPENDIXG
TROUBLESHOOTING GUIDE
High Tube Side Severe fouling inside the tubes Clean the inside of the lubes
Pressure Loss
A large percentage of plugged tubes Replace plugged tubes
Improper Venting of Blocked air vents Inspect and repair vent opening as
Waterbox required.
Insufficient air vent capacity. Calculate piping system air release and
check vent size.
Insufficient cooling water pump Check cooling water piping and tubes for
capacity blockage. Check cooling water pumps for
wear. Review overall system hydraulics.
Missing automatic air release valve Check high points in cooling water
system for automatic air release valves.
Missing vacuum check valve Where vacuum exists in top of boxes and
piping high points (once through siphon
systems) include vacuum check valve on
air release valves.
Lagging Failure Improper attachment oflagging Inspect lagging attachment prior to plant
(For Extraction Piping startup, and during plant outages to
and Condenser Neck make sure all lagging parts are securely
Mounted Heater) installed.
Physical impact from failed expansion Repair failed expansion joint and replace
joint lagging section.
Local Overheat Operating conditions exceeding design Re-evaluate internal dispersion design
(Hot Spots) parameters
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APPENDIX G
TROUBLESHOOTING GUIDE
Low Hotwell Insufficient free fall (distance from Hotwellievel is above design or normal
Temperature bottom tube to liquid level) level. Operate at design leveL Check
(Condensate Subcooling) instrumentation.
Operation off designllow load operation Expected at low load. Possibly alleviated
with steam sparging in hot well
Unusual Sounds Broken or loose components inside the Repair broken or loose components
condenser
Water hammer impact inside the Check for proper operation of cooling
waterbox water system
Tube Failures Worn or damaged internal connection Inspect connections for damage. Review
baffles or spray pipes actual operating conditions with manu-
facturer. Repair connection, plug or
replace tubes.
Stagnant water during extended Tubes may need to be rinsed and dried
shutdown for extended shutdown.
Ammonia attack - copper alloy tubing Check with plant water chemistry
specialist
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Contact Details
Tanmay Raha
Email: tanmay.raha@larsentoubro.com
Tel: +91-22-67053053
Mob: +91-9820126978
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THANK YOU
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