Unit 22 Condensers

BY DEBAPRATIM DEBNATH M.
TECH (TPE)
contents
purpose of condensers water-cooled and air-cooled condensers types of water-cooled condensers operating differences between wastewater and recirculating water systems operation and function of a cooling tower methods that facilitate low ambient system operation
THE CONDENSER
Heat exchange surface that rejects system heat Rejects sensible heat
Desuperheating vapor refrigerant from the compressor Subcools refrigerant at the outlet of the condenser
Rejects latent heat during the condensing process The greatest amount of heat is transferred during the change of state Condenser is on the high pressure side of the system
WATER-COOLED CONDENSERS
More efficient than air-cooled condensers Water temperature can be maintained Water temperature directly affects system pressures Three types of water-cooled condensers
Tube within a tube condenser Shell and coil condenser Shell and tube condenser
TUBE WITHIN A TUBE CONDENSER

Heat exchange takes place between the fluids in the inner and outer tubes Refrigerant flows in the outer tube Water flows in the inner tube Refrigerant and water flow in opposite directions to maximize the heat transfer rate Depending on the construction, the condenser can be cleaned mechanically or chemically
Water to tower (95F) Cool water from the cooling tower 85F Water
Hot discharge gas from the compressor Subcooled liquid to the receiver
Cross-Section of a tube within a tube condenser
Surrounding air
Hot discharge gas from compressor (outer tube)
Water from tower (inner tube)
Discharge gas transfers heat to both the surrounding air and the water in the inner tube
110F 85F WATER TUBES 95F Discharge gas 200F
85F
90F
MECHANICALLY CLEANABLE CONDENSERS

Tube within a tube condenser has end flanges Flanges are removed to access the water circuit The mechanically cleanable tube-intube condenser is more costly than the chemically cleanable version of the condenser
MECHANICALLY CLEANABLE TUBE WITHIN A TUBE CONDENSER
Water connections
MECHANICALLY CLEANABLE TUBE WITHIN A TUBE CONDENSER
Access to interior of water tubes
SHELL AND COIL CONDENSERS

Coil of tubing enclosed in a welded shell Water flows through the coil Cooling Water from the compressor is discharged into the shell The shell also acts as the receiver When steam comes in contact with the cool coil, it condenses and falls to the bottom
This condenser must be cleaned chemically
Shell and Coil Condenser

Shell Water coil Hot discharge gas from turbine Droplets of condensed steam Cool water in
Warm water out
Bottom of shell acts as a receiver
Subcooled liquid from condenser
turbine discharge gas is piped into the shell Water flows through the tubes in the condenser The ends of the shell are removed for cleaning The shell acts as a receiver Cooling water circuit is not disturbed when the ends of the shell (water boxes) are opened
SHEL AND TUBE CONDENSERS Can be cleaned mechanically
Shell Warm water out
Water Tubes
Hot discharge gas from turbine
Cool water in Bottom of the condenser acts as the receiver Subcooled liquid from condenser
Hot discharge gas from turbine Water out
Water in Subcooled liquid from condenser
RECIRCULATED WATER SYSTEMS

The water flowing through the condenser is pumped to a remote location, cooled and reused Design water temperature is 85F The water leaving the condenser is about 95F There is a 10 degree split across the water circuit
EVAPORATIVE CONDENSERS
Designed to operate full of liquid A latent heat transfer takes place throughout the coil Coil efficiency is maximized Other devices must be used to prevent liquid from entering the turbine Normally use a float-type metering device to keep the liquid level in the coil high
AIR-COOLED CONDENSERS
Uses air to absorb heat rejected by the system Used in locations where water is difficult to use Horizontal, vertical, or side intake and top discharge Hot gas enters the condenser from the top For standard efficiency systems, the cooling water will condense at a
HIGH-EFFICIENCY CONDENSERS
Have larger surface areas than standard condensers Allow systems to operate at lower pressures Allow systems to operate more efficiently Can operate with head pressures as low as 10F higher than the outside ambient temperature
THE CONDENSER AND LOW-AMBIENT CONTROLS Condensing temperatures drop when the outside ambient temperature drops The condensing pressure must be at least 75 psig higher than the evaporator pressure in order for the metering device to operate properly Low ambient controls
Designed to maintain the desired head pressure Needed on systems that operate year-round
HEAD PRESSURE CONTROL FAN CYCLING DEVICES
Used on air-cooled condensers As the head pressure drops, the fan cycles off As the head pressure rises, the fan cycles on Some condensers have more than one fan
Some fans remain on all the time Others cycle on and off to maintain proper pressure
HEAD PRESSURE CONTROL VARIABLE SPEED MOTORS
Motor speed changes to maintain head pressure As the head pressure drops, the fan slows down As the head pressure rises, the fan speeds up Can utilize variable frequency drives (VFD) Maintains a more constant head pressure Can be controlled by pressure or
HEAD PRESSURE CONTROL AIR SHUTTERS OR DAMPERS

Located at the inlet or outlet of the condenser Opens and closes by a pressurecontrolled piston Controls airflow through the condenser coil As ambient temperature drops, the dampers close to reduce the amount of airflow through the coil As ambient temperature rises, the
conclusion
The condenser is the system component responsible for rejecting system heat Condensers reject both latent and sensible heat Water-cooled condensers are more efficient than air-cooled condensers Three types of water-cooled condensers are the tube within a tube, shell and coil, and the shell and tube Mineral deposits in the water circuit reduce the heat transfer rate between the water and the refrigerant
Evaporative condensers use a combination of water and air to achieve the condensing process High efficiency condensers operate with lower head pressures than standard efficiency condensers

Unit 22 Condensers

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BY DEBAPRATIM DEBNATH M.

TUBE WITHIN A TUBE CONDENSER

Cross-Section of a tube within a tube condenser

Hot discharge gas from compressor (outer tube)

Water from tower (inner tube)

110F 85F WATER TUBES 95F Discharge gas 200F

MECHANICALLY CLEANABLE CONDENSERS

MECHANICALLY CLEANABLE TUBE WITHIN A TUBE CONDENSER

MECHANICALLY CLEANABLE TUBE WITHIN A TUBE CONDENSER

Access to interior of water tubes

SHELL AND COIL CONDENSERS

This condenser must be cleaned chemically

Shell and Coil Condenser

Warm water out

Bottom of shell acts as a receiver

Subcooled liquid from condenser

SHEL AND TUBE CONDENSERS Can be cleaned mechanically

Shell Warm water out

Hot discharge gas from turbine

Hot discharge gas from turbine Water out

Water in Subcooled liquid from condenser

RECIRCULATED WATER SYSTEMS

HEAD PRESSURE CONTROL FAN CYCLING DEVICES

HEAD PRESSURE CONTROL VARIABLE SPEED MOTORS

HEAD PRESSURE CONTROL AIR SHUTTERS OR DAMPERS

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