Product Application Data
Condensate Return
PROCESS DESCRIPTION
From the boiler, high-pressure steam is delivered to a
high-pressure turbine (HPT). The steam is returned to
the boiler for reheating to high-pressure steam as a first
step in obtaining an optimum process. This steam is then
fed to an intermediate pressure turbine (IPT), and then
finally to a low-pressure turbine (LPT), all of which are
driving the turbine shaft. At various steps in this process,
steam is extracted from the IPT and LPT for purposes of
heating the water in the reheater stages.
Steam leaving the LPT is passed through a condenser.
The condenser is a heat exchanger that lowers the
steam temperature, thereby converting it into water.
Cooling water for this process is commonly supplied
from a reservoir. The condensed steam is collected in
the hotwell. From there, the condensate is combined
with makeup water and pumped to the condensate
polishing system.
The design of the condensate polisher depends on
variables unique to each power plant, but it typically
consists of a cation bed, anion bed, and mixed bed
demineralizer.
A Siebe Group Company
PAD P4100-028
Water from the polisher is then sent to a series of
reheaters. Heat exchangers in each reheater are
connected to sections of the IPT and LPT. The number
of reheaters and the amount of steam drawn off each
turbine is part of the thermodynamic design of the
individual powerhouse.
A deaerator, positioned between the feedwater
reheaters, is used to purge the makeup water of any
entrapped air. Dissolved oxygen from the air, which
can enter the system from bearings or seal leaks in the
turbines and pumps, and from air leaks in the
condenser and hotwell, can lead to corrosion if not
lowered to acceptable levels.
APPLICATION CHALLENGE
Conductivity measurements are employed throughout
the condensate return process to protect against
scaling and corrosion of the turbines and boiler
components. Conductivity measurements are all used
to safeguard the long life of extremely expensive
capital equipment and ensure an efficient and
uninterrupted flow of electricity from the plant. Any one
PAD P4100-028
Page 2

of the following measurements, if in an alarm state,
could be justification to divert water flow or shut down
the boiler. Therefore, it is imperative that these
measurements be made with the utmost accuracy
and reliability.
Condensate Pump Outlet: Conductivity measured
at this location serves as a double check against leak
detection systems installed in the condenser and
hotwell.
Condensate Polisher: Conductivity is measured at
the inlet and the outlet of the polisher. Comparison of
inlet and outlet measurements yields an indication of
the efficiency of the polisher. The conductivity value
at the outlet is used to schedule a switchover to a
fresh bed and regeneration of a spent bed.
LP and HP Heaters: Conductivity is used to track
water purity through these elements to ensure that
contamination has not been introduced at any point.
Deaerator: As with the LP and HP heaters,
conductivity is found at the deaerator to guard
against the introduction of any ionizable species via a
small leak in the system.
The 870ITCR is a premier, intelligent, two-wire
transmitter, patterned after its predecessors, the
intelligent 870IT pH and electrodeless conductivity
transmitters. These transmitters have a track record
of high reliability in challenging process control
applications. With an accuracy of ±0.1%, and an
intuitive operator interface with easy-to-understand
prompts, the 870ITCR delivers a rare combination of
features — high performance and ease of use.
Foxboro’s 871CR conductivity sensors use a
universal bore piece design which eliminates cable
wind-up during installation and removal. Their 1000Ω,
3-wire RTDs provide rapid and accurate temperature
measurement for automatic temperature
compensation. Cell factors are measured to an
accuracy of ±0.1%, complementing the accuracy of
the companion 870ITCR transmitter.
Foxboro’s 870ITCR and 871CR combination set the
new standard for conductivity instrumentation in
power industry condensate measurements.

SOLUTIONS
Condensate conductivity measurements are normally
in the range of 0.055 µS/cm to single digit µS/cm. As
conductivity measurements go, these are among the
most sensitive in the process industries. Unlike
chemical concentration measurements in
applications such as demineralizer regeneration,
where high conductivity ranges permit the use of Figure 1. Typical Intelligent Conductivity Transmitter
electrodeless conductivity technology, condensate
applications are almost always addressed with
contacting conductivity sensors.
Fortunately, the problems associated with contacting
sensors in many applications are not an issue in
power plant condensate. The sample tends to be
very clean, and quite often conditioned such that its
temperature and pressure set is benign.
Conductivity measurement solutions for critical power
industry applications must satisfy three key criteria —
high reliability, high accuracy, and ease of use.
Foxboro designed its 870ITCR and 871CR products
with the power industry in mind. Figure 2. Typical Contacting Conductivity Sensors

The Foxboro Company Foxboro is a registered trademark of The Foxboro Company.

33 Commercial Street Siebe is a registered trademark of Siebe, plc.
Foxboro, MA 02035-2099
United States of America
http://www.foxboro.com
Inside U.S.: 1-888-FOXBORO
(1-888-369-2676)
Outside U.S.: Contact your local
Foxboro Representative. Copyright 1999 by The Foxboro Company
Facsimile (508) 549-4492 All rights reserved

A Siebe Group Company MB 040, 042 Printed in U.S.A. 0499