condenser sizing calculation

KUDGI SUPER THERMAL POWER PROJECT STAGE-I (3X800 MW)

OWNER

NTPC Limited (A Government of India Enterprise)

CONTRACTOR TOSHIBA JSW TURBINE & GENERATOR PRIVATE LIMITED

CONTRACT NO. CS-9573-110-2-FC-COA-5661, CS-9573-110-2-SC-COA-5662, CS-9573-110-2-TC-COA-5663

SUB-CONTRACTOR TOSHIBA CORPORATION, JAPAN

OWNER’S DOC. NO. 9573-110-PVM-U-018

SUB-CONTRACTOR’s DOC. NO.

REV. DDKV71215 d

DRG. / DOC. TITLE SIZING CALCULATION OF CONDENSER

PURPOSE FOR APPROVAL / FOR INFORMATION

[Revision Status for Owner’s Document No.]

02 13/Sep/2012 Revised as per design progress R. Y Y. F Y. F

01 25/July/2012 Revised as per design progress R. Y S. M Y. F

REV. NO. DATE DESCRIPTION REVISED BY CHECKED BY APPROVED BY

ISSUED BY - TOSHIBA JSW TURBINE & GENERATOR PVT. LTD.

NAME SIGNATURE

APPROVED BY Y. Fuki Y. F REV. NO. 00

CHECKED BY Y. Fuki Y. F

PREPARED BY S. Mori S. M DATE 7/June/2012

TOSHIBA JSW TURBINE & GENERATOR PVT. LTD.

© THE INFORMATION IN THIS MATERIAL IS CONFIDENTIAL AND CONTAINS TOSHIBA’s INTELLECTUAL PROPERTY INCLUDING KNOW-HOW. IT SHALL NOT BE DISCLOSED TO ANY THIRD PARTY, COPIED, REPRODUCED, USED FOR UNAUTHORIZED PURPOSES NOR MODIFIED WITHOUT PRIOR WRITTEN CONSENT OF TOSHIBA.

RE

VIS

ION

NTPC

DummyComment

DD KV71215-d

20 1

社内配付先

DISTRIBUTION

NETSU-SETSU

発行部課名

ISSUED BY

承認 APPROVED BY

タービン機器部

熱交換器設計担当

調査 REVIEWED BY 担当 PREPARED BY

R.Yasuki

TURBINE PLANT EQUIPMENT DEPT. HEAT EXCHANGER DESIGN GROUP

Sep.13.2012

設計要項表 Design Data Sheet

名称 TITLE

Sizing Calculation of Condenser

客先名 CUSTOMER ： NTPC Limited 系統機器 EQ/SYS. ： Condenser 製番 JOB ： -- プラント PROJECT ： KUDGI SUPER THERMAL POWER PROJECT

STAGE-I (3X800 MW)

The information in this material is confidential and contains Toshiba’s intellectual property including know-how. It shall not be disclosed to any third party, copied, reproduced, used for unauthorized purposes nor modified without prior written consent of Toshiba.

Toshiba Corporation

布木

KDMS：調査／承認（一般：ENG）

布木

KDMS：調査／承認（一般：ENG）

DD KV71215-d

20 2 設計要項表 Design Data Sheet

Contents

1. Design Specification 3

2. Calculation of Circulating Water flow rate 4

3. Thermal Calculation 5

3.1 L.P. Condenser 5

3.2 H.P. Condenser 8

4. Hydraulic Calculation 11

4.1 L.P. Condenser 11

4.2 H.P. Condenser 12

4.3 Total loss of Condenser 12

5. Hotwell Storage Capacity 13

6. Steam and Condensate flow 14

Appendix

・ UNCORRECTED HEAT TRANSFER COEFFICIENTS Figure 1 *

・ INLET WATER TEMPERATURE CORRECTION FACTOR Figure 2 *

・ TUBE MATERIAL AND GAUGE CORRECTON FACTORS Table 3 *

・ TEMPERATURE CORRECTION FOR FRICTION LOSS IN TUBES Figure 7 *

・ WATER BOX AND TUBE END LOSSES SINGLE PASS CONDENSER Figure 8 *

*HEI STANDARD for STEAM SURFACE CONDENSERS 10th EDITION

DD KV71215-d


1.Design Specification

Number One(1)/unit (L.P.)

One(1)/unit (H.P.)

Type Horizonal surface cooling

Tube surface area (m2) 29,011 (L.P.)

29,011 (H.P.)

Tube Specification

Material ASTM A249 TP316L (Stainless)

Outside diameter (mm) D=25.4

Thickness (mm) t=0.711 (Refer to below table.)

(mm) t=0.889 (Refer to below table.)

Effective length (mm) 14,375

Overall length (mm) 14,431

Number of tubes (per shell)

Location Thickness (mm) Number

Condensing Zone t=0.711 22,764

t=0.889 2,528

Total - 25,292

Number of water passes One(1)

Cooling water source Fresh Water

Cleanliness factor Fc=0.90 (90%)

Main Cooling Water (m3/min.) 1,310 (78,600 m3/hr)

Applied Codes & Standards

Heat Exchange Institute 10th (HEI 10th)

d d

DD KV71215-d


2.Calculation of Circulating Water flow rate.

a.Heat duty (L.P.Condenser)

Flow RateSpecificEnthalpy

HEAT(Enthalpy)

kg/h kcal/kg kcal/kg kcal/hMain Turbine Exhaust 659,579 × （ 564.1 － 40.9 ）＝ 3.4509173E+08BFP Turbine Exhaust 67,223 × （ 590.2 － 40.9 ）＝ 3.69256E+07Turbine Gland Seal Steam 1,614 × （ 750.4 － 40.9 ）＝ 1.14513E+06

Total ＝ 3.83162E+08Heat Duty ： 3.83162E+08

b.Heat duty (H.P.Condenser)

Flow RateSpecificEnthalpy

HEAT(Enthalpy)

kg/h kcal/kg kcal/kg kcal/hMain Turbine Exhaust 695,547 × （ 570.1 － 46.1 ）＝ 3.6446663E+08BFP Turbine Exhaust 68,895 × （ 594.5 － 46.1 ）＝ 3.77820E+07Drain from Gland Steam Condenser 1,339 × （ 99.1 － 46.1 ）＝ 7.09670E+04Drain From LP No.1Heater 173,689 × （ 53.0 － 46.1 ）＝ 1.19846E+06Make-up Water 73,656 × （ 46.1 － 46.1 ）＝ 0.00000E+00L.P Condenser Drain 728,416 × （ 40.9 － 46.1 ）＝ -3.78776E+06

Total ＝ 3.99730E+08Heat Duty ： 3.99730E+08

c.Circulating Water

Ｃｐ・γ＝ 9.920E+02 kcal/m3℃

Upper Limit of Temperature Rise ：Δｔ’ 10.04 ℃

9.920E+02 10.04

1310Circulating Water Flow Rate

1310 m3/min(78600 m3/h)

Enthalpy ofCondensate

Heat Balance : 3GMG04302(VWO, 3% m.u.,67mmHg)

7.82893E+08

Heat Balance : 3GMG04302(VWO, 3% m.u.,67mmHg)

Enthalpy ofCondensate

＝ m3/min

D1 ＝ kcal/h

Ｑ＝

Q＝ D1 + D2

Cp ・ γ ・ Δt’

＝

＝ x/60

D2 ＝ kcal/h

d

d

d

d

d

d

DD KV71215-d


3.Thermal Calculation

3.1L.P. Condenser

a.Water velocity in Tubes

Thickness 0.711 mm Number of Tube 22,764 Inner Diameter of Tubes di1 ＝ 0.0240 m Thickness 0.889 mm Number of Tube 2,528 Inner Diameter of Tubes di2 ＝ 0.0236 m

(1) Water velocity in Tubes ： V1 m/s ( Thickness 0.711 mm )

Q

13100.0236

0.0240 22764 0.023622 2528 0.0240 )

1.919 m/s

V1 ＝ 1.92


　　　　V1 Ｘ di2di1

1.92× 0.02360.0240

＝1.900m/s

V2 ＝ 1.90

2π4

×60

N1 ＝

＝

＝

m/s

V1 ＝π4

・ 60 ・（d i1 2・ N1 + d i2 2・ N2・(di2/di1)（1/1.4)　）

×(

N2 ＝

2 （1/1.4)

m/s

V2 ＝（1/1.4)

（1/1.4)

＝

× + +

× ×

DD KV71215-d


b.Heat Transfer Coefficient

Heat Transfer Coefficient ： U kcal/m2 h ℃

U ＝ U1×FW×FM×FC

U1 ： Uncorrected Heat Transfer Coefficients（Figure.1）FW ： Inlet Water Temperature Correction Factor（Figure.2）FM ： Tube Material and Gauge Correction Factor（Table.3）FC ： Cleanliness Factor

(1) Heat Transfer Coefficient : Ua ( Thickness 0.711mm )3220.7 kcal/m2 h ℃

from Fig.1 V＝ 1.92 m/s ( 6.299 ft/s ) , Diameter of Tubes 25.4　mmU1＝ 659.71 ( 1.0 in )

1.079

from Fig.2 Inlet Water Temperature 33.0 ℃ ( 91.4° ) Correction Factor

0.854

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.711mm ) Correction Factor

0.9Cleanliness Factor ： 90%

3220.7 1.079 0.854 0.90 2670.9

(2) Heat Transfer Coefficient : Ub ( Thickness 0.889mm )

3203.5 kcal/m2 h ℃

from Fig.1 V＝ 1.900 m/s ( 6.233 ft/s ) , Diameter of Tubes 25.4　mm U1＝ 656.19 ( 1.0 in )

0.815

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.889mm ) Correction Factor 0.9

Cleanliness Factor ： 90%

3203.5 1.079 0.815 0.90 2535.3

(3) Average Heat Transfer CoefficientUa Ｘ N1+ Ub Ｘ N2N1 + N2

2670.9 22764 2535.3 252822764 2528

2657.35

2657.3 kcal/m2 h ℃

U1 ＝

F

FW ＝

FM ＝

FC ＝

Ua ＝ × × Ｘ kcal/m2 h ℃

U m＝

＝

FM ＝

FC ＝

Ub ＝ × × kcal/m2 h ℃ ＝

U1 ＝

Um ＝

＝× ＋ ×

＋

＝

Btu/h･ft2･F

Btu/h･ft2･F

： Um

×

d

d

d

d

d

DD KV71215-d


c.Logarithmic Mean Temperature Difference ： θm

Circulating Water Temperature rise ： Δt

3.83162E+089.920E+02 1310

4.91 ℃

40.84

37.91

4.9133.0

7.84 － 2.93 4.98

7.84 2.93

d.Required Tube Surface Area ： Areq m2

3.83162E+082657.3 4.98

28953.9

e.Actual Tube Surface Area :A

Ａ＝ π × 0.02540 × 14.375　×　 25292　＝　 29011.8　m 29011　m > Areq

Δt ＝ D1

Cp ・ γ ・ Q ・ 60＝

＝

t2 =　　　　　℃

Δt = ℃

ts = ℃ ( at 702.1mmHg_vac)

θm＝( ts － t1 )－( ts － t2 )

( ts － t1 )( ts － t2 )

ln＝

ln＝ ℃

t1 = ℃

Areq ＝ D1Um ・ θm

＝×

＝ m2

2 →

2

Ｘ

Saturated SteamTemperature

× 60

d

d

d

d

DD KV71215-d


3.2H.P Condenser

a.Water velocity in Tubes

Thickness 0.711 mm Number of Tube 22,764 Inner Diameter of Tubes di1 ＝ 0.0240 m Thickness 0.889 mm Number of Tube 2,528 Inner Diameter of Tubes di2 ＝ 0.0236 m


Q

13100.0236

0.0240 22764 0.023622 2528 0.0240 )

1.919 m/s

V1 ＝ 1.92


　　　　V1 Ｘ di2di1

1.92× 0.02360.0240

＝1.900m/s

V2 ＝ 1.90

2π4

×60

N1 ＝

＝

＝

m/s

V1 ＝π4

・ 60 ・（d i1 2・ N1 + d i2 2・ N2・(di2/di1)（1/1.4)　）

×(

N2 ＝

2 （1/1.4)

m/s

V2 ＝（1/1.4)

（1/1.4)

＝

× + +

× ×

DD KV71215-d


b.Heat Transfer Coefficient

Heat Transfer Coefficient ： U kcal/m2 h ℃

U ＝ U1×FW×FM×FC

U1 ： Uncorrected Heat Transfer Coefficients（Figure.1）FW ： Inlet Water Temperature Correction Factor（Figure.2）FM ： Tube Material and Gauge Correction Factor（Table.3）FC ： Cleanliness Factor

(1) Heat Transfer Coefficient : Ua ( Thickness 0.711mm )3220.7 kcal/m2 h ℃

from Fig.1 V＝ 1.92 m/s ( 6.299 ft/s ) , Diameter of Tubes 25.4　mmU1＝ 659.71 ( 1.0 in )

1.101

from Fig.2 Inlet Water Temperature 37.91 ℃ ( 100.2° ) Correction Factor

0.854

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.711mm ) Correction Factor

0.9Cleanliness Factor ： 90%

3220.7 1.101 0.854 0.90 2725.4

(2) Heat Transfer Coefficient : Ub ( Thickness 0.889mm )

3203.5 kcal/m2 h ℃

from Fig.1 V＝ 1.900 m/s ( 6.233 ft/s ) , Diameter of Tubes 25.4　mm U1＝ 656.19 ( 1.0 in )

0.815

from Table.3 Tube Material (Stainless Steel), Thickness ( 0.889mm ) Correction Factor 0.9

Cleanliness Factor ： 90%

3203.5 1.101 0.815 0.90 2587.0

(3) Average Heat Transfer CoefficientUa Ｘ N1+ Ub Ｘ N2N1 + N2

2725.4 22764 2587 2528

22764 2528

2711.57

2711.6 kcal/m2 h ℃

U1 ＝

F

FW ＝

FM ＝

FC ＝

Ua ＝ × × Ｘ kcal/m2 h ℃

U m＝

＝

FM ＝

FC ＝

Ub ＝ × × kcal/m2 h ℃ ＝

U1 ＝

Um ＝

＝× ＋ ×

＋

＝

Btu/h･ft2･F

Btu/h･ft2･F

： Um

×

d

d

d

d

d

DD KV71215-d


c.Logarithmic Mean Temperature Difference ： θm

Circulating Water Temperature rise ： Δt

3.99730E+089.920E+02 1310

5.13 ℃

46.09

43.04

5.1337.91

8.18 － 3.05 5.2

8.18 3.05

d.Required Tube Surface Area ： Areq m2

3.99730E+082711.6 5.20

28349.5

e.Actual Tube Surface Area :A

Ａ＝ π × 0.02540 × 14.375　×　 25292　＝　 29011.8　m 29011　m > Areq

Δt ＝ D2

Cp ・ γ ・ Q ・ 60＝

＝

t2 =　　　　　℃

Δt = ℃

ts = ℃ ( at 683.9mmHg_vac)

θm＝( ts － t1 )－( ts － t2 )

( ts － t1 )( ts － t2 )

ln＝

ln＝ ℃

t1 = ℃

Areq ＝ D2Um ・ θm

＝×

＝ m2

2 →

2

Ｘ

Saturated SteamTemperature

× 60

d

d

d

DD KV71215-d


4.Hydraulic Calculation (As per clause 4.5 of HEI 10th)

4.1 L.P. Condenser

(a)Basic information

CW Nozzle Size ID2,400

CW Flow per nozzle (m3/min) 655

CW Velocity per nozzle (m/sec) 2.42

(ft/sec) 7.94 (Vw)

CW Velocity per tube (m/sec) 1.92

(ft/sec) 6.30 (Vw)

CW Inlet / Outlet temperature (Deg.C) 33.0 / 37.91

(Deg.F) 91.4 / 100.24 (T1/T2)

Tube inside diameter (mm) 23.98

Tube inside diameter (in) 0.94 (Di)

Tube length (m) 14.431

(ft) 47.346 (Lt)

(a)Waterbox and Tube End Losses

End loss (ft) 0.70 Curve (a) of Figure 8

Waterbox Inlet (ft) 0.98 Curve (b) of Figure 8

Waterbox Outlet (ft) 0.30 Curve (c) of Figure 8

Sum of above (ft) 1.98 (ΣRe)

(b)Tube Loss

Tube loss (uncorrected) (ft of water/ft length) 0.173 (R2 x Rt)

Temperature correction factor - 0.954 (R1: Figure 7)

Tube loss per length (ft of water/ft length) 0.165 (Rt x R2 x R1)

Tube loss (ft) 7.81

(c)Total Loss

(a) + (b) (ft) 9.785 (Rtt)

(mAq) 2.983

Hydraulic loss adapted (5% Margin) (mAq) 3.140

d

DD KV71215-d


4.2 H.P. Condenser

(a)Basic information

CW Nozzle Size ID2,400

CW Flow per nozzle (m3/min) 655

CW Velocity per nozzle (m/sec) 2.42

(ft/sec) 7.94 (Vw)

CW Velocity per tube (m/sec) 1.92

(ft/sec) 6.30 (Vw)

CW Inlet / Outlet temperature (Deg.C) 37.91 / 43.04

(Deg.F) 100.24 / 109.47 (T1/T2)

Tube inside diameter (mm) 23.98

Tube inside diameter (in) 0.94 (Di)

Tube length (m) 14.431

(ft) 47.346 (Lt)

(a)Waterbox and Tube End Losses

End loss (ft) 0.70 Curve (a) of Figure 8

Waterbox Inlet (ft) 0.98 Curve (b) of Figure 8

Waterbox Outlet (ft) 0.30 Curve (c) of Figure 8

Sum of above (ft) 1.98 (ΣRe)

(b)Tube Loss

Tube loss (uncorrected) (ft of water/ft length) 0.173 (R2 x Rt)

Temperature correction factor - 0.936 (R1: Figure 7)

Tube loss per length (ft of water/ft length) 0.162 (Rt x R2 x R1)

Tube loss (ft) 7.66

(c)Total Loss

(a) + (b) (ft) 9.638 (Rtt)

(mAq) 2.938

Hydraulic loss adapted (5% Margin) (mAq) 3.080

4.3 Total loss of Condenser

LP Condenser + HP Condenser (mAq) 6.220

These value do not include loss of CW piping and inter-connecting piping between

LP and HP Condenser.

d

DD KV71215-d


5.Hotwell storage Capacity

a.Condensate Water

Condensate Flow : Qc1741639 kg/h

29.03 m3/min

b.Required storage capacity

3 minutes storage capacity

Qc×3 ＝ 87.08 m3

c.Required Hotwell Height : Hreq

Size of Cond Lower Shell

13895

7960

87.0813895×7960

＝ 787.3 mm

Height of LLWL - Bottom : HLLWL-B

200 mm

Hreq' + HLLWL-B ＝ 987.3 mm

d.Actual Hotwell Height : H (Height of NWL - Bottom)

Height of NWL - LLWL : HNWL-LLWL

800 mm

1000 mm > Hreq

Ｑc ＝

Qreq＝

＝

Qreq

a

b

Size of Cond Lower Shell

a＝

b＝

Hreq' ＝a×b

×109 ＝ ×109

Hreq ＝

H ＝

HLLWL-B ＝

HNWL-LLWL ＝

HNWL-LLWL + HLLWL-B ＝

DD KV71215-d


6. Steam and condensate flow

The condensate (generated in LP Condenser) passing through the perforated plates is reheated by the steam from HP

Condenser. The condensate is led to HP Condenser through connection pipe between HP and LP Condenser.

The Hotwell of LP Condenser has two different pressure zones.

The pressure zone (Reheating Section) has the same pressure as HP Condenser.

Condenser is designed for exhaust steam from steam turbine, BFP drive turbine, LP bypass system, heater drains and

vents, boiler separator drains during start up, low load and abnormal conditions and other miscellaneous drains.

DD KV71215-d


Appendix

DD KV71215-d


DD KV71215-d


DD KV71215-d


DD KV71215-d


DD KV71215-d


変更 REV. PAGE

変更箇所及び内容

CHANGED PLACE AND CONTENT

承認

APPROVED

調査

REVIEWED

担当

PREPARED

a - Initial Issue Y.Fuki

Jun.05.2012

Y.Fuki

Jun.05.2012

S.Mori

Jun.05.2012

b 11,12 Corrected value. Y.Fuki

Jun.07.2012

Y.Fuki

Jun.07.2012

S.Mori

Jun.07.2012

c - Revised as marked according to progress of design. Y.Fuki

Jul.25.2012

S.Mori

Jul.25.2012

R.Yasuki

Jul.25.2012

d - Revised as marked according to progress of design. Written in

page 1.

Written in

page 1.

Written in

page 1.

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condenser sizing calculation