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Ecolaire: Global Supplier of Steam Condensers and Related Technology

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This bulletin outlines many of the factors that go into the engineering, design, fabrication, installation and testing of Ecolaire’s condensers. . .factors that contribute to their worldwide reputation for efficient performance and long life. It describes the many special features available to meet diverse needs and to enhance reliability.
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Global Supplier of Steam Condensers and Related Technology
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Page 1: Ecolaire: Global Supplier of Steam Condensers and Related Technology

Global Supplier of Steam Condensersand Related Technology

Page 2: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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Engineering Expertise

Quality and innovation go into the building of each Ecolaire steam surface condenser. . .on the drawing board, on the assembly floor, in the test lab, and at your jobsite. The result is a condenser specifically engi-neered to meet the needs of your application. . .and built to perform at full design efficiency.

This bulletin outlines many of the factors that go into the engineering, design, fabrication, installation and testing of Ecolaire’s condensers. . .factors that contribute to their worldwide reputation for efficient performance and long life. It describes the many special features avail-able to meet diverse needs and to enhance reliability.

We start by designing each condenser on an individual basis, to meet the specifications for your system. Our engineering staff considers every element that will affect condenser efficiency over your specified plant operating range to offer you the best possible heat rate over the widest range.

This basic system data includes:

•Monthlygeneratingloadchanges. •Averageinletcoolingwatertemperatures,

monthly. •Worst-casecoolingwatertemperature(s). •HeatBalancesfor25%,50%,75%,100%

and VWO. •Turbineresponsecurves(%changesin

heatrate). •Specificcyclerequirements.

Basedonthesystemdatayouprovide,weengineeracondensertomeetyourspecificsiterequirements.WedesignandbuildittoHeatExchangeInstituteStandards,andwepayattentiontodetail.Servicecon-nections are designed for both static and dynamic reac-tions and to cope with potential erosion. We give the same attention to these connections as to the unit itself because we believe a service connection malfunction should never be the cause of a condenser being taken off-line.

BasicConstruction

-Modularconstructionwithshop-installedtubes-Anti-vortexbafflesoncondensateoutlets-Cascadingaircooler-Bolted-ontubesheets- Rolled tube sheets-Bolted-onwaterboxes-ASTMA516,Gr.70carbonsteelshell- Vaned steam dome-Slidingsupportfeet-20”diameterquick-openingmanways-Allrequiredserviceconnectionsincludinginternal

baffles and spray pipes

SystemOrientedFeatures

-Heaterandextractionpipingsupports-Extractionsteampiping- Lagging-Extractionpipingmanifold-Fairingenclosures- Isolation support plates-Circulatingwatercrossoverpiping-Circulatingwaterstandpipes- Retention hotwells- Divided hotwells- Double-effect hotwells- Welded-on tube sheets- Double tube sheets- Integral groove tube sheets-Serratedtubeholes-Flaredtubeends- Welded tube ends-Welded-onwaterboxes-Linedwaterboxes- Lubricated support-feet pads-Rubber“U”steaminletexpansionjoints-Rubberbeltsteaminletexpansionjoints-Stainlesssteelsteaminletexpansionjoints-24”diameterquick-openingmanholes-Condensateoutletscreens- Dirt collars-Soleplates-Fieldinstallationoftubes-Steamdumpsystems-Alternatematerialsofconstruction- On-line condensate leak detection systems- Turbine isolation dampers-Springsupports

Page 3: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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ManufacturingCapabilities

Ecolaire’s230,000sqft.manufacturingfacilityislocat-edinTulsa,Oklahoma,ona38acreimprovedsite.Ecolaire’sweldersarequalifiedunderASMESectionIX.PresentlyweholdtheASMESectionVIIIDivision1and2“U”,“S”and“R”stamps.Ourmanufacturingfacil-ityalsoisChineseSQLandISO9001certified.

A key to the successful manufacturing of steam condensers is the ability to drillalargequantityofprecisionholes.Ecolairehasfive(5)multi-spindleCNCdrillingmachines(upto41spindles)that drill tube sheets and support plates to ensure proper hole tolerances.

The combination of machined cast iron leveling tables and right angle strong backs provide a base for accurate construction of condenser assemblies. This combination enables ease of tubing and assures proper alignment during field erection.

Stateoftheartautomaticoxy/fuel plasma cutting machine prepares all plates for assembly. This machine pro-vides and simplifies cutting operations thus enhancing the productivity in the assembly operation.

Page 4: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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Utility and IndependentPower Producers

Ecolaire has been producing condensers for power productionsince1920andtodatehasproducedover3,600condensers.Thoseinoperationhavesurfaces upto1,400,000squarefeetandserveplantsupto1300MW.Thisextensiveexperienceincludesfossil-fueledinstallationswithpressuresupto3,500psigandnuclear installations on virtually every type of reactor system built.

This two-shell, multi-pressure 600MWcoal-firedcondenserisready for installation under a four-flowdownexhauststeamturbine.The458,704squarefootunitincludes steam bypass provisions and low-pressure feedwater heat-ers in the steam dome.

Primary concern is always ease of installation; Ecolaire designs minimize fieldtime.This126,340square-footcondenserwasinstalledin45calendardaysbyasix-mancrewworkingfour,10-hourdayswithnoovertime.Itwasshippedinfourmajorshell/hotwellandshell/steamdomesections,plusfourwaterboxesandtwoextensionnecks.

Twosteamdomehalvesfora183MWcondenser with the openness of the Ecolaire vaned design easily seen. This feature minimizes cross-bracing and pro-duces minimum pressure drop as steam distributes from the turbine to the tube bundles, thus increasing turbine efficiency.

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Ecolaire’scommitmenttoexcellencehasresultedinpioneering the path of advancement in condenser technology.Thereareover80multi-pressureunitsinoperationwithuptosixpressurelevels.Double-effecthotwellsareinoperationrecoveringtheauxiliarytur-bine steam heat content that would otherwise be lost to thecoolingsystem.Close-spaceddoubletubesheetsare protecting condensate systems from cooling water inleakageatvariousinstallations.Steamdumpsystemswith capacities to full steam generator flow are operat-ing reliably.

Ecolaire has continued to advance condenser technol-ogy by designing and producing the first major con-densersusingAusteniticStainlessSteelAL-6XN® tubes andAL-6-XN® tubesheets,plusunitsusingFerriticStainlessSteelAL29-4C®tubesandType904Ltubesheets.Thesematerialsrequirethedevelopmentofheat transfer parameters as well as tooling and other manufacturingtechnologiestoensureaqualityproductwith high reliailty.

Whateveryourcycleormaterialrequirements,youcanrely onEcolairetoprovideyouwithqualitycondensersthat have a tradition of high availability and maintain-ability.

Final shop-tubed shell sections for two condensers are loaded in the hold of anexclusive-useshipforprotectionfromtheelements.Shippedcompleteon one vessel, they are destined for an 800MWcombined-cyclefacilityintheUnitedKingdom,transportationFOBjobsite arranged by Ecolaire.

Thisthree-shell,900,000square-foot900MWPWRcondenserepito-mizestheexperienceofdesignavailableatEcolaire.Cycleefficiencyismaximizedbyutilizingathree-shellthree-pressuremulti-pressuredesignwith each shell having optimum surface with different tube lengths. Double-effect hotwells reheat condensate with reactor feed pump tur-bineexhauststeamtofurtherimprovecycleefficiency.Sixcoolingwatercircuitsprovidemaximumflexibilityofoperation.Placingthefirstfourstages of feedwater heaters in the steam dome in the initial design stage reducedoverallplantspacerequirements.

Page 6: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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RevampingEcolaireprovidedthefirstmajorrevampingoftwo815MW,650,870square-footPWRnuclearcondenserswithtitaniumtubesandtubesheetsin1981.Plantcon-struction dictated that an in-place step-by-step proce-dure be used rather than modules. The methodology and special handling systems engineered by Ecolaire allowed completion of this revamping well within the schedule.

Sincethenrevampingshavebeenprovidedforcon-densersrangingfrom3,600squarefeetto718,590squarefeetandfromonetosixtubebundlesper project.Extensiveengineeringsupportisavailablefor:

•tubevibrationstudies •supportloadings •structuralanalysis •serviceconnectionanalysis •performanceanalysis

regardlessoftheoriginalequipmentmanufacturer.

Experiencedservicepersonnelareavailabletoguideany revamping work to ensure timely and accurate completion of the installation.

Vacuum-bubble testing of a com-plete module to prove the integrity of the welded tube ends, as well as the entire tube length. Vacuum-bubble testing ensures that the moduleis100%leak-free,thuspromoting reliability.

Oneof12totalmodules from two units designed for atwin,1,100MWBWRnuclearpower plant. Each 151,000-poundmoduleis10’4”widex13’10”highx50’1”longandcontains459,000linear feet of titanium tubingwith18,360tube ends, rolled and seal-welded into solid titianium tube sheets.

Two of four modules for a350MWfossilpowerplant in final prepara-tion for shipment. Each modulecontains69,732squarefeet,istubedwithType439stainlesssteeltubes and has Locktite® applied to tube ends for enhanced seal integrity.

Page 7: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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Refurbishing and Life Extensions

Refurbishments,upgradesandlifeextensionsaredesigned by Ecolaire to provide the highest reliability for the specified service life. Refurbishing and upgradings range from new service connection review and rede-signtonewwaterboxesandreplacementtubesheets.Experiencedpersonnelwillfollowyourjobthroughevery step to the project’s completion.

Ecolaire is not just a new condenser manufacturer. Its engineers are prepared to service and upgrade the myriad operational units fabricated by other manufactur-ers, some no longer in business. If you have condenser unitsthatrequireparts,serviceandconnectionupgrad-ing as time passes and cycles are modernized, call Ecolaire. Our engineering capabilities can easily handle your needs.

There are many condensers on salt water cooling systems with original cast ironwaterboxesthatarefastapproach-ing their service life. These replacement waterboxeswillbelinedandwillexactlymatchthetubesheet-to-waterboxbolt-ingpatternbecauseofouruniquetem-plate matching to the original unit.

These titanium tube sheets replace original muntz metal tubesheets on a condenser whose manufacturer is no longer in business. Notethatthetubepatternisnotonagridpre-cluding the use of a multi-spindle drill. Ecolaire has tape-controlled drilling machines designed to drill any pattern.

Examplesoftheengineeringser-vices Ecolaire can perform, regardless of condenser type or manufacturer include: addition of new or upgrading of old service connections due to cycle changes; spring support analysis and vibration studies when retubing with a different weight and wall gauge mate-rial;additionofexhausthoodcoolingsprays when changing to prolonged steamdumpcycles.Experiencedengi-neering support is available for any condenser-relatedrequirement.

Page 8: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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CogenerationRefuse RecoveryIndustrial“Thesamebutdifferent”isprobablythemostapteuphemismforapplicationsintheseareas.The“same”is the primary function to condense steam from the tur-bine to increase its efficiency while maintaining a high availability.The“butdifferent”aretheuniquerequire-ments of the various cycles involved; some of which are:

•supporttheturbine •condensesteamfrommorethanoneturbine

at a time •accepthighsteamdumpvolumesindefinitely •usemorethanonecoolingwatersourcecon-

currently •handleextremelyhighvolumesofmakeup

Withour85+yearsofcontinuouscondenserdesignandfabrication,Ecolaireisinauniquepositiontoprovidesolutionsforanyindividualcyclerequirement.Ifitcanbe done in or handled by the condenser, we will engi-neer the solution to operate reliably over the life of the installation.

The burning of culm is an excellentexampleofcogen-eration helping the environ-ment. This power plant with its 34MWdownexhaustturbineand40,570square-foot condenser will aid in reduc-ing the hills of coal tailings in Pennsylvania.

Servinga25MWverticalexhauststeamturbineaspart of a combined cycle installation,this20,000square-footunitincludesapressurebalancedexpan-sion joint and crossover duct designed by Ecolaire

This33,840square-foot50MWaxialexhaustcondenserboltsdirectly to the steam turbine with metal to metal machined flange. The condenser supports and is the anchor point for the LP tur-bine.Expansioniscontrolledbya series of keys and guides.

Page 9: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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Destined for the Peoples RepublicofChina,this11,065square-footaxialexhaust condenserservinga17MWturbine is designed to be turbine centerline mounted. The unit supports the turbine and is mounted on rocker col-umnsforexpansion.

These two condenser shell sections with hotwell attached willserveatwin55MWcoalfiredcogeneration power station. The 35,945square-footcondenserincludesextractionpipingforthesteam host, provisions for high makeup and steam dump.

In the final stages of completion, this 79,280square-foottwinshellsideexhaustcondenserservesa125MWsteamturbineata340MWcombinedcycleinstallation.The top of the left hand shell supports a feedwater heater conserving plant space.

This3,420square-footcon-denser will serve a heat pump compressor drive turbine in an ethylene plant in SouthAmerica.

Page 10: Ecolaire: Global Supplier of Steam Condensers and Related Technology

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Turbine Isolation

Ecolaire continues to pioneer in the condenser market byofferingreliablesolutionsascyclerequirementsevolve. In many combined cycle and refuse-recovery plantsthereisarequirementtooperatetheboilerwhilesimultaneously performing maintenance on the steam turbine.

Traditionally this has been accomplished with a sepa-rate dump condenser. The method is costly in both equipmentandspaceandcanbefraughtwithcontroland operational problems.

Ecolaire has developed a zero-leakage turbine isolation damper that will allow the main condenser to accept the steam from the operating boiler, thus eliminating thedumpcondenserandattendantsystems.Automaticoperation allows complete isolation typically in less than 10minutes.

Illustrated here are two of many installations that have proven their reliability and availability. In one instance, the turbine was damaged on initial start-up. The con-denser then successfully operated in the isolated dump modeforoversixmonthswhileturbinerepairsweremade.

Thelargestisolationdampertodateisa24’10”x24’8”double-drawunittoisolatea180MWsteamturbine.Essential to the reliable operation of large isolation dampers is integral design with the condenser to ensure vacuum and pressure loadings are properly balanced for all modes of operation.

This7’1”x10’11”damperwilliso-latea60MWturbinefroma45,300square-footcondenserinarefuserecovery facility. The damper is fab-ricated as a separate unit for instal-lation on top of the condenser. Test plates are being installed to test the seal for zero leakage at plus and minus15psidifferential.

This6,575square-footcondenser serves a 15MWturbineinacombined cycle facility. The shell is oversize to dissipate the thermal and kinetic energy of the steam dump. The 9’2”x2’5”isolationdamper is integral with-in the top of the shell.

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GeothermalGeothermalcondensersareuniqueinthepowergener-atingfield.FromthepioneeringdaysofGeysersinthelate1950sandearly1960s,Ecolairehasappliedbothits field and in-house test results to produce reliable designs in both surface and direct contact condensers.

Uniquetogeothermalunitsistheextremelylargeamountonnoncondensibles,asmuchas10%ormoreofthesteamflow.Bycomparisonatypicalpowerplanthaslessthan1/10%noncondensibleflow.Ecolaire’sdesigns include allowances for the heat transfer degra-dation by the noncondensibles and minimizing vapor carryovertoreducegasremovalequipmentpower consumption.

To negate the effects of corrosive steam, geothermal condensers are typically constructed entirely of stain-lesssteel.Our230,000square-footmanufacturingfacil-ityisqualifiedtohandlevirtuallyanyhigh-alloymaterialrequired.

Until the well field is complete, operating actual noncondens- ible flow is unknown. To protect against any major variances, this shop-tubed shell section from a single pass 169,200square-footunithasagas cooler section specifically designed to handle up to twice the amount of design noncondensibles.

This noncondensible gas removal system including precooler has multiple ejectors to match capacity to actual noncondensible flow.

Material selection and other sizingcriteriamayrequirechange as a geothermal field ages. To ease replacement, if the situation arose, Ecolaire constructed this shop-tubed tube bundle for a two pass 104,800square-footcondenserto slide in or out of the unit. This condenser also features a built-inprecooler,NESTS® sup-ports and a tube pattern spe-cifically designed to enhance H2Spartitioning.

Page 12: Ecolaire: Global Supplier of Steam Condensers and Related Technology

2121 NORTH 161 EAST AVENUETULSA, OKLAHOMA 74116UNITED STATES918 234 [email protected]

In the interest of technological progress, all products are subject to design and/or material change without notice. ©2009 SPX Cooling Heat Transfer, Inc. Printed in USA | ECOLAIRE-09


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