FEEDWATER HEATER PERFORMANCE

Engineering & Technical Services

Feedwater Heater Operation

The feedwater heaters preheat

the boiler feed water using
extraction steam from the
turbine.

High pressure feedwater heaters

are typically a three-zone
(desuperheating, condensing,
and drains subcooling) design,
while low-pressure feedwater
heaters are generally a two-zone
(condensing and drains
subcooling) design.
Feedwater Heater Performance

Three important operating parameters

that describe feedwater heater
performance are the Terminal
Temperature Difference (TTD), the Tsat @ Ext. Press
Drain Cooler Approach (DCA) and the Tout
Feedwater Temperature Rise (FTR).

Tin
Tdrains
Feedwater Heater Performance

The TTD is the difference between

the saturation temperature of the
extraction steam associated with
the feedwater heater flange Tsat @ Ext. Press
pressure and the temperature of Tout
the feedwater leaving the heater,
or:

Tin
Tdrains
Feedwater Heater Performance

The DCA is the difference

between the temperature of
the drains leaving the heater
and the feedwater entering the Tsat @ Ext. Press
heater, or: Tout

Tin
Tdrains
Feedwater Heater Performance

The FTR is the temperature

difference between temperature
of feedwater leaving and entering
the heater, or: Tsat @ Ext. Press
Tout

Tin
Tdrains
Feedwater Heater Diagnostics

When diagnosing feedwater heater

performance problems, keep in mind that
there are relatively few problems that
occur in this equipment. The most likely
problems and corroborating indicators
include:

• Fouling

• Inadequate Venting

• High Drain Level

• Low Shell Pressure

• Pass Partition Plate Failure

Feedwater Heater Diagnostics

Fouling

A fouled feed water heater typically demonstrates a high TTD and a high DCA. In other
words, the heater has a problem heating the feed water as well as cooling the drains
because of poor heat transfer.

Corroborating evidence includes other heaters in a similar condition (fouling is rarely

localized to just one heater) as well as indications of turbine steam path fouling.

A visual inspection during an outage through a safety valve flange or any other available
point will confirm the presence of steam side fouling.
Feedwater Heater Diagnostics

Inadequate Venting

A heater that is operating with improper venting generally has a high TTD and a normal
or better than design (low) DCA. The insulating effect of the non-condensible gases
inhibit heat transfer to the feedwater and as a result decrease the amount of extraction
steam flowing into the heater.

Opening the shell side "start-up" vents to see if performance improves, is one way to
confirm a shell-side venting problem. If confirmed, external vent system piping and
valving should be inspected and eliminated as a possible cause of inadequate venting
before proceeding with an internal inspection of the heater.
Feedwater Heater Diagnostics

High Drain Level

A heater that is operating with tubes "flooded” on the shell side has less area available
for heat transfer. The decreased heat transfer area results in less condensing action and
therefore less steam flow into the heater. This results in a high TTD and a low DCA (since
the drain cooler area has been effectively increased).

To confirm that a high shell side "drips" level is the problem, the drain valve should be
manually opened until the drain temperature "kicks" high (i.e., very high DCA). At this
point, the water seal on the drain cooler inlet (snorkel) has been lost due to a low shell
side level. If the TTD returns to normal, a level control problem exists.
Feedwater Heater Diagnostics

Low Shell Pressure

There is the possibility that the feed water heater performance is inadequate due to a
restriction of steam flow between the turbine and the heater inlet.

To confirm a low shell-side pressure is the cause of inadequate feedwater heating, the
heater's flange pressure should be compared to the associated turbine extraction
pressure. A typical design value is approximately a four to five percent pressure drop.

If a high pressure drop exists, the NRVs should be checked for freedom of operation,
counter weight position, and that the "dump valve" closing mechanism is free and clear
of the NRV. If the NR V appears normal, the isolation valve(s) should be visually checked
to verify that it is in the full open position.
Feedwater Heater Diagnostics

Pass Partition Plate Failure

If all four of the typical problem areas discussed above have been eliminated, there is a
high probability that the feedwater is internally bypassing the heat transfer sections
within the heater. Typically, this results in a high TTD with a normal DCA.

Unfortunately, this is a difficult condition to verify without isolating the heater and
entering the channel section to visually inspect the integrity of the plate's seal between
the inlet and outlet channels.

It is recommended that the four areas discussed above be eliminated as possible causes
of poor performance before taking this action.
Feedwater Heater Diagnostics

TTD DCA FTR

Fouling High High Low
Inadequate Venting High Normal – Low Low
High Drain Level High Low Low
Low Shell Pressure High Low Low
Pass Partition Plate High Normal Low
Failure

As per the Heat Exchanger Institute standards, normal Terminal Temperature Difference (TTD) range
is -5°F to 0°F for HP heaters and 2°F to 5°F for LP heaters.

The normal Drains Cooler Approach (DCA) ranges from 8°F to 15°F but HEI recommends a DCA of
10°F.
Feedwater Heater Analysis

Abnormal FWH Operation %Heat Rate

Top Heater Out of Service 1.2%
Next to Top Heater Out of Service with Top Heater Drain to Condenser 1.8%
Both High Pressure Heaters Out 2.2%
One High Pressure Heater Out 1.1%
One Low Pressure Heater Out 0.3%-0.5%
Next to Top Heater Drain to LP rather than DA 0.2%
Top Heater Extraction Line DP +10% 0.2%
Other Heater Extraction Line DP +10% 0.04%-0.06%
Feedwater Heater Analysis

If feedwater heater problems cause the feed water

temperature entering the economizer to be five degrees
low, the turbine cycle heat rate increases by slightly
more than 0.1% at rated load.
Activity

Given the following data, do a simple analysis on the condition of the feedwater heater,
identify symptoms, conduct diagnostics and give your interpretation.
Thank You