The condenser is a large shell-and – tube type heat exchanger. This is positioned next to the turbine in order to receive a large flow rate of low pressure steam. This steam in condenser goes under a phase change from vapour to liquid water. In thermal power plants, the primary purpose of a surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency, and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the steam generator or boiler as boiler feed water.

1. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp. 37-46© IAEME
37
THEORETICAL ANALYSIS OF THE PERFORMANCE OF
DUAL PRESSURE CONDENSER IN A THERMAL POWER
PLANT
K.K.Anantha Kirthan* S. Sathurtha Mourian* P. Raj Clinton*
*Department of Mechanical Engineering (SW)
PSG College of Technology (Autonomous Institution)
Coimbatore – 641 004
ABSTRACT
The condenser is a large shell-and – tube type heat exchanger. This is positioned next to the
turbine in order to receive a large flow rate of low pressure steam. This steam in condenser goes
under a phase change from vapour to liquid water. In thermal power plants, the primary purpose of a
surface condenser is to condense the exhaust steam from a steam turbine to obtain
maximum efficiency, and also to convert the turbine exhaust steam into pure water (referred to as
steam condensate) so that it may be reused in the steam generator or boiler as boiler feed water. A
Dual -pressure condenser results in efficiency improvement because the average turbine back
pressure is less compared with that of a single-pressure condenser. The average exhaust pressure of
the LP turbines becomes lower than the single pressure condenser.
This paper presents the theoretical analysis that shows the significant of dual pressure
condenser application in thermal power plants for improved efficiency over the conventional single
pressure condensers. Condenser performance is discussed in detail and the analytical results are
given with respect to dual pressure operation of condensers.
In India, the subcritical and supercritical units of thermal power plants which were supplied
by Chinese have adopted with the dual pressure condenser technology. This report introduces the
theoretical approach to the above technique with a brief description.
Keywords: Thermal Power Plant, Condenser, Single Pressure and Dual Pressure Condenser, LMTD,
Steam Cycle LP Turbine Efficiency, Condenser Effectiveness
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ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 6, Issue 2, February (2015), pp. 37-46
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2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp.
NOTATIONS
݉ሶ C Mass flow rate of cooling water
ܶܿ Condensing or saturation temperature
specific heat
Q Heat transfer
U Overall heat transfer coefficient
ܶ‫1ݓ‬ Cooling water inlet temperature
ܶ‫2ݓ‬ Cooling water outlet temperature
high pressure condenser
ܶ‫3ݓ‬ Cooling water outlet temperature at high pressure condenser
TTD Terminal temperature difference
∆t Diff between cooling water inlet & outlet temperature
δt Difference between
ln Natural logarithm
Tm Log mean temperature difference
hfg Specific enthalpy of steam
1. INTRODUCTION
Condenser is a heat –exchanger apparatus and is vital for a thermal power plant because the
efficiency of the turbine is fully d
increased by enhancing the heat transfer rate of a condenser; this can be achieved by reducing the
turbine exhaust pressure. The condenser is positioned next to the turbine in order to receive
flow rate of low pressure steam. This steam in the condenser goes under a phase change from vapour
to liquid water. External cooling water is pumped through thousands of tubes in the condenser to
transport the heat of condensation of the steam away
condensate is at a low temperature and pressure. Removal of this condensate may be considered as
maintaining the low pressure in the condenser continuously. The phase change in turn depends on
the transfer of heat to the external cooling water. The rejection of heat to the surroundings by the
cooling water is essential to maintain the low pressure in the condenser.
the back pressure a little bit increases the work of the turbine, inc
reduces steam flow for a given output.
2. DUAL PRESSURE CONDENSER
Large power plant condensers are usually 'shell and tube' heat exchangers
fluids do not come in direct contact and the heat released by the c
through the walls of the tubes into the cooling water continuously circulating inside them. In a “Dual
pressure condenser” the two shells operate at different pressures. The bottom sides (hot well) of both
the condensers are connected.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
e), Volume 6, Issue 2, February (2015), pp. 37-46© IAEME
38
Mass flow rate of cooling water
Condensing or saturation temperature
Overall heat transfer coefficient
Cooling water inlet temperature at Low pressure condenser
Cooling water outlet temperature at Low pressure condenser and inlet to th
high pressure condenser
Cooling water outlet temperature at high pressure condenser
Terminal temperature difference
Diff between cooling water inlet & outlet temperature
between the steam saturation temp & cooling water o
mean temperature difference (LMTD)
Specific enthalpy of steam
exchanger apparatus and is vital for a thermal power plant because the
efficiency of the turbine is fully dependant on it. The thermal efficiency of a power plant can be
increased by enhancing the heat transfer rate of a condenser; this can be achieved by reducing the
turbine exhaust pressure. The condenser is positioned next to the turbine in order to receive
flow rate of low pressure steam. This steam in the condenser goes under a phase change from vapour
to liquid water. External cooling water is pumped through thousands of tubes in the condenser to
transport the heat of condensation of the steam away from the plant. Upon leaving the condenser, the
condensate is at a low temperature and pressure. Removal of this condensate may be considered as
maintaining the low pressure in the condenser continuously. The phase change in turn depends on
f heat to the external cooling water. The rejection of heat to the surroundings by the
cooling water is essential to maintain the low pressure in the condenser. In condenser, by lowering
the back pressure a little bit increases the work of the turbine, increases the plant efficiency, and
reduces steam flow for a given output.
DUAL PRESSURE CONDENSER
Large power plant condensers are usually 'shell and tube' heat exchangers
fluids do not come in direct contact and the heat released by the condensation of steam is transferred
through the walls of the tubes into the cooling water continuously circulating inside them. In a “Dual
pressure condenser” the two shells operate at different pressures. The bottom sides (hot well) of both
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
© IAEME
at Low pressure condenser and inlet to the
steam saturation temp & cooling water outlet temp
exchanger apparatus and is vital for a thermal power plant because the
ependant on it. The thermal efficiency of a power plant can be
increased by enhancing the heat transfer rate of a condenser; this can be achieved by reducing the
turbine exhaust pressure. The condenser is positioned next to the turbine in order to receive a large
flow rate of low pressure steam. This steam in the condenser goes under a phase change from vapour
to liquid water. External cooling water is pumped through thousands of tubes in the condenser to
from the plant. Upon leaving the condenser, the
condensate is at a low temperature and pressure. Removal of this condensate may be considered as
maintaining the low pressure in the condenser continuously. The phase change in turn depends on
f heat to the external cooling water. The rejection of heat to the surroundings by the
condenser, by lowering
reases the plant efficiency, and
Large power plant condensers are usually 'shell and tube' heat exchangers where the two
ondensation of steam is transferred
through the walls of the tubes into the cooling water continuously circulating inside them. In a “Dual
pressure condenser” the two shells operate at different pressures. The bottom sides (hot well) of both

3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 2, February (2015), pp. 37-46© IAEME
39
Figure-1 Dual pressure condenser arrangement
For the convenience of cleaning and maintenance, cooling water flows through the tubes and
steam condenses outside the tubes. These condensers can be classified based on the cooling water
flow as single or multi pressure, depending on whether the cooling water flow path creates one or
more turbine back pressures and thereby increasing the turbine efficiency. Dual pressure condensing
system is incorporated with two condensers. These condensers have different internal pressure from
each other and are installed below the each low pressure turbines LPT-A & LPT-B as shown in the
figure-1.
SERIES TYPE COOLING WATER FLOW ARRANGEMENT
In case of a serial configuration, the total cooling water mass flow rate enters the low
pressure condenser and upon exiting enters the high pressure condenser as in figure-2. Structurally,
the unit can be thought of as two separate condenser shells, although the actual design is often a
single shell with a pressure tight partition separating the high pressure condensing region (A) from
the lower pressure region (B).
Figure-2 Cooling water flow arrangement – series type
While part of the steam is expanded to a lower pressure and temperature (TCB < TC), the
remainder is discharged at a somewhat higher temperature (TCA > TC). Different condenser pressures
are achieved (Figure-3).

4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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40
Figure-3 Temperature profile of dual pressure condenser
Assuming equal mass flow rates for the cooling water in both configurations, the average
condenser pressure in the serial arrangement is lower. In general, the lower the condenser pressure
the higher the efficiency of the overall plant.
CHARACTERISTICS OF CONDENSER
• Double-shell: Steam side divided by a sealed partition plate into two parts, shell A and shell B,
respectively
• Cooling water in B is colder than A
• Pressure in B lower than A as well
• Average pressure is lower at same heat transfer area and cooling water flow, higher vacuum
and thermal economy
• Single-pass: once-through
ADVANTAGES OF DUAL PRESSURE CONDENSER
The Dual pressure condenser is configured such a way that to obtain the
• Temperature of the condensate can be increased considerably. Both the hot wells are
interconnected at bottom which is having different temperature due to difference in saturation
pressure.
• A Dual -pressure condenser results in efficiency improvement because the average turbine
back pressure is less compared with that of a single-pressure condenser (Which is determined
by the highest circulating water temperature). The average exhaust pressure of the LP turbines
becomes lower than the single pressure condenser. (PA + PB)/2 < PS
• The TTD can be made larger in dual pressure condenser thereby the cooling area can be
reduced.
• Cooling water flow is reduced because it flows once through both condensers consecutively in
series. As a result, cooling tower size can be reduced and also, the pumping cost can be
reduced.
CONDENSER OPERATING CHARACTERISTICS
• Relationship of condenser vacuum , steam load, cooling water inlet temperature, circulating
water flow rate and the TTD is called operating characteristics, or thermal characteristics of
condenser
• The corresponding variation curve is called curve of condenser operating characteristics
• Vacuum of condenser corresponds to condensing water temperature Tc. So the factor which
affects the condenser vacuum also affects Tc

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41
FACTORS AFFECTING THE OPERATING CHARACTERISTICS
These following 3 factors affect the vacuum in condenser
Tw1 - cooling water inlet temperature
∆t- (Tw2 - Tw1) diff between cooling water inlet & outlet temperature
δt –temp diff between steam saturation temp & cooling water outlet temp
Cooling water inlet temp (Tw1)
• If cooling water temperature (Tw1) decreases, saturation temperature of condensing steam (Tc)
also decreases, then vacuum will increase
• If cooling water temperature (Tw1) increases, saturation temperature of condensing steam (Tc)
also increases, then vacuum will decrease
Cooling water Temp rise (∆t )
• If t1, δt and exhaust steam constant, ∆t inversely proportional to cooling water flow.
• So, water flow ↓, ∆t ↑, vacuum ↓;
• water flow ↑, ∆t ↓, vacuum ↑
Steam load & δt
• ∆t proportional to exhaust steam,
• So, exhaust↑, ∆t↑, vacuum↓; vice versa
• In case of t1 and ∆t are constant, δt↓, vacuum↑; δt ↑, vacuum ↓
3. ANALYSIS OF DESIGN & TEST PARAMETERS OF CONDENSER
The Surface condenser - double back pressure, divided water box - double shell & single pass
condenser is considered for this analysis.
Table-1 Design & test data’s
Description Unit Design Data Test Data
Unit load MW 600 602
Total active area of the condenser m2
32150 32150
Numbers of pass and shell 1/2 1/2
Net heat carried away under the condition of circulating water kJ/s 795300 718907*
Circulating water flow kg/hr 68400000 63390000
Cooling water inlet temp (Tw1) ℃ 32 34.4
Cooling water outlet temp (Tw3) ℃ 42 44.1
CW inlet / outlet pressure in the water chamber MPa 0.3 0.27/ 0.22
Cleanness factor 0.85 -
Condenser inlet steam temp ℃ 48
Steam flow at condenser inlet
(LP turbine outlet)
kg/hr 1146000 1146000
Design TTD of the condenser 6.69/6.51 8 /3.39*
Condenser pressure KPa 10.13 12.9
Condensate (Hot well) temp ℃ 45.6 47.1
* calculated values

6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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DATA ANALYSIS
Heat flow is one of the most critical parameters required for condenser performance
monitoring. Two methods are available to calculate this value: the water side Q and steam side Q. In
theory both value should be identical if it is assumed that no heat energy is lost from the steam side
through radiation from the condenser shell.
Parameters furnished in the TEST data column in the above table are considered for this
analysis of condenser performance.
4. PERFORMANCE ANALYSIS OF DUAL PRESSURE CONDENSER
If cooling water is supplied to condenser in series flow arrangement, the performance of
condenser can be: Let as assume that basis construction of both the condensers are same.
Figure - 4 cooling water flow in dual pressure condenser
Performance of low pressure condenser
Water side parameters of Low Pressure Turbine (B) at rated load of 600 MW:
Tw1 =34.4
Tw2 = ?
mሶ C = 63,390 m3
/hr = 17,608 kg/Sec
Heat gained by cooling Water in Condenser-B
Cooling waterside ‘Q’ is calculated from the relationship:
QGain = mሶ C X Cp (Tw2 - Tw1) -------- (A)
Where
Tw1 is the inlet cooling water temperature ( )
Tw2 is the outlet cooling water temperature ( )
mሶ C is the cooling water flow rate (kg/sec)
Cp is the specific heat of water, which may be assumed to be 4.19 kJ/kg
= 17,608 X 4.19 X (Tw2 - 34.4)
= 73777 X (Tw2 - 34.4) kJ/sec ------- (1)
Steam side Parameters of Low Pressure Turbine (B) at rated load of 600 MW
Total steam flow (at 2 LP Turbines) = 1146 T/hr
(The steam flow has been taken as half of the total flow but in actual condition it may vary due to
dual pressure at condensers)

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Steam inlet at LP turbine (B) =
ଵଵସ଺
ଶ
= 573 T/hr @ 48 = 159 kg/sec @ 48
Therefore Heat value of steam at condenser inlet 12.9 kPa @ 48
From steam table, hfg = 2387 kJ/kg
Qlost by steam = 159 X 2387 = 379533 kJ/Sec ------ (2)
Heat gained by cooling water = Heat lost by the steam
From Equation (1) and (2)
73777 X (Tw2 - 34.4) = 379533, Tw2 = 5.1 + 34.4 = 39.5
Cooling water temperature at outlet of low pressure condenser-B (Tw2) = 39.5
Performance of high pressure condenser
Cooling water inlet temperature at high pressure condenser is 40
Hence, heat gained by the cooling water at high pressure condenser
QGain = ݉ሶ CP (Tw3 - Tw2) = 17,608 x 4.19 x (44.1 – 39.5) = 73777 x (44.1 - 40) = 339374 kJ/sec
Details of enthalpy gained by cooling water in series flow configuration
Hence, heat lost by steam at condenser-A = 339374 kJ/Sec = 159 kg/sec
159 X hfg = Qlost, hfg = 339374 / 159 = 2134 kJ/kg
The saturation temperature can be fixed for specific enthalpy of evaporation - 2134 kJ/kg & 90%
dryness fraction, the saturated steam temperature would be – 54.5
Calculation of LMTD for series flow configuration
LMTD of LOW pressure condenser ( Tm) - B:
Tw1 is the inlet cooling water temperature ( ) = 32
Tw2 is the outlet cooling water temperature ( ) = 39.5
Let us assume that the inlet temperature of steam & the out let temperature of condensate below the
condenser are same (since the latent heat alone is removed in condenser). At 12.9 kPa pressure
Tm (LP condenser-B) =
ሺ்௖ ି ்௪ଵሻ ି ሺ்௖ ି ்௪ଶሻ
௟௡
ሺ೅೎ ష ೅ೢభሻ
ሺ೅೎ ష ೅ೢమሻ
=
ሺସ଼ ି ଷସ.ସሻ ି ሺସ଼ ି ଷଽ.ହሻ
୪୬
ሺరఴ ష యర.రሻ
ሺరఴ ష యవ.ఱሻ
= 10.85
LMTD of HIGH pressure condenser ( Tm)-A
Tw2 is the inlet cooling water temperature ( ) = 39.5
Tw3 is the outlet cooling water temperature ( ) = 44.1
Let us assume that the inlet temperature of steam & the out let temperature of condensate below the
condenser are same (since the latent heat alone is removed at condenser).
Tm (HP condenser-A) =
ሺ48 ି39.5ሻ ି ሺ48 ି 44.1ሻ
ln
ሺ48 ష 39.5ሻ
ሺ48 ష 44.1ሻ
= 5.97
Average LMTD of series flow cooling water 10.85 & 5.97 = 8.41
Effectiveness of condenser in series flow
(For design value) =
ሺTw2 ି Tw1ሻ
ሺTs ି Tw1ሻ
=
ሺ42 ି 32ሻ
ሺ45.6 ି 32ሻ
= 0.735
Effectiveness of condenser in series flow
(For Test data) =
ሺ44.1 ି 34.4ሻ
ሺ47.1 ି 34.4ሻ
= 0.764

8. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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5. RESULTS AND DISCUSSIONS
All the calculations during this analysis have been performed on the basis of available plant
data and first law of thermodynamics. The intention of this analysis is to observe the causes which
affect the performance of the condenser. Based on the following assumption, the above calculations
were carried out and the results are tabulated as below:
The quantity of steam inlet at condenser is same as the design value
The dryness fraction of the steam at condenser inlet is 90%
Table-2 Calculated data of dual pressure condenser
Condenser ‘B’ Condenser ‘A’
Heat lost by steam kJ/Sec 379533 339374
Saturation temperature of steam entering the
turbines
℃ 48 48
Cooling water inlet temperature ℃ 34.4 (Tw1) 40 (Tw2)
Cooling water out let temperature ℃ 40 44.1 (Tw3)
Cooling water temperature difference ℃ 5.6 4.1
TTD ℃ 8 3.9
Saturated steam temperature ℃ 48 54.5
Corresponding saturation pressure at kPa 12.9 14.05
LMTD ℃ 10.85 5.97
Average LMTD ℃ 8.41
Effectiveness in dual flow 0.764
From the table, the followings are inferred:
It could be seen that the heat gained by the cooling water at condenser – A is less than
condenser-B by 11%. – This is due to higher CW inlet temperature at condenser-A.
Different saturation temperature of the steam at condenser inlet confirms the dual pressure
operation of the condenser.
Cooling Water inlet temperature at condenser inlet is higher than the design value. Cooling
water temperature is changing with weather conditions in particular region, and cannot be
changed in order to achieve better condenser performance. However, the test ∆ (9.7ºC) is
almost equal to the design value (10ºC). This can be increased by means of supplying more
quantities of cooling water.
The cooling water supplied to the condenser for rated load is less than the design value. Due
to higher cooling water inlet temperature, the condenser pressure is high.
Due to large LMTD, rate of heat transfer is more in dual pressure condenser which will
increase the work output of turbine.
The analysis is show that TTD is higher than the design value. This rise in TTD is due to
increase in cooling water inlet temperature. The TTD can be made larger in dual pressure
condenser thereby the cooling area can be reduced.

9. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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45
Performance test confirmed that the effectiveness of the condenser equaled or surpassed the
design value.
6. CONCLUSION
The technological investigations and analysis of various important characters affecting the
dual pressure condenser performance and other related factors responsible for deviation from ideal
working of condensers have been discussed. Also, the analytical results of dual pressure condenser
are presented in detail. From the analysis, it can be concluded that the causes which effecting the
performance of condenser are:
Deviation due to cooling water inlet temperature
Deviation due to water flow rate and
Deviation due to condenser pressure
In general, the lower the condenser pressure the higher the turbine efficiency and hence, the
overall plant cycle efficiency is improved. This performance test confirmed that the effectiveness of
the condenser is equaled or surpassed the design value. However, the following measures are
suggested to achieve the design performance and to ensure the sustained performance.
Cooling water flow can be increased to increase the condenser heat transfer rate for the given
cooling water temperature.
The total efficiency of the power plant can be increased considerably by overcome above
deviations in the condenser.
ACKNOWLEDGMENT
The authors would like to express their profound gratitude and deep regards to Mr.R.
VENKATESH for his exemplary guidance, monitoring and constant encouragement throughout the
course of this thesis. The blessing, help and guidance given by beloved principal shall carry them a
long way in the journey of life on which they are about to embark.
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AUTHORS DETAILS
Name : ANANTHA KIRTHAN K K
Degree : Bachelor o f Engineering
Field : Mechanical Engineering (SW)
Institution : PSG College of Technology
City : Coimbatore
State : Tamilnadu
Country : India
Name : SATHURTHA MOURIAN S
Degree : Bachelor o f Engineering
Field : Mechanical Engineering (SW)
Institution : PSG College of Technology
City : Coimbatore
State : Tamilnadu
Country : India
Name : RAJ CLINTON P
Degree : Bachelor o f Engineering
Field : Mechanical Engineering (SW)
Institution : PSG College of Technology
City : Coimbatore
State : Tamilnadu
Country : India