Condenser Services

LRVP or SJAE Capacity Testing

Large surface condensers play a crucial role in power plants by recycling exhaust steam and maintaining optimal vacuum conditions for turbine operation. However, vacuum leaks are a significant concern that can compromise the efficiency and output of these systems.

The Impact of Vacuum Leaks

Vacuum leaks can increase turbine backpressure, leading to reduced efficiency and output. To mitigate this, effective vacuum pump systems, such as Liquid Ring Vacuum Pumps (LRVP) and Steam Jet Air Ejectors (SJAE), are essential for removing accumulated air and non-condensable gases that result from leaks.

Importance of Regular Testing

The performance of these vacuum systems directly affects condenser operation. Therefore, regular capacity testing of LRVP and SJAE is vital to prevent vacuum leaks and ensure optimal performance. Poor or reduced exhauster capacity will have the same detrimental effect as excessive air in-leakage; increased condenser pressure caused by air storage. This relationship highlights the importance of monitoring both air in-leakage and exhauster capacity.

relationship between water-to-air mass ratio and hei performance factor
Figure 1 – Bionetics recommends performing air in-leak testing to develop a curve for each unit like the one shown above, the relationship between water-to-air mass ratio and HEI performance factor, to determine the threshold mass ratio for a specific unit. If the testing cannot or has not been completed, then a mass ratio value of 3 should be used until such testing can be performed. Bionetics is available to provide on-site testing and data analysis to produce these results.
  • SJAE Testing: The performance of Steam Jet Air Ejectors is assessed by measuring mass flow versus absolute pressure at the suction inlet. This testing helps identify the effects of air in-leakage and evaluates overall vacuum system performance.
  • LRVP Testing: The effectiveness of Liquid Ring Vacuum Pumps is determined by monitoring actual volumetric flow versus absolute pressure at the suction inlet over time.

Streamlined Testing with Bionetics

Historically, testing for SJAE and LRVP was conducted during scheduled maintenance outages, often requiring manufacturer support, making it time-consuming and costly. Bionetics offers a solution with our online vacuum pump efficiency testing services, allowing for real-time assessments without the downtime associated with traditional methods.

By choosing Bionetics, you can enhance the performance of your large surface condensers and ensure reliable turbine operation.

exhauster comparison
Figure 2- shows RheoVac output parameters for a set of two Nash AT 1004 liquid ring vacuum pumps. Plant operators noticed a 0.2”Hg difference in back pressure between pumps and believed that one of their two Nash AT1004 exhausters was in need of maintenance. By performing a pump swap test and observing the RheoVac capacity parameters as evidence, operations can clearly show that one pump is underperforming. Pump A is pulling less than 1/3 of the volumetric flow (ACFM) that Pump B is removing from the condenser.

How It is Done?

Bionetics uses RheoVac probes, which are inserted directly into the vacuum line through a customer-installed 1.5″ ball valve. This non-intrusive, online vacuum equipment testing method helps measure the vacuum equipment’s performance without system shutdown. The probes monitor key parameters such as flow rate, pressure, and temperature in real-time, comprehensively analyzing the system’s capacity.

Exhauster Capacity Curve
Figure 3- RheoVac data shows LRVP performance curves for pump A and B. Pump A is working as expected, while data collected on pump B shows it operating at a degraded level of performance.

What It Shows?

Our online capacity testing service provides critical insights into the performance of your vacuum systems:

  • Capacity Measurement: Our vacuum pump capacity testing services help measure the capacity of LRVPs and SJAEs, ensuring they operate at optimal levels.
  • System Health: Our online capacity testing services help identify the overall health of the vacuum system, detecting potential issues before they escalate into costly repairs or downtime.
  • Air Flow Analysis: The testing helps determine the amount of air entering the vacuum equipment, helping identify leaks, blockages, or inefficiencies in your vacuum equipment.
  • Data-Driven Recommendations: We provide detailed reports that offer actionable insights, guiding maintenance decisions and system adjustments for improved performance.

Our Online Vacuum Pump Efficiency Testing Services

We provide online vacuum pump efficiency testing services tailored to meet diverse customer needs.

  • Equipment Rental: Bionetics offers the option of renting the necessary equipment to customers who wish to conduct the vacuum capacity test themselves. This provides flexibility and allows customers to perform the test at their convenience.
  • Field Service: For customers who prefer to outsource the testing process, Bionetics can provide field service engineers or technicians to perform the test and report their findings. This ensures that the test is conducted accurately and efficiently by experienced professionals.
AIL Testing
Figure 4- RheoVac data can be used to characterize a condenser’s response to varying levels of air in-leak. Each condenser’s response to air in-leak can vary greatly, even between condensers that are “identical” or built by the same manufacturer.

Benefits of Online Vacuum Capacity Testing

Bionetics delivers a streamlined online testing solution that ensures several benefits:

  • Accurate Assessment: Online testing provides a reliable and accurate assessment of vacuum equipment capacity.
  • Efficiency: The process is efficient and minimizes downtime for the customer.
  • Cost-Effective: Online testing can be a cost-effective solution compared to traditional methods.
  • Expert Analysis: Bionetics offers expert analysis of the test results, providing valuable insights into the equipment’s performance.

Contact Us for more information on how Bionetics can assist you with understanding and identifying problems with your condenser-related systems.