KUDGI SUPER THERMAL POWER PROJECT

STAGE-I (3X800 MW)

OWNER

NTPC Limited
(A Government of India Enterprise)
TOSHIBA JSW TURBINE & GENERATOR PRIVATE LIMITED CS-9573-110-2-FC-COA-5661, CS-9573-110-2-SC-COA-5662, CS-9573-110-2-TC-COA-5663 TOSHIBA CORPORATION, JAPAN

CONTRACTOR CONTRACT NO. SUB-CONTRACTOR OWNERS DOC. NO. 9573-110-PVM-U-018 SUB-CONTRACTORs REV. DDKV71215 DOC. NO. DRG. / DOC. TITLE PURPOSE

SIZING CALCULATION OF CONDENSER FOR APPROVAL / FOR INFORMATION

[Revision Status for Owners Document No.]

REVISION

02 01
REV. NO.

13/Sep/2012 25/July/2012
DATE

Revised as per design progress Revised as per design progress

DESCRIPTION

R. Y R. Y REVISED BY

Y. F S. M CHECKED BY

Y. F Y. F APPROVED BY

ISSUED BY - TOSHIBA

JSW TURBINE & GENERATOR PVT. LTD.

NAME SIGNATURE REV. NO.

00

APPROVED BY CHECKED BY PREPARED BY

Y. Fuki Y. Fuki S. Mori

Y. F Y. F DATE S. M

7/June/2012

TOSHIBA JSW TURBINE & GENERATOR PVT. LTD.

T ID T PROPERTY INCLUDING KNOW-HOW. IT SHALL NOT BE DISCLOSED TO ANY H MIS E A LI I N T As INTELLECTUAL FE N OR D RI ML C A I O TS N I OC T NO I I NN N FS TI HE O SN H A T B A A A THIRD PARTY, COPIED, REPRODUCED, USED FOR UNAUTHORIZED PURPOSES NOR MODIFIED WITHOUT PRIOR WRITTEN CONSENT OF TOSHIBA.

 Design Data Sheet

TITLE

DD KV71215-d
1 20

Sizing Calculation of Condenser

CUSTOMER EQ/SYS. JOB PROJECT NTPC Limited Condenser - KUDGI SUPER THERMAL POWER PROJECT

STAGE-I (3X800 MW)

The information in this material is confidential and contains Toshibas intellectual property including know-how. It shall not be disclosed to any third party, copied, reproduced, used for unauthorized purposes nor modified without prior written consent of Toshiba. Toshiba Corporation

DISTRIBUTION ISSUED BY

APPROVED BY

Y.Fuki Sep.13,2012
REVIEWED BY

TURBINE PLANT EQUIPMENT DEPT. HEAT EXCHANGER DESIGN GROUP

Y.Fuki Sep.13,2012
PREPARED BY

NETSU-SETSU

R.Yasuki Sep.13.2012

 Design Data Sheet

Contents

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1. Design Specification 2. Calculation of Circulating Water flow rate 3. Thermal Calculation 3.1 L.P. Condenser 3.2 H.P. Condenser 4. Hydraulic Calculation 4.1 L.P. Condenser 4.2 H.P. Condenser 4.3 Total loss of Condenser 5. Hotwell Storage Capacity 6. Steam and Condensate flow

3 4 5 5 8 11 11 12 12 13 14

Appendix UNCORRECTED HEAT TRANSFER COEFFICIENTS INLET WATER TEMPERATURE CORRECTION FACTOR TUBE MATERIAL AND GAUGE CORRECTON FACTORS TEMPERATURE CORRECTION FOR FRICTION LOSS IN TUBES WATER BOX AND TUBE END LOSSES SINGLE PASS CONDENSER
*HEI STANDARD for STEAM SURFACE CONDENSERS 10th EDITION

Figure 1 * Figure 2 * Table 3 * Figure 7 * Figure 8 *

 Design Data Sheet

1.Design Specification Number Type Tube surface area Tube Specification Material Outside diameter Thickness Effective length Overall length (mm) (mm) (mm) (mm) (mm) D=25.4 t=0.711 (Refer to below table.) t=0.889 (Refer to below table.) 14,375 14,431 (m2) One(1)/unit One(1)/unit (L.P.) (H.P.)

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Horizonal surface cooling 29,011 29,011

d d

(L.P.) (H.P.)

ASTM A249 TP316L (Stainless)

Number of tubes (per shell) Location Condensing Zone Total Number of water passes Cooling water source Cleanliness factor Main Cooling Water (m3/min.) Thickness (mm) t=0.711 t=0.889 Number 22,764 2,528 25,292 One(1) Fresh Water Fc=0.90 (90%) 1,310 (78,600 m3/hr)

Applied Codes & Standards Heat Exchange Institute 10th (HEI 10th)

 Design Data Sheet

2.Calculation of Circulating Water flow rate. a.Heat duty (L.P.Condenser) Heat Balance : 3GMG04302 (VWO, 3% m.u.,67mmHg) Main Turbine Exhaust BFP Turbine Exhaust Turbine Gland Seal Steam Enthalpy of Condensate kcal/kg 40.9 40.9 40.9 Total

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Specific Flow Rate Enthalpy kg/h kcal/kg 659,579 564.1 67,223 590.2 1,614 750.4
d

HEAT (Enthalpy) kcal/h 3.4509173E+08 3.69256E+07 1.14513E+06

3.83162E+08

Heat Duty D1

3.83162E+08

kcal/h Enthalpy of Condensate kcal/kg 46.1 46.1 46.1 46.1 46.1 46.1 Total kcal/h

b.Heat duty (H.P.Condenser) Heat Balance : 3GMG04302 (VWO, 3% m.u.,67mmHg) Main Turbine Exhaust BFP Turbine Exhaust Drain from Gland Steam Condenser Drain From LP No.1Heater Make-up Water L.P Condenser Drain
d

Flow Rate kg/h 695,547 68,895 1,339 173,689 73,656 728,416

Specific Enthalpy kcal/kg 570.1 594.5 99.1 53.0 46.1 40.9

HEAT (Enthalpy) kcal/h 3.6446663E+08 3.77820E+07 7.09670E+04 1.19846E+06 0.00000E+00 -3.78776E+06

3.99730E+08

Heat Duty D2 c.Circulating Water 9.920E+02

3.99730E+08

kcal/m 3 10.04 7.82893E+08 9.920E+02 x 10.04 m 3/min m 3/min /60

d

Upper Limit of Temperature Rise Q D1 + D2 Cp t

1310 Circulating Water Flow Rate 1310 (78600 m3/h)

 Design Data Sheet

3.Thermal Calculation 3.1L.P. Condenser a.Water velocity in Tubes Thickness 0.711 mm Number of Tube N1 Thickness 0.889 mm Number of Tube N2 (1) Water velocity in Tubes V1 m/s V1 Q 4 60 d i1 N1 + d i2 2 N2(di2/di1) 1/1.4) 1310 22764 + + 0.023622
2
2

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22,764 2,528

Inner Diameter of Tubes di1 0.0240 m Inner Diameter of Tubes di2 0.0236 m

( Thickness 0.711 mm )

2 60 ( 0.0240 4 1.919 m/s

2528

0.0236 0.0240

1/1.4)

V1 1.92 m/s (2) Water velocity in Tubes V2 m/s V2 V1 di2 di1 0.0236 0.0240 1/1.4) ( Thickness 0.889 mm )

1.92 1.900m/s

1/1.4)

V2 1.90 m/s

 Design Data Sheet

b.Heat Transfer Coefficient Heat Transfer Coefficient U U U 1FWFMFC U1 FW FM FC Uncorrected Heat Transfer CoefficientsFigure.1 Inlet Water Temperature Correction FactorFigure.2 Tube Material and Gauge Correction FactorTable.3 Cleanliness Factor kcal/m2 h

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(1) Heat Transfer Coefficient : Ua U1 3220.7 kcal/m2 h

( Thickness 0.711mm ) , Diameter of Tubes 25.4mm ( 1.0 in )

from Fig.1 V 1.92 m/s ( 6.299 ft/s ) U1 659.71 Btu/hft2F FW 1.079 from Fig.2 Inlet Water Temperature 33.0 FM 0.854
d

F ( 91.4 ) Correction Factor

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.711mm ) Correction Factor FC 0.9 Cleanliness Factor 90%
d

Ua 3220.7

1.079

0.854

0.90 ( Thickness 0.889mm )

2670.9 kcal/m2 h

(2) Heat Transfer Coefficient : Ub U1 3203.5 kcal/m2 h

from Fig.1 V 1.900 m/s ( 6.233 ft/s ) U1 656.19 Btu/hft2F FM 0.815

d

, Diameter of Tubes

25.4mm ( 1.0 in )

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.889mm ) Correction Factor FC 0.9 Cleanliness Factor 90%
d

Ub 3203.5

1.079

0.815 0.90

2535.3

kcal/m2 h

(3) Average Heat Transfer Coefficient Um Ua N1+ Ub N2 Um N1 + N2 2670.9 22764 22764 2535.3 2528 2528

2657.35 U m2657.3 kcal/m2 h

d

 Design Data Sheet

c.Logarithmic Mean Temperature Difference m Circulating Water Temperature rise t t D1 3.83162E+08 Cp Q 60 9.920E+02 1310 4.91
d

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60

Saturated Steam Temperature

ts =

40.84 ( at 702.1mmHg_vac) 37.91 t2 =

d

t1 =

33.0

t = 4.91

( ts t1 )( ts t2 )

7.84 2.93 4.98

ln

( ts t1 ) ( ts t2 )

ln

7.84 2.93

d.Required Tube Surface Area Areq m2 Areq D1 Um m

2 28953.9m

3.83162E+08 2657.3 4.98

e.Actual Tube Surface Area :A 0.02540 14.375 25292 29011.8m 29011m

2 2

> Areq

 Design Data Sheet

DD KV71215-d
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3.2H.P Condenser a.Water velocity in Tubes Thickness 0.711 mm Number of Tube N1 Thickness 0.889 mm Number of Tube N2 (1) Water velocity in Tubes V1 m/s V1 Q 4 60 d i1 N1 + d i2 2 N2(di2/di1)1/1.4) 1310 22764 + + 0.023622
2
2

22,764 2,528

Inner Diameter of Tubes di1 0.0240 m Inner Diameter of Tubes di2 0.0236 m

( Thickness 0.711 mm )

2 60 ( 0.0240 4 1.919 m/s

2528

0.0236 0.0240

1/1.4)

V1 1.92 m/s (2) Water velocity in Tubes V2 m/s V2 V1 di2 di1 0.0236 0.0240 1/1.4) ( Thickness 0.889 mm )

1.92 1.900m/s

1/1.4)

V2 1.90 m/s

 Design Data Sheet

b.Heat Transfer Coefficient Heat Transfer Coefficient U U U1FWFMFC U1 FW FM FC Uncorrected Heat Transfer CoefficientsFigure.1 Inlet Water Temperature Correction FactorFigure.2 Tube Material and Gauge Correction FactorTable.3 Cleanliness Factor kcal/m2 h

DD KV71215-d
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(1) Heat Transfer Coefficient : Ua U1 3220.7 kcal/m2 h

( Thickness 0.711mm ) , Diameter of Tubes 25.4mm ( 1.0 in )

from Fig.1 V 1.92 m/s ( 6.299 ft/s ) U1 659.71 Btu/hft2F FW 1.101 from Fig.2 Inlet Water Temperature 37.91 FM 0.854
d

F ( 100.2

) Correction Factor

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.711mm ) Correction Factor FC 0.9 Cleanliness Factor 90%
d

Ua 3220.7

1.101

0.854

0.90 ( Thickness 0.889mm )

2725.4 kcal/m2 h

(2) Heat Transfer Coefficient : Ub U1 3203.5 kcal/m2 h

from Fig.1 V 1.900 m/s ( 6.233 ft/s ) U1 656.19 Btu/hft2F FM 0.815

d

, Diameter of Tubes

25.4mm ( 1.0 in )

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.889mm ) Correction Factor FC 0.9 Cleanliness Factor 90%
d

Ub 3203.5

1.101

0.815 0.90

2587.0 kcal/m2 h

(3) Average Heat Transfer Coefficient Um Ua N1+ Ub N2 Um N1 + N2 2725.4 22764 22764 2587 2528 2528

2711.57
d

U m2711.6 kcal/m2 h

 Design Data Sheet

c.Logarithmic Mean Temperature Difference m Circulating Water Temperature rise t t D2 3.99730E+08 Cp Q 60 9.920E+02 1310 60 5.13
d

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Saturated Steam Temperature

ts =

46.09 ( at 683.9mmHg_vac) 43.04 t2 =

t1 = 37.91
( ts t1 )( ts t2 )

t = 5.13

8.18 3.05 5.2

ln

( ts t1 ) ( ts t2 )

ln

8.18 3.05

d.Required Tube Surface Area Areq m2 Areq D2 Um m

2 28349.5m

3.99730E+08 2711.6 5.20

e.Actual Tube Surface Area :A 0.02540 14.375 25292 29011.8m 29011m

2 2

> Areq

 Design Data Sheet

4.Hydraulic Calculation (As per clause 4.5 of HEI 10th) 4.1 L.P. Condenser (a)Basic information CW Nozzle Size CW Flow per nozzle CW Velocity per nozzle CW Velocity per tube CW Inlet / Outlet temperature Tube inside diameter Tube inside diameter Tube length (m3/min) (m/sec) (ft/sec) (m/sec) (ft/sec) (Deg.C) (Deg.F) (mm) (in) (m) (ft) (a)Waterbox and Tube End Losses End loss Waterbox Inlet Waterbox Outlet Sum of above (b)Tube Loss Tube loss (uncorrected) Temperature correction factor Tube loss per length Tube loss (c)Total Loss (a) + (b) (ft) (mAq) Hydraulic loss adapted (5% Margin) (mAq) (ft of water/ft length) (ft of water/ft length) (ft) (ft) (ft) (ft) (ft) ID2,400 655 2.42

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7.94 (Vw) 1.92 6.30 (Vw) 33.0 / 37.91 91.4 / 100.24 (T1/T2) 23.98 0.94 (Di) 14.431 47.346 (Lt)
d

0.70 Curve (a) of Figure 8 0.98 Curve (b) of Figure 8 0.30 Curve (c) of Figure 8 1.98 (Re)

0.173 (R2 x Rt) 0.954 (R1: Figure 7) 0.165 (Rt x R2 x R1) 7.81

9.785 (Rtt) 2.983 3.140

 Design Data Sheet

4.2 H.P. Condenser (a)Basic information CW Nozzle Size CW Flow per nozzle CW Velocity per nozzle CW Velocity per tube CW Inlet / Outlet temperature Tube inside diameter Tube inside diameter Tube length (m3/min) (m/sec) (ft/sec) (m/sec) (ft/sec) (Deg.C) (Deg.F) (mm) (in) (m) (ft) (a)Waterbox and Tube End Losses End loss Waterbox Inlet Waterbox Outlet Sum of above (b)Tube Loss Tube loss (uncorrected) Temperature correction factor Tube loss per length Tube loss (c)Total Loss (a) + (b) (ft) (mAq) Hydraulic loss adapted (5% Margin) (mAq) 4.3 Total loss of Condenser LP Condenser + HP Condenser (mAq) 6.220 (ft of water/ft length) (ft of water/ft length) (ft) (ft) (ft) (ft) (ft) ID2,400 655 2.42

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7.94 (Vw) 1.92 6.30 (Vw) 37.91 / 43.04 100.24 / 109.47 (T1/T2) 23.98 0.94 (Di) 14.431 47.346 (Lt)
d

0.70 Curve (a) of Figure 8 0.98 Curve (b) of Figure 8 0.30 Curve (c) of Figure 8 1.98 (Re)

0.173 (R2 x Rt) 0.936 (R1: Figure 7) 0.162 (Rt x R2 x R1) 7.66

9.638 (Rtt) 2.938 3.080

These value do not include loss of CW piping and inter-connecting piping between LP and HP Condenser.

 Design Data Sheet

5.Hotwell storage Capacity a.Condensate Water Condensate Flow : Qc c b.Required storage capacity 3 minutes storage capacity Qreq Qc3
87.08 m
3

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1741639 29.03

kg/h m 3/min

c.Required Hotwell Height : Hreq Size of Cond Lower Shell a b 13895 b 7960 a Size of Cond Lower Shell Hreq' Qreq ab 109 Height of LLWL - Bottom : HLLWL-B HLLWL-B Hreq Hreq' + HLLWL-B 87.08 138957960 109

787.3 mm

200 mm 987.3 mm

d.Actual Hotwell Height : H (Height of NWL - Bottom) Height of NWL - LLWL : HNWL-LLWL HNWL-LLWL H HNWL-LLWL + HLLWL-B

800 mm 1000 mm > Hreq

 Design Data Sheet

6. Steam and condensate flow

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The condensate (generated in LP Condenser) passing through the perforated plates is reheated by the steam from HP Condenser. The condensate is led to HP Condenser through connection pipe between HP and LP Condenser. The Hotwell of LP Condenser has two different pressure zones. The pressure zone (Reheating Section) has the same pressure as HP Condenser.

Condenser is designed for exhaust steam from steam turbine, BFP drive turbine, LP bypass system, heater drains and vents, boiler separator drains during start up, low load and abnormal conditions and other miscellaneous drains.

 Design Data Sheet

Appendix

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 Design Data Sheet

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 Design Data Sheet

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 Design Data Sheet

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 Design Data Sheet

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 Design Data Sheet

REV.

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PAGE CHANGED PLACE AND CONTENT

PREPARED S.Mori Jun.05.2012 S.Mori Jun.07.2012

APPROVED REVIEWED Y.Fuki Jun.05.2012 Y.Fuki Y.Fuki Jun.05.2012 Y.Fuki Jun.07.2012

Initial Issue

11,12

Corrected value.

Jun.07.2012

Y.Fuki

S.Mori Jul.25.2012 Written in page 1.

R.Yasuki Jul.25.2012 Written in page 1.

Revised as marked

according to progress of design.

Jul.25.2012 Written in

Revised as marked

according to progress of design.

page 1.