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Southern Company
Heat Rate Conference
Auburn, Alabama
October 24 & 25, 2006
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HEAT RATE (Btu/Kwh)
What influences Heat Rate?
The type and quality of fuel
How efficiently its burned
Turbine efficiency whether the unit is equipped with emission
controls
capacity factor, etc. etc.
Typical Heat Rates for Coal Fired Units
typically 9,000 - 12,000 btu/kwh
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HEAT RATE (Btu/Kwh)
How much influence can we exert on Heat Rate
on a given generating Unit?
a reasonable expectation for potential heat rateimprovement under retail competition is about 8%
How can this be achieved?
Improvements in combustion/generationtechniques
improved fuel quality
targeting design operating conditions
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HEAT RATE (Btu/Kwh)
Targeting Design Operating Conditions
Prime Target: Turbine / Condenser Performance
Condenser/Turbine Back Pressure
400-800 MW Unit
Delta 0.2 HgA = ~ 0.5% Delta in Output (MW)
Result: Delta 2-4 MW in Output
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HEAT RATE (Btu/Kwh)
How do we get a 0.2 HgA improvement
in Back Pressure?
Improve the Heat Transfer Rate,
or conversely
Reduce the Heat Transfer Resistance in the
condenser tubes by reducing tube side fouling
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HEAT RATE (Btu/Kwh)
Steam Side Water Film 18%
Steam Side Fouling 8%
Tube Wall 2%
Chart accounting for
Heat Transfer Resistance
in a condenser
Water Side Fouling 33%
Water Side Film 39% 72%
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HEAT RATE (Btu/Kwh)
In terms of Tube Side Fouling or Tube Cleanliness:
Improving the tube cleanliness factor (Cf) byapprox. 15-25 % points; i.e. from ~70-75% Cf
to 90-95% Cf
can translate to a 0.15 - 0.20 HgA improvement incondenser backpressure and corresponding
improvement in heat rate.
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On-Line Mechanical Condenser Tube CleaningSystem
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On-Line Condenser Tube Cleaning Systems
On-line systems maintain condenser tube
cleanliness at a constant high level cleanliness
level between unit outages
Higher tube cleanliness levels correspond tobetter condenser performance in terms of lower
turbine backpressure, higher generating capacity
and lower fuel consumption/cost
Stainless steel tube condensers typically attainand m ainta incleanliness factors in the range of
95% in conjunction with on-line tube cleaning
systems
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How does your condenser operate - line C or D?
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On-Line Sponge Ball Cleaning & Debris Filtration Systems
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Typical Types ofCondenser Tube Fouling
Bio-Fouling
Sediment Fouling
Scaling / Mineral
Deposits
Corrosive Fouling
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TAPROGGE Makes 1800 Different Types of Sponge Cleaning Balls
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Types of Cleaning Balls
Standard Cleaning Balls, Type S
typical ball type for tube cleanliness level maintenance
typical cleaning ball of bio-fouling and mild scaling applications
suitable for all tube materials
Corundum Coated Balls, Types T and R
for more aggressive cleaning
suitable for harder tube materials such as stainless steel andtitanium
may be used continuously or intermittently for period
comprehensive cleaning
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Types of Cleaning Balls (cont)
Polishing Balls, Type P
specifically formulated for continuous circulation with stainless
steel and titanium tubes to maintain high tube cleanliness level
Specialty Balls,
High temperature balls, to 140 oC, for desalination applications
Granulate Ball - Plastic coated for aggressive anti bio-fouling
applications, stainless steel and titanium tubes
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Ball Selection, Criteria
Ball Size & Oversize
Based on Tube ID,
typically ID + 3 mm
Ball Oversize (+1, +2, +3 mm): Ball oversize is based
in available pressure drop across the tube sheets
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HOW DO YOU KNOW EVERY TUBE GETS CLEANED ?
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On-Line Sponge Ball Cleaning & Debris Filtration Systems
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TAPROGGE On-Line
Condenser Tube Cleaning
System, Type D2
Strainer Section Screens
in Operate Position
Patented Vortex Induced
Sponge Ball Extraction
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Type D2 Strainer SectionScreens in Operate Position
Type D2 Strainer Section
Screens in Backwash Position
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Ball Extraction Port
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TAC-1020
US Nuclear Station
Condenser Tube Cleaning System Installation
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Debris Filter Systems
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Inlet Tube Sheet laden with Debris
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On-Line Sponge Ball Cleaning & Debris Filtration Systems
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* >2000 Filters Delivered
* First High Performance
Filter
* Pressure Relieve Backwash
* Large Debris Removal
Capacity
* 3%-4% of CW for Flushing
* 10-20 sec. Flushing Cycle
* Compact Installation
TYPE BW800
TAPROGGE DEBRIS FILTER
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Basic Filtering Element
Configuration
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State-of-the-Art High Performance Debris Removal Capacity
The Maximum CW System Macro-Fouling Protection
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US Nuclear Power Plant Inlet Waterboxes
TAC-1022
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US Nuclear Power Plant Inlet with PRBW-800 Installation
TAC-1027
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High Performance Filtration Technology has Resulted in
the Development of the TAPROGGE IN-TA-CT Concept
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OPERATION UNDER SEVERE DEBRIS LOADING
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On-Line Sponge Ball Cleaning & Debris Filtration Systems
