Troubleshooting Surface Condenser Venting Systems

J.R. LINES, R.E. ATHEY AND L.L. FRENS GRAHAM MANUFACTURING COMPANY

ABSTRACT In an ideal situation, the condensing pressure achievable in a steam surface condenser is determined by the exiting cooling water temperature. However the failure of the venting system to properly remove noncondensible gases from the steam condenser will result in elevated condenser pressures. Information is presented in this paper relative to the most common venting systems available, as well as providing procedures for troubleshooting each type of system. A description is given of the various operating characteristics, along with narrative discussions of field problems and experiences. Simple visual, audible and physical guides to the analysis of venting system problems are discussed. Power plant operating personnel will be able to utilize this information when investigating steam condenser performance problems. A checklist is provided which can be used to isolate these performance problems.

tem related problems designed into the system, or caused by a venting system malfunction. Steam condenser venting equipment is sometimes misdesigned, improperly installed, or required to operate beyond its capabilities. The recent trend to part load operation has accentuated the problem. If the venting system is unable to remove the noncondensible gases at the pressure which is achievable by the condenser the condenser back pressure will rise. In this case the condenser does not control the back pressure. Rather the venting system is the controlling factor. It is worth noting that any time the back pressure is higher than necessary due to air retained in the condenser the plant heat rate will reflect this condition. Manufacturers that provide both condensers and vacuum equipment to the power industry are involved in the design, fabrication, testing, and repair of condensers, ejectors, and liquid ring vacuum pumps. In this capacity, those manufacturers understand the relationship between the steam surface condenser and the venting system. The authors of this paper have accumulated a great deal of experience in field service troubleshooting having various types of venting problems. The methods outlined in the following analysis should prove to be a valuable tool in the assessment of steam condenser performance and in solving venting related problems.

INTRODUCTION The condensing pressure achieved in a steam surface condenser is determined by the exiting cooling water temperature if the conditions are ideal. All other factors steam condenser design operate to limit this optimum condition and to raise the condensing pressure, which results in increasing the plant heat rate. Some of the factors which have a negative impact on the condenser pressure include inadequate tube surface area, both vapor and cooling water maldistribution, air inleakage, resistance due to tube bundle layout and/or baffle placement, and an inadequate venting system capability. These factors may act independently, or concurrently. Although it would seem obvious that the failure of venting systems to properly remove noncondensible gases from the steam condenser must result in elevated condenser pressures, customer requests for field service have often revealed a lack of understanding of the relationship between the steam condenser and the venting system servicing it. Unfortunately this can lead to delays in remedying many problems, and in a costly waste of effort in attempts to repair that which was not defective in the first place. The operating characteristics of the venting system are often misunderstood, which can result in inherent limitations of steam condenser performance. Sometimes condenser fouling or condenser design deficiencies are suspected and investigated, when failure to achieve the required vacuum level is due to venting sysThe American Society of Mechanical Engineers

CHARACTERISTICS OF SURFACE CONDENSER VENTING EQUIPMENT Before examining the various methods of identifying and dealing with condenser venting systems, it is essential to have an understanding of the several types of vacuum producing devices that are most commonly used in conjunction with steam surface condensers. These include ejector systems (usually comprised of several stages with 1

intercondensers and aftercondensers), liquid ring vacuum pumps (either single stage or two stage pumps), and the hybrid system (consisting of a combination of ejectors and a liquid ring vacuum pump). Ejector Venting Systems Figure 1 is a schematic diagram of a typical two stage steam motivated ejector system. Air and water vapor are removed from the main steam surface condenser, enter the first stage ejector and are compressed to the intercondenser operating pressure by means of the motive steam. After exiting the first stage ejector both the load (noncondensible gases and associated water vapor) and the

motive nozzle than is necessary for compression. If the actual motive steam pressure is below design, or if the steam temperature is greater than intended, then, within limits, an ejectors nozzle can be rebored to a larger diameter. The larger nozzle diameter allows more steam to flow through and expand across the nozzle. This increases the energy available for compression. The ejector manufacturer should be consulted when considering reboring a motive nozzle. Another potential ejector performance problem that is related to motive steam occurs if the supply pressure is greater than 20% above design. When this happens, too much steam will expand across the nozzle. This has a tendency to choke the diffuser. Whenever this occurs, less suction load can be handled by the ejector, and the suction pressure rises. If an increase in suction pressure is not acceptable, then the ejector nozzle must be replaced with one having a smaller throat diameter, or the steam pressure must be corrected. Steam quality is another important performance variable. Wet steam is generally damaging to an ejector. Moisture in the motive steam is noticeable when inspecting ejector nozzles, because the moisture droplets in the steam lines are accelerated to near sonic velocities. This causes erosion of the nozzle internals by etching a striated pattern on the diverging section of the nozzle, which may actually wear out the nozzle mouth, or the inlet diffuser taper(s) and throat will show signs of erosion. On larger ejectors, the exhaust elbow located at the discharge of the ejector can erode completely through the metal. Severe tube impingement in the intercondenser can also occur; but this is dependent upon the ejector orientation relative to the intercondenser. Finally, wet steam can cause performance problems. When water droplets pass through an ejector nozzle, they decrease the energy available for compression. The effect is a decrease in load handling capability and/or instability of the ejector. Furthermore, water droplets vaporize within the diffuser and then act as additional load, which must also undergo compression. To solve wet steam problems, all lines leading to the ejector should be well insulated. In addition, a steam separator with a trap should be installed immediately prior to the motive steam inlet connection. The maximum discharge pressure (MDP) is the highest pressure that an ejector can attain while utilizing a given amount of motive steam having a specified amount of energy. If the actual discharge pressure exceeds the MDP the ejector will become unstable and break operation. When this occurs, a dramatic increase in suction pressure is common. As an example, when an ejector designed to produce 1 inch HgA of suction pressure breaks operation, the suction pressure increases sharply to 2-3 inches HgA. Therefore, it is important to make certain that the ejectors do not exceed their MDP. Since increasing the discharge pressure above the MDP causes a loss of performance, it seems logical that lowering the discharge pressure below the MDP should have the opposite effect. This, however is not the case. Ejectors with a compression ratio (discharge pressure divided by suction pressure) higher than 2:1 are termed critical ejectors. The performance of a critical ejector

motive steam are discharged to the intercondenser where a major portion of the water vapor load and the motive steam are condensed. Noncondensible gases (air) and the remaining water vapor are then directed to the second stage ejector where further compression to atmospheric pressure takes place. Finally, the gases are discharged through the aftercondenser. Two stage condensing ejector systems can be designed to operate at any reasonable condenser pressure, and the design is not limited by the temperature of the available cooling water to the intercondenser. These systems have no moving parts, are the most reliable, require the least maintenance of all venting systems, and are the least expensive in their initial cost. The ejector systems require a reliable motive steam source, generally in the range of 100-150 PSIG. One drawback to this type of system is that the motive steam pressure must be maintained at a relatively constant value in order to prevent instabilities (accompanied by a resulting loss of vacuum). Proper motive steam conditions are always essential to the satisfactory operation of an ejector. The manufacturer will have designed the system to maintain stable operation with steam pressures at, or above, a minimum value. If the motive steam pressure falls below the minimum design value, then the motive nozzle will pass less steam than required to operate the ejector. When this happens, the ejector is not provided with sufficient energy to compress the design load to the design discharge pressure. The same problem occurs when the motive steam temperature rises above the design value, resulting in a larger specific volume than is acceptable. Again, this results in less steam passing through the The American Society of Mechanical Engineers

will not improve even if the discharge pressure is reduced. This is primarily due to the presence of the shock wave in the diffuser throat of the ejector. Ejector designers summarize the critical data on a performance curve. Figure 2 shows a typical performance curve for a single stage ejector. The information displayed on this performance curve gives the suction pressure a function of the water vapor equivalent load. (Equivalent load is used to express a non condensible gas and water vapor process stream in terms of an equivalent amount of water vapor load.) The performance curve can be used in two ways. First, if the suction pressure is known for an ejector, the equivalent vapor load it handles may be determined. Secondly, if the loading to an ejector is known, the suction pressure can be found. If field measurements differ significantly from the performance curve, this indicates that there may be a problem with either the process utilities or the ejector. Liquid Ring Vacuum Pump Venting Systems Liquid ring vacuum pumps are often used as condenser exhausters. The primary components of a liquid ring vacuum pump are the impeller, the pump casing and the seal liquid. The impeller is mounted eccentrically in a round casing, which is partially filled with the seal liquid. As the impeller rotates, the seal liquid is acted on by centripetal forces to produce a liquid ring which is concentric with the casing. It is the eccentricity of the impeller with respect to the liquid ring and casing that provides compression of the gases inside the pump. Noncondensible gas (along with accompanying water vapor) enters the vacuum pump where compression takes place. Condensation of a portion of the water vapor also occurs inside the pump. The remaining water vapor and noncondensible gas is segregated from the seal liquid in a separator, where the gas is discharged to the atmosphere. The seal liquid is usually cooled and returned to the pump, although once-through coolant systems are sometimes used. In addition to being the compressing medium, the liquid ring absorbs the heat generated by gas compression, condensation of the water vapor and friction. Figure 3 illustrates a typical liquid ring vacuum pump system having a recirculating seal liquid arrangement. Under normal operating conditions the seal liquid temperature will be 3-5 F warmer than the inlet cooling water the pump heat exchanger. The vacuum attainable by a liquid ring vacuum pump is limited by the vapor pressure of the seal liquid. As the suction pressure approaches the vapor pressure of the seal liquid, it will flash into vapor. This reduces the capacity of the liquid ring pump, as more of the impeller space is occupied by vapor from the seal liquid, leaving less space available to accept the incoming load gas. If this condition is allowed to persist, cavitation will occur, resulting in possible severe damage to the internal surfaces, and preventing the pump from achieving design vacuum levels. Even if a pump with greater capacity is used, it will not be possible to obtain lower pressure levels than permitted by the vapor pressure of the seal water. This limitation can be a significant disadvantage when The American Society of Mechanical Engineers

the condenser is operated under part load conditions. The amount of seal liquid also has a significant impact on the performance of a liquid ring vacuum pump. A seal water flow rate that is too low will result in the temperature rise across the pump being excessive. This causes the previously described effect where the seal liquid flashes and limits the pressure level obtainable by the pump. Alternately, if the seal liquid flow rate is too high, the performance of the unit will probably be adversely affected due to high horsepower requirements and/or a loss of capacity. The performance of a liquid ring vacuum pump may also be adversely affected as a consequence of operating at a speed that is not at the design condition. This will either result in poor performance, or in a breakdown of the gas compression process. When the pump is rotating at a speed greater than optimum, the efficiency is decreased due to high velocities of the gas and vapor. At a speed that is below the optimum it is possible that the liquid ring will collapse and reduce the compression of the gas. The effect of attempting to compress to a discharge pressure that is greater than design is identical to the case where the pump speed is too low. Again, the liquid ring may potentially collapse. Hybrid Venting Systems (Ejector intercondenser / Liquid Ring Vacuum Pump) A hybrid venting system is a combination of an ejector and a liquid ring vacuum pump. Figure 4 illustrates a typical hybrid system consisting of an ejector, an intercondenser, and a vacuum pump. The vacuum pump operates at a higher interstage pressure

than would otherwise be obtained through the use of only a vacuum pump). Three advantages are found when utilizing a hybrid vacuum system: The pump suction pressure is higher than the vapor pressure of the seal water. This means that the seal water temperature does not limit the suction pressure achievable; The major portion of the motive steam used by the ejector is condensed in the intercondenser leaving only a relatively small amount which enters the liquid ring vacuum pump; The volume of noncondensible gas and water vapor to be compressed by the vacuum pump will be reduced at a fairly high interstage pressure, which results in a smaller pump being used.

equipment pressure remains approximately the same, the air leak is probably in the venting equipment. While there are numerous ways to detect air leakage, the most commonly used methods include: (1) hydrotest; (2) a shaving cream test; (3) a smoke test; (4) a gas sniffer test; or (5) a soap bubble test. II. The second most common problem is the accuracy of the pressure gauge. Absolute pressure type instruments are strongly recommended. Pressure gauges that are open to the atmosphere are subject to changes in barometric pressure, which can be +/- 2 inches Hg. The best way to verify the accuracy of the pressure gauge reading for the condenser is to compare the value of the gauge against the condensate temperature. The temperature of the condensate can never be higher than the saturation temperature corresponding to the condenser pressure, but it can sometimes be colder. Cold condensate can occur with severe tube leaks, partial flooding of the tubes, cold makeup or dump water returns, and sometimes under light condenser loads. III. A determination of whether the venting equipment or the condenser is setting the operating pressure is important. Once that has been established, a systematic approach to troubleshooting is possible. One technique of determining which component is controlling can be accomplished by increasing the venting equipment capacity. This can be done by adding a redundant vacuum element, or by turning on the hogging unit (if available). When this is done, if the operating pressure in the condenser decreases, then the venting equipment is the controlling factor. If the condenser operating pressure remains unchanged, then the condenser is limiting the vacuum level. 1. If the condenser is limiting the vacuum level, the following items need to be checked: a. Cooling water inlet and outlet temperatures - If either the temperature of the inlet cooling water, or the cooling water temperature rise, is greater than design, the condenser pressure may be higher than design. A high cooling water temperature rise means that the condenser is either over loaded, or that the cooling water flow rate is below design. Cooling water inlet and outlet pressures - If the cooling water pressure drop is below the design value, the cooling water flow rate is probably too low. if the cooling water pressure drop is above the design value, either the cooling water flow rate is above the design value (this can be checked by observing a low temperature rise across the tubes), or tubeside fouling could be present. (Note: A high cooling water flow rate rarely poses a performance problem.)

TROUBLESHOOTING THE CONDENSER VENTING SYSTEM Troubleshooting a surface condenser venting system requires a systematic procedure in order to insure that the problem is both identified and corrected. The following procedure is used by engineers in field situations to isolate venting problems: I. The first point that should be checked when poor performance occurs is air leakage. This is the most common cause of poor performance, and is probably the easiest one to identify, but often the hardest to find. The most common sources of air leakage in a condenser/venting system are at: (1) the turbine gland; (2) large diameter flanges, such as the steam inlet or turbine exhaust; (3) open valves; or (4) a loose steam chest on the ejectors. To identify air leakage as the problem, check the vent of the vacuum equipment, because any air leak in the system must exit at this point. In the case of an ejector system, the vent is the vapor outlet connection of the aftercondenser. If the venting equipment comprises vacuum pumps, the vent is located on the discharge of the separator. In both cases, the air leakage rate should be checked when only the normal venting equipment is operating, i.e., without a hogger unit in operation. The majority of venting equipment is supplied with some type of air leakage flow device, but if one is not available, or if it is suspect, a simple plastic bag and stopwatch will accomplish the same results. The average air leakage rate, regardless of which type of venting equipment design is employed, should not exceed 15 pounds per hour for most commercial systems. If the measured air flow is in this range, air leakage is probably not the problem. If the measured air flow is above this rate, even if it is below the specified venting equipment design flow rate, it is recommended that a search be made for air leaks. If air leakage has been determined to be a problem, it is important to locate and isolate the problem. It is essential to know whether the air leak path is present in the condenser or in the venting equipment. The easiest way to determine this is to close the isolating valve between the venting equipment and the condenser. If the condenser pressure rises, and the venting equipment pressure decreases, the problem is in the condenser. If the condenser pressure remains relatively unchanged and the venting The American Society of Mechanical Engineers

b.

2.

If the venting equipment is limiting the vacuum level, and the venting system utilizes ejectors, the following items should be checked: a. Motive steam pressure - If the motive steam pressure is below design by more than 5%, or above design by 20%, poor performance may occur with a resulting increase in the condenser pressure.

b.

Motive steam quality - Wet motive steam will cause poor performance as well as ejector wear. Superheated steam having a temperature greater than 50 F above the saturation temperature will also cause poor performance if not considered in the design. Intercondenser shellside pressure drop - If the shellside pressure drop is greater than 5% of the absolute operating pressure, then either shellside fouling or flooding of the condenser could be present. Check the trap or loop seal on the condensate outlet for proper drainage. Ejector internals - Check for internal wear, as well as checking the critical dimensions. Both the steam nozzle and ejector diffuser throat dimensions should be measured. If the cross section area at those locations is greater than 7% above the design values, performance problems are likely. Examine the motive steam nozzle for steam leaks around the threads. Cooling water parameters on the inter- and aftercondensers - Use the same procedure as described for the main condenser.

3.

If the venting equipment is limiting the vacuum level, and the venting system utilizes a liquid ring vacuum pump, the following items should be checked: a. Seal water inlet and outlet temperature - Higher than design inlet or outlet temperatures will cause poor performance. When the outlet seal water temperature is high, this indicates either low seal water flow a high inlet temperature, or a malfunction of the seal cooler. Operating pressure of the pump - When this pressure is too low, the problem may be due to low noncondensible gas loading or a cooling water temperature that is lower than design. The concern is for cavitation of the pump performance.

c.

b.

d.

e.

IV. If the problem does not appear to be items I, II or III, check all vapor lines between the condenser and the venting equipment for any low point areas where condensation could occur and create a large pressure drop.

TROUBLESHOOTING ASSISTANCE CHARTS The following charts are useful in identifying the causes of common venting system problems, and in helping to define the corrective action that is necessary to remedy the problems.

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Selected Case Histories Of Venting System Problems

The following case histories are drawn from among the field problems which have been experienced by the operators of condenser vacuum systems. The approach previously described was utilized to identify and correct the problem.

for several feet and then went vertically downward. After a drop of approximately 6 ft., the piping traveled horizontally for another 6 ft. and then went vertically upward to the venting system. The loop in the noncondensible gas extraction piping was immediately suspected. When systems are shut down, vapor within the piping condenses and liquid resides in low horizontal sections of the piping loop. Upon startup, a liquid slug restricts extraction flow to the venting system. If liquid entirely fills the horizontal run, a pressure differential must be established to overcome the difference between the operating pressure of the condenser and that of the venting system in order to force the liquid slug to pass through to the venting system. When the horizontal portion of the loop is partially filled, a significant pressure within the condenser increases to create a driving force of sufficient magnitude to overcome any pressure resistance associated with the restriction. To remedy the problem, it was determined that it was too costly to modify the piping. The installation of a drain connection in the horizontal section of the piping was all that was necessary. This drain connection permitted removal of residual water from the loop prior to startup. Once the water was removed, the system was restarted and the condenser pressure was brought to design levels with only one liquid ring vacuum pump on operation. Plant operators were given instructions to open the drain connection prior to each startup.

CASE HISTORY I: IMPROPER PIPING LAYOUT BETWEEN STEAM SURFACE CONDENSER AND VENTING SYSTEM Problem: A combined cycle cogeneration facility could not maintain design vacuum at the turbine discharge. The turbine was supported by a steam surface condenser with twin 100% liquid ring vacuum pump condenser exhausters. Even while operating under part load conditions, the vacuum level could not be reduced below 3.1 inches HgA. This was the case even when the venting system was functioning with both 100% vacuum trains in operation. When one of the pumps was shut down, an increase in operating pressure of only 0.12 inch Hg was measured. Solution: A 1.45 inch Hg pressure drop (3.1 inch HgA - 1.65 inch HgA) between the steam surface condenser and the venting system seemed excessively high and quite uncustomary. Shutting down the second liquid ring vacuum pump and achieving only a slight increase in operating pressure suggested that air inleakage was not the problem. As with any troubleshooting exercise, it is always appropriate to examine the equipment layout. This should include the motive steam piping to the ejector system, condensate drain to the hotwell, all miscellaneous connections entering the condenser, cooling water piping, and vent piping from the steam surface condenser to the venting equipment. While conducting the layout survey, it was noticed that piping between the steam surface condenser and venting equipment was not properly routed. Between the condenser and the venting system the noncondensible gas extraction piping exited the condenser shell, traveled horizontally The American Society of Mechanical Engineers

CASE HISTORY II MOTIVE STEAM PRESSURE BELOW DESIGN PRESSURE Problem: A combined cycle cogeneration plant supplying both steam and power for a paper mill experienced erratic pressure fluctuations in the steam surface condenser. The surface condenser had a two stage, twin-element ejector system for removal of the noncondensible gas. Pressure measured in the condenser would be established at the design point of 2 inches HgA, when suddenly a dramatic increase in pressure would occur. At this time the condenser pressure would sharply increase to 4.5 inches HgA. After the sharp increase, the condenser would gradually return to the design operating pressure. Solution: A review of the piping layout revealed that this was not the source of the problem. Recognizing that a variable operating pressure may be due to excessive air inleakage, an air leakage meter was installed. It was determined that the air leakage was 85 pounds per hour, while the design for this system was 45 pounds per hour. Both 100% second stage ejectors were then operated simultaneously to overcome this excessive air load, because their combined capacity exceeded the leakage rate. The condenser still experienced pressure excursions ranging from 2 inches HgA to 4.5 inches HgA. Another possible cause was the motive steam pressure. As previously discussed, when the motive steam pressure falls below the design value, an ejector may have insufficient energy to compress noncondensible gases and the associated water vapor. When this occurs, the ejector will break operation. One noticeable effect of an ejector in a broken condition is a sharp increase in the operating pressure.

A review of the plant operating conditions revealed that the supplier of the motive steam used by the ejector system also supplied steam to other process equipment within the paper mill. When steam demand by other process equipment increased, the pressure of the steam was reduced. The motive steam pressure to the ejector was monitored over time, and it was verified that the line pressure did vary. Steam pressure ranged from 40 PSIG to 33 PSIG. To insure stable operation of the system it was necessary to design the nozzles based on the lowest expected operating pressure. In this case, 33 PSIG was selected as the lowest pressure. The ejector nozzles were rebored based on this minimum steam pressure. In doing this, the entire system was maintained at the design point, even when other process equipment experienced high demand for low pressure steam.

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CASE HISTORY III CAVITATION OF LIQUID RING VACUUM PUMP CONDENSER EXHAUSTER Problem: The venting system for a central power plant consisted of twin 100% liquid ring vacuum pump condenser exhauster packages. A complaint was received that the vacuum pumps were operating noisily. Also, the pressure at the pump suction was measured and found to be significantly lower than the operating pressure of the surface condenser. Solution: Because the operator reported the vacuum pumps were running noisily, it was initially thought that the problem could be either cavitation or alignment of the pump. In order to investigate the possibility of pump cavitation, it was necessary to compare the operating pressure of the pump against the vapor pressure corresponding to the temperature of the seal water exiting the pump. The vapor pressure of water at 75 F is 0.88 inch HgA. Since the pump was operating with a suction pressure of 0.83 inch HgA, the conclusion was that the pump was cavitating due to liquid in the ring flashing into vapor. This would also explain the fact that the pump was excessively noisy during operation. Based on measurements from an air leakage meter installed on the system, it was apparent that the air inleakage was very low. As previously discussed, a liquid ring vacuum pump requires some noncondensible gas load to prevent cavitation. Without this load, the pump will operate at a pressure that results in cavitation. A vacuum relief valve was included as part of the condenser exhauster packages. However this valve was found to be closed. The solution to this particular problem was to open the relief valve to provide additional air inleakage to the pumps. Once this

was done, and an artificial air load was introduced into the system, the suction pressure of the vacuum pumps increased to approximately the same pressure as the condenser operating pressure. The noise level of the vacuum system also decreased to acceptable levels.

CONCLUSION Steam surface condensers are directly affected by the performance of their venting systems which are used for the continuous removal of noncondensible gases. The failure of these venting systems to properly remove the noncondensible gases from the condenser results in elevated condenser pressures. Therefore, it is essential to the operation of the overall power plant to be able to maintain the venting devices at their optimum performance level. Troubleshooting a surface condenser venting system requires a systematic procedure in order to insure that the problem is both identified and corrected. Information relative to the most common vacuum producing devices has been presented, along with a discussion of some of the most common problems which occur. Utilization of the troubleshooting guidelines presented in this paper, along with an understanding of the various devices, should be helpful when investigating steam condenser performance problems.

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