Bypass Systems

Designed to Improve
Efficiency and
Flexibility of Thermal
Power Plants
...................................................

By Ulrich Kgi

22591 Avenida Empresa

Rancho Santa Margarita, CA 92688
949.858.1877 ! Fax 949.858.1878 ! ccivalve.com
390

06/00 ! 2000 CCI ! DRAG is a registered trademark of CCI.

In the early 1930s new boiler types, e.g., the Sulzer monotube

Bypass Systems Designed

to Improve Efficiency and
Flexibility of Thermal
Power Plants

steam generator, were developed. Because this boiler did not have
a large accumulator in the form of a steam drum anymore, it
required automatically controlled valves and a fully automatic
control system for stable operation. The boiler was started up
with the evaporator and superheater full of water and already

" By Ulrich Kgi, CCI AG (Switzerland)

under pressure. It required therefore a bypass valve at the

Presented at the Future Strategies and Technologies for Development

of Thermal Power International Conference, Dec. 1417, 1999,
in New Delhi, India

outlet of the boiler to control the boiler pressure immediately

after light-off, when the water in the boiler expanded and

Abstract

this type of boiler successfully.

steam production started. A fully hydraulic control system and

hydraulically operated valves were developed in order to operate

urbine bypass valves were first used in the early 1930s with the
newly developed once-through steam generators. Today, bypass

With the development of boilers with reheaters, bypass systems

as we know them today, with HP- and LP-bypass, were
introduced. Fig.1 shows the water/steam cycle of a single reheat

systems are not only essential for the flexible operation of large
coal fired power plants, but play an equally important role in

power plant with HP- and LP-bypass. In the effort to increase

advanced combined cycle power plants. Bypass systems permit the

efficiency and reduce cost per installed megawatt, unit sizes were

boiler and the steam turbine to be separated during startup, shut-

increased along with higher temperatures and pressures at the

down and load disturbances. This reduces fuel consumption and

superheater and reheater outlet. In the 1960s the first plants were

enhances operational flexibility during all those transient operating

operated in sliding pressure mode.

modes. Startup and reloading timesand therefore fuel costsare

reduced. Other advantages are reduced lifetime consumption of

In continental Europe it became customary to utilize the

HP-bypass valves as safety valves to protect the superheater

major plant components, and higher overall availability of the

against excessive pressure. The design of the bypass valves had

plant. The latest bypass-valve technology improvements make sure

that bypass systems fulfill all the operational requirements of

to follow the trend of ever-increasing steam flow together with

higher temperature and pressure. In the 1970s, bypass systems

todays advanced thermal power plants. Longer overhaul cycles and

reduced maintenance are important features in todays increasingly
competitive market. New plants are not the only ones that

were applied in increasing numbers also to enhance the flexibility

of large drum type boiler units. The Indian power industry was at
the forefront of bypass application in these power plants.

can profit from the advantages of state-of-the-art bypass systems.

Bypass systems can be added to existing plants, and existing bypass

2. Function of Turbine Bypass Systems

valves can be upgraded to the latest technologies.

Turbine bypass systems can contribute to flexible plant operation

1. Introduction

mainly by supporting:
"
Repeatedly attainable fast startups
with the greatest possible regard to the
lifetime of heavy-walled components.
HP

IP

LP

"
Quickest possible restoration of
power supply to the grid after any disturbance

PT
PT

1
3

2
77

1
2
3

HP-Bypass Valve
Spraywater Control Valve
Spraywater Isolation Valve

Therefore, bypass systems contribute to the

6
7
8

LP-Bypass Control Valve

Desuperheater
Spraywater Control Valve

electric power at minimum total cost.

CL

2.1
7

PT

overall target of safe and efficient supply of

Plant startup

During unit startup, the bypass system

essentially allows the separation of boiler and

TT

turbine operations by diverting all the steam,

which cannot be accepted by the turbine or
other consumers, through the bypass. This
allows the boiler to reach the desired steam

Figure 1Single Reheat Plant with HP- and LP-Bypass

Bypass Systems Designed to Improve Efficiency and Flexibility of Thermal Power Plants | 390

qualities as quickly as possible to start the

turbine.
2000 CCI. All rights reserved.

Without a bypass it is difficult to control two output variables

of the boiler (pressure and temperature) with only one input

500

bar
300

4.2

variable, the firing rate. If there is no steam flow through the

reheater and almost no steam flow through the superheater, the
firing rate is limited to very low values. Such low firing rates

400

4.1

300
200

do not allow a quick warm-up of the boiler. Increased slagging

200

and fouling of the boiler can be, besides high fuel consumption,
the result of slow warm-up. Because of the low boiler load, the
attainable superheater outlet temperature is limited. Changes in

%
100

100

100

the firing rate will always affect pressure and temperature. Fast
pressure transients during startup are not desirable because they
result in temperature transients in heavy-walled parts, such as the

3.2


boiler drum or the startup separator.

2.1

The bypass therefore allows faster boiler warm-up through higher

boiler load, reduces thermal transients in the boiler, and by

Bypass
Operation

2.3

2.2
1.1

2.4

attaining good steam-to-metal temperature matching also allows

0
0

shorter turbine startup times with reduced life time consumption.

Light up

2.1.1 The HP-Bypass During Hot Start

100

50

Synchr.

min

Full Load

Pulverizers

The hot start characteristics of a coal-fired 500 MW unit (Fig.

2) shows how a bypass system can contribute to a quick and
lifetime-saving startup. The boiler is a once-through type with
nominal superheater outlet conditions at full load of 254 bar

1.1 Firing Rate

2.1
2.2
2.3
2.4

Feedwater Flow
Waterwall Flow
Steam Flow (Superheater)
Steam Flow (Turbine)

3.1 Superheater Pressure

3.2 Reheater Pressure
4.1 Superheater Temperature
4.2 Reheater Temperature

(3683 psig) and 541oC (1000oF). After an overnight shutdown the

unit is restarted at a superheater pressure of approx. 80 bar (1160

Figure 2Hot start of a coal-fired supercritical 500 MW unit

psig). This is, at the same time, the pressure for turbine start,
so no large pressure transients are to be expected. Immediately

In the startup diagram of Fig. 2, the reheat pressure during startup

after light-up, the bypass opens and starts to control constant

is kept at 12 bar (175 psig). This keeps the exhaust pressure of the

pressure. The firing rate is quickly increased in order to match

HP-Turbine low enough to avoid overheating of the last turbine

the superheater outlet temperature with the turbine metal

stages through ventilation losses. The LP-bypass must therefore

temperature. For this unit, the desired steam temperature after

be sized for the startup flow at this reduced pressure.

an overnight shutdown is approximately 450 oC (842 oF). Two

2.2 Load rejection

pulverizers are started before the turbine is started. This keeps

temperature transients, invariably associated with the start of the

2.2.1 HP-Bypass

first pulverizers, away from the heavy wall turbine parts. The

An HP-bypass with capacity of 100% BMCR at rated pressure can,

bypass compensates for load swings originating from pulverizer

in case of a load rejection or a turbine trip, immediately take

start. The reheater pressure is quickly increased to approx. 12 bar

over all excess steam. This has the following advantages for the

(175 psig) which allows auxiliary steam to be supplied from the

plant operation:

reheater.
2.1.3 The LP-Bypass During Startup

" The boiler can remain in operation and immediate reloading

of the turbine is possible

The LP-bypass is diverting the hot reheated steam directly to the

" No lift of superheater safety valves

condenser. The LP-bypass should have at least a capacity which

is equal to the HP-bypass flow during startup, including the

" Superheater and reheater are continuously cooled by steam

flow

HP-bypass spraywater flow. The reheater pressure during startup

is determined by various considerations:

" Unnecessary pressure and temperature transients are avoided

" Use of reheat steam as auxiliary steam

" The boiler can run back to a stable minimum load in a

controlled manner

" Desired reheat pressure for IP/LP turbine warming

" Desired HP-turbine exhaust pressure for startup

2000 CCI. All rights reserved.

" No immediate pulverizer trips are necessary

" House load operation is possible
390 | Bypass Systems Designed to Improve Efficiency and Flexibility of Thermal Power Plants

" Reheat steam is available as auxiliary steam

3. Turbine Bypass Systems

in Combined-Cycle Power Plants

" Part load trip in sliding pressure mode without unnecessary

pressure transients

Bypass systems are not only essential for flexible operation of

large coal-fired power plants, they are also part of any of todays

A smaller bypass of 6070% MCR usually allows the keeping

advanced combined-cycle power plants. Fig. 4 shows the bypass

of the boiler in operation. At high loads the superheater safety

system of an advanced Combined Cycle Power Plants (CCPP)

valves will have to open for a brief period and pressure and

with a three-pressure Heat Recovery Steam Generator (HRSG).

temperature transients are not avoided completely.

The purpose of the bypass system in this type of power plant

2.2.2
LP-Bypass

bar Pressure

is in principle the same as in the coal-fired plants. It has to

40

compensate for the differences in the startup sequence between

Due to limited

the steam generator and the steam turbine. The steam production

capacity of the

of the boiler is determined primarily by the gas turbine operation

condenser, the

and therefore the available thermal energy at the outlet of the gas

LP-bypass

20

turbine. By controlling the steam flow of the HRSG, it is possible

usually cannot

to reach the steam conditions desired for a smooth and lifetime-

dump 100%

10 bar

saving start of the steam turbine. Sizing considerations are similar

MCR flow into

Flow

the condenser.
When
determining the
maximum
allowable

Bypass Flow 25%

50

100

Flow limitation
Boiler Flow 35%
Turbine House Load Flow 10%

to those for a coal-fired power plant. The possible separation of

the steam generator and the steam turbine during disturbances
plays an even-more-important role in the CCPP because the
steam generator operation is directly coupled with the gas
turbine. The separation therefore allows independent operation

Figure 3LP-Bypass After Load Rejection

LP-bypass flow,
the high LP-bypass spraywater flow of approx. 25% of steam flow
has to be taken into account. On the other hand, it is desirable
from a turbine operating point of view, to have for house load
operation and reloading a HP-Turbine exhaust pressure as low as
possible, and therefore a large LP-Bypass.

of gas and steam turbines.

4. Design Considerations
Bypass systems are installed to enhance the flexibility of power
plant operation and to protect and save life-time of critical plant
components. Bypass systems are themselves subject to frequent
high thermal stress caused by normal startups and shutdowns

The result of the two contradictory requirements is very

often a LP Bypass with a 100% MCR capacity at full
reheat pressure but a flow limitation introduced in the
control system. Fig. 3 illustrates house load operation
with an LP-bypass.
The operating conditions are assumed as follows:
" Minimum stable boiler load approx. 35%
" Required steamflow for house load approx. 10%
" LP-bypass flow (including HP-bypass spraywater)
approx. 25% MCR
" Max. reheat pressure of 10 bar (145 psig) at house
load (25% of full load pressure)

1
GT

HP

IP

LP

As Fig. 5 shows, the resulting size of the LP-bypass

valves is 100% MCR at full reheater pressure.
3

If the maximum allowable flow through the LP-bypass

is less than 100%, the reheater safety valves will have to
open in the initial phase of a load rejection from full

1
2
3

HP-Bypass
IP-Bypass
LP-Bypass
2

load. The reheat safety valves have to dump the excess

steam to atmosphere until the boiler has been run back
to a load corresponding to the capacity of the LP-bypass.

Figure 4Bypass Ssytem in a Combined-Cycle Power Plant

Bypass Systems Designed to Improve Efficiency and Flexibility of Thermal Power Plants | 390

2000 CCI. All rights reserved.

as well as disturbances in the plant operation. Additional stress

The wing-type plug used in this

is caused by the inherent function of pressure and temperature

valve has evolved over many years

reduction. Bypass valves must be designed so that they are not by

of experience and is the best-

themselves a limitation to the operational flexibility of the plant

suited stem shape for this type

and never result in additional stress or damage to the plant.

of valve. The wings split up

the steam flow into a number

Goals of a good bypass valve design are therefore:

of small jets, which efficiently

" Tolerance to frequent high thermal stress due to pressure and

temperature transients

reduces noise and vibration inside

" Little regular maintenance required for any mechanical

components

The valve-in features integrated

the valve.

spraywater injection. Proper

" Easy accessibility to all valve internals for inspection and
maintenance

design of an integrated injection

requires a detailed understanding

" Replacement of any parts must be possible without cutting the

valve out of the pipe

valve during all load conditions.

In order to achieve the above goals, the following rules should be

Analysis and optimization of

applied for the design of bypass valves:

these flow patterns including

" Thin pressure boundary walls reduce actual thermal stress in

the material due to temperature transients

of the flow pattern inside the

Figure 5HP-Bypass Valve

spraywater atomization and

evaporation is today possible with dynamic numerical
calculation.

" Spherical shapes result in the thinnest-possible pressure

boundary walls for given pressure and temperature
" Smooth transitions between different wall thicknesses and no
unnecessary material accumulation
" Pressure boundary walls must be protected from being hit by
spraywater
" Avoid thermal stress due to temperature differences in any
parts which are already subject to high mechanical stress (e.g.,
no spraywater injection through valve stems)

The spray water is injected through a high number of small

injection nozzles directly into the zone of highest turbulence of
the steam flow. This ensures excellent atomization of the injected
water, good mixing with the steam, and due to the small droplet
size, very fast evaporation of the injected water. The spraywater
nozzle body which is subject to the differential temperature
between steam and injection water is not under mechanical load.
The cage around the desuperheating area prevents the pressureretaining walls from being hit by water droplets, which would

" Efficient cooling of the steam by good mixing and evaporation

of the injected water

cause high local thermal stress. Hole pattern, shape and material

" Good atomization of the injected spraywater by high injection

speed or injection into the high steam turbulence zone

integrated injections.

selection of the cage are the result of long experience with

Due to the optimal atomization and evaporation of the

" Good mixing of the injected water by high turbulence or deep
penetration of the injected water into the steam jet

spraywater, the water is essentially evaporated at the outlet of

the valve which gives maximum freedom in placing the valve in

" All parts must be accessible and exchangeable from the top

the plant.

The following examples of an HP- and an LP-bypass valve show

4. 2 LP-Bypass Valve

the application of the above listed design rules.

In the LP-bypass valve shown in Fig. 6, the steam flows in the

closing direction. This is the normal flow direction for LP-bypass

4.1 HP-Bypass Valve

Fig. 5 is a sectional drawing of an HP-bypass valve. Since this
valve is designed to be used also as a combined bypass and safety

valves because the LP-bypass usually has a safe closing function

to protect the condenser from too high a thermal load.

valve, the steam flow is in the opening direction of the valve.

The valve has an inlet cage, seat ring and outlet cage, all easily

Because the high pressure (thick wall) part of the valve consists

removable from the top.

essentially only of the inlet nozzle, this design minimizes

stress due to thermal cycling. The valve body has a spherical
shape to minimize the wall thickness. Any unnecessary material
accumulation is avoided. The valve is especially suited as an
HP-bypass for supercritical plants.
2000 CCI. All rights reserved.

The spraywater is injected downstream of the valve through

spring-loaded nozzles. The outlet cage is guiding the steam flow
towards the spray nozzles. The spring-loaded nozzles ensure a
minimum injection pressure for all flow rates, and therefore a
high injection velocity and good atomization. High spraywater

390 | Bypass Systems Designed to Improve Efficiency and Flexibility of Thermal Power Plants

velocity results also in deep

penetration of the injected

safety valves with sliding pressure opening mode, it is the

water into the steam jet

LP-bypass controller which generates the signals to keep the

at the outlet of the valve,

reheater safety valves open as long as there is too much reheat

and therefore good mixing

steam flow to be dumped only through the LP-bypass.

of water and steam. The

defined injection velocity
makes sure that the injected
water is not hitting the
pipe walls downstream of
the injection nozzles. The
nozzles are arranged

Figure 6LP-Bypass Valve

during all operating modes. In case of power-operated reheater

Because the steam conditions after the LP-bypass desuperheater

are usually at or near saturation conditions, the temperature
after injection cannot be used as a control signal. The necessary
injection water flow and corresponding injection valve position
must be calculated on basis of the steam flow and desired
conditions after desuperheating.

around the whole

As mentioned above, the actual signal interchange between the

circumference of the pipe,

HP-/LP-bypass controller and other control systems is small, and

and the number of nozzles

the required functions for startup and other operating conditions

is selected so that a large

can be clearly defined. It is therefore advantageous to procure the

area of the steam jet exiting

bypass system including bypass controller as one package. The

the valve is penetrated by

bypass supplier is best suited to implement all required control

the injection water. All the above design features together result

functions for a smooth operation of the bypass system. This is

in a good water/steam mixing and quick evaporation of the

certainly the case if safety functions and coordination with power

injected spraywater.

operated reheater safety valves are involved.

4.3

5. Conclusion

Turbine Bypass Controller

A well-matched bypass controller will contribute a great deal

The main reason for installing turbine bypass systems is

to the flexible and lifetime-saving operation of the plant. The

improving flexibility in plant operation, especially during startup,

bypass is controlling the boiler pressure during the critical period

shutdown and disturbed plant operation. Benefits of this

of the boiler startup when pressure transients can lead to high

enhanced flexibility are faster startup times, reduced downtime,

unnecessary temperature transients in heavy walled components

and higher availability of the plant, resulting in less fuel costs

of the boiler and the turbine. The key part of the HP-Bypass

and lower overall plant-operating costs. These desired results

pressure controller is the setpoint generator. It has to produce

are only achievable when all components are designed and

the correct setpoint for all the different operating modes during

selected to suit the specific needs of a bypass system, and all

startup, load operation, load rejection and shutdown. Core

components are well-matched. This is achieved when the whole

of the setpoint generator is a rate limiter, which limits the

systemvalves, actuators, and controlsare from one supplier

gradient of any pressure increase during all operating modes,

with years of experience in the design and operation of bypass

thus protecting the heavy-walled parts from pressure/temperature

systems and the ability to integrate all components. A good

transients. Operating modes are mainly determined by process

technical specification which addresses all the requirements is a

conditions, namely the superheater pressure and the valve

customers most effective instrument in receiving a well-designed

position. The bypass controller is therefore independent and

and matched bypass system. Some design criteria for reliable

does not rely on many signals from the boiler or turbine

bypass valves are listed above.

controller.

6. References

The HP-spraywater control, although at first glance a very simple

1. Assessment of Fossil Steam Bypass Stations

EPRI CS-3717, Final Report, 1984

piece of equipment, has to deal with large variations in process

gain and time delay as well as process disturbances. The use
of an advanced control strategy, i.e., a state controller with
observer (SCO), can considerably improve accurate control under
different operating conditions, and is therefore an important life-

2. R. Rohner, Sulzer Bypass-Systems for Fossil Power Stations

I Mech E Power Conference 1988
3. W. Bung and B. Fllmer, Controlled Safety Valves in Power
Plants in Accordance with the German Standards
VGB Kraftwerkstechnik 75 (1995) Number 9

conserving factor for valves and piping.

The LP-bypass pressure controller controls reheat pressure during
startup and load rejections. Similar to the HP-pressure controller,
it has a setpoint generator producing the correct pressure setpoint

Bypass Systems Designed to Improve Efficiency and Flexibility of Thermal Power Plants | 390

2000 CCI. All rights reserved.