The growing demand for electricity worldwide has led to larger power plants.
Coal-fired thermal power
plants are a common and traditional method of bulk electrical power generation, meeting the needs of
over 7 billion people globally.
Larger power plants require more fuel. However, coal reserves are finite, making power generation
increasingly expensive over time.
Additionally, major thermal power plants have many complex instruments, each with power loss. This
limits the plant’s efficiency to only 20% to 26%, depending on capacity.
These challenges highlight the need to economise power generation. An economiser helps achieve this
by improving efficiency. Let’s explore how economizer work in more detail.
Water hammer, also known as hydraulic shock, occurs when fast-moving water suddenly hits an
obstruction in a piping system, like a bend or valve. It is defined as a sudden increase in pressure due to
the abrupt halt or change in direction of fluid motion.
An example of water hammer occurs during the startup of a long steam line when steam and
condensate mix. In daily life, it happens when we suddenly open or close a water tap, causing a sudden
increase in pressure.
Misunderstood Concept about Water Hammer
Many thermo-hydraulic phenomena are often mistaken for water hammer, such as hydraulic and
thermal shocks. Water hammer typically occurs due to a lack of awareness and poor operation and
maintenance practices. As the saying goes, “prevention is better than cure.”
Thermodynamic Phenomenon Location of Occurrence
Water hammer In Steam pipes and headers
Water Piston (unstable horizontal waves) Storage tank (like Deaerator)
Flash condensation and evaporation shock In Deaearators
Water induction, distortion of rotor or casing In Steam turbine and steam piping
Occurrence of Water Hammer
When steam leaves the boiler, it travels a distance before reaching its point of use, like a steam turbine
or heat exchanger. During this journey, the steam loses heat and starts to condense. During plant
startup, the rate of condensate formation is very high because the system starts from a cold state.
During the operation these droplets of condensate starts building up along the length of steam pipe net
work and thus forming a solid slug of condensate as shown in the given
water hammer
Condensation creates water droplets that gradually build up along the pipe, forming a solid slug. When
this slug encounters an obstruction, like an orifice, valve, or bend, it suddenly stops. The kinetic energy
of the slug then converts to pressure energy, which the pipe network must handle.
Impact of Water Hammer
It is necessary to understand the serious impact of water hammer in equipments used in the plants.
Given below example clearly explains the destructive nature of water hammer:
For Saturated steam recommended velocity is 25 to 35 meters per second
For water in a pipe network recommended velocity is 2 to 3 meters per second
When water hammer occurs, condensate slug is dragged by steam and thus the water slug travels with a
velocity equal to that of steam which is ten times more than that of water velocity. Thus water hammer
is always associated with very high pressure.
Factors help in avoiding water hammer
Steam system is very complex and dynamic, thus avoiding water hammering is a challenging task. But
with the help of following the best engineering practices its occurance can be easily surmount by
adopting:
Proper inclination should be provided in the steam lines in the direction of flow.
Steam trap installation at regular interval and that too at the lowest points. Installation of the steam
trap at the lowest points ensure the removal of condensate from the system.
Factors help in avoiding water hammer
Pipe sagging results in formation of condensate in the piping network and may result in increasing the
chances of water hammering. Thus steam pipes should be properly supported to avoid any sagging.
Standard start up procedures are required for cold start of the plant. Operators should be properly
trained to take care of the openly of isolation valve slowly.
Proper sizing of the drain pockets, to ensure that the condensate should not jump or pass it easily. The
purpose of drain packet should not be defeated to collect all the condensate and pass the same through
the trap.
Type of reducers shall be eccentric instead of concentric reducers.
Water Hammer in Power Plants
Water hammer occurs when water, accelerated by steam pressure or a low-pressure void, is suddenly
stopped by impact on a valve or fitting, such as bend or tee, or on a pipe surface. Water velocities can be
much higher than the normal steam velocity in the pipe, especially when the water hammer is occurring
at startup.
When these velocities are destroyed by impact, the kinetic energy in the water is converted into
pressure energy, and a pressure shock is applied to the obstruction. In mild cases, there is noise and
perhaps movement of the pipe.
More severe cases lead to fracture of the pipe or fittings with almost explosive effect and consequent
escape of live steam at the fracture. Fracturing of pipes or steam system components can propel
fragments that can cause injury or loss of life on it.
Various Phase Condition under which Water Hammer Occurs
Design
Inadequate number or poor placement of steam traps and drains.
Unstable water level i.e creates waves in tank and pipies.
Difference in design vs as built.
Inadequate drain size
Operation
Poor start-up procedure (either opening the valve too quickly or failing to pre-heat the pipes).
Un professional lockout practices.
Inadequate operators training or start-up procedures.
Maintenance
Steam traops blocked by corrosion products or scale.
Defective components
Improper pipe insulation
Lack of proper preventive maintenance.
Flooded manholes.
