Heater Performance Analysis

Contents:
Sl No Topic Slide No

1 Why Feed water heating is required??? 03-04

2 Description of Regenerative Feed Water Heating System 05-06

3 Calculation of TTD, DCA and Temp rise in all heaters 07

4 Comparison with designed parameters 08-09

6 Evaluation of steam side heat transfer in different heat zones, ie De- 12-13
superheating, Condensing and Drain cooling

8 Comparison of performance indicators with common problems in 14-19

Heaters

9 Effect of HPH being out on turbine pressure profiles 20-29

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Why Feed water Heating is required?
In a regenerative Cycle , Steam is extracted from steam Turbine at various stages
and used to heat the feed water.
This results in a higher cycle Efficiency by increasing the temperature of the feed
water and by reducing the amount of energy lost in the condenser.

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Regenerative Feed Water Heating System
Increasing the average temperature of heat addition can also be accomplished by
increasing the temperature of the feed water entering the boiler. To realize a gain in
efficiency, heat from within the cycle is used to elevate the feed water temperature. This
can be done by extracting a portion of the partially expanded steam from the turbine and
directing it to a heat exchanger that heats the feed water to the boiler. This process is
called regenerative feed water heating. Steam bled from a turbine for feed heating will
surrender its superheat, latent heat and, possibly, some sensible heat to the feed water
thus relieving the boiler of a comparable amount of work. If there had been no feed
heating the steam would have surrendered a large quantity of heat to the C.W. system
where it is a waste, whereas with feed heating it is employed usefully.

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Thermal improvement due to Feed Heating

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Heater Selection and Final Feed Water Temperature

 In order to maximize the heat rate gain possible with supercritical steam conditions,
the feed water heater arrangement also needs to be optimized.
 In general, the selection of higher steam conditions will result in additional feedwater
heaters and a economically optimal higher final feedwater temperature.
 In many cases the selection of a heater above the reheat point (HARP) will also be
warranted.

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Effect of Final Feed Water Temperature and Reheat
Pressure on Turbine Net Heat Rate

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Improvement in efficiency due to reheating in a reheat-
regeneration cycle

Reheat-Regeneration
cycle

Regeneration cycle

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Different Heat Transfer Zones

1) De-superheating zone (DS): In the de-superheating section, the superheated steam

is cooled in a contact with dry tubes of the U-tube bundle to the saturation temperature.
The heat transfer is written as,

2) Condensing zone (CD): In the condensing zone, the steam condenses in a

contact with tubes where it changes its phase from saturated vapor to saturated
liquid and releases the latent heat of vaporization.

• The driving force for condensation is the difference between the temperature of
cold wall surface and the bulk temperature of the saturated vapor.

3) Sub cooling zone (SC): In the sub-cooling zone, the tube side and shell side fluids
are liquids i.e. single phase and the heat exchange occurs in form of sensible heat
transfer. The values of heat transferred, LMTD, overall heat transfer coefficient, area of
zone and length of tube can be calculated using same equations as that of the de-
superheating zone.

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Performance Indicators of Heaters

Temperature Rise = FW Outlet temp-FW outlet temp

TTD =Tsat-FW outlet temperature

ITD = Tsat-FW inlet temperature

DCA =Drain Temperature- FW inlet temperature

LMTD= [(ITD-TTD)/Log(ITD/TTD)]

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Design Vs Actual KPI’s of Heaters
. HP Heater Performance Analysis

Extraction Flow Calculation Design parameter at Actual parameter Remarks

actual load
Parameter Design Design Unit#2 Unit#5 Unit#6 Unit#2 Unit#5 Unit#6 Unit#2 Unit#5 Unit#6
(660 MW) (694MW)

Load 660 694 681.4 680.3 681.6 681.4 680.3 681.6 NA NA NA

FW Flow(DCS) 1976 2096 2051.5 2047.9 2052.3 2050.0 2024.7 2063.2 OK Lesser Higher
HPH-8 I/L ext steam enthalpy 3076.5 3085.8 3082.3 3082.1 3082.4 3100.0 3086.4 3111.4 Higher OK Higher
HPH-8 drain enthalpy 1152.4 1169.3 1163.0 1162.5 1163.1 1137.2 1135.2 1181.3 Low Low Higher
HPH-8 I/L water enthalpy 1125.4 1141.1 1135.3 1134.8 1135.4 1108.0 1111.7 1126.4 Low Low Low
HPH-8 O/L water enthalpy 1233.9 1252.4 1245.5 1245.0 1245.6 1225.4 1224.9 1243.5 Low Low OK
Ext-8 steam flow 111.5 121.8 118.0 117.6 118.0 122.7 117.4 125.1 OK OK Higher
HPH-7 ext steam enthalpy 3003.3 3011.3 3008.3 3008.1 3008.4 3013.9 3006.0 3026.2 Higher OK Higher
HPH-7 drain enthalpy 945.1 957.8 953.1 952.7 953.2 946.2 936.1 956.9 Low Low OK
HPH-7 I/l FW enthalpy 930.4 942.9 938.3 937.9 938.3 922.4 918.0 933.2 Low Low Low
HPH-& O/L FW enthalpy 1125.4 1141.1 1135.3 1134.8 1135.4 1108.0 1111.7 1126.4 Low Low Low
Ext-7 steam flow 175.9 189.8 184.6 184.2 184.7 172.7 178.2 179.1 Low Low Low
HPH-6 I/L ext steam enthalpy 3382.7 3380.5 3381.3 3381.4 3381.3 3425.2 3410.9 3415.0 Higher Higher Higher
HPH-6 drain enthalpy 824.1 835.2 831.1 830.7 831.1 839.6 832.0 833.5 Higher OK OK
HPH-6 I/L water enthalpy 814.5 825.6 821.5 821.1 821.5 807.9 806.8 806.5 Low Low Low
HPH-6 O/L water enthalpy 930.4 942.9 938.3 937.9 938.3 922.4 918.0 933.2 Low Low Low
HPH-6 ext steam flow 75.9 81.6 79.5 79.3 79.5 78.6 75.4 86.7 OK OK Higher
D/A ext steam enthalpy 3198.2 3195.7 3196.6 3196.7 3196.6 3209.9 3199.9 3203.2 Higher OK Higher

D/A I/L condensate enthalpy 606.9 614.7 611.8 611.6 611.9 603.1 608.2 602.0 Low OK Low

D/A O/L condensate enthalpy 773.7 783.6 779.9 779.6 780.0 787.0 780.3 779.9 Higher OK OK
D/A ext steam flow 96.7 103.6 101.0 100.8 101.1 115.3 105.4 109.9 Higher OK Higher
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Design Vs Actual KPI’s of Heaters
.
Key performance Indicators Analysis Design KPI's at actual Actual KPI's Remarks
load
TTD Design(660 MW) Design(@694 MW) U#2 U#5 U#6 U#2 U#5 U#6 U#2 U#5 U#6

HPH-8 -1.70 -1.58 -1.6 -1.6 -1.6 3.2 3.4 0.7 High High High
HPH-7 0.00 0.0 0.0 0.0 0.0 4.1 4.3 2.2 High High High
HPH-6 0.00 0.0 0.0 0.0 0.0 2.9 4.7 0.5 High High OK
D/A 2.80 0.0 1.0 1.1 1.0 2.3 3.3 4.3 High High High
DCA Design(660 MW) Design(@694 MW) U#2 U#5 U#6 U#2 U#5 U#6 U#2 U#5 U#6

HPH-8 5.50 5.60 5.6 5.6 5.6 5.9 4.8 11.0 OK OK High
HPH-7 5.50 5.50 5.5 5.5 5.5 5.2 3.9 5.1 OK OK OK
HPH-6 5.50 5.60 5.6 5.6 5.6 7.1 5.6 6.0 High OK OK
D/A NA NA NA NA NA NA NA NA
TR Design(660 MW) Design(@694 MW) U#2 U#5 U#6 U#2 U#5 U#6 U#2 U#5 U#6

HPH-8
22.90 23.40 23.2 23.2 23.2 23.3 22.4 23.0 OK Low Rise Low Rise
HPH-7
43.20 43.80 43.6 43.6 43.6 39.2 40.9 40.6 Low Rise Low Rise Low Rise
HPH-6
26.60 26.90 26.8 26.8 26.8 25.3 24.6 28.0 Low Rise Low Rise OK
D/A 38.40 38.80 38.7 38.6 38.7 42.1 39.4 40.8 OK OK OK

BFP 5.80 6.00 5.9 5.9 5.9 4.7 6.0 6.0 Low Rise OK OK
Total
136.9 138.90 138.2 138.1 138.2 134.6 133.3 138.3 Low Rise Low Rise OK

Maximum amongst 03 units

Minimum amongst 03 units

Intermediate

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Heat Transfer in different heat zones of Heaters
HPH-8 HPH-7 HPH-6
Parameter Unit Design Actual Design Actual Design Actual
Source steam Heat content KJ 343193 369103 656786 652304 528422 546638
Dry saturated heat KJ 310030 338400 492137 479287 212525 226876
Wet saturated heat KJ 137464 150719 197861 192561 69812 75023
Drain heat content KJ 128475 137548 271603 271631 299412 307498
Heat transfer in Superheated
Zone KJ 33163 30703 36174 35469 44295 48131
Heat transfer in Condensing
Zone KJ 172566 187681 294275 286726 142713 151853
Heat transfer in Drain cooling
Zone KJ 8989 13172 54733 58477 42002 39156
Total Heat Transfer KJ 214718 231555 385183 380673 229010 239140
Enthalpy Design Actual Design Actual Design Actual
Superheated steam KJ/Kg 3078 3032 3003 3005 3383 3394
Dry saturated steam KJ/Kg 2781 2780 2798 2798 2799 2800
Wet saturated steam KJ/Kg 1233 1238 1125 1124 920 926
Drain KJ/Kg 1152 1130 945 927 824 822
Temp Design Actual Design Actual Design Actual
Superheated steam temp Deg 365 350 321 322 462 467
Dry sat steam temp Deg 279 280 258 258 215 216
Wet sat steam temp Deg 279 280 258 258 215 216
Drain temp Deg 264 259 220 216 194 193

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 Heat Transfer in different heat zones of Heaters….

HPH-8 design HPH-8 actual HPH-7 design HPH-7 actual HPH-6 design HPH-6 actual

500
Superheated Ext Steam(Start of De-SH
Zone
450

400
Temperature(Deg)

350 Saturated Liquid(Start of Saturated Vapor (Start of

Drain Cooling Zone) condensing zone)
300

250

200

150

100
500 1000 1500 2000 2500 3000 3500 4000

Enthalpy(KJ/Kg)
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Interfering factors with Heat transfer in Heaters

1. Air Blanketing

Probable cause:

• Inadequate venting of Heaters

• Position of air vents
• Air ingress at steam side valve flanges(applicable in LP Heaters)

Effects:

• Lower temperature rise

• Higher TTD
• Higher DCA

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 2. Water side contamination

Probable cause:

• Oil deposition through condensate system on HP Heaters tube inner

wall

Effects:

• Lower temperature rise

• Sudden increase in TTD of the Heaters
• Sudden increase in DCA

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 Case study(Water Side Contamination)

Serious oil contamination occurred on a 120

MW unit when one of the
turbine LP cylinder bearings leaked oil which
got into the condenser and
thence into the feed. Figure shows how
dramatically the TTD was affected. Actually
all the HP heaters were badly affected but
No. 6 heater was the worst. Several chemical
cleans failed to remove the deposit and
finally the only partial cure that could be
found was to use a high-pressure(620 bar)
jet of water down each individual tube. This
reduced the TTD to about one third of the
contaminated condition.

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 2. Steam side contamination of the tubes

Probable cause:

• Exfoliation of water tubes by steam impingement

• Change in steam velocity profile of extraction steam

Effects:

• Lower temperature rise

• High TTD with gradual increase
• High DCA

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 Case study(Steam side Contamination)

Figure shows how the terminal

temperature difference increased
on a particular heater as
exfoliation progressed. Note that
the rate of rise is slow over a
number of years, unlike the case
of oil contamination where the
increase occurred at a specific
time, after which it was rapid. The
heater to which Figure refers was
so badly affected that the tube
thickness had been halved and
the space between the tubes was
almost blocked solidly.

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Comparison of KPI’s With Common Heaters Problem

Probable Problem TR TTD DCA HPH-8 HPH-7 HPH-6

Inadequate vent Decrease Increase Increase 0 1 0 1 1 0 1 1 0

Level Increase Decrease Increase Decrease 0 1 0 1 1 1 1 1 1

Level decrease Increase Decrease Increase 1 0 0 0 0 0 0 0 0

Tube fouling Decrease Increase Increase 0 0 0 1 1 0 1 1 0

Tube leak Decrease Increase Increase 1 1 0 1 1 0 1 1 0

High FW flow Decrease Increase Increase 1 1 0 1 1 0 1 1 0

Plugged tubes Decrease Increase Increase 1 1 0 1 1 0 1 1 0

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Effect on turbine due to HPH 8
bypass

SASAN Ultra Mega Power Project

(6*660 MW)
Operation with HPH-8 OUT

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 Flow comparison for with on HPH 8 bypass and VWO condition

Unit 1 Unit 3 Unit 4

(HBD) (HBD) (Actual) (Actual) (Actual)
All HP
27/03/2018 Flow Flow Flow Flow Flow HPH 8 heater
reading reading reading reading reading BYPASS bypass
(HBD) (HBD)
MW MW 660 694 671 664 677 660 660
MS flow TPH 1976 2096 1935 1912 1937 1899 1728
CRH flow TPH 1658 1752 1734 1698 1740 1687 1696
RH flow TPH 0 0 44 49 61 0 0
Actual
operation HRH flow TPH 1658 1753 1778 1747 1801 1687 1696
LPT I/L flow TPH 1398 1472 1518 1467 1500 1428 1518
Steam flow 2.88 2.88 2.86
/MW
MS flow TPH 1888 1905
CRH FLOW TPH 1688 1710
HRH FLOW TPH 1732 1772
LPT I/L flow TPH 1474 1471
Suggested Flow deviation Ok
operation from MS flow TPH 46 32
MW Need to
reduced MW 16 11
New MW for
Confidential safe op MW 655 665 Slide
 Turbine pressure survey:
Unit 1 Unit 3 Unit 4
(HBD) (HBD) (Actual) (Actual) (Actual) (HBD) (HBD)

27/02/2018 MW 660 694 671 664 677 660 660

19/03/18 27/02/18 24/02/18

Design
pressure Design Actual Actual Actual HPH 8 All
Parameter 100% pressure pressure pressure pressure BYPASS heater
TMCR VWO bypass

MS pressure Kg/cm2 245.74 245.74 245.25 247.73 246.41 245.7381 245.74

1st stage pressure Kg/cm2 191.33 203.75 189.82 184.29 189.90 185.08 168.94

EX 8 Kg/cm2 65.35 69.29 69.70 70.37 71.81 66.82 64.59

EX 7 Kg/cm2 46.45 49.12 46.97 47.38 47.82 46.10 48.03
CRH Kg/cm2 46.45 49.12 46.83 46.22 47.57 47.30 48.03
HRH Kg/cm2 41.90 44.30 44.35 44.63 45.09 47.30 43.62
EX 6 Kg/cm2 20.89 22.08 22.31 22.25 22.70 21.29 22.70
D/A Kg/cm2 10.33 10.91 11.52 11.25 11.39 10.57 11.36
IP EX Kg/cm2 10.10 10.67 11.52 12.09 11.54 10.34 11.11
LP 4 Kg/cm2 3.65 3.88 3.49 3.52 3.70 3.74 4.07
Confidential Slide 26
Unit 1 : Turbine Pressure survey
69.70
70.0

65.0

60.0

55.0

50.0
46.83
45.0 44.35

40.0

Design pressure 100% TMCR

35.0 69.29 design pressure
Actual pressure
30.0

25.0
49.12 22.31
44.30
20.0

15.0
11.52 11.52
22.08
10.0

5.0 10.91 10.67 3.49

65.4 46.5 41.9 20.9 10.3 10.1 3.63.88

0.0
EX 8 CRH HRH EX 6 D/A IP EX LP 4

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 Unit 3 : Turbine Pressure survey

70.4
70.0

65.0

60.0

55.0

50.0
46.2
44.6
45.0

40.0
Design pressure 100% TMCR
35.0 69.3 Design pressure VWO
Actual pressure
30.0

25.0 49.1 22.2

44.3
20.0

15.0
11.3 12.1
22.1
10.0

5.0 10.9 10.7 3.5

65.4 46.5 41.9 20.9 10.3 10.1 3.6 3.9
0.0
EX 8 CRH HRH EX 6 D/A IP EX LP 4

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 Unit 4 : Turbine Pressure survey
71.81
70.0

65.0

60.0

55.0

50.0
47.57
45.09
45.0

40.0
Design pressure 100% TMCR
35.0 69.29 Design pressure VWO
Actual pressure
30.0

25.0 49.12 22.70

44.30
20.0

15.0
11.39 11.54
22.08
10.0

5.0 10.91 10.67 3.70

65.4 46.5 41.9 20.9 10.3 10.1 3.63.88

0.0
EX 8 CRH HRH EX 6 D/A IP EX LP 4

Confidential Slide 29
Unit 1 : turbine pressure and flow comparison with VWO condition
and different load condition

Actual pressure at Actual pressure after

Design pressure
Generation Unit normal operation load reduction (659
VWO (694 MW)
(671 MW) MW)

MS pressure Kg/cm2 245.74 245.25 244.78

1st stage Kg/cm2 203.75 189.82 188.64
pressure
EX 8 Kg/cm2 69.29 69.70 69.21
CRH Kg/cm2 49.12 46.83 46.46
HRH Kg/cm2 44.30 44.35 43.96
EX 6 Kg/cm2 22.08 22.31 22.11
D/A Kg/cm2 10.91 11.52 11.43
IP EX Kg/cm2 10.67 11.52 11.44
LP 4 Kg/cm2 3.88 3.49 3.47
MS flow TPH 2096 1935 1908
CRH flow TPH 1752 1734 1708
RH flow TPH 0 44 44
HRH flow TPH 1753 1778 1752
LPT I/L flow TPH 1472 1518 1495
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 Unit 1 : Turbine Pressure survey at different load and comparison
with VWO condition.

75.00

70.00 69.21

65.00

60.00

55.00

50.00
46.46
45.00 43.96

40.00
Design pressure VWO (694 MW)
Actual pressure at normal operation (671 MW)
35.00 69.70
Actual pressure after load reduction (659 MW)
30.00

25.00
46.83 22.11
44.35
20.00

15.00
11.43 11.44
22.31
10.00

5.00 11.52 11.52 3.47

69.29 49.12 44.30 22.08 10.91 10.67 3.49
3.88
0.00
EX 8 CRH HRH EX 6 D/A IP EX LP 4

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THANK YOU