OPERATION AND PROTECTION OF 210 MW TURBINE CONDENSATION EXTRACTON PUMP AND CONDENSATION CYCLE

Presented by Er. D. R. Bansod

Introduction of Condenser
After work done in turbine, Steam cannot exhausted to atmosphere because that steam pressure is below atmospheric pressure so recover that steam required a closed vessel into which steam exhausted and condensate, that close vessel pressure is below atmosphere.

Condenser system consists

Condenser (including hot-well) Condensate pumps Air Extraction System Gland coolers and L.P. heaters Deaerator

Condenser cycle

Function of Condenser
To maintain low pressure (below atmosphere), so obtain maximum energy. To convert exhaust steam to water for reuse thus saving on feed water requirement. Deaeration of make-up water in the condenser.

To form a convenient point for introducing required make up water

Advantage of Condenser
Increase Plant efficiency. Reduce temperature of exhaust steam.

Reused condensate as a feed

Features of Good Condenser

Minimum quantity of circulating water. (cold water velocity 3m/sec ) Minimum cooling surface area per kW capacity Minimum auxiliary power. Maximum steam condensed per m2 of surface area We required cold water for better performance of condenser

Type of Condenser
Condenser is basically two type
Jet Condenser Surface Condenser

Jet type condensation of steam takes place by directly mixing exhaust steam and cooling water Parallel Flow Steam & water enter from same side Counter Flow - Steam & water enter from Opposite side

Surface type condensation of exhaust steam takes place on the outer surface of the tubes which are cooled by water flowing inside

Compression between Condenser

Jet Condenser Steam & water mixed Less capacity plant
Condensate not reused Maintenance s cast low

Surface Condenser Steam & water not mixed High capacity plant
Condensate reused Maintenance cast high

Surface type is generally used for modern steam turbine installations.

Working Principle of Condenser

Condenser work on DALTONS Law DALTONS Law Total pressure exerted by mixture of gas is equal to sum of individual partial pressure of mixture Pt = Ps +Pa Pt = Total condenser pressure Ps = Steam pressure Pa = Air pressure

Condenser heat transfer

Condenser is basically a heat exchanger Heat lost by steam = heat get by water Q = Mw ( Two Twi ) Heat transfer by convection KA T Q = --------------x

Condenser Construction Detail

Copper alloys are preferred as copper has very high heat transfer coefficient so it used for materials for condenser tubes (I) Brasses, (ii) Cupro-nickel and (iii) Bronzes Copper alloys are basically used Titanium used for high corrosive environment

Air Ejection System

The air ejection system is used to extract the non condensable gases from the condenser, and thereby creating vacuum in the system It consists of one starting ejector two main ejectors and one gland steam cooler starting ejector is used which extracts the non condensable gases from the system. When the vacuum in the condenser reaches 600-600 mm of Hg. column, the starting ejector i switched off, Out of the two main ejectors, one is for continuous operation while the other one serves as standby gland steam cooler has its own ejector which sucks the air steam mixture from the end sealing glands of the turbine

Starting Ejector
Starting ejector is recommended to be used for accelerating the initial pulling of vacuum Pressure and temperature of this steam are not to exceed 4.5 Kg/cm2 and 250C This ejector is switched off as and when the vacuum in the condenser reaches 500-600 mm of Hg column

Main Ejector
The suction chamber has been divided into three stage The convergent divergent nozzle has been designed to accelerate the steam flow and thereby reduce the pressure of steam to 0.03 Kg/cm . in the 1st stage of suction chamber. The low pressure in suction chamber sucks the noncondensible gases from the condenser

Gland Steam Cooler

Gland steam cooler has been provided to suck and cool the air steam mixture F from the turbine gland seals Gland steam cooler sucks the air steam mixture has its own ejector

Regenerative system LP Heater - 1

Two sections of low pressure heater No. 1 have also been located inside the upper parts of condenser The heater is of horizontal surface type consisting of two halves, each half has been located inside the upper part of each condenser U shaped tubes have been used to ensure independent expansion of tubes 19 mm external dia 1 mm & 0.75 mm thick and are expanded by rolling into the tube plate at both the ends

Regenerative system LP Heater - 2,3 & 4

These heaters identical in construction are of vertical surface type and are designed for the steam to pass over the tubes and the condensate to flow through them. Tube system consists of U shaped brass tubes 16 mm external dia 1mm thick and are expanded by rolling into tube plate at both the ends.

Condenser Leakage Protection

Source of air into the condenser
Dissolved air in feedwater (DM water) Air leakage into condenser through various joint

Effect of air leakage

It reduce vacuum It reduce efficiency It required large auxiliary power It required more water for cooling

Condenser Leakage Protection

Internal Leakage Protection of cooling
water into the condensate can be caused by several faults Tube to tube plate fixings leakage Internal corrosion and erosion of the tubes External erosion of the tubes, Fatigue and stress cracking of the tubes

External leakage from condenser water boxes

and joint is usually due to metal removal by erosion or corrosion

Condensate Extraction Pump Specification

PUMP MOTOR

Make:-Kirloskar Bros. Ltd. Make:-N G E F Flow:- 281 m3/hr Capacity:-250KW(300hp) Head:- 200 m Voltage/Current:- 6.6KV Speed:-l490rpm Speed:- 1490rpm Stage 8 ( unit 5) 5 ( unit 6&7)

C E P Pre check
Ensure all relevant maintenance permits are cancelled. Ensure condenser manhole are tightly closed. Ensure condenser hotwell drain valve & dummy are in place. Hotwell gauge glass, level switches, transmitters are in service. Ensure G.S. cooling water is available for bearing cooling & DM water is available for condenser makeup. Ensure that hotwell level is filled up to of gauge glass.

C E P Pre check
Ensure 6.6 kv breaker is ready & its cold trials are OK Motor direction trials are Ok. Ensure pump thrust bearing oil level is normal. Ensure bearing cooling water & DM gland sealing water flow is established. Pump is charged after opening of suction valve. Keep following valves closed:
i) Discharge valve & its bypass. ii) Valve of FC NRV line. iii) LP bypass spray valve. iv) MC-39 MC-57 v) 15 m syphon filling valve. vi) Syphon filling valve of main ejector

C E P Pre check
Ensure air supply is available for pneumatic valves. Isolating valves of CV-6 are open Open inlet & outlet isolating valves of MC-36. close bypass. Open condensate inlet & outlet valves of main ejector, LP-1, LP-2, LP3 close bypass of GC, close LP heater-4 outlet valve. Open GC1,LP1, LP2 vents. Open pump discharge header vents.

 Put selector switch of pump on local & start the pump. Open bypass valve of discharge valve for charging the line. Open discharge valve slowly monitoring pump discharge pressure & close bypass valve. Observe the motor current & discharge header pressure. Close vents of discharge header after sufficient water comes out & air is expelled from system. Measure the vibrations of pump &motor bearing. Monitor thrust bearing temp. observe the oil level for any leakages.

C E P Operation

C E P Operation
Monitor hotwell level, if required CV-7 isolating valve can be opened. Open MC36 valve partially & charge GC2, LP2,3,4 from condensate side. Close vents after sufficient water comes out. Open LP heater4 outlet valve for deaerator make up if needed. Open discharge valve of stand by C.E.P. & keep selector switch on remote.

C E P Interlocks
Hot well level very low Discharge pressure low (< 14.0 kg/cm2 ) Stand by pump pick up at the time of following condition
If running pump trip on motor portion If discharge header pressure is low (< 14.0 kg/cm2 )

C E P Koradi Unit-5

C E P Koradi Unit-6&7