Performance Characteristics of An Air-Cooled Condenser Under Ambient Conditions
Performance Characteristics of An Air-Cooled Condenser Under Ambient Conditions
Performance Characteristics of An Air-Cooled Condenser Under Ambient Conditions
becomes apparent that increased interest started around the work has been expended in trying to rectify this. Based on
mid 1980s has generally continued to grow, particularly over various analyses the actual corrosion appears to be a flow-
the last 10 years. accelerated corrosion (FAC) derivative where local
indigenous magnetite is removed from the surface of the ACC
IV. THE IMPACT OF AIR COOLED CONDENSER ON PLANT tube leaving a very intergranular surface appearance.
DESIGN AND OPERATIONS. Adjacent to these areas where the local turbulence of the two-
Air-cooled condensers were first introduced into the U.S. phase media is not as great, the magnetite deposits on the
power industry in the early 1970s, but only during the last surface. There are clear boundaries between the regions
decade has the number of installations greatly increased, where corrosion/ FAC takes place (white bare metal) and
largely in response to the growing attention being paid to regions where deposition (black areas) occurs.
environmental concerns. The rising importance of this rather
different technology for the condensing and recovery of
exhaust steam calls for a broader understanding of the
associated design and application principles involved, as well
as of the performance monitoring techniques and cleaning
methods that have to be applied.
Over the past 30 years there has been a growing and
competing demand for water for both domestic and industrial
use and this has brought an increased interest in the use of air
as a cooling medium in place of water. In the utility industry,
the earliest applications for the air-cooled condensing of
exhaust steam were modified air-cooled heat exchangers
similar to those already in use by the process industries.
Eventually, air-cooled condensers designed for the utility
industry evolved into a configuration that recognized the Fig. 2 DHACI Indices 1-5 for upper ducts and tube entries.
special needs of condensing a large volume of low pressure
vapor as well as the removal of non-condensable. ACC Corrosion Index:
After inspecting a number of ACCs around the world, two
of the authors developed an index for quantitatively defining
V. THE ENVIRONMENTAL PROTECTION AGENCY AND DRY the internal corrosion status of an ACC. This is known by the
COOLING acronym DHACI (Dooley Howell ACC Corrosion Index).
In 2000, the U.S. Environmental Protection Agency The index separately describes the lower and upper sections
conducted a comparative study of the environmental impacts of the ACC, according to the following
of wet vs. dry cooling. Their conclusion was that the energy Upper Section
consumption per lb. condensate was higher for dry cooling
than for wet cooling and that the atmospheric emissions Upper duct/header, ACC A-frame tube entries. Index: 1, 2, 3,
associated with that energy consumption was also higher. 4 or 5.
These disadvantages are offset by the cooling water intake 1. Tube entries in relatively good shape; possibly some areas
flow being reduced by 99% over that required by a once- with dark deposits in first few inches of tube interior. No
through system; or 4-7% over a closed cooling water system. corrosion or FAC.
They also noted that dry cooling eliminates visual plumes, 2. Various black/grey deposits on tube entries as well as
fog, mineral drift and water treatment and waste disposal flash rust areas, but no white bare metal areas. Minimal
issues. However, their conclusion was that, dry cooling does corrosion/FAC.
not represent the Best Technology Available (BTA) for 3. Few white bare metal areas on a number of tube entries.
minimizing environmental impact. Some black areas of deposit mild corrosion/FAC.
Much of the E.P.As concern is that the high costs and 4. Serious white (bare metal) areas on/at numerous tube
energy penalty of dry cooling systems may remove the entries. Extensive areas of black deposition adjacent to
incentive for replacing older coal-fired plants with more white areas within tubes. Serious corrosion/FAC.
efficient and environmentally favorable new combined-cycle
5. Most serious. Holes in the tubing or welding. Obvious
facilities, the latter presumably equipped with wet-cooling
corrosion on many tube entries.
systems.
VII. CLEANING TECHNIQUES FOR AIR-COOLED CONDENSERS
VI CORROSION PROBLEMS WITH AIR COOLED CONDENSERS.
The three principal methods for cleaning the external
Corrosion of the carbon steel components in these large
surfaces of air-cooled condensers are as follows:
systems has been a concern because of the impact of high iron
Fire hose
levels and air in-leakage. The maximum corrosion has been
observed at the entries to the A-frame ACC tubes. The High pressure Handlance
mechanism of this corrosion is not fully understood and little Semi-Automated cleaning machine
INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY, AHMEDABAD 382 481, 08-10 DECEMBER, 2011 3
TABLE II
THERMAL AND HYDRAULIC SPECIFICATIONS
steam ejector. For any condenser condensation of steam as speeds of 800 to 1400 r/min are considered for the
well as removal of dissolved gases are important. Each comparison and analysis.
condenser contains six fans. Fan no. 1, 3, 4 & 6 are for the
condensation of turbine outlet steam. Fan no. 2 & 5 are for
dephlegmator section. Dephlegmator section is connected
with steam ejector system. For this particular plant being at
sea shore ambient temperature playing effective roll.
Due to sea shore it is not going as higher as compared to
interior regions. As shown in the sketch dephlegmator section
is just like sandwich form. A-Frame air cooled condenser is
shown in the sketch.
1) Effect of Wind Velocity on Hot Air Recirculation Fig. 6 Heat Recirculation as a function of Fan speed.
From the above results, it is found that the HAR of the
ACC system is extremely serious when the wind blows According to the relation that the volume flow rate is
normal to the boiler house. proportional to the rotational speed, in the ACC cells around
the edge of ACC platform shown in the graph. The
temperature of the fans boundary and the ambient temperature
are both 30C. The ambient wind speed is in between 6 to 9
m/s. The graph shows that how the HRR varies with the
increases of rotational speed. It is concluded that the HRR
gradually reduce with the acceleration of rotational speed.
The reasonable explanations causing this phenomenon are
that accelerating the rotational speed of the edge fans leads to
the increment of fan flow rate, which makes inlet and outlet
wind speed of the ACC both increase correspondingly, thus
aggravating the convective heat exchange between the
cooling air and the finned tubes. The temperature of the hot
Fig. 5 Heat Recirculation at different Wind velocities. air exhausted from the ACC has aggrandized, but the kinetic
energy along the vertical direction will increase, which can
In order to the further understand the impact of the weaken the entrainment phenomena of flow-field around the
unfavorable wind condition on the HAR, twelve wind speeds ACC on the hot exhaust air. Finally, the hot air involved into
are selected for the numerical calculation. The curve shows fan-inlet is to reduce and its temperature is to lower.
that the HRR varies with the wind speeds. It is clearly seen
that HRR maintains the growing trend with the increase of 3) Effect of wind velocity on effectiveness:
wind speed. With the increase of the wind speed, the As the wind speed increases inlet flow distortion
interaction and disturbance between hot exhausted air and experienced. The thermal effectiveness decreases as the wind
weak flow of leeward side of the boiler house and turbine velocity increases as shown in the graph. The flow distortion
room are gradually enhanced, and in the addition of intensive and regarding low pressure region at the upstream region of
suction of axial flow fans, a lot of hot exhausted air involves the fan contributes in the decrease of ACC performance. The
into the fan-inlet of the edge of the ACC platform. However, wind itself has positive impact on certain fans also.
when the wind speed reaches up to very high level reduction
is possible of the HAR of the ACC system. The main reason
that causes this reduction trend is that under the strong wind
conditions, the forced convection action of oncoming wind
and hot exhausted air are evidently reinforced, therefore most
of the heat quantity are transferred and diffused to the
downwind of the ACC platform.
X. CONCLUSION
The primary focus of this study was to determine
performance trends of an ACC under atmospheric parameters.
Ambient temperature plays key role in the performance
of ACC. Generally ACC is advisable where ambient
temperature not rising much, especially at sea shore
areas. More than that ambient temperature also effects on
turbine back pressure which can reduce output power. In
both these cases ambient temperature impact is
considerable.
After ambient temperature wind velocity is the secondary
parameter which affects on ACC performance. As the
wind velocity increases effectiveness (thermal and
volumetric) decreases and hot air recirculation increases.
Hot air recirculation is generally observed in so many
plants. To minimize fan rotational speed to be increased.
This is not the solution because electrical energy
consumption by fan will increase. The optimum solution
is wind wall on the sides of the radiator.
Various techniques for cleaning are adopted to increase
heat transfer rate. As the cleaning progresses for various
heat transfer coefficients (air side) improves. Ultimately
which accelerates heat rejection rate to atmosphere.
XI. REFERENCES
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investigation of fan performance in a forced draft air-cooled steam
condenser Department of Mechanical Engineering, University of
Stellenbosch, Private Bag X1, Matieland 7602, South Africa.
[2] Richard E. Putman and Dirk Jaresch (2006) The Impact of an Air
cooled condenser on Plant Design and Operation.
[3] J. A. van Rooyen, (2007) Performance trends of an air cooled steam
condenser under windy conditions. Thesis presented in degree of
Master Science in Mechanical Engineering at Stellenbosch University.
[4] X.F. Gao, C.W. Zhang, J.J. Wei, B. Yub (2010) Performance
prediction of an improved air-cooled steam condenser with deflector
under strong wind. State Key Laboratory of Multiphase Flow in Power
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Xian 710049, Peoples Republic of China.
[5] M.T.F. Owen, D.G. Krger, (2010) The effect of screens on air-cooled
steam condenser performance under windy Conditions. Department of
Mechanical and Mechatronic Engineering, University of Stellenbosch,
Private Bag X1, Stellenbosch 7599, South Africa.
[6] Operation Manual (Steam Turbine Section) for 4X23M Thermal Power
Plant at Gujarat Cement Works, Document NO.: CMEC-GCW-OM-
001
[7] Thermal Power Plant Diary with Specifications, for 4X23M Thermal
Power Plant at Gujarat Cement Works, Rajula.