condensate system

power plant condensate system

1. WHY CONDENSERWHY CONDENSER

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

3. Condensate system
• Condensate Extraction Pump :
To pump out the condensate to D/A through
ejectors, GSC and LPH
• Gland Steam Condenser :
To increase the temperature of condensate.
• Condensate polishing unit :
To remove cat-ion and an-ion from the
condensate.

4. CEP
• Converts last stage steam of LPT to water
CONDENSER
CEP
GSC
CONDENSER
CPU
DEAREATO
R LEVEL
CONTROL
Minimum recirculation to condenser

5. Condensate PumpsCondensate Pumps
The function of these pumps is The function of these pumps is
to pumps out the condensate to to pumps out the condensate to
the deaerator thru' ejectors, the deaerator thru' ejectors,
gland steam cooler, and L.P. gland steam cooler, and L.P.
heaters. These pumps have heaters. These pumps have
FIVE stages and since the FIVE stages and since the
suction is at a negative suction is at a negative
pressure, special arrangements pressure, special arrangements
have been made for providing have been made for providing
sealing.sealing.

6. Stages:Stages:
The pressure build up in 5 stages The pressure build up in 5 stages
as suction is at negative pressure.as suction is at negative pressure.
Recirculation:Recirculation:
It is done when the de aerator level It is done when the de aerator level
controller trips in order to prevent controller trips in order to prevent
cavitations.cavitations.

9. CEP LINE UPCEP LINE UP
Ensure PTW cancelledEnsure PTW cancelled
Ensure box upEnsure box up
Suction strainer drain/vent closeSuction strainer drain/vent close
Open canister ventOpen canister vent
Open re-circulation manual v/vOpen re-circulation manual v/v
c/v inst. Air v/vc/v inst. Air v/v
Seal water chargeSeal water charge
Bearing cooling water chargeBearing cooling water charge
Bearing oil level normalBearing oil level normal
Relief v/v manual v/v openRelief v/v manual v/v open
Suction v/v open Suction v/v open
Relies EPBRelies EPB

10. Supply normal Supply normal
Hotwell level N low ( > - 250mm)Hotwell level N low ( > - 250mm)
SWGR availableSWGR available
SWGR not disturbedSWGR not disturbed
Thrust brg temp not highThrust brg temp not high
Motor brg. Temp not highMotor brg. Temp not high
Motor wdg temp not highMotor wdg temp not high
R/c v/v open > 40 %R/c v/v open > 40 %
Discharge vent open Discharge vent open
Discharge v/v close or stand by selected Discharge v/v close or stand by selected

11. CEP ISOLATIONCEP ISOLATION
EPB pressedEPB pressed
Breaker rack outBreaker rack out
Is R/c v/v passingIs R/c v/v passing
Close suction v/vClose suction v/v
By pass relief v/v closeBy pass relief v/v close
Close re-circulation v/v Close re-circulation v/v
Close canister vent v/vClose canister vent v/v
Discharge vent manual v/v closeDischarge vent manual v/v close
Close sealing water v/vClose sealing water v/v
Close cooling water v/vClose cooling water v/v
Crack open strainer vent. Is there any air Crack open strainer vent. Is there any air
sucking?sucking?

12. To give the required pressure to To give the required pressure to
the feed water before entering the feed water before entering
into boilerinto boiler
 Horizontal barrel type multi Horizontal barrel type multi
stage pump. stage pump.
Boiler Feed PumpBoiler Feed Pump

13. BOILER FEED BOILER FEED
PUMPPUMP
NDE BEARING DE BEARING
SOLE PLATE
(BASE PLATE)
FOUNDATION BOLT
KEY
SLEEVE
18

14. Booster
Pump
Motor
Main
Pump
Suction
Strainer
S S for
Main Pump
Feed Water
From D/A
Hydraulic
Coupling
To HPH.Recirculation to FST
General Arrangement of BFP

15. Booster Pump
To Ensure a Net Positive Suction Head (NPSH) for
Main Feed Pump
Saves a Costly Main Pump due to any damage from
Cavitation.
Typically a single-stage, centrifugal pump
Recirculation :
To maintain the Continuous flow of feed water when
the valve to Economizer is Closed
Components of BFP

16. Suction Strainers
To Protect Booster pump and main pump against
Catastrophic failure due to entry of coarse
particles
Hydraulic Coupling
Used to Transmit power from motor to pump as
per the
Load requirement
Components of BFP

17. NPSH is an acronym for Net Positive Suction Head. It
shows the difference, in any cross section of a generic
hydraulic circuit, between the pressure and the liquid vapor
pressure in that section.
NPSH is an important parameter, to be taken into account
when designing a circuit : whenever the liquid pressure drops
below the vapor pressure, liquid boiling occurs, and the final
effect will be cavitations : vapor bubbles may reduce or stop
liquid flow.
In pump operation, two aspects of this parameter are called
respectively NPSH (a) Net Positive Suction Head (available)
and NPSH (r) Net Positive Suction Head (required), where
NPSH(a) is computed at pump inlet port, and NPSH(r) is the
limit NPSH the pump can withstand without cavitating.
NPSH

18. Booster PumpBooster Pump
Major damage in BF pump is Major damage in BF pump is
from cavitation or vapour from cavitation or vapour
bounding.bounding.
Provides positive pressure at Provides positive pressure at
the pump suction.the pump suction.

19. BFP CARTRIDGE

20. BFP WITH COMMON FOUNDATION FRAME

21. BFP SEAL COOLER PIPING

22. MECHANICAL SEAL
•The use of mechanical seal reduces the loses of feed water
in the stuffing box to a minimum.
•Working ability of the feed pump increases.
•Cooling of stuffing box space should be perfect by the use
of mechanical seal.
•Cooling is carried out by the circulation of water between the
stuffing box space and the cooler. Even after stopping the
pump stuffing box cooling should be continued as its cooling
circuit is different from the seal cooler.
•Coolers are designed to keep the stuffing box space
temperature below 80
0
C.

23. It consists of two highly polished surfaces, one surface connected to
the Shaft and the other to the stationary part of the Pump.
•Both the surfaces are of dissimilar materials held in continuous
contact by a spring.
•These wearing surfaces are perpendicular to the axis of Shaft.
•A thin film of working fluid between these faces provides cooling &
lubrication.
MECHANICAL SEAL

24. SEAL HOUSING
It houses the Mechanical Seal.

25. •They give radial positioning to the rotor.
•They are of two types :
•Antifriction Bearings
•Sleeve Bearings
Line Bearings

26. They locate the rotor axially & take residual axial
thrust.
•They are fitted in the NDE Bearing Housing.
•They have 8 white metal lined tilting pads held in a
split Carrier Ring positioned on each side of the
Thrust Collar.
Thrust Bearings

27. •They house Journal Bearing at the DE side and both
Journal & Thrust Bearings at the NDE side.
•These are in the form of cylindrical castings split on
the horizontal Shaft axis, located one each at DE &
NDE sides of the Pump.
BEARING HOUSINGS

28. It houses the hydraulic components of Pumps.
•It prevents the leakage and guides the liquid in a
proper direction.
•It is closed by Suction Guide at it’s suction side and
Discharge Cover at it’s discharge side.
PUMP CASING

29. •It guides the fluid from suction pipe to the eye of the
Impeller.
•It closes the drive end of Pump Casing and forms
the suction annulus.
SUCTION
GUIDE

30. It closes the NDE of Pump Casing and forms the
balance chamber.
•It is closed by NDE Water Jacket and Mechanical
Seal Housing.
•A Spring Disc is located between the last stage
Diffuser and the Discharge Cover Balance Drum
Bush.
DISCHARGE COVER

31. It rotates the mass of fluid with the peripheral speed of
its vane tips, thereby determining the head
developed or the Pump working pressure.
IMPELLER

32. IMPELLER

33. •It converts Kinetic energy of the fluid into Pressure
Energy.
DIFFUSE
R

34. •It consists of Shaft, Impellers, Balance Drum, Thrust
Collar, rotating parts of Mechanical Seals and the Pump
Half Coupling.
•It is dynamically balanced.
ROTATING ASSEMBLY

35. Balancing Device
•A small portion of the feed water in the order of about 10% which is
not calculated to the guaranteed delivery capacity is taken off from
the space behind the last impeller for the operation of the
automatic balancing device to balance the hydraulic axial thrust of
the pump rotor.
•The purpose of the balancing device is to take up thrust pressure
in a similar way as the thrust bearing.
BALANCE DRUM

36. The Balancing Chamber is connected either to The Balancing Chamber is connected either to
the Pump suction or to the Deaerator, thus the the Pump suction or to the Deaerator, thus the
back pressure in Balancing Chamber is back pressure in Balancing Chamber is
slightly higher than the suction pressure.slightly higher than the suction pressure.
 95% of axial thrust is balanced by the 95% of axial thrust is balanced by the
Balancing Drum.Balancing Drum.
Residual axial thrust is taken by Thrust Residual axial thrust is taken by Thrust
Bearing.Bearing.
Provision of Thrust Bearing is recommended Provision of Thrust Bearing is recommended
for varying condition of Head and Flow which for varying condition of Head and Flow which
affect the axial thrust.affect the axial thrust.
BALANCE DRUM

41. MDBFP LINE UPMDBFP LINE UP
OIL SIDEOIL SIDE
1.1.HC oil level normalHC oil level normal
2.2.Cooler line upCooler line up
3.3.Start AOPStart AOP
4.4.Lube oil WO pr. OkLube oil WO pr. Ok
5.5.Bearing oil flow normal Bearing oil flow normal
6.6.No oil leakageNo oil leakage

42. Suction v/v open fullySuction v/v open fully
R/c v/v manual v/v open R/c v/v manual v/v open
R/c v/v c/v inst. Air v/v open*R/c v/v c/v inst. Air v/v open*
Motor wdg cooling water supply/ return line v/v openMotor wdg cooling water supply/ return line v/v open
Cooling water header pressure okCooling water header pressure ok
Main p/p and booster pump mechanical seal water / Main p/p and booster pump mechanical seal water /
cooling water charge cooling water charge
Venting done*Venting done*
EPB released EPB released
Discharge v/v close and IBV closeDischarge v/v close and IBV close
Header drain /recirculation/casing drain close * Header drain /recirculation/casing drain close *

43. TDBFP LINE UPTDBFP LINE UP
OIL SIDE OIL SIDE
FEED WATER SIDE FEED WATER SIDE
GLAND SEAL STEAM/ VACUUM GLAND SEAL STEAM/ VACUUM
SIDESIDE
EXTRACTION STEAM SIDEEXTRACTION STEAM SIDE
BARRING SIDEBARRING SIDE

44. TDBFP LINE UPTDBFP LINE UP
 PTW CANCELLEDPTW CANCELLED
 BOXED UPBOXED UP
OIL SIDEOIL SIDE
1.1. LOTLOT level normal level normal
2.2.CCooler line up from oil /water sideooler line up from oil /water side
3.3. AOP/EOP/JOPAOP/EOP/JOP suction/discharge v/v open suction/discharge v/v open
4.4.Governing oil manual v/v openGoverning oil manual v/v open
5.5.All lops supply normalAll lops supply normal
6.6.Start EOP and check oil lkg.Start EOP and check oil lkg.
7.7.Start JOP and check oil lkgStart JOP and check oil lkg
8.8.Pump/turbine freeness checking, observe RPMPump/turbine freeness checking, observe RPM
9.9.Stop barring engage/disengage main p/p and do Stop barring engage/disengage main p/p and do
FW chargingFW charging
10.10.Vapour extraction fan i/sVapour extraction fan i/s

45. 
FWFW charging charging
1.1.Open Open BP/BFP/suction strainer BP/BFP/suction strainer ventvent
2.2.Charge mechanical seal water BP/BFPCharge mechanical seal water BP/BFP
3.3.Charge jacket cooling wtr and one set of Charge jacket cooling wtr and one set of
coolercooler
4.4.Crack open suction v/v *Crack open suction v/v *
5.5.Taking on barring along with Taking on barring along with FWFW
charging?charging?
6.6.Close all drain /ventsClose all drain /vents

46. Gland seal steam /vacuum sideGland seal steam /vacuum side
1.1.Open aux stm. drain at 8.5 M then crack Open aux stm. drain at 8.5 M then crack
chargecharge
2.2.Open seal steam /aux c/v drain and crack Open seal steam /aux c/v drain and crack
charge 8.5 m iso. v/v charge 8.5 m iso. v/v
3.3.Charge seal stm / leak off stm sideCharge seal stm / leak off stm side
4.4.Open turbine drains to flash tank to take Open turbine drains to flash tank to take
vacuumvacuum
5.5.Crack open exhst. block v/v and close ,try Crack open exhst. block v/v and close ,try
againagain
Extraction stem sideExtraction stem side
1.1.Open drain/vent before ESVOpen drain/vent before ESV
2.2.Open manual v/v Open manual v/v
3.3.Open mot. v/vOpen mot. v/v