CONDENSATE

SYSTEM
RAVI PAL SINGH
DUSHYANT SINGH
(GROUP-C)

LAYOUT

CONDENSATE FLOW
EXTRACTION STEAM AND DRIP FLOW
CONDENSER
CEP
SJAE
CSC & GSC
LPH
PARAMETERS CHART OF LP HEATERS
START UP PROCEDURES
SHUTDOWN PROCEDURES

CONDENSATE FLOW

CONDENSER

CONDENSER
Functions
Acts as a heat sink to complete the Rankine cycle
Creates vacuum to provide a favorable back pressure
Removes non condensable gases
Serves as a drain receptacle
Serves as a convenient site for providing feed water makeup
Specifications
Number
Two nos.
Each of condenser cooling area
3380 m2
Quantity of cooling water
15400 m3/Hr. (330C)
Steam flow
267t/hr
No. of tubes in each condenser
6800
Material of Tubes
AL brass

WHY IMPERATIVE TO PROTECT

VACUUM IN CONDENSER
Sources :
Condenser vacuum continuously compromised due to air
ingress because of vacuum
Decomposition of water into hydrogen and oxygen due to
thermal and chemical reactions

Effects:

Rise in backpressure hampers efficiency and work output

Blanketing of tubes by non condensable gases further
hampers heat interaction, leading to further
deterioration of vacuum
Corrosiveness of condensate increases as oxygen content
increases , detrimental especially to the boiler

WHY IMPERATIVE TO PROTECT

VACUUM IN CONDENSER
Indicators of degraded performance:

Degradation of vacuum reading

Increased DO
Increased TTD on shell side
Measured increase in Heat Rate

Sites to check for air ingress:

Vacuum breaker
Diaphragm
Turbine instrumentation lines
LPHs drains and vents
Manholes
CEP seals
HP flash tank

THE FLIP SIDE OF HIGH VACUUM

Increased wetness in last stages of LPT
Under cooling of condensate causing less effective
regeneration
APC of additional CW Pumps and CT fans

CEP
Functions
Flow in condensate cycle from Hot well to
Deaerator
CEP discharge gives a provision for the following:

Exhaust hood spray

HP/LP bypass valve cooling
LP bypass spray
PRDS spray
HP/LP dozing

CEP and Hotwell level

NPSH
All pumps have a designed NPSH (Net Positive Suction Head) requirement for
their operation
Cavitation
If the suction head is reduced (due to low hot well level) to a value such that
the net head at suction falls below atmospheric pressure at that temperature,
cavitation , in other words localized boiling of the working liquid is impending
Localized vapourization occurs and bubbles move through the impeller at near
sonic velocities
When these bubbles suddenly burst on collision with impeller, severe
vibrations and noise is observed
Cavitation causes reduced pump capacity, metal removal, reduced flow, loss in
efficiency and noise.

CEP EMERGENCIES
If CEP motor tripped reduce load to maintain deaerator
level, try starting standby CEP.
If CEP tripped on hot well level low, increase hot well
level by immediately starting all CTP and take CEP in
service one by one.
If CEP tripped on discharge pressure low (malfunctioning
of CDP-207 /208), manually operate their bypass valves
and take CEP in service one by one.
If CEP rotating in reverse direction due to passing in NRV,
possible threat of pump seizure, immediately close
discharge valve.

SJAE
An ejector has two inlets: one to
admit the motive fluid, usually
steam and the other to admit the
air to be evacuated or pumped
Steam when passes through the
nozzle its velocity increases
creating a low pressure region in
the mixing chamber
Air is sucked into this mixing
chamber because of this low
pressure.
The
mixture
so
obtained
undergoes increase in pressure as
it progresses through the diffuser
and finally reaches tube bunch

SJAE = SAVING IN POWER?

Better energy conversion in SJAE(low grade
thermal energy) in comparison to vacuum
pumps (higher grade electrical energy).
Drip formation in the condensing steam,
provides regenerative heat to the condensate.
Absence of moving mechanical parts in SJAE
eliminates wear and tear of components.

CSC & GSC

CSC

Seal steam from last stage of the

labyrinth sealing is utilised for
regenerative heating of the
condensate

GSC
Seal steam from second last stage
of the labyrinth sealing of HP
front, rear and MP front is utilised
for regenerative heating of the
condensate

LP HEATER
CONDENSATE INLET

CONDENSATE OUTLET

EXTRACTION STEAM INLET

DRIP OUTLET

WHY LP HEATERS?
Regenerative heating and thus overall
efficiency gain.(lead to Carnotization of
Rankine cycle )
Reduction in loading on LP turbine(design
criteria).
Minimizing thermal effects in boiler.

DRIP IN LP HEATERS

PERFORMANCE OF LP HEATER
If,
Th1

Th1= Steam inlet temperature

Th2= Drip temperature
Tc1= Condensate inlet temperature
Tc2= Condensate outlet temperature
P = Shell pressure of the heater
Tsat= Saturation temperature at shell pressure
ms = Steam flow rate
mc= Condensate flow rate

TTD
DCA

Tc1

Th2

Then,

Tc2

Th1

=
=

Tsat-Tc2
Th2-Tc1

Tc2

Th2
Tc1

PERFORMANCE OF LP HEATER
PARAMETER

UNIT

Bleed steam source

LPH-1

LPH-2

LPT 4th
stage

LPT 3rd
stage

LPH-3

LPH-4

LPH-5

LPT 1st
MP
MP 10TH
stage EXHAUST
stage

Bleed steam pressure

kg/cm2

0.208

0.442

0.959

2.240

5.180

Bleed steam temperature

DEG C

60.500

79.000

146.000

219.000

311.000

Condensate flow

T/hr

250

250

300

300

300

Condensate inlet
temperature

DEG C

67.000

72.800

114.270

Condensate outlet
temperature

DEG C

95.000

114.270

147.060

Saturation temperature

DEG C

100.966

126.479

158.032

TTD

DEG C

5.966

12.209

10.972

Drip temperature

DEG C

DCA

?
?

60.492

77.808

LPH EMERGENCIES
LPH out on drip level high
Ensure all motorized valves and extraction NRVs
are closed.
Check all drip valves are open.
If heater level still rising, suspected tube leakage,
immediately isolate from condensate side.

HEATER DRAIN TANK

AND BOOSTER PUMP
Condensate flow at low power pump
(compared to CEP) to meet the main
condensate flow requirement.
Direct mixing of high energy drip (compared
to hot well) to condensate flow.

STARTUP PROCEDURES

No PTWs are pending.

Electrical supplies should be normal.
CW to condenser charged.
Suction valves of all CEPs and CBPs are open
Equalizing valve to CEPs are opened
Cooling lines of CEP and CBP are charged.
Vents of LP heaters, HDT and GSC should be opened.
Hot well level should be normal.
Close discharge valve of 1st CEP.
Give start command to 1st CEP and open discharge valve slowly.
Close all the vents when continuous flow of water is observed.
Now maintain hot well and deaerator level, if necessary take
successive CEPs in service.

SHUTDOWN PROCEDURES
Ensure all extractions NRVs and motorized
valves are closed.
Maintain hot well and deaerator level by
running of at least one CEP.
In case of long shut down open vacuum
breaker and isolate PRDS.

THANK YOU