Condenser Tube Fouling and Failures: Cause and Mitigation

Abstract

The two most common condenser tube problems faced by chemists are internal tube fouling and tube failure. Fouling can have a major impact on power station generating efficiency and capacity, and tube leaks can seriously impact unit availability and reliability. Fundamental understanding of the root cause(s) of these issues, and their mitigation, is essential to resolving these problems and/or preventing their occurrence.

Functional Graphenic Materials That Seal Condenser Tube Leaks in Situ

“…Condenser tube leaks in Rankine cycle power plants are commonly observed, which create conditions that can be detrimental to the overall plant production. − Leaks result in reduced power output, increase the burden on downstream equipment, and cause sizable revenue losses. − Condenser tube leaks can only be addressed with temporary remedial measures . Currently, often the permanent remediation measure is the complete replacement of damaged tubes, which requires a significant investment of time and money …”

“…3 Currently, often the permanent remediation measure is the complete replacement of damaged tubes, which requires a significant investment of time and money. 4 Physical clogging with particles, such as wood flour, is the industrial standard for temporarily sealing small defects in condenser tubes. 3,5 Wood flour is utilized as an in situ sealing method, where it is added into the open cooling water that flows through to the condenser tubing to plug leaks from the inside of the tube.…”

Failure Analysis of Condenser Tube in Unit 1 of the Tenayan Steam Power Plant 2 X 110 MW

“…Wang, Y. (2007) also said the condenser pipe's lifetime directly affects the operational status of the power plant unit [2,3].…”