Each participant will receive text material that will serve as a guide and will minimize the need for note taking.
Background information, copies of diagrams, and relevant papers
will be included in the text. STEAM SURFACE CONDENSER & CLOSED FEEDWATER HEATER OPERATION, MAINTENANCE AND PERFORMANCE
Thirteen Sessions Totaling 4 Days
Each participant will receive text material that will serve as a guide and will minimize
the need for note taking. Background information, copies of diagrams, and relevant papers
will be included in the text.
| COURSE DESCRIPTION | COURSE DIRECTOR | WHO SHOULD ATTEND |
| COURSE OUTLINE | LEARNING OBJECTIVES | COURSE FEE |
This 4 day seminar provides more indepth information than the 3 day seminar in regards to how condensers, feedwaters and tubes are fabricated and designed. The seminar is conducted in a slide assisted lecture/ discussion format. The seminar instructors are highly experienced power plant heat exchanger engineers. The seminar content is directed towards plant engineers, results/performance engineers and plant operations/ maintenance supervisors. The intent of the seminar is to provide the participants with the necessary background information that is required to identify, evaluate, and correct condenser and feedwater heater performance, operation and maintenance problems. This information includes a review of the related heat transfer principles, and techniques for identifying mechanical failures and heat transfer deficiencies. The multiple choices of possible corrective actions that can be taken in each given are presented. These seminar segments are followed by discussions of the methods that are employed to select the optimum technical-economic corrective action, amongst all of the choices that were previously described.
Upon completion of this course, participants will understand the principles of operation of a steam surface condenser and a feedwater heater and will be able to develop strategies for performance improvement and increased availability. The participants will also learn about steam surface condenser design; aqueous corrosion; heat exchanger fouling; condenser performance monitoring and testing; retubing; and non-destructive examination of heat exchanger tubes.
The Course Director is Mr. Robert J. Bell, President of Heat Exchanger Systems, Inc., a consulting engineering and non-destructive testing firm in Boston, Massachusetts. He specializes in the analysis and specification of steam surface condensers and associated systems. Mr. Bell's experience includes performance testing, performance monitoring, corrosion failure analysis, vendor surveillance, materials selection, consultation on operation and maintenance, condenser retubing and troubleshooting.
This course is intended for those plant engineers, results performance engineers, and plant operation/maintenance supervisors. Also, support staff that are concerned with specification, operation, maintenance and repair of steam surface condensers and closed feed water heaters. The program is of special value to personnel who are required to evaluate the condition and operation of existing equipment, make "repair or replace" decisions, and resolve operating problems.
Advantages to your company include:
The participants will substantially increase their ability to evaluate the condition and operation of existing steam surface condensers and closed feedwater heaters.
Increased technical background to make repair or replace decisions.
Interaction of your plant engineers, results/performance engineers, and plant operation/maintenance supervisors.
Customization of this course for your plant.
Potential increase in heat exchanger components life.
STEAM SURFACE CONDENSER & CLOSED FEEDWATER HEATER OPERATION, MAINTENANCE AND PERFORMANCE
SESSION 1 - Heat Transfer Principles For Steam Surface Condensers - The seminar builds upon simple conduction through a solid plate of a homogeneous material and adds the complexity of evaluating heat transfer through a series of plates of different materials to demonstrate the analysis of multiple heat transfer resistances. In addition, circular geometry is discussed. This leads to the analysis of heat transfer in a heat exchanger tube. Temperature duty diagrams for the condensing phase are reviewed. The five resistances to heat transfer are identified and related to steam surface condenser rating methods.
SESSION 2 - Steam Surface Condenser Functions and Theory of Operation - The heat transfer principles of single tube condensing are applied to large tube bundles. Bundle design principles such as radial flow are discussed. The theory of tube bundle operation is reviewed. In addition, the functions of a steam surface condenser in today's power plants are identified.
SESSION 3 - Feedwater Heater Functions and Theory of Operation/Application - The functions of a feedwater heater are discussed. The types of feedwater heaters and the types of feedwater heaters zones are identified and advantages and disadvantages of each are discussed. The vent and drain system design practices are reviewed. Design practices for preventing turbine water induction are also identified
SESSION 4 - Selected Heat Exchanger Design and Construction - Topics Include: Drawn Tube Fabrication, Seam Welded Tube Fabrication, Condenser Tubesheet Design, Tube-to-Tubesheet Connections, Impingement Baffles, Zone Baffles, Support Plates, and Bundle Arrangement
SESSION 5 - Fouling in a Steam Surface Condensers - Forms of macrofouling and microfouling in various environments are discussed. Control methods and condenser cleaning technologies are identified
SESSION 6 - Feedwater Heater Failure Causes - An overview of the most frequent failure causes such as impingement erosion is presented. The relationship between feedwater design, feedwater heater normal and abnormal modes of operation, alternate tube materials and other component failures such as impingement plates are discussed.
SESSION 7 - Feedwater Heater Operation and Maintenance - The functions of a feedwater heater are discussed. The types of feedwater heaters and the types of feedwater heaters zones are identified and advantages and disadvantages of each are discussed. The vent and drain system design practices are reviewed. Design practices for preventing turbine water induction are also identified.
SESSION 8 - Condenser Failure Causes - An overview of the most frequent tube problems both on the steamside (impingement attack, flow induced vibration, condensate corrosion and stress corrosion cracking) and on the waterside (such as galvanic corrosion, dealloying, pitting, and sulfide attack) is presented. Proper design, operation and maintenance methods are also identified.
SESSION 9 - Condenser Instrumentation and Performance Testing - Circulating waterside and steamside monitoring parameters and the instrumentation for determining these parameters on-line and in testing are identified. Performance testing is discussed including the need for testing, available codes, and alternate techniques.
SESSION 10 - Condenser Operation and Maintenance - Operation and maintenance practices for the steam surface condensers are identified. These include performance monitoring and economic cleaning schedules. The methods of equipment condition monitoring and assessment are also discussed. These include recordkeeping, visual examination techniques, non-destructive examination techniques, and destructive examination. Tube plugging and life extension technologies are also identified.
SESSION 11 - Nondestructive and Destructive Examination Techniques - Principles of various techniques, including eddy current testing and ultrasonic testing will be discussed and their application to condensers and feedwater heaters will be identified.
SESSION 12 - Condition Assessment - Condition assessment methods are discussed. Examples of condenser and feedwater heater assessments are used.
SESSION 13 - Condenser Retubing and Rebundling - The available methods and tooling will be identified and the advantages and limitations of each will be discussed.
The fee for this course will be determined based on the number of participants and the course location. To receive a quotation or to arrange for this in-plant course, please contact Joyce Kelly at (781) 337-9400 or send email to: joyce@heatexsys.com.
Please contact Robert J. Bell at (781) 337-9400 regarding any technical questions/information pertaining to this course.
Utilities that have attended this course:
Lansing Board of Water of Light
Hawaiian Electric Company
Pennsylvania Power & Light Company
New York Power Authority
Quebec Hydro
Northeast Utilities Company
Niagara Mohawk Power Corp.
Florida Power & Light Co.
Washington Public Power Supply
Boston Edison Company
Pacific Gas & Electric
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