Feedwater Heater: Performance Test Protocol GP-FWH-001
Feedwater Heater: Performance Test Protocol GP-FWH-001
Feedwater Heater: Performance Test Protocol GP-FWH-001
Heater
PERFORMANCE TEST PROTOCOL
GP-FWH-001
January 2001
Approved/Reviewed by:
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TABLE OF CONTENTS
1 GENERAL
1.1 Purpose and Scope............................................................................................................... 1-3
1.2 Technical Discussion............................................................................................................. 1-3
1.3 Methodology.......................................................................................................................... 1-3
1.4 Documentation and Reporting............................................................................................... 1-3
1.5 Test Engineer........................................................................................................................ 1-3
2 DEFINITIONS.............................................................................................................................. 2-3
3 TEST REQUIREMENTS
3.1 General................................................................................................................................. 3-3
3.2 Pre-Test Activities................................................................................................................. 3-3
3.3 Test Conditions..................................................................................................................... 3-3
3.4 Deviation from Test Conditions.............................................................................................3-3
3.5 Instruments and Data Collection...........................................................................................3-3
3.6 Sample Locations and Measurements..................................................................................3-3
3.7 Test Personnel Requirements............................................................................................... 3-3
4 PROCEDURE
4.1 Operating Conditions............................................................................................................. 4-3
4.2 Test Duration......................................................................................................................... 4-3
4.3 Data Collection...................................................................................................................... 4-3
4.4 Test Log................................................................................................................................ 4-3
4.5 Restoration............................................................................................................................ 4-3
5 CALCULATION OF RESULTS
5.1 Data Reduction and Validation.............................................................................................. 5-3
5.2 Terminal Temperature Difference......................................................................................... 5-3
5.3 Drain Cooler Approach.......................................................................................................... 5-3
5.4 Feedwater Temperature Rise................................................................................................ 5-3
5.5 Feedwater Pressure Drop..................................................................................................... 5-3
5.6 Feedwater Heater Design Data............................................................................................. 5-3
5.7 Requirement for Further Testing........................................................................................... 5-3
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7 TEST REPORT
7.1 Content.................................................................................................................................. 7-3
7.2 Format................................................................................................................................... 7-3
7.3 Distribution............................................................................................................................ 7-3
8 REFERENCES......................................................................................................... 8-3
APPENDICES
A DATA SHEETS...................................................................................................................... A-1
Manual Feedwater Heater FW-1 (Every 5 Minutes)
Manual Feedwater Heater FW-2 (Every 5 Minutes)
B DATA POINT LISTS.............................................................................................................. B-1
Manual Recording Data Points
Automatic Recording Data Points
C FEEDWATER HEATER DESIGN PERFORMANCE DATA.....................................................C-1
D HEAT BALANCE................................................................................................................... D-1
LIST OF TABLES
5-1 Feedwater Heater Design Performance................................................................................5-3
LIST OF FIGURES
1-1 Typical Feedwater Heater Temperature Profiles...................................................................1-3
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Performance Test Protocol Feedwater Heater
1 GENERAL
1.1 Purpose and Scope
Each high-pressure feedwater heater (FW-1 and FW-2) should be individually tested on
a routine basis to determine its current performance level. The important feedwater-
heater performance indices are terminal temperature difference, drain cooler approach,
feedwater temperature rise, and corrected pressure drop across the heater.
This test protocol provides a method for measuring feedwater heater performance on a
repeatable basis. These measurements allow you to reliably detect changes in
equipment condition. Where applicable, test results are compared to design and
previous test results. The protocol follows the ASME Performance Test Code 12.1,
Closed Feedwater Heaters, as a guide. Strict adherence to the PTC is not feasible or
desirable for practical routine performance testing of feedwater heaters.
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between the saturation temperature of the steam condensing in the heater and the
feedwater temperature leaving the heater. As TTD increases from design, heat
transfer is less effective. Design TTDs typically range from –5°F to +5°F.
Superheated steam is required to achieve a negative TTD (see Figure 1-1).
Figure 1-1
Typical Feedwater
Heater
Temperature
Profiles
1.3 Methodology
Both feedwater heaters are tested at full load to obtain test results that may be compared
to previous full load tests. Feedwater heater testing can be done concurrently with
turbine or turbine cycle testing. Full load is established by bringing the turbine to valves
wide open with normal steam conditions at the turbine valves. Testing at lower loads is
not necessary unless knowledge of specific performance at low loads is desirable. Data
from both feedwater heaters are taken simultaneously. Calculations, including
numerical averages from multiple readings, are kept separate for each feedwater heater.
The following data is taken and recorded in the manner described:
Terminal Temperature Difference is determined for each feedwater heater
by calculating the difference between the saturation temperature corresponding to
measured shell pressure and the feedwater outlet temperature.
Drain Cooler Approach is determined by calculating the difference in drain
temperature and the feedwater inlet temperature.
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2 DEFINITIONS
The definitions and description of terms used in this protocol are found in section 2.0 of
ASME PTC 12.1-1978 (R1987).
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3 TEST REQUIREMENTS
3.1 General
Feedwater heaters are tested with the steam turbine-generator at full load under design
steam conditions. Test conditions are described in section 3.3. Before scheduling a test,
the feedwater heaters should be considered in suitable condition for testing. This
requires that the heater shell is properly and continuously drained of condensate and all
heater levels maintained at their design values. The steam- and water-sides should be
vented of non-condensible gases. Any external sources of non-condensible gases, such
as vents from other apparatus, should be diverted during the test run.
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4 PROCEDURE
4.1 Operating Conditions
Operating conditions are listed in section 3.3.
4.5 Restoration
Advise operating personnel when testing is complete.
Remove test instrumentation.
Reset the EtaPRO System’s historical archive interval to original 5-minute setting.
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5 CALCULATION OF RESULTS
Detailed instructions are included in this section for computation of all feedwater-heater
performance indices.
All thermodynamic properties are determined using the 1967 ASME Steam Tables. These properties are
available in hard copy directly from ASME, New York, New York. A useful and accurate software version,
GPSteam, is available from General Physics Corporation, Amherst, NY.
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Equation 5.4-3
where
TR Feedwater temperature rise, °F
Tfo Feedwater temperature leaving heater, °F
Tfi Feedwater temperature entering heater, °F
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FW--1 heater water outlet temperature is measured at two locations: at the heater (Point 1), and downstream
of the feedwater flow nozzle and the high-pressure heater bypass tie-in (Point 2). If the temperature Point 2 is
lower than Point 1, the motor-operated bypass valve may be leaking by.
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7 TEST REPORT
7.1 Content
The test report should contain the following information.
Data sheets
Calibration records
Results of efficiency calculations
Comparison of test results to design parameters and previous test results
Assessment of the feedwater heater condition
7.2 Format
The test report should include the following sections.
Executive Summary
Introduction
Unit Description
Test Program Description
Test Results
Conclusions
Discussion of test results and a summary of the condition of the feedwater
heater as it compares to design
7.3 Distribution
The preliminary test report is sent to the Plant Engineer for review and comment. The
final test report is distributed to the appropriate plant personnel.
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8 REFERENCES
ASME PTC 12.1-1978, Closed Feedwater Heaters, American Society of Mechanical
Engineers, New York, 1990.
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Performance Test Protocol Feedwater Heater Data Sheets
Time Feedwater Feedwater Feedwater Feedwater Heater Shell Heater Drain Fwh #1
Inlet Outlet Inlet Outlet Pres, psig Temp, °F Steam Inlet
Temp, °F Temp, °F Pres, psig Pres, psig PG0406 TG2106 Temp, °F
TG0553 TG0556 PG0557 PG0555 TG0405
1
Use additional sheets, if necessary.
Time Feedwater Feedwater Feedwater Feedwater Heater Shell Heater Drain FWH #1
Inlet Outlet Inlet Outlet Pres, psig Temp, °F Steam Inlet
Temp, °F Temp, °F Pres, psig Pres, psig PG0406 TG2106 Temp, °F
TG0553 TG0556 PG0557 PG0555 TG0405
2
Use additional sheets, if necessary.
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Performance Test Protocol Feedater Heater Data Point LIsts
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Performance Test Protocol Feedwater Heater Design Performance Data
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Performance Test Protocol Heat Balance
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