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to Steam
Conditioning
Overview of CHP
Overview of CHP
usable heat (usually steam and sometimes hot water) and power (usually
energy centres and total energy. The basic elements of a CHP plant comprise
one or more prime movers usually driving electrical generators, where the
Condensing
Desuperheater
10
heat generated in the process is utilized via suitable heat recovery equipment
for a variety of purposes including: industrial processes, district heating and
space heating. Figure 1 shows a possible conguration for a CHP plant. For the
purposes of this document we will cover Large Industrial Users.
The heat source can be established from many different sources. Waste heat
from process (e.g. ethylene, ammonia plants), incineration of waste, and waste
heat from gas turbine (also electricity generator) by a heat recovery steam
VST-SE
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VLB
12
Once the industry has established its need for heat, it then has to determine
DRAG
13
Desuperheating
15
Figure 1: Typical simple CHP scheme with gas turbine, heat recovery steam
generator (HRSG) and steam turbine
Figure 2 shows typical percentage gains and losses for conventional fossil
fuelled power station. Figure 3 similarly indicates typical gures for combined
cycle power plant (CCPP) incorporating electricity generated from the gas
turbine and a steam turbine. Figure 4 shows the immediate benets in useful
energy in CHP when the steam turbine exhaust/extraction steam is utilised
as heat energy. Figure 5 indicates CHP plant with CCPP where electricity is
generated from the gas turbine and steam turbine and the exhaust heat energy
from the steam turbine is used for the process. Note that owing to the gas
turbine the proportion of useful electrical energy on Figure 5 is higher than
that in Figure 4.
Ammonia/fertilizer plants
Sugar/food
Incineration plants
Chemical plants
District heating
Pharmaceutical plants
Universities/hospitals
District/Community heating
Fish farming
Universities/hospitals
The CHP steam conditioning valve will operate more frequently and can
depend on several factors.
a)
b)
Export of electricity to the grid may or may not be required and the
bypass will provide the required exibility in operation.
c)
d)
Every CHP plant is unique and requires system understanding to provide not
only the correct equipment, but also knowledge and experience regarding
aspects such as installation and control. Consult with CCI, who have more
than 80 years of expert knowledge and experience, to establish best practice
and operational performance for your CHP plant.
Turbine Extraction/Exhaust
The outlet steam temperature from extraction or exhaust varies depending
on the steam going through the steam turbine. For example, considering
exhaust steam only, as the steam ow through the turbine decreases, the
outlet temperature increases. Depending on the exhaust ow in general as
the extraction ow reduces, the extraction steam temperature increases. This
means to obtain a constant set temperature downstream, the proportion of
spraywater required at low ow is higher than compared to at full ow where
the requirement will be small if any at all.
On most CHP plants, the exhaust line can be of a large diameter and in
view of the conditions detailed above combined with the large diameter and
potentially low ow, providing good temperature control to the process close to
saturation can be extremely difcult and needs special consideration.
CCI with extensive experience and knowledge can provide installation
guidelines and recommendations in conjunction with the correct product
Figure 8: Turbine extraction/exhaust
desuperheating
Solutions Recommended
Steam pressure
Exhaust
Extraction
Inline repairability
Solutions Recommended
High rangeability of
steam ow
Steam atomization
Noise requirements
Failure mode
Inline repairability
Solutions Recommended
Condenser pressure
a nal control of the temperature close to process using the steam. It should
also be noted that there may be more than one process demanding the steam
and each one may require a separate desuperheating station to control the
temperature.
As the process will benet from a temperature close to saturation, and with the
little superheat available in the steam, the energy available for atomising the
spraywater is low and this application sometimes requires special consideration
particularly in large diameter piping and high turndown requirements.
Solutions Recommended
10
Inline repairability
Solutions Recommended
Other severe service valves and desuperheaters which are covered in other CCI
literature. They include:
recirculation
intermittent
Spraywater control
inter-stage
(3 way valve)
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The Solution
The VST-SE design is unique as it can simply and easily cater for these
requirements as the valve was designed to provide solutions to these
requirements.
Thermal shock: forged fully machined valve body both inside and
outside to handle thermal fatigue, critical for reliable service.
the positioning of the main plug and which uncovers sequential holes
Figure 15: VST-SE features
leading to the atomizing channel. Above 15% (5% ow), then the main
cage proper opens and the steam ow modulates normally through
control section providing a linear characteristic. The total characteristic
will therefore be modied linear providing excellent control at low ow.
With steam atomization the VST-SE will achieve turndown with respect to
desuperheated steam ow of greater than 50 to 1.
Flexible seat and excellent guiding. Thermal change can cause crushing
of the seat as the body contracts. The special two piece seat prevents
crushing of the seat. Good guiding ensure that the valve can be installed
horizontally or vertically without risk of sticking.
12
To suit application
III, IV or V, MSS SP 61
28-400 mm/1.1 16
Modied Linear
Yes
To Cl 2500 (PN420)
Up to 600 C
Up to 8
vibration.
understanding implemented.
onerous.)
thermal shock.
application.
The Solution
The VLB design in conjunction with a CCI dump tube can simply and easily
cater for these requirements as the valve was designed to meet these arduous
requirements.
Thermal shock: forged fully machined valve body both outside and inside
to handle thermal fatigue which is critical for reliable service.
Flexible seat and excellent guiding. Thermal change can cause crushing
of the seat as the body contracts. The special two piece seat prevents
crushing of the seat. Good guiding ensure that the valve can be installed
horizontally or vertically without risk of sticking.
13
The uid in a valve reaches its maximum velocity just slightly downstream of
the valve trims vena contracta or minimum ow area. This high velocity in a
single path or multi-path design can produce cavitation, erosion and abrasion
Vena
Contracta
all of which can quickly destroy the valve. Even before damaging the valve,
the symptoms of excessive noise, severe vibration, poor process control and
product degradation may be observed.
V2
DRAG velocity control valves from CCI solved the problem a generation ago.
DRAG valves prevent the development of high uid velocities at all valve
settings. At the same time, they satisfy the true purpose of a nal control
element: to effectively control system pressure over the valves full stroke.
V1
V2 =
Heres how the DRAG valve accomplishes what the others can only approach:
2gh
V2 > V1
turnsa tortuous path where each turn reduces the pressure of the owing
medium. By increasing the number of turns, damaging velocity can be
controlled while an increased pressure drop across the control valve can be
successfully handled.
In the DRAG trim, the resistance, number and area of the individual ow
passages is custom matched to the specic application and exit velocities
are kept low to eliminate cavitation of liquids and erosion, vibration and
noise in gas service.
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Vent valves
Vent resistor
Startup valves
provide reduced total system noise rather than just individual product.
Desuperheater Technology
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Quality of atomization
proportional velocity2 (steam)
Installation
Solutions
CCI have several innovative styles of desuperheaters, but for extraction &
exhaust solutions, review and advice of the system is necessary. Aspects such
as liners, control, reduced sections of piping, location of instrumentation and
installation are all aspects necessary to meet performance requirements.
There are 3 stages to desuperheating:
Primary. The spraywater is admitted into the steam via the nozzle.
Secondary. This is where the momentum of the steam accelerates the water
droplets and this action breaks up the water droplets. The higher the velocity
of the steam the better the secondary atomization.
Tertiary. This is where the water droplets evaporate in the steam when being
transported. If the velocity is to low or the size of the water droplets too
large, there will be water fall out. Time is required to complete this process.
To achieve excellent primary desuperheating:
cross section.
CCI FK
(Fluid Kinetics)
Telephone: 805 644 5587
Fax: 805 644 1080
2368 Eastman Avenue, Suite 8
Ventura
California 93003
USA
CCI Austria
(Spectris Components GmbH)
Telephone: 43 1 869 27 40
Fax: 43 1 865 36 03
Carlbergergasse 38/Pf.19
AT-1233 Vienna
Austria
CCI Italy
(STI)
Telephone: 39 035 29282
Fax: 39 035 2928247
Via G. Pascoli 10 A-B
24020 Gorle, Bergamo
Italy
CCI China
Telephone: 86 10 6501 0350
Fax: 86 10 6501 0286
Room 567/569
Ofce Tower, Poly Plaza
14 Dongzhimen South Avenue
Beijing 100027
China
CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567-0051
Japan
CCI Korea
Telephone: 82 31 980 9800
Fax: 82 31 985 0552
26-17, Pungmu-Dong
Gimpo City
Kyunggi-Do 415-070
Republic of Korea
CCI Sweden
(BTG Valves)
Telephone: 46 533 689 600
Fax: 46 533 689 601
Box 603
SE-661 29 Sfe
Sweden
CCI Switzerland
(Sulzer Valves)
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
Hegifeldstrasse 10
CH-8404 Winterthur
Switzerland
Contact us at:
info@ccivalve.com
Visit us online at:
www.ccivalve.com
DRAG is a registered trademark of CCI.
2003 CCI
539
3/03 7K