ARANI POWER SYSTEMS LIMITED

BOP REPORT
(CONDENSATE SYSTEM)

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WHAT IS STEAM ?
As the temperature increases and the water approaches its boiling condition, some molecules attain enough kinetic energy to reach velocities that allow them to momentarily escape from the liquid into the space above the surface, before falling back into the liquid. Further heating causes greater excitation and the number of molecules with enough energy to leave the liquid increases. As the water is heated to its boiling point, bubbles of steam form within it and rise to break through the surface. Considering the molecular structure of liquids and vapors, it is logical that the density of steam is much less than that of water, because the steam molecules are further apart from one another. The space immediately above the water surface thus becomes filled with less dense steam molecules. hen the number of molecules leaving the liquid surface is more than those re!entering, the water freely evaporates. At this point it has reached boiling point or its saturation temperature, as it is saturated with heat energy.

"f the pressure remains constant, adding more heat does not cause the temperature to rise any further but causes the water to form saturated steam. The temperature of the boiling water and saturated steam within the same system is the same, but the heat energy per unit mass is much greater in the steam. At atmospheric pressure the saturation temperature is #$$%C. &owever, if the pressure is increased, this will allow the addition of more heat and an increase in temperature without a change of phase. Therefore, increasing the pressure effectively increases both the enthalpy of water, and the saturation temperature. The relationship between the saturation temperature and the pressure is known as the steam saturation curve.

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ater and steam can coexist at any pressure on this curve, both being at the saturation temperature. 'team at a condition above the saturation curve is known as superheated steam( Temperature above saturation temperature is called the degree of superheat of the steam. below the curve is called sub!saturated water. "f the steam is able to flow from the boiler at the same rate that it is produced, the addition of further heat simply increases the rate of production. "f the steam is restrained from leaving the boiler, and the heat input rate is maintained, the energy flowing into the boiler will be greater than the energy flowing out. This excess energy raises the pressure, in turn allowing the saturation temperature to rise, as the temperature of saturated steam correlates to its pressure. ater at a condition

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THE RANKINE CYCLE The )ankine cycle is the standard for steam power plants that are built around the world. The basic )ankine cycle consists of four main components( #. 'team *enerator +. Turbine ,. 'team Condenser -. .ump

The actual )ankine cycle used in modern power plants has many more components, but the above four components are common to all power plants. "n this cycle, water is heated in the steam generator to produce high temperature and pressure steam. This steam is then expanded in a turbine to produce electricity from a generator that is connected to the turbine. The steam from the turbine is then condensed back into water in the condenser. The pump then returns the water to the steam generator. Thus, the main purposes of the condenser are to condense the exhaust steam from the turbine for reuse in the cycle and to maximi/e turbine efficiency by maintaining proper vacuum. As the operating pressure of the condenser is lowered 0vacuum is increased1, the enthalpy drop of the expanding steam in the turbine will also increase. This will increase the amount of available work from the turbine 0electrical output1. 2y lowering the condenser operating pressure, the following will occur( 3 "ncreased turbine output

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3 "ncreased plant efficiency 3 )educed steam flow 0for a given plant output1 "t is therefore very advantageous to operate the condenser at the lowest possible pressure 0highest vacuum1. CONDENSER TYPES: There are two primary types of condensers that can be used in a power plant( #. 4irect Contact +. 'urface DIRECT CONTACT CONDENSERS condense the turbine exhaust steam by mixing it directly with cooling water. The older type 2arometric and 5et!Type condensers operate on similar principles. STEAM SURFACE CONDENSERS are the most commonly used condensers in modern power plants. The exhaust steam from the turbine flows on the shell side 0under vacuum1 of the condenser, while the plant6s circulating water flows in the tube side. The source of the circulating water can be either a closed! loop 0i.e. cooling tower, spray pond, etc.1 or once through 0i.e. from a lake, ocean, or river1. The condensed steam from the turbine, called condensate, is collected in the bottom of the condenser, which is called a hot well. The condensate is then pumped back to the steam generator to repeat the cycle. STEAM SURFACE CONDENSER OPERATION The main heat transfer mechanisms in a surface condenser are the condensing of saturated steam on the outside of the tubes and the heating of the circulating water inside the tubes. Thus for a given circulating water flow rate, the water inlet temperature to the condenser determines the operating pressure of the condenser. As this temperature is decreased, the condenser pressure will also decrease. As described above, this decrease in the pressure will increase the plant output and efficiency.

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4ue to the fact that a surface condenser operates under vacuum, non condensable gases will migrate towards the condenser. The non condensable gases consist of mostly air that has leaked into the cycle from components that are operating below atmospheric pressure 0like the condenser1. These gases can also result from caused by the decomposition of water into oxygen and hydrogen by thermal or chemical reactions. These gases must be vented from the condenser for the following reasons( The gases will increase the operating pressure of the condenser. 'ince the total pressure of the condenser will be the sum of partial pressures of the steam and the gases, as more gas is leaked into the system, the condenser pressure will rise. This rise in pressure will decrease the turbine output and efficiency. The gases will blanket the outer surface of the tubes. This will severely decrease the heat transfer of the steam to the circulating water. Again, the pressure in the condenser will increase. The corrosiveness of the condensate in the condenser increases as the oxygen content increases. 7xygen causes corrosion, mostly in the steam generator. Thus, these gases must be removed in order to extend the life of cycle components. STEAM SURFACE CONDENSER AIR REMOVAL

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The two main devices that are used to vent the non condensable gases are 'team 5et Air 89ectors and :iquid )ing ;acuum .umps. 'team 5et Air 89ectors 0'5A81 use high!pressure motive steam to evacuate the non condensable, from the condenser 05et .ump1. :iquid )ing ;acuum .umps use a liquid compressant to compress the evacuated non condensable and then discharges them to the atmosphere. To aid in the removal of the non condensable gases, condensers are equipped with an Air!Cooler section. The Air! Cooler section of the condenser consists of a quantity of tubes that are baffled to collect the non condensable. Cooling of the non condensable reduces their volume and the required si/e of the air removal equipment. Air removal equipment must operate in two modes( hogging and holding. .rior to admitting exhaust steam to a condenser, all the non condensable must be vented from the condenser. "n hogging mode, large volumes of air are quickly removed from the condenser in order to reduce the condenser pressure from atmospheric to a predetermined level. 7nce the desired pressure is achieved, the air removal system can be operated in holding mode to remove all non condensable gases.

STEAM SURFACE CONDENSER CONFIGURATIONS 'team surface condensers can be broadly categori/ed by the orientation of the steam turbine exhaust to the condenser. <ost common are side and down exhaust. "n a side exhaust condenser, the condenser and turbine are installed ad9acent to each other, and the steam from the turbine enters from the side of the condenser. "n a down exhaust condenser, the steam from the turbine enters from the top of the condenser and the turbine is mounted on a foundation above the condenser. Condensers can be further delineated by the configuration of the shell and tube sides. The tube side of a steam surface condenser can be classified by the following( 3 =umber of tube side passes 3 Configuration of the tube bundle and water boxes <ost steam surface condensers have either one or multiple tube side passes. The number of passes is defined as how many times circulating water travels the length of the condenser inside the tubes. Condensers with a once!through circulating water system are often one pass. <ultiple pass condensers are typically used with closed!loop systems.

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HOT WELL The condensate collects in a low point in the condenser called the hot well. A stand pipe is connected to the hot well and level gauge is installed on the stand pipe. :evel *auge measures the level of the hot well level switches also installed on the stand pipe 0:':, :'::, :'& and :'&&1.when the level varies then the switches give alarm according to the level of the hot well. From here, the condensate flows to one or both Condensate pumps 0C.1 from the main condenser and each auxiliary condenser>s auxiliary condensate pump. These pumps discharge the condensate at +$!+? psig to provide enough pressure head to flow through the condensate system. CONDENSATE PUMPS The condensate water is drawn from the condenser hot well by two #$$@ motor!pump sets. 8ach pump is of the multistage, vertical type with barrel. "nitially one will be in working condition and the other will be in standby mode. "f there is any pressure drop from the working pump then the other takes charge over it.

CONTROL VALVE Temperature, pressure, level, and flow instruments all sense a process parameter and produce a signal for indication or controller input. "f we want to control a process parameter, the controller output must convert to a signal that can translate to and subsequently drive a control valve. The control valve is a final control element. A final control element is any device or element that changes the value of a manipulated variable. ;alves and heaters are common examples. :et>s look at control valves and the devices that process the signal supplied to the control valve.

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"n this illustration you can see the controller output sends an electronic signal to the current!to!pressure transducer 0"A.1, which sends a pneumatic signal to the control valve. The control valve position changes in response to the signal to ad9ust flow to the setpoint. As the flow changes, it is sensed by the flow transmitter. hen the flow sensed is equal to setpoint, the valve position remains the same. Any time there is a disturbance to the system or a change in setpoint, the flow control loop automatically responds to achieve the programmed setpoint. A block diagram of this concept is here. The final control element can be proportional control or 7=!7FF control. For 7=!7FF control, a controller output relay changes the state of the relay contact, which completes the circuit for a solenoid valve to energi/e. The solenoid valve opens to allow air to open 0or close1 a control valve. The first component in the final control subsystem is the signal conditioner. The signal conditioner amplifies and, if necessary, converts the signal for compatibility with the actuator. Typical devices used as signal conditioners include current!to!pneumatic transducers, current!to!voltage 0"A81 transducers, amplifiers 0electronic or pneumatic1, relays, digital!to!analog converters, or analog!to! digital converters. The most common signal conditioner in a proportional control loop is an "A. transducer. A typical "A. transducer is a force balance device in which a coil suspends and hangs in the field of a magnet. Current flowing through the coil generates axial movement of the coil, which causes movement of the beam. The beam controls the backpressure against the no//le by controlling the restriction of airflow through the no//le. This backpressure acts as a pilot pressure to control the outlet pressure. The /ero ad9ustment causes the beam to move relative to the no//le. The span ad9ustment is a potentiometer that limits the current through the coil. The "A. transducer must be supplied with instrument air within the range specified by the manufacturer, usually at least +$ psig. The typical "A. transducer is calibrated for a -!+$ mA input B ,!#? psig output. <ost "A. transducers can be configured for direct action 0output pressure increases as input signal increases1 or reverse action 0output pressure decreases as input signal increases1. The next component in the final control subsystem, if applicable, is the actuator. The actuator receives the conditioned signal and changes it to some form of mechanical energy or motion.

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Typical devices used as actuators include solenoids, pneumatic valve positioners, AC and 4C motors, stepper motors, hydraulic motors, and hydraulic pistons. <any control valves include a pneumatic valve positioner. POSITIONER A valve positioner is a device used to increase or decrease the air pressure 0from the "A.1 operating the control valve actuator. .ositioners usually mount to the control valve actuator and connect mechanically to the valve stem for position indication.

A positioner is a type of air relay, which acts to overcome hysteresis, packing box friction, and effects of pressure drop across the valve. "t assures exact positioning of the valve stem and provides finer control. There are many types of positioners. The basic principles of operation are similar for all types. The instrument pressure 0from an "A., for example1 acts on the input module, which controls the flapper! no//le system of the relay. 'upply pressure applies to the relay and the output pressure of the relay goes to the control valve actuator.

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<ost positioners can set up and function for direct or reverse action. For a direct!acting positioner, increasing the instrument pressure causes the input module to pivot the beam. The beam pivots the flapper and restricts the no//le. The no//le pressure increases and causes the relay assembly to increase output pressure to the actuator. ith a direct!acting actuator, the increased pressure moves the actuator stem downward. The positioner connects mechanically to the stem of the valve. 'tem movement feeds back to the beam by means of a feedback lever and range spring, which causes the flapper to pivot slightly away from the no//le to prevent further increase in relay output pressure. =ote that some positioners accept a milliamp input and include an integral "A. transducer.

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valve. The pneumatic signal from the positioner 0or "A. if a positioner is not used1 applies directly to the actuator. For this control valve, the air enters above the diaphragm and pushes against spring pressure to close the valve. The valve fully closes when the plug seats tightly against the seat ring. As air pressure decreases, the spring pressure causes the diaphragm, stem, and plug to move upward, opening the valve. This means a loss of pressure would cause the valve to open. This is a fail!open valve. 4ifferent configurations of air inlet, spring location, and valve seat arrangement result in different fail positions and determine whether the valve is direct! or reverse!acting. For example, this same valve, with the plug below the seat ring 0reverse!seated1, would open with increased air pressure and would fail closed on loss of air pressure. 'o, all components in the final control subsystem must be configured correctly for the system to work properly. The fail!safe positions must be correct for the application, and the action must produce the desired results. These configurations must be properly documented and utili/ed during calibration, loop checks, or troubleshooting.

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BELLOW "n any piping system, there is a degree of flexibility inherent in the design. This flexibility results from change in direction of the pipe system as it connects the various components to each other. This inherent flexibility may be insufficient, in which case it becomes necessary to develop additional flexibility. This can be achieved by locating 8xpansion 9oints at strategic points in the system. 8xpansion 9oints help in reducing stresses in the pipe or force at the anchors, to accommodate the strains of thermal growth in a restricted space. The previous method of achieving flexibility, by creating pipe loops or direction change, is more costly than the use of 8xpansion 9oints, because of piping material, space problems, pressure drop, increased power requirements, for fans, blowers, etc. This can be eliminated by the use of C2ellows 8xpansion 5ointsC. 2ellow absorbs the force 0load1 of the turbine and does not let the force fall on the condenser.

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SYSTEM PROCESS The exhaust steam from the turbine enters into the condenser, in bAw a bellow is mounted as it absorbs the force 0load1 of the turbine D doesn6t not let the load fall on the condenser. Turbine exhaust pressure is monitored by pressure switch, provided at condenser, "n case Turbine vacuum crosses the set point, 0beyond safety setting1, the pressure switch initiates tripping signal. The function of the condenser is to condense exhaust steam from the steam turbine by re9ecting the heat of vapori/ation to the cooling water passing through the condenser. The temperature of the condensate determines the pressure in the steamAcondensate side of the condenser. This pressure is called the turbine backpressure and is usually a vacuum. 4ecreasing the condensate temperature will result in a lowering of the turbine backpressure. Note( turbine. ithin limits, decreasing the turbine backpressure will increase the thermal efficiency of the

The condensate is collected in the condenser hot well, from which the condensate pumps
take their suctionE

.rovide short!term storage of condensateE .rovide a low!pressure collection point for condensate drains from other systems in the
plantE

.rovide for de!aeration of the collected condensate.

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The condensate water is drawn from the condenser hot well by two #$$@ motor!pump sets. 8ach pump is of the multistage, vertical type with barrel. "nitially one will be in working condition and the other will be in standby mode. "f there is any pressure drop from the working pump then the other takes charge over it.a pressure switch is installed on the condensate extraction line, which senses the pressure drop and gives signal to <CC to start other pump as first pump is tripped. The condensate will be supplied to the Eje to! S"#te$ to remove vacuum content present in it. HOTWELL LEVEL CONTROL A stand pipe installed to the &7T ' "TC&8'. :T :': :'& ! ! ! :evel Transmitter :evel 'witch :ow Alarm :evel 'witch :ow :ow 0Trip1 :evel 'witch &igh Alarm :evel 'witch &igh &igh 0Trip1 8:: consists of :8;8: T)A='<"TT8) D :8;8:

:':: ! :'&& !

Two :evel control valves #. Air to Close

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+.

Air to 7pen.

"nitially the two valves will be in open condition "f the level of the hot well increases, level transmitter senses it and transmits an signal to the :8;8: "=4"CAT"=* C7=T)7::8), this -!+$ mA signal is sent to "A. converter which converts into 0$.+ to # bar1 .neumatic signal. This .neumatic signal is transmitted to control valve positioner. A valve positioner is a device used to increase or decrease the air pressure 0from the "A.1 operating the control valve actuator. .ositioners usually mount to the control valve actuator and connect mechanically to the valve stem for position indication. According to the condition the valve slowly closes till the hot well level reaches the set point. hen this valve comes to close condition automatically the other valve will be opened and the condensate with high pressure flows through it to 48A8)AT7). All 4rains from 89ector systems are connected to condenser and hotwell through F:A'& .".8. 7ne side of the flash pipe is connected at the top of the condenser i.e ;A.7F) '8CT"7= of condenser and the other side is connected to the hot well.