Condenser Modules: Modular replacement
Condenser modular change-outs are an alternative to the conventional retube. Power stations are no longer subject to the, often outdated, designs of existing equipment. Complete surface condenser retrofits are possible and can offer a multitude of benefits.
Existing condensers can be refurbished, redesigned, and even upgraded to meet new performance demands and power requirements
What are condenser modules?
Condenser modules are fully assembled shop fabricated tube bundles that replace existing condenser surface. Each module is designed using specific operating criteria to replace condenser internals. Tubesheets, support plates and tubes are removed and new bundles are shipped whole or in sections, and installed in the existing shell.
- Fit into existing condenser space leaving all external walls intact
- Use existing internal support system
- Maintain existing sidewalls, hotwell, transition, ball cleaning assemblies, priming systems, FWH’s etc.
- Can be designed to re-use existing water boxes or use new ones
Why condenser modules?
No longer the panacea once thought, copper based alloys can cause deposition problems in boilers, turbines and steam generators. In addition, water treatment chemistry may have changed or salinity and/or pollutant levels in cooling water may no longer be compatible with existing tube materials.
The existing condenser can no longer or has never achieved the designed backpressure. Re-tubing cannot change venting capabilities, flow configurations, tube patterns, etc. Uprate criteria can be incorporated into new designs and new bundle configurations can improve backpressure at higher steam flows thereby increasing mega-watt output.
New bundle designs are not limited to the existing tube pattern (different diameter tubes can be used to increase performance), existing support plate spacing (lighter gage tubing will vibrate in the existing unsupported span), and out dated deaeration designs (TEi uses the latest proven deaeration designs to eliminate air blanketing while maintaining oxygen guarantees). Bundles are designed for power uprate criteria and for up to full load operation with one bundle out of service. In addition modular designs can balance the circulation water systems to optimize pumping costs, cooling water usage and hardware costs.
Module designs take advantage of more erosion resistant tube materials and better designed deaeration capabilities. Optional tube joint seal welding eliminates a potential leak path and provides 100% reliability at the tube and tubesheet joints. Reduced unsupported tube spans eliminate vibration as a source of failure.
Circular Shell Condensers
TEi designs an economically sized condenser suitable for smaller turbine ratings. The circular configuration is compact for easy shipping and maintains the level of quality afforded all of our condenser designs.
Rectangular Shell Condensers
Surface Condensers – Rectangular Shell – Heat Exchangers
A surface condenser is critical to the efficient operation of a power plant. Tube leaks, improper deaeration, flow-induced damage and other condenser design maladies can adversely affect plant operation and reduce power output. There is no need to experience these problems. With decades of practical working experience, TEi is a world leader in the design and manufacture of steam surface condensers. Using the latest welding, engineering design, manufacturing, and testing techniques, TEi produces a condenser with superior mechanical design that offers maximum thermal efficiency. For longevity and trouble free operation, TEi is the company to turn to for your next surface condenser.
TEi’s Superior Mechanical Design Provides…
- Protection against tube leakage and condensate contamination
- Protection against destructive vibration
- Controlled thermal expansion
- Conservatively designed steam lanes for maximum steam penetration
- Ease of field fit-up / assembly
- Protection from high energy fluid damage
- Control of excessive loads and stresses