A STUDY ON LIFE MANAGEMENT AND ECONOMIC ANALYSIS OF

FEED 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

NATIONAL POWER TRAINING INSTITUTE (HPTC)

(AN ISO 9001:2000 & 14001 ORGANISATION)
UNDER MINISTRY OF POWER, GOVT. OF INDIA
NANGAL, 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. SAURABH
KUMAR,RESHAB GOHAIN,SUNNY DEOL,SANJAY SHARMA under my
supervision in partial fulfillment for the requirement of Post Graduate Diploma
Course in Thermal Power Plant Engineering, during the session 2013-2014 in
National Power Training Institute, Nangal (HPTC), PUNJAB-140124.

GUIDED BY
SH. RAJNEESH VACHASPATI
ASTT. DIRECTOR
NPTI, HPTC,NANGAL

COURSE DIRECTOR
SH. RAJNEESH VACHASPATI
ASTT. DIRECTOR
NPTI, HPTC, NANGAL

Sh. S.K. SINHA

DIRECTOR
NPTI, HPTC, NANGAL

Sh. M.R. CHAUBE

PRINCIPAL DIRECTOR
NPTI, HPTC, NANGAL

ACKNOWLEDGEMENT

I am thankful to Shri M.R. CHAUBE, Principal Director, NPTI (HPTC),

NANGAL, for extending valuable training reserve unit facilities.
I am also thankful to Sh. S.K. SINHA, Director, NPTI (HPTC), NANGAL.
I gratefully acknowledge my guide Sh. Rajneesh Vachaspati , Astt. Director,
NPTI (HPTC), NANGAL for his advice and guidance which formed the backbone
of this project study. His sincere involvement with his originality has triggered and
nourished my intellectual maturity that I will benefit from, for a long time to come.
I am thankful to him for his constructive criticism and appraisal of the work. I
express my deepest gratitude to him.
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.

SAURABH KUMAR
RESHAB GOHAIN
SUNNY DEOL
SANJAY SHARMA

ABSTRACT
Life Management of feed water heater
3

As part of a strong life management program, a life evaluation can postpone the replacement of
major components to future years. A physical condition assessment is the first step in a life
evaluation. It requires the following information: 1) Original design data; 2) Component
operating data; 3) Knowledge of current industry practices; and, 4) Detailed component
inspections.

Economic analysis
A small fraction of steam expanding through the turbine is bled off from different stages of
Turbine before reaching the Condenser. Bled off steam is used to heat feed water feed heaters.
The highest theoretical temperature to which the feed water may be raised in the heater is the
saturation temperature of the bled steam. Maximum Feed water temperature rise with minimum
loss of Mechanical power at the Turbine. The steam having given up a proportion of its work to
the Turbine. Thus gives up all its latent heat, which would otherwise be lost to the condenser
circulating water.
The factors governing the feed heaters performance and its impact on various parameters like
Terminal temperature difference, drain cooling approach, temperature rise in feed water are to be
analyzed.
A very important economic analysis in feed heaters. If one of the H.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. 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.
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; 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.

CONTENTS
No.

Details

Page

1.
2.

3.

4.

5.
6.

Introduction
1.1 Importance of Regenerative Feed Heating System
Regenerative Feed Heating System
2.1 Qualities of Steam Extraction
2.2 Advantages
2.3 Disadvantages
2.4 Types of Feed Heaters
2.5 Governing Parameters of Heater Performance
2.6 Main Factors Considered For Feed Water Heating System
2.7 Low Pressure Heaters
2.8 High Pressure Heaters
2.9 Feed Regulating Station
Life Management of Feed Water Heaters
3.1 Failure Modes of Feed Water Heaters
3.2 Physical Condition Assessment
3.3 Economic Assessment
Economic Analysis
4.1 Factors Influencing Feed Heater Performance
4.2 Analysis without HP-5
4.3 Analysis without HP-6
4.4 Analysis without Both Heaters
Conclusion
References

LIST OF FIGURES

S. No.

Detail

Page No.

Thermal cycle with regenerative feed heating system

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

Heat Transfer within a High Pressure Feed Water Heater

15

HP Heater Carbon steel Tube Life Cycle

19

Feed Heater

22

Fig 1.Basic graphical representation of thermal cycle with regenerative feed heating system
6

These conclusions emphasis the importance of feed heating and its impact and another
simple way of improving the plant thermal efficiency.

Sl.
No.

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

Both HP
Heaters in
Service

2012.7

Base

2410C

640

440

2.

HPH 5 not in
service

2020.2

7.5

2300C

610

450

3.

HPH 6 not in
service

2035.5

22.8

2000C

600

4.

Both HP
Heaters not in
service

2048.2

35.5

1750C

580

210

Steam Flow
Condenser T /
hr

455
475

FINAL CONCLUSIONS:
1) It improves cycle efficiency by around 6% to 7%.
2) Metal temperature of boiler pressure parts is reduced and hence longer running life.
3) Reduction in super heater & Re-heater attemperation.
7

4) Reduction in steam flow to condenser.

5) Reduction in cooling water in condenser.
6) Reduction in the size of the condenser.
7) Reduction in the size of the Cooling Tower.

5. REFERNCES
1. Beckerdite, G., 1991, Life Assessment and Management Program for Feedwater
Heaters, KCPL LAMP, Kansas City Power and Light Company, Kansas City, MO
2. Bell, R., 1995, Condition Assessment of Closed Feedwater Heater, EPRI FW Heater
Technology Symposium, Electric Power Research Institute, Palo Alto, CA, September
22-24.
3. Bell, R., and Diaz-Tous, I., 1984, High Reliability Feedwater Heaters, Edison
Electric Institute Prime Movers and Nuclear Committee, Edison Electric Institute, New
Orleans, LA, January 29.
4. Jacobstein, A.R., Quinn, J.A., Wadsworth, F.L., and Wellens, R.S., 1981, Failure Cause
Analysis Feedwater Heaters, Electric Power Research Institiute, Technical Report
Number CS-1776, April.
5. Krzywosz, K., 1995, Feedwater Heater Condition Assessment- an NDE Perspective,
EPRI FW Heater Technology Symposium, Electric Power Research Institute, Palo Alto,
CA, September 22-24.
6. Linley, F., 1988, Feedwater Heater Life Extension via Programs for Shell Liquid Level,
Venting and Allied Systems, EPRI FW Heater Technology Symposium, Electric Power
Research Institute, Palo Alto, CA.
8

7. Energy audit report of unit 3 and 5,of Guru Gobind Singh Thermal Plant, Roopnagar.
Project report no. 2007IE07