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Boiler_Condensate and Feed Water System_Principle_Components_Problemsشرح نظام المتكاثف والمياه ا
WEBVTT Kind: captions Language: en
00:00:01.129 the main steam system in a power plant 00:00:03.97000:00:03.980 controls the flow of high-temperature 00:00:06.34900:00:06.359 high-pressure steam as it moves from a 00:00:09.14000:00:09.150 boiler to a turbine and is used to drive 00:00:11.50900:00:11.519 a generator to increase overall plant 00:00:14.81000:00:14.820 efficiency some steam is extracted from 00:00:17.39000:00:17.400 the turbine and used to heat the feed 00:00:19.70000:00:19.710 water for the boiler the rest of the 00:00:22.51900:00:22.529 steam is exhausted from the turbine to a 00:00:24.56000:00:24.570 main condenser condensate from the main 00:00:28.31000:00:28.320 condenser goes through the condensate 00:00:30.56000:00:30.570 system and becomes feed water that 00:00:34.28000:00:34.290 returns to the boiler through the feed 00:00:36.08000:00:36.090 water system in this way the condensate 00:00:39.79900:00:39.809 in feed water systems work together to 00:00:42.20000:00:42.210 supply water at the proper rate to 00:00:44.54000:00:44.550 support normal boiler operation because 00:00:47.86900:00:47.879 the functions of these two systems are 00:00:49.72900:00:49.739 interdependent they're often considered 00:00:52.27900:00:52.289 one system the condensate and feed water 00:00:55.25000:00:55.260 system to maintain normal operation of a 00:00:59.75000:00:59.760 power plants boiler the water going into 00:01:02.77900:01:02.789 the boiler must be equal to the amount 00:01:05.45000:01:05.460 of steam that leaves the boiler and 00:01:07.64000:01:07.650 enters the main steam system keeping the 00:01:11.12000:01:11.130 boiler supplied with the proper amount 00:01:12.98000:01:12.990 of water is the job of the condensate 00:01:15.59000:01:15.600 and feed water system this simplified 00:01:19.07000:01:19.080 illustration shows the arrangement or 00:01:21.26000:01:21.270 layout of some of the major components 00:01:23.06000:01:23.070 of a typical condensate in feed water 00:01:25.78900:01:25.799 system and a main steam system included 00:01:29.71900:01:29.729 are a boiler a turbine a main condenser 00:01:36.10900:01:36.119 a feed water storage tank and various 00:01:41.89900:01:41.909 pumps heaters valves and piping the area 00:01:50.27000:01:50.280 between the main condenser and the 00:01:52.10000:01:52.110 suction of this pump the boiler feed 00:01:54.80000:01:54.810 pump is the condensate side of the 00:01:57.53000:01:57.540 system we'll look at it first additional 00:02:02.89900:02:02.909 systems are often connected to the basic 00:02:05.17900:02:05.189 condensate system that we've just seen 00:02:07.90000:02:07.910 typically a chemical addition system is 00:02:11.30000:02:11.310 connected to the condensate system 00:02:13.77000:02:13.780 in some cases however a chemical 00:02:16.05000:02:16.060 addition system may be connected to both 00:02:18.36000:02:18.370 the condensate side and the feed water 00:02:20.88000:02:20.890 side of the system or just to the feed 00:02:23.43000:02:23.440 water side in any case the chemical 00:02:26.58000:02:26.590 addition system has equipment for adding 00:02:28.92000:02:28.930 chemicals that minimize corrosion and 00:02:31.44000:02:31.450 control the pH of the condensate or 00:02:33.87000:02:33.880 water pH is a measure of how acid or 00:02:37.68000:02:37.690 alkaline the water is usually a 00:02:40.92000:02:40.930 condensate system also has a make up 00:02:43.62000:02:43.630 water system that is connected to the 00:02:45.84000:02:45.850 hot well the makeup water system 00:02:48.51000:02:48.520 includes a condensate storage tank and 00:02:51.22900:02:51.239 purification equipment that is used to 00:02:53.52000:02:53.530 add pure water to the condensate system 00:02:56.39000:02:56.400 the added water compensates for water 00:02:59.61000:02:59.620 losses that may occur during normal 00:03:01.94900:03:01.959 system operation or from leaks finally 00:03:05.82000:03:05.830 various components in the condensate 00:03:08.04000:03:08.050 system are also equipped with 00:03:09.84000:03:09.850 instruments that measure pressures 00:03:11.82000:03:11.830 temperatures levels and flows these 00:03:15.90000:03:15.910 measurements are used in control loops 00:03:18.15000:03:18.160 that regulate operation of the system 00:03:20.34000:03:20.350 and give operators an indication of how 00:03:22.94900:03:22.959 the system is functioning we've covered 00:03:26.49000:03:26.500 the condensate side of the condensate in 00:03:28.92000:03:28.930 feed water system next we'll look at the 00:03:32.75900:03:32.769 feed water side now let's trace the flow 00:03:38.46000:03:38.470 of feed water through the system 00:03:40.17000:03:40.180 starting with the boiler feed booster 00:03:42.75000:03:42.760 pumps not all feed water systems have 00:03:45.96000:03:45.970 boiler feed booster pumps but in this 00:03:48.50900:03:48.519 case there are three of them these pumps 00:03:51.75000:03:51.760 increase the pressure of the feed water 00:03:53.69900:03:53.709 coming from the intermediate pressure 00:03:55.50000:03:55.510 heaters and send the water to the boiler 00:03:58.50000:03:58.510 feed pumps in this example there are two 00:04:02.49000:04:02.500 boiler feed pumps they increase the feed 00:04:05.97000:04:05.980 water pressure further so it's high 00:04:08.16000:04:08.170 enough for the water to move through the 00:04:10.14000:04:10.150 downstream components from the boiler 00:04:13.59000:04:13.600 feed pumps the feed water enters a 00:04:15.81000:04:15.820 series or train of high pressure feed 00:04:18.71900:04:18.729 water heaters after passing through 00:04:21.59900:04:21.609 these heaters the feed water is ready to 00:04:24.48000:04:24.490 go to the boiler 00:04:27.18000:04:27.190 feedwater regulating valve controls the 00:04:30.30000:04:30.310 flow of feed water from the 00:04:31.68000:04:31.690 high-pressure heaters into the boilers 00:04:33.87000:04:33.880 economizer the economizer is the section 00:04:38.34000:04:38.350 of the boiler where combustion gases 00:04:40.44000:04:40.450 leaving the boiler are used to preheat 00:04:43.14000:04:43.150 the feed water that is entering the 00:04:45.15000:04:45.160 boiler finally as with the condensate 00:04:49.02000:04:49.030 system the feed water system also 00:04:51.36000:04:51.370 includes instruments for level flow 00:04:54.23000:04:54.240 temperature and pressure indication and 00:04:57.06000:04:57.070 control one more system that we need to 00:05:03.36000:05:03.370 look at is the extraction steam system 00:05:06.33000:05:06.340 which serves both sides of the 00:05:08.46000:05:08.470 condensate and feed water system steam 00:05:11.40000:05:11.410 is extracted from the turbine and used 00:05:13.95000:05:13.960 as the heating fluid in heaters 00:05:15.81000:05:15.820 throughout the condensate and feed water 00:05:17.76000:05:17.770 system steam from a high pressure 00:05:20.91000:05:20.920 section of the turbine is generally used 00:05:23.67000:05:23.680 in the high-pressure feed water heaters 00:05:26.60000:05:26.610 steam from the intermediate pressure 00:05:29.04000:05:29.05000:05:31.68000:05:31.690 in the intermediate pressure heaters and 00:05:33.84000:05:33.850 in the deaerator 00:05:35.75000:05:35.760 steam from the low-pressure section of 00:05:38.46000:05:38.470 the turbine is used in the low pressure 00:05:40.53000:05:40.540 heaters heating the condensate in feed 00:05:43.53000:05:43.540 water with the steam from the different 00:05:45.45000:05:45.460 sections of the turbine increases 00:05:47.82000:05:47.830 overall plant efficiency 00:05:51.40900:05:51.419 although the examples that we've looked 00:05:53.88000:05:53.890 at are typical layouts there are also 00:05:56.70000:05:56.710 many other ways that a condensate and 00:05:59.04000:05:59.050 feed water system can be arranged you'll 00:06:02.15900:06:02.169 need to look at your plants piping and 00:06:04.17000:06:04.180 Instrumentation diagrams to check the 00:06:06.75000:06:06.760 exact layout of the system in your 00:06:08.67000:06:08.680 facility although the exact arrangement 00:06:13.89000:06:13.900 of components in a condensate and feed 00:06:16.20000:06:16.210 water system can vary several pieces of 00:06:19.20000:06:19.210 equipment are common to most systems in 00:06:22.08000:06:22.090 this part we'll look at the major 00:06:24.06000:06:24.070 components of a typical condensate in 00:06:26.52000:06:26.530 feed water system we'll begin with the 00:06:30.09000:06:30.100 hot well the hot well is the bottom 00:06:32.85000:06:32.860 section of the main condenser condensate 00:06:36.09000:06:36.100 from the main condenser collects here 00:06:38.19000:06:38.200 and is then sent on through the con 00:06:40.50000:06:40.510 seyton feed water system where the 00:06:42.81000:06:42.820 temperature and pressure of the 00:06:44.19000:06:44.200 condensate are gradually increased sight 00:06:48.00000:06:48.010 glasses indicate the level in the hot 00:06:50.13000:06:50.140 well a level control loop is used to 00:06:53.49000:06:53.500 maintain the correct level of condensate 00:06:56.72000:06:56.730 maintaining the correct level in the hot 00:06:59.04000:06:59.050 well is critical for proper operation of 00:07:01.92000:07:01.930 the main condenser also a low level in 00:07:05.82000:07:05.830 the hot well could cause the condensate 00:07:08.01000:07:08.020 pumps downstream to lose their prime and 00:07:10.74000:07:10.750 be damaged a condensate and feed water 00:07:16.35000:07:16.360 system also has several condensers and 00:07:19.44000:07:19.450 heaters most of these are some type of 00:07:22.95000:07:22.960 shell and tube heat exchanger for 00:07:25.52000:07:25.530 example the initial warming of the 00:07:28.32000:07:28.330 condensate from mehat well is achieved 00:07:31.05000:07:31.060 by using the condensate as the cooling 00:07:33.66000:07:33.670 fluid in condensers glands steam 00:07:37.35000:07:37.360 condensers recover heat from the steam 00:07:39.60000:07:39.610 used in the plants gland steam system 00:07:43.04000:07:43.050 error ejected n sirs recover heat from 00:07:46.89000:07:46.900 the steam in the main condensers air 00:07:48.75000:07:48.760 removal system both of these types of 00:07:52.59000:07:52.600 condensers are usually shell and tube 00:07:55.02000:07:55.030 heat exchangers a shell and tube heat 00:07:57.87000:07:57.880 exchanger has a shell or casing with a 00:08:01.95000:08:01.960 bundle of tubes inside the area that's 00:08:05.55000:08:05.560 within the shell and outside of the 00:08:07.65000:08:07.660 tubes is called the shell side of the 00:08:10.11000:08:10.120 heat exchanger the area that's within 00:08:13.53000:08:13.540 the tubes is called the tube side of the 00:08:16.17000:08:16.180 heat exchanger the heat exchangers that 00:08:20.01000:08:20.020 are used as condensers in the condensate 00:08:22.62000:08:22.630 and feed water system have condensate in 00:08:25.59000:08:25.600 the tube side and steam from the gland 00:08:29.10000:08:29.110 steam system or the air removal system 00:08:31.74000:08:31.750 in the shell side during the heat 00:08:34.83000:08:34.840 exchange process the steam is cooled and 00:08:37.77000:08:37.780 the condensate in the condensers is 00:08:39.96000:08:39.970 heated you tube shell and tube heat 00:08:43.50000:08:43.510 exchangers are used as heaters to heat 00:08:46.56000:08:46.570 the condensate and feed water that moves 00:08:48.60000:08:48.610 through the system 00:08:51.05000:08:51.060 condensate or feed water flows through 00:08:53.64000:08:53.650 the two 00:08:54.12000:08:54.130 side of the heater and extraction steam 00:08:57.48000:08:57.490 from the appropriate section of the 00:08:59.25000:08:59.260 turbine flows through the shell side 00:09:02.30000:09:02.310 because the steam doesn't come in 00:09:04.59000:09:04.600 contact with the condensate or feed 00:09:06.57000:09:06.580 water in the heater the heater is called 00:09:09.30000:09:09.310 a closed heater some plants have 00:09:13.08000:09:13.090 parallel trains or strings of heaters 00:09:15.63000:09:15.640 with several heaters in each train all 00:09:18.99000:09:19.000 the heaters use extraction steam from 00:09:21.42000:09:21.430 the turbine to heat condensate or feed 00:09:23.64000:09:23.650 water typically to recover the maximum 00:09:28.56000:09:28.570 amount of heat from the extraction steam 00:09:30.69000:09:30.700 a train of heaters uses a cascading 00:09:34.08000:09:34.090 drain system in each heater in the Train 00:09:37.71000:09:37.720 drips are sub cooled by the transfer of 00:09:40.35000:09:40.360 heat to the feed water in the heaters 00:09:42.75000:09:42.760 drain cooler section this helps keep the 00:09:45.60000:09:45.610 drips from flashing to steam in the 00:09:47.85000:09:47.860 drain line the flow of drips moves from 00:09:51.12000:09:51.130 the highest pressure heater to the lower 00:09:53.28000:09:53.290 pressure heaters that is the drips flow 00:09:57.03000:09:57.040 through the normal drain line from one 00:09:59.13000:09:59.140 heater into the shell side of the next 00:10:01.71000:10:01.720 heater in the Train this heater has a 00:10:04.50000:10:04.510 lower temperature and a lower shell side 00:10:07.11000:10:07.120 pressure than the first heater has the 00:10:10.77000:10:10.780 drips flash to steam because of the 00:10:13.29000:10:13.300 lower pressure within the heater shell 00:10:15.47000:10:15.480 the drips also mix with the extraction 00:10:18.51000:10:18.520 steam that's already in the shell thus 00:10:21.54000:10:21.550 the drips are another source of heat to 00:10:24.15000:10:24.160 be transferred to the feed water in the 00:10:26.10000:10:26.110 tube side of the heater in our example 00:10:29.79000:10:29.800 the flashing and condensing process for 00:10:32.61000:10:32.620 the drips continues through the Train of 00:10:35.04000:10:35.050 heaters until the drips from the heater 00:10:37.47000:10:37.480 that has the lowest shell temperature 00:10:39.48000:10:39.490 and pressure flow into the deaerator 00:10:42.00000:10:42.010 and become part of the feed water in 00:10:45.00000:10:45.010 other cases such as in the operation of 00:10:47.46000:10:47.470 low pressure heaters the drips from the 00:10:50.13000:10:50.140 heater with the lowest pressure and 00:10:51.84000:10:51.850 temperature flow into the main condenser 00:10:56.51000:10:56.520 the deaerator heats condensate and also 00:11:00.66000:11:00.670 helps remove air and non condensable 00:11:02.85000:11:02.860 gases that can cause corrosion as this 00:11:06.90000:11:06.910 cutaway 00:11:07.62000:11:07.630 raishin shows unlike a shell and tube 00:11:10.47000:11:10.480 heat exchanger the deaerator is an open 00:11:14.04000:11:14.050 or direct contact heater that is 00:11:17.12000:11:17.130 condensate is heated when extraction 00:11:19.92000:11:19.930 steam and condensate contact each other 00:11:22.35000:11:22.360 and mix in the deaerator as heat is 00:11:26.37000:11:26.380 transferred from the steam to the 00:11:27.96000:11:27.970 condensate some of the steam condenses 00:11:30.63000:11:30.640 and some of the condensate is heated 00:11:33.47000:11:33.480 this action strips or removes air and 00:11:37.14000:11:37.150 other non condensable gases from the 00:11:39.15000:11:39.160 condensate the heated and deaerated 00:11:43.05000:11:43.060 condensate that collects in the bottom 00:11:45.24000:11:45.250 of the heater is actually a mixture of 00:11:47.76000:11:47.770 condensate and drips from the heater 00:11:50.21000:11:50.220 from the deaerator the liquid will go to 00:11:53.55000:11:53.560 the hot surge tank for storage from 00:11:56.61000:11:56.620 there it will go on through the 00:11:58.20000:11:58.210 condensate and feed water system to the 00:12:00.63000:12:00.640 boiler air and non condensable gases 00:12:04.83000:12:04.840 that are removed from the condensate 00:12:07.08000:12:07.090 flow out of the deaerator through a vent 00:12:10.07000:12:10.080 the vent may vent directly to the 00:12:13.14000:12:13.150 atmosphere or it may connect to the main 00:12:15.96000:12:15.970 condenser or to a vent condenser the hot 00:12:20.55000:12:20.560 surge tank which may also be called a 00:12:23.34000:12:23.350 feed water storage tank or a deaerator 00:12:26.16000:12:26.170 storage tank receives the condensate 00:12:29.10000:12:29.110 from the bottom of the deaerator the 00:12:33.93000:12:33.940 level of condensate or water in the tank 00:12:36.39000:12:36.400 supplies net positive suction head for 00:12:39.90000:12:39.910 pumps that have their suction piping 00:12:41.94000:12:41.950 connected to the tank the correct net 00:12:45.03000:12:45.040 positive suction head is essential to 00:12:47.82000:12:47.830 keep the pumps from being damaged during 00:12:49.77000:12:49.780 operation also the volume of water 00:12:53.55000:12:53.560 called the surge volume contained in the 00:12:56.67000:12:56.680 tank is used to meet changes in demand 00:12:59.28000:12:59.290 during operation of the condensate and 00:13:01.29000:13:01.300 feed water system for example if boiler 00:13:05.70000:13:05.710 demand increases the boiler feed pumps 00:13:08.76000:13:08.770 begin pumping feed water from the 00:13:10.80000:13:10.810 storage tank at a rate that's greater 00:13:13.20000:13:13.210 than the rate at which condensate is 00:13:15.21000:13:15.220 being fed to the tank by the condensate 00:13:17.64000:13:17.650 system the hot surge tank 00:13:21.09000:13:21.100 supplies enough feed water to meet the 00:13:23.34000:13:23.350 increased demand for the short time it 00:13:25.68000:13:25.690 takes for the condensate flow and the 00:13:28.08000:13:28.090 feed water flow to become equal again 00:13:31.25000:13:31.260 both deaerators and hot surge tanks 00:13:34.59000:13:34.600 often have additional connections 00:13:37.31000:13:37.320 examples are connections from the higher 00:13:39.99000:13:40.000 pressure feedwater heaters cascading 00:13:42.42000:13:42.430 drain system and connections to the vent 00:13:45.36000:13:45.370 system from the high pressure heaters 00:13:50.81000:13:50.820 proper boiler operation requires the 00:13:54.03000:13:54.040 flow of feed water into the boiler to 00:13:56.76000:13:56.770 equal the flow of steam leaving the 00:13:59.10000:13:59.110 boiler if too much feed water flows into 00:14:02.76000:14:02.770 the boiler moisture could eventually 00:14:05.04000:14:05.050 build up and carry over into the main 00:14:07.68000:14:07.690 steam system on the other hand if 00:14:11.01000:14:11.020 there's not enough feed water flow to 00:14:13.29000:14:13.300 meet the demands of the boiler the 00:14:15.21000:14:15.220 boiler could boil dry feed water flow 00:14:19.29000:14:19.300 can be controlled in various ways a feed 00:14:22.41000:14:22.420 water regulating valve may be used or as 00:14:25.53000:14:25.540 in this system feed water flow can be 00:14:28.35000:14:28.360 controlled simply by varying the speed 00:14:31.02000:14:31.030 of the boiler feedwater pumps other 00:14:33.84000:14:33.850 systems control feed water flow by using 00:14:36.63000:14:36.640 a combination of varying the speed of 00:14:39.33000:14:39.340 the boiler feedwater pumps and changing 00:14:42.09000:14:42.100 the position of a feed water regulating 00:14:44.22000:14:44.230 valve two additional systems are 00:14:49.95000:14:49.960 normally associated with a condensate in 00:14:52.26000:14:52.270 feed water system they are a chemical 00:14:55.56000:14:55.570 addition system and a make up water 00:14:58.83000:14:58.840 system the chemical addition system may 00:15:02.76000:15:02.770 be connected to the condensate system 00:15:04.95000:15:04.960 the feed water system or both it 00:15:08.49000:15:08.500 generally includes pumps and associated 00:15:11.13000:15:11.140 equipment for adding chemicals such as 00:15:13.44000:15:13.450 hydrazine to prevent corrosion and 00:15:15.99000:15:16.000 ammonia to control pH the make up water 00:15:21.06000:15:21.070 system is connected to the main 00:15:23.13000:15:23.140 condensers hot well this system adds 00:15:26.22000:15:26.230 pure water to the condensate system to 00:15:29.16000:15:29.170 compensate for water losses that may 00:15:31.20000:15:31.210 occur due to condensate sampling 00:15:34.30000:15:34.310 to steam or water leaks in the system 00:15:36.99000:15:37.000 the makeup water is stored in a 00:15:39.79000:15:39.800 condensate storage tank makeup water 00:15:43.00000:15:43.010 system designs vary but most also 00:15:45.91000:15:45.920 include purifying equipment such as 00:15:48.37000:15:48.380 evaporators and demineralize errs if 00:15:53.71000:15:53.720 you're responsible for keeping a 00:15:55.54000:15:55.550 condensate and feed water system running 00:15:57.82000:15:57.830 smoothly 00:15:58.42000:15:58.430 you must be thoroughly familiar with 00:16:00.97000:16:00.980 normal operating conditions for the 00:16:02.95000:16:02.960 system so you can distinguish between 00:16:05.01000:16:05.020 usual and unusual conditions making 00:16:08.92000:16:08.930 regular checks of levels temperatures 00:16:11.50000:16:11.510 pressures flows and valve positions 00:16:14.86000:16:14.870 throughout the system as it operates 00:16:16.56000:16:16.570 helps you detect problems early so that 00:16:19.84000:16:19.850 major trouble and costly downtime can be 00:16:22.66000:16:22.670 prevented specific concerns associated 00:16:25.99000:16:26.000 with the operation of your facility's 00:16:28.42000:16:28.430 condensate and feed water system are 00:16:30.91000:16:30.920 usually covered in your plants standard 00:16:33.19000:16:33.200 operating procedures and in the 00:16:35.26000:16:35.270 operating manuals for the individual 00:16:37.32900:16:37.339 pieces of equipment in this part however 00:16:40.15000:16:40.160 we'll look at some basic operating 00:16:42.43000:16:42.440 checks that are common for most 00:16:44.11000:16:44.120 condensate in feed water systems a 00:16:50.01000:16:50.020 typical condensate in feed water system 00:16:52.90000:16:52.910 includes several multistage centrifugal 00:16:55.75000:16:55.760 pumps checking the pressures 00:16:58.39000:16:58.400 temperatures and lubrication for the 00:17:00.91000:17:00.920 pumps during normal operation of the 00:17:02.86000:17:02.870 system is a routine operator 00:17:05.05000:17:05.060 responsibility checking pump suction and 00:17:10.12000:17:10.130 discharge pressures periodically helps 00:17:12.69900:17:12.709 ensure that each pump is operating 00:17:14.29000:17:14.300 correctly and that proper flow through 00:17:17.07900:17:17.089 the system is maintained proper bearing 00:17:20.50000:17:20.510 lubrication is critical to keep the 00:17:22.68900:17:22.699 pumps in a condensate and feed water 00:17:24.57900:17:24.589 system in good working order to make 00:17:27.69900:17:27.709 sure that a pumps bearings are being 00:17:29.50000:17:29.510 properly lubricated you should check for 00:17:32.02000:17:32.030 overheating excessive vibration 00:17:35.37000:17:35.380 contaminated lubricant and low lubricant 00:17:38.53000:17:38.540 level one way to check for overheating 00:17:41.98000:17:41.990 or excessive vibration is by touching 00:17:44.59000:17:44.600 the bearing housing you can also use an 00:17:48.16900:17:48.179 instrument called a pyrometer to measure 00:17:50.45000:17:50.460 the temperature at the bearing housing 00:17:52.46000:17:52.470 and a vibration meter to measure the 00:17:55.97000:17:55.980 amount of vibration to check the flow 00:17:59.69000:17:59.700 level and condition of the lubricant 00:18:01.99900:18:02.009 sight glasses are commonly used 00:18:04.73000:18:04.740 if lubricating oil in a sight glass has 00:18:07.75900:18:07.769 an unusual color this could be a sign 00:18:10.54900:18:10.559 that the oil has been contaminated and 00:18:12.64900:18:12.659 should be replaced for this pump a gauge 00:18:16.63900:18:16.649 measures the temperature of the 00:18:18.40900:18:18.419 lubricating oil leaving the pumps 00:18:20.18000:18:20.190 bearings 00:18:20.81000:18:20.820 if the reading isn't within the normal 00:18:23.33000:18:23.340 temperature range there's generally a 00:18:25.63900:18:25.649 problem that should be reported many 00:18:28.85000:18:28.860 pumps use cooling water to cool the 00:18:31.07000:18:31.080 pumps bearings when you check these 00:18:33.52900:18:33.539 pumps make sure that the valves in the 00:18:35.81000:18:35.820 cooling water lines are open a 00:18:38.71000:18:38.720 centrifugal pump often uses seal water 00:18:41.89900:18:41.909 to help keep fluid from leaking out of 00:18:44.14900:18:44.159 the pump during normal operation you 00:18:47.18000:18:47.190 should check the seal water to be sure 00:18:49.15900:18:49.169 it's working properly 00:18:51.99900:18:52.009 also if funnel drains are used for seal 00:18:55.34000:18:55.350 water leak off check the drains for 00:18:57.79900:18:57.809 proper seal water flow if the flow is 00:19:01.07000:19:01.080 greater than normal this could indicate 00:19:03.04900:19:03.059 a leaking seal if a pump has a minimum 00:19:08.84000:19:08.850 flow requirement a flow rate less than 00:19:11.81000:19:11.820 the minimum causes higher turbulence and 00:19:14.29900:19:14.309 greater friction which generates heat in 00:19:16.90900:19:16.919 the pump so recirculation lines and 00:19:20.18000:19:20.190 valves are used to maintain minimum flow 00:19:23.02900:19:23.039 and prevent overheating if flow through 00:19:26.84000:19:26.850 the pump goes below the minimum flow 00:19:28.94000:19:28.950 requirement the valves in the 00:19:30.98000:19:30.990 recirculation line are opened to 00:19:33.32000:19:33.330 maintain minimum flow but when flow 00:19:36.23000:19:36.240 through the pump is above the minimum 00:19:38.09000:19:38.100 level the valves in the recirculation 00:19:40.43000:19:40.440 line should be closed condensate pumps 00:19:44.93000:19:44.940 usually have suction and discharge vent 00:19:47.62900:19:47.639 lines that are connected to the main 00:19:49.63900:19:49.649 condenser in most cases the valve in the 00:19:53.41900:19:53.429 discharge vent line is closed after the 00:19:56.38900:19:56.399 condensate pump has been started and is 00:19:58.75900:19:58.769 operating normally 00:20:02.43000:20:02.440 allô hot well level occurs when the 00:20:05.52900:20:05.539 amount of condensate leaving the main 00:20:07.50900:20:07.519 condenser is greater than the amount of 00:20:10.29900:20:10.309 steam that's condensing this condition 00:20:13.57000:20:13.580 could cause the condensate pumps to lose 00:20:15.75900:20:15.769 their prime a high hot well level occurs 00:20:19.77900:20:19.789 when the amount of steam condensed in 00:20:22.33000:20:22.340 the main condenser is greater than the 00:20:24.78900:20:24.799 amount of condensate removed by the 00:20:26.91900:20:26.929 condensate pumps this condition could 00:20:30.36900:20:30.379 flood the lower sections of the tubes in 00:20:32.61900:20:32.629 the main condenser and reduce the 00:20:34.89900:20:34.909 condensers overall condensing ability in 00:20:38.20000:20:38.210 an extreme case water from the main 00:20:40.69000:20:40.700 condenser could get up into the turbine 00:20:43.21000:20:43.220 and destroy it's moving blades a level 00:20:47.08000:20:47.090 control loop is used to maintain the 00:20:49.23900:20:49.249 correct level of condensate in the hot 00:20:51.43000:20:51.440 well basically condensate flow out of 00:20:55.06000:20:55.070 the hot well is decreased if the level 00:20:57.78900:20:57.799 falls below a preset minimum and 00:21:00.26900:21:00.279 increased if the level exceeds a preset 00:21:03.58000:21:03.590 maximum a typical condensate in feed 00:21:09.66900:21:09.679 water system has several shell and tube 00:21:12.19000:21:12.200 heat exchangers or closed heaters some 00:21:15.78900:21:15.799 may be used as condensers but most are 00:21:18.58000:21:18.590 used as low intermediate or high 00:21:20.61900:21:20.629 pressure heaters for the condensate in 00:21:22.98900:21:22.999 feed water the levels temperatures and 00:21:26.83000:21:26.840 pressures for all the closed heaters 00:21:29.08000:21:29.090 should be checked periodically during 00:21:31.14900:21:31.159 normal system operation to make sure 00:21:33.78900:21:33.799 that these operating variables remain 00:21:36.31000:21:36.320 within predetermined normal ranges we'll 00:21:40.45000:21:40.460 look at some operating checks for a high 00:21:42.66900:21:42.679 pressure closed feed water heater most 00:21:45.82000:21:45.830 of the checks for this type of heater 00:21:47.52900:21:47.539 also apply to low and intermediate 00:21:50.25900:21:50.269 pressure condensate or feed water 00:21:52.06000:21:52.070 heaters to monitor the level in the 00:21:55.48000:21:55.490 shell side of the heater you can usually 00:21:58.02900:21:58.039 check a sight glass on the heater an 00:22:00.77900:22:00.789 abnormal level in the sight glass could 00:22:03.58000:22:03.590 indicate a problem that should be 00:22:05.04900:22:05.059 reported temperature gauges indicate the 00:22:09.78900:22:09.799 temperature of the feed water leaving 00:22:11.76900:22:11.779 the heater and the temperature of the 00:22:14.16900:22:14.179 extract 00:22:14.77000:22:14.780 steam entering the heater for proper 00:22:18.04000:22:18.050 system performance and the overall 00:22:19.81000:22:19.820 efficiency of the plant it's very 00:22:22.15000:22:22.160 important that these temperatures stay 00:22:24.46000:22:24.470 within their normal operating ranges 00:22:26.94000:22:26.950 pressure gauges are used to monitor the 00:22:29.77000:22:29.780 pressure of the extraction steam that 00:22:32.11000:22:32.120 enters the heater and the feed water 00:22:34.42000:22:34.430 that passes through the heater the 00:22:36.33000:22:36.340 reading for the extraction steam 00:22:38.65000:22:38.660 pressure normally varies with turbine 00:22:41.17000:22:41.180 load the greater the turbine load the 00:22:43.96000:22:43.970 higher the extraction steam pressure 00:22:46.83000:22:46.840 feed water heaters and many condensate 00:22:49.72000:22:49.730 and feed water systems are installed in 00:22:52.27000:22:52.280 trains or strings that are monitored as 00:22:55.09000:22:55.100 a unit during normal operation of the 00:22:57.25000:22:57.260 system in this arrangement the final 00:23:00.52000:23:00.530 feed water outlet temperature is 00:23:02.74000:23:02.750 commonly used as one way to monitor the 00:23:05.47000:23:05.480 performance of the heaters the final 00:23:08.80000:23:08.810 feed water outlet temperature is the 00:23:11.20000:23:11.210 temperature of the feed water coming out 00:23:13.24000:23:13.250 of the highest pressure feed water 00:23:15.13000:23:15.140 heater on its way to the boilers 00:23:17.17000:23:17.180 economizer checking this temperature is 00:23:20.35000:23:20.360 the quickest way to get an overall 00:23:22.24000:23:22.250 picture of how well the feed water 00:23:24.25000:23:24.260 heaters are doing their job if the final 00:23:27.94000:23:27.950 feed water outlet temperature is at the 00:23:30.40000:23:30.410 expected level for the given load then 00:23:33.01000:23:33.020 each of the feed water heaters in the 00:23:34.93000:23:34.940 Train is probably transferring heat at 00:23:37.69000:23:37.700 the proper rate but sometimes a heater 00:23:41.23000:23:41.240 within the Train may be transferring 00:23:43.51000:23:43.520 heat at an improper rate even though the 00:23:46.51000:23:46.520 final feed water outlet temperature is 00:23:48.79000:23:48.800 at the expected level so periodically 00:23:51.64000:23:51.650 you should also check the outlet 00:23:53.98000:23:53.990 temperature of each heater in the Train 00:23:56.02000:23:56.030 the deaerator 00:23:59.62000:23:59.630 which is an open heater and the hot 00:24:02.35000:24:02.360 surge or deaerator storage tank that's 00:24:05.08000:24:05.090 associated with the deaerator must also 00:24:07.81000:24:07.820 be monitored when a condensate and feed 00:24:10.15000:24:10.160 water system is in operation check the 00:24:13.42000:24:13.430 level of water in the hot surge tank 00:24:15.57000:24:15.580 there's usually a level sight glass on 00:24:18.55000:24:18.560 the tank that's used for this purpose if 00:24:21.73000:24:21.740 the level is too high water could flow 00:24:24.28000:24:24.290 into the deaerator and in extreme cases 00:24:26.97000:24:26.980 even into 00:24:28.24000:24:28.250 the extraction system piping if the 00:24:31.57000:24:31.580 level is too low the net positive 00:24:33.88000:24:33.890 suction head for the pumps downstream of 00:24:36.55000:24:36.560 the tank is reduced as a result the 00:24:39.67000:24:39.680 pumps could be damaged monitoring the 00:24:43.27000:24:43.280 performance of the D aerator is 00:24:45.30000:24:45.310 important for maintaining overall system 00:24:48.28000:24:48.290 and plant efficiency check the 00:24:51.01000:24:51.020 appropriate gauges for the proper 00:24:52.96000:24:52.970 extraction steam temperature and 00:24:54.73000:24:54.740 pressure look for any signs of leakage 00:24:58.48000:24:58.490 and make sure that all the valves for 00:25:01.33000:25:01.340 the deaerator are in the proper 00:25:03.16000:25:03.170 positions 00:25:04.41000:25:04.420 watch for excess venting from the 00:25:07.12000:25:07.130 deaerator that can cause a major loss of 00:25:10.06000:25:10.070 heat energy and fluid from the deaerator 00:25:12.34000:25:12.350 which will decrease plant efficiency 00:25:15.30000:25:15.310 also watch for insufficient venting that 00:25:19.09000:25:19.100 will allow oxygen and other gases to 00:25:21.46000:25:21.470 remain in the condensate and feed water 00:25:23.35000:25:23.360 system and cause problems downstream 00:25:28.29000:25:28.300 problems can occur with any of the 00:25:30.79000:25:30.800 components in a condensate in feed water 00:25:33.01000:25:33.020 system including the pumps heaters 00:25:35.83000:25:35.840 storage tanks and their auxiliaries such 00:25:39.34000:25:39.350 as valves vents motors couplings and 00:25:42.70000:25:42.710 piping in this part we'll look at 00:25:46.03000:25:46.040 typical examples of dealing with some 00:25:48.10000:25:48.110 operating problems that are common in 00:25:50.41000:25:50.420 most condensate and feed water systems 00:25:52.54000:25:52.550 but keep in mind that you'll need to 00:25:55.24000:25:55.250 review your plants standard operating 00:25:57.58000:25:57.590 procedures to learn the exact steps to 00:26:00.37000:26:00.380 follow in your facility many operating 00:26:03.91000:26:03.920 problems in a condensate and feed water 00:26:06.16000:26:06.170 system are relatively simple to correct 00:26:09.00000:26:09.010 however a problem in one component 00:26:12.21000:26:12.220 usually affects the operation of other 00:26:14.86000:26:14.870 components in the system as well 00:26:17.10000:26:17.110 consequently some operating problems can 00:26:20.41000:26:20.420 require considerable troubleshooting 00:26:22.45000:26:22.460 skills 00:26:25.29000:26:25.300 several heaters are included in a 00:26:27.73000:26:27.740 condensate in feed water system so 00:26:30.25000:26:30.260 heater problems are a typical operating 00:26:32.92000:26:32.930 concern we'll look at some problems in a 00:26:35.95000:26:35.960 closed high-pressure feed water heater 00:26:39.69000:26:39.700 improper venting of the heater 00:26:42.04000:26:42.050 can cause air binding when this occurs 00:26:45.04000:26:45.050 air is trapped in either the tube side 00:26:47.77000:26:47.780 or the shell side of the heater air that 00:26:51.52000:26:51.530 collects in the waterboxxes on the tube 00:26:53.59000:26:53.600 side of the heater can restrict the flow 00:26:56.17000:26:56.180 of water through some of the tubes the 00:26:58.96000:26:58.970 restricted flow causes the velocity of 00:27:01.69000:27:01.700 the feed water to increase because the 00:27:04.60000:27:04.610 same amount of water must go through 00:27:06.40000:27:06.410 fewer tubes the increased feed water 00:27:10.03000:27:10.040 velocity can cause the terminal 00:27:12.43000:27:12.440 temperature difference or TTD to 00:27:15.31000:27:15.320 increase although the drain cooler 00:27:17.98000:27:17.990 approach or DCA remains normal another 00:27:23.23000:27:23.240 indication of air binding in the 00:27:24.94000:27:24.950 waterboxxes is an increase in the 00:27:27.58000:27:27.590 differential pressure or Delta P across 00:27:30.58000:27:30.590 the heater if air binding is indicated 00:27:33.94000:27:33.950 by either an increased TTD or an 00:27:36.85000:27:36.860 increased Delta P venting the air from 00:27:39.79000:27:39.800 the water boxes should return the feed 00:27:42.01000:27:42.020 water flow and pressure to normal air 00:27:45.16000:27:45.170 binding also occurs if air and gases 00:27:48.34000:27:48.350 collect on the shell side of the heater 00:27:50.31000:27:50.320 the increasing volume of air blankets 00:27:53.77000:27:53.780 the tubes and prevent steam from 00:27:55.96000:27:55.970 contacting them this in turn reduces the 00:27:59.29000:27:59.300 amount of heat transferred by the heater 00:28:01.21000:28:01.220 as a result the feed water outlet 00:28:04.96000:28:04.970 temperature decreases the TT D however 00:28:08.94000:28:08.950 increases because the extraction steam 00:28:12.07000:28:12.080 temperature remains the same even though 00:28:14.86000:28:14.870 the feed water outlet temperature has 00:28:16.87000:28:16.880 gone down the efficiency of the drain 00:28:20.05000:28:20.060 cooler isn't affected so the dca remains 00:28:23.47000:28:23.480 normal you can usually correct the 00:28:26.80000:28:26.810 problem of air binding on the shell side 00:28:28.66000:28:28.670 of a heater by venting the shell side to 00:28:31.75000:28:31.760 remove the air the TT D should then 00:28:34.69000:28:34.700 return to normal as a result of the 00:28:39.07000:28:39.080 restricted heat transfer caused by a 00:28:41.17000:28:41.180 high heater level the TT D increases the 00:28:45.55000:28:45.560 dca however usually remains normal 00:28:48.34000:28:48.350 because the flow of drips through the 00:28:50.62000:28:50.630 drain cooler may not change or it may be 00:28:53.50000:28:53.510 less than normal 00:28:55.72000:28:55.730 to determine whether an increased TTD is 00:28:58.15000:28:58.160 caused by air binding or by a high-level 00:29:00.90000:29:00.910 check the sight glass for the shell side 00:29:03.64000:29:03.650 of the heater if the level in the sight 00:29:06.19000:29:06.200 glass is high then the problem is most 00:29:09.04000:29:09.050 likely caused by an abnormal level not 00:29:11.83000:29:11.840 by air binding if a heaters level is too 00:29:18.31000:29:18.320 low steam is able to blow through the 00:29:21.10000:29:21.110 heater and out the drain in turn the 00:29:24.16000:29:24.170 flow of extraction steam increases and 00:29:26.68000:29:26.690 this can cause erosion inside the heater 00:29:29.32000:29:29.330 and eventually tube failure because the 00:29:33.31000:29:33.320 low level allows steam to flow through 00:29:35.47000:29:35.480 the heaters drain cooler without 00:29:36.94000:29:36.950 condensing a low level causes the dca to 00:29:41.05000:29:41.060 increase drastically 00:29:42.82000:29:42.830 while the TTD typically remains at or 00:29:45.91000:29:45.920 near normal tube leaks are another 00:29:50.44000:29:50.450 common operating problem associated with 00:29:53.08000:29:53.090 closed heaters like this high-pressure 00:29:55.30000:29:55.310 feed water heater even small leaks can 00:29:58.96000:29:58.970 significantly increase the volume of 00:30:01.09000:30:01.100 water in the drips causing the lower 00:30:03.55000:30:03.560 tubes in the heater to be blanketed with 00:30:05.74000:30:05.750 feed water tube leaks also make the 00:30:08.98000:30:08.990 heaters level control valve open farther 00:30:11.47000:30:11.480 than normal as a tube leak becomes 00:30:14.83000:30:14.840 larger the volume of water flowing into 00:30:17.71000:30:17.720 the shell side of the heater can exceed 00:30:20.20000:30:20.210 the level control valves capacity then 00:30:23.41000:30:23.420 the emergency drain valve must be used 00:30:25.78000:30:25.790 to control the level in the heater a 00:30:28.38000:30:28.390 large tube leak is a serious problem 00:30:31.18000:30:31.190 that calls for immediate attention 00:30:33.36000:30:33.370 because it can allow water to enter the 00:30:36.31000:30:36.320 turbine to prevent damaging or 00:30:38.95000:30:38.960 destroying the turbine you should 00:30:40.93000:30:40.940 isolate and bypass the heater as soon as 00:30:43.75000:30:43.760 possible of course operating with even a 00:30:47.56000:30:47.570 relatively small tube leak is 00:30:49.39000:30:49.400 inefficient so it's important to find 00:30:52.45000:30:52.460 small leaks early and get them corrected 00:30:55.11000:30:55.120 small tube leaks may be difficult to 00:30:57.73000:30:57.740 detect though because they don't show up 00:31:00.22000:31:00.230 on instrumentation but some small leaks 00:31:03.67000:31:03.680 may become noticeable when you calculate 00:31:05.98000:31:05.990 the TTD and the dca for a heat 00:31:10.45000:31:10.460 in many cases operators must determine 00:31:14.06000:31:14.070 exactly which heater in a train is not 00:31:16.61000:31:16.620 operating properly in this example one 00:31:20.21000:31:20.220 heater in a train of high-pressure 00:31:21.91900:31:21.929 feedwater heaters is malfunctioning as a 00:31:25.34000:31:25.350 result there's an increase in the 00:31:27.76900:31:27.779 temperature difference or delta T across 00:31:30.44000:31:30.450 the higher pressure heaters downstream 00:31:33.08000:31:33.090 from the malfunctioning one the 00:31:36.20000:31:36.210 increased delta T causes more heat to be 00:31:39.47000:31:39.480 transferred in the downstream heaters 00:31:41.49900:31:41.509 making up some of the difference caused 00:31:44.06000:31:44.070 by the heater that's not operating 00:31:45.98000:31:45.990 properly to locate the heater that's not 00:31:49.36900:31:49.379 operating properly you should generally 00:31:52.19000:31:52.200 start by checking the final feed water 00:31:54.76900:31:54.779 outlet temperature to see if that value 00:31:57.56000:31:57.570 is within the normal range then work 00:32:00.52900:32:00.539 backwards noting the heater outlet 00:32:03.01900:32:03.029 temperature for each heater in the Train 00:32:04.97000:32:04.980 if the difference between the actual 00:32:07.61000:32:07.620 reading and the expected one becomes 00:32:10.61000:32:10.620 greater with each heater there's a 00:32:12.76900:32:12.779 malfunctioning heater upstream to 00:32:16.31000:32:16.320 pinpoint the exact heater that's causing 00:32:18.35000:32:18.360 the problem follow a step-by-step 00:32:20.95000:32:20.960 troubleshooting procedure which includes 00:32:23.86900:32:23.879 checking the temperature rise across 00:32:25.90900:32:25.919 each heater calculating their T TDs and 00:32:29.21000:32:29.220 DCA's and checking the positions of 00:32:32.24000:32:32.250 their normal drain valves then comparing 00:32:35.65900:32:35.669 the actual conditions with the expected 00:32:38.38900:32:38.399 normal conditions for the heaters at the 00:32:40.54900:32:40.559 given load a typical condensate in feed 00:32:47.48000:32:47.490 water system also has several pumps so 00:32:50.99000:32:51.000 operating problems often involve 00:32:53.09000:32:53.100 troubleshooting pump malfunctions 00:32:55.48000:32:55.490 for example this operator notices that 00:32:59.57000:32:59.580 although this boiler feed pump is 00:33:01.46000:33:01.470 operating at top speed the flow of feed 00:33:04.49000:33:04.500 water to the boiler is inadequate to 00:33:08.09000:33:08.100 keep the situation from getting worse 00:33:10.00900:33:10.019 a second boiler feed pump is brought 00:33:12.64900:33:12.659 online 00:33:13.24000:33:13.250 this increases the feed water flow to an 00:33:16.54900:33:16.559 adequate rate to keep the boiler 00:33:18.50000:33:18.510 operating properly then company 00:33:21.56000:33:21.570 procedures are follow 00:33:22.85000:33:22.860 to analyze and correct the problem 00:33:25.78000:33:25.790 detailed troubleshooting could determine 00:33:28.58000:33:28.590 that the inadequate feed water flow was 00:33:31.16000:33:31.170 caused by an operating problem in the 00:33:33.44000:33:33.450 first boiler feed pump on the other hand 00:33:36.53000:33:36.540 further analysis could show that the 00:33:38.99000:33:39.000 pump is working properly and a 00:33:41.09000:33:41.100 malfunction elsewhere in the condensate 00:33:43.22000:33:43.230 in feed water system could be the cause 00:33:45.38000:33:45.390 of the inadequate feed water flow
Office location
Engineering company LOTUS®
Russia, Ekaterinburg, Lunacharskogo street, 240/12