CONDENSATE & FEED WATER CYCLE

Condensate cycle
 In condenser, steam is converted into condensate by heat exchange
done with cooling water.
 This condensate collects in the hotwell located below the conderser.
 The condensate is taken to deareator by using CEPs
( condensate extraction pumps) through GSC, drain coolers, LP
heaters.
 While passing through GSC, drain coolers and LP heaters condensate
gains heat to improve thermal efficiancy.
 Gland steam condenser (GSC) is provided for condensing the gland
seal leak steam thereby heating the condensate.
 Drain coolers are utilised to reheat condensate.
 LP heaters further heats the condensate by utilising bleeding steam
from LP turbine( extractions).
 In Deaerator , extraction steam from IP turbine is used to remove
dissolved gases (O2 & CO2) by heat exchange method and after
removal of these gases, the feed water is taken into Dearator feed
storage tank. This is done for safe operation of boiler . The operating
Pressure in dearator is 11.8 bar and temperature is 186.3 deg C.
Feed water cycle
 Feed water is pumped from dearator to economiser using
one MDBFP (Motor driven) and two TDBFPs ( turbine driven).

 This feed water is heated using HP heaters 6A,6B, &7A,7B,

8A,8B.

 The FW parameters are ..

Before HPH – 350 bar, 200 degC, 2520
T/hr
After HPH - 293 bar,299.2
degC,2585 T/hr

 FW in boiler is controlled by using feed control station which

comprises of 1x30% Control valve operates in wet mode at
30-40% BMCR( load) and 1x100% control valve in dry
mode.
Steam turbine extractions
 CONDENSERS

DESCRIPTION UNIT CONDENSER-1 CONDENSER-2

Design C.W Temperature oC 33.0 37.72

C.W Temperature raise oC 4.72 4.66

Condenser back Pressure mmHg (a) 56.93 72.96

C.W Flow Quantity TPH 84200

C.W side Pressure Drop MLC 2.86 2.86

No. of Tubes No. 29755 29755

CONDENSERS
CONDENSERS
 CONDENSATE EXTRACTION PUMP
( CEP)
PURPOSE:
•Extract condensate from the condenser
( hotwell) and feed it into the cycle.
•It is the driving force of the condensate
cycle up to De- Aerator

Canister type vertical centrifugal pump

with 5 stages

3 x50 % capability pumps are provided.

2 in service and other as standby
CONDENSATE EXTRACTION PUMP
( CEP)
CEP MOTOR Technical Data:

Make : BHEL , BHOPAL

Type of Motor/Enclosure: SCIM / TETV
Rated Continuous Output (KW) : 1450 KW
Rated Speed (rpm)/ Slip (%) : 1492 / 0.53
Rated Voltage : 3300 V
Full Load Current (apms) : 302.0
No load Current (apms) : 61.5
No Load losses (KW) 31
Full Load Efficiency (%) : 95.5
Noise Level : 85 dB (A)
Vibration Level (Rigid Mounting) : 37 µ (displacement) /2.3 mm/s
CEP PUMP Technical Data:

Model of Pump : 144RND

Make : BHEL, HYDERABAD
No. of Pumps /Orientation : 3X50% duty / Vertical
Impeller Type : 1st stage double Suction and other stages single Suction
No. of Stages 4
Design flow : 925 m3/Hr
TDH Developed at design flow : 335 mlc
Temp. of Condensate water : 42.7 oC
Specific weight : 991 Kg/ m3
Pump Efficiency: 77.5 %
Pump input power at design flow : 1079 KW
Minimum flow through pump : 270 m3/Hr
Suction Pressure at design capacity : 0.66Kg/cm2
Discharge Pressure at design capacity : 33.9 Kg/cm2
Maximum Vibration level : 10 mm/sec (rms)
Noise Level : 85 dB (A) at 1meter from equipment.
Type of Bearing : Tilting Pad
Suction Strainer mesh size : 350 microns
Pressure Drop (kg/cm2) : 0.06 (Clean) & 0.10 (50% clogged)
 GLAND STEAM CONDENSER
(GSC)
PURPOSE:
•To quench the sealing steam coming out
of last gland seal of HPT, IPT AND LPT.
•Also works as a heat exchanger, adding
sensible heat to condensate.

Sealing steam after condensation forms

drip which goes to LP flash box.
GLAND STEAM CONDENSER
 GLAND STEAM CONDENSER

DESCRIPTION UNIT Data (full vacuum)

Shell side Design Pressure Kg/cm2 (g) 47

Tube side Design Pressure Kg/cm2 (g) 47

Shell side Design Temperature oC 250

Tube side Design Temperature oC 100

Surface area Provided m2 60.17

No. of Tubes No. 862

CONDENSATE POLISHING UNIT
 Regeneration System for
CONDENSATE POLISHING UNIT
Impurities Removed by CPU in condensate :

• Iron oxides, possibly with lower quantities of other metal oxides, derived from
corrosion of the steam/water circuit

• Silica arising from the wash-off of turbine blades during the shutdown
process

• Sodium, chloride, sulfate and potentially other salts from cooling water in-
leakage into the condenser hotwell during the shutdown period

• Carbon dioxide from air ingress

• Products of combustion, including sulfur oxides, if reheater leaks are present

• Silica and other miscellaneous impurities arising from repair and inspection
procedures after a maintenance shutdown
LP HEATERS
LP HEATERS
 LOW PRESSURE HEATERS

•A Feed water heater is a component used to

pre-heat water delivered to the boiler.
Preheating the feedwater reduces the amount
of energy needed to make steam and thus
reduces plant operation costs. This improves
the thermodynamic efficiency of the system.

CLASSIFICATION

PARALLEL FLOW
CROSS FLOW
COUNTER FLOW
 HEAT EXHANGERS
In parallel-flow heat exchangers, T1 T2
the two fluids enter the exchanger
at the same end, and travel in T1
parallel to one another to the T2
other side.
T2

In cross flow heat exchangers, T1

heating medium is perpendicular T2
T1
to the medium being heated

In counter-flow heat exchangers T1 T2

the fluids enter the exchanger
from opposite ends. The counter T1 T2
current design is most efficient, in
that it can transfer the most heat.

COLD MEDIUM HOT MEDIUM T2 > T1

SHELL AND TUBE HEAT EXCHANGER

Two fluids, of different

starting temperatures, flow
through the heat
exchanger. One flows
through the tubes (the tube
side) and the other flows
outside the tubes but inside
the shell (the shell side).
Heat is transferred from
one fluid to the other
through the tube walls,
either from tube side to
shell side or vice versa.. In
order to transfer heat
efficiently, a large heat
transfer area should be
 CONDENSER

• Converts last stage steam of LPT to

water
 LP HEATERS

Description LP Heater 1A/1B LP Heater2A/2B

Type Shell & Tube Shell & Tube

Design Pressure (Kg/cm2g) Shell side 47&Full Vacuum 47&Full Vacuum

Tube Side 3.0& Full Vacuum 3.0& Full Vacuum

Design Temperature (oC) Shell side 150 150

Tube Side 150 150

Total Tube surface area (m2) 698.2 649.6

No. of water passes Two Two

Total No of U tubes 348 348

 LP HEATERS
Description Unit LP Heater-3 LP Heater-4
Steam entering Pressure ATA 2.71 5.12
Drain Entering Pressure ATA ~ 5.4 --
Condensate entering Pressure ATA 15.8 14.8
Condensate Leaving Pressure ATA ~ 14.8 ~ 13.8
Drain leaving Pressure ATA ~ 2.5 ~ 5.4
Steam entering Temperature oC 190.4 255.2
Drain Entering Temperature oC 131.7 NA
Condensate entering Temperature oC 80.0 127.0
Condensate Leaving Temperature oC 126.6 149.2
Drain leaving Temperature oC 129.6 131.7
Steam entering Quantity T/Hr 130.048 67.942
Drain Entering Quantity T/Hr 67.942 ---
Condensate entering Quantity T/Hr 1526.438 1724.427
Condensate Leaving Quantity T/Hr 1526.438 1724.427
Drain leaving Quantity T/Hr 197.989 67.942
No of tube passes/tubes provided No 2 / 1145 2/ 1145
Condensate velocity m/sec 1.65 1.87
Design tube Pressure ATG 47 & FV 47 & FV
Design Temperature (shell / Tube) oC 210/152 275/173
DEAERATOR
DEAERATOR
DEAERATOR
DEAERATOR
 DEAERATOR
Description Steam Condensate Feedwater
entering entering Leaving
Pressure ( ata) 11.85 -- 11.85
Quantity (TPH) 107.250 1724.427 2313.765

760.3 149.3 189.0

Enthalpy (Kcal/Kg)
No of spray valves / 144 / 792
trays
Design pressure (ATG) 14 & FV

Design temperature 395 / 260 Deg.C

(Dea heater /tank)
Operating Pressure / 11.8 Ata /186.3 Deg.C
Temperature
TDBFP & MDBFP
SYSTEM
Requirement
• To pump feed water from
deaerator to Boiler
Type of BFP
• Horizontal
• Barrel type outer casing
• Multistage

Configuration of BFP
• For 800MW
2x50% TDBFP & 1x50% MDBFP
• For 200MW
3x50% MDBFP
• Meets IBR requirements of two
independent source
• Incase one running TDBFP is out, full
unit load can be maintained with 50%
MDBFP.
• Can facilitate cold as well as hot unit
start ups
• Unit Start up is faster.
• Better availability and Operational
flexibility.
THE BOILER FEED WATER PUMP
Efficiency of generator = 98% (Say)
Efficiency of UAT= 97% (Say)
Efficiency of Elect. system = 98% (Say)
Efficiency of BFP Motor = 97% (Say)
Efficiency of Hyd. coupling = 87% (Say)
Total percentage utilisation when MDBFP used= 78.6%
(0.98 X 0.97 X 0.98 X0.97 X 0.87 = 0.786)
Power consumed by two TDBFP = 15 MW (approx.) ??
Saving in MW when TDBFP used = 3.21 MW
(15 X (1-0.786) = 3.21 MW)
TD BFP

TD BFP – Turbine Parameters

 TDBFP NOS 2X50%

 STEAM PRESSURE Mpa 1.018
 STEAM TEMP. Deg C 353.9
 STEAM FLOW TPH 108.4
TD BFP

 Numbers Nos 2x50%

 Rated Capacity Cum/Hr 1150
 Suction Pressure Kg/Cm2 12(a)
 Discharge Pressure Kg/Cm2 250(a)
 NPSH Required mlc 36
 Pump Efficeincy % 82
TD BFP’s BOOSTER PUMP

 Numbers Nos 2x50%

 Rated Capacity Cum/Hr 1150

 Suction Pressure Kg/Cm2(a) 0.8

 Discharge Pressure Kg/Cm2 (a) 12

 NPSH Required mlc 3.8

 Pump Efficeincy % 80

 Motor Rating kw 540

 Gain in Heat Rate When TDBFP Used
When TDBFP used
•Heat rate (as per EPDC) for 800 MW TG – 1900 Kcal/kwhr
When MDBFP used
• Additional power required to be generated = 3.21MW
• Net Generator output =(660 + 3.21) MW
= 663.21 MW
• Total Heat addition in the system – 663.21 X 1900 M cal
Saving in HR with TDBFP = {(663.21 X 1900)/660} - 1900
= 9.24 kcal / kwhr
~ 9 - 10 kcal / kwhr
TDBFP
MD BFP

 MDBFP NOS 1X35%

 Motor Capacity Kw 12000

MDBFP
MDBFP
MDBFP
TDBFP
TDBFP
TDBFP
TDBFP
 HPHEATERS

Description Pressur Temp (oC)

Quantit
e (Ata) y
(TPH)
Steam entering 23.50 393.278 48.332
Drain Entering ~58.6 222.0 192.712
Feed Water entering 302.86 191.8 1156.88
2
Feed Water Leaving ~299.3 217.3 1156.88
3 2
Drain leaving ~ 22.5 196.6 241.044
No of tube passes/tubes 2 / 1850 “U” tube
provided
Feed Water velocity 1.74 m/sec
Design tube /shell Pressure 350 / 32 &
FV
Design Temperature (shell / 325 / 240 / 325 OC
Tube/skirt)
 HPHEATERS
Description Pressure(Ata) Temp (oC) Quantity(TPH)

Steam entering 23.53 460.3 48.332

Drain Entering -- -- --

Feed Water entering 297.33 292.3 404.91

Feed Water Leaving 296.33 300.30 404.91

Drain leaving ~ 23.5 308.30 48.332

No of tube passes/tubes provided 2 / 720 “U” tube

Feed Water velocity 2.47 m/sec

Design tube/shell Pressure 350 / 32 & FV

Design Temperature (shell / Tube/skirt) 480 / 330 / 480 OC

 HPHEATERS

Description Pressure Temp (oC) Quantity

(Ata) (TPH)

Steam entering 59.12 343.9 137.277

Drain Entering ~ 78 278.6 55.435

Feed Water entering 299.33 217.3 1156.882

Feed Water Leaving ~ 298.33 273.9 1156.882

Drain leaving ~ 58.6 222.0 192.712

No of tube passes/tubes provided 2 / 1850 “U” tube

Feed Water velocity 1.8 m/sec

Design tube/shell Pressure 350 / 74 & FV

Design Temperature (shell / Tube/skirt) 290 / 290 / 370 OC

 HPHEATERS

Description Pressure(Ata) Temp (oC) Quantity(TPH)

Steam entering 78.59 383.5 55.435

Drain Entering -- -- --
Feed Water entering 298.33 273.9 1156.882
Feed Water Leaving ~ 297.33 292.3 1156.882
Drain leaving ~ 78 278.6 55.435
No of tube passes/tubes provided 2 / 1850 “U” tube
Feed Water velocity 1.81 m/sec
Design tube/shell Pressure 350 / 98 & FV

Design Temperature (shell / Tube/skirt) 310 / 310 / 405 OC

HPHEATERS
 Extractions :
Purpose: To improve thermal efficiency of rankine cycle ,it
is used to reheat the condensate and feed water by using
extraction steam from HP, IP & LP turbines, CRH line.
 The temperature gained by condensate in LP heaters is
approx. 140 degC and the heat gained by the feed water in
HP heaters is approx. 110DegC.
 The extraction steam for the top HP heaters-8A & 8B is
extracted from HP turbine intermediate stage (Ext-08)
P=95kg/cm2,T=400 DegC
 HP heaters-7A & 7B are fed with steam drawn from the cold
reheat pipe(CRH) P= 73.5kg/cm2,T=360 DegC
 HP heaters-6A & 6B are fed with steam extracted from the
IP turbine intermediate stage (Ext-06), after desuperheating
by HPH-6A & 6B desuperheaters P= 30kg/cm2,T=320
DegC
 During normal operation deaerator and boiler feed pump
turbines are fed with steam drawn from IP turbine
intermediate stage(Ext-06), beyond approx. 30% load.
P= 14 kg/cm2,T=360 DegC
 During start-up, steam for deaerator pegging and BFP turbine is supplied
from cold reheat line (CRH) as well as external supply source i.e. auxiliary
steam header

 Extraction to LP heater-4 is taken from IP turbine exhaust (Ext-04)

P= 7 kg/cm2,T=260 DegC
 Steam for the LP heaters nos. 1, 2 & 3 are extracted from various stages of
the LP turbines ( Ext-03) P= 3.5 kg/cm2,T=200 DegC

 Pneumatically operated non-return valves are provided in extraction lines to

HPH-8A/8B (common line), HPH-6A/6B desuperheaters (common line),
deaerator & BFP turbines, LPH -4 and LPH-3 to prevent back flow of steam
into the turbine during a trip. These valves are controlled from ATRS.

 Motorized block valves are provided in individual extraction lines to HPH-8A

& 8B, HPH-7A & 7B, HPH-6A/6B desuperheaters, deaerator & BFP turbines,
LPH-4 & LPH-3.

 Extraction lines to HPH-8A/8B (common line), HPH-7A & 7B (individual lines),

HPH-6A & 6B desuperheaters (common line), deaerator & BFP turbines, LPH-
4 are also provided with ordinary non return valves.
Turbine drains system
 During startup or restart after a prolonged outage, the steam turbine
casing and the steam lines belonging to the steam turbine must be
warmed up to a temperature which allows run up and loading of the steam
turbine, without loads on the piping and casing resulting from different
temperatures exceeding permissible limits.

 Purpose : The process engineering function of the drain system is to

remove the condensate which forms during the warm up phase on casing
and piping walls as long as their temperature is lower than the saturated
steam temperature.

 The drain valves in the steam lines belonging to the turbine are also used
to remove the condensate which arises when the steam flow velocity in the
lines is too low and the steam cools to saturation temperature.
 If drains are insufficient, this can result in the following abnormal operating
conditions which can result in damage to the turbine generator unit:

◦ Deformation of casings and shafts through considerable cool down in the

event of the ingress of condensate from steam lines into the turbine

◦ Deformation of turbine casings through one-sided cooling by condensate

collecting in the turbine lower sections

◦ Damage to piping and supports, as well as changes in turbine alignment

as a result of water hammer

◦ Faults in shaft seal steam pressure control system owing to condensate

collecting in the shaft seal steam header
• The drain lines are connected to headers (collecting branches).

• These headers then route the steam to two condenser standpipes.

• The standpipes are connected to the condenser on the one hand through a loop
seal to condenser hotwell and on the other hand to the condenser shell side via the
condenser neck.

• The steam introduced into the standpipe together with the drains is cooled through
continuous injection of attemperating water. This prevents excessively hot steam
from directly ingressing the condenser and causing damage to the condenser.

• During warm up, the valves of the drain system located upstream of the main and
reheat control valves are used not only as drain valves but also for removal to the
condenser of the steam required for warming up the main steam and reheat line
and the bodies of the main and reheat valves.

• The drain valves are controlled by drain sub-loop controls as a function of

component temperature, superheating or position of emergency stop valves.

• Open close status of each drain valve is available in HMI system in CCR thru
various position limit switches.
Turbine drain system componants:
 Drain valve upstream of main control valve 1

 Drain valve upstream of main control valve 2

 Drain valve upstream of overload valve

 Drain valve downstream of overload valve

 HP turbine casing drain valve downstream

 HP turbine casing drain valve

 Drain valve for cold reheat line

 Drain valve upstream of reheat stop valve 1

 Drain valve upstream of reheat stop valve 2

 Drain valve upstream of reheat control valve 1

 Drain valve upstream of reheat control valve 2

 Drain valve downstream of reheat control valves 1 and 2

 Drain valve for leak off steam header MAL25AA051

 Drain valve upstream check valves extraction A9

 Drain valve upstream check valves extraction A7

 Drain valve upstream check valves extraction A6

 Drain valve upstream check valve extraction A5

 Drain valve upstream check valve extraction A3

 Drain valve upstream check valve extraction A4

 Drain valve for seal steam header

 Drain for seal steam header, orifice

 YOU
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