Feed water Heating

DMR Panda

ENERGY AND EFFICIENCY MANAGEMENT GROUP HP HEATERS PERFORMANCE TEST

UNIT : I S.No DESCRIPTION READINGS: 1 UNIT LOAD 2 FW PRESSURE 3 FW INLET TEMPERATURE 4 FW OUTLET TEMPERATURE 5 SHELL PRESSURE 6 EXT STEAM TEMPERATURE 7 DRAIN OUTLET TEMP. 8 DRIP LEVEL 9 FW FLOW UNITS MW KSC Deg. C Deg. C KSC Deg. C Deg. C mm T/Hr HPH 5 DESIGN TEST 200 190 189.33 212.23 19.94 194.33 584 203 177.3 190.7 213.9 20.00 473.3 195.9 218 558

6th July 05 HPH 6 DESIGN TEST 200 190 212.23 240.08 33.88 217.23 584 203 177.3 213.9 247.7 38.10 355.8 215.8 266 558

CALCULATIONS: 10 SATN. TEMP.OF STEAM Deg. C 11 FW I/L ENTHALPY Kcal/kg 12 FW O/L ENTHALPY Kcal/kg 13 EXT ENTHALPY Kcal/kg 14 DRIP O/L ENTHALPY Kcal/kg 15 DRIP I/L ENTHALPY Kcal/kg 16 DRIP I/L FLOW T/hr 17 TTD (10-4) Deg. C 18 DRAIN APPROACH (7-3) Deg. C 10 NET HEAT LOAD 10^6 KCAL 11 SUB COOLING (10-7) Deg. C 12 EXtn STEAM FLOW T/hr 13 FW `DT' (4-3) Deg. C OBSERVATIONS AND RECOMMENDATIONS: 1. HPH-5 & 6 performance is satisfactory.

211.2 194.23 218.36 813.40 197.61 222.47 -1.00 5.0 14.09 16.9 22.89 22.9

213.9 195.51 220.03 814.15 199.28 220.93 39.41 -0.02 5.2 13.68 17.98 22.25 23.2

239.6 218.36 248.53 731.72 222.47 -0.50 5.0 17.62 22.3 34.60 27.9

247.9 220.03 256.95 743.71 220.93 0.15 1.9 20.61 32.05 39.41 33.8

Structure
Physical arrangements Construction Thermodynamics and other theories

Performance

Physical Arrangements

General James M. Gavin Plant's units 1 and 2 are 1300 MW capacity each. (1974). With a total generating capacity of 2,600 MW, Gavin Plant ranks as the largest generating station in the state of Ohio. It is located along the Ohio River at Cheshire, Ohio, and has an average daily coal consumption of 25,000 tons at full capacity

Typical number of feed water Heaters

UNIT SIZE (MW) 0 50 50-100 100-200 Over 200

Number of Heaters 35 5 or 6 5-7 6-8

200 MW LMZ Unit [NTPC- Vindhyachal]

No of extraction Steam extraction stages Connection to Extraction steam pr, kg/cm2 Extraction steam temp, 0C Steam flow T/hr

Ist -HPT 2nd -CRH 3rd -IPT

9 12 / CRH 15

HPH-7 HPH-6 / Deaerator HPH-5 / Deaerator

30 26.2 11.96

337 314 433

88 77 16.2

4th - IPT
5th IPT 6th - IPH 7th - LPT

18
21 23 25

LPH-4
LPH-3 LPH-2 LPH-1
12 stages, 11 stages 2 * 3 stages

6.47
2.78 1.28 0.28

368
252 172 40-50

26
23 28 12.6

HP Turbine: IP Turbine: LP Turbine:

200 MW LMZ Unit [NTPC- Vindhyachal]

0.91 bar , 45 0C 21 bar 47.5 0C 690C
LPH-2

Main Ejector

GSC-I

LPH-I

GSC-2

1020C
LPH-3

1260C
LPH-4

FRS

2470C

HPH 7

HPH-6

1830C

HPH-5

ECO

2760C Boiler drum

500 MW LMZ Unit [NTPC- TALCHER-K]

No of extraction Steam extraction stages Connection to Extraction steam pr, kg/cm2 Extraction steam temp, 0C Steam flow T/hr

Ist -CRH 2nd -IPH 3rd -IPT

CRH 5 13

HPH-6 HPH-5 Deaerator / TDBFP

40 28 22

340 390 385

4th LPT 5th - LPH 6th - LPT

1 3 4

LPH-3 LPH-2 LPH-1

4-5 1.3 0.2- 0.3

270 180 < 120

HP Turbine: IP Turbine: LP Turbine:

12 stages, 2*16 stages 2 * 5 stages

500 MW KWU Unit [NTPC- Talcher-K]

0.91 bar , 45 0C 35 bar
GSC

46 0C
DC

47 0C
LPH-I

670C
LPH-2

870C
LPH-3

1200C
LPH-4

220 bar, 1800C

ECO-1 FRS

2950C
ECO-2

210 bar, 2560C

HPH-6

HPH-5

, 206 bar, 3070C Boiler drum

Closed feed water heaters with backward cascading

Heater drain cycle with drain injected down stream of heater (forward cascading)

Steam power plant with one open and three closed feedwater heaters

 Which type of arrangements are (a) and (b)?

What are the merits and limitations of each?

Open type Feedwater heaters

Open type Feedwater heaters

Open type Feedwater heaters

Drain System

Normal drain system

Emergency drain system

HPH 5

HPH 6

HPH 7 ECO

HPH > 4 Mpa > LPH

LPH 4 LPH 3 LPH 2 CEP

Drip Pump DRIP SYSTEM

Heater Drains

Construction of Feedwater Heaters

Single tube feedwater heater with floating reverse channel

Low-Pressure, Single-Zone Horizontal Feedwater Heater

Typical straight condensing U tube feedwater heater

Typical two zone [ Condensing, Drain cooler] feed water heater

Typical two zone [ Condensing, Drain cooler] feed water heater

Details of Drain Cooler design

Typical three zone feed water heater

H P Heater
Drain inlet Extraction steam inlet FW outlet

Drain outlet FW inlet

Low pressure feedwater heater Alstom

Typical arrangements of HP Heater

Desuperheating zone

Condensing zone
Drain cooling zone

Desuperheating zone Condensing zone

Drain cooling zone

HP Feedwater Heater with Tubular Header [660 MW, CEGB]

STEAM

Feed water outlet

HP Heater in Vindhyachal 200 MW LMZ Unit Desuperheating zone

In Plan View of Spirals of Tubes

Condensing zone

Feed water inlet

Drain cooling zone

Overall Size

Tube Size

Nos. of Tubes Weight

Tube Sheet OD 1560 mm , Total Length = 3350 mm 16 Dia. mm x 1.0 mm Thk x 2850 mm Leg Length 1150 Nos. 5.0 M.Ton (Approx.)

Tube Tubes Sheets

Ad. Brass to BS 2871 Pt.-3 CZ-111 SA-516 Gr. 70

HP, LP Feed water Heater

North-dakota Fixing the Feed water heater

working on the main piping connection welds, trim piping and level control instrumentation on the feedwater heaters.

Level Control Instrumentation

Trim Piping and Insulation

A large tubesheet after drilling and overlay being moved to assembly area

A large tubesheet after drilling and overlay being moved to assembly area

LP Fedwater-1 heater in the condenser Neck

For 210 MW, low pressure heater, at Satpura T.P.S. Sarni Project,.

Overall Size

Tube Size Tube Tubes Sheets Ad. Brass to BS 2871 Pt.-3 CZ-111 SA-516 Gr. 70

Nos. of Tubes Weight

Tube Sheet OD 1560 mm , Total Length = 3350 mm 16 Dia. mm x 1.0 mm Thk x 2850 mm Leg Length 1150 Nos. 5.0 M.Ton (Approx.)

Other Merits of Feedwater Heating?

A smaller condenser and boiler

Less steam to pass in the last stages of the turbine, eliminating the difficulties caused by passing large amount of steam Better turbine drainage
Shorter blades at the low pressure part of the turbine?

Thermodynamic Analysis

Effect of no. of feed-water heaters on thermal efficiency of the cycle

Example 4 - Superheat
An internally reversible Rankine cycle is determined by specifying a maximum temperature of 427o C, a quality at the turbine discharge of 0.9, and a minimum condensing temperature of 21.1oC. Compare the thermal efficiency with that of a Carnot cycle operating between the same temperature limits.

b T

pa
a

pd
s

Example 4 - Given and computed data

State a b c d T R 530 1260 530 530 P psi 84 84 0.3631 0.3631 h BTU/lbm 38.3 1429.5 988 38 s BTU/lbm-R 0.0745 1.8645 1.8645 0.0745 x 0.9 0

Process

H BTU/lbm 1391 -441.5 -950 0.5 0

W BTU/lbm 0 441.5 0 -0.5

Q BTU/lbm 1391 0 -950 0 441

a-b b-c c-d d-a N et

Example 4 - Thermal efficiency

Rankine Thermal efficiency

441 0.316 1391

The Carnot efficiency

TC 294.26 C 1 1 0.579 TH 699.81

Key Performance Indicator

TTD DCA TR PRESSURE DROP

Terminal Temperature Difference

TTD = TS - FW OUTLET TEMP

TS saturation temperature corresponding to shell pressure

Thermal profile in different zones of H P HEATER Sensible heat transfer Latent heat transfer Sensible heat transfer

Extn
FW Ts TTD

Drain DC A FW Drain Cooling Zone Condensing Zone Desuper heating Zone

High TTD
Non condensable gases (Air) blanketing Flooding
Tube leakage Level control

Causes Tube fouling/Plugging

Heater concerned Subsequent heater Turbine steam flow

Effects Bled steam flow

Low shell pressure Excessive venting

TTD and Feed Water temp

Feedwater outlet temperature [0C]
30-110 110 -148.9 148.9 204.4 204.4 273.9

Terminal difference [0C]

2.8 5.6 8.3 11.1

Drain Cooling Approach

DCA = Drain out let temp - FW inlet temp

Thermal profile in different zones of H P HEATER Sensible heat transfer Latent heat transfer Sensible heat transfer

Extn
FW Ts TTD

Drain DC A FW Drain Cooling Zone Condensing Zone Desuper heating Zone

High DCA
Low water level

Causes Tube fouling/Plugging

LCV malfunction

Drain cooler inlet not submerged

Heater concerned Subsequent heater Turbine steam flow

Effects Bled steam flow

NTHR : Net Turbine Heat Rate

Temperature Rise

TR= FW outlet temp - FW inlet temp

Low TR
DCA high

Causes TTD high

Heater concerned Subsequent heater Turbine steam flow

Effects Bled steam flow

Sample Calculation for Feedwater Heater

Plot the points and calculate TTD DCA, TR, Extraction flow

Terminal Temperature (TTD) TTD = t sat t fw out = 252.8- 251.1 =1.7 0C. Drain Cooler Apporach Temperature (DCA) DCA = t drains - t fw in = 202.8- 194.3 = 8.5 0C.. Temperature Rise (TR) TR = t fw out t fw in = 251.1-194.3 = 56.8 0C Extraction Steam Flow = (Qe) = [Qf (hfw out hfw in) + Qdrain in (hdrains out- hdrains in)] / (hext hdrains out ) Where: Qf = Feed Flow; Qdrain in = Drain Inlet flow; h fw out = Feed Water Enthalpy at HPH Out.; hfw in = Feed Water Enthalpy at HPH in hdrains out = Enthalpy of Drain Out; hdrains in = Enthalpy of Drain In hext = Enthalpy of Extraction Steam 751.2* (259.7 196.8)+0 Qe = ------------------------------------- = 90.2 t/hr (729.4 205.95)

Why Performance Testing?

Prior to outage - Plan maintenance Post outage - Evaluate effect of work done Normal operation
Trending HR deviation accounting Optimize operation
FW temp 1C results in 2.2 kcal/kwhr ( 200 MW) > 3336 Rs/day 1.34 kcal/kwhr (500 MW) > 4299 Rs/day

How Performance Deviates?

Input parameters / process variables
FW inlet temp/ Extrn Steam inlet Pre & temp

Deterioration of equipment or system itself

Tube failure, exfoliation, blocking of tubes

Generic problems
Malfunction of one of its components like DCV

Design problems
System resistance, size or capacity

HEATER PERFORMANCE DETERIORATION

Air accumulation Steam side fouling Water side fouling Drainage defects Parting plane leakage

Air accumulation
Increased TTD Possible elevation of steam-to-heater temperature Reduced temperature rise of feed water or condensate. 0.5 % steam is venting inevitable for good venting

Steam side fouling

Progressive increase of TTD Drain temperature unaffected Reduced feed water temperature rise Eventual tube failure due to mechanical weakening Accumulation of debris in the heater shell.

Water side fouling

Gradual increase of TTD. Oil
LPT bearing oil through seals Deposition occurs in HP heaters, worst hit at highest pressure heater.

Drainage defects
Damaged flsahbox internals Reduced orifice opening Enlarged orifice opening Heater drain CV/ bypass valve malfunction.

Parting plane leakage

Short circuiting of FW TTD high DCA high TR less

Feedwater Heater Impact on Thermal Performance

ENERGY AND EFFICIENCY MANAGEMENT GROUP HP HEATERS PERFORMANCE TEST

UNIT : I S.No DESCRIPTION READINGS: 1 UNIT LOAD 2 FW PRESSURE 3 FW INLET TEMPERATURE 4 FW OUTLET TEMPERATURE 5 SHELL PRESSURE 6 EXT STEAM TEMPERATURE 7 DRAIN OUTLET TEMP. 8 DRIP LEVEL 9 FW FLOW UNITS MW KSC Deg. C Deg. C KSC Deg. C Deg. C mm T/Hr HPH 5 DESIGN TEST 200 190 189.33 212.23 19.94 194.33 584 203 177.3 190.7 213.9 20.00 473.3 195.9 218 558

6th July 05 HPH 6 DESIGN TEST 200 190 212.23 240.08 33.88 217.23 584 203 177.3 213.9 247.7 38.10 355.8 215.8 266 558

CALCULATIONS: 10 SATN. TEMP.OF STEAM Deg. C 11 FW I/L ENTHALPY Kcal/kg 12 FW O/L ENTHALPY Kcal/kg 13 EXT ENTHALPY Kcal/kg 14 DRIP O/L ENTHALPY Kcal/kg 15 DRIP I/L ENTHALPY Kcal/kg 16 DRIP I/L FLOW T/hr 17 TTD (10-4) Deg. C 18 DRAIN APPROACH (7-3) Deg. C 10 NET HEAT LOAD 10^6 KCAL 11 SUB COOLING (10-7) Deg. C 12 EXtn STEAM FLOW T/hr 13 FW `DT' (4-3) Deg. C OBSERVATIONS AND RECOMMENDATIONS: 1. HPH-5 & 6 performance is satisfactory.

211.2 194.23 218.36 813.40 197.61 222.47 -1.00 5.0 14.09 16.9 22.89 22.9

213.9 195.51 220.03 814.15 199.28 220.93 39.41 -0.02 5.2 13.68 17.98 22.25 23.2

239.6 218.36 248.53 731.72 222.47 -0.50 5.0 17.62 22.3 34.60 27.9

247.9 220.03 256.95 743.71 220.93 0.15 1.9 20.61 32.05 39.41 33.8

EEMG HPH PERFORMANCE TEST REPORT UNIT IV S.No DESCRIPTION UNITS DESIGN HPH 5 HPH 5A HPH 5B DESIGN HPH 6 1 UNIT LOAD MW 500 513 500 2 FW PRESSURE KSC 218 203.4 203.4 218.0 3 FW INLET TEMPERATURE Deg. C 166.7 173.5 173.6 208.1 4 FW OUTLET TEMPERATURE Deg. C 208.1 216.2 212.7 253.7 5 DRIP O/L FLOW (INDICATION) T/Hr 122.35 148 135 45.27 6 EXT STEAM PRESSURE KSC 18.63 21.00 19.89 43.00 7 EXT STEAM TEMPERATURE Deg. C 429 411.5 411.5 342.6 8 DRAIN OUTLET TEMP. Deg. C 171.5 183.4 181.4 212.9 9 DRIP LEVEL mm -10 -6 10 FW FLOW T/Hr 770 771.0 771.0 770.0 CALCULATIONS: 1 SATN. TEMP.OF STEAM Deg. C 207.8 216.3 213.6 253.4 2 FW I/L ENTHALPY Kcal/kg 171.2 178.0 178.1 214.2 3 FW O/L ENTHALPY Kcal/kg 214.2 222.7 219.0 263.8 4 EXT ENTHALPY Kcal/kg 791.3 781.5 781.9 733.5 5 DRIP O/L ENTHALPY Kcal/kg 173.5 186.0 183.9 217.8 6 DRIP I/L ENTHALPY Kcal/kg 217.8 225.4 225.0 7 DRIP I/L FLOW T/hr 67.7 72.9 8 TTD Deg. C -0.3 0.1 0.9 -0.3 9 DRAIN APPROACH Deg. C 4.8 9.9 7.8 4.8 10 NET HEAT LOAD 10^6 KCAL 33.146 34.49 31.53 38.17 11 SUB COOLING Deg. C 32.9 32.2 12 EXtn STEAM FLOW T/hr 48.3 57.91 52.72 74.05 13 FW `DT' Deg. C 41.4 42.7 39.1 45.6 PREVIOUS TEST RESULTS 9/5/05 1 TTD Deg. C -0.3 0.2 1.2 -0.3 2 DRAIN APPROACH Deg. C 4.8 7.6 8.3 4.8 3 NET HEAT LOAD 10^6 KCAL 33.1 31.8 31.2 38.2 4 SUB COOLING Deg. C 33.1 32.7 5 EXtn STEAM FLOW T/hr 48.3 52.8 52.1 74.1 6 FW `DT' Deg. C 41.4 40.5 39.8 45.6 OBSERVATIONS AND RECOMMENDATIONS: 1. HPH-5B FW DT is less and DCA is more.Its performance is to be observed.

RAMAGUNDAM DATE: 9-Jul-05 HPH 6A HPH 6B 513 202.8 202.8 216.2 212.7 257.1 256.9 134.9 126.0 45.1 45.0 350.6 350.6 219.8 219.5 -1 5 771.0 771.0 257.7 222.7 267.6 736.8 225.4 0.6 3.6 34.61 37.91 67.66 40.9 0.3 6.3 36.3 38.2 71.9 44.2 0.7 6.8 37.31 38.07 72.89 44.2 0.4 7.8 37.4 38.1 74.0 45.5 257.6 219.0 267.4 736.9 225.0

Heat transferred
Q= U* A* LMTD LMTD = (ITD-TTD) / Loge (ITD/TTD) Heat Balance Extrn steam flow*( h ext h drainout) = Qfw *( h fwout- h fwin) Qdrainin *(h drainout- h drainin)

Determine the condition at Pt 6 and on T-S diagramme, show all the points?
The pump has isentropic efficiency of 80%.

Why NRVs are provided in Steam extraction lines ?

When the turbine trips, the reheat stop and intercept valves close rapidly. The closing of the turbine valves causes a momentary vacuum that moves through the turbine stages. This vacuum tends to pull the extraction steam back into the turbine and decrease the extraction stage pressure. As a result, the heater shell pressure drops, causing a rapid decrease in the saturation temperature in the heater shell. With a supply of hot water in the heater shell, the water flashes to steam and attempts to flow back to the turbine extraction. This influx of energy back into the turbine causes a rapid overspeed condition. As a result, a non-return valve is installed in each extraction line that automatically closes the line to prevent steam from re-entering the turbine. In some cases, two non-return valves are installed in series. The non-return valve is a check-type valve because a gate valve could not close fast enough. When heaters are installed in the upper part of the condenser, there is no room for a non-return valve. As a result, the quantity of water held in the shell is limited, and an anti-flash baffle may be installed above the water level to restrict the flow of any flashing steam.

Drain System- Alarm & Interlocks

High heater water level - alarm High-high heater water level actuation of check valves, closing of extraction line isolation valve, actuation of bypass Automatic switch to emergency drain system when the heater that the condensate is flowing into, is shut off or is at too low a pressure at low load operation Automatic limitation of load when strings or feedwater heaters are shut off and the feedwater heater is not designed for the corresponding operation

Automatic Extraction

100 0C

75 0C

200 % 300 %

50 0C

TTD 15 5
100 %

Heat Capacity in %