TOPIC - 4

CONDENSER AND FEED WATER

SYSTEMS
CONDENSER AND COOLING
WATER SYSTEMS
CONDENSER
Surface condenser of type 1000-96000-1-is designed to condense low-
potential steam exhausted from the turbine for the further use of the
generated condensate in the thermodynamic cycle of the turbine plant rated
1000 MW for KUDANKULAM NPP.
The condenser is designed for operation with sea cooling water at a
temperature from 15 C to 36 C.

The two-flow system makes it possible to isolate and to clean any tube bundle
of the condenser when the turbine is running.

The turbine main condenser system consists of three condensers.

Cooling water comes to each condenser through two pipelines and goes
away also through two pipelines.
Each condenser consists of connecting pipe branch, casing, tube system,
hotwell and water chambers.
The connecting pipe branch is made of carbon steel sheets and is welded to
turbine exhaust branch. Inside the connecting pipe branch there are the
BRU-K steam receiving devices and the low pressure heaters No1.
2
CONDENSER
The tube system consists of titanium tube bundles
which are expanded in the tube sheets and are
supported by intermediate partitions installed within the
shell.
The tube sheets are made of carbon steel covered with
titanium from the water side. Tube to tube sheet joint is
rolled seal welded.
The water chambers made of stainless steel of
removable type are bolted to the main tube sheets with
flanges.
Shape of the tube bundles and spacing between the
tubes in the bundles ensure minimum hydraulic
resistance to steam flow and exclude stagnant areas.
CONDENSER
The shell of each condenser is made of carbon
steel sheets.
The hotwell is made of carbon steel sheets and
welded to the condenser shell.
The connecting pipe branch of the condenser is
welded to LPC exhaust parts, i.e. the condenser
shell and LPC are rigidly connected.
The condenser rests on the foundation by means
of spring supports that bear the load of the dry
condenser. The springs are assembled in the
spring units: 4 units of 20 springs each for each
shell of the condenser.
 The spring is compressed and takes the
condenser weight after its erection has been
finished and before connecting it to LPC
exhaust part by welding. All loads of the
condenser in the working condition are
transferred to the turbogenerator foundation
bypassing the spring supports of the
condenser. The spring supports take the heat
expansions of the condenser shell ( together
with the built-in LP heater-1) in all directions.
CONDENSER

Geometric features for each body of condenser:

Height, m 15,880
Width, m 8,800
Length, m 20,200
Mass in working order, t 1500
Mass under hydraulic test, t 2800
CONDENSER
Main technical features of condenser for nominal
mode:
Heat-transfer surface, m2 105885
Amount of cooling tubes, pcs. 90300
ID/OD of tubes, m 0,025/0,0238
Length of tubes, m 15,000
Steam rate in to condenser, kg/s 876,94
Cooling water rate, m3 /s 91667
Temperature of cooling water in inlet, 32
CONDENSER

Most possible pressure (gage) inwardly water

space of condenser, Mpa 0,12
Cooling water number pass 1
Cooling water number flow 6
Hydraulic pressure, kPa 65,4
Absolute steam pressure in condenser,kPa 7,52

Steam temperature in condenser, 40,5

CONDENSER COOLING SYSTEM
Functional requirements to the system
The circulation water system is intended for
steam condensation heat removal from the
turbine condensers, turbine feeding pumps
condensers and water supply to turbine plant
ejectors lifting pumps.
Design basis

The design of the circulation water system and its components is based on
satisfaction of the requirements below.
The circulation water system should be designed based on once-through
seawater supply and operate in the normal operation mode.
The system should operate under the following cooling seawater
temperatures:
- the turbine condensers and auxiliary systems connected with electric
power generation should ensure turbine rated power generation with the
condenser inlet seawater temperature of plus 31 ;
- the minimal cooling water temperature is plus 21 .
The cooling seawater temperature at the discharge point should not exceed
the temperature of the water taken from the sea by not more than 7 .
The system should cool the turbines condensers in the entire range of the
turbine plant loads.
DESCRIPTION OF THE SYSTEM
The circulation water system consists of six supply
pipelines of Dn 2400 delivering seawater from the
coastal pump station to the main turbine condensers
and six discharge pipelines removing seawater from the
condensers to the discharge channel, as well as of pipe-
lines, which supply water to TFP condensers and
ejectors lifting pumps.
The system has a once-through arrangement with single
seawater circulation via heat exchanging equipment.
The system will have a Tube cleaning system (PAH) for
mechanical treatment of the heat exchanging
equipment (turbine condensers, turbine feed pump
condensers).
Mussel filters (PBB) are installed in each pipeline for
cooling water supply to the heat exchanging equipment.
 Each of the six pumps supplies the flow rate of 44000
t/h to each condenser half over a separate pipeline.
To rough down the condenser drain chamber at the
startup of the main cooling water pumps and maintain
the vacuum in the condenser drain chamber, the
circulation system ejectors will be connected to them.
A valve for the air release from the condenser drain
chamber is also installed in the system. The valve
performs a double function:
- rapid air release and prevention thereby of a hydraulic
shock at the main cooling water pump startup;
- air intake at the pump disconnection and prevention
thereby of the cooling water backflow and elimination of
the external pressure effects on the condensers water
chamber walls.
To avoid the fouling of the systems equipment
and pipelines, it is stipulated that:

- sodium hypochlorite will be dosed;

- the water rate in the pipelines will be 3 m/s;

- mussel filters and bubble treatment

equipment will be installed.
VACUUM SYSTEM
THE VACUUM SYSTEM (MAJ) IS INTENDED :
To build up vacuum at turbine exhaust in order to utilize as
much of the working medium heat drop as possible by
means of cooling with the circulation water and
condensation of steam wasted in the turbine;
To evacuate steamair mixture from the turbine condenser
and to attain vacuum, as deep as possible, required for
reliable and efficient operation of the turbine;
To create the required rarefaction in the gland steam
condenser (GSC);
To create the required rarefaction in the upper area of the
condenser water chambers when filling the condensers with
water during Unit start-up and to maintain this rarefaction in
the process of operation in order to reduce the required
head of the circulation water pumps.
THE VACUUM SYSTEM SHALL PROVIDE FOR:

development of high vacuum in turbine condensers at preset

rate from the beginning of start-up and maintaining this
vacuum at turbine operation;
cooling water for condenser and ejectors is sea water with
temperature of +15 C to 36 C;
development of vacuum in GSC sufficient to exclude steam
leakage through the turbine end glands into the service room;
supply of working medium to the ejectors and its discharge
should be implemented individually;
a possibility of vacuum break in emergency;
warm-up of circulation water in condenser should not exceed
5
THE VACUUM SYSTEM SHALL PROVIDE FOR:
noncondensable gases from the condenser should be evacuated in the
area of the highest partial air pressure in the area with the coolest
(incoming) water thus providing the deepest vacuum and the lowest
condensate loss with the evacuated steam-air mixture;
undercooling (below saturated temperature) of the formed condensate
by cooling water should be excluded;
the inner surface of the condenser tubes should be cleaned during
operation with the rubber balls; independently from ball cleaning
provision should be made for shutting off at circulation water side and
for mechanical cleaning of the half of the tubes of each condenser body
when operating at load;
connection of tubes with the tube sheets should exclude to the greatest
extent inflows of raw water into the condenser;
provided should be the devices for normal and emergency make-up of
chemically purified water, for admittance of design steam dumps
(particularly from BRU-K), water and steam-air mixture into the
condenser when operating at load.
SYSTEM INCLUDES:
main water-jet ejectors (MAJ11BN001,
MAJ12BN001, MAJ13BN001, MAJ14BN001);
water-jet ejector of GSC (MAJ15BN001);

water-jet ejector of the circulation system

(MAQ41BN001, MAQ42BN001);
lifting pump (PCC11AP001, PCC12AP001,
PCC13AP001, PCC14AP001)
pipings;

valves.
 Vacuum is developed and maintained in the
condensers by the main ejectors. The quantity of
ejectors, which are to be in operation, when the
turbine is operating on load, depends on steam
flow into the condenser and the tightness of the
vacuum system. Working water is supplied to
each ejector from the pressure header of the
lifting pumps.
To prevent air inflow into the condenser, an ejector
being shut off from the header, suction line of
each main ejector is equipped with a non-return
valve.
 The ejector of the sealing system is connected to GSC at
steam side on opening of the gate valve at the
respective line PCB25 and is operating during the whole
time of turbine operation. As there is no any rotating,
moving, wearing parts in the ejector and because it is
not desirable to install additional valves which may
happen to be a source of failures, it is not reasonable to
provide for a stand-by ejector for the sealing system.
The ejectors of the circulation system are brought into
operation when filling the condenser tube system with
cooling water as well as in case of level drop in an inlet
water chamber of any of the condensers.
For turbine emergency shut-down the condenser
vacuum break gate valves are installed.
ONLINE TUBE CLEANING SYSTEM
Condenser ball cleaning system (PAH) is
intended:

To ensure design vacuum in the turbine

condenser through maintaining cleanliness of
the inner surface of the condenser tubes
achieved with the help of elastic balls passing
inside the tubes;
To ensure ball recirculation in the system
delivery circulating water line condenser -
discharge circulating water line - delivery
circulating water line.
Condenser ball cleaning system is functioning in 2
operating modes:
Continuous operating mode, when the process of ball
circulation in the condenser tubes is maintained;
Temporary starts starting the ball cleaning system
periodically, duration of operation up to several hours.

The condenser ball cleaning system should provide as

follows:
Uniform over the height of the water chambers ball
supply to the condenser tubes;
Ball evacuation from the discharge circulating water
line;
Collection of balls in the loading chamber.
SYSTEM DESCRIPTION
The condenser ball cleaning system consists of 6 ball cleaning
groups one group per each delivery circulating water line.

The group includes as follows:

loading chambers PAH11BB001 ,PAH12BB001,
PAH21BB001, PAH22BB001, PAH31BB001, PAH32BB001;
ball-catching device PAH11AT001 ,PAH12AT001,
PAH21AT001, PAH22AT001, PAH31AT001, PAH32AT001;
water-jet ejector, PAH11BN001, PAH12BN001,
PAH21BN002, PAH22BN001, PAH31BN001, PAH32BN001;
piping;

valves.
 From the upper compartment of the loading chamber
(LC) the elastic balls are supplied through the
distributing device to, entrained by circulating water flow
to the condenser tubes. The balls constricted to the
tube inner diameter pass the tubes along their whole
length and clean their inner surface.
Having passed the tubes the balls enter the discharge
circulating water line where they are caught by the ball-
catching device (BCD).
Due to rarefaction created by a water-jet ejector the
balls are fed from BCD through the lower compartment
of the loading chamber to the distributing device for
taking the balls into the delivery circulating water line.
Working water for operation of the ball cleaning system
ejectors is supplied from the ejector lift pumps.
TECHNICAL CHARACTERISTICS
Parameters
Values
Ball diameter
25
Initial amount of balls for adjustment of equipment and in the first year of
condenser operation, pcs 100 000
Spare set of balls for three year operation period, pcs
200 000
Water pressure upstream of ejector, MPa
0.5
Water flow per ejector , m3 /h
80
Maximum velocity of water through BCD, m/s
3
BCD pressure loss, kPa
20
ND of BCD discharge pipe branch, mm
150
Quantity of water-jet ejectors to provide ball circulation through one group,
pcs 1
Quantity of loading chambers in a group, pcs
1
DEAERATOR AND FEED WATER
SYSTEM
DEAERATOR
PURPOSE

High-pressure steam deaerator with the 6000 t/h

capacity shall be a part of the turbo unit with 1000
MW capacity for NPP Kudankulam, India.

The deaerator is used for expulsion of corrosive

gases from feed water, for water heating under
typical, starting and transient operation modes of
the power generating unit, as well as for reserving
the feed water in the deaerator tank.
Weight and overall dimensions of the deaerator column :

Shell capacity, m3 150

diameter (conventional), mm 3000
length, mm 21780
weight, kg - 71500

Weight and overall dimensions of the deaerator tank :

Shell capacity, m3 - 400
diameter (conventional), mm 3800
length, mm 36000
weight, kg - 149200
BASIC ENGINEERING DATA

Operating, rated, excessive pressure,

MPa (kg f/cm2) 0,97 (9,91)
Specified temperature, 185,2
Deaerator rated output (design), tph 6000
Design heating of the deaerator water at the

Content of dissolved oxygen in the deaerated

water, mg/kg, no more than 10
Content of dissolved oxygen in the source water,
mg/kg, no more than 300
DEAERATOR DESIGN AND OPERATION
Turbine condensate (1) is fed to low-pressure water-distributing
device of the deaerator column (3), consisting of 4 spray atomizers
(2), splits into flushes and drops and pours down on the perforated
tray (4). Flows of periodic replenishment, those of auxiliary feedwater
pump recirculation and steam gen-erator blowdown are also fed to
this tray.
The water streams down through the openings of the upper tray to the
lower perforated tray (5) whence it proceeds to the lower part of the
column. It further pours down to the deaerator tank (6) through
branches connecting col-umn and the tank (7) and downpipes (8).
After having been exposed and treated in the bubbler, the deaerated
water is drained through the delivery unions (9).
 The main flow of heating steam is fed to the deaerator through
unions (10) located in the column bottoms and then proceeds
under the lower jet tray through the holes in the lower part of
the end baffles (false bottoms) (11). After that the steam
consecutively goes through the jet cascades streaming down
from the lower and upper trays and through those leaving the
atomizer. Going through the jet stages and the atomizing zone,
the steam becomes almost fully condensed while heating and
treating the source water (turbine condensate).
The residuary gas-vapor mixture (vented steam) is drained
through outlets (12) located in the upper part of the column.
 The bubbler consists of delivery line (13) and vertical
perforated pipes (14). The steam escaping from the
openings of the bubble pipes passes through
the sheet of water in the tank, thus treating and
reheating the water up to the saturation temperature.
After that this steam, together with that generated on
intake of the ebullient flows into the tank (high-pressure
heater condensate, drain water of separator-steam over
heater (SSOH), etc.) ventilates the tank
vapor space and is forwarded to the column through the
steam pipes (16) under the lower tray, where it mixes
with the main stream of the heating steam.
 The deaerator design is mainly based on well-
known engineering solutions proved in operation.
Jet device (spray atomizers) used as a water-
distributing device in the upper part of the column
provides for an additional
contact surface of the water and vapor phases in
order to improve the heat-mass exchange thus
increasing the efficiency of the deaerator column.
The required
level of water heating and deaeration is assured
by the use of two jet stages in the column and a
submerged bubbler in the tank.
FEED WATER SYSTEM
MAIN FEED WATER SYSTEM(LAB)

The feed water system is designed for:

- original steam generator fill in with feed
water;
- water supply to the steam generators to
provide their required steam capacity in the
modes of the normal operation and in the
modes of the disturbed operation;
- level maintaining in the steam generators;
- prevention of feed water supply in case of the
steam generators overtopping;
DESIGN PRINCIPLES
In the normal operation the system maintains the level
in the steam generators and supplies the feed water
into them.
In normal and partly abnormal mode the system is
responsible for the continuous supply of water into
steam generators with flow rate 300 - 6000 t/h through
the main control feed valves and with the flow rate not
less, than 350 t/h through bypass control valves with
pressure of the live steam downstream of the steam
generators 6,27 MPa. In the mode of the heat residues
removal one bypass line with a control valve shall
provide pass of water with flow-rate not less, than 150
t/h with live steam pressure 7,2 MPa downstream of
the steam generators.
DESCRIPTION OF THE SYSTEM

LAB system consists of two main feed turbo

pumps (2 50%), two stand-by motorized feed
pumps (2 25%), valves and pipework. In
addition the system comprises a hydraulic
turbo drive of the pump, which returns the
condensate of the heating steam directly into
the feed lines after the rotary air heaters (HPH).
The detailed information on this equipment is
given in the description of the turbo plant.
DESCRIPTION OF THE SYSTEM

Feed water coming out of the deaerator is delivered with

two feed turbo pumps (LAC10,20AP001,002) by two
individual suction and discharge pipelines into the
common manifold before the HP heaters. Further feed
water passes in two parallel lines of the HP heaters to
the second common manifold downstream of the HP
heaters, intended to equalize the temperature of the
feed water before the steam generators. From the
second manifold feed water goes in four lines to the
steam generators. A supply center is provided in each
line of the feed water. It consists of the main (Dn 400)
and by-pass (Dn 100) pipeline.
AUXILIARY FEEDWATER PIPING SYSTEM (LA)
The auxiliary feedwater system is provided to:
- supply steam generators with feedwater under normal
operation conditions: start-up (pre-start-up hydraulic tests,
heating of steam pipelines of a fresh steam), hot shutdown,
cooling down;
- supply steam generators with feedwater during operational
occurrences related to outage and a subsequent cool-down
in conditions of loss of normal heat removal via the
secondary circuit (via turbine condenser) and during loss of
power supply to the auxiliaries as well;
- supply steam generators with feedwater during failures that
are followed by restrictions of water supply from the main
feedwater pumps during power operation of the plant;
- ensure pre-start feedwater de-aeration (together with the
secondary de-aerator); - ensure steam generator additional
cooling under water to water conditions during plant outage.
 Design Basis

The system works:

- during normal operation (pre-start de-aeration, steam
generators filling, heating up from the cold state at a
rate of not more than 20 o/h, planned cooldown at a
rate of not more than 30 o/h);
- during operational occurrences related to restriction of
main power supply, loss of power supply to the
auxiliaries, loss of vacuum in the condenser.
During accidents at the plant the system operation is
not required. Nevertheless, if electric power supply is
maintained or restored from the common-plant Diesel
generator it can perform its function.
The system consists of one pump, valves and pipelines

The feedwater from the de-aerator ends is extracted by two

pipelines that further are combined into a common pump
suction line (LAJ00AP001) of the auxiliary feedwater (water
extraction from the ends is provided to reduce the
temperature difference across the de-aerator from top to
bottom during the de-aerator pre-start). On the pump suction
line the stop valve LAH01AA101 and mesh filter are
arranged. On the end of the pump pressure pipeline, a
distribution collector is arranged. Water from the collector via
four pipelines is supplied to the make-up assemblies of the
steam generators of the LAB system. The pipelines are
connected to the feeding assemblies through the bypass
lines. The system pump has a re-circulation (minimum flow
rate) line, connected to the deaeration column.
TURBINE DRIVEN FEED PUMP
 The feed turbo pump set consists of the driving
turbine of -10-5/3400 type, preliminary
(booster) pump P 3800-20-2 and main pump
P 3750-75-2. The both pumps are actuated
with one driving turbine. The preliminary
(booster) feed pump is driven from the second
end of the lines of shafts via the reducing gear.
PRELIMINARY (BOOSTER) PUMP

BOOSTER FEED WATER PUMP

(LAC10, 20AP001)

Booster feed water pump is a centrifugal

horizontal single stage pump with a
double entry impeller (suction). The end
shaft sealing is of the mechanical type.
PRELIMINARY (BOOSTER) PUMP
Performances and technical characteristics in
the nominal mode:
Delivery, m3/hour 3800
Head, m WC 170
Pressure at inlet, MPa 1,5
Power, kW 1783
Admissible NPSH, m WC. 16
Speed of rotation, rev/min 1602
PRELIMINARY (BOOSTER) PUMP
PUMP CASING

FEED WATER OUTLET

MECHANICAL SEAL

MECHANICAL SEAL

PLAIN BEARING

PLAIN BEARING

SHAFT

MECHANICAL MECHANICAL
SEAL
SEAL

FEED WATER OUTLET

FEED WATER INLET

MAIN FEED PUMP

MAIN FEED PUMP (LAC10, 20AP002)

The main feed pump is centrifugal horizontally

arranged 3-stage, double casing, two radial,
one thrust bearing with balancing piston and
end seal of mechanical type.
The bearings have forced lubrication
performed from the individual oil system.
MAIN FEED PUMP
Performances and technical characteristics of the
power efficiency in the rated mode:

Delivery, t/h 3750

Head, m WC 810
Pressure at inlet, MPa 1.5
Maximum allowable pressure at the outlet , MPa
11,76
Speed of rotation, rev/min 3500
Power, kW 8785
MAIN FEED PUMP
INTER STAGE SEAL
ELECTRIC DRIVEN FEED PUMP

STANDBY ELECTRIC FEED PUMP

(LAC30, 40AP001)
Standby electric feed pump PEA 1650-80-1 is
of centrifugal horizontal, 4-stage, double
casing, two plain bearing ,one thrust bearing
with the drum type hydro balancing and end
sealing of mechanical type.
The bearings have forced lubrication performed
from the individual oil system.
ELECTRIC DRIVEN FEED PUMP
Performances and technical characteristics of the
power efficiency in the rated mode:

Delivery, m3/h 1650

Head, m 910
Admissible pressure at the inlet, MPa 1,5
Maximum allowable pressure at outlet , Mpa
11,76
Admissible NPSH, m WC 12
Speed of rotation, rev/min 2979
Power consumed by the set, kW 4464
ELECTRIC DRIVEN FEED PUMP
INTER STAGE SEAL