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BoilersBoilers

BOILER TRAININGBOILER TRAININGEng: Hafez YakoutEng: Hafez Yakout

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Main Condensate and Feed SystemsMain Condensate and Feed Systems

BOILER TRAININGBOILER TRAINING

Eng: Hafez YakoutEng: Hafez Yakout

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ObjectivesObjectives  Purpose of Condensate and Feed Systems Purpose of Condensate and Feed Systems

and key component functionsand key component functions

 Principles of operation and key Principles of operation and key

components of the automatic boiler control components of the automatic boiler control 

systemssystems

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 M ain Condensate System Purpose M ain Condensate System Purpose

Condense steam to water Condense steam to water   Pump condensate from main condenser  Pump condensate from main condenser 

to DFT to DFT 

 Provide cooling for air ejector condenser  Provide cooling for air ejector condenser 

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Condensate System ComponentsCondensate System Components

 Main Condenser  Main Condenser HotwellHotwell

 Main Circulating Water System Main Circulating Water System  Main Condensate Pump Main Condensate Pump

 Air Ejectors Air Ejectors

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Condenser  M U FeedTank

Condensate

PumpAir Ejector 

Condenser 

CONDENSATION

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 M ain Condenser 

 M ain Condenser 

Operates at a vacuum to lower theOperates at a vacuum to lower the

condensation temperature whichcondensation temperature which

increases plant efficiencyincreases plant efficiency

 Prevents condensation of steam in the Prevents condensation of steam in the

turbineturbine

Typically a SINGLE PASS, CROSS Typically a SINGLE PASS, CROSS 

FLOW, INDIRECT CONTACT FLOW, INDIRECT CONTACT 

 H otwell  H otwell -- -- Stores condensateStores condensate

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 M ain Condensate Pump M ain Condensate Pump

H otwell to DFT  H otwell to DFT 

TypeType

 ±  ±   Normally electric driven. Normally electric driven.

 ±  ±   Non Non--positive displacement positive displacement

 Located below hotwell to provide sufficient  Located below hotwell to provide sufficient 

 NPS  H TO PREVENT CAVITATION!!! NPS  H TO PREVENT CAVITATION!!!

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 Air Ejectors Air Ejectors  Remove non Remove non--condensable gases fromcondensable gases from

condenser condenser 

Two stagesTwo stages

Warms condensateWarms condensate

 Draws initial vacuum on the Main Cond. Draws initial vacuum on the Main Cond.

Steam activated jet pumpsSteam activated jet pumps

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 M ain Feed System Purpose

 M ain Feed System Purpose

 Deaerate Deaerate

 Preheat  Preheat 

Store/Transport water from DFT to boiler Store/Transport water from DFT to boiler 

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 M ain Feed System Components M ain Feed System Components

 Deaerating feed tank (DFT) Deaerating feed tank (DFT)

M ain Feed Boost Pump M ain Feed Boost Pump

M ain Feed Pump M ain Feed Pump

Feedwater Control ValveFeedwater Control Valve

 Economizer  Economizer 

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DFT

B t r 

P u m p

F

Pump

FEED (DFT, MFBP, MFP)

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 Deaerating Feed Tank (DFT) Deaerating Feed Tank (DFT)

 Preheats feedwater  Preheats feedwater 

 Deaerates feedwater  Deaerates feedwater 

 Stores feedwater  Stores feedwater 

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Deaeration

STORAGE

SECTION

EAERATING

SECTION

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Deaeration

STORAGE

SECTION

TRAYS

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Deaeration

STORAGE

SECTION

St m

Inlet

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Deaeration

STORAGE

SECTION

Condensate

Retur n

Steam

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Deaeration

STORAGE

SECTION

Vent

Condensate

Retur n

Steam

To  eed Water Pumps

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 Main Feed Boost Pump (  Main Feed Boost Pump (  M 

FBP) M 

FBP)  Ensure there is always sufficient NPS  H  for  Ensure there is always sufficient NPS  H  for 

the MFP, preventing vapor lock the MFP, preventing vapor lock 

(Typically a single(Typically a single--stage, double stage, double--suction, suction,

centrifugal pump)centrifugal pump)

 Electric Motor  Electric Motor 

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 M  AIN FEED PU 

 M  P ( 

 M FP)

 M  AIN FEED PU 

 M  P ( 

 M FP)

 Provides water to the boilers at a Provides water to the boilers at a

 sufficient rate and pressure to ensure sufficient rate and pressure to ensure

boiler level is maintained boiler level is maintained 

Typically: Multistage, highTypically: Multistage, high--speed, speed,

centrifugal pump. May be either steamcentrifugal pump. May be either steamor electric drivenor electric driven

 Discharge pressure up to Discharge pressure up to 13001300 psig  psig 

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Feedwater Control Valve (FRV)Feedwater Control Valve (FRV)

 Maintains boiler water level in Maintains boiler water level in

 steam drum steam drum  Normally controlled by Automatic Normally controlled by Automatic

 Boiler Control System Boiler Control System

 ±  ±  Air controlled valveAir controlled valve

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ECONOM

IZER ECONOM

IZER 

U  ses the exhaust of the boilersU  ses the exhaust of the boilers

to preheat the incoming water to preheat the incoming water   Increases temperature by Increases temperature by

approximately 140F approximately 140F 

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MAKE

MAKE--UP/EXCESSUP/EXCESSFEED SYSTEMFEED SYSTEM

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AUTOMATIC BOILERAUTOMATIC BOILERCONTROL SYSTEMSCONTROL SYSTEMS

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 Automatic Boiler Control Systems Automatic Boiler Control Systems

 Automatic Combustion Control (ACC) Automatic Combustion Control (ACC)

±± Maintains boiler¶s steam drum pressure by Maintains boiler¶s steam drum pressure by 

controlling rate of combustion (air/fuel)controlling rate of combustion (air/fuel) Feedwater Control System (FCS)Feedwater Control System (FCS)

±± Regulates flow of feedwater to boiler toRegulates flow of feedwater to boiler to

maintain levelmaintain level Diff Control System of MFP (DCS)Diff Control System of MFP (DCS)

±± Maintains feedwater supply pressure aboveMaintains feedwater supply pressure abovesteam drum pressuresteam drum pressure

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 I. I. Automatic Combustion Control  Automatic Combustion Control  System (ACC) System (ACC)

 Purpose: To maintain the boiler steam Purpose: To maintain the boiler steam--

drum pressure at a constant 165bar during drum pressure at a constant 165bar during  steady and changing steam conditions steady and changing steam conditions

 ±  ±  Measures (steam drum pressure)Measures (steam drum pressure)

 ±  ± 

Compares (actual pressure to desired)Compares (actual pressure to desired) ±  ±  Computes (error signal)Computes (error signal)

 ±  ±  Corrects (air and fuel flow to furnace)Corrects (air and fuel flow to furnace)

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Automatic CombustionAutomatic Combustion

Control (ACC) SystemControl (ACC) System

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 II. II. F  F eedwater Control Systemeedwater Control System

(FWC)(FWC)  Purpose: To regulate the supply of  Purpose: To regulate the supply of 

 feedwater sent to the boiler for use in steam feedwater sent to the boiler for use in steam

 production production

 ±  ±  Measures (fw flow, steam flow, boiler Measures (fw flow, steam flow, boiler 

HH220 level)0 level)

 ±  ±  Compares (actual level to desired level)Compares (actual level to desired level)

 ±  ±  Computes (error signal)Computes (error signal)

 ±  ±  Corrects (feedflow via FRV)Corrects (feedflow via FRV)

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Feedwater Control System (FCS)Feedwater Control System (FCS)

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 III. III. M FP Differential Pressure M FP Differential Pressure

Control SystemControl System

 Purpose: Ensures that the feedwater  Purpose: Ensures that the feedwater--supply supply

 pressure is maintained at a constant value pressure is maintained at a constant value

above the steamabove the steam--drum pressuredrum pressure

Measures (MFP disch press/ Stm drum press)Measures (MFP disch press/ Stm drum press)

 ±  ±  Compares (D/P)Compares (D/P)

 ±  ±  Computes (error signal)Computes (error signal)

 ±  ±  Corrects (alters MFP speed via stm supply)Corrects (alters MFP speed via stm supply)

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The End The End 

Thank you for listening«.Thank you for listening«.

Q uestions?

Q uestions?