Professional Documents
Culture Documents
Applications in Fossil
Power Plants
Secondary
Superheater
Primary
Superheater
200
204
Capillary
system
2
203
202-1
201
Turbine
205
207
202-2
220
231
Boiler
221
240
Flash
Tank
230
Dea
storage
Main FW
pump
241
L.P.
Heaters
cond
pump
Polishing
equip.
This handbook was published thanks to the creation and direction of Curtis Sterud, CCI Valve Doctor.
With over 40 years of experience in the valve industry, Curtis is one of the industrys most respected
engineers and severe service valve experts.
Table of Contents
i.
ii. 502
iii. 518
iv. 519
f)
501
ALVE
V
No.
205
205C
207
210
218
219
220
221
230
231
240
241
401
PURPOSE
LP Superheater Stop
LP Throttle Control
Secondary Bypass
Turbine Bypass
SSH Outler Steam Attemporator
Reheat SH Steam Attemperator
HP HTR Steam Level
Flash Tank to HTR
DEA Steam Pegging
Flash Tank Level
Flash Tank Pressure
Flash Tank Level
HP Throttle Control
Ahead of the SSHTR
Heater Drains
Auxiliary Steam
SamplingVarious Locations
501 VALVE
500
VALVE
RY
NDA
SECO HEATER
R
SUPE
STEAM
DRUM
T
A
E
REH ATER
RHE
SUPE
ARY
ER
PRIM RHEAT
E
SUP
STACK
10 TEHEAT
E
SUR
HEATER
PRES
LVE
HIGH RS
DRUM VA
E
HEAT
MAIN STREAM
GEN
ERAT
OR
R
EEDE
S
ER F
BOIL C VALVE
IR
C
E
R
ER
MIS
NO
ECO
542
AIR
R
HEATE
ER
E
WAT
FEED ROL VALV
T
CON
0
BN10
EMP
P ATT
PUM
Y
SPRA
5788
CO
ND
EN
SE
R
ALVE
502 V
SATE
DEN
N
O
C
VEL
R LE
RATO
E
DEAE ROL VALV
T
CON
EAM
STR
ION
RAT
E
EXT
SUR
PRES
LOW ATERS
HE
AM
STRE
MAIN P SPRAY
M
ATTE
578
ROL
ONT
ER C
FEED VALVE
MP
N PU
RIVE )
P
OR D
MOT (STARTU TER
A
W
P
FEED
PUM
MAIN DRIVEN
INE
TURB
FWN
This particular application in the plant is where the condensate is taken from
the condenser hotwell, circulated through the low pressure heaters, and to the
deaereator.
The condenser acts as a heat exchanger that serves the purpose of creating
a vacuum which increases the efficiency of the turbine and for recovery of
quality feedwater (condensate).
Shown below is a schematic of a typical condensate system:
a) Condensate Pump Recirculation Valve:
The condensate pump must have a minimum amount of flow through it at
% Cv V5 % STROKE
100
Therefore, a recirculation valve and line runs from the pump outlet line back
80
to the condenser. When the boiler load is low the flow of condensate required
70
is less than the pump minimum flow requirement. The recirculation valve
60
is used to allow the additional flow required through the pump. The pump
% Cv
90
50
outlet pressure varies from 300 psi to 600 psi with fluid temperature from
40
100 to 150F.
30
20
The recirculation line dumps into the condenser which is at vacuum. Usage of
10
10
20 30
40
50
60
70 80
90 100
% STROKE
(the outlet pressure at the valve is higher than condenser vacuum because of
pipe friction, elevation and sparger back pressure).
This valve must have positive shutoff. To assure proper shutoff, the valve must
800
TURBINE
PUMP PRES
600
CONDENSATE PUMP
RECIRC VALVE
400
200
RE A P R
0
25
SURE
DEAERATOR
E
ESSUR
50
75
100
CONDENSER
HOT WELL
CONDENSATE
PUMP
LOW PRESSURE
HEATER
DEAERATOR LEVEL
CONTROL VALVE
Condensate System
Angle
Globe
High rangeability
Tight shut-off is not essential because this valve is open at all times the
plant is up and running.
The feedwater system is where feedwater is taken from the deaereator by the
boiler feedpumps and sent through the high pressure heaters, the economizer,
and finally into the boiler. The fluid is brought to full outlet pressure of the
boiler and its temperature raised by heat recovery for efficiency of the system.
a) Boiler Feedpump Recirculation Valve:
b) Boiler Feedwater Regulator:
Depending on the A/E, utility and boiler manufacturer, the feedwater flow
will be controlled either by a variable speed feedpump or a high capacity
control valve.
The boiler pumps may be motor driven, which are generally constant
speed and therefore constant outlet pressure, or steam driven with variable
output. (A fluid coupling on a constant speed motor driven pump can be
utilized to get variable output.)
In any case, a control valve for feedwater regulation to the boiler takes the
fluid from the pump outlet and regulates the outlet flow rate to the boiler
demand.
The service of this valve is similar to the DEA level control valve, except at
a significantly higher pressure.
The fluid is taken from the DEA into the boiler feedpump and the pressure
is raised to boiler operating pressure (most cases are over 3,000 psi).
This is the inlet pressure to the feedwater regulator. At start-up and low
loads, the pumping load is small and the pump outlet pressure is high
and the drum pressure is not built up yet. In this case, there is a need for
cavitation prevention and the flow capacity is very low. As the plant load
increases, drum pressure increases and flow rate increases. The pump
cannot maintain the same pressure head at these higher flows. The result is
lower inlet pressure to the valve and high back pressure on the valve. These
higher flows with lower pressure drops create a need for high capacity of
the valve with less resistance in the trim. Many plants utilize a start-up
valve and a main valve for this service. The start-up valve would have trim
to cope with the low flow and cavitation condition, and the main valve
take over the flow increased and differential pressure decreased. CCI can
provide a customized valve featuring DRAG technology that can be built
with characterized trim to cover the full range of operation conditions in
one valve.
Requirements of this valve:
High rangeability
10
DRUM
DEAERATOR
BOILER FEEDPUMP
RECIRC VALVE
MAIN FEEDWATER
REGULATOR
BOILER FEEDPUMP
HIGH PRESS
HEATER
STARTUP
FEEDWATER
REGULATOR
START UP
FWR
3500
3000
2000
MAIN FWR
PUMP PRESSURE
DRUM PRESSURE
1000
10 20 30 40 50 60 70 80 90 100
11
The main steam system covers the portion of the plant that takes the steam from the boiler, sends it through the superheaters,
and into the high-pressure turbine. The steam exiting the high-pressure turbine is sent through a reheater, then fed into the
low-pressure turbine. Finally, after all potential energy is extracted from the steam, it is dumped into the condenser to start
the whole process over again.
Large generating units were designed generally for base-loaded operation. However, with increased emphasis on planned cycling
operation of fossil-fired boilers, there are new demands on the control of boilers during start-up and low load operation.
Conventional drum boilers can be operated with wide variation in load, including complete shutdown and re-start, without
sacrificing heat rate or cyclic life. Modes of operation include variable drum pressure, constant throttle pressure and dual pressure.
With variable drum pressure, the turbine throttle valves are nearly wide open and the throttle pressure varies with drum
pressure. This operation is relatively slow in response to load demand.
With constant drum pressure, the turbine throttle valves are nearly wide open and the throttle pressure varies with drum
pressure. This operation is relatively slow in response to load demand.
BW100Feedwater Regulator
BW501Secondary Superheater
BW502Primary Superheater
BW518Main Steam
BW510Turbine Bypass
12
With constant drum pressure, the turbine load is changed by modulating the turbine throttle valves. The low load efficiency
is achieved by sequenced turbine control valves and partial ARC throttling at the expense of a large change in impulse
chamber temperature.
Dual pressure operation involves wide variable throttle pressure, with the pressure controlled by wide range superheater
division valves. The drum pressure is controlled at a high pressure above 2000 psi. For this type of control, there is little
change in turbine metal temperatures, or in drum saturation temperature over the load range. Load response will be at least
comparable to that for constant throttle pressure operation.
The dual pressure mode of operation is a system incorporated in some B& W drum boilers. B&W incorporated CCI DRAG
valves in five locations of this system.
The superheater division valves (BW500 and BW501) are used below about 70% load to maintain drum pressure, yet provide
reduced throttle pressure to the turbine. The BW502 valve permits firing proportional to steam flow during an unloaded
transient, and limited over-firing at low load. The 502 from the drum with the steam exiting the superheater and reheater to
hold temperature at the turbine without the concern for water into the turbine, which might result from water attemperation.
The BW100 feedwater regulator is a high rangeability valve for this service.
The 500 and 501 valves have been closed to bottle up the boiler overnight. The boiler pressure will have decayed
somewhat, so initial firing will be to bring drum pressure and temperature up. The 502 valve is used to bypass the steam to
the condenser. When steam temperature is established, the 501 valve is opened to admit steam through the superheater and
initially through the 510 valve to the condenser. This if for warming flow. The 510 valve is closed, and turbine throttle valves
are opened to 70%. The turbine is rolled (turbine throttle pressurized at about 200 to 300 psi. The 501 valve opens to increase
the turbine throttle pressure which is turbine load. With the low flows involved, the steam attemperation at superheater outlet
(518 valve) and reheater outlet (519 valve) controls the turbine temperature without the danger of water into the turbine at
less than 15% load. As load goes above 70%, the BW500 valve is opened to 100% open and the turbine throttle valves control
load of the turbine from there to full load.
The 502 valve starts with low temperature water at drum pressure ( ~ 2000 psi and 300F). The flow rapidly changes in
temperature as the leg of water is displaced by 2000 psi saturated steam which is approximately 650F; this is a significant
thermal transient. The valve should be over the plug, gasket seal, with linear disk stack for this service.
13
Shut-down (continued)
The 501 valves starts with high inlet pressure (approximately 2400 psi) and very low outlet pressure (0 to 100 psi). The valve
must control flow to load the turbine and then control flow as turbine load (pressure) is raised. This requires a characterized
disk stack similar to the BW100 feedwater regulator valve. This allows for the system to have an inherent linear characteristics,
i.e. valve stroke linear with load increase.
The 518 and 519 valve flow conditions are about the same, i.e. ~ 2000 psi saturated steam ~ 650F inlet and 0 to 300 psi outlet
pressure. The trim can be linear, and under plug flow.
There are other severe service applications which are common to both drum and once-through units. These are attemperator
spray valves, soot blower control valves (for plants which use steam for soot blowing), and auxiliary steam valves for steam
from main steam to boiler feedpump turbine.
14
Multi-Stage Disk
(Showing Right Angle Fluid Trim)
SOOTBLOWER
HEADER
CONTROL VALVES
RELIEF
RELIEF
VALVE
VENT VALVE
SOOTBLOWER
VENT
HEADER
PRESSURE
CONTROLLER
CONTROL VALVES
PRESSURE CONTROLLER
AIR SUPPLY
AIR SUPPLY
AIR
AIR
FILTER REGULATOR
PRESSURE
FILTER REGULATOR
PRESSURE
SENSING
SENSING
ELEMENT
ELEMENT
SOOTBLOWER
SHUTOFF
VALVES
SOOTBLOWER
HEADER
SOOTBLOWER
HEADER
SOOTBLOWER
SHUTOFF
VALVES
15
? Box
Bonnet
Body
Stem/Plug
Seat Ring
Disk Stack
Staggering of
Alternate Disks
Plug/Seat Interface
Flow Streamlines
16
The same valve for both areas. The disk stack is characterized with 14 turn and
8 turn expanding disks with (PER) for minimum fluid velocity with reheat
spray and wide rangeability in both applications. The flow is over the plug to
protect the seat surfaces from trash damage. The plug is unbalanced with a high
actuator load for shutoff.
17
There are two sets of heater systems in a normal power plant. The lowpressure heaters heat the condensate coming from the condensate pump so
it is near saturation when it gets to the deaereator. The other set, called highpressure heater, heats the feedwater coming from the boiler feedwater pump
so that it is near saturation when it enters the boiler. Both systems work in
similar manners, with the exception of the heating fluid. In the low-pressure
heaters, exhaust steam from the LP turbine is used, while the high-pressure
heaters use extraction team from the reheat section. See typical schematic,
below.
The level of condensate in the heaters must be controlled for the highest
level of system efficiency, so the drain system is fairly elaborate. There are
emergency heater drain valves which bypass the fluid to the condenser. Each
heater is at a lower pressure than the preceding heater. The fluid in the first
heater is saturated water as the fluid flows through the drain valve to the next
heater, the fluid flashes, the flashed steam passes over the tubes containing
the condensate, and the heat of the steam is absorbed by the tubes warming
the condensate. At the same time the steam temp is reduced to saturated
water. This saturated water is let down to the next heater and the same process
occurs.
Globe DRAG Heater Drain Valve with
Flow Distributer Integral with the Seat
Ring
18
The problem is that the condensate in the bottom of the heater is at saturation. When the condensate is drained and loses
just a small amount of pressure, it flashes, and erosion damage to the control valve and associated piping is common. The
important thing in choosing control valves in this application is to use a characterized disk stack to range low flow away from
the seat, with sufficient turns to keep velocity as low as possible. Angle valves, or globe valves with oversized ends and a flow
distributor integral with the seat ring to limit velocity will also combat erosion. In addition, the body material should be
A217C5, or A182F5.
19
All boilers require a minimum fluid flow through the furnace wall tubes at
even a minimum firing rate to protect the furnace tubes from overheating.
Protection is provided by circulation of a minimum amount of feedwater and
the use of a start-up bypass system.
20
Many variations exist when comparing the start-up systems provided by each of the boiler manufacturers. Functionally, they
all have a common purpose as elaborated below. Notice in Figures 3, 4 and 5, the physical differences illustrated for each of
the once-through boiler manufacturers. Combustion Engineering, Inc., (Figure 5 on Page 44) provides circulation pumps
to recirculate fluid through the furnace pumps and convection walls and, in this way, protect the tubes from overheating.
(Figure 7 on Page 44) Babcock & Wilcox Company and Foster Wheeler Corporation (Figure 3 on Page 42) require a minimum
pumping rate be established to provide this same protection.
Because of these individual differences, control systems vary on each of these units insofar as the actual coordination of the
valves in each start-up system. However, again analyzing the job that has to be performed, the functional objectives of all
systems are the same, namely:
1) As noted above, provide protection to keep furnace tubes from overheating by maintaining a minimum flow of fluid
through the furnace. Care must be taken to keep the pressure of the fluid in the furnace circuit at a pressure well above
saturation, thus preventing any flashing from occurring in the furnace circuit.
2) All systems provide some means of circulating water through the system for both a cold and hot water cleanup through
the use of a polishing system.
3) All systems provide for an orderly sequence to start-up and initially load the unit as follows:
a) By rejecting flow to the flash tank or separator during start-up, provisions are made for hot cleanup operation and
initial build up of enthalpy.
b) To assist in building up the heat in the boiler, in a minimum time, both the water and steam in the flash tank are put
back into heat recovery in the deaereator and/or feedwater heaters during start-up and low-load operation.
c) When the enthalpy level in the flash tank or separator reaches some minimum desired level, steam can be admitted
to the superheater and main steam lines for warming purposes.
d) By bypassing steam to the condenser through a turbine bypass valve and/or the turbine above seat drains while
regulating the heat input, better matching of steam temperature to turbine metal temperature is achieved prior to
rolling the turbine. This improvement is relative to that obtained with a drum type boiler where temperature is
obtained as a function of the firing requirements for the pressure required.
The turbine bypass valves function to provide initial steam to heat steam lines and roll the turbine. Through these
valves, it is possible to establish steam flow through the superheater to turbine roll and synchronize the turbine
with minimum upsets. (B&W = 210, FW = U, CE = SD)
e) Following turbine synchronization, turbine load is increased using flash tank or separator steam available. When the
available flash tank or separator steam is depleted, additional load is obtained by opening the in-line stop valves,
thus, admitting furnace outlet fluid directly into the superheater. In the case of a Combustion Engineering or Riley
boiler, pumping rate must be increased at the same time. Once the stop valves are fully opened, the flash tank or
separator are taken out of service.
21
Control systems must be properly programmed to recognize the following facets during this period:
1) Furnace circuit pressure must always be maintained.
2) Throttle pressure is increasing during this period; thus, the amount of stored fluid and heat must be increased. Load and
steam temperatures are likewise increasing, which also demands additional heat and fluid storage.
3) Saturated steam from the flash tank or separator to the super heater is being replaced with steam directly from the
evaporating section of the boiler. This means the enthalpy leaving the furnace section must be maintained at an enthalpy
level approximately that of steam leaving the flash tank. By properly programming the opening of the inline stop valves
(B&W = 200, FW = Y, CE = BT)and changes in pumping and firing rate, outlet steam temperatures can be maintained
during this transfer to straight through operation.
Thus during start-up and low load operation prior to the turbine load exceeding the minimum feedwater flow, the control
system must utilize the bypass system valves as an extension of pressure control and feedwater flow control. During this
period, the heat input must be properly controlled to provide the required steam conditions at the turbine, recognizing
that some heat is being lost through the bypass system until it is taken out of service.
22
The Previous diagrams show typical B&W units with Bailey valves in an older plant, and CCI DRAG valves in a plant after 1974.
This design requires a start-up flow of 25% to 30% of rated capacity.
For start-up, these units circulate the fluid thru the boiler, 202 & 207 valves, the flash tank and to the condenser, until the fluid
temperature is proper for steam at about 600 psi in the flash tank. Then steam flow is allowed through the 205 valve to the
secondary superheater and 210 valve for warming. Then, when the temperature is OK, the 210 is closed and the turbine is loaded
to minimum load. This could be 800 psi throttle pressure and about a 25% load. Pressure upstream of the primary superheater
would be about 3500 psi for supercritical units and about 2800 psi for sub-critical units. The turbine throttle valves are set at
this minimum load setting. Then the 201 valve is opened as the 202 and 207 are closed to pressurize the downstream secondary
superheater.
During the start-up, primary superheater pressure control is maintained by the 202 valve. When the pressure drop across the 200
(201) valve is about 300 psi, the 200 valve is opened 100%. Note that when secondary superheater pressure is higher than the
flash tank, the 205 valve closes (its a check valve). Load is now increased to 100% by opening the turbine throttle valves. At this
time, the controls are set to open the 202 valve if the primary superheater pressure exceeds a certain limit.
The load can be varied by turbine throttle valves. However, the load must be changed very slowly because when the throttle
changes to change load, there is a change in steam temperature across the turbine. Turbines are not to be thermally cycled.
Therefore this type of unit is base loaded, that is, operated at constant load.
B&W introduced cycling of their once through units by incorporating a 401 valve. This valve replaces the 200 & 201 valves.
Note: Flow rate in lbs/hr is estimated by multiple of 7000 x MWE of the unit. Example: 500 MWE unit would have 3500000#/hr flow at 100% load
The 202 valve generally was 2 or more valves is the total flow: if there are two valves then each valve is sized for the flow
Schematic of a base loaded B&W once-through unit using DRAG valves in the start-up system
23
24
25
The 220 (H.P. heater steam control valve) and the 240 (flash tank overpressure control valve) will open to limit the flash
tank pressure at its set point of 500 PSI.
8. During this period, the secondary superheater will be boiling out to remove all water.
9.
26
When the capacity of the 220 valve is exhausted, the steam entering the turbine should be increased to 1000 PSI. This
will increase the flash tank set point to 1000 PSI.
8. The 220 and 240 valves are automatically set to hold the flash tank at its set point of 1000 PSI
9. At a flash tank pressure of 1000 PSI, the turbine can be synchronized and loaded. The unit load is ramped to
approximately 7% load.
10. The 210 valve is closed after the turbine is synchronized.
27
28
pressure operation.
Constant pressure has two adverse effects when large load changes occur. First,
the turbine will experience temperature fluctuations, which will create fatigue
and reduce its life. Second, the net thermal efficiency or heat rate of the turbine
drops at lower loads.
Sliding pressure operation is designed to eliminate these problems.
Figure 1 shows the constant pressure system. With this system the turbine
throttle valves control the inlet pressure to the turbine proportional to plant
load.
Figure 2 shows a sliding pressure system. Here, a control valve (401) is installed
upstream of the secondary superheater. Although the turbine throttle valves are
still in the system, they are held wide open and plant load (turbine pressure)
is varied by the sliding pressure control valves. The temperature change
29
With constant pressure systems, the transfer is at approximately 25% load. Pressure at the turbine throttle valves is brought up to
approximately 3500 psi and load on turbine raised via the turbine throttle valves.
With sliding pressure control there are options of 70% or 100% sliding pressure control.
With 70% sliding pressure control, a larger 201 valve is installed. The turbine throttle valves are set at 70% load and the
turbine throttle pressure is controlled by the 201 valve up to that load. The 200 valve is opened and then the load is raised on
constant pressure control by the turbine throttle valves to 100%.
With 100% sliding pressure control, the 201 and 200 valves are replaced by valves which combine the functions of the 201 and
200 valves. These valves are called 401 valves. Systems with this design operate by setting the turbine throttle valves wide open
and controlling the turbine throttle pressure with these 401 valves throughout the load range.
30
The sliding pressure unit has a few modifications designed to satisfy three basic requirements of operation. These requirements are:
1. Capability to be reliably started up and shut down to make them available for two-shift operations.
2. Extended unit load turndown while operating in the once-through mode. To maximize the capability to reduct unit load during
off-peak demand periods without placing the boiler bypass system in service; thus maintaining reasonable heat rates at reduced
loads.
3. Capability of variable pressure operations the once-through mode to optimize operation of the unit for load cycling. To extend
the range of operation of the unit in the once through mode it is necessary to reduce the boiler minimum feedwater flow
requirements for furnace protection.
Modifications
1. In constant pressure units, the first pass of the furnace consists of four parallel riser circuits (sidewalls and front and rear walls).
In sliding pressure units this consists of two passes in series; pass 1 is through sidewall risers and pass 2 is through front and
rear wall risers. In addition a bypass valve around pass 1 is installed (263 valve), to limit the flow through the sidewalls to
125% of original design. This bypass is to limit the additional pressure drop created by the dual pass arrangement of the lower
furnace. A second bypass valve (264 valve) around pass 2 is added to further reduce this pressure drop; this allows a minimum
feedwater flow rate of approximately 10% of full load flow.
2. For capability of the boiler/turbine temperature matching during start-up and for accurate mainstream and hot reheat
control while operating on the bypass system, steam attemperators are added for the secondary superheater and reheater. The
second superheater steam attemperator requires the addition of valves 218 and 205C. The latter is used to maintain enough
differential pressure between the flashtank and the throttle to support the attemperation function. The flash tank steam is
used for superheat steam attemperation, since
this function is required only while on the
bypass system. The reheat steam attemperation
requires a 219 valve which takes steam from
downstream of the 401 valve, since this reheat
steam attemperation is needed while on
the bypass system and also during oncethrough operation at low load generator.
3.
401 Valve
31
P2
SECONDARY SUPERHEATER
P1
4000
PRIMARY SUPERHEATER
P1
3500
3000
PESSURE
P2
PSI SECONDARY SUPERHEATER
P2
SECONDARY SUPERHEATER
2000
1000
207
VALVE
(CLOSED) TURBINE
TURBINE
10 20 30 40 50 60 70 80 90 100
% LOAD
205 VALVE
(CLOSED)
205 VALVE
FLASH
TANK
CONDENSER
(CLOSED)
FLASH
TANK
4000
3500
100
P1
90
80
3000
PESSURE
PSI
2000
CONDENSER
P2
PESSURE
70
PSI
60
P2
2000
1000
30
1000
0
3000
50
40
Disk Stack
Characterization
4000% Cv V5 % STROKE
P1
3500
EX
I ST
IN
n AtPRIMARY
25% full
load, the SSH pressure will
SUPERHEATER
P1 be approx. 1000psi.
UP
DA
TE
% Cv
20
10 20 30 40 50 60 70 80 90 100
% LOAD
10
10 20 30 40 50 60 70 80 90 100
% LOAD
10
20 30
40
50
60
70 80
90 100
% STROKE
% Cv V5 % STROKE
% Cv V5 % STROKE
100
90
32
Once-through steam generators by Foster Wheeler incorporate start up bypass systems to maintain a minimum cooling flow
through the furnace circuits when starting up. Other provisions are also built into the system to satisfy turbine throttle steam
requirements and to give maximum heat recovery during starting. There are two designs; one using an external flash tank,
and one using integral separators.
1.
A bypass system utilizing an external flash tank system for rolling, synchronizing and initial loading of the turbine is shown
first. At some load, usually that which matches 1000 psi throttle pressure, the steam flow to the turbine is switched from the
external flash tank circuit to the main line flow path. In this system, shown in the schematic (Figure 2 on Page 45), throttle
steam to the turbine is initially furnished through valve N with division valve V closed. When throttle pressure is to be
ramped from the 1000 psi level to full pressure for loading to 25% of full load, division valve V is slowly opened and valve N
is closed. Valve P closes to generate the pressure ramp.
System Drawbacks
When the external flashtank system is used with a cycling unit, it is difficult to provide optimum steam conditions to the
turbine (temperature and pressure) during loading and ramping to obtain minimum starting time without degradation of
turbine cycling life. This characteristic is especially true when the pressure ramp achieves full pressure at 25% load.
In general, the flash tank system, to achieve proper fluid enthalpy at the boiler division valve, starts the ramp at a higher than
optimum load and, as a result, turbine control valves close slightly during ramping to properly follow the ramp program
(pressure versus load). In addition to this effect, throttle steam temperature to the turbine may decrease (dip) or exhibit reversing
trends during ramping as a result of changing from the external flash tank loop to the main flow path. The cumulative effect
of the foregoing for a hot start is to cause a decrease in turbine first stage shell temperature. The first stage outlet inner shell
temperature is measured and used as an indication of adjacent shaft surface temperature. For repeated hot starting, fatigue
damage causing surface cracks on the shaft must be avoided. To keep cycling life expenditure for the turbine at a chosen level
when starting in this manner, either the time for hot starting must be greatly increased or the number of hot starts at minimum
time must be limited. For cycling service, this restriction on operation is unacceptable.
Valves
W
33
Flash tank level. This valve is the same as the B&W 241
valve.
34
Valves
W
Flash tank level. This valve is the same as the B&W 241 valve.
Flash tank level (along with D valve). This valve is the same
as the B&W 221 valve.
Flash tank to H.P. heater. This valve is the same as the B&W
220 valve.
35
36
The combustion engineering combined-circulation supercritical boiler incorporates a start-up system which has many of
the same features and benefits as the B&W design. The main unique feature which differentiates the CE unit from the B&W
unit is the integral recirculation system in the boiler, which separates waterwall protection from flow requirements. Integral
recirculation allows for lower minimum flow of approximately 10% of full boiler load flow which not only minimizes heat
rejection during start-up but allows the transfer from the bypass system to once-through operation to take place without a
sudden drop in steam temperature. For the CE unit, the transfer from recirculation to once-through operation occurs without
operator intervention. Increasing waterwall pressure drop, which is due to increased flow, causes a reversal of pressure across
the check valve in the recirculation line. Once the check valve is closed, the operator has the option of leaving the recirculation
pumps in service or shutting them down. The concept of separating waterwall protection from plant cycle requirements is also
used in CEs sliding pressure units. (Figure 3 on Page 42, Figure 6 on Page 44)
37
BT Valve
BT VALVE
WATER WALL
13 PR
13
TURBIN
BE
PSH
SA
3500
WATER WALL
3000
RECIRC
SYSTEM
SSH
LE
TT
PESSURE
PSI
RO
2000
E
IN
TH
COND
B
UR
1000
10 20 30 40 50 60 70 80 90 100
BT VALVE OPERATING RANGE
100
90
80
70
% Cv
60
50
BT
30
40
BT
20
10
0
10
20 30
40
50
60
% STROKE
Disk Stack Characterization
70 80
90 100
38
In a drum unit, circulation of water within the unit provides a cooling flow in
BE
BTB
BT
SA
SP
WD
the total flow through the walls to a safe level, regardless of feedwater flow.
IS
system equals the head produced by the circulation pump and the stop-check
IR
SD
FWB Feedwater control valve. Controls feedwater flow from 5% to 25% unit flow.
the lower load range in a manner which protects the furnace walls by raising
At approximately 10% load, the pressure drop through the furnace wall
positive head to the total unit through-flow, in this manner acting as a booster
to the boiler feedpump.
39
The start-up shown is for a base loaded unit. The Sulzer valves and actuators are designed to be operated within the conditions
shown.
For instance, the first BT valve is shown to start to open at 18% load. The pressure drop across this valve at 18% load is 1700 psi.
The BT actuators are sized for that pressure drop. The valve should not (and probably cannot) be opened at less than 18% load
because of the greater pressure drop. The valve, plus packing friction, is the actuator load. Thus, actuator load is proportional to
system pressure drop.
For lowload operation at less than 30%, the unit may operate with the turbine throttle valves at 30% and the BT and BTB valves in
control between 10% and 30% load. The unit could also operate at less than 10% by transfer from once- through to the BE valve
and separator start-up system.
40
To reduce load down to the low load is a reverse of the start-up. The turbine
throttle valves are used to change the load down to 30%, the BT valves are
brought down to control, and then the BTB valves are as well. The load reduction
via the turbine throttle valves must be done slow enough so as to minimize
thermal stresses on the turbine. There is a fluid temperature reduction with
throttling. Once on the BT valves, the pressure throttling is across the BT valves
and the temperature to the turbine remains constant because of the superheaters
after the BTs. Changing load while on the BT valves is sliding pressure. This
means that varying the load in the 30% to 100% load range on the turbine
throttle valves is slow, but once on the BTs, the load can vary relatively fast as far
as the turbine is concerned.
The Sulzer BE, BTB, and BT valve are extremely heavy-duty valves. They were
designed for the start-up and shutdown of the unit as discussed so far. However,
extended time at low load using these valves and actuators was not in the
original scope.
So the question is, What should be done to address extended low load or sliding
pressure operation of the unit?
If sliding pressure (extended service time) is done, the BT valve trim should be
changed from linear to equal-percentage flow characteristic. Also the actuator
size should be increased to enable full pressure range operation on the BT valves.
The equal-percentage characteristic is required so there is a smooth change
in flow as each successive BT valve is opened or closed. Especially important
is when the first BT is opened. At that time the BTB is controlling waterwall
pressure. The BTB trim has about 10 times less plug area than the BT plug area.
When the BT opens, the BTB valve must close to maintain waterwall pressure as
the flow is increased through the BT valve. With the significant difference in plug
size, the equal percentage trim in the BT would allow smooth increase of flow
while minimizing waterwall pressure swing. The equal-percentage trim requires
a larger seat ring bore in the BT valve in order to maintain the same maximum
capacity (Cv). The BT valves combined maximum capacity must be at least the
same as before. The resistances between the pump and turbine (called parasitic
power) must not increase. The forgoing is addressing extended operation on the
BT and BTB valves down to about 10% load on once-through operation.
The unit could transfer to the start-up system for low load down to
approximately 7%. However, transfer from once-through to the start-up system
introduces problems of feedwater control and feedwater chemistry. The frequent
cycling of the unit for sliding pressure or for low load operation is best done on
once-through operation.
41
With BT valves modified with equal-percentage trim, increased seat ring size for capacity, and larger actuators, the unit can be
operated on sliding pressure to a higher load than 30%. Shown below is a 70% system showing the start-up and once-through
ranges of the Sulzer valves:
This system could be configured with only the BT valves. However the BTB capacity addition at 100% load is of benefit for
minimizing parasitic power.
42
The operation of the bypass system can be broken down into two basic areas of control: the low load and pressure portion of
the pumping and firing controls, and the flash tank sub-loop controls.
The pumping and firing rate controls include the control of the boiler feedpump, the firing rate and control of critical control
valves.
Control Valve
Primary
Secondary
Manufacture
Control Valve
Base Lord
Function
B&W
Manufacture
Cycling
bypass
bypass
H1 Press
Pressure
Turbine
Function
These critical valves
for the three
major once-through
boiler
manufacturers
are shown
below:
Superheater
Superheater
Superheater
201
Pressure
Reducing
207
P
201
W
200
Y
210
U
N/A
N/A
207
P
401
W (large)
N/A
Y
210
U
N/A
BE
P
N/A
W
BTB
Y
BT
U
SD (U)
N/A
BE
P
N/A
W (large)
Y
BT by CCI N/A
U
SD/U
Base Lord BE
N/A
BTB
BT
SD (U)
Cycling
N/A
BT by CCI
N/A
SD/U
Base Lord
Foster
Base Lord
Comb.
Wheeler
Cycling
Eng.
Cycling
Comb.
Eng.
bypass
stopvalve
Secondary
207
Superheater
bypass
207
BFoster
&W
Wheeler Cycling
Cycling
Primary
202
Superheater
bypass
N/A
Reducing
BE
401
H1 Press
200
210
Turbine
Superheater
bypass
stopvalve
N/A
210
The flash tank subloop controls include the following valves in the three boiler designs.
Control Valve
Function
Manufacture
Control Valve
B & WFunction
Manufacture
Foster Wheeler
Superheater
stopvalve
205
Superheater
stopvalve
N
High
Deaerater
pressure
Pegging
heater steam
Flash
tank over
pressure
Flash
tank level
control
High
220
231
Deaerater
pressure
Pegging
heater steam
C
B
Flash
240
tank over
pressure
A/F
Flash
241
tank level
control
D
B&W
Comb. Eng.
205
SA
220
?
231
dea peg
240
SP
241
WD
Foster Wheeler
A/F
Comb. Eng.
SA
dea peg
SP
WD
Figures 1 Through 3
Base-Loaded Configurations
Figure 1
Babcox & Wilcox
Once Thru Unit
Figure 2
Foster Wheeler
Once Thru Unit
Figure 3
Combustion Engineering
Once Thru Unit
43
44
Figure 4
Riley Stroker
Once Thru Unit
Figures 4
Base-Loaded Configuration
Figures 5 Through 7
Sliding Pressure Configurations
Figure 5
Babcox & Wilcox
Once-Through Unit
Figure 6
Foster Wheeler
Once-Through Unit
Figure 7
Combustion Engineering
Once-Through Unit
45
46
47
48
49
50
51
52