A STUDY ON LIFE MANAGEMENT AND ECONOMIC ANALYSIS OFFEED WATER HEATERS A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT FOR THE REQUIREMENT OF POST GRADUATE DIPLOMA IN THERMAL POWER PLANT ENGINEERING 2013-2014 SUBMITTED BY SANJAY SHARMA SAURABH KUMAR RESHAB GOHAIN SUNNY DEOL SINGH UNDER THE GUIDANCE OF SH. RAJNEESH VACHASPATI ASSISTANT DIRECTOR NPTI, HPTC, NANGAL NATIONAL POWER TRAINING INSTITUTE (HPTC) (MINISTRY OF POWER, GOVT. OF INDIA) NANGAL,PUNJAB-140124 HPTC. M. GOVT. DIRECTOR NPTI. OF INDIA NANGAL. PUNJAB-140124. CHAUBE PRINCIPAL DIRECTOR NPTI. S. HPTC. DIRECTOR NPTI. SINHA DIRECTOR NPTI.NATIONAL POWER TRAINING INSTITUTE (HPTC) (AN ISO 9001:2000 & 14001 ORGANISATION) UNDER MINISTRY OF POWER.K.SANJAY SHARMA under my supervision in partial fulfillment for the requirement of Post Graduate Diploma Course in Thermal Power Plant Engineering.RESHAB GOHAIN. RAJNEESH VACHASPATI ASTT. NANGAL Sh. RAJNEESH VACHASPATI ASTT. during the session 2013-2014 in National Power Training Institute. GUIDED BY SH.SUNNY DEOL. NANGAL Sh. NANGAL 2 . HPTC. Nangal (HPTC). SAURABH KUMAR.R.NANGAL COURSE DIRECTOR SH. HPTC. PUNJAB-140124 CERTIFICATE This is to certify that the work entitled “A COMPARATIVE STUDY OF DRUM LEVEL CONTROL BY BFP SCOOP OPERATION IN THREE ELEMENT MODE INSTEAD OF DP MODE” has been carried out by Mr. I express my deepest gratitude to him. CHAUBE. Director. I gratefully acknowledge my guide Sh. NPTI (HPTC). for a long time to come. SINHA. S. NANGAL. I am thankful to him for his constructive criticism and appraisal of the work. Director. NPTI (HPTC). SAURABH KUMAR RESHAB GOHAIN SUNNY DEOL SANJAY SHARMA ABSTRACT Life Management of feed water heater 3 . for extending valuable training reserve unit facilities. His sincere involvement with his originality has triggered and nourished my intellectual maturity that I will benefit from. Astt.K. NPTI (HPTC). At last but not the least I would like to express my sincere thanks to all who contributed directly and indirectly for completion of my project.ACKNOWLEDGEMENT I am thankful to Shri M. NANGAL. I am also thankful to Sh.R. Principal Director. NANGAL for his advice and guidance which formed the backbone of this project study. Rajneesh Vachaspati . If one of the H. The steam having given up a proportion of its work to the Turbine.As part of a strong life management program. Similarly when both of the heaters are out of service and its added cost for same power output are to be discussed in the project.P heaters is not present or out of service it will cause excess heat rate on Turbine for same power output In turn more fuel is spent for raising feed water temperature. It requires the following information: 1) Original design data. 4) Detailed component inspections. 3) Knowledge of current industry practices. Bled off steam is used to heat feed water feed heaters. Maximum Feed water temperature rise with minimum loss of Mechanical power at the Turbine. a life evaluation can postpone the replacement of major components to future years. which would otherwise be lost to the condenser circulating water. Details Page 4 . associated performance indicators and the positive or negative impact of level control on overall plant efficiency as related to net unit heat rate and cost containment. Thus gives up all its latent heat. The highest theoretical temperature to which the feed water may be raised in the heater is the saturation temperature of the bled steam. and. A very important economic analysis in feed heaters. drain cooling approach. A physical condition assessment is the first step in a life evaluation. 2) Component operating data. The project will also deal with how to minimize controllable losses tied to feed water heater performance by gaining additional insight into the basic feed water heater and power cycle operations. temperature rise in feed water are to be analyzed. The factors governing the feed heaters performance and its impact on various parameters like Terminal temperature difference. Economic analysis A small fraction of steam expanding through the turbine is bled off from different stages of Turbine before reaching the Condenser. CONTENTS No. 1 Qualities of Steam Extraction 2.3 Disadvantages 2. 3. 1 Thermal cycle with regenerative feed heating system 4 2 High Pressure Feed Heater 9 5 5 5 5 5 5 6 6 6 7 8 8 9 10 10 13 18 20 20 22 23 24 26 28 .1 Factors Influencing Feed Heater Performance 4. Detail Page No.6 Main Factors Considered For Feed Water Heating System 2. 4.9 Feed Regulating Station Life Management of Feed Water Heaters 3. 5.7 Low Pressure Heaters 2. Introduction 1.4 Types of Feed Heaters 2.1.2 Advantages 2.5 Governing Parameters of Heater Performance 2.2 Analysis without HP-5 4.2 Physical Condition Assessment 3. No. 2.1 Importance of Regenerative Feed Heating System Regenerative Feed Heating System 2.3 Analysis without HP-6 4. 6.4 Analysis without Both Heaters Conclusion References LIST OF FIGURES S.1 Failure Modes of Feed Water Heaters 3.3 Economic Assessment Economic Analysis 4.8 High Pressure Heaters 2. 3 Heat Transfer within a High Pressure Feed Water Heater 15 4 HP Heater Carbon steel Tube Life Cycle 19 5 Feed Heater 22 Fig 1.Basic graphical representation of thermal cycle with regenerative feed heating system 6 . 2 7. No.These conclusions emphasis the importance of feed heating and its impact and another simple way of improving the plant thermal efficiency. Availability of HP Heaters Gross Heat Rate Kcal / kWhr Increase in Heat rate Kcal / kWhr Feed Water temp to boiler Main Steam Flow T/hr Unit Load MW 1 Both HP Heaters in Service 2012.5 2300C 610 450 3.8 2000C 600 4. Sl. 7 . 3) Reduction in super heater & Re-heater attemperation.5 1750C 580 210 Steam Flow Condenser T / hr 455 475 FINAL CONCLUSIONS: 1) It improves cycle efficiency by around 6% to 7%.2 35. Both HP Heaters not in service 2048. 2) Metal temperature of boiler pressure parts is reduced and hence longer running life. HPH 5 not in service 2020.5 22. HPH 6 not in service 2035.7 Base 2410C 640 440 2. CA. Electric Power Research Institiute.” EPRI FW Heater Technology Symposium.A. Venting and Allied Systems. 8 . Electric Power Research Institute. and Diaz-Tous.. CA.. F.” EPRI FW Heater Technology Symposium.. “Condition Assessment of Closed Feedwater Heater. “Life Assessment and Management Program for Feedwater Heaters. 1988. 3.” KCPL LAMP. Electric Power Research Institute. Kansas City. “Feedwater Heater Life Extension via Programs for Shell Liquid Level. April.R. K. Wadsworth.S.an NDE Perspective. 6) Reduction in the size of the condenser. Krzywosz. Failure Cause Analysis Feedwater Heaters.. R. R. 6. ”EPRI FW Heater Technology Symposium. “High Reliability Feedwater Heaters. G.. Beckerdite. LA. Linley.. R. 7) Reduction in the size of the Cooling Tower. 5) Reduction in cooling water in condenser.4) Reduction in steam flow to condenser. CA. New Orleans. and Wellens. MO 2. F. J. 1995.. 1984.” Edison Electric Institute Prime Movers and Nuclear Committee. Quinn.. 1995. Bell. A. Jacobstein. Palo Alto. Edison Electric Institute.. “Feedwater Heater Condition Assessment. REFERNCES 1. January 29.. 4. Technical Report Number CS-1776. Bell. 5. Electric Power Research Institute. September 22-24. Kansas City Power and Light Company.L. 1991. Palo Alto. 5. September 22-24. 1981. I. Palo Alto. Project report no.7. Energy audit report of unit 3 and 5. 2007IE07 9 . Roopnagar.of Guru Gobind Singh Thermal Plant.