ASME PTC 12.2 – 2010 Steam Surface Condensers Performance Test Codes AN AMERICAN NATIONAL STANDARD Three Park Avenue † New York, NY † 10016 USA
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Their Components To Minimize Oxygen Induced. Corrosion”, EPRI NP-2294. [8]. “Steam Suace Condensers: Performance Test Codes”,. ASME PTC 12.2-2010 Revision of ASME PTC 12.2 -. 1998 (R2007). [9]. Richard E. Putman and Dr. Joseph W. Harpster, “The. Meas
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Troubleshooting Steam Surface Condensers
Troubleshooting Steam Surface Condensers HTS Forum 12 September 2012
Steam Condenser Troubleshooting What is a steam surface condenser? Troubleshooting tools Is there a problem? Fault diagnosis Locating air leaks Condenser monitoring
Condenser Vacuum Pumps Condensers are provided with vacuum pumps/ejectors The condenser creates the vacuum, NOT the vacuum pump Vacuum pumps are there to extract air and pump it up to atmospheric pressure A startup ejector (“hogger”) is provided to create a rough vacuum in order to start the turbine
Is There a Problem? Plant operator is typically concerned about turbine exhaust pressure First task is to establish whether the exhaust pressure is higher than expected Two issues: – The plant measurement may not be accurate – The turbine exhaust pressure will naturally vary with plant load and CW temperature
Identifying Faults Three most common causes of condenser performance problems: – Air accumulation in condenser – Cooling water fouling – Reduced cooling water flow
Unfortunately, all have the same effect on condenser performance: – Increase in turbine exhaust pressure
Condenser Temperature Profile Temperature, °C
Temperature approach
Tsat CW out
∆T
CW in
Condenser duty
Duty, kW
What is the response to the three most common faults?
No air Air “blanket” Steam condenses easily Steam must diffuse Minimal sub-cooling Sub-cooling The presence of air reduces the heat transfer rate
Fault Diagnosis To differentiate between the various causes of high turbine exhaust pressure, examine temperatures, not pressure: – CW flow reduction is indicated by increase in CW temperature rise – Fouling is indicated by increase in temperature approach (Tsat – CW out) – Air accumulation is indicated by increase in temperature approach and increased ∆T between Tsat and condensate temperature
Confirming and Fixing Faults Reduction in cooling water flow is caused by fouling or a pump fault Fouling can be confirmed by inspection (most condensers have divided waterboxes) Air accumulation is a more complex issue For air to accumulate: – Vent rate too low (vacuum pump fault) – Ingress rate too high (air leak)
Vacuum Pump Faults Generally rare, although original specification may be deficient For LRVPs check seal water temperature For steam ejectors check motive steam pressure (too high or too low) Detailed troubleshooting outside scope of this presentation
Air Leaks Some in-leakage is expected (hence the vacuum pump) Vacuum pump is usually over-specified (especially if to HEI Standard) Once excess capacity is used, any additional in-leakage will cause turbine exhaust pressure to rise Vacuum boundary must be maintained
Air Leakage Points Turbine burst disc Expansion joint
Tracer Gas Testing - Tips Always check the detector is working before you start Avoid false indications: – Helium: work from top to bottom – Halogen: work from bottom to top – Time the response
Consider testing under low load conditions: – The vacuum boundary is more extensive at low loads
Case Study 200MW electrical generation unit in Ireland High turbine exhaust pressure on startup after outage, close to turbine trip point Outage scope had included: – Condenser cleaning – LP turbine rotor removal
Heat balance indicates full CW flow Hotwell temperature inconclusive
Case Study - Actions Evidence suggests air leak High probability of leak at turbine shaft seals Helium testing ordered to confirm diagnosis: – – – –
Warranty issue Shutdown required to repair Which shaft seal is leaking? Other leaks?
Case Study - Results Leakage at both turbine shaft seals confirmed Additional leakage also found at: – Turbine bursting disc – Cracked weld on pipe – Plugged connection on condenser shell
Resolution of non-shaft leaks moved turbine pressure away from trip point without shutdown
Condenser Monitoring Critical situations can be avoided by regular monitoring Monitoring pressure not very useful Monitor key temperature differences: – (CW out – CW in) – (Tsat – CW out) – (Tsat – Thotwell)
Perform vacuum decay testing – Isolate vacuum pump and measure rate of pressure increase
