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Flownex Applications on a Coal Fired

Power Plant
Deaerator /
Gland Steam Steam
Feedwater Tank
System Circuits

Boiler Steam
Circuits
Lubrication
and Control
Fluid Systems

Boiler Water
Circuits

Ash Removal

Boiler Draught
System
Cooling Water
Condenser Feedwater Feedwater
Circuits
Heaters Pumps

Click on a label to jump to that system


 Consists of: Superheated
 Superheaters Steam Outlet
Steam Drum
 Reheaters
Superheater

 Flownex can: Reheater


 Simulate attemperation control to evaluate
system reaction to operational changes
Downcomer
 Calculate flow distribution in
superheater/reheater in the event of a tube
leak;

 Calculate
C l l t tube
t b wallll ttemperature
t change
h d
due
to excessive fouling (inside and outside)

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 Consists of:
 Primary and Secondary Air Circuits
 Air Heaters
 Precipitator
 Fans
 Dampers

 Flownex can:
 Simulate dynamic adjustment of fan speed in
order to find optimum control characteristics for
efficient combustion.

 Determine effect of air heater performance


degradation over time due to air inleaks.

 Determine overall system flow distribution and


performance, incorporating air inleaks in order
to identify losses and performance reducing
areas.

 Determine system performance degradation


over time due to bag filter fouling.

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 Flownex can:
 Simulate flow distribution and
damper control for optimum
primary
i and
d secondary
d ffuell
mixing in burner operation in
order to reduce NOx and SOx.

 Design flow distribution between


burners and Secondary Overfire
Air (SOFA) in new or retrofitted
plants.
 Consists of:
 Boiler Wall Tubes
 Steam Drum
 Downcomers
 Water headers

 Flownex can:
 Design flow distribution through water
walls (orifice sizing etc.).

 Incorporate natural convection effects.

 Calculate two phase flow in tubes and


steam drum.

 Track the level in the steam drum


during dynamic transients such as blow
downs.

 Design
g forced convection flow
distribution and pump sizes.

 Determine heat transfer degradation


due to water wall fouling (inside and
outside).

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 Consists of:
 Main/Live Steam System
 Cold Reheat System
 Hot Reheat System
Main/Live Steam

HP Bypass

 Flownex can:
 Determine system heat Superheater
loss given a specific
insulation thickness. Spraywater
Attemperator HP IP LP
Turbine Turbine Turbine
 Determine flow losses
(friction, bends, valves,
etc.). Cold Reheat Steam

Reheater IP Bypass
 Calculate required Safety Valve
Hot Reheat Steam
attemperation spray water Condenser
flow rates during a turbine
Spraywater
trip. Reheater Attemperator

 Calculate system
conditions (temperatures,
pressures) in bypass
systems, condenser and
reheater during a turbine
trip event.

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 Consists of:
 Exhaust Steam Inlet
 Heat Transfer Tubes
 Water Boxes
 Hotwell

 Flownex can:
 Calculate degradation in heat transfer due to
internal and external tube fouling or
blockages.
blockages

 Calculate the effects on condenser pressure


due to air (incondensable gasses) leaked into
the system
system.

 Calculate condenser conditions (level,


pressure, temperature) during turbine trips,
steady state or other abnormal operating
conditions.

 Design cooling water pump requirements.

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 Consists of:
 Feedwater Tank Shell
 Steam Distribution Pipes
 F d t Sprayers
Feedwater S
 Air Vent
 Perforated Trays (some types)

 Flownex can:
 Calculate deaerator conditions (pressure, level, temperature) during various operating
conditions.

 Design required steam flow for sufficient heating and deaeration.

 Evaluate or design the air vent pipe’s capacity to handle the required venting capacity.

 Track the level dynamically during transient events,


events such as condensate stop.
stop

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From LP
Heaters
 Typically consists of:
 1 x 100% duty steam/electrically driven pump
 2 x 50% duty pumps
 Feed Pump Turbine
Deaerator /
Feedwater Tank

Extraction
 Flownex can: Steam
 Do system integration, incorporating pump Main Feedwater
characteristics charts from manufacturers. Pump

 Evaluate nominal pressure suction head


changes during system transients.
Boiler Feed To
 Design boiler feed pump turbine/feedwater Pump Turbine Condenser
pump integration
integration. (BFPT)

 Simulate system feedpump and BFPT control


mechanisms. To HP Electric Backup /
Heaters Startup
 Dynamically simulate switch-over
switch over from Feedwater Pumps
backup / start up feedpumps to main
feedpump.

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 Consists of:
 FWH Shell
 Tubes
 De-superheating Zone
 Condensing Zone
 Drain Sub-cooling Zone

 Flownex can:
 Be used to simulate accident scenarios, like bursting pipes,
loss of cooling
g water etc.

 Calculate FWH conditions (level, pressure/ temperature) during


transient events (such as condensate stop, turbine load
changes. Etc.).

 Track the level in the shell during operational transients or


accidents.

 Simulate safety valve operation during tube breach scenario.

 Evaluate nominal pressure suction head (NPSH) on drain


pumps during all operational conditions.

 Calculate or evaluate required incondensable vent capacity.

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Demin Water Inlet
 Consists of:
 Main Cooling Circuit Aux.
 Secondary Cooling Circuit Cooling
Water Other Turbine Generator Aux.
 Auxiliary Cooling Circuit Tank Consumers Consumers Consumers Cooling
Water
P
Pumps
 Flownex can:
Auxiliary Cooling
Circuit
 Be used to study the effects of a
plant alteration on the capacity of Secondary Cooling
the cooling circuits. Circuit
M i Cooling
Main C li Circuit
Ci it

 Evaluate if sufficient cooling Steam Inlet Water/Water


capacity reaches each cooing Pumps Strainers Coolers
load under all operating
conditions and during all system
transients
transients. Main Condenser BFPT
Condenser

 Can be used to identify


suspected leakages. Condensate Outlet Hot Duct

To Cooling
 Calculate minimum valve closing Tower
times to avoid water hammer.
Cold Duct

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 Consists of:
 Steam distribution pipes
 Steam seals
 Valves
 Draining Lines

 Flownex can:
 Calculate distribution of pressure and flow throughout the steam supply lines, which consists of a large
number of pipelines, valves and bends.

 Calculate whether the required steam can be delivered to all components throughout the system under all
operating conditions
conditions.

 Evaluate the effect of labyrinth seal wear caused by seal face rubbing during turbine starts and stops.

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 Consists of:
 Lubrication Oil Circuit;
 Jacking Oil System;
 Control Fluid Circuit;
 Lubrication Oil Drain Circuit;
 Oil Coolers;
 Oil Heaters;

 Flownex can:
 Simulate the flow of oil in pipes, tanks,
pumps, etc.

 Calculate the flow distribution through the


entire system
system.

 Find out if the oil temperature will be within


specifications through the whole system.

 Evaluate
E l t if sufficient
ffi i t oilil pressure iis available
il bl
to all components under all operating
conditions.

 Evaluate the effectiveness of the logic control


systems and the effects of a control
malfunction.

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 Consists of:
 Slurryy Pumps
p
 Slurry Transport Line
 Ash Water Pump
 Ash Water Return Pipeline

 Fl
Flownex can:
Ash Hopper  Simulate the flow of slurry through the slurry pipeline in order to
evaluate installed pump capacity or to design correct pipe diameters on
new or retrofitted plants.

 Simulate the ash water return flow pump and pipeline

 Be used to evaluate the effect of the amount of ash water mixed into
the slurry on the pressure drops and flow characteristics of the system.
A hW
Ash Water
t
Slurry Pumps

Water

Ash

Ground Level

Ash Water Pump

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