COURSE OVERVIEW:

The steam condenser is a critical heat exchanger in the power generation cycle, acting as the heat sink that allows for maximum energy extraction from the steam turbine. This course provides a detailed exploration of the thermal and mechanical principles governing surface condensers and their associated circulating water systems. Participants will examine how the maintenance of a high vacuum is essential for plant efficiency and how the condenser interface directly impacts the heat rate of the entire facility.

The scope of this training includes the mechanics of heat transfer across condenser tubes, the role of air extraction systems, and the dynamics of large-scale circulating water pumps. We will analyze the various factors that degrade condenser performance, such as tube fouling, air ingress, and cooling water temperature fluctuations. The course provides a technical roadmap for monitoring the "cleanliness factor" and "terminal temperature difference" to quantify efficiency losses in real-time.

Coverage extends to advanced troubleshooting of the circulating water circuit, including intake structures, debris filters, and cooling tower integration. Attendees will learn how to diagnose vacuum leaks, manage macro-fouling from biological sources, and implement effective tube cleaning strategies. By the end of this course, participants will be equipped with the expertise to optimize condenser performance and resolve the complex issues that limit the output of steam power plants.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the role of the condenser in the Rankine cycle.
2. Identify the major components of surface condensers and air ejectors.
3. Calculate condenser backpressure and its impact on turbine heat rate.
4. Describe the principles of heat transfer and the effect of fouling.
5. Monitor and interpret the Condenser Terminal Temperature Difference (TTD).
6. Execute effective vacuum leak detection using helium or ultrasonic tools.
7. Manage the operation of circulating water pumps and intake screens.
8. Understand the impact of non-condensable gases on vacuum stability.
9. Evaluate the performance of steam jet air ejectors and vacuum pumps.
10. Identify the causes and effects of tube vibration and erosion.
11. Implement chemical and mechanical tube cleaning programs.
12. Diagnose hydraulic issues in the circulating water piping and tunnels.
13. Develop a performance-based maintenance schedule for the heat rejection system.

TARGET AUDIENCE:

Power Plant Operators, Performance Engineers, Maintenance Technicians, and Mechanical Supervisors are involved in steam cycle management.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.