Surface condenserFrom Wikipedia, the free encyclopediaJump to: navigation, search

Surface condenserA surface condenser is a commonly used term for a water-cooled shell and tube heat exchanger installed on the exhaust steam from a steam turbine in thermal power stations.[1][2][3] These condensers are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below atmospheric pressure. 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.Surface condensers are also used in applications and industries other than the condensing of steam turbine exhaust in power plants.Contents[hide] 1 Purpose 2 Why it is required 3 Diagram of water-cooled surface condenser 3.1 Shell 3.2 Vacuum system 3.3 Tube sheets 3.4 Tubes 3.5 Waterboxes 4 Corrosion 4.1 Effects of corrosion 4.2 Protection from corrosion 5 Effects of tube side fouling 6 Other applications of surface condensers 7 Testing 8 See also 9 References 10 External linksPurpose[edit]In thermal power plants, the primary purpose of a surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency, and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the steam generator or boiler as boiler feed water.Why it is required[edit]The steam turbine itself is a device to convert the heat in steam to mechanical power. 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 pound or kilogram 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 conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenserDiagram of water-cooled surface condenser[edit]

Diagram of a typical water-cooled surface condenserThe adjacent diagram depicts a typical water-cooled surface condenser as used in power stations to condense the exhaust steam from a steam turbine driving an electrical generator as well in other applications.[2][3][4][5] There are many fabrication design variations depending on the manufacturer, the size of the steam turbine, and other site-specific conditions.Shell[edit]The shell is the condenser's outermost body and contains the heat exchanger tubes. The shell is fabricated from carbon steel 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 lengths.At the bottom of the shell, where the condensate collects, an outlet is installed. In some designs, a sump (often referred to as the hotwell) is provided. Condensate is pumped from the outlet or the hotwell for reuse as boiler feedwater.For most water-cooled surface condensers, the shell is under vacuum during normal operating conditions.Vacuum system[edit]

Diagram of a typical modern injector or ejector. For a steam ejector, the motive fluid is steam.For water-cooled surface condensers, the shell's internal vacuum is most commonly supplied by and maintained by an external steam jet ejector 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 Venturi effect, which is a particular case of Bernoulli's principle, applies to the operation of steam jet ejectors.Motor driven mechanical vacuum pumps, such as the liquid ring type, are also popular for this service.Tube sheets[edit]At each end of the shell, a sheet of sufficient thickness usually made of stainless steel 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 eddies 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 expansion 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.Tubes[edit]Generally the tubes are made of stainless steel, copper alloys such as brass or bronze, cupro nickel, or titanium 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 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 55 ft (17 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.Waterboxes[edit]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.These waterboxes on inlet side will also have flanged connections for cooling water inlet butterfly valves, small vent pipe with hand valve for air venting at higher level, and hand operated drain valve at bottom to drain the waterbox for maintenance. Similarly on the outlet waterbox the cooling water connection will have large flanges, butterfly valves, vent connection also at higher level and drain connections at lower level. Similarly thermometer pockets are located at inlet and outlet pipes for local measurements of cooling water temperature.In smaller units, some manufacturers make the condenser shell as well as waterboxes of cast iron.Corrosion[edit]On the cooling water side of the condenser: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 electrolyte between the metallic composition of tubes and water boxes. This will give rise to electrolytic corrosion which will start from more anodic materials first.Sea water based condensers, in particular when sea water has added chemical pollutants, have the worst corrosion characteristics. River water with pollutants are also undesirable for condenser cooling water.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 sodium hypochlorite, or chlorine, 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.On the steam (shell) side of the condenser: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 manufacturers provide higher corrosive resistant tubes in this area.Effects of corrosion[edit]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 steam generators. The other parts of water boxes may also get affected in the long run requiring repairs or replacements involving long duration shut-downs.Protection from corrosion[edit]Cathodic protection is typically employed to overcome this problem. Sacrificial anodes of zinc (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.Effects of tube side fouling[edit]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 tubing itself. Tube side fouling for surface condensers falls into five main categories; particulate fouling like silt and sediment, biofouling like slime and biofilms, scaling and crystallization such as calcium carbonate, macrofouling which can include anything from zebra mussels that can grow on the tubesheet, to wood or other debris that blocks the tubing, and finally, corrosion product (discussed previously).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 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 CO2 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 nameplate capacity. A variety of methods for cleaning are available including online and offline options depending on the plant's site-specific conditions.Other applications of surface condensers[edit] Vacuum evaporation Vacuum refrigeration Ocean Thermal Energy (OTEC) Replacing barometric condensers in steam-driven ejector systems Geothermal energy recovery Desalination systemsTesting[edit]National and international test codes are used to standardize the procedures and definitions used in testing large condensors. In the U.S., ASME 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.See also[edit] Condensing steam locomotive Deaerator Feedwater heater Fossil fuel power plant Jet condenser Power stationReferences[edit]1. Jump up ^ Robert Thurston Kent (Editor in Chief) (1936). Kents Mechanical Engineers Handbook (Eleventh edition (Two volumes) ed.). John Wiley & Sons (Wiley Engineering Handbook Series). 2. ^ Jump up to: a b Babcock & Wilcox Co. (2005). Steam: Its Generation and Use (41st edition ed.). ISBN 0-9634570-0-4. 3. ^ Jump up to: a b Thomas C. Elliott, Kao Chen, Robert Swanekamp (coauthors) (1997). Standard Handbook of Powerplant Engineering (2nd edition ed.). McGraw-Hill Professional. ISBN 0-07-019435-1. 4. Jump up ^ Air Pollution Control Orientation Course from website of the Air Pollution Training Institute5. Jump up ^ Energy savings in steam systems Figure 3a, Layout of surface condenser (scroll to page 11 of 34 pdf pages)External links[edit] Overview of power plant condenser and cooling systems

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Worked example of cable calculationFrom Electrical Installation GuideJump to: navigation , searchGeneral rules of electrical installation design

Connection to the MV utility distribution network

Connection to the LV utility distribution network

MV and LV architecture selection guide for buildings

LV Distribution

Protection against electric shocks and electric fires

Sizing and protection of conductors

Conductor sizing and protection Conductor sizing: methodology and definition Overcurrent protection principles Practical values for a protective scheme Location of protective devices Conductors in parallel Practical method for determining the smallest allowable cross-sectional area of circuit conductors General method for cable sizing Recommended simplified approach for cable sizing Sizing of busbar trunking systems (busways) Determination of voltage drop Maximum voltage drop limit Calculation of voltage drop in steady load conditions Short-circuit current Short-circuit current at the secondary terminals of a MV/LV distribution transformer 3-phase short-circuit current (Isc) at any point within a LV installation Isc at the receiving end of a feeder as a function of the Isc at its sending end Short-circuit current supplied by a generator or an inverter Particular cases of short-circuit current Calculation of minimum levels of short-circuit current Verification of the withstand capabilities of cables under short-circuit conditions Protective earthing conductor (PE) Connection and choice for protective earthing conductor Sizing of protective earthing conductor Protective conductor between MV/LV transformer and the main general distribution board (MGDB) Equipotential conductor The neutral conductor Sizing the neutral conductor Protection of the neutral conductor Breaking of the neutral conductor Isolation of the neutral conductor Worked example of cable calculation

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Contents[hide] 1- Worked example of cable calculation 2- Calculation using software Ecodial 3- The same calculation using the simplified method recommended in this guide 3.1- Dimensioning circuit C1 3.2- Dimensioning circuit C3 3.3- Dimensioning circuit C7 3.4- Calculation of short-circuit currents for the selection of circuit-breakers Q1, Q3, Q7 (see Fig. G67) 3.5- The protective conductor 3.6- Protection against indirect-contact hazards 3.7- Voltage drop

Worked example of cable calculation (see Fig. G65)The installation is supplied through a 630 kVA transformer. The process requires a high degree of supply continuity and part of the installation can be supplied by a 250 kVA standby generator. The global earthing system is TN-S, except for the most critical loads supplied by an isolation transformer with a downstream IT configuration.The single-line diagram is shown in Figure G65 below. The results of a computer study for the circuit from transformer T1 down to the cable C7 is reproduced on Figure G66. This study was carried out with Ecodial software (a Schneider Electric product).This is followed by the same calculations carried out by the simplified method described in this guide.

Fig. G65: Example of single-line diagram

Calculation using software Ecodial General network characteristics

Number of poles and protected poles4P4d

Earthing systemTN-STripping unitMicrologic 2.3

Neutral distributedNoOverload trip Ir (A)510

Voltage (V)400Short-delay trip Im / Isd (A)5100

Frequency (Hz)50Cable C3

Upstream fault level (MVA)500Length20

Resistance of MV network (m)0.0351Maximum load current (A)509

Reactance of MV network (m)0.351Type of insulationPVC

Transformer T1 Ambient temperature (C)30

Rating (kVA)630Conductor materialCopper

Short-circuit impedance voltage (%)4Single-core or multi-core cableSingle

Transformer resistance RT (m)3.472Installation method F

Transformer reactance XT (m)10.64Phase conductor selected csa (mm2)2 x 95

3-phase short-circuit current Ik3 (kA)21.54Neutral conductor selected csa (mm2)2 x 95

Cable C1 PE conductor selected csa (mm2)1 x 95

Length (m)5Cable voltage drop U (%)0.53

Maximum load current (A)860Total voltage drop U (%)0.65

Type of insulationPVC3-phase short-circuit current Ik3 (kA)19.1

Ambient temperature (C)301-phase-to-earth fault current Id (kA)11.5

Conductor materialCopperSwitchboard B6

Single-core or multi-core cableSingleReferenceLinergy 800

Installation methodFRated current (A)750

Number of layers1Circuit-breaker Q7

Phase conductor selected csa (mm2)2 x 240Load current (A)255

Neutral conductor selected csa (mm2)2 x 240TypeCompact

PE conductor selected csa (mm2)1 x 120ReferenceNSX400F

Voltage drop U (%)0.122Rated current (A)400

3-phase short-circuit current Ik3 (kA)21.5Number of poles and protected poles3P3d

Courant de dfaut phase-terre Id (kA)15.9Tripping unitMicrologic 2.3

Circuit-breaker Q1 Overload trip Ir (A)258

Load current (A)860Short-delay trip Im / Isd (A)2576

TypeCompactCable C7

ReferenceNS1000NLength5

Rated current (A)1000Maximum load current (A)255

Number of poles and protected poles4P4dType of insulationPVC

Tripping unitMicrologic 5.0Ambient temperature (C)30

Overload trip Ir (A)900Conductor materialCopper

Short-delay trip Im / Isd (A)9000Single-core or multi-core cableSingle

Tripping time tm (ms)50Installation methodF

Switchboard B2 Phase conductor selected csa (mm2)1 x 95

ReferenceLinergy 1250Neutral conductor selected csa (mm2)-

Rated current (A)1050PE conductor selected csa (mm2)1 x 50

Circuit breaker Q3 Cable voltage drop U (%)0.14

Load current (A)509Total voltage drop U (%)0.79

TypeCompact3-phase short-circuit current Ik3 (kA)18.0

ReferenceNSX630F1-phase-to-earth fault current Id (kA)10.0

Rated current (A)630

Fig. G66: Partial results of calculation carried out with Ecodial software (Schneider Electric)

The same calculation using the simplified method recommended in this guide Dimensioning circuit C1 The MV/LV 630 kVA transformer has a rated no-load voltage of 420 V. Circuit C1 must be suitable for a current of: per phase Two single-core PVC-insulated copper cables in parallel will be used for each phase.These cables will be laid on cable trays according to method F.Each conductor will therefore carry 433A. Figure G21a indicates that for 3 loaded conductors with PVC isolation, the required c.s.a. is 240mm.The resistance and the inductive reactance, for the two conductors in parallel, and for a length of 5 metres, are: (cable resistance: 22.5 m.mm2/m) X = 0,08 x 5 = 0,4 m (cable reactance: 0.08 m/m) Dimensioning circuit C3 Circuit C3 supplies two 150kW loads with cos = 0.85, so the total load current is: Two single-core PVC-insulated copper cables in parallel will be used for each phase. These cables will be laid on cable trays according to method F.Each conductor will therefore carry 255A. Figure G21a indicates that for 3 loaded conductors with PVC isolation, the required c.s.a. is 95mm2.The resistance and the inductive reactance, for the two conductors in parallel, and for a length of 20 metres, are:

Dimensioning circuit C7 Circuit C7 supplies one 150kW load with cos = 0.85, so the total load current is: One single-core PVC-insulated copper cable will be used for each phase. The cables will be laid on cable trays according to method F.Each conductor will therefore carry 255A. Figure G21a indicates that for 3 loaded conductors with PVC isolation, the required c.s.a. is 95mm2.The resistance and the inductive reactance for a length of 20 metres is:(cable resistance: 22.5 m.mm2/m) (cable reactance: 0.08 m/m)

Calculation of short-circuit currents for the selection of circuit-breakers Q1, Q3, Q7 (see Fig. G67) Circuit componentsR (m)X (m)Z (m)Ikmax (kA)

Upstream MV network, 500MVA fault level (see Fig. G34)0,0350,351

Transformer 630kVA, 4% (see Fig. G35)2.910.8

Cable C10.230.4

Sub-total3.1611.5511.9720.2

Cable C32.371.6

Sub-total5.5313.1514.2617

Cable C71.180.4

Sub-total6.7113.5515.1216

Fig. G67: Example of short-circuit current evaluation

The protective conductor When using the adiabatic method, the minimum c.s.a. for the protective earth conductor (PE) can be calculated by the formula given in Figure G58: For circuit C1, I = 20.2kA and k = 143.t is the maximum operating time of the MV protection, e.g. 0.5sThis gives: A single 120 mm2 conductor is therefore largely sufficient, provided that it also satisfies the requirements for indirect contact protection (i.e. that its impedance is sufficiently low).Generally, for circuits with phase conductor c.s.a. Sph 50 mm2, the PE conductor minimum c.s.a. will be Sph / 2. Then, for circuit C3, the PE conductor will be 95mm2, and for circuit C7, the PE conductor will be 50mm2.

Protection against indirect-contact hazards For circuit C3 of Figure G65, Figures F41 and F40, or the formula given page F25 may be used for a 3-phase 4-wire circuit.The maximum permitted length of the circuit is given by: (The value in the denominator 630 x 11 is the maximum current level at which the instantaneous short-circuit magnetic trip of the 630 A circuit-breaker operates).The length of 20 metres is therefore fully protected by instantaneous over-current devices.

Voltage drop The voltage drop is calculated using the data given in Figure G28, for balanced three-phase circuits, motor power normal service (cos = 0.8).The results are summarized on figure G68:c.s.a.C1C3C7

2 x 240mm2 x 95mm1 x 95mm

U per conductor(V/A/km) see Fig. G280.210.420.42

Load current (A)866509255

Length (m)5205

Voltage drop (V)0.452.10.53

Voltage drop (%)0.110.530.13

Fig. G68: Voltage drop introduced by the different cables

The total voltage drop at the end of cable C7 is then: 0.77%. Retrieved from "http://www.electrical-installation.org/enw/index.php?title=Worked_example_of_cable_calculation&oldid=14909"Category: Chapter - Sizing and protection of conductors

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