How do you calculate the Deaerator & HP heaters steam consumption???

DEAERATORS:

What is the function of Deaerator?

Functions of deaerator

To remove the dissolved oxygen from deaerator & bringing down to <0.005 ppm

To heat the feed water

To provide NPSH to Boiler feed pumps

Acts as surge for feed water storage device

2-Which steam is used for deaerator?

Saturated steam having pressure from 0.3 to 3 kg/cm2 and temperature 130 deg C to 200 deg C

3-What are the pipe lines connected to Deaerator & storage tank?

Inlet lines:

• Make up water line
• Condensate water line from CEP
• Return condensate water from process
• Recirculation water line from BFP
• Balance leak off water lines from BFP
• Condensate water from HP & LP heaters
• Steam line from turbine extraction or PRDSH

Out let lines:

• Feed water line to BFP suction
• Deaerator overflow line
• Deaerator storage tank drain line

Understanding with examples.

1-Calculate the steam consumption of deaerator based on following given data

Sl No.	Particular	UOM	Value
1	LP steam flow to deaerator at pressure 1.5kg/cm2G & temperature 135 deg C t	TPH	?
2	Feed water outlet temperature from deaerator	0C	105
3	Feed water outlet flow from deaerator	TPH	125
4	CEP water flow to deaerator at temperature 50 deg C flow	TPH	120
5	Make up water to deaerator at temperature 25 deg C	TPH	5

        

 

 

 

 

 

 

 

 

 

Solution:

Enthalpy of steam at pressure 1.5 kg/cm2 & temperature 135 deg C = 653 kcal/kg

Enthalpy of CEP water at temperature 50 deg C = 50 kcal/kg

Enthalpy of makeup water at temperature 25 deg C = 25 kcal/kg

Enthalpy of deaerator outlet feed water = 106 kcal/kg

Mass of steam = (Feed water flow X Enthalpy –CEP flow X Enthalpy-Makeup water X Enthalpy) / (Enthalpy of steam-Enthalpy of deaerator outlet water)

Mass of steam      = 125 X 106 -120 X 50 -5 X 25 / (653-106)

Mass of steam = 13.02 MT

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2-Calculate the steam consumption of deaerator based on following given data

Sl No.	Particular	UOM	Value
1	LP steam flow to deaerator at pressure 2.5 kg/cm2G & temperature 150 deg C t	TPH	?
2	Feed water outlet temperature from deaerator	0C	128
3	Feed water outlet flow from deaerator	TPH	210
4	CEP water flow to deaerator at temperature 45 deg C flow	TPH	30
5	Make up water to deaerator at temperature 25 deg C	TPH	20
6	Process return condensate at temperature 95 deg C	TPH	160

        

 

 

 

 

 

 

 

 

 

 

 Solution:

Enthalpy of steam at pressure 2.5 kg/cm2 & temperature 150 deg C = 658.4 kcal/kg

Enthalpy of CEP water at temperature 45 deg C = 45 kcal/kg

Enthalpy of makeup water at temperature 25 deg C = 25 kcal/kg

Enthalpy of deaerator outlet feed water = 129 kcal/kg

Enthalpy of return condensate water = 96 kcal/kg

Mass of steam = (Feed water flow X Enthalpy –CEP flow X Enthalpy-Makeup water X Enthalpy-Return condensate X Enthalpy) / (Enthalpy of steam-Enthalpy of deaerator outlet water)

Mass of steam      = (210 X 129 -30 X 45 -20 X 25-160 X 96) / (658.4-129)

Mass of steam = 18.66 MT

HP & LP heaters:

1-What are the applications of HP & LP heaters?

HP & LP heaters are used to heat the feed water & to improve the cycle efficiency

 

2-What are the various pipe lines connected to HP heaters?

Inlet lines:

1-Feed water inlet line

2-Bleed steam line from Turbine

Outlet lines:

1-Feed water outlet line

2-Condensate outlet line

Understanding with examples.

A HP heater is used to heat the 105 TPH feed water from 105 °C to 150 °C by using turbine bleed steam at 8 kg/cm2 and 200 °C. The condensate returning from heater is at 125 °C, calculate the quantity of steam used.

 Given that,

Qf = 105 TPH

Tf1 = 105 °C

Tf2 = 150 °C

Hg at pressure 8 kg/cm2 & temperature 200 °C =677 kcal/kg

Enthalpy of condensate water Hf = 126 kcal/kg

Heat lost by the steam = Heat gained by feed water

Ms X (Hg-Hf) = Mw X (Tf2-Tf1)

Ms X (677-126) = 105 X (150-105)

Ms = 8.57 TPH

 

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Power plant & Calculations

Codes & standards of practice for thermal power plant equipments

Sl No.	Particular	Code/standards of practice
A	Boilers
1	Code of practice for Constructions in steel	IS 800
2	Rules for construction of power boilers	ASME Section I
3	IBR materials	ASME BPVC SEC-II
4	Construction of heating boilers	ASME BPVC SEC-IV
5	Non-destructive testing	ASME BPVC SEC-V
6	Code of practice for design loads for buildings structures.	IS 875
7	Criteria for Earthquake Resistant – Design of Structures	IS 1893
8	Code for unfired pressure vessels	IS 2825
9	Indian Boiler Regulation	IBR 1950
10	Welding and Brazing Qualifications	ASME Section IX
11	Power piping	ASME B 31.1
12	Construction of pressure vessels	ASME BPVC SEC-VIII
13	Acceptance test for steam generator	DIN 1942
14	APH performance test code	ASME PTC 4.3
15	Boiler performance test	ASME PTC 4.1
16	Deaerator performance test code	ASMEPTC 12.3
17	Specification for wrought aluminium and aluminium alloys sheet and strip (For General Engineering Purpose)	IS 737
18	Design & construction of RCC chimney	IS 4998-1992
B	REFRACTORY & INSULATION
1	Moderate heat duty fire clay refractories Group-A	IS:6
2	High heat duty fire clay refractories	IS:8
3	Insulating bricks	IS : 2042
4	Method of determination of thermal conductivity of thermal insulation material	IS3346
5	Code of practice for storage and handling of insulating materials	IS10556
6	Industrial application and finishing of thermal insulting materials at temperatures above 80 deg C and up to 700 Deg. C	IS14164
7	Specification for Bonded Mineral Wool	IS: 8183
8	Hexagonal wire netting for general purpose	IS 2150
9	Methods of test for mineral Wool Thermal Insulation Material	IS3144
C	STEAM TURBINE & AUXILARIES
1	Duplex oil coolers design	ASME SEC-VIII, TEMA “C”
2	Steam ejector design	ASME SEC-VIII, DIV-1,TEMA “C”
3	Steam condenser design	HEI-IX EDITION
4	Thermal acceptance test for steam turbine	DIN 1943
5	Steam turbine performance test	ASME PTC 6
6	Surface condenser performance test codes	ASME PTC 12.2
7	Overall plant performance	ASMEPTC 46
D	WTP
1	Chemical dosing tanks design	BS 4994 1987
2	DM water storage  tank	IS 803
3	WTP vessels design	IS 2825
E	PUMPS ,COMPRESORS & FANS
1	Centrifugal pumps performance test code	ASME PTC 8.2
2	Design of Pumping Systems that use Centrifugal Pumps	PIP RECP001
3	Design of ASME B73.1 and General Purpose pump Base plates	PIP RESP002
4	Seal Flush and Lubrication Guidelines for Centrifugal Pumps	PIP REEP001
5	Compressors  performance test codes	ASMEPTC 10
6	Guide for selection installation and maintenance of air Compressor up to 10 bars.	IS 6206
7	Code of practice for testing of positive air displacement type Compressors and exhausters	IS 5456
8	Air receivers for compressed air installation	IS: 7938
9	Fans  performance test codes	ASMEPTC 11
F	BELT CONVEYORS
1	Specification for troughed belt conveyors	IS: 1891
2	Code of practice for conveyor safety	IS: 4776
3	Specification for pulleys for belt conveyors	IS: 7403
4	Specification for idlers for belt conveyors	IS8598
G	MAINTENANCE
1	Bars and Keyways for Flexible couplings	AGMA 9002
2	Pipe Threads, General Purpose	ASME B1.20.1
3	Cast Iron Pipe Flanges and Flanged Fittings	ASME B16.1
4	Pipe flanges and flanged fittings	ASME B 16.5
5	Roller Bearings –Dynamic Load Ratings and Rating Life – Part 1 : Calculation Methods.	ASME STD 9
6	Specification  for  Forgings,  Carbon  steel,  for  Piping Components	ASTM  A105
7	Specification for Seamless Carbon Steel Pipe for High Temperature Service.	ASTM A106
H	ELECTRICAL & INSTRUMENTATION
1	Design of Power transformer	IS 2026
2	Code of practice for earthing.	IS: 3043 - 1987
3	Guide for safety procedures and practices in electrical work: General.	IS: 5216(Part-1)-1982
4	General requirements for switchgear and control gear for voltages not exceeding 1000 V AC or 1200 V DC	IS:4237 - 1983
5	Air break switches, air break dis-connectors, air-break switch disconnectors and fuse-combination units for voltages not exceeding 1000 V AC or 1200 DC : General requirements	IS:4064(Part-1)-1978
6	Miniature air break circuit breakers for voltages not exceeding 1000 volt	IS: 8828 - 1978
7	Residua current operated circuit breakers.	IS:12640 - 1988
8	Contactors for voltages not exceeding 1000 V AC or 1200 V DC.	IS:2959 - 1985
9	PVC Insulated cables for working voltages up to and including 1100 V.	IS:694 - 1990