262:
containing copper. Titanium condenser tubes are usually the best technical choice, however the use of titanium condenser tubes has been virtually eliminated by the sharp increases in the costs for this material. The tube lengths range to about 85 ft (26 m) for modern power plants, depending on the size of the condenser. The size chosen is based on transportability from the manufacturers’ site and ease of erection at the installation site. The outer diameter of condenser tubes typically ranges from 3/4 inch to 1-1/4 inch, based on condenser cooling water friction considerations and overall condenser size.
31:
185:
386:(being cheapest) plates are mounted at suitable places inside the water boxes. These zinc plates will get corroded first being in the lowest range of anodes. Hence these zinc anodes require periodic inspection and replacement. This involves comparatively less down time. The water boxes made of steel plates are also protected inside by epoxy paint.
235:
at the inlet of each tube giving rise to erosion, and to reduce flow friction. Some makers also recommend plastic inserts at the entry of tubes to avoid eddies eroding the inlet end. In smaller units some manufacturers use ferrules to seal the tube ends instead of rolling. To take care of length wise
354:
The concentration of undissolved gases is high over air zone tubes. Therefore, these tubes are exposed to higher corrosion rates. Some times these tubes are affected by stress corrosion cracking, if original stress is not fully relieved during manufacture. To overcome these effects of corrosion some
410:
Depending on the extent of the fouling, the impact can be quite severe on the condenser's ability to condense the exhaust steam coming from the turbine. As fouling builds up within the tubing, an insulating effect is created and the heat-transfer characteristics of the tubes are diminished, often
270:
The tube sheet at each end with tube ends rolled, for each end of the condenser is closed by a fabricated box cover known as a waterbox, with flanged connection to the tube sheet or condenser shell. The waterbox is usually provided with man holes on hinged covers to allow inspection and cleaning.
157:
plates and is stiffened as needed to provide rigidity for the shell. When required by the selected design, intermediate plates are installed to serve as baffle plates that provide the desired flow path of the condensing steam. The plates also provide support that help prevent sagging of long tube
394:
As one might expect, with millions of gallons of circulating water flowing through the condenser tubing from seawater or fresh water, anything that is contained within the water flowing through the tubes can ultimately end up on either the condenser tubesheet (discussed previously) or within the
116:
of steam to mechanical power in the turbine, the better is its efficiency. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount of heat available for
261:
depending on several selection criteria. The use of copper bearing alloys such as brass or cupro nickel is rare in new plants, due to environmental concerns of toxic copper alloys. Also depending on the steam cycle water treatment for the boiler, it may be desirable to avoid tube materials
70:. Where cooling water is in short supply, an air-cooled condenser is often used. An air-cooled condenser is however, significantly more expensive and cannot achieve as low a steam turbine exhaust pressure (and temperature) as a water-cooled surface condenser.
108:. 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 from the turbine represents the heat which is converted to mechanical power. Therefore, the more the conversion of heat per
240:
of tubes some designs have expansion joint between the shell and the tube sheet allowing the latter to move longitudinally. In smaller units some sag is given to the tubes to take care of tube expansion with both end water boxes fixed rigidly to the shell.
411:
requiring the turbine to be slowed to a point where the condenser can handle the exhaust steam produced. Typically, this can be quite costly to power plants in the form of reduced output, increase fuel consumption and increased CO
312:
The tubes, the tube sheets and the water boxes may be made up of materials having different compositions and are always in contact with circulating water. This water, depending on its chemical composition, will act as an
348:, to ensure there is no marine growth on the pipes or the tubes. This practice must be strictly regulated to make sure the circulating water returning to the sea or river source is not affected.
415:
emissions. This "derating" of the turbine to accommodate the condenser's fouled or blocked tubing is an indication that the plant needs to clean the tubing in order to return to the turbine's
460:
publishes several performance test codes on condensers and heat exchangers. These include ASME PTC 12.2-2010, Steam
Surface Condensers, and PTC 30.1-2007, Air cooled Steam Condensers.
686:
145:
as well in other applications. There are many fabrication design variations depending on the manufacturer, the size of the steam turbine, and other site-specific conditions.
620:
363:
As the tube ends get corroded there is the possibility of cooling water leakage to the steam side contaminating the condensed steam or condensate, which is harmful to
231:
is provided, with holes for the tubes to be inserted and rolled. The inlet end of each tube is also bellmouthed for streamlined entry of water. This is to avoid
679:
200:
system. Such an ejector system uses steam as the motive fluid to remove any non-condensible gases that may be present in the surface condenser. The
1561:
367:. The other parts of water boxes may also get affected in the long run requiring repairs or replacements involving long duration shut-downs.
456:
National and international test codes are used to standardize the procedures and definitions used in testing large condensers. In the U.S.,
419:. A variety of methods for cleaning are available, including online and offline options, depending on the plant's site-specific conditions.
672:
648:
130:
1136:
407:
that can grow on the tubesheet, to wood or other debris that blocks the tubing, and finally, corrosion products (discussed previously).
286:
at bottom to drain the waterbox for maintenance. Similarly on the outlet waterbox the cooling water connection will have large flanges,
395:
tubing itself. Tube-side fouling for surface condensers falls into five main categories; particulate fouling like silt and sediment,
137:
The adjacent diagram depicts a typical water-cooled surface condenser as used in power stations to condense the exhaust steam from a
1636:
1131:
604:
576:
73:
Surface condensers are also used in applications and industries other than the condensing of steam turbine exhaust in power plants.
89:, and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the
1595:
1507:
340:
The corrosive effect of sea or river water has to be tolerated and remedial methods have to be adopted. One method is the use of
436:
1566:
1401:
1210:
196:
For water-cooled surface condensers, the shell's internal vacuum is most commonly supplied by and maintained by an external
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43:
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165:(often referred to as the hotwell) is provided. Condensate is pumped from the outlet or the hotwell for reuse as
59:
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The shell is the condenser's outermost body and contains the heat exchanger tubes. The shell is fabricated from
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1374:
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of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser.
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30:
403:, scaling and crystallization such as calcium carbonate, macrofouling which can include anything from
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At the bottom of the shell, where the condensate collects, an outlet is installed. In some designs, a
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1225:
1164:
1025:
891:
839:
776:
729:
533:(Eleventh edition (Two volumes) ed.). John Wiley & Sons (Wiley Engineering Handbook Series).
526:
142:
67:
1534:
1068:
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859:
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375:
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pockets are located at inlet and outlet pipes for local measurements of cooling water temperature.
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between the metallic composition of tubes and water boxes. This will give rise to electrolytic
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These waterboxes on inlet side will also have flanged connections for cooling water inlet
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17:
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In smaller units, some manufacturers make the condenser shell as well as waterboxes of
290:, vent connection also at higher level and drain connections at lower level. Similarly
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66:
which convert steam from its gaseous to its liquid state at a pressure below
1215:
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318:
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227:
At each end of the shell, a sheet of sufficient thickness usually made of
1104:
345:
258:
197:
189:
113:
400:
1220:
957:
355:
manufacturers provide higher corrosive resistant tubes in this area.
173:
94:
739:
595:
Thomas C. Elliott, Kao Chen, Robert
Swanekamp (coauthors) (1997).
283:
279:
183:
128:
117:
conversion to mechanical power. Most of the heat liberated due to
81:
In thermal power plants, the purpose of a surface condenser is to
47:
29:
664:
457:
383:
162:
101:
668:
441:
Replacing barometric condensers in steam-driven ejector systems
172:
For most water-cooled surface condensers, the shell is under
34:
Surface condenser with end plate extended to reveal tube banks
333:, have the worst corrosion characteristics. River water with
282:
for air venting at higher level, and hand-operated drain
85:
the exhaust steam from a steam turbine to obtain maximum
188:
Diagram of a typical modern injector or ejector. For a
636:
from website of the Air
Pollution Training Institute
100:
The steam turbine itself is a device to convert the
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1525:
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321:which will start from more anodic materials first.
133:
Diagram of a typical water-cooled surface condenser
337:are also undesirable for condenser cooling water.
329:, in particular when sea water has added chemical
208:, applies to the operation of steam jet ejectors.
378:is typically employed to overcome this problem.
680:
8:
619:: CS1 maint: multiple names: authors list (
351:On the steam (shell) side of the condenser:
309:On the cooling water side of the condenser:
597:Standard Handbook of Powerplant Engineering
1336:
1275:
962:
744:
687:
673:
665:
599:(2nd ed.). McGraw-Hill Professional.
590:
588:
562:
560:
253:, copper alloys such as brass or bronze,
219:type, are also popular for this service.
125:Diagram of water-cooled surface condenser
634:Air Pollution Control Orientation Course
423:Other applications of surface condensers
1562:Glossary of steam locomotive components
518:
656:Figure 3a, Layout of surface condenser
612:
546:
536:
531:Kents' Mechanical Engineers' Handbook
7:
176:during normal operating conditions.
658:(scroll to page 11 of 34 pdf pages)
1414:National Museum of Scotland engine
25:
567:Babcock & Wilcox Co. (2005).
1596:List of steam technology patents
249:Generally the tubes are made of
204:, which is a particular case of
646:Energy savings in steam systems
1581:Murdoch's model steam carriage
1567:History of steam road vehicles
46:installed to condense exhaust
1:
1508:Murray's Hypocycloidal Engine
569:Steam: Its Generation and Use
44:shell and tube heat exchanger
1231:Return connecting rod engine
390:Effects of tube side fouling
278:, small vent pipe with hand
192:, the motive fluid is steam.
1155:Condensing steam locomotive
476:Condensing steam locomotive
437:Ocean Thermal Energy (OTEC)
1668:
1462:"Coalbrookdale Locomotive"
529:(Editor in Chief) (1936).
444:Geothermal energy recovery
326:Sea water based condensers
1468:"Pen-y-Darren" locomotive
1137:Single- and double-acting
371:Protection from corrosion
18:Condenser (steam turbine)
1637:Power station technology
1307:Newcomen Memorial Engine
211:Motor driven mechanical
1611:Timeline of steam power
1606:Stationary steam engine
1489:Woolf's compound engine
1396:Soho Manufactory engine
1251:Steeple compound engine
918:straight line mechanism
491:Fossil fuel power plant
104:in steam to mechanical
1616:Water-returning engine
1590:Lean's Engine Reporter
1363:Chacewater Mine engine
1236:Six-column beam engine
193:
134:
97:as boiler feed water.
56:thermal power stations
35:
27:Steam engine component
1456:London Steam Carriage
506:Thermal power station
206:Bernoulli's principle
187:
132:
33:
1402:Bradley Works engine
1226:Reciprocating engine
1049:Babcock & Wilcox
892:Centrifugal governor
527:Robert Thurston Kent
447:Desalination systems
433:Vacuum refrigeration
359:Effects of corrosion
143:electrical generator
68:atmospheric pressure
943:Sun and planet gear
376:Cathodic protection
342:sodium hypochlorite
1443:Richard Trevithick
1041:Water-tube boilers
855:Gresley conjugated
651:2007-09-27 at the
549:has generic name (
429:Vacuum evaporation
417:nameplate capacity
380:Sacrificial anodes
194:
135:
42:is a water-cooled
36:
1647:Energy conversion
1624:
1623:
1550:
1549:
1429:
1428:
1113:
1112:
1013:Fire-tube boilers
868:
867:
571:(41st ed.).
198:steam jet ejector
40:surface condenser
16:(Redirected from
1659:
1574:fardier Ă vapeur
1408:Whitbread Engine
1369:Smethwick Engine
1337:
1276:
1095:Feedwater heater
963:
745:
689:
682:
675:
666:
659:
643:
637:
631:
625:
624:
618:
610:
592:
583:
582:
564:
555:
554:
548:
544:
542:
534:
523:
486:Feedwater heater
365:steam generators
288:butterfly valves
276:butterfly valves
167:boiler feedwater
21:
1667:
1666:
1662:
1661:
1660:
1658:
1657:
1656:
1642:Heat exchangers
1627:
1626:
1625:
1620:
1546:
1521:
1494:
1475:
1425:
1382:
1326:
1314:Fairbottom Bobs
1299:Newcomen engine
1293:
1265:
1211:Expansion valve
1184:
1170:Watt's separate
1141:
1109:
1083:
1035:
1007:
952:
928:Parallel motion
864:
815:Stephenson link
796:
734:
703:Operating cycle
698:
693:
663:
662:
653:Wayback Machine
644:
640:
632:
628:
611:
607:
594:
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579:
566:
565:
558:
545:
535:
525:
524:
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515:
510:
466:
454:
425:
414:
399:like slime and
392:
373:
361:
307:
268:
251:stainless steel
247:
229:stainless steel
225:
182:
151:
127:
91:steam generator
79:
64:heat exchangers
28:
23:
22:
15:
12:
11:
5:
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1399:
1392:
1390:
1384:
1383:
1381:
1380:
1372:
1366:
1360:
1352:
1349:Kinneil Engine
1345:
1343:
1334:
1328:
1327:
1325:
1324:
1321:Elsecar Engine
1318:
1310:
1303:
1301:
1295:
1294:
1292:
1291:
1284:
1282:
1273:
1267:
1266:
1264:
1263:
1258:
1253:
1248:
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1241:Steeple engine
1238:
1233:
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1223:
1218:
1213:
1208:
1203:
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1123:
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1115:
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1111:
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1100:Feedwater pump
1097:
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1015:
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1008:
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1005:
1000:
995:
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985:
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966:Simple boilers
960:
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950:
948:Watt's linkage
945:
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935:
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909:
904:
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897:Connecting rod
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202:Venturi effect
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1449:Puffing Devil
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1288:Savery Engine
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1261:Working fluid
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938:Rotative beam
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915:hypocycloidal
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1652:Steam power
1332:Watt engine
1132:Oscillating
1088:Boiler feed
933:Plate chain
912:Tusi couple
825:Walschaerts
710:Atmospheric
315:electrolyte
292:thermometer
223:Tube sheets
217:liquid ring
141:driving an
1631:Categories
1541:Ljungström
1527:High-speed
1420:Lap Engine
1376:Resolution
1280:Precursors
1165:Kirchweger
1127:Locomotive
1074:Three-drum
1054:Field-tube
1021:Locomotive
1003:Lancashire
923:Link chain
907:Crankshaft
874:Mechanisms
802:Valve gear
513:References
397:biofouling
335:pollutants
331:pollutants
266:Waterboxes
87:efficiency
60:condensers
1572:Cugnot's
1515:Salamanca
1216:Hydrolock
1201:Crosshead
1147:Condenser
983:Egg-ended
615:cite book
539:cite book
481:Deaerator
471:Tube tool
319:corrosion
305:Corrosion
299:cast iron
238:expansion
158:lengths.
1555:See also
1481:Compound
1356:Old Bess
1196:Blowback
1119:Cylinder
1105:Injector
1064:Stirling
1059:Sentinel
973:Haystack
887:Cataract
860:Southern
850:Caprotti
725:Compound
649:Archived
464:See also
401:biofilms
346:chlorine
259:titanium
114:kilogram
83:condense
58:. These
1271:History
1180:Surface
998:Cornish
958:Boilers
840:Corliss
777:Corliss
760:D slide
730:Uniflow
720:Cornish
452:Testing
77:Purpose
50:from a
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782:Poppet
767:Piston
748:Valves
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233:eddies
174:vacuum
95:boiler
1189:Other
993:Flued
978:Wagon
902:Crank
845:Lentz
835:Baker
830:Allan
755:Slide
344:, or
284:valve
280:valve
257:, or
245:Tubes
149:Shell
110:pound
106:power
48:steam
1341:Beam
882:Beam
792:Bash
772:Drop
715:Watt
621:link
601:ISBN
573:ISBN
551:help
458:ASME
384:zinc
163:sump
102:heat
62:are
1160:Jet
988:Box
820:Joy
810:Gab
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