CONDENSER AND COOLING WATER PLANT

CONDENSER
1.1. INTRODUCTION.

The functions of the condenser are to:

(a) Provide the lowest economic heat rejection temperature for the steam cycle.
(b) Convert the exhaust steam to water for re-use in the cycle.
The associated cooling plant maintains a supply of cooling medium to extract the necessary heat
for these functions.
The field cycle which attempted to pressurise exhaust steam without first condensing it was
not an economic proposition. The condensing plant is, therefore, still an integral part of the
cycle and is likely to remain so unless a method is adopted of utilising the 'low. grade' heat that
is rejected to waste. District heating and sea water distillation plant are possible substitutes for
the condenser.
It follows that the main problem in condenser design is to achieve conditions which will
ensure that only the unusable heat in the steam at the turbine exhaust is rejected. Any
deviation from these conditions will cause a decline in efficiency and a very small departure
from the optimum back-pressure can, if continuous, add thousands of pounds to the annual
cost of running a machine.
Modern condensers are generally of the surface type operating under vacuum. There are limits
to the vacuum which can be economically employed, since the volume of each pound of steam
increases rapidly with decrease in pressure. For a given size of l.p. cylinder, the velocity of
the steam leaving the last row of blades can be such that the loss due to kinetic energy in the
exhaust steam ('leaving loss') outweighs the gain from improved vacuum. Within the limits of
'leaving loss' the vacuum should be as high as possible, but in practice it is dictated by the size
of the condenser, cooling plant, cooling towers, pumps, culverts, screens, etc. A point would be
reached when the efficiency advantage of better vacuum would be outweighed by the increased
cost of the cooling plant. This is an example of the 'law of diminishing returns'.
In addition to its main functions the condenser is a suitable point at which to reintroduce into the
feedwater line, drains from the turbine feedheating and other auxiliary plant and also any boiler
feedwater make up which may be required. If used in conjunction with a 'once through' boiler
the condenser must be capable of accepting steam direct' from the steam raising unit. On startup this steam may be of a low quality that is unsuitable for use in the turbine. When steam is
passed direct to the condenser it is referred to as 'steam dumping'.
Air extraction equipment is necessary to remove the air and incondensable gases from the
steam space in the condenser and the considerations governing its design are dealt with. The
possibility and effect of leakages of air and cooling water into the steam space will be discussed.

The objectives of condenser design can be summarised as: to condense the exhaust steam while
providing:abcdef-

The lowest economic heat sink temperature.

minimum undercooling of the condensate.
minimum pressure drop on the steam side.
effective removal of incondensables in the steam, and air from leakages.
effective deaeration of condensate.
effective prevention of water leakages.

all these objectives to be qualified by the following practical considerations:

(i)
(ii)
(iii)
(iv)

Economy of overall size, i.e. surface.

Economy of space usage for a given size while still allowing good steam flow,
small pressure drops, etc.
Economy of cooling water pumping power.
Ease of maintenance and construction.

1.2.1. Construction
The condenser is placed adjacent to the turbine exhaust so that the pressure losses in the
turbine/condenser connecting pieces are minimal. Manufacturers adopt various relative
arrangements of turbine and condenser and also different methods of support; however,
the basic components of a condenser are similar and may be shown in the diagrammatic
cross sectional arrangement of a typical condenser as shown in Figure 1.2.1a.
Figure 1.2.1b shows several ways in which the basic condenser pattern is arranged relative
to the turbine.
The condenser consists essentially of a shell, which encloses the steam space, and of tubes
carrying cooling water, which pass through the steam space but are hydraulically separate
from it.
The condenser shell of a modern unit is a very large construction (Fig. 1.2.1a) and would be
difficult to transport as a complete component from the place of manufacture to site. The
main shell, which is of mild steel, is therefore fabricated in several sections to be assembled
finally at site. The joints between the various sections are made by butt- welding, bolting
coupled with seal welding or by bolting coupled with a suitable jointing material. The shell is
tested for air tightness either hydraulically as a unit or by examination and testing of the
individual joints.
The complete shell is attached to the turbine exhaust again either by butt-welding or a bolting
method. A condenser plus l.p. turbine components in normal running condition, for a 500
MW unit may weigh 1750 tons. The condenser may be supported either (a) completely
separately from the turbine or (b) integrally with the l.p. turbine or (c) by a method in which
the load is shared between independent supports, the turbine and the turbine foundation block
(see section 1.2.3).

1.
2.
3.
4.
5.
6.
7.

Condenser shell
Inlet end waterbox
Outlet end waterbox
Tube plate assembly
Inspection doors
Tube support plates
Tubes and staybars

8.Codensate outlet
9. Expansion bellows
10.Tube plate tube-end pattern
11. Air extraction boffle
12.Air extraction
13.Air-cooler section
14.Accers lare

FIG. 1.2. 1a. Diagrammatic arrangement of a condenser

1.2. 1b. Condenser positions relative to l.p. turbine