Condenser Problem Analysis

Condenser-related problems, such as condenser back pressure, inefficient heat transfer, vacuum issues, and noncondensable gas buildup, can reduce the efficiency of power plants. Thus, addressing these issues is essential for minimizing operational costs and maintaining power efficiency of power plants. This is where Bionetics can help. Our advanced capabilities in solving condenser-related problems and helping boost condenser performance has made us a leader in this segment. Since 1994, we have been at the forefront of research on condenser dynamics, thanks to our innovative RheoVac instrument.

Condenser Problem Analysis with RheoVac and Comprehensive Condenser Model and Methods (C2M2)

The RheoVac is a specialized instrument designed to measure the mixture of water vapor and noncondensable gas in the vent line. Bionetics developed the Comprehensive Condenser Model and Methods (C2M2) using data from RheoVac and other plant metrics. The C2M2 is a sophisticated model grounded in physical principles. It has been rigorously validated under various operating conditions, making it a reliable resource to identify deficiencies in condenser design and operational and maintenance issues.

Optimize Your System with our Streamlined Condenser Performance Evaluation

Bionetics offers a unique 4-step Condenser Performance Evaluation process designed to help clients achieve and maintain peak condenser performance. This process, combined with the advanced RheoVac instrumentation, provides a thorough analysis and actionable insights tailored to each facility’s specific needs.

Partner with Bionetics for Optimal Condenser Performance

To improve your condenser’s efficiency and address performance challenges, fill out the form on this page, and let Bionetics provide expert assistance.

Explore Real-World Results in Our Case Studies

Explore our Case Studies section to see how we have successfully supported other power plants in enhancing their condenser performance.

Key Problems Affecting Condenser Performance

Here are some key problems affecting condenser performance:

• High Condenser Pressure
• Corrosion/ Dissolved Gases
• Low Cleanliness Factor/ Low Heat Transfer Coefficient
• Air In-Leakage
• Tube Fouling
• Low Pump/Exhaust Capacity
• Other Efficiency/Maintenance/Design/Operations Concerns

High Condenser Pressure

High condenser back pressure is the critical issue that results in lost revenue or excess operating costs. Elevated exhaust back pressure affects turbine efficiency by reducing power output, affecting the generator’s ability to enable conversion of mechanical energy into electrical power. This excess back pressure means reduced efficiency and financial losses. Complete the form on this page to let Bionetics analyze your condenser back pressure problem and resolve it effectively.

Understanding How Excess Back Pressure Impacts Profits

Revenue and profit losses can be substantial when condenser pressure in steam power plant rises, even slightly. The charts below illustrate that even a small increase in condenser back pressure dramatically impacts the performance of a turbine. A PEPSE analysis of a 525MW generating unit reveals that each 0.1″ HgA rise in back pressure results in a 0.17% increase in heat rate. In short, an excess back pressure of 0.3″ HgA in a base-loaded plant condenser corresponds to a 2.68MW power loss and nearly $770,000 in lost annual revenue.

Corrosion/Dissolved Gases (Oxygen, Carbon Dioxide, Ammonia, etc.)

Dissolved gases like oxygen, carbon dioxide, and ammonia are a major cause of corrosion in the steam cycle, leading to forced outages and escalating maintenance costs. A common misconception is high DO levels is concurrent with high air-leak rate; however, this is not necessarily true. High DO and elevated condensate CO₂ levels, alongside low air in-leakage, may indicate an inadequate condenser configuration. Complete the form on this page to let Bionetics assess your system and assist in addressing issues with corrosion or dissolved gases effectively.

The Bionetics Condenser Services team has helped reduce DO levels by over 70% at Entergy’s Little Gypsy plant. [Discover the details (PDF)]

Low Cleanliness Factor/Low Heat Transfer Coefficient

The Cleanliness Factor (CF) is determined by calculating the ratio of the actual heat transfer coefficient to the HEI-specified design heat transfer coefficient. A low CF indicates reduced power generation efficiency, which can be due to various underlying issues within the plant and ultimately lead to financial losses. Complete the form on this page to let Bionetics assess your system and assist in addressing low cleanliness factors or insufficient heat transfer efficiency.

Air In-Leakage

There are multiple pathways for air in-leakage into the steam path in the sub-atmospheric side of steam turbine power plants. Air in the steam path, combined with deficiencies in condenser configuration, leads to several plant-related issues such as excess back pressure, dissolved oxygen, corrosion, and low cleanliness factor. Accurate quantification of air in-leakage is essential for maintaining plant operations. This is where RheoVac instruments can help. They are reliable solutions for measuring air in-leakage.

The RheoVac instrument accurately calculates air-in leakage, as it directly measures the vent line gas parameters. Moreover, RheoVac instruments provide plant operators with vital data to address common plant maintenance issues, such as monitoring exhaust pump capacity, real-time leak repair verification, steam turbine condenser vacuum problem assessment, and tube fouling. Complete the form on this page to allow Bionetics to assess your system and help resolve your air in-leakage issues effectively.

Tube Fouling

Tube fouling occurs when biological growth or material deposits obstruct the cooling water flow through condenser tubes. This issue can manifest in various plant measurements. Without direct measurement of individual tube flow rates, however, other problems such as poor condenser configuration can lead to incorrect assumptions of tube fouling. Bionetics offers instrumentation specifically designed to monitor individual tube fouling. Complete the form on this page to let Bionetics assist you in addressing your tube fouling challenges.

Low Pump/Exhaust Capacity

Maintaining exhaust pump capacity is essential to ensure effective air removal from the condenser. Insufficient air removal can result in increased back pressure, high dissolved oxygen, and low cleanliness. RheoVac instruments provide an accurate and real-time measurement of pump capacity. Complete the form on this page to let Bionetics assist you in understanding and solving your low pump/exhaust capacity issues.

Other Efficiency/Maintenance/Design Concerns

For decades, Bionetics has successfully addressed flow and engineering challenges for many customers. Our success stems from a deep understanding of physics and engineering, supported by a team of knowledgeable and experienced science and engineering professionals. Leverage Bionetics’ experience in resolving power plant condenser-related issues by contacting us today through the form on this page.