Steam Condenser Not Working: Pressure & Temperature Issues

In summary, it sounds like the condenser is not catching exhaust from a steam turbine and that there are differences in reheat spray and sealing steam flows. The condensate drain from a steam condenser is expected to be about 50 deg C. It's only 38 deg C or so. There's a mix of steam and non condensable gases coming into the condenser. Its pressure seems slightly higher, being about 0.25 bar abs instead of 0.2 bar. What does it indicate? Also, no significant difference in cooling water flow and the inlet outlet temps, compared to other healthy units under similar load conditions.
  • #1
Nirmsing1411
1
0
The condensate drain from a steam condenser is expected to be about 50 deg C. It's only 38 deg C or so. There's a mix of steam and non condensable gases coming into the condenser. Its pressure seems slightly higher, being about 0.25 bar abs instead of 0.2 bar. What does it indicate? Also, no significant difference in cooling water flow and the inlet outlet temps, compared to other healthy units under similar load conditions.
 
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  • #2
You should do a heat balance on this condenser and one of the others and compare the numbers. It sounds wrong that you have these differences but zero difference in the cooling water flow or temperatures.

You don't really give enough information, but it sounds like the flow rate (pounds per second) of moisture and/or steam into that condenser is different than the other condensers. Presumably, they should be the same. Look for differences in the upstream drains between this condenser and the others.

Are these condensers catching exhaust from steam turbines? If so, also check for differences in reheat spray, and for abnormal sealing steam flows.
 
  • #3
Nirmsing1411 said:
The condensate drain from a steam condenser is expected to be about 50 deg C. It's only 38 deg C or so. There's a mix of steam and non condensable gases coming into the condenser. Its pressure seems slightly higher, being about 0.25 bar abs instead of 0.2 bar. What does it indicate? Also, no significant difference in cooling water flow and the inlet outlet temps, compared to other healthy units under similar load conditions.

How's the air ingress on those other units?

In a condenser, steam flowing toward the tubes should reheat the water dripping from them back up to nearly saturation.
Too much air interferes with that.
Our condenser had trays interspersed in the tube bundle to catch the condensate and route it out of the tubes on an inclined plane, providing lots of surface area for heat transfer from incoming steam. That brings condensate back closer to saturation temperature.

upload_2017-6-20_0-47-4.png

image courtesy of these guys
http://www.hts.org.uk/downloads/TroubleshootingSteamSurfaceCondensers.pdf

Cooling water temperature rise shouldn't be much different between your condensers,,, .
Compare :
the enthalpy change between saturated vapor and saturated liquid
to
the enthalpy change between saturated vapor and your twelve degrees subcooled liquid.
Divide one by the other, i wager you get pretty close to 1.That's my guess.

Is the air ejector howling ? What tests can you run ?

@Nirmsing1411 have you gone away ?
 
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1. Why is the steam condenser not working?

The steam condenser may not be working due to a variety of reasons, such as a leak in the condenser tubes, buildup of debris or deposits, malfunctioning valves or pumps, or inadequate cooling water flow. It is important to troubleshoot and identify the specific issue in order to properly address it.

2. How does pressure affect the performance of a steam condenser?

Pressure plays a crucial role in the function of a steam condenser. If the pressure in the condenser is too low, it can result in poor condensation and reduced efficiency. On the other hand, if the pressure is too high, it can cause excessive backpressure in the system and lead to reduced power output. Maintaining optimal pressure levels is key to ensuring the proper functioning of the steam condenser.

3. What is the ideal temperature for a steam condenser?

The ideal temperature for a steam condenser varies depending on the type of condenser being used. Generally, a lower temperature is preferred as it allows for better condensation and higher efficiency. However, the temperature should not be too low as it can cause condensate to freeze and damage the condenser tubes. It is important to monitor and maintain the temperature within a safe and efficient range.

4. Can temperature fluctuations cause issues with the steam condenser?

Yes, temperature fluctuations can have a significant impact on the performance of a steam condenser. Sudden changes in temperature can cause thermal stress on the condenser tubes, leading to cracks or leaks. This can also affect the efficiency of the system. It is important to maintain a consistent temperature to prevent any potential issues.

5. How can I prevent pressure and temperature issues with my steam condenser?

Regular maintenance and monitoring are crucial in preventing pressure and temperature issues with a steam condenser. This includes checking for leaks, cleaning and removing any deposits, and ensuring proper functioning of valves and pumps. It is also important to maintain optimal pressure and temperature levels and address any fluctuations or abnormal readings immediately to prevent further issues.

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