boiler feed water system
TRANSCRIPT
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Boiler Feedwater Sy
S Shariq Asst. General M
Allied Energy Systems PS Shariq Ahmed
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INTRODUCTION
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Function
Boiler feedwater is water used to supply ("feed") a boiler to generate
steam or hot water. At thermal power stations the feedwater is usuallystored, pre-heated and conditioned in a feedwater tank and forwarded
into the boiler by a boiler feedwater pump
The function of the Feedwater System is to supply high-pressure water
the boiler during start-up, normal, and emergency operations.
The System automatically maintains the proper flow to and water leve
the boiler drum.
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Function
The Feedwater System also supplies water for Desuperheater Sprays thcontrol the Superheat steam temperature.
The feed water used in the steam boiler is a means of transferring heaenergy from the burning fuel to the mechanical energy of the spinningsteam turbine.
The total feed water consists of re-circulated condensate water andpurified makeup water.
The makeup water in a 500 MW plant amounts to perhaps 20 US galloper minute (1.25 L/s) to offset the small losses from steam leaks in the
system.
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Basic System Description
Feedwater is supplied by the Deaerators, which
also provides the necessary Net Positive SuctionHead (NPSH) to the Boiler Feed Pumps.
The Boiler Feed Pumps (BFP) must supply a
constant flow necessary to replace water in the
boilers that has been changed to steam.
The Boiler Feed Pumps (BFP) must also develop
the required pressure to overcome head and
drum pressure.
Deaerators
Boiler Feed Pu
Feedwater He
Feed Water Regu
Valves
Boiler Econom
Inlets
Feedwater System
Diagram
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Basic System Description
Boiler Feed Pumps on Units supply the
Feedwater System High Pressure Heaters and
Header.
The Feedwater header supplies heated, high-
pressure water, through level control valves, to
the boiler drums on Units
The Feedwater Header supplies Desuperheater
Sprays to control the steam temperature.
Deaerators
Boiler Feed Pu
Feedwater He
Feed Water Regu
Valves
Boiler Econom
Inlets
Feedwater System
Diagram
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System Flow Path
The Feedwater System starts at the
bottom of the Deaerator.
The Feedwater exits the bottom of th
Deaerator to the suction of the Boile
Feed Pumps (BFP).
The Deaerators are high enough to
supply the Net Positive Suction Head
(NPSH) to the Boiler Feed Pumps.
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System Flow Path
Boiler Feed Pumps, are motor driven
turbine driven pump.
The pumps can provide Feedwater to
of the High Pressure (HP) Feedwater
Heaters.
After the Feedwater is heated in the
heaters it is then sent through drum
control valves on the boilers and from
the drum level control valves to the
Economizer inlet valves.
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System Flow Path
The Feedwater System starts in the
Deaerator Storage Tank; water exits t
Deaerator Storage Tank and is high
enough to supply the NPSH (Net Posi
Suction Head) for the suction of the
Boiler Feed Pumps.
The Boiler Feed Pumps can also pum
water to any of the HP heaters and
boilers.
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System Flow Path
The Deaerator Storage Tank provides
NPSH to the Boiler Feed Pumps suctio
The Boiler Feed Pumps pump the
Feedwater through the drum level
control valve to the Low Temperature
Economizer.
There is a tie line between the Deaer
on Units.
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System Flow Path
With this tie line Feedwater from Uncan supply the Boiler Feed Pumps on
Unit and vice versa.
The Feedwater System also suppliesfeedwater to the De-Superheater Sprnozzles to cool the steam between th
465 pound steam system and the 165pound steam system.
The De-Superheater Sprays are also uto control steam temperatures from Boilers.
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System Flow Path
In the Feedwater System is a shell an
tube Feedwater Cooler, which uses
cooling water from the Cooling Towe
cool the feedwater.
This cooler takes a portion of the
feedwater from the High TemperaturFeedwater Heater off boiler, this wat
passes through the cooler and discha
the cooler feedwater to the Deaerato
Storage Tank. At the present time thi
cooler is not in service.
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SYSTEM MAJOR COMPONENTS
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System Major Components
The Feedwater System consist of the following major components:
Boiler Feed Pumps
Feedwater Heaters
Feedwater Regulation
De-Superheating Spray
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Boiler Feed Pumps (BFP)
Boiler Feed Pumps are motor driven and turbine
driven.
Although steam turbines cannot be used for
start-up unless a separate source of steam is
available for there operation.
With any pump, the pressure tends to fall as the
throughput increases rises, on the other hand
due to the effect of friction, the resistance
offered by the boiler system to the flow of water
increases as the flow rate increases.
Boiler Feed Pum
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Boiler Feed Pumps (BFP)
Therefore the pressure drop across the valve will be highest at low flow
It is wasteful to operate with the pressure drop which is significantly
above that at which effective control can be maintained, both because
entails an energy loss and also because the corrosion of valve internals
increases with high pressure drops.
With fixed speed pumps there is nothing can be done about this but a
improvement can b made if variable speed pumps are used.
Variable speed pumps are more expensive but the increase in cost ten
to be offset by the operational cost savings.
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Boiler Feed Pumps (BFP)
Such savings are increased if the plant operates for
prolonged periods at low throughputs and are most
apparent with the larger boilers.
From the engineers view point, variable speed
pumps are an attractive option because of the
following reason:
They enable the control system to be linearized over
a wide range of flows, leading to improved
controllability.Boiler Feed Pu
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Boiler Feed Pumps (BFP)
All of the pumps are centrifugal pumps.
The pumps are equipped with recirculation valves.
When operating the BFP's for some time at
reduced capacity, much of the pump horsepower is
transferred into the liquid in the form of heat.
A recirculation line prevents the liquid in the pump
from becoming hot enough to vaporize and causing
cavitation and possible BFP impeller damage.
Boiler Feed P
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Boiler Feed Pumps (BFP)
The recirculation lines are piped from the
discharge line of each of the BFP's prior to
the discharge check valve.
The recirculation flow is routed through a
manual block valve, air-operated valve,
orifice and another manual block valve to
the suction line of the BFPs.
Boiler Feed Pumps
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Boiler Feed Pumps (BFP)
The recirculation valve automatically opens when the BFP discharge
decreases to approximately 45,000 pounds per hour flow to assure a f
above the minimum flow required. At 40,000 pounds per hour an alarm
sounded in the Control Room.
Each pump has a recirculation valve which recirculates water back to t
suction line.
Each pump has a recirculation valve which recirculates water back to t
condensate inlet of the Deaerator. These BFPs only supply feedwater t
Low Temperature Economizer inlet.
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Boiler Feed Pumps (BFP)
Boiler Feed Pump Controls
All the Boiler Feed Pumps are controlled
and monitored from the DCS displays in the
Control Rooms.
Boiler Feed Pumps
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Feedwater Heaters
A feedwater heater is a power plant component used to pre-heat wate
delivered to a steam generating boiler.
Preheating the feedwater reduces the irreversibility involved in steam
generation and therefore improves the thermodynamic efficiency of th
system.
This reduces plant operating costs and also helps to avoid thermal sho
to the boiler metal when the feedwater is introduced back into the ste
cycle.
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Feedwater Heaters
Pressure classification
Low pressure heater
A heater located between the
condensate pump and either the
boiler feed pump or , if present , an
intermediate pressure (booster)pump. It normally extracts steam
from the low pressure turbine.
It normally extracts steam from the
low pressure turbine
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LP Closed Feed Water Heater
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Feedwater Heaters
Pressure classification
Intermediate pressure heater
A heater located between the booster pump and the boiler feed pum
Usually the tubeside pressure is within 200-300 psi of the low pressur
heaters , and the steam is extracted from the intermediate pressure
turbine.
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Feedwater Heaters
Pressure classification
High pressure heater
A heater located downstream of the boiler feed pump.
Typically, the tubeside design pressure is at least 1500 psig, and the st
source is the high pressure turbine.
With a similar purpose to the low pressure feed heaters, the high pres
feed heaters are the last stage of feedwater heating before the feedw
enters the boiler system at the economizer
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High Pressure Heater
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HP Closed Feed Water Heater
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Feedwater Heaters
Orientation
Vertical, Channel Up
These are the least frequently used.
Disassembly is by means of bundle removal.
If a subcooling zone is present, it must extend the full length of the
bundle, since the water must enter the bottom and exit at the top en
the heater.
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Feedwater Heaters
Orientation
Horizontal
Most heaters are of this configuration.
These are the most stable in regard to level control, although they occ
more floor space.
Disassembly is by means of either shell or bundle removal.
Most are floor mounted, although some are mounted in the condenseexhaust neck.
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Feedwater Heaters
Zones
Zones are separate areas within the shell in a feedwater heater
Condensing Zone
All feedwater heaters have this zone. All of the steam is condense
this area , and any remaining non condensable gases must be
removed. A large percentage of energy added by the heater occu
here.
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Feedwater Heaters
Zones
Zones are separate areas within the shell in a feedwater heater
Subcooling Zone
The condensed steam enters this zone at the saturation tempera
and is cooled by convective heat transfer from the incoming
feedwater.
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Feedwater Heaters
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Feedwater Heaters
Type of feedwater heaters
Open feedwater heater.
An open feedwater heater is merely a direct-contact heat exchanger i
which extracted steam is allowed to mix with the feedwater
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Feedwater Heaters
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Feedwater Heaters
Type of feedwater heaters
Closed feedwater heater.
Closed feedwater heaters are typically shell and tube heat exchanger
where the feedwater passes throughout the tubes and is heated by
turbine extraction steam
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Feedwater Heaters
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Feedwater Heaters
Feedwater Heaters are of the shell and tube, extraction steam type an
are flue gas type heaters.
Steam from the turbine extraction or from the steam header can supp
these heaters
The feedwater heaters are shell and tube, U-tube type heaters.
Feedwater enters the bottom of the heater and passes through the tu
picking up heat from the steam on the shell side of the heater; the
feedwater exits the top of the heater.
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Feedwater Heaters
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Feedwater Heaters
Feedwater Heater Controls
The inlet and outlet feedwater valves to the Extraction Steam Feedwater
Heaters on Units are manually operated valves.
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Feedwater Regulation
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Feedwater Regulation
The objective of feed water control may seem simple : it is to supply
enough water to the boiler to match the rate of evaporation.
But doing so is a complex mission because of the following reasons:
There are difficulties even in the basic level drum measurements on which
control system depends.
Interactions occurring within the boiler system and the effects of these
interactions are smaller or greater at various points in the boilers load ran
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Feedwater Regulation
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Feedwater Regulation
The Feedwater Regulation is controlled from the DCS (distributed cont
system) in the Control Rooms.
The Feedwater Regulation maintains a constant boiler drum level by
regulating feedwater flow to the boiler drums.
The system provides for drum level control from startup through thenormal full operating load range.
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Feedwater Regulation
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Feedwater Regulation
Feedwater Flow is controlled by two (2) separate modes of control:
Single element The single-element system responds to the drum level to
control the level control valve. The level controller compares the drum lev
set point, set on the DCS to the actual drum level. The controller in AUTO
generates a signal, which regulates the level control valve to maintain the
drum level. In MANUAL the level is controlled by the operator.
Three-element The three-element system utilizes measurements of stea
flow, feedwater flow and drum level to control feedwater flow.
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Feedwater Regulation
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Feedwater Regulation
Single Element Control
The level of water in the drum provides and immediate indication of the w
contained by the boiler.
If the mass flow of the water into the system is greater than the mass flow
steam out of it, the level of water in the drum rises and vice versa.
As the level of water in the drum rises , the risk increases of water being
carried over into the steam circuits.
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Feedwater Regulation
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Feedwater Regulation
Single Element Control
If the level of water falls there is a possibility of the boiler being damaged
partly because of the loss of essential cooling of the furnace water-walls
The target of feed water control system is to keep the level of water in the
drum to approximately the midpoint of the vessel.
The level of water is affected by transient changes of pressure within the d
and the sense in which the level varies is not necessarily related to the sen
in which the feed flow must be adjusted.
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Feedwater Regulation
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Feedwater Regulation
Single Element Control
The situation arises due the following effects:
Swell
Shrinkage
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Feedwater Regulation
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Feedwater Regulation
Single Element Control
The situation arises due the following effects:
Swell
Boiling water comprises a turbulent mass of fluid containing man
steam bubbles, and as the boiling rate increases the quantity of
bubbles which are generated also increases.
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Feedwater Regulation
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g
Single Element Control
The situation arises due the following effects:
Swell
The mixture of water and bubbles resemble foam, and the volum
occupies is dictated both by the quantity of water and by the am
of the steam bubbles within it.
If the pressure within the system is decreased, the saturation
temperature is also lowered and the boiling rate therefore increa
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Feedwater Regulation
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g
Single Element Control
The situation arises due the following effects:
Swell
As the boiling rate increase, the density of water decreases, but
the mass of water and steam has not changed , the decrease in
density must be accompanied by an increase in volume of the
mixture.
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g
Single Element Control
The situation arises due the following effects:
Swell
By this mechanism the level of water in the drum appears to rise
phenomenon referred to as SWELL.
The rise of level is misleading, it is not indicative of the real incre
in mass of the water of system, which would require the supply o
water to be cut back to maintain the status quo.
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Feedwater Regulation
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g
Single Element Control
The situation arises due the following effects:
Swell
If the drop in pressure is the result of the steam demand sudden
increasing , the water supply will need to be increased to match increased steam flow.
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Feedwater Regulation
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g
Single Element Control
The situation arises due the following effects:
Shrinkage:
It is the opposite of swell.
It occurs when the pressure rises.
The mechanism is exactly the same as that for swell, but in the
reverse direction.
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Feedwater Regulation
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Single Element Control
The situation arises due the following effects:
Shrinkage:
It causes the level of water in the drum to fall when the steam flo
decreases, and once again the delivery of water to the boiler murelated to the actual need rather than to the possibly misleading
indication provided by the drum level transmitter.
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Feedwater Regulation
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Single Element Control
The situation arises due the following effects:
Shrinkage:
The effect of swell and shrinkage in addition to being determined
the rate of change of pressure, also depends on the relative size the drum and the pressure at which it operates.
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Feedwater Regulation
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Single Element Control
The situation arises due the following effects:
Shrinkage:
If the system pressure is low the effect will be larger than with a
boiler operating at higher pressure, since the effect of a givenpressure change on the density of water will be greater in the lo
pressure boiler than it would if the same pressure change were t
occur in a boiler operating at higher pressure.
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Feedwater Regulation
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Single Element Control
The situation arises due the following effects:
Shrinkage:
The simplest solution for these is implementation of a two elem
system since it is based on the use of two process measurementplace of the single drum-level measurements used.
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Single Element Control
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Feedwater Regulation
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Two element system
A valve with a linear characteristic is employed in conjunction with atransmitter that produces a signal proportional to steam flow.
If the transmitter produces a signal which is equal to the steam flow at all
loads and if the flow through the valve is matched with this signal at every
point in the flow range, a controller gain of unity is will ensure that ,throughout the dynamic range of the system, the flow of water will always
equal to the flow of steam.
The correct gain of the controller can be determined from a knowledge of
swell and shrinkage effects within the boiler.
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Feedwater Regulation
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Two element system
Theoretically better results can be obtained by carrying out tests to determthe swell effect at various points in the load range and introducing a non-
linear function within the level controller to compensate for the difference
across the range.
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Two Element System
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Feedwater Regulation
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Three element system
In two element system it is assumed that the feed water valve characterislinear and the valve is sized to produce a fixed flow when it is 100% open.
However the flow through the valve depends both on its opening and on t
pressure drop across it.
In a feed water system, the pressure drop across the valve varies from inst
to instant, and the flow through it at any given opening will therefore vary
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Feedwater Regulation
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Three element system
The varying flow results in the level control becoming offset, to restore thesteam flow/ feed flow balance. This offset is undesirable since it needlessl
erodes the safety margin provided by the presence of the drum.
One method of correcting this error produced by the feed valve is the
addition of a third element to the system- a measurement of feed-water f
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Feedwater Regulation
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Three element system
Ways of implementing a three element system are:
1st Method
The output of the drum level controller is trimmed by a signal
representing the difference between the feed flow and the steamflow signals.
A gain block is introduced to compensate for any difference betw
the ranges of the two transmitters.
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Feedwater Regulation
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Three element system
Ways of implementing a three element system are:
1st Method
In most cases the steam flow and the feed flow signals will cance
out, and the drum level controller will be modulating the feed floto keep the level at the set point.
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Three Element System (1st Method)
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Feedwater Regulation
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Three element system
Ways of implementing a three element system are:
2nd Method
In this method a cascading control technique is applied.
The drum level controller compares the measured level signals w
set value and produces a bipolar output proportional to any erro
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Feedwater Regulation
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Three element system
Ways of implementing a three element system are:
2nd Method
This trims a modified steam flow signal , which is acting as the
desired value for a closed loop feed water controller.
As previously a gain block adjusts for any range difference betwe
the steam flow and the feed flow transmitters.
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Three Element System (2nd Method)
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Feedwater Regulation
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Discrepancies between drum readings
Density errors- differences between installations can cause one instrumebe more affected by density factors than another.
Turbulence- standing waves exists around the downcomers, affecting som
measurement points more than the others.
Flashing off- differences in the geometry of the measuring systems can ca
some measurements to be more affected than the others by flashing off
during the pressure changes.
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Feedwater Regulation
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Discrepancies between drum readings
Calibration- it is vital that all the transmitters are carefully and accuratelycalibrated, and that any density compensation is correctly set up.
Installation- errors or sluggish response can be the result of partial or
complete plugging of impulse lines, or imperfect blow down operations.
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Feedwater Regulation
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In AUTOMATIC, the steam flow is the primary signal to the drum level
controller.
The drum level controller then compares drum level to drum level setpoin
on the DCS.
The output signal from the drum level controller is equal to steam flow if
actual boiler drum level is equal to boiler drum level setpoint.
An actual low boiler drum level is corrected by the drum level controller
generating an output signal greater than steam flow.
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Feedwater Regulation
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In AUTOMATIC, the steam flow is the primary signal to the drum level
controller.
An actual high boiler drum level is corrected by the drum level controller
generating an output signal less than steam flow.
Thus, the output of the drum level controller is the desired Feedwater flow
which is equal to steam flow if the actual boiler drum level is at setpoint.
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SYSTEM OPERATION
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System Startup
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All system components that have been tagged out for maintenance ha
had tags cleared and removed.
All control and indication instrumentation on which maintenance or
calibration has been preformed has been returned to service. The
Instrument Air System is in service.
The system should be walked down to verify that all pump and motorlubrication are at their proper levels.
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System Startup
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That the systems valves have been placed in their proper startup posit
with all drains closed except where otherwise noted.
That all AC and DC electrical power supplies has been racked in and re
for service.
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Normal Operation
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All systems should be monitored for pressures, temperatures, flows, a
levels.
Pump and motor lubrication are monitored and filled as required.
Any abnormal conditions should be reported and corrective action tak
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System Shutdown
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The Feedwater System is normally in operation.
All pumps should be taken out of service and breakers racked out.
Close valving to isolate the system and open drain valves where system
needs draining.
Any part of the Feedwater System is to be worked on, proper clearanc
and tagging should be obtained.
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