251:
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.
20:
174:
375:(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.
224:
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
343:
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
399:
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
259:
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.
146:
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
383:
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
105:
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
250:
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
59:. 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.
97:. 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
229:
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.
400:
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
301:
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
337:, 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.
404:
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
449:
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.
119:
134:
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.
352:
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
220:
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
675:
189:
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
609:
1390:
356:. The other parts of water boxes may also get affected in the long run requiring repairs or replacements involving long duration shut-downs.
445:
National and international test codes are used to standardize the procedures and definitions used in testing large condensers. In the U.S.,
408:. A variety of methods for cleaning are available, including online and offline options, depending on the plant's site-specific conditions.
637:
396:
that can grow on the tubesheet, to wood or other debris that blocks the tubing, and finally, corrosion products (discussed previously).
275:
at bottom to drain the waterbox for maintenance. Similarly on the outlet waterbox the cooling water connection will have large flanges,
384:
tubing itself. Tube-side fouling for surface condensers falls into five main categories; particulate fouling like silt and sediment,
668:
126:
The adjacent diagram depicts a typical water-cooled surface condenser as used in power stations to condense the exhaust steam from a
62:
Surface condensers are also used in applications and industries other than the condensing of steam turbine exhaust in power plants.
78:, and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the
1550:
329:
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
1423:
1560:
818:
185:
For water-cooled surface condensers, the shell's internal vacuum is most commonly supplied by and maintained by an external
1456:
1229:
661:
1125:
1625:
1120:
593:
565:
1268:
1584:
1496:
425:
154:(often referred to as the hotwell) is provided. Condensate is pumped from the outlet or the hotwell for reuse as
1450:
142:
The shell is the condenser's outermost body and contains the heat exchanger tubes. The shell is fabricated from
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1199:
1444:
843:
32:
1431:
1219:
1569:
1287:
1259:
1143:
755:
698:
464:
110:
of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser.
1158:
1635:
1037:
392:, scaling and crystallization such as calcium carbonate, macrofouling which can include anything from
150:
At the bottom of the shell, where the condensate collects, an outlet is installed. In some designs, a
1589:
1578:
1436:
1135:
748:
522:(Eleventh edition (Two volumes) ed.). John Wiley & Sons (Wiley Engineering Handbook Series).
48:
1630:
1363:
1295:
353:
283:
pockets are located at inlet and outlet pipes for local measurements of cooling water temperature.
194:
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1515:
1384:
1239:
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906:
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1163:
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813:
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between the metallic composition of tubes and water boxes. This will give rise to electrolytic
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1115:
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713:
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44:
1529:
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1214:
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1014:
880:
828:
765:
718:
515:
131:
56:
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These waterboxes on inlet side will also have flanged connections for cooling water inlet
8:
1523:
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931:
848:
838:
583:
364:
330:
622:
1019:
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In smaller units, some manufacturers make the condenser shell as well as waterboxes of
279:, vent connection also at higher level and drain connections at lower level. Similarly
75:
1320:
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79:
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641:
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52:
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808:
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1619:
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903:
489:
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127:
55:
which convert steam from its gaseous to its liquid state at a pressure below
40:
1477:
1234:
981:
966:
921:
775:
770:
684:
393:
243:
143:
107:
98:
71:
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At each end of the shell, a sheet of sufficient thickness usually made of
1329:
900:
870:
743:
303:
280:
205:
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1351:
976:
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385:
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514:
173:
1204:
1189:
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459:
344:
manufacturers provide higher corrosive resistant tubes in this area.
307:
287:
118:
1093:
334:
247:
186:
178:
102:
584:
Thomas C. Elliott, Kao Chen, Robert
Swanekamp (coauthors) (1997).
106:
conversion to mechanical power. Most of the heat liberated due to
70:
In thermal power plants, the purpose of a surface condenser is to
389:
653:
1209:
946:
430:
Replacing barometric condensers in steam-driven ejector systems
162:
83:
161:
For most water-cooled surface condensers, the shell is under
23:
Surface condenser with end plate extended to reveal tube banks
728:
322:, have the worst corrosion characteristics. River water with
272:
268:
36:
113:
446:
411:
372:
151:
90:
271:
for air venting at higher level, and hand-operated drain
74:
the exhaust steam from a steam turbine to obtain maximum
555:
177:
Diagram of a typical modern injector or ejector. For a
625:
from website of the Air
Pollution Training Institute
89:
The steam turbine itself is a device to convert the
310:which will start from more anodic materials first.
122:
Diagram of a typical water-cooled surface condenser
326:are also undesirable for condenser cooling water.
318:, in particular when sea water has added chemical
197:, applies to the operation of steam jet ejectors.
1617:
367:is typically employed to overcome this problem.
378:
669:
608:: CS1 maint: multiple names: authors list (
359:
340:On the steam (shell) side of the condenser:
298:On the cooling water side of the condenser:
586:Standard Handbook of Powerplant Engineering
676:
662:
588:(2nd ed.). McGraw-Hill Professional.
579:
577:
551:
549:
242:, copper alloys such as brass or bronze,
208:type, are also popular for this service.
114:Diagram of water-cooled surface condenser
623:Air Pollution Control Orientation Course
412:Other applications of surface condensers
172:
117:
18:
1551:Glossary of steam locomotive components
347:
1618:
645:Figure 3a, Layout of surface condenser
574:
546:
657:
520:Kents' Mechanical Engineers' Handbook
165:during normal operating conditions.
647:(scroll to page 11 of 34 pdf pages)
13:
1403:National Museum of Scotland engine
14:
1652:
683:
556:Babcock & Wilcox Co. (2005).
1585:List of steam technology patents
238:Generally the tubes are made of
193:, which is a particular case of
168:
635:Energy savings in steam systems
1570:Murdoch's model steam carriage
1556:History of steam road vehicles
628:
616:
508:
211:
35:installed to condense exhaust
1:
1497:Murray's Hypocycloidal Engine
558:Steam: Its Generation and Use
501:
254:
33:shell and tube heat exchanger
1220:Return connecting rod engine
379:Effects of tube side fouling
293:
267:, small vent pipe with hand
181:, the motive fluid is steam.
7:
1144:Condensing steam locomotive
465:Condensing steam locomotive
452:
426:Ocean Thermal Energy (OTEC)
10:
1657:
1451:"Coalbrookdale Locomotive"
518:(Editor in Chief) (1936).
440:
433:Geothermal energy recovery
315:Sea water based condensers
65:
1543:
1514:
1487:
1468:
1457:"Pen-y-Darren" locomotive
1422:
1375:
1328:
1319:
1286:
1267:
1258:
1177:
1134:
1126:Single- and double-acting
1106:
1076:
1028:
1000:
954:
945:
861:
789:
736:
727:
691:
360:Protection from corrosion
1626:Power station technology
1296:Newcomen Memorial Engine
233:
200:Motor driven mechanical
137:
1600:Timeline of steam power
1595:Stationary steam engine
1478:Woolf's compound engine
1385:Soho Manufactory engine
1240:Steeple compound engine
907:straight line mechanism
480:Fossil fuel power plant
93:in steam to mechanical
1605:Water-returning engine
1579:Lean's Engine Reporter
1352:Chacewater Mine engine
1225:Six-column beam engine
182:
123:
86:as boiler feed water.
45:thermal power stations
24:
16:Steam engine component
1445:London Steam Carriage
495:Thermal power station
195:Bernoulli's principle
176:
121:
22:
1391:Bradley Works engine
1215:Reciprocating engine
1038:Babcock & Wilcox
881:Centrifugal governor
516:Robert Thurston Kent
436:Desalination systems
422:Vacuum refrigeration
348:Effects of corrosion
132:electrical generator
57:atmospheric pressure
932:Sun and planet gear
365:Cathodic protection
331:sodium hypochlorite
1432:Richard Trevithick
1030:Water-tube boilers
844:Gresley conjugated
640:2007-09-27 at the
538:has generic name (
418:Vacuum evaporation
406:nameplate capacity
369:Sacrificial anodes
183:
124:
31:is a water-cooled
25:
1636:Energy conversion
1613:
1612:
1539:
1538:
1418:
1417:
1102:
1101:
1002:Fire-tube boilers
857:
856:
560:(41st ed.).
187:steam jet ejector
29:surface condenser
1648:
1563:fardier Ă vapeur
1397:Whitbread Engine
1358:Smethwick Engine
1326:
1325:
1265:
1264:
1084:Feedwater heater
952:
951:
734:
733:
678:
671:
664:
655:
654:
648:
632:
626:
620:
614:
613:
607:
599:
581:
572:
571:
553:
544:
543:
537:
533:
531:
523:
512:
475:Feedwater heater
354:steam generators
277:butterfly valves
265:butterfly valves
156:boiler feedwater
1656:
1655:
1651:
1650:
1649:
1647:
1646:
1645:
1631:Heat exchangers
1616:
1615:
1614:
1609:
1535:
1510:
1483:
1464:
1414:
1371:
1315:
1303:Fairbottom Bobs
1288:Newcomen engine
1282:
1254:
1200:Expansion valve
1173:
1159:Watt's separate
1130:
1098:
1072:
1024:
996:
941:
917:Parallel motion
853:
804:Stephenson link
785:
723:
692:Operating cycle
687:
682:
652:
651:
642:Wayback Machine
633:
629:
621:
617:
601:
600:
596:
582:
575:
568:
554:
547:
535:
534:
525:
524:
513:
509:
504:
499:
455:
443:
414:
403:
388:like slime and
381:
362:
350:
296:
257:
240:stainless steel
236:
218:stainless steel
214:
171:
140:
116:
80:steam generator
68:
53:heat exchangers
17:
12:
11:
5:
1654:
1644:
1643:
1638:
1633:
1628:
1611:
1610:
1608:
1607:
1602:
1597:
1592:
1587:
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1527:
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1406:
1400:
1394:
1388:
1381:
1379:
1373:
1372:
1370:
1369:
1361:
1355:
1349:
1341:
1338:Kinneil Engine
1334:
1332:
1323:
1317:
1316:
1314:
1313:
1310:Elsecar Engine
1307:
1299:
1292:
1290:
1284:
1283:
1281:
1280:
1273:
1271:
1262:
1256:
1255:
1253:
1252:
1247:
1242:
1237:
1232:
1230:Steeple engine
1227:
1222:
1217:
1212:
1207:
1202:
1197:
1192:
1187:
1181:
1179:
1175:
1174:
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1140:
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1132:
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1129:
1128:
1123:
1118:
1112:
1110:
1104:
1103:
1100:
1099:
1097:
1096:
1091:
1089:Feedwater pump
1086:
1080:
1078:
1074:
1073:
1071:
1070:
1065:
1060:
1055:
1050:
1045:
1040:
1034:
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1026:
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1023:
1022:
1017:
1012:
1006:
1004:
998:
997:
995:
994:
989:
984:
979:
974:
969:
964:
958:
956:
955:Simple boilers
949:
943:
942:
940:
939:
937:Watt's linkage
934:
929:
924:
919:
914:
909:
898:
893:
888:
886:Connecting rod
883:
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873:
867:
865:
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210:
204:, such as the
191:Venturi effect
170:
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67:
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15:
9:
6:
4:
3:
2:
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1438:Puffing Devil
1435:
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1427:
1425:
1424:High-pressure
1421:
1410:
1407:
1404:
1401:
1398:
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1377:Rotative beam
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1308:
1305:
1304:
1300:
1297:
1294:
1293:
1291:
1289:
1285:
1278:
1277:Savery Engine
1275:
1274:
1272:
1270:
1266:
1263:
1261:
1257:
1251:
1250:Working fluid
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948:
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938:
935:
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928:
927:Rotative beam
925:
923:
920:
918:
915:
913:
910:
908:
905:
904:hypocycloidal
902:
899:
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1121:Oscillating
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922:Plate chain
901:Tusi couple
814:Walschaerts
699:Atmospheric
304:electrolyte
281:thermometer
212:Tube sheets
206:liquid ring
130:driving an
1620:Categories
1530:Ljungström
1516:High-speed
1409:Lap Engine
1365:Resolution
1269:Precursors
1154:Kirchweger
1116:Locomotive
1063:Three-drum
1043:Field-tube
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912:Link chain
896:Crankshaft
863:Mechanisms
791:Valve gear
502:References
386:biofouling
324:pollutants
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1561:Cugnot's
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1205:Hydrolock
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972:Egg-ended
604:cite book
528:cite book
470:Deaerator
460:Tube tool
308:corrosion
294:Corrosion
288:cast iron
227:expansion
147:lengths.
1544:See also
1470:Compound
1345:Old Bess
1185:Blowback
1108:Cylinder
1094:Injector
1053:Stirling
1048:Sentinel
962:Haystack
876:Cataract
849:Southern
839:Caprotti
714:Compound
638:Archived
453:See also
390:biofilms
335:chlorine
248:titanium
103:kilogram
72:condense
47:. These
1260:History
1169:Surface
987:Cornish
947:Boilers
829:Corliss
766:Corliss
749:D slide
719:Uniflow
709:Cornish
441:Testing
66:Purpose
39:from a
1572:(1784)
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834:Lentz
824:Baker
819:Allan
744:Slide
333:, or
273:valve
269:valve
246:, or
234:Tubes
138:Shell
99:pound
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37:steam
1330:Beam
871:Beam
781:Bash
761:Drop
704:Watt
610:link
590:ISBN
562:ISBN
540:help
447:ASME
373:zinc
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