Steam Turbine Condenser

a.k.s.raghava

Flow Cycling : A Holistic Process in for A Power

Plant

A Device to Convert Dead Steam into Live Water

Dead Steam

Water ready to take

Rebirth

Layouts of A Condenser

Layouts of A Condenser

An Integral Steam Turbine and Condenser System

Steam Condenser

Steam condenser is a closed space into which steam exits the turbine
and is forced to give up its latent heat of vaporization.
It is a necessary component of a steam power plant because of two
reasons.
It converts dead steam into live feed water.
It lowers the cost of supply of cleaning and treating of working fluid.
It is far easier to pump a liquid than a steam.
It increases the efficiency of the cycle by allowing the plant to operate
on largest possible temperature difference between source and sink.
The steams latent heat of condensation is passed to the water flowing
through the tubes of condenser.
After steam condenses, the saturated water continues to transfer heat
to cooling water as it falls to the bottom of the condenser called, hot
well.
This is called sub cooling and certain amount is desirable.
The difference between saturation temperature corresponding to
condenser vacuum and temperature of condensate in hot well is called
condensate depression.

Two-Pass Surface Condenser

Thermal Processes Occurring in Condensers

The condenser never receives pure steam from the turbine.

A mixture of steam and non-condensable gases (Air-steam
mixture) enters the condenser.
The ratio of the quantity of gas that enters the condenser to the
quantity of steam is called the relative air content.

m air

mc,s
The value of , depends on type, capacity, load and design dimensions
of the condenser plant.

Variation of Steam-air Mixture Parameters

m c , s m air

pc psteam

pc psteam pair

Tsat

e
s

pae

'
Tc Tse

Using Daltons Law:

pc p s p a

Gas laws:

Volumes and temperatures are same.

pa v a m a RaTa & ps v s m s RsTs

pa Ra m a
0.622

ps Rs m
s
ps

pc
1 0.622

At the entry to condenser the relative content of air is very low

and partial pressure of steam is almost equal to condenser
pressure.
As air-steam mixture moves in the condenser, steam is
condensed and the relative content of air increases.
Accordingly, the partial pressure of steam drops down.
The pressure in the bottom portion of condenser is lower than
that of the top portion.
The pressure drop from inlet to exit of condenser is called steam
exhaust resistance of a condenser.

pc pc pce

The partial pressure of air at the bottom of the condenser

cannot be neglected.

The temperature of steam is a

function of condenser pressure.
As the air-steam mixture moves
through the condenser and the
steam is condensed, its
temperature decreases owing
to decreasing partial pressure
of saturated steam.
This is due to increase in
relative content of air in the
mixture.
The pressure also decreases
due to resistance to flow of
steam.
The zone of intensive
condensation.
The zone of cooling of airsteam mixture.

pc psteam

Tsat

Ts

' T
c
pse

pae

Tc Tse

Effect of Air Leakage & Irreversibilities On Condenser

Performance

m c , s m air

pc psteam

pc psteam pair

Tsat

e
s

pae

'
Tc Tse

Variation of Steam Partial Pressure & Saturation Temperature

70
60
50

Saturation Temperature, 0C
Tcw,out

40
Tcw,in

30
20

Steam Partial Pressure, kPa

10
0
1
Inlet

6
exit

Condensate Depression
The temperature of condensate is always a few degrees
lower than the coincident condensing steam
temperature.
Sub cooling of condensate is undesirable on two
accounts:
It lowers the thermodynamic efficiency of the power
cycle.
It enhances the propensity of the condensate to
reabsorb non-condensable.

Energy Balance of A Condenser

Energy balance:

m c hc h m CW CW TWe TWi

e
c

The temperature rise of cooling water:

6 to 7 degree C for single pass.
7 to 9 degree C for single pass.
10 to 12 degree C for four pass.

A Device to Convert Dead Steam into Live Water

Dead Steam

Water ready to take

Rebirth

Condenser Pressure, mm of Hg

Effect of Air Leakage on Condenser Pressure

Air pump controlling the back pressure

Condenser controlling the back pressure

Air pump controlling the back pressure

Condenser controlling the back pressure

10

30
40
50
20
Cooling water Inlet Temperature

Power Loss Due to Excess Back Pressure

Performance Loss Due to Scaling & Fouling

Thermal Model of A Steam Condenser

m steam

& Ts ,in

m cw
m cw

& Tcw,in

m steam

& Ts ,out

& Tcw,out

Overall Heat Transfer Coefficient for the

Condenser

The overall heat transfer coefficient for clean surface (Uc)

Considering the total fouling resistance, the heat

transfer coefficient for fouled surface (Uf) can be
calculated from the following expression:

Cooling Water Outlet Temperature

Calculation
The outlet temperature for the fluid flowing through
the tube is

Tcw,out

m steam h

Tcw,in
m cwc p ,cw

The surface area of the heat exchanger for the fouled con

Q transfer AsurfaceU f F LMTD m h

Correlations for Condensing Heat Transfer

Choice of a correlation depend on whether you are looking
at horizontal or vertical tubes, and whether condensation is
on the inside or outside.
Preliminaries
The condensate loading on a tube is the mass flow of
condensate per unit length that must be traversed by the
draining fluid.
The length dimension is perpendicular to the direction the
condensate flows;
the perimeter for vertical tubes,
the length for horizontal tubes.

Condensate Loading

Mass flor of condensate

Perimeter
m condensate

d 0
m condensate

Ltube

for vertical tubes.

for horizontal tubes.

This can be used to calculate a Reynolds number

Re condensation

film

Flow is considered laminar if this Reynolds number is less than 1800.

The driving force for condensation is the temperature difference
between the cold wall surface and the bulk temperature of the saturated
vapor

Tdriving Tsat Twall Tvapour Tsurface

The viscosity and most other properties used in the condensing
correlations are evaluated at the film temperature, a weighted mean of
the cold surface (wall) temperature and the (hot) vapor saturation
temperature

T film

3Tdriving
3
Tsat Tsaturation Twall Tsat
4
4

Wall Temperatures
It is often necessary to calculate the wall temperature
by an iterative approach.
The summarized procedure is:
1. Assume a film temperature, Tf
2. Evaluate the fluid properties (viscosity, density, etc.)
at this temperature
3. Use the properties to calculate a condensing heat
transfer coefficient (using the correlations to be
presented)
4. Calculate the wall temperature. The relationship will
typically be something like

Twall Tsat

1
UA T T

sat
coolant
1
ho Ao

5. Use the wall temperature to calculate a film

temperature
6. Compare the calculated film temperature to that
from the initial step. If not equal, reevaluate the
properties and repeat.
Laminar Flow Outside Vertical Tubes
If condensation is occurring on the outside surface of vertical tubes, with
a condensate loading such that the condensate Reynolds Number is less
than 1800, the recommended correlation is:

hcond

1.47

3 Re
condensation

k 3f f f v g

Since the vapor density is usually much smaller than that of the
condensate film, some authors neglect it and use the film density
squared in the denominator.
The presence of ripples (slight turbulence) improves heat transfer, so
some authors advocate increasing the value of the coefficient by
about 20%.
Another form of writing h is :

k f f v g

hcond 0.925

3
f

this may also be compensated for rippling (0.925*1.2=1.11).

Turbulent Flow Outside Vertical Tubes

When the condensate Reynolds Number is greater than 1800, the

recommended correlation is :

hcond

f
f
v
0 .4
0.0076 Re

2
f

3
f

Laminar Flow Outside Horizontal Tubes

When vapor condenses on the surface of horizontal tubes, the flow is
almost always laminar.
The flow path is too short for turbulence to develop. Again, there are two
forms of the same relationship:

hcond

k f f v g

1.51

3 Re
condensation

k f f v gh fg

f Tdriving d 0

3
f

hcond 0.725

3
f

The constant in the second form varies from 0.725 to 0.729.

The rippling condition (add 20%) is suggested for condensate Reynolds
Numbers greater than 40.

Condenser tubes are typically arranged in banks, so that the

condensate which falls off one tube will typically fall onto a tube
below.
The bottom tubes in a stack thus have thicker liquid films and
consequently poorer heat transfer.
The correlation is adjusted by a factor for the number of tubes,
becoming for the Nth tube in the stack

hcond

k f f v gh fg
0.725

N f Tdriving d 0

3
f

htop
4

Splashing of the falling fluid further reduces heat transfer, so some

authors recommend a different adjustment

hcond

k 3f f f v gh fg
0.725

N f Tdriving d 0

htop
6

Overall Heat Transfer Coefficient for the

Condenser

The overall heat transfer coefficient for clean surface (Uc)

Considering the total fouling resistance, the heat

transfer coefficient for fouled surface (Uf) can be
calculated from the following expression:

( C ) Variation Due to Condenser Heat Load:

Design Heat Load

238745.8

Kcal/hr

Actual Heat Load

290000

Kcal/hr

New CW Rise

10.73778

New LMTD

9.558772

ln T1/T2

1.123343

T1/T2

3.075117

Tsat

48.91232

Back Press

0.12

Deg C
Kg/SqC
mm

Loss in Vacuum

0.0167

KSC

Total loss in vacuum

0.01371

KSC

Due to high CW temp,CW flow & High cond heat load

Total loss in vacuum

0.00299

KSC

Due to tube fouling & air ingress

Total loss in vacuum

0.0167

KSC

OBSERVATION :
Reasons for low vacuum:1. Low cleanliness factor
2. Excess Air ingress
3. Increase in CW I / L temp
4. Excess condenser Load
5. Decrease in CW flow
6. Air Handling Equipment
Analysis:Low CF:

High LMTD & TTD indicates poor heat transfer which may be due to dirty condenser tubes
and air blanketing of tubes

CALCULATION :
(A) Variation Due to CW I/L Temp:
New Mean CW Temp

35.42

Deg C

New LMTD

7.978177

Deg C

ln T1/T2

1.108023

T1 = Tsat - Tin

T1/T2

3.028364

T2 = Tsat - Tout

Tsat

44.19819

Deg C

Back Press

0.10851

KSC

Loss in Vacuum

0.00521

KSC

New Temp Rise

8.230345

Deg C

New LMTD

7.593163

Deg C

ln T1/T2

1.083915

T1/T2

2.956231

Tsat

45.43759

(B) Variation Due to CW Flow :

Deg C

Back Press

0.0951

KSC

Loss in Vacuum

-0.0082

KSC

LMTD =

(T1 - T2)
ln (T1/T2)

Condenser
Energy audit

DESIGN DATA :
Design CW I/L Temp

3
1

33

Deg C

Cw Temp rise

8.84

Deg C

CW O/L Temp

41.84

Deg C

4
1
2
9
0
0
0

Cw flow Qty

27000

m3/hr

Cw velocity

1.808

m/sec

Cw side Pr. Drop

3.6

mWC

Cond. Back Pr.

76

mmHga

7
6

mmHg

7
4
0

KSC

0
.
1
2

Barometric Pressure

Back Press

740

0.1033

Saturation Temp

46.1

Deg C

Mean CW temp rise

37.42

Deg C

LMTD

7.87

Deg C

TTD

4.26

Deg C

Atm. Press

1.006

KSC

7
.
8
7

CONDENSER PERFORMANCE REPORT :

UNIT-1

CONTROL ROOM DATA :

Date : 19.02.2004

10.00 Hr

Actual

Designed

Load

211

MW

210

Freq.

49.7

Hz

50

Cond. Vacuum

0.886

KSC

0.9

Cond Back Press

0.12

KSC

0.1033

Sat Temp

49.4

Deg C

LPT Exhaust Hood Temp

52

Deg C

CW Inlet Temp L / R

31

Deg C

33

CW O/L Temp L / R

41

Deg C

41.84

CW Flow

29000

m3/hr

27000

CW Dp L/R

0.52 / 0.54

KSC

Ejector Air Temp A/B

41.5

Deg C

LMTD

12.75

Deg C

7.87

TTD

8.4

Deg C

4.26

Air Depression Temperature

7.9

Deg C

46.1

3.6 mWC

Cooling water flow through the condenser will decrease if the

condenser tubes become fouled or if a large number of tubes are
plugged over a period of time. Any reduction in cooling water flow
would result in a higher cooling water temperature rise across the
condenser. But the same could also result from an increase in
condenser heat load, generally caused by passing of high-energy
drains. Water box priming should be continuously maintained so
that the condenser tubes run full and the water box differential
should be monitored.

Probable causes of low cleanliness factors are:

Tube fouling

Excessive air in leakage

Low levels in water boxes

These deviations could be corrected by starting an additional ejector or a
vacuum pump, eliminating the air-in-leakage, filling the water boxes, or
cleaning the condenser at the next available opportunity.
If the cleanliness factor is acceptable, but he condenser pressure is high,
possible causes include:

Excess condenser load

Low cooling water flow

Increase in CW inlet temperature (which could be either due to

changes in ambient conditions or problems with cooling tower performance)
These deviations could be corrected by increasing the CW flow (increasing
the opening of the inlet or outlet valves, starting an additional CCW pump,
cleaning the tube sheet, etc.), putting additional cooling tower in service, or
locating an eliminating the source of the additional heat load on the
condenser.

T in correction factor = correction factor for actual C. W inlet

temp (from HEI standard Appendix H table H.2)
Tube correction factor = correction factor for tube material and
tube wall gauge (from HEI standard Appendix H table H.3)]
Condensate Depression is calculated by subtracting the
Condensate Temperature from the steam temperature
corresponding to the condenser pressure:
Condensate Depression = Tsat -Condensate Temperature
The degree of sub cooling of the air/steam mixture (going to the
vacuum pumps/steam jets) is calculated by subtracting the
air/steam mixture temperature from the steam temperature
corresponding to the condenser pressure:
Air/steam Sub cooling = Tsat -Air/steam mixture temperature

Density of water = 1000 kg/ cu.m

Area condensing = m 2 (condensing surface area)
Tout -Tin
LMTD = --------------------- deg,C
Tsat -Tin
Ln ------------Tsat -Tout
U theoretical = Ubase x Tin correction factor x tube
correction factor x 4.882428
Where:
U theoretical = Kcal/hr. sq. m . deg. C
Ubase = heat transfer coefficient in Btu/hr sq ft. At 70 deg.F
C.W inlet temp., 18 BWG and Admiralty Metal (from HEI standard
Appendix H table H.l)

Calculations:
Condenser Cleanliness factor (CF) is calculated to determine
the degree of tube fouling. The Heat Exchange Institute (HEI)
condenser cleanliness factor is a comparison of the as operating
thermal performance of the condenser to the as designed thermal
performance of the condenser with 100% clean tubes for a given
set of operating conditions. The cleanliness factor as defined
mathematically by HEI is given below.
CF = (U actual) / (U theoretical)
CCWF x Cp x (CCWTO -CCWTI) x Density of
water
U actual =
------------------------------------------------------------------------------A condensing x LMTD
Where:
Uactual = kcal/hr sq.m. C

Parameters to be Monitored:
CW Inlet Temperature - (Use RTD's at Intake of Condenser or
take readings from the Control room)
CW Outlet Temperature -(Use RTD's at Exhaust of condenser or
take readings from the Control room)
Condenser Vacuum -(Use Vacuum Gauge or Vacuum Pressure
Transmitter )
And for flow use Ultrasonic flow meter.

Condenser heat duty = (Heat Added MS + heat added by CRH 860 (Pgen + Pgen Losses + Heat Loss rad.)
6
Condenser heat duty = 369.463* 10
6
860(169500+94+169.5)=369.463* 10 145.966* 10 6 kcal/hr
= 223.497 Mkcals
Determination of cooling water flow rate
CW flow rate = condenser heat duty/Cp (Tout Tin). D
6
10
Where, condenser duty = 222.314 *
kcal/hr
Cp = 1.0 kcal/kg
D
= 1000kg/M3
Tout = 41.170C
Tin
= 32.450C
6
Therefore CW flow = 223.497 *10 kcal/hr /(41.17 32.45) x
1000xCF
Where CF= Cleanness factor
= 25630/CF CMH (CF is always less than 1)
Compared to rated 27,000 CMH CW flow, the as run value of
over 25630 CMH flow indicates that CW flow is adequate.

HEAT ADDED BY MAIN STEAM

Main steam flow = 514.75 T/hr
(Since main steam flow is inclusive of Attemperation flow,
separate Attemperation quantity is not taken into account in heat
load calculation)
Steam pressure: 98.1 kg/cm2.g, steam temperature =523 0 c
HMS=822.32 kcal/kg, hFW =179.75 kcal/kg
Heat added MS=514.75(822.32-179.75) x1000 kcal/hr
=330762907.5 kcal/hr

a)HEAT ADDED CRH

Flow CRH = 0.99X 536.051T/H
= 530.69 T/H, [CRH steam flow is 99% of ms steam flow, hCRH = 741 kcal/kg ,
hCRH = 813.93 kcal/kg
Heat added CRH = 530.69 (813.93-741) x1000 kcal/hr
= 38703221 kcal/hr
a)HEAT LOSS BY Pgen + Pgen Losses + Heat Loss radiation:
Heat Loss radiation = 0.1% of Pgen (Radiation Losses) kW
Pgen =Gross gen output (KW)=169.5x1000=169500 KW
Radiation loss = 0.1/100(169500)=169.5 KW
Pgen Losses*= kW (Mech Losses + Iron Losses + Stator Current Losses)
No data is available for generator losses. Data from reliable source say that at 80%load
of generator the iron and copper loss is 0.094 MW. Here the generator loading is
169.5/210x100 or, 80.71%, so the expected loss is 0.094 MW. Pgen losses= 94 KW.
Condenser Heat addition Items

Mkcals/hr

Sl no
1

Heat added by main steam

330.76

Heat added CRH

38.703

Total

369.463

HEAT ADDED BY MAIN STEAM

Main steam flow = 514.75 T/hr
(Since main steam flow is inclusive of Attemperation flow,
separate Attemperation quantity is not taken into account in heat
load calculation)
Steam pressure: 98.1 kg/cm2.g,
steam temperature =523 deg. c
HMS=822.32 kcal/kg, hFW =179.75 kcal/kg
Heat added MS=514.75(822.32-179.75) x1000 kcal/hr
=330762907.5 kcal/hr

HEAT ADDED BY MAIN STEAM

Main steam flow = 514.75 T/hr
(Since main steam flow is inclusive of Attemperation flow,
separate Attemperation quantity is not taken into account in heat
load calculation)
Steam pressure: 98.1 kg .g, steam temperature =523 deg,C
cm 2

HMS=822.32 kcal/kg, hFW =179.75 kcal/kg

Heat added MS=514.75(822.32-179.75) x1000 kcal/hr
=330762907.5 kcal/hr

THERMAL LOAD ASSESSMENT

Condenser Duty = (Heat Added MS + Heat Added CRH + ) - 860 (Pgen + Pgen Losses + Heat Loss
rad.)
Parameter

Description

Sl.
No.
Where :
1.

Condensed. Duty

= kcal/hr

2.

Heat Added MS

= Flow MS (HMS - hFW ) kcal/hr

3.

Flow MS

= kg/hr ( Flow Main Steam excluding SH Attemperation )

4.

HMS

= kcal/kg (Enthalpy of Main Steam)

5.

hFW

= kcal/kg (Enthalpy of Feed water)

6.

Heat Added CRH

= Flow CRH (hCRH - hCRH) kcal/h

7.

Flow CRH

= kg/hr Flow Cold Reheat Steam

8.

hCRH

= kcal/kg (Enthalpy of Hot Reheat Steam)

9.

hCRH

= kcal/kg (Enthalpy of Cold Reheat Steam)

10

Heat Loss rad

= 0.1% of Pgen (Radiation Losses) kW

11

Pgen

= kW (Gross Generator Output)

12

Pgen Losses*

= kW (Mech Losses + Iron Losses + Stator Current Losses)

CONDENSER DESIGN DATA (source: Technical Diary)

Station: : 210 MW U # 4 :
DESCRIPTION

UNITS

VALUE

Unit Name Plate Rating

DVC unit-IV-condenser

Type

Twin shell design

Number of Passes

Number

No passes of circulating water

NUMBER

Heat Load Considered for Design

Mkcals/hr

285.88

Consumption of cooling water

Pressure at turbine exhaust

M3/hr

2x13500

Kg/cm2.a

0.1

Tube Length Between Tube Plates

meters

10

Total Number of Tubes

Number

2x7810

Total number of blocked tubes

Number

78(east side) and 77(west side)

ID of condenser tube
Tube Material

Cooling surface area

Cleanliness Factor
Design pressure at tube and water boxes

mm

Sq.meter

28
Admiralty brass or cupronickel
90/10 depending upon cooling
water condition
2x7300

85

Kg/sq.cm.a

CW Temp. Rise

TTD at Design CW Flow & Inlet Temp.

3.4

ANNUAL BENEFITS
Condenser heat rate savings x unit generation
Annual heat savings (kCal) = ------------------------------------------------------------Boiler efficiency
= (54 X 1337.166*X106) / 0.7973 kcal
= 9.056X1010 kcal / annum.

Annual coal savings (MT)

Annual heat (kcal) savings

= ----------------------------------------------1000 x GCV
= (9.056X1010) / (1000 x 4428) MT per annum

Annual Coal Savings

Annual Rupee Savings

= 20451 MT per annum.

= 20451 x Rs.1700 / MT of coal

= Rs. 347.667 Lacs per annum

JUSTIFIABLE INVESTMENT
Justifiable investment for 3 years simple payback period for O&M, R&M.
= Rs. 1043 Lacs.
Actual generation = 1225.736 MU
Therefore, projected annual Generation (2006-07) = 1225.736 x (12/11) MU
= 1337.166 MU

1.Cost Benefit Analysis of Encon Options as follows:

Scope of Condenser Vacuum improvement with better Condenser

performance

Basis:
Condenser heat rate savings margin = 54 Kcal / kWh
Annual unit generation
= 1337.166* MU
Boiler efficiency
= 79.73%
GCV of Coal
= 4428 Kcal/Kg
Cost of Coal
= Rs. 1700 per MT

The design backpressure with clean tubes at 33 deg C cooling

water inlet temperature = 92.11 mbar (with respect to 175 MW
load).
Saturation temperature predicted = 33 deg C + design cooling
water temperature drop + design TTD =
33 + 9 + 3.4 = 45.4 deg C.
Actual saturation temperature is 53.5 deg C and corresponding
back pressure 146.38 mbar.
As against design vacuum of 92.11 mbar at 175 MW unit
load, the as run value of 146.38 mbar indicates a major scope
area for improvement and heat rate reduction with a norm of 1
Kcal/kwh for 1 mbar, the scope for heat rate reduction works
out to 54 Kcal/Kwh. The fact that 3 CW pumps are operational
indicates adequacy of CW flow and the fact that both steam jet
ejectors are required to be operational indicates in-leakage and
fouling effects.
It is recommended to plan a major overhaul at the earliest, to
identify and bring out necessary improvements.

CW FLOW ADEQUACY:
The as-run differential pressure of 11.0 mWC across condenser
as against design value of 3.25 mWC may be on account of
higher CW flow and/or tube fouling/choking. Physical
inspection/overhauling may reveal problem areas. Based on
thermal load, CW flow has been assessed to be above 25630
CMH (Details are presented in Exhibit 2). This is also
substantiated by the fact that 3 CW pumps (each of 13,500 CMH
capacity) are operational.
CONDENSER VACUUM:
The condenser backpressure is well above the design condition
despite the CW inlet temperature being close to rated value.
Following analysis substantiates the observation.

CONDENSER EFFECTIVENESS:
The as-run effectiveness of condenser is 0.46, which is lower than
rated effectiveness of 0.72, indicating scope for improvement. This
performance drop is likely to be on account of tube fouling.

TTD (TERMINAL TEMPERATURE DIFFERENCE):

The as-run TTD value of 11.5 Deg C as against rated value of
3.40C indicates significant scope for improvement.
Higher TTD is normally due to unclean tubes and/or less water
velocity

1. CONDENSER THERMAL LOAD

The condenser thermal load works out to 222.314 Mkcals/hr at a
unit load of 170 MW, whereas, the design thermal load is
285.822 Mkcals/hr at 210 MW, indicating that thermal load is
about 3.91% lower in comparison to pro-rata value.
The higher thermal load is impacted by loss of HP heaters 5, 6 & 7
from the turbine cycle since all the extraction steam will
manifest as additional load on condenser.
Rectification and Re-introduction of HP heater 5, 6 and 7 can help
to raise unit generation capability close to rating as, in case of
any increase of unit output in present circumstances, the
condenser may turn out to be a bottle neck.