INTERNAL EPOXY COATING IN

SURFACE CONDENSER
-: PRESENTED BY :SANKET CHAUDHARI (096380319510) ARGHYA GOSWAMI (096380319523)

P A R U L I N S T I T U T E O F E N G I N E E R I N G & T E C H N O L O G Y ( D S ) 2 ND S H I F T LIMDA, DIST. VADODARA. YEAR: 2011-12

INTRODUCTION
DEFINITION :Steam condenser is an appliance in which the steam exhausted from a steam engine is condensed. Condenser is installed such that the exhaust steam from a Steam Engine is delivered into it. In the condenser, the heat is removed from the exhausted steam in form of latent heat by means of cooling water which absorbs this latent heat. The exhaust steam after losing its latent heat changes its state into water, which is termed as Condensate and this process, is called as condensation.

INTRODUCTION

INTRODUCTION
Elements of Condensing Plants : Condenser where steam is condensed, Hot well in which the condensate is collected. Pump for circulating Cooling Water, supply of Circulating Cooling Water, Air pump (or ejector) to remove air and non-condensing gases from the

condenser
Condensate Pump (extraction pump) to remove Condensate from the

condenser,
Feed Pump for supplying feed water from De aerator to the boiler.

INTRODUCTION

INTRODUCTION
FUNCTIONS : Reduce the back pressure of steam primemovers. Increases the expansion ratio of steam hence thermal efficiency . Decreases the temperature of the exhaust steam & increases power

output.
Supply of clean & soft water to the boiler. It stores water, hence additional storage space is not required. Because of higher temperature of feed water thermal stresses are

reduced.

PROBLEM IDENTIFICATION
1. 2. 3.

Corrosion High Condenser Back Pressure Tube fouling

4.
5. 6. 7. 8. 9.

Low Cleanliness Factor

Low Heat Transfer Air In-Leakage Dissolved Gases (Oxygen, Carbon Dioxide, Ammonia, etc.) Low Pump/Exhaust Capacity Other Efficiency/Maintenance/Design/Operations Concerns

EXPECTED OUTCOME

Condenser fouling is a major economic problem, and maintenance costs are estimated to account for 0.25% of the world GDP (Gross domestic product). To remain competitive and reduce energy costs

power plant operators must pay attention to the small details

involved in the proper maintenance of tubular systems in condensers, heat exchangers and other heat transfer equipment to realize

significant savings. By utilizing the best available technology

reliability, and energy efficiency gains can be realized.

EXPECTED OUTCOME
Another method to cut plant and equipment downtime, recover energy

efficiency, and achieve fewer stoppages for routine maintenance is by using thin film polymer coatings applied to full length tube IDs. This

process is low cost procedure to solve condenser tube fouling and

corrosion problems.
When a thin layer of epoxy is applied in the inner wall of shell and

tubes, tube sheet and water box, the effect of corrosion and erosion is
almost eliminated. Hence the service life increases and efficiency is also maintained.

EXPECTED OUTCOME
Polymer tube linings have always suffered from an initial perception of

heat transfer penalties due to their lower thermal conductivities but quantitative data and strong long term case history has demonstrated

just the opposite. Decades of service history have shown that tube
coatings can enhance heat transfer and overall performance to a significant degree. While the thermal conductivity of the coating is

much less than the parent tube, this factor is mitigated by inherent
properties of the coating. The impact to overall thermal conductivity is nil or minor.

EXPECTED OUTCOME

21 mm brass tube x 2.3 mm wall - conditions 1. Average scaled - < 0.150 mm

Thermal conductivity W/ m K 14.9

2. 100% solids applied at 75 microns

average 3. Epoxy phenolic applied at 75

2.737

microns average
4. Epoxy phenolic proprietary pigment loading

8.82

14.764

EXPECTED OUTCOME
ADVANTAGES
By this method service life of condenser increases & efficiency is

maintained.
It reduces downtime & maintenance cost upto 50% compared to

retubing.
Feed water process cost also reduces.

DISADVANTAGE
Efficiency may be reduced by 0.5 % to 0.7 % which can be considered as

negligible.

CONCLUSION
As this method reduces the maintenance cost it direct affects the energy

production cost, gives strong support to the power plant operators to remain in this competitive market & helps to get out from the energy

crisis.
Thus by application of epoxy coating in some parts of condenser the

major problems can be minimized like,

Corrosion, Tube fouling, Low cleanliness, Chocking of tubes etc.