6 - Feed Cycle - 210-279

POWER PLANT SIMULATOR TRAINING INSTITUTE
Bakreswar Thermal Power Project : WBPDCL
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WATER AND STEAM CIRCUIT OF 210 MW THERMAL POWER STATION
INTRODUCTION
Thermodynamic cycle continuously converts the heat energy into kinetic energy or vice versa. The working
fluid is required for storing and converting the energy according to the process. So, working fluid layout is
important for thermodynamic cycle requirement.
For thermal power plant Rankin cycle is used for conversion of heat energy into kinetic energy and ultimately
into electrical energy.
In this article author discuss the working fluid layout for 210 MW thermal power plants.
LAYOUT
Working fluid layout consists of :
1. Condensate cycle
2. Feed water cycle
3. Boiler water circuit
4. Boiler superheated circuit
5. Superheated steam circuit
6. Auxiliary steam circuit
CONDENSATE CYCLE
CEPs suck the condensate from Hotwell and discharge the same at about 20 kgf cm-2. From CEP discharge
condensate flows through the Main Ejector, Gland Steam Condenser, Drain Cooler, LP Heater #1, LP Heater
#2, LP Heater #3 to Deaerator. In this cycle condensate recovers heat from the above-mentioned equipments
to increase the temperature and reduce the heat losses in the thermodynamic cycle. The minimum condensate
flow is controlled by ‘condensate minimum flow re-circulation controller’ (CD # 41) and Hotwell level is
controlled by ‘hotwell level controller’ (CD # 19). Normal deaerator level control and high deaerator level
control are done by CD # 23 and DM # 53 respectively.
FEED WATER CYCLE

Boiler Feed Pumps suck the feed water from Deaerator and discharge to Economizer through HP Heater #5
and HP Heater #6. Feed water flow is controlled by feed control valve (FD 14 or FD 17 or FD 20) and BFP
scoop engagement. Feed water receives heat form HP Heater #5 and HP Heater #6.
BOILER WATER CIRCUIT

Feed water is supplied to economizer inlet header (E 1) via feed control station and economizer feed check
valve. The feed water flow is upward through the economizer coils. After feed water is collected by the
economizer intermediate header (E -2A, E –2B and E –2C) it passes through economizer hanger tubes to reach
top economizer outlet header (E 3). The water from economizer outlet header moves to drum through
economizer connecting links. Water from the drum comes to the bottom ring header (H1, H2, H3 and H4)
through six numbers of down-comers. From ring headers it raises through front, side and rear water wall
panels and absorb radiant heat and some amount of water is converted into saturated steam. This water steam
mixture is collected at top header (H5, H6, H7, H8 & H9). Extended water wall receives water from header
H10 and H11. From top water header, water steam mixture is fed to boiler drum through riser tubes.
BOILER STEAM CIRCUIT

Saturated steam leaves the drum and enters superheater radiant roof inlet header (SHH 1) through superheater
connecting pipes. Then it forms boiler radiant roof and the superheated steam is collected at SHH2 header. The
steam leaving the roof outlet header (SHH 2) enters the rear pass sidewall inlet header (SHH 3L and SHH 3R).
From rear side inlet header, the steam flows down and forms rear side steam wall and it is collected at SHH 4L
and SHH 4R header. Both SHH 4L and SHH 4R are connected to SHH 5 and SHH 8.
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Superheated rear pass front inlet header (SHH 5) feeds the steam to junction header SHH7 via rear pass front
wall. It also feeds the extended sidewalls header (SHH6) through connecting tubes. The panels from SHH6
cover the bottom and side portions of extended region and connected to a separate header at top on either side
(SHH – 3A Left, SHH – 3A Right). The steam from these headers reaches to the junction header (SHH 7)
through connecting tubes.
The rear pass junction header (SHH 3) supplies steam to rear pass roof tubes. These tubes form steam cooled
rear roof and steam cooled rear wall are connected to Low Temperature Superheater (LTSH) inlet header.
Also a portion of steam from SHH 4L and SHH 4R on either side enters SHH 8 through elbow connection.
SHH 8 header supplies the steam to rear pass rear wall and connected to LTSH inlet header (SHH 9).
The LTSH inlet header is connected to LTSH outlet header (SHH 10). Soot blowing steam bleeds form LTSH
outlet header. LTSH outlet header and Platen Super Heater header (SHH 11) are connected by two link tubes.
The platen superheater tubes are connected to platen superheater outlet header (SHH 12). From platen
superheater outlet header the steam is fed to final super heater inlet header (SHH 13) by two connecting links.
Final super heater tubes are connected to final super heater outlet header (SHH 14). The main steam lines are
connected to final superheater outlet header.
The cold reheat lines are connected to reheat inlet header (RHH 1). Some reheater tubes (from reheater inlet
header) are connected to reheater outlet header (RHH 2) and rests of the tubes are connected to reheater outlet
header (RHH 3). Both reheater outlet headers are connected to hot reheat steam line. Figure 4 shows the boiler
steam circuit for Bakreswar Thermal Power Station.
SUPERHEATED STEAM CIRCUIT
TWO MS lines connect superheater outlet header and HP Turbine stop valves. Main steam stop valve at boiler
end (MS 1 and MS 2) and its bypass valves (MS 3,4,5 and 6) are normally used to isolate the HP Turbine from
main steam flow. For protection of turbine, two main steam stop valves (MSV 1 and MSV 2) at turbine end are
also provided and for controlling the main steam flow through HP Turbine four number of main steam control
valve (MCV 1,2,3 and 4) are provided. MS 101, 102, 105, 106 are the drain valves for draining condense main
steam.
Reheated steam lines are connected to IP Turbine through IV 1, IV 2 and IPCV 1,2. HRH 101 and 102 are the
drain valves for reheat line.
IP turbine outlet and LP turbine inlet are connected by cross around pipe (CAP) for steam flow from IP turbine
to LP turbine and LP turbine outlet is connected to condenser. Figure 5 shows the superheated steam circuit for
Bakreswar Thermal Power Station.
AUXILIARY STEAM CIRCUIT
Auxiliary steam is used for heating and running some auxiliary equipments like main ejector, atomizing fuel
oil, heating heavy oil and deaerator pegging etc. Turbine auxiliary steam is tapped just after main steam stop
valve (MS 1 and MS 2).
This superheated steam is depressurised by depressurising valve [AS 32 (when consumption is low) and AS 22
(when consumption is high)] and de-superheated by spraying water into the steam by de-superheating valve
[CD 71 (when consumption is low) and CD 65 (when consumption is high)].
This depressurised and de-superheated steam is used for gland seal system, ejector system, deaerator pegging
and initial heating system and also supply steam to TPRDS station header.
Boiler auxiliary steam is tapped just before main steam stop valve (MS 1 and MS 2).
This superheated steam is depressurised by depressurising valve [AS 56 (when consumption is low) and AS 46
(when consumption is high)] and de-superheated by spraying water into the steam by de-superheating valve
[CD 83 (when consumption is low) and CD 77 (when consumption is high)].
This depressurised and de-superheated steam is used for SCAPH system, heavy oil atomizing system, HFO
heating system and also supply steam to BPRDS station header. Figure 6 and 7 shows the auxiliary steam
circuit of TPRDS and BPRDS respectively for Bakreswar Thermal Power Station.
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CONDENSATE EXTRACTION PUMP
1. INTRODUCTION :
Condensate from condenser hot-well is pumped through LP heaters up to deaerator by three numbers of 50%
capacity condensate extraction pumps (CEP). In full load operation two pumps will be in operation and one
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standby condition. The CEP is of the vertical, seven stage, centrifugal, canister type. Each pump is directly
driven through a flexible coupling by a 300 KW electric motor and is capable of delivering up to 402 TPH
condensate. However rated capacity of pump is 350 TPH at total dynamic head 18.5 MWC. All the CEPs are
connected to a common header through individual non-return valve and motorized discharge valve. From that
discharge header condensate passes through gland steam condenser (GSC) and then through a control valve
(CD 19) called hot well level controller. By modulating this valve hot-well level is maintain according to set
the point given from control room. A recirculation valve (CD 41) is provided before hot-well level control
valve to maintain a minimum condensate flow (220 TPH) through the pump. Minimum condensate flow set
point can be set from control room depending on number of pump running. A condensate dump to CST line is
also provided with one control valve (CD 23) and it’s by pass valve (CD 25) from CEP discharge header. The
main condensate is passes through main ejector, drain cooler, GSC, LP heater # 1, LP heater # 2, LP heater # 3
and finally stored in Deaerator. Beside this CEP discharge water is also used in the following areas: -
a) BPRDS attemperation, b) TPRDS attemperation ,c) L.P. turbine exhaust hood spray, d) L.P. by pass spray,
e) Gland sealing of valves connected to condenser, f) Flush box spray, g) Chemical dosing system, h) CEP
gland for gland sealing , i) Vacuum breaker down stream line loop.
2. CONSTRUCTION :
Condensate extraction pump assembly has following parts :
• Motor
• Seven stage centrifugal pump
• Coupling
• Thrust & journal bearing assembly
• Stuffing box assembly
• Canister
• Head piece
2.1. Motor :
The vertical driving motor develops 300 KW at 1489 RPM. The motor is air cooled and mounted on the head
piece; correct location ensured by a spigot face provided on the head piece.
2.2. Centrifugal Pump Stage Assembly:
First Stage Pump Assembly:
The first stage pump assembly comprises the pump casing, a double entry impeller keyed to the shaft and a
suction bell- mouth. The pump shaft is radially located by eight cut-less rubber bearings, one being fitted in the
bell mouth and one in the first stage casing. The remaining bearings are each located in the 2nd to 7th stage
casing. The bearings are lubricated by the condensate handle by the pump.
2nd To 7th Stage Pump Assemblies:
The second to seventh stage pump assemblies spool pieces are secured together by nuts, bolts and lock
washers and connected to head piece by means of the seventh stage casing. Each of the second to seventh
stages of the pump are almost similar, comprising a pump casing and impeller.
2.3. Coupling:
The main coupling between motor and pump is a spacer type flexible coupling. Each half coupling is keyed to
its respective shaft. The halves being connected by means of a spacer which incorporates flexible membranes
at each end. The coupling is designed to accommodate a certain amount of offset and angular misalignment
and also free end float or vertical movement of the shafts.
2.4. Thrust & Journal Bearing Assembly :
An oil lubricated water cooled type 5-SNT combined thrust and journal bearing assembly is mounted in the
head piece and absorbs the pump hydraulic thrust and the weight of the pump rotating assembly. A thrust
collar is keyed on the shaft and retained in position by a thrust collar nut and lock-washer. The thrust is
absorbed by the tilting white metal faced thrust pads fitted to the base plate, under the collar. White metal lined
journal pads are fitted in the casing and locate the shaft radially. The bearing casing is supplied with cooling
water inlet and outlet line for thrust bearing cooling. This cooling water is taken from DMCW(T) discharge
line.
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2.5. Stuffing Box :

Stuffing box is provided to seal the gland of the pump. Sealing water for the gland stuffing box is supplied
from CEP discharge itself during running condition of CEP.
Initially i.e. before start up of CEP, gland ailing water is supplied from DMSW pump discharge.
2.6. Canister :
The canister is a fabricated tubular chamber formed with a dished bottom end. On the top of the canister a
flange with tapered holes and clearance holes are welded. This flange provides the means for locating and
supporting the head piece.
2.7. Head Piece:

The fabricated head piece which is secured to the pump canister with screws incorporates the discharge and
suction branches and supports the thrust bearing housing and driving motor. The head piece is sealed where
the shaft passes through a stuffing box which incorporates soft packing. Connections for a discharge pressure
gauge, discharge pressure switch and an air vent cock are provided on the discharge branch. A suction pressure
gauge is installed on the head piece. An air vent pipe is also provided within the head piece for connection for
to the condenser tank.
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3. TECHNICAL SPECIFICATION:
Make & Type : M/S. BHEL & EN 7H 32
Direction of rotation viewed from drive end : Clock wise
Rated flow : 350 M3 / hr.
Total dynamic head : 185 Mewl
Condensate temperature : 46.10C
Specific gravity : 0.99 kg/ M3
No. of stages : Seven
Suction bore diameter : 300 mm
Discharge bore diameter : 200 mm
Speed : 1480 rpm
Power absorbed : 216 KW
Efficiency : 81%
Motor rating : 300 KW
4. START PERMISSIVE OF C.E.P:
4.1. Manual Start Permissive: ~
• Suction v/v = Open.
• Recirculation v/v open ≥80%.
• Vent v/v = Open.
• Discharge v/v = Close.
• Hot-well level = Adequate (≥ 0 mm).
4.2. S.L.C. Auto-start Permissive: ~
Out of three pumps, one no., selected as ‘main’ (say pump-
A), is started & between the remaining two pumps-B & C; anyone, say pump-C is kept in
Stand-by mode and thereafter SLC is made ‘on’ .In this condition, the logics are as follows:
• If ‘main ’pump-A runs single, pump-B will start in ‘auto’ when m/c load is > 50%.
• If single running ‘main’ pump-A trips or its discharge header pressure becomes < 16.5
Kg/cm2 when m/c load is > 50%, then pump-B will start in ‘auto’. If m/c load is < 0%,then stand-by pump-C
will start in ‘auto’ instead of pump-B when discharge header pressure becomes < 16.5 kg./cm2.Stand-by
pump-C will also take start in ‘auto’ when common discharge header pressure becomes < 16.5kg/cm2 in case
both pumps-A & B are running.
• Discharge v/v of ‘stand-by’ pump-C will open when common discharge header press.≥ 16kg/cm2.
If M.S. flow & L.P.B.P.CV position are > 60% each, then one or two pumps which are not running, all will
take start. If ‘main’ pump-A or pump-B trips & the reason for tripping is withdrawn then the tripped pump will
start instantaneously irrespective of stand-by pump-C is running or not.
5. INTERLOCK & PROTECTION:
Interlock and protection of condensate extraction pumps are given in the “INTERLOCK & PROTECTION
BOOK” in separate manual.
6. OPERATING PROCEDURE OF C.E.P:

6.1. Pre–Start Checks:
• Ensure that thrust bearing oil level is normal through gauge glass.
• Ensure that thrust bearing cooling water is available from DMCW (T) discharge header.
• Ensure that gland sealing water is available to the stuffing box.
• Ensure pump discharge valve is closed. Pump may be started with discharge valve open, if one pump is
already running or discharge header is full of water, to prevent the pump running out of its characteristic
and imposing an overload on the driving motor.
• Ensure that pump suction valve is fully open and “OPEN” feed back is available in the CRT (control
room VPC) and flood the canister.
• Ensure that all instrument line isolating valves are open and all the instruments are in service.
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• Ensure that vent valve on the air vent pipe to the condenser is open.6.6 KV circuit breaker is “Racked
In” condition, selector switch in on normal position, DC control power in ON, all relays are reset
condition and LOS normal.
• Ensure that discharge valve MCC is “ON” and selector switch is in “Trial” mode for first pump starting
and selector switch is in “Normal” mode for the other pumps.
• Ensure that recirculation line isolating valves are open.
• Gland steam cooler (GSC) bypass valve is open and main line is closed.
• Ensure that CEP discharge header vent valve is fully opened for first pump running.
6.2. Starting Of First Pump:
After ensuring the pre-start checks have been carried out, start the pump from control room. Partially open
discharge valve from local push button and fill up CEP discharge header gradually. After proper venting CEP
discharge header, close vent valve and open discharge valve gradually up to full open condition. Now change
the discharge valve MCC selector switch to normal mode.
[Warning: Pump should not rum for an extended period with discharge valve open.]
After starting of the pump check the following:
• Pump suction pressure is normal.
• Pump discharge pressure is normal (>17 kgf cm-2)
• Pump suction temperature is normal (is equal to hot-well temperature)
• Motor current is normal (≈22 A)
• Check the oil level is normal and thrust bearing oil temperature is bellow 60 °C.
• Check the stuffing box gland for excessive leakage. Ensure that satisfactory leakage is
• Maintained and gland does not over heated.
• Check that there is no leakage in any joint.
• Check that there is no abnormal noise and vibration.
• Check that motor driving and non-riving bearing temperature is normal.
• Check that motor winding temperature is normal.
6.3. Starting Of 2nd Pump:
After proper line up as in case of first pump, 2nd pump may took start if the pump selected as “Standby” mode
and SLC made ON & unit load > 125 MW or running CEP discharge header pressure < 17 kg/cm2. Pump may
be started from control room when pump is not on “standby” mode and discharge valve closed position & vent
valve open condition.
6.4. Pump Normal Running Check Up:
• Suction pressure is normal and DP across the suction strainer is normal
• Discharge pressure of individual pump is normal (20 kgf cm-2)
• Suction temperature
• Motor current
• Check the oil level in the thrust bearing
• Motor bearing temperature
• Thrust bearing oil temperature
• Check for abnormal noise and vibration
6.5. Shut Down procedure when the Pump is to be Isolated:
a. Stop the pump driving motor from control room. Isolate the power supply to the motor i.e. lock out
switch is pressed, DC control power is off, and circuit breaker is racked out.
b. Close the pump discharge valve along with manual equalizing valve. Isolator of discharge valve MCC
is made off and pressed the discharge valve lock out switch.
c. Shut the pump suction isolating valve.
d. Isolate the supply of cooling water to the thrust bearing.
e. Isolate the air vent valve to condenser and lock the valve.
f. Isolate the gland sealing water supply to stuffing box.
g. Isolate the instrument line of that pump.
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BOILER FEED PUMP
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1. INTRODUCTION :
Boiler Feed Pump is a six stage horizontal centrifugal pump of barrel casing design (type FK6D30). It sucks
water from Deaerator storage tank at 26 Mtr. elevation and variable pressure from 2.5 kg / cm2 to 5.3 kg / cm2
and feed it to the economizer inlet either through HP Heaters or by passing HP Heaters one or both. Three nos.
constant speed motor driven variable speed boiler feed pumps ( 50% capacity each) have been provided for
each unit. The pump internals are designed as cartridge which can be easily removed for maintenance without
disturbing the suction and discharge piping work or the alignments of the pump and the hydraulic coupling. As
BFP is handling the feed water of 1600C, so net positive suction head (NPSH) requirement of BFP must be
maintained.
To meet this NPSH requirement BFP suction pressure is being increased by : (i) Placing
deaerator at higher elevation and pressurizing deaerator with pegging steam. (ii) Using booster pump (iii)
Using both (i) & (ii) simultaneously.
The Booster Pump : - Each BFP set consists of a ‘FA1B 56’ Booster Pump directly driven from one end of
an electrically driven motor of which the BFP is driven from opposite end ofthe motor shaft through hydro
coupling. Booster pump suction is from deaerator and discharge is at BFP suction. The bearings in the booster
pump, boiler feed pump and the motor are lubricated from a forced lubricating oil system incorporated in the
hydro coupling. The booster pump is a single stage, horizontal, axially split casing type, having the suction and
discharge branches on the casing bottom half to allow the pump internals to be removed without disturbing the
suction and discharge pipe work or the alignment between the pump and the motor.
The pump shaft is sealed at the driving end and non-driving end by mechanical seals which are flushed by DM
water from DMCW (T) discharge line. The rotating assemblies is supported by plain white metal lined journal
bearings and axially located by glacier double tilting pad thrust bearing. The coupling motor and booster pump
is a diaphragm type spacer flexible coupling.
2. CONSTRUCTION :
The Boiler Feed pump consists of the following main components:-
• Pump casing
• Discharge cover
• Suction guide
• Ring section assembly
• Rotating assembly
• Mechanical seal
• Journal and thrust bearing
• Hydraulic balance
• Coupling
2.1. Pump Casing :

The pump casing consists of a forged steam barrel with welded suction, discharge branches and mounting feet.
The drive end of the casing is closed by a suction guide which is entered from non-driving end of the casing.
The non-driving end of the casing is closed by a discharge cover. The feet are secured to the base plate
pedestals in such a way that it allowing expansion. Provision is made on the pump casing for a drain
connection and temperature probe.
2.2. Discharge Cover :
The discharge cover closes the non-driving end of the pump casing and also forms the balance chamber which,
in turn , is closed by the non-driving end water jacket and mechanical seal housing. The last stage diffuser is
free to slide the balance drum bush which is shrunk into the discharge cover bore to minimize the flow of
liquid to the balance chamber. Holes are drilled radially through the periphery of the discharge cover to
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provide outlet connections through which the liquid from the balance chamber is returned to the pump suction
pipe.
2.3. Suction Guide :
The suction guide closes the drive end of the pump casing and forms the suction annulus. As a section of the
pump cartridge, the suction guide is not secured to the pump casing, but is held against the internal shoulder in
the casing by the ring section assembly, the discharge cover and the spring disc.
2.4. Ring Section Assembly :
The ring section assembly consists of ring sections which locate one to another by spigots and are secured to
each other by socket head screws in counter bored holes ; sealing is being effected by metal to metal joint
faces and ‘O’ rings with back up rings located in grooves in the ring section spigots. Diffusers are dowelled
and spigot located to the ring sections and to the suction guide. The last stage diffuser is secured to the last
stage ring section with socket head screws in counter bored holes ; the screws being locked in position by
locking strips. The ring sections and the diffusers form the passages from the impeller outlet of one stage to the
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impeller inlet of the next stage of the pump. Diffusers are designed to convert some of the kinetic energy of the
product into pressure energy.
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2.5. Rotating Assembly :

The dynamically balanced rotating assembly consists of the shaft, impellers, abutment rings, keys, the rotating
parts of the mechanical seal, shaft nuts , balance drum, thrust collar and the pump half coupling. The shaft is
chromium plated at each end where it is supported by the journals bearings and its diameter increases in
increments from the non-drive end towards the drive end to facilitate the filling and removal of the impeller.
The impellers are of the single entry shrouded inlet type and keyed and shrunk into the shaft. The keys, one per
impeller, being
alternately fitted on the diametrically opposite sides of the shaft to maintain rotational balance. The balance
drum is keyed and shrunk into the shaft and held in place against the shaft locating shoulder by the balance
drum nut and lock washer
2.6. Mechanical Seal (Stuffing Box) :
The mechanical seals are fitted at each end of the pump. Each seal comprises a seal body assembly secured to
a seal housing which contains the rotating components of the seal. Each seal consists of a rotating tungsten
carbide sheet, mounted in a carrier, running against a stationary carbon face. Contact between the face and the
seal is maintained by hydraulic pressure during running and by a spring pressure during start up. As BFP
handle hot water (≈ 160 °C) the seal is designed to circulate the pumped water through a seal cooler to
maintain acceptable temperature in the region of the seal face. In seal cooler mechanical seal water is cooled
by DM cooling water for turbine auxiliaries.
2.7. Journal & Thrust Bearing:
The rotating assembly is supported at each end of the shaft by a white metal lined journal bearing and the
residual thrust is carried by a tilting pad thrust bearing mounted at the non-driving end of the pump. The
journal bearing shells are of mild steel, white metal lined, thick wall type and are split on horizontal plane
through the shaft axis The thrust bearing has eight white metal lined tilting pads held in split carrier ring
positioned on each side of the thrust collar. The carrier rings are prevented from rotating with the shaft by
dwell pins. A split flowing oil sealing ring is located in a group in the thrust bearing housing to restrict escape
of ubricating oil from the thrust bearing chamber. To ensure that the thrust remains flooded an orifice is fitted
at the oil outlet. The bearings are supplied with lubricating oil from the forced lubricating oil system.
Bearing Housing :-
The bearing housings are in the form of cylindrical casting split on the horizontal shaft axis. The drive end
bearing housing is secured to the bearing housing bracket. Oil guards fitted in a groove at each end of the
bearing housing are dowel located and serve to prevent oil escaping from the housing. An air breather is
screwed into a tapped hole in the top bearing housing.
The non-drive end bearing housing, which contains both journal and thrust bearing is secured to the bearing
housing bracket by studs and nuts.
2.8. Hydraulic Balance :
The rotating assembly is subject to varying force due to the differential pressure forces acting on the impellers.
The thrust caused by the suction pressure acting on the area inside the wear ring on the inlet side of each
impeller is overcome by the much greater thrust caused by discharge pressure acting on these equal areas,
tends to move the rotating assembly towards the suction side of the pump. Therefore the pump has been
designed so that the shaft is kept in tension by the location of a balance drum at the non-drive end and is
hydraulically balanced so that only a small residual thrust remains. This residual thrust is carried by the thrust
bearing.
The main components of hydraulic balancing are the balance chamber in the discharge cover, the balance
drum and the balance drum bush. The balance drum is secured to the shaft and the balance drum bush is the
bore of the discharge cover.
Working principle of hydraulic balance arrangement: -
The pump discharge passes from the last stage of the pump between the balance drum and the bush, and enters
the balance chamber at a pressure approximately equal to the suction pressure. Two ports in the pump back to
the pump discharge cover allow the product to be piped back to the pump suction. The pressure difference
across the balance drum is therefore equal to discharge pressure minus suction pressure. The cross section area
of the balance drum sized in such a way that total thrust across the impeller is almost balanced by this balance
drum. The small residual thrust acts towards the drive end of the pump and taken care by the tilting pad thrust
bearing.
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2.9. Coupling :
2.9.1. Flexible coupling:
The flexible coupling between the hydraulic coupling and the pump shaft consist of two halves flexibly
connected through laminated stainless steel elements to a tubular spacer.
2.9.2. Hydraulic coupling:
Introduction: - To get high amount of discharge with high discharge head, as in the case of boiler feed pump,
centrifugal pump with high blade tip velocity or pump with multi staging have to be used. High blade tip
velocity can be achieved by increasing impeller diameter or by increasing pump rpm. Pump number of stage
could not be increased beyond a certain value due to pump size and inter stage leakage problem. Again drum
pressure varies during start up, shut down and in different load condition. To cope up with this situation BFP
discharge pressure have to vary with drum pressure to get almost constant feed control differential pressure,
which is important for controlling drum level. To fulfill all the above criteria i.e. high tip velocity for high
discharge head with variable discharge pressure, hydraulic coupling with gear arrangement is used. First by
gear arrangement, pump speed is being increased up to 5150 rpm from 1485 motor speed and then control the
speed by hydraulic coupling. Here Voith geared variable speed hydraulic coupling is used.
VOITH Variable Speed Coupling: -

Main components of this type of coupling are
(i) Input shaft, (ii) gear and pinion, (iii) primary shaft, (iv) hydro coupling primary wheel, (v) hydraulic
coupling secondary wheel, (vi) scoop tube, (vii) working oil / lube oil pump with spar and bevel gear, (viii)
auxiliary lube oil pump assembly. Input shaft of hydraulic coupling is coupled with motor shaft through 8 nos.
bolt standard spacer coupling. Power is transmitted to the gear through this shaft. Here gear and pinion has 163
and 47 no. of teeth respectively. So gear ratio is 163/47. From the pinion power is transmitted to the hydro
coupling primary wheel through a shaft called primary shaft. Then power / torque is transmitted to secondary
wheel by pump and turbine action of primary and secondary wheel respectively. A scoop arrangement control
the speed of the secondary wheel by controlling quantity of working oil in the coupling chamber between
primary and secondary wheel. The coupling size is selected so that the full power can be transmitted with a
low slip.
Oil Circuit : -
The same oil is used as working oil and lube oil. The working oil pump (13) [centrifugal pump] and the main
lube oil pump (14)[ gear pump] are combine to form a pump set driven by the input shaft of geared variable
speed turbo coupling. The electric motor driven the auxiliary lube oil pump (15) [AOP] lubricates the unit at
start up, during shut down and in case of interferences.
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Working Oil Circuit: -

The working oil consists of a closed circuit superimposed by an open circuit so that the filling can be changed.
In the closed circuit, the oil which flows into the coupling (55) via the circulation control valve for power
transmission and heat dissipation, is removed by the displaceable scoop tube (50). Under the action of dynamic
pressure, the oil flows through the scoop tube housing, oil cooler (34) and circulation control valve (32) back
into the coupling (55). The open circuit is made up of the working oil pump (13), throttle (30) and pressure
relief
valve (31). The geared variable speed turbo coupling (55) is filled with oil flows from the open to the closed
circuit. Excess oil supplied by the working oil pump flows through the pressure relief valve (31) back into the
sump. The same applies when the coupling filling is reduced.
The connecting pipe with orifice plate (71) between lube oil and working oil circuit is provided for faster
filling of the working oil circuit during start-up. The operating pressure of working oil is set on the pressure
relief valve (31). If the closed circuit is interrupted and the geared variable speed turbo coupling oil
temperature rises to 160° C, the fusible plugs blow due to a temporary thermal overloading of the oil circuit
e.g. due to cooler failure or overloading of coupling, the control behavior of the coupling changes slightly.
Lube Oil Circuit:-

The main lube oil pump (14) pumps oil out of the sump through the non-return valve (17), pressure relief valve
(24) , lube oil cooler (28) and the reversible double filter (26) to the bearing points, pressure switches and the
gear wheels. The lube oil pressure is set to approx. 2.5 bar on pressure valve (24). To ensure the bearing are
coated with an oil film during start up, shut down and failure, they are supplied with oil by the auxiliary lube
oil pump (15) before the drive motor is switched on and after it is switched off. The auxiliary lube oil pump,
which is driven by the electric motor (16), draws lube oil out of the sump and pumps it through a non return
valve (17) into the lube oil circuit. Lube oil for external units (e.g. drive motor, driven machine or connecting
coupling) are supplied from the same lube oil circuit and return to the oil sump.
Scoop Tube Control:-
The scoop tube which regulates the amount of oil in the coupling is controlled by the actuator turning the cam
disc (37), positioning the scoop tube (50) accordingly.
Step up speed control: -
The scoop tube moves away from the oil ring in the coupling, the amount of oil scooped up decreases, the
pressure in the circulating control valve (32) drops, the pressure relief valve (31) closes, the quantity delivered
by the working oil pump (13) is also used to fill the working chamber.
3. TECHNICAL SPECIFICATION :
221
BOOSTER PUMP :
Type / Make : Centrifugal / BHEL
Dynamic head : 100 M
Rated capacity : 400 m3/hr
Speed : 1485 rpm
4. INTERLOCK & PROTECTION AND START PERMISSIVE :

Interlocks, protection and start permissive of Boiler Feed Pump are discussed in the “Interlock & Protection
Book”.
5. OPERATING PROCEDURE OF B.F.P :
5.1. Pre-Start Checks :
• Ensure that deaerator is filled with DM water to normal working level.
• Check all instruments of BFP set are fitted and showing correct readings at local panel.
• Ensure the drain valves of Booster pump casing and BFD line are closed.
222
• Check BFP discharge valve and its equalizer position. MCC and LOS of these valves should be ON and
Normal. Discharge valve should be ‘Closed’ if it the first pump and discharge valve should be
‘Opened’ if it the second or standby pump.
• Open the booster pump air vent valve and BFD line drain valves (if 1st pump) ; then crack open the
BFP suction valve. Any trapped air will be released through these vent valves. After sufficient water
coming out through these vent valves, close the vent valves and then fully open the BFP suction valve.
Confirm that “suction valve open” feed back appeared in CRT (control room).
• Check Booster pump suction pressure is 3.0 kg/cm2 or more in cold condition. In hot condition this
should be more than 8.0 kg/cm2.
• Check the mounted instruments of Pump, Motor and Hydraulic Coupling.
• Check recirculation manual isolating valve at Deaerator floor & pneumatic control valve are “OPEN”.
Repeat for full open. Air line for recirculation control valve should be opened and kept the recirculation
controller in “AUTO” position i.e. indicator is in middle position so that valve can operate from control
room.
• Check DMCW (T) system is in service.
• Check manual isolating valves for lube oil cooler and working oil cooler are open i.e. lube oil cooler
and working oil cooler are in service.
• Open the BFP driving end and non driving end mechanical seal cooler circulating
• water inlet and outlet valves. Vent the mechanical seal cooler properly.
• Ensure cooling water supply to BFP & Booster pump stuffing box is established.
• Check that motor armature cooling inlet and outlet manual isolating valves are open. MCC & LOS of
motorized valve (DMCW-63A/B/C) should be “ON” & “Normal” condition.
• Ensure the Voith coupling oil level normal and check auxiliary oil pump (AOP) is running and the lube
oil pressure is ≥ 2.0 kg/cm2. Check differential pressure (DP) across the lube oil strainer ; it should be <
0.2 kg/cm2.
• Check the Voith coupling oil color.
• Check the smooth operation of hydro-coupling scoop from control room. After that scoop tube position
should be kept at minimum (25-30%).
• Ensure 6.6 KV power supply is available in all respect i.e. 6.6 KV Breaker is Rack
• In, Normal, DC ON and all relays are reset condition. After that release the lock out switch of the
pump.
5.2. Running Of Pump :
After fulfilling the above points and satisfying the start permissive of BFP, boost up the bus
voltage at least 6.7 to 6.8 KV and then start the BFP. Motor armature cooling water valve
DMCW-63A/B/C will open automatically.
Observe closely the shifting of magnetic centre of motor (axial play) and it will take about 25
to 30 seconds to be steady position.
Observe that the AOP will cut out at > 2.8 kg/cm2 lube oil pressure (AOP will cut in
automatically at lube oil pressure ≤ 1.5 kg/cm2).
5.3. Check After Start Of BFP :
• Check the discharge pressure of BFP is ≥ 50 kg/cm2 at minimum scoop with discharge
• valve closed condition.
• Check the Voith coupling oil level is normal and no leakage in the working oil and lube
• oil system.
• Check the working oil pressure and temperature. The recommended values are < 2.5
• kg/cm2 & < 1000C respectively. Observe the rate of increase of working oil temperature.
• Check lube oil pressure at common header is 2.5 kg/cm2. Check the bearing oil pressure
in all the bearings. The normal values are as follows :-
- Booster pump thrust bearing lub. oil pressure 0.8 kg/cm2
- Booster pump NDE bearing lub. oil pressure 0.8 kg/cm2
- Booster pump DE bearing lub. oil pressure 0.8 kg/cm2
- Motor bearing BP end lub. oil pressure 0.8 kg/cm2
223
- Motor bearing HC end lub. oil pressure 0.8 kg/cm2

- BFP DE Jrnl. Brg. Lub. oil pressure 0.8 kg/cm2
- BFP NDE Jrnl. Brg. & Thrust Brg. Lub. oil pressure 0.8 kg/cm2
• Recirculation valve will modulate to ensure the minimum flow of 100 TPH through
the pump.
• Check the motor current is normal.
• Check the BFP set for any abnormal sound or behaviour.
• Check lube oil DP across strainer. Its operating value is 0.2 kg/cm2.
• Check DP across booster pump suction strainer. Its operating value is 0.1 kg/cm2.
• Check balance leak off pressure and it should be 17 – 18 kg/cm2.
• Check dT across BFP suction and discharge. Its recommended value is 40C.
• Check the vibrations of all the bearings of pumps and motor. The following vibration
levels of the pump bearings are recommended :-
- 7 mm/sec. (Normal)
- 10 mm/sec. (Satisfactory).
- 13 mm/sec. (Unsatisfactory).
- These are the peak to peak values.
Check the bearing temperatures of Hydraulic coupling, specially for Bearing No.6.The recommended
values of the bearing temperatures of the BFP set are as follows :-
- BP NDE Journal bearing temperature 800C
- BP DE Journal bearing temperature 800C
- BFP DE Journal bearing temperature 800C
- BFP NDE Journal bearing temperature 800C
- BP Thrust bearing temperature 750C
- BFP Thrust bearing temperature 750C
- HYD Coupling Jrnl. Brg.1 temperature 800C
- HYD Coupling Thrust Brg. 3/4 temperature 750C
- HYD Coupling Jrnl. Brg.7,8/9,10 temperature 750C
Check the bearing drain oil temperatures. The recommended values by the manufacturer
are as follows:-
- BP NDE Journal Bearing & Thrust Bearing drain oil temperature 650C
- BP DE Journal bearing drain oil temperature 650C
- Motor bearing (BP end) drain oil temperature 650C
- Motor bearing (HC end) drain oil temperature 650C
- BFP DE Journal bearing drain oil temperature 650C
- BP NDE Journal Bearing & Thrust bearing drain oil temperature 650C
5.4. Auto Start-up Sequences:
5.4.1) Step-01 = Pump start permissive.
5.4.2) Step-02 = a] Selected stand-by pump’s lamp indication appears.
b] A.O.P. takes start & L.O. press. > 2 kg./cm2.
c] Discharge v/v. of the pump along with its I.B.V. close.
d] Recirculation v/v. opens.
e] Scoop position becomes minimum.
5.4.3) Step-03 = a] Pump takes start.
b] DMCW I/L v/v. opens.
5.4.4) Step-04 = a] Pump scoop changes over from ‘man’ to ‘auto’ mode.
b] Scoop position matches as per demand.
5.5. Auto Shut-down Sequences:
5.5.1) Step-51 = Shut-down-selected pump stop command.
224
5.5.2) Step-52 = a] A.O.P. takes start.

b] DMCW I/L v/v. closes.
c] Recirculation v/v. opens.
225
35
C.W. AND A.C.W. PUMPS
Introduction:-
In Turbine & Auxiliary System of operation different sub-system are incorporated such as Main Steam
System, Feed System, Cooling System, Lub Oil System, Gas System, Regenerative Feed Heating System,
Auxiliary Cooling Water System, Generator Seal Oil System, Condensate System, etc. Feed Water Cycle
System starts from condensate system and ends at Boiler Drum through regenerative system & boiler feed
station. The cooling water system comprises of two main systems.
(a) Circulating Water system (CW)
(b) Auxiliary Cooling Water system (ACW).
The function of Circulating water system is to remove the latent heat of steam in condenser & transform
exhaust steam to water.
Auxiliary cooling water system which removes heat content of turbine lub oil cooler, hydrogen cooler, seal oil
cooler, compressor cooler indirectly or directly through heat exchanger.
Feed cycle operation is carried out in two parts. 1st part is to drive condensate water from Hotwell to Deaerator
through LP Heater, Drain Cooler and Gland Steam Cooler, Ejector by CEPs and the 2nd part is Boiler Feed
system to drive feed water from Deaerator to Boiler drum through HP Heater, Feed Control Station,
Economiser by BFP’s.
AUXILIARY COOLING WATER PUMP & SYSTEM (ACW):
In ACW pump there are 6 nos. of line shafts including pump shaft and head shaft. All shafts are inter
connected with the help of shaft coupling. The pump shaft is radially located by cutless rubber bearing. The
pump impeller is fitted on the pump shaft with impeller key. This impeller assembly is fitted inside the bowl
assembly. Water is entering into the impeller from feed pool through the bell mouth of the bowl assembly. The
pump & shaft assembly is located inside the column pipes to guide water to discharge through discharge pipe.
A combined Deep groove ball & Spherical roller thrust bearing is used to take the axial thrust of the pump.
The same water flowing through a cooling coil fitted inside the bearing housing does cooling of this bearing.
Oil is given inside the bearing housing for lubrication of bearing. At the top of the bearing housing one ratchet
plate is fitted to restrict the reverse rotation of the pump in case of back flow. Gland packing asbestos rope is
used inside the stuffing box for sealing of water leakage.
Auxiliary cooling water system water is required to cool or reduce the temperature of main cooling water like
DM water. DM water system is required to cool the temperature of different lub oil system of various
equipments. The ACW system starts from ACW Pumps. Two nos. ACW pumps of 100% capacity each are
provided for each unit for meeting the cooling water requirement. The ACW pumps take suction from feed
pool. The discharge headers of all the three units are inter connected with an isolating valve to increase the
flexibility of operation. ACW strainers are provided in the common discharge header of ACW pump to
prevent particles of size more than 2 mm to pass through the system.
The ACW pumps supply water through DMCW(T) PHE at the rate of 500 M3/hr per PHE, DMCW(B) PHE at
the rate of 325 M3/hr per PHE, seal oil cooler at the rate of 90 M3/hr per cooler, Turbine oil cooler at the rate
of 200 M3/hr per cooler.
The warm cooling water from the above coolers and heat exchangers returned to the circulating water outlet
line of condenser and then back to the feed pool again via cooling tower. The feed pool receives make up
water from Raw Water system.
Technical Information: -
1. Model - TM24TC.
2. Type - Vertical, Mixed flow, Non-pull out.
3. Rated Capacity - 2400 M3/hr.
4. Rated TDH - 40 MWC / 4 Kg/Cm2
5. Efficiency - 74.7%.
6. Speed - 1480 rpm.
226
7. Motor Rating - 350 KW.

8. Operating Floor - 80 M RL.
9. Sub-floor - 76 M.
10. Max. WL in - 74.5 M.
11. Min. WL in - 72.75 M.
12. Emergency Trip Level - 72.3 M.
227
36
THERMODYNAMICS IDEA OF REGENERATIVE FEED HEATING SYSTEM:
Study of the Rankin Vapour Cycle has shown that improvement requires either an increase in the thermal state
of the high-pressure steam, a decrease of that of the exhaust steam, or both. In other words, increased
efficiency requires increased boiler pressure, initial superheat and condenser vacuum. These improvements
reached natural limits of boiler strength, high temperature metallurgy and available condensing water
temperature. While the upper temperature limit is slowly being increased, the ideal Rankin Cycle performance
is relatively static. Progress has come with other cycles – primarily the Regenerative feed heating cycle has
been considered in order to improve the cycle efficiency. This modified cycle is definitely more efficient than
the simple Rankine Cycle for the same terminal steam conditions. Its principal feature is a thermal
regeneration of condensate in to high temperature feed water by the use of steam bled from the prime mover at
points intermediate between throttle & exhaust.
The advantage of regenerative cycle over the Rankine Cycle is that the heating steam, as extracted from the
prime mover, has released considerable amount of mechanical work represented in its available energy while
retaining most of its feed water heating availability. By extracting a portion of the main flow before it reaches
too low a thermal state it still contains most of the initial enthalpy. When the feed water is progressively heated
nearly to boiler saturation temperature, the necessary heat input to the cycle is decreased. As this decrease is
greater than the mechanical work lost by prematurely extracting a small quantity of steam from the turbine, the
cycle efficiency is higher than that of the non-extracting or Rankine Cycle.
The flow diagram of the regenerative cycle with saturated steam at the inlet to the turbine and the
corresponding T-S diagram are shown in Fig.-1 & Fig.-2 respectively. For every kg of steam entering the
turbine, let m1 kg steam be extracted from an intermediate stage of the turbine where the pressure P2 (State 2)
and it is used to heat up feed water (1-m1) kg at state 8 by mixing the heater 1. The remaining (1-m1) kg of
steam then expands in the remaining stages of the turbine to pressure P4, gets condensed into water in the
condenser and then pumped to heater 2, where it mixes with m2 kg of steam extracted at pressure P3. Then (1-
m1) kg of water is pumped to heater – 1 where it mixes with m1 kg of steam extracted at Pressure P2. The
resulting 1 kg of steam is then pumped to the boiler where heat is supplied from an external source.
The amounts of steam m1 & m2 extracted from the turbine are such that at the exit from each of the heaters,
the state is saturated liquid at the respective pressures. The heat & work transfer quantities of the cycle are:
Turbine work, Wt = 1(h1 – h2) + (1-m1) (h2 – h3) + (1-m1 - m2) (h3 – h4) KJ/ kg. ----------(1).
Pump work, WP = WP1 + WP2 + WP3
= (1-m1 - m2) (h6 – h5) + (1-m1) (h6 – h7) + (h10 – h9) KJ/ kg. ----------(2).
Heat Addition, QA = 1(h1 – h10) KJ / kg.
Heat Rejection, QR = (1-m1 - m2) (h4 – h5) KJ / kg.
Cycle efficiency, η cycle = (QA - QR )/ QA = (WT - WP ) / QA
Steam Rate = (3600) / (WT - WP ) kg/KW-hr.
Heat Rate = (3600 QA) / (WT - WP ) KJ / Kw-hr.
= (3600 / η cycle) KJ / Kw-hr.
In the Rankine cycle operating at the given pressures, P1 & P4, the heat addition would have been from
State 6 to State 1. By using two stages of regenerative feed water heating, feed water enters the boiler at State
10, instead of State 6, and heat addition is, therefore, from state 10 to State 1.
Therefore, (Tm) with regeneration = (h1 – h10) / (S1 – S10) ---------(3).

Since, (Tm) with regeneration > (Tm) without regeneration, the efficiency of the regeneration cycle will
be higher than that of the Rankine cycle.
The energy balance for heater 2 gives,

m1 h2 + (l – m1) h8 = h9
228
m1 = (h9 – h8) / (h2 – h8 ) -------- (4).
The energy balance for heater 1 gives,

m1 h3 + (1- m1- m2) h6 = (1 – m1 ) x h7
or, m2 = (1 – m1 ) ( h7 – h6 )/ ( h3 – h6 ) … … … (5)
From equation (4) & (5), m1 & m2 can be evaluated.
Equations (4) & (5) can also be alternately written as
(1 - m1) ( h9 – h8) = m1 (h2 – h3)
(1 - m1 – m2) ( h1 – h6) = m2 (h3 – h7)
Energy gain of feed water = Energy given off by Vapour in condensation.
Heaters have been assumed to be adequately insulated and there is no heat gain from, or heat loss to, the
surroundings.
Thus the heating of feed water by steam bled from the turbine, known as, regeneration, is used to
improve the efficiency of the cycle (3 to 4% gain in cycle efficiency).
The heat rejected QR in the cycle decreases from (h4 – h5) . There is also loss in work output by the
amount (area under 2-21 + area under 31 – 3” - area under 4 – 41), as shown by the hatched area in fig 2(b).So
the steam rate increases by regeneration for the same reason, i.e. more steam has to be circulated per hour to
produce unit shaft output.
Regenerative Feed heating system at Thermal Power Plant:
Steam from the boiler enters into the turbine with high pressure and high temperature. In the turbine this high
pressure & high temperature steam expands and thermal energy in the steam is converted into mechanical
energy. Finally, steam is condensed into water in the condenser and water is being reused as feed water in the
boiler. During condensation latent heat in the steam is taken out from the system by cooling water – this is the
major loss in Turbine cycle. If some amount of heat is taken out from the turbine after partial expansion before
going to condenser and is used for heating up the condensate / feed water, then total heat including latent heat
in the steam will remain within the cycle. In this way, condenser loss is reduced and cycle efficiency increases
up to 4%.
Specific work out put (power output per kg of steam) of cycle decreases due to regenerative feed heating as
some amount of steam is taken out from the earlier stages of turbine which is not doing any work in the
remaining stages of the turbine. For this reason, maximum 30% steam can be extracted from turbine for
regenerative feed heating purpose.
Feed water temperature at the economizer inlet also increases due to regenerative feed heating – as a result of
that, Boiler efficiency decreases due to high stack loss.
The regenerative feed heating cycle starts from condenser at low-pressure end and ends at economizer inlet at
high-pressure end. Steam extraction points have been taken from turbine to provide uncontrolled steam flow to
2 – inverted U type HP heaters and 3 – inverted U – type LP heaters and to deaerator which is of direct contact
type. These extraction points are described below: -
Extraction No. 6 : Extraction 6 is taken from cold reheat line and connected to HP Heater-6. At 210 MW, its
parameters are: Pr = 37.23 ATA
TEMP. = 340.78 oC
Flow = 59.309 T/H.
Extraction No.5: It is taken from 10th stage of IP turbine and connected to HP Heater-5. At 210 MW its
parameters are: Pr = 15.42 ATA
TEMP. = 423.57 oC
Flow = 34.673 T/H.
Extraction No. 4 : Extraction – 4 is taken from cross around pipe to Deaerator. Its parameters are: Pr = 6.30
ATA
229
TEMP. = 306.69 oC
Flow = 33.481 T/H.
Extraction No. 3 : It is taken from 3rd stage of LP turbine to LP Heater – 3. At full load, extraction pressure =
2.185 ATA
Temp. = 191.91 oC
Flow = 26.390 T/H.
Extraction No. 2: It is taken from 5th stage of LP turbine to LP H-2. At full load, its parameters are: Pressure
= 0.799 ATA
Temp. = 101.81 oC
Flow = 28.343 T/H.
Extraction No. 1: It is taken from 7th stage of LP Turbine to LPH-1. At full load, its parameters are: Pressure
= 0.204 ATA
Temp. = 46.15 oC
low = 5.527 T/H.
All the extraction lines except Extraction-1 consist of one non-return valve (check valve) and a motorized gate
valve. Both these valves close under the following conditions:
a). If, turbine trips due to any reason.
b). If, Heater level is very high (to safeguard turbine from water ingress).
c). Secondary oil pressure < 2.80 kg / cm2
d). Cross around pipe pressure <2.73 kg / cm2
e). The NRV of extraction – 4 will close if –
i). Deaerator level becomes very high (>465 mm wc)
ii). Secondary oil pressure is low (< 2.8 kg / cm2 )
iii). Check valve dp <0.6 kg / cm2
iv). Turbine is in tripped condition.
v). Cross around pipe pressure < 2.73 kg / cm2
The motorized valves and NRVs will get the permissive for opening when the above mentioned conditions
will be withdrawn.
Extraction – 1 line consists of a motorized valve only – No NRV is provided at Extraction –1 line.
HEATERS
Heater is a special form of a shell and tube heat exchanger designed for the unique application of recovering
the heat from the extracted steam (bled from turbine for heating up condensate or feed water and as a result of
that heat exchange feed water enters the economizer at higher temperature.
Types of Heaters:
i). Open Type Heater: In an open type heater, extracted steam is allowed to mix with condensate water
and both leave the heater at common temperature. The advantages of open type heaters are simplicity; lower
maintenance requirement and high heat transfer capacity. The only open type heater, used in thermal power
plant is ‘deaerator’ primarily for the purpose of ‘deaeration’ (Details of deaerator will be discussed separately).
ii). Closed Type Heater: In a closed type heater, feed water or condensate water flows through the tubes
in the heater and the extracted steam condenses on the outside of the tubes in the shell. Heat released by the
process of condensation is transferred to the feed water through the walls of the tubes. Closed type heater can
be classified into two categories:
(a). High Pressure Heaters: The heaters which are placed in feed cycle (i.e. after BFP discharge) where water
pressure as well as extraction pressure are high, called high pressure heaters. Not only extraction pressure but
also the extraction temperatures of HP Heaters are also high. Two nos. of HP heaters are provided in Bk.TPP
units, namely HPH-5 & HPH-6.
(b). Low Pressure heaters: The heaters, placed at condensate line (at the CEP discharge) handle low water
pressure as well as low extracted steam pressure & temperature. These heaters are called LP
heaters. Three numbers of LP heaters are provided at Bk.TPP units, namely, LPH-1, LPH-2 & LPH-3.
Cascading system and Drip system:
230
In a heater, feed water or condensate water flows through the tubes and the extracted steam condenses into
water. This condensed water is known as heater drip. The condensed water or drip leaves the heater either in
saturated or sub-cooled state.
Drip from a heater operating at higher pressure passes to another heater, operating at lower pressure by either a
natural pressure difference or sometimes by drip pumps. When transfer of drip from one heater to other occurs
by pressure difference (without the use of a pump) is called cascading system. When drip pumps are used to
feed the drip directly into feed or condensate water stream (at a suitable point where parameters are matched
properly)- it is called drip system.
Only cascading system is used at Bk.TPP units. The normal level of drip in HP heater –6 is maintained by
normal level controllers by cascading the drain to HP heaters-5 or deaerator through two separate control
valves.
In case of high level (due to tube leakage etc.) of heater –6, drip is transferred to HP flash tank (condenser).
Normal and High levels of HPH-5 are maintained by cascading the drip to deaerator & HP flash tank
respectively through two separate control valves.
The normal levels of LPH-3 & LPH-2 are maintained by cascading the drip to LPH-2 & LPH-1 respectively
whereas high levels of LPH-3 & LPH-2 are controlled by transferring the drip to LP flash tank of condenser
through respective drip level controllers.
No drip level controller is provided to control the drip of LPH-1. The drip of LPH-1 is transferred to LP flash
tank of condenser in an uncontrolled way (by pressure difference).
Heater Construction: A heater is a special form of a shell and tube heat exchanger. Its principal parts are a
channel and tube sheet, tubes and a shell. It can be designed for either low or high feed water pressures and
may be installed either horizontally, vertical channel down or vertical channel up. The tubes may be either
bent tubes or straight tubes.
The major parts of a heater are:
1) A shell with a steam connection which is a cylindrical body fabricated from cast steel and sealed at
lower end by a cast steel water box.
2) A nest of tubes which consists of channel, tube sheet and ‘U’ tubes. Baffles are provided to ensure that
the steam is directed across the tubes. Inverted ‘U’ tubes are made of stainless steel.
A water box, with water line connection :
Heater vents & drains: Continuous venting is necessary to clear the no condensable gases from the heater in
order to get better performance of heater. Vent lines of LP heaters and HP heaters are connected to condenser
and Deaerator respectively. Vent lines are provided with an orifice and a valve to restrict the vent flow.
Drain lines are provided at extraction lines, drip lines & Heater body (shell drain) which are kept open during
initial charging of heater to avoid hammering of the above mentioned lines.
There are three heat transfer zones in a typical H.P.Heater –

a). Desuperheating Zone: This zone is the last feed heater zone through which the feed-water passes before
leaving the heater. When the feed water enters the zone it has been heated in the condensing zone to within a
few degrees of the saturation temperature, corresponding to the bled steam pressure at the entry to the feed
heater. Although the Desuperheating zone adds only a small percentage of the total heat transferred in the
heater, this small rise in feed water temperature is very valuable in terms of thermal economy. The heat in the
zone is transferred by convection – the superheater steam can be considered to behave as a normal gas.
The steam normally leaves the Desuperheating zone in super heated condition. The tube wall temperature is
above the saturation temperature of the bled steam and therefore, there is no problem of droplet formation by
the condensed steam. Otherwise the droplets may carry over to the condensing zone with relatively high
velocity and could cause impingement at the exit from the zone.
b) Condensing Zone: In the condensing zone, overall coefficient of heat transfer is high. The main problem in
a larger heater is to obtain good steam distribution to the condensing surface with the minimum pressure loss.
Continuous venting is necessary to help the steam distribution and to clear any non-condensable gases to get
better performance of the heater.
c) Drain-cooling Zone: In this zone, heat is rejected by the drip below saturation temperature and the feed
water gains heat. This zone is the first feed heater zone, where, feed water is entering the heater.
Technical data for HPH – 5 & 6:
231
HPH - 5 HPH - 6
Type U Tube, Vertical U Tube, Vertical
Number of Tube 1029 ‘U’ 1055 ‘U’
Tube material SS 688 TP 304 SS 688 TP 304
Number of Pass 2 2
Number of heat Transfer Zones 3 3
Feed water velocity 1.74 m/sec. 1.76 m/sec.
Quantity of extraction steam 35 T/H 60.231 T/H
Quantity of feed water 631 T/H 631 T/H
TERMINAL TEMPERATURE DIFFERENCE: Difference between the saturation temperature at steam

extraction pressure and the temperature of feed water or condensate water leaving the heater is known as
terminal temperature difference (TTD).
TTD = Saturation temperature of steam at extracted pressure

Temperature of feed water leaving the heater.
At 75% load TTD ofHPH-5 is – 1.8 oC and for HPH-6 it is – 1`.0 oC
At 100% load, TTD values for HPH-5 & 6 are 0 oC
Drain Cooler Approach: Difference of temperature between the drip leaving a heater and feed water entering
the heater is known as Drain Cooler Approach (DCA).
At full load, DCAs for HPH-5 & 6 are 6 oC each.
Optimization of Number of Heaters:
The higher the number of heaters used, the higher will be cycle efficiency. As per R.W Haywood (See,
Analysis of Engineering Cycles by R.W Haywood. Pergamon Press, 1973), if ‘n’ number of heaters are used,
then greatest gain in efficiency occurs when overall temperature rise is about n / (n +1) times the difference
between boiler and condenser saturation temperatures.
If (∆t) o = t (Boiler sat. temp.) – t (Condenser sat. temp.)
And (∆t) fw = temp. rise of feed water, then
n = 0, (∆t) fw = 0
n = 1, (∆t) fw = ½ (∆t) o ½ (∆t) o
n = 2, (∆t) fw = 2/3 (∆t) o 1/6 (∆t) o
n = 3, (∆t) fw = 3/4 (∆t) o 1/12 (∆t) o
Since, Cycle efficiency is proportional to (∆t) fw, the efficiency gain follows the law of diminishing
return with the increase in number of heaters. For this reason, the number of heaters gets optimized because
cost of adding another heater sometimes does not justify the saving in heat addition (QA) or there may be
marginal increase in efficiency. Generally five or six points of extraction are often used in a thermal power
plant.
*** *** ***
337
CONDENSATE AND AIR EJECTION SYSTEM, PRINCIPLE OF
DEAERATION & CONSTRUCTIONAL DETAILS OF DEAERATION.
Condensate System:
For extracting the condensate from condenser Hotwell and feeding it into the cycle, 3X 50% condensate
pumps have been provided. Normally two condensate extraction pumps are working while the third pump is
standby.
232
Any one of the pump can be selected as working with the help of a switch. One pump will be in operation up
to 50% load. In case header pressure falls below set value, pressure switch will give signal to other two pumps
to cut in.
In case of high-pressure drop alarm in the suction strainer, the working pump is to be isolated and standby
pump has to be brought into service remote manually.
Following systems are supplied condensate from condensate pump discharge:
1. LP Bypass spray.
2. Turbine Exhaust Hood Spray.
3. Turbine Flux Boxes Spray.
4. Chemical Dilution.
5. Condensate pump sealing.
6. Vacuum breaker sealing.
7. Valve Gland Sealing.
8. Auxiliary PRDS spray.
9. Spray to HP drain flash tank.
Condensate from pumps passes through main ejectors, gland steam condenser (GSC), drain cooler,
low pressure heaters 1,2 & 3(LPH 1, LPH 2, LPH 3) and finally to Deaerator.
After CEP condensate passes through main ejector. Both the main ejectors are providing with valves at
condensate inlet and outlet for individually isolating the ejector on condensate side. These valves are provided
with limit switch. Each ejector is design for 50% condensate flow through tubes. In case a main ejector is
isolated from condensate side, manual regulating bypass valve (CD- 41) shall be open to allow 50%
condensate flow through bypass line. Restriction orifice provided in the bypass line balance out the pressure
drop across the effected ejector.
After main ejector, the equipment in condensate line is Gland steam condenser (GSC). GSC has been
provided with inlet and outlet isolating valves and a bypass valve. In case GSC is isolated from condensate
side, bypass valve has to open. Recirculation control valve is provided after GSC to ensure condensate flow
through main ejector and GSC even when there is no flow to Deaerator. A Hotwell level control valve is
provided in condensate line at that position. After Hotwell control valve a line with a control valve and
motorized bypass valve is provided which is called excess return. This line is connected to condensate storage
tank.
After that condensate enter into Drain cooler and then into LP heater-1. Drain cooler and LP heater-1
are provided with common inlet and outlet motorized valve and a common motorized bypass valve. After LP
heater -1 condensate passes through LP heater-2 and three respectively. Both the heater has provided with
motorized valve in inlet and outlet and a motorized bypass valve. After LPH-3 condensate enter into
Deaerator, which is the last equipment in condensate cycle.
DM make-up water system, Deaerator level control, Hotwell level control:

Normal cycle make-up is added to condenser Hotwell through make-up control valve DM-53 by gravity from
condensate storage tank. A bypass line is provided with one motorized valve (DM-55), which may be used in
case of control valve failure. Maximum 3% make-up is allowed for continuous operation. However, amount of
make-up water should be as minimum as possible. In case make-up demands increases due to system leakages,
DMSW pump is brought into service manually and make-up to Hotwell is supplied through motorized
regulating valve (DM-46) in emergency make-up line by control engineer intervention. One pump can meet
the emergency make-up requirement of the unit and one is standby.
Deaerator Level Control: The normal level in the Deaerator is maintained by positioning the control valve
(DM-53) in make-up line to condenser Hotwell & a valve (CD-23) in excess condensate dump line from
condensate pumps discharge. The normal level is controlled in such a way that if, Deaerator level falls valve
normal level, the controller operates normal gravity make-up control valve (DM-53) to supply make-up water
to condenser Hotwell. (For this purpose two electronics level transmitters ‘1 out of 2’ logic is being used) As
the Hotwell level rises, the main condensate control valve (CD-19) opens further to increase condensate flow
to Deaerator. If level further goes down, DMSW pump is brought into service manually and additional make-
up is added into Hotwell through motorized regulating valve (DM-46) in emergency make-up line by operator
intervention. Normal make-up control valve DM-53 remains open. In addition, two condensate transfer pumps
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are provided, with one pump running on intermittent basis for initial filling of Deaerator through motorized
valve (DM-39). It may also be used on emergency basis brought into service manually and additional make-up
is added into Hotwell through motorized regulating valve (DM-46) in emergency make-up line by operator
intervention. Normal make-up control valve (DM-53) remains open. In addition, two condensate transfer
pumps are provided, with one pump running on intermittent basis for initial filling of Deaerator through
motorized valve (DM-39). It may also be use on emergency basis. When the level in the Deaerator tanks to
raise above the normal level, the level controller at the higher level operates excess dump control valve (CD-
23) to dump surplus condensate to condenser storage tank.
When Deaerator level rises 100 mm above high level, a level switch opens the Deaerator overflow control
valve (DR-38) to dump the excess condensate from Deaerator to LP drain flash tank. A level switch closes the
overflow valve when the level falls to 100 mm below the high level.
Hotwell level control: Two electronics level transmitter in ‘1 out of 3’ logic is used for Hotwell level control.
Hotwell level controller maintains normal level in Hotwell by positioning main condensate control valve (CD-
19) in condensate discharge line. As the level rises, the condensate control valve opens to increase the flow
from the Hotwell & maintain the constant level in the Hotwell.
AIR EVACUATION SYSTEM:

Air evacuation system is needed to extract air and non-condensable gases from the condenser for maintaining
vacuum.
Amount of air to be extracted from condenser during start up is quite large and the extraction should be done
as rapidly as possible to allow the turbine to be started.
Under normal operating conditions quantity of air to be extracted is lower. It consists of air leakage into the
condenser via flanges and glands and also very little non condensable gases present in steam.
The guard against excessive water vapour extraction along with air, the space beneath the air extraction baffles
has been provide with its own cooling tubes in order to condense as much as much water vapour as possible
and thus preventing its removal from condenser.
AIR EJECTORS
The operating medium of the air ejector can be either high-pressure gas or liquid. In thermal power stations
steam of low parameter (Aprox. 7 kg/cm2, 230 0 C) is used for the air ejector. Steam is passed through a nozzle
and the pressure energy converted into kinetic energy. A vacuum is created in the throat of the nozzle and it
aspirates air and other non-condensable gases from the condenser. Now this high velocity steam along with
gases moves into diffuser, which re converts the kinetic energy into pressure energy. The pressurized mixture
of steam and air is exhausted, either directly to atmosphere or through coolers to convert the steam in the form
of condensate.
STATING EJECTOR
Starting ejector is recommended to be used for accelerating the initial pulling of vacuum. During this period
starting ejector operates alone or in parallel with main ejector. When the vacuum in the condenser reaches
around 600 mm of Hg column, starting ejector is withdrawn. In starting ejector steam along with the mixture
of air and other gases is exhausted t the atmosphere. Generally starting ejector is single stage and has high
steam consumption.
MAIN EJECTOR
The main ejector with a stand by unit is usually provided for normal operation. The min ejector is a multi stage
type, the number of stages depends on the cooling water condition. Steam at suitable pressure is passed
through a convergent – divergent nozzle and the pressure energy of steam is converted into velocity energy.
This high velocity steam jet entrains air and then enters a diffuser, steam air mixture is then cooled in the first
stage shell by condensate. Steam is thus condensed, heat in the operating steam is thus partly recovered and the
steam /air mixture volume is reduced. Now this steam /air mixture is sucked by second stage nozzle and its
steam consumption is reduced. The second stage cooler can be followed by a third stage nozzle and its coolers
and finally discharge to atmosphere. Drains are usually return to the condenser via suitable loop seals.
Condensate as a cooling medium is taken from the CEP discharge. An air-measuring device for measurement
234
of air discharge from condenser may be fitted at the air exit of the ejector. It measures dry air discharge while
the condenser and ejector in operation.
AIR PUMP:
In the ejector system high quality seam from boiler is used by reducing both pressure and temperature. For this
reason steam operated air ejector, which in other circumstances is perfectly satisfactory, is not ideal for used
high pressure and high pressure and high temperature units. Hence, now days air pumps are being used in the
condensers of the 50 MW units.
Air pumps allow greater flexibility as it not dependent on the boiler for raising vacuum. Air pumps operate on
a separates water circuit and there is no risk of concentration of soluble condensable gases in the condensate.
Air pump can be ideal with both starting and normal conditions and therefore separate starting equipment is
unnecessary.
Air pumps are of three types: rotary, liquid ring and hydraulic. Detail of these pumps are discussed in this text
as now a days these are not used in 210 MW or below capacity power plant
DEAERATOR:
INTRODUCTION: Dissolve oxygen and carbon dioxide in the feed water will create chemical corrosion by
reacting with iron in the boiler internal in high temperature and pressure and form iron oxides. To avoid this
type of corrosion oxygen must have to remove from feed water before entering into boiler. This can be done
by chemical means or by mechanical means. In Chemical de-aeration, Hydrazine (N2H4) is used. Hydrazine in
reaction with dissolve oxygen gives water and nitrogen, which is chemically inert in normal condition. But
chemical means being costly and considering other chemical hazard mechanical process of de-aeration found
most effective. However to remove trace of oxygen from feed water chemical means must have to use after
mechanical de-aeration. For mechanical de-aeration a system is used called Deaerator.
Deaerator is a direct contact condensing type heat exchanger. The function of Deaerator is to remove
dissolved non-condensable gases and to heat boiler feed water. A Deaerator consists of a pressure vessel in
which water and steam are mixed in a controlled manner. When this occurs, water temperature rises and all
non-condensable dissolve gases are liberated and removed and the effluent water may be considered corrosion
free from oxygen or carbon dioxide standpoint. The major two functions of Deaerator are 1) To remove
dissolve non-condensable gases from feed water by mechanical means 2) Used as feed water heater 3) Act as
storage tank of boiler feed water.
PRINCIPAL OF DE-AERATION:
There is physical law (Henry’s laws), which states that the solubility of any gas in a liquid is directly
proportional to the partial pressure of the gas above liquid surface. Another law states, the solubility of a gas in
a liquid decreases with an increase in temperature of the liquid. Therefore in the Deaerator, feed water must
first heat up to as high temperature as possible i.e. to the temperature corresponding to the steam pressure. It
must vigorously boil and scrub the heater water with fresh steam, which can carry to the liquid surface any
traces of oxygen and carbon dioxide. The partial pressure of the oxygen and carbon dioxide in the steam
atmosphere must be maintained as low as possible, particularly at the point where the de-aerated water
separates from the steam. Non-condensable gases must be continually withdrawn from the Deaerator at the
rate at which they are being liberated.
Major components of Deaerator are:

o De-aerating chamber.
o Feed Storage Tank.
De-aerating Chamber: De-aerating chamber is placed above feed storage tank and. Process of de-aeration
took place in this chamber. Condensate water from CEP discharge is taken to de-aerating chamber through LP
Heaters. In de-aerating chamber water is broken into smaller particle first in spray nozzle and then in tray
banks. Heating steam is provided from TASH, CRH or CAP in different load conditions. Non-condensable
gases are removed through 3 nos. air release vent line provided with orifice in top of the de-aerating chamber.
In addition to a start up vent valve is provided in the vent line to release excess amount of air during start up.
235
Some of the cases a vent condenser is provided in the deaerator vent system to use the steam leaving with the
non-condensable gases through the vent. In that case, condensate is passes through the vent condenser before
going to the Deaerator. Condensate form in the vent condenser is return back to deaerator. A safety relief
valve is provided in deaerating chamber to relieve excess pressure which might occur in the deaerating heater
when steam is flashed from high temperature water return to the deaerator in the form of tapped discharges,
condensate returns, etc.
HPH-5 & HPH-6 drip lines are connected to this chamber through drip level control valves (DR-13 and DR-6).
HPH heaters and CBD tank vents are also connected to this chamber.
Feed Storage Tank : Boiler feed water after de-aeration store in a tank called feed storage tank which is
installed just below the de-aerating chamber and connected to FST by 4 nos. connecting pipe. Two of the
connection pipes are called pressure-equalizing line. This two connection are a little bit extended in deaerating
chamber and used as pressure equalizing line between deaerating chamber and feed storage tank. The capacity
of FST is design in such a way that it can store feed water for about six to ten minutes without getting make up
from condensate system or from external sources at boiler MCR. BFPs’ are taking suction from this FST by
individual suction line connected from FST. BFPs’ recirculation lines are connected to FST individually. A
Vacuum breaker is provided in FST to safeguard the vessel from collapse due to any vacuum that may create
when there is an insufficient supply of steam.
Ammonia and hydrazine dosing connection are provided in de-aerating chamber and FST connection pipe.
Over flow line is connected from FST to Hotwell through a solenoid operated valve which is inter
locked the FST level switch.
A drainpipe is connected from FST to atmosphere by a manual operated isolation valve.

To take fresh water from CST an initial filling line is connected to FST through a valve from CTP discharge.
Stand pipe (02 nos.) are connected to FST for level measurement, control and level switch connection.
Operation: A Deaerator utilizes steam by spraying water into an atmosphere of steam in the preheater section
(1st stage). It then mixes this water with fresh incoming steam in the Deaerator section (2nd stage).
In the 1st stage the water is heated to within 2 degrees of steam saturation temperature and virtually all of the
oxygen and free carbon dioxide are removed. This is accomplished by spraying the water through self-
adjusting spray valves, which are designed to produce a uniform spray film under all conditions of load and
consequently a constant temperature, and uniform gas removal is obtained at his point.
From the 1st stage the preheated water, containing minute traces of dissolve gases, flows into the 2nd stage.
This section consists of several assembles of trays. Here the water is in intimate contact with excess of fresh
gas-free steam. The steam passes into this stage and it is mixed with the preheated water. Very little steam is
condensed here as the incoming water has a rises to the 1st stage and carries the small traces of residual gases.
In the 1st stage most of the steam is condensed and remaining gas pass to the vent where the non-condensable
gases flow to the atmosphere. The water, which leaves the second stage, falls to the storage tanks where it is
stored for used. Here dissolve O2 is <0.05 ppb.
Deaerator Pressure Control : Variable pressure operation of Deaerator has been envisaged in the cycle.
Normally Deaerator is supplied with steam from turbine extraction from cross around pipe. The pressure in
Deaerator varies as per turbine extraction pressure from 2.5 Kg/Cm2 at approximately 50% load to 5.3 Kg/Cm2
at 100% load. A minimum 2.5 Kg/Cm2 pressure is to be always maintained in the Deaerator by pegging steam
from turbine extraction / CRH line. At low load when turbine extraction pressure is less than 2.5 Kg/Cm2, the
Deaerator is supplied steam from CRH line and pressure of Deaerator is maintain at 2.5 Kg/Cm2. The
Deaerator is also provided with steam supply from TPRDS from where steam is supplied to Deaerator prior to
and during start up of boiler. During cold start up Deaerator pressure is maintained at 0.5 Kg/Cm2 and during
worm/hot start up Deaerator pressure is maintained at 2.5 Kg/Cm2. Steam is supplied from TPRDS through
pressure control valve AS-2. This 2.5 Kg/Cm2 set point has to give manually be the control engineer.
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During starts ups when steam pressure in CRH reaches 8 Kg/Cm2, change over from TPRDs to CRH & vice-
versa will take place gradually. The change from CHR line to turbine extraction starts around 55% turbine load
when extraction pressure is more than 2.5 Kg/Cm2.
For initial heating and deaerating of stored water in Deaerator, prior to or during cold start up, heating steam is
supplied from auxiliary steam header at 11 ata & 2100C through a motorized regulating valve (AS-7). This
valve is remote manually closed when just over 1000C is achieved.
Technical Data :
1. Type - Spray-cum-Tray.
2. Heater Assembly-
a) Dia x Thk. (in mm) - OD-2224 x 12
b) Length (in mm) - 8200
c) Operating Pressure (Kg/Cm2) - 5.08
d) Condensate Inlet Qty (T/hr) - 495.210
e) No. of Trays - 240
f) No. of Spray Valve - 44
3. Feed Water Storage Tank-

a) Dia x Thk (in mm) - ID-3500 x 16
b) Length (in mm) - 24700
c) Capacity (NWL to LLL) - 130
d) Operating Temperature (in 0C) - 158.6
237
38
FEED WATER REGENERATIVE CYCLE
238
If heat is absorbed or picked up by any fluid and is sent back to its source, the process is called Regeneration.
In case of Regenerative Feed Heating Cycle, original source of heat is Boiler drum and heat is returned back
through Feed Water after absorbing from bleed steam. The same process is followed for Air Pre-Heater.
REGENERATIVE FEED HEATING:
A small part of steam from different stages of Turbine is extracted for heating feed water. Hence some work
done in turbine is sacrificed but that heat loss is utilized to heat the feed water. Thus heat coming from boiler
drum is sent back to its original source. This process is called Regenerative Feed Heating.
QUALITY OF EXTRACTION STEAM:
Extraction steam should be neither LIVE Steam nor fully expanded steam. If it is live steam, there will be
wastage of heat/torque in turbine and if it is fully expanded steam. No heat will be available from it. Thus
Extraction Steam should be of partially expanded steam.
ECONOMICS OF REGENERATIVE FEED HEATING SYSTEM:
After partial work done by a small portion of steam is extracted for heating Feed Water. This extracted steam
by doing partial work offsets its cost of generation and is used for feed water heating. That is why it is
economical.
ADVANTAGES OF REGENERATIVE FEED HEATING:

a. Improves cycle efficiency.
b. Generating cost reduces.
c. Boiler tube metal temperature reduces, hence reduces boiler tube leakages.
d. Extraction steam from LP turbine reduces water droplets impact on turbine blades, hence reduces
blade damage.
DIS ADVANTAGES OF REGENERATIVE FEED HEATING:
a. Less work done is achieved with same steam flow.
b. Economiser heat gain from flue gas is less.
c. Cost of heaters & associated pipe lines etc. is high.
Considering both advantages and disadvantages it is seen that the number of heaters for 210 MW / 500 MW
units should be 6 to 7, which increases cycle efficiency by 5% to 6% approximately.
TEMPERATURE GAIN BY REGENERATION:
239
For 150 kg/cm2 drum pressure boilers around 70% of saturation temperature (say around 2380C) is gained by
putting the regenerative feed water heaters in service. From Economizer. Feed water gains temperature slight
below the saturation temperature to avoid steaming in economizer.
Selection of Extraction Steam:

If final heater outlet feed water temperature is to be maintained at 2380C, then the saturation temperature of
final heater extraction stream should also to be at 2380C and its corresponding saturation pressure is 33 kg/cm2
. Hence final FW heater extraction steam pressure should be 33 kg/cm2 to obtain this steam pressure the
location of extraction point in turbine is ascertained.
Now if there are seven (7) FW heaters, and L.P. heater #1 inlet main condensate temperature is 48 0C and
H.P. heater outlet feed water temperature is 2380C, then average temperature gain in each heater should be
(238 0C - 48 0C ) / 7 = 27 0C.
Hence 6th.Extraction temperature should be = 238 0C- 27 0C = 2110C & its corresponding saturation pressure =
20 kg/cm2
PARAMETERS OF 210MW LMW TURBINE WITH / WITHOUT HEATERS IN SERVICE:
Sl.No. Description Without Heater With Heater
01. Steam Consumption (T/H) 563 662

02. Enthalpy of steam at turbine inlet (Kcal/ kg) 823 823
03. Heed Water temperature at boiler inlet ( 0 C ) 48 243
04. Total heat of Feed Water inlet in boiler (Kcal / kg) 48 251
05. Total heat in turbine inlet (Kcal / hour) [ 01 X 02 ] 463349000 544826000
06. Total heat in feed water at boiler inlet ( Kcal / hour) 27024000 166162000
[ 0! X 04]
07. Heat supplied in boiler ( Kcal / hour) [ 05 - 06] 436325000 378664
08. Generation out put (Kcal / hr.) 210 MW x 1000 180600000
x 860 =
180600000
(since 1 kwh =
860 kcal)
09. Cycle efficiency ( Considering Boiler efficiency 41.39 % 47.69 %
=100%)
[08 / 07]
It is seen from sl.no.09 that cycle efficiency increases ( 47.69 – 41.39 ) % = 6.3% if all heaters are kept in
service.
10. Cycle efficiency ( Considering Boiler efficiency 35.60% 41.01 %
=86%)
[08 / 07]
Cycle efficiency increases normally by 5 – 6% if all heaters are put into service. And considering the
economy maximum number of heaters should seven.
FEED WATER HEATERS :
In power stations normally two types of heaters are used;

1 Surface type feed water heater or indirect feed water heater.
2. Direct feed water heater.
Surface type heater:

Feed water passes through tubes located inside a heater shell and steam passes through the shell. Extraction
steam is cooled by feed water and condensed. Hence feed water gains latent heat of steam and increases its
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temperature. Condensate (calls drip) collected in the shell and is cascaded to maintain a normal level inside the
heaters.
Direct type:
Feed water directly mixes with extraction steam. Hence latent heat of steam as well as condensate goes to
increase feed water temperature.
LOW PRESSURE HEATERS:

In low pressure heaters bled steam from turbine is used to heat the feed water i.e. Condensate Extraction Pump
discharge main condensate water (Header pressure: 20 kg/cm2). Generally three L.P heaters are provided for
210 MW units.
DEAERATOR:
It is a direct heating L.P. heater. It serves not only to heat feed water but also to remove oxygen or any
dissolved gas from feed water. Temperature of Feed Water in Deaerator is 1600C. Dissolved gases are
removed following the principle of Dalton’s theory i.e. amount of dissolved gas in any liquid varies inversely
proportional to the increase of temperature and direct proportion to the increase of pressure.
HIGH PRESSURE (H.P) HEATERS :

Feed water after Boiler Feed Water Pump ( Pressure : 160 kg/cm2) passes through H.P. heaters. For KWU
turbine 2 H.P. heaters and for LMW turbine 3 H.P. heaters are provided.
FUNCTION OF GLAND COOLER (GC) / GLAND STEAM CONDENSER (GSC):
Main Ejectors and Gland Steam Coolers are also contributing heating of feed water.
Main condensate after discharge of Condensate Extraction Pumps passes through GC-1 & GC-2 to gain
temperature. Heating steam is taken from 1st gland for GC-1 and 3rd. gland for GC-2. for LMW turbine. For
KWU turbine only one Gland Steam Condenser is provided. Water flows through ‘U’ tubes and steam flows
through shell.
GLAND STEAM COOLER / GLAND COOLER No;: 1 :
A steam ejector is provided in Gland Cooler No. 1 for LMW turbine. Air & steam mixture fro turbine gland
no. 1 is sucked by this ejector. This mixture is being cooled by main condensate water discharged by C.E.
Pump. Drip of GC-1 is routed to Condenser following a U loop and air & remaining steam is discharged to
atmosphere.
In case of KWU turbine an exhauster is provided at the end of the Gland Steam Cooler to suck air-steam
mixture and it is cooled by the main condensate like GC-1.
Gland Cooler No.2 (GC-2):
In case of LMW turbine, Leak off steam from turbine gland no. 3 is connected to Gland Cooler No.2, whereas
this steam line connected to L.P. heater extraction line in case of KWU turbine.
The vent of GC-2 is connected to condenser and drip is pumped to L.P. heater -2 main condensate outlet lines
by a drip pump...
In LMW turbine Leak off steam from 3rd. & 4th. glands of turbine are connected to Extraction steam of GC-II
& L.P. heater No. 3 respectively. Leak off steam from 5th. Gland of HP Turbine inlet side is connected to
exhaust steam from HP turbine.
To summarize the above it may be noted:
Turbine Gland No. 1 (from air side) : Connected to GC-1.
Turbine Gland No. 2 (from air side) : Connected to supply of gland steam from TAS.
Turbine Gland No. 3 (from air side) : Connected to GC-1I/ LP Htr.
Turbine Gland No. 4 (from air side) : Connected to LP Htr.-4.
Turbine Gland No. 5 (from air side) : Connected to HPT exhaust.
To maintain continuous water flow through Gland Steam Condenser (GSC), the recirculation line of C.E.
Pump is taken after GSC.
241
CONNECTIONS FOR MAIN CONDENSATE:
242
Each heater has a bypass of in the condensate line or feed water (FW) line. Condensate / FW may be passed
through the heaters or bypassing the heaters. However it is wise to take it through the heaters in normal case.
HEATING ZONES OF HEATERS :
Total space of the heaters can be are divided into three zones –
a. De-superheating zone.
b. Condensing Zone
c. Sub-cooling zone.
De-superheating zone :
This is the last zone of the heater through which feed water passes before leaving the heater. Feed water outlet
temperature increases nearer to the saturation temperature of bled steam.
Condensing Zone :
Latent heat of the extraction steam is transferred to the feed water through this zone. Hence maximum heat
transfer is done here. For better performance continuous venting is required to extract any non-condensable
gases in the steam.
Sub-cooling zone :
Here feed water is heated by the drip of the condensate. The drip is cooled from its saturation temperature to
heat the feed water.
CASCADING OF HEATERS :
Extraction steam is condensed in heaters to form drip. Drip is drained from high pressure heater to next low
pressure heater and again to next lower pressure heater and ultimately to Condenser for L.P. heaters and to
Deaerator in case of H.P .Heaters.
WORKING OF LP HEATERS :
LEVEL CONTROL :
Drip of LP heaters are collected at the bottom of the shell. For sub-cooling a minimum level of L.P. heaters is
maintained... In case of very high drip level the heater will automatically bypasses both steam & water sides.
EXTRACTION STEAM ( for 210 MW LMW turbine) :
Tag No. Parameters Units Press.(ATA) Temp. (0C) Enthalpy Quantity

(Kcal/Kg) (T/H)
E7 To HP Htr.-7 42.76 381 751 32
E6 To HP Htr-6. 28.36 329 734 46
E5 To HP Htr.-5 13.18 447 803 16
ED To Deaerator 13.18 447 803 2.7
E4 To HP Htr.-4 7.05 365 763 23
E3 To HP Htr.-3 3.02 264 715 22
E2 To HP Htr.-2 1.39 184 678 26
E1 To HP Htr.-1 0.3007 99 622 8.2
No. of stages of turbine blades (210 MW) :
Turbine H.P.T I.P.T L.P.T

LMW Turbine 12 11 4 x 2 ( double flow)
KWU Turbine 25 20 x 2 ( double flow) 8 x 2 ( double flow)
(200 MW)
BkTPP 210 MW 23 17 8 x 2 ( double flow)
Turbine
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DEAERATOR :
The deaerator is a direct contact type heat exchanger. It also removes dissolved gases from the condensate.
PRINCIPLE OF DEAERATOR :
The solubility of any gas dissolved in any liquid is directly proportional to the partial pressure of the gas and
inversely proportional to the temperature of the liquid.
STEAM TO DEAERATOR :
There are three sources of steam to supply in deaerator :
i. Turbine Auxiliary Steam (TAS).
ii. Cold Reheat Steam.
iii. Extraction Steam from Turbine.
Supply of steam is selected as per requirement according to loading of the unit.

Inside the Deaerator dome trays are fitted through which water passes after dividing into droplets. The
extraction steam moving upwards comes in direct contact with water droplets moving downwards. Water is
heated up and steam is condensed into water. Now dissolved gases particularly oxygen in water is liberated to
vent out along with uncondensed steam to atmosphere.
The condensed water with heated up water is stored in a deaerator storage tank. Boiler Feed Pumps suck water
from this storage tank and feed to boiler drum through HP heaters & economizer. The deaerator storage tank is
located at a higher elevation to maintain net positive suction head ( NPSH).
In some deaerators Vent Condenser is provided above the deaerator dome. Its function is like a LP heater.
Main Condensate before entering in deaerator dome and the uncondensed steam leaving the dome is the
heating media of this vent condenser.
After removal of dissolved oxygen in deaerator, hydrazine ( N2H4, H2O) is fed in deaerator outlet pipe to
remove further oxygen, if any :
N2H4 + O2 = 2 H2O + N2
HP HEATERS:
HP Heater Connections:
Boiler Feed Pump discharge water enters in H.P. Heaters and exit from it after heating by extraction steam.
Condensed steam is called drip. Drip level in HP heaters is controlled by drip level controller. Vent of HP
heater is connected to Deaerator.
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TERMINAL TEMPERATURE DIFFERENCE (TTD):
In any particular heater feed the temperature difference between feed water outlet and extraction steam
saturation temperature is called Terminal Temperature Difference (TTD). The value of TTD should be
maintained nearer to designers’ recommendation. Higher value of TTD indicates heater tubes fouling or
blanketing of heater tubes by non-condensable gases. To avoid this venting of heater should be ensured.
DRAIN COOLER APPROACH (DCA):

DCA is the temperature difference between feed water inlet and drip water temperature. Higher DCA indicates
the fouling or leakage of heater tubes.
FEED WATER TEMPERATURE:

FW outlet temperature less indicates heater fouling and high indicates less flow of FW through heater.
Normally FW gain in each HP heater should be around 180 C.
EFFECTIVENESS OF HEATER:
GLAND STEAM COOLER / GLAND COOLER of 210 MW KWU / LMW Turbine:
KWU TURBINE LMW TURBINE
It is called Gland Steam Cooler and only one GSC It is called Gland Cooler and two nos. are
is provided. provided – GC-1 & GC-2.
The outer most gland steam is taken into GSC, The outer most gland steam is taken into GC-1
and 3rd. gland steam is taken to one LP heater. and 3rd. gland steam is taken into GC-2.
Down stream of GSC is connected to an exhauster Power steam is provided to draw steam from
to maintain vacuum. gland no.1 for GC-1.
HEATERS OF LMW / KWU Units:
No. of Heaters:
H.P.Heaters - 2 Nos. H.P.Heaters – 3 nos.
L.P. Heaters- 3 nos. L.P. Heaters- 4 nos.
Drip Pump – not provided. Drip Pump – 2 x 100% provided.
Location of Extractions :
LPH-1 : 7th. Stage of LPT LPH-1 :3rd. . Stage of LPT
LPH-2 : 5th. Stage of LPT LPH-2 :IPT outlet.
LPH-3 : 3rd. stage of LPT LPH-3 : 9th. Stage of IPT
Deaerator : IPT outlet LPH -4 : 6th. Stage of IPT
HPH-5 : 11th. Stage of IPT Deaerator : 3rd. stage of IPT. & CRH
HPH-6 : CRH line. HPH-5 : 3rd. stage of IPT
HPH-6 : CRH line.
HPH-7 : 9th. Stage of HPT.
245
Extraction parameters:
KWU UNIT LMW UNIT
Extraction No. Steam Press. Steam Temp. Extraction No. Steam Press. Steam Temp.
(kg/cm2) (0C) (kg/cm2) (0C)
HPH-6 39 335 LPH=7 43 384
HPH-5 17 432 HPH-6 29 331
Deaerator 7 315 HPH-5 13 447
LPH-3 2.4 200 Deaerator 13 447
LPH-2 0.86 108 LPH-4 7 384
LPH-1 0.22 62 LPH-3 3 265
LPH-2 1.39 183
LPH-1 0.29 Dryness 0.99
Condenser Level Controller :

Two separate control valves are used – one for Single stem control cum recirculation valve is
controlling hot well level and other is to used.
maintain minimum recirculation flow.
39
FEED WATER HEATER PERFORMANCE
Intrduction :
A feed water heater is a special form of a shell and tube heat exchanger designed for the unique application of
recovering the heat from the turbine extraction steam for pre-heating the boiler feed water.
Its principal parts are a channel and tube sheet, tubes and a shell. Each feed water heater will contain three
separate heat transfer areas or zones. These are the condensing, desuperheating and sub-cooling zones.
Steam from the boiler enters into the turbine with high pressure and high temperature. In this high pressure and
high temperature steam expands and thermal energy is converted into mechanical energy. Finally, steam is
condensed into water in the condenser and water is being reused as feed water in the boiler. During
condensation latent heat in the steam is taken out from the system by cooling water – this is a major loss in the
turbine cycle. It some amount of heat is taken out from the turbine after partial expansion before going to
condenser and is used for heating up the condensate /feed water, then the total heat including latent heat in the
steam will remain within the cycle. In this way condenser loss is reduced and cycle efficiency increase up to
4%.
Specific work output (output per kg of steam) of cycle decreases due to regenerative but again feed water
temperature at the economizer inlet increases the necessary heat input to the system decreases thus resulting in
increased cycle efficiency.
HEAT TRANSFER IN A H.P.HEATER:
As mentioned earlier there are three heat transfer zones in a typical HP heater namely the:
Desuperheating zone: where feed-water passes before leaving the heater and adds a small percentage of the
total heat transferred in the heater, which is very valuable in terms of thermal economy (heat transfer mode in
this zone being convection).
Condensing zone: where the Minimum heat in transferred to the feed water from the bled steam, which gets
condensed to form the drip.
Drain –cooling zone: where heat is rejected by the drip below saturation temperature and the feed water
gains heat.
Normally the ratio of heat transferred in the three areas is in the range of 1:8 :2/1:5:1.
246
Please refer the figure /graph showing the temperature variation of the extraction steam and the feed
water versus the area / length of the heater consisting of three heat transfer zones.
(SEE FIGURE – 1)
As given in the figure some definitions needs to be given here.
Terminal temperature difference (TTD): Difference between the saturation temperature at steam extraction
pressure and the temperature of feed water leaving the heater.
Drain cooler approach (DCA): Difference of temperature between the drip leaving the heater and the feed
water entering the heater.
Drain under cooling (DUC): Difference between saturation temperature of extracted steam and the drip
temperature.
The performance of a feed water heater depends on the above parameters wide deviation of the above
parameters from the normal or designed values indicates deterioration in performance of the respective heater.
Normally,
At 75% load TTD of HPH5 is -1.8°C and for HPH6 it is -1.0°C
At 100% load TTD valves for HPH 5 & 6 are O°C
At full load DCAs for HPH 5 & 6 are 6°C
(See Figure – 2)
The above figure shows the heat transfer nature in a feed water heater in the condensing portion (please note
that maximum heat transfer occurs in the condensing portion) .
Heat Transfer (Q) for the above U.A .Øm
Where U = Overall Heat transfer co-efficient
A = Area of Heat transfer
Øm = Log of mean temperature difference (LMTD)
Ø1-Ø2
=
ln Ø1
Ø2
Ø1-Ø2 …………(1)
So, Q = UA
ln Ø1
247
Ø2
Heat gained by the feed water Q´ = wc (t2-t1) …….. (2)

= wc (Ø1-Ø2 )
where w - mass of water & c - heat capacity of the feed water
Now Q =Q´ , so from (1) & (2)
UA (Ø1-Ø2 ) = wc (Ø1-Ø2 )
ln Ø1
Ø2
wc Ø1 K ln Ø1 wc
A= ln = K= = Constant
u Ø2 Ø2 u
Or A= K ln (t2-t1) + Ø2 = K ln (t2-t1) + TTD
Ø2 TTD
1 + t2-t1
= K ln
TTD
The expression shows the heat transfer area or rather the heater effective area w.r.t. the design TTD of a feed
water heater.
(SEE FIGURE – 3 )
The above curve represents the heater area required versus design TTD for a feed water heater. As it is clear
from the figure that the steepness of the curve is greater towards the lower TTD regions. It can be considered
that after TTD = 1°C further lowering of TTD requires a greater increment of the surface area of the heater.
Generally. Low-pressure heaters are designed to have a TTD of 5-6°C or less. However, modern high-pressure
heaters are capable of negative terminal temperature difference.
Factor affecting heater performance:
The failure of a feed water heater to perform satisfactorily may be caused by one or more factors such as:
Air or non-condensable gas blanketing: resulting from improper piping installation or lack of suitable
venting. Proper venting is necessary on feed water heaters. The venting system in a feed water heater is
designed to assure that all points where non-condensable gases could collect are vented. Failure to utilize
all of the operating air vents can lead to corrosion damage / or loss of performance. Vent flow control is
the best accomplished through the use of stainless steel or other suitable erosion /corrosion resistant
material.
Steam side fouling: resulting from oxygen present above or equal to 100ppb which causes rust formation and
resulting in steam path fouling in the shell side. With cupronickel material for heater tubes exfoliation of
tube material results. In exfoliation metal flake off like dead skin. This material blocks the spaces between
the tubes solid and thickness of the tube is slowly reduced till the tube fails. After discovery of the
problem now tubes are made of 90/10 Cu-Ni. Mild steel or stainless steel.
Waterside fouling: Oil or dirt on the inside of the heater tubes causes interference with the heat transfer and
lower the outlet feed temperature. The effect on feed heater TTD of a turbine bearing oil leakage into the
condenser and hence into the feed can be seen to be quite appreciable and is very difficult to be removed
by chemical cleaning. A high temperature jet of water through each tube could only partially cure the
heaters.
248
Flooding resulting from inadequate drainage of condensate: If a drain line is blocked it can cause
upstream level to increase and may cause flooding of the flash box. Also the heater level will rise if drain
valve is closed.
Tubing failure: Abrupt flooding, unusual noise of feed water temperature rise can indicate tube failure. This
condition requires the heater to be immediately removed from service. Tube failure tends to have a chain
reaction effect; impingement on adjacent tubes can cause additional failures.
Operating condition differing from design conditions: This may happen due to say maintaining a heater
drip level low. A low liquid level in the feed water heater occurs when the level indicates below the
normal liquid level. Low liquid level of heater results in decrease of the drain cooling approach
temperature (DCA). Low-level operation by the heaters results in flashing at the sub-cooling zone inlet.
This flashing case lead to erosion failure of the tubing.
HP HEATER PERFORMANCE TEST
The performance of feed water heaters can be analyzed by monitoring the terminal temperature difference
(TTD), drain cooler approach temperature (DCA), the pressure drop on the feed waterside and the
temperature rise across the heater. To monitor these it is desirable to carry out a simplified routine
performance test on feed water heaters at a specified frequency. This will help in identifying the level of
deviations and trending of performance. The purpose of this document is to lay out a standard test
procedure for all units.
Objective & Scope :
The objective of the routine high pressure feed water heater test are :-
Prior to an outage, provide information to determine whether corrective action is required to
maintain optimum feed water heater performance and providing guidance in determining
materials, tools and equipments, workers, cost estimates and scheduling.
Following an outage, provide information to allow evaluation of the effect of work on the
feed water heater.
During normal operation provide information to allow identification of abnormal changes in
heater performance and provide information to arrest in identifying the source of the change.
During normal operation, provide information to assist in optimizing the operation of the
heater.
During normal operation provide information to allow accounting for the contribution of
heater performance deficiencies on unit heat rate and capacity.
TEST MEASURMEENT
The parameters to be monitored to conduct the HPH performance test consist of temperature, pressure /
differential pressure instruments.
The number of instruments required per heater is as follows: -
Measurement Temperature Pressure

FW I/L to heater 1 1
FW O/L to heater 1 1*
Extn. Steam at turbine 1 1
Drain temp. 1
FW differential pressure - 1*
Shell pressure - 1
Preferably individual heater or differential pressure across the heater train.
TEST INSTRUCTIONS:
• Unit should be in operation at normal feed water flow steady state condition.
• Ensure the heater drains are cascading as per the specified cycle conditions.
249
• Ensure the venting of steam side and waterside to remove non-condensable gases.
• Operation of the feed water heater shall be brought to the steady state condition prior to
• Indicating the test run. It shall be kept at this condition throughout the test run.
• Every effort shall be made to conduct the test runs under design conditions. Allowable variation from
design conditions in feed water flow and extraction steam shall not exceed ± 10%.
• First rest run is conducted at heater water level at normal design value. Subsequently, other test runs
are conducted by varying the heater levels above and below the normal level.
TEST FREQUENCY & DURATION :

• Routine testing every 6 months.
• Special requests for various reasons.
• Each run shall continue for a period sufficiently long to ensure accurate and consistent results test
duration should be 20 minutes long after steady state conditions.
CALCULATIONS AND ANALYSIS
Calculate and Analysis:

Calculate the Terminal Temperature Difference (TTD), Drain Cooler Approach temp. (DCA) & the
temperature rise across each feed water heater. Analyze calculated values plot TTD, DCA and
temperature rise on separate control charts or a time line graph showing the historical and expected data.
Look for adverse trends sudden changes, etc. and identify areas for possible improvement.
Report:
The test should be then followed by a report, which should include a narrative describing unusual
findings and conclusions and recommendation for performance improvements.
FAULT TREE
• Excessive make up
• Poor feed water heater performance
• High terminal temperature difference (TTD)
• Excessive venting
Worn vent
- Altered set point
- Vent malfunction
- High water level
- Tube leaks
- Improper setting
Header partition leaks
Non-condensable gases in shell side
Excessive tube bundle pressure drop
- Excessive number of tubes plugged
- Tubes fouled internally
High drain cooler approach temperature (DCA)
Drain cooler inlet not submerged
- Low water level
- Improper setting
Excessive FW heater drain bypass
- Improper setting
- Bypass valve left open
- Bypass valve malfunction
- Bypass valve leaks
Excessive tube bundle pressure drop
- Excessive number of tubes plugged
Tubes found internally
250
Feed water heater bypassed

FW heater bypass valve leaks
CONDENSER PERFORMANCE
What is a condenser?
A condenser is equipment, which is used to condense exhaust steam from the turbine. It operates at a lower
pressure than atmospheric pressure.
There are two objects of using a condenser in a steam plant.
It increases the plant efficiency and specific output of turbine by reducing turbine exhaust pressure. Low
temperature circulating water flows through condenser to maintain a vacuum (low back pressure) for the
turbine. This pressure is equal to the saturation pressure corresponding to the condensing steam temperature
(say 0.074 bar at 40°C).
As the high quality water is used in the boiler for less corrosion we can reuse the condensate water by
condensing steam in the condenser. This water is again fed to the boiler in a closed cycle.
Surface condenser Surface condenser is mostly used in power plants. They are essentially shell and tube
heat exchangers. Cooling water flows through tubes and steam condenses outside the tubes. It consists of a
steel shell with water boxes on each side. At each end there are tube sheets into which the water tubes are
rolled. This prevents leakages of calculating water into the steam. An expansion joint allows for the different
rates of expansion joint between tubes and shell. There are vertical plates at intermediate paints between the
two tube sheets to provide support to the long tubes and to prevent tube vibration. The hot well acts as a
reservoir of the condensate.
Heat Transfer in a condenser

Steam enters the tube bundles in two separate sections from the top, sides and bottom and flows toward the
center of the tube nest in each section. At the point most of the steam has condensed leaving only air and other
non-condensable gases, which are removed by ejector.
See Figure – 4
Fig 1 & Fig 2 above shows a schematic diagram of the condenser and the graphical heat transfer nature
between steam and circulating water respectively. The various parameters indicated in the figures have the
following meanings:
ws = mass of steam, kg / s
251
wc= mass of cooling water, kg/s

h = enthalpy at different points.
T1 = Cooling water I/L temp (°C )
To = Cooling water O/L temp.(°C)
Ts = Saturation temperature (°C)
U = Overhaul heat transfer co-efficient , KW/m²K
Cp = Specific heat of water = 4.127 KJ/kg
Now Heat transferred Q = UAØm

Where U = Overall heat transfer co-efficient
A = Area of heat transfer
Øm = Log of mean temperature difference
Ø1 – Ø2
=
Ø1
ln
Ø2
Ø1 = Temperature difference at I/L =Ts-T1
Ø2 = Temperature difference at O/L= Ts-To
Calculation of U:
If do = outer demometer of cw tube
di = Inner deaerator of cw tube
K = Heat transfer co-efficient of the CW tube metal.
hi = Heat transfer co-efficient of water film inside the tube.
ho= Heat transfer co-efficient of outer film.
It can be shown than
do 1 do-di do 1
U= x + x +
di hi do+di k ho
Please note : For details please refer Engineering. Thermodynamics by P.K. Nag.
Chapter : Elements of Heat Transfer
Calculation of A
Effective area of heat transfer A = П.do.l.n
Where do = outside diameter of tubes
l = length of tubes
n = no. of tubes.
Calculation of Ø m
Ø1- Ø 2 (Ts –Ti) – (Ts-To)

Øm= =
ln (Ø 1 / Ø 2 ) ln (Ts-Ti/ Ts-To)
To - Ti
=
ln (Ts –Ti) / TTD)
The temperature difference at exit Ø2 in the terminal temperature difference (TTD) of the condenser . The
cooling water temperature should be sufficiently low have a good vacuum in the condenser shell. It is
recommended that Ø1 or TTD should not be less than 3°C.
Factors affecting the condenser performance :

Condenser vacuum is the most important parameter affecting unit efficiency. So, the condenser performance
depends on how good the condenser vacuum is maintained close to the designed value.
252
The vacuum efficiency of a condenser is given by ,

Vacuum efficiency = Actual vacuum
Ideal vacuum
Barometric pr.- partial pr. of air in condenser – partial pr. of steam
=
Barometric pr. – partial pr. of steam
As clear from the above that the condenser vacuum will increases if the process of air removal from the
condenser by ejectors is effective and if air ingress to the condenser can be avoided . Generally, the
concentration of condenser CW tubes around the air tubes is higher which decreases the steam loss through the
air tubes. Because of the concentration of condenser CW tubes around the air tubes the air temperature comes
down.
If there is air ingress into the condenser then the temperature of the air-steam (amount of steam being small)
mixture will fall down. The more amount of air ingress the lesser the air (or air–steam mixture) outlet
temperatures. Hence, the temp. difference between the condenser steam temp. and the air outlet temp. indicates
the amount of air ingress into the condenser. This is unknown as the ‘Air suction depression’. This affects the
condenser vacuum and hence its performance.
Again note that the vacuum that can be ideally maintained in a condenser under specified condition depends
on the saturated steam temperature (which determines the partial pressure of steam). Lesser the saturated steam
temperature more the ideal vacuum in the condenser. Hence, the amount of heat transfer from the condensate
/steam mixture to the CW water influences the vacuum and hence the condenser performance.
The usual reasons for departure of condenser condition from the optimum are: -
CW I/L temp. Different from design.
CW quantity flowing through the condenser incorrect.
Fouled tube plates.
Dirty tubes.
Air ingress into the system under vacuum.
CW I/L temp. high : If Ti is higher other for the same increase in CW temp. (i.e. To-T1) and to maintain
the same TTD (Ts-To) Ts will increase . So the saturated steam temperature increases resulting in
decreased condenser vacuum or back pressure.
CW I/L quantity flowing through the condenser incorrect:

SEE FIGURE – 5
FIG-5
Please refer to the energy flow diagram of a condenser as given above, here:
Ms1, ms2 - Mass of steam entering into and going out of the condenser respectively
(note ms1 >> ms2 )
ma1, ma2 - Mass of air entering into and going out of the condenser respectively.
(note ma1=ma2)
Mc - Mass of condensate water going out of the condenser . Then Heat Transfer Q is given by
Q= ms1 x hs1 + ma1 x ha1- ( ms2hs2+ma2ha2 ) –mchc
= (ms1 hs1 - mas2hs2 ) + (ma1ha1 – ma2 ha2) – mchc
253
= ms1hs1 - mchc [ since, ms1>> ms2 & ma1=ma2

ha1= ha2
= ms1 hs1 - ms1hc [ since, ms1 ≈ mc ]
= ms1 (hs1 – hc) = ms1 ( hw + xl – hc ) ----- (1)
Heat gained by the CW = mw (To-Ti) ……. (2)
Therefore, mw (To-Ti) = ms1 (hw + xl –hc )
Or mw = ms1 . x.l ( since , hw = hc) ………… ……… (3)

To –Ti
The above expression gives the mass of water flow required for a particular quality of saturated steam
condensed in the condenser and the CW I/L & O/L temperature difference.
From the above expression it is clear that if mw i.e. the CW flow decreases then To-Ti will increase. If Ti is
fixed then To and hence Ts (If the some TTD is maintained) will increase resulting decreased condenser
vacuum.
(3) Fouled Tube Plates / Dirty tubes : The effect of this is to increase the TTD above the optimum value (
due to poor heat transfer) with the result that Ts increases resulting decreased condenser back pressure. The
main reasons for such decreased condenser performance being
(a) Water side scaling / fouling of condenser tubes
Water side film formation
(b) Steam side film formation
Steam side Fouling
(c ) Corrosion (d) Microbiological fouling.
Water side scaling & fouling: comes under the division of deposition problems in condenser cooling water
systems . The next common type of scale found on the heat exchanger surfaces are of calcium or
Magnesium bicarbonate scale. The origin of the scale being the bicarbonate salts present in the cooling water
. It normally results from the breakdown of bicarbonates due to aeration , heat and increase in pH.
Ca(HCO3)2 --- CaCO3 + CO2 + H2O.
A water which is supersaturated w.r.t. Ca/Mg carbonate is potentially scaling. Such deposition results in (a)
reduced heat transfer (b) Restricted water flows (c) reduced efficiency (d) cleaning costs.
While blow down is an effective method for limiting dissolved solids concentrations and hence the scaling
potential the circulating water, acid treatment is also done for reducing such problems.
Corrosion: High dissolved solids, high chlorides dissolved oxygen carbon dioxide are the main contributing
factors for corrosion. Almost all-natural water contains Ca/Mg bicarbonates. It is possible to develop a thin
layer of Ca/Mg bicarbonates, which can provide corrosion protection without interfering with the heat transfer.
ON LOAD CONDENSER TUBE CLEANING SYSTEM
It is an essential to maintain the heat transfer rate and co-efficient close to the designed parameters for an
improved steam condensation. Hence, the cleanliness of the condenser tubes should be kept as high as possible
to the design condition valves in order to increase the condenser efficiency, which will result in an optimum
power generation.
On line tube cleaning of the condensers by using sponge rubber balls has been in use all over the world. This
system is found to be an effective solution for maintaining the cleanliness factor at the optimum level.
Sponge rubber balls with a special composition and size 1 to 3 mm greater than the inner diameter of the
condenser tubes are injected into the cooling water stream at inlet. These balls, which have a specific gravity,
some as that of the cooling water are carried into the condenser by the velocity of the inlet water. Cleaning
balls are then pushed through the tubes by the differential pressure existing across the condenser. While
passing through the condenser tubes, the balls are pressed against the walls of the tubes removing all deposits
on the inner surface of the tubes. Specially designed screen arrangement called the ball separator separate the
balls going out of the cooling water system and the balls are collected in the Ball vessel through the Ball
Transport pipes . The balls are injected into the cooling water through the Ball recirculating Pump.
254
The main advantages of a tube cleaning system are :

(a) Increase in the heat transfer rate.
(b) Optimum turbine back pressure
(c ) Increased generation efficiency
(d) Avoidance of corrosion in tubes
(e) Avoidance of shut down for manual cleaning
(f) Reduction of chemical costs for water treatment
(g) Reduction in fuel costs.
DEBRIS FILTER
Debris such as shells, sticks , stones and plastics are common cause of failure in condensers. Localised attack
(erosion – corrosion) leading to rapid failure is the consequences. It has been seen that this is the major cause
of tube failures.
Improvements in the primary screening would only lead to partial solution. It would only lead to a partial
solution. It would not solve the problem of debris from within the CW system itself. Similarly chlorination can
be used can be used to kill themselves etc. but will not prevent the shells entering the condenser. Recognition
of these problems and severe consequences of debris trapped in the condenser tubes has meant that some form
of secondary screening, located as close as possible to the inlet water box, is now regarded as essential.
Condenser debris filter fulfill their requirements.
When water flows through the condenser tubes, a shear stress is produced in the tube surface is dependent on
the cw velocity. For each alloy there is a critical shear stress (corresponding to a critical).
The free cross sectional area at a lodged obstruction is reduced and this leads to a corresponding increase in
the CW velocity locally ( to maintain volume flow). This increase may then be sufficient for the critical shear
stress to be exceeded and for erosion –corrosion to take place. Erosion –corrosion is partially a rapid form of
attack. The protective oxide film is removed and attack of the tube material can therefore proceed virtually
unimpeded. Tube penetration in a few thousand hours in common whereas extremely large number of tubes
are blocked by debris, it is possible that the CW velocity in the remaining tubes will be sufficiency high to
cause film breakdown and subsequent erosion –corrosion.
Microbiological fouling :
Biological fouling in open re-circulating cooling water system is the result of excessive growth and
development of different members of lower forms of plants namely Algae, fungi & bacteria . Abundant algae
growth occur in the exposed parts of cooling towers as sunlight in necessary for the growth. The principal
types of biological growth that occur in the non-exposed portions of the cooling system is slime. Slime is an
accumulation of microorganism and their excrotions together with whatever inorganic and or inorganic
debris may be embedded in the mass. Slime growths contain various bacteria, filamentous fungi, yeast and
occasionally protozoa . Slime deposits on process equipment will retard the heat transfer so as to create a
remain loss in efficiency. Biological fouling on metal surfaces will create differential oxygen concentration
cells and result in serious pitting on metal surfaces.
Control Of Biogrowth & Biofouling :

Chlorine is the agent most widely employed for control of biogrowths and microdiposits. Chlorine residual
of 0.3-1.00 ppm will usually destroy most microorganism. Intermittent chlorination is a common practice
because of the economy that can be secured . It is usually possible to adequately control biological fouling by
means of a programme of intermittent chlorination. A programme which is generally successful is to chlorinate
daily until a free residual of 1ppm. Chlorine is added by means of a chlorinator which is a metering instrument
capable of varying the rate of addition within certain limits.
Effect of our ingress has already been discussed :

Please refer FAULT TRACING INSTRUCTIONS of CONDENSER for further details.
(See Annexure – 1 enclosed )
Effect of high vacuum on efficiency:
255
If CW flow is more than To will comedown and hence Ts. So vacuum increases .
If Ti is less than To & Ts comes down and vacuum increases . Hence, overall cycle efficiency can be
increased by maintaining a high condenser vacuum i.e. lower condenser back pressure . However, the trouble
is that as the back pressure improves certain losses increase . There are mainly
(a) CW pumping power (b) Leaving loss (c) Reduced condensate temp (e) Increased wetness of steam.
Increased CW pumping power : The increased amount of CW flow required for increasing the condenser
vacuum (for a fixed CW I/L temp. T1) results in increased CW pumping power. Thus the gain from
improved condenser back pressure must be offset against extra power absorbed by the pumps.
Increased leaving loss: The steam last row at a velocity which depends upon the conditions prevailing at that
point. As this velocity is not utilized fully it represents a loss of possible work known as leaving loss.
Reduced condensate temp. / increased bled steam: If back pressure is reduced saturation temp. will drop.
Hence, the condensate temp is reduced and consequently when the condensate water enters the 1st LP heater
it will be cooler and consequently more steam will automatically be bled to the heater . So, the turbine will be
deprived of steam extra steam and hence work output reduces.
Increased wetness of steam : The lower the back pressure the greater the wetness of steam. The extra
moisture could result in damage to the morning blades. The extra moisture could result in damage to the
moving blades. More the wetness heavier droplets being heavier than steam move slowly. The front edge has
to push through the droplets and very result in blade damage.
CONDENSER PERFORMANCE TEST:
After steam has transferred its useful heat to the turbine, it passes into the condenser. The work obtained by
the turbine from the turbine will increase as the back pressure is reduced, so it is always desirable to keep the
back pressure at minimum achievable level. In fact, condenser back pressure is the most important operating
parameter of a unit, therefore, the factors which worsen back pressure must be cleanly identified so that
effective remedial measures can be taken once they are detected.
There are various controllable parameters to improve / maintain the condenser performance, such as
cleanliness, air ingress, CW flow etc.
In view of this it is recommended to carry out simplified routine performance test on the condenser at certain
frequency to identify the level of deviations and performance trend . The intent of this document is to layout a
standard test procedure for adoption at all units / plants. This tests procedure checks the condenser
performance with regard to one or more performance indices as follows:-
(a) Absolute back pressure deviation from expected value.
(b) Terminal Temp. difference (TTD).
(c ) Cleanliness Factor
(d ) Sub-cooling of air steam mixture and condensate
(e) Heat transfer co-efficient
(f) Effectiveness of cleaning the tubes
(g) Effects of physical changes in the condenser like new tubes etc.
(h) Circulating water velocity in the tubes.
(i) Circulating water temperature rise
(j) Flow of air steam Mixture.
(k) Dissolved oxygen in condensate
(l) Effect on heat rate and its financial implications.
Plant specific datas and characteristics required are given as follows:-

(a) Condenser design data
(b) Heat load Vs condenser back pressure for different CW I/L temperatures
(c ) CW Pp characteristic curves
256
(d) Generator loss curve

(e) VWO Heat Balance
Test instrumentation and measurement required (for a 200MW unit).
Measurement Temperature Pressure Flow Remarks

CW I/L temp. 2 - -
CW O/L temp. 8 - -
CW flow - - **
Condensate temp. 2 - - One on each O/L leaving hot
wells
Condenser Back Pressure (Abs) - 2 -* One on each half of the
condenser grid
Water box diff. pr. - 2 -
Air steam mixture Temp. 2 - - One on each half of the
condenser grid
** CW flow measurement to be taken from

(a) calibrated elbow temp. differential pressure (e.g. available)
(b) Annubar (If available)
(c ) calculated from condenser heat load (generator loss curve required)
(d) calculated from CW pump characteristic curve
Each test run may be conducted for a period of 15-20 mins. after achieving minimum uncertainty.
Computation of condenser duty:

Condenser duty = (Heat added MS + Heat added SH attemperation + Heat added CRH + Heat added by BFP +
Heat added by RH attemperation) -860/ P gen + Pgen losses + Heat loss rod).
WHERE :
Cond. duty = K cal / hr.
Heat added MS = Flow MS (hms – hcw) k cal / hr.
Flow MS = Kg/hr(flow main steam excluding SH attempt.)
hms = K cal/kg (Enthalpy of main steam)
hfw = K cal /kg (Enthalpy of feed water)
Heat added CRH = Flow CRH/hHRH - hCRM ) & cal / hr.
Flow CRH = Kg/ hr flow cold reheat steam
hHRH = K cal /kg / Enthalpy of hot Reheat steam)
hCRM = K cal /kg (Enthalpy of cold Reheat steam)
Heat added by BFP = Flow FW / hBFP out – hBFP) k cal/hr.
Flow FW = Total FW flow kg / hr.
hBFP out = K cal / kg (Enthalpy of Fw at BFP O/L
hBFP in = K cal / kg
Heat added by = Flow RH attempt.(hHRH – hRHATT) / K cal/hr.
RH attempt.
hHRATT = K cal/kg(FW Enthalpy at RH attempt. source)
Heat added by SH = Flow SH attempt.(hms-hsHATT)/ K cal/hr.
attempteration
hSHATT = K cal /kgCW Entahlpy at SH attempt. Source)
Heat loss red = 0.1% OF Pgen (radiation losses) kw
Pgen = KW(Gross Generator output)
Pgen losses = KW (Mech losses + Iron losses + Stator current losses)
** Valves to be taken from Generator loss curve

DETERMINATION OF CONDENSER FLOW:
257
Cond. Duty
CW Flow = m³/ hr
CP(To-T1) X D
Where CW flow = m³/ hr, cond. Duty = K cal / hr.
Cp = 1 cal/kg°C ( Specific heat of water)
D = 1000kg/cubic meter (Density of water)
To = °C (Average CW O/L temp. )
T1 = °C (Average CW I/L temp.)
Water velocity in condenser tube
CW flow Rate X 106

Tube velocity =
3600 X Tube Area X ( No. of Tubes – No. of tubes plugged )
Tube velocity = m /sec.

CW flow Rate = m³ / hr.
Tube area = mm²
Computation of LMTD LMTD = To-Ti
In Ts-T1
Ts -To
Where LMTD = °C
Ts = °C ( Saturation temp corresponding to back pressure).
Determination of cleanliness factor :
Cf (cleanliness factor) = U actual (actual heat transfer co-efficient)
U theoretical (theoretical heat transfer co-efficient)
U actual = Condenser flow x Cp (To-T1) X density of water
A condensing X LMTD
U actual = k cal / hr m²°C
Density = 1000 kg / m³
A condensing = m²/ (condensing surface area )
U theoretical = U x Ti correction factor x tube correction factor x 4.882428

Where U theoretical = k cal / hr m²°C
U = heat transfer co-efficient in Btu/hr. sqft
At 70°F CW I/L temp., 18BWG Admiralty metal
(to be taken from HEI standard for steam surface condenser)
T1 correction factor = correction factor for actual
CW I/L temp. (to be taken from HEI standard for steam surface condenser)
Tube correction factor = correction factor for tube material and tube wall gauge (to be taken from HEI
standard for steam surface condenser).
Determination of expected LMTD for deviation from design value.
Correction for CW I/L temp. (ft)

Saturation temp. test LMTD test ¼
ft =
Saturation Temp.. design –LMTD design
Correction for CW flow (tw)
fw = Tube velocity test ½
Tube velocity design
Correction for condenser heat load (fq)
Cond. duty design
fq =
Cond. duty test
Expected LMTD = LMTD test x ft x fw x fq °C
Determination of expected saturation temperature.
(taking into consideration deviation in operating valve from design values).
258
T1-To . ez °C
Sat temp. expected =
(I-ez )
To-T1
Where Z =
(Expected LMTD)
Determination of break up of condenser back pr. deviation.
On arriving at the back pr. deviation with respect to expected back pr., the following steps shall be adopted
for calculating its break up i.e. deviation due to CW I/L tempt. CW flow and effect of air ingress / dirty tubes
a) From design data develop a graph for a range of loads for optimum CW, temp rise &TTD.
b) From curve (a) above generate curve for all conditions likely to be met in practice to determine
expected back pr. for any load and for any probable CW I/L temp.
c) Compute the deviations.
From the above deviations identity the areas for possible improvement.
REPORT :
The test should be then followed by a report which should include a narrative deserving unusual findings and
conclusions and recommendations for performance improvement .
…..
ANNEXURE-1
Fault tracing instructions :
Condenser ∆P= C.W. pressure ∆h/ ∆t = Rate of t = (t2-t1), CW

1.1 Symbols used drop across the vacuum drop in temp. rise
condenser tube the condenser ∆h = Vacuum
drop in mm Hg.
P = Reference power t3 = Hotwell condensate t9 = (t4-t2), TTD ∆t = Time in
output temp. steam / CW minutes
t1 = C.W. I/L temp. t4 = Exhaust steam t91 = (t3-t2), , TTD
t2 = C.W. O/L temp temp condensate /
CW
SL. FAULT SYMPTOMS CAUSE REMEDY

NO.
1.0.1 Low vacuum (i) t= high C.W. flow being less Attend the defective pump
(a) One of the CW - do-
(ii) t= higher corresponding pumps defective Clean the tubes
to turbine loading and (b) Malfunctioning of Locate and plug the points
excessive ∆P CW Pp of air ingress
(iii) tg & tgl excessive Cond. tubes Attend the air venting
choked. equipment
(a) Excessive air Correct seal steam supply
ingress pressure.
iv) tg = high, tgl = normal (b) Malfunctioning of Attend the fault
and air venting
flooding of equipment. Attend the defective Pump.
condenser. (c ) Gland seal steam
pressure low.
Fault in hot well
level
Condensate Pp
defective
1.0.2. Turbine Cond. vacuum low Refer 1.0.1 above At specified at 1.0.1. above
259
tripping due Cond. vacuum normal Fault in low vac. trip .

to low system Attend the fault
vacuum
1.0.3 Rapid fall in i) CW supply, turbine a) Severe air ingress Locate & plug the points of
cond. gland seal system, air air ingress
vacuum venting & condensate b) Vacuum breaker Close the v/v
transfer system normal. valve open Replace the diaphragm
c) Rupturing damaged
diaphragm damaged Close the v/v
d) Condenser drain Repair / replace level gauge
valve open Locate & plug the leakage
e) Local level gauge points.
damaged.
f) Lkg. in piping of
vacuum system
1.0.4 Leak test Vacuum pps not in Air leakage in turbine

reveals high operation Rectify the gland seal
∆h / ∆t Turbine gland seal system defect
system defective Attend v/v seat
Lkg. of air from Leakage from v/v Improve sealing water
vac.breaker valve seat supply
Improper seal water
supply to the
v/v gland
No water supply to Leakage through the Establish sealing water
gland of valves valve glands supply
connected with
vacuum system due to
stoppage of seal water
.
Air bubble in water Water level indicators Attend the level indicator
level indicators leaking glands
Rate of condenser Suction valve glands Overhaul the valves during
vacuum drop of its flanged the next available
lower when all air connection on the air opportunity
venting venting equipment
equipments leaking
operate with
suction valves
closed
No leakage through the Leaking into the Locate and plug the points
above vacuum system of air ingress
Rate of vacuum drop Leakage through Locate and plug / repair the
high at lower piping / equipments leaking points.
turbine loads than connected to turbine
at higher turbine vac. system which
loads remain under pr. at
high / normal loads
but under vacuum at
low loads.
260
1.0.5 Higher tg & (a) tl,t (corresponding to Leakage into vacuum Attend the problem as per
tgl than at the power output) & ∆h & system as per 1.03 & 1.03 & 1.04 above.
reference ∆t higher 1.04 above
power (b) tl.t. ∆p & ∆h/ ∆t Defect in the air Operate the system with
normal venting equipment stand by.
( c) tl & ∆h / ∆t normal t Condenser tubes Clean the tubes
& ∆p high fouled on CW side
(d) tl & ∆h/ ∆t normal, Defective condensate Attend and rectify the
condensate level high transfer system system defect .
1.0.6 Tg higher Condensate level in Rectify condensate transfer
than tgl hotwell high system
1.0.7 Conductivity C.W. leakage into the Locate the failed tube and
of condensate condenser plug its ends.
high
1.0.8. Dessolved (a) Excessive air ingress Locate and plug the
O2 in into the vacuum system leaking points.
condensate
high
(b) Air venting system choked Clean the air venting system(c) Excessive quality of cold make up Improve
system tightness to reduce make up1.0.9Condenser hot well level high Hotwell level control system
malfunctioning Set level controls system on MANUAL and control the level. Find out the fault and rectify.
Running CEP tripped Start stand by CEP Same as 1.07Refer 1.07 above 1.10Condenser hotwell level low
Level control instrument / control valves malfunctioning Refer 1.09 (a) above.
41
AUXILIARY PRDS SYSTEM & TURBINE LUB OIL SYSTEM
Auxiliary PRDS system consists of a Turbine PRDS control system as well as Boiler PRDS control system.
The controller is pneumatically controlled. Both the systems are identical in nature i.e. TPRDS & BPRDS.
Turbine PRDS system is designed to maintain the auxiliary steam at 14 kg/cm2 and 2600C at the aux. steam
header. This steam is required for various applications like turbine gland sealing, starting & main ejectors,
initial heating & pegging stem for deaerator.
Boiler PRDS system is designed to meet the requirements of atomizing steam for oil burners, heating steam for
HFO and steam inerting for coal mills.
Auxiliary steam is tapped from the main steam line and its pressure is reduced and de-superheated to the
required temperature and pressure. The spray water for de-superheating is supplied from the CEP discharge
header. In order to obtain better operational flexibility and controllability range, the system has been split into
two identical PRDS system such as low capacity PRDS and high capacity PRDS.
The low capacity is of 30% of that of the high capacity line. Each system comprises of the pressure controller,
one desuperheater and one spray water flow controller.
AUX. STEAM PRESSURE CONTROL:
The auxiliary steam pressure control valve (PRDS) supplies steam to TAS/BAS by maintaining TAS/BAS line
pressure constant at the set point. Downstream pressure of PRDS valve is taken as controlled pressure.
AUX. STEAM TEMP. CONTROL:
261
The auxiliary PRDS spray water flow control valve (CD) maintains the TAS / BAS line temperature constant
at the set point. The downstream temp. of PRDS valve is taken as controlled temperature.
INTERLOCKS OF TPRDS :
Under failure of power supply or failure of compressor the control valves will remain in stay put condition.
When PRDS steam pressure control valves open more than 2%, the corresponding temperature control valves
will open automatically after opening their motorized isolating valve.
When PRDS steam pressure control valves close less than 2%, a force close command goes to the respective
temperature control valves.
PRDS steam control valve will trip at V. High temperature (3000C). Temperature High alarm will appear at
2800C.
SELECTION OF HC TPRDS & LC TPRDS:
During unit start up auxiliary steam for turbine is supplied to the starting & main ejectors, deaerator initial
heating & pegging, turbine gland sealing. To meet this high demand of aux. steam HC PRDS should be put
into service.
After required condenser vacuum reached, starting ejector is withdrawn, so the aux. steam supply to starting
ejector is cut off. After unit synchronization and at about 30 to 40% of unit load deaerator pegging is supplied
from CRH / turbine extraction line (CAP) and pegging from TRDS is cut out. At about 40% unit load also,
turbine gland sealing supply valve from TPRDS closes as turbine becomes self-sealing condition.
At that position aux. steam from PRDS is supplied to main ejector only. To meet this very low demand of aux.
steam , LC PRDS should be put into service, because it will be very difficult to control TPRDS steam pressure
by HC PRDS valve which may cause of safety valve popping of TPRDS system.
FIG. PRDS SYSTEM
TURBINE LUBRICATING OIL SYSTEM

**********************************************
Forced lubrication of the turbine bearing is essential in order to prevent damage due to wear or excessive white
metal bearing temperature. Before starting to turn the main rotating element, it is necessary to lift the rotors
clear of the bearing surface by using jacking oil system.
262
The purpose of the forced lubrication of the main bearings is:-

To provide a hydrodynamic oil wedge between the bearing surface and the journal bearing of sufficient
thickness so that the particles normally present in the oil will not damage the bearing surface.
To provide a flow of cooling fluid sufficient to maintain the bearing metal temperature below 1100C,
dissipating the heat at the bearing due to:-
• Thermal conduction.
• Friction between the journal, oil film and white metal.
• Turbulence with the oil itself.
In our Bk.T.P.P. unit, the lubricating oil system is integrated with the turbine control and protection oil system.
The lube and control oil system provides oil to the turbine generator system for the following purpose :-
lubrication and cooling of turbine and generator bearings.
Drive of oil hydraulic turning gear at the start up & shut down of turbine.
Jack-up of rotor at the start and shutdown time of turbine.
Operation of servo-motor of steam control valves, main stop valves and protection devices.
The system consists of the following components:-

- Main oil tank (MOT).
- Auxiliary oil pump.
- AC / DC motor driven Emergency oil pumps (EOP).
- Oil ejector.
- Main oil pump MOP).
- Main oil tank vapor extractors.
- AC / DC motor driven jacking oil pump (JOP).
- Lube oil coolers.
- Lube oil filters.
- Jacking oil filters.
- Strainer in the MOT.
- Level & pressure instrumentations.
The main oil tank provides the storage of oil for the lube oil system. As the oil is returned back from the
system, it collects back into the main oil tank ready to be used again. The tank oil level high and low is
monitored on the DCS control room with alarms. A vapor extractor is provided to remove oil vapor and
moisture from the main oil tank and creates a slight vacuum inside the tank
The auxiliary oil pump driven by AC motor supplies oil to the turbine / generator bearings during starting and
shutdown and to the oil hydraulic turning device during turning operation. The main oil pump, which is driven
by the turbine generator shaft, supplies oil to the turbine / generator bearings servo motors during normal
operation, main stop valves, solenoid valves and the other protection and control devices. It also supplies oil to
the oil ejector which supplies pressure oil to the main oil pump itself and control oil to the servo motors in the
event of total load rejection. As the main oil pump is driven by TG shaft and has sufficient capacity, the
pressure dip in the control oil will not occur on changeover from the main to auxiliary oil pump and in any
transient operation without an accumulator.
The main oil supply for the turbine / generator bearings flows through two 100% lube oil coolers and filters
before being distributed to the different bearings and return back to the main oil tank.
AC / DC motor driven jacking oil pumps are used to lift the turbine / generator shaft during start up and
shutdown. AXC / DC motor driven emergency oil pumps will only provide enough oil to protect the bearings
of the turbine / generator in the event of failure of the main and auxiliary oil pumps or in the event of
shutdown of total plant electric sources (black out). As the turbine should be immediately brought to the still
state in the event as mentioned above, the turning operation is omitted. Therefore the emergency oil pump
does not supply oil for the turning device.
263
The main oil pump driven by turbine shaft installed inside bearing No.1 pedestal feeds all required oil to the
lubricating oil system under the normal operating condition. The oil ejector is arranged to the suction side of
the main oil pump.
The auxiliary oil pump is installed for backing up the main oil pump by feeding the system oil at the start up
and shutdown process of turbine. When the turbine is started, the main oil pump can’t discharge all the oil
which is required for the system, so the auxiliary oil pump feeds all required oil until the turbine speed is
reached to 90% of the rated speed.
The check valves are mounted on the discharge side of auxiliary oil pump and emergency oil pumps so as to
prevent the reverse flow of oil when the pumps are not operating. The oil from the main oil pump and the aux.
oil pump is entered into the oil cooler via three way valve. The oil from the oil cooler is adjusted to the
required lubricating oil flow by the throttle mounted in each bearing lubricating oil pipe, and supplied to each
bearings.
If the main oil pump can’t obtain the specified pressure by a certain cause, the pressure switch at the main oil
pump outlet line activates the aux. oil pump to automatically start operating to feed oil.
A part of discharge oil from the aux. oil pump is supplied to the oil hydraulic turning device via turning oil
supply valve during turbine turning operation. The jacking oil pump supplies the high pressure oil to the lower
half of each bearing for securing the turning operation.
Also, emergency oil pumps are installed as back up for the bearing oil pressure to stop the turbine safely. If the
bearing oil pressure abnormally becomes lower, emergency oil pumps automatically start to feed the bearing
lubricating oil so as to prevent the damage of the bearing. The discharge oil from the emergency oil pumps are
supplied directly to the bearing lubricating oil line, bypassing each oil cooler and oil filter because it is mainly
used for finally backing up the bearing oil pressure.
The oil vapor extractor prevents the leakage of inflammable gas from each bearing pedestals to atmosphere by
setting the interiors of these equipments and piping to slight negative pressure.
**** **** *****
264
41
VACUUM PULLING THROUGH STARTING EJECTOR
A. TURBINE GLAND STEAM:
1) Verify turbine is on turning gear

2) Open the condensate water inlet , outlet isolating v/vs (manual) & close the by pass v/v of gland
steam condenser.
3) There should be minimum condensate flow through GSC .
4) Open the isolating v/vs (inlet & outlet) of gland steam exhauster.
5) Open the isolating inlet and outlet v/vs of gland steam exhaust controller
6) Check the both bypass motorized v/vs of gland steam exhauster and gland steam exhaust
controller. (Whether it is operating or not). But the v/vs will be in closed condition.
7) Open the As-9 motorised v/vs (from TPRD’s header) for supply steam to gland steam controller
from CRT and open the CRH -7 motorised v/v (from CRH line).
8) Keep open the motorized drain v/v of gland steam pipe. Both drum lines are connected with HP
flash tank. The valves will be in open condition up to ≤ 20% load.
9) TPRDS pressure should be 9.5Kg/cm²
10) Wait for temp. Increase at the controller (inlet at least 210°C). This is the interlock to open the
controller.
11) Set the header pr. set of point at 0.068 kg/cm². Open the gland steam supply controller slowly to
match the pr. with set point and then put the both supply & exhaust controller are in ‘Auto’.
12) Check gland steam controller inlet temp. must be greater than 198°C
B. CHECKING BEFORE VACUUM PULLING
1) Turbine should be in turning gear.

2) Air steam pr. of TPRDS must be near about 10 kg /cm².
3) Check at least one CW Pp & one CEP are in running condition
4) Close all atmospheric drains which are connected to condenser
Like (a) CRH atmospheric drain & Reheater vent (drum floor).
(b) All HP & LP heaters atmospheric drain -2 vents
(c ) Deaerator atmospheric vent
5) Ensure water supply to stand by CEP and all valves (condensate cycle).
6) Check ejector loops are sealed to normal level.
7) Main ejector condensate line will be in open condition
8) One of the gland steam exhauster is in running condition.
9) Open the v/vs. of air off take line at condenser side
10) Now open the isolating v/vs of ejector controller and check the by pass motorized v/vs.
11) Set the ejector steam pr. controller set point at 6.5 kg /cm² & put the controller in ‘auto’.
12) Check the condenser pump header pr > 18kg/cm²
13) Check 220V DC voltage is available for ‘vacuum breaker’
CONDENSER VACUUM PULLING
1) Open the starting ejector steam v/v.

2) Check the condenser pressure is < 0.26 kg / cm²
3) Open air v/v of starting ejector
4) When vacuum reaches 15mm Hg then establish the gland steam sealing by opening the gland steam
controller manually and after reaching to 0.068 kg / cm² pr. controller will be putted in ‘Auto’.
265
5) When vacuum reaches up to 200mm Hg close the vacuum breaker .

6) When vacuum reaches 680mm Hg, open the steam v/v of main ejector A or B and then open the air v/v
of that ejector.
7) Close the air valve (first) and steam inlet v/v of starting ejector.
8) Wait for the condenser vacuum is > 700mm Hg & generator load is >5%.
9) Then any one of two main ejector out from service and then check the condenser vacuum.
Vacuum Tightness Test

This test is done by filling water up to one meter above the top row of condenser cooling water tubes. Then all
the drains of water side are to be closed. Then check that is there any leakage from that circuit. But in this
process leakage points one meter above the tube nest remain undetected. Previously “From Gas” detection was
employed for the same, but due to environmental degradation this process are now not used.
Now illustrating the procedure of leak detect in the above mentioned undetected are, which will remain under
vacuum even at the load of 80-100%, by steam pressurization.
STEAM PRESSURISATION
It has three following steps.
(a) Prepare the system for vacuum tightness. Water filled for vacuum lightness test (up to
one meter above tube nest) to be retained for steam pressurization.
(b) Preparation of thermal scheme of turbine for steam pressurization.
(c) Steam pressurization of vacuum system.
Preparation of thermal scheme
(a) For pipe lines of line steam of HPC.

Close the MSVs (turbine side). Starting device to kept at 0%.
(b) All pipe lines of cold and hot reheat pipe lines and 1PC.
Close reheat stop valves

Close drain v/vs of alternate drains of HRH & CRH lines connection to HP flash tank.
Close v/vs. HP & LP bypass system and their spray lines
(c) On condenser
condenser springs are locked as the same is done in case of water till test.
ensure water boxes of circulating water are completely drained.
(d) On ejectors
Isolate the steam supply lines to ejectors
close air line v/vs to all ejectors. Vacuum breaker valve will be closed.
check the NRVs in the air exhaust line of main ejectors
(e) On HP heaters & deaerator
- close extraction v/vs of HP heater and deaerator
- close drip line from HP heater to condenser
(f) On turbine
-Atmospheric relief diaphragms on exahsut past of LP are to be in operational condition.
-switch on all turbovisory instruments.
- Install pressure gauge with a range of zero to 1.0 kg/cm² on exhaust part of turbine for measuring the pr. in
condenser. All vacuum gauges are to be isolated.
- LP exhaust hood temp. gauge to be replaced with gauge having a range of 0-200°C.
- Switch on oil supply system of turbine
- Put TG set on turning gear
266
- Ensure readiness of supply of steam to LP exhaust from Aux. PRDS. A temporary line from Aux. PRDS to
seal steam station.
11. Steam pressurization of vacuum system.

- Steam parameters (Saturated)
Temp. 120 -150°C , pressure 5kg /cm².
After stabilizing the parameters of turbine supervisory system and ensuring that they are within permissible
limit. Start the steam pressurization of vacuum system for which the following should be done.
Manually open the steam supply valves, which supplying steam to the LP exhaust and raise the
pressure in steps of 0.05 kg / cm².
Wait till the parameters of steam turbine are stabilized like diff. expansion of HP, LPC & IP, Axial
shift, exhaust hood temp. and record the reading.
With a stable turbine parameters increase the steam pressure up to 0.2kg/cm². If any one of the turbine
parameters exceeds the limits pressurization should be stopped by culling steam supply.
Locate the leaking points. Special attention should give in the following points.
- Flange and welding connection of turbine and condenser.

- Connections of cross around pipes.
- Manhole covers, atmospheric relief diaphragm
- All compensators, including flash tank and all connections to flash tank
- LP turbine parting line.
- Condenser neck joint welding
- Thermo well pockets, etc.
Repeat the process after attending the leaky points till no leaks are observed.
Status of equipments is as follows.
(a) CW Pump - Not in operation.
(b ) CEP - Not in operation
(c) BFP - Not in operation
(d) Gland steam exhauster – Not in operation
Saturated steam parameters:

Pressure : 5 kg /cm²
Temperature : 120 -150°C
267
42
HP – LP BYPASS SYSTEM
The HP – LP Bypass System is designed to maintain the M. S. Pressure at Turbine end at a pre-set desire value
during the different Load Conditions of the machine.
Functions:
The main functions of HP-LP Bypass System are:
• Maintains Turbine end Main Steam Pressure at a pre-set desire value by dumping the excess steam,
which is generated in the Boiler, directly to the Condenser by bypassing its normal flow path.
• Reduces Start-up Time by circulating huge quantity of steam in the bypass path, which causes faster rise
of steam parameters (mainly steam temperature and pressure), during start – up period.
• Introduces Economic Operation by saving D. M. Water loss particularly during start-up.
• Drastically cuts down the Sound Pollution Level particularly during start-up.
• Protects Super-heater and Re-heater Coil against over-heating by circulating steam through it
particularly during start-up.
HIGH PRESSURE BYPASS i.e. HP BYPASS SYSTEM :
Introduction:
• As the name indicates, the HP Bypass System dumps the Main Steam (MS) from MS Line to CR Line
directly by bypassing the H. P. Turbine.
• The main object of H. P. Bypass System is to maintain Main Steam Pressure at H. P. Turbine end at a
pre-set desire value by dumping the excess main steam to the C. R. Line in such a way so that the
parameters (Pressure and Temperature) of the dumped steam will matches with the design parameters
(Pressure and Temperature) of the C. R. Pipe Line.
• The schematic diagram of HP Bypass System is shown in Fig - 1 bellow.
• From the schematic diagram of HP Bypass Station, it is clear that there are two numbers Steam Valve
namely HBP–1 & HBP–2 and three numbers Spray Water Valve namely BPE–1, BPE–2 & BD.
• All these five valves are basically Control Valve.
HBP–1 & HBP–2:
268
• Now, HBP–1 & HBP–2 are the Pressure Controller, which controls its Upstream Pressure i.e. HBP–1 &
HBP–2 controls the M. S. Pressure at H. P. Turbine inlet at a pre-set desire value by dumping the excess
main steam, if there, directly to the C. R. Line.
• The valve HBP–1 & HBP–2 starts to “OPEN” when M. S. Pressure at H. P. Turbine inlet rises above the
pre-set desire value and starts to “CLOSE” when M.S. Pressure at H. P. Turbine inlet falls below the
pre-set desire value.
BPE–1 & BPE–2:

• Now, BPE–1 & BPE–2 are the Temperature Controller, which maintains the Down Stream Temperature
of HBP–1 & HBP–2 respectively at a pre-set desire value by spraying water into the dumped steam.
• Basically it controls the quantity of attemperation flow (Spray Water). So, BPE-1 & BPE–2 are the
Spray Water Flow Controller.
• The valve BPE–1 starts to “OPEN” when the Down Stream Temperature of HBP–1 valve rises above
the pre-set desire value and starts to “CLOSE” when the Down Stream Temperature of HBP–1 valve
falls below the pre-set desire value.
• The valve BPE–2 starts to “OPEN” when the Down Stream Temperature of HBP–2 valve rises above
the pre-set desire value and starts to “CLOSE” when the Down Stream Temperature of HBP–1 valve
falls below the pre-set desire value.
BD:
• Basically, BD is a Pressure Controller, which controls its Down Stream Pressure i.e. the Spray Water
Pressure at the inlet of BPE–1 & BPE–2 valves at a pre-set desire value (Say 100 Kg/cm2).
• Practically, BD is the Spray Water Pressure Controller.
• The valve BD starts to “OPEN” when its Down Stream Spray Water Pressure falls below the pre-set
desire value [Spray Water Pressure is less than 100 Kg / cm2 - say] and starts to “CLOSE” when its
Down Stream Spray Water Pressure rises above the pre-set desire value [Spray Water Pressure is more
than 100 Kg / cm2 - say].
How HP Bypass Station Controls M.S. Pressure at H. P. Turbine Inlet and the Temperature of the
steam, which is dumped into the C. R. Line:
Pressure Control:
• When High Pressure Steam (fluid) mixes with the comparatively Low Pressure Steam (fluid), then there
are the chances of creation of turbulence. Some times, the energy of this turbulence may be so high that it
may collapse the system. So, whenever, we will mix high-pressure steam with comparatively low pressure
steam, then we have to take care to avoid turbulence.
• Now, HP Bypass Station dumps the high-pressure main steam to the CR Line, through which low pressure
cold reheat steam is flowing.
• Now, without taking any precautionary measure, if HP Bypass Station directly dumps the high-pressure
main steam to the CR Line, then huge turbulence will be generate inside the CR Line when high-pressure
main steam will try to mix with the comparatively very low pressure Cold Reheat Steam. The energy of
the said turbulence will be so high that it will totally destroy the whole CR Line.
• To avoid this, the HB Bypass Station reduces the pressure of the dumped steam before dumping it into the
CR Line. The HP Bypass Vales are itself a PRDS Unit. The Valves are designed & constructed in such a
fashion so that a huge pressure drop takes place inside the valve.
• To reduce the pressure further, a Throttling Device is erected on the down steam of each HP Bypass
Valve and pressure drop is assured by increasing the area (i.e. volume) of the steam flow path, just after
the Throttling Device, suddenly.
• In the Fig. – 2, an attempt has been taken to explain the construction of PRDS (Pressure Reducing and De-
super Heating) unit and Throttling Device of the H. P. Bypass Station.
• HP Bypass Station dumps main steam to CR Line by controlling the OPENING of its two steam valve BP-
1 & BP-2. One Pressure Master Controller and two Slave Controller control the opening of steam valve
BP-1 & BP-2.
269
• The Pressure Master Controller is common for both BP-1 & BP-2 but Slave Controller is separate and
independent for BP-1 & BP-2. Out of above said two Slave Controller, one is for BP-1 and other one is
for BP-2.
• The Pressure Master Controller comprises of Pressure Transmitter (PT) and Current to Voltage converter
(I/E), Pressure Setter, Error Generator and one PI Controller.
• The Slave Controller comprises of Memory Card, Position Feedback Transmitter and Current to Voltage
converter (I/E), Error Generator, Output amplifier and Electro-Hydraulic Actuator.
• Actual MS Pressure at HPT end is sensed (measured) by Pressure Transmitter (PT) and Position Feedback
Transmitter (F/B Transmitter) is used to measure the actual opening the valve (here either BP-1 or BP-2).
Pressure Setter is to generate Desire Set Value for main steam at HP turbine end.
• Depending upon the difference between Actual MS Pressure and Set Pressure, Pressure Master Controller
generates the signal (PI position demand signal) for final opening position of BP-1 & BP-2.
• Now, if the memory is in AUTO mode then the Slave Controller will take action to re-position the valve, if
required, after comparing the actual valve position (Output of F/B Transmitter) with PI position demand
signal.
• Control Scheme for BP-1 is shown in Fig. – 3 bellows.
How Controller is Functioning to control MS Pressure at HPT end?
• To Control the Upstream Pressure i.e. M. S. Pressure at HPT Inlet, the M. S. Pressure (P actual) is
compared with the Pre-set desire Pressure (P set).
• If the actual M. S. Pressure (P actual) is higher than the Pre-set desire Pressure (P set), then HP Bypass
Valve will start to “OPEN”.
• If the actual M. S. Pressure (P actual) is lower than the Pre-set desire Pressure (P set), then HP Bypass
Valve will start to “CLOSE”.
270
• In both the above cases, the HP Bypass Valves will continue to OPEN / CLOSE till the actual M. S.
Pressure is not matching with the Pre-set desire Pressure.
• As soon as the actual M.S. Pressure matched with the set Pressure, the HP Bypass Valve will stand hold
at its last position.
• The schematic diagram of the Pressure Control Loop of HP Bypass System is shown in Fig.- 3 bellow.
Fig. - 3: Loop Diagram of the Pressure Controller of HP Bypass System.HP Bypass

Station’s Down Stream Temperature Control i.e. HP Bypass Station’s Spray
Water Flow Control:
For what Temperature Control of dumped main steam is essential?
• When High Temperature Steam mixes with the comparatively Low Temperature Steam, then there are the
chances of development of thermal stress. Some times, the energy of this thermal stress may be so high
that it may be the cause thermal failure of the system. So, whenever, we will mix high-temperature steam
with comparatively low temperature steam, then we have to take care to avoid thermal stress.
• Now, HP Bypass Station dumps the hot main steam, having temperature in the range of 540 oC, to the
CR Line, through which comparatively low hot cold reheat steam, having temperature in the range of
360 oC - 380 oC, is flowing.
• Now, without taking any precautionary measure, if HP Bypass Station directly dumps the hot main steam
to the CR Line, then huge thermal stress will be develop inside the CR Line when hot main steam will try
to mix with the comparatively cool Cold Reheat Steam. The energy of the said thermal stress will be so
high that it will totally destroy the whole CR Line.
• To avoid this, the HB Bypass Station reduces the temperature of the dumped steam before dumping it into
the CR Line.
271
How the Temperature of dumped main steam is controlled?
• To reduce the temperature of the dumped steam, in the Valve Chamber, attemparation water is sprayed
into the dumped steam. We said early that the HB Bypass Valves are itself a PRDS unit. The valves are
designed / constructed in such a manner so that its attemparator breaks spray water into particle before
injecting it into the dumped steam.
• Spray water is sprayed after breaking it into particle for the reason so that it can easily mix with the
dumped steam completely and no water particle can reach into the re-heater coil.
• It is clear that by injecting attemparation water, HP Bypass Station controls the temperature of the dumped
steam i.e. the downstream temperature HP Bypass Station.
How the HP Bypass Temperature Controller i.e. HP Bypass Station’s Spray Water Flow Controller is
Functioning ?
• The HP Bypass station has two steam valves, which dumps main steam into the CR Line. Now, these two
valves may dump different quantity (Tonnage) of main steam. So, downstream temperature of these valves
may be different. As a result, the downstream temperature of each HP Bypass Valves is controlled
separately.
• To control the temperature, the actual downstream temperature (Tactual) of each valve is separately
compared with a pre-set desire value (Tset).
• If Tactual > Tset, then the corresponding attemparation flow control valve [BPE –1 for HBP –1 and BPE –2
for HBP –2] will start to “OPEN”.
• Now, if Tactual < Tset, then the corresponding attemparation flow control valve [BPE –1 for HBP –1 and
BPE –2 for HBP –2] will start to “CLOSE”.
• As soon as Tactual matches with Tset, then the corresponding attemparation flows control valve [BPE –1 for
HBP –1 and BPE –2 for HBP –2] will stand hold at its latest position.
• The schematic diagram of the Temperature Control Loop of HP Bypass System is shown in Fig. – 4
bellow.
272
Spray Water Pressure Controller i.e. the Function of BD Valve of HP Bypass

System:
• The function of HP Bypass Spray Water Pressure Controller is to maintain pre-set (desire) water
pressure at Up-stream of the valves BPE –1 & BPE –2 by re-positioning the Valve BD, which is
basically a Control Valve.
• So, Valve BD controls its down-stream pressure.
• We know that a Flow Control Valve i.e. a Flow Controller will function smoothly and properly if dp
(Differential Pressure) across the related Flow Control Valve is maintained at a fixed constant value.
• Now, here, to maintain the down-stream temperature of HP Bypass Station, we are using attemperation
water from BFP discharge header.
• Now, the water pressure at BFP Discharge Header is variable and varying with Boiler Drum Pressure.
• So, without deploying any pressure control valve i.e. spray water pressure controller, if we use water
directly from BFP Discharge Header for down-stream temperature control of HP Bypass Station then the
said Temperature Controller will not able to control the downstream temperature smoothly and
perfectly.
273
• So, for the interest of smooth and proper downstream temperature control, Spray Water Pressure
Controller i.e. Spray Water Pressure Control Valve (BD) becomes essential for HP Bypass System.
• Schematic diagram of HP Bypass Spray Water Pressure Control Loop is shown Fig. – 5 bellow.
• The main object of HP Bypass Spray Water Pressure Control Valve BD is to maintain its downstream
pressure (P Spray (Actual)) at a pre-set desire value (P Spray (Set)), which is fixed (Normally 100 Kg / cm2).
• Now, when the measured pressure (P Spray (Actual)) becomes higher than the set pressure (P Spray (Set)), then
the BD valve will start to “CLOSE”.
• Again, when the measured pressure (P Spray (Actual)) becomes lower than the set pressure (P Spray (Set)), then
the BD valve will start to “OPEN”.
• Now, when the measured pressure (P Spray (Actual)) becomes equal to the set pressure (P Spray (Set)), then
the BD valve will hold standstill at its last position.
LOW PRESSURE BYPASS i.e. LP BYPASS STATION:

• Bypassing the IP Turbine and LP Turbine, the LP Bypass Station dumps Hot Re-heat Steam directly into
the Condenser.
• The main object of LP Bypass System is to maintain Hot Re-heat Steam Pressure at IP Turbine inlet at a
pre-set desire value by dumping excess Hot Re-heat Steam, if any, directly into the Condenser in such a
manner so that the parameters (Pressure & Temperature) of the dumped steam matches with the design
parameters of the Condenser.
• Practically, the LP Bypass Station dumps Hot Re-heat steam into the STD (Steam Throw-off Device) of
the Condenser in such a way so that the jet of the dumped steam does not damage the Copper Tube of
the Condenser.
• The schematic diagram of LP Bypass Station is shown in Fig. – 6 bellow.
• It is clear that there are Two numbers Steam Valves, namely LBP – 1 & LBP – 2, and Two numbers
Spray Water Valves, namely LBPE – 1 & LBPE – 2, in LB Bypass System.
• All these four valves are Control Valve in type.
• The task of LP Bypass System is to maintain the IP Turbine inlet pressure of Re-heat Steam at the pre-
set desire value and dumps excess Re-heat Steam, if any, after lowering down the pressure &
temperature within the permissible limit of the Condenser, directly in to the Condenser.
LBP – 1 & LBP – 2:
• The Steam Valves LBP – 1 & LBP – 2 are responsible for controlling the Re-heat Steam pressure at IP
Turbine Inlet at a pre-set desire value. Now, this set pressure is Load dependent i.e. it depends upon the
actual machine load (MW) and when the machine is connected with grid, the set pressure is derived
from the chamber pressure of the HP Turbine (True for BkTPP) by means of special electronic ckt.
• Now, to control Hot Re-heat Steam Pressure at IP Turbine inlet, the steam valves LBP – 1 & LBP – 2 of
LP Bypass System dumps the excess Re-heat steam, if any, directly into the Condenser in such a manner
so that the parameters i.e. the pressure of dumped Re-heat steam matches with the allowable design
steam pressure of the Condenser.
• In short, the steam valves LBP – 1 & LBP – 2 of LP Bypass System maintains the Hot Re-heat Steam
Pressure at the pre-set desire value and if necessary, bypassing the IP Turbine and LP Turbine, dumps
Re-heat Steam, after changing its pressure which is in the allowable / permissible limits of the
Condenser, directly in to the Condenser.
• To control i.e. to reduce the pressure of the dumped steam, special care has been taken in the design of
the valve LBP – 1 & LBP – 2. These two valves are designed in such a fashion so that they act as PR
Unit (Pressure Reducer).
• So, basically, the valve LBP – 1 & LBP – 2 are the pressure control valves which is driven by a single
Master Pressure Controller and two separate Slave Controller.
274
275
LP Bypass Pressure Controller:

• The schematic diagram of Pressure Control Loop is shown in Fig.: 7 bellow.
276
• To Control the Upstream Pressure i.e. HR Steam Pressure at IPT Inlet, the HR Steam Pressure (P actual) is
compared with the Pre-set desire Pressure (P set).
• If the actual HR Steam Pressure (P actual) is higher than the Pre-set desire Pressure (P set), then LP Bypass
Valves LBP-1 & LBP-2 will start to “OPEN”.
• If the actual HR Steam Pressure (P actual) is lower than the Pre-set desire Pressure (P set), then LP Bypass
Valves LBP-1 & LBP-2 will start to “CLOSE”.
• In both the above cases, the LP Bypass Valves LBP-1 & LBP-2 will continue to OPEN / CLOSE till the
actual HR Steam Pressure is not matching with the Pre-set desire Pressure.
• As soon as the actual HR Steam Pressure matched with the set Pressure, the LP Bypass Valve will stand hold
at its last position.
LP Bypass Temperature Controller i.e.

LP Bypass Spray Water Flow Controller:
• The schematic diagram of Temperature Control Loop of LBPE -1 is shown in Fig.: 8 bellow.
277
The LP Bypass station has two steam valves, which dumps HR Steam into the Condenser. Now, these two
valves may dump different quantity (Tonnage) of HR Steam. So, downstream temperature of these valves may
be different. As a result, the downstream temperature of each LP Bypass Valve is controlled separately.
• To control the temperature, the actual downstream temperature (Tactual) of each valve is separately
compared with a pre-set desire value (Tset).
• If Tactual > Tset, then the corresponding attemparation flow control valve [LBPE –1 for LBP –1 and LBPE
–2 for LBP –2] will start to “OPEN”.
• Now, if Tactual < Tset, then the corresponding attemparation flow control valve [LBPE –1 for LBP –1 and
LBPE –2 for LBP –2] will start to “CLOSE”.
• As soon as Tactual matches with Tset, then the corresponding attemparation flow control valve [LBPE –1
for LBP –1 and LBPE –2 for LBP –2] will stand hold at its latest position.
278
Fig – 9: Servo – Valve.
Fig – 10: Blocking Element.
279

6 - Feed Cycle - 210-279

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6 - Feed Cycle - 210-279

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POWER PLANT SIMULATOR TRAINING INSTITUTE

Bakreswar Thermal Power Project : WBPDCL

FEED WATER CYCLE

BOILER WATER CIRCUIT

BOILER STEAM CIRCUIT

2.5. Stuffing Box :

2.7. Head Piece:

6. OPERATING PROCEDURE OF C.E.P:

2.1. Pump Casing :

2.5. Rotating Assembly :

VOITH Variable Speed Coupling: -

Working Oil Circuit: -

Lube Oil Circuit:-

4. INTERLOCK & PROTECTION AND START PERMISSIVE :

- Motor bearing HC end lub. oil pressure 0.8 kg/cm2

5.5.2) Step-52 = a] A.O.P. takes start.

7. Motor Rating - 350 KW.

Therefore, (Tm) with regeneration = (h1 – h10) / (S1 – S10) ---------(3).

The energy balance for heater 2 gives,

m1 = (h9 – h8) / (h2 – h8 ) -------- (4).

The energy balance for heater 1 gives,

Equations (4) & (5) can also be alternately written as

(1 - m1) ( h9 – h8) = m1 (h2 – h3)

(1 - m1 – m2) ( h1 – h6) = m2 (h3 – h7)

Energy gain of feed water = Energy given off by Vapour in condensation.

Cascading system and Drip system:

There are three heat transfer zones in a typical H.P.Heater –

TERMINAL TEMPERATURE DIFFERENCE: Difference between the saturation temperature at steam

TTD = Saturation temperature of steam at extracted pressure

n = 1, (∆t) fw = ½ (∆t) o ½ (∆t) o

n = 2, (∆t) fw = 2/3 (∆t) o 1/6 (∆t) o

n = 3, (∆t) fw = 3/4 (∆t) o 1/12 (∆t) o

DM make-up water system, Deaerator level control, Hotwell level control:

AIR EVACUATION SYSTEM:

Major components of Deaerator are:

A drainpipe is connected from FST to atmosphere by a manual operated isolation valve.

3. Feed Water Storage Tank-

REGENERATIVE FEED HEATING:

QUALITY OF EXTRACTION STEAM:

ECONOMICS OF REGENERATIVE FEED HEATING SYSTEM:

ADVANTAGES OF REGENERATIVE FEED HEATING:

TEMPERATURE GAIN BY REGENERATION:

Selection of Extraction Steam:

PARAMETERS OF 210MW LMW TURBINE WITH / WITHOUT HEATERS IN SERVICE:

Sl.No. Description Without Heater With Heater

01. Steam Consumption (T/H) 563 662

FEED WATER HEATERS :

In power stations normally two types of heaters are used;

Surface type heater:

LOW PRESSURE HEATERS:

HIGH PRESSURE (H.P) HEATERS :

FUNCTION OF GLAND COOLER (GC) / GLAND STEAM CONDENSER (GSC):

CONNECTIONS FOR MAIN CONDENSATE:

HEATING ZONES OF HEATERS :

Tag No. Parameters Units Press.(ATA) Temp. (0C) Enthalpy Quantity

No. of stages of turbine blades (210 MW) :

Turbine H.P.T I.P.T L.P.T

Supply of steam is selected as per requirement according to loading of the unit.

TERMINAL TEMPERATURE DIFFERENCE (TTD):

DRAIN COOLER APPROACH (DCA):

FEED WATER TEMPERATURE:

GLAND STEAM COOLER / GLAND COOLER of 210 MW KWU / LMW Turbine:

KWU TURBINE LMW TURBINE

*