Digitally signed by

S.Biswas
DN: cn=S.Biswas,
o=DCPL, ou=Power Cell,
email=swarajb@in.dclgr
oup.com, c=IN
Date: 2021.02.08
21:29:30 +05'30'
 Please identify all
CONDENSER-1 DATA changes in the document
with revision tag.
CONDENSER-1

i) Heat Load, HL= {(529.94X553.7) + (55.53X569.4) + (0.48X737.8) + (87.41X47.6) +

(6.23X46.8) - (679.59X40.247}X1000
= 302.501 x 106 kCal / hr

Corresponding to HBD Doc. No. PE-DG-445-100-N150, R00 (DWG Sheet No. 675-STE-
TC-S0211, R01)

Please refer CRS for

ii) Design Pressure (Refer HBD) Ps = 0.0762 ata balance comments

Saturation temp corresponding to 0.0762 ata Ts = 40.247 °C

iii) Design C.W. Inlet temperature Ti = 33° C

iv) Design C.W. flow Q = 68570 m3/hr

v) Specific Heat cp =1.0 Kcal/Kg °C

vi) Density ρ = 1000 kg/m3

vii) C.W. Mass Flow m = 68570 x 1000 = 68570,000 Kg/Hr

viii) Tube Details:

Size = OD 25.000 mm x (0.7112 mm/ 0.889mm (top two

rows)) thick
Length = 13500 mm (LBTP i.e. Length between Tube Plates)
Tube nos. = Total 26400 Nos. (344 Nos. of 0.889mm thk in top two
rows)
Material = Welded Stainless Steel as per ASTM A-249 TP-304

ix) Number of water passes, Np =1

 Please 5% tubes in plug-
Calculation for Surface Area in condition and reduce
the quantity of tubes
under service
No. of Tubes = 26400
Surface Area provided, Ap = п X 0.025 X 13.5 X 26400
= 27991.591 m2

Tube side flow area, Af =(π/4)X(25.0-2X0.7112)2X26056X10-6

+ (π/4) X (25.0-2X0.889)2 X 344 X 10-6
= 11.522 m2

C.W. Temperature Rise TR = HL/ (cp x m) = 4.41 °C

C. W. Outlet temperature To = (Ti+TR) = (33+ 4.41) = 37.41 °C
Initial Temperature Difference ITD = (Ts-Ti) = (40.247 – 33) = 7.247°C
Terminal Temperature Difference TTD = (Ts – To) = (40.247 – 37.41) = 2.837 °C
Log Mean Temperature LMTD = [TR/ ln (ITD/TTD)] = 4.7 °C

Tube side velocity V = [(Q X Np) / (Af X 3600)]

= 1.65 m/sec
Please submit relevant
Uncorrected Heat transfer Coefficient U0 = 3063.585 Kcal/hr-m2- °C page of HEI.
(from HEI of steam surface condenser Table I, 12 th edition)

Inlet cooling water correction factor fw =1.0788 (fig 2)

Cleanliness factor fc = 0.9

Tube Gauge Correction Factor fg = 0.8615

Corrected Heat Transfer Coefficient U = fw x fc x fg x U0

(for 22 BWG & 20 BWG) = 2562.529 Kcal/hr-m2- °C

Required Surface Area Ar = HL / (U x LMTD)

= 25724.611 m2
Please check and correct.

Surface Area provided Ap = п X 0.025 X 13.5 X 26400

= 27991.591 m2

Surface Area at 5% tube plugged, = п X 0.025 X 13.5 X (26400-1320)

= 26592.011 m2
CONDENSER-2 DATA

i) Heat Load, HL = {{(543.42X558.6)+ (57.1X574.6)}-{(600.52X44.758}}X1000

= 309.485 x 106 kCal / hr

Corresponding to HBD Doc. No. PE-DG-445-100-N150, R00 (DWG Sheet No. 675-STE-
TC-S0211, R01)

ii) Design Pressure (Refer HBD) Ps = 0.0965 ata

Saturation temp corresponding to 0.0965 ata Ts = 44.758 °C

iii) Design C.W. Inlet temperature Ti = 37.41° C

iv) Design C.W. flow Q = 68570 m3/hr

v) Specific Heat cp =1.0 Kcal/Kg °C

vi) Density ρ = 1000 kg/m3

vii) C.W. Mass Flow m = 68570 x 1000 = 68570,000 Kg/Hr

viii) Tube Details:

Size = OD 25.000 mm x (0.7112 mm/ 0.889mm (top two

rows)) thick
Length = 13500 mm (LBTP i.e. Length between Tube Plates)
Tube nos. = Total 26400 Nos. (344 Nos. of 0.889mm thk in top two
rows)
Material = Welded Stainless Steel as per ASTM A-249 TP-304

ix) Number of water passes Np = 1

 Please 5% tubes in plug-
Calculation for Surface Area in condition and reduce
the quantity of tubes
under service
No. of Tubes = 26400
Surface Area provided, Ap = п X 0.025 X 13.5 X 26400
= 27991.591 m2

Tube side flow area, Af =(π/4)X(25.0-2X0.7112)2X26056X10-6

+ (π/4) X (25.0-2X0.889)2 X 344 X 10-6
= 11.522 m2

C.W. Temperature Rise TR = HL/ (cp x m) = 4.51 °C

C. W. Outlet temperature To = (Ti+TR) = (37.41+ 4.51) = 41.92 °C
Initial Temperature Difference ITD = (Ts-Ti) = (44.758 – 37.41) = 7.348°C
Terminal Temperature Difference TTD = (Ts – To) = (44.758 – 41.92) = 2.838 °C

Log Mean Temperature LMTD = [TR/ ln (ITD/TTD)] = 4.74 °C

Tube side velocity V = [(Q X Np) / (Af X 3600)]

= 1.65 m/sec

Uncorrected Heat transfer Coefficient U0 = 3063.624 Kcal/hr-m2- °C Please submit relevant

page of HEI.
(from HEI of steam surface condenser Table I, 12 th edition)

Inlet cooling water correction factor fw =1.0980 (fig 2)

Cleanliness factor fc = 0.9

Tube Gauge Correction Factor fg = 0.8615

Corrected Heat transfer Coefficient U = fw x fc x fg x U0

(for 22 BWG & 20 BWG) = 2608.169 Kcal/hr-m2- °C

Required Surface Area Ar = HL / (U x LMTD)

= 25639.093 m2 Please check and correct

Surface Area provided Ap = п X 0.025 X 13.5 X 26400

= 27991.591 m2

Surface Area at 5% tube plugged, = п X 0.025 X 13.5 X (26400-1320)

= 26592.011 m2
 HYDRAULIC CALCULATION

PRESSURE DROP CALCULATIONS ACROSS CONDENSER as per HEI of Steam Surface

Condenser.

Calculation for CW Side Pressure drop

CW Nozzle ID = Dia 2300 mm mention the Nozzle Thickness too

CW Velocity Thro’ Nozzle = (68570x4)/(2x2.32x π x3600) m/sec
= 2.29 m/sec
= 7.513 ft/sec

Tube End Loss (Combined inlet and Outlet) = 0.99 ft -- Curve A (fig .8)
Water Box Inlet Loss = 0.86 ft -- Curve B (fig. 8)
Water Box outlet Loss = 0.26 ft -- Curve C (fig.8)

Sum Of above Losses = 2.11 ft

=0.643 MWC --------- (a)

Friction Loss = 0.00642V 1.75

Di 1.25
(including gauge correction factor) (refer clause 4.5; sheet 15)

= 0.00642X(5.41) 1.75
(0.9282) 1.25

=0.1352 ft/ft of tube length

For Condenser 1:
Temperature correction factor = 0.954 (figure 7)
(Corresponding to average CW temp.
of 35.205 deg C (average of CW inlet 33 deg C
& CW outlet 37.41 deg C in Condenser 1))

Friction loss at 35.205 deg C = 0.1352 x 0.954

Avg. CW temp. = 0.1289 ft / ft of length
=0.1289 m/m of length

Total Length of tube = 13.6 M

Pressure Drop in Tube = 13.6 x 0.1289

= 1.753 MWC ----------- (b)

For Condenser 2:
Temperature correction factor = 0.938 (figure 7)
(Corresponding to average CW temp.
of 39.665 deg C (average of CW inlet 37.41 deg C
& CW outlet 41.92 deg C in Condenser 2))
Friction loss at 39.665 deg C = 0.1352 x 0.938
Avg. CW temp. = 0.1268 ft / ft of length
=0.1268 m/m of length

Total Length of tube = 13.6 M

Pressure Drop in Tube = 13.6 x 0.1268

= 1.724 MWC ----------- (c)

Total Pressure Drop:

In Condenser1 = (a) + (b) =0.643 + 1.753 = 2.396 MWC
In Condenser2 = (a) + (c) =0.643 + 1.724 = 2.367 MWC

Pressure Drop Adopted = 2.4 MWC for one condenser

Total pressure drop adopted = 4.8 MWC

(Between CW inlet & outlet flanges of water box)