Condensate System Components and Functions

CONDENSATE
SYSTEM
1
PURPOSE OF THE SYSTEM
· To extract condensate accumulated in the condenser hotwell
· Delivery of main condensate from hotwell of the condenser to the Deaerator

through condensate polishing unit, GSC, LP Heaters.
· To supply spray water for Low temperature auxiliary steam attemperators.
· Condensate spray to the TG exhaust hood
· To provide spray water to the condenser spray system during LP bypass

operation
· To provide spray water to flash tanks ,VAM, make up to Stator cooling water
system.
COMPONENTS OF CONDENSATE SYSTEM
(FLOW
COMPONENTS PATH)
OF CONDENSATE SYSTEM
• Condensate Storage Tank

Condensate Storage Tank
• Hotwell
Hotwell
• Condensate Extraction Pumps (2 X 100%)
• Condensate Extraction
Condensate Polishing UnitPumps (2XX50%)
(CPU) (2 100%)
• Condensate
Gland Steam Polishing
CondenserUnit
(GSC)(CPU) (2 X 50%)
• Gland Steam
Deaerator Condenser
Level (GSC)
Control Station
• Deaerator Level
Duplex heater Control
1A/1B (LPH-1)Station
• Duplex
Duplex heater 1A/1B(LPH-2)
heater 2A/2B (LPH-1) & 2A/2B (LPH-2)
• LP
LPHeater-
Heater- 3
• LP
LPHeater-
Heater- 4
• Deaerator
Deaerator

Hotwell
Condensate Extraction Pumps (2 X 100%)
Condensate Polishing Unit (CPU) (2 X 50%)
Gland Steam Condenser (GSC)
Deaerator Level Control Station
Duplex heater 1A/1B (LPH-1) & 2A/2B (LPH-2)
LP Heater- 3
LP Heater- 4
Deaerator
CONDENSATE STORAGE TANK
• Nos.: 02 (One for #10&20 and other for #30,40 & 50)
• Capacity: 1000m3 each
• Total height of tank: 13.0 m
• NWL : 5.35 m
• LWL : 1.25 m
• HWL : 12.2 m
PUMPS INSTALLED AT CST

Hotwell
Duplex heater 1A/1B (LPH-1)
LP Heater- 3
LP Heater- 4
Deaerator
HOT WELL
• Material : SA 516 Gr.485

• Length : 13.156 M (Each Shell)
• Width : 7.54 M (Each Shell)
• Depth : 1.214 M (Each Shell)
• Vol. up to normal level : 52.9 M3 (Each Shell)

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
CONDENSATE EXTRACTION PUMP
• CEP is of vertical wet pit type, mounted in a steel barrel. The first stage
impeller is of double suction to meet low NPSH requirements.
• Pump and motor are coupled with a flexible coupling. Vent line from the
pump canister is connected to the condenser shell.
• A strainer is located at the suction side of each CEP. Motor operated valves
with integrated bypass are installed at the suction and discharge of CEP.
Differential Pressure across strainer is monitored regularly and an ‘Alarm’
will be initiated for ‘Higher differential pressure’.
• Relief valve is provided between the suction isolation valve and pump
suction in order to prevent over pressurization on suction line due to
leakage through the non return valve during operation of the other pump
while suction valve closed.
• A tap off from Hotwell make-up pump discharge is taken to CEP for sealing
its mechanical seal, during its start up. In normal operation, sealing water
will be tapped from the discharge of the first stage pump impeller internally.
CONDENSATE EXTRACTION PUMP
WKTA 350/3
PREDICTED PERFORMANCE CURVE
CEP START PERMISSIVES
• Winding/Bearing Temperature not high
• CEP No Reverse Rotation
• Hotwell Level Normal (Hi:+75mm, Lo-282mm, LoLo-
382mm)
• Seal Water Flow not Low
• CEP Lockout relay not energized.
• EPB not pressed.
• Suction Strainer DP not high (<640mmwcl)
• CEP Suction valve open.
• CPU manual bypass valve open
• GSC I/L & O/L valve open or its Bypass Valve open
CEP TRIP PROTECTIONS
• CEP flow at GSC O/L < 450 TPH with 2 min. Time Delay.
• Motor Winding Temp. High (1300C).
• EPB pressed.
• Hot well Level Low (-382mm).
• Motor/Pump Bearing Temp. High(950C).
• CEP Discharge Valve closed.
• When standby CEP started on AUTO and flow < 1000 TPH.
• Motor/ Pump Bearing Vibration High (7.2 mm/sec.).


Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
CONDENSATE POLISHING UNIT
The Condensate Polishing Unit removes

'crud' - corrosion products consisting
oxides of iron, dissolved solids such as
sodium chloride and silica and carbon
dioxide. Condensate polishing units are
typically installed for super thermal power
station with the main objective of
improving the boiler water quality.
Condensate polishers are typically ion exchange,

resin-based systems. Driplex condensate
polishing system feature a mixed bed design,
which uses both cation and anion bead resins.
Also referred to as deep bed systems, these
polishers use strong acid and strong base resins
to produce a very high quality DM water. When
the exchange capacity of the resins are
exhausted, the "spent" resin is transferred to an
external system for regeneration.
• The Condensate Polishing Unit will treat the

entire condensate.
• CPU serves two functions:
a) Filtration of practically all suspended solids
like crud (loose ferric hydroxide and loose
magnetite) from the condensate.
b) Removal of dissolved solids by ion-
exchange process.
BENEFITS OF CPU
• Improvement in the quality of condensate and
"cycle" clean up
• Reduced blow down & make up requirements
• Improvement in boiler water quality for drum
type boilers
• Quick start up and as a result, full load
conditions are reached early giving economics
• Orderly shutdown possible in case of condenser
tube leak conditions
• Improvement in quality of steam which results in
enhanced turbine life
CPU DESIGN DATA
• Make: Driplex Water Engg., New Delhi

• Design Flow rate/ Unit.: 1985 m3/hr
• Max. Design Temperature: 55 (0C)
• Max. Pressure drop across service vessel
(a) With clean resin bed: 2.1 (Kg/cm²)
(b) Under dirty condition: 3.5 (Kg/cm²)
• Minimum Bed depth: 1100 mm
• Resin Ratio Cation: Anion: 2:1
• Design pressure of service vessel: 45 Kg/cm2g
CPU D E S I G N W A T E R A N A L Y S I S
EFFLUENT
PARTICULARS INFLUENT CONDITION CONDITION
AMMONIA, ppb 100 0
CRUD, ppb 50 5
SILICA, ppb 30 5
COPPER, ppb 10 3
IRON, ppb 50 5
SODIUM, ppb 10 2
CHLORIDE, ppb 10 2
TDS, ppb All Influents incl. NH3 25
CONDUCTIVITY, micro
< 0.1 at 25 deg.C
mho/cm
RESINS USED IN CPU
The resin being used in the CPU’s are :-
• Cation resin - Lewatit SP 112H (6.3m3)

• Anion resin - Lewatit MP 500 (3.15m3)

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
GLAND STEAM CONDENSER
• Leak off steam from turbine sealing system is
used to heat the condensate in the GSC .
• Two Air exhauster (one standby and one
working) are provided to exhaust the gases that
do not condense inside GSC.
• Number : One (1 X 100%)
• Tube Material : Stainless Steel
• No. of passes : Two
• Design condensate flow through gland steam
condenser =419 Kg/sec
• Normal Operating Pr. Limit: (-)0.36 to (-)0.50 psi
OUTLINE OF GSC
GSC & Gland Steam Exhauster

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
DEAERATOR LEVEL CONTROL STATION

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
VARIOUS ZONES IN A HEATER
DUPLEX LPH 1A/2A & 1B/2B
• Make: Larsen & Toubro Ltd.
• Position/ Location : Horizontal/ Inside condenser neck
• TTD/DCA : 2.8/5.6 0C
• Shell Side (Extraction Steam) Data LPH1 LPH2
Flow (Kg/Hr) : 2 x 28555 2 x 26813
Inlet enthalpy( Extraction steam) (Kcal/kg) : 594.77 620.57
Inlet temperature ( ºc) : 64.70 83.90
Shell inlet pressure (Kg/cm² a) : 0.25 0.56
• Tube Side Data:
Feed water flow (Kg/Hr) : 2 x 892889 2 x 892889
Inlet/Outlet enthalpy (Kcal/kg) : 42.51/62.12 62.12/81.30
Inlet/Outlet temperature (º c) : 42.30/61.90 61.90/81.10
Inlet pressure (Kg/cm²) : 29.53 28.92
No. of U Tubes : 563 527
Tube Material : SA 688 TP304
DCA: Heater Drain O/L Temp.-Feed water I/L Temp
TTD = (saturation temp. of steam corresponding to shell pressure within feed water heater) - (Feed water O/L Temp.)
GENERAL ASSEMBLY OF DUPLEX
LPH 1A/2A & 1B/2B
DUPLEX LPH ARRANGEMENT

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
LP HEATER- 3
• Make : Larsen & Toubro Ltd.
• Position : Horizontal
• Shell ID : 1499mm
• Nominal length of tube : 10636mm
• Extraction steam flow :67647 Kg/hr
• Steam Inlet Pr. / Temp. : 1.248Bar / 125.18 0C
• Condensate Flow Rate :1738731 Kg/Hr
• TTD/ Drain Cooler Approach : 2.8 0C/5.60C
• Feed Water outlet temp. : 87.160C
• Feed Water Outlet Enthalpy : 366.3 KJ/kg
• Tube Material : SA 688 TP304
• No. of U Tubes : 996
GENERAL ASSEMBLY OF LPH-3

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
LP HEATER- 4
• Make : Larsen & Toubro Ltd.
• Position : Horizontal
• Shell ID : 1422mm
• Nominal length of tube : 9527mm
• Extraction steam flow :65968 Kg/hr
• Steam Inlet Pr. / Temp. : 2.56Bar / 188.55 0C
• Condensate Flow Rate : 1785778 Kg/Hr
• TTD/ Drain Cooler Approach : 2.8 0C/5.60C
• Feed Water outlet temp. : 124.70C
• Feed Water Outlet Enthalpy : 524.5 KJ/kg
• Tube Material : SA 688 TP304
• No. of U Tubes : 1013
GENERAL ASSEMBLY OF LPH-4
LPH’s DETAIL
LP Heater Extraction TTD/ Surface Extraction Tempera
from DCA Area(m2) Steam ture
(oC) Temp. Gain
(oC) (oC)
DUPLEX 6th Stage of 2.8/5.6 2X783.8 64.70 19.60

LPH 1A/B LPT
DUPLEX 5th Stage of 2.8/5.6 2X675.3 83.90 19.20

LPH 2A/B LPT
LPH 3 2nd Stage of 2.8/5.6 1167.23 125.18 22.80

LPT
LPH 4 1st Stage of 2.8/5.6 1109.63 188.5 20.80

LPT
FACTORS AFFECTING HEATER PERFORMANCE
• Tube fouling/ Deposit on Tubes

• Inadequate heater venting
• Internal Leaks like tube leaks
• Water box partition plate passing
• High TTD
• Improper heater Level
• Heater bypass valve passing

Hotwell
LP Heater- 3
LP Heater- 4
Deaerator
FUNCTION OF DEAERATOR
• The Stork feed water deaerator is designed to extract oxygen out of
the feed water by using steam as per Henry’s Law . Extracting
oxygen is of essential need in systems where water is used
because small amounts of oxygen cause great corrosive activity in
the system. The incoming water (condensate / make-up) is put in to
the deaerator through a sprayer and at the same time steam is
injected under the water level.
• Pre-deaeration in which water is sprayed in a part of the steam
space.
• Final deaeration in the water tank where steam is brought in close
contact with the water.
• The sprayer and the internal steam rake are specifically designed
to de-aerate the incoming water. The deaerator is at the same time
used as a mixer / preheated and storage tank.
DEAERATOR SPECIFICATION
• Make Larsen & Toubro Ltd.
• Type Stork Spray Type
• Capacity 302m3(Up to NWL)
• Weight 108000kg
• Dimension 25.358*5.350*6.008 m
• Design Pressure 9.2 Bar g
• Working pressure 7.45 Bar a
• D/A condensate water incoming temp 124.70C
• Temp of D/A water 168.60C
• Condensate inflow 1785.77 TPH
• O2 in D/A 7ppb
• Sprayer 2 Nos.
• Manhole door 3 nos.
• Max Capacity of each Sprayer 1320 TPH
• Deaerator floor Elevation EL 27.00 m
DEARATOR LEVEL
• High high water level : (+) 951 mm

• High water level : (+) 901 mm
• Normal water level : (+) 801 mm
• Low water level : (-) 1799 mm
• Low low water level : (-) 1899 mm
4

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Condensate System Components and Functions

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CONDENSATE

· Delivery of main condensate from hotwell of the condenser to the Deaerator

· To supply spray water for Low temperature auxiliary steam attemperators.

· Condensate spray to the TG exhaust hood

· To provide spray water to the condenser spray system during LP bypass

• Condensate Storage Tank

Condensate Storage Tank

Condensate Storage Tank

• Material : SA 516 Gr.485

Condensate Storage Tank

• Motor Winding Temp. High (1300C).

• Hot well Level Low (-382mm).

• Motor/Pump Bearing Temp. High(950C).

• CEP Discharge Valve closed.

• Motor/ Pump Bearing Vibration High (7.2 mm/sec.).

Condensate Storage Tank

The Condensate Polishing Unit removes

Condensate polishers are typically ion exchange,

• The Condensate Polishing Unit will treat the

• Make: Driplex Water Engg., New Delhi

The resin being used in the CPU’s are :-

• Cation resin - Lewatit SP 112H (6.3m3)

Condensate Storage Tank

Condensate Storage Tank

Condensate Storage Tank

Condensate Storage Tank

Condensate Storage Tank

DUPLEX 6th Stage of 2.8/5.6 2X783.8 64.70 19.60

DUPLEX 5th Stage of 2.8/5.6 2X675.3 83.90 19.20

LPH 3 2nd Stage of 2.8/5.6 1167.23 125.18 22.80

LPH 4 1st Stage of 2.8/5.6 1109.63 188.5 20.80

• Tube fouling/ Deposit on Tubes

Condensate Storage Tank

• High high water level : (+) 951 mm

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