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Feedwater heater control: Level

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Feedwater Heater Control: Bring Your Efficiency to a New Level -- Kevin Hambrice, Global Factory Sales and Marketing Manager-Level, K-TEK, A Member of the ABB Group

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Feedwater heater control: Level

  1. 1. WMP-113-1 Feedwater heater control: Bring your efficiency to a new LEVEL ABB Automation & Power World: April 18-21, 2011 © ABB Inc. May 31, 2011 | Slide
  2. 2. WMP-113-1 Feedwater heater control: Bring your efficiency to a new LEVEL <ul><li>Speaker name: Kevin Hambrice </li></ul><ul><li>Speaker title: Global Factory Sales & Marketing Manger - LEVEL </li></ul><ul><li>Company name: K-TEK, A Member of the ABB Group </li></ul><ul><li>Location: Prairieville, LA </li></ul>© ABB Inc. May 31, 2011 | Slide
  3. 3. © ABB Inc. May 31, 2011 | Slide Feedwater Heater Control Why is feedwater heater level control important? <ul><li>Heaters preheat feedwater before boilers converted it to steam </li></ul><ul><li>“ Preheating” reduces energy to flash the water into steam </li></ul><ul><li>Liquid level of condensate is formed as steam condenses </li></ul><ul><li>Level is controlled to create a seal and prevent steam blow-through </li></ul><ul><li>Accurate and repeatable level measurement keep boiler fuel consumption down </li></ul>
  4. 4. Feedwater Heater Control What are you controlling and why? © ABB Inc. May 31, 2011 | Slide Injected steam condenses and acts as a seal to prevent blow-through of steam in the heater Maximum thermal transfer between steam & feedwater takes place when largest tube area exposed to steam Small increase in condensate level (2-in to 4-in) over minimum greatly reduces the heat rate efficiency)
  5. 5. Feedwater Heater Control Traditional Devices Used for Feedwater Level Measurement <ul><li>Mechanical displacement type level systems with pneumatic controllers have been used </li></ul><ul><li>Two major issues </li></ul><ul><ul><li>Mechanical nature requires high maintenance due to seal and bearing failures and air supply issues </li></ul></ul><ul><ul><li>Varying liquid density of water and steam creates significant measurement errors in displacer. </li></ul></ul>© ABB Inc. May 31, 2011 | Slide Sight Glass Displacer Differential Pressure Conductivity Probes
  6. 6. Feedwater Heater Control Best Practice Feedwater Level Control <ul><li>Magnetic level gauges and magnetostrictive level transmitter used to improve control </li></ul><ul><li>Performance and reliability control condensate level at 2” to 3” above the drain </li></ul><ul><li>More tube area is exposed to heat and additional feedwater with the same energy input </li></ul><ul><li>Increases heater throughput and efficiency </li></ul><ul><li>Accuracy (±1”) of the system prevent steam blow-through </li></ul>© ABB Inc. May 31, 2011 | Slide Certified to ANSI/ASME B31.1 360º Magnetic Ring 75 Grams Buoyancy
  7. 7. Feedwater Heater Control Precision Measurement for Changing Process Conditions <ul><li>Thermocouple can be installed to compensate for density changes of the condensate </li></ul><ul><li>Small small change float buoyancy affects accuracy </li></ul><ul><li>Simples correction in DCS, allows lower condensate levels in the heater </li></ul><ul><li>Improves efficiency even more </li></ul>© ABB Inc. May 31, 2011 | Slide
  8. 8. Feedwater Heater Control Proven Success <ul><li>“ We saw a return on investment and efficiency gain within 6 months” </li></ul><ul><li>“ I’ve been pleased with the significant maintenance savings with the elimination of sight glass repairs.” </li></ul><ul><li>“ We were looking for a reliable solution that would be accurate and repeatable – we got this with the MLT technology.” </li></ul>© ABB Inc. May 31, 2011 | Slide
  9. 9. Improving Power Plant Efficiency ABB – Your partner for Measurement Solutions <ul><li>World class instrumentation solutions built on over 100 years of experience </li></ul><ul><li>Built upon the leading names and brands in the automation world: </li></ul><ul><li>Unrivalled in its scope and applications expertise </li></ul><ul><li>Solutions certified to international standards </li></ul><ul><li>Worldwide network of sales offices and manufacturing plants </li></ul>
  10. 10. © ABB Group May 31, 2011 | Slide