Main Condensate &

Feed Systems
Objectives

● Components of Main Condensate System

and purposes of each
● Components of Main Feed System and
purposes of each
● Operation of Automatic Control Systems
● Interrelationship of systems during operations
● Provides condensation phase of the main
steam cycle
● Condenses steam from turbines to liquid
● Pumps condensate from main condenser to
the Main Feed System
Main Condenser

● Indirect, shell-and-tube, cross flow heat

exchanger
● Two flow paths through condenser
● Condensate collects in hotwell
○ Provides NPSH to condensate pumps
Main Condensate Pumps

● Centrifugal pumps
● Usually 2 pumps per condenser
● NRV on discharge of pump to prevent
backflow
● Lowest pressure in MS cycle at
suction of pumps
 What is condensate?

Steam that has been condensed back into water

by either raising its pressure or lowering its
temperature.
Not Demineralized
De-ionized
Make up
Softened water
When the condensate enters the boiler feed pump
additional chemicals are added and the product is
 Condensate come from

Condenser hotwells, the bottom part of the condenser

Steam traps
Heat exchangers ( Heater drip)
Condensate must be removed to allow the heat transfer.
Or any other place that you are using steam.
 Dissolved oxygen
Contribute to corrosion

Boilers ph of somewhere between 9 and 11.

Hot water is almost the perfect solvent. It will dissolve

anything.

It is the oxygen in the condensate that makes

condensate a strong oxidizing agent that can attack
metals.

The condensate temperature determines the amount of

dissolved oxygen. You are trying to conserve the energy
 Oxygen comes from

Through the packing of condensate pumps

The stuffing box is under a negative pressure,

and air that is one third oxygen, leaks in.

Valves above the water line can introduce oxygen

as the velocity of the water lowers the pressure at
the valve stem.

Flanges can have the same problem as valves.

Oxygen is dissolved in makeup water that was
 How to remove dissolved oxygen

Add chemicals to convert it. Hydrazine is an example.

You are adding hydrogen that will combine with the
oxygen to form water.
Deaerate the condensate. This is normally done by
heating the condensate with steam in a deaerating
tank

Convert to balanced, o-ring mechanical seals that will

prevent air from coming into the stuffing boxes of
condensate pumps through packing
Carbon dioxide in condensate systems?

Carbon dioxide (CO2) will combine with water

(H2O) to form Carbolic acid (H2CO3) that will
lower boiler ph.
CO2 comes from

● Mammals exhale CO2. It enters condensate and

feed water:

○ Through the packing in condnsate pumps

that take a suction on hot wells

○ Valves above the water line

○ Gaskets
Make up water in boiler

● Because we lose so much of it.

○ Condensate pump discharge recirculation lines that
are trying to put a positive pressure on packing are a
common source of condensate loss.

○ Boiler blow down is a major problem.

○ Steam tools.

○ Air ejectors that are used to create a vacuum in

receivers etc.

○ Steam traps that drain to the ground.

Methods for conserving condensate
The discharge recirculation line used with packed pumps
is a big waste. Convert to a balanced o-ring seal and save
a pile of condensate.
Stop air from entering the system. The air is causing
frequent boiler blowdowns. You can easily seal flanges,
valves and rotating shafts.
Do not drain steam traps to the ground. Collect it in a tank
that can be pumped back into the system.
If condensate is being circulated through the cooling
jacket on a pump, make sure it is not being discharged to
a drain. There is no reason it cannot be returned to the
condensate system.
If condensate is being circulated between dual
mechanical seals, it is not a good idea to return it to the
LP HEATER
750 MW Ultra-Supercritical Double Reheat

4 HP HEATERS & 4 LP HEATERS