SINGRENI THERMAL POWER STATION

(2X600 MW)

DESCRIPTION & MAINTENANCE INSTRUCTIONS

FOR
CONDENSER & HEAT EXCHANGERS

NTPC DRG.NO.9661-110-01HW-PVM-X-002, Rev.-02

HEAT EXCHANGER ENGG

BHARAT HEAVY ELECTRICALS LTD HARDWAR
Digitally signed
Signature Not
by PVerified
R SEN
Date: 2015.11.05
18:50:27 IST
Reason: CAT IV
Location:
NTPCEOC
 CONTENTS
Section A: Description & Maintenance Instructions
for Condenser & Heat Exchangers

Section B: Fault Tracing Instructions

Section C: EQUIPMENT DRAWINGS

SECTION-A

DESCRIPTION & MAINTENANCE INSTRUCTIONS

FOR
CONDENSER & HEAT EXCHANGERS

List Of Equipments :
1. CONDENSER
2. CONTROL FLUID COOLER
3. L.P. HEATER
4. GLAND STEM CONDENSER
5. TURBINE OIL COOLER

SECTION-B

FAULT TRACING INSTRUCTIONS

SECTION-C

EQUIPMENT DRAWINGS
1. CONDENSER
2. CONTROL FLUID COOLER
3. L.P. HEATER
4. GLAND STEM CONDENSER
5. TURBINE OIL COOLER
1.0 DESCRIPTION & MAINTENANCE OF SURFACE CONDENSER :

1.1 DESCRIPTION :

Condenser is used to condense the exhaust steam from L . P. Cylinder and to produce
the deepest possible vacuum in order to maximise the heat drop and the turbine output .
For maintaining the desired condenser vacuum, the air/non-condensibles are continuously
removed from condenser by vacuum pumps /steam jet ejectors . It also facilitates reuse of
condensate .

Optimum utilisation of steam space by providing rectangular cross section of tube -nest
is an added feature of this condenser. For ensuring equitable loading of condenser tubes
in the bottom rows without incurring appreciable steam side pressure drop , tubes have
been segregated in small bunches leaving wide lanes between them . Tube bundle is kept
0 inclined towards front water base for self draining during C .W. pump tripping and
shut down .

The condenser water chambers have provision for the isolation of half of the condenser for
leak detection of tubes without tripping the plant .

The 600MW rating has two LP Cylinder for which two identical Condensers are provided in
parallel. The following features are common two both condensers.

1.1.1 CONSTRUCTIONAL FEATURES OF CONDENSER :

It is a rectangular surface condenser having suitably stiffened steam dome , consisting

of stiffening pipes , welded on either side with the opposite side wall of dome shell .
Except tubes , the remaining construction is of fabricated type . The tubes have been
expanded into main tube plates and are supported by the tube support plates at
intermittent planes to prevent their sagging and to curb the flow induced vibrations,
Non-condensible gases are continuously extracted in order to maintain vacuum in the
condenser.

Tube material is selected to provide trouble free operation .Refer data sheet for details .
Wherever LP Heater no. 1 is mounted in condenser dome wall , shell internals & dome
internal structure is suitably designed /stiffened to take care of the additional load .
Condenser is supported on springs to take care of vertical thermal movement and
vibrations experienced during operation.

Water boxes removal /handling arrangement /crane type handling device has been
provided to facilitate the removal of covers to enable re-tubing and cleaning of tubes etc .
Water boxes are further provided with suitable manholes for carrying out maintenance
works without opening them .

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 For inland water application water box inside surface and circulating water side of
water chamber including Carbon Steel main tube plates have been protected against
corrosion by application of protective coating over the surface in contact with cooling
water.

L .P. Heater No. 1 has been installed inside the condenser neck to save floor space
01 and piping cost . Two numbers Steam Throw Devices have been incorporated in each
condenser for dumping steam during start-up and sudden load throw off. Steam dumping
system is designed for continuous operation with 60 % by -pass load .

1.1.2 FITTINGS :

Following fitting have been provided on the condenser :

(a ) Level indicators for Condensate level.

(b ) Level switches with isolation valves .

(c ) Two Nos . stand pipes with provision for isolation and draining .

(d) Vent and drain valves for water boxes .

(e ) Condensate drain valves .

All fittings supplied are suitable for vacuum service .

1.2 DATA SHEET FOR CONDENSER :

(Refer enclosed Annexure - 1 for condenser data )

1.3 INSTALLATION :

Condenser is floated on the springs which takes the empty weight of condenser
alongwith partial operating weight, if any, depending upon design of condenser, remaining
weight is taken by the turbine foundation. Tube
installation is tested by filling water into steam space upto 1 meter above tubes .For
checking vacuum system tightness water may be filled upto LP turbine blade tip. Before
filling water into the condenser steam space for the above testing, jacking bolts provided
with condenser support assembly must be raised to support the bottom plate and pass on
the additional weight to the condenser foundation.
02
Caution
After water fill test and draining of filled water, the jacking bolts must be lowered to float
the condenser on springs.
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1.4 POINTS TO BE CHECKED PRIOR TO COMMISSIONING THE SYSTEM :

(i) Check operation of level switches , level controller and level detectors .

(ii) Check proper closing of drain and vent valves provided with the stand pipe
level switches , level gauges and water boxes .

(iii) Check and ensure proper quality and type of valves used for the replacement
of defective ones .

(iv) Ensure that the bolt /stud /nut used for the replacement of worn -out fasteners
used for tightening of water chamber /box joint , is of right type , since these
fasteners have been manufactured from high tensile alloy steel .

(v) Ensure proper operation of the valve provided in the condensate line meant for
spraying condensate for the cooling of steam in the steam throw device .

(vi) Ensure that condenser water boxes -front and rear, are fully vented by keeping
the water box valves open at the time of charging . Close the values when water
starts coming out indicating proper venting . In case of syphonic system , operate
priming pump /priming ejectors will water starts coming out from their exhausts .
Also , in case auto operations feature in priming pump exists , ensure its
effectiveness .

(vii) Check air leakage in condenser by operating Rotameter mounted on the

condenser vacuum pump . Air ingress in excess of 2 0 - 3 0 kg /hr must be eliminated
through methods like Steam -pressurisation , Water fill test , Helium leak detection
etc as recommended by Power sector-Technical Services of BHEL . In case of
steam jet ejectors , measurement of air may be done by operating air measuring
device .

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1.5 CHECK POINTS FOR VACUUM PUMP OPERATION : 02

1. For efficient operation of vacuum pump as per design requirement , check that temp.
of cooling water for heat exchanger is same as condenser C .W. This is
mandatory.

2. Before starting the pump first time , rotate the pump manually to check if it is
free .

3. Check that level gauge and its isolating and drain valves are clean .

4. Check that rotameter glass and its vent and drain valves are clean .

5. Check that drops or fine stream of water is coming out of the pump glands .

6. Ensure cleaning of heat exchanger tubes at regular intervals .

7. Design C .W. flow rate should be maintained for Heat Exchanger. This can be
done by using flow meters or by measuring temp . differential .

8. Check that Air-Steam inlet valve is not passing .

9. Check that seal water spray (if provided with pump ) is working .

10. System vacuum tightness should be checked at regular intervals .

11. Check all auto systems in the pump package are working satisfactorily.
Note : -For detail instructions refer O & M manual of vacuum pump supplier.

1.6 POINTS TO BE CHECKED DURING OPERATION : 02

02

(i) Locate and plug the leaking tube ends on noticing higher conductivity of
condensate . change in conductivity of condensate (deviation in
conductivity from that of DM water) is the measurement parameter to
identify tube leakage. Use brass /stainless steel plugs for plugging tube
ends .

(i) Attend /Replace the instruments and fitting found not functioning properly.

(iii) Check tube cleanliness if appreciable variation in C .W. side pressure drop across
condenser tube system is noticed .

(iv) Check reasons for low flow if excessive rise in C .W. temperature across condenser
is noticed .
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(v) Investigate the reason for condenser poor vacuum commensurate to turbine
loading , C .W. inlet temperature , site barometric pressure etc . and attend to the
possible causes . The best possible obtainable condenser vacuum at a particular C
.W. inlet temperature is the pressure corresponding to saturation temperature
obtained by adding approximately 4 0 C for terminal temperature difference to the
condenser C .W. outlet temperature .

(vi ) Maintain the record of data collected from condenser operation , at least once in
a day. Recording of data should be done as per clause 1 . 6 . 1 .

(vii ) Excessive air leakage (more than 2 0 - 3 0 hg /hr. ) into the vacuum system which
includes condenser, lowest L .P. Heater, Drain Cooler, L .P. Flash Tank , inter
connecting steam /drain side piping , fitting etc . cause deterioration in condenser
vacuum . To ensure that air leakage is not excessive , conduct vacuum drop test
by shutting off vacuum pump /ejector and noting down the vacuum drop rate . An
acceptable vacuum system shall have the vacuum drop rate within 1 - 2 mm /min .

(viii ) C .W. side should be charged only after ensuring priming / venting of C .W. system .

(ix ) Periodically check the vacuum system tightness using Water fill Test of Shell side
as recommended in the condenser drg . , Steam Pressurisation Test and Helium
Leak Detection .

1.6.1 DATA FOR CONDENSER OPERATION

Sl . No. DESCRIPTION DATA

(i ) C .W. inlet temperature 0 C
0
(ii) C .W. outlet temperature C
(iii) Turbine load in M .W.
(iv) Particular of heaters out of circuit .
(v) Condenser vacuum . mm Hg (a )
(vi) C .W. side pressure drop . mwc
(vii) Barometric pressure . mm Hg (a )

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1.7 TUBE FOULING , TUBE SCALING , TUBE FAILURE AND THEIR PREVENTION ;

Tube failure is caused by corrosion and erosion . Corrosion failures are due to presence
of electrochemically active elements in the medium in contact with tube inside and outside
surface . Control of water and steam chemistry, treatment and maintaining absolute tube
cleanliness is required .

Erosion failure is caused by impingement of high temperature steam , high water velocity,
heavy deposits in water and poor tube side venting . To prevent erosion following steps
are required : -

- Ensure proper condensate spray in the Steam Dumping Device

and Flash Boxes . 02
- Flow of cooling water to be controlled nearer to design
requirement .
01
Deposits like silica , sand etc . in water must not be present .

1.7.1 SCALING OF TUBES :

Scaling of tubes is caused by poor water quality /improper treatment . It can be

eliminated by the following : -

a) Timely commissioning and regular operation of condenser On -Load Tube

Cleaning System (COLTCS ) .

b) Regular analysis of water quality to ensure suitable water treatment .

1.7.2 CLEANING OF TUBES :

Method of cleaning the tubes will depend on the nature of deposit . Selection of most
suitable method of cleaning is left to the plant maintenance engineers :

(a ) Cleaning of condenser tubes by brushes usually gives satisfactory

results . Care should be taken to ensure in case of metallic bristles that they are
not harder than required for loosening the deposit . The use of steel wire bristle is
strictly prohibited , as these are likely to damage the tube surfaces .

(b ) The general practice for removing hard scales is by hydro jetting at

suitable pressure . However, the recent trend indicates use of Bullet Cleaning
for effectively removing the scales . Selection of bullets depend upon the

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 tube material and type of scale .

(c) Chemical cleaning should be resorted to only when no other method

of cleaning is left . If it is decided to be done , it should be carried out under the
guidance and supervision of a competent chemist . However, it is a must that no
traces of cleaning solution are left behind .

1.7.3. FAILURE OF TUBES :

Titanium stainless steel and 9 0 / 1 0 cupro Nickel tubes have good record against
tube failure . If operating parameters such as temperature , pressure , air
concentration etc . in condenser are maintained or allowed to very with acceptable
range ,long and reliable service is assured . However, poor water chemistry control
and poor tube cleanliness can always be a major cause far tube failure in case of
non-ferrous tubes . In case of SS tubes , algae attacks and micro -bio -fouling can
be damaging to tubes . Some of the specific care that need to be taken prevent
tube failure are discussed below.

(a ) Chlorination may be required to prevent bio fouling in Cu -Ni tubes .This however,
must be carefully done to prevent tube damage .Improper treatment will lead to
chain of failures at later date . (only in case of non-ferrous tubes )

(b ) Micro -biological corrosion may cause failure in SS tubes . Where as bio -fouling
is easily detectable , micro -biological fouling cannot be detected and special tests
are required for the same . The following approach may be necessary to check
failures due to micro -bio corrosion :

(i ) Measurement of Sulphate Reducing Bacteria (SRB ) and Total Bacteria Count

(TBC ) present in condenser circulating water system may be done once in a
month either internally or from any reputed internally. Samples should be
collected preferably at 2- 3 locations . 02

(ii ) It is advisable to install test coupons having same metallurgy as the tubes in CW
system at convenient locations . Periodic inspection ( Avai lab le oppor t unit y) of
the test coupons would assist in monitoring tube condition .

(iii ) Bacteria control program shall include biocide treatment of CW. A combination of
bio -cide / bio -dispersant / bio -stat shall ensure removal of microbiological deposits .

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 (iv ) Controlled Chlorination , under direct supervision of a competent chemist , is
also recommended . (for non-ferrous tube )

(v ) Iron contents in CW shall not exceed 0 . 2 ppm .

1.8 TUBE PLUGGING & REPLACEMENT :

Plugging of tubes is carried out generally during operation as a temporary emergency

measure .When tube failure occurs it is noticed in the form of high silica content /high
conductivity. When tube plugging exceeds the permissible limits , tube replacement may
become necessary.

Steps identified in para 1 . 8 . 2 may be followed for tube replacement .How ever, designer's
views may also be considered .

1.8.1 TUBE PLUGGING :

Failed tubes may be identified and plugged using tapered plugs as per designer's
recommendation .Failed /leaky tubes may be identified following the instructions
given in paras 1 . 8 . 1 . 1 .and 1 . 8 . 1 . 2 . below.

1.8.1.1. WHEN TURBINE IS IN OPERATION :

Each Condenser has been provided with the divided water chambers thus making it
possible to locate the leaking tube and plugging its ends , even when turbine is in
operation .

For locating the leaked tube , concerned portion of water chambers should be isolated
on C .W. side and tube plate should be dried commencing from top to bottom by the
application of dry air. During isolation of one half on C .W. side , turbine load should be
reduced to 50 to 60 % . For attending above job individual can enter into the water box
through the water box man -hole opening .

(a ) Tube openings should be covered with a thin polythene sheet , which

will get sucked into the failed tube end , alternatively tube ends should be scanned
through with a lighted candle -stick /smoke generator. The flame /smoke will get
attracted in the leaky tube end .

(b ) Leaky tube can also be detected by the use of U -tube manometer.

Plug one end of the tube with soft rubber plug and connect the other tube end
with U -tube manometer having coloured water. Coloured water will get sucked

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 into the tube in case of leaky tube , otherwise water level will remain unchanged .

1.8.1.2 WHEN TURBINE IS UNDER SHUT DOWN :

Drain the water boxes and fill condenser steam space with DM water only upto one
meter above the top tube row. Prior to D .M . water filling in steam space , condenser
should be supported as described in Section 1 . 3 .

1.8.2 REPLACEMENT OF TUBES :

For roller expanded tubes , the following instructions for tube replacement may be
adopted : -

(i) Insert the tube drift at tube end on the water box side where
space has been provided for tube insertion and tap the tube out of expansion
by first skimming the flared portion of the tube with a trimming tool . If on trial it is
found that the expansions are very tight and can not be freed easily, weaken the
tube plate joint by using tube revolving tool to a depth slightly less than the tube
plate thickness , thus leaving a thin shell of metal on the tube plate .
Alternatively, tube ends may be cut by internal tube cutter and cut ends of the
tubes may be removed from the tube plates by a tube puller.

(ii) Insert the tube drift at the above water box end of the tube and
release the tube from the tube plate .

(iii) After the tube has been moved by about 25 mm from the above
end , insert the inter -connector into the end of old tube and then connect the
new tube with inter-connector.

(iv) Push the new tube in , the old tube would act as a guide .

(v) After full insertion of new tube , expand and bell /flare the inlet
and outlet ends . If projection is excessive , trim the end to get the desired
projection and debur the end .

NOTE : Expertise of erection agency may also be used while carrying out
the above .

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 01

1.8.3. GENERAL INSTRUCTIONS FOR EXPANDING THE TUBE ENDS :

(i ) Tube holes and tube ends should be thoroughly cleaned . These surfaces should be
free from dust , dirt , scale , oil , protective coating , etc . Presence of foreign material
between the tube outer surface and interior hole surface will result into a leaky
joint . Cleaning of tube ends may be accomplished with an emery cloth . Protective
coating in the tube holes can be cleaned with application of thinner. 02

(ii ) Tube ends should be so expanded that thinning of tube wall does not exceed the 5-
10 % after metal to metal contact. Tubes should neither be under expanded nor over
expanded . Under expansion would result into the weak joint, leading toleakage.
Over expansion would result into excessive elongation of the tubes , inducing
severe stresses on the tube joint . Expanding tool will obviously be subjected to
greater wear, thus reducing its life .

1.8.4. CAUTION :

(i) Tubes should not be over expanded in any case . Under expanded joint can be
rectified by re -rolling , whereas over -expanded joints can only be remedied by
replacement of tubes . To ensure proper expansion , tube inner and outer diameter
should be measured before and after expansion for each setting to the expander.

(ii) Expander setting should be checked daily and each time when rollers or
mandrels are changed .

(iii) Expander gets heated up during expanding operation , hence coolant (a mixture
of soft soap and glycerin ) should be used to cool the expander and to remove
the slag . It is advisable to use two expanders for continuous operations .

(iv) Expanders should be inspected frequently for wear of rollers and mandrels
and these should be changed on first sign of wear.

1.9. SALIENT FEATURES FOR MAINTENANCE & OVERHAUL :

(i) Check the interior surface of water boxes and water side of tube
plates at regular intervals of 6 months . On finding paints peeled -off , repainting of
the local surface should be done by the recommended paint , after a thorough
cleaning of the local surfaces .
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 (ii) Check the inlet end of tubes for erosion /corrosion . On finding
eroded tube ends , plastic inserts may be provided .

(iii) Clean the Hot -well to remove slugs and debris .

(iv) Clean the interior of the tubes .

(v) Carryout water fill test and plug /replace the leaking tube .

(vi ) Check operation of level switches, level transmitters and level indicators for proper
functioning

(vii) Check cleanliness of impulse tubing connecting condenser with the instruments .

(viii) General inspection of load bearing parts like hinge arrangement .

(ix ) Replace all gaskets sealing of water boxes , instruments during capital overhaul ,
if opened .

(x) In case of high air ingress noticed in the system , steam pressurisation
Test and Helium Leak detection test shall be conducted .

(xi) In the event of any reworking /welding is done in the vacuum system , special
care should be taken and weld seams should be tested as per drawing
requirement .

1.9.1 DOs FOR MAJOR SHUT-DOWN :

(i) Carry out visual inspection of upper shell internals , lower shell internals
etc . for possible abnormalities . Take corrective action wherever required .

(ii) During long shut down hot air should be blown into the condenser through hot
well drain connection for drying the condenser internals .

(iii) Check coating of water box internal and C .W. side main tube plate surface .
Recoat the spot where the paint has peeled off with the recommended paint .

(iv) Gland packing of valves should be attended and replaced if excessive air ingress
into the system has been experienced .

(v) Torque controlled spanners should only be used for the tightening of fasteners
for water chamber and water box joints , if required .
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 (vi ) Check for cleanliness and erosion of holes of the make -up line dispersers .

(vii ) (a ) During plant shut down for less than 3 days , water side should be kept
in operation to avoid any deposition in the tube .

(b ) For short idle period less than three days , lower C .W.
velocity (but not less than 1 . 2 m /s ) is also permissible provided it does not
lead to the fouling of tubes .

1.9.2. DONTs FOR SHUT-DOWN:

(i) Do not resort to chemical cleaning of tubes unless recommended

by a competent chemist .

(ii) Do not use steel wire brushes /hard brushes for cleaning of tubes .

(v) Do not use levers for breaking joints .

(vii) Do not attempt to replace the tube when turbine is in operation .

(ix ) Do not leave condensate inside condenser during its isolation .

1.10 LIST OF RECOMMENDED SPARES :

(i) Condenser tubes .

(ii) Level Gauges and Level Switches .

(iii) Rubber gasket for water boxes /chambers .

(iv) Isolating valves for level instruments .

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2.0 CONTROL FLUID COOLER

2.1 DESCRIPTION

The function of the control fluid cooler is to cool the control fluid used for the control
system of turbine.

Essentially, the cooler consists of tube-nest, shell & water boxes. The fluid to be
cooled enters the cooler shell through the inlet nozzle at the top and flows through
the baffles. The baffles are held in position by spacers mounted on steel rods. This
arrangement forces the fluid to follow a cross flow pattern while flowing to the outlet
nozzle at the bottom. Tubes are roller expanded in the tube plates.

The lower water box with partition between cooling water inlet and outlet branches,
is bolted with the shell flange and lower tube plates. The tube nest is free to expand
upwards due to differential thermal expansion.

2.2 DATA SHEET FOR CONTROL FLUID COOLER :

(Refer enclosed Annexure-2 for data sheet)

2.3 SALIENT FEATURES FOR MAINTENANCE

(i) Inspect tube inlet ends for erosion/corrosion.

(ii) Ensure cleanliness of the tubes.

(iii) Locate and plug leaking tubes if any.

(iv) Check the condit ion of the rubber O-rings and their proper seating ;
replace the O-rings if necessar y.

2.4 LIST OF SPARES

(i) Rubber O-rings for upper tube plate.

(ii) Tu b e s .
3.0 LOW PRESSURE HEATER :

3.1 DESCRIPTION :

A feed water heater is a shell & tube type Heat Exchanger which heats the condensate
passing through its tubes by means of steam (for condensing zone) / condensate (for
drain cooling zone) on the shell side. Steam which is extracted from turbine gets
condensed in this process. 01

L.P. Heaters can be horizontal having 2-pass on water side with welded ( water box -
tube plate- shell) type construction (refer equipment drawing / data sheet).

Shell side drain is cascaded during normal operation to lower heater and through
Drain Cooler which is connected to the Condenser through Flash Tank. Provision
has also been made for diver ting the drain of L.P. Heater-2 & L.P. Heater-3 to
Condenser through flash tank by-passing the Drain Cooler and L.P. Heater 1.
Ar rangements have been made for taking care of the abnor mal conditions of shell
side flooding of the heaters due to failure of tubes etc.

Heaters have been provided with shell withdrawal / tube bundle withdrawal (for
heaters placed inside the Condenser neck) arrangement to facilitate to major
maintenance / inspection activities at site.

Heaters have been provided with shell and tube side vent & drain connections. Shell
side vent connection has been connected to the condenser dome.

The following are the main sub-assemibiles of this heater :

(i) Shell

(ii) Tube System

(iii) Water Box

(i) Shell : Shell is of cylindrical construction of Carbon Steel having dished end welded
at one end and other end welded/bolted to tube plate depending upon the
arrangement (Refer equipment drawing). Heaters having welded construction
are provided with cutting line on the shell to facilitate bundle / shell removal.
Horizontal heaters (outside Condenser neck) are supported on saddle with
rollers to take care of thermal expansion and facilitate shell pulling. The shell is
provided with suitable steam inlet, drain inlet / outlet, vent and stand pipe
connection. All level control and indication instruments have been provided on
the stand pipes along with instrument isolation valves.

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 01
11
(ii) Tube System : Tube system consists of U-Tubes made of SS 304
11
11 into the
(welded). material (refer data sheet). Tubes are roller expanded
tubesheet holes.. For heaters inside condenser neck, trolley is11
provided to
facilitate tube system removal. 1

To protect the tubes from impingement failure due to high temperature

and high velocity of incoming steam and drain, SS 304 impingement
plates have been provided at nozzle entr y. Suitably spaced baffles /
support plates have been provided for ensuring uniform distribution
of steam and proper support to the tubes to avoid excessive vibrations.

Heaters having shell cutting line are provided with stainless steel
protector band to avoid approach of flame to the tube while cutting
shell.

(iii) Water Box (Channel) : Water Box is fabricated construction of carbon

steel to facilitate condensate entry into the tubes. It can have flanged
or welded joint with tubesheet at one end and flat cover or dished
end at the other end. Welded water box having dished end has been
provided with access opening for carrying out maintenance / inspection
activities. Par tition plate has been provided for making the heater two/
four-pass.

3.2 The following fittings have been supplied along with the equipments :

(i) Level indicators.

(ii) Level switches/L evel Transmitters with isolating valves.

(iii) Water Box vent valve.

(iv) Pressure gauge with three way needle valve.

(v) Dial type thermometers with thermowells.

(vi) Shell side Relief valve.

(vii) Tube side Relief valve.

3.3. INSTALLATION :

During installation of heaters, the following points should be kept in view :-

(i) No cold pulling of the equipment due to fault in the piping installation.

( i i ) S e t p r e s s u r e of sh e l l a n d t u b e si d e sa f e t y va l ve s s h o u l d b e ch e c k e d
and ensured.

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 3.4 OPERATION :

Points to be checked prior to putting the heater in operation :

(i) Operation of level switches.

(ii) Proper setting of annunciation points for maintaining drip level

and giving alarm.

(iii) Proper adjustment of drip control valves.

(iv) Placement of orifices in the vent lines and their condition.

3.5 DATA SHEET FOR L.P. HEATERS

(Refer enclosed Annexure-3 for L.P. Heater data sheet)

3.6 DOs/DONTs FOR OPERATION :

3.6.1 DOs :

(i) Ensure heater operation is close to design regime only.

(ii) Charge condensate side prior to charging the steam side.

(iii) Intermittently check the operation of level switches/transmitters.

(iv) Ensure no passing of valves as it can reduce condensate pressure in

the main condensate pipe line, i.e. valves in the drain line of main
condensate pipe lines, valves in the re-circulation line etc. During
tripping of the condensate pump, passing of these valves will cause
draining of pipe line and equipments which will result in water hammer
in above equipments and pipe line when CEP restarts. This will result
into leakage from the flanged joints and possible failure of tubes.

(v) Open the vent valves for venting air prior to charging of the equipment
on tube side.

(vi) In case of very high level in L.P. Heater No. 1, isolate heater alongwith
Drain Cooler. Check each for possible tube failures.

3.6.2 DONTs:

(i) Do not operate higher heater with immediate two lower heaters out
of circuit.

(ii) Do not operate the heater if level control instruments i.e. Level
Switch/Transmitters are not working. Such operation will endanger
the turbine due to water entry if tube puncture in the heater occurs.

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 3.7 MAINTENANCE :
3.7.1 Salient features for overhauling :

(i) Inspect inlet ends of the tubes for erosion/corrosion.

(iii) C h e c k t h e l e ve l g a u g es , p re s s u r e g a u g e s , l e ve l s wi tc h e s , l e ve l
controller for proper functioning.

(vii) Check the vent orifices on vent pipe for erosion and if required replace
them by new ones.

(viii) Ensure proper venting / syphon operation (especially L. P. Heater

No. 1)

(ix) Replace the defective / damaged instruments / fittings.

3.7.2 DOs :

(i) Use of proper techniques for draining, drying and storage of heater
during long shut down.

(ii) Use the press out bolt provided on the flange for breaking the joint.

(iii) Isolate heaters before attempting any maintenance work.

(iv) Replace defaced and worn out fasteners.

(v) After erection, remove the bolts meant for supporting the tube
bundle during transit and plug the holes per manently.
(For Ver tical Heaters)

(vi) Expanded length of the tube should always be kept less than tube
plate thickness.

(vii) Check and ensure cleanliness of tubes/pipes connecting level switches/

transmitters and other control instruments for annunciation purposes.

3.7.3 DONTs :

(i) Do not expand the tube more than 10% wall thinning after metal to
metal contact.

(ii) Do not use levers for breaking the joints. They will damage the gasket
seating surfaces which will lead to leakage.

3.7.4 TUBE CLEANING :

Under normal circumstances, it will not be necessary to clean the inside of the
tubes although at certain instances where a deposit of hard scale is encountered it
may be necessary to resort to chemical cleaning. Chemical cleaning should only

A -4
 be carried out under the supervision of a chemist who will decide the nature and
strength of the cleaning solution suitable for particular type of scale present
and material of construction of equipment.

No traces of cleaning solution should be left after completion of the cleaning,

which can be accomplished by testing the outgoing flushing water for neutral
reaction.

3.7.5 TESTING FOR LEAKAGE :

If leakage in the tube system is suspected, pressure test may be conducted

by applying hydraulic pressure on the steam side equal to Shell side test pressure
(Refer Datasheet). Tube end openings on water box side are fully approachable
by opening Water Box cover / manhole to detect the leaking tube. Water coming
out of tubes would indicate leaking joint or punctured tube. Joint leakage can
be arrested by re-expanding the tube. This can be conducted by isolating
heaters on shell and tube side, even when the turbine is in operation.

3.7.6 PLUGGING OF TUBES :

Both ends of the defective tube should be plugged by a slightly tapered S.S.
plug. While plugging the leaking tubes, care should be taken to ensure that
the tube hole and ligament of adjacent holes are not damaged.

Number of plugged tubes should not exceed 10%, as it will have detrimental
effect on the equipment performance. In such cases, retubing of outer periphery
tubes or replacement of tube bundle should be considered.

3.7.7 LEAKAGE THROUGH JOINT GASKETS :

Leakge through flange gaskets should be given immediate attention. Nuts should
be tightened to ensure proper tightness of flange joint. If leak still persists then
heater should be isolated at first available opportunity and joint should be
dismantled and inspected for any damage to flange / gasket. Gasket seat should
be thoroughly cleaned and new gasket should be put whenever joint is
dismantled. Prolonged leakage through flange joint can erode the gasket seating
sur faces which may require major repair.

3.8 LIST OF SPARES (Recommended) :

(i) Level switch / transmitters.

(ii) L evel indicator.

(iii) Isolating valves suitable for level instruments.

(iv) Fastners / Gaskets of all types.

(v) Tube Plugs

(vi) Vent orifice plate

A -5
4.0 GLAND STEAM CONDENSER :

4.1 DESCRIPTION :

4.1.1 G l a n d steam condenser along with exhausters has been provided for
condensing the gland seal leak steam, thereby retrieving the heat energy by heating
the condensate and to maintain the desired steam pressure in the turbine gland seals.

4.1.2 G l a n d s t e am c o n d e n s e r i s s u p p o r t e d b y 2 x1 0 0 % a ir -ex h au s t er s f o r r em o va l
of air f r om t he system . O ne of t he exhauster s is m eant f or nor m a l oper at io n
a n d t h e o t h e r o n e , a l o n g wi t h t h e c h i m n e y, i s f o r s t a n d b y p u r p o s e . W h e n
G l a n d S t e a m c o n d e n s e r n e e d s i s o l a t i o n , t h e c h i m n e y p r o vi d e d i n g l a n d
sealing s ys t e m cuts into operation through
which gland steam is directly led to atmosphere. Isolation and cut
t i ng i n of t h e e xh aust e r, g la n d s t e am con d en se r an d c h im n e y i s d o n e m a n u
ally. Siphon has been provided in the air drain pipe line connection of gland
steam condenser to ensure draining of condensate into condenser in the
event of tube failure. This prevents water entry into turbine.

4.1.3 Exhauster removes the non condensable gases along with the left
out vapour of the gland seal leak steam, thereby inducing flow of turbine
gland seal leak steam into the heat exchanger where heat energ y is retrieved
by regenerative heating of ondensate.

4.1.4 G l a n d s t e a m c o n d e n s e r i s a s h e l l a n d t u b e t y p e o f h e a t e xc h a n g e r. I t
does not h a ve c o n v e n t i o n a l t yp e w a t e r b o xe s . P i p e s t u b s / r e d u c e r s a r e
p r o vi d e d or e it he r si d e of t u b e p lat e f o r c on ne ct in g wi t h co n de ns at e p i pes
a t i n l e t / o u t l e t e n d. Tu be s ha v e b e e n f ixe d o n e it h e r e n ds i n t h e e n d t u be
plates by roller expansion. Condensate and leak steam are kept on
t u b e s i d e a n d s h e l l s i d e r e s p e c t i ve l y. S h e l l i s c o n n e c t e d w i t h t h e e xh a u s t e r
f o r d i s c h a r g i n g n o n - c o n d e n s a b l e g a s e s a l o n g wi t h v a p o u r e i t h e r t h r o u g h
the exhauster discharge end or through the chimney as the case may be.

4.1.5 Air E xhaust e r is a centrif ugal f an; the motor is direct l y mounted on the f a n
casing. The assembly of exhauster and motor is mounted on foundation.
4.2 DOs & DONTs FOR OPERATION :

4.2.1 DOs :

(i) Ensure proper operation of level gauge and level swithches by their
periodic inspection and testing.

(ii) Charge condensate side prior to steam side.

(iii) Attend the problem in exhauster or gland steam condenser at the earliest and put
back exhauster along with heat exchanger into operation so that energy can be
retrieved by heating of condensate.

4.2.2 DONTs :

Do not operate gland steam condenser with high drip level in the equipment for long.

4.3 SALIENT FEATURES FOR MAINTENANCE :

(i) Ensure cleanliness of syphon.

(ii) Ensure proper operation of level switches and level gauges.

(iii) Locate and plug the leaking tubes.

4.4 LIST OF SPARES :

(i) Gauge glass

(ii) Isolation valves

5.0 TURBINE OIL COOLER :

5.1 DESCRIPTION :

The function of the Oil Cooler in the bearing oil circuit is to cool the pressure oil used for
lubricating and cooling the turbine/generator bearings.

Essentially, the Oil Cooler consists of a tube-nest, inner and outer casings, upper and
lower water boxes. The oil to be cooled enters the cooler outer casing through the inlet
nozzle at the top, flows to the inner casing, and through the disc and dough-nut baffle
openings. The baffles are held in position by spacers mounted on steel rods. This
arrangement forces the oil to follow in a cross flow pattern while flowing to the outlet
nozzle at the bottom. The inner casing, holding the dough-nut baffles, is in two halves,
bolted together and is attached to the lower tube plate by screws. Tubes are roller expanded
in the tube plates.

The lower water box, with partition between cooling water inlet and outlet branches, is
bolted with the shell flange and lower tube plates. The upper tube plate is floating type.
The tube nest is free to expand upwards due to differential thermal expansion.

5.2 DOs & DON'Ts for OPERATION :

5.2.1 DOs

(i) W h i l e f i l l i n g i n o i l , c l o s e t h e s h e l l d r a i n va l v e a n d o p e n t h e s h e l l
vent valves.

(ii) Fo r l i f t i n g t h e t u b e n e s t , r e m o v e t h e M 3 6 s c r e w o n t h e u p p e r t u b e
plate after removing the upper water box and use lifting eye-bolt (M36) in its
place.

(iii) Maintain water quality to prevent corrosion/erosion/fouling of tubes. Carry

out chemical dosing, if necessary, only under the super vision of a competent
chemist. Also, ensure adequate quantity of water through tubes.

5.2.2 DONTs

(i) Do not lift the tube nest without first withdrawing the insert-pipe
a ss em b l y.
5.3 DATA SHEET FOR TURBINE OIL COOLER :

(Refer enclosed Annexure-4 for data sheet)

5.4 SALIENT FEATURES FOR MAINTENANCE

(i) Inspect tube inlet ends for erosion/corrosion.

(ii) Ensure cleanliness of the tubes.

(iii) Locate and plug leaking tubes if any.

(iv) Check the condition of the rubber O-rings and their proper seating.
Replace the O-rings if necessary. Use only the recommended O-rings/gaskets as
per technical specification. Take care of not damaging the O-ring/gasket seating
surfaces, as they are critical.

(v) Care may be taken during handling of Outer/Inner casing to avoid

damage to prevent oil leakage.

5.5 LIST OF SPARES

(i) Rubber O-rings for upper tube plate.

(ii) Rubber O-ring for inser t pipe assembly.

(iii) Tu b e s .
FAULT T R AC I NG I NS T R UC T I O NS :

1 . 0 C O ND E NS E R :

1.1 S YMB O L S US E D :

= Reference power output h /t = Rate of vacuum drop in the condenser

t1 = C.W. Inlet temperature tg = (t 4-t 2), TTD steam/CW
t2 = C.W. Outlet temperature tg t g1 == (t 3-t 2), TTD condensate/CW
= C.W. Pressure drop across the condenser tube t = (t 2-t 1), CW temperature rise
t3 = Hotwell condensate temperature h = Vacuum d rop in mm Hg.
t4 = Exhaust steam temperature t = Time in minutes.

Sl. Fa ult S y mp to ms Ca use Re me dy

1.01 Low vacuum )

i t=high C.W. flow being less
a) One of the CW pumps Attend the defective pump
defective
i) t=higher corresponding -Do-
to turbine loading and b ) Malfunctioning of CW Clean the tubes
excessive pump, Condenser tubes
iii) tg & tgl excessive choked Locate & plug the points of air
ingress.
a ) Excessive air ingress A t t e n d t h e a i r- v e n t i n g
equipment.
b ) Malf unctioning of air Correct seal steam supply
venting equipment. pressure.
c) Gland seal steam pressure
low.

B-1
Sl. Fa ult S y mp to ms Ca use Re me dy

iv) tg=high , tgl=normal and a ) Fault in hotwell level Attend the f ault
flooding of condenser

b ) Condensate pump defective Attend the defective pump

1.02 Turbine tripping due to i ) Condenser vacuum low Ref er 1.0.1 above A s s p e c if i e d a t 1 . 0 . 1
low vacuum ii) Condenser vacuum normal above

1.03 Rapid f all in i) C.W. supply, turbine gland Fault in low vac. trip system Attend the f ault
condenser vacuum seal system, air venting & con- a ) Severe air ingress Loca te & plu g the po ints
densate transfer system normal of air ingress

b) Vacuum breaker valve open Close the valve

c) Rupturing diaphragm Replace the diaphragm
d) damaged Condenser drain Close the valve
e) valve open Local level Repair/replace level gauge.
f) gauge damaged Leakage in Locate & plug the leakage
piping of vacuum system point

1.04 Leak test reveals high i) Vacuum pumps not in Air leakage in turbine. Locate & plug the leakage
h/ t operation points
ii) Turbine gland seal steam Tu r b i n e g l a n d s e a l s y s t e m Rectify the gland seal sys-
pressure low defective tem defect

i i i ) Leakage of air f rom a ) Leakage from valve seat Attend valve seat
vacuum breaker valve
b) Improper seal water supply to I mp ro ve s e a l in g wa t e r
the valve gland supply

B-2
Sl. Fa ult S y mp to ms Ca use Re me dy

iv) No water supply to gland Leakage through the valve glands Est ablish se alin g wa ter
of valves connected with vacuum system due supply
to stoppage of seal water

v) Air bubble in water level Water level indictors leaking Attend the level indicator
indicators glands

vi) Rate of condenser vacuum Suction valve glands of its flanged O v e r h a u l t h e v a l v e s

d ro p lo we r whe n all air co n n e ct i o n o n t h e a ir ve n t in g during the next available
venting equipments operate equipment leaking opportunity
with suction valves closed

v ii ) No leakage through the

above Leaking into the vacuum system Loca te & plu g the po ints
of air ingress
v ii i) Ra te o f va cu um d ro p
high at lower turbine loads L e a k a g e t h r o u g h p i p i n g / L o cat e a n d p lu g / rep a ir
than at higher turbine loads equipments connceted to turbine the leaking points
vac. system which remain under
pr. at high/normal loads but under
vacuum at low loads.
i) t1, t (corresponding to the
1.05 Hig her tg & tg l than at power output) & h/ t Leakage into va cuum system as Attend the problem as per
reference power higher per 1. 03 & 1.04 above 1.0 3 & 1. 04 abo ve.

i i ) t1, t, & h/ t normal

De f e ct in the a ir v e n t i n g Operat e the syste m with
equipment stand by.

B-3
Sl. Fa ult S y mp to ms Ca use Re me dy

i i i ) tl & h/ t normal. t & high Condenser tubes fouled on CW side Clean the tubes

iv) tl & h/ t n ormal, low CW f low lower than required Increase CW flow through
& t high condenser

v) tl, t, & h/ t normal; Defective condensate transfer system A t t e n d a n d r e c t if y t h e

condensate level high system defect

1.06 tg higher than tgl Condensate level in hotwell high R e c t i f y c o n d e n s a t e

transfer system

1.07 Conductivity of C.W. Leakage into the condenser Locate the f ailed tub e &
condensate high plug its ends
a ) Excessive air ingress into the
1.08 Dissolved oxygen in vacuum system Locate & plug the leaking
condensate high points
b ) Air venting system choked
Clean the air venting system
c) Excessive quality of cold make up
Improve system tightness to
reduce make up
a ) Hotwell level control system
1.09 Co nd en ser h ot we ll malf unctioning Set level control system on
level high MANUAL and control the level.
Find out the fault & rectify.
b ) Running CEP tripped
Start stand by CEP
c) Same as 1.07
Refer 1.07 above
Level control instrument/control
1.10 Co nd en ser h ot we ll valves malf unctioning Refer 1.09 (a) above
level low

B-4
Sl. Fa ult S y mp to ms Ca use Re me dy

2.0 G L AND S T E AM C O ND E NS E R :

2.1 Vapour escaping f rom i) Exhauster in operation. (i ) Air valve closed Open air valve
shaft gland seals.
( i i ) Steam valve to GSC not f Open steam valve
ully open

(iii) Water level high

(a) Drain valve closed Open drain valve
(b) Drain systems Operate steam trap by pass.
malfunctioning Rectify defect in steam trap.
Open gland seal steam vent
valve to atmosphere; isolate
GSC on tube side; trip fan-
exhauster.

(c) Tube f ailure Plug the leaky tube and restore

GSC and fanehauster to service.

i i ) Exhauster tripped i) Motor overloaded due to pre- Locate reason for high
sence of moisture in vent air. moisture content and attend it.
Wait until over current
protection has released,
then restart the exhauster.

i i ) Motor defective due to Find the cause of moisture

moisture ingress and rectify the same,
Check the motor and repair it if
necessary.

B-5
Sl. Fa ult S y mp to ms Ca use Re me dy

Exhauster not switched on. Mal-operation Switch on exhuster.

2.2 High level alarm. Same as at S l. 2 .1 iii) Sam e as ar sl 2. 1 (iii)

above above.

2.3 St eam escaping f rom No water level in the loop. Mal-operation

emergency syphon loop. Fill the loop with wa ter.

B-6
 Sl. Fa ult S ymptoms/ Ca use Re me dy

3.0 D RAIN C O O LE R & L . P. HE AT E R S :

3.1 Low level ala rm in (i ) Malfunction of high level controller/alter- Close the alternate drain control valves. Find
L.P.H.-1 nate drain control valves. the f ault and rectify.
( i i ) Malf unction of normal level controller/ Find the f ault and rectif y.
normal drain control valve.

3.2 Hi g h l evel al arm in Tube leakage in L.P.H.-1. If the leakage is heavy it will lead to high level
LP H-1 in the heater. If leakage is small heater level
may persist arou nd high le vel. Att end the
heater during the next shutdown.

3.3 Hig h-hig h level alarm Tube leakage in L.P.H.-1. Close condensate inlet/outlet valves and
in L.P.H.-1 open by pass valves. Close isolating valve
for dran control f or d rains f rom L.P.H.-2.

3.4 High level alarms in (i ) Ma lf u n ct io n o f n o rma l le ve l co n t ro lle r/ Find the f ault and rectif y.
LPH-2 or LPH-3. normal drain control valve.

( i i ) Normal drain control valve closed because No operator action is required. The level
of high-high level in succeeding L.P. heater. will ret urn t o no rmal once the conditions
(iii) Tube leakage in respective heater. in the succeeding heater are normal.
(iv)Disperser f itted drain inlet nozzle in lower clean the disperser holes.
heater got chocked.
3.5 Hig h-hig h level alarm Tube leakage in respective heaters. Observe that heater g ets isolated o n
in L.P. H.-2 /3. steam side by the closure of steam
extraction valve.

B-7
 Sl. Fa ult S ymptoms/ Ca use Re me dy

Iso late the heate r on the conden sate side by

opening the bypass valves first and then closing
the isolating valves.

3.6 Temperature rise of conden- (i ) Heater not or insuff iciently vented. Open heater vent valves.
sate higher than design
( i i ) Heater vent orif ices chocked. Clean the vent orifices.

( i i i ) Air leaks Find air leaks and seal.

(iv) S ca le f orma t i o n o n t h e in t e rio r Clean the tube system.

surfaces.

(v) Condenser bypass valves not fully Close the bypass valve tightly or
closed or heavily passing. lap valve seat.

B-8
Sl. Fa ult S y mp to ms Ca use Re me dy

4.0 T UR B I NE O I L C O O L E R / C O NT R O L F L UI D C O O L E R :

4.1 Outlet oil tempera ture Cooler body very hot (i ) C.W. flow less than required. Improve C.W. f low.
high
( i i ) Excessive fouling or deposites Ca rry ou t c lean ing
in the tubes. o f tubes.

(iii) Large no. of tubes have R e p l a c e p lu g g e d

been plugged. t u b e s wit h new tube s
af ter p ut- tin g the
stan dby cooler in
the system.

B-9
 ANNEXURE-1
CONDENSER DATA SHEET

Sl. No. Description Data Unit

(i) Design C.W. Temperature 33.0 C

(ii) C.W. Temperature rise 10.3 C
(iii) Condenser back pressure 77 mm Hg (a)
(iv) C.W. flow quantity 2x31650 m3/hr
(v) C.W. side pressure drop 4.1 mwc
(vi) No. of C.W. pass 2
(vii) No. of tubes : 2x17266 No.
(viii) Tube dimensions :
(a) Tube OD x thickness 28.575x0.7112 mmxmm
28.575x0.889 mm (Top 2 Rows)

(b) LBTP 13000 mm

(ix) Tube material : Welded SS TP 304
(x) Percentage tube thinning 7 to 10%
(xi) Water box design pressure 5.0 kg/cm2(g)
Full vacuum
(xii) Water box Hydraulic test pressure 7.5 kg/cm2(g)
 ANNEXURE - 2

DATA SHEET FOR CONTROL FLUID COOLER

(Data for one cooler)

S. Description Unit Data

No.
(i) Cooling surface area provided m2 31.4

(ii) Oil flow m3/hr 30.09

(iii) Heat dissipating capacity kw 90

0
(iv) Oil inlet temperature C 60
0
(v) Oil outlet temperature C 54

(vi) Oil side pressure drop mwc 2.5

0
(vii) CW inlet temperature (design) C 38
0
(viii) CW outlet temperature (design) C 39.29

(ix) CW Flow m3/hr 60

(x) CW side pressure drop (apprx.) mwc 2.4

(xi) Design pressure CW side kg/cm2 10

(xii) Design pressure Oil side kg/cm2 13

(xiii) Material of (a) Tube Stainless steel

(b) Tube Plates Stainless steel

(c) Casing (Shell) Stainless steel

(d) Water boxes Carbon steel

Note : Refer Drg. for details.

A-25
 ANNEXURE-3

DATA SHEET FOR L.P. HEATER No.1

Description (Unit) Data

(i) Type Shell & Tube

(ii) Design Pr. (kg/cm2g) (a) Tube side 39

(b) Shell side Full Vacuum & 3.0

(iii) Design Temp (0C) (a) Tube side 150

(b) Shell side 150

(iv) Total tube surface area (M2) 605

(v) No. of water passes Two

(vi) Tube outside Dia x 16x1.0

Tk. (mm x mm)

(vii) Tube material Welded SS TP-304

(viii) Total No. of U-tubes 553

(ix) Weight of Heater (MT)

(a) Empty 14.0
(b) Opening 18.44
(c) Flooded 24.79

NOTE : Refer Drg. For details.

 ANNEXURE-4
GSC DATA SHEET

Sl. No. Description Data Unit

Full Vaccum and
(i) Shell side Design pressure 39 kg/cm2(g)
(ii) Tube side Design pressure 39 kg/cm2(g)
(iii) Shell side Design Temperature 310 C
(iv) Tube side Design Temperature 100 m3/hr
(v) Surface area provided 60.17 m2
(vi) No. of water pass 1
(vii) No. of tubes : 862 No.
(viii) Tube dimensions :
(a) Tube OD x thickness 19X0.889 mmxmm
(b) LBTP 1170 mm
(ix) Tube material : Welded SS TP 304
 01
ANNEXURE - 5

DATA SHEET FOR TURBINE OIL COOLER

(Data for one cooler)

S. Description Unit Data

No.
(i) Cooling surface area provided m2 640

(ii) Oil flow m3/hr 182.304

(iii) Heat dissipating capacity KW 1907.67

0
(iv) Oil inlet temperature C 65
0
(v) Oil outlet temperature C 45

(vi) Oil side pressure drop mwc 4.0

0
(vii) CW inlet temperature (design) C 38
0
(viii) CW outlet temperature (design) C 41.3

(ix) CW Flow m3/hr 500

(x) CW side pressure drop (apprx.) mwc 3.5

(xi) Design pressure CW side kg/cm2 10.0

(xii) Design pressure Oil side kg/cm2 9.4

(xiii) Material of (a) Tube Admiralty Brass

(b) Tube Plates Carbon steel

(c) Casing (Shell) Carbon steel

(d) Water boxes Carbon steel

Note : Refer Drg. For details.

 NAME OF PLANT:

PLANT AREA : TURBINE AND AUXILIARY DOCUMENT NO

PROCEDURE FOR VACUUM TIGHTNESS TEST

Annexure 6

WRITE UP ON STEAM PRESSUIZATION TEST

Air ingress in condenser, more than the design value, is not desirable. It decreases
the condenser vacuum. Efficiency of the machine reduces with increase of air
ingress. This article spells out the procedure of vacuum leak detection in steam
turbines by steam pressurization.

1. FACTORS RESPONSIBLE FOR LOW VACUUM

The factors are :
i) Air ingress through leaking joints.
ii) Insufficient cooling water flow.
iii) Fouling of cooling water tubes of condenser.
iv) Malfunctioning of vacuum-pulling equipment e.g. vacuum Pump, Ejectors
etc.
v) Excessive thermal loading of condenser due to leaking drain valves and
HP/LP by-pass.
The following sections bring out the procedure of detecting leakage points in
the above-mentioned undetected area by steam pressurisation. The purpose
of this test is to check leakages in those areas, which will remain under
vacuum even at a load of 80 to 100% on the machine. This procedure is to be
adopted during commissioning as well.

2. STEAM PRESSURISATION OF VACUUM SYSTEM

Steam Pressurisation of vacuum system is done in an absolutely cold
machine and piping system. It involves the following three stages:

Prepare the system for vacuum tightness. Fill the water in the system up to
one metre above the tube nest. Normally, to check the level of water, a
polythene tube is used. Mark the level of water in the tube. Check for any
fall of level in 24 hours. Attend to the leakages if any fall of level is noticed.

Preparation of thermal scheme of turbine for steam pressurisation.

Steam pressurisation of vacuum system.

NAME OF PLANT:

PLANT AREA : TURBINE AND AUXILIARY DOCUMENT NO

PROCEDURE FOR VACUUM TIGHTNESS TEST

2.1. Process of Steam Pressurisation

After noting down the initial readings of the turbine supervisory system,
start the Steam Pressurization of vacuum system, for which the following
should be done:
Manually open the steam supply valves supplying steam to the LP
exhaust, and raise the pressure slowly. It takes around 4 - 6 hours for
the pressure to start building up.
Keep a watch on the operational parameters of steam turbine, e.g.
differential expansion of HP, IP & LP cylinders, axial shift, exhaust-
hood temperature, exhaust-hood pressure, and record the readings.
At an exhaust-hood pressure of 0.10 to 0.20 kg/cm2, start checking
the leakage points.
If any of the turbine parameters is going out of limits, further
pressurization should be stopped by cutting off the steam supply to
turbine.
Vacuum line to speed control rack, LP bypass rack and vacuum
pressure switches rack
LP bypass downstream connection to condenser, welding joint with
condenser
LP gland boxes joint
Instruments tapping point on the above mentioned areas
TD BFP exhaust steam connection up to its isolating values
Various flange connection with IP casing
Note: Repeat the Steam Pressurisation process after attending to
the leakage points, till no leaks are observed.

3. Status of Equipment During Test: Following should be the

status of equipments during test

C.W.pumps - Not in operation

Condensate extraction pumps - Not in operation

Boiler feed pumps - Not in operation
NAME OF PLANT:

PLANT AREA : TURBINE AND AUXILIARY DOCUMENT NO

PROCEDURE FOR VACUUM TIGHTNESS TEST

Gland steam exhauster - Not in operation

Condenser completely drained on C.W. box side and to be on jacks.

 Bharat Heavy Electricals Limited
(A Govt. of India Undertaking, ISO 9001 Company)
HEAVY ELECTRICAL EQUIPMENT PLANT (HEEP)
Ranipur, Haridwar-249403 (Uttrakhand) / (01334) 227350, / (01334)223948.

Ref: HWR/HXE/FES/MSK/1.01

Subject: Hydro fill test procedure on steam side of Condenser.

1. After the tubing has been completed, including the trimming of the tubes. Then Hydro
-fill test is to be conducted on the steam side of condenser.

2. Lock the spring supports in position.

3. Gradually fill the steam space with water. A water tube arrangement is to be installed,
so that the level of water can be monitored.

4. During filling, constantly check the tubes for any leakage. In case any leakage is observed,
that particular tube should be further expanded.

5. In case any tube is not getting sealed, it may be plugged after concurrence taken from
concerned unit.

6. Fill the water upto 1m over the top rows of tubes and leave for 24 hours. Check
thoroughly for any leakages.

7. Add a fluorescent dye (sodium fluorescence) to filled water in condenser to concentration

of 2-3ppm (approx. 2 kg). Water shall be bubbled with compressed air for proper mixing
of dye in filled water.

8. Leave water for another 24/36 hours.

9. Finally inspect the tube by ultra violet light with the help of some UV lamp.

10. When no fluorescence is observed, it can be referred that there is no leakage.

11. During this test, other connected areas (falling under vacuum during operation can be
inspected for any leakages).

12. Release the condenser springs, after all water has been drained from both the steam
space/CW side. The springs are finally set as per drawings.

Note: Water should never be filled on both steam side and CW side at the same time.

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PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT