Condensate System

By Ahsan Alam

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 What is condensate
• The steam after condensing in the condenser known as condensate, is
extracted out of the condenser hot well by condensate pump and taken
to the deaerator through gland steam cooler and series of LP heaters.

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Condensate system
• Condensate Pump :
To pump out the condensate to D/A through GSC and
LPH

• Gland Steam Condenser :

To condense gland seal steam.

• Condensate polishing unit :

To maintain condensate proper quality

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Condensate System

• LPH :
To increase the temperature of condensate

• Deaerator :
To remove the dissolved gases from the feed water and
to increase the temperature of condensate

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 Condensate System Cycle
Gland steam
Condensate pumps Polishing Unit
condenser

LP heaters No.1A/2A
LP heater No.4 LP heater No.3
and 1B/2B

Deaerator

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Condensate Pumps
• The function of these pumps is to pumps out the condensate to the
deaerator through gland steam cooler, and L.P. heaters.

• These pumps have the suction is at a negative pressure.

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Condensate Pumps

• Shaft Power : 1485KW

• Flow : 1560t/h
• Speed : 1480rpm
• Power : 2200KW
• Voltage: 11KV
• Rate Current : 114.3A

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Condensate Pump Tripping
conditions
• Thrust Bearing Temp > 95 *C
• Motor stator temperature > 130 *C
• motor bearing temperature > 85 *C
• Condensate pump inlet valve not fully opened.
• After the condensate pump starts 10S, the condensate pump
outlet valve is still closed
• Hotwell level < 150mm
• The condensate flow is low < 450t/h and the opening of the
recirculation valve is less than 30%
• Vibration high (0.12mm)
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 Hotwell Water High
Level Dump Line
• The hotwell high level dump line is located downstream
of Polishing Unit, the line go to CONDENSATE
STORAGE TANK. The line contains a control station
consisting of one control valve with two isolation valves
and a bypass valve. The control valve opens at high level
in the hotwell . The control valve closes automatically
when level in the hotwell returns to normal.

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 System Minimum Flow
Recirculation
• The Condensate System minimum flow recirculation line
originates downstream of the Gland Steam Condenser
(GSC) and discharges into the condenser. This line
provides a minimum flow recirculation protection for the
condensate pumps and the GSC.

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 Makeup System
• One outdoor condensate storage tank is provided for
makeup and initial fill of the condensate system. The
condensate storage tank also receives excess condensate
from the hotwell dump line.
• Makeup to the condensate storage tank is provided from
the makeup demineralizing water treatment system.
• Two condensate transfer pump is located in the makeup
line to the condenser hotwell.

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 Makeup System
• During normal operation the condenser vacuum will
produce sufficient differential pressure to induce makeup
to the condenser without using the transfer pump. For
this purpose a bypass line with a check valve is provided
around the condensate transfer pump.

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 LP Heaters
• From the deaerator level control station the condensate
flows to the low pressure heaters.
• The low pressure heaters are tube and shell heat
exchangers. The condensate flows through the tubes and
is heated by low pressure turbine extraction steam which
condenses in the heater shell.

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 LP Heaters
• The condensate first enters low pressure heaters
No.1A/2A and1B/2B which are located in the condenser
neck.

• Downstream of the duplex heaters the condensate is

combined in a single line and flows through the
remaining LP heaters No.3 and No.4 into the deaerator

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 Deaerator
• The deaerator is an open type heat exchanger in which
the condensate is mixed with steam extracted from the
intermediate-pressure turbine NO.5 extraction steam.
The steam condenses as it loses heat to the condensate.
The condensate is heated to the saturation temperature
corresponding to the steam pressure. Heating releases
oxygen and other gases from the condensate. During
start-up and low load, auxiliary steam is used in the
deaerator until extraction steam is available.

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What is deareator?
• Deaerator is a device for air removal from water to make it non-
corrosive. Deaerator generally implies not only the deaerator but also
the feed water tank below where deaerated water is stored and fed to
the suction of boiler feed pumps.

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Deaerator
• The presence of certain gases, principally oxygen, dissolved in water
is generally considered harmful because of their corrosive attack on
metals, particularly at elevated temperatures.
• function is to remove dissolved gases from the feed water by
mechanical means.

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PMI Revision 00 18
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 THANK YOU

February 3, 2024 20