Test Procedure

8.4 Condenser Performance Test

Table of Contents

Sr. No. Contents

8.4.1 Introduction

8.4.2 Objectives

8.4.3 Plant Specific Data

8.4.4 Test Procedure

8.4.5 References

8.4- 1
8.4 CONDENSER PERFORMANCE TEST

8.4.1 Introduction

Steam after doing its useful work in the turbine, is dumped into the condenser
for condensation and further recycling. The amount of work that can be
extracted from the steam in the turbine will be more if the condenser
performance is better. Monitoring of condenser performance assumes much
significance because of this.

8.4.2 Objective

This test procedure shall determine the condenser performance with regard to
one or more performance indices as follows.
i Absolute Back Pressure Deviation from Expected Valve.
ii Effect on Heat Rate deviation and its Financial Implications
iii Terminal Temperature Difference (TTD).
iv Sub-cooling of Air-steam Mixture and Condensate.
v Effectiveness of Cleaning the Tubes.
vi Circulating Water Temperature Rise.
vii Flow of Air-steam Mixture.
viii Effects of Physical Changes in the Condenser like New Tubes, etc.
ix Circulating Water Velocity in Tubes.

8.4.3 Plant Specific Data and Characteristics

i Condenser Design Data as per Format 8.4.1

ii Heat Load Vs. Condenser Back Pressure for Different C.W Inlet
temperature

iii Generator Loss curve

iv VWO Heat Balance

8.4.4 Test Procedure

8.4.4.1 Instrumentation
The Instrumentation required for conducting performance test are :
( Refer to sketch given below – Fig- 8.4.1 & Fig 8.4.2)

8.4- 2
i Condenser Back Pressure (L&R)
ii CW Inlet Temperature (L&R)
iii CW Outlet Temperature (L&R)
iv Condensate temperature
v Air-steam mixture temperature (L&R)
vi Water box differential pressure (L&R)
vii CW flow

TYPICAL CONDENSER INSTRUMENTATION

STEAM INLET NON-CONDENSABLE

OUTLET T
F

P
NON-COND.
AIR/VAPOR REMOVAL
OUTLET SYSTEM

P P P
W W

CONDENSATE W T

LEVEL
P
P
∆ P)
(∆
WATER OUTLET

CIRCULATING
WATER INLET

∆ P)
(∆ T
CIRCULATING

DO S
CONDENSATE
LEVEL F PERF. TEST
T 4 Nos. CONNECTION
F = FLOW MEASUREMENT T = TEMPERATURE MEASUREMENT SUPPLEMENTAL
W = WATER LEVEL MEASUREMENT DO= DISSOLVED OXYGEN MEASUREMENT TEST CONNECTION
P = PRESSURE MEASUREMENT S = SALINITY MEASUREMENT

Fig-8.4.1

8.4- 3
 Condenser BackPressure andCWInlet / Outlet Temperature Measurement

ATOPERATING
FLOOR.

~~

Side View Plan

Tapping Arrangement for Measurement
of Condenser BackPressure
Note: 1. Tapping maybe kept nearer
to LPCand Condenser joint.
2. Near tappingno protruding
obstructionexist.
Note: 1 Slope of impulse line
kept towards condenser.
2. Two separate grid to be brought
at operatingfloor for installation
of two absolute pressure
transmitters.

C. W. Inlet / Outlet Temp. Measurement

300 – tohave
glass thermometer

TWat 900 angle Detail ‘A’

Detail ‘A’

Note:
1. Four Nos. thermowell tobe provided on each
CWOutlet line at a location convenient to
CWOutlet CWInlet use from‘0’ meter.
2. One No. thermowell on each CWInlet line.
3. thermowell approx. A nnexure
300 mmdepth -V

Fig-8.4.2

8.4- 4
8.4.4.2 Test Set Up

i Ensure that condenser water box is full of water by operating water

box vents.

ii Unit should be in operation at normal full load in steady state

condition.

iii Effort should be made to conduct the test runs close to normal
operating parameters.

iv Ensure that unit is operating under specified cycle condition, for

example, cascading of H.P heater drip to deaerator.

v No make up should be taken during test.

vi High energy drains passing if any to be attended/recorded.

vii As far as possible, the condenser hot well level should be kept
constant.

viii The condenser C.W. outlet valves should be set at 100% open or as
wide as possible maintaining a full water box.

ix Make notes of any abnormal conditions pertaining to the test.

8.4.4.3 Duration of Test and frequency of readings

i. Form a data group in the DAS for Data collection during the test (see
format 8.4.2).
ii. Each test must be conducted for about 30 min for the purposes of
data collection.
iii.The frequency of data collection in DAS should be 1 min or minimum
possible to achieve, depending upon the data collection rate of DAS.

8.4.4.4 CW Flow Measurement

CW Flow measurement can be determined

i By pitot survey in the CW outlet / inlet duct
ii By Calculation of Condenser Heat Load and thereby CW flow

8.4- 5
It is recommended to use pitot traverse for determining CW flow The procedure
for measurement for computation of CW flow using pitot is given in the CT test
procedure in section 8.5. However in case pitot is under procurement, till then
condenser heat load method may be used to arrive at CW flow.
If Condenser Heat load method will be used for CW flow calculation, the
condenser performance test may be done along with GTCHR so that same data
can be used for condenser heat load calculation.(see format-8.4.3)

8.4.4.4.1 Determination of Condenser Duty

Condenser Duty = (Heat Added MS + Heat added by SH Attemperation +

Heat Added CRH + Heat added by BFP + Heat added
by RH Attemperation) - 860 (Pgen + Pgen Losses +
Heat Loss rad.)
Where:
Cond.Duty = kcal/hr

Heat Added MS
= Flow MS * (hMS - hFW), kcal/hr
Flow MS = (Flow Main Steam excluding SH Attemp ), kg/hr
hMS = (Enthalpy of Main Steam), kcal/kg
hFW = (Enthalpy of Feed water), kcal/kg
Heat Added CRH
= Flow CRH* (hHRH - hCRH),kcal/hr
Flow CRH = Flow Cold Reheat Steam, kg/hr
hHRH = (Enthalpy of Hot Reheat Steam), kcal/kg
hCRH = (Enthalpy of Cold Reheat Steam), kcal/kg

Heat Added by BFP

= Flow FW*(hBFP Out-hBFPIn) Kcal/hr
Flow FW = Total FW flow kg/hr
hBFP Out = (Enthalpy of FW at BFP Outlet), Kcal/kg
hBFP In = (Enthalpy of FW at BFP Inlet), Kcal/kg

Heat added by RH Attemp

= Flow RH Attemp * (hHRH-hRHATT) Kcal/hr

hRHATT = (Enthalpy of RH Attemp ), Kcal/kg
Flow RH Attemp = Kg/hr

Heat added by SH Attemp

= Flow SH Attemp* (hMS-hSHATT) Kcal/hr

hSHATT = (Enthalpy of SH Attemp ), Kcal/kg
Flow SH Attemp = Kg/hr
Heat Loss rad = 0.1% of Pgen (Radiation Losses) kW

8.4- 6
Pgen = (Gross Generator Output), kW
Pgen Losses* = (Mech Losses + Iron Losses +Stator Current Losses),
kW

* Values to be taken from Generator Loss Curve

8.4.4.4.2 Determination of CW Flow:

Cond Duty
CW Flow = ------------------------------ m3/hr
Cp (Tout – Tin) x •

Where:
C.W Flow = m3/hr
Cond Duty = kcal/hr
Cp = 1 kcal/kg o C (Specific heat of water)
• = 1000 kg/cubic meter (Density of water)
o
Tout = C (Average C.W Outlet temp.)
o
Tin = C (Average C.W Inlet temp.)

8.4.4.5 Water Velocity in Condenser Tube

Tube Velocity

C.W Flow Rate x 106

= ----------------------------------------------------------------------------------
3600 x Tube Area x (No of Tubes – No of Tube Plugged)

Where:
Tube Velocity = m/sec
3
C.W Flow Rate = m /hr
Tube Area = mm2 (Cross sectional area of water flow
Passage)

8.4.4.6 Determination actual Log Mean Temperature Difference (LMTD):

Tout - Tin
LMTD = -------------------
Tsat – Tin
Ln ----------
Tsat – Tout

Where:

LMTD = oC

8.4- 7
 o
Tsat = C (saturation temperature corresponding to condenser
back pressure)

8.4.4.7 Determination of Expected LMTD :

* Correction for C.W. inlet temperature (ft)

| Saturation Temp Test - LMTD test |¼

ft = | ------------------------------------------------ |
| Saturation Temp Design - LMTD design |

* Correction for C.W. flow (fw)

| Tube velocity test | 1/2

fw = | ----------------------- |
| Tube velocity design |

*Correction for condenser heat load (fq)

Cond. duty design

fq = ------------------------
Cond. duty test

*Expected LMTD
o
LMTD expected = LMTD test x ft x fw x fq C

8.4.4.8 Determination of Expected Saturation Temperature:

[Tin – Tout x eZ]

Sat. Temp. Expected: = --------------------------- oC
[1 - eZ]

Where:

Tin = Design C.W. inlet temp.

Tour = Design C.W. outlet temp.

Tout – Tin
Z = --------------------
Expected LMTD

8.4- 8
Expected Back Pressure = Derived from Steam Table Corresponding to
expected Saturation Temperature

8.4.4.9 Determination of Breakup of Condenser Back Pressure Deviation:

On arriving at the backpressure deviation with respect to expected

backpressure, the following steps shall be adopted for calculating its break up,
i.e., deviation due to C.W. inlet temp, C.W. flow and effect of air ingress/dirty
tubes.

a) From design data develop a graph for a range of loads for optimum C.W.
temperature rise and TTD (Curve-II).
b) From curve-II generate another curve (load Vs BP) for different CW inlet
temperatures likely to occur as per various seasons. This curve is used to
derive expected BP for any load and for any probable CW inlet temperature
(Curve-I).
c) For computing the deviation refer the table given in Format 8.4.4

Sample test report format is given in format 8.4.5

8.4.5 References

ASME Performance Test code 12.2-1988 on steam surface Condensers.

ASME Performance Test Code 19.2-1987, Pressure Measurement
ASME Performance Test Code 19.3-1974, Temperature Measurement.

8.4- 9
CONDENSER DESIGN DATA

Station: ...................... Unit: .........................

DESCRIPTION UNITS VALUE

Unit Name Plate Rating

Number of Passes Number

Heat Load Considered for Design

(Condenser Duty) kcal/hr

Condenser Flow m3/hr

Condenser Vacuum with CW Inlet Temp.

mm Hg
Tube Length Between Tube Plates meters

Total Number of Tubes Number

OD of Condenser Tubes mm

Thickness of Tubes mm

Tube Material --

Surface Area of tube mm2

Cleanliness Factor %

Water Box Diff. Pressure mwc

0
CW Temp. Rise C

Velocity Through Tubes m/sec

0
TTD at Design CW Flow & Inlet Temp. C
0
LMTD C

Fromat-8.4.1

8.4-10
TEST READINGS

Station: ...................... Unit: ................ Test Date: ...........

S No. DESCRIPTION UNITS TEST
READINGS
0
1. CW Inlet Temp(Left) C
0
2. CW Inlet Temp(Right) C
0
3. CW Outlet Temp(Left-1) C
0
4. CW Outlet Temp(Left-2) C
0
5. CW Outlet Temp(Left-3) C
0
6. CW Outlet Temp(Left-4) C
0
7. CW Outlet Temp(Right-1) C
0
8. CW Outlet Temp(Right-2) C
0
9. CW Outlet Temp(Right-3) C
0
10. CW Outlet Temp(Right-4) C
0
11. Condensate Temp(Left) C
0
12. Condensate Temp(Right) C
0
13. Air/Steam Temp(Left)* C
0
14. Air/Steam Temp(Right)* C
15. Cond B.P (Left) mmHg

16. Cond B.P (Right) mmHg

17. Water Box Diff(Left)* kg/cm2(abs)

18. Water Box Diff(Right)* kg/cm2(abs)
19. Load MW

Note : * These readings are not required for performance calculations

but needed for diagnosis of deviations/condenser performance problems

Format-8.4.2

8.4-11
DAS Readings For Heat Load Calculation

S.N PARAMETER UNIT Test Data

1 Unit Load MW
2 MS Press bef ESV kg/cm2 (a)
3 MS Temp bef ESV Deg C
4 CRH Press HPT Exh kg/cm2 (a)
5 CRH Temp HPT Exh Deg C
6 HRH Press bef IV kg/cm2 (a)
7 HRH Temp bef IV Deg C
8 FW Press bef Eco kg/cm2 (a)
9 FW Temp bef Eco Deg C
10 FW Flow t/hr
11 SH Attemp. Flow t/hr
12 RH Attemp. Flow t/hr
13 HP Leak off Flow t/hr
14 HPH Extr. Temp Deg C
15 HPH Extr. Press kg/cm2 (a)
16 FW Inlet Temp Deg C
17 FW Outlet Temp Deg C
18 Drain Outlet Temp Deg C
19 Drain Inlet Temp (If applicable) Deg C
20 Drain Inlet Flow (If applicable) t/hr
21 FW Inlet Press (Optional) kg/cm2 (a)
22 FW Outlet Press (Optional) kg/cm2 (a)
23 BFP Inlet Press kg/cm2 (a)
24 BFP Inlet Temp Deg C
25 BFP Outlet Press kg/cm2 (a)
26 BFP Outlet Temp Deg C

Format-8.4.3

8.4-12
Condenser Heat Load Calculation

Parameters Units Data

1 Unit Load MW 200

2 MS Press bef ESV kg/cm2 (a) 148.17
3 MS Temp bef ESV Deg C 537.42
4 CRH Press HPT Exh kg/cm2 (a) 38.645
5 CRH Temp HPT Exh Deg C 352.115
6 HRH Press bef IV kg/cm2 (a) 36.275
7 HRH Temp bef IV Deg C 526.575
8 FW Press bef Eco kg/cm2 (a) 169.77
9 FW Temp bef Eco Deg C 244
10 FW Flow t/hr 703.92
11 SH Attemp. Flow t/hr 0
12 RH Attemp. Flow t/hr 6.64
13 HP Leak off Flow t/hr 0.54

HP Heater Parameters

14 HPH Extr. Temp Deg C 335.2

15 HPH Extr. Press kg/cm2 (a) 42.742
16 FW Inlet Temp Deg C 203.3
17 FW Outlet Temp Deg C 253.4
18 Drain Outlet Temp Deg C 208.1
19 Drain Inlet Temp (If applicable) Deg C 0
20 Drain Inlet Flow (If applicable) t/hr 0
21 FW Inlet Press (Optional) kg/cm2 (a) 0
22 FW Outlet Press (Optional) kg/cm2 (a) 0

BFP Parameters

23 BFP Inlet Press kg/cm2 (a) 7

24 BFP Inlet Temp Deg C 162
25 BFP Outlet Press kg/cm2 (a) 205
26 BFP Outlet Temp Deg C 166

27 Generator Losses MW 8.489

8.4-13
 Condenser Parameters

28 Condenser Back Pressure mm Hg 77

29 CW Inlet Temp Deg C 33
30 CW Outlet Temp Deg C 43.45
31 No. of Cond Tubes No. 24398
32 No. of Cond Tubes Plugged No. 0
33 Tube OD mm 31.75
34 Tube ID mm 30.3276
35 Tube Length m 14.73

Condenser Duty kcal/hr 25367508

CW Flow T/hr 2428
Tube Velocity m/sec 0.077
LMTD Deg C 6.843
LMTD Expected Deg C 1.477
Saturation Temp Expected Deg C 43.459
Expected Back Pressure mm Hg 66.361

Deviation in Condenser Back Pressure mm Hg 10.639

8.4-14
DETERMINATION OF BREAKUP OF CONDENSER BACK PRESSURE
DEVIATION

SR TEST UNIT
No
NO LOAD MW
. Description Derivation Unit

1. Unit - Load MW 200

2. Back pressure Plant mm Hg 120.8
o
3. Corresponding Sat. steam temp. C 55.56
o
4. CW inlet temp. Plant C 34.16
o
5. CW outlet temp. (Mean) Plant C 45.09
o
6. * Condensate temp. (Left) Plant C 55
* Condensate temp. (Right) Plant 55
o
7. *Air Suction temp. (Left) Plant C 48.9
* Air Suction temp. (Right) Plant 50.04
8. *CW Outlet Valve (Left) Plant % 100
* CW Outlet Valve (Right) 100
9. Target back press Curve-I mm Hg 85
o
10. Optimum CW rise Curve-II C 10
o
11. Optimum TTD Curve-II C 2.5
12. Back pressure due to CW inlet temp. (4)+(10)+(11) mm Hg 79
13. Back pressure due to CW (5) + (11) mm Hg 81
flow & CW inlet temp.
14. Variation due to CW inlet temp. (12)-(9) mm Hg -6
15. Variation due to CW flow (13)-(12) mm Hg 2
16. Variation due to air/dirty tubes (2)-(13) mm Hg 39.8
17. Total variation (2)- (12) mm Hg 41.8
18. No. of air pumps/ejector in service 1 No. 1
o
19. Air Suction Temp Depression (L) (3)-(7) C 6.66
o
20. Air Suction Temp Depression (R) (3)-(7) C 6.66
o
21. Condensate Sub Cooling (L) (3)-(6) C 0.56
o
22 Condensate Sub Cooling (R) (3)-(6) C 0.56

Remarks

Format-8.4.4

8.4-15
 C u r v e -I
V a r ia tio n o f B a c k P r e s s u r e w it h L o a d &
C W T e m p e r a t u r e

0.120

0.100 35 °C
30 °C
Ba ck Pr es s u r e

0.080
25°C
0.060
20°C

0.040

15°C
0.020

0.000
15 25 35 45 55 65 75 85 95 105

% o f L o a d

8.4-16
 Curve-II

10.0
9.0
8.0
D
CW Temp Rise
7.0
TT
eE
T
mM
6.0
pP
eE
rR 5.0
aA
tT
uU 4.0
rR
eE
TTD
3.0 TTD

2.0
1.0
0.0
0 10 20 30 40 50 60 70 80 90 100 110

% of Load

8.4-17
 CONDENSER PERFORMANCE TEST REPORT

STATION Report Date:

S.N Description →
Unit No→ Unit-1 Unit-2 Unit-3 Unit-4
Date →
1 Load MW
2 Condenser Back pressure mm Hg
o
3 CW inlet temp. C
o
4 CW outlet temp. (Mean) C
o
5 Condensate temp. (L&R) C
o
6 Air Suction temp. (L&R) C
7 Expected Back pressure mm Hg
8 Target Back pressure mm Hg
9 Variation due to CW inlet mm Hg
temp.
10 Variation due to CW flow mm Hg
11 Variation due to air/dirty mm Hg
tubes
12 Total variation mm Hg
o
13 Air suction Temp. C
Depression

Test Condition

Remarks

Format 8.4.5

8.4-18
8.4-19