Condenser Corrosion Protection and Scale Cleaning

Cooler is one of the key equipment during the production process. Statistics show that about 60% of the daily accidents rush repairs are caused by condenser tubing corrosion damage. It has serious impacts on equipments’ secure, stable and full capacity operation. In addition , when cooling water has a heat transfer with high temperature medium (most of water through tube pass), it is easy to form scale and rust layers, which increase thermal resistance, serious decline heat exchange efficiency and dissatisfy production needs. At the same time, due to the different condenser structures, materials, service conditions and cooling water quality, tube bundles, nozzles and tube plates often have corrosion and leakage problems, resulting in condensation water pollution, serious deterioration of feeding water quality, scaling and corrosion of boiler “four tubes” even blasting accidents. Condenser leakage damage will force units to limit load operation even shut down, so the condenser corrosion protection work is crucial.

Tube plate corrosion leakage impacts and solutions

Tube-type heat ex-changer production, shielded metal arc welding is used for welding the tube plates and tube nests. There are varying degrees defects in weld shape such as dents, holes, slag inclusions, as well as uneven weld stress distribution. During operation, tube plate parts usually contact with industrial cooling water which impurities, salts, gases and microbes will constitute corrosion to tube sheets and welds. Studies have shown that both fresh water and sea water have a variety of ions and dissolved oxygen. The concentration changes of chloride ions and oxygen play an important role in metal corrosion shapes. In addition, the metal structure complexity will also affect corrosion forms. Therefore, the tube plate and tube weld corrosion is mainly pitting and crevice corrosion. From the outside, there will be a lot of corrosion products and deposit sediments on the tube sheet surface with various distributions and sizes. Seawater media also will cause galvanic corrosion. " Bimetallic corrosion "is also a common phenomenon in the tube plate corrosion.


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Condenser scaling impacts and solutions

Condensing equipment plays a cold source role in turbine device’s thermodynamic cycle. Reducing the turbine exhaust gas temperature and pressure can improve the thermal cycling efficiency. Condenser’s main roles include establishing and maintaining high vacuum in steam turbine exhaust port, also feeding water to the boiler using exhaust steam condensation water; to form a complete circle. The condenser has heated exchange with circulating water to let condenser maintain high vacuum. Low vacuum will seriously affect safe operation of power station units, however, condenser cooling tube scaling is one major reason for low vacuum. Condenser scaling will affect its performance, increase terminal temperature difference, reduce vacuum, and increase exhaust temperature and influence turbine efficiency and safety.


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