Flow Meters - Case Studies | Bionetics Corporation

Enhancing Condenser Efficiency with Bionetics’ Retrofit Solution: A Case Study

Background: Addressing the Westinghouse Starburst Tube Bundle Challenge

A Westinghouse-designed condenser with a “starburst” tube bundle faced chronic performance issues due to inefficient removal of non-condensable gases. This resulted in air binding, reducing heat transfer efficiency and underutilizing 15-25% of the condensing surface area. Key challenges included low vapor velocity and accumulation of non-condensable gases, leading to increased operational costs and reduced plant efficiency.

The Solution: Bionetics’ Innovative Retrofit Design

Bionetics’ retrofit solution focuses on improving the steam/air dynamics within the condenser. Key modifications to the Air Removal Section (ARS) significantly enhance air removal efficiency, leading to a lower condenser back pressure and better overall performance.

In 2013, Bionetics collaborated closely with plant personnel to monitor and analyze condenser performance. In 2015, advanced instrumentation, including real-time sensors measuring circulating water temperature, condenser pressure, and total water flow rate, provided comprehensive performance insights. In 2020, the installation of High-Density Temperature Arrays (HDTA) enabled precise thermal mapping, further identifying and addressing air binding locations before and after the retrofit.

Key Performance Improvements

The Bionetics retrofit solution yielded measurable and impactful performance enhancements:

1. Reduced Condenser Pressure: Although stainless-steel tubes (which lowers the heat transfer coefficient by 16%) were used, the retrofit resulted in lower back pressure post-installation. This improvement enhanced system efficiency, reducing the unit trip risks, particularly during peak load conditions in warmer months.
2. Enhanced Cleanliness Factor: The retrofit increased the maximum achievable cleanliness factor from 72% to 95%, demonstrating a substantial improvement in heat transfer efficiency.
3. Eliminated Air Binding Issues: Post-retrofit HDTA data confirmed that significant air binding areas, previously problematic, were effectively eradicated. Even with air in-leakage at 60 SCFM, no major air accumulation was detected, showcasing the retrofit’s effectiveness in mitigating air-related performance degradation.
4. Improved Immunity to Air In-Leakage: Air in-leakage testing conducted before and after the retrofit underscored the dramatic improvement in condenser stability:

a. Pre-Retrofit: A 60 SCFM air in-leakage caused a 5-6% cleanliness factor degradation and an increase in condenser pressure of 0.1 to 0.3 in. HgA.
b. Post-Retrofit: Cleanliness factor degradation was reduced by only 1-2% at 60 SCFM, while condenser pressure increase was minimized to just 0.05 to 0.1 in. HgA.

These results highlight the retrofit’s ability to maintain performance even under challenging conditions.

Learn More about Enhancing Condenser Efficiency with Bionetics’ Retrofit Solution

Bionetics’ Role in the Trace Contaminant Control System (TCCS) and Ensuring Astronaut Safety

Background: The ISS Incident and the Need for Immediate Action

On November 23, 2024, an alarming incident unfolded aboard the International Space Station (ISS) when Russian cosmonauts reported a toxic smell on the Progress MS-29 cargo spacecraft. Launched from Baikonur Cosmodrome on November 21, the Progress MS-29 delivered routine fuel and food supplies to the team of astronauts aboard the ISS. The source of the toxic smell was identified to trace contaminants that posed a potential health risk to the crew. NASA and Roscosmos immediately activated air-scrubbing systems across the station to purify air. Additionally, NASA initiated the Trace Contaminant Control Subassembly (TCCS)—a critical air purification system, deployed to filter the contaminants, purify the air, and ensure the astronauts’ safety. The NASA controllers confirmed that the ISS atmosphere had returned to normal by November 24, 2024, due to the TCCS.

This case study explores The Bionetics Corporation’s involvement in developing, integration, and testing of the TCCS. It highlights how the company has helped NASA address this urgent situation.

The Challenge: Developing a Critical Air Purification System for Space

Space missions like the ISS utilize flawless life support systems to ensure the safety of astronauts. Any failure of life support systems on the ISS can endanger lives. The development of the TCCS used for purification was challenging. The aim was to create a system capable of air purification while withstanding the demands of a vacuum where temperature fluctuate drastically. The TCCS system designed to purify the air aboard the ISS comprised several complex components, including a Flow Meter (Developed by Bionetics), Electrical Interface Assembly, Charcoal Filter Bed Assembly, Catalytic Oxidizer Assembly, and Blower Assembly. These components had tight tolerances and demanding engineering specifications and required precise integration. Each part had to be perfectly engineered to work in a highly sensitive environment. Additionally, the system had to be assembled and tested under tight tolerances to meet NASA standards.

Learn More about Bionetics’ Role in the Trace Contaminant Control System (TCCS)

Case Study: Dual Probe Air In-Leak Detection for Power Plant Condensers

This case study examines how our field engineering team resolved a complex condenser air in-leakage problem involving dual off-takes leading into a vacuum pump. Due to system design constraints, probe placement was limited to one RheoVac® probe in the individual vent line and a second probe in the common vent line, requiring a targeted diagnostic approach.

Key Equipment and Diagnostic Methods

Dual RheoVac® Probe System: Used to continuously monitor
air in-leak rates and evaluate the effectiveness of repairs in real time.
Helium Leak Detection Surveys: Performed along condenser piping and vent lines to accurately locate and confirm leak sources.

Key Findings and Results

Analysis of RheoVac® airflow data allowed the team to isolate the problem to one side of the condenser. Further investigation revealed several uncapped pipes as the primary source of air in-leakage. After completing corrective repairs, follow-up RheoVac® measurements confirmed a significant reduction in air in-leak rates and a measurable improvement in overall condenser efficiency.

This case study demonstrates how combining RheoVac condenser monitoring technology with helium leak detection provides a highly effective method for diagnosing, quantifying, and resolving air in-leakage issues in complex power plant condenser systems.

Case Study: Single MSP System for Advanced Air In-Leak Detection in Condenser Units

This case study highlights the use of a single MSP (Multi Sensor Probe) system for air in-leak detection in a combined-cycle power plant condenser. The unit featured a single vent line, limited physical access, and a side-exhausting steam turbine—conditions that required a precise and strategic diagnostic approach.

Key Equipment and Diagnostic Methods

RheoVac® Single MSP System: Selected for its compact design and ability to operate reliably in tight spaces with restricted access, making it well-suited for complex condenser environments.
Helium Leak Detection Surveys: Used to evaluate the entire condenser system within a single day, enabling fast and accurate identification of air in-leak sources.

Key Findings and Results

Analysis of RheoVac airflow data revealed an air in-leakage rate of approximately 30 CFM out of 50 CFM, traced to the hood spray pipe. This high-vibration area is prone to cracking across multiple units. Identifying the leak allowed for timely corrective action, reducing efficiency losses and highlighting areas requiring structural reinforcement.

Case Study: Improved Air In-Leak Detection and Leak Location Identification

This case study demonstrates the use of advanced air in-leak detection methods at a
power plant to address high air in-leakage rates and limited exhauster capacity. By applying proven diagnostic technologies, our engineering team accurately identified and located the sources of air in-leakage affecting system performance.

Key Equipment and Diagnostic Methods

RheoVac® Multi Sensor Probes (MSP): Used to measure critical condenser and vent line parameters, including mass ratio, ACFM (Actual Cubic Feet per Minute), mass flow, and pressure. These measurements are essential for quantifying air in-leakage and evaluating vacuum system performance.
Helium Leak Detection: Applied to precisely locate individual leak points within the system and confirm repair priorities.

Key Findings and Results

Data collected from the RheoVac MSP probes provided detailed insight into:

Overall air in-leakage rates
Vacuum quality and stability
Volumetric and mass flow rates
Exhauster pressure performance

Using these diagnostic results, the team was able to pinpoint air in-leak sources, reduce performance losses, and improve overall plant efficiency. This case study highlights the diagnostic power of the RheoVac MSP system in resolving complex air in-leakage problems and enhancing long-term operational performance.

Case Study: Pump Capacity Analysis Using Bionetics RheoVac System

This case study highlights how the Bionetics RheoVac system was used to identify performance issues in a Liquid Ring Vacuum Pump (LRVP) at a power plant. The customer suspected that one pump was underperforming but lacked the necessary data to confirm the issue. By installing the RheoVac system, engineers were able to collect detailed pump performance metrics and compare results before and after a pump swap. The analysis confirmed that one pump was degraded, providing clear evidence for corrective action.

Key Benefits and Insights

Data-Driven Pump Monitoring: RheoVac provides accurate measurements of pump capacity and operational performance.
Preventive Maintenance: Early detection of pump degradation helps prevent unexpected equipment failures.
Optimized Plant Efficiency: Using pump capacity curves and real-time data, plants can maintain peak vacuum system performance.

This case study demonstrates how RheoVac systems enable plant operators to improve reliability, extend equipment life, and make informed decisions based on real-time vacuum pump diagnostics.

Case Study: Enhancing Pump Capacity and Efficiency with Bionetics RheoVac System

This case study demonstrates how Bionetics successfully improved pump efficiency for a client experiencing performance challenges. During a requested helium leak audit, the Bionetics RheoVac system was temporarily installed to measure pump capacity and identify factors affecting performance.

Key Findings and Diagnostic Methods

RheoVac Condenser Monitoring: Detected leaks in bearing seals that were reducing pump efficiency.
Targeted Leak Audits: Conducted across multiple pumps to quantify air in-leakage and provide actionable recommendations.
Performance Optimization: Insights from the RheoVac system guided repairs and adjustments to restore optimal flow and improve operational reliability.

This case study highlights Bionetics’ commitment to using innovative pump monitoring solutions to enhance pump system efficiency and operational performance. Discover how Bionetics RheoVac technology can help your facility reduce energy losses, prevent failures, and maximize pump reliability.

RheoVac Condenser Monitor Case Study: Identify and Repair Air In-Leakage

In this case study, Bionetics CESG demonstrates the use of the
RheoVac Condenser Monitor to detect and resolve air in-leakage in
power plant condensers. The video showcases the essential instrumentation and techniques used to determine whether condenser performance issues are caused by air leakage or other operational factors. Learn how advanced RheoVac technology provides accurate diagnostics and actionable solutions to improve condenser efficiency.

Discover practical strategies to minimize losses caused by high condenser pressure and boost overall plant reliability.