-: PRESENTED BY :-

SANKET CHAUDHARI (096380319510)

ARGHYA GOSWAMI (096380319523)

PARUL INSTITUTE OF ENGINEERING & TECHNOLOGY (DS) 2ND SHIFTLIMDA, DIST. VADODARA.

YEAR: 2011-12

INTERNAL EPOXY COATING

IN SURFACE CONDENSER

INTRODUCTION

DEFINITION :-

Steam condenser is an appliance in which the steam exhausted

from a steam engine is condensed. Condenser is installed such

that the exhaust steam from a Steam Engine is delivered into it.

In the condenser, the heat is removed from the exhausted

steam in form of latent heat by means of cooling water which

absorbs this latent heat. The exhaust steam after losing its

latent heat changes its state into water, which is termed as

Condensate and this process, is called as condensation.

INTRODUCTION

INTRODUCTION

Elements of Condensing Plants :- Condenser where steam is condensed,

Hot well in which the condensate is collected.

Pump for circulating Cooling Water, supply of Circulating Cooling

Water,

Air pump (or ejector) to remove air and non-condensing gases from the

condenser

Condensate Pump (extraction pump) to remove Condensate from the

condenser,

Feed Pump for supplying feed water from De aerator to the boiler.

INTRODUCTION

INTRODUCTION

FUNCTIONS :- Reduce the back pressure of steam primemovers.

Increases the expansion ratio of steam hence thermal

efficiency .

Decreases the temperature of the exhaust steam & increases

power output.

Supply of clean & soft water to the boiler.

It stores water, hence additional storage space is not required.

Because of higher temperature of feed water thermal stresses

are reduced.

PROBLEM IDENTIFICATION

1. Corrosion

2. High Condenser Back Pressure

3. Tube fouling

4. Low Cleanliness Factor

5. Low Heat Transfer

6. Air In-Leakage

7. Dissolved Gases (Oxygen, Carbon Dioxide, Ammonia, etc.)

8. Low Pump/Exhaust Capacity

9. Other Efficiency/Maintenance/Design/Operations Concerns

EXPECTED OUTCOME

Condenser fouling is a major economic problem, and

maintenance costs are estimated to account for 0.25% of

the world GDP (Gross domestic product). To remain

competitive and reduce energy costs power plant operators

must pay attention to the small details involved in the

proper maintenance of tubular systems in condensers, heat

exchangers and other heat transfer equipment to realize

significant savings. By utilizing the best available

technology reliability, and energy efficiency gains can be

realized.

EXPECTED OUTCOME

Another method to cut plant and equipment downtime,

recover energy efficiency, and achieve fewer stoppages for

routine maintenance is by using thin film polymer coatings

applied to full length tube IDs. This process is low cost

procedure to solve condenser tube fouling and corrosion

problems.

When a thin layer of epoxy is applied in the inner wall of shell

and tubes, tube sheet and water box, the effect of corrosion

and erosion is almost eliminated. Hence the service life

increases and efficiency is also maintained.

EXPECTED OUTCOME

Polymer tube linings have always suffered from an initial

perception of heat transfer penalties due to their lower

thermal conductivities but quantitative data and strong long

term case history has demonstrated just the opposite.

Decades of service history have shown that tube coatings can

enhance heat transfer and overall performance to a

significant degree. While the thermal conductivity of the

coating is much less than the parent tube, this factor is

mitigated by inherent properties of the coating. The impact to

overall thermal conductivity is nil or minor.

EXPECTED OUTCOME

21 mm brass tube x 2.3

mm wall - conditions

Thermal conductivity

W/ m K

1. Average scaled - < 0.150 mm14.9

2. 100% solids – applied at 75

microns average2.737

3. Epoxy phenolic – applied at 75

microns average8.82

4. Epoxy phenolic – proprietary

pigment loading14.764

EXPECTED OUTCOME

ADVANTAGES By this method service life of condenser increases &

efficiency is maintained.

It reduces downtime & maintenance cost upto 50% compared

to retubing.

Feed water process cost also reduces.

DISADVANTAGE Efficiency may be reduced by 0.5 % to 0.7 % which can be

considered as negligible.

CONCLUSION

As this method reduces the maintenance cost it direct affects

the energy production cost, gives strong support to the power

plant operators to remain in this competitive market & helps

to get out from the energy crisis.

Thus by application of epoxy coating in some parts of

condenser the major problems can be minimized like,

Corrosion,

Tube fouling,

Low cleanliness,

Chocking of tubes etc.