WO1992002761A1 - Exploitation de condensateur avec une boucle de mesure en ligne isolee - Google Patents
Exploitation de condensateur avec une boucle de mesure en ligne isolee Download PDFInfo
- Publication number
- WO1992002761A1 WO1992002761A1 PCT/US1991/005682 US9105682W WO9202761A1 WO 1992002761 A1 WO1992002761 A1 WO 1992002761A1 US 9105682 W US9105682 W US 9105682W WO 9202761 A1 WO9202761 A1 WO 9202761A1
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- WIPO (PCT)
- Prior art keywords
- tubes
- condenser
- tube
- water
- steam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22D—PREHEATING, OR ACCUMULATING PREHEATED, FEED-WATER FOR STEAM GENERATION; FEED-WATER SUPPLY FOR STEAM GENERATION; CONTROLLING WATER LEVEL FOR STEAM GENERATION; AUXILIARY DEVICES FOR PROMOTING WATER CIRCULATION WITHIN STEAM BOILERS
- F22D11/00—Feed-water supply not provided for in other main groups
- F22D11/006—Arrangements of feedwater cleaning with a boiler
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K21/00—Steam engine plants not otherwise provided for
- F01K21/06—Treating live steam, other than thermodynamically, e.g. for fighting deposits in engine
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28B—STEAM OR VAPOUR CONDENSERS
- F28B11/00—Controlling arrangements with features specially adapted for condensers
Definitions
- the present invention relates to steam-fired power plants, and particularly to condensers for use in such power plants.
- stages such as an intermediate-pressure turbine, a re-heating cycle, a bottoming cycle (to extract the last economical bit of mechanical energy from the steam), and heat exchangers (which scavenge heat from the depleted steam for feed- water heating, process heat, or other such purposes), etc.
- Such depleted steam is normally fed into a condenser.
- a condenser is a type of heat exchanger, which cools the depleted steam so that it turns back into liquid water.
- the liquid water has a much smaller volume than the gaseous steam it is condensed from. This volumetric drop in the condenser reduces the back-pressure seen at the last turbine stage, and thus provides
- the water recovered by the condenser is relatively pure, and can be reused for boiler feedwater.
- Figure 5 schematically shows the architecture of a surface condenser.
- Each tube 420 has one end connected to an inlet water box 430, and the other end connected to an outlet water box 430. Cooling water is pumped into the inlet water box
- the design specification requires that the condenser condense 2,472,000 pounds of steam per hour. (Thus, the volume of steam flowing into the condenser will be several hundred thousand liters per second.)
- the condenser used, in this example is a surface condenser with 326,000 square feet of cooling area. This cooling area is provided by3ft,568 tubes, through which 323,637 gallons per minute of cooling water are flowed. The cooling water is taken directly from a large lake, and therefore its temperature varies seasonally from about 60e>F to about 95°F.
- cooling water flows are typically so large that they must be taken directly from a river, lake, or bay.
- ocean water is often used as a cooling water source; in such cases corrosion and biological fouling may be significant problems.
- 430 and drained from the outlet water box 430, to remove heat from the condenser tubes. As the steam passes over the tube bundle, it is cooled below its boiling point (at the ambient pressure), and condenses. The resulting condensate is collected in a "hot well" 132 below the tube bundle.
- the condenser tubes are normally made of fairly thin-wall tubing Typically this tubing is made of stainless steel.
- the condenser tubes also normally have a fairly small diameter, 5 to maximize the surface over which thermal coupling occurs. Therefore, water 15 flow in the tubes is sensitive to blockage. Blockage can occur, for example, due to biological fouling or scale deposition.
- the velocity of flow in the condenser tubes is typically rather high. 6 Such flow velocities imply that a large amount of shear will be present near the tube wall, and this shear condition helps to retard deposition of all 20 kinds, including scale deposition and biofouling.
- the condenser tubes are 22 gauge, and have a wall thickness of Its than a sixteenth of an inch.
- the individual tubes have an outside diameter of 0.875 inches and a length of 50 feet.
- this velocity is specified at 6.9 feet per second.
- Vibrational Loading A condenser is inherently subject to high vibrational loads.
- the steam turbines and the generator armature are necessarily massive, and are constantly rotating at a frequency which is locked to that of the electrical grid.
- a 500 MW turbine/generator set would typically include several tons of mass rotating at 3600 rpm.
- a well-balanced piece of machinery is still likely to apply significant vibrational forces, at 60 Hz and 120 Hz, to its support.
- imbalances may appear in service from bearing wear or inelastic mechanical deformation.
- the condenser Since the steam inlet to the condenser is necessarily closely coupled to the steam exhaust from the turbine, the condenser will normally also be coupled to the vibration generated by the rotating, machinery. Variation in the steam flow, due to combustion irregularities or acoustic resonances, may also sometimes be seen at the condenser. Normally a large rubber isolation element is used to reduce the mechanical coupling of vibration from the turbine to the condenser, but the vibration forces can still be quite large. Vibration is highly variable from unit to unit, and can even change fairly rapidly, over a period of time, at a given unit.
- thermo pollution For purposes of environmental regulation, it is desirable to keep the cooling water temperature far below boiling, to ensure 100% condensation of the steam.
- the temperature rise in the cooling water is typically held to 20 ⁇ F or less.
- Any natural source of water will contain a significant fraction of dissolved ionic species, such as Na + , Ca ++ , COf Cl ⁇ , and many others. As the water temperature rises, some of these impurities will precipitate out.
- the most common scale-forming dissolved mineral is calcium carbonate. 7
- other minerals can also cause scaling problems, under various water conditions.
- other calcium 20 salts including calcium sulfate (CaS0 ) and calcium phosphate (Ca 3 (P0 4 ) 2 ) can also form scale.
- Magnesium sulfate (MgSO,,), iron oxide, and manganese dioxide* also sometimes occur.
- Calcium carbonate (CaC0 3 ) can be deposited whenever the produ ⁇ of the calcium ion concentration and the carbonate ion concentration reaches a certain temperature-dependent value, regardless of what the original source of the ions may have been.
- the chemistry of water supplies (and therefore the chemistry of scale formation) varies significantly from site to site, and from season to season, and even sometimes from week to week. Moreover, the heat transfer dynamics of different condenser designs will be different, and the degree of scale formation in any specific tube will be dependent on the degree of heat burden carried by that tube. (The water treatment must be sufficient for the worst case possible.) Thus, the amount of water treatment needed, at some specific installation for some specific week, cannot be accurately predetermined. The normal approach to this problem is to use a quantity of water treatment which is more than sufficient. However, this approach wastes money. For example, conventional cooling water treatment methods at a 1000 MW plant can cost $1,000,000 per year or more for chemicals.
- the inventions disclosed in this patent application permit the admixture of cooling water treatment chemicals to be controlled far more precisely. This has two advantages: the cost of chemicals is reduced; and the reliability of scaling control is increased, reducing the downtime required for descaling.
- a condenser structure wherein at least one tube, which is physically located among the other (numerous) tubes of the condenser's tube bundles, is not connected to the inlet water box nor to the outlet water box; instead, this tube is provided with separate inlet and outlet connections.
- the tube thus isolated is chosen to be among the tubes with the highest heat load, so that this tube provides a worst-case proxy for scaling in the other condenser tubes.
- the isolated tube is frequently inspected for scaling (at intervals of a week or so), and addition of anti-scaling chemicals to the cooling water is controlled with reference to the scaling (or lack thereof) seen in the isolated tubes.
- the level of treatment chemicals is held at a lower level in the isolated test loop than in the primary cooling water supply.
- Water flow in the monitored tube is preferably isolated by using isolation tubes.
- One isolation tube reaches through the inlet water box, to mate with one end of the monitored condenser tube; and the other isolation tube reaches through the outlet water box, to mate with the other end of the monitored condenser tube.
- These isolation tube emplacements unlike the inspection tubes described below - are semi-permanent installations. Endoscopic inspection of the monitored tube can be performed at any time, simply by inserting the flexible probe through the isolation tube into the monitored tube.
- the present inventors used an isolation tube with a tapered tip, and wedged this tip into the end of the monitored tube.
- the other end of the isolation tube was welded to the water box endwall.
- the vibration present was so high that the weld broke.
- the present inventors used rubber to support the isolation tube through the water box endwall.
- the other end of the isolation tube had O-rings to provide a hydraulic seal to the end of the condenser tube, but also had some metal-to-metal contact with the condenser tube. In this case, the condenser tube wore through and failed at the site of the metal-to-metal contact.
- condenser mechanical structure which permits endoscopic examination of condenser tubes in situ, without taking any part of the condenser off-line (except the specific tube being examined). This is accomplished by providing one or more inspection ports in the outlet water box, and providing a hollow rigid inspection probe which can be inserted through the outlet water box to dock with the end of a tube in the condenser. A flexible endoscopic probe can then be inserted through the rigid probe, to inspect the interior of the tube thus accessed.
- the outlet water box will normally be under a slight vacuum (due to the siphoning effect of the drain).
- inspection ports in the outlet water box require only cover plates, and do not even require valves (although gate valves may be used if desired).
- inspection through the outlet water box is more convenient. If the endoscopic probe is long enough, it is not necessary to access tubes through the inlet water box at all (at least not for endoscopic inspection access).
- the inlet water box will normally be under a few psi of pressure.
- inspection ports in the inlet water box are preferably built using modest-sized gate valves (e.g. 2" or 3" gate valves). When the valve is opened to insert the inspection probe, some water will pour out, but this flow can be stemmed when the inspection probe is in place.
- a related problem in cooling water treatment is the control of biological fouling.
- the cooling water path may provide sites for biological growth which will reduce flow and heat transfer.
- the first organisms to appear will be bacterial colonies, of the type which excrete a protective slime coating. This slime provides an adherent site which collects various forms of debris. Thereafter, in an uncontrolled situation, other life forms may appear, including higher plants or even barnacles.
- Biological fouling can be avoided with a variety of additives, such as sodium hypochlorite or bromide salts. However, such additives are not free.
- Figure 1 is an overall schematic view of a steam-powered electric generating station which may contain the disclosed innovations
- Figure 2 is slightly more detailed schematic view of such a steam-powered electric generating station, showing additional details of condensate and feedwater handling
- Figure 3 schematically shows some important control points in such a system.
- Figure 1 is an overall schematic view of a steam-powered electric generating station which may contain the disclosed innovations.
- FIG. 2 is slightly more detailed schematic view of a steam-powered electric generating station, showing additional details of condensate and feedwater handling.
- Figure 3 is a schematic flow diagram of a sample 545 MW baseload steam-powered electric generating station, showing flows, temperatures, and pressures at various points of the water and steam flows.
- Figure 4 is a perspective view of a typical large condenser, such as would be used in the generating station of Figure 1.
- Figure 5 is a schematic sectional view of the flows of water and steam in a condenser.
- Figure 6 shows a water box, for use at one end of one tube bundle in a large condenser like that shown in Figure 4, with inspection ports through which a rigid inspection probe can be manually inserted to dock into one end of a tube in the condenser.
- Figure 7 is a detailed view of the tip of the isolation conduit, in the presently preferred embodiment, which mates with the monitored condenser tube.
- Figure 8 shows the flexible endoscopic probe used in the presently preferred embodiment.
- Figure 9A shows how an isolation conduit 710 has been semi- permanently emplaced through the endwall of a water box 430' .
- Figure 9B shows how a rigid inspection probe can be inserted and docked with the end of a tube 420 in the end tube support 422'.
- Figure 1 is an overall schematic view of a steam-powered electric generating station which may contain the disclosed innovations;
- Figure 2 is an overall schematic view of a steam-powered electric generating station which may contain the disclosed innovations;
- a boiler 100 is supplied by feedwater pump 109 with slightly more
- 25 downcomer and waterwall tubes 104 and 106 provide good scavenging of the heat generated by burner 113.
- the steam is further heated in superheater 106, to about 1000 "F, and fed to high-pressure turbine 120.
- the pressure at the intake to this turbine is about 3675 psia, and the pressure at the exhaust is slightly over
- reheater 108 and provided to the intake of intermediate-pressure turbine 122.
- the temperature at the intake to intermediate-pressure turbine 122 is about 1000 "F, and the pressure at this turbine's exhaust is slightly over 175 psia.
- the exhaust from the intermediate-pressure turbine 122 is provided to the intake of low-pressure turbine 124.
- the exhaust from the low-pressure turbine 124 is at a fairly constant temperature of about 160- 165 "F, and is fed directly into the condenser 130.
- the low-pressure turbine in the presently preferred embodiment, sits directly on top of the condenser 130.
- the pressure at the exhaust of the low-pressure turbine 124 is slightly negative - less than atmospheric - due to the volumetric change which occurs in the condenser 130.
- the temperature will no more than 140 ⁇ F (and typically about 125 ° F), and the absolute pressure will be about 3 inches of Hg. (This is a vacuum of about 13 psi relative to the atmosphere.)
- the condensate is then pumped (by pump 134) through minimal further processing stages 133 and 136, into the low-pressure feedwater heater 107, deaerator 111, feedwater pump 109, and high-pressure feedwater heater 105.
- FIG. 5 is a highly simplified schematic sectional view of the flows of water and steam in a condenser. Cooling water flows from inlet water box 430, through the condenser tubes 420, into an outlet water box 430. Each of the tubes is supported at its ends by endpoint tube supports 422', and these endpoint tube supports 422' also serve to isolate the water boxes 430 from the interior of the condenser. In the interior of the condenser, depleted steam contacts the cold tubes 420, and condenses into water, which is collected in hot well 132.
- FIG 4 is a perspective view of a typical large condenser, such as would be used in the generating station of Figure 1.
- the exterior of the condenser is a vacuum vessel 410.
- Inlet hood 412 receives the steam exhausted from the low-pressure turbine 124.
- the steam condenses as it contacts the cold condenser tubes 420 (which are supported by tube supports 422).
- Each of the tubes in the presently preferred embodiment, is 50 feet long, and is supported along its length by multiple tube supports 422.
- a flange is provided which mates with the flange 434 on an outlet water box 430.
- the example shown includes two bundles of tubes 420, so that two outlet water boxes 430 would actually be used; but for clarity, only one outlet water box 430 is shown, so that the end of one bundle of tubes can clearly be seen.
- the massive flow of steam through hood 412 keeps the box 410 filled with steam.
- the volumetric change as the steam condenses causes a continuous radial inflow toward the center of each of the tube bundles. (This flow will be parallel to each of the tube supports 422.)
- the liquid water which results from this condensation is collected in a hot well, as described above.
- FIG. 6 shows the presently preferred embodiment of a water box, for use at one end of one tube bundle in a large condenser like that shown in Figure 4, with inspection ports 600 through which a rigid inspection probe can be manually inserted to dock into one end of a tube 420 in the condenser.
- the water box 430' of Figure 6 has a slightly different shape from the water box 430 of Figure 4.
- the shape of the mounting flange 434' in the water box 430' of Figure 6 is slightly narrowed at the top, unlike that of flange 434 on the water 430 of Figure 4.
- inspection openings 600 which are present in the water box 430 ' of Figure 6, and not in the water box 430 of Figure 4. These inspection openings permit a rigid inspection probe to be inserted and docked with the end of a tube 420.
- Figure 9B shows how a rigid inspection probe can be inserted and docked with the end of a tube 420 in the end tube support 422'.
- the modified inspection port 600' uses a gate valve 916 welded to the endwall of the water box.
- the rigid probe 910 preferably has an outside diameter smaller than the inside diameter of the tubes 420, so that it can be inserted at a slight angle as shown. It is not necessary that the probe 910 make a tight contact .to the tube 420; in fact, it is advantageous to have the contact somewhat loose. (Otherwise the vacuum in the outlet box may suck the water out of the tube 420, obscuring vision.)
- the rigid inspection probe is made from a piece of extra-thick-wall 3 A" steel tubing, with an outside diameter of about 1.1".
- this inspection probe has enough rigidity to be manually inserted through the water flow into the ends of the top tubes in the condenser. (Insertion into the lower tubes is more difficult; but since these tubes have a lower heat load, they are much less likely to scale, and inspection of them is less critical.)
- an endoscopic camera like that shown in Figure 8, can be inserted.
- the specific flexible endoscopic probe of the presently preferred embodiment is made by Welch-Allen, and is shown generally in Figure 8; but of course other brands can be used instead.
- Figure 9A shows how an isolation conduit 710 has been semi- permanently emplaced through the endwall of a water box 430' .
- the isolation conduit 710 - unlike the probe 910 - preferably is inserted essentially straight in, ie. coaxially aligned with the tube 420 into which the conduit 710 is inserted.
- This conduit 710 is shown leading into a gate valve 916, tee fitting 920, and another gate valve 930.
- the piping 940 provides the connection for the isolated test loop.
- the complete test loop would connect to another isolation conduit 710 on the input end of the same tube 420, and also may include a chemical admixture point, a pump or flow regulator, inlet and outlet thermometers, as well as on-line chemical monitoring equipment if desired.)
- Figure 7 is a detailed view of the tip of the isolation conduit 710, in the presently preferred embodiment, which mates with the monitored condenser tube 420 in the end tube support 422'. Note that O-rings 712 provide hydraulic seal and some vibration isolation between the isolation conduit 710 and the condenser tube 420 where it is fitted into the end tube support 422'.
- test site has been operated both with an isolated test loop (using an isolation conduit, as shown in Figure 9A, on both ends of a monitored condenser tube), and also with periodic in-situ in-service inspection of other tubes, using an inspection probe as shown in Figure 9B.
- Assay reagents can be used to provide early detection of microscopic changes, such as bacterial colony initiation or calcium carbonate nucleation.
- samples are taken for laboratory analysis, of factors such as pH, turbidity, phosphates, phosphonates, orthophosphates, PNM alkalinity, Ca ++ concentration, Mg ++ concentration. If desired, the detailed data thus collected can be translated into any of the available scaling index numbers, such as Puckorius, Langelier's, the Ryzner index, the EPRI index, or others.
- Such data can be used in combination with the various solubility-product-calculation computer programs which are now available, to provide more accurate prediction for a given site.
- a monitored condenser tube is used as a proxy for the worst-case biological fouling conditions in the other condenser tubes, it is necessary to make sure that the monitored tube really is among the worst-case tubes. To ensure this, it may be desired to reduce the flow through the monitored tube, or even to add nutrients.
- a monitored condenser tube is used as a proxy for the worst-case corrosion conditions in the other condenser tubes, it is necessary to make sure that the monitored tube really is among the worst-case tubes. To ensure this, it may be desired to add acid, add brine, or even add a trickle current between the monitored tube and its contents.
- this conduit could be brazed into the end of the condenser tube.
- some flex can be added, e.g. by including a section of flexible conduit near the tip of the conduit 710.
- the inspection openings in the outlet water box are preferably less than 24" wide, and ideally less than 12" wide. This permits the use of many inspection openings without degrading the mechanical strength of the water box structure. An aperture of even a few inches is sufficient for insertion of an inspection probe like that in the presently preferred embodiment, described above.
- the disclosed structures and methods could be adapted for use in heat exchangers; but it should be noted that the problems of steam condensers, and more particularly of steam-fired power plants, differ in several significant respects from those of other heat exchanger applications:
- Such condensers are normally very large structures with fragile walls, which operate under very mild temperature and pressure conditions (as compared to those used in chemical refineries).
- Such condensers normally operate with a relatively low temperature difference through the tube wall. Thus, any change in the thermal coupling through the tube wall is significant. Such condensers are required to effect a large transfer of heat at near-ambient temperatures, and hence must use very large flows of cooling water, hence the cost of any water quality treatment is very high.
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- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Water Supply & Treatment (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
Structure de condensateur dans laquelle les deux extrémités d'au moins un tube (420), qui est physiquement placé parmi (un grand nombre) d'autres tubes (420) du faisceau de tubes du condensateur, ne sont reliées ni à la boîte à eau d'entrée (430) ni à la boîte à eau de sortie (430); en effet, ce tube est muni de raccordements d'entrée et de sortie séparés, par l'intermédiaire d'un conduit d'isolement séparé (710). Le raccordement d'entrée séparé reçoit de préférence un apport de produits chimiques de traitement de l'eau commandé séparément. On décrit aussi une méthode innovatrice pour l'exploitation d'un condensateur de vapeur. Un ou plusieurs tubes, placés physiquement parmi (un grand nombre) d'autres tubes (420) du condensateur, sont isolés pour former une boucle de mesure en temps réel. Le tube ainsi isolé est choisi parmi les tubes qui ont la charge de chaleur la plus élevée, afin que ce tube représente le cas le plus défavorable pour le calaminage dans les autres tubes du condensateur. Le tube isolé est soumis à des inspections de calaminage fréquentes (à des intervalles d'une semaine ou à des intervalles de cet ordre), et l'apport de produits chimiques anti-calaminage à l'eau de refroidisement est déterminé en fonction du calaminage (ou de l'absence de calaminage) relevé dans le tube isolé. De préférence, le niveau de produits de traitement est maintenu à un niveau inférieur dans la boucle de mesure isolée que dans l'alimentation en eau de refroidissement primaire.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/566,222 US5060600A (en) | 1990-08-09 | 1990-08-09 | Condenser operation with isolated on-line test loop |
| US565,600 | 1990-08-09 | ||
| US566,222 | 1990-08-09 | ||
| US07/565,600 US5083606A (en) | 1990-08-09 | 1990-08-09 | Structure and method for on-line inspection of condenser tubes |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO1992002761A1 true WO1992002761A1 (fr) | 1992-02-20 |
Family
ID=27073913
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1991/005682 Ceased WO1992002761A1 (fr) | 1990-08-09 | 1991-08-09 | Exploitation de condensateur avec une boucle de mesure en ligne isolee |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO1992002761A1 (fr) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4599975A (en) * | 1983-09-01 | 1986-07-15 | 471199 Ontario Limited | Control of boiler operations |
| US4703264A (en) * | 1985-05-13 | 1987-10-27 | Combustion Engineering, Inc. | Self-orienting conduit probe |
| US4920994A (en) * | 1989-09-12 | 1990-05-01 | The United States Of America As Represented By The United States Department Of Energy | Laser removal of sludge from steam generators |
-
1991
- 1991-08-09 WO PCT/US1991/005682 patent/WO1992002761A1/fr not_active Ceased
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4599975A (en) * | 1983-09-01 | 1986-07-15 | 471199 Ontario Limited | Control of boiler operations |
| US4703264A (en) * | 1985-05-13 | 1987-10-27 | Combustion Engineering, Inc. | Self-orienting conduit probe |
| US4920994A (en) * | 1989-09-12 | 1990-05-01 | The United States Of America As Represented By The United States Department Of Energy | Laser removal of sludge from steam generators |
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