International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 8, August 2017, pp. 14901495, Article ID: IJMET_08_08_155

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

IAEME Publication Scopus Indexed

PERFORMANCE ANALYSIS OF
REGENERATIVE FEEDWATER HEATERS IN
210MW THERMAL POWER PLANT
A. Ashok Kumar, A. Buckshumiyanm
Assistant Professor, Bharath University, Chennai, Tamilnadu, India

ABSTRACT
The Regenerative system of a Thermal power station consists of low pressure
heaters, deaerator and high pressure heaters. All the components of the regenerative
system as whole, and heaters in particular, play a vital role in increasing the thermal
efficiency of the power plant.
In this work, an attempt has been made to evaluate the performance of the various
components of the regenerative system in our project titled PERFORMANCE
ANALYSIS OF REGENERATIVE FEED WATER HEATERS IN 210MW
THERMAL POWER PLANT. The working principle, construction and operation
which may frequently occur in the system are also narrated. [1-5]
The features like Terminal Temperature Difference, Drain Cooler Approach,
Temperature Rise and steam flow rate used in the components are clearly explained
and the evaluation is made by comparing the calculated values with that of design
values.
Key word: Thermal Power Plant, Feed Water Heaters
Cite this Article: A. Ashok Kumar and A. Buckshumiyanm, Performance Analysis of
Regenerative Feedwater Heaters In 210mw Thermal Power Plant, International
Journal of Mechanical Engineering and Technology, 8(8), 2017, pp. 14901495.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

1. INTRODUCTION
Neyveli Lignite Corporation Limited, a Navratna Government of India Enterprise, under the
administrative control of MOC has a chequered history of achievements in the last 56 years
since its inception in 1956.A pioneer among the public sector undertakings in energy sector,
NLC operates. Three Thermal Power Stations with a total installed capacity of 2490 Mega Watt
at Neyveli.
All the Mines of NLC are ISO Certified for Quality Management System, Environmental
management System and Occupational Health& Safety Management System. All the Power
stations of NLC are also ISO Certified for Quality Management System and Environmental
Management System. NLCs growth is sustained and its contribution to Indias social and
economic development is significant. The Regenerative system of a Thermal power station
consists of low pressure heaters, deaerator and high pressure heaters. All the components of

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 A. Ashok Kumar and A. Buckshumiyanm
the regenerative system as whole, and heaters in particular, play a vital role in increasing the
thermal efficiency of the power plant.
In this work, an attempt has been made to evaluate the performance of the various
components of the regenerative system in our project titled PERFORMANCE ANALYSIS
OF REGENERATIVE FEED WATER HEATERS IN 210MW THERMAL POWER
PLANT. The working principle, construction and operation which may frequently occur in
the system are also narrated.[10-14]
The features like Terminal Temperature Difference, Drain Cooler Approach, Temperature
Rise and steam flow rate used in the components are clearly explained and the evaluation is
made by comparing the calculated values with that of design values.
In unit-I performance test for heaters are conducted. The observations made are according
to plants current condition and is tabulated [15-18]. Calculation regarding TTD (Terminal
Temperature Difference), DCA (Drain Cooler Approach), TR (Temperature Raise),
Qe(Extracted Steam Quantity) are made.
The tabulation (TABLE-A) mentioned below is the average of five readings of all low
pressure and high pressure heaters and deaerator.

The table (Table-2) mentioned the readings are taken by considering the 100% D.C (Drain
condensate) flow in cascading order where there is no flow of D.C to F.T (flash tank) and the
observations are made. The readings of the table below are the average of the five readings.

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 Performance Analysis of Regenerative Feedwater Heaters In 210mw Thermal Power Plant

The indivisual table and Calculation for all the LPH (Low pressure heaters), HPH (high
pressure heaters) and Deaerator are given below along with the master Table i,e TABLE-B.

2. CERTAIN IMPORTANT CONCEPTS OF FEEDHEATERS

Feed heaters are said to be self-regulating as there are no control valves in the extraction steam
piping and yet the steam now adjusts itself in response to varying operating conditions [19-20].
Here is how it happens.
At any thermal equilibrium, the. Steam now rate equals the rate at which the steam condenses
in the feed heater. Steam leaks (eg. Through the feed heater vents, extraction steam piping
drainage equipment, etc.) and condensation in the piping are ignored here because they are
usually verysmall in comparison with the rate at which the steam condenses in the feedheater.
If we neglect the heat losses through the feed heater shell, the rate of steam condensation
depends on the rate at which
heat (h) is transferred from the
steam, as expressed by the familiar equations:
Q = UATm

3. VARIOUS OPERATING CONDITIONS AFFECT FACTORS OF THIS

EQUATION
The various operating conditions affect factors of this equation.
The overall heat transfer coefficient (U) depends on the tube cleanliness, concentration of gases
in the feed heater shell, and feed water and steam Velocities
The tube surface area available to heating steam (A) depends on the drains level and the number
of tubes plugged.
The mean temperature difference across the feed heater tubes depends on many operating
parameters as follows:
1. The feed water flow rate and inlet temperature because they affect the average feedwater
temperature inside the feed heater tubes.
2. The ternperature and pressure of the extraction steam at the feed heater inlet and the temperature
and flow rate of cascading drains (if any) because they affect the average temperature of steam
and drains outside the tubes.
If anyone of these parameters changes, the rate of heat transfer from the steam changes
accordingly. Consequently, the rate of steam condensation in the feed heater changes

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 A. Ashok Kumar and A. Buckshumiyanm
temporarily, ie. Before a new thermal equilibrium is established. This rate differs from the
extraction steam flow rate in the extraction steam piping. As a result, shell pressure changes as
well. This, combined. With a possible change in the extraction steam pressure at the turbine
end of the extraction steam piping (eg. due to turbine loading), affects the pressure drop across
this piping, and causes a corresponding change in the steam flow rate. These processes continue
until a new thermal equilibriumis reached. When the extraction steam flow rate balances the
rate of steam condensation.
The self-regulation is facilitated by small friction losses in the extraction steam piping
whose diameter is large enough to keep the steam velocity relatively low. Thus, it takes a small
change in the pressure drop in the piping to effect a large change in the steam flow. From the
above description, we can see how and why various operating conditions affect heat transfer
through feedheater tubes, [15] and consequently, the extraction steam flow. For example,
increased feed-water flow and solo wered inlet temperature enhance the heat transfer (by
increasing 6.Tm), thereby resulting in increased extraction steam flow. A similar effect is
caused by loss of the cascading drains or increased extraction steam temperature.
On the contrary, tube flooding or fouling, or poor venting of the feed heater shell impairs
heat transfer, thereby reducing the extraction steam flow.

4. SIGNIFICANCE OF FEED HEATER DRAINS LEVEL

If a feed heater drain level is too high,
3. May result in water induction to the turbine via the extraction steam piping. This may severely
damage the machine.
4. Reduces the overall thermal efficiency due to lowered feedwater outlet temperature as less heat
is transferred to the feedwater due to tube flooding.
5. 3. Decreased turbine efficiency due to a deviation from the design distribution of the extraction
steam. Flows to individual feedheaters. This changes the steam pressure profile along the
turbine and thus, the pressure ratio in groups of turbine stages between individual extraction
steam points. Impaired moisture removal from the turbine as the extraction steam flow is
decreased.
6. 4. Dumping of hot drains to the condenser (this is one of the automatic actions taken in response
to a high drains level). Not only does it cause a loss of drains heat from the cycle, but it can
also increase condenser pressure slightly.
Possible need to valve out the whole bank of feed heaters to prevent water induction to the
turbine. If a feed heater drains level is too low,
1. Equipment damage may occur due to the following some steam may leak into the drains
subcooling section. When pockets of this steam condense in the drains subcooling section,
water columns collide which produce violent steam hammer. The drains subcooling section
may suffer severe damage. If the level drops so much that steam can blow through the drains
subcooling section and the drains piping, the slugs of water carried by the blowing steam can
damage this equipment through water hammer.
2. Thefeedheater internals (tubes. baffles, impingement plates) can getdamaged due to
impingement and high flow induced vibration if Steam flows through the feedheater too fast.
This can happen
(Particularly in the HP feedheaters) if the drains dump valve failed in the open position,
creating a large pressure difference between the feedheater shell and the condenser.
3. The overall thermal efficiency is decreased if the low level is caused by the drains dump valve
failed open such that some of the feedheater drains flow directly to the condenser, the design
distribution of the extraction steam flows to individual feedheaters is upset. This happens when
the drains level is so low that some steam blows through the drains piping to the adjacent
feedheater operating at a low.
Performance test was conducted for feed water heaters in unit I. Initially with existing
condition using the test setup standards, test was conducted. In this test it was observed that

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 Performance Analysis of Regenerative Feedwater Heaters In 210mw Thermal Power Plant
TTD, DCA, TR and extraction steam flow of heaters vary with the design -values. Reason for
this variation was analyzed and found, that is due to improper functioning of Drain condensate
level control valves. Then by manual intervention with due care, maintaining drain condensate
level at design value, drain condensate flow made only through cascading order. This time the
values of key elements come closer to design value. Based on the analysis we recommend,
1. HPH-7 to HPFT.
2. HPH-6 to HPFT.
3. LPH-4 to LPFT.
Level control pneumatically operated valves are to be replaced. Remaining all LCVs to be
corrected by calibration.
Moreover sluggishness in LCV operation may lead to water entry to turbine also. To avoid
this LCV operation logic modification also possible. i.e , HPH-7, 6 to HPFT. LCV opens on
DC very high level logic to be modified to LCV opens on DC level high logic.
On the event of Turbine trip, extraction MOV to be closed. This logic may be included.
Preventive maintenance required for,
1. All extraction MOVs.
2. All FCNRV

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