Test Procedure

8.4 Condenser Performance Test

Table of Contents
Sr. No.
8.4.1

Contents
Introduction

8.4.2

Objectives

8.4.3
8.4.4

Plant Specific Data

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

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

NON-CONDENSABLE
OUTLET T

STEAM INLET

NON-COND.

AIR/VAPOR REMOVAL
OUTLET SYSTEM
P

(
P)

DO

CIRCULATING
WATER INLET

CIRCULATING
WATER OUTLET

CONDENSATE
LEVEL

(
P)

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

Fig-8.4.1

8.4- 3

PERF. TEST
CONNECTION
SUPPLEMENTAL
TEST CONNECTION

Condenser BackPressure andCWInlet / Outlet Temperature Measurement

ATOPERATING
FLOOR.

~~

Side View
Tapping Arrangement for Measurement
of Condenser BackPressure
Note: 1. Tapping maybe kept nearer
to LPCand Condenser joint.
2. Near tappingno protruding
obstructionexist.

Plan
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

CWOutlet

CWInlet

Note:
1. Four Nos. thermowell tobe provided on each
CWOutlet line at a location convenient to
use from0 meter.
2. One No. thermowell on each CWInlet line.
nnexure
-V
3. thermowell approx. A
300
mmdepth

Fig-8.4.2

8.4- 4

Detail A

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
= (Enthalpy of Cold Reheat Steam), kcal/kg
hCRH
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
=
hSHATT
=
Flow SH Attemp =
Heat Loss rad
=

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

(Enthalpy of SH Attemp ), Kcal/kg
Kg/hr
0.1% of Pgen (Radiation Losses) kW
8.4- 6

Pgen
Pgen Losses*

= (Gross Generator Output), kW

= (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:
CW Flow

Where:

C.W Flow
Cond Duty
Cp

Tout
Tin

=
=
=
=
=
=

Cond Duty
-----------------------------Cp (Tout Tin) x

m3/hr

m3/hr
kcal/hr
1 kcal/kg o C (Specific heat of water)
1000 kg/cubic meter (Density of water)
o
C (Average C.W Outlet temp.)
o
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
C.W Flow Rate
Tube Area

= m/sec
3
= m /hr
= mm2 (Cross sectional area of water flow
Passage)

8.4.4.6 Determination actual Log Mean Temperature Difference (LMTD):

LMTD

Tout - Tin
= ------------------Tsat Tin
Ln ---------Tsat Tout

Where:
LMTD = oC
8.4- 7

Tsat

= C

(saturation temperature corresponding to condenser

back pressure)

8.4.4.7 Determination of Expected LMTD :

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

| Saturation Temp Test - LMTD test

|
| ------------------------------------------------ |
| 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)
fq =

Cond. duty design

-----------------------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:
Sat. Temp. Expected: =

[Tin Tout x eZ]

--------------------------- oC
[1 - eZ]

Where:
Tin
Tour

= Design C.W. inlet temp.

= Design C.W. outlet temp.

Tout Tin
= -------------------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: ......................
DESCRIPTION

Unit: .........................
UNITS
VALUE

Unit Name Plate Rating

Number of Passes

Number

Heat Load Considered for Design

(Condenser Duty)

kcal/hr
m3/hr

Condenser Flow
Condenser Vacuum with CW Inlet Temp.
Tube Length Between Tube Plates

mm Hg
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
Velocity Through Tubes

m/sec

TTD at Design CW Flow & Inlet Temp.

LMTD

C
Fromat-8.4.1

8.4-10

TEST READINGS
Station: ......................
Unit: ................ Test Date: ...........
DESCRIPTION
UNITS
TEST
S No.
READINGS
0
1.
CW Inlet Temp(Left)
C
2.

CW Inlet Temp(Right)

3.

CW Outlet Temp(Left-1)

4.

CW Outlet Temp(Left-2)

5.

CW Outlet Temp(Left-3)

6.

CW Outlet Temp(Left-4)

7.

CW Outlet Temp(Right-1)

8.

CW Outlet Temp(Right-2)

9.

CW Outlet Temp(Right-3)

10.

CW Outlet Temp(Right-4)

11.

Condensate Temp(Left)

12.

Condensate Temp(Right)

13.

Air/Steam Temp(Left)*

14.

Air/Steam Temp(Right)*

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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

PARAMETER
Unit Load
MS Press bef ESV
MS Temp bef ESV
CRH Press HPT Exh
CRH Temp HPT Exh
HRH Press bef IV
HRH Temp bef IV
FW Press bef Eco
FW Temp bef Eco
FW Flow
SH Attemp. Flow
RH Attemp. Flow
HP Leak off Flow
HPH Extr. Temp
HPH Extr. Press
FW Inlet Temp
FW Outlet Temp
Drain Outlet Temp
Drain Inlet Temp (If applicable)
Drain Inlet Flow (If applicable)
FW Inlet Press (Optional)
FW Outlet Press (Optional)
BFP Inlet Press
BFP Inlet Temp
BFP Outlet Press
BFP Outlet Temp

UNIT
MW
kg/cm2 (a)
Deg C
kg/cm2 (a)
Deg C
kg/cm2 (a)
Deg C
kg/cm2 (a)
Deg C
t/hr
t/hr
t/hr
t/hr
Deg C
kg/cm2 (a)
Deg C
Deg C
Deg C
Deg C
t/hr
kg/cm2 (a)
kg/cm2 (a)
kg/cm2 (a)
Deg C
kg/cm2 (a)
Deg C

Test Data

Format-8.4.3

8.4-12

Condenser Heat Load Calculation

1
2
3
4
5
6
7
8
9
10
11
12
13

Parameters

Units

Unit Load
MS Press bef ESV
MS Temp bef ESV
CRH Press HPT Exh
CRH Temp HPT Exh
HRH Press bef IV
HRH Temp bef IV
FW Press bef Eco
FW Temp bef Eco
FW Flow
SH Attemp. Flow
RH Attemp. Flow
HP Leak off Flow

MW
kg/cm2
Deg C
kg/cm2
Deg C
kg/cm2
Deg C
kg/cm2
Deg C
t/hr
t/hr
t/hr
t/hr

Data
(a)
(a)
(a)
(a)

200
148.17
537.42
38.645
352.115
36.275
526.575
169.77
244
703.92
0
6.64
0.54

HP Heater Parameters
14
15
16
17
18
19
20
21
22

HPH Extr. Temp

HPH Extr. Press
FW Inlet Temp
FW Outlet Temp
Drain Outlet Temp
Drain Inlet Temp (If applicable)
Drain Inlet Flow (If applicable)
FW Inlet Press (Optional)
FW Outlet Press (Optional)

Deg C
kg/cm2 (a)
Deg C
Deg C
Deg C
Deg C
t/hr
kg/cm2 (a)
kg/cm2 (a)

335.2
42.742
203.3
253.4
208.1
0
0
0
0

kg/cm2 (a)
Deg C
kg/cm2 (a)
Deg C

7
162
205
166

MW

8.489

BFP Parameters
23
24
25
26

BFP
BFP
BFP
BFP

Inlet Press
Inlet Temp
Outlet Press
Outlet Temp

27

Generator Losses

8.4-13

Condenser Parameters
28
29
30
31
32
33
34
35

Condenser Back Pressure

CW Inlet Temp
CW Outlet Temp
No. of Cond Tubes
No. of Cond Tubes Plugged
Tube OD
Tube ID
Tube Length

mm Hg
Deg C
Deg C
No.
No.
mm
mm
m

77
33
43.45
24398
0
31.75
30.3276
14.73

Condenser Duty
CW Flow
Tube Velocity
LMTD
LMTD Expected
Saturation Temp Expected
Expected Back Pressure

kcal/hr
T/hr
m/sec
Deg C
Deg C
Deg C
mm Hg

25367508
2428
0.077
6.843
1.477
43.459
66.361

Deviation in Condenser Back Pressure

mm Hg

10.639

8.4-14

DETERMINATION OF BREAKUP OF CONDENSER BACK PRESSURE

DEVIATION
SR

TEST

NO
.

LOAD MW

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22

Description

UNIT
No
Derivation

Unit - Load
Back pressure
Corresponding Sat. steam temp.
CW inlet temp.
CW outlet temp. (Mean)
* Condensate temp. (Left)
* Condensate temp. (Right)
*Air Suction temp. (Left)
* Air Suction temp. (Right)
*CW Outlet Valve (Left)
* CW Outlet Valve (Right)
Target back press
Optimum CW rise
Optimum TTD
Back pressure due to CW inlet temp.
Back pressure due to CW
flow & CW inlet temp.
Variation due to CW inlet temp.
Variation due to CW flow
Variation due to air/dirty tubes
Total variation
No. of air pumps/ejector in service
Air Suction Temp Depression (L)
Air Suction Temp Depression (R)
Condensate Sub Cooling (L)
Condensate Sub Cooling (R)

Unit

Curve-I
Curve-II
Curve-II
(4)+(10)+(11)
(5) + (11)

mm Hg
o
C
o
C
mm Hg
mm Hg

200
120.8
55.56
34.16
45.09
55
55
48.9
50.04
100
100
85
10
2.5
79
81

(12)-(9)
(13)-(12)
(2)-(13)
(2)- (12)
1
(3)-(7)
(3)-(7)
(3)-(6)
(3)-(6)

mm Hg
mm Hg
mm Hg
mm Hg
No.
o
C
o
C
o
C
o
C

-6
2
39.8
41.8
1
6.66
6.66
0.56
0.56

Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant

MW
mm Hg
o
C
o
C
o
C
o
C
o

Remarks

Format-8.4.4

8.4-15

V a r ia tio n

o f B a c k P r e s s u r e w it h
C W
T e m p e r a t u r e

C u r v e -I
L o a d &

0.120

Ba ck Pr es s u r e

0.100

35 C
30 C

0.080

25C

0.060

20C

0.040

15C

0.020
0.000
15

25

35

45

55

o f

65

L o a d

8.4-16

75

85

95

105

Curve-II

10.0
9.0
8.0
TT
eE
M
m
pP
eE
rR
aA
tT
uU
rR
eE

7.0
6.0

D
T

CW Temp Rise

5.0
4.0

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
S.N

Report Date:
Description

Unit No

Unit-1

Unit-2

Unit-3

Date
1

Load

Condenser Back pressure

CW inlet temp.

CW outlet temp. (Mean)

Condensate temp. (L&R)

Air Suction temp. (L&R)

Expected Back pressure

mm Hg

Target Back pressure

mm Hg

Variation due to CW inlet

temp.

mm Hg

10

Variation due to CW flow

mm Hg

11

Variation due to air/dirty

tubes

mm Hg

12

Total variation

mm Hg

13

Air suction Temp.

Depression

MW
mm Hg

Test Condition

Remarks

Format 8.4.5
8.4-18

Unit-4

8.4-19