Impact of Tube Plugging on Condenser Efficiency and Retubing Strategy in a 600 MW Steam Power Plant

Deni Budi  Utomo; Sri Widodo Agung  Suedy; Marcelinus  Christwardana; Jaka  Windarta; Muchammad

doi:10.54783/ijsoc.v8i3.1337

Deni Budi Utomo Universitas Diponegoro, Semarang, Indonesia
Sri Widodo Agung Suedy Universitas Diponegoro, Semarang, Indonesia
Marcelinus Christwardana Universitas Diponegoro, Semarang, Indonesia
Jaka Windarta Universitas Diponegoro, Semarang, Indonesia
Muchammad Universitas Diponegoro, Semarang, Indonesia

DOI: https://doi.org/10.54783/ijsoc.v8i3.1337

Keywords: Steam Power Plants, Condenser, Plugging Tube, Retubing.

Abstract

This study aims to evaluate the effect of condenser tube plugging on the thermal performance of a 600 MW steam power plant and to determine the technical and economic feasibility of condenser retubing using Cost-Benefit Analysis (CBA) and Net Present Value (NPV) as decision-making approaches. This study was conducted using operational and maintenance data from the 2021 overhaul of Unit 7 at the Suralaya Power Plant Units 5–7, employing a quantitative approach to evaluate the impact of condenser tube plugging on condenser performance. The analysis included the calculation of technical parameters, such as condenser effectiveness, pressure drop, heat transfer rate, Fouling Factor (Rf), and thermal efficiency loss, together with economic evaluation using Cost-Benefit Analysis (CBA) and Net Present Value (NPV) to assess the feasibility of condenser retubing. The results showed that increasing the plugging level significantly degraded condenser performance, as indicated by an increase in condenser pressure from 10.999 kPa to 13.448–13.533 kPa at 30% plugging, accompanied by reductions in the overall heat transfer coefficient (U), effectiveness, and Number of Transfer Units (NTU), which consequently reduced heat transfer capability and overall plant efficiency. The condenser operated optimally at plugging levels of 0–10%, while 20% represented a warning threshold and 30% indicated a critical condition, suggesting that retubing should be performed before plugging reaches 20–30% to minimize performance degradation and maintain Rankine cycle efficiency. The economic evaluation further demonstrated that retubing is financially feasible when it produces a positive Net Present Value (NPV) and a Cost-Benefit Ratio (CBR) greater than one. Therefore, implementing retubing under high plugging conditions can effectively restore condenser performance, reduce fuel consumption, improve power generation efficiency, and provide long-term economic benefits.

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