Feed Heaters & Condenser

Performance

By:
M.V. Pande
Director
NPTI, Badarpur
Steam & Feedwater 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
Zones of Feed Water Heaters
Horizontal Feed Water Heater
Vertical Feed Water Heater
HP Heater
HP Heater
HP Heater Installation
 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
High TTD Causes
TTD and Feed Water Temp.
 High Drain Cooling Approach - DCA

(Level control valve)

Temperature Profile of a closed Feed
Water Heater
Effect of HP Heaters TTD on NTHR
(Net Turbine Heat Rate)
Effect of LP Heaters TTD on NTHR
(Net Turbine Heat Rate)
 Effect of DCA on NTHR
(Net Turbine Heat Rate)
 Low Temperature Rise
TR = FW outlet temp - FW inlet temp
 Feed Heaters Survey
Feed heaters survey evaluate the performance
of heaters & predicts the deterioration causes
Following parameters are noted down
- Steam pressure at heater
- Steam temperature at heater
- Feed water inlet & outlet temperature
- Heater drain temperature
 Feed Heaters Survey
Evaluate the steam flow to each heater by heat
balance
Compare the flow values with optimum
Calculate T.T.D. for each heater
The results indicate following problems
- The elevated TTDs on the heater train suggests water
side contamination (oil)
- The high steam flow to particular heater may be due
to lower feed water inlet temperature,suggesting the
problem in previous heater
Sample Data for Feedwater Heater
Calculations
 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
Partition Plane Damage
Heat Exchanger Tubes Scaling
SURFACE CONDENSER
EFFECT OF VARYING THE BACK PRESSURE

A large amount of the extra work is done by the

steam, when the back pressure is reduced.
However, the trouble is that as the back pressure
improves, certain losses also increase-
1) CW Pumping Power.
2) Leaving losses.
3) Reduced condensate Temperature.
4) Wetness of the steam.
 Increased CW Pumping Power

Assuming that the CW inlet temperature is low

enough, the back pressure can be reduced by
putting more and more CW through condenser
tubes.
However, this will require more CW pumping
power and the gain from improved back pressure
must be offset against extra power absorbed by
the pumps. So, the CW pumps should be run only
when the cost of running the pump is equal to, or
less than the gain in output from the machine.
 Increasing leaving loss

The steam leaves the last row at a velocity

which depends upon the conditions prevailing
at the point. As this velocity is not utilized
usefully, it represents a loss of possible work
known as the leaving loss. So velocity steam
through fixed annulus must also double. But
leaving losses varies as square of the velocity.
So it will increase four times.
 Reduced condensate temperature /
increased bled steam
The condensate in the condenser is at
saturation temperature corresponding to the
back pressure. It back pressure is reduced,
saturation temperature will drop. When it
enters first LP heaters it will be cooler than
before consequently more steam will
automatically be bled to the heater. The extra
steam is no longer available to do work in the
turbine will be deprived of some work.
 Increase wetness of the steam

The lower the back pressure, the greater the wetness of

steam. The extra moisture could result in damage to the
moving blade. Also with increased wetness, volume of
steam is reduced water droplets being heavier than steam
moves slowly. So the front edge of moving blades have to
push the droplets out of the way. This can cause damage to
blades. Therefore, it is usual to fit satellite erosion shields
to the leading edge to reduce this damage. As a rough
guide, it can be assumed that every 1% wetness will reduce
efficiency of associated stage by 1%.
The reduction in back pressure will result in net
improvement in heat consumption until a point is reached
beyond which benefit due to improve back pressure is
outweighed by the losses and heat consumption increase.
Blades erosion damage due to wet steam
Condenser Low
Vacuum Causes
Vacuum Efficiency & Condenser Efficiency
Vacuum Efficiency
It is the ratio of the actual vacuum at the steam inlet to
the maximum obtainable vacuum in a perfect
condensing plant, i.e., it is the ratio of
actual vacuum to ideal vacuum.

Condenser Efficiency
In thermal power plants, the purpose of a
surface condenser is to condense the exhaust steam
from a steam turbine to obtain maximum efficiency,
and also to convert the turbine exhaust steam into
pure water (referred to as steam condensate) so that it
may be reused in the steam generator or boiler as
boiler feed water.
Condenser Condition Graph
 Deviation due to CW inlet
temperature
Plot a line vertically from the actual CW inlet
temperature to intersection with the optimum
CW rise. Then plot horizontally to the intersection
with optimum terminal difference (TTD) line, and
then vertically downwards to cut the saturated
steam temperature line to obtain the
corresponding back pressure. (Refer fig in
previous slide)
Hence the loss due to the high CW inlet
temperature can be calculated by subtracting the
optimum value from the actual back pressure
 Deviation due to C.W. flow
Plot a line from the actual CW inlet
temperature vertically to the intersection with
actual CW rise Then plot horizontally to the
optimum TTD, then vertically downward to
the saturation steam temperature to obtain
the actual back pressure. the difference
between the actual back pressure and the
optimum back gives the loss due to the
incorrect CW flow.
 Deviation due to air/dirty tubes
The effect of the air and dirty tubes on the
heat transfer is to increase the TTD above
optimum. As they both give the same effect ,
they are clubbed together in this exercise. Plot
line from the actual CW inlet temperature to
the actual CW rise and then across the actual
TTD line plotting vertically downwards to
adjacent steam temperature back pressure. So
the deviation due to air/dirty tubes can be
found out.
 CASE STUDY
Khaparkheda Thermal Power Station (MSPGCL)
 Design Data.
Condenser tubes specification
1. Tube diameter (outside diameter)
25.4mm
2. Tube thickness 1.0mm
3. Tube diameter ( inside diameter)
23.4mm
4. Tube length 7.5m
5. Number of tubes 19208
6. Cross sectional area per tube
430.05m3
7. Surface area per tube 0.60m2
8. Total surface area of tube 11495
m2
9. Specific heat of CW 1.00kcal/kg/0C
10. Density of CW 1000kg/ m3
11. Condenser vacuum 650.06mm of
Hg
12. Condenser back pressure
0.09kg/cm2
13. Sat. temperature at condenser back
pressure 43.6 oC
14. Average temperature of CW inlet
30.500C 30.50 oC
15. Average temperature of CW at
outlet 39.20 oC
16. CW temperature rise across
condenser 8.79 oC
17. Terminal temperature difference
4.40 oC
 Calculation for the TEST-1
1) If all values of C.W. Inlet (C.W.), C.W. Rise (C.W.R) ,T.T.D. are as per design then
C.W.I+C.W.R.+T.T.D. = 30.5 + 8.79 +4.4 = 43.7 = 89.11 mbar
2) If only inlet water temperature is actual then
(C.W.I)a.+C.W.R.+T.T.D.=29 +8.79 +4.4 = 42.2= 82.46 mbar
3) If both the inlet temperature and temperature rise is actual then
(C.W.I)a.+C.W.R)a.+T.T.D.=29 +10.2 +4.4 = 43.6 = 89.11 mbar
4) If all parameters are actual then
(C.W..I)a.+(C.W.R)a.+(T.T.D)a=29+10.2 +7.1 =46.3 = 102.4 mbar

Now effect of various parameters is as a follows

#1) Cooler Circulating Water improves vacuum by
(82.46 -89.11) = -6.65 mbar = - 5 mm of Hg.
#2) Dirtiness of tubes deteriorates vacuum by
(89.11 - 82.46) = 6.65 mbar = 5 mm of Hg.
#3) Air ingress deteriorates vacuum by
(102.4 - 89.11 ) = 13.29 mbar = 10 mm of Hg.
 Conclusion:

#1) Inlet temperature is slightly lower than

design value and hence little improvement in
vacuum by 5 mm of Hg.
#2) Tubes are dirty which deteriorates vacuum
by 5mm of Hg.
#3) There is a little air ingress which causes
vacuum deterioration by 10mm of Hg.
 Calculation for the Test - 2
1) If all values of C.W. Inlet C.W. Inlet (C.W.), C.W. Rise (C.W.R) , T.T.D.
are as per design then-
C.W.I.+C.W.R.+T.T.D. =30.5 +8.79+4.4 =43.7 = 89.11 mbar
2) If only inlet water temperature is actual then
(C.W.I)a. +C.W.R.+ T.T.D.= 22 + 8.79 + 4.4 =35.19 = 56.6 mbar
3) If both the inlet temperature and temperature rise is actual then
(C.W.I)a.+(C.W.R)a.+ T.T.D.=22 + 10 +4.4 =36.4 =61.18 mbar
4) If all parameters are actual then
(C.W.I)a.+(C.W.R)a.+(T.T.D)a= 22+10+7.9=39.9=73.15 mbar
Now effect of various parameters is as a follows
#1) Cooler Circulating Water improves vacuum by
(56.6 - 89.11) =-32.5 mbar =-24.4 mm of Hg.
#2) Dirtiness of tubes deteriorates vacuum by
(61.18 - 56.6) = 4.58 mbar =3 mm of Hg.
#3) Air ingress deteriorates vacuum by
(73.15 - 61.18) = 12 mbar = 9 mm of Hg.
 Conclusion

#1) Inlet temperature is slightly lower than

design value and hence little improvement in
vacuum by 24.4 mm of Hg.
#2) Tubes are dirty which deteriorates vacuum
by 3mm of Hg.
#3) There is a little air ingress which causes
vacuum deterioration by 9mm of Hg.
 Calculation for the TEST - 3
1) If all values of C.W. Inlet (C.W.), C.W. Rise (C.W.R) , T.T.D. are as per
design then
C.W.I.+C.W.R.+T.T.D.=30.5 + 8.79 +4.4 = 43.7 89.11 mbar
2) If only inlet water temperature is actual then
(C.W.I)a.+C.W.R.+T.T.D. =27.82 + 8.79 +4.4 =41 = 73.5 mbar
3) If both the inlet temperature and temperature rise is actual then
(C.W.I)a.+(C.W.R)a.+T.T.D.=27.82 + 11 +4.4 = 43.2 = 87.11 mbar
4) If all parameters are actual then
(C.W.I)a.+(C.W.R)a.+(T.T.D)a=27.82+11+15.4 = 54.22 = 151.62 mbar

Now effect of various parameters is as follows

#1) Cooler Circulating Water improves vacuum by
(73.5 - 89.11) = -15.61 mbar = -11.74 mm of Hg.
#2) Dirtiness of tubes deteriorates vacuum by
(87.11 - 73.5) = 13.61 mbar =10.23 mm of Hg.
#3) Air ingress deteriorates vacuum by
(151.62 - 87.11) = 64.51 mbar = 48.5 mm of Hg.
 Conclusion

#1) Inlet temperature is slightly lower than

design value and hence little improvement in
vacuum by about 13 mm of Hg.
#2) Tubes are dirty which deteriorates vacuum
by 10.23 mm of Hg.
#3) There is a little air ingress which causes
vacuum deterioration by around 50 mm of Hg