PROCESS CONSIDERATIONS IN SURFACE

CONDENSER DESIGN
G.T.Polley A.Terranova A.C.P.Capel
Consultant Yuba Heat Transfer Division Yuba Heat Transfer Division
A Division of Connell Limited Partnership A Division of Connell Limited Partnership
Abstract
Condenser design engineers and process engineers need to work closely together if efficient designs are to
be made. This paper examines the importance of such interactions and outlines how it can be achieved.
Introduction
Localised power generation is important for a
number of chemical production Wlits. For
instance, over the past two/three years we have
seen at least 150 large scale stearn turbine
systems and around 300 small scale systems
ordered for use in ethylene plants worldwide.
The design of such systems is important in
terms of both process economics and
environmental impact. Design of the surface
condenser is of particular importance. The
condenser has a major influence upon the
energy efficiency of the whole system. Choose
the wrong condenser and the lifetime costs
incurred are orders of magnitude greater than
the purchase price of the unit
As with most heat exchangers, two separate
groups are involved in the specification and
design of surface condensers: the process
engineers and the equipment design engineers.
The process engineers are responsible for the
primary specification of the needs of the unit.
They make decisions regarding allowable
cooling water pressure drop. They specify the
cooling water temperature at the inlet to the
unit and either the available flowrate or the
permissible temperature rise. They specify the
allowance that should be made for fouling of
the unit (either in the form of a fouling
resistance or a cleanliness factor). They specify
what materials of construction should be used.
Finally, they specify the perfonnance
flexibility requirements of the unit
The requirements of the process engineer are
encapsulated in the 'process specification' for
the equipment. This is what the equipment
vendor receives and what forms the basis for
the subsequent equipment design. It is here
that the engineering system falls down.
Engineerin2: System Problems
The system falls down because the process
engineer has usually made decisions without
any reference to their impact upon the
equipment design. Let's look at some
examples.
Titanium is generally perceived to be an
expensive material. The process engineer
specifies what may be considered to be a more
economical alternative. The superior resistance
of titanium to both corrosion and erosion
allows for the use of very thin walled tubing.
In addition, the maximum velocity that the
cheaper material will accommodate is much
lower than that permitted with titanium. The
result of using the cheaper material can be a
larger and heavier unit and one that may be
more prone to fouling. The choice of cheaper
material may result in both a more expensive
unit and much higher life time costs.
Allowable tubeside pressure drop can have a
controlling influence upon condenser design.
Yet this is not set by the equipment designer
but by the process engineer. It is often set quite
arbitrarily. For instance, it is corrunon to find
that value in the range 0.3 to 0.5 bar has been
specified. This can be fine for a single pass
condenser operating at a stearn pressure of
O. 12 bar abs. However, a two pass unit
operating at 0.07 bar abs. would require a
pressure drop in the range 0.5 to 1.0 bar for the
unit to be truly cost effective.
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
Further problems arise when the process
engineer lacks detailed knowledge and
understanding of how condensing systems
operate. This can lead to the engineer
specifying an impossible flexibility
requirement on the design.
For instance, it is not uncommon to find that
the process engineer wants the equipment to
maintain the specified vacuum with a 5%
increase in stearn load. However, the engineer
has not indicated how much additional water
(and associated pressure drop) are available to
ensure that this can occur.
Correctly designed systems can only be
achieved if process engineers and equipment
designers work together in an effective and
efficient manner. This can be achieved if each
group has an understanding of the others task
and the means of effective interaction.
Recognising this Yuba Heat Transfer brought
together people experienced in the
development of process design technology and
condenser designers and set them the task of
developing a computer program that provided
the needs of both engineering groups. Using
this program both groups can work together to
ensure that the most cost effective designs are
achieved and that proper system flexibility is
ensured.
Poddar Plot for Surface Condensers
ShelI-and-tube exchanger design procedures
took a significant step forward with the
introduction by Tarun Poddar (2) of the design
space plot - referred to here as the Poddar
Plot.
Several constraints must be observed in the
design of shell-and-tube heat exchangers:
the tubeside velocity must be above a
minimum value
the tubeside vleocity must be below a
maximum value
the exchanger must transfer a specified
heat load
the tubeside pressure drop must be below
a maximum value
the shelIside pressure drop must be below
a maximum value
The sheIl-and-tube exchanger design space
can be considered to be two dimensional: tube
count and tube length. Each of the above
constraints can be displayed as a line within
th is design space.
Knowing the flow through the exchanger
tubes the tube count associated with the
minimum velocity is easily calculated. This
yields line AB in the design space. Acceptable
designs fall below this line.
Tube Count Max. Length
A
C
Minimum Velocity Line B
o
Tube Length
Figure 1. Poddar Plot for Shell-8j1fi-tube Heat Exchanger Design
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
The tube count associated with maximwn
velocity is calculated in a similar manner. This
yields line CD. Acceptable designs lie above
this line.
Each tube count is associated with a specific
tubeside velocity and hence, tubeside heat
transfer coefficient. It is also associated with a
fixed shell diameter. If the baffle configuration
has been set, the shellside heat transfer
coefficient can be calculated. From knowledge
of the overall coefficient the surface area
required for the thermal duty is calculated.
Since, the tube count has been set, this area
requirement can be associated with a required
tube length. The result is a line (EF) relating
the length of exchanger necessary for the
required heat transfer as a function of tube
count. Designs that transfer the necessary
amount of heat lie on this line. The region to
the right of this line contains geometries that
will transfer more than the required quantity of
heat.
Pressure drop per unit length of tube is easily
calculated from tube velocity (in the case of
tubeside pressure drop) and bWldle velocity (in
the case of shellside pressure drop). These
calculations provide lines GH and GI on the
plot. Acceptable designs lie to the left of each
of these lines.
The economical exchanger is generally the
thinnest. So, for the example shown in Figure
1 acceptable designs fall in the space EXHB
with the optimwn configuration being at point
X.
The design space concept can be readily
extended to surface condensers. The Heat
Exchanger Institute Standard (1) has, for many
years, provided the accepted design procedure
for surface condensers. This standard provides
clean Overall Heat Transfer Coefficients as a
function of tube velocity with corrections
being applied for tube material and cooling
water inlet temperature. Values are given over
the velocity range 3 to 12 ft/s. Given an
existing fonnulation in tenns of velocity, the
easiest way of extending the design space
concept to surface condensers is to work in a
design space defined by velocity and tube
length (rather than tube count and tube length).
For the individual velocity points in the HEI
Tables the clean O.H.T.C. is detennined. Tube
material and water temperature corrections are
then applied. The duty O.H.T.C. is obtained by
multiplying this clean value by the specified
cleanliness factor (or, if a fouling resistance
approach is required, by incorporating a
specified value in the nonnal way). The tube
length required to achieve the specified
thennal duty is then calculated. The result is a
line moving upwards from left to right on the
plot. In order to obtain an appreciation of the
influence of the specification of the cleanliness
factor on the design we produce contours
around this line for differing values of
cleanliness factor (from 1.0 down to 0.7).
Designs which just transfer the required
quantity of heat (at the specified cleanliness
factor) lie on the solid line. Those which
transfer more than this quantity lie to the right
of the line.
The maximwn allowable velocity is a function
of specified tube material. The Yuba program
identifies this maximum and produces a
horizontal line on the plot. Acceptable designs
lie below this line.
Tubeside pressure drop infonnation derived
from the HEI method can be incorporated in
the plot in the manner developed for shell-and
tube heat exchangers. The result would be a
curve moving downwards as we move from
left to right. Designs which have a tubeside
pressure drop less than the maximwn
allowable value lie below and to the to the left
of this line. The influence of specified pressure
drop on design is highlighted by placing
contours to the right hand side of solid line.
These contours represent 10% increments on
the specified maximwn.
Moving from Design Space to Design.
The HEI method provides design information
as a function of tube velocity. This information
is provided at 0.5 ft/s velocity intervals
between a bottom bound of 3 ft/s and an upper
bound of 12 ft/s. For velocity values falling
between these intervals linear interpolation is
used.
All of the design infonnation is incorporated
into the lines on the parameter plot. Therefore,
all that is required to finalise the thenno
hydraulic design is the specification of tube
length and tube velocity.
32
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
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igure 2. Poddar Plot for Surface Condenser
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
Knowing the two parameters the data used to
derive the plot can be examined and the design
completed.
Designs can be controlled by the tube velocity
constraint or by the tube pressure drop
constraint. If the velocity line is positioned
below the pressure drop line the design is
controlled by the velocity.The optimum design
generally occurs at the intersection of the
thermal duty line with the controlling
constraint line. The Yuba Steam Surface
Condenser program provides the designer with
the option of automatically identifYing and
generating a design at this point
However, there are cases in which the designer
may wish to introduce other considerations
into the design. There may be a space
limitation to be considered or tubes of a
specific length are most readily available. The
engineer is therefore given the option of
deriving a design for any point in the design
space.
A third option is provided. 'That is a rating
option. When considering the flexibility of a
unit the performance of a specific geometry
under varying conditions has to be examined.
Consequently, the engineer is also allowed to
specify a full geometry at this stage.
Whichever of the above options is adopted the
engineer can produce a design very rapidly for
only two or three parameters need to be
specified.
Most importantly, by incorporating budget cost
estimations and a general arrangement drawing
package in the program, it is possible to
generate a 'relative cost' and setting plan as
well as a detailed design.
Changing the Design Space.
The Poddar Plot clearly ilIustreates how the
process constrainls (cleanliness factor,
allowable pressure drop and tube material
limitations) influence the design. The engineer
can change the design space by changing these
constrainls. The lines clearly show the
direction in which changes should be made.
For instance, if the design is being controlled
by the velocity through the exchanger tubes,
the engineer can consider changing the tube
material.
However, some of the decisions made by the
designer also influence the design space. The
space is a function of tube size and number of
tube passes. The influence of these parameters
on the design space must also be explored.
The Yuba program uses 'radio buttons' to
specify tube material, tube size and number of
tube passes. These specifications can therefore
be changed very quickly and the new design
space generated rapidly. Given the ease with
which the design space can be examined and
manipulated and the ease with which the
designer can move backwards and forwards
between design space and design the process
engineers and condenser designer can work
together to rapidly identify the optimum
design.
Condenser Behaviour
Equipment design is generally conducted
against a process specification which lists
cooling water inlet temperature, stearn
flowrate, cleanliness factor etc. Design is then
conducted with the aim of condensing the
required steam flow whilst achieving a
specified vacuum. The stearn flow and the
vacuum drawn control the power generation of
the turbine.
Whilst design is conducted for a specified
power system operating condition the actual
plant will rarely operate at this condition. The
cooling water inlet temperature will be subject
to seasonal variations. The condenser could be
subject to fouling. In which case the level of
fouling could vary with time of operation or, in
the case of biological fouling, could also show
seasonal variations. The demands made for
power will vary. Consequently, the flow of
stearn to the condenser will be subject to some
variation.
Changes in fouling resistance, cooling water
temperature, stearn flow etc. all affect the
performance of the condenser. Once a
condenser has been constructed the engineer
can do little about the installed surface area.
Once, the cooling water pumps have been
purchased and installed the designer is
restricted in what can be done regarding
cooling water flow.
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
Condenser perfonnance can, on occasions be
improved through the use of tube inserts to
augment turbulence (3), but under perfonnance
is often a difficult problem to solve. It is a
problem that leads to large life time cost
penalties. Therefore, the affect of changed
operating conditions upon condenser
perfonnance must be considered at the design
stage.
'Condenser Response Curves' can be
generated by simulating condenser conditions.
An example of such a curve derived using
Yuba's program is shown in Figure 3. This
curve shows the relationship of steam flowrate
(an alternative representation uses heat load)
and condenser pressure. It gives the engineer a
clear insight into the behaviour of the power
system.
Feed more steam to the turbine and the
pressure in the condenser increases - the
power generation per unit flow of steam falls.
Rather than provide just a single curve,
relating to the specified cooling water
temperature and flow, a family of curves is
provided. Each of the 'dotted' curves relates to
a different cooling water temperature. The
curves above the main line are at higher inlet
temperatures (the temperature interval between
the curves being SF). The ones below the main
curve are at lower inlet temperatures. From
these curves the engineer can quickly see how
the system behaviour will vary with seasonal
changes.
Evaluating Flexibility Needs.
The principle use of the 'condenser response
curves' comes in the evaluation of system
flexibility needs and determining how these
are to be satisfied through good design. Let's
consider some examples.
There is a seasonal variation for power
demand. The process engineer wants to be able
to cope with a S% increase in demand during
winter months.
The power generation is controlled by two
factors: the steam flowrate and the pressure
differential across the turbine. The pressure
differential is fixed by feed pressure and tile
vacuum developed in the surface condenser.
The engineer examines whether or not a
proposed design is suitable by examining the
condenser response curve generated for the
winter cooling water inlet temperature. By
feeding the information from this curve into
the steam turbine performance model, power
generation under winter conditions can quickly
be established.
Let's assume that the system under performs
for the additional power needs in winter
conditions - despite the additional vacuum
developed as a result of using water at a lower
temperature. The engineers are then left with
two alternatives: the winter conditions are
recognised as providing the critical design
point and the condenser is redesigned (the
result being a larger more expensive unit); or,
means of improving the heat transfer within
the condenser are examined. The easiest means
of improve the heat transfer is to increase the
water throughput. If the unit is tube velocity
limited this may require a change in tube
material. Otherwise, it will mean a relaxation
in the pressure drop constraint (Le. an increase
in allowable pressure drop) and changes to the
cooling water pump specifications.
Given the ease with which the results of the
Yuba program can be interpreted and the speed
at which designs can be produced and
evaluated, the process engineer can work with
the designer to resolve the flexibility problem.
Let's now consider another type of flexibility
problem: the fouling problem. Fouling results
in the deterioration of heat transfer within the
condenser. The results are increased pressure
and subsequent fall off in power generation by
the turbine. By generating condenser response
curves over a range of fouling resistances and
cleanliness factors the effects of fouling on
condenser pressure can be established. If the
fouling behaviour is known this information
can be converted into a fouling cost analysis.
(Where the fouling behaviour is unknown an
alternative is to set up a number of fouling
'what if' scenarios.).
This cost analysis can then be used to evaluate
the potential cost benefits offouling mitigation
methods (e.g. water addatives, the installation
of Taprogge systems etc.). Such an analysis
would also consider the benefits of deliberate
over surfacing of the condenser.
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999
The cost of the over surface would be partially
recouped through increased power system
efficiency whilst the Unit was clean and
reduced plant downtime required for cleaning
purposes.
A sensible cost analysis would also include a
consideration of condenser cleaning strategy.
The dual waterbox design allows the operator
to shut-off part of the condenser (for cleaning
purposes) whilst maintaining system operation
with using the remainder of the bundle.
Flexibility problems come in many fonns. The
Yuba program has been developed as a tool for
use in the solution of such problems. Howver,
the effective solution of such problems also
requires a change in 'mind set'. Our
universities train engineers, both process
engineers and equipment designers, to solve
'close ended' design problems: design a unit to
perfonn at a fixed point
Our industrial structures re-enforce this
approach: the customer provides a
specification sheet the vendor offers a design.
The equipment rarely, if ever, operates at the
specified design point TItis should be
recognised. To obtain the best designs the
flexibility of the equipment must be
considered.
Equipment should be designed to operate over
a range of conditions and the cost benefits of
different designs evaluated.
Summary and Conclusions.
An inter-disciplinary approach is necessary if
the most cost effective and energy efficient
surface condenser designs are to be achieved.
Equipment users and designers must work
together. TItis can only be achieved through
the effective use of information technology.
Recognising this Yuba brought together
experienced process engineers, design
engineers and software specialists to produce a
program that allowed each engineering
discipline to understand the work of the other.
TItis program incorporates accepted
technology and allows the rapid design of
surface condenser to established industrial
standards.
The program is already bearing fruit and is
radically changing the way in which an
equipment supplier works and interacts with its
customers.
References.
1. Heat Exchanger Institute, Standards for
Steam Surface Condensers, 9
th
ed. (1995)
2. Poddar T.K. & Polley G.T. Heat
Exchanger Design Through Parameter
Plotting, Trans.I.Chem.E. 74A,849-852
(1996)
3. ESDU Item 97007 (1998), Heat transfer
enhancement in heat exchanger design and
utilisation, ESDU International, 27
Corsharn St London
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Proceedings from the Twenty-first National Industrial Energy Technology Conference, Houston, TX, May 12-13, 1999