Clean condenser tubes are essential to the efficient operation of a power plant. Even though the condenser operates one component within a steam power plant, its cleanliness has a very large effect on the overall efficiency of the entire unit. With the steam condenser playing such a vital role in overall unit efficiency, it is very crucial to frequently clean condenser tubes.
Regular condenser cleanings can ensure that the steam turbine is operating closer to the desired megawatt output. Ultimately, the more megawatts a power plant can produce, the more revenue that plant can earn. Estimates have shown that additional revenues from annual cleanings of a main condenser can net upwards of $250,000 per year. Dollar estimates like this are hard to nail down exactly because the additional revenue gained is dependent on so many different plant specific factors. Specific condenser performance data points are easier to measure, and these data points directly influence megawatt output and thus influence additional revenue gains from cleaning.
Below, we share some of these performance data points from one of our recent projects to clean condenser tubes. At this power plant, Projectile used its Patented Metal Projectile to remove calcium based mineral scaling from the tubes.
Calcium Carbonate Based Scaling
Metal Projectile Tube Cleaner
Cleanliness Factor
Cleanliness factor is calculated by measuring a facility’s current heat transfer coefficient as a percentage of the system’s design specified heat transfer coefficient. Higher percentages mean that the system is operating closer to its design specification than lower percentages. The graph below shows before cleaning and after cleaning cleanliness factor statistics:
After cleaning of the condenser, there was approximately a 5% increase in the cleanliness factor of the unit.
Back Pressure
High condenser back pressure is one of the most obvious indicators of potential lost revenues. Higher back pressure directly impacts the output of the steam turbine, making it less efficient and causing more fuel input to achieve the same output. Some estimates show that a 0.05 inHgA increase in back pressure will result in a decreased load production of 0.5 megawatts. The graph below shows the back pressure before and after condenser cleanings:
The graph shows that there was a significant decrease in back pressure of as much as 0.70 inHgA with an average decrease of about 0.5 inHgA. Assuming that the above back pressure to megawatt figure is correct, a 0.5 in HgA decrease in back pressure could result in an additional 5 megawatts of output. Generating an additional 5 megawatts in output has huge implications for the revenue of this facility.
Flow Rates
Deposit in condenser tubes slows the flow of water through the condenser. Slower water temperature becomes hotter and the overall heat transfer capability of the condenser system decreases. The graph below shows that the post tube cleaning flow rate increased by approximately 5,000-10,000 gallons per minute.
Taken together, each of these condenser performance data points discussed above show that overall performance has increased after cleaning the condenser tubes. It is clear that the condenser cleaning has had a large positive impact on the performance of this unit. Better performance on the condenser equates to additional megawatt output and the additional megawatts add to the revenue of the plant. Thus clean condenser tubes are one essential element to running a financially healthy and successful thermal power plant.
Given the current economic situation of the power generation industry today, plants need to be investing in solutions that can increase profitably. Condenser cleaning is clearly one of the maintenance solutions that can quickly and easily add to the bottom line of a power plant. Ultimately, plants cannot afford not to clean their condensers regularly.
For more information on Projectile Tube Cleaning’s Condenser Tube Cleaning Services please feel free to contact us:
