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HP Heater Performance

Wednesday, June 28, 2017   By: India [1739] 1 Stars
Dear All

We have been operating a power plant of capacity 27 MW with a single HP Heater. The design data and the operating data for two days at a PLF of 103% is indicated in that table below.

Parameter Unit HPH -Design 24-Jun-17 25-Jun-17

Feed Flow rate through Heater TPH 111.88 115.02 116.53

Feed Water Pressure at Heater Inlet kg/cm2 130 124.57 125.12

Feed Water Inlet Temperature Deg C 176.2 177.69 178.02

Feed Water Pressure at Heater Outlet Deg C 129 123.99 124.53

Feed Water Outlet Temperature Deg C 235 230.47 230.85

Heater Shell Pressure kg/cm2 32.955 35.40 35.47

Temperature of Extraction Steam Deg C 387.3 396.6 396.9

Heater Drain Outlet Temperature Deg C 182.2 195.65 202.93

From the above data it is clear that we are not able to achieve the design outlet temperature of 235 Deg c. The heater has been cleaned , the end cover opened and checked for any leakage/bypass.

We are contemplating to even replace the Heater but not able to do so since we are not sure if the new one will help us to achieve. I would like to have your suggestions of what further checking needs to be done on the heater and also any designer who can vet my existing design and confirm the possibility of achieving the out let temperature.

Thanks in advance
Regards

Nachaippan

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Wednesday, June 28, 2017   By: Ahsan [2077] 1 Stars
Dear Nachaippan,
According to Your provided data of 3 days Feed water outlet temperature is: 235, 230.47, 230.85 *C.
Isnt it very close to the design point 235 *C ?

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Wednesday, June 28, 2017   By: Ross [390] 5 Stars
I think the layout meant to say the design is 235C and the 1st day is 230.47C and the next day the temperature is 230.85C.

Ross

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Thursday, June 29, 2017   By: Ahsan [2077] 1 Stars
Oh! yes. My mistake.

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Thursday, June 29, 2017   By: Jim Watts [764] 5 Stars
One of the biggest problems occurring in HP heaters is level control in the heater.
Your drain temperature variation over the two days indicates your level is not constant and is also low.
You should stabilize the heater level at its correct height and check performance again. The level will be about correct when the drain temperature is about design temperature.

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Tuesday, July 11, 2017   By: Nachiappan [1739] 1 Stars
We have tried changing the level in the Heater and the current level is the most optimum point Any increase or decrease in level was leading to lower temperatures ie. below 230 deg c.

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Wednesday, July 12, 2017   By: Jim Watts [764] 5 Stars
You cannot be at optimum as it is not a constant level. Your drain temperature should be the same all the time.

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