What the plant's own readings say about the condenser today. Representative values; a modelled unit replaces them.
Cleanliness factorwarning
0.78design 0.92 · trigger 0.82
Back pressurewarning
3.06 inHgAexpected 2.50 at design cleanliness
Tubes pluggedwarning
6.0 %1,200 of 20,000 · 150 a year
Excess back pressure1
0.14 inHg
Heat-rate impact2
0.21 %
Extra fuel3
9.6 MMBtu/hr
Cost4
$22 /hr
Fuel penalty5
$161,000 /yr
Services AES can perform
Tick a service to see what it restores. Each effect is a range, low to high; the result shows both ends. Representative until the unit is modelled.
Cleanliness after0.78
Back pressure after3.06 inHgA
Recovered$0 /yr
Retubing
Retubing is in the scope. This is what the plugged tubes cost the unit today, and what each tube material and gauge gives back over its life, not only at the quote. Representative tube data; the bundle drawings and the plant's water chemistry replace it.
Plugged tubes today
Tubes plugged
1,200 of 20,000 · 6.0 %
Heat transfer lost1
6.0 %
Back pressure added2
0.06 inHg
Fuel penalty from plugging
$70,000 /yr
Retube
Tube options
Pick the tube to propose. Heat transfer is the tube wall against the installed tube; a thinner wall or a more conductive metal moves more heat, and a longer-lived tube spreads its price over more years.
Tube
Heat transfer3
Back pressure, clean
Fuel vs installed
Retube price4
Tube life
Price + fuel over life
Per year of life
heat transfer in proportion to the tubes left in service; plugged tubes carry no cooling water, and the model holds the water flow through the rest unchanged
the back pressure at today's cleanliness with the plugged share, against the same cleanliness with none plugged
wall resistance = 1 / water film + wall thickness / conductivity + 1 / steam film, with film coefficients 1,500 and 2,000 Btu/hr·ft²·°F; shown against the installed tube. HEI's correction factors replace it
tubes × a representative price per tube at the gauge, plus labor and outage work; tube life is representative for the material and depends on the plant's water chemistry
Result and proposal
With the selected services the unit returns to 0.88 and recovers about $560,000 a year.
As read
After service
Delta
Price against value
The last cycleCleanliness from the last cleaning to today, and on as readValue recoupedCumulative from service, against the unit left as readAfter a cleaning: the same cycle against the serviced unitMonths after a cleaning · where each curve meets the trigger is its service life
with Efficiency Signal
Condenser service proposalExample Station · Unit 2
The unit as read
Services proposed
Service
What it does
What changes
As read
After service
Delta
Price against value
Retubing options
Tube
Heat transfer
Back pressure, clean
Fuel vs installed
Retube price
Tube life
Price + fuel over life
Per year of life
After a cleaning: same cycle against the serviced unit
Value recouped
Basis
Representative figures for discussion. The value chain is the one Efficiency Signal runs on a modelled unit (excess back pressure → heat-rate impact → extra fuel → cost); the sensitivity, service effects, tube data and prices here are placeholders until this unit's own specifications and readings are in. Dollar figures are internal until proven on the unit.
with Efficiency Signal