Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 4	OF 22

5.1 Test Instrumentation & Measurement Required (typical for a 200 MW unit)

Measurement	Temp.	Pressure	Flow	Remarks
C.W Inlet Temp.	2	-	-
C.W Outlet Temp.	8	-	-
C.W Flow	-	-	**
Condensate Temp.	2	-	-	One on each outlet
				leaving hotwell
Condenser	-	2	-	One on each half of
Back Pressure(Abs.)				condenser grid
Water Box Diff. Press	-	2	-
Air/Steam Mixture	2	-	-	One each in outlet
Temperature				of each half of the
				Condenser

**C.W. Flow measurement to be taken from:

a.Calibrated elbow tap differential pressure (if available)

b.Annubar (if available).

c.Calculated from condenser heat load (generator loss curve required).

d.Calculated from C.W Pump characteristics curve.

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 5	OF 22

5.2Instrument Accuracy Requirements

The instrument will be accurate to the specifications as listed below:

Instrument	Unit	Range	Accuracy	Qty.	Remarks
RTD’s	oC	0-100	+/- 0.3	14	12 Point
					cal. curve
					to be used
Glass Thermometer	oC	0-50	+/- 0.1	8	For
(Partial immersion					validation/
type)					manual testing
Abs. Pressure	kg/cm2 0- 0.35		+/-0.075%	2	12 Point cal
Transmitter					curve to be
					used
Diff. Pressure	kg/cm2 0-1.5		+ /-0.075%	2
Transmitter
Barometer	-	-	-	-	Facility
					available at
					station may
					be used

5.3Instrument Calibration

Instrumentation required by this procedure will be calibrated once in two years. Calibration records for these instruments will be maintained as permanent records and reference to current calibration will be made in the report.

5.4The performance test data from test instruments will be recorded using the sample format attached at Annexure - II

5.5Measurements required from the station instruments are listed in Annexure - III. This format will be used for collecting station measurement during performance test.

6.0Instrument Installation

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 6	OF 22

The test instruments required for the test must be assembled, installed and operability verified. The following precautions are advised:

6.1Pressure Measurement

Above Atmospheric Pressure - Pressure sensing lines should be plumbed with a continuous downward slope from the pressure tap to the sensor to prevent pockets of steam or air. The lines must be blown down prior to installing the pressure instruments, and the instrument vented after pressurization. The appropriate water leg measurements for each pressure instruments should be made and entered as part of the data.

Below Atmospheric Pressure - Instruments must be plumbed with a continuous upward slope from the pressure tap to the sensor to prevent the formation of pockets of condensate. A means to vent instruments which operate below atmospheric pressure prior to the start of each test run must be provided.

Further, the following precautions should be taken for measurement of condenser back pressure:

•tapping on condenser should be close to the joint connecting turbine and condenser.

•there should not be any protruding obstructions near the pressure taps.

•minimum two taps (one on ‘A’ & ‘B’ row side) on each half of condenser should be provided (as shown in sketch attached, refer to Annexure - IV )

•taps of each half of condenser should be connected to form a grid and terminated at convenient location for transmitter installation.

•instead of surface taps, static pressure basket tips should be used.

•transmitter installation point and sensing line free from excessive vibration.

6.2Temperature Measurements

Following aspects should be taken care for proper measurement:

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 7	OF 22

•all thermowells (TW) should be cleaned and bottom polished prior to installing the temperature sensors

•RTD’s should be installed in a manner to ensure good contact with the bottom of TW and should be held firmly against the bottom during use. Entry point of TW should be sealed with cotton rope.

•thermowells should be kept slanted upwards from the tapping so that it can hold glass thermometer as well as water for better contact.

6.3C.W. Flow Measurement

In case Annubar is available for C.W. flow measurement, it should be kept clean by utilizing suitable opportunity. Alternatively C. W. flow may be derived from C.W. pump characteristics curve or heat balance or calibrated elbow tap difference pressure.

6.4Data Acquisition System (DAS) and Processor & Analyzer System

It is preferable to use portable DAS and processor & analyzer for performance testing. This will ease the testing process and provide on line monitoring of test data and results. It will also help in tracking the process stability and thereby reduce the uncertainty level of results.

6.4.1Portable Data Collection Unit

One/two portable units may be used to cover the inputs at the test location. Each DAS unit should have a minimum of 16 universal inputs as given below:

a)PT 100, 4 Wire RTD

b)4-20 mA, 2 Wire Transmitter output with a built-in facility to power the Transmitter.

6.4.2Portable Processor & Analyzer Unit

• IBM compatible portable machine with a Pentium processor.

• Graphic display compatibility.

• megabytes of RAM

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 8	OF 22

• Windows 95 with Microsoft Excel version 7.0

•IDAAS and DALITE Software as analyzer.

6.4.3Installation

The following precautions should be taken during installation of the data collection unit with the portable processor.

•Identify the location of power supply

•List out the inputs with respect to Channel No.

•Review the status of fuses.

•Tag input leads at both ends by masking tape, etc.

•Connect the inputs as per channel listing. Cascade the output from one data collection unit to the other, connect network cable from data collection to the interface unit/portable processor unit.

•The network cable should be laid away from movement areas, without obstructing the plant equipment, and 2-3 meters above the floor level.

•Ensure the tightness of all connections.

•Charge the power supply and check for the channels healthiness.

•Verify the system is networking.

•Carry out a test run to scan and ensure proper system functioning.

7.0Test Instructions

7.1Opening and closing position of valve which are under vacuum zone should be checked with respect to operating instructions.

7.2Ensure that condenser water box is full of water by operating water box vents.

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 9	OF 22

7.3Unit should be in operation at normal full load in steady state condition.

7.4Effort should be made to conduct the test runs close to normal operating parameters.

7.5Ensure that unit is operating under specified cycle condition, for example, cascading of H.P heater drip to deaerator.

7.6No make up should be taken during test.

7.7High energy drains passing if any to be attended/recorded.

7.8.As far as possible, the condenser hot well level should be kept constant.

7.9.The condenser C.W. outlet valves should be set at 100% open or as wide as possible maintaining a full water box.

7.10.Make notes of any abnormal conditions pertaining to the test.

8.0Test Frequency

8.1Routine testing every 3 months.

8.2Before and after each time the tubes and water box are cleaned.

8.3Special requests for various reasons.

9.0Personnel Needed

The test requires three persons, two for test set-up and for taking data at site, and one for taking data at control room.

10.0Test Set Up

10.1First notify the Shift Incharge Unit Controller about the program for conducting the test and inform about test equipment/instrument being installed.

10.2Install the RTDs (as per clause No. 6.2) in following thermowells: 10.2.1 One each in C.W. inlet pipe near condenser.

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 10	OF 22

10.2.2Four each in C.W. outlet pipe near condenser.

10.2.3One each in condensate pipe leaving the hotwell.

10.2.4One each in air/steam extraction line from each half of condenser. This is required to monitor the level of sub-cooling of air steam mixture.

Note: (i) Similar installation arrangement may be adopted in case glass thermometers are used instead of RTDs for taking manual readings.

(ii) Each thermowell must have at least one inch of water in it. After installing glass thermometer in each thermowell, pull it back out of the thermowell. If it has a drop of water on its tip, than it has enough water, otherwise put some more water.

10.3Install the absolute pressure transmitters, differential pressure transmitters (as per clause No.6.1) one on each half of the condenser terminal points at test station. Also install pressure gauge on the respective unit C.W pump discharge.

10.4The output of transmitters and RTDs is to be connected to the data collection unit and this in turn is to be connected to the data processing unit as indicated in Clause No.6.4.

11.0Duration of Test Run and Frequency of Readings

11.1CASE I - Testing by Using DAS and Processor & Analyzer System

11.1.1Test Duration: Each test run may be conducted for a period of 1520 min., after achieving minimum uncertainty.

11.1.2Frequency of Test Data: - After achieving the point of minimum uncertainty as shown by the data processor, the test may be commenced and the readings taken at a frequency as given below:

•test instrument readings by data processor as per normal scan rate.

• manual readings from control room at an interval of 5 min.

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 11	OF 22

11.2CASE II - Testing by Manual Data Collection

11.2.1Test Duration: - Each test run may be conducted for a period of 3045 min after achieving stable parameters.

11.2.2Frequency of Test Data: All readings may be taken at an interval of 5 min.

11.3Data Verification

During the course of testing, compare the historical performance data showing the expected value of the critical measurements as appropriate. This will help in assessing the error, if any, in data being collected.

12.0Computation of Test Results

12.1Determination 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	= kg/hr (Flow Main Steam excluding SH Attemp )
hMS	= kcal/kg (Enthalpy of Main Steam)
hFW	= kcal/kg (Enthalpy of Feed water)
Heat Added CRH	= Flow CRH (hHRH - hCRH) kcal/hr
Flow CRH	= kg/hr Flow Cold Reheat Steam
hHRH	= kcal/kg (Enthalpy of Hot Reheat Steam)
hCRH	= kcal/kg (Enthalpy of Cold Reheat Steam)
Heat Added by BFP	= Flow FW(hBFP Out-hBFPIn) Kcal/hr
Flow FW	= Total FW flow kg/hr
hBFP Out	= Kcal/kg (Enthalpy of FW at BFP Outlet)
hBFP In	= Kcal/kg (Enthalpy of FW at BFP Inlet)
Heat added by RH
Attemp	= Flow RH Attemp (hHRH-hRHATT) Kcal/hr

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 12	OF 22

hRHATT	= Kcal/kg (FW Enthalpy at RH Attemp Source)
Heat added by sH
Attemp	= Flow SH Attemp (hMS-hSHATT) Kcal/hr
hSHATT	= Kcal/kg (FW Enthalpy at SH Attemp Source)
Heat Loss rad	= 0.1% of Pgen (Radiation Losses) kW
Pgen	= kW (Gross Generator Output)
Pgen Losses*	= kW (Mech Losses + Iron Losses +
	Stator Current Losses)

*Values to be taken from Generator Loss Curve

12.2Determination of Condenser Flow:

	Cond Duty
CW Flow =	------------------------ m3/hr
	Cp (T out – T in ) x D

Where:

C.W Flow	= m3/hr
Cond Duty	= kcal/hr
Cp	= 1 kcal/kg o C (Specific heat of water)
D	= 1000 kg/cubic meter (Density of water)
Tout	= oC (Average C.W Outlet temp.)
Tin	= oC (Average C.W Inlet temp.)

Alternate Method for Determination of Condenser Flow

Head developed by C.W. pump transferred to design speed (Head computed):

	Head Computed =	Head Developed x (Nd) 2
		-----------------------------------(N) 2
	Where:
	Head Computed	= mwc
	Head Developed by Pump	= mwc
	Pump Running Speed ‘N’	= rpm
	Pump Design Speed ‘Nd’	= rpm

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 13	OF 22

C.W. flow to be found out from C.W pump characteristic curve corresponding to Head Computed.

12.3Water Velocity in Condenser Tube

C.W Flow Rate x 106

Tube Velocity = -----------------------------------------------------------------

3600 x Tube Area x (Number Tubes - Number Plugged)

Where:
Tube Velocity	= m/sec
C.W Flow Rate	= m3/hr
Tube Area	= mm2

12.4Computation of Log Mean Temperature Difference (LMTD):

Tour - Tin

LMTD = -------------------

Tsat – Tin

Ln ----------

Tsat – Tout

Where:

LMTD	= oC
Tsat	= oC (saturation temperature corresponding to
	back pressure)

12.5Determination of Cleanliness Factor

U actual (actual heat transfer coefficient)

Cf (Cleanliness factor) = -----------------------------------------------------------

U theoretical (theoretical heat transfer coefficient)

Condenser Flow x Cp x (Tour – Tin) x Density of water U actual = ------------------------------------------------------------------

A condensing x LMTD

Where:

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 14	OF 22

U actual	= kcal/hr m2 oC
Density of water	= 1000 kg/m3
A condensing	= m2 (condensing surface area)

U theoretical = U x Tin correction factor x tube correction factor x 4.882428

Where:

U theoretical	= kcal/hr m2 o C
U	= heat transfer coefficient in Btu/hrsqft. at 70oF
	C.W inlet temp., 18 BWG and Admiralty Metal (to
	be taken from HEI standard for Steam Surface
	Condenser)
Tin Correction Factor		= correction factor for actual C.W.
		inlet temperature (to be taken from HEI
		standard for Steam Surface Condenser)
Tube Correction Factor		= correction factor for tube material and tube
		wall gauge (to be taken from HEI standard
		for steam surface condenser)

12.6Determination of Expected LMTD for Deviation from Design Value:

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

	| Saturation Temp Test - LMTD test		| ¼
ft =	| ------------------------------------------------		|
	| 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)

Cond. duty design fq = ------------------------

Cond. duty test

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 15	OF 22

*Expected LMTD

LMTD expected = LMTD test x ft x fw x fq oC

12.7Determination of Expected Saturation Temperature:

(taking into consideration deviation in operating value from design values)

	[Tin – Tour x eZ]
Sat. Temp. Expected: = --------------------------- oC
	[1 - eZ]
Where:
Tin	= Design C.W. inlet temp.
Tour	= Design C.W. outlet temp.
	Tour – Tin

Z= --------------------

Expected LMTD

Note: Tin and Tour may be used for base line data in case the back pressure is required to be compared with base line test.

12.8Determination of Breakup of Condenser Back Pressure Deviation:

On arriving at the back pressure deviation with respect to expected back pressure, 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.

b)From curve (a) above generate curve for all the conditions likely to be met in practice, i.e., to determine expected back pressure for any load and for any probable C.W inlet temperature.

c)For computing the deviation refer the table given in Annexure -V.

d)Further analysis can be carried out with the help of fault tree given in Annexure -VI.

13.0 Analysis

	Centre For Power Efficiency And Environmental	Procedure Number
NTPC	Protection, NOIDA	CENPEEP/EFF/TP/302
	TITLE	Rev. 1 /EMS
CENPEEP	Condenser Performance Test	Issue Date: 20/04/2000
		Page: 16	OF 22

Needs to be performed.

14.0Report

The report should include a narrative describing any unusual findings as well as the following:

14.1Executive Summary

14.2Objective

14.3Scope

14.4Background

14.5Test Methodology

14.6Results

14.7Discussions

14.8Conclusions

14.9Recommendations

14.10Acknowledgment

14.11References

14.12Complete set of Appendices

14.12.1Analysis and Results

14.12.2Test Data

14.12.3Test Equipment and Instrumentation