CONDENSER, ST COOLERS & LP HEATERS

STEAM TURBINE & AUXILIARIES

PART II A

BY

M.K.LAHOTI DGM(HXE)

N.P.MATHUR DGM(HXE)

HEAT EXCHANGER ENGINEERING BHEL HARDWAR

SURFACE CONDENSER

1.0

INTRODUCTION : Condenser is used to condense the exhaust steam from L. P. Cylinder of Steam Turbine and to produce the deepest possible vacuum in order to increase the heat drop and the turbine output. It also facilitates reuse of condensate thus obtained. CONDENSER (KWU DESIGN) : Optimum utilisation of steam space by providing rectangular cross section of tube-nest is an added feature of this condenser. For ensuring equitable loading of condenser tubes in the bottom rows without incurring appreciable steam side pressure drop, tubes have been segregated in small bunches leaving wide lanes between them. Tube bundle has been kept 1/2o inclined towards front water box for its self-draining during C.W. pump tripping and shut down. The condenser water chambers have provision for the isolation of half of the condenser for leak detection of tubes without tripping the plant. CONDENSER (LMW DESIGN) : This is a twin shell condenser, each connected with exhaust part of low pressure casing. A bypass branch pipe interconnects the two shells. Special feature of this condenser is the tube layout which has been evolved after a long and intensive research work in laboratories with a view to ensure efficient heat transfer from steam to cooling water flowing through the tubes. Bowing of tubes has been used for its self-draining during C.W. pump tripping and shut down.

2.0

CONSTRUCTION : CONDENSER (KWU DESIGN) : It is a rectangular surface condenser having suitably stiffened dome, consisting of stiffening pipes, welded on either side with the opposite side wall of dome shell. Except tubes, the remaining construction is of fabricated type. The tubes have been expanded into main tube plates and are supported by the tube support plates at intermittent points to prevent their sagging and to curb the flow induced vibrations. Non-condensable

gases are continuously extracted in order to maintain vacuum in the condenser. Water box removal/handling arrangement has been provided to facilitate the removal of covers for enabling re-tubing and cleaning of tubes etc. Water boxes are further provided with suitable manholes for carrying out maintenance works without removing them. Water box inside surface and circulating water side of water chamber including carbon steel main tube plates have been protected against corrosion by application of protective coating over the surface in contact with cooling water. LP Heater No. 1 has been installed inside the condenser neck (mainly in 500 MW sets) to save floor spare and piping cost. Two numbers Steam throw devices have been provided in each condenser for dumping steam during start-up and sudden load throw off. Steam dumping system is designed for continuous operation with 60% by-pass load. CONDENSER (LMW DESIGN) : Each condenser shell has been divided into upper and lower parts. Front water box, shell and rear water box constitute the lower part. Two tube plates and six support plates are located inside the lower body of the condenser. Front water boxes have been divided into two parts to make the condenser two pass. End cover of water boxes is kept removable for facilitating repairs and replacement of tubes. Manholes have been provided for routine maintenance and visual inspection. Condenser tubes are secured to the end tube plates by expanding and flaring of tube ends which provides good sealing against entry of cooling water into steam space. The tubes have been so arranged that there is equal distribution of steam on the tube nest with minimum pressure drop. With a view to allow relative expansion between tubes and the body of lower part, lens type compensator has been provided in the body itself at the rear water box end. The arrangement prevents deformation of the body and damage to joint between tube and end tube plate. Upper part of condenser has been designed to allow smooth flow of steam over tube nest. It consists of steel flat walls strengthened from inside by gratings of longitudinal and transverse rods and from outside by channels. These rigid bars help the condenser to retain its shape against

atmospheric pressure. Bellow has been provided in upper part to take care of relative expansion between turbine and condenser. Two sections of Low pressure heater no. 1 have also been located inside the upper part of condenser. Condenser is supported on springs in order to allow expansion along the height. The weight of condenser is taken by the springs whereas weight of CW and condensate collected in hotwell as well as the thrust of springs during operation is transferred to turbine foundation. Steam throw device has been incorporated in each condenser for dumping of steam into condenser during start up and sudden load throw off. Steam dumping system is suitable for continuous operation with 30% by-pass load. 3.0 OPERATION REGIMES : Condenser back pressure at rated conditions with clean tubes is normally as follows : 76 mm Hga with CW inlet temperature of 33 o C and 89 mm Hga with CW inlet temperature of 36 o C. Back pressure changes with change in water inlet temperature. CW temperature rise across condenser is normally kept as 8-10 o C and TTD as 4-5 o C. When we add up CW inlet temperature, temp. rise across condenser and TTD we arrive at saturation temp. of steam in condenser. Condenser back pressure can be further worked out for the saturation temperature of steam by referring to steam table. The available back pressure of condenser can be compared with the calculated back pressure to know the health of condenser. Further, CW side pressure drop across condenser varies depending upon tube length, water velocity in tubes, cleanliness of tube etc. Higher pressure drop in condenser indicates fouling of tubes. 4.0 CRITICAL COMPONENTS : (i) (ii) (iii) (iv) (v) 5.0 Tubes Tube plates Rubber cord Bellows, Springs Steam throw device

FAILURE MECHANISM : (i) Tubes : Erosion/corrosion/fouling of tubes caused by poor maintenance / non-operation of COLTCS / poor quality of cooling water resulting in poor condenser vacuum / frequent shut downs due to tube failures.

(ii) (iii) (iv) (v) (vi) (vii) (viii) 6.0

Tube plates : Corrosion/pitting of tube plates and other surfaces coming in contact with raw water. Damage to surface of tube plate during re-expansion of tubes. Damage to protective coating / lining in water boxes. Cracks in Bellows/Springs which are constantly expanding/ contracting. Cracks/pitting of weld joints. Deformation of rubber cord. Erosion of Steam throw device holes. Mechanical damage to condenser internals and other stressed components.

CONDITION ASSESSMENT : (i) Condenser tubes : Visual examination to assess tube condition such as discoloration, bending/deformation and fouling. Hydraulic test / Water fill test to identify tube failure and reexpansion work. Eddy Current Testing (ECT) of approx. 10 % tubes of condenser, especially if history indicates frequent tube replacements.

(ii)

Water Boxes, Water chamber and Tube Plates : Visual inspection of tube plate for any mechanical damage or corrosion marks. Visual inspection of water box, water chamber walls for corrosion, pitting and condition of protective coating/painting. Visual inspection of all weld seams on internal and external surfaces. DPT / 10% UT of welds. Visual examination of bolts/fasteners for any damage, sample hardness/microstructure test for their strength.

(iii)

Shell Internals, Stiffening pipes / Rods : Visual inspection of tube bundle for bending or any other type of damage to baffles, tube hole and tube interface area for any mechanical damage etc. Visual inspection of weld joints, tie rods / stiffening pipe / rod joints etc. Visual inspection of air ducts / air pipes & their seal welds. DPT / 10% UT of welds depending upon their requirement.

(iv)

Bellows, Springs, STD holes : Visual inspection of bellows, welding joint of involutes, spring elements, spring cages, STD holes, dimensional check of springs. DPT / 10% UT of bellow joints.

(v)

Condenser vacuum : Water fill test of condenser steam space. Helium Leak Detection of vacuum system.

MULTI-FREQUENCY EDDY CURRENT TESTING (ECT) Eddy Current Testing is based on inducing electric currents in a conducting material using a high frequency alternating current through a coil. The changing magnetic field induces circular currents known as eddy currents in the job. Magnetic field produced by eddy currents opposes the primary magnetic field which gives rise to change in impedance. Surface defects such as cracks, pits, change in dimensions alter the eddy current pattern. These variations are electro-magnetically decoded to produce the flaw pattern in the material. ECT has been widely used world over to assess tube condition and integrity, especially the remaining wall thickness. The ECT System essentially consists of multi-frequency eddy current generator, a transducer, a pneumatically driven probe driver mechanism for travel into the tubes, signal recorder, software, calibrated probes etc. The failure signals received during eddy current testing in-situ is marred by signals picked up from the interface surfaces of tube and support plate. By employing multi frequency testing technique, such additional signals are neutralized producing accurate and true results of defects.

HELIUM LEAK DETECTION TECHNIQUE Various methods are being / have been adopted by power station maintenance engineers for arresting air leakage. Water fill tests, smoke test, steam pressure test, ultrasonic test, freon tests are some of the common ones. However, each is associated with one or the other deficiencies and therefore are not independently effective. For example, the water fill test requires a shut down of the unit and incase of an error, cannot be repeated; it requires large amount of DM water and can be less effective if stations other water systems are also leaking. Also, due to environmental regulations, some of these are banned.

Helium Leak Test is practically found to be the most sensitive and convenient method. As the detection can be conducted during operation of the TG Set, it is repeatable and therefore finds favour with O&M staff. Use of helium is VACUUM EXHAUST TO

AIR, VAPOUR & HELIUM FROM CONDENSER

PROBE

BASIC very sensitive. The test kit includes a base unit which is complete with helium sensor, probe, helium pump, LCD indicators, console, power unit etc; portable leak indicator integral with spray arrangement and portable HELIUM LEAK DETECTION (remote) receiver. Helium is advantageous because it is non toxic, non inflammable, relatively inexpensive and quickly diffuses through small leaks. In addition, helium is non reactive with other chemicals and its very low presence in atmosphere, makes leak detection The process of leak detection is carried out during operation of TG set. No specific preparation is required before the test. The helium detector is placed near the vacuum pump / ejector with detector probe connected to their (air evacuating devices) exhaust. The portable indicator is connected to a portable helium cylinder while the remote sensor is fastened to the belt of the personnel carrying the indicator. Alternately, welding torch with extra long hoses is connected to helium cylinders and carried along for spraying the gas at the suspected joints / parts. As helium is lighter than air, spraying commences from the operating floor such as the L P T joints, glands moving down to lower floors till the ground / condenser level is very sensitive. The test kit includes a base unit which is complete with helium sensor, probe, helium pump, LCD indicators, console, power unit etc; portable leak indicator integral with spray arrangement and portable (remote) receiver. Helium is advantageous because it is non toxic, non inflammable, relatively inexpensive and quickly diffuses through small leaks. In addition, helium is non reactive with other chemicals and its very low presence in atmosphere, makes leak detection nonvenient. The process of leak detection is carried out during operation of TG set. No specific preparation is required before the test. The helium detector is placed near the vacuum pump / ejector with detector probe connected to their (air evacuating devices) exhaust. The portable indicator is connected to a portable helium cylinder while the remote sensor is fastened to the belt of the personnel carrying the indicator. Alternately, welding torch with extra long hoses is connected to helium cylinders and carried along for spraying

the gas at the suspected joints / parts. As helium is lighter than air, spraying commences from the operating floor such as the L P T joints, glands moving down to lower floors till the ground / condenser level is reached. Sprayed helium enters the vacuum system along with the air and travels into condenser, to the vacuum pump / ejector and finally exhausted into atmosphere. Here, the probe of the detector allows part of the mixture to get sucked towards the base unit where the helium is sensed and a signal is received both in the base unit and the remote unit. This helps the operator to cover a large area with ease. The time taken by helium to travel from being sprayed till receive of signal, is 20 30 seconds. Advantages : The following are benefits of adopting helium leak test : 7.0 Detects the smallest of air leakage thus improving condenser vacuum. Possible to carry-out test during unit operation; shutdown not required. Minimum manpower required; two persons are sufficient. Attending leakage and simultaneous retest possible to gauge effectiveness. Conducting test is economical.

R&M AND LIFE EXTENSION : Based on 6.0 as above a comprehensive component material defect information is generated. This is compared with and supplemented by operational and historical data. Wherever applicable, mechanical and thermal calculations are also performed to assess remaining life. The above analysis shall form the basis for redesign, replacement and repair in order to meet improved performance and life expectancy. The RLA study will also bring out the need to have better maintenance and inspection schedules. *****

CONDENSER (LMW DESIGN)

CONDENSER (LMW DESIGN)

S.T. COOLERS
TURBINE OIL COOLER (210/250/500 MW) & CONTROL FLUID COOLERS (500 MW) 1.0 INTRODUCTION : TURBINE OIL COOLER: The function of the oil cooler in the bearing oil circuit is to cool the oil used for lubricating and cooling the turbine/generator bearings. CONTROL FLUID COOLER: The function of the control fluid cooler is to cool the control fluid used for the control system of turbine. 2.0 CONSTRUCTION : TURBINE OIL COOLER: Essentially, the oil cooler consists of tube-nest, inner and outer casings, upper and lower water boxes. The oil to be cooled enters the cooler outer casing through the inlet nozzle at the top, flows to the inner casing, and through the disc and doughnut baffle openings. The baffles are held in position by spacers mounted on steel rods. This arrangement forces the oil to follow a cross flow pattern while flowing to the outlet nozzle at the bottom. The inner casing, holding the doughnut baffles, is in two halves, bolted together and is attached to the lower tube plate by screws. Tubes are roller expanded in the tube plates. The lower water box, with partition between cooling water inlet and outlet branches, is bolted with the shell flange and lower tube plates. The tube nest is free to expand upwards due to differential thermal expansion. Dummy rods have been provided in the tube nest in line with the partition wall to check oil bypassing within the tube nest. CONTROL FLUID COOLER: The cooler consists of tube-nest, shell & upper and lower water boxes. The fluid to be cooled enters the cooler shell through the inlet nozzle at the top and flows through the baffles. The baffles are held in position by spacers mounted on steel rods. This arrangement forces the fluid to follow a cross flow pattern while flowing to the outlet nozzle at the bottom. Tubes are roller expanded in the tube plates.

The lower water box with partition between cooling water inlet and outlet branches, is bolted with the shell flange and lower tube plates. The tube nest is free to expand upwards due to differential thermal expansion. 3.0 OPERATION REGIMES : Each TG set is provided with 2X100% coolers. While one cooler is put in operation the other one remains as stand-by. Oil cooler is designed with temperature of oil at inlet to cooler as 65 oC and 45oC at outlet. These temperatures are 55 oC and 45oC respectively for LMW set. Control fluid cooler is designed with temperature of fluid at inlet to cooler as 55oC and 49oC at outlet. 4.0 CRITICAL COMPONENTS : (i) (ii) (iii) 5.0 Rubber O-rings Cooling tubes Tube plates

FAILURE MECHANISM : (ix) O-rings : These are provided between parting planes for sealing purpose and get damaged due to wear & tear. Whenever the cooler is disassembled for attending to leakage or servicing, these are to be replaced. Tubes : Erosion/corrosion of tubes is caused by poor maintenance / poor quality of cooling water resulting in tube failure. Tube plates : Corrosion/pitting of tube plates coming in contact with raw water. Damage to surface of tube plate during re-expansion of tubes. Poor maintenance of water box internal surface / protective coating.

(x) (xi)

6.0

CONDITION ASSESSMENT : (i) (ii) (iii) (iv) (v) (vi) Visual examination to assess tube condition such as discoloration, bending/deformation and fouling. Hydraulic test to identify tube failure and re-expansion work. Visual inspection of tube plate for any mechanical damage or corrosion marks. Visual inspection of water box for corrosion, pitting and condition of protective coating/painting. Visual inspection of all weld seams on internal and external surfaces. DPT / 10% UT of welds depending upon their requirement.

(vii) (viii)

Visual examination of bolts/fasteners for any damage, sample hardness/microstructure test for their strength. Visual inspection of tube bundle for bending or any other type of damage to baffles, tube hole and tube interface area for mechanical damage etc.

8.0

R&M AND LIFE EXTENSION : Based on 6.0 as above a comprehensive component material defect information is generated. This is compared with and supplemented by operational and historical data. Wherever applicable, mechanical and thermal calculations are also performed to assess remaining life. The above analysis shall form the basis for redesign, replacement and repair in order to meet improved performance and life expectancy. The RLA study will also bring out the need to have better maintenance and inspection schedules.

L.P.HEATERS (210/250/500 MW)

1.0 INTRODUCTION : L P Heaters are employed in regenerative feed heating cycle of Turbine. Their function is to heat up the condensate flowing through the tubes by using the heat of extracted steam on shell side so as to improve the overall cycle efficiency. 2.0 CONSTRUCTION : Two types of LP Heater designs generally are provided i.e. Vertical LP Heaters and Horizontal LP Heaters based on layout requirement of power station. Where as vertical LP Heaters have been provided only in 210 MW thermal sets, horizontal LP Heaters are being provided in 210 / 250 / 500 MW sets due to their better design features. 2.1 VERTICAL LP HEATER: This type of heater is vertically mounted, with bolted joint between shell, tube system and water box, which enables the withdrawal of tube bundle for maintenance work by dismantling the bolted joint. Shell is made of carbon steel with cylindrical construction that accommodates steam inlet, shell drains, drains inlet from higher heater, shell vent and shell relief valve connections. Dished end welded at lower end and upper end is provided with flange which is bolted with tube plate and water box. Steam inlet connection is kept near upper end of shell. Supports are also provided for vertical mounting of heater. Tube nest consists of Admiralty Brass U-tubes for LP Heater No.1&2 and 90/10 Cu-Ni U-tubes for LP Heater No.3, Carbon steel tube plate, baffles, impingement baffles for steam inlet and drain inlet. Tubes are rollerexpanded in tube plate holes. Suitable arrangement is provided for continuous venting of non-condensable which ensures efficient use of surface area provided. Impingement plate is provided at the steam inlet connection to avoid direct impingement of steam on the tubes. Water box is welded carbon steel construction provided with dished end at upper end. Pass partitions are welded in water box to make it a four-pass design. Condensate inlet and outlet connections are provided on water box. Sentinel type water expansion valve is provided to protect the heater against excessive pressure. Suitable lifting lugs are provided for handling of water box and heater assembly.

2.2 HORIZONTAL LP HEATER: This type of heater is horizontally mounted, with shell welded to the tube plate through a skirt. Instead of tube bundle withdrawal, shell withdrawal is provided for major maintenance work for which a shell cutting-line is provided. Carbon steel cylindrical shell is completely welded type that accommodates steam inlet, shell drains, drains inlet from higher heater, shell vent and shell relief valve connections. Dished end is welded at one end and other end is welded with tube plate through shell skirt. Steam inlet connection is kept at thermal balance of tube Nest. Lugs are provided for transportation and lifting during its withdrawal. Tube nest consists of welded stainless steel U-tubes to ASTM-A688 TP304, Carbon steel tube plate, baffles, impingement baffles for steam inlet and drain inlet. Tubes are roller-expanded in steel tube plate holes. For best utilization of tube surface, central air duct is provided for continuous venting of non-condensable. With central air ducting, steam from all round is directed to center, thus air blanketing is avoided. A short skirt, which form part of shell during assembly, is welded to tube plate. Stainless steel ring is welded over the tube nest at the location of shell cutting to avoid approach of flame at the tubes while shell cutting. Water box of carbon steel plate is welded to tube plate on the other side. Pass partition is welded to tube plate on one side and bolted to inner cover on other side, so that tube plate is accessible for plugging and inspection. Suitable supports are provided for mounting of heater. 3.0 OPERATION REGIMES : Four LP Heaters are provided in 210 MW Russian variant, i.e. LP Heater No. 1,2,3 and 4 where as three LP Heaters are provided in 210 / 250 / 500 MW KWU variant, i.e. Heater No. 1,2 & 3. Heater No. 1 may be provided inside or outside the condenser dome based on layout of the power station however LP Heater No. 1 for 500 MW set is invariably provided in condenser dome. Shell side of LP Heaters is designed for 7.0 Kg/cm 2 (g) & 3.5 Kg/cm2 (g) pressure for Russian & KWU sets respectively. The tube side design pressure corresponds to shut off head of the condensate extraction pump. A typical value of temperature rise of condensate between lowest LP Heater and highest LP Heater is given as below: 500 MW set: 480 C to 123.50 C (from LPH-1 inlet to LPH-3 outlet)

210 MW/250 MW (KWU): 48.50 C to 1210 C (from LPH-1 inlet to LPH-3 outlet) 210 MW (Russian): 51.50 C to 1570 C (from LPH-1 inlet to LPH-4 outlet) 4.0 CRITICAL COMPONENTS: (i) Tube bundle (Vertical LP Heaters with non-ferrous tubes specially with admiralty brass tubes. Tube bundle in horizontal heaters with welded SS tubes though critical in application but no failure has been reported so far from any site indicates better reliability and rather maintenance free operation of horizontal design.)

5.0 FAILURE MECHANISM: (i) Erosion / corrosion of non-ferrous tubes (mainly admiralty brass tubes) is caused under following circumstances : a) During by passing of one the heater in the chain, additional flows are coming to heater under operation leading to higher steam velocities resulting in tube failure. b) Dezincification of admiralty brass tube is caused due to copper pick leading to tube failures. c) In case parameters of extraction steam (especially in LPH-4 of Russian variant) are not properly controlled then it will expose the tubes to high temperature leading to tube failure. (ii) (iii) Tube failure may also be caused due to excessive vibration under reasons given at (i) a) and (i) c) above. Wear and tear and mechanical damages are also reasons of failure of tubes and other components e.g. baffles etc.

6.0 CONDITION ASSESMENT : (i) (ii) (iii) (iv) (v) (vi) Visual inspection of tube bundle for failure/damage of tubes and damage to other parts e.g. baffles etc. Hydraulic testing to identify tube failure and plugging of failed tubes. Visual inspection of tube plate for any mechanical damage. Visual inspection of water box and shell internal surfaces for any damage. Visual inspection of all weld-seams. DPT of weld seams to assess soundness of the welds.

7.0

R&M AND LIFE EXTENSION : Based on 6.0 as above a comprehensive component material defect information is generated. This is compared with and supplemented by operational and historical data. Wherever applicable, mechanical and thermal calculations are also performed to assess remaining life. The above analysis shall form the basis for redesign, replacement and repair in order to meet improved performance and life expectancy. The RLA study will also bring out the need to have better maintenance and inspection schedules.