Feed Water Heaters

Sankar Bandyopadhyay
Email : sankarbando1956@gmail.com
Feed water Heating
Advantage by Heater in Rankine Cycle
Effect of no. of feed-water heaters on thermal
efficiency of the cycle
 Vital Measures of an Operating Heater

Terminal temperature difference (TTD) =

inlet steam saturation temperature -Feedwater
outlet temperature
Drains cooler approach (DCA) = shell drains
outlet temperature - feedwater inlet temperature
Feedwater temperature rise (TR) = feedwater
outlet temperature - feedwater inlet temperature
Zones of Feed Water Heaters
Horizontal Feed Water Heater
Horizontal Feed Water Heater
Vertical Feed Water Heater
Vertical Feed Water Heater Channel Down
 HP Heater

FW outlet
Drain inlet
Extraction steam
inlet

Drain outlet
FW inlet
HP Heater
HP Heater
Low pressure feedwater heater
Low pressure feed water heater

UNIT SIZE (MW) Number of Heaters

0 – 50 3–5
50-100 5 or 6
100-200 5-7
Over 200 6-8
 Extraction Connection To Heaters

No of Steam Connection to Extraction steam Extraction Steam flow

extractio n extractio n pr, kg/cm2 steam temp, T/hr
0C
stages

Ist -HPT 9 HPH-7 30 337 88

2nd -CRH 12 / CRH HPH-6 / Deaerator 26.2 314 77

3rd -IPT 15 HPH-5 / 11.96 433 16.2

Deaerator

4th - IPT 18 LPH-4 6.47 368 26

5th – IPT 21 LPH-3 2.78 252 23

6th - IPH 23 LPH-2 1.28 172 28

7th - LPT 25 LPH-1 0.28 40-50 12.6

 Key Performance Indicator

 TTD - Terminal Temperature Difference

TTD = TS - FW OUTLET TEMP

TS saturation temperature
corresponding to shell pressure
DCA
TR
PRESSURE DROP
 Thermal profile in different zones of H P HEATER

Sensible heat Latent Sensible heat

transfer transfer
heat transfer

Extn

FW
Ts TTD

Drain

DC A

FW Drain Cooling Condensing Desuper

Zone heating
Zone
Zone
 High TTD
Causes Effects

Tube fouling/Plugging

Non condensable gases Bled steam flow

(Air) blanketing Heater concerned

Flooding Subsequent heater

Tube leakage Turbine steam flow

Level control
Low shell pressure
Excessive venting
TTD and Feed Water temp

Terminal difference
Feedwater outlet
[0C]
temperature [0C]

30-110 2.8

110 -148.9 5.6

148.9 – 204.4 8.3

204.4 – 273.9 11.1

 Drain Cooling Approach - DCA
DCA = Drain out let temp - FW inlet temp

HIGH - DCA
Causes Effects

LCV malfunction •Tube fouling/Plugging

•Bled steam flow
•Low water level
•Heater concerned
•Subsequent heater
•Drain cooler inlet not
submerged
Temperature Profile of a closed Feed water Heater
NTHR – Net Turbine Heat Rate
NTHR – Net Turbine Heat Rate
NTHR – Net Turbine Heat Rate
NTHR – Net Turbine Heat Rate
 Temperature Rise

TR = FW outlet temp - FW inlet temp

LOW TR
Causes Effects

TTD high
Bled steam flow
DCA high
Heater concerned
Subsequent heater
Turbine steam flow
Sample Calculation for Feedwater Heater
Terminal Temperature (TTD)
TTD = t sat – t fw out = 252.8- 251.1 =1.7 0C.

Drain Cooler Apporach Temperature (DCA)

DCA = t drains - t fw in = 202.8- 194.3 = 8.5 0C..

Temperature Rise (TR)

TR = t fw out – t fw in = 251.1-194.3 = 56.8 0C
Extraction Steam Flow =
(Qe) = [Qf (hfw out – hfw in) + Qdrain in (hdrains out- hdrains in)] / (hext – hdrains
out )
Where:
Qf = Feed Flow; Qdrain in = Drain Inlet flow;
h fw out = Feed Water Enthalpy at HPH Out.; hfw in = Feed Water Enthalpy at HPH in
hdrains out = Enthalpy of Drain Out; hdrains in = Enthalpy of Drain In hext = Enthalpy of
Extraction Steam
751.2* (259.7 – 196.8)+0
Qe = ------------------------------------- = 90.2 t/hr
(729.4 – 205.95)
 DETERIORATION

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

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

• Progressive increase of TTD

• Drain temperature unaffected
• Reduced feed water temperature rise
• Eventual tube failure due to mechanical
weakening
• Accumulation of debris in the heater shell.
 Water side fouling

• Gradual increase of TTD.

• Oil
– LPT bearing oil through seals
– Deposition occurs in HP heaters, worst hit at
highest pressure heater.
 Drainage defects

• Damaged flsahbox internals

• Reduced orifice opening
• Enlarged orifice opening
• Heater drain CV/ bypass valve
malfunction.
 Parting plane leakage

• Short circuiting of FW
• TTD high
• DCA high
• TR less
 HP Heater Performance Report - 210 MW

Sr. No Parameter Unit Test Data

HPH - 5 HPH - 6 HPH - 7
1 Unit Load MW 178 178 178
2 FW Flow t/hr 649 649 649
3 HPH - Extr. Temp (Htr End) Deg C 200 335 390
4 HPH - Extr. Press (Htr End) kg/cm2 (a) 14.5 29 36
5 FW Inlet Temp Deg C 165 180 215
6 FW Outlet Temp Deg C 180 215 232
7 HPH Drain outlet Temp Deg C 150 200 240
8 Drain inlet Temp to HPH Deg C 200 240 --

TTD Deg C 15.8 15.9 11.0

DCA Deg C -15.0 20.0 25.0
Extraction Flow to HPH t/hr 12.9 43.8 23.7
FW Temp rise in HPH Deg C 15.0 35.0 17.0
Partition Plane
Thanks