HEAT EXCHANGE INSTITUTE, INC. STANDARDS for STEAM SURFACE CONDENSERS ELEVENTH EDITION Copyright October 2012 by Heat Exchange Institute 1300 Sumner Avenue Cleveland, Ohio 44115-2851 Reproduction of any portion of this standard without written permission of the Heat Exchange Institute is strictly forbidden. i
CONTENTS Page 1.0 NOMENCLATURE 1 2.0 DEFINITIONS 3 2.1 Absolute Pressure 3 2.2 Circulating Water Velocity 3 2.3 Cleanliness Factor 3 2.4 Condensate Temperature Depression (Subcooling) 3 2.5 Condenser Duty 3 2.6 Condenser Heat Transfer Coefficient 3 2.7 Condenser Pressure 3 2.8 Condensing Steam Temperature 3 2.9 Effective Surface 3 2.10 Effective Tube Length 3 2.11 Hotwell Capacity 3 2.12 Initial Temperature Difference 3 2.13 Logarithmic Mean Temperature Difference 3 2.14 Static Pressure 3 2.15 Temperature Rise 3 2.16 Terminal Temperature Difference 3 3.0 SYMBOLS AND UNITS 4-5 4.0 CONDENSER PERFORMANCE 6 4.1 General Considerations 6 4.2 Heat Transfer Rates 6 4.3 Oxygen Content of Condensate 13 4.4 Performance Curves 15 4.5 Hydraulic Loss-Circulating Water Pressure Loss 15 4.6 Condensate Temperature Depression 18 4.7 Geothermal Applications 25 5.0 SERVICE CONNECTIONS 26 5.1 General Considerations 26 5.2 Flow Data 26 5.3 Connection Locations 26 5.4 Connection Design Guidelines 27 5.5 Turbine Bypass Guidelines 28 6.0 VENTING EQUIPMENT CAPACITIES 29 6.1 Venting Requirements 29 6.2 Design Suction Pressure 29 6.3 Design Suction Temperature 29 6.4 Calculation of Water Vapor Load Component 29 6.5 Minimum Recommended Capacities 29 6.6 Rapid Evacuation Equipment 30 7.0 ATMOSPHERIC RELIEF DEVICES 35 7.1 General 35 7.2 Atmospheric Relief Valves 35 7.3 Rupture Devices 35 8.0 CONSTRUCTION 36 8.1 General 36 8.1.1 Design Philosophy 36 8.1.2 Materials of Construction 36 8.1.3 Design Pressures 36 8.1.4 Hydrostatic Testing 36 8.1.5 Corrosion Allowances 37 8.2 Design And Construction Methods 38 8.2.1 Design Factors of Safety 38 8.2.2 Design By More Exact Analyses and By Empirical Formula and Testing 38 8.2.3 Shell Design 38 8.2.4 Support Plate Design Guidelines 40 8.2.5 Water Box Thickness Design Guidelines 44 iii
8.2.6 Design Procedures For Flanges and Bolting 46 8.2.7 Tubesheet Design Guidelines 46 8.2.8 Condenser Tube Ends 50 8.2.9 Tubesheet and Support Plate Hole Criteria 50 8.3 Welding 52 8.4 Lagging for Extraction Lines and Feedwater Heaters 52 8.5 Fabrication for Geothermal Service 54 8.6 Condenser Support Systems 55 9.0 INSPECTION, QUALITY, TRANSPORTATION, AND FIELD INSTALLATION 56 9.1 Inspection and Quality of Welding Standards 56 9.2 Surface Preparation Requirements 56 9.3 Painting, Coating, Linings, and Corrosion Protection 60 9.4 Quality Assurance 60 9.5 Dimensional Tolerances 61 9.6 Shipping and Site Storage 61 9.7 Field Installation 61 9.8 Erection Superintendent Duties 62 9.9 Post Erection Walk Down 62 APPENDICES APPENDIX A Typical Specification for Steam Surface Condensers 66 APPENDIX B Metric Conversion Factors 71 APPENDIX C Areas of Circular Segments 75 APPENDIX D Procedure for Calculating Allowable Nozzle External Forces and Moments in Cylindrical Vessels 76 APPENDIX E Air and Water Vapor Mixture Data (Dalton s Law) 81 APPENDIX F Mechanical Characteristics of Tubing 83 APPENDIX G Troubleshooting Guide 87 APPENDIX H HEI Surface Condenser Data Sheet 91 APPENDIX I Condenser Tubes Stress Values 92 APPENDIX J Condenser Material Stress Values 93 APPENDIX K Tubes Material Properties 94 APPENDIX L Condenser Performance 95 TABLES TABLE 1 Uncorrected Heat Transfer Coefficients U 1 7 TABLE 2 Inlet Water Temperature Correction Factor F W 9 TABLE 3 Tube Material and Gauge Correction Factors F M 11 TABLE 4 Venting Capacity and Oxygen Content 13 TABLE 5 Gauge Correction Factor for Friction Loss R 2 18 TABLE 6 Rapid Evacuation Equipment Dry Air Capacities 31 TABLE 6A Venting Equipment Capacities: One Condenser Shell 32 TABLE 6B Venting Equipment Capacities: Two Condenser Shells 33 TABLE 6C Venting Equipment Capacities: Three Condenser Shells 34 TABLE 7 Atmospheric Relief Valve Sizes 35 TABLE 8 Typical Materials of Construction 37 TABLE 9 Correction Factor K 1 TABLE 10 Correction Factor K 2 TABLE 11 Correction Factor K 3 TABLE 12 Support Plate Hole Size Limits 50 TABLE 13 Tubesheet Hole Size Limits 50 TABLE 14 Weld Acceptance Criteria 58 TABLE 15 Condenser Surface Preparation Requirements 63 FIGURES CONTENTS (continued) FIGURE 1 Uncorrected Heat Transfer Cofficeints U 1 8 FIGURE 2 Inlet Water Temperature Correction Factor F W 10 FIGURE 3 Absolute Pressure Limit Curves for Oxygen Content 14 FIGURE 4 Sample Performance Curve 15 FIGURE 5 Absolute Pressure Limit Curves 16 FIGURE 6 Friction Loss for Water Flowing in 18 BWG Tubes R T 19 FIGURE 7 Temperature Correction for Friction Loss in Tubes R 1 20 FIGURE 8 Water Box and Tube End Losses Single Pass Condensers R E 21 iv
CONTENTS (continued) FIGURE 9 Water Box and Tube End Losses Two Pass Condensers R E 22 FIGURE 10 Water Box and Tube End Losses Three Pass Condensers R E 23 FIGURE 11 Water Box and Tube End Losses Four Pass Condensers R E 24 FIGURE 12-13 Point Support Pipe 38 FIGURE 14 Point Support Double Clips 39 FIGURE 15 Point Support Single Clips 39 FIGURE 16 Ribs 39 FIGURE 17 Design Nozzle Loading on Flat Plate 39 FIGURE 18 Spacing of Longitudinal Stiffeners 40 FIGURE 19 Cylindrical Condenser Shell Thickness 41 FIGURE 20 Stiffening Rings Required Moment of Inertia 42 FIGURE 21 Determination of L U 43 FIGURE 22 Rib Supported Panels 44 FIGURE 23-24 Bolting of Flat Faced Flanges 46 FIGURE 25 Gasket Seating Pressure 46 FIGURE 26-28 Required Flange Thickness 46 FIGURE 29 Idealized Representation of Tubesheet Loading 50 FIGURE 30 Tubesheet Showing Beam-Strip Locations 51 FIGURE 31 Beam-Strip for a Tube Pattern of Triangular Pitch 51 FIGURE 32 Beam-Strip for a Laned Tube Pattern of Triangular Pitch 51 FIGURE 33 Section AA through Beam-Strip of Figure 32 51 FIGURE 34 Structural Model for Beam-Strip of Figure 33 51 FIGURE 35 Moment and Deflection Curves for Beam-Strip of Figure 32 51 FIGURE 36-42 Typical Condenser Welds 52 FIGURE 43 Weld Geometries 53 FIGURE 44 Welding Nomenclature 57 FIGURE 45 Standard Tolerances for Interfaces and Supports English Units 64 FIGURE 45M Standard Tolerances for Interfaces and Supports Metric Units 65 v
HEAT EXCHANGE INSTITUTE, INC. Addendum 1 STANDARDS for STEAM SURFACE CONDENSERS Copyright August 2014 by Heat Exchange Institute 1300 Sumner Avenue Cleveland, Ohio 44115-2851 Reproduction of any portion of this addendum without written permission of the Heat Exchange Institute is strictly forbidden. i