Condenser

EFFICIENCY ENHANCEMENT
in
THERMAL POWER STATIONS
Factors influencing performance in

condenser,
SURFACE CONDENSOR
CONSTRUCTIONAL FEATURES
1.Shell and tube nest arrangement with water box on either side
2. Steam side connected to exhaust hood of LP Turbine
3. Water side divided into two independent halves
4. Tubes are roller expanded in the tube plate

5. Number of support plates along length of tube at suitable
intervals.
6. Tube plates separates shell to water side.

7. Tubes provided with bowing for water draining
8. The condensate stored in hot well and extracted by CEPs
SURFACE CONDENSOR
9.
The air is sucked off from air cooling zones.
10.
Tube bundles at air cooling zones segregated

from the rest by baffle plates. The steam and air
mixture under cooled at this zones.
By under cooling partial pressure of air increases
and hence proportion of steam drawn is reduced.
11.
The condenser supported by springs on

foundation OR supported firmly on foundation
and connected to turbine with bellows to take
care of expansions.
SURFACE CONDENSOR
12.
Tube bundles are arranged in bundles separated by

sufficiently wide steam lanes. Ensures adequate
velocities of steam and water droplets, and
prevents formation of condensate film over the tubes
which otherwise retards heat transfer.
13.
Bursting diaphragm provided on LP turbine/Exhaust

hood to avoid over pressurization inside condenser.
Main functions of condenser

1. To condense the steam exhausted from turbine.
2. To maintain vacuum so that heat drop utilized in
turbine is maximum.
3. To maintain condensate temperature to saturation
level so that dissolved gases are liberated.
4. To form convenient point for introducing make up
water to the cycle.
5. To prevent under-cooling of condensate so that
thermal losses are minimized.
6. To facilitate extraction of air and other gases.
Operating performance parameters

Hot well level.
Condenser Vacuum in absolute pressure useful to

ascertain the performance of condenser.
Air leakage (ingress to the system)
Vacuum Tightness. Isolate air valve and check the drop

in vacuum. Average fall should be less than 3 mm Hg.
Circulating water inlet temperature. T1
Determines the condenser pressure.
Depends on ambient conditions / climate.
Below the design value may give very high

vacuum, but may not be efficient
Operating performance parameters

Circulating water outlet temperature.
T2 Depends on condenser steam loading and CW mass
flow.
Terminal Temperature Difference
TTD= Sat. temp at cond pr. - CW outlet temp.
TTD increases on poor heat transfer due to deposits inside
tube OR excess air in shell side.
Condensate temperature
For optimum efficient opn. of condenser, Temp. of
condensate is nearly equal to temperature of exhaust
steam. Cooling water should carry only latent heat of
evaporation.
CONDENSOR FAULTS
1. Low vacuum.
Low CW flow. (T2-T1) will be more.
Seal steam pressure low. High TTD
Vacuum pump/ Ejector system failure.
Excessive air leakage due to various reasons.
Hot well level abnormally high.
2. High DP across condenser.

Fouling of condenser tubes.
Foreign bodies at the inlet of condenser.
Deposits can be solid suspended matter, which are to be
removed by jet cleaning with balls, or it can be precipitation
of micro organisms to be avoided by intermittent
chlorination.
CONDENSOR FAULTS
3. (T2-T1) more than specified.
Due to condenser fouling
Due to low CW mass flow.
4. Sub cooling of condensate.
High hot well level or,

More air in the condenser system
5. Conductivity more than normal.
Raw water mixing due to damaged tube.
6. High Oxygen content.
More air leakages (ingress).
NORTH CHENNAI - 210 MW UNIT 2
Condenser monitoring
DT
= CW outlet temp CW inlet temp
TTD
= Hot well temp - CW outlet temp
(difference in temperature between CW inlet and outlet should be about

8 -10 deg C at full load of 210 MW. More means less CW flow, less could
mean mixing: confirm this by seeing TTD values also.)
(Terminal Temperature Difference values of 5-6 deg C are normal.

Values above 10 indicate worsening condenser performance. 20 or more
means very poor heat exchange possibly due to fouling of condenser
tubes or mixing of inlet and outlet CW.)
DP and FLOW:
Higher motor currents in axial flow CW pumps could mean restrictions

in discharge flow due to choking in debris filter, and higher DP across
CW tubes may mean choking in the tubes.
CASE STUDY III : NORTH CHENNAI
debris filter
III
DESIGN PROBLEMS :
01
Effective flow area limited by

filter configuration
Design to be reviewed.
(cylindrical portion not effective

: outlet flow area restriction)
02
Debris discharge negligible as

DP increases beyond 0.5 Ksc
Flushing pump cannot disturb
debris.
See annexure: shows original & modified

suction. The increased suction pressure
due to modified location has stabilized the
debris filter back flushing effectiveness.
03
Flushing butter-fly valve size

limitations
BF removed and spool piece provided to

observe the performance.
Improved
removal of debris suggests design for
increased diameter at butterfly valve.
04
Debris draining provision not

there and hence shut down is
warranted for cleaning
Design to be reviewed to include draining

provision.
CASE STUDY III : NORTH CHENNAI
debris filter arrangement

CW PUMPS
Motorized discharge
valve
vent
1
CW out
Condenser
CW still basin
CW in
Seawater booster pump
Original suction
Debris filter
Backwash pump
Modified
suction
Sequential
Cladding
recommended
repair
works
before
v Clean the condenser tubes from water side thoroughly

by suitable, safe technique.
v Subject all the tubes to Eddy Current Test to evaluate
the condition of the tubes.
v
Replace all the tubes that are identified, having
pinholes, pores and cracks.
v It is preferable to replace those tubes that are thinned

more than 40 %
110 MW Vacuum System improvement

Unit 3 Ennore TPS
Condenser water tightness test

The Condenser tightness test was conducted by filling
water upto TG floor (7.9 meters). Water was retained
in the condenser for 36 hours and zero drops in level
was achieved for this period after attending all the
leaks.
LP Gland Steam header drain modified.
A drain was introduced in the LP Gland Steam header,
with a steam trap and trap bypass to condenser, since
it caused hammering in the sealing steam lines every
time these lines were charged during vacuum pulling.

Unit 3 Ennore TPS
With this, most of the air ingress to condenser and its thermal
loading points have been taken care of. The drain modifications
were undertaken by TNEB on the request of PSSR, on the
original SKODA system, with the support of BHEL Hyderabad T
& C Engineering for attaining full load and improved steady
state behavior of the machine at higher loads.
The unit was restarted in March 2006. During the restart when
vacuum was pulled in this modified system, 0.95 ksc (approx
720 mm Hg of mercury) vacuum was achieved with STG on
barring gear.
715 mm Hg of vacuum was found to be maintaining stably
under steam dumping, rolling, synchronization, and load
conditions.

Unit 3 Ennore TPS
At 90 MW the turbine was running better than at 80 MW.
We see that the turbine is (1) showing better thermal
behavior as load approaches rated load, and (2)
performing as well as other similar machines, within
limits imposed by poor vacuum. From the data below it
appears that the turbine can be loaded comfortably to
higher loads once condenser performance is made
good.
(90 MW on 1.06.06, all heaters in service, 1st stage
pressure 83 ksc. vacuum -0.73 ksc, CW inlet/outlet
29/39 C, and LP Exhaust temperatures 75,75,75,68
C)
(80 MW 0n 9.6.06 , all heaters in service, 1st stage
pressure 78.5 ksc, vacuum -0.72 ksc, CW inlet/ outlet
31/41 C and LP Exhaust temperatures 92, 92 C.)

Unit 3 Ennore TPS
While observing the performance of the boiler at
80-90 MW load, we have found that sufficient
margin is available in, the draft system with
respect to FD Fan capacity, pressure drop
across APH and ducting, O2 in flue gas and ID
Fan capacity. Fuel firing system is also in good
operating condition with sufficient margin to raise
the unit load to 110 MW.
There is continuous drop in vacuum with
increase of load and CW inlet/outlet
temperatures reaching limits of its designs. This
is the critical limitation for increasing the load in
Unit-3 to 110 MW.

Unit 3 Ennore TPS
Condenser Cleaning in ETPS Unit-3 24th - 29th June,
06
When the CW water boxes were inspected, many
kilograms of corroded flake material from the MS inlet
pipes were removed. Similar debris was found lodged in
the inlet sections of the CW tubes when the tubes were
cleaned with water jets and the physical blockages at the
inlet of the condenser tubes were removed. In D
condenser these scales had jammed in the tubes of the
condenser. These are suspected to be coming out due
to the corrosion of CW pipe from the debris filter to the
condenser inlet piping.

Unit 3 Ennore TPS
TNEB adopted a process of chemical cleaning using the
services of a consultant.
During the process, each quarter pass i.e. A,B,C,D, of
the condenser was subjected to circulation with
chemicals for a period of 24 hrs. The chemicals added
were proprietary preparations i.e. 200 Kgs of chemicals
made up of polymeric dispersant inclusive of 16 kg
ortho-phosphoric acid added to 30 m3 of water. This was
circulated for 24 hours in each pass. The circulation was
maintained at 90 TPH by a single pump. Finally before
completion, the system was drained and rinsed.
Chemical cleaning debris
Flakes found in inlet

Unit 3 Ennore TPS
After chemical cleaning of these condenser
tubes the unit 3 has been generating 90
100 MW steadily. CW tubes have to be
cleaned every 2 months to sustain this
load.
During Boiler PG Test in July 2006, unit
load of 104 MW was demonstrated for 5
hrs and max load achieved for short time
A. WELDED WATER BOX IN CONDENSER
W/CHAMBER
DOME WALLS
FRONT
W/BOX
REAR
W/BOX
HOT WELL
SIDE WALL
FLANGED CONFIGURATION WAS USED TO

FACILITATE REMOVAL OF W / BOXES TO :
CARRY OUT RETUBING OF CONDENSER.
ATTEND GASKET LEAKAGE.
COMPLETE RELINING OF WATER BOX INSIDE
SURFACE.
PRESENT SCENARIO:
RELIABILITY OF SS TUBES HAS BEEN
WELL PROVEN IN THE LAST 20 YEARS.
OPENING OF BOTH WATER BOXES MAY BE

REQUIRED FOR COMPLETE RETUBING IF
AT ALL ENVISAGED.
MAINTENANCE OF TUBE / WATER SIDE IS
BEING DONE THRO MANHOLE.
Debris discharge
Flow into existing

conical strainer
BACKWASH
INLET
CW
inlet
DEBRIS
FILTER
BACKWASH
INLET
CW
inlet
Flow into reversed

conical section
Debris discharge
(design suggested)
FLANGED CONFIGURATION WAS USED TO

FACILITATE REMOVAL OF W / BOXES TO :
CARRY OUT RETUBING OF CONDENSER.
ATTEND GASKET LEAKAGE.
COMPLETE RELINING OF WATER BOX INSIDE
SURFACE.
PRESENT SCENARIO:
RELIABILITY OF SS TUBES HAS BEEN
WELL PROVEN IN THE LAST 20 YEARS.
OPENING OF BOTH WATER BOXES MAY BE

REQUIRED FOR COMPLETE RETUBING IF
AT ALL ENVISAGED.
MAINTENANCE OF TUBE / WATER SIDE IS
BEING DONE THRO MANHOLE.
WELDED WATER BOX

EXISTING
PROPOSED
ADVANTAGES:
1. CYCLE TIME REDUCTION.
2. COST SAVING.
3. INCREASED RELIABILITY.
4. LESS MAINTENANCE.
HANDLING ARRANGEMENT FOR FRONT WATER BOXES
B.MEASURES TO ARREST AIR INGRESS

INTO CONDENSER & VACUUM SYSTEM
AIR INGRESS RESULTS IN..
FALL IN CONDENSER VACUUM

INCREASED DISSOLVED OXYGEN CONTENT IN
HOTWELL CONDENSATE
TUBE FAILURES IN L P HEATERS
HIGH DOZING OF HYDRAZINE
ASSOCIATED COMMERCIAL LIABILITIES.
PENALTIY OF Rs 2.0 Rs 3.5 CRORES PER MM HG

SHORTFALL IN VACUUM
DEMONSTRATION OF SYSTEM TIGHTNESS
DEMONSTRATION OF CONDENSATE QUALITY
LEAK PRONE AREAS
FLANGE JOINTS, VALVE GLANDS, BELLOWS
BFPT EXHAUST & ASSOCIATED FITTINGS

FLASH TANK & ASSOCIATED FITTINGS
CEP SUCTION LINE FITTINGS
RECOMMENDATIONS.
IMPLEMENTATION OF 1997 TASK FORCE

RECOMMENDATIONS
USE OF VACUUM TESTED & DEEP GLAND VALVES IN
VACUUM SYSTEM
VACUUM SUITABILITY OF FITTINGS ON FLASH TANK, CEP
SUCTION LINE & BFPT EXHAUST
CONVERSION OF ALL FLANGED JOINTS INTO WELDED
JOINT
RELOCATION OF PRESSURE TAPPING POINTS ON BFPT

EXHAUST AT CONVENIENT LOCATION
SHELL SIDE WATER FILL TEST UPTO THE TIP OF LAST
STAGE LPT BLADES.
Self cleaning strainer

TALCHER 500 MW
ACW system
Debris discharge pipe

Condenser

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EFFICIENCY ENHANCEMENT

Factors influencing performance in

4. Tubes are roller expanded in the tube plate

6. Tube plates separates shell to water side.

The air is sucked off from air cooling zones.

Tube bundles at air cooling zones segregated

The condenser supported by springs on

Tube bundles are arranged in bundles separated by

Bursting diaphragm provided on LP turbine/Exhaust

Main functions of condenser

6. To facilitate extraction of air and other gases.

Operating performance parameters

Condenser Vacuum in absolute pressure useful to

Vacuum Tightness. Isolate air valve and check the drop

Determines the condenser pressure.

Depends on ambient conditions / climate.

Below the design value may give very high

Operating performance parameters

2. High DP across condenser.

High hot well level or,

More air leakages (ingress).

NORTH CHENNAI - 210 MW UNIT 2

= CW outlet temp CW inlet temp

= Hot well temp - CW outlet temp

(difference in temperature between CW inlet and outlet should be about

(Terminal Temperature Difference values of 5-6 deg C are normal.

Higher motor currents in axial flow CW pumps could mean restrictions

CASE STUDY III : NORTH CHENNAI

Effective flow area limited by

(cylindrical portion not effective

Debris discharge negligible as

See annexure: shows original & modified

Flushing butter-fly valve size

BF removed and spool piece provided to

Debris draining provision not

Design to be reviewed to include draining

CASE STUDY III : NORTH CHENNAI

debris filter arrangement

v Clean the condenser tubes from water side thoroughly

v It is preferable to replace those tubes that are thinned

110 MW Vacuum System improvement

Condenser water tightness test

110 MW Vacuum System improvement

110 MW Vacuum System improvement

110 MW Vacuum System improvement

110 MW Vacuum System improvement

110 MW Vacuum System improvement

Chemical cleaning debris

Flakes found in inlet

110 MW Vacuum System improvement

A. WELDED WATER BOX IN CONDENSER

FLANGED CONFIGURATION WAS USED TO

OPENING OF BOTH WATER BOXES MAY BE

Flow into existing

Flow into reversed

FLANGED CONFIGURATION WAS USED TO

OPENING OF BOTH WATER BOXES MAY BE

WELDED WATER BOX

HANDLING ARRANGEMENT FOR FRONT WATER BOXES