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Condensor EPRI

This document discusses condenser components, troubleshooting issues, fouling and cleaning methods, air and water in-leakage detection and correction, failure modes, maintenance repairs, remaining life assessment, and condition-based maintenance of steam condensers. It describes the main components of condensers including shells, tubesheets, tubes and air removal equipment. It also outlines various issues that can occur like increased pressure, fouling, leaks and failures as well as repair and testing techniques to address problems.

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168 views6 pages

Condensor EPRI

This document discusses condenser components, troubleshooting issues, fouling and cleaning methods, air and water in-leakage detection and correction, failure modes, maintenance repairs, remaining life assessment, and condition-based maintenance of steam condensers. It describes the main components of condensers including shells, tubesheets, tubes and air removal equipment. It also outlines various issues that can occur like increased pressure, fouling, leaks and failures as well as repair and testing techniques to address problems.

Uploaded by

lacoste11111
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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2 TUTORIAL

2.5 Condenser Components


2.5.1 Condenser Shell
2.5.2 Hotwell
2.5.3 Waterbox
2.5.4 Tubesheet
2.5.5 Tubes
2.5.6 Air-Removal Equipment
2.5.6.1 Steam Jet Air Ejector
2.5.6.2 Vacuum Pump
3 TROUBLE-SHOOTING
3.1 Increased Condenser Pressure
3.2 Air Binding Problems
3.3 Air-Removal Equipment Problems
3.3.1 Poor Vacuum
3.3.2 Gradual Loss of Vacuum
3.3.3 Poor Vacuum and/or High Outlet Water Temperature
3.3.4 Faulty Operation of the Steam Jet Air Ejectors
3.3.5 Ejector Field Testing
3.3.6 Problems with Liquid Ring Vacuum Pumps (LRVPs)
3.3.7 LRVP Checklist of Operating Variables
5 FOULING
5.1 Macrofouling
5.2 Macrofouling Control Technologies
5.3 Microfouling
5.4 Microfouling Chemical Treatment
5.5 Fouling Monitor
5.6 Targeted Chlorination With Fixed Nozzles
6 CLEANING
6.1 Mechanical On-Line Cleaning Systems
6.1.1 Sponge Ball System
6.1.2 Brush and Cage System
6.1.3 Self-Aligning Rockets
6.2 Mechanical Off-Line Cleaning Systems
6.2.1 Air/Water-Driven
6.2.2 Mechanically Driven Systems
6.2.3 Pressure-Driven Systems
6.2.4 Waste Disposal
6.2.5 Advantages and Disadvantages of Off-Line Systems
6.3 Chemical Cleaning
7 AIR/WATER IN-LEAKAGE
7.1 Air In-Leakage Effects
7.1.1 Air In-Leakage Costs
7.1.2 Condensate/Feedwater Chemistry
7.1.3 Condensate Reheating
7.1.3.1 Condensate Steam Sparging
7.1.3.2 Hotwell Deaeration
7.1.3.3 Condenser Drains
7.1.3.4 Makeup Water
7.2 Air In-Leakage Detection Methods
7.2.1 Tracer Gas Testing
7.2.1.1 Tracer Gas Equipment
7.2.1.2 Data Interpretation
7.2.1.3 Tracer Gas Selection
7.2.1.4 Testing Areas
7.2.1.5 Air In-Leakage Checklist
7.2.1.6 Off-Line Testing
7.2.2 Multisensor Probe
7.2.3 Infrared Technology
7.3 Correcting Air In-Leakage
7.4 Water In-Leakage Effects
7.4.1 Condensate Chemistry Detection
7.4.2 Water Leakage in PWRs
7.4.3 Water Leakage in BWRs
7.5 Water In-Leakage Detection Methods
7.5.1 Tracer Gas Method
7.5.2 Plastic Film Testing
7.5.3 Soap Film Testing
7.5.4 Non-Destructive Methods
7.5.5 Smoke Method
7.5.6 Rubber Stoppers
7.5.7 Individual Tube Pressure/Vacuum Testing
7.5.8 Hydrostatic Testing
7.5.9 Miscellaneous Problems
7.5.10 On-Line Leak Detection
7.6 Correcting Water In-Leakage
8 FAILURE MODES
8.1 Failure Data
8.1.1 Just-in-Time Operating Experience
8.1.2 Significant Event Evaluation Information Network (SEE-IN)
8.1.3 Licensee Event Reports (LERs)
8.1.4 Plant Events Database
8.1.5 Operating Plant Experience Code (OPEC)

8.2 Failure Mechanisms


8.2.1 Condensate Corrosion
8.2.2 Crevice Corrosion
8.2.3 Dealloying
8.2.4 Erosion-Corrosion
8.2.5 Galvanic Corrosion
8.2.6 General Surface Corrosion
8.2.7 Hydrogen Damage
8.2.8 Random Pitting
8.2.9 Steam Side Erosion
8.2.10 Stress Corrosion Cracking
8.2.11 Vibration Damage
8.2.12 Summary of Failure Mechanisms

8.3 General Corrosion Prevention Practices


8.3.1 Cathodic Protection
8.3.2 Debris Filtration/Removal
8.3.3 Proper Lay-Up
8.3.4 Design Modifications
9.4 Non-Destructive Examination (NDE)
9.4.1 Magnetic Particle Testing (MT)
9.4.2 Liquid Penetrant Testing (PT)
9.4.3 Ultrasonic Testing (UT)
9.4.4 Eddy Current Testing (ET)
9.4.4.1 Planning the Eddy Current Test
9.4.4.2 Tube Map
9.4.4.3 Benchmark Data Set
9.4.4.4 Data Comparisons and Trending
9.4.4.5 Maintenance Practices
9.4.4.6 Figures of Merit
9.4.4.7 Management Report
9.4.4.8 Pre-Outage Activities
9.4.4.9 Outage Activities
9.4.4.10 Post-Outage Activities
9.4.4.11 ET Flowchart
10 MAINTENANCE REPAIRS
10.1 Plugging Tubes
10.1.1 Preparation for Tube Plugging
10.1.2 Tube Plug Selection
10.1.3 Tube Plug Types
10.1.3.1 Hammer-In Taper Plugs
10.1.3.2 Elastomer Plug
10.1.3.3 Mechanical Plug
10.1.3.4 Welded Tube Plug
10.1.3.5 Tube Plugs Available
10.1.4 Tube Plug Removal
10.1.4.1 Hammer-In Taper Plugs
10.1.4.2 Elastomer Plugs
10.1.4.3 Mechanical Plugs
10.1.4.4 Welded Plugs
10.2 Tube Inserts
10.3 Tube Sleeves
10.4 Tube End Coatings
10.5 Full-Length Tube Liners
10.6 Full-Length Tube Coatings
10.7 Re-Expanding the Tube-to-Tubesheet Joint
10.8 Coating of Tubesheets
10.9 Tube Staking for Vibration
10.10Waterbox Repairs
10.10.1 Waterbox Coating Techniques
10.10.2 Waterbox Flange Seams
10.11Tubesheet Repairs
10.12Tube Pulling
10.13Miscellaneous Repairs
11 REMAINING LIFE, MATERIALS, AND CONSTRUCTABILITY
11.1 Remaining Life Assessment
11.1.1 NDE Testing Techniques Used to Assess Remaining Life
11.1.2 Remaining Life Formula
11.2 Tube Material Selection
11.2.1 Titanium
11.2.2 High Performance Stainless Steels
11.2.2.1 Initial Installations
11.2.2.2 Water Type Significance
11.2.2.3 Tube-Related Problems
11.2.3 Austenitic Stainless Steel
11.2.4 Copper Alloys
11.2.5 Summary of Material Specification
11.2.6 Material Comparison
11.3 Tubesheet Joints and Material Selection
11.3.1 Expanded Joint
11.3.2 Expanded and Grooved Joint
11.3.3 Packed Joint
11.3.4 Expanded and Welded Joint
11.3.5 Joint Adhesives
11.3.6 Material Selection
11.4 Waterbox and Shell Materials
11.5 Constructability Issues
11.5.1 Retubing
11.5.1.1 Waterbox Removal and Installation
11.5.1.2 Tube Removal
11.5.1.3 Breaking Tubesheet Joints
11.5.1.4 Removing Tubes
9 CONDITION-BASED MAINTENANCE
9.1 Records
9.2 Periodic Inspections
9.2.1 Waterbox
9.2.2 Tubesheet
9.2.3 Hotwell
9.2.4 Tube Bundles
9.2.5 Structural Components
9.3 Preventive Maintenance (PM)
9.3.1 Cleaning
9.3.2 Performance Monitoring
9.3.3 Operator Rounds
9.3.4 Preventive Maintenance Summary Tables
9.4 Non-Destructive Examination (NDE)
9.4.1 Magnetic Particle Testing (MT)
9.4.2 Liquid Penetrant Testing (PT)
9.4.3 Ultrasonic Testing (UT
9.4.4 Eddy Current Testing (ET)
9.4.4.1 Planning the Eddy Current Test
9.4.4.2 Tube Map
9.4.4.3 Benchmark Data Set
9.4.4.4 Data Comparisons and Trending
9.4.4.5 Maintenance Practices
9.4.4.6 Figures of Merit
9.4.4.7 Management Report
9.4.4.8 Pre-Outage Activities
9.4.4.9 Outage Activities
9.4.4.10 Post-Outage Activities
9.4.4.11 ET Flowchart

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