Condenser 69-83
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INPLANT TRAINING REPORT
CONDENSER Condenser is an equipment working under vacuum, which
is
used to
condense
exhaust steam
from
steam
turbine to re-use in power plant cycle.
CONDENSER - FUNCTIONS
Primary Functions:-
•
Provide minimum temperature heat sink in the plant.
•
Condense exhaust steam from turbine.
•
Maintain constant back pressure at turbine exhaust, for
optimum turbine efficiencies.
Secondary Functions:-
•
Deaeration of condensate / make-up water.
•
Removal of non-condensables.
•
Provide storage capacity of condensate.
•
Act as receiver of system drains.
FEATURES OF GOOD CONDENSER DESIGN
Lowest back pressure for condensing surface provided.
Return condensate to cycle at the highest possible
temperature (i.e. minimum subcooling).
Remove oxygen from condensate to reduce system
corrosion.
Maximum venting of insoluble gases.
Uniform pressure drop through any section of condenser.
V .J .T. I , MATUNGA
Page 69
INPLANT TRAINING REPORT
MAIN PARTS OF CONDENSERS
Shell.
Hotwell.
Exhaust hood.
Tube-sheet & baffle plates.
Condensing Tubes.
Inlet & Return Water Box.
Condenser Shell
Section where condensation of steam over tubes
takes place.
Consist of :-
•
Shell side construction.
•
Tube Bundle.
•
Tube sheets.
•
Support Plates.
•
Air Removal Section.
Condensers
outermost
body
containing
heat
exchanger tubes.
Fabricated from C.S plates & stiffened as needed to
provide rigidity for the shell.
Baffles are inserted as intermediate plates that
provide the desired flow path for the condensing steam & provide support that prevents sagging of long tubes.
Tube sheets V .J .T. I , MATUNGA
Page 70
INPLANT TRAINING REPORT
At each end of the shell, a sheet of sufficient thickness usually made of stainless steel is provided, with holes for the tubes to be inserted and rolled.
Hold tubes firmly.
Separate shell from water boxes.
Tubes
Tubes are made of stainless steel, copper alloys
such as brass or bronze, cupro nickel, or titanium depending on several selection criteria.
Use of copper bearing alloys such as brass or cupro
nickel is rare in new plants, due to environmental concerns of toxic copper alloys.
Titanium tubes are usually the best technical choice,
however the use of titanium condenser tubes has been virtually eliminated by the sharp increases in the costs for this material
The tube lengths range to about 55 ft (17 m) for
modern power plants, depending on the size of the condenser. The size chosen is based on transportability from the manufacturers’ site and ease of erection at the installation site.
The outer diameter of condenser tubes typically
ranges from 3/4 inch to 1-1/4 inch, based on condenser
V .J .T. I , MATUNGA
Page 71
INPLANT TRAINING REPORT
cooling
water
friction
considerations
and
overall
condenser size.
Condenser Water boxes. The tube sheet at each end with tube ends rolled, for each end of the condenser is closed by a fabricated box cover known as a water box, with flanged connection to the tube sheet or condenser shell.
Receives & delivers cooling water to Circulating
water system.
Inlet Water box: Receives cooling water from
circulating water system in the plant & passes the water to the tubes.
Outlet Water box: Receives water from the tubes &
delivers to the circulating water system.
Return Water box: Acts as transition piece between
two passes in case of multi-pass condensers.
The water box is usually provided with many holes
on hinged covers to allow inspection and cleaning.
Inlet Water Boxes will also have flanged connections
for cooling water inlet butterfly valves, small vent pipe with hand valve for air venting at higher level, and hand operated drain valve at bottom to drain the water box for maintenance.
Similarly on the outlet water box the cooling water
connection will have large flanges, butterfly valves, vent connection also at higher level and drain connections at lower.
V .J .T. I , MATUNGA
Page 72
INPLANT TRAINING REPORT
Hotwell Hotwell hangs at the bottom of the shell to collect the condensate water.
Air-removal Section
Removes accumulated air & non-condensable gases.
Isolation of section of tubes.
Support Plates
Provides supporting structure to tubes.
Minimizes tube vibration.
Provides additional stiffening to shell from inside.
Condenser Support
Circular condensers are supported on saddles.
Rectangular condensers are directly mounted on hot
well bottom plate.
Baffles: Baffles are the metallic plates with holes or
corrugated strips for the tubes support. It also diverts the shell side fluid and gives it the
required
number of passes.
The clearance between the shell and baffles and
tubes and baffles must be minimum required; it avoids the bypassing of fluid.
However the clearance should be enough to permit
the insertion of tubes into baffles and the insertion of whole tube bundle into shell.
Baffles in steam generator are made up of Inconnel
strips.
These are designed so to, provide a free flow of
secondary sodium. V .J .T. I , MATUNGA
Page 73
INPLANT TRAINING REPORT
These are aluminized to prevent damage of tube
outer surfaces.
MATERIAL OF CONSTRUCTION
Typical Materials used in construction of Condensers.
Tubes
Stainless Steel
-A213 TP304,316
•Al.
Brass
- B111 C44300
•Al.
Brass
- B111 C68700
•Al.
Bronze
- B111 C60800
•Cupro-Nickel
- 90:10, 70:30
•Titanium
- B338 Gr.1,2
Pipes
Carbon Steel •
Boltings
V .J .T. I , MATUNGA
- A106 Gr.B
Stainless Steel - A312 TP304,316
High Tensile
- A193, A194
Page 74
INPLANT TRAINING REPORT
CONDENSER – TYPES
Direct Contact Condenser
Surface Condenser
V .J .T. I , MATUNGA
Page 75
INPLANT TRAINING REPORT
Based on Number of Passes
Single Pass.
No Divisions.
Double Pass.
Single Divisions.
Based on Number of Pressure Zones
Single Pressure.
V .J .T. I , MATUNGA
Dual Pressure.
Page 76
INPLANT TRAINING REPORT
Based on Steam Entry Location
Vertical Entry
V .J .T. I , MATUNGA
Side Entry
Page 77
INPLANT TRAINING REPORT
SURFACE CONDENSER - OPERATION Condenser Start-up
Ensure readiness of Auxiliary Equipment like CEP,
evacuation system etc, for start-up.
Shell side water fill-up test & tube side hydro test.
Fill hot well up to NWL with make-up water and
prime the CEP lines.
Circulate cooling water.
Start Air Evacuation System.
When condenser pressure reaches the desired
value, condenser is ready to receive steam from turbine exhaust.
Condenser Normal Operating Mode
No dump steam.
Condenser operating at designed parameters.
Condenser Abnormal Operating Mode
Steam Dump Operation.
Higher Back Pressure.
Condenser Shut-Down
All flows to condenser stopped.
Shut down Air Evacuation System.
Condenser vacuum to be broken using vacuum
breaker.
After shell side is cooled down, shut down circulating
water pump.
CONDENSER MAINTENANCE
V .J .T. I , MATUNGA
Page 78
INPLANT TRAINING REPORT
Periodic Inspection of Condenser.
Accumulation of Debris, Scale Deposit inside Waterbox &
Tubes. •
Mechanical Cleaning.
•
On-Line Tube cleaning System.
•
Cathodic Protection Anode Check.
Waterbox painting check.
Gasket replacement.
Tube Failure.
Plugging of Tubes.
• •
Schedule of Preventive Maintenance.
Every shut-down. Once in six month.
Condenser Protection during shut-down.
Deviation & their causes Low Vacuum.
•
Primary Causes of Low Vacuum.
Air leakage.
Poor Heat Transfer.
Faulty Air Removal System.
• •
Tube Leakage.
Tube Rupture. Tube to tube sheet joint failure.
V .J .T. I , MATUNGA
Page 79
INPLANT TRAINING REPORT
Air Leakage.
•
•
Locations.
Bolted Joints.
CEP shaft seal leaks.
Piping Valve Stem leaks.
Weld Cracks.
Air Leak Detection.
Water Fill Test.
Soap bubble Test.
Flame test.
Poor Heat Transfer.
•
Low Quantity of Circulating Water.
•
Air Blanketing of Tubes.
•
High Circulating Water Inlet Temperature.
•
Scale Built-Up.
Faulty Air Removal System.
•
Mal-functioning of Air Extraction Equipment.
•
Internal Damage to Air Cooler Zone.
•
Improper routing of Air Extraction Piping.
Tube Leakage
•
Tube Rupture.
•
Tube to Tube sheet joint leakage.
•
Can be detected using pH / conductivity analyzers.
•
Tube Plugging.
V .J .T. I , MATUNGA
Page 80
INPLANT TRAINING REPORT
L&T CONDENSERS FEATURES OF L&T CONDENSER
Tube
layout resulting
into
low
pressure
drop,
minimum sub-cooling, maximum reheating of condensate.
V .J .T. I , MATUNGA
Page 81
INPLANT TRAINING REPORT
Minimum steam travel distance across the tube
bundle.
Structural
arrangements
designed
to
minimize
obstructions in the high velocity steam paths assure minimum back pressure.
Centrally located and enclosed zone with ample
heat transfer surface effectively cools and removes noncondensables from the tube bundle.
Equal Tube
Bundle
penetration paths promote
effective use of all condensing surfaces.
Full peripheral entry of steam results in low entry
velocities and negligible pressure drops.
Internal provisions to reheat & deaerate the drains.
Steam
dump
system
designed
to
effectively
introduce and distribute large quantities of steam.
Optimum design velocities within shell as well as
tubes.
Use of sacrificial anodes resulting in minimum
corrosion of water boxes.
Fabrication sequence for circular condenser
Shell assembly.
Both side annular ring and shell nozzle set up.
V .J .T. I , MATUNGA
Page 82
INPLANT TRAINING REPORT
Hot-well and saddle set up.
One side tube sheet set up.
Baffle insertion and alignment.
Air hood set up & deflector.
Tubing.
Second side tube sheet set up.
Expansion from one side.
Second side trimming and expansion.
Inlet/outlet & return water-box set up.
Shell side hydro.
Tube side hydro.
Shot blasting and painting.
WHY CONDENSER OPERATES AT VACUUM?
As the operating pressure of condenser is reduced,
enthalpy drop of the expanding steam in turbine will increase. This will also increase the amount of available work from the turbine. By lowering condenser pressure, following will occur
Increased turbine output.
Increased plant efficiency.
V .J .T. I , MATUNGA
Page 83
CONDENSER Condenser is an equipment working under vacuum, which
is
used to
condense
exhaust steam
from
steam
turbine to re-use in power plant cycle.
CONDENSER - FUNCTIONS
Primary Functions:-
•
Provide minimum temperature heat sink in the plant.
•
Condense exhaust steam from turbine.
•
Maintain constant back pressure at turbine exhaust, for
optimum turbine efficiencies.
Secondary Functions:-
•
Deaeration of condensate / make-up water.
•
Removal of non-condensables.
•
Provide storage capacity of condensate.
•
Act as receiver of system drains.
FEATURES OF GOOD CONDENSER DESIGN
Lowest back pressure for condensing surface provided.
Return condensate to cycle at the highest possible
temperature (i.e. minimum subcooling).
Remove oxygen from condensate to reduce system
corrosion.
Maximum venting of insoluble gases.
Uniform pressure drop through any section of condenser.
V .J .T. I , MATUNGA
Page 69
INPLANT TRAINING REPORT
MAIN PARTS OF CONDENSERS
Shell.
Hotwell.
Exhaust hood.
Tube-sheet & baffle plates.
Condensing Tubes.
Inlet & Return Water Box.
Condenser Shell
Section where condensation of steam over tubes
takes place.
Consist of :-
•
Shell side construction.
•
Tube Bundle.
•
Tube sheets.
•
Support Plates.
•
Air Removal Section.
Condensers
outermost
body
containing
heat
exchanger tubes.
Fabricated from C.S plates & stiffened as needed to
provide rigidity for the shell.
Baffles are inserted as intermediate plates that
provide the desired flow path for the condensing steam & provide support that prevents sagging of long tubes.
Tube sheets V .J .T. I , MATUNGA
Page 70
INPLANT TRAINING REPORT
At each end of the shell, a sheet of sufficient thickness usually made of stainless steel is provided, with holes for the tubes to be inserted and rolled.
Hold tubes firmly.
Separate shell from water boxes.
Tubes
Tubes are made of stainless steel, copper alloys
such as brass or bronze, cupro nickel, or titanium depending on several selection criteria.
Use of copper bearing alloys such as brass or cupro
nickel is rare in new plants, due to environmental concerns of toxic copper alloys.
Titanium tubes are usually the best technical choice,
however the use of titanium condenser tubes has been virtually eliminated by the sharp increases in the costs for this material
The tube lengths range to about 55 ft (17 m) for
modern power plants, depending on the size of the condenser. The size chosen is based on transportability from the manufacturers’ site and ease of erection at the installation site.
The outer diameter of condenser tubes typically
ranges from 3/4 inch to 1-1/4 inch, based on condenser
V .J .T. I , MATUNGA
Page 71
INPLANT TRAINING REPORT
cooling
water
friction
considerations
and
overall
condenser size.
Condenser Water boxes. The tube sheet at each end with tube ends rolled, for each end of the condenser is closed by a fabricated box cover known as a water box, with flanged connection to the tube sheet or condenser shell.
Receives & delivers cooling water to Circulating
water system.
Inlet Water box: Receives cooling water from
circulating water system in the plant & passes the water to the tubes.
Outlet Water box: Receives water from the tubes &
delivers to the circulating water system.
Return Water box: Acts as transition piece between
two passes in case of multi-pass condensers.
The water box is usually provided with many holes
on hinged covers to allow inspection and cleaning.
Inlet Water Boxes will also have flanged connections
for cooling water inlet butterfly valves, small vent pipe with hand valve for air venting at higher level, and hand operated drain valve at bottom to drain the water box for maintenance.
Similarly on the outlet water box the cooling water
connection will have large flanges, butterfly valves, vent connection also at higher level and drain connections at lower.
V .J .T. I , MATUNGA
Page 72
INPLANT TRAINING REPORT
Hotwell Hotwell hangs at the bottom of the shell to collect the condensate water.
Air-removal Section
Removes accumulated air & non-condensable gases.
Isolation of section of tubes.
Support Plates
Provides supporting structure to tubes.
Minimizes tube vibration.
Provides additional stiffening to shell from inside.
Condenser Support
Circular condensers are supported on saddles.
Rectangular condensers are directly mounted on hot
well bottom plate.
Baffles: Baffles are the metallic plates with holes or
corrugated strips for the tubes support. It also diverts the shell side fluid and gives it the
required
number of passes.
The clearance between the shell and baffles and
tubes and baffles must be minimum required; it avoids the bypassing of fluid.
However the clearance should be enough to permit
the insertion of tubes into baffles and the insertion of whole tube bundle into shell.
Baffles in steam generator are made up of Inconnel
strips.
These are designed so to, provide a free flow of
secondary sodium. V .J .T. I , MATUNGA
Page 73
INPLANT TRAINING REPORT
These are aluminized to prevent damage of tube
outer surfaces.
MATERIAL OF CONSTRUCTION
Typical Materials used in construction of Condensers.
Tubes
Stainless Steel
-A213 TP304,316
•Al.
Brass
- B111 C44300
•Al.
Brass
- B111 C68700
•Al.
Bronze
- B111 C60800
•Cupro-Nickel
- 90:10, 70:30
•Titanium
- B338 Gr.1,2
Pipes
Carbon Steel •
Boltings
V .J .T. I , MATUNGA
- A106 Gr.B
Stainless Steel - A312 TP304,316
High Tensile
- A193, A194
Page 74
INPLANT TRAINING REPORT
CONDENSER – TYPES
Direct Contact Condenser
Surface Condenser
V .J .T. I , MATUNGA
Page 75
INPLANT TRAINING REPORT
Based on Number of Passes
Single Pass.
No Divisions.
Double Pass.
Single Divisions.
Based on Number of Pressure Zones
Single Pressure.
V .J .T. I , MATUNGA
Dual Pressure.
Page 76
INPLANT TRAINING REPORT
Based on Steam Entry Location
Vertical Entry
V .J .T. I , MATUNGA
Side Entry
Page 77
INPLANT TRAINING REPORT
SURFACE CONDENSER - OPERATION Condenser Start-up
Ensure readiness of Auxiliary Equipment like CEP,
evacuation system etc, for start-up.
Shell side water fill-up test & tube side hydro test.
Fill hot well up to NWL with make-up water and
prime the CEP lines.
Circulate cooling water.
Start Air Evacuation System.
When condenser pressure reaches the desired
value, condenser is ready to receive steam from turbine exhaust.
Condenser Normal Operating Mode
No dump steam.
Condenser operating at designed parameters.
Condenser Abnormal Operating Mode
Steam Dump Operation.
Higher Back Pressure.
Condenser Shut-Down
All flows to condenser stopped.
Shut down Air Evacuation System.
Condenser vacuum to be broken using vacuum
breaker.
After shell side is cooled down, shut down circulating
water pump.
CONDENSER MAINTENANCE
V .J .T. I , MATUNGA
Page 78
INPLANT TRAINING REPORT
Periodic Inspection of Condenser.
Accumulation of Debris, Scale Deposit inside Waterbox &
Tubes. •
Mechanical Cleaning.
•
On-Line Tube cleaning System.
•
Cathodic Protection Anode Check.
Waterbox painting check.
Gasket replacement.
Tube Failure.
Plugging of Tubes.
• •
Schedule of Preventive Maintenance.
Every shut-down. Once in six month.
Condenser Protection during shut-down.
Deviation & their causes Low Vacuum.
•
Primary Causes of Low Vacuum.
Air leakage.
Poor Heat Transfer.
Faulty Air Removal System.
• •
Tube Leakage.
Tube Rupture. Tube to tube sheet joint failure.
V .J .T. I , MATUNGA
Page 79
INPLANT TRAINING REPORT
Air Leakage.
•
•
Locations.
Bolted Joints.
CEP shaft seal leaks.
Piping Valve Stem leaks.
Weld Cracks.
Air Leak Detection.
Water Fill Test.
Soap bubble Test.
Flame test.
Poor Heat Transfer.
•
Low Quantity of Circulating Water.
•
Air Blanketing of Tubes.
•
High Circulating Water Inlet Temperature.
•
Scale Built-Up.
Faulty Air Removal System.
•
Mal-functioning of Air Extraction Equipment.
•
Internal Damage to Air Cooler Zone.
•
Improper routing of Air Extraction Piping.
Tube Leakage
•
Tube Rupture.
•
Tube to Tube sheet joint leakage.
•
Can be detected using pH / conductivity analyzers.
•
Tube Plugging.
V .J .T. I , MATUNGA
Page 80
INPLANT TRAINING REPORT
L&T CONDENSERS FEATURES OF L&T CONDENSER
Tube
layout resulting
into
low
pressure
drop,
minimum sub-cooling, maximum reheating of condensate.
V .J .T. I , MATUNGA
Page 81
INPLANT TRAINING REPORT
Minimum steam travel distance across the tube
bundle.
Structural
arrangements
designed
to
minimize
obstructions in the high velocity steam paths assure minimum back pressure.
Centrally located and enclosed zone with ample
heat transfer surface effectively cools and removes noncondensables from the tube bundle.
Equal Tube
Bundle
penetration paths promote
effective use of all condensing surfaces.
Full peripheral entry of steam results in low entry
velocities and negligible pressure drops.
Internal provisions to reheat & deaerate the drains.
Steam
dump
system
designed
to
effectively
introduce and distribute large quantities of steam.
Optimum design velocities within shell as well as
tubes.
Use of sacrificial anodes resulting in minimum
corrosion of water boxes.
Fabrication sequence for circular condenser
Shell assembly.
Both side annular ring and shell nozzle set up.
V .J .T. I , MATUNGA
Page 82
INPLANT TRAINING REPORT
Hot-well and saddle set up.
One side tube sheet set up.
Baffle insertion and alignment.
Air hood set up & deflector.
Tubing.
Second side tube sheet set up.
Expansion from one side.
Second side trimming and expansion.
Inlet/outlet & return water-box set up.
Shell side hydro.
Tube side hydro.
Shot blasting and painting.
WHY CONDENSER OPERATES AT VACUUM?
As the operating pressure of condenser is reduced,
enthalpy drop of the expanding steam in turbine will increase. This will also increase the amount of available work from the turbine. By lowering condenser pressure, following will occur
Increased turbine output.
Increased plant efficiency.
V .J .T. I , MATUNGA
Page 83
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