HEI 2622-2015 Standard For Closed Feed Water Heaters PDF

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for
NINTH EDITION
STANDARDS
CLOSED FEEDWATER HEATERS

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Copyrighted material licensed to Arina Kornilieva on 2015-12-22 for licensee's use only.
Copyrighted material licensed through Normdocs LLC on 2015-12-22 for licensee's use only. No further reproduction or networking is permitted. Distributed by Thomson Reuters (Scientific) LLC, www.techstreet.com.
Heat Exchange Institute, Inc.
PUBLICATION LIST
TITLE CLOSED FEEDWATER HEATER TECH SHEETS
Standards for Closed Feedwater Heaters, Tech Sheet #106: Specification of Tube Hole Sizes
9th Edition, 2015 and Tolerances for Support and Baffle Plates
Tech Sheet #127: Basics of Closed
Standards for Shell and Tube Heat
Feedwater Heaters
Exchangers,
5th Edition, 2013 Tech Sheet #128: Typical Feedwater Heater
Cold Start-Up
Standards for Tray Type Deaerators,
9th Edition, 2011 Closed Feedwater Heater Specification Sheets -
English Units and SI Units
Performance Standards for Liquid Ring All closed feedwater heater tech sheets are available for
Vacuum Pumps, download on the HEI web site: www.heatexchange.org.
4th Edition, 2010
Standards for Direct Contact Barometric

and Low Level Condensers,
8th Edition, 2010
Standards for Steam Jet Vacuum Systems,

7th Edition, 2012
Standards for Steam Surface Condensers,

11th Edition, 2012
No further reproduction or networking is permitted.

Standards for Air Cooled Condensers,
1st Edition, 2011
Standards for Gasketed Plate Heat

Exchangers,
1st Edition, 2014
Distributed by Thomson Reuters (Scientific) LLC, www.t

HEAT
EXCHANGE
INSTITUTE, INC.
STANDARDS for
CLOSED FEEDWATER
HEATERS

NINTH EDITION

Copyright 2015 by
Heat Exchange Institute
1300 Sumner Avenue
Cleveland, Ohio 44115
Reproduction of any portion of this standard without written permission of the

Heat Exchange Institute is strictly forbidden.
i
HEAT
EXCHANGE
INSTITUTE, INC.
CLOSED FEEDWATER
HEATERS
American Exchanger Services, Inc.
Greenfield, WI 53228

Holtec International
Marlton, NJ 08053
Hydro Dyne, Inc.

Massillon, OH 44646
SPX Heat Transfer, LLC

Tulsa, OK 74116
Thermal Engineering International USA, Inc.

Santa Fe Springs, CA 90670
ii
CONTENTS
Page
FOREWORD vii
1. DEFINITIONS 1
1.1 Closed Feedwater Heater 1
1.2 Heater Duty 1
1.3 Design Maximum Working Pressure 1
1.4 Operating Pressure 1
1.5 Terminal Temperature Difference (TTD) 1
1.6 Drain Subcooler Approach (DCA) 1
1.7 Logarithmic Mean Temperature Difference (LMTD) 1
1.8 Pressure Loss 1
1.9 Heat Transfer Coefficient 1
1.10 Desuperheating Zone (DSH) 1
1.11 Condensing Zone 1
1.12 Drain Subcooling Zone (DC) 1
1.13 Drains 1
1.14 Total Surface 1
1.15 Effective Surface 1
1.16 Integral Flash Chamber 1
2. FEEDWATER HEATER PERFORMANCE 2
2.1 Heater Performance 2
2.1.1 Minimum Data Required to be Supplied by the Purchaser 2
2.2 Thermal Resistance 2
2.2.1 Tube Wall Resistance 2
2.2.2 Fouling Resistance 3
2.3 Terminal Temperature Difference 3
2.4 Drains Subcooling Zone Approach 3
2.5 Tube Side Velocity 3

2.6 Shell Side Pressure Loss 3
2.7 Tube Side Pressure Loss 3
2.8 Nozzle Sizes 7
2.9 Steam Nozzle Location and Steam Distribution Dome 7
2.9.1 Single Nozzle Heaters 7
2.9.2 Multi-Nozzle Heaters 8
2.10 Drain Nozzle 8
2.11 Control of Feedwater Heaters 10
2.11.1 General Control Considerations 10
2.11.2 Capacitance Requirements for Vertical Heaters 10
2.12 Overload and Abnormal Operating Modes 10
2.13 Vent Off-Take Piping 10
2.14 Oxygen Content in a Deaerating Heater 11
3. MECHANICAL DESIGN STANDARDS 11
3.1 Code Requirements 11
3.1.1 Corrosion Allowance 11
3.2 Design Pressure 11
3.3 Design Temperature 11
3.4 Hydrostatic Test 12

3.5 Nil Ductility Temperature 12
3.6 Tubes 12
3.6.1 Tube Metal Temperature 12
3.6.2 Tube Joint Temperature 12
3.6.3 Tube Wall Thickness Limitations 12
3.6.4 Tube Length 12
3.6.5 U-Tubes 12
3.6.6 Stress Relieving U-Bends 13
3.6.7 Tube Plugging 13
3.7 Tube Bundle 13
3.7.1 Tube Layout 13
3.7.2 Baffles and Support Plates 13
3.7.2.1 Tube Holes 13
3.7.2.2 Spacing and Tube Vibration 13
iii
CONTENTS (continued)
3.7.2.3 Support of U-Bends 13

3.7.2.4 Thickness 13
3.7.2.5 Drain Subcooling Zone End Plate 13
3.7.2.6 Shrouds and Longitudinal Baffles 13
3.7.2.7 Impingement Baffles 13
3.8 Tubesheet 13
3.8.1 Tubesheet Corner Radius 14
3.8.2 Tube Hole Diameters and Tolerances 14
3.8.3 Ligament Widths and Tolerances 15
3.9 Channel Covers 15
3.10 Heater Supports 15
3.11 Condenser Installation 15
3.12 Welded Joint Construction 16
3.13 Connections-Nozzle Length 16
3.14 Nozzle Loads 16
3.14.1 Nomenclature 16
3.14.2 External Forces and Moments 16
3.14.3 Sample Problem 17
3.15 Tolerances 17
4. MATERIAL DESIGN STANDARDS 23

4.1 Materials 23
4.2 Quality 23
4.3 Specifications 23
5. DESIGN AND SPECIFICATION OF REPLACEMENT HEATERS/BUNDLES 24
5.1 Replacement Heaters/Bundles 24
6. FEEDWATER HEATER PROTECTION 25

6.1 Safety Requirements 25
6.1.1 Tube Side Relief Valves 25
6.1.2 Shell Side Relief Valves 25
6.2 Flashback Protection 25
6.3 Cleanliness and Corrosion Protection 25
6.4 Venting and Draining 26
7. INSTALLATIONS 26
8. CHANNEL TYPES 27
8.1 Full Diameter Access Channels 27
8.1.1 Low Pressure, Full Access 27
8.1.2 High Pressure, Full Access 27
8.2 Manway Access Channels 28
8.2.1 Minimum Access Manway Sizes 28
8.2.1.1 Minimum Manway Sizes 28
8.2.1.2 Pass Partition Cover Design and Type 28
8.2.2 Low Pressure, Manway Access 29
8.2.3 High Pressure, Manway Access 30
9. TYPICAL FEEDWATER HEATER INTERNAL ARRANGEMENTS 31
APPENDICES Distributed by Thomson Reuters (Scientific) LLC, www.t

Appendix A GUIDELINES FOR INSTALLATION, OPERATION, AND MAINTENANCE OF
FEEDWATER HEATERS 41
A1 INSTALLATION OF CLOSED FEEDWATER HEATERS 41
A1.1 General Considerations 41
A1.2 Installation Under Freezing Conditions 41
A1.3 Pre-Operational Cleaning and Flushing Operation 41
A1.4 High Level Condensate Dump 41
A1.5 Accessories 41
A2 CLOSED FEEDWATER HEATER OPERATION 42
A2.1 Initial Start-Up Precautions 42
A2.2 Liquid Level Control 42
iv
A2.3 Liquid Level Control in Vertical Channel Down Heaters 43

A2.4 False Liquid Level Indication 44
A2.5 Effect of Low Liquid Levels on External Drain System 44
A2.6 Effect of Load Rejection on Shell Liquid Level 44
A2.7 Effect of Failed Tubes on Heater Operation 44
A2.8 Effect of Plugged Tubes 45
A2.9 Start-Up Limitations 45
A2.10 Shutdown Limitations 45
A3 MAINTENANCE OF FEEDWATER HEATERS 46
A3.1 In-Plant Cleaning 46
A3.2 Chemical Cleaning 46
A3.3 Stagnant or Entrapped Areas 46
A3.4 Special Product Warnings (Safety) 46
A3.5 Lay-Up Procedure for Non-Operating Heaters 46
A3.6 Repair Procedures 47
A3.6.1 Tube Leak Repairs 47
A3.6.2 Pressure-Boundary Repairs 47
A3.7 Spare Parts and Special Tools 47
A3.7.1 Spare Parts 47
A3.7.2 Special Tools 47
A3.8 Inspection 47
A3.9 Alterations or Repairs 47
Appendix B GENERAL FEEDWATER HEATER INFORMATION 48
B1 Vertical Feedwater Heaters 48
B2 Cycling and Off Load Conditions 48
B3 Material Compatibility in Operating Environments 48
B3.1 Compatibility of Tube Materials 49
B4 Specific Zone Designs 50

B4.1 Desuperheating Zone 50
B4.1.1 Dry Wall Safety Margins at DSZ Outlet 50
B4.2 Condensing Zone 50
B4.3 Subcooling Zone 50
B5 Heaters Removed from Service 51
B6 Manway Sizes for Hemispherical Heads 51
B7 Integral Flash Chamber Considerations 51
B8 Floating Pass Partitions 52
B9 Emergency Liquid Bypass for Feedwater Heaters 52
B10 High Pressure Closures: Gasketed vs. Welded Diaphragm 53
B11 Drains and Vents for Heaters 53
Appendix C REFERENCE DATA 56

C1 Metric Conversion Factors 56
C2 Areas of Circular Segments 60
C3 Modulus Of Elasticity E of Materials For Given Temperatures 61
C4 Thermal Conductivity of Materials for Given Temperatures 63
C5 Mechanical Characteristics of Tubing 64
C6 Mechanical Characteristics of Steel Tubing 66
C7 Chart for Solving LMTD Formula 67

C8.1 Closed Feedwater Heater Specification Sheet - English Units 68
C8.2 Closed Feedwater Heater Specification Sheet - SI Units 69
C8.3 Closed Feedwater Heater Specification Sheet - MKH Units 70
Appendix D TROUBLESHOOTING GUIDE 71
FIGURES
Fig. No. 1 Feedwater Specific Volume Ratios 4
Fig. No. 2 Design Feedwater Velocity at 60F 5
Fig. No. 3a Density Correction Factor 6
Fig. No. 3b Loss Correction Factor for Tube Configuration 6
Fig. No. 4 Steam Nozzle Location-Single Inlet 8
Fig. No. 5 Steam Nozzle Location-Multiple Inlets 9
Fig. No. 6a Tubesheet Formula Perimeter Calculation 14
v
Fig. No. 6b Wall Thickness/I.D. Ratio for Integral Tubesheets 14

Fig. No. 7 Nozzle Load Nomenclature 16
Fig. No. 8 Allowable Nozzle Loads (a) 18
Fig. No. 9 Allowable Nozzle Loads (() 19
Fig. No. 10 Allowable Nozzle Loads (D) 20
Fig. No. 11a Standard Tolerances for Nozzles and Support Locations - English Units 21
Fig. No. 11b Standard Tolerances for Nozzles and Support Locations - SI Units 22
Fig. No. 12 Horizontal Installation 26
Fig. No. 13 Horizontal In Condenser Neck Installation 26
Fig. No. 14 Vertical Channel Up Installation 26
Fig. No. 15 Vertical Channel Down Installation 26
Fig. No. 16 Welded Type Pass Partition Cover Design 27
Fig. No. 17 Gasketed Channel Cover Pass Partition Design 27
Fig. No. 18a High Pressure, Full Access Channel 27
Fig. No. 18b High Pressure, Full Access Channel 27
Fig. No. 19 Typical Full Access Bolted Pass Partition Cover 28
Fig. No. 20 Hemispherical Head Channel Design-LP 29
Fig. No. 21 Elliptical Head Channel Design-LP 29
Fig. No. 22 Hemispherical Head Channel Design-HP 30
Fig. No. 23 Combination Tubesheet Channel Type Design-HP 30
Fig. No. 24 Modified Hemispherical Head Design-HP 30
Fig. No. 25 Straight Condensing Feedwater Heater - Horizontal Mounting 31
Fig. No. 26 2-Zone Feedwater Heater - Horizontal Mounting 32
Fig. No. 29 Straight Condensing Feedwater Heater - Vertical Channel Down Mounting 35
Fig. No. 30 2-Zone Feedwater Heater - Vertical Channel Down Mounting 36
Fig. No. 31 3-Zone Feedwater Heater - Vertical Channel Down Mounting 37
Fig. No. 32 Straight Condensing Feedwater Heater -Vertical Channel Up Mounting 38

Fig. No. 33 2-Zone Feedwater Heater -Vertical Channel Up Mounting 39
Fig. No. 34 3-Zone Feedwater Heater -Vertical Channel Up Mounting 40
Fig. No. 35 Bolt Tightening Sequence 42
Fig. No. 36 Liquid Level Test 43
Fig. No. 37 Liquid Level Controls for Typical Vertical Channel Down Heater 43
Fig. No. 38 Liquid Level Controls for Typical Horizontal Heater 45
Fig. No. 39 Free Surface Area for Shell Liquid Level Control 49
Fig. No. 40 Integral Flash Chamber 52
Fig. No. 41 Emergency By-pass to Prevent Water Damage 53
Fig. No. 42 Recommended Schematic Piping Arrangement for Feedwater Heaters 54
TABLES
TABLE I Maximum Tube Side Velocity 3
TABLE II Maximum Metal Temperatures for Tube Materials 12
TABLE III Maximum Temperature of Expanded Tube Joints 12
TABLE IV Design Minimum Tube Wall Thickness 12
TABLE V Tube Hole Diameters and Tolerances for Tubesheets 14
TABLE VI Tubesheet Drilling Tolerances 15
TABLE VII Steam Flow Multiplier 51
vi
FOREWORD
The ninth edition of these standards has been developed by the Closed Feedwater
Heater Section of the Heat Exchange Institute, Inc. The technical information in
these standards combines present industry standards, typical Purchaser require-
ments, and Manufacturers experience. In addition, the standards outline the im-
portant design criteria for closed feedwater heaters.
These standards provide practical information on nomenclature, dimensions,

testing, and performance. Use of the standards will ensure a minimum of misun-
derstanding between Manufacturer and Purchaser, and will assist in the proper
selection of equipment best suited to the requirements of the application.
Some of the new material incorporated into the ninth edition of these standards
include new information in Section 2.1, Heater Performance, revisions to Section
2.7, Tube Side Pressure Loss, new information in Section 3, Mechanical Design
Standards, and new materials added to Section 4, Material Design Standards, just
to name a few.
In preparation of this standard, consideration has been given to the work of other
organizations, such as the American Society of Mechanical Engineers, the Ameri-
can Society of Testing Materials, the former Feedwater Heater Manufacturers As-
sociation, the Tubular Exchanger Manufacturers Association, and others. Credit is
herby given to all those whose standards may have been helpful in this work.
The publication of the ninth edition of Standards for Closed Feedwater Heaters

represents another step in the Heat Exchange Institutes continuing program to
provide standards which reflect the latest technological advancements in the field
of heat exchange equipment. The Standards for Closed Feedwater Heaters are con-
tinually reviewed by the Technical Committee at scheduled meetings under the
direction of the Closed Feedwater Heater Section. Suggestions for improvement of
these standards are welcome and should be sent to the Heat Exchange Institute,
Inc., 1300 Sumner Ave., Cleveland, Ohio, 44115, or via telephone at 216-241-7333,
via fax at 216-241-0105, or email the HEI at hei@heatexchange.org. Additional in-
formation, such as tech sheets, member company profiles, membership information
and a complete listing of all HEI Standards, can be found at www.heatexchange.org
vii
viii
1. DEFINITIONS
1.1 Closed Feedwater Heater ture difference and the lesser temperature difference
A closed feedwater heater is defined as a shell and to the Napierian Logarithm (Natural Log) of the ratio
tube type unit which heats feedwater or condensate(1) of the greater temperature difference to the lesser
passing through its tubes by means of steam or temperature difference.
condensate on the shell side. 1.8 Pressure Loss
Closed feedwater heaters are used in a regenerative
The tube side pressure loss consists of the friction
steam cycle to improve the thermodynamic gain. This
loss through the tubes, including channel losses and
is accomplished by extracting steam at various points
turning losses. The total shell side loss is the pres-
from the turbine and condensing it using boiler feed-
sure loss through the zones of the heater. Neither side
water. The resultant heating of the feedwater aids in
includes any static losses.
avoiding thermal shock to the boiler and reduces the
fuel consumption required to convert the feedwater 1.9 Heat Transfer Coefficient
to steam. Since the work lost by extracting the steam The heat transfer coefficient for each zone of the
is derived from sensible heat, i.e. no change of phase, heater is the average rate of heat transfer from steam
the much greater latent heat recovered in the feed- to feedwater or from condensate to feedwater and is
water heater by changing phase from steam to water expressed in Btu/hr-ft2-F.
results in a net energy gain. Without a feedwater
heater, the latent heat is wasted or thrown out in the 1.10 Desuperheating Zone (DSH)
main condenser or cooling tower. Therefore, feedwater The desuperheating zone removes a portion of the
heaters(1) also help to reduce thermal pollution. sensible heat of the superheated extraction steam to
elevate the temperature of the feedwater.
for the purposes of this standard, wherever feed-
(1)
1.11 Condensing Zone
water is used, it shall also mean condensate passing
through its tubes. The condensing zone heats the feedwater by con-
densing steam.
1.2 Heater Duty 1.12 Drain Subcooling Zone (DC)

The drain subcooling zone reduces the temperature
Feedwater heater duty consists of the net heat
of the drains leaving the condensing zone below the

transferred to the feedwater and is expressed in
saturation temperature by transferring heat to the
Btu/hr. The heat duty obtained from feedwater flow
entering feedwater.
and enthalpy parameters shall be calculated for each
applicable zone. The sum of individual zone heat 1.13 Drains
duties shall be the overall heater duty. Entering drains into a feedwater heater are defined
as any liquids which enter the heater from higher
1.3 Design Maximum Working Pressure
pressure stages or sources and combine with the shell
Design maximum working pressure is the pressure side condensate.
of the tube and shell sides for which the vessel is
structurally designed. 1.14 Total Surface
The total outside tube surface in the heater includes:
1.4 Operating Pressure (a) Effective tube surface
The shell side operating pressure is the pressure (b) Tube surface within tubesheet
for which the unit is thermally designed and rated. (c) Flooded surface
The tube side operating pressure is the normal dis- (d) Inactive surface
charge pressure of either the steam generator feed or
condensate pump. 1.15 Effective Surface
The effective surface is that portion of the total
1.5 Terminal Temperature Difference (TTD) surface excluding:
Terminal temperature difference is the difference (a) tube surface within the tubesheet
between saturation temperature corresponding to the (b) condensing zone surface which is flooded
entering extraction steam and the outlet feedwater (c) surface not exposed to flowing steam and/or
temperature. This value could be either positive or condensate on the shell side
negative. (d) tubes that are plugged
1.6 Drain Subcooler Approach (DCA) 1.16 Integral Flash Chamber
The drain subcooler approach is the temperature Integral flash chamber is a shell extension beyond
difference between the drains leaving the shell side the U-bends which provides an area for incoming
of the heater and the entering feedwater on the tube drains to flash.
side.
1.7 Logarithmic Mean Temperature
Difference (LMTD)
Logarithmic mean temperature difference is the
ratio of the difference between the greater tempera-
1
2. FEEDWATER HEATER PERFORMANCE
2.1 Heater Performance Steam Enthalpy total______________ Btu/lbm

It is recognized that the performance of a feedwater Steam Temperature saturated____________F
heater cannot be exactly predicted under each one of Steam other sources
a number of possible operating conditions; therefore, Source_________________________________
the heater should be designed for the one specific Flow____________________________lbm/hr
condition termed the design point. Pressure___________________________ psia
Heater design performance is stated as the capability to Temperature total___________________F
heat a given flow of feedwater in terms of TTD and DCA, Enthalpy total________________ Btu/lbm
if applicable, with the following parameters specified:
(a) Feedwater inlet and outlet temperatures Drains in
(b) Drains outlet temperature Source_________________________________
(c) Steam pressure and enthalpy Flow____________________________lbm/hr
(d) Feedwater pressure loss Temperature_________________________F
(e) Shell side pressure loss, if paragraph Enthalpy______________________ Btu/lbm
2.6(c) applies Note: If there is more than one source for
The procedures of the ASME Performance Test incoming drains, state conditions for each
Code for Feedwater Heaters-PTC 12.1, latest edition, source separately.
may be followed in evaluating the performance capa- Drains out
bility of any closed extraction feedwater heater built State the downstream pressure to which
to these Standards. Note that research has shown the outgoing drains are being
that although ASME PTC 12.1 calculations are a discharged_______________________ psia
reasonable estimate for off-design performance, they Flow____________________________lbm/hr
are not accurate enough to be used for determination Temperature_________________________F
of design point performance compliance (including Enthalpy______________________ Btu/lbm
TTD, DCA, and pressure drop); as the cumulative
Drains Subcooler Approach
effect of calculation approximations and instrumen-
Temperature_________________________F
tation tolerances can vary the results considerably.
Considerations shall be given for such in the perfor- Pressure Loss
Desuperheater max. ________________ psi

mance evaluation of feedwater heaters.(2)
Drains Subcooler max. _____________ psi
2.1.1 Minimum Data Required to be Supplied Design Pressure______________________ psig
by the Purchaser Design Temperature____________________F
(a) Item, heater or stage number Minimum Design Metal
Installation: (Horizontal, Vertical Channel Temperature_________________________F
Down, Vertical Channel Up) (e) Overload and Abnormal Conditions
Arrangement: (single or multiple stream) State operating conditions other than design
Space limitations: (overall length or overall which will result in increased steam, drains or
length plus withdrawal clearance) feedwater flow rates (See Paragraph 2.12). The
(b) Tube Side following information should be provided:
Feedwater Flow____________________lbm/hr Mode of Operation________________________
Feedwater Terminal Temperature Feedwater Oper. Temp. in____________F
Difference___________________________F Feedwater Oper. Pressure___________ psia
Feedwater Temperature in_____________F Feedwater Flow Rate_____________lbm/hr
Feedwater Enthalpy in__________ Btu/lbm Extraction Steam Temp.______________F
Feedwater Temperature out____________F Extraction Steam Enthalpy_____ Btu/lbm
Feedwater Enthalpy out_________ Btu/lbm Extraction Steam Pressure__________ psia
Feedwater Velocity Drains Flow in__________________lbm/hr
maximum__________ft/sec at___________F Drains Enthalpy in____________ Btu/lbm

Feedwater Pressure Loss
Pressure Loss for Overload Operating Point:
maximum___________________________ psi
Desuperheater max. ______________ psi
Feedwater Connection Size_______ ID inches
Drains Subcooler max. ____________ psi
Operating Pressure___________________ psia
Tube Side max___________________ psi
Design Pressure______________________ psig
(f) Maximum back pressure at shell safety valve
Design Temperature____________________F
outlet connection_____________________ psig
Minimum Design Metal
Temperature_________________________F 2.2 Thermal Resistance
(c) Tube Material____________________________ 2.2.1 Tube Wall Resistance
(d) Shell Side The tube wall metal resistance can be calculated
Steam Extraction Flow_____________lbm/hr for the selected tube material using the thermal
Steam Pressure________________________ psia conductivity from the reference data in Appendix
Steam Temperature total________________F C4 at the average tube wall temperature by the fol-
lowing formulae(1), which applies to plain tubes.
2
TABLE I
Maximum Tube Side Velocity
rw = 24k
d
3
( ( )d
ln
d-2t
) Feedwater
Velocity
Tube Material Vt (ft/sec)
Stainless Steel, 70-30 Nickel Copper 10.0
where:
Copper Nickel (70-30, 80-20, 90-10) 9.0
d = Outside diameter of tube, in Low Alloy Steel 9.0
k = Thermal conductivity, Admiralty and Copper 8.5
BTU-ft/hr-ft2-F or (BTU/hr-ft-F) Carbon Steel 8.0
t = Tube wall thickness, in The corresponding feedwater velocity at 60 F can

be determined from the following formula:
v
V60F = Vt 3 60F
hr 3 ft2 3 F vt
r w =
Btu where:
V60F = feedwater velocity at 60 F (ft/sec)
(1) Tubular Exchanger Manufacturers Association Vt = Feedwater velocity at average tempera-
(2) ASME PTC 12.1
ture for design point operation (ft/sec)
vt = Specific volume of saturated water at
2.2.2 Fouling Resistance average temperature for design point
It is recommended that a minimum fouling resis- operation (ft3/lbm)
tance of 0.0002 units be applied to the tube side sur- v60F = specific volume for saturated water at
face and corrected to the outside effective surface. An 60 F (ft3/lbm)
additional fouling resistance of 0.0003 units should
be applied for the outer tube surfaces in the desuper- Fig. No. 1 shows the relationship of the ratio of
heating and drains subcooling zones. specific volumes vs. average operating temperature.
These minimum values are applicable to all When the feedwater velocity for the tube material

materials. selected is the maximum per Table I, the design feed-
water velocity at 60 F may be determined directly from
2.3 Terminal Temperature Difference Fig. No. 2.
It is recommended that heaters without desuper-
heating zones should not be designed for a Terminal 2.6 Shell Side Pressure Loss
Temperature Difference of less than 2 F. For the design operating conditions, the pressure
losses through the shell side of the heater should be
2.4 Drains Subcooling Zone Approach limited as follows:
Performance of an integral subcooling zone is
dependent upon many factors such as: heater ori- (a) The overall pressure loss should not exceed 30
entation, feedwater temperature rise, drain cooling percent of the differential pressure between
range, quantity of drains, and reheating of subcooled heater stages.
condensate. Since experience has determined that (b) The pressure loss within any one zone should
the closest approach (temperature of drains minus not exceed 5 psi.
temperature of entering feedwater) that can be (c) Where line losses and static head are an
assured is 10 F, it is recommended that heaters not appreciable portion of the pressure difference
be designed for less than that temperature approach. between heater stages, it may be necessary for
A separate drain subcooler should be used for those the user to specify lower pressure losses than
conditions where a closer approach is required. indicated in (a) and (b) above.
2.5 Tube Side Velocity 2.7 Tube Side Pressure Loss

The feedwater velocity through the tubes at Below is a method of determining the tube side
average temperature (arithmetic average of the inlet pressure losses from and including the channel inlet
and outlet temperatures) for design point operating and outlet nozzles (pressure losses are calculated for
conditions should not exceed the values contained in
friction, nozzles, tube entrance, exit and turn). This
Table I.
method only considers U-tube configurations with
tubes projected from the tubesheet (tubes expanded
or fillet welded) and tubes welded to the tubesheet
3
with slightly rounded edges. There are numerous Inside Tubes

specifications providing wall tolerances for their
()
1.396 3 1027 w 2 L
respective tube specifications; therefore, this standard DP 5 f
provides a method to determine the nominal ID for T C At d
use in calculating the tube side pressure loss. The
method is only applicable to clean smooth tubes with where: f 5 0.0014 1 0.125 (RE) 2.32
turbulent flow for the friction factor. Accurate data on
wd
friction factors for the different tube materials is not RE 5
0.201389 At
available due to the wide range of tube manufactur-
ing practices. Therefore, the Purchaser must consider
that the actual tube side pressure drop can vary from Nozzle Losses
( )
the calculated value. 2
3.195 3 1029 w
The tube side pressure loss calculation method DP 5 3
shown below is a condensed method which is pro NI C AN
vided to give the user/consultant a method to check
( )
2.034 3 1029 w 2
pressure losses in his evaluation of equipment he DPNO 5 3
C AN
plans to purchase. It is to be understood that the final
thermal and hydraulic calculations will be based upon
the final calculated wall thicknesses. In addition, the Tube Entrance, Exit and Turn Losses
Purchaser must consider that tubes with ferrules/
()
inserts or flow straighteners, etc., will have an effect 2.896 3 1029 w 2N
on tube side pressure loss. DPE 5 Kt
C At 2

Average Feedwater Operating Temperature (F)

FEEDWATER SPECIFIC VOLUME RATIOS
Fig. No. 1
4
Definitions C 5 Density correction factor at average

operating temp. (See Fig. No. 3a)
DPT 5 Pressure loss through tubes, psi

DPNI 5 Pressure loss through channel inlet f 5 Friction factor
nozzle, psi AN 5 Feedwater nozzle area, in2
5 Note: For tapered nozzles use mean area.
DPNO 5 Pressure loss through channel outlet
nozzle, psi Kt 5 Loss correction factor for tube configuration
(See Fig. No. 3b)
DPE 5 Tube entrance, exit and turn losses, psi
N 5 Number of tube passes
w 5 Feedwater flow, lbm/hr
RE 5 Reynolds number
L 5 Total length of tube travel, ft
5Viscosity, cp
At 5 Flow area of tubes per pass, in2

d 5 Nominal inside diameter of tubes, in
For minimum wall tube: NOTE: CONSTANTS SHOWN INCLUDE A 5%
nominal ID 5 nominal OD of tube SAFETY FACTOR.
2 2 3 (quoted minimum wall thick-
ness 1 1/2 wall tolerance)
For average wall tube:
nominal ID 5 nominal OD of tube 2 2
3 (quoted average wall thickness)

DESIGN FEEDWATER VELOCITY at 60 F (Ft/Sec)

DESIGN FEEDWATER VELOCITY AT 60 F.
Fig. No. 2
5

Density Correction Factor

Fig. No. 3a
Kt = 1.6 Kt = 1.3
Projected Tube Expanded Welded Tube with Slightly

or Fillet Welded Rounded Edges
LOSS Correction Factor FOR TUBE CONFIGURATION

Fig. No. 3b
6
2.8 Nozzle Sizes 2.9 Steam Nozzle Location and Steam

It is recommended that nozzle sizes based on the Distribution Dome
inside diameter be selected so that velocities listed The diameter of straight condensing heaters, as
below will not be exceeded at the design point oper- well as two zone (integral drains subcooler) heaters,
ating condition. If a standard pipe reducer is utilized is greatly dependent on the location of steam nozzles
on external piping to the heater in order to meet the and the resultant size of the steam distribution dome
maximum velocities listed below, it is recommended within the shell. The maximum velocity in the distri-
that the reducer be located at least 10 times the larger bution dome at the maximum flow point along the
diameter from the point of attachment to the closed longitudinal axis of the heater should be no great-
feedwater heater. For feedwater inlet nozzles, a tran- er than the steam inlet nozzle velocity given in
sition piece with a 7 degree included cone angle may Paragraph 2.8(d). The escape velocity into the dome as
be attached to, or be integral with, the inlet connec- defined by the flow past the conical segment between
tion in lieu of utilizing the pipe reducer. Piping con- the penetration point of the nozzle into the shell and
figurations not in compliance could result in undue the impingement plate should be no greater than the
wear, which is a situation the user must consider dome velocity; but, in no case is the distance between
when designing the total system. These guidelines nozzle penetration point and impingement plate to
related to reducers and tapered nozzles, though rec- be less than the inside nozzle diameter divided by 4.
ommended for replacement heaters, may not always An impingement plate under the nozzle shall be
be applied/considered due to space considerations. provided and sized to prevent impingement of steam
(a) Feedwater Nozzles 10ft/sec at 60 F (for on the tube bundle assuming a minimum angle of
Carbon Steel tubed heaters see Paragraph 3.6). diffusion of 45 from the point at which the nozzle
(b) Condensate Drain Outlet Nozzles: penetrates the shell.
Subcooled Drains 2.9.1 Single Nozzle Heaters
4 ft/sec at operating temperature
The steam nozzle should be located on the thermal
Saturated Drains centerline of the bundle. The thermal centerline is
1) Water level controlled in heater the point along the tube bundle where the steam flow
4 ft/sec at operating temperature (and duty) is distributed equally in both directions.
2) Water level not controlled in heater This will provide 2-way flow from the nozzle as shown
2 ft/sec at operating temperature in Fig. No. 4 as well as resulting in a dome area equal
(c) Drain Inlet Nozzles: to 1/2 the nozzle area and minimum shell diameter.

1) Flashing Liquid For any other location, it may be necessary to increase
G2 the shell diameter.
= 4,000
r
G 4 Mass velocity, lbm/sec/ft2

(G not to exceed 250)
r 4 Density of the mixture, lbm/ft3
(pounds per hour of mixture
divided by ft3/hr of liquid
plus ft3/hr of vapor at
actual conditions)
2) Steam from Flash Tanks
G2
r 41,000 (150 ft/sec max. line
velocity)
G 4 Mass velocity, lbm/sec/ft2
r 4 Density of vapor, lbm/ft3
3) Liquid from Flash Tanks 4 ft/sec at

operating temperature
(d) Steam Inlet Nozzle

250
V= ft/sec
(psia).09
7

STEAM NOZZLE LOCATION SINGLE INLET
Fig. No. 4

2.9.2 Multi-Nozzle Heaters 2.10 Drain Nozzle
The ideal location for nozzles located along the The location of the drain outlet nozzle on a heater
length of the heater shell is on the respective thermal without a drains subcooler zone should be based on
center-line for the section of the bundle to which the the criteria of 2-way flow into the nozzle. The flow
nozzle provides steam. In practice this cannot always centerline should be determined, taking into consider-
be achieved; therefore, it may be necessary to increase ation the location and flow rate of drains entering the
the shell diameter. However, in no case should the heater, as well as the uneven distribution of conden-
nozzles be located closer than the minimum dimen- sate draining off the tube bundle. If the drain nozzle
sion given in Fig. No. 5 in order to prevent undue is located at a point other than on the flow centerline,
restriction of the entrance area into the bundle. If the drain area should be increased accordingly so that
nozzles are located closer, consideration should be the maximum velocity at any point in the drain area
given to offsetting the nozzles, thus staggering the does not exceed the velocity in the drain nozzle.
impingement plates along the length of the heater.
8
1 ZONE MULTIPLE NOZZLES
9
Fig. No. 5
A = DISTANCE NECESSARY FOR DOME AREA REQUIREMENT AS DEFINED IN 2.9
STEAM NOZZLE LOCATION MULTIPLE INLETS

MINIMUM DISTANCE BETWEEN MULTIPLE STEAM NOZZLES
2.11 Control of Feedwater Heaters The following describes the relationship between the
variables:
2.11.1 General Control Considerations
Careful consideration must be given to the location C= T
K 3 P.B.
of equalizer connections for level controllers and gage
glasses to avoid false water levels. Because of the inter- where:
nal construction of feedwater heaters, changes should K 4 Proportionality constant compatible with
not be considered before contacting the Manufacturer. the level controller.
In horizontal heaters, equalizing connections must C 4 Required Capacitance, gal/in. This is the
be located in or near a vertical plane where they will condensate volume per inch of depth,
not be subject to any differences of pressure. Heaters within the control band.
with an integral drains subcooler must have the level
controller equalizer connections located at or near the T 4 Throughput, gal/min. This is the shell side
entrance to the zone. flow leaving the heater.
In vertical heaters, the level controller equalizer con- P.B. 4 Proportional Band Setting, percent.
nections must straddle the level to be controlled. The
The smaller the band, the more accurate must be
amount of rise in level permitted is governed by the
the level controller, but this increases the required
internal construction of the heater. The Manufacturer
volume within the heater.
shall indicate on his drawings the maximum rise in con-
In determining water levels in a heater, certain
densate level that may be permitted without seriously
dimensions must be maintained. The high and low
affecting the performance of the heater. The Purchaser
water levels are normally two inches on either side
should be guided by this information when setting high
of the normal water level. This provides the available
water alarms.
volume for capacitance. If a desuperheating zone is
Each heater shall have its own independent level
supplied, the distance from the maximum water level
controller even though several heaters are operating
to the exit of the zone must be at least twelve inches.
in parallel. The level controller selected must be of a
Similarly, the low level should be maintained s everal
type that is capable of maintaining the level of conden-
inches above the drains subcooling zone inlet.
sate in the heater shell under steady load conditions
within plus or minus limits on the level indicated by 2.12 Overload and Abnormal Operating Modes
the Manufacturer. Where a heater, or bank of heaters, is operated at a
Separate equalizer connections should be considered level exceeding the design point, the flow rates may

for gage glasses, level controls, and water alarms. be increased to a level which will cause malfunction
Independently connected controls and alarms assure or damage to the operating units.
the operation of at least one element in the event a line Listed below are three of the many possibilities that
becomes plugged. When arrangements require a single can result in overload or abnormal conditions.
set of equalizer connections, provisions should be made
to assure that lines are free from sediment. (a) Doubling the condensate or feedwater flow
causes approximately twice the steam to be
2.11.2 Capacitance Requirements for extracted.
Vertical Heaters (b) By-passing a heater or group of heaters causes
For proper operation of vertical feedwater heaters the feedwater to enter the next higher stage at
(specifically Channel Down designs) the water level a colder temperature. This will result in g
reatly
must be accurately controlled. The level controller, increased extraction steam flow into the next
which in turn operates the heater control valve, is higher stage operating heater or group of heat-
activated by changes in the condensate reservoir ers.
within (or external to) the heater. (c) Operation of the turbine generator at the over-
The net control volume of condensate available load limit will increase the shell and tube side
within the heater will depend upon the specific type flows.
of heater design. For example, a two zone heater When such operation is anticipated, the effect on
(condensing zone and drains subcooling zone) will have, each individual heater must be considered and speci
for the same shell diameter, more condensate volume fied so that the internals can be properly designed.
than a three zone heater (desuperheating zone added).
(See Paragraph 2.1.1 [e]).
The net volume available within the control range is If design limits are exceeded, metal wastage and
determined by calculating the gross volume less the failure may occur within the feedwater heater. There
total volume of tubes within this volume. are no correlations presently available that can
In order to avoid increasing the diameter of the adequately determine the relationship of wastage
heater to obtain required control volume, an exter- to length of time at overload or abnormal operating
nal reservoir can be used. This is possible as the conditions. Refer to Appendix B5 for guidelines for
required volume per inch of level (see equation below) heaters out of service.
is only dependent upon the diameter of heater and not
overall length. As the object in providing required 2.13 Vent Off-Take Piping
heater volume and control systems is to ensure that Each feedwater heater continuous venting system
the heater operates within the design control range, all should be individually piped to the condenser or
factors involved in the total system must be compatible. deaerator as applicable. Manifolding or cascading of
vents is not recommended. The vent off-take piping
system should be adequately sized to remove the
10
expected non-condensible flow. The off-take system er, as solubility of gas is directly proportional to the
should be routed in the most direct manner possible partial pressure of gas above the liquid Henrys law).
eliminating any loop seals that can trap condensate. The guaranteed oxygen content in drains leaving
The continuous vent off-take system should be insu- the heater, considering venting, shall be as agreed
lated to minimize potential for condensate build-up. upon by Manufacturer and Purchaser. However, it is
Shell side start-up vents should not be routed into recommended that guaranteed oxygen content not be
the continuous vent off-take system unless the sys- lower than 70 PPB.
tem has been designed for this service. They should The measurement of the oxygen level shall be
be piped directly to the condenser or to atmosphere in accordance with the HEI Standard Method
depending upon the pressure. and Procedure for the Determination of Dissolved
Tube side start-up vents should not be routed into Oxygen.
the continuous vent off-take or the shell side start- As indicated above, in order to guarantee the
up system unless those systems have been designed oxygen content of drains leaving the heater, the fol-
for this service. These vents can be piped to atmo- lowing shall be specified by the Purchaser:
sphere except in those nuclear installations where (a) The oxygen content in the extraction steam.
radioa ctivity potential dictates directing these (b) The oxygen content of entering drains.
start-up fluids to the condenser or other specialized (c) The oxygen content of steam from other sources.
off-gas systems. The Purchasers specified levels of oxygen entering
Provisions should be made for venting a minimum of the heater shall not be exceeded in order to maintain
0.5% of the steam entering the heater. See Fig. No. 42 the Manufacturers guarantee of oxygen in the drains
in Paragraph B12. leaving the heater.
Where specific data on oxygen levels cannot be pro-
2.14 Oxygen Content in a Deaerating Heater vided, the specific levels shall be based on calculations
Under certain operating conditions, and with spe- by the dilution method.
cial design considerations incorporated into units, In order to maintain required oxygen level in a
maximum oxygen levels may be guaranteed for closed deaerating closed feedwater heater, special consid-
deaerating feedwater heaters (drains leaving units). erations should be given by the Manufacturer to the
The maximum oxygen content in the drains leaving design of the internals and venting arrangement of
the heater will be a function of several variables and the unit. The specific design shall be the responsi
shall be determined in each case. bility of the Manufacturer. The Purchaser should be
The applicable parameters will be the oxygen aware that the magnitude of the vent system flow

content of extraction steam, the oxygen content in the removed may be more than normally required for a
drains introduced into the heater, and the operating non-deaerating heater.
conditions (i.e., temperature and pressure in the heat-
3. MECHANICAL DESIGN STANDARDS
3.1 Code Requirements 3.2 Design Pressure

The design and construction of all feedwater heat- The Purchaser shall specify the design pressures for both
ers shall meet the requirements of the ASME Boiler the shell and tube sides. In addition, if the shell side of the
& Pressure Vessel Code, Section VIII, Division 1, heater is subjected to vacuum under any conditions, the
including applicable addenda and case rulings. This Purchaser shall so specify.
Code is hereinafter referred to as the ASME Code. All 3.3 Design Temperature
units shall be stamped with the ASME Code Symbol. The Purchaser shall specify the design temperatures on
Variances brought about by other applicable codes both the shell and tube sides. It is suggested that these design
shall be specified by the purchaser. temperatures be established as follows:
3.1.1 Corrosion Allowance (a) Shell Side Enter the Mollier Diagram at the normal
Corrosion allowance will be provided in accordance operating steam temperature and pressure and follow
with the table below: a constant entropy line to the maximum operating

pressure. Read the temperature at that point and
Pressure Part round off to the next higher 10 F. For a heater with
Thickness Corrosion Allowance a desuperheating zone, only the shell skirt need be
up to .25" per paragraph UG-25 designed for this temperature. The design tempera-
of the ASME Code ture of the main shell barrel of such heater shall be
over .25" 0.0 at least equal to the saturation temperature at the
design pressure.
tubes 0.0
(b) Tube Side The maximum design temperature shall be
Any corrosion allowance in excess of the above the saturated steam temperature corresponding to the
alues shall be provided when specified by the
v shell side design pressure. Where a desuperheating zone
purchaser. No corrosion allowance need be considered is employed, the temperature of the straight lengths of
for internal parts such as pass partition, desuperheat- tubes in the desuperheating zone shall be considered
ing and draincooling shrouds, support plates and to be 35 F higher than the saturated steam tempera-
baffles, etc ture corresponding to the shell side design pressure.
The design temperature of tube sheet shall be as a
minimum, same as tube side design temperature.
11
(c) The Purchaser shall specify the minimum water at the specified operating conditions. Welded
design metal temperature (F) for both the tube joints should be used when temperatures range
shell and tube side as required by ASME Code, from the v
alues in Table III up to the maximum metal
Section VIII, Division 1, paragraph UG-20. temperatures given in Table II.
3.4 Hydrostatic Test TABLE III
The test pressure shall be in accordance with the Maximum Temperature of Expanded
ASME Code, Section VIII, Division 1, paragraph Tube Joints
UG99. The test temperature should be established
as recommended by the ASME Code. Temp.
Material F
3.5 Nil Ductility Temperature
Arsenical Copper 350
It is recommended that all materials used for forged
carbon steel channels and tube sheets of high pres- Admiralty Metal 350
sure heaters be procured to the minimum require- 90-10 Copper-Nickel 400
ment of Charpy V notch values of 15 foot-pounds 80-20 Copper-Nickel 450
average for 3 tests and 12 foot-pounds minimum for 70-30 Copper-Nickel (Annealed) 500
any one test, at a maximum test temperature of 40 F.
70-30 Copper-Nickel (Stress Relieved) 500
3.6 Tubes 70-30 Nickel-Copper (Annealed) 550
The useful life of a heater tube is normally affected 70-30 Nickel-Copper (Stress Relieved) 550
by the conditions of service, such as: water chemistry, Carbon Steel 650
operating temperatures and fluid velocities, as well
as the effects of short and long term shutdowns. Stainless Steel 500
These factors must be taken into consideration by the
Purchaser when making a tube material selection. 3.6.3 Tube Wall Thickness Limitations
In the case of carbon steel tubed feedwater heaters,
Average wall or minimum wall tubes are equally
various combinations of nozzle and tube velocities and
acceptable providing that, in the case of average wall
channel configurations, as well as factors listed above,
tubes, the calculated thicknesses for pressure require-
can contribute to inlet metal wastage.
ASME/ASTM do not have mandatory requirements ment takes into consideration the plus or minus toler
for UT examination of tube weld seam on certain ance in wall thickness.

Feedwater Heater tube materials. HEI recommends TABLE IV
all welded Feedwater Heater tubing be subject to UT
Design Minimum Tube Wall Thickness
examination at the mill, subject to customer request,
in order to increase reliability and quality of the final Copper and Copper Alloy 0.049" avg. wall
product prior to installation in the vessel. Nickel Alloy 0.049" avg. wall
3.6.1 Tube Metal Temperature Stainless Steel (U-Tubes) 0.035" avg. wall
It is recommended that the maximum tube metal Stainless Steel (Straight Tubes) 0.028" avg. wall
temperature shown in Table II not be exceeded. Carbon Steel 0.050" avg. wall
TABLE II Low Alloy Steel 0.050 avg. wall
Maximum Metal Temperatures for
For design purposes, tube wall thickness should not
Tube Materials
be less than those shown in Table IV. For U-Tubes, the
Temp. minimum thickness per Table IV, is prior to bending.
Material F
3.6.4 Tube Length
Arsenical Copper 400
Circumferential welding of tubes to extend their
Admiralty Metal 450 lengths is not recommended.
90-10 Copper-Nickel 600
80-20 Copper-Nickel 700 3.6.5 U-Tubes

70-30 Copper-Nickel (Annealed) 700 The minimum radius of U-bends should be 1-1/2
times the tube diameter. The following formula should
70-30 Copper-Nickel (Stress Relieved) 800
be used to determine the required thickness of the tube
70-30 Nickel-Copper (Annealed) 900 wall before bending.
70-30 Nickel-Copper (Stress Relieved) 800
Carbon Steel
Stainless Steel
800
800
t4

P 3 d
3 11
2S 1.8P (
4R
d
)
t 4 Tube wall thickness before bending, in
d 4 Outside diameter of tube, in
3.6.2 Tube Joint Temperature
P 4 Design pressure, psig
Where tubes are installed in steel tubesheets by
expansion only, the recommended maximum tem- R 4 Radius of bend at centerline of tube, in
perature at the joint for which the tube materials S 4 Allowable design stress at the appro-
shall be specified is tabulated in Table III. For this priate design temperature defined
purpose, the temperature of the tube joint shall be in Paragraph 3.3 (b), psi
considered to be the outlet temperature of the feed-
12
3.6.6 Stress Relieving U-Bends As a minimum requirement, baffles and support plates
Cold work in forming U-bends may induce suscepti- shall be spaced so that the unsupported straight lengths
bility to stress corrosion cracking in certain materials of the tubes will be no greater than 48 inches for 5/8 inch
and environments. The Purchaser should specify if OD tubes, 54 inches for 3/4 inch OD tubes, 57 inches for 7/8
stress relief of the U-bends is required. inch OD tubes and 60 inches for 1 inch OD tubes. Each leg
of all U-bends in the condensing zone shall be supported
3.6.7 Tube Plugging within 8 inches of the point of tangency. These maximum
Tubes will occasionally fail when the assembled unsupported lengths are established for mechanical sup-
bundle is hydrostatically tested to Code pressure. port of the tube bundle only.
Where the location is either inaccessible or imprac-
tical for replacement, the defective tube may be 3.7.2.3 Support of U-Bends
plugged by an acceptable permanent procedure and the Any U-bend tubes wherein the diameter of the bend plus
Purchaser notified. twice the length from the tangent point to the last support
plate exceeds the values given in Paragraph 3.7.2.2 shall
3.7 Tube Bundle have provisions in the U-bend area for support of such tubes.
All baffles and support plates in the tube bundle
should be securely held in place by tie rods and
3.7.2.4 Thickness
spacers, or equivalent construction. The tube bun- The minimum thickness of support plates and baffles in
dle shall be removable from the shell or the shell the desuperheating and condensing zones shall be 3/8 inch
removable from the tube bundle. Straight tube/fixed for shell diameters of 18 inches and smaller and 5/8 inch for
tubesheet feedwater heater is exempted from the larger diameter shells.
removable requirements. The minimum thickness of baffles in the subcooling zone of
all heaters shall be 1/4 inch for spacing less than 18 inches,
3.7.1 Tube Layout and 3/8 inch for spacings of 18 inches and greater.
It is recommended that tubes be laid out on a
3.7.2.5 Drain Subcooling Zone End Plate
triangular pitch. Tubes shall have a minimum center-
The end plate of the drain subcooling zone in
to-center spacing equal to the tube diameter plus
horizontal heaters should be designed to prevent leak-
3/16 inch or 1.25 times the nominal tube OD,
age of steam from the condensing zone into the drain
whichever is greater.
subcooling zone. Close tube to tube hole clearance
3.7.2 Baffles and Support Plates and adequate end plate thickness is provided for this

reason. To ensure that the latter is obtained, the end
3.7.2.1 Tube Holes plate tube hole drilling, exclusive of over-tolerance,
Baffle holes and tube support plate holes shall be shall be the same as that used for the tubesheet as
drilled 1/64 inch greater than nominal outside diam- provided in Table V. In addition, the end plate thickness
eter of tubes, except that baffles in subcooling zones shall be not less than two inches.
may have holes 1/32 inch greater than nominal OD of
tubes. All burrs shall be removed to prevent damage 3.7.2.6 Shrouds and Longitudinal Baffles
to the tubes. Shrouds and longitudinal baffles should have a mini-
mum thickness of 1/4 inch.
3.7.2.2 Spacing and Tube Vibration
The design of the spacing of tube supports is a
3.7.2.7 Impingement Baffles
complex problem which has been studied in great The tube bundles of feedwater heaters should be designed
depth by the HEI. However, since tube vibration is to avoid direct impingement of incoming shell side fluids on
affected by many factors, including but not limited the tubes. A stainless steel impingement plate shall be placed
to: (a) fluid entrance port geometry, (b) fluid exit port in front of each shell inlet nozzle. Flow area not less than the
configuration, (c) the cross-flow and longitudinal flow nozzle area shall be provided between the nozzle and the
impingement plate (See Paragraph 2.9). The flow passages for
components as influenced by the baffle configuration
distribution of fluids into the tube bundle should be designed
(e.g. segmental or other variations), it has not been
to minimize tube vibration.
possible to establish definitive criteria for calculation
of support spans for all specific designs. 3.8 Tubesheet

It is recommended that the basic criteria should be ASME Code, Section VIII, Division 1, Part UHX, provides
the fluidelastic method described by H.J. Connors, Jr. specific rules for calculating the thickness of tubesheets for
(ASME, Dec. 1970 pp. 42-56). Also, in liquid to liquid shell and tube heat exchangers for both bending and shear.
zones such as integral or separate drain subcooling Part UHX-12 specifically deals with rules for design of
zones, vortex shedding criteria may be used as a sec- U-tube tubesheets.
ondary check. It is necessary for each Manufacturer Refer to the appropriate section of ASME code, as the cal-
to establish the necessary coefficients and factors by culations are too extensive to be included in this Standard.
test, experience or analytical methods compatible ASME may not be the design code or the specific design
with the individual design configuration. It should may not be addressed by ASME. In these cases, the mini-
be recognized that due to the various derivations of mum tubesheet thickness calculations may be based on the
methods and the number of different values used for following:
variables as criteria for vibration analysis, results will
vary and are not definitive.
13
a) Bending For supported tubesheets (e.g. fixed tubesheets and

Tb =
FG
3 =P
hS
floating type tubesheets) integral with either or both
sides F shall be the value as determined by the curve
H in Fig. No. 6b.
where:
Tb = Thickness of tubesheet (in bending)
measured at bottom of partition grooves, in
G = Inside diameter of channel when
tubesheet is integral with channel, in
P = Design pressure, psig
S = Code allowable stress in tension, psi, for
tubesheet material at design metal
temperature
(1)
Tubular Exchanger Manufacturers Association.
Wall Thickness/I.D. Ratio for
F 5 Design factor. See Paragraph 3.8.1 for Integral Tubesheets
values of F
Fig. No. 6b
1 0.785
for square or rotated
(
Pitch
)
2
square tube patterns NOTE: If the tubesheet is integral with both the
tube O.D.
h tube side and shell side, Wall Thickness and I.D. are
0.907 to be based upon the side that would yield the s maller
1 for triangular or rotated value of F.
(
Pitch
)
2
triangular tube patterns
tube O.D. 3.8.1 Tubesheet Corner Radius
All Manufacturers have established corner radii
b) Shear
that they have determined through experience are
)( )
0.31 DL P suitable for most applications. Integral tubesheets
TS 4
( do S with larger corner radii than the Manufacturers
1 standards are sometimes justified. The variables
Pitch that affect this area of discontinuity stresses are too


numerous to permit the use of an empirical relation-
where: ship. It is suggested that a minimum radius be speci-
TS 5 Effective tubesheet thickness fied with the other data provided as recommended in
(in shear), in Paragraph 2.1.1. Additionally, the expected operating
conditions, including the number of expected cycles
DL 5 4A 5 Equivalent diameter of the tube (such as number of cold starts, hot restarts, load trips,
C center limit perimeter, in etc.), and the temperature and pressure ranges should
C 5 Perimeter of the tube layout measured be identified as well as the expected rate of change
stepwise in increments of one tube should be defined in the Purchasers specification. An
pitch from center-to-center of the outer evaluation of the expected operating history can then
most tubes, in. Fig. No. 6 shows the appli- be made by the Manufacturer to determine if larger
cation to typical triangular and square corner radii are justified for the specific conditions
tube patterns defined.
3.8.2 Tube Hole Diameters and Tolerances(2)
Tube holes in tubesheets should be finished to the
sizes and tolerances shown in Table V; 96% of the tube
holes must not exceed the value for standard over-
tolerance. The tube holes shall be smooth, and burrs
shall be removed to prevent damage to the tubes.

TABLE V
Tubesheet Formula Perimeter Calculation Tube Hole Diameters and Tolerances for Tubesheets
Fig. No. 6a
Nominal
Tube Hole Diameter & Under Tolerance Over Tolerance
Tube inStandard Fit inClose Fit in
O.D. Nominal Under Nominal Under
A 5 Total area enclosed by perimeter C, in2 Standard Max.
in Diameter Tolerance Diameter Tolerance
P 5 Design pressure, psig 5/8 0.635 0.004 0.633 0.002 0.002
0.010
S 5 Code allowable stress in tension, psi, 3/4 0.760 0.004 0.758 0.002 0.002 0.010
for tubesheet material at design metal 7/8 0.885 0.004 0.883 0.002 0.002 0.010
temperature 1 1.012 0.004 1.010 0.002 0.002 0.010
do 5 Outside tube diameter, in
NOTES:
Pitch 5 Tube center-to-center spacing, in
1) Special close fit tolerances are recommended
NOTE: Shear will not control when for tubes subject to work hardening.
( )
do (2) Tubular Exchanger Manufacturers Association
P , 2
1.6 1
S Pitch 14
2) In no case shall the tube hole in the tubesheet that required by the appropriate Code formula
minus the maximum O.D. of the tube be less and thicker if required to meet proper deflection
than 0.002 inches. criteria.
3.8.3 Ligament Widths and Tolerances The recommended limit for channel cover deflection is:
Table VI tabulates the widths for nominal ligament, 0.03" for nominal diameters through 24"
minimum standard ligament and minimum permis- 0.125% of nominal diameter (nominal diameter/800)
sible ligament for the tube pitches shown. 96% of for larger sizes
the ligaments must be at least equal to the value for A method for calculation of channel cover deflection is:
minimum standard ligament width and the remain- G (4)
der must be at least equal to the value for minimum

Y 5
ET3
~ 0.0435G
3
P 1 0.5S B
A B
h !
g
permissible ligament width.

where:
TABLE VI
Tubesheet Drilling Tolerances (3) Y 5 Channel cover deflection at the center, i n
Nominal Nominal G 5 Gasket load reaction diameter as defined by the
Tube Nominal Minimum Standard Ligament Minimum
Tube Tube Hole Ligament Width, in Permissible Code, in
O.D. Pitch Dia. Width Tubesheet Thickness, in Ligament E 5 Modulus of elasticity at design temperature, psi
in in Std. Fit in 3 4 5 6 Width, in.
T 5 Thickness under consideration, in
5 8 13 16 0.635 0.178 0.133 0.128 0.122 0.117 0.090
2732 0.209
0.164 0.159 0.153 0.148 0.105
P 5 Design pressure, psi
7 8 0.240
0.195 0.190 0.184 0.179 0.120 SB 5 Allowable bolting stress at design temperature,
psi
3 4 15 16 0.760 0.178 0.135 0.131 0.126 0.122 0.090
31 32 0.209 0.166 0.162 0.157 0.153 0.105 AB 5 Actual total cross-sectional root area of bolts, in2
1 0.240 0.197 0.193 0.189 0.184 0.120 hg 5 Radial distance from diameter G to bolt
1 1 16 0.303
0.259 0.255 0.251 0.247 0.150 circle, in
11 8 0.365 0.322 0.318 0.314 0.309 0.185
If the calculated deflection is greater than the recom-
7 8 1 3 32 0.885 0.209 0.168 0.164 0.160 0.157 0.105 mended limit, the deflection may be reduced by accept-
11 8 0.240 0.199 0.195 0.192 0.188 0.120 able methods such as:
1 3 16 0.303 0.261 0.257 0.254 0.250 0.150 (a) Increase channel cover thickness by the cube
1 14 0.365 0.324 0.320 0.317 0.313 0.185 root of the ratio of calculated deflection to the

1 1 14 1.012 0.238 0.198 0.195 0.192 0.189 0.120 recommended limit.
1 5 16 0.301 0.260 0.257 0.254 0.251 0.150 (b) Use of strong backs.
13 8 0.363 0.323 0.320 0.317 0.314 0.185
(c) Change type of construction.
The above table of minimum standard ligaments is 3.10 Heater Supports
based on a ligament tolerance not exceeding the sum
Heater shall be supplied with two or more bracket-
of twice the drill drift tolerance plus 0.030". Drill drift
type supports. These should be suitably proportioned
tolerance = 0.0016 x (thickness of tubesheet in tube
to carry the flooded heater loadings. Projection of the
diameters), in.
supports on horizontally installed heaters shall be
NOTES: greater than the nozzle projections (if possible) to avoid
1. Interpolate for intermediate tubesheet interference with the pedestals or operating floor.
thicknesses. The Manufacturer provides the magnitude of the
static reactions at each support that the heater will
2. For thicknesses over 6" the minimum standard
impose on the building support structure in the flooded
ligament is calculated using procedure below
condition. This data is based on the heater weight only
Table VI.
and shown on the Outline Drawing.
3. For tubesheet thicknesses below 3" use values The power plant designer must consider the effect
indicated for 3". of the piping system in addition to the static reactions.
When these reactions at each support are combined at

3.9 Channel Covers the heater support, the load transmitted to the building
(a) With Partition Seal Covers support structure can be significantly increased.
When using the construction illustrated in 3.11 Condenser Installation
Fig. No. 16, where the partition rib does not form When a feedwater heater is designed for installation
a gasketed joint with the channel cover, the in the condenser exhaust neck, the fixed end closure
appropriate ASME Code formula shall be used seal plates that seal the heater to the condenser shall
to calculate the thickness of the channel cover. be shipped loose and welded in the field by the erectors
(b) Without Partition Seal Covers after the heater is in place. Provision for differential
When using the construction illustrated in expansion between the heater and the condenser neck
Fig. No. 17, the effective thickness of a flat chan- should be provided by the condenser manufacturer.
nel cover shall be the thickness at the bottom of Provisions for attaching lagging or shrouding on feed-
the pass partition groove (or the face if there is water heaters within the condenser neck should be
no groove) minus corrosion allowance in excess furnished by the Manufacturer.
of groove depth. The thickness is to be at least (3,4) by Tubular Exchanger Manufacturers Association
15
The arrangement of the extraction lines and sup- actual loads. The procedure below permits estimating
ports of the feedwater heater are subject to the nozzle loads for cylindrical shells. The procedure is
approval of Manufacturer (See Paragraph 2.9). based in part on the design data included in Welding
Research Council Bulletin 107(5). The allowable loads
3.12 Welded Joint Construction have been linearized to show the interaction between
Where welded joints (shells, channels, tube ends) the maximum permitted external radial load and the
are specified, construction details and procedures maximum permitted applied moment vector.
shall be determined by the Manufacturer. Due con- The procedure represents a simplification of the
sideration must be given to design features, quality method of WRC 107 and users of the procedure
of materials and ease of maintenance where welded
included in this standard are cautioned that more
joints are used.
exact analysis is required to verify the adequacy of
3.13 Connections-Nozzle Length final designs. The stresses considered in developing
Nozzle projections for flanged and butt welded the procedure have been defined as secondary stress-
connections should be between 6 and 8 inches. es with stress limits established according to that
definition. Although the effect of internal pressure
3.14 Nozzle Loads has been included in the combined stresses, the effect
The determination of acceptable nozzle loads is a of pressure on nozzle thrust has not been included and
complex problem involving the interaction of external requires combination with other radial loads.
forces and moments applied at the vessel wall. These Loads exceeding those calculated by this method
loads are functions of the piping mechanical and ther- usually require additional reinforcement. The user
mal design. Frequently, the pipings designer needs is cautioned that the higher allowable loads obtained
to know the allowable loads at the nozzle in order to through design modification may require strengthen-
determine the piping configuration and generate the ing other parts; such as supports, supporting struc-

NOZZLE LOAD NOMENCLATURE
Fig. No. 7
tures and floors. It should be understood by the user a 5 Dimensionless Number

that the heaters are not intended to serve as anchor S 5 Dimensionless Number
points for the piping. D 5 Dimensionless Number
PROCEDURE FOR CALCULATING
FRRF 5 Maximum Resultant Radial Force, lbf*
NOZZLE EXTERNAL FORCES MRCM 5 Maximum Resultant Circumferential
AND MOMENTS IN CYLINDRICAL VESSELS Moment, in-lbf*
3.14.1 Nomenclature MRLM 5 Maximum Resultant Longitudinal
Moment, in-lbf*

P 5 Design Pressure, psig
ro 5 Nozzle Outside Radius, in FRF 5 Maximum Resultant Force, lbf*
Rm 5 Mean Radius of Shell, in MRM 5 Maximum Resultant Moment, in-lbf*
T 5 Shell Thickness, in *Use absolute values.
**Per ASME Section VIII, Division 1 Code.
Sy 5 Yield Strength of Shell material
At Design Temperature, psi** 3.14.2 External Forces and Moments
s 5 Stress Due to Design Pressure, psi To calculate the maximum force and moment,
Sa 5 Allowable Stress of Shell material first evaluate b and g. Then determine a, S and D
At Design Temperature, psi** from Fig. Nos. 8, 9 and 10 for the specified b and g,
b 5 Dimensionless Number substitute into the equations below and calculate
FRRF, MRCM, and MRLM.
g 5 Dimensionless Number
(5) Local Stresses in Spherical and Cylindrical Shells Due to
External Loadings, K.R. Wichman, A.G. Hopper and J.L.
Mershon Welding Research Council. Bulletin 107/August,
1965 Revised Printing March, 1979.
16
( )
Calculate Pressure Stress
r Rm
b = 0.875 o g=
Rm T
Determine a, (, and D from Fig. Nos. 8, 9 and 10.
s =
2P
T m
R 2
(T
2
=
)
Calculate Pressure Stress (s).
2 (150)
.75
37.5 2
(.75
2 ) =
s =
T m
2P
(
R 2
T
2 ) 14,850 psi , Sa = 20,000 psi
If s is greater than Sa, then use Sa as the stress Use s = 14,850 psi in the equations for calculating
due to design pressure: FRRF and MRLM.
( )
R 2 Calculate Allowable Forces and Moments
FRRF = m Sy 2 s
a
R 2r S
MRCM = m o y

R 2
FRRF = m
a (Sy 2 s
) =
(

(37.5)2
440 (
31,600 2 14,850
) = 53,533 lbf

R 2r
MRLM = m o
D (Sy 2 s
) MRCM =
Rm2 ro Sy
=
(
Plot the value of FRRF as FRF and the smaller of MRCM
and MRLM as MRM. The allowable nozzle loads are (37.5)2 (15) (31,600)
bounded by the area FRF, 0, MRM. = 605,966 in-lbf
1,100
FRF
M
RLM
=
Rm2 ro
D ( Sy 2 s
) =

(37.5)2 (15)

340 ( 31,600 2 14,850
) =
0 1,039,177 in-lbf
MRM
Plot the value of FRRF as FRF and the smaller of
MRCM and MRLM as MRM. The allowable nozzle loads are
3.14.3 Sample Problem bounded by the area of FRF, 0, and MRM.
Determine Resultant Force and Moment
Rm = 37.5 in Sy = 31,600 psi @ 460

FRF = 53,533 lbf
ro = 15 in Sa = 20,000 psi
T = 0.75 in
P = 150 psig
0
( ) r
b = 0.875 o
Rm
= 0.875
( )
15
37.5
= 0.35 MRM = 605,966 in-lbf
T ( )
R
g = m =
37.5
0.75
= 50 Therefore, a nozzle reaction of F 5 20,000 lbf and
M 5 100,000 in-lbf would be allowable (point A) but Distributed by Thomson Reuters (Scientific) LLC, www.t
a nozzle reaction of F 5 5,000 lbf and M 5 605,000*
From Fig. No. 8, a = 440 in-lbf would not be allowable (point B).
From Fig. No. 9, ( = 1,100 ______
From Fig. No. 10, D = 340
*Note: Use absolute values in the graph.
3.15 TOLERANCES
Standard tolerances for nozzle end prepara-
tions and nozzle support locations are indicated
in Figure Nos. 11a and 11b.
The average inside diameter of nozzle weld
preparations may be measured after machining
but prior to installation on the vessel.
17
18
Fig. No. 8
ALLOWABLENOZZLELOADS
19
Fig. No. 9
20
Fig. No. 10
21
Fig. No. 11a
Standard Tolerances for Nozzles and Support Locations - English Units
22
Fig. No. 11b
Standard Tolerances for Nozzles and Support Locations - SI Units
4. MATERIAL DESIGN STANDARDS
4.1 Materials ASME SA-516

The materials used for pressure parts shall be in Alloy Steel
accordance with ASME material specifications, and ASME SA-204
the stress values used shall be those permitted by the ASME SA-387 Grade 2 Class 1;
ASME Code. Grade 11 Class 1 or 2;
The following materials are typical and are pro- Grade 12 Class 1 or 2
vided as a reference only. For information regarding 3) Forged Steel
material compatibility, refer to Paragraph B3. Carbon Steel
4.2 Quality ASME SA-181
All materials specified shall be considered the ASME SA-105
minimum qualities of their kind but specifications ASME SA-266 Grade 1 to 4
shall not exclude the use of any material of equal or ASME SA-350 Grade LF2
superior quality. Alloy Steel
ASME SA-182
4.3 Specifications
(d) Tubesheets
(a) Shells and Shell Covers
1) Plate
1) Pipe Carbon Steel
Carbon Steel ASME SA-285 Grade C
ASME SA-106 ASME SA-515
ASME SA-53 Grade A or B (0.35 percent ASME SA-516
maximum carbon)
Stainless Steel
Alloy Steel ASME SA-240
ASME SA-335 Grade P1, P2, P11, P12 or P22
2) Forgings
2) Plate Carbon Steel
Carbon Steel ASME SA-181
ASME SA-285 Grade C ASME SA-266 Grade 1-4
ASME SA-515

ASME SA-350 Grade LF2
ASME SA-516
Alloy Steel Alloy Steel
ASME SA-204 ASME SA-182
ASME SA-387 Grade 2 Class 1; ASME SA-336
Grade 11 Class 1 or 2; Stainless Steel
Grade 12 Class 1 or 2 ASME SA-182
(b) Channels and Channel Covers (e) Tubes
1) Plate Refer to paragraph 3.6 concerning tube
Carbon Steel material selection
ASME SA-285 Grade C 1) Carbon Steel
ASME SA-515 ASME SA-214, UNS K01807 (Welded)
ASME SA-516 ASME SA-557-A2, UNS K01807 (Welded)
2) Forged Steel ASME SA-557-B2, UNS K03007 (Welded)
Carbon Steel ASME SA-557-C2, UNS K03505 (Welded)
ASME SA-181 ASME SA-179 (SMLS)
ASME SA-105 ASME SA-210 A-1, UNS K02701 (SMLS)
ASME SA-266 Grade 14 ASME SA-210-C, UNS K03501 (SMLS)
ASME SA-350 Grade LF2 ASME SA-556-A2, UNS K01807 (SMLS)
3) Pipe ASME SA-556-B2, UNS K02707 (SMLS)

Carbon Steel ASME SA-556-C2, UNS K03006 (SMLS)
ASME SA-106 2) Copper and Cooper Alloys
ASME SA-53 Grade A or B (0.35 percent Arsenical Copper - DPA
maximum carbon) ASME SB-395, UNS C14200 (SMLS)
(c) Shell and Channel Nozzles Admiralty Metals - B/C/D (SMLS)
ASME SB-395, UNS C44300, C44400,
1) Pipe C44500 (SMLS)
Carbon Steel
ASME SA-106 70-30 Copper-Nickel
ASME SA-53 Grade A or B (0.35 ASME SB-395, UNS C71500 (SMLS)
percent maximum carbon) 80-20 Copper-Nickel
Alloy Steel ASME SB-395, UNS C71000 (SMLS)
ASME SA-335 Grade P1, P2, P11, P12 or P22 90-10 Copper Nickel
2) Plate ASME SB-395, UNS C70600 (SMLS)
Carbon Steel 3) Low Alloys
ASME SA-285 Grade C ASME SA-213 T11, UNS K11597 (SMLS)
ASME SA-515 23 ASME SA-213 T22, UNS K21590 (SMLS)
4) Nickel Alloys Carbon Steel

70-30 Nickel-Copper ASME SA-285 Grade C
ASME SB-163, UNS N04400 (SMLS) ASME SA-515
5) Stainless Steel - Austenitic ASME SA-516
ASME SA-688 TP304, TP304L, TP304N (g) Bolting
(UNS S30400, S30403, S30451 (Welded)) 1) Stud and Stud Bolts
ASME SA-688 TP316, TP316L
(UNS S31600, S31603 (Welded)) ASME SA-193 Grade B7, SA-320 Grade L7.
ASME SA-249 TP316N, UNS S31651 Threads to be in accordance with ANSI B1.1 for
(Welded) high strength bolting. Sizes 1 inch and smaller
ASME SB-676, UNS N08367 (Welded) shall be threaded in accordance with the coarse
ASME SA-213 TP304, TP304L, thread series, and 1-1/8 inch and larger in
TP304N, TP316, TP316L diameter with the 8-pitch-thread series.
(UNS S30400, S30403, S30451, 2) Nuts
S31600, S31603 (SMLS)) ASME SA-194 Grade 2H, Grade 7. Threads
6) Stainless Steel - Ferritic shall be in accordance with those on studs, as
ASME SA-803 TP439, UNS S43035 noted above.
29Cr-4Mo (h) Gaskets
ASME SA-268, UNS S44735 (Welded) The choice of a suitable gasket materi-
(f) Flanges al depends on the design of the closure,
1) Forged Flanges and therefore, the selection shall be in
Carbon Steel accordance with the standards of the heat-
ASME SA-181 er Manufacturer or as specified by the
ASME SA-105 Purchaser.
ASME SA-350 Grade LF2 (i) Baffles and Support Plates
Alloy Steel 1) Plate
ASME SA-182 Commercial Quality Steel
2) Plate Flanges (j) Tie Rods and Spacers
1) Commercial Quality Steel

5. DESIGN AND SPECIFICATION OF REPLACEMENT HEATERS/BUNDLES
5.1 Replacement of Heaters/Bundles It should be recognized that it is not always possible
Experienced personnel knowledgeable in past to meet all of the original features of arrangement,
and present industry practice including metallurgy, envelope size, or nozzle locations due to improvements
fabrication, design and all phases of heater operation in the state of the art and changes in specification
should be consulted when the replacement of feedwater requirements. Terminal points and overall dimensions
heaters or tube bundles is being considered. Information may be affected by internal design changes necessitated
required when specifying replacement equipment by, for example, tube material changes. Therefore, the
should include the entire original heat bal-ance, the Purchaser should review structural and piping draw-
actual operating conditions, and any abnormal and/or ings of the area near and around the heater showing
overload conditions that may affect the redesign and adjacent equipment. It is also recommended that
selection of the replacement equipment. evaluation parameters be given for relocation of each
Additional data should include tube material of nozzle; for example, state the order of importance of
all the heaters and condenser and any pertinent meeting certain nozzle locations. Continuous vent
information concerning water chemistry and feedwa- piping will likely require revisions since the state of the
ter treatment. Replacement tube material should be art has advanced.
compatible with existing system materials. Many plant design parameters are established
When specifying, the Purchaser should identify based on the original equipment design and it is
all the causes and types of failures, so that problems recommended that the outline drawing of the heater
inherent in the original equipment or system can be included. If available, any additional information
be avoided. Many failures, such as corrosion, drain concerning structural and piping, such as forces and
cooler inlet erosion, and leaking welded tube joints moments, should be included.
can be strictly equipment related or the result of When retubing heaters, experienced Manufacturers
system or operational malfunctions. A change in tube and designers can analyze and recommend any required
material, in addition to affecting surface area and/ design changes. However, before considering retubing
or performance, may require changes in baffling, rather than replacement, the condition of pressure bear-
desuperheating zone, and drain cooler zone to avoid ing components should be evaluated closely.
recurrence of original problems. Therefore, it is recom- For replacement heaters, the maximum tube side
mended that the Purchaser consult with experienced pressure loss should be given along with the method
Manufacturers and designers on current needs when or penalty of evaluation. Where the restrictive or
developing specifications for replacements. available heater size is given, the tube side pressure
loss can be controlling.
24
6. FEEDWATER HEATER PROTECTION
6.1 Safety Requirements (e) Back pressure at the valve outlet connection shall
Because of the variety of protective measures and be considered zero psi unless otherwise specified
devices in common use, compliance with the provisions (See Paragraph 2.1.1 [f]).
of the ASME Code for protection of closed feedwater
6.2 Flashback Protection
heaters against over-pressure is the responsibility of
the Purchaser. Certain design features may be required in the feed-
water heater to restrict the stored volume of the con-
6.1.1 Tube Side Relief Valves tained liquid and to confine flashed vapor. Details of the
The tube side of the heaters shall be protected flashback protection provisions shall be incorporated in
against over-pressure from water expansion when the the initial inquiry by the Purchaser.
water inlet and outlet valves are closed. A minimum The Manufacturer can provide the following infor-
3/4" connection for installation of a relief valve shall mation to assist in the Purchasers evaluation of
be provided between the water inlet and outlet valves. turbine overspeed during load rejections.
(a) Steam volume
6.1.2 Shell Side Relief Valves
When the shell design pressure is less than the tube (b) Condensate volume at the normal operating level
design pressure, a connection for a relief valve shall be (not including drain volume in drain cooling zone).
provided to protect the shell from over-pressure in case (c) Drain volume in drain cooling zone.
of tube or tubesheet failure. The design temperature (d) Flow area at entrance to drain cooler.
and pressure of the valve should be equal to the design
(e) Flow area through flashback system. This area
temperature and pressure of the shell.
will be the total flow area through flashback baffle
When no valves are present in the extraction line
as well as clearance areas between drains cooling
and there are no means of isolating the heater shell
zone and shell I.D.
from the turbine, the user should be certain that the
control arrangements (high level alarms, emergency Maximum flow areas should be furnished by the tur-
dump systems, etc.) are such that corrective steps bine manufacturer; however, the design of the heater
can be taken before condensate (from tube rupture) will not be compromised to meet this requirement.
reaches the turbine. 6.3 Cleanliness and Corrosion Protection
Although the shell side relief valve is normally

Internal surfaces of all heaters shall be cleaned as neces-
exposed only to steam during normal operation of the
sary to remove loose scale. Dirt, weld-rod stubs, and other
heater when not relieving, it may be required to pass
foreign objects shall be removed prior to final assembly
water (possibly flashing) when relieving, as the shell
of heater parts. Excess oil and grease shall be removed
will fill with water. Hence the valve should be sized
by wiping.
for liquid service. It is suggested that this relief valve
Liquids used for hydro-testing or cleaning shall be
be sized to pass the larger of the following flows at 10
drained from the heaters. All nozzles and openings shall
percent accumulation:
be covered to guard against damage and the entrance of
(a) Minimum of 10 percent of the maximum over- foreign objects during shipment.
load feedwater flow specified through the heater When heaters are tubed with carbon steel, water used
based on water at Tv (See Paragraph 2.1.1[e]). for hydrostatic testing should be treated with a suitable
(b) Flow based on the clean rupture of one heater rust-inhibiting agent. Prior to shipment, the heaters shall
tube resulting in two (2) open ends discharging be drained and all openings sealed in accordance with
as orifices. Flow shall be determined for orifices the Manufacturers commercial procedure. Due to the
of a diameter equal to the nominal inside diam- complex internal design features of a feedwater heater, it
eter of the tubes using an orifice coefficient of 0.9, is not practical to completely eliminate all moisture from
a pressure differential across the orifice equal to the heater.
the difference between the tube and shell design Heaters should be thoroughly drained by tilt-
pressures, and water at Tv. ing and maneuvering as required to ensure that all
Q = 54 d2 Pt 2 Ps pockets are cleared. It is recommended that carbon
steel tubed heaters be heated and evacuated to remove
Where Q = Flow of water, gal/min at 70 F
additional trapped moisture and that the heater be
d = Nominal inside diameter of tubes, in purged and blanketed to a positive pressure with
Pt = Tube side design pressure, psig an inert atmosphere, such as nitrogen, immediately
Ps = Shell side design pressure, psig after evacuation. Some means to monitor the pressure
Tv = The temperature to be used for valve selection during shipment and storage should be provided by
is the average tube side temperature at the the Manufacturer. The Purchaser should moni-
normal operating conditions, F. tor the pressure immediately after receipt and on a
weekly basis thereafter to insure that the inert blan-
(c) In no event shall the value of Q be greater than
ket is maintained continuously. The above procedure
the specified maximum overload feedwater flow.
will eliminate the excessive moisture that could be
(d) The valve manufacturer shall be responsible detrimental to the tubing material. The user should inspect
for the selection of the valve based on data and record the condition of all covers and seals upon receipt
supplied by the heater Manufacturer and/or the of the heater at the job site. Any damaged or defective seals
user. must be reported immediately to the Manufacturer.
25
After seals are broken and covers removed to permit 6.4 Venting and Draining
installation and attachment of piping, the user should All high and low points on shell and tube spaces
protect the heater internals against corrosion and of a heater, not otherwise vented or drained by nozzles,
contamination and periodically inspect the heater, shall be provided with connections for vents and drains.
prior to operation and during shut-down periods, for See Fig. No. 42 Paragraph B11 and Paragraph 2.13.
corrosion damage. Appendix A should be consulted for
additional information.
7. INSTALLATIONS
The type of installation selected must consider, as plant designer consult this Standard for guidance in
a minimum, space allocation, piping arrangements, the selection. The standard arrangements available
access for maintenance and repair, and operational are depicted in Fig. No. 12 thru 15 below.
considerations. It is recommended that the power
HORIZONTAL INSTALLATION
Fig. No. 12

HORIZONTAL IN CONDENSER NECK INSTALLATION
Fig. No. 13
VERTICAL CHANNEL UP INSTALLATION VERTICAL CHANNEL DOWN INSTALLATION

Fig. No. 14 Fig. No. 15
26
8. CHANNEL TYPES
8.1 Full Diameter Access Channels b) Without Partition Seal Covers

For maintenance purposes, full diameter access The pass partition design shown in Fig. No. 17 is
channels are more desirable than limited access chan- more prone to interpass leakage due to deflection of the
nels; however, the full diameter access channels are channel cover. However, when used, this design is rec-
generally more costly than the limited access channels. ommended for channel diameters less than 40 inches.
The common types of channels are discussed below:
8.1.2 High Pressure, Full Access
8.1.1 Low Pressure, Full Access Fig. No. 18a shows a full access channel where the
hydraulic load is transmitted to the channel barrel
Full diameter, bolted and gasketed channels as by means of shear members, not by bolts in tension.
shown in Fig. Nos. 16 and 17 are recommended The final closing joint (water-tight seal) may be either
for low pressure heater designs where the channel welded or mechanically sealed.
diameters are less than 48 inches. Fig. No. 18b illustrates a full access channel where
a) With Partition Seal Covers the hydraulic force against the cover is taken by bolts
The pass partition cover design shown in Fig. No. 16 in tension. Sealing is accomplished by either a gasket
is the welded type; if desired, the pass partition cover or a seal-welded diaphragm.
may be bolted and gasketed. These types of channels provide considerably larger
access openings, but at very large diameters and high
pressures the availability of the large forgings becomes
a problem. The need for special cover handling equip-
ment should be considered. The cost will generally be
more than that of manway access channels.

WELDED TYPE PASS PARTITION COVER DESIGN
Fig. No. 16
HIGH PRESSURE, FULL ACCESS CHANNEL

Fig. No. 18a
GASKETED CHANNEL COVER PASS

HIGH PRESSURE, FULL ACCESS CHANNEL
PARTITION DESIGN
Fig. No. 17 Fig. No. 18b
27
8.2 Manway Access Channels tition section that is perpendicular to the tubesheet
face. Pass partition covers are to be designed for the
8.2.1 Minimum Access Manway Sizes maximum expected differential pressure.
When the user has decided upon a manway access Pass partition covers should be sectioned as
channel, the following should be considered: required to remove them through the manway, rather
than having personnel being restricted by the covers
8.2.1.1 Minimum Manway Sizes lying in the bottom of the channel. Should welded pass
The minimum acceptable manway sizes partition covers be used, they should not be thermally
are 12" x16" elliptical and 16" circular. cut closer than 1/2" to the pressure boundary.
8.2.1.2 Pass Partition Cover Design and Type The pass partition cover type is an option for
the Purchaser to consider. Welded covers provide a
Pass partition cover design must be such that it
more positive seal but require thermal cutting for
does not restrict channel entry through the access
access. Bolted and gasketed covers are more read-
opening. A design with a pass partition cover which
ily removable but are more susceptible to interpass
is parallel with the tubesheet face may require a
leakage. Shown in Fig. No. 19 is a typical full access
larger manway opening in order to gain access. This
bolted and gasketed pass partition cover design. It is
entry restriction can be eliminated by sloping the pass
important that fasteners be locked in place in order
partition cover. The end of the cover adjacent to the
to avoid having stray fasteners introduced into the
center of the tubesheet should be approximately four
condensate/feedwater system. Recommended weight
(4) inches from the tubesheet face; however, this dis-
of removable sections should not exceed 50 pounds
tance will vary because of hydraulic and maintenance
for ease of handling.
considerations required for the design of the pass par-

TYPICAL FULL ACCESS BOLTED PASS PARTITION COVER
Fig. No. 19
28
8.2.2 Low Pressure, Manway Access heater designs could be one of the two (2) designs
Manway access channels used for low pressure shown below:
Option A Option B Option C

HEMISPHERICAL HEAD CHANNEL DESIGN - LP ELLIPTICAL HEAD CHANNEL DESIGN-LP
Fig. No. 20 Fig. No. 21
Fig. No. 20 shows a channel design using a hemi- The manway sealing joint would be one of the
spherical head which may present difficulties in fit- configurations shown above Fig. Nos. 20 and 21. One
ting nozzles and manway around the hemispheres configuration (Option A) has a seal welded dia-
periphery. This design generally has a greater access phragm which provides all welded construction when
restriction. Due to the nozzle centerlines being required. The other optional configurations have gas-
approximately 30 off the vertical plane, 30 elbows keted joints with one being externally gasketed and
are generally required in the piping if vertical runs the other having an internal gasket which is called a
are required. Fig. No. 21 shows channel design using pressure sealing type design.
an elliptical head which provides greater access and
does not have the nozzle configuration complications

of the hemispherical head.
29
8.2.3 High Pressure, Manway Access heater designs could be one of the three (3) designs
Manway access channels used for high pressure shown below:
Option A Option B Option C

HEMISPHERICAL HEAD COMBINATION TUBESHEET MODIFIED HEMISPHERICAL
CHANNEL DESIGN-HP CHANNEL TYPE DESIGN-HP HEAD DESIGN-HP
Fig. No. 22 Fig. No. 23 Fig. No. 24
Fig. No. 22 shows a channel design using a The manway sealing joint would be one of the
hemispherical head which may present difficulties in c onfigurations shown above Fig. Nos. 22, 23, and 24.
fitting nozzles and manway around the hemispheres One configuration (Option A) has a seal welded dia
periphery. This design generally has a greater access phragm which provides all welded construction when
restriction. Due to the nozzle centerline being approx- required. The other optional configurations have gas-
imately 30 off the vertical plane, 30 elbows are keted joints with one being externally gasketed and
generally required in the piping if vertical runs the other having an internal gasket which is called a
are required. Fig. Nos. 23 and 24 show channel pressure sealing type design. The pressure sealing

designs which do not have the nozzle configuration type is used when bolting may be too large for the
complications of the hemispherical head. externally gasketed joint.
30
31
Fig. No. 25
HORIZONTAL MOUNTING
STRAIGHTCONDENSINGFEEDWATERHEATER
9. TYPICAL FEEDWATER HEATER INTERNAL ARRANGEMENTS
32
Fig. No. 26
HORIZONTAL MOUNTING
2-ZONE FEEDWATER HEATER
(Condensing and Subcooling Zones)
SEE FIG. No. 16
THRU 18 AND
20 THRU 24
FOR TYPICAL
CHANNEL
CONFIGURATIONS
33
Fig. No. 27
HORIZONTAL MOUNTING
(Desuperheating and Condensing Zones)
SEE FIG. No. 16
THRU 18 AND
20 THRU 24
FOR TYPICAL
CHANNEL
CONFIGURATIONS
34
Fig. No. 28
HORIZONTAL MOUNTING
(Desuperheating, Condensing and Subcooling Zones)
SEE FIG. No. 16
THRU 18 AND
20 THRU 24
FOR TYPICAL
CHANNEL
CONFIGURATIONS
35
Fig. No. 29
Vertical Channel Down Mounting
STRAIGHT CONDENSING FEEDWATER HEATER
CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
36
Fig. No. 30
2-ZONEFEEDWATERHEATER

CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
37
Fig. No. 31

(Desuperheating, Condensing and Subcooling Zones)
CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
38
Fig. No. 32
Vertical Channel Up Mounting
STRAIGHT CONDENSING FEEDWATER HEATER
CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
39
Fig. No. 33
CHANNEL
20 THRU 24
FOR TYPICAL
THRU 18 AND
SEE FIG. No. 16
CONFIGURATIONS
40
Fig. No. 34
(Desuperheating, Condensing and subcooling Zones)
APPENDIX A
GUIDELINES FOR INSTALLATION, OPERATION,
AND MAINTENANCE OF FEEDWATER HEATERS
A1 INSTALLATION OF CLOSED FEEDWATER HEATERS
A1.1 General Considerations A1.4 High Level Condensate Dump

Feedwater heaters should be installed with If a high level condensate dump connection has
sufficient clearance to allow convenient and proper been provided, also referred to as a drains subcooling
maintenance of the units without disturbing adja- zone by-pass or an emergency dump, this should be
cent equipment. Installation should be made so that routed directly to the condenser.
cranes and hoists installed in the plant can be used to
service the heaters. Ample space should be provided A1.5 Accessories
for the removal of covers, shells, or bundles and for the Accessories required by the Purchaser can be
retightening of all bolted joints. Similarly, for heat- provided by the Manufacturer. The normal practice
ers with welded joints, space should be provided to is to have the Manufacturer provide shell side safety
permit disassembly and rewelding of all joints. For valves, tube side thermal relief valves, and operating
heaters to operate properly, they must be correctly air vent orifice plates (when external orifice plates are
oriented. Horizontal heaters should be installed level required) with the remaining accessories provided by
and vertical heaters should be installed plumb. the Purchaser.
For condenser neck mounted heaters, shell Prior to purchase and operation, the Purchaser
protective stainless steel lagging and condenser neck should consider the following accessories, which
closure plate, when required, are shipped loose for are required for proper operation and testing of a
field attachment. feedwater heater:

(1) Gage glass with a sight range equal to or exceed-
A1.2 Installation Under Freezing Conditions ing the maximum liquid level range.
In order to avoid damage from freezing, the user
must prevent water from remaining in a heater (2) Diaphragm control valve and level controller for
exposed to freezing conditions after a plant is shut maintaining the liquid level within the heater.
down. The user should also provide and maintain (3) High and low level alarms to alert the operator
proper protection from freezing of the equipment of any abnormal levels within the heater.
before, during and after installation. It has been (4) Pressure measuring equipment should be pro-
demonstrated that tubes in horizontal positions will vided for the following:
not drain sufficiently by gravity alone to preclude
a. Feedwater inlet and outlet connections.
freezing damage.
b. Steam inlet connection.
A1.3 Pre-Operational Cleaning and Flushing c. Drains outlet connection.
Operation d. Shell.
The pre-operational cleaning and flushing opera- (5) Temperature measuring equipment should be
tion must consist of chemicals and water that are not provided for the following:
detrimental to the equipment (tubing in particular). a. Feedwater inlet and outlet connection.
It is recommended that the Purchasers metallurgist b. Steam inlet connection.
be consulted for specific cleaning procedures or the c. Drains outlet connection.
Purchaser should engage a chemical company which d. Shell vapor.
can provide them with this service.

e. Shell condensate.
Under no circumstances should the heater be laid
up using the flushing or cleaning solutions.
41
A2 CLOSED FEEDWATER HEATER OPERATION
A2.1 Initial Start-Up Precautions Improper liquid levels may result in the loss of the water
It is important that all bolted joints be tightened seal allowing steam to flow directly into the drain pip-
uniformly and in a diametrically staggered pattern as ing or through the entrance to the drains subcooling
illustrated in Fig. No. 35, except for special closures zone. Steam flow into a drains subcooling zone reduces
or spiral wound gasketed closures, when the instruc- its effectiveness for subcooling and can lead to erosion
tions of the Manufacturer should be followed. and/or vibration. In horizontal heaters with a drains
The bolts should be retightened shortly after the subcooling zone, the loss of the water seal may elimi-
heater has been put in service for the first time. nate essentially all of the subcooling. This two-phase
Operational factors, including thermal cycling, pres- flow through the subcooling zone can result from steam
sure surges/spikes, etc., can lead to loosening of bolted by-pass leaking through the end plate of a horizontal
joints. Periodic checks should be made during the subcooling zone and/or flashing of the incoming drains
first six months of operation and routinely thereaf- entering the integral subcooling zone.
ter to insure that all bolted joints remain tight. It is Liquid level standpipes and their associated gage
recommended that removable insulation be used at glasses sense the level through static taps. In both verti-
cal and horizontal heaters, the steam flow velocity past
the higher connection may be different from the velocity
at the liquid surface. In the absence of shock or friction
losses, the pressure of the stream having the lesser veloc-
ity will be greater as a result of Bernoulli or momentum
exchange effects. More common is steam flow into the
vapor equalizing line of the standpipe. Condensation
in the vapor equalizing line results in a lower pressure
above the float than inside the heater leading to a higher
level in the float cage. These effects result in measuring
higher levels than actually exist inside the heater. This
leads, in some cases, to loss of the necessary submer-
gence on the entrance to the subcooling zone, resulting
in flashing.

Although the required liquid level location can be
accurately marked, measurement of the actual liquid
level can be difficult. In heaters with drains subcooling
zones, the proper location can be obtained by the liquid
level test stated below.
Steam flow paths in heaters are complex and the effect
Method of Tightening Bolted Joint. upon liquid levels of flow maldistribution cannot always
(1) Tighten all bolts hand tight. be evaluated. When liquid level connections can not be
(2) Tighten bolts, one flat at a time in pattern shown. located in areas of low steam velocities, the proper level
(3) Continue until joint is tight. location must be established by test.
Momentum effects will generally affect the
measured level if one of the control connections is located
BOLT TIGHTENING SEQUENCE
near a steam or drains inlet. When tubes in drains sub-
Fig. No. 35 cooling zones near the zone entrance fail prematurely
or when drain subcooling zones fail to properly subcool,
false liquid levels are usually the cause of the difficulty
all major bolted connections on the shell and heads and the level should be raised.
so that these joints can be checked and tightened In the case of a horizontal heater with an integral
as noted in Fig. No. 35. Retightening of bolts and drain cooler having a siphon-type inlet (as opposed to
periodic verification of bolt torque should only be

a full-length, submerged drain cooler), consideration
done when the vessel is not pressurized. Refer to the should be given to performing a test to establish a
Manufacturers instruction manual for additional
true level at the subcooler inlet. This would avoid (a)
precautions and specific operating procedures. (Refer
severe erosion due to steam entering the drain cool-
to Paragraph A3.4 concerning safety precautions).
ing zone due to an excessively low level, or (b) a less
A2.2 Liquid Level Control dangerous, but expensive scenario where a loss of
The control of the liquid level is important to the performance occurs due to an excessively high level in
proper operation of the heater. The liquid level is used the heater.
to provide a water seal between the condensing zone In this test the drain cooler approach is measured at a
and the entrance to the integral drains subcooling series of liquid levels, as illustrated in Fig. No. 36, begin-
zone or the heater drain connection. This serves the ning with a relatively high level, and incrementally drop-
same purpose as a steam trap and will isolate one ping the level until the knee in the curve is reached. At
extraction point from another. The primary purpose this point the level is low enough that the seal at the inlet
of the condensate seal is to promote single phase to the drain cooling zone is broken and the steam enters
condensate flow through the drains subcooling zone. or condensate flashes, creating a two-phase mixture.
42
measured either from the bottom of the shell or from

the heater shell centerline. When the operating level
at the design load results in a DCA approaching the
design DCA, the level should be set, as a minimum,
2" above that test elevation but should not be set
lower than the Manufacturers original level marker.
This set point for the Normal Liquid Level should
be marked on the level indicator as well as on any
level plate provided on a shell mounting bracket,
if available.
Parallel heaters may operate at slightly different
pressures as a result of differing steam piping, foul-
ing, or maldistribution of feedwater flow between
the heaters. Individual liquid level controls and gage
glasses are required to provide proper level locations
under operating conditions that will differ between
parallel operated heaters.
A2.3 Liquid Level Control in Vertical Channel
Down Heaters
The subcooling zone arrangement and level control
settings for a typical channel down heater are covered
in Fig. No. 37.
LIQUID LEVEL TEST The vertical channel down feedwater heat-
Fig. No. 36 er arrangement is more forgiving with respect to
mechanical damage to the tubes and baffles of the
To avoid premature tube failures, a level test should subcooling zone caused by a low shell liquid level,
be conducted as soon as possible, preferably within than with a horizontal heater with a full pass short
the first month of operation. The level test should drain cooler. Inadequate subcooling performance in
monitor the Drain Cooler Approach (DCA) tempera- either case results in the drains out flow being close
ture difference against the elevation of the liquid level to or at the saturated condition.

Note: All numbers
shown are for exam-
ple only. Individual
heater designs
and levels vary.
LIQUID LEVEL CONTROLS FOR TYPICAL VERTICAL CHANNEL DOWN HEATER

Fig. No. 37
43
A2.4 False Liquid Level Indication associated with two-phase flow in a piping system. If
Of all the possible reasons for false sensing of the system utilizes a heater drain pump, the loss of
vapor/liquid interface levels in closed feedwater subcooling can have a significant adverse effect on
heaters, the following appear to be most commonly the necessary net positive suction head requirement
encountered. Note that when a false high shell liquid and/or cavitation.
level indication is adjusted down to the normal Heater liquid levels should be controlled by dis-
set level, the actual liquid level in the shell is set placement sensors or by any other type of sensors that
equivalently too low. are responsive to rapid changes in the shell liquid
E xcessive condensing in a top equalizing leg level and that faithfully reflect changes in extraction,
that is too long induces a compensating flow cascaded drains or possible internal leakage flows.
into the leg. This results in a pressure loss Although heater levels must be set by temperature,
causing a rise of the level in the sensor and namely the level that provides the rated drains
gage glass relative to the actual level in the approach temperature, heater levels are not to be
shell. It should be obvious that the longer the controlled by temperature. Time delays in sensing
vapor equalizing leg, the greater will be the temperature changes would probably result in unac-
discrepancy between indicated level outside the ceptable, erratic level swings.
heater and actual level inside the heater. For
any given vapor equalizing leg length, insula- A2.6 Effect of Load Rejection on Shell
tion of the equalizing piping will minimize the Liquid Level
false level indication. Shell liquid levels are affected by rapid increases
A high localized velocity of steam across the top or rejection of unit load. Both cases, in their own
equalizing connection opening in the shell aspi- way, can cause a sharp rise in shell liquid level and
rates or reduces pressure in the top equalizing an adequate margin between the normal and alarm
leg, which raises the level in the sensor relative or dump levels must be allowed. Traditionally, the
to the actual level in the shell. normal and alarm levels have been set too close. This
A cascade of condensate flowing down a vertical does not permit reasonable load swings, without
channel down shell into the top equalizing con- alarm, or allow adequate range of level adjustment
nection tends to flood the sensor and thus raise to obtain the specified drains approach temperature.
the level indication relative to the actual level Also, on a sudden, high rate of load reduction, vapor
in the shell. is generated in the condensate in the shell, as the
S ediment or partially closed valve settings in saturation temperature drops below the actual con-

the bottom equalizing leg inhibit the return of densate temperature. A small amount of vapor, due
excess condensate to the shell, resulting in a
to its much greater specific volume, sharply increases
higher level in the sensor than actually exists in
the overall volume of the condensate/vapor mix in the
the shell.
shell until the turbine extraction pressure stabilizes
Any loop seals trapping condensate in the top
and the vapor is released from the condensate. This
equalizing leg or high points trapping gas in the
bottom leg will cause a false level indication. transient, which may best be called a swell, must be
I mproperly installed or closed gage glass valves accommodated without unnecessary alarm or dump-
result in false indications. ing as long as the level is controlled within safe limits
Often a false level indication tends to be relatively as shown in Fig. No. 38 for horizontal heaters and
stable at a given load and unstable fluctuations in Fig. No. 37 for vertical channel down heaters.
indicated level generally result from some other A2.7 Effect of Failed Tubes on
cause. Whatever the cause and magnitude of a false
Heater Operation
level indication, regular monitoring of the drains
approach temperature will provide an immediate, The shell liquid level is also significantly affected
accurate determination as to whether the actual shell by continued operation with failed tubes. The drains
liquid level is adequate. control system is required to pass the added flow from
There will always be some discrepancy between the the two broken ends of each clean ruptured tube and
indicated level and the actual level, since condensa- from impingement failures. With continued operation,
tion in the vapor equalizing leg will always be present failed tubes have the potential to seriously damage

to some degree. For this reason, as well as the com- surrounding tubes, tube holes, internal structures,
bined effect of the other factors identified above, the pressure parts, etc. Feedwater entering the shell thru
heater operating level should always be established a failed tube will flash into a two-phase mixture and
by conducting a level test. Please see Paragraph A2.2 combine with the shell side flow. This can initiate
for level test recommendations. vibration as well as erosion of components. In addi-
tion, high velocity water jets (if present) can erode and
A2.5 Effect of Low Liquid Levels on External penetrate thru pressure parts. (Refer to Paragraph
Drain System A3.4 concerning safety precautions).
The suppression of subcooling due to low shell It will be noted that flow from only a few ruptured
liquid levels causes the heater drains to approach the tubes will exceed 10% of rated feedwater flow in
saturation temperature. Any subsequent line pres- short order, particularly in high pressure heaters.
sure loss through valves and/or in the piping causes Continued operation with damaged tubes can rap-
condensate flashing, with gross tendencies toward idly escalate leakage flows due to secondary failures
vapor binding, slug flow, and resultant problems resulting from feedwater impingement on adjacent
such as pipe movement, and/or banging and choking tubes. Oversized valves in low pressure heater drain
44
Note: All numbers

shown are for example
only. Individual heater
designs and levels vary.
LIQUID LEVEL CONTROLS FOR TYPICAL HORIZONTAL HEATER

Fig. No. 38
systems often mask increasing leakage by maintaining end plate, permitting the bypass of wet vapor from

ing a normal liquid level until additional tubes fail. the condensing zone into the subcooling zone. This
To keep this condition from occurring, any incom- not only leads to erosion of the tube, if carbon steel,
ing drains should be diverted to the condenser when and of the hole in the end plate, but also can produce
the level rises above the normal high operating level a similar effect on performance as an inadequate shell
at least 3" to 6". Additionally the station operators liquid level.
should mark the valve stem position of the Drain
Another liquid level test should be performed to
Control Valve in its normal 100% drain flow posi-
tion. On each shift the valve stem position should be reestablish the normal level. As a recommended prac-
checked, and if the valve opening is greater than the tice when tubes are plugged in the bottom rows, the
marking, then a broken tube is very likely introducing controlled level should be raised to submerge these
feedwater into the heater shell. plugged tubes when the row is 50% plugged or more.
In any discussion of the operation of a closed feed-
water heater with tube leaks, it is very important
A2.9 Start-Up Limitations
to keep in mind the fact that a shell safety valve is For normal start-ups, the entire string of heaters is
designed to release a given amount of water (not subjected to increasing feedwater flow rates. This is
steam) at a shell pressure 10% above the design normal and will usually be acceptable provided the
pressure of the shell. If tubes continue to fail, it must flow rates are changed gradually and within the tem-
be recognized that the safety valve capacity will perature ramp rates provided in the Manufacturers
be exceeded. In such a case, the shell pressure will instruction manual, if any.
continue to rise and, in short order, can cause the shell One start-up condition that requires special pre-

to rupture. In other words, a safety valve provides a cautions is when one heater of the string has been
limited margin of time to get the heater off line to out of service and is cold and needs to be restarted.
avoid an accident. This situation occurs when one heater is isolated for
A2.8 Effect of Plugged Tubes maintenance or repairs and the remaining heaters
When a tube is plugged and becomes inactive in a are kept in service. When this heater is ready to be
horizontal heater that has a short drain cooler, two put back into service, a different start-up procedure
corollary events must be considered. If the plugged may be required. The owner should either follow the
tube is in a bottom row, it contributes to pressure loss Manufacturers instruction manual or call the
of the entering saturated condensate without atten- Manufacturer directly for specific instructions.
dant subcooling. Several such tubes can aggravate the
failure problem and a liquid level test is necessary to A2.10 ShutdownLimitations
establish a new adequate shell liquid level. Please The same precautionary measures used at start-
see Paragraph A2.2 for level test recommendations. up are also recommended for shutdown in order to
Further, the condensate choke is lost between the prevent thermal shock by rapid or forced cooling.
inactive tube OD and the drilled hole in the subcool-
45
A3 MAINTENANCE OF FEEDWATER HEATERS
A3.1 In-Plant Cleaning 6. All external leaks must be repaired immediately.

It must be recognized that many solutions used At the first sign of any internal or external leak, it
in the cleaning operating may contain corrodents is recommended that the heater should be imme-
which will have an effect on the materials in a feed- diately taken out of service and repaired.
water heater. Use of such solutions must be done in a 7. If a heater has temporary non-welded tapered
controlled manner, and care must be taken to assure tube plugs installed, a pneumatic test might
that the accumulated effect does not affect the thick- be considered for determining if plugs are leak-
ness of pressure-bearing components or contaminate ing. The pressure should be limited to fifty
the materials. In-plant cleaning of the feedwater percent of the shell design pressure or 10 psig,
heater internals is generally accomplished by a pre- whichever is lower.
operational cleaning and flushing operation used to 8. All gage glasses must be protected against
clean all vessels, piping, etc., prior to initial operation. damage, as this can be a source of dangerous
Also, in-plant cleaning of the feedwater heater tub- leakage.
ing surface is required when the heater performance
becomes impaired due to fouling of the tubing. Due 9. The following must be observed when personnel
to the triangular pitch, it is not possible to mechani- plan to enter or are working near a heater.
cally clean other than the perimeter tubes surfaces; A. Positive lock stops should be used to prevent
therefore, the generally accepted cleaning method is accidental opening of any steam or water
chemical cleaning. valves.
A3.2 Chemical Cleaning B. If any insulation is removed, precautions
It is recommended that the Purchasers should be observed to avoid injuries (both
metallurgist be consulted for specific cleaning pro- during repair/inspection operations and after
cedures or the Purchaser should engage one of the start-up).
chemical cleaning companies which can provide them C. Proper ventilation must be supplied when
with this service. making internal repairs on a heater.
A3.3 Stagnant or Entrapped Areas D. Prior to performing work on nuclear installa-
It is imperative that all stagnant or entrapped tions the radioactivity level should be deter-

areas within the heater are properly flushed in order mined to be certain it is within acceptable
to avoid excessive exposure to the chemical levels.
cleaning agent. E. Do not use chlorinated solvents (or similar
A3.4 Special Product Warnings (Safety) solvents) such as carbon tetrachloride, etc.,
Ultimate responsibility for the safe operation and inside a unit for weld repair processes, etc.
maintenance of heaters rests with the user, but the F. Pools of water must be dried prior to use
following will provide a description of areas where of electrical devices including electric arc
special precautions should be observed. cutting and/or arc welding equipment.
It is imperative that the user become thorough-
G. The user shall pay particular attention to any
ly familiar with all instruction manuals that are
safety notices on the heater.
provided, as these documents will provide important
safety instructions. A number of applicable areas A3.5 Lay-Up Procedure for Non-Operating
to be observed prior to and during operation will
Heaters
be described below. (The list is not intended to be
all inclusive). In order to reduce shell and tube side corrosion to a
minimum in non-operating heaters, the following lay-
1. Prior to performing any work on a unit, be cer- up procedures are recommended.
tain that all valves are tagged and all pressures For heaters expected to be out of service for an
on the unit are relieved. If maintenance cannot extended period, both the shell and tube sides
be performed during an outage, then personnel should be drained, dried, and, after air is removed, a

should be protected from incoming fluids by nitrogen blanket at 5 psig should be maintained. This
double valves. applies to heaters with all types of tube materials.
2. Any temporary gaskets are to be replaced prior The above is also the preferred method for units
to initial operation (with required permanent temporarily out of service, or in by-pass mode
gaskets). (for limited period), but if this is not possible then the
3. Do not gag any safety valves during operation. following procedures should be observed.
4. Be certain that all closures are secured as 1. Tube side condensate should be maintained in
required prior to pressurizing a unit. the system with a pH compatible with all tube
materials.
5. The nameplate maximum allowable work-
ing pressures are not to be exceeded. The 2. Shell side air must be removed from the shell
Manufacturers instructions on test water side as soon as the unit is shut down and a
temperature should be observed to avoid nil nitrogen blanket at 5 psig should be maintained.
ductility temperature problems. Note: As an alternate to nitrogen blanketing,
steam blanketing may be considered. Steam
temperature should not exceed tubeside design
46 temperature.
A3.6 Repair Procedures A3.7.1 Spare Parts

Repair welding after the heater has been in service The recommended spare parts for feedwater heaters
can be broken down into the following categories: are listed below.
Typical
A3.6.1 Tube Leak Repairs Spare Parts Quantity Comments
1. Refer to Manufacturers instruction manual for Tube Plugs 10% of To include
specific repair sequence recommendations. tube count special welding
2. Isolate heater from operating systems and allow supplies if welded
to cool down to safe working temperature. If plugs are used.
valves leak, keep heater out of service until Bolting:
unit can be taken off the line. Refer to Manway Cover, 10% of A set implies a
Paragraph A3.4 concerning safety precautions. Channel Cover, or Sets bolt and nut.
3. Record tube failure location by establishing all Pass Partition
the data listed below which will permit an early Cover
diagnosis of potential failure modes. A layout Gaskets 2 Sets This set should
of the tube pattern is usually provided in the include gaskets
instruction manual for this purpose. for pass partition
The data to be recorded is: row number, tube cover.
number, inlet or outlet tube leg, and longitudinal NOTE: Proper
failure location with respect to the tubesheet storage procedures
face. This can be done by pressurizing the shell must be observed
side with nitrogen at 10 psig maximum and by since some gasket
inserting a plug along the length of the tube and materials can
observing changes in the direction of flow. Eddy deteriorate in a
current devices may also be used. Proper safety short time if
precautions shall be observed when working in improperly stored.
the presence of nitrogen. Diaphragm (if used) 1 Set Including special
4. Defective tube welds can be repaired by follow- welding supplies if
ing the Manufacturers instructions. required.
Accessories As recommended by

5. Failed tubes can be plugged with tapered
(when supplied the accessory
drive plugs when tube joint is mechanically
by the heater manufacturer.
expanded only. Welded tube joints must be
Manufacturer)
plugged by the installation of a welded tube
Pass Partition Nuts 1 Set
plug or specialty plug as recommended by the
Manufacturer.
6. Tubes that are ruptured completely in two must A3.7.2 Special Tools
be anchored as recommended by the Manu The recommended special tools for feedwater heaters
facturer prior to plugging the tube ends. are listed below:
7. Leak testing and hydrostatic testing of the repair Special Tools Typical Quantity Comments
should be in accordance with the Manufacturers
recommendations. Tube 1 set roller Drivers optional
8. Specifications for feedwater heaters should Expanders expanders for Spare rolls
require that tube plugging procedures be includ- each tube optional
ed in instruction manuals. diameter
and gage
A3.6.2 Pressure Boundary Repairs
1. The recommendation of the Manufacturer A3.8 Inspection
should be solicited when this type of repair is Feedwater heaters should be inspected periodi-

contemplated. cally to reveal any evidence of corrosion or other
2. Any repair or penetration of the heater pressure a b n o r m a l c o n d i t i o n s w h i ch m ay a f f e c t t h e
boundary should be reviewed with the local performance and life of the equipment.
Authorized Inspection Agency servicing the
plant site prior to the repair. Approval of the A3.9 Alterations or Repairs
repair method by the Authorized Inspector is It is recommended that any alterations or repairs
necessary to preserve the integrity of the vessel which may become necessary during installation, test-
as an ASME Code approved pressure vessel. ing or operation be made under the Manufacturers
direction and in accordance with his recommendations.
A3.7 Spare Parts and Special Tools
The following list of typical spare parts and spe-
cial tools should be considered by the Purchaser of
feedwater heaters. The specific parts and quantities
should be listed in the specifications. In the prepara-
tion of the specification the Purchaser should consider
pre-operational and post-operational spares.
47
APPENDIX B
GENERAL FEEDWATER HEATER INFORMATION
B1 Vertical Feedwater Heaters heater shells, which basically have less free surface
The majority of feedwater heaters are installed in area within the confines of the cross section of the
a horizontal position. However, some users prefer a shell I.D., may require a 1/2 inch damping orifice in
vertical installation since less floor space is required. the bottom equalizing leg to increase the effective
The channels can be either above or below the shells capacitance. The damping orifice will reduce the effect
with most installations using the channel below the of short rapid level fluctuations but will not affect
shell, commonly called channel down. This design level trends. In this manner the small capacitance of
enables the plant designer to run the feedwater piping the vertical heater becomes more effective. The cross
between the heaters at a lower, more consistent eleva- sectional area of the vertical channel down heater
tion and shell removal may be somewhat simplified. shell may be enlarged to increase capacitance as
If the channel is above (channel up), the tube bundle required and shown in Fig. No. 39. Capacitance of a
must be removed, necessitating breaking the major vertical heater can also be increased by increasing the
connections and handling heavier parts to gain similar level control range from a minimum of 2" to 3" or
access. In either of the vertical heater configurations 4" or as required to satisfy drain flow of the heater.
complete tube bundle access may be more difficult than As this control range is increased consideration
in the case of horizontal heaters. should be given to increasing the float of the controller
Other considerations for vertical heaters involve to longer float lengths.
proper distribution of steam and condensate within As the level is dropped in a vertical channel down
the shell. In some designs the condensate will fall like heater, the point is reached where the indicated level
rain from the tube supports while steam usually rises coincides with the top of the draincooler shroud.
against the flow. A means of separation is required to This point must be indicated on the gage glass and
preclude the steam flow from holding up the conden- also on the level indication in the control room. The
sate with a resulting slugging or surging which could heater should never be operated below this point since

result in heater vibration, hydrodynamic instability, control of drain flow through the subcooler and the
and impaired thermal performance. normal drain outlet piping would be completely lost.
In vertical channel down feedwater heaters, the All of the above considerations should be evaluated
desuperheating zone must be longer than the drain by the Purchaser against the advantages described in
subcooling zone to prevent flooding and possible water the first paragraph.
backflow to the turbine. This may require an inac-
tive tube section below the desuperheating zone and/ B2 Cycling and Off Load Conditions
or thermal limitations to the design such as reduced Since the performance of a feedwater heater is
subcooling and no desuperheating. guaranteed at one specific design point condition
A channel down feedwater heater with a drain (refer to Paragraph 2.1), other possible operating
subcooling zone and no desuperheating zone requires conditions, referred to as off load conditions, must be
flooded, ineffective surface alongside the drain evaluated by varying some of the terminal conditions
subcooling zone. A channel up heater with a drain in order to predict the possible performance for the
subcooling zone requires a full length section to accom- same heater design. This is more common with cycling
plish a siphon-type lifting of the condensate. Part-load units, which vary load with demand rather than base
operation must be considered to assure sufficient pres- units, which typically meet a constant load. Cycling
sure differential with the downstream heater to lift the makes it difficult to optimize heater design since
drains without flashing. System upsets which break limits on velocities and pressure drops, for example,
this siphon can occur, and it should be recognized that must be checked for worst case conditions, which
reestablishing the siphon is difficult, if not impossible, can alter the design significantly. One major area of

without a shutdown. Either flashing or breaking the concern with cycling is when a desuperheating zone
siphon could result in a vapor-water mixture with is used. Developing a design to prevent wet tubes at
resulting tube erosion and vibration. all required conditions is often very difficult. (Refer
Water level control becomes more critical in ver- to Paragraph B4.1)
tical channel down heaters, especially those with Plant cycling can be detrimental to existing equip-
desuperheating zones since there is less capacitance ment because, until recently, most equipment was not
(storage volume per inch of water level) available. designed to accommodate the fatigue effects of daily
This may require a larger diameter shell or a greater thermal and mechanical cycles.
level control band. Generally, more sophisticated level
control systems are required to compensate for low
capacitance. B3 M
aterial Compatibility in Operating
As shown in Fig. No. 39, vertical feedwater heaters Environments
present a unique level control requirement. Unlike Tubing is protected from chemical attack as the
horizontal heaters, which have a large surface area at result of passivation, the or the formation of protective
the condensate-vapor interface, vertical channel down films. If the integrity of the film is destroyed, the base
48
FREE SURFACE AREA FOR SHELL LIQUID LEVEL CONTROL

Fig. No. 39
material may enter into solution, gradually reducing B3.1 Compatibility of Tube Materials
the wall thickness. Each tube material has a pH range When selecting tube materials for mixed systems

within which chemical attack on the protective films (different alloys in the feedwater heaters and surface
or on the base material is minimized. Certain envi- condensers), the chemistry (specifically pH) of the con-
ronments enhance the formation of protective films. densate system is of primary importance and must be
Chemical additives which are introduced to main- considered.
tain proper feedwater quality can break down, produc- The mechanism of failure will be peculiar to the
ing gases that are corrosive to some tube materials. specific alloy proposed and will involve the following
Control of pH alone is not necessarily a true represen- for indicated alloys. Corrosion of copper-based alloys
tation of the gas content. The operator must assure will eventually result in the copper pickup plating
that proper measurement of corrosion-producing out in the system (turbine, etc.), while carbon steel
gases is obtained to assure good water chemistry. In erosion-corrosion problems can cause tube failures
addition to pH control, it is recommended that electri- (especially at tube inlets and drain cooler inlet area
cal resistivity also be checked.
on the shell side). The optimum pH required to con-
The tubing material must be selected in conjunc-
trol copper-base material problems is not the same as
tion with other materials used in the system. Early
that required for carbon steel, and this is the basis of
failures result from lack of consideration of the com-
the problem. For example, carbon steel alloys require
patibility of the various system materials that must
operate in a common environment. a pH of about 9.5, while the corresponding pH for
During the life of a generating unit, advances are copper-base materials is between 8.8 and 9.0. In a mixed
made in chemical treatment of feedwater. Before system, a compromise pH level, usually in the range of
adopting new technologies, the system materials 9.2, would be selected.
should be reviewed to determine whether or not the If stainless steel tubes are used with carbon steel

new treatment will be compatible. For example, the tubes, a pH of 9.5 is often maintained.
change from solids treatment to volatile treatment The above mentioned pH levels provide the
has resulted in rapid attack of some types of feedwa- normally selected values for some materials and
ter heater tubing. mixed systems; however, these are only examples. It is
Heaters removed from service for relatively long recommended that the user consult a chemist to deter-
periods of time are sometimes filled with treated mine the pH level best suited for their system when
water. These additives should also be reviewed for considering all parameters.
compatibility with the tubing. Chemical cleaning In addition to pH, there are other parameters to
solutions should be carefully reviewed for compat- consider in reducing potential metallurgical problems
ibility as well as complete drainage and flushing in tubing (e.g. velocity, temperature, oxygen content,
requirements. chloride level, etc.); therefore, the particular station
The responsibility for the operating environment chemistry, and history of any tube problems, must be
is with the user. For this reason, the user is respon- considered in the analysis. Some of the operating param-
sible for the initial material selection and material eters may not be able to be changed to accommodate
compatibility with the intended environment. alloy selection, but their effect upon specific alloys
must be considered in the selection process.
49
B4 S
pecific Zone Designs (See Figures in It must be recognized, however, that the dry wall
Paragraph 9) safety margin varies with every set of operating con-
ditions. Check rating the optimized heater design at
B4.1 Desuperheating Zone other off design or off load conditions will show
Without a desuperheating zone, the feedwater can a range of varying safety margins, which could be
only approach the saturated steam temperature, but higher or lower than the minimum. The margin could
cannot equal or exceed it. Additional temperature rise even appear to be negative (i.e. producing wet tubes).
can be obtained by use of a desuperheating zone which This is not a concern with base-loaded units which
exchanges the sensible heat in the steam through operate at or near the design point continuously and
the influence of the large temperature difference may only experience wet tubes during infrequent
between the steam and the feedwater. Although the shut downs and restarts. The varying safety margin
heat transfer rate in a gas to liquid heat exchanger is is a concern, however, when units are subjected to
less than that in the condensing zone, the temperature cycling load operation that may occur on a continual
difference is much greater and, therefore, each basis.
square foot of surface in the desuperheating zone will Designing a heater for a minimum safety margin
transfer a significant amount of heat. at off load conditions may require decreasing the
Using a desuperheating zone permits heating of surface in the desuperheating zone to increase tube
the feedwater to a temperature higher than the shell wall metal temperature at the DSZ outlet. This will
side saturation temperature.When superheat is avail- result in a larger and more costly heater. It is difficult
able, the additional cost of a desuperheating zone is to design a heater to avoid wet tubes at all loads,
usually economically justifiable due to the cycle effi- as noted in paragraph B2; therefore, when units are
ciency improvement which is realized. subjected to cycling load operation, consideration
The use of a desuperheating zone is subject to some must be given to the potential for a less than opti-
limitations. First, the steam temperature at the exit mized heater design which may include minimized
of the zone must be sufficient to heat the exposed desuperheating zone length and options such as (a)
tubing to a temperature exceeding the condens- an increase in heater size to obtain full performance,
ing temperature. Secondly, there must be sufficient (b) optimized heater size but with decreased heater
heat in the entering steam to permit heating the performance or (c) elimination of the desuperheating
feedwater to the desired outlet temperature. zone with decreased heater performance, if design
The requirements on steam temperature leaving the temperatures allow.
desuperheating zone indicated above apply not only to
B4.2 Condensing Zone

design conditions. Other operating parameters should
be considered to avoid wet tube conditions. The condensing zone is the major internal sec-
The amount by which the tube wall metal tem- tion of all feedwater heaters. A large amount of tube
perature within the zone exceeds the saturated steam surface area, held in place by tube support plates,
temperature at the corresponding pressure is referred condenses all of the incoming steam and additional
to as dry wall safety margin. This should be a steam produced by flashing of incoming drains, if any.
minimum of 2F at the design point. In the process of condensing the steam, entrained
non-condensible gases must be continuously removed
B4.1.1 Dry Wall Safety Margins at DSZ Outlet in order to prevent blanketing of surfaces, result-
The condition known as wet tubes occurs when ing in loss of performance and corrosion (refer to
the tube wall metal temperature within the desu- Paragraph 2.13).
perheating zone is at or below the saturated steam B4.3 Subcooling Zone
temperature at the corresponding pressure (i.e. inlet
The use of a subcooling zone exchanges sensible
steam pressure minus desuperheating zone pressure
heat between the saturated condensate and the colder
drop) allowing steam to condense on the tube wall.
incoming feedwater. The drains outlet temperature
The lowest tube wall metal temperature within the
is subcooled below the saturation temperature of the
desuperheating zone occurs at the shell side outlet
condensate, thus reducing the potential for flashing
of the zone; therefore, if the tube wall temperature is
and erosion in piping and valves.
designed to be at some safety margin value above
When the shroud of the subcooling zone is exposed
the saturated temperature at the desuperheating zone
to the steam within the shell, a certain amount of

outlet, the tube wall at the outlet as well as throughout
heat is transferred from the hotter steam through the
the entire desuperheating zone will remain dry.
shroud to the colder condensate within the zone. This
Since steam velocities within the desuperheating
is referred to as reheat since it is adding heat back
zone are relatively high, it is important to avoid any
into the condensate, which is being cooled. A calcula-
condensation of the steam on the outside of tubes
tion is done to produce a corrected MTD which adds
within the desuperheating zone because entrained
in additional surface area to compensate for the added
water droplets at high velocity can cause major
duty. Shrouds which are covered with saturated
damage. A calculation for dry wall safety margin
condensate in the shell, referred to as flooded zones,
at the desuperheating zone outlet is performed at
have much less reheat since the transfer of heat is
the optimized design point condition. The designer
lower for liquid than condensing vapor. The only
can adjust the margin by changing the superheated
way to obtain no reheat is through the use of an
steam outlet temperature and pressure drop of the
external drain cooler.
desuperheating zone to obtain the desired minimum
A frequently requested optional feature is a drains
safety margin value and optimized heater design at
subcooling zone by-pass, or emergency dump con-
the design point condition.
50
nection on the shell. If significantly large shell side B6 Manway Sizes for Hemispherical Heads
overload conditions are possible that require conden- From an accessibility standpoint, it is obviously
sate dumping, this allows condensate to be removed desirable to make the manway as large as possible,
directly from the shell without passing through the but there are size, weight, and economic consequences
subcooling zone, thus reducing the restriction to flow to consider.
and decreasing the potential for mechanical damage An optimum choice for most purposes is an 18"
to the zone. The emergency dump connection should I.D. if it is round, or an 18" x 14" opening if it has an
be at least as large as the normal drains outlet. obround profile. There are a number of older heaters
that have been built with smaller openings, such as
B5 Heaters Removed from Service 16" I.D., but access into them is usually difficult.
Todays large installations frequently require more Larger sizes (such as 20" or 24") may seem desir-
than one stream, so that heaters operate in parallel able, but can be very costly, as these sizes often
as well as in series. When one of the parallel heaters require an enlargement of the hemispherical head,
is isolated for maintenance, the total stream may flow which also affects the tubesheet thickness. The fea-
through the remaining heaters unless by-passes are sibility of larger sizes depends on the bundle size,
provided or load limitations are imposed. the design pressure, as well as the orientation of the
Feedwater heater piping systems, valves, and the nozzles and manway. For the configuration of Fig. No.
feedwater heater itself shall be designed with con- 22 of Paragraph 8.2.3 (which includes the majority of
sideration given to the fact that the steam flow to a hemispherical head designs), the head size is particu-
feedwater heater will increase when a parallel heater larly sensitive to the manway size. For the low pres-
or stream is removed from service. sure hemispherical head of Fig. No. 20, Paragraph
The increase in steam flow is related to the thermal 8.2.2, or the hemi-plus-barrel design shown in Fig.
effectiveness which is defined as: No. 24 of Paragraph 8.2.3, the sensitivity is less.
t t1 Dt2 1 In a retrofit situation, where there are limitations
P = 2 =1 = 1 on space, it may be impossible to use a manway with
Ts t1 Dt1 eUA/WC
an I.D. of 20" or larger without increasing the feedwa-
Where: ter nozzle projection or in the case of vertical heaters,
t2 5 condensing zone outlet temperature, F relocating structural members.
t1 5 condensing zone inlet temperature, F In the case of feedwater heaters designed for new
power plants, where the diameter is not limited,
TS 5 saturated steam temperature, F
then the economics may be the main consideration in

Dt2 5 condensing zone outlet temperature determining the manway size. If an access opening
difference 5 TS2 t2, F diameter greater than 20" is selected, consideration
Dt1 5 condensing zone inlet temperature should be given to a configuration other than hemi-
difference 5 TS2 t1, F spherical.
U 5 heat transfer rate, Btu/hr-ft2-F
B7 Integral Flash Chamber Considerations
A 5 heating surface, ft2
Integral flash chambers are shell extensions
W 5 feedwater flow, lbm/hr beyond the U-bends for flashing drains inlets. They
C 5 feedwater heat capacity, Btu/lbm-F are unique to horizontal feedwater heaters and come
in varying designs. Fig. No. 40 shows just one possible
arrangement. The purpose of integral flash cham-
Each feedwater heater system is unique; however,
bers is to conservatively allow for the introduction
typical changes in steam flow are given in the Table VIII
of flashing drains into the heater. The empty space
below. (Note: as indicated, the multipliers are typical
behind the U-bends allows for maximum entrance
only for a specific design and should not be used as
area to disperse the kinetic energy of the flashing
the basis of design performance.)
drains and minimizes any droplet entrainment of the
STEAM FLOW MULTIPLIER flashing steam as it enters the tube bundle. Integral
(One stream to be removed) flash chambers may also be lined with stainless steel
Design Condensing material depending on design. The result is a reduced
Zone Thermal Original Streams potential for damaging tube vibrations, erosion, and

Effectiveness 2 Streams 3 Streams in some rare cases reduced condensing zone perfor-
mance due to flooding of the condensing zone tubes.
.88 1.58 1.33 One should consider an integral flash chamber if one
.90 1.61 1.35 of the following conditions occur:
.92 1.64 1.36 Experience with previous equipment in a similar
.94 1.67 1.38 service indicates additional protection for the inlet
drains is required.
Table VII
The system designer shall determine the specific

steam flow multiplier for his system upon selection
of his feedwater heaters.
51
A large quantity of inlet drains being introduced equipment into the turbine occurs mainly due to
into the feedwater heater. One typical installa- problems arising during start-up and shut-down and
tion that experiences large drain inlet flows is is often associated with once through flow steam
nuclear power stations. generator units. Feedwater heaters however can also
Excessive kinetic energy being released due to the become a source of water ingress during operational
percentage of flashing of the incoming drains and periods when tubes rupture, or when normal drains
the configuration of the shell and bundle. As a back up, if the appropriate bypass mechanisms are
minimum, G2/r as defined in Paragraph 2.8.c should not in place. An additional source of water that needs
always be less than 4,000 for the entrance area. to be considered in the design of the bypass is the
Based on the design, this may require an integral cascading of drains that typically occurs from higher
flash chamber. to lower pressure heaters. It is recommended that
mechanisms be in place that will isolate all of these
Before specifying an integral flash chamber, one sources of water.
should consider the following factors: Two suggested external system arrange-
Only horizontal heaters may have an integral flash ment options are provided in the ASME TDP-1
chamber. Vertical heaters would require a separate Recommended Practices for The Prevention of Water
external flash-pot arrangement. Damage To Steam Turbines Used for Electric Power
Integral flash chambers take up additional shell Generation to achieve this goal. The first option would
length. An integral flash chamber would result in be provision of a bypass in the Primary drain line
a larger tube bundle and shell if the heater length from the heater as well as automatic isolation of the
were limited. This may cause further shell and steam extraction to the heater. The second option pro-
channel piping changes for a replacement heater. vided mainly for condenser neck heaters would be to
At minimum, the piping location for the drains inlet isolate the tubeside flow in place of the extraction line
line would change. isolation in the first option. Schematics for both of
these arrangements can be found in the ASME TDP-1.
The level control is integral to all of these suggested
arrangements. With heaters that have drains cooling
zones level controls are provided to maintain adequate
height above the entrance to the drains cooling zone in
addition to monitoring high levels for possible liquid
ingress into the turbine. Location and accurate level

indication are critical to the prevention of damage
to the heater and turbine. Additional guidelines are
described in Paragraphs A2.2 thru A2.6 and in addi-
tion the OEM should be consulted on specific heater
designs.
INTEGRAL FLASH CHAMBER Also with respect to heaters having inte-
gral drains cooling zones, an additional emer-
Fig. No. 40 gency bypass can be located on the feedwater
B8 Floating Pass Partitions heater itself. A suggested schematic is shown in
Floating pass partitions are a design concept to Fig. No. 41. The nozzle should be located in an area
aid in minimizing the temperature effects due to the that will facilitate drainage. Due to the variety of
temperature difference of the incoming fluid versus configurations the final location should be discussed
the outgoing fluid. This design is generally not used with the OEM. The connection should be sized to 4 ft/
in feedwater heaters as the temperature rise in low sec maximum liquid velocity at operating conditions.
pressure heaters is in the 50 degree F. range and in On Fig. No. 41, level connections for normal opera-
high pressure heaters is in the 100 degree F. range. tion and for emergency dump are shown separately.
Feedwater heater manufacturers have standards If the same level stand is used the level should be
for the utilization of floating pass partitions that located as close to the drains cooling inlet area as
have been established through experience and/or possible so that proper level readings for the inlet
analysis. The Manufacturer will determine whether are obtained.
a floating pass partition design is warranted based on
Although Fig. No. 41 is for horizontal heaters,
the information provided by the purchaser as recom- an additional emergency bypass can be beneficial
mended in Paragraphs 2.1.1 and 2.1.2. to a Vertical Head Up (VHU) heater also. In those
Concern for weld fatigue of pass partitions under VHU heaters with an integral drains cooling zone,
normal and cyclic operation has been minimized due the condensate must be pushed upward from the
to todays weld techniques, joint geometry and addi- bottom of the shell to the drains outlet just below
tional non-destructive examination. the tubesheet. Under low load conditions, a reduced
pressure condition in the shell, in addition to a pos-
B9 Emergency Liquid Bypass for Feedwater sible lower differential pressure with the next shell,
Heaters can cause the water level to rise within the shell. In
The main function of shell side liquid by-pass con- addition to loss of performance due to flooding surface,
nections on feedwater heaters is to prevent water there is a potential for the water level to rise to the
from flooding and damaging associated components height of the steam inlet nozzle. A drains bypass can
connected to the heater like vents and most impor- be located in the bottom of the shell or shell cover for
tantly the steam turbine. Water induction from plant this specific design.
52
A further note should be made on the capacitance Gasketed Closures

of Vertical Head Down (VHD) Feedwater heaters. As
a result of the arrangement of VHD heaters the avail- Advantages:
able volume to be filled (capacitance) before water Quick access for maintenance crews.
enters the steam inlet is much less than in horizontal Requires no burning, grinding, or welding
heaters. For this reason the drains by-pass connec- operations.
tion is important in protecting from drains flowing
into the DSZ and ultimately the turbine. Disadvantages:
More subject to leakage than a welded
diaphragm.
Generally requires larger bolting.
Generally results in larger channels.
Higher initial capital cost.
Welded Diaphragm Closures
Advantages:
Less subject to leakage than a gasketed
closure.
Generally requires smaller bolting.
Generally results in smaller channels.
Lower initial capital cost.
Disadvantages:
Longer access times required for maintenance
crews.
Requires burning and/or grinding along with
welding operations.
EMERGENCY BY-PASS TO PREVENT Safety Issue Care must be taken to prevent
WATER DAMAGE TO TURBINE FOR HEATERS pressurization of the channel side without the

WITH DRAINS COOLING ZONES. channel cover (properly bolted) in place.
(ADAPTED FROM ASME TDP-1 - 1998)
Fig. No. 41 B11 Drains and Vents for Heaters
Every Closed Feedwater Heater should be properly
B10 High Pressure Closures: designed with drain ports and vent ports where there
Gasketed vs. Welded Diaphragm is possible accumulation of drains and non-condens-
The selection between gasketed or welded dia- able gases at any location.
phragm closures is usually a matter of preference for The specific number of drains and vents will
plant maintenance personnel. These preferences are depend on the particular configuration of the
individually derived from plant experiences. Both clo- heater. Normally, the shell side drain ports and
sures are acceptable for most channel arrangements; tube side vent ports in a Vertical Channel Down
i.e. full access and manway access. Option A & Option heater, for example, can be best located at the
B in Paragraph 8.2.3 are typical arrangements for tubesheet (provided that the tubesheet is thick
these closures. enough to accommodate the hole area). Careful
Gasketed closures may be limited by bolting for consideration must be given to the location of the
certain arrangements due to channel design pressure Desuperheating Zone drain connection to avoid any
and/or the channel ID opening. entrapment of condensate that may cause flashing
when steam is introduced.
It is also worth knowing that the design and
operation of external drains and vent piping are

significant factors in the performance of the total
draining and venting systems of closed feedwa-
ter heaters. The following are some recom-
mended external piping arrangement for closed
Feedwater heaters.
53
54
Fig. No. 42
(Vertical Channel Down Only)
(Horizontal with Side Outlet or Vertical Channel Down)

RECOMMENDED SCHEMATIC PIPING ARRANGEMENT FOR FEEDWATER HEATERS
55
(Vertical Channel Up Typical)
Fig. No. 42 Continued
RECOMMENDED SCHEMATIC PIPING ARRANGEMENT FOR FEEDWATER HEATERS
APPENDIX C REFERENCE DATA
C-1 METRIC CONVERSION FACTORS

NOMENCLATURE
NAME SYMBOL OTHER UNITS
inch/inches in
foot/feet ft
meter (SI) m
millimeter mm
square inch in2
square foot ft2
square meter (SI) m2
square centimeter cm2
square millimeter mm2
cubic inch in3
cubic foot ft3
gallon (US liquid) gal
cubic meter (SI) m3
liter L
pound mass (avoirdupois) lbm
kilogram (SI) kg
pound force (avoirdupois) lbf
kilogram force kgf
newton (SI) N m z kg/s2
degree Fahrenheit F
kelvin (SI) K Note 5.

degree Celsius (SI) C Note 5.
British thermal unit
(International Table) Btu
kilocalorie
(International Table) kcal
joule (SI) J N z m, m2 z kg/s2
kilojoule kJ
second (customary) sec
second (SI) s
minute min
hour (customary) hr
hour (metric) h
watt (SI) W J/s, N z m/s, m2 z kg/s3
megawatt MW
pound force/square inch psi lbf/in2
inches of mercury in Hg
feet of water ft H O

2
pascal (SI) Pa N/m2, kg/(m z s2)
kilopascal kPa
bar bar
millimeter of mercury mmHg
torr torr
centipoise cp
Notes:
1. (SI) Denotes an International System of Units unit.
2. Pressure should always be designated as gage or absolute.
3. The acceleration of gravity, g, is taken as 9.80665 m/s2.
4. One gallon (U S liquid) equals 231 in3.
5. For temperature interval, 1K = 1C exactly.
56
APPENDIX C-1 Continued
PREFIXES DENOTING DECIMAL MULTIPLES OR SUBMULTIPLES

PREFIX SYMBOL MULTIPLICATION FACTOR
micro m 0.000 001 5 10-6
milli m 0.001 5 10-3
centi c 0.01 5 10-2
deci d 0.1 5 10-1
deca da 10 5 101
hecto h 100 5 102
kilo k 1 000 5 103
mega M 1 000 000 5 106
giga G 1 000 000 000 5 109
CONVERSION FACTORS
LENGTH
MULTIPLY BY TO OBTAIN
in 2.540 3 10-2 m (SI)
in 2.540 3 101 mm
ft 3.048 3 10-1 m (SI)
ft 2.540 3 102 mm
AREA
in2 6.451600 3 10-4 m2 (SI)
in2 6.451600 3 102 mm2
ft2 9.290304 3 10-2 m2 (SI)

ft 9.290304
2
3 104 mm2
VOLUME
in3 1.638706 3 10-5 m3 (SI)
in3 1.638706 3 10-2 L
ft 2.831685
3
3 10-2 m3 (SI)
ft 2.831685
3
3 101 L
gal 3.785412 3 10-3 m3 (SI)
gal 3.785412 L
MASS
lbm 4.535924 3 10-1 kg (SI)
FORCE
lbf 4.448222 N (SI)
lbf 4.535924 3 10-1 kgf

kgf 9.806650 N (SI)
TEMPERATURE
K 5 (F 1 459.67)/1.8 K 5 (C 1 273.15) (SI)
C 5 (F 2 32)/1.8 C 5 ( K 2 273.15) (SI)
F 5 1.8 C 1 32 F 5 1.8 K 2 459.67
ENERGY, WORK OR QUANTITY OF HEAT

Btu 1.055056 3 103 J (SI)
Btu 2.519958 3 10-1 kcal
ftzlbf 1.355818 J (SI)
ftzlbf 3.238316 3 10-4 kcal
57
POWER (ENERGY/TIME)
Btu/hr 2.930711 3 10-1 W (SI)
Btu/hr 2.930711 3 10-7 MW (SI)
Btu/hr 2.519958 3 10-1 kcal/n (SI)
PRESSURE OR STRESS (FORCE/AREA)

psi 6.894757 3 103 Pa (SI)
psi 6.894757 kPa
psi 6.894757 3 10-2 bar
psi 7.030696 3 10-2 kgf/cm2
lbf/ft 4.788026
2
3 101 Pa (SI)
lbf/ft 4.788026
2
3 10-2 kPa
lbf/ft
2
4.882428 kgf/m2
inHg (32F) 3.38638 3 10 Pa
3
(SI)
inHg (32F) 3.38638 kPa
inHg (32F) 3.38638 3 10-2 bar
inHg (32F) 3.45315 3 10-2 kgf/cm2
inHg (32F) 2.540 3 101 mmHg
torr (0C) 1.33322 3 102 Pa (SI)
torr (0C) 1.0 mmHg
ftH2O (39.2F) 2.98898 3 103 Pa (SI)
ftH2O (39.2F) 2.98898 kPa
ftH2O (39.2F) 3.047915 3 102 kgf/m2

VELOCITY (LENGTH/TIME)
ft/sec 3.048000 3 10-1 m/s (SI)
ft/min 5.080000 3 10-3 m/s (SI)
MASS FLOW RATE (MASS/TIME)

lbm/hr 1.259979 3 10-4 kg/s (SI)
lbm/hr 4.535924 3 10-1 kg/h
VOLUME FLOW RATE (VOLUME/TIME)

ft3/min 4.719474 3 10-4 m3/s (SI)
ft3/min 1.699011 m3/h
gal/min 6.309020 3 10 -5
m3/s (SI)
gal/min 2.271247 3 10 -1
m3/h
gal/min 3.785412 L/min

MASS VELOCITY (MASS/TIME-AREA)
lbm/(hr z ft2) 1.35623 3 10-3 kg/(s z m2) (SI)
lbm/(hr z ft2) 4.882428 kg/(h z m2)
lbm/(sec z ft )
2
4.882428 kg/(s z m2) (SI)
SPECIFIC VOLUME (VOLUME/MASS)

ft3/lbm 6.242797 3 10-2 m3/kg (SI)
ft3/lbm 6.242797 3 101 L/kg
gal/lbm 8.345406 3 10-3 m3/kg (SI)
gal/lbm 8.345406 kg/L L/kg
58
DENSITY (MASS/VOLUME)
lbm/in3 2.767990 3 104 kg/m3 (SI)
lbm/in3 2.767990 3 101 kg/L
lbm/ft3
1.601846 3 101 kg/m3 (SI)
lbm/ft3 1.601846 3 10-2 kg/L
lbm/gal 1.198264 3 102 kg/m3 (SI)
lbm/gal 1.198264 3 10-1 kg/L
ENTHALPY (ENERGY/MASS)
Btu/lbm 2.326000 3 10 J/kg
3
(SI)
Btu/lbm 2.326000 kJ/kg
Btu/lbm 5.555556 3 10-1 kcal/kg
HEAT CAPACITY AND ENTROPY (ENERGY/MASS-TEMPERATURE)

Btu/(lbm z F) 4.186800 3 103 J/(kg z C) (SI)
Btu/(lbm z F) 4.186800 kJ/(kg z C)
Btu/(lbm z F) 1.000000 kcal/(kg z C)
THERMAL CONDUCTIVITY (ENERGY-LENGTH/TIME-AREA-TEMPERATURE)

Btu z in/(hr z ft2 z F) 1.442279 3 10-1 W/(m z C) (SI)

Btu z in/(hr z ft2 z F) 1.240137 3 10-1 kcal z m/(h z m2 z C)
Btu z ft/(hr z ft2 z F) 1.730735 W/(m z C) (SI)
Btu z ft/(hr z ft2 z F) 1.488164 kcal z m/(h z m2 z C)
DYNAMIC VISCOSITY (MASS/TIME-LENGTH OR FORCE-TIME/AREA)

cp 1.000000 3 10-3 Pa z s (SI)
cp 1.000000
mPa z s
lbm/(hr z ft) 4.133789 3 10-4 Pa z s (SI)
lbm/(hr z ft) 4.133789 3 10-1 cp
lbm/(sec z ft) 1.488164 Pa z s (SI)
lbm/(sec z ft) 1.488164 3 103 cp
lbf z sec/ft2 4.788026 3 101 Pa z s (SI)
lbf z sec/ft 4.788026
2
3 10 4
cp
HEAT FLUX DENSITY (ENERGY/TIME-AREA)

Btu/(hr z ft2) 3.154591 W/m2 (SI)

Btu/(hr z ft2) 2.712460 kcal/(h z m2)
HEAT TRANSFER COEFFICIENT (ENERGY/TIME-AREA-TEMPERATURE)

Btu/(hr z ft2 z F) 5.678263 W/(m2 z C) (SI)
Btu/(hr z ft z F)
2
4.882428 kcal/(h z m z C)
2
FOULING RESISTANCE (TIME-AREA-TEMPERATURE/ENERGY)

hr z ft2 z F/Btu 1.761102 3 10-1 m2 z C/W (SI)
hr z ft z F/Btu
2
2.048161 3 10-1
h z m2 z C/kcal
59
60
APPENDIX C-2 AREASOFCIRCULARSEGMENTS
ASMESection II, Part D
61
APPENDIX C-3
MODULUS OF ELASTICITY E OF MATERIALS FOR GIVEN TEMPERATURES
ASMESection II, Part D
62
MODULUS OF ELASTICITY E OF MATERIALS FOR GIVEN TEMPERATURES
Thermal Conductivity k, Btu-ft/hr-ft2-F for Temp F of

70 100 150 200 250 300 350 400 450 500 550 600 650 700
Carbon Steel
ASME SA-214, UNS K01807 (Welded) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-557-A2, UNS K01807 (Welded) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-557-B2, UNS K03007 (Welded) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-557-C2, UNS K03505 (Welded) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-179, UNS K01200 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-210 A-1, UNS K02701 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-210-C, UNS K03501 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-556-A2, UNS K01807 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-556-B2, UNS K02707 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
ASME SA-556-C2, UNS K03006 (SMLS) 30.0 29.9 29.6 29.2 28.9 28.4 28.0 27.6 27.1 26.6 26.1 25.6 25.1 24.6
Copper and Copper Alloys

Arsenical Copper - DPA
ASME SB-395, UNS C14200 (SMLS)) 112
Admiralty Metals - B/C/D (SMLS)
ASME SB-395, UNS C44300, C44400, C44500 64.0 65.4 67.7 70.1 72.4 74.7 77.1 79.4
70-30 Copper-Nickel
ASME SB-395, UNS C71500 (SMLS) 17.0 17.5 18.3 19.1 19.9 20.8 21.6 22.4 23.2 24.0 24.8 25.7 26.5 27.3
80-20 Copper-Nickel
ASME SB-395, UNS C71000 (SMLS) 21.0 21.5 22.3 23.1 23.9 24.7 25.5 26.3 27.1 27.9 28.7 29.5 30.3 31.1
90-10 Copper Nickel
ASME SB-395, UNS C70600 (SMLS) 26.0 26.9 28.4 29.9 31.5 33.0 34.5 36.0 37.5 39.1 40.6 42.1
63
Low Alloys
ASME SA-213 T11, UNS K11597 (SMLS) 25.8 25.9 25.9 25.8 25.6 25.4 25.2 24.9 24.6 24.2 23.8 23.4 23.0 22.6
APPENDIX C-4
ASME SA-213 T22, UNS K21590 (SMLS) 20.9 21.0 21.2 21.3 21.4 21.5 21.5 21.5 21.5 21.4 21.3 21.1 20.9 20.7
Nickel Alloys
70-30 Nickel-Copper 12.6 12.9 13.4 13.9 14.5 15.0 15.6 16.1 16.6 17.0 17.5 17.9 18.4 18.9
ASME SB-163, UNS N04400 (SMLS)
Stainless Steel - Austenitic

ASME SA-688 TP304, TP304L, TP304N 8.6 8.7 9.0 9.3 9.6 9.8 10.1 10.4 10.6 10.9 11.1 11.3 11.6 11.8
UNS S30400, S30403, S30451 (Welded)
ASME SA-688 TP316, TP316L 7.7 7.9 8.2 8.4 8.7 9.0 9.2 9.5 9.8 10.0 10.3 10.5 10.7 11.0
UNS S31600, S31603 (Welded)
ASME SA-249 TP316N, UNS S31651 (Welded) 7.7 7.9 8.2 8.4 8.7 9.0 9.2 9.5 9.8 10.0 10.3 10.5 10.7 11.0
ASME SB-676, UNS N08367 (Welded) 6.7 7.1 7.4 7.7 8.0 8.3 8.6 8.9 9.2 9.5 9.8 10.1
THERMAL CONDUCTIVITY OF MATERIAL FOR GIVEN TEMPERATURES
Stainless Steel - Ferritic

ASME SA-803 TP439, UNS S43035 (Welded) 12.3 12.5 12.6 12.8 12.9 13.1 13.3 13.4 13.6 13.8 13.9 14.1
29Cr-4Mo
ASME SA-268, UNS S44735 (Welded) 10.1 10.3 10.5 10.7 10.8 11.0 11.2 11.3 11.5 11.7 11.8 12.0
References: ASMESection II, Part D, 1995 Edition 1988 Tubular Exchanger Manufacturers Association
Allegheny Teledyne Incorporated Copper Development Association
APPENDIX C-5 MECHANICAL CHARACTERISTICS OF TUBING
Nominal External Nominal Nominal Trans-

Tube Surface BWG Thick- Tube Internal Ratio Constant Wt/Ft verse Moment of
OD per Ft. of Gauge ness ID Area OD/ID C* (Steel) Metal Inertia
(in) Tube (ft )
2
(in) (in) (in ) 2
(lbm/ft) Area (in ) (in4)
2
10 0.134 0.232 0.0423 2.155 66. 0.524 0.1541 0.002926

11 0.120 0.260 0.0531 1.923 83. 0.487 0.1433 0.002844
12 0.109 0.282 0.0625 1.773 97. 0.456 0.1339 0.002758
13 0.095 0.310 0.0755 1.613 118. 0.411 0.1209 0.002615
14 0.083 0.334 0.0876 1.497 137. 0.370 0.1087 0.002457
15 0.072 0.356 0.0995 1.404 155. 0.329 0.0968 0.002280
1
2 0.1309 16 0.065 0.370 0.1075 1.351 168. 0.302 0.0888 0.002148
17 0.058 0.384 0.1158 1.302 181. 0.274 0.0805 0.002001
18 0.049 0.402 0.1269 1.244 198. 0.236 0.0694 0.001786
19 0.042 0.416 0.1359 1.202 212. 0.206 0.0604 0.001598
20 0.035 0.430 0.1452 1.163 227. 0.174 0.0511 0.001390
21 0.032 0.436 0.1493 1.147 233. 0.160 0.0470 0.001294
22 0.028 0.444 0.1548 1.126 242. 0.141 0.0415 0.001160
10 0.134 0.357 0.1001 1.751 156. 0.703 0.2067 0.006693
11 0.120 0.385 0.1164 1.623 182. 0.648 0.1904 0.006412
12 0.109 0.407 0.1301 1.536 203. 0.601 0.1767 0.006143
13 0.095 0.435 0.1486 1.437 232. 0.538 0.1582 0.005733
14 0.083 0.459 0.1655 1.362 258. 0.481 0.1413 0.005311
15 0.072 0.481 0.1817 1.299 283. 0.426 0.1251 0.004863
5
8 0.1636 16 0.065 0.495 0.1924 1.263 300. 0.389 0.1144 0.004543
17 0.058 0.509 0.2035 1.228 317. 0.352 0.1033 0.004195

18 0.049 0.527 0.2181 1.186 340. 0.302 0.0887 0.003704
19 0.042 0.541 0.2299 1.155 359. 0.262 0.0769 0.003285
20 0.035 0.555 0.2419 1.125 377. 0.221 0.0649 0.002833
21 0.032 0.561 0.2472 1.114 386. 0.203 0.0596 0.002528
22 0.028 0.569 0.2543 1.098 397. 0.179 0.0525 0.002345
10 0.134 0.482 0.1825 1.556 285. 0.882 0.2593 0.012882
11 0.120 0.510 0.2043 1.471 319. 0.808 0.2375 0.012211
12 0.109 0.532 0.2223 1.410 347. 0.747 0.2195 0.011600
13 0.095 0.560 0.2463 1.339 384. 0.655 0.1955 0.010704
14 0.083 0.584 0.2679 1.284 418. 0.592 0.1739 0.009822
15 0.072 0.606 0.2884 1.238 450. 0.522 0.1534 0.008912
3
4 0.1963 16 0.065 0.620 0.3019 1.210 471. 0.476 0.1399 0.008278
17 0.058 0.634 0.3157 1.183 492. 0.429 0.1261 0.007601
18 0.049 0.652 0.3339 1.150 521. 0.367 0.1079 0.006661
19 0.042 0.666 0.3484 1.126 543. 0.318 0.0934 0.005874
20 0.035 0.680 0.3632 1.103 567. 0.268 0.0786 0.005036
21 0.032 0.686 0.3696 1.093 577. 0.246 0.0722 0.004661
22 0.028 0.694 0.3783 1.081 590. 0.216 0.0635 0.004145

pounds per tube per hour
*Liquid velocity in feet/second 5 Specific gravity of water at 60 deg. F 5 1.0
C 3 specific gravity of liquid
For weights of other materials, multiply carbon steel weights by the following factors:
90-10 CuNi UNS C70600 1.140 Nickel-Copper (Alloy 400) 1.126
70-30 CuNi UNS C71500 1.140 Nickel-Iron-Chrome (Alloys 800/800H) 1.013
Arsenical Cu UNS C14200 1.140 300 Series Stainless Steel 1.013
Admiralty UNS C44300 1.088
64
APPENDIX C-5 MECHANICAL CHARACTERISTICS OF TUBING - Continued
Nominal External Nominal Nominal Trans-

Tube Surface BWG Thick- Tube Internal Ratio Constant Wt/Ft verse Moment of
OD per Ft. of Gauge ness ID Area OD/ID C* (Steel) Metal Inertia
(in) Tube (ft ) (in) (in) (in )
2 2
(lbm/ft) Area (in ) (in4)
2
10 0.134 0.607 0.2894 1.442 451. 1.061 0.3119 0.022110

11 0.120 0.635 0.3167 1.378 494. 0.969 0.2846 0.020793
12 0.109 0.657 0.3390 1.332 529. 0.893 0.2623 0.019628
13 0.095 0.685 0.3685 1.277 575. 0.792 0.2328 0.017966
14 0.083 0.709 0.3948 1.234 616. 0.703 0.2065 0.016370
15 0.072 0.731 0.4197 1.197 655. 0.618 0.1816 0.014758
8
7 0.2291 16 0.065 0.745 0.4359 1.174 680. 0.563 0.1654 0.013653
17 0.058 0.759 0.4525 1.153 706. 0.507 0.1489 0.012484
18 0.049 0.777 0.4742 1.126 740. 0.433 0.1272 0.010882
19 0.042 0.791 0.4914 1.106 767. 0.374 0.1099 0.009558
20 0.035 0.805 0.5090 1.087 794. 0.314 0.0924 0.008161
21 0.032 0.811 0.5166 1.079 806. 0.288 0.0847 0.007539
22 0.028 0.819 0.5268 1.068 822. 0.254 0.0745 0.006689
10 0.134 0.732 0.4208 1.366 657. 1.241 0.3646 0.034994
11 0.120 0.760 0.4536 1.316 708. 1.129 0.3318 0.032711
12 0.109 0.782 0.4803 1.279 749. 1.038 0.3051 0.030731
13 0.095 0.810 0.5153 1.235 804. 0.919 0.2701 0.027957
14 0.083 0.834 0.5463 1.199 852. 0.814 0.2391 0.025339
15 0.072 0.856 0.5755 1.168 898. 0.714 0.2099 0.022732
1 0.2618 16 0.065 0.870 0.5945 1.149 927. 0.650 0.1909 0.020965
17 0.058 0.884 0.6138 1.131 957. 0.584 0.1716 0.019111

18 0.049 0.902 0.6390 1.109 997. 0.498 0.1464 0.016594
19 0.042 0.916 0.6590 1.092 1028. 0.430 0.1264 0.014529
20 0.035 0.930 0.6793 1.075 1060. 0.361 0.1061 0.012367
21 0.032 0.936 0.6881 1.068 1073. 0.331 0.0973 0.011411
22 0.028 0.944 0.6999 1.059 1092. 0.291 0.0855 0.010106
10 0.134 0.857 0.5768 1.313 900. 1.420 0.4172 0.052150
11 0.120 0.885 0.6151 1.271 960. 1.289 0.3789 0.048516
12 0.109 0.907 0.6461 1.240 1008. 1.184 0.3479 0.045409
13 0.095 0.935 0.6866 1.203 1071. 1.046 0.3074 0.041113
14 0.083 0.959 0.7223 1.173 1127. 0.925 0.2717 0.037110
15 0.072 0.981 0.7558 1.147 1179. 0.811 0.2382 0.033167
118 0.2945 16 0.065 0.995 0.7776 1.131 1213. 0.737 0.2165 0.030516
17 0.058 1.009 0.7996 1.115 1247. 0.662 0.1944 0.027750
18 0.049 1.027 0.8284 1.095 1292. 0.564 0.1656 0.024021
19 0.042 1.041 0.8511 1.081 1328. 0.486 0.1429 0.020982
20 0.035 1.005 0.8742 1.066 1364. 0.408 0.1199 0.017818
21 0.032 1.061 0.8841 1.060 1379. 0.374 0.1099 0.016423
22 0.028 1.069 0.8975 1.052 1400. 0.328 0.0965 0.014525

pounds per tube per hour
*Liquid velocity in feet/second 5 Specific gravity of water at 60 deg. F 5 1.0
C 3 specific gravity of liquid
65
66
APPENDIX C-6 MECHANICAL CHARACTERISTICS OF STEEL TUBING
APPENDIX C-7 CHART FOR SOLVING LMTD FORMULA
LESSER TERMINAL TEMPERATURE DIFFERENCE

GREATER TERMINAL TEMPERATURE DIFFERENCE
NOTE 1 For points not included on this sheet multiply Greater Terminal Temperature Difference and Lesser
Terminal Temperature Difference by any multiple of 10 and divide resulting value of curved lines
by same multiple.
NOTE 2 The determination of the LMTD must be done for each individual zone of a feedwater heater.
67
APPENDIX C-8.1 CLOSED FEEDWATER HEATER SPECIFICATION SHEET ENGLISH UNITS
Customer Date
Engineer/Consultant Cust. Ident. No.
Address Mfg. Ident. No.
Plant Name Proposal No.
Plant Location Job No.
01 Service of Unit Item No.
02 Size Type Prepared By
03 Surface Per Shell Effective Sq. Ft. Total Sq. Ft.
04 No. of Shells Per Unit No. of Units Position
PERFORMANCE OF ONE SHELL
Shell Side Tube Side
05 Fluid Circulated Steam Drains Feedwater
06 Total Fluid Entering #/HR.
07
08 Inlet Enthalpy BTU/#
09 Outlet Enthalpy BTU/#
10 Inlet Temperature F ( SAT.)
11 Outlet Temperature F
12 Operating Pressure PSIA
13 Number of Passes
14 Velocity FT/SEC Not Applicable
15 Pressure Drop PSI DSH DC
Surface Transfer Rate Reference
Heat Exchanged Sq. Ft. LMTD BTU/HR- Baffle Temperature
BTU/HR Effective F SQ. FT. - F Spacing Differences

16 Desuperheating Zone
TTD F
17 Condensing Zone
18 Drain Subcooling Zone DCA F
CONSTRUCTION EACH SHELL
19 Design Pressure PSIG
20 Test Pressure PSIG
21 Design Temperature F SHELL SKIRT
22 Minimum Design Metal Temperature F Shell Side Tube Side
23 Tubes No. (Us) (STR) O.D. BWG WALL (avg/min) Length
24 Shell Steel I.D. THICKNESS Pitch TRIANGULAR
25 Shell Cover Steel Welded to Shell Shell Skirt THICKNESS
26 Channel Steel Channel Cover Steel
27 Tubesheet Steel Overlay
28 Support Plates Steel Air Baffle Zone Baffle Steel
29 Shrouds: DSH DC Impingement Baffles
30 Type JointsShell Side Tube Side

31 Gasket-Shell Channel
32 Connections: Steam Inlet (W.E.) (FLGD) Drains Inlet (W.E.) (FLGD)
33 Drains Outlet (W.E.) (FLGD)
34 Feedwater Inlet (W.E.) (FLGD) Outlet (W.E.) (FLGD)
35 Code Requirements: ASME SECT. VIII DIV. Heat Exchange Institute
36 Weights Shell and Bundle Bundle Flooded
37 Accessories: Shell Relief Valve Tube Side Relief Valve
38 Shell Gage Glass
39 Method of Tube Attachment (Rolled) (Welded)
40 Remarks:
41
42
43
68
APPENDIX C-8.2 CLOSED FEEDWATER HEATER SPECIFICATION SHEET SI UNITS
Customer Date
03 Surface Per Shell Effective m2 Total m2
06 Total Fluid Entering Kg/s
07
08 Inlet Enthalpy kJ/Kg
09 Outlet Enthalpy kJ/Kg
10 Inlet Temperature C ( SAT.)
11 Outlet Temperature C
12 Operating Pressure (abs) kPa
13 Number of Passes
14 Velocity m/s Not Applicable
15 Pressure Drop kPa DSH DC
Surface Reference
Heat Exchanged m2 LMTD Transfer Rate Baffle Temperature
MW Effective C w/m2 C Spacing Differences

TTD C
17 Condensing Zone
18 Drain Subcooling Zone DCA C
19 Design Pressure kPag
20 Test Pressure kPag
21 Design Temperature C SHELL SKIRT
22 Minimum Design Metal Temperature C Shell Side Tube Side

38 Shell Gage Glass
40 Remarks:
41
42
43
69
APPENDIX C-8.3 CLOSED FEEDWATER HEATER SPECIFICATION SHEET MKH UNITS
Customer Date
03 Surface Per Shell Effective m2 Total m2
06 Total Fluid Entering Kg/h
07
08 Inlet Enthalpy kcal/Kg
09 Outlet Enthalpy kcal/Kg
10 Inlet Temperature C ( SAT.)
11 Outlet Temperature C
12 Operating Pressure (abs) kg/cm2
13 Number of Passes
14 Velocity m/s Not Applicable
15 Pressure Drop kg/cm2 DSH DC
Surface Transfer Rate Reference
Heat Exchanged m2 LMTD kcal/h - Baffle Temperature
kcal/h Effective C m2 - C Spacing Differences

TTD C
17 Condensing Zone
18 Drain Subcooling Zone DCA C
19 Design Pressure k/cm2g
20 Test Pressure k/cm2g
21 Design Temperature C SHELL SKIRT
22 Minimum Design Metal Temperature C Shell Side Tube Side

38 Shell Gage Glass
40 Remarks:
41
42
43
70
TROUBLESHOOTING GUIDE
APPENDIX D
This troubleshooting guide has been prepared to assist operators of closed feeedwater heaters. The guide provides
general guidance, and operators are advised to consult with the manufacturer when necessary for specific instruc-
tions regarding their equipment. Many of the items listed below are not in the scope of the heat exchanger manu-
facturer; however, these items do affect operation and must be considered by operators.
Please submit all questions and inquiries to the HEI at hei@heatexchange.org, or visit the HEI website at
www.heatexchange.org.
Symptoms Possible Causes Possible Solutions
Pass Partition Leaks Pass partition gasket failure Consult supplier for appropriate replace-
(Exhibited by reduced ment
feedwater temperature
rise, and higher TTD.) Pass partition nut failure due to Consult supplier over stud and nut
cycling operation material selections, and consider tack
welding replacement nuts, self locking
nuts, or tension controlled washers
Pass partition cracking due to cycling
Consult supplier over possible repairs
Water hammer or abnormal operating
conditions Make repairs as required and review
operating procedures
Erosion damage from feedwater inlet
nozzle Consult supplier and review pass parti-
tion plate material
Tube Failures Excessive tube vibration due to abnor-

mal operating conditions Correct abnormal conditions. Contact

supplier for reevaluation
Excessive tube vibration due to loca-
tion of connections Reevaluate connections for baffles,
shields, or impingement protection
Chloride attackstainless steel tub-
ing Review water chemistry and tube com-
patibility
Stagnant water during extended shut- Tubes may need to be rinsed and dried
down for extended shutdown.
Ammonia attackcopper alloy tubing Check with plant chemist
Maintenance or construction damage Plug or replace as required
Tube inlet erosion Check water flow and adjust to design.

Check water quality, especially suspend-
ed solids

Fluctuating or Malfunctioning level controller / con-
Unstable Liquid trol valves Check to ensure that level controller and
Levels control valves are functioning properly.
Ensure that control valves are correctly
Improper piping size sized
Check for any reduction in the conden-

sate outlet piping size that may cause a
Transient operating conditions restriction to flow
False instrumentation readings Evaluate after steady state is reached
Check calibration of instrumentation

(See Paragraph A2.4).
71
APPENDIX D - Continued
Symptoms Possible Causes Possible Solutions
Inadequate controller response for Check to ensure that level controller and
available capacitance (Vertical Head control valves are correctly selected to
Down) achieve specified level range with avail-
able capacitance. Check level controller
feedback gain setting.
Decreased Inspect and repair vent opening(s) and

Performance Due to Blocked air vents orifice plate(s) as required
Improper Venting
Calculate piping system air release and
Insufficient air vent piping capacity check vent size. Check that vent piping
area is greater than or equal to the com-
bined vent lines areas if manifolded.
Check that all startup vents are piped

Missing or unused startup vent line or and valves are being opened during start-
valves up and closed when operating.
Check that all orifice plates are located in

Improper vent piping a horizontal run of piping that is sloping
away from the heater and not trapping
condensate that could stop venting. Any
vertical piping run should have an appro-

priate drainer at the bottom.
Unusual Sounds:
Horizontal Heaters, Consult the supplier of the equipment for
Vertical Channel evaluation.
Down Heaters,
Vertical Channel Up Remove shell and repair weld
Heaters Weld failure in drains cooler shroud or
end plate
Open cooling zone start up vent or add
Air trapped in drains cooling zone additional vent in shell skirt section
Repair failed tube, check operating water

Condensate or feedwater entering level or check for functioning steam trap
desuperheating zone at desuperheater drain
Decreased Check to ensure liquid levels are being

Draincooler Low liquid levels properly maintained. Perform a Liquid

Performance-Higher Level Test as described in Paragraph A2.2
than expected DCA
Consult the supplier of the equipment for
Draincooler shroud damage possible repairs
Consult the supplier of the equipment for

Draincooler endplate damage possible repairs
Operating conditions other than the

Abnormal operating conditions Design Case will result in different
DCA readings
72
Heat Exchange Institute, Inc.
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HEI 2622-2015 Standard For Closed Feed Water Heaters PDF

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CLOSED FEEDWATER HEATERS

Heat Exchange Institute, Inc.

Standards for Direct Contact Barometric

Standards for Steam Jet Vacuum Systems,

Standards for Steam Surface Condensers,

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Standards for Gasketed Plate Heat

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Reproduction of any portion of this standard without written permission of the

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3.7.2.3 Support of U-Bends 13

4. MATERIAL DESIGN STANDARDS 23

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A2.3 Liquid Level Control in Vertical Channel Down Heaters 43

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Appendix C REFERENCE DATA 56

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Appendix D TROUBLESHOOTING GUIDE 71

Fig. No. 6b Wall Thickness/I.D. Ratio for Integral Tubesheets 14

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These standards provide practical information on nomenclature, dimensions,

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1.2 Heater Duty 1.12 Drain Subcooling Zone (DC)

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2. FEEDWATER HEATER PERFORMANCE

2.1 Heater Performance Steam Enthalpy total______________ Btu/lbm

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t = Tube wall thickness, in The corresponding feedwater velocity at 60 F can

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with slightly rounded edges. There are numerous Inside Tubes

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Average Feedwater Operating Temperature (F)

Definitions C 5 Density correction factor at average

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Average Feedwater Operating Temperature (F)

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Density Correction Factor

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Projected Tube Expanded Welded Tube with Slightly

LOSS Correction Factor FOR TUBE CONFIGURATION

2.8 Nozzle Sizes 2.9 Steam Nozzle Location and Steam

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G 4 Mass velocity, lbm/sec/ft2

3) Liquid from Flash Tanks 4 ft/sec at

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