Customized solution for steam power systems surface. This diploma thesis deals with design of surface condensers with axial steam inlet which are widely used in the energy industry. Algorithm ga to optimize the cost of steam surface condenser using four variables for optimization of design i. Flanges can be added on the outer surface for easy integration with instruments or radiators the flange is an integral part of the extrusion. The crossflow condenser is typically used for lowpressure applications, in which there is a large volume. By producing a vacuum at the turbine discharge, condensers increase the overall cycle efficiency. The essential objective in surface condenser design is to provide equal access of vapor to all the surface. The crossflow condenser is similar to the surface condenser. Graham has more than 70 years of design and fabrication experience in the steam surface condenser field. This chapter addresses the design and costing of refrigerated surface condenser systems only.
A steam surface condenser is a critical component of a power plant. The surface condenser is a critical component in the operation of a steam power plant. T otit sti as the coil surface temperature, t s, must be free to vary thus ensuring that. Ejector condensers are either direct contact or surface condensers typically in the same form as the main condenser. Systems that have dry cooling sometime use direct contact condensers. It operates independently of a users location or ip address. Spx heat transfer engineers know what to anticipate.
Parameter design operating condenser vacuum 694mmhg 612mmhg condenser ttd 4. R sekulib university of kentucky introduction a heat exchanger is a device that is used for transfer of thermal energy enthalpy between two or more fluids, between a solid surface and a fluid, or between solid particulates and a. The condenser performance test and thermal performance. Hei issues 12th edition of standards for steam surface. Steam surface condenser design based on cost optimization.
Air cooled condensers, steam surface condensers, closed feedwater heaters, shell and. Marine condenser design, condensers, computerized condenser design. Heat pipes hardware m t l l i t b ith th i fmetal aluminum tube with grooves on the inner surface cold t ild extrusion grooves are filled with the working fluid water, ammonia, propylene, etc. Condenser failures can result in forced outages and loss of generation capacity.
Parametric analysis of surface condenser for thermal power. In the practical part, hydraulic and heat calculation, dumptube design and calculation of bypass were made to design surface condenser with axial steam inlet. The heat exchange institute hei standards for steam surface condensers were promulgated to design and predict the performance of surface condensers for power plant applications by providing basic overall tube bundle heat transfer rates and correction factors to be applied to account for different tube diameters, wall thicknesses bwgtube materials, circulating water inlet temperatures and. Whereas the previous edition was mainly focused on conducting a rigorous fullscale acceptance test, the current edition includes a less rigorous test that would also be. The shellside flow path is designed such that the vapor flows mainly in crossflow direction to the tubes. For such models detailed correlations for local heat transfer and frictional pressure loss are required. In surface condenser even impure water can be used for cooling purpose whereas in jet condensers cooling water must be pure.
The heat exchange institute hei standards for steam surface condensers were promulgated to design and predict the performance of surface condensers for power plant applications by providing basic overall tube bundle heat transfer rates and correction factors to be applied to account for different tube diameters, wall thicknesses bwgtube materials, circulating water inlet temperatures. Economical design of a condenser will result with t. The primary modules are responsible for the majority of the heat transfer and condensing, while the secondary. Steam surface condenser design based on cost optimization using genetic algorithm. A surface condenser is a commonly used term for a watercooled shell and tube heat exchanger installed to condense exhaust steam from a steam turbine in thermal power stations. The condensate generated is usually recirculated back into the boiler and reused. Early attempts to provide overall heat transfer coefficients for the design of steam condensers took no account of the detailed layout of the tubenest, e. Sinha agm netra, ntpc limited abstract the demands placed on the condensers of utility generating units are significant. Direct aircooled condenser units in power plants usually consist of finned tubes arranged in the form of a delta or aframe to drain condensate effectively, reduce distribution steam duct lengths and minimize the required ground surface. Maarky condensers are designed to provide the lowest backpressure which, in turn, maximizes the output from the power plant. Condensers are delivered as fully tubed modules, so that little welding is required on site. The function of a surface condenser is to create the lowest possible turbine or process operating back pressure while condensing steam. It consists of a shell containing tubes through which the coolant flows. Aspects of failure of condenser tubes and their remedial.
An introduction to condensers and auxiliary equipment for. Secondly, the steam is passed through a series of tubes and water is allowed to flow in the form of thin film outside the tubes. The optimum thermal design of a shell and tube heat exchanger involves the consideration of many interacting design parameters which can be summarized as follows. In ga, these four variables are coded to evaluate the design of condenser and hence find out the optimum solution. The detailed design of the condenser and its associated cw system requires careful optimisation of parameters which include material selection, cooling water flowrate, condenser surface areas, and turbine exhaust pressure, etc. Modular changeouts are an efficient alternative to the conventional retube. As the innovator in heat transfer technology, tei provides exceptional modular changeout options for steam surface condensers. For thermal and mechanical design and sizing of steam surface condensers based on heat transfer coefficients in accordance with hei standards. It is a device or an appliance in which steam condenses and heat released by.
Design hot well for positive gravity head of condensate npsha available and eliminate swirling. In pt02 the condenser cleanliness coefficient was dropped to 0. The primary purpose of hei is to develop and publish standards which advance the technology, increase the efficiency, and promote the use of heat exchange and vacuum apparatus. Titanium design and fabrication handbook for industrial. Customized solution for steam power systems surface condenser surface condenser is the commonly used term for a watercooled shell and tube heat exchanger installed on the exhaust steam side from a steam turbine in thermal power stations. The generating capacity of a power plant is dependent on the performance of the steam surface condenser. The condenser terminal difference is the difference in temperature between the steam saturation temperature t s corresponding to condenser pressure and the outlet cooling water temperature t 2. Ract conionu sm revee oldoei owooi ie d iwe dw f fr bm wee b b a comparison between a computer model of a steam surface condenser and data from a machinery test of a ddg37 class engineering plant is provided. Parametric analysis of surface condenser for thermal power plant. The steam can be condensed in surface steam condenser in two ways. Moreover, significant volumes of leakage air will penetrate into large vessels, and those substances that are being vaporized or dried will release additional air that is contained in pores or dissolved in liquids. Example of condenser for operation using r449a if this condenser is now to be operated using the refrigerant r449a, a recalculation gives us a different picture see figure 4.
Both of these operations are accomplished at the best efficiency consistent with the everpresent problem of economy. Example of condenser for operation using r404a figure 4. Our knowledge allows for an expedient, accurate design and fabrication process. Firstly, cooling water is passed through a series of tubes and steam passes over the tubes. A digest of the rules for the design of condensers and air. A steam jet ejector system with surface condensers normally requires more motive steam and condensing water than the one with direct contact condensers, and is the most expensive. Although the capital cost and the space required is more in surface condensers but it is still preferred due to its low running cost and high thermal efficiency of plant. We can get the following conclusions according to the. Surface condenser an overview sciencedirect topics. Steam surface condensers water cooled maarky power. Members are involved in various sections focused on technology. Where cooling water is in short supply, an aircooled condenser is often used. Thermodynamic design of condensers and evaporators. The condenser houses the first two stages of low pressure heaters for simplified arrangement of the turbine building.
Setting shell side and tube side pressure drop design limits. Shell and tube ejector condensers should be straight tube units, single or double pass with removable heads. Introduction a condenser is a type of heat exchanger in which vapors are transferred into liquid state by removing the latent heat with the help of a coolant such as water. These condensers are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below atmospheric pressure. Process fluid assignments to shell side or tube side.
Improving future air cooled condenser designs optimizing fin and bundle design fin heights, downflowtubes versus reflux tubes, tube size minimize plot area reduce fan power improving fan efficiencies reduce noise and required power augmenting performance on summer days fin surface texture enhancements other strategies. This program is valid for small cylindrical units or larger condensers used in thermal and nuclear power plants. In many vacuum processes drying, distillation, large volumes of vapor are released that have to be pumped down. Yuba steam surface condensers provide significant performance advantages, including typically longer service lives.
Performance characteristics of an aircooled condenser. Aksjournal2010 page 1 of 20 aspects of failure of condenser tubes and their remedial measures at power plants ashwini k. Schematic diagram of a shell and tube surface condenser mccabe and smith, 1976. The parts of shell and tube condensers and plate condensers involved in the transfer of heat from the steam and condensate to the cooling. Surface condensers also allow for direct recovery of vocs from the gas stream. The total number of cells or modules is the sum of the primary and secondary modules. Design pump to minimize npshr required and air infiltration. Steam surface condensers condense turbine exhaust steam. Pdf titanium benefits in steam surface condensers tony. The 12th edition of standards for steam surface condensers primarily updates the previous edition with new revisions and insights on fm tube material, gauge correction factors, pressure design equations, nuclear applications, condenser hotwells, atmosphere relief devices, vacuum breaker valves, condenser tube cleaning, steam inlet expansion. This type of condenser is used in applications where the cooling water is the same quality as the steam condensate. Tei condensers represent an evolution of advanced technology, offering improved thermal efficiency and advanced mechanical design to reduce forced outages and increase availability. Compliance with hei, asme, ped and other design codes and engineering standards as per project.