KNOWLEDGE MANAGEMENT SERIES:

LOW VACUUM IN STEAM TURBINE

1. INTRODUCTION 2.1.1. Action
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to be

Taken

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O&M Engineers

Improvement in Power Plants operating performance is the continuing goal of Electricity generating companies to achieve lowest cost of generation. Survey of Indian Thermal Power Stations revealed that Low Vacuum is one of the major reason for poor heat rate of the machine. Maintaining the design vacuum in the condenser is, therefore, vital for achieving an optimum heat rate/ efficiency in a Thermal Power Plant. If existing Indian Thermal Power Stations run with designed vacuum, not only results in saving of money for power generation companies but also results in significant reduction in CO2 emission in the environment and thus provides better future for our coming generation. 2. MAIN REASONS OF POOR VACUUM AND ACTION TO BE TAKEN BY O&M ENGINEERS

Proper commissioning of priming system to ensure that there is no air lock in CW water box. Ensure all valves in CW line are fully open. Thermal scanning of CW inlet/outlet water box to rule out passing of CW inlet/outlet water box through partition plate. Ensure CW motor running at rated current and voltage. Inspection of Sacrificial anode during overhauling. Ensure proper cleaning of CW inlet/ outlet pipelines and CW inlet ducts during initial commissioning.

2.2. Deposits in the Condenser Tubes

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2.1. Low CW Flow in Condenser Tubes

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Chocking of condenser tubes Improper functioning of Traveling water screens Non-commissioning of Condenser On load Tube Cleaning System (COLTS) Poor Quality of Cooling Water (mud/slime/algae/sewage etc.)

Poor priming boxes

of Cooling Water

Partial opening of inlet/outlet of valves of condenser CW system Passing of CW inlet/outlet water box partition plate Problem related with CW system Low CW discharge pressure High resistance in CW inlet/ outlet pipelines due to dirtiness Erosion of CW pump impeller
BHEL FEEDBACK Journal, June 2010

In closed cycle it will results in salt deposits in condenser tubes in short duration of operation (if proper care is not taken wrt Chemical Dozing, Blow down in Cooling Tower)
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In open cycle, Improper functioning of Traveling water screens,

LP front and rear gland expansion bellows LP casing Parting Plane Bursting diaphragms area LP front & rear diffuser vertical gasket joints Gland Steam leak off valve and its surrounding area Extraction-1/2 pipe line from condenser to LP heater-1/2 Condenser neck welding area LP by pass (both side) control valve and its downstream pipeline up to condenser Turbine/HP/LP flash boxes and its bellows CEP suction line area Hot well/LP heaters stand pipes Condenser man hole joints Vacuum pump suction line valves flange joints Boiler Feed Pump Drive Turbine (BFPDT) exhaust flange (applicable only for 500 MW, KWU machines, where BFPDT is provided) Pressure/temperature tapping points provided for PG test in vacuum system Plug point for PG test thermo well/ spare points Air ingress from turbine glands due to low gland steam header pressure
to be

High salt level/turbidity in cooling water (Normally observed in closed cooling water circuit) Improper functioning of debris filters Oil/Grease deposit in condenser tubes
to be

2.2.1 Action
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Taken

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O&M Engineers

Clean the condenser tubes by High Pressure Bullet Cleaning/Chemical Cleaning prior to conductance of PG Test in new machines. Periodic maintenance of water screen/debris filters. traveling

Ensure adequate blow down, chemical dozing in cooling tower system. Ensure commissioning of COLTS prior to first synchronization. Periodic cleaning of the condenser tubes/water boxes.

2.3. High CW inlet temperature

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Cooling
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Improper Tower

functioning

of

High CW inlet temperature due to summer season.

to be

2.3.1 Action
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Taken

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O&M Engineers

Periodic maintenance of cooling tower for its proper functioning.

2.4.1. Action
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Taken

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O&M Engineers

2.4. High Air Ingress in Condenser

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Measure air ingress with the help of installed rotameter. Conduct Condenser Water Fill Test for points below LP blade tip and ensure that there is no fall in water level in 24 hrs.
BHEL FEEDBACK Journal, June 2010

Probable locations for air ingress in vacuum system: LP front and rear glands
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Steam Pressurization Test for points which are not covered by condenser water fill test. Helium Leak Detection test for all points during operation of the machine. Ensure proper functioning of Gland Seal Steam System. Ensure water is filled in vacuum breaker, GSC siphon, and Main ejector siphons. Ensure glands of the valves operating in vacuum system are properly sealed by CEP water. Ensure hotwell level is normal and hotwell level controller is on Auto.

High temperature of inlet air coming from condenser

to be

2.5.1. Action
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Taken

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O&M Engineers

Ensure shut off vacuum of each ejector/ vacuum pump is as per design value. Ensure proper functioning of seal water heat exchanger, in case of vacuum pump. Periodic maintenance of vacuum pump/main ejector during planned overhaul. Incase of high temperature of inlet air to vacuum pump/main ejector, inspect air suction line coming from sub cooling zone of condenser for any puncture/leakage. Loading of

2.5. Poor Prformance of the Vacuum Pulling Device (Poor shut off Vacuum)
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In case of Vacuum pumps: High seal water inlet temperature Low seal water inlet pressure Low seal water inlet flow Improper functioning of heat exchanger provided for cooling of seal water Leaking of Vacuum pump glands High temperature of inlet air coming from condenser In case of Main Ejectors: Erosion of nozzle/diffuser Failure of gaskets inter-stage sealing steam

2.6. Excessive Thermal Condenser

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Passing of high temperature drains Non availability of CEP spray to Flash box/tank Insufficient CEP spray during steam dumping operation
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2.6.1. Action
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Taken

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O&M Engineers

Passing of high pressure drains can easily be detected by measuring temperature across drain valves with the help of laser thermometer. Maintenance of LP bypass/CEP spray system and Inspection of Steam throw device during overhauling. CONCLUSION

Deviation of inlet parameters to ejectors High condensate temperature inlet

3.

Insufficient condensate water water

Improvement of vacuum in thermal power station will increase the profit of the power generating companies and hence will help in nations growth in a big way. It has been experienced that most of the low vacuum
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BHEL FEEDBACK Journal, June 2010

problems at site are related to High air ingress, Condenser tube chocking, and Poor performance of vacuum pulling device. Hence, if all the care mentioned in this write up is taken care of, the performance of the machine can be enhanced with improvement in vacuum. REFERENCE
Articles published in FEEDBACK Journal: l Innovative use of a new technology to solve low vacuum problem in a 210 MW set by Sh. N.K.Bansal & Sh. N.S.Tomar (Issue : March 2005) Sacrificial Anode in Condenser Cooling Water box A Case Study by Sh. N.K.Bansal, Sh. N.S.Tomar (Issue : January 2007) Procedure of Vacuum leak detection in

KWU Steam Turbine by Steam Pressurization by Sh. N.K.Bansal, Sh. A.K.Khan, Sh. N.S.Tomar (Issue : September 2000) l Descaling of Stainless steel tubes in condensers by sulphamic acid An experience by Sh. W.R.Aswar (Issue : September 2000) On load acid cleaning of Condenser at Khaperkheda TPS by Sh. Anil Dattaray Palamwar , Bhalchandra Vinayak Gokhale, Hemchandra Dharmadas Wasnik (Issue: July 2004) Vacuum leak detection in KWU Steam Turbine by Steam Pressurization of Condenser A Feedback by Sh. M.K. Sharma, H.R.Singh (Issue: September 2000)

BHEL Haridwar supplied 210/250/500 MW KWU Design Steam Turbine O&M Manual: l Chapter on Fault Tracing for Low Vacuum

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BHEL FEEDBACK Journal, June 2010