Modernization & Upgrades for Condenser

Lower condenser pressure for higher efficiency & reliability

The overall efficiency of a fossil or nuclear power plant is strongly influenced by the performance of its condenser. Poor condenser performance results in performance losses which reduce the profitability of your power plant. Another important factor is the condenser’s operating reliability. In the worst case, the entire water/steam cycle could be damaged by corrosion effects triggered by condenser problems. You can upgrade your condenser by implementing optimized tube bundle design and tube material to achieve and sustain low condenser pressure. As a result, you experience an improved utilization of the thermal potential in the water/steam cycle.

Overview Siemens Energy can offer the following products for upgrading and modernizing your condenser

Study to analyze condenser configuration with regard to performance and potential issues

Tube Bundle Replacement

Tube Bundle Optimization

Condenser Assessment

Optimization of Air Removal and Evacuation System

Erosion Protection Sleeves

Cooling Water System Analysis and Optimization

Replacing the complete tube bundle(s) can improve condenser performance in various areas. The unique Siemens Energy condenser tube bundle design provides a uniform steam flow to all tubes, thus reducing the pressure drop and therefore lowering the backpressure at the turbine exhaust.
The condenser pressure can be reduced by optimization of the existing tube bundle configuration through selective pulling of tubes.
Using high-grade tube and tubesheet materials like stainless steel and titanium can significantly reduce or prevent the occurrence of erosion and pitting, often observed with copper alloys, as a function of the mineral salt and suspended matter content of the circulating water.

To improve the cleanliness factor of the condenser tubes and to reduce bio-fouling to maintain the design heat transfer rate, a continuous tube cleaning system and water filters can be installed.
Erosion protection sleeves provide protection against droplet erosion, thus avoiding repair of leaking condenser tubes, especially in saturated steam turbine units. Siemens Energy holds a patent on a unique type of erosion protection sleeve and the installation method.
An analysis of the complete cooling water cycle includes all relevant components of the cooling water system, like condenser, cooling towers, cooling water pumps, etc. and proposes the necessary measures to fully utilize the potential of the steam turbine.

Benefits Condenser upgrades help to reduce maintenance expenditures and promote increased revenue through

Power Increase

Reduced condenser pressure – increased power output and efficiency of the steam turbine

Reliability Increase

Increased condenser operating reliability and reduced forced outages

Availability

Reduced cooling water in-leakage and air ingress
Reduced condenser tube corrosion
Avoided corrosion effects in the water/steam cycle

Sustainability

Reduced bio-fouling and improved cleanliness factor

Cost Optimization

Lower future condenser maintenance expenditures

References

RWE

Ibbenbueren

Germany

Modernizing of Steam Turbines and Condenser

Modernization of the steam turbines as well as the two condensers.
Replacement of the four tube bundle modules in both condensers with cutting edge technology.
The whole modernization package resulted in additional power output of 86 MW.

Modernizing of Steam Turbines and Condensers

Contact If you have any questions or would like to find out how we can help you to modernize or upgrade your condenser, please let us know.

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