Total Systems Approach to Condenser Oxygen Control as Applied to a Combined Cycle Cogeneration Power Plant

R. E. ATHEY, GRAHAM MANUFACTURING COMPANY, INC., BATAVIA, NEW YORK E. SPENCER, CONSULTANT, CRANBURY, NEW JERSEY

ABSTRACT multifaceted approach to condenser design was applied to the Gilroy Foods Cogeneration Plant in order to optimize oxygen control. This unique design incorporated the following components: A vacuum deaerator to remove noncondensible gases from the makeup water. The deaerator is connected to the condenser through steam piping and a return line to the hotwell A segregated condensate reheat hotwell to further deaerate the water from both the condenser and the vacuum deaerator. Steam injected into the hotwell reheats the condensate and acts to scrub out any reabsorbed gases; An enhanced venting system ensuring that whatever noncondensible gases are released will be removed and which maintains a low air partial pressure within the condenser.

removal of oxygen from condensate returns, and the problems inherent with the addition of significant amounts of makeup water saturated with oxygen are common to many power plant operations. All of these situations are aggravated during part load operations. The increasing need to run power plants (which are generally designed for base load operation on a cycling or twoshift basis has accentuated the necessity for the effective removal of noncondensible gases from the condenser. In addition to cogeneration plants of this type, district heating plants must also control dissolved oxygen in the condensate despite continuous large inputs of fresh makeup water. Damage to plant equipment from high levels of dissolved oxygen in the condensate water (especially during frequent startups in two-shift plants) can be partially controlled by proper condenser system design. The methods described in this paper can be applied to two-shift and cycling operation of base load power plants and to district heating stations, cogeneration plants, or any plant requiring deaeration of makeup water exceeding 3-5% of the total condenser steam flow rate. Several reports have discussed the problem of high dissolved oxygen in condensate water. Those that are of particular interest are the following: Reference 2 - Discusses venting system inadequacy and Henrys Law considerations; Reference 3 - Appraises USSR experiences and bubbler hotwells; Reference 4 - Provides a thorough discussion of many aspects of the dissolved oxygen problem, offering suggestions and potential solutions; Reference 5 - Gives a detailed discussion of why many venting systems in existing power plants simply are inadequate for proper dissolved oxygen control, and also are unable to maintain proper vacuum at off-design conditions.

INTRODUCTION Power plant designers, operators and manufacturers are only now beginning to appreciate the interrelationship between the condenser, the vacuum level, deaeration, and the system venting equipment. Low load operation with coincident low cooling water temperature requires a venting equipment modification to cope with operating pressures and increased water vapor carryover affecting both power train efficiency and condensate dissolved oxygen. The Gilroy Foods Cogeneration Project offered an opportunity to apply several concepts of improved oxygen removal in the steam condenser. This plant has a wide range of operating conditions including severe, coincident parameters of low condenser load, low incoming water temperature, and high makeup water flow to the unit. Stringent oxygen removal requirements will have to be maintained under all flow conditions. The bottoming cycle design for the Gilroy Foods plant, as proposed by Bechtel Western Power Corporation and described in Reference 1, utilizes no feedwater heating or separate deaerator. Thus, the cold water return to the heat recovery boiler extracts the maximum amount of energy from the gas turbine exhaust for improved cycle efficiency. However, the type of system required here is not useful only to this facility. The need for low dissolved oxygen, the elimination of a pressure deaerating heater, the

This paper will cover the design approach to the system, including the effect of cooling water temperature, condenser vacuum, vapor loading, condenser vapor subcooling, condenser load variation, air leakage, and excessive makeup water on the oxygen removal characteristics of the condenser. Test results on the deaerating device for Gilroy Foods are also included.

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THEORETICAL CONSIDERATIONS FOR OXYGEN CONTROL IN A CONDENSER It has been recognized that the performance of a surface condenser is dependent on numerous factors. The amount of noncondensible gases in the condenser tube bundle space is certainly one of the most important variables, since the amount of dissolved oxygen in the outlet condensate is related to the concentration in the vapor phase. In order to maintain a low concentration of dissolved oxygen in the outlet condensate, it is essential to: Reduce air intake to the condenser; a) as air inleakage b) dissolved in either makeup water or return condensate streams Minimize absorption of oxygen into the condensate; a) maintain low oxygen partial pressure inside the condenser b) prevent subcooling of the condensate Remove dissolved oxygen from the condensate by reheating to the saturation temperature corresponding to the pressure inside the condenser.

There are limitations to the effectiveness of a condenser operating in deaerating mode. Certainly the condenser designer can utilize proven techniques such as proper steam flow patterns, acceptable tubesheet occupied areas, and adequate steam lanes. However, the most important factor that can be manipulated is the partial pressure of noncondensible gases inside the unit. Henrys Law relates the amount of noncondensible gases which will dissolve in water to the mole fraction of each component in the vapor phase and to the temperature of the water. The reduction of dissolved oxygen in the condensate outlet water requires a low partial pressure in the vapor phase. This means that conditions inside the condenser shell must be maintained such that whatever oxygen is released is effectively removed by the vacuum system. It is recognized that a subcooled liquid will increasingly absorb gases. Good condenser design partially limits subcooling by using steam lanes, small surface area to condenser volume ratios, and a condenser tube bundle arrangement that promotes condensate reheat as it drips off the lower portion of the tube bundle prior to entering the hotwell. This all works well at, or near, base load design conditions. At partial load, however, less of the available condenser tube surface area is required to accomplish condensation and more area is available to subcool the descending condensate. Tube wall temperatures are lower (especially if the cooling water temperature is below design conditions), thus increasing the ability to subcool the condensate. In addition to the problem of excess condenser surface under reduced loading which leads to condensate subcooling, is that of undersized vent equipment. Any time the venting equipment cannot follow the condenser to its lowest attainable pressure, air will be retained in the condenser. Condensate on the tube surface will be colder than the temperature corresponding to the pressure maintained by the inadequate venting system. This point is graphically demonstrated in Figure 1(7) and described in Reference 5.

A significant factor toward these objectives is the elimination of noncondensible gases from the condenser. This involves a twostep process of release and removal. The need to minimize air leakage into the condenser requires constant vigilance. In cycling plants with load fluctuations causing temperature changes in the condenser (and at times increasing the portion of the power train subject to vacuum), and with thermal expansion and contraction continuously exposing new leak paths, prevention of leakage can become an overwhelming task. Reference 4 indicates that air leakage at low loads with coincident low temperature cooling water can be double the normal rate. The need to remove dissolved oxygen from makeup water is not as obvious. Little attention has been paid to this problem in the past since makeup requirements were seldom more than 3-5% of total condenser steam flow. Under base load conditions reasonable deaeration of makeup water occurs within the condenser. At partial loads, and during low temperature cooling water conditions, condenser deaeration capabilities decrease rapidly. When makeup needs reach 25-85%, as in the case of the Gilroy Foods installation, very special treatment is required. Condensation from a mixture of steam and noncondensible gases involves simultaneous heat and mass transfer from the gas phase to the condensate surface. This was recognized by Colburn and Hougen (6) who used film theory to predict local heat and mass transfer rates based on the gas phase thermal and molecular diffusivities for a binary vapor system. As the gas mixture becomes enriched in noncondensible gases, further condensation Of the steam is controlled by diffusion of the water molecules through the gas mixture. In order to enhance condensation, it is necessary to control both the noncondensible gas concentration and its distribution inside the condenser.

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To prevent this phenomenon, venting equipment selection must take into account the lowest anticipated condenser operating pressure and the greatest possible air leakage rate, as well as the limitation of the venting equipment itself. As the condenser pressure decreases, venting system capacity decreases while air leakage is increasing. Power plants generally have spare venting capacity available which can be used to compensate for the above condition. Depending on the type of venting equipment and actual air leakage rate, this may be sufficient to compensate for the offdesign conditions. In summary, the deaeration of water to a dissolved oxygen level of 0.005 cc/liter is difficult under ideal conditions, and impossible under many circumstances. Although literature supplied by condenser manufacturers has traditionally insisted that their systems meet this level of oxygen removal, actual testing has proven that this is not always the case. This is in line with the recognition that a steam condenser does not possess proper liquid/gas ratios, water retention time, sufficient contact area, etc. Also, any subcooling in the condenser is in direct opposition to the promotion of good deaeration. To solve this problem for the Gilroy Foods condenser, several modifications to conventional condenser design were employed: Because the condenser makeup requirements varied between 25-85% of total condenser flow, a separate deaerating device was designed to be an integral part of the main condenser. This device utilizes stripping steam from the condenser shell and returns deaerated water into the condenser hotwell at the same temperature and pressure as the main condensate flow; An oversized hybrid vacuum system was used to lower oxygen partial pressure inside the condenser; A condensate reheat hotwell decorator chamber was utilized to compensate for any condensate subcooling which might occur.

remains relatively constant. At times the seal water temperature within the pump will be higher than the attainable condensing temperature, and thus the venting equipment is inadequate and excess air is retained in the condenser.

INADEQUACY OF CONVENTIONAL TREATMENT This specific application is intended for use in a cogeneration system where approximately 13 of the boiler steam is consumed within the plant during normal operation. Under these circumstances the addition of makeup water containing up to 10 ppm of oxygen Into the condenser would result in an unacceptable concentration in the condensate leaving the condenser hotwell. It is apparent that additional deaeration is required. The advantages of removing oxygen from the makeup water in a separate deaerator section are: (1) the proper operating parameters can be developed, and (2) if operational changes dictate modification, the equipment affected is a small portion of the overall system. For these reasons it was decided to treat the incoming makeup water in a deaerator vessel connected to the main condenser, but functionally independent of it. Two traditional types of deaerators are available for this kind of application. These are (1) a thermal deaerator, and (2) a vacuum degasifier. Both types have characteristics that render them unsuitable for the specific job being considered. Conventional oxygen removal in a power plant environment utilizes a thermal deaerator operating under positive pressure, usually between 5-50 psig. This type of deaerator is desirable because the solubility of oxygen is at its lowest point at a water temperature of 228 F (corresponding to 5 psig pressure). However, the high temperature deaerated water would be unacceptable in the Gilroy Foods cycle, as previously discussed. Relying on a vacuum degasifier avoids the inherent problem of deaerated water at an elevated temperature, but does require more stringent deaerating conditions. Because a vacuum degasifier does not enjoy the use of stripping steam, it loses the scrubbing action that helps to drive the gases out of solution. It is extremely difficult to achieve a dissolved oxygen concentration of less than 0.035 cc/liter (50 ppb) using a vacuum degasifier. In addition, the outlet water temperature would be below that of the condensate in the hotwell. The possibility of operating a system with a combination of features from the two standard types of deaerators was considered. If steam from the main surface condenser could be used to heat the incoming makeup water while still under vacuum, the result would provide some scrubbing action and still not exceed the desired outlet water temperature. Venting of the noncondensable gases and water vapor would be through the use of an ejector system. The term vacuum deaerator will be used to designate this type of equipment.

Before describing these modifications in detail, it is important to discuss two other factors: (1) limitations to the vacuum system, and (2) the inadequacy of conventional deaerator/degasifier treatment systems.

VACUUM SYSTEM LIMITATION One type of vacuum equipment which has been highly favored in recent years has a fundamental limitation to its performance capability. It is not generally understood in the power industry that liquid ring vacuum pumps are limited as to the vacuum which can be achieved by the temperature of the leaving seal water. The seal water for liquid ring vacuum pumps used in power plants is usually cooled in a separate heat exchanger by the same cooling water entering the steam condenser. Because of this, the recirculated seal water can be warmer than the condenser water. Under part load conditions, the cooling water temperature rise in the condenser can be 10-20% of the design value. The water temperature rise through the liquid ring vacuum pump, however,

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VACUUM DEAERATOR DESCRIPTION Design parameters for the Gilroy Foods Cogeneration Plant were established by Bechtel Western Power Corporation in conjunction with Gilroy Energy Company. These design conditions were based on meeting four separate operating conditions. The most important parameters affecting the design of the vacuum deaerator, and the specified ranges, are: Makeup water flow rate: 140-230 gpm Makeup water temperature: 60 F Turbine back pressure: 0.68-3.19 inches Hg absolute Deaerated outlet water temperature: Saturation temperature at the condenser pressure (68-117 F) Noncondensible gases at inlet: Assume saturated at makeup water temperature Oxygen content of condenser hotwell water: 0.005 cc/liter

From the spray section the water falls through a vent-condenser chamber onto the packing. Steam from the main condenser heats the water to within a few degrees of the saturation temperature in this chamber and releases the majority of the noncondensible gases at this point. Steam velocities are such that the desired scrubbing action is accomplished. The remainder of the noncondensible gas removal is done in the packing section, where both contact area and residence time are achieved. The basic design approach was to use a high performance metal tower packing. Liquid/gas ratios were based on a percentage of flooding velocity. All materials in contact with the liberated oxygen were fabricated from stainless steels. Water that leaves the packing returns to the main condenser hotwell through the connecting piping. At this point the water has been degasified and is near the saturation temperature of the condenser. Noncondensible gases and water vapor from the vacuum deaerator are vented by a small booster ejector to the hybrid vacuum system. It is essential to have this independent venting arrangement in order to assure positive steam flow to the vacuum deaerator.

SEGREGATED CONDENSATE REHEAT HOTWELL DESCRIPTION Condensate rain from the condenser tube bundle sometimes subcools as it descends toward the hotwell. Reabsorption of noncondensible gases will occur under these conditions unless condensate reheat is promoted. In the Gilroy Foods system, degasified water from the vacuum deaerator joins with the condensate from the main condenser and is collected in a hotwell trough which runs the width of the condenser. The hotwell trough provides a submerged point for the deaerator water to discharge into and prevents backflow of steam into the deaerator. This water is then directed over a mesh pad where it is contacted countercurrently with fresh steam. The steam reheats the condensate and acts to scrub the gases out in the same manner as previously described for the vacuum deaerator. It should be emphasized that this final stage of deaeration is a polishing action only, and cannot be considered as a primary method of removing noncondensible gases from saturated makeup water.

The system that was designed to deaerate the makeup water is shown schematically in Figures 2 and 3. This system consists of the main condenser, the connecting vacuum deaerator, a separate condensate reheat region of the condenser, and an enhanced venting system. The deaerator is a self-supported vessel connected to the condenser through the steam piping and the return line to the hotwell. As illustrated in Figure 3, the packing operates in a countercurrent manner. Both noncondensible gases and water vapor are released and flow upward to the vapor outlet nozzle. It is important that the vacuum deaerator have a separate noncondensible gas removal system. Once the oxygen has been removed from the makeup water, venting it back into the main condenser would be a serious mistake. Water to be degasified enters at the top through a water box. In the first step of degasification the water is subdivided into small droplets. This is accomplished by spraying the water through selfadjusting spray valves which are designed to produce a uniform spray film under all conditions of load, and consequently a uniform gas removal is obtained.

ENHANCED VENTING SYSTEM In order to attain a low oxygen partial pressure inside the entire condenser under less than optimum conditions, it is necessary to use enhanced venting. The air removal system for Gilroy Foods was designed to remove approximately 10 times the amount of water vapor per pound of noncondensible gas relative to a typical installation. This is in accordance with the ratios suggested in Reference 2, and is in excess of HEI recommendations. The HEI approach utilizes the air subcooling section to reduce the load to

Surface Condenser Design, Installation, and Operating Experience - NE-Vol. 1

the venting system by subcooling the noncondensible gases in order to achieve a ratio of approximately 2.2 pounds of water vapor per pound of noncondensible gas. The Gilroy Foods Cogeneration Plant utilizes a hybrid vacuum system to remove the noncondensible gases and the large quantity of accompanying water vapor from the condenser. The hybrid system consists of a steam ejector discharging into a surface intercondenser, which is then exhausted into a liquid ring vacuum pump (Figure 2). This system eliminates the temperature limitation problem since the intercondenser and liquid ring pump are operated at the discharge temperature of the ejector and the seal water temperature is no longer limiting. This phenomena is described in Reference 5.

with the average at 10 ppb. This is essentially equivalent to 0.007 cc/liter. The deaerated makeup water will subsequently be blended with the condensate (containing essentially no dissolved oxygen) and then routed through the segregated reheat hotwell. Water leaving the condenser hotwell will have an oxygen content of less than 0.005 cc/liter.

SUMMARY A multifaceted approach to oxygen control in a condenser utilized several components. These include (1) a vacuum deaerator connected to the condenser to treat the large quantity of makeup water required by the system, (2) a segregated condensate reheat hotwell to strip any reabsorbed noncondensible gases from the condensate/deaerated water mixture, and (3) an enhanced venting system to effectively remove all noncondensible gases released in either the main condenser or the vacuum deaerator. The vacuum deaerator was tested and found to function satisfactorily. After the system reached equilibrium, the measured oxygen content of the outlet water averaged 10 ppb (0.007 cc/liter). This deaerated water is subsequently blended with the main condensate flow and reheated to drive off any reabsorbed gases. The vacuum deaerator, condenser, and vacuum equipment were shipped to the Gilroy Foods Cogeneration Plant, where installation is underway.

VACUUM DEAERATOR TESTING Because the vacuum deaerator/condenser concept is a unique application, it was necessary to test the full scale vacuum deaerator under actual operating conditions. A summary of the recorded data is given in Table I. The maximum throughput of water that was attained was 200 gpm. At an outlet temperature of 96 F, the steam flow rate was approximately 3160 pounds per hour. The result of the test was that the vacuum deaerator performance was successful. After the system reached equilibrium, the measured oxygen content of the outlet water ranged from 7-15 ppb,

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REFERENCES 1. Stanley, R.B., Case Study - Real Life Optimization of a 120 MW Combined Cycle Cogeneration Plant, Joint Power Generation Conference, October 4-8, 1987. EPRI NP-2294, Guide to the Design of Secondary Systems and Their Components to Minimize Oxygen-Induced Corrosion, Bechtel Group (S.W.S. Shor, et al), March 1982. EPRI NP-2448, Evaluation of Secondary Systems Oxygen Control in PWR Plants, Burns & Roe (I. Oliker, et al), June 1982. EPRI NP-3020, Evaluation and Improvement of PWR Secondary-System Oxygen Control Measures, Westinghouse Electric Corp., July 1983. ASME 84-JPGC-Pwr-32, Enhanced Condenser Venting for Condensate Oxygen Control, E. Spencer and A.M. Impagliazzo, 1984. Colburn, A.P. and Hougen, O.A., Design of Cooler Condensers for Mixtures of Vapors with Noncondensing Gases, Industrial and Engineering Chemistry, Vol. 26, November 1984, p. 1178. Harrington, R.L., et al, Marine Engineering, SNAME, 1971 Edition, p. 460.

SI UNITS CONVERSION CHART From F inches Hg lb GPM PSIG To C mm Hg kg M3/h KpA Action Subtract 32, Divide by 1.8 (F-32)/1.8 Multiply by 25.4 Multiply by 0.45359 Multiply by 0.2271 Multiply by 6.895

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