Troubleshooting vacuum systems : steam turbine surface
Contents
1. Troubleshooting Vacuum Systems Steam Turbine Surface Condensers and Refinery Vacuum Towers Authored by Norman P Lieberman 4D Jae Publishing WILEY Contents Preface xiii Introduction xv Definition of Terms xix Other Books by Author xxiii 1 How Jets Work 1 1 1 The Converging Diverging Ejector 1 1 2 Interaction of Steam Nozzle with Converging Diverging Diffuser 5 1 3 Compression Ratio 6 1 4 Converging Diverging Ejector 7 1 5 Velocity Boost 9 1 6 Surging 10 1 7 Critical Discharge Pressure 11 1 8 Observing the Conversion of Heat to Velocity 12 1 9 Jet Discharge Pressure 13 1 10 Reducing Primary Jet Discharge Pressure 14 1 11 Bypassing First Stage Ejectors 15 2 Making Field Measurements 17 2 1 Getting Started 17 2 2 How to Unscrew Steel Plugs 23 2 3 Effect of Barometric Pressure on Indicated Vacuum 24 2 4 Use of Piccolo 25 2 5 Measuring Deep Vacuums using an Hg Manometer 27 2 6 Measurement of a Deep Vacuum without Mercury 28 2 7 Measuring Condensibles in Feed to First Stage Ejector 30 2 8 Identifying Loss of Sonic Boost by Sound 31 vii viii CONTENTS 2 9 Identifying Air Leaks 2 10 Air Leaks in Flanges 2 11 Vacuum Measurement Units 3 Tabulation of Vacuum System Malfunctions 3 1 3 2 3 3 3 4 39 3 6 3 7 3 8 Tidal Flop in Delaware Critical Discharge Pressure Fouling in Final Condenser Reduction in Back Pressure Loss of LVGO Pan Level Variations in Cooling Water Temperature Multi Componen2. learance Fouling Mechanism in Vacuum Tower Surface Condensers Surface Condenser Impingement Plate Oversized Impingement Plate Impingement Plates as Vapor Distributors 16 Optimizing Vacuum Tower Operation 16 1 16 2 16 3 16 4 16 5 16 6 Steam to Heater Passes LVGO Pan Level Loss Causes a Loss in Vacuum Carry Over of LVGO Pumparound Spray Optimizing Vacuum Tower Top Temperature Plugged Vacuum Tower Top Demister Bypassing Primary Ejector 17 Frequently Asked Questions 17 1 Vacuum Systems The Norm Lieberman DVD Video Library Index 189 193 194 197 197 198 200 202 203 204 205 206 208 208 209 211 212 212 214 215 217 218 220 226 227 229 232 233 233 243 247
3. sized Condenser Drain Nozzle Seal Drum Level Indication Leaking Gauge Glass on Surface Condenser Boot Condensate Pump Cavitation Due to Air Leaks Condensate Back Up in Surface Condenser Boot Experiment with Condensate Back Up Condensate Back Up 13 Seal Leg Drainage 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 Sludge Accumulation in Seal Drum Seal Leg Leak Inside Seal Drum Seal Leg Flange Leak Outside Seal Drum Seal Leg Design Inadequate Seal Leg Length for Hydrocarbons Inadequate Seal Leg Capacity High Back Pressure from Seal Drum Detecting Condensate Back Up in Seal Legs Condensate Back Up Due to Air Leak in Barometric Drain Line 13 10 Seal Drum Design 128 129 130 130 131 132 135 141 143 143 145 148 149 151 153 155 157 161 162 165 166 169 169 171 174 177 180 182 183 184 186 188 CONTENTS Xi 13 11 Seal Drum Fills with Corrosive Deposits 13 12 Seal Drum Design Tips 13 13 An Unfortunate Incident 14 Other Types of Vacuum Equipment 14 1 14 2 14 3 14 4 14 5 14 6 Hogging Jets Use of Hogging Jet on Surface Condenser Liquid Seal Ring Compressors Gas Ejectors Liquid Ejectors Ejector Compression Efficiency 15 Air Baffle and Impingement Plate in Surface Condensers 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 Mechanical Configuration of Seal Strips Corroded Brass Seal Strips Air or Vapor Baffle Leak Identifying Defective Seal Strips Air Baffle C
4. t Malfunctions Partial Tabulation of Vacuum System Malfunctions 4 Effect of Water Partial Pressure on Jet Efficiency 4 1 Vapor Pressure of Water Limits Vacuum 4 2 Reminder about Water Partial Pressure 4 3 Air Leaks in Steam Turbine Surface Condensers 4 4 Variable Cooling Water Temperature 4 5 Loss of Sonic Boost 4 6 Relative Jet Efficiency 4 7 Definition of Vacuum Breaking 4 8 Critical Discharge Pressure Exceeded 5 Air Leaks 5 1 Upper Explosive Limits 5 2 How to Find Air Leaks 5 3 Diffuser Air Leaks 5 4 Air Leaks on Vacuum Towers 5 5 Air Leaks in Heater Transfer Lines 5 6 Air Leaks Turbine Mechanical Seal 6 Sources and Disposal of Hydrocarbon Off Gas 6 1 6 2 6 3 6 4 6 5 6 6 Evolution of Cracked Gas Sources of Cracked Gas Cracked Gas Evolution from Boot Air Equivalent Overloading Vacuum Jets Excess Cracked Gas Flow 32 34 35 39 40 43 43 45 45 47 50 51 55 56 59 59 60 60 62 63 64 67 67 68 69 70 71 72 75 75 78 80 81 84 85 CONTENTS ix 6 7 Field Checking Gas Flow Meter in Vacuum Service 85 6 8 Surging 3rd Stage Jet Bogs Down Primary Jet 89 6 9 Exchanger Leaks Overloads Jets 90 6 10 Poor Vacuum Tower Feed Stripping 92 6 11 Level Connection Purges and Pump Mechanical Seal Gas 94 6 12 Effect of Heater Outlet Temperature 95 6 13 Extracting H S from Vacuum Tower Off Gas Upstream of Ejectors 97 6 14 Disposal of Seal Drum Off Gas 99 6 15 Fouling of Waste Gas Burner 100 7 Moti
5. ve Steam Conditions 101 7 1 Effect of Wet Steam 102 7 2 Water in Motive Steam 103 7 3 The Tale of Weak Steam 104 7 4 Internal Freezing of Steam Nozzle 105 7 5 High Pressure Superheated Motive Steam 108 7 6 Effect of Moisture Content of Saturated Steam on Temperature 108 7 7 Steam Pressure Affects Vacuum 109 7 8 Effect of Superheated Steam 111 8 Mechanical Defects of Ejectors 113 8 1 Steam Nozzle Testing 113 8 2 Other Mechanical Defects of Jets 114 8 3 Fouled Steam Nozzles 117 8 4 Diffuser Erosion 118 8 5 Repair of Ejector Body 119 8 6 Changing Worn Steam Nozzles 119 8 7 Restoring Critical Flow 120 9 Condenser Fouling and Cleaning 123 9 1 Fouling Mechanism in Condensers for Refinery Vacuum Towers 123 9 2 Fouling Due to Chemical Additives 124 9 3 Minimizing Condenser Fouling in Vacuum Towers 125 94 Fouled Pre condenser 126 x CONTENTS 9 5 9 6 9 7 9 8 9 9 9 10 Fixed Tube Sheet Condensers Cleaning Condensers On Stream Optimum Condenser Bundle Configuration Chemically Cleaning Condensers Ball Cleaning Condenser Tubes Corrosion Control by Better Desalting 10 Pressure Control of Vacuum Towers 10 1 Positive Feedback Loop 11 Condenser Cooling Water Flow 11 1 11 2 11 3 11 4 Cooling Water Flow Configuration Air Evolving from Cooling Water Reduces Cooling Water Flow Cooling Water Pressure to Surface Condensers Tube Leaks 12 Condensate Back Up in Condensers 12 1 12 2 12 3 12 4 12 5 12 6 12 7 Under
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