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December 2005
Condensers
Condenser Tube Fouling and
Failures: Cause and Mitigation
JIOan
Cvcle Chemistry Moniloring
Process Monitoring: What
Really Matters
clams). The primary effect is reduced flow to certain tubes, An off-line chemical cleaning to remove scale or corrosion
which results in particulate deposition and increased products in condenser tubes is likely to be successful, pro-
opportunity for microbiological growth. If major tubesheet vided the process is correctly designed and implemented.
blockage occurs, the condenser vacuum can be signifi- However, a number of drawbacks to chemical cleaning
cantly degraded. must be considered, including:
• safety
Foulant Removal • cost
There are a number of approaches to removing foulants • waste disposal
from condenser tubes. To select the optimum removal • time required
method, the foulant must first be identified, if possible. If • insuring complete foulant removal
the unit can be brought off-line for inspection, material in • maintaining integrity of base metal
the condenser tube can be collected and analyzed.
Microbiological fouling may be difficult to identify when
wet, but typically forms flakes that readily detach from the Incomplete foulant removal can occur when the foulant is
tube wall when dry. Macrofouling of the tubesheet can be dislodged from the tube during a chemical clean, but not
recognized by the presence of debris in the waterbox, completely dissolved or adequately rinsed, leaving a
which tends to fall off the tubesheet when flow is discon- residue of sludge. Alternatively, part of the foulant may be
tinued. dislodged from the tube, and part remain adherent (partic-
ularly with scale that is a composite of multiple minerals).
The tubes should not be left in a "half-cleaned" condition,
On-Line Foulant Removal Efforts to remove certain
as increased corrosion may occur where base metal is
foulants on-line can be successful when the probable
exposed. In either case, following a chemical clean with
foulant is known from experience. The pH can be lowered
mechanical removal, if feasible, is a good practice to
to remove specific foulants such as calcium carbonate
insure tube cleanliness.
(pH < 5.8) and calcium phosphate (pH < 4.0), although
there is a risk to the system by exposure to low pH. If
Several techniques are commonly utilized to mechanically
mechanical cleaning systems are in place (abrasive
remove foulants. Mechanical scrapers (metal or plastic) are
sponge balls or similar recirculating cleaning tools), they
widely applied, and specific scrapers have been designed
can be used; such systems are likely to be effective with
to remove virtually all common foulants, even hard mineral
very soft foulants (microbiological or deposits), but may
not be helpful for scale or corrosion product removal. scale such as calcium carbonate (Figures 1 and 2).
Dosing with high levels of biocides for short periods may Scrapers are propelled at 3-6 m . S-1 (10 to 20 ftls) by pres-
help to remove biofilms, although established microbiolog- surized water at about 2 MPa (300 psig), so loosened
ical growths are resistant to biocides. If flow can be debris is rinsed from the tube with the scraping process.
increased, settled particulates might be removed, pro- Concern has frequently been expressed regarding the
vided caution is exercised in units having copper-alloy affect of metal scrapers on base metal. Careful evaluation
tubes. over many years has led to the conclusion that there is vir-
tually no risk of base metal damage with metal scrapers
that are properly designed and used [2]. One advantage of
Off-Line Foulant Removal Removal of foulants with metal scrapers is that they are effective against a variety of
the unit off-line is frequently the most effective approach. foulants, so may be useful for general purpose cleaning if
The tubes and system can be examined directly, so identi- the foulant is not identified. However, some foulants are
fication of the problem is more certain, and therefore better removed by identification and matching with a spe-
selection of the best means of removal is more likely. cific scraper design [3].
.. .. ..
~. . ij:
•
.
..,.
~' - f
~
' f •
•
'" '" (~1 "
Figure 1: Metal tube scrapers, Hex Cleaners, for general Figure 2: Cal Buster, designed for breaking up hard
purpose tube cleaning (Conca Systems, Inc.). calcium carbonate scale (Conco Systems, Inc.).
Figure 3:
Stainless Steel Tube Clean-
ing Brush, for general pur-
pose tube cleaning, includ-
ing when scrapers will not fit
properly due to inlet-end
inserts or epoxy coating
(Con co Systems, Inc.).
Figure 5: Admiralty brass tube, failed by impact damage condenser at startup, after turbine outage.
due to unknown object propelled into
S042-
°2
SO}- CI- °2 so:- °2
cr CI- so:-
°2 CI-
°2
CI-
°2
so CI- sot °2 so:-
CI-
»<«
Cu Cu Cu Cu Cu
Figure 13: Crevice (under-deposit) corrosion: cross- Figure 14: Crevice (under-deposit) corrosion: enlarge-
section depicting local deposit on tube ment of Figure 13, showing crevice between
surface. deposit and tube metal.
Base metal
Figure 15: Crevice (under-deposit) corrosion: Figure 16: Crevice (under-deposit) corrosion: cuprous
electrochemical interactions under deposit in chloride and cuprous sulfate salts accumulate
cooling water: (1) electrons released from in crevice, as base metal is lost.
copper are reduced by oxygen, (2) anions are
attracted to positively charged metal ions in the
crevice.
passive surface oxide layer on stainless steels, when dis- Tube Failure Mechanisms Not Caused by Service
rupted, subjects base metal to an intense focus of anodic Condenser tubes may fail in service due to specific situa-
current. Microorganisms can provide such a disruption. tions other than the service environment. Off-line chemical
Besides serving as a deposit under which crevice corro- cleaning, if not accomplished properly, can cause tube
sion can occur, microorganisms may generate corrodents damage that later results in failures (Figure 18). Manu-
(converting sulfate to hydrogen sulfide) or deposition factured defects, such as incomplete or improperly formed
(manganese dioxide, iron oxides) that accelerate corrosion weld seams, or denting during handling, can lead to fail-
(Figure 1l). ures (Figures 19 and 20). During tube installation, rolling
tubes into the tubesheet requires precise quality control to
avoid excessive stresses or crevices (Figure 21).
• capacity of condensate tification, the hotwell is tubesheets are examined a pattern of repeat failure
polishers (if present) flooded with for those with water mech- anisms must be
condensate, and running out. A fluorescent addressed at the earliest
• whether the unit can be
brought to half-load, or dye can help greatly in opportunity; at
must be taken off-line distinguishing leaking
tubes from those that may
Identification of which still have water draining
waterbox is leaking, for slowly. Although the
typical units with split theory behind the
waterboxes, can identification of leaking
accelerate repair of the tubes is relatively simple
failure. This can be done and straightforward,
at full load by tracer there are numerous pitfalls
gas injection upstream of that occur in practice, and
the waterbox (sulfur experience in locating
hexafluoride, SF6, or pos- leaking tubes is invaluable.
Figure 18: Severe
sibly helium for large
leaks), or by isolating pitting in Figure 19: 304
When a leaking tube is
one waterbox 90-10 stainl
located, both ends of the
and draining cooling water copper- ess
tube must be plugged with
until evidence of nickel steel
water-tight seals. A variety
sodium/cation conductivity tube, tube
of tube plugs are available
disappears (this will following with
for this function, but all defect
provide approximate leak chemical
must be applied prop- erly s at
level, as well as cleaning
for long-term reliability, incom
confirming which half of that
and (sometimes) with a pletel
the condenser contains included
excessive view towards future y
the leak). In cases where
exposure recovery of either the forme
multiple leaks are pres-
ent, and at different rates to leaking tube, or its d
of inleakage, this process cleaning replacement. weld
may be impossible to chemical. seam.
conduct adequately. Magnifica Of critical importance to Magni
tion 2x. addressing condenser ficatio
Several approaches to tube leaks is identification n 4x.
identifying the specific of the root cause,
tube/tubes that are leaking particularly for repeat
have been used. For on- leaks in the same
line identification with an condenser over a short
isolated, drained waterbox time frame, which may
(at half-load), both ends of be due to the same
a leaking tube will be failure mechanism.
pulling in air from the Extracting a tube from the
tubesheets. Tracer gas bundle for laboratory
injection (helium or sulfur examina- tion may add a
hexafluoride) is a very few hours to an outage,
Figure 20: Admiralty
effective and sensitive and detract from the
brass tube
means of locating the plant's immediate Figure 21: Titanium
with
leaking tube(s); SF6 is objective of minimizing tube that
internal
very sensitive, and downtime. However, failure failed at
pitting, in
particularly useful for to address repeat weld seam
correspon
small leaks. Less dence condenser tube leaks upon rolling
sophisticated indicators with early on may ultimately into
such as shaving cream or external result in very high costs tubesheet,
thin plastic wrap (must dents. for equip- ment repair due to
be applied to both inlet (e.g., turbine blade manufacturi
and outlet ends of the cracking), along with multi- ng
tube), or a flame/smoke, ple outages to plug embrittleme
are often effective in continuing leaks. nt,
identifying the leaking Condenser tube leak combined
tube(s). For off-line iden- incidents that may fall into with
Condenser Tube Fouling and Failures: Cause and Mitigation PPChem
freezing
while filled
with water
during
temporary
storage.
PPChern Condenser Tube Fouling and Failures: Cause and Mitigation
----
Condenser Tube Fouling and Failures: Cause and Mitigation PPChem
the very least, several fouling and corrosive Walker, R., Proc., [3] Howell, A. G.,
failed tubes should be situations should be International Con- Saxon, G., Proc.,
designated for removal in applied. Those damage ference on Power Condenser
conjunction with a mechanisms that Station Maintenance Technology
planned unit outage. commonly afflict certain 2000 (Oxford, United
tube alloys (e.g., erosion- Kingdom), 2000. The Conference, 2005
The cost for addressing corrosion in admiralty Institution of (San Diego, CA,
the root cause of brass) should be Mechanical U.S.A.). Electric
condenser tube failures considered a constant Engineers, London, Power Research
can vary from minor threat, and preventive United Kingdom, Institute, Palo Alto,
(e.g., replacing corroded measures evaluated (such 161. CA, U.S.A.,
screens for removing as installation of inlet-end 1010322.
macrofoulants) to major metallic inserts that are
[4] Putman, R. E.,
(e.g., replac- ing all more resistant to flow- Condenser In-Leakage
condenser tubes with a induced damage). Guide, 2000.
problem-resistant alloy). It Electric Power
is important to Research Institute,
understand and evaluate Palo Alto, CA,
the actual and potential CONCLUSIONS U.S.A., TR-112819.
costs of condenser tube
The fouling and failure of [5] Howell, A. G.,
leaks to steam cycle
condenser tubes is an Kendall, D.,
components in order to
expensive and frustrating Corrosionl1993,
choose a cost-effective
problem for many electric- 1993 (New Orleans,
course of action for
generating sta- tions. LA, U.S.A.). NACE
correction.
However, the causes of International,
these troubles are Houston, TX, U.S.A.,
Preventionl Avoidance of generally well understood, Paper #93046.
Condenser Tube Failures and their correction is
[6] Howell, A. G.,
often very straight- forward, Kendall, D., Materials
Companies operating
although not necessarily Performance,
power stations with
inexpensive. Diligence in 1
water-cooled condensers
following best industry 9
should strive to apply
practices will go a long 9
state-of-the-art, indus- try- 3
ways towards preventing
proven technology to ,
such problems. If a repeat
prevent or minimize 3
condenser tube failure 1
condenser tube failures.
scenario exists, identifying (
Alloys that have proven
the root cause and 1
reliably failure-resist- ant
correcting it in a timely 2
for a specific application )
manner is of vital
should be installed in ,
importance.
new units. Non-destructive 4
evaluation by eddy 2
current testing should be .
applied periodically to [7] Howell, A. G.,
determine the status of REFERENCES
Schwarz, R.,
flaws in the tubes (pre- [1] Shields, K., EPRI Condenser
existing or developing). McNaughton, w., Technology
Eddy cur- rent testing also Syrett, B., Conference, 1993
permits plugging of those Condenser Tube (St. Petersburg, FL,
tubes that are determined Failures: Theory U.S.A.). Electric
to have considerable wall and Practice. Power Research
loss, thereby avoid- ing Electric Power Institute, Palo Alto,
failure and contamination Research Institute, CA, U.S.A.
of the high-purity steam Palo Alto, CA,
cycle water, as well as unit U.S.A., 1010188, to
unavailability to repair the be published in
Paper presented at the
leaks. Chemistry control 2005.
Eskom International
programs most
[2] Putman, R. E., Conference on Power
appropriate to avoid
PPChern Condenser Tube Fouling and Failures: Cause and Mitigation
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