Water Circuit Process Flow and Equipment Functions

SAN MIGUEL CONSOLIDATED POWER CORPORATION
SAFETECH POWER SERVICES CORPORATION
Water Circuit
(From Hotwell to Steam Drum)

Objectives:
 To know the basic process flow of the Water Circuit
System.
 To understand the basic concepts of the Water Circuit
System.
 Identify the major equipment involved in the Water
Circuit System, its functions and specifications.

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Boiler water is liquid water within a boiler, or in
associated piping, pumps and other equipment, that is
intended for evaporation into steam.
Water Circuit
Condensate is the liquid phase produced by the
condensation of steam or any other gas.

Water Circuit
What is Condenser?
It converts steam from vapor to liquid state by
means of heat exchange using seawater as
cooling medium. By condensing the exhaust
steam, the turbine exhaust pressure is maintained
at a vacuum. It means that the difference in
pressure between the turbine inlet and exhaust is
high, thus, a high turbine efficiency.
Condenser
Equipment Specification:
- Quantity: 1 set per unit
- Type: Shell and Tube type
- Shell side: Steam; 316 T/H
- Tube side: Sea Water: 31,500 T/H
- Dimension of tube: Dia.20 x. 05t x 12,3201L
x 1960pcs
- Heating transfer Area: 9,898 m²

Water Circuit
Condensate extraction pumps (CEP) extract the
condensate water from the condenser and pump
it through the condensate polishing system and
the LP heaters to the deaerator feed water tank.
Condensate extraction pumps (CEP)
Equipment Specification:
- Quantity: 2 sets per unit
- Type: Vertical type
- Capacity: 400 m³/h
- Total dynamic head: 180m
- Minimum recirculation flow: 100 m³/h
- Number of Pump stage: 3 stage
- Motor: 325kW x 4P x 6.6kV x 60Hz

Water Circuit
Steam jet air ejector condenser is used
to collect condensate and condenses
the steam that used as motive steam
for the ejector system.
Steam jet air ejector condenser

Water Circuit
Gland steam condenser is used to
collect condensate and condenses
the steam that used for
sealing steam turbine which would
preheat the condensate water.
Gland steam condenser

Water Circuit
Low pressure heater 1 (LPH1) is a shell
and tube heat exchanger, used to
increase the condensate temperature
which is passing through the tubes and
the extraction no. 6 steam is being
utilized and admitted to the shell.
Equipment Specifications:
- Type: Shell/Tube type
- Shell side: Steam/Condensate
45.4T/H*0.354ksca*72.5/45.6C
- Tube side: Water
362.2 T/H*11.7ksca*40/70.18C
- Tube formation: U shape; 2 pass; 394 tubes
per pass
- Heating transfer area: Total 485m²
- Flow direction: counter flow
Low pressure heater 1 (LPH1)

Water Circuit
and tube heat exchanger, used to further
27.5T/H*0.785ksca*105.7/76.4C
- Tube side: Water
363 T/H*10.5ksca*70.8/90.7C
per pass

Water Circuit
and tube heat exchanger, used to further
15.2T/H*1.818ksca*181/96.3C
- Tube side: Water
363 T/H*9.89ksca*90.7/115C
per pass

Water Circuit
Deaerator is a device that removes oxygen and other dissolved gases from liquids.
Deaerators are commonly used to remove dissolved gases in feedwater for steam-
generating boilers.
The typical tray-type deaerator has a vertical domed deaeration section mounted above a
horizontal boiler feedwater storage vessel. Boiler feedwater enters the vertical deaeration
section above the perforated trays and flows downward through the perforations.
Low-pressure deaeration steam enters below the perforated trays and flows upward
through the perforations.
The steam strips the dissolved gas from the boiler feedwater and exits via the vent valve
at the top of the domed section.
The deaerated water flows down into the horizontal storage vessel (deaerator storage
tank) from where it is pumped to the steam-generating boiler system.

Water Circuit
- Inlet flow: 26.79T/H (steam) ;
362.59T/H (water)
- Operating temp: 310.3C(steam);
158.4C (water)
- Operating Pressure: 5.05 kscg
- Outlet flow: 458.73 T/h
- Design temp: 380 C
- Outlet oxygen content: 7 ppb
- Water tank volume: 120.9 m³
Deaerator & Deaerator storage tank

Water Circuit
Boiler feed pump (BFP) is a
centrifugal pump used to pump
feedwater into a steam boiler with a
quantity of feed water corresponding
to the quantity of steam emitted.
- Quantity: 2 sets per unit
- Type: Horizontal, Centrifugal, Multi-Stage
(7 stage) type
- Capacity: 491 T/H x 1750m
- Bleed (3rd) stage pressure: 69.4 kscg
- Minimum recirculation flow: 137.3 t/H
- Balancing flow: 7.093 T/H
- Motor: 3,550kW x 2P x 6.6kV x 60Hz
Boiler feed pump (BFP)

Water Circuit
Automatic recirculation control valve (ARCV)
or Automatic minimum flow valve is applied in
order to provide an automatic leak-off flow in
case of low load conditions.
The valve protects centrifugal pumps,
especially BFP, by maintaining automatically, a
minimum flow.
Automatic recirculation control valve (ARCV)

Water Circuit
High-pressure heater 1&2 (HPH1&2)
is a heat exchanger of the shell and
tube type which further heats the
feedwater before entry to the boiler.
Further heat may be added to the
feedwater without its becoming
steam since its pressure has now been
raised by the feed pump. The
feedwater passing through the tubes
and the high pressure extraction no. 1
& 2 steam being admitted to the shell.
High-pressure heater 1
(HPH1)
High-pressure heater 2
(HPH2)

Water Circuit
Drum level control valve or Feedwater control
valve (FWCV) maintain a constant level in a
liquid supply such as a steam drum. Level
control valve do this by regulating the flow into
the liquid supply which maintains a
constant level to meet the usage demands.
Drum level control valve or
Feedwater control valve (FWCV)

Water Circuit
Economizers are mechanical
devices intended to reduce
energy consumption, or to
perform useful function such as
preheating the feedwater.
Economizer

Water Circuit
ECO-1
COMMON
ECO-2S
ECO-2R
ECO-3
ECO-3
ECONOMIZER PROCESS FLOW:
Feedwater is supplied to the economizer inlet header via
stop and check valve. The feedwater flow is upward through
the economizer, that is, counterflow to the hot flue gases.
Most efficient heat transfer is hereby accomplished, while
the possibility of steam generation within the economizer is
minimized by the upward water flow.
From the common economizer (ECO-1) tube assembly,
heated water splits into two parallel paths and flows
through each parallel economizers (ECO-2R and ECO-2S) in
each reheater and superheater backpass respectively, and
then recombines at junction header. The combine heated
water flows through ECO-3 assemblies with counterflow to
the hot flue gases, and to the economizer outlet header.
The heated feedwater is then led to the steam drum via the
economizer outlet link.
Feedwater
from
HPH#2
CONVECTIVE
BACKPASS

Water Circuit
Furnace side walls, front and
rear walls and floor and evaporator panel
are of membrane wall construction. This
results in a leak proof enclosure,
eliminating gas leakage and corrosion of
casing as seen in boilers with refractory.
Furnace walls are consisted of tube or
water wall tube which acts as heat
exchanger with the feedwater to produce
saturated steam that will be separated on
the seteam drum.
Furnace

Water Circuit
The function of the steam drum internals
is to separate the water from the steam
generated in the waterwalls of the
furnace and to reduced dissolve solids
contents of the steam to below the
prescribed limit.
Separation of steam from water in the
drum is generally performed in three
stages; with the first two stages occurring
in the turbo separators, and the final
stage taking place at the top of the drum
just before the steam enters the
superheater.
Steam drum

Water Circuit – Steam Drum Internals
Downcomer
Waterwall Risers
Steam/Water mixture
Turbo Separator
Water
Screen Dryer
Saturated Steam
Outlet
Feedwater
from
Economizer
Wet
Steam
The primary separation stage is formed into
two concentric cans. Spinner blades impart a
centrifugal motion to the mixture of steam
and water flowing upward through the inner
can, thereby throwing the water to the
outside and forcing the steam to the inside.
The steam proceeds to secondary separation
stage consist of two opposed banks of closely
spaced thin, corrugated metal plates which
directs the steam through a tortuous path
and force entrained water against the
corrugated plates.
From the secondary separators the steam
flows uniformly and with relatively low
velocity upward to the series of screen
dryers. These dryers perform the final stage
of separation.

Thank You and God Bless!!! 

Water Circuit Process Flow and Equipment Functions

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