Control Valves for Turbine Bypass

DOs and DON'Ts of Steam Conditioning Valves

Ted Geelhart Steam Conditioning Manager

Don Sarpong Control Valve Specialist

Canadian HRSG Forum

 Attemperation vs. Steam Conditioning
Attemperation process accurately controls steam temp by introducing
small quantities of water.
installed to protect downstream equipment from thermal fatigue and
premature failure over time.
Attemperators are installed upstream of the turbine to ensure the
turbines design temperature limitations are not exceeded
Typical applications include inter-stage attemperation (HP, RH), final
stage attemperation, terminal reheat steam
Conditions vary from Pressures of 250psi to 2500 psi
Temperatures of 900F -- 1075 F

Steam Conditioning uses an upstream PRV

and downstream DSH in conjunction for the
accurate control of both downstream pressures
and temperatures
Typical applications are HP, HRH, LP turbine
bypass

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 2
What is Turbine Bypass?
Turbine Bypass System: used to bypass steam around the turbine as steam
temperature and pressure build. The bypass valve designed to simulate the
turbine and is used during steam turbine trip.
Allows Combustion Turbines or Boiler to continue operation until steam turbine can be brought back
on-line
Enables daily cycling of power plant
Temperature matching of turbine blades at start-up
Controlled shut-down of power plant
Combined Cycle Power Plant
Typical Service Conditions & Requirements
HP: P1=1880 psig, P2= 550 psig, T1=1070F, T2=600F,
Q=71,000 - 500,000 lb/hr
Turbine Bypass
F91 material required, noise abatement trim, 12-16
valve, 500-1000 Cv capacity 8. HP Bypass

HRH: P1=1100 psig, P2= 90 psig, T1=1030F, T2=345F, 9. HRH Bypass

Q=100,000 - 500,000 lb/hr 10. LP Bypass

F91 material required, noise abatement trim, 24-36

valve, 3000-6000 Cv capacity
LP: P1 = 200 psig, P2= 0 psig, T1=675 F, T2= 300F, Q=
100,000 - 500,000 lb/hr
SA105 material, noise abatement trim, 16-20, 800-
1500 Cv capacity

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 3
Increasing Demands on Turbine Bypass
Increased temps - rapidly exceeding 1100 F
Increased cycling of plants 250+
Start/stops per year
Increased Noise requirements 85dBa or
less
Plants in residential areas
More stringent noise limitations (overall and
spectral noise)
High cost of real estate
Shortened start-up schedule 18-24 months
or less
Maintenance fewer, less experienced
people

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 4
 Rapid Start Model Turbines
Many of todays turbine designs
and control systems uses a
rapid start technology.
This allows them to be online
within 10-30 minutes,
depending on vendor and style
Although this is provides power
plants great flexibility, it can
cause issues for valves and
other components that werent
designed around this
technology

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 5
 TBS Valve Challenges in Combined Cycle
Applications
Material Requirements
Special hardness levels & chemistry often required

Optimum Temperature Control

Spray pattern, water capacity, rangeability
designed for wide range of process conditions
Minimize straight pipe length (SPL) & temperature
sensor length (TSL) without water fallout

Easy plant start up and commissioning

Ensure particulate is removed from pipe,
equipment is properly set up, and trim is properly
stored until needed

Rapid Thermal Cycling

Trim materials selected to prevent sticking,
premature wear, and fatigue

Tight Shutoff Requirements

Class V shutoff capabilities must be met to ensure
optimum seat life

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 6
 Material Challenges: F91
Material specification for processing Grade 91
materials need to get aligned with state-of-the-
art methods that go well beyond the code
minimums
Chemical Composition limits plus N / Al ratio control
Hardness limits for material procurement to ensure 200 HBW at
shipment, after welding / HT
Tightly controlled tempering temperatures to control loss of hardness
at PWHT
Normalizing/Tempering procedure for use where necessary to
increase hardness on raw material
Tighter control of PWHT time and temperature
Hardness testing techniques to ensure consistency

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 7
 Why Desuperheat?
Desuperheating is most often
used to:
Improve thermal efficiency of heat
transfer processes by using
steam near saturation
Control unintentional superheat
from pressure reduction of steam
Protect downstream equipment
and piping from elevated
temperatures and pressures

Goal: Reduce temperature setpoint at shortest possible

piping distance & elapsed time while avoiding damage from
two-phase flow

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 8
 Critical Parameters
Temperature Setpoint DO: Respect the SPL &
TSL provided by your
Spraywater Temperature manufacturer
Initial and Final Steam
Superheat
Spraywater Pressure
Minimum Steam Velocity
Maximum Steam Velocity
Pipeline Size
Downstream Straight Pipe
Length
Steam Pipe Liner

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 9
 Installation DO: Understand installation &
Parameters orientation for proper selection

Optimum Temperature Control

Nozzle selected with spray pattern, spraywater capacity
requirements, rangeability to operate over wide range of process
conditions
Attemperator design must ensure evenly distributed temperature
profile at minimum straight pipe length (SPL) and temperature
sensor length (TSL) without water fallout

Water Impingement
and Fallout
Ideal Concentric Laminar Temperature Zones

Single Nozzle Multiple Nozzles Reqd

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 10
 Installation Parameters
DO: Understand installation
Installation Orientation & Accessibility and orientation for proper
Orientation can affect the speed of vaporization. selection
Horizontal installations are most common.
Vertical flow up installations perform slightly better because of the positive
effect gravity
Vertical flow-down pipe perform less efficiently because of the negative
effect of gravity reducing residence time.

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 11
 DO: Understand what affects SPL & TSL

Many variables change SPL &

TSL
Increasing dP across nozzles
Changing nozzle sizes
Water temp
% spray water
Initial & Final superheat
Pipe size
Flow direction
All these factors work together
to set SPL & TSL.
Changing one or more factors
may alter distances 10%-30%+

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 12
 Benefit Discussion: SPL vs
Nozzle Selection and Water Conditions
SPL/TSL is directly affected by droplet size and steam
velocity.

Droplet size is directly affected by Nozzle Size and

Nozzle dP
Smaller nozzles yield smaller droplets, but more nozzles would
then be required to get the same capacity
Larger dP yields smaller droplets, so improvements can be made
by taking water from higher pressure source or adjusting
valve/nozzle pressure split

Small pipe size or schedule changes can have

significant impact on required pipe length

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 13
 Bore Scope Inspection:
Manifold Inside Wall
Maintenance and Inspection Weld Joint between Valve & Manifold
Weld Joint between Manifold & Header
Diffuser (if used)
Spray Water Nozzle
Cooler Manifold

Downstream
Flanged or Welded

Ensure spring tension remains

strong enough to close nozzle
Spray Annulus Surface should
not contain any damage
Water Injection holes should be
clear, debris free, and not
contain erosion damage
Nozzle opening should free of
rust and debris that would
prevent it from opening or
Flow Down Turbine Bypass System closing properly

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 14
 DO: Look for enlarged holes or cracks between
holes

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 15
 DO: verify holes are open and clear

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 16
 DO: Evaluate Diffuser Condition

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 17
 DO: Evaluate Diffuser Condition

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 18
 DONT: install nozzles
without an appropriate
selected mesh size filter
Nozzle Operation
When nozzle clog or function
improperly, this results:
Inability to provide proper cooling
spray
Inadequate spray
Too much spray
Not enough spray
Damage to piping or other
components
Strainers upstream of spraywater
valve recommended to ensure
optimum performance, efficiency, and
reliability.
Replace nozzles for optimal
performance and prevention of costly
repairs
Remove Nozzles during cleaning
operations at startup

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 19
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 20
 Nozzle Inspection

DO: For optimal performance, nozzles should be inspected every 18-24

months and replaced every 24-36 months (depending on usage)

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 21
 Case History Nozzle Inspection

1
2
4

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 22
Small process conditions changes
can make a big overall difference
Max Cv = 8000, Noise = 89dBa Max Cv = 5600, Noise = 92dBa
dP = 13psi SPL = 20.9Ft dP = 23 psi, SPL = 21.9

Do: Consider small changes in process conditions to shrink valve sizes

[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 23
 Particulate
Plug to cage clearances are very
small; small particulate can get
caught in this space
When material gets caught:
galling damage requires repair or
replacement
inability to control properly or stroke
trip of combustion turbine
loss of revenue
possible blow by sky vents

DO: Always use a blow thru or blow out kit at

startup to remove particulate from pipelines

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 24
 Start-up and Flushing Trims
Startup trim is used to allow particulate to be
flushed out of the process before startup Bonnet connection customized to
This prevents weld slag, particulate, and other customer preference
matter from getting clogged in small hole trims
Removes risk of delayed startup, trim damage,
or unplanned shutdown due to clogged cages
or particulate damage
O-ring used to seal against
inside of SR

Hydro-Trim
Plug used to allow hydro
Blow thru plug used to allow testing of piping upstream of
fluid to pass through body valve
without impinging on seat ring
surfaces
O-ring used to seal against
inside of SR

Seat Ring shutoff surfaces

protected by blow thru plug Hollow plug used to allow
fluid to pass through the plug
and flush upstream piping

Blow Thru Trim Blow Out Trim

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 25
 Failure to complete proper steam blows
results in heavy Particulate damage

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 26
 Improper Trim Storage

DO: Properly store valve trims to ensure they do not become damaged during
startup and commissioning
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 27
Dealing with Magnetite
A cycling power plant over time will likely experience Flow Accelerated Corrosion
(FAC). FAC will eventually result in a system where particulate is present
Trim designed to protect seal from
magnetite
Prevents premature wear on seal
and cage
Minimize sticking issues due to
buildup of magnetite in seal and
piston rings
Works by causing vortices that will
drop magnetite out of the flow steam
before reaching top of plug

DO: upgrade valve trim

to include catcher and
prevent sticking issues

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 28
 Effects of Wet Steam

DONT run wet steam through the

control valve for lengthy periods or at
low travels
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 29
 Turbine Bypass Equipment Selection
Steam conditioning equipment can come in
many different forms
When compared to equivalent desuperheater
and pressure reduction station, steam
conditioning valves provides:
better temperature control
improved noise abatement
fewer piping and installation restrictions
Turbine Bypass valve designs can vary
considerably depending on applications
Particular characteristics or options that yield
efficient customer specified requirements.
Selection done based on specific process
conditions and desired plant outcomes.

No one-size fits all device exists.

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 30
 Turbine Bypass Technologies

Standard Globe Body with Angle body with diffuser Angle body flow up with Angle body flow down with
DSH device technology noise abatement technology noise abatement technology

Most economical Fits traditional flow Becoming the new Fits traditional flow
choice down approach standard down approach but
Use noise abatement meets todays
Use noise abatement Available with
technology stringent noise
technology diffuser technology
requirements
Can be provided as Common in HRH, Common in HRH,
Use noise abatement
integral or separate HP, and other steam HP, and other steam
conditioning technology
unit conditioning
applications applications Common in HRH,
Common in LP,
HP, and other steam
repowering projects,
conditioning
and small plants
applications

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 31
 Valve Orientation
Horizontal Stems
Pros
Traditional approach for turbine bypass
For some process designs, requires smaller
footprint
Cons
Gravity is a NEGATIVE
Increased wear on parts
Maintenance can be challenging
Vertical Stems
Pros
Maintenance friendly
Less wear on trim parts extend their life and time
between turn around
Natural fit for noise abatement trim
Becoming the New Normal
Cons
Retrofits into existing installations can be
challenging

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 32
 Warm Up lines
Large thermal transients cause the body and trim to heat
at different rates
Warm up lines help valve and trim come to thermal
equilibrium before valve is operated
Goal is to preheat the valve adequately with the
minimum of piping/valve cost and least energy
consumption.
Time is critical: 30+ minutes required at very high
temperature steam to allow the body and trim
temperatures to reach thermal equilibrium.
If this time is not reached, the warming loop may not
function correctly and sticking of the trim parts may
occur.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 33
 Preheating guidelines

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 34
 Designing for Rapid Thermal
Transients
Clamped trims need to be adapted to
allow for rapid thermal expansion
Due to high surface area to mass ratio
of the trim compared to low surface
area to mass of the body

Hung style trims are designed for DSS

and base loaded plants
Cage is allowed to expand/contract
independent of body or seat ring
Trims capable of large thermal
transients without fear of crushing trim

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 35
 Fast Stroke Pneumatics to
Meet <2 seconds
Customer demands are constantly evolving
EPC & End User specifications indicate a need for
both high speed and precise control in some cases
Optimized actuation packages designed
specifically to process needs
High speed requirements (<2 secs open)
Precise control (large & small steps)
Easy tuning (no more quick exhausts)
Considerations
Digital Positioners
Very Large Volume Boosters
Solenoids
Fail Mode Do: use appropriate
accessories to obtain the
correct stroking speeds

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 36
 Attemperators

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 37
 Critical Parameters
Temperature Setpoint
Spraywater Temperature
Initial and Final Steam
Superheat
Spraywater Pressure
Minimum Steam Velocity
Maximum Steam Velocity
Pipeline Size
Downstream Straight
Pipe Length
Steam Pipe Liner

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 38
Types of Desuperheaters
Insertion style
Insertion Style desuperheaters can be used to efficiently reduce the
temperature of superheated steam to the desired set point.

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 39
 Ring style Attemperators
Ring-Style Desuperheater incorporates a spraywater manifold with variable geometry
nozzles that produce an optimized spray pattern over a wide operating range.

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 40
 Questions

[File Name or Event]

Emerson Confidential
27-Jun-01, Slide 41