DINESH KUMAR MANDA

Emp. No. 103428

CONDENSATE SYSTEM
FUNCTION OF CONDENSATE SYSTEM

 The purpose of this system is to supply

condensate from the condenser hot well to the
deaerator and also to various other services
like sealing system , attemperation water
system etc
MAIN COMPONENTS IN CONDENSATE SYSTEM

Condenser Hotwell

Condensate Extraction Pump (CEP)

Gland Steam Condenser(GSC)

Attemperation lines

Sealing System

Condensate Circulation line

Condensate Pre-heaters

Deaerator
 From DM Tank

Deaerator RFWT

To WIPs

To CCPs HOTWELL
CPHR

To Drain Tank

CPHs

Minm circultn flow line

To Condenser

GSC

To CEP & CEP Suction Valve

To Condenser Hotwell Regulation Cylinder

To Bypass Attemperation
To CEP Recirculation Line Min. & Bypass Valves

To Vacuum Pump Suction Valves & Separator

Sealing Water

To Deaerator Low Level Control Valves

Condensate Scheme
HOTWELL

 The condenser hotwelll serves as a water

reservoir for the turbine cycle.
 CEP take suction from the hotwell.

 Capacity of hotwell 55 cu.m(3min)

Between normal and low level
 Condensate Temp 42.8 deg. C
CONDENSATE EXTRACTION PUMP

It extracts condensate from hotwell through

strainers.

Condensate is pumped through the GSC and
condensate pre-heater to the deaerator

Suction pressure of CEP is 0.5 bar.
TECHNICAL SPECIFICATION OF CEP

 No of CEP 2*100%
 Type 3 Stage , Vertical
 Impeller Type Double suction 1st Stage
 Capacity 1212 m3/hr
 TDC 115 wmc/11.2 bar
 Speed 990 rpm
 Motor 600 KW / 6.6. KV
OPERATION OF CEP
 At starting of first CEP it suction v/v open and
discharge v/v is keep close.
 When 1st CEP is running then for 2nd CEP both
suction and discharge v/v are open.
 CEPs is start only if the level in hotwell is more
than a preset value (>-600 mm) and GSC and
minimum circulation path is open and
discharge header pressure is not below a
preset value(< 7.8 bar)
 The 2 CEP have a common recirculation line
with a minimum recirculation control valve.
 This valve is used to maintain a minimum
flow rate in main condensate line.
 It has also a motor operated bypass valve.

 The motorized bypass valve is used during

change over of pump.
No Protection Action
1 One CEP has been in service for 120 secs AND condensate-flow < Trip
390.2 T/hr (2V3 from 19LCA20CF002,003,004_XG62
2 Suction valve (14LCA01/02CG001) NOT open. Trip

3 De-aerator Level > Max (2V3 from 19LAA10CL002,003,004_XQ50). Alarm at > 3099
mm, Trip at >
3400 mm

4 Both CEPs are in service AND condensate-flow < 780.5 T/hr (2V3 Trip (after 10
from 19LCA20CF002,003,004_XG61). secs delay)
5 CEP ON for 10 secs AND CEP discharge pressure < 7.8 bars (from Trip (after 3 secs
14LCA11/12CP001_XQ50). delay)
6 Hotwell level < -600 mm (2V3 from 14MAG10CL003,004,005). Trip
7 Motor temp Alarm >130 C
8 Bearing temperature Alarm at > 75 C

9 Vibration Alarm at >

7mm/sec, Max >
18 mm/sec
GLAND STEAM CONDENSER

 Gland steam condenser is meant for

condensing the steam which is used for sealing
the LABYRINTH GLAND and reusing it in the
cycle.
 Recirculation is taken after gland seal
condenser for sufficient feeding of GSC even on
low flow.
 TECHNICAL SPECIFICATIONS OF GLAND
STEAM CONDENSER
 Number of Units one
Size (Dia x length) 609 x2800 mm
Vapour flow in/out 1245/333 Kg/hr
Condensate formed 9.2 kg/hr
Design pressure shell side -1 to +0.51 bar
Design pressure tube side 20 bar
Number of tubes 580 (15 dia. X
1 thick)
Heat exchanger area in/out 43.7 sq.m
Main condensate temperature 51/51.9 C
ATTEMPERATION LINES
 The attemperation condensate line branches off the MC
line b/w GSC and the branch of minimum circulation
line.
 Attemperation water flows through a mechanical filter ,
before it reaches to attemperation consumers.
The attemperation line goes to-

Flash box of main condenser

L.P. Bypass station

H.P. Bypass station

Gland steam Cooler

L.P. turbine exhaust nozzle spray
 Attemperation
line

GSC
CONDENSATE CIRCULATION PUMP

At certain load conditions and also depending

on ambient temperatures, it is necessary to
increase the condensate temperature before
entering the pre-heater. This is to avoid drop of
the flue gas temperature below dew point,
which would cause cold-end corrosion at the
pre-heaters.
 CPH

CPHR

CCP-D
CCP -
Suction
 For this purpose 3x50% condensate circulation
pumps are installed. These pumps take
automatic start when the condensate
temperature falls below a certain limit.
 Condensate temp is near 45 deg. C , we want
this temp increase to 60 deg. C
 Suction from incoming line to deaerator (CPHR)
from condenser pre-heater to Main condensate
is used to increase temp of main condensate
from 45 deg to 60 deg C.
TECHNICAL SPECIFICATIONS OF CCP

 NO of pumps 3 * 50%
 Capacity 529 m3/hr
 Total head 38 MWC
 Speed 1397
 Motor 110 KW/415 V
CONDENSATE PRE- HEATER

 Before entering the feed water tank the

condensate is passed through the condensate
pre-heaters which are situated at the WHRB
and heated by the flue gas to achieve
the highest cycle efficiency
SEALING SYSTEM

 Before the CEP start-up inner side is in

vacuum condition , there shaft seal
portion(mechanical seal) shall be sealed and
flushed by the sealing water to prevent air
contamination from atmosphere.
 This sealing water is extracted from MC line
after GSC.
 There are sight glass to confirm seal water flow
when pump stops.
•During the normal operation of the pump , it is not
necessary to supply the sealing water to
mechanical seal.

•However, the self pumping water for sealing of

mech seal has to circulated and reversed to the
pump barrel to prevent it from overheating.

•When pumps are stopped , then external sealing

water shall be provided through back-up line from
the RFWT to prevent air coming into mech seal.

•Sealing Water Quantity required 300 Litres/Hr for

sealing.
SEALING WATER IS USED IN

1.To CEP & CEP Suction Valve

2. To Condenser Hotwell Regulation Cylinder
3. To Deaerator Low Level Control Valves
4. To Vacuum Pump Suction Valves &
Separator
5. To CEP Recirculation Line Min. & Bypass
Valves
DEAERATOR

 Dissolved oxygen in our feed water can cause

corrosion, affecting the production at our plant.
 Deaerator storage tanks remove oxygen and other
non-condensable gasses to keep heating systems
and pumps working.
 Spray-
Spray-type – water is sprayed into the tank through
nozzles before being deaerated. A single vessel
contains both the deaeration section and the
storage tank which feeds the heating circuit.
TECHANICAL DATA

 Size Dia * length 4500*19,790 mm

 Working Temperature 105-115 deg C
 Working Pressure 1.23-1.46 kg/cm sq.
 Design Temperature 150 deg C
THANK YOU