ATMOSPHERIC FLASH TANK

Condensate temperatures in high-pressure steam systems generally are only slightly less than the saturated
temperature of the steam. When hot condensates are discharged into lower-pressure areas, condensate
temperature immediately drops to the saturated temperature of the low-pressure area. As the result of the drop in
temperature, heat released evaporates a portion of the condensate, generating flash steam. To return condensate to
the boiler or to discharge it to the sewer, it is necessary to separate flash steam from the condensate. This is
accomplished by discharging condensate through steam traps into a vented tank, referred to as a flash tank. Flash
steam produced in the flash tank may be vented to the atmosphere or piped to a low-pressure main. Condensate
remaining may then be returned to the boiler or discharged to drain.

1. Condensate from various points of operation enters the flash tank at relatively high pressure.
As the condensate enters the low pressure flash tank, part of the condensate flashes into steam.
The tangential inlet of the flash tank forces the incoming condensate into a funnel type motion
forcing the denser entrained water to the outside of the flash tank to collect on the walls and fall
to drain. This leaves dry low pressure steam in the centre of the flash tank to rise and exit the
flash tank through the vent.
2. The flash steam exits through the vent at the top of the tank and is either vented to
atmosphere or piped to a low pressure line for use in low pressure steam applications.
3. The condensate is discharged through the bottom of the flash tank. When piping flash steam
into a low pressure steam line and discharging condensate directly to a return line, it is important
that the condensate has enough of a pressure differential to overcome any back pressure from
the return line. Additionally, the placement of a steam trap after the flash tank would be
necessary to prevent blow through of steam. If a steam trap is necessary, an inverted bucket (IB)
trap is suggested. The trap should be sized with a 3:1 safety factor. If back pressure exceeds tank
pressure, the use of a reservoir and pumping trap may be necessary to ensure proper drainage.
If the flash tank is held at atmospheric pressure, the use of a steam trap on the discharge line
would not be necessary since the flash steam is being vented to atmosphere. The condensate, in
this case, would be drained by gravity to a vented receiver which would be placed below the
level of the flash tank.

How vacuum is created?

Basic vacuum created in the LPT exhaust side is because of condensing process. Phase change is
occurring at the exhaust side i.e. conversion of steam into water. Specific volume of water is
much lower than the steam. Hence when the condensing process happens, volume of steam
reduces and basic vacuum is created.
Apart from this, vacuum pumps are provided to remove non condensable gases/air ingress which
reduces heat transfer effectiveness.
Why vacuum is created?
To improve LPT cylinder efficiency & thus the load/work done shall be improved.
Effect of over vacuum?
It causes sub-cooling effect where hot well temperature reduces more than design which
required to be added in boiler leads to heat loss. Also flow accelerated erosion in LPT last stages.
Effect of under vacuum?
LPT efficiency reduction which causes lesser work done & leads to reduced load output.
How is the washing of turbine blades carried out with the condensate?
The washing is carried out with the condensate at 100C.
The turbine is cooled or heated up to 100C and filled with the condensate via a turbine drain.
The rotor is turned or barred by hand and the condensate is drained after 2 to 4 hours.
It is then again filled with the condensate at 100C (but up to the rotor centre-level), the rotor is
rotated and the condensate is drained after sometime. This process is repeated several times.
How is turbine blade washing with wet steam carried out?
Wet steam produced usually by injecting cold condensate into the superheated steam, is
introduced to the turbine which is kept on running at about 20% of nominal speed.
For backpressure turbine the exhaust steam is let out into the open air through a gate valve. For
a condensing turbine, the vacuum pump is kept out of service while cooling water is running,
with the effect that the entering cooling steam is condensed. The condensate is drained off.
The washing steam condition is gradually adjusted to a final wetness of 0.9 to 0.95.
Note, it is important:
Not to change washing steam temperature by 10C/min,

To keep all turbine cylinder drains open.

If deposits form, they are removed by washing the blades with wet steam where upon
water soluble deposits are transferred into the washing giving rise to partial washingof