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CCI Valve In-Power-Applications PDF
CCI Valve In-Power-Applications PDF
Applications
by
Curtis Sterud
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BOILING WATER
REACTOR
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Drum Boilers
n Drum boilers vary in size, from small boilers used to generate steam
industrial heating up to the large public utility boilers which produce
enough steam to generate up to 900 MW of power, such as the Lake
Cayuga Plant of New York Electric and Gas.
n We supply the Bailey thermo-hydraulic feedwater regulators for small
boilers. The cogenerating units are between 50 MW to 200 MW in size.
In these units, we supply feedpump recirc. valves, and auxiliary steam
valves. Vents are another application.
n Combined-cycle plants often require turbine bypass valves of 50100%
capacity.
n Large utility drum boilers have more severe service applications which
require DRAG valve technology. These boilers also require turbine
bypass valves.
Shown on the following pages are the typical schematics and diagrams of areas
which require a DRAG valve. These applications see either the potential for
cavitation, flashing, or a combination of high-pressure drop and low flow rate.
There are four areas that we will discuss:
I. CONDENSATE SYSTEM
a) Condensate Pump Recirculation Valve
b) Deaereator Level Control Valve
II. FEEDWATER SYSTEM
a) Boiler Feedwater Pump Recirculation Valve
b) Boiler Feedwater Regulator Valve (B&W 100)
III. MAIN STEAM SYSTEM
a) Start-Up System Valves (B&W)
i. 501
ii. 502
iii. 518
iv. 519
b) Superheater Attemperator Spray Valve
c) Reheater Attemperator Spray Valve
d) Turbine Bypass Valve (B&W 510This is a small bypass)
e) Deaereator Steam Pegging Valve
f) Soot Blower Valve
IV. HEATER DRAIN SYSTEM
a) High Pressure Heater Drain Valves, Emergency Heater Drain
b) Low Pressure Drain Valves
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G Heater Drains
H Auxiliary Steam
J SamplingVarious Locations
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I. Condensate System
This is the portion of the plant where 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).
The condensate pump must have a minimum amount of flow through it at all
times to prevent it from overheating and to protect it from cavitation. Therefore,
a recirculation valve and line runs from the pump outlet line back to the
condenser. When the boiler load is low the flow of condensate required is less
than the pump minimum flow requirement. The recirc. valve is used to allow
the additional flow required through the pump. The pump outlet pressure varies
from 300 psi to 600 psi with fluid temperature from 100 to 150F.
An 800D is the valve for this service. This valve must have positive shutoff.
To assure good shutoff, the valve must have a soft seat.
As the plant load increases, the need for high flows and the condensate
pump cant maintain the same pressure head at these higher flows. The result
is lower inlet pressure to the valve. Concurrently, the line pressure to the
deaereator is building, putting backpressure on the valve. These higher flows
with lower pressure drops create a need for higher capacity of the valve but
less resistance in the trim.
n High rangeability
n Cavitation protection at low flows
n Low resistance at increasing flows
n Tight shut-off is not essential because this valve is open at all times the
plant is up and running.
This is the portion of the plant 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.
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. The CCI DRAG valve can be built with characterized trim to cover the full range of
operation conditions in one valve.
n High rangeability
n Cavitation protection at low flows
n Low resistance at maximum flow
n This valve should have at least Class IV shut off.
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Feedwater Regulation
Bailey D10 and DRAG
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In a power plant, the boiler water is circulated in a closed loop by a feedpump driven either by electric motor or steam
turbine. The pump takes the water from the deaereator or high pressure heaters and boosts the pressure to the system
requirements (38005500 PSI in a supercritical universal pressure boiler). These pumps require a certain minimum
amount of flow to avoid overheating and cavitation problems. In order to protect the pump when the boiler feed flow
requirement is less than the minimum permissible flow through the feedpump, a recirculation system is used to return a
portion of the high pressure flow back to the condenser (or sometimes to the deaereator) and thence to the pump. (see
diagram for a system schematic.)
Ideally, the recirculation system would meter the flow in response to the pumps requirements. This indicates the need for a
modulating control valve which normally would be closed, but if power to the valves actuator should fail, the valve would
need to open. Also, if the system is off, the valve is fully open. When the pump is turned on, the valve is flowing 100%
and closes as system flow increases. The valve would need to handle water with thermodynamic conditions at the inlet of
38005000 PSIG to 10 PSIG. Thus, during modulation of full flow conditions, the valve must handle high pressure drop
and substantial flashing, yet manage to minimize erosion, cavitation and noise problems.
While minimum flow protection would normally be required only during station startup and shutdowns, in actual practice,
such systems might be used for extended periods of peak power or in the case of nuclear plants, forced operation at reduced
percent power to qualify operating permits. It is apparent that minimum flow systems must be capable of continuous
operationtheir purpose is to protect $100,000-plus feedpumps from severe damage. Since spare feedpump capacity is
not generally used, damage to a feedpump can have serious consequences in terms of restricting full power capability for
extended periods of time. Each feedpump is always installed with an individual recirc. system.
When shut, the pressure could build up to as high as 5500 PSIG and the valve can be expected to hold drop-tight against
leakage. Should the valve leak, even the tiniest amount of flashing seat and water mixture would cut the seating surface like
a rough wire and in a short while, the shutoff function of the valve would be lost. (See diagram). Excessive leakage cuts into
the efficiency of the plant, both through direct energy loss and because the boiler cannot be fed the full rated flow. In the
extreme case, a shutdown of an entire power plant may be necessitated because of a single leaking valve.
Thus, the statement of the problem is this: there is a need for a boiler feedwater pump recirculation valve (BFPRV) that
will:
1) Break down water pressure from ~ 4000 PSI to atmospheric or vacuum pressure:
n Without trim erosion due to flashing service conditions.
n Without cavitation
n Without mechanical vibrations and noise.
2) Remain leak-tight for long periods of time. (one year or more).
3) Modulate automatically and open in case of failure of power to the valve operator.
This application is probably the most severe application of a control valve in the power plant.
Some customers specify Stellite #6 for seat surface. Corrosion problems may occur in feedwater systems. Typically, boiler
feedwater is treated with ammonia at the deaereator to eliminate excess oxygen. Ammonia, combined with hydrazine
create amines which attack the cobaltchrome material in Stellite#6. The net result is corrosion, and subsequent errosion
of Stellite #6.
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Seat designs and materials have varied widely over the years. Sterud
considers that most of them have been inadequate and favors a design
that uses a relatively soft 300-series stainless steel seat and a hardened
400-series stainless steel plug. A 3 difference between the machined faces
of the valves conical seat and plug (last figure) produces a line contact
between plug and seat.
This seat design is used with a closing force of about 1000 lb./linear inch of
seat/plug mating. This far exceeds the yield strength of the softer seat material
and is almost 50% higher than the seat load used in most recirculation-valve
designs.
To eliminate the possibility of uneven downward flow around the plug
during very low-flow operation, the actuator is provided with snap-action
relay that closes the valve completely below about 10% of rated flow.
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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.
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. These valves are:
n BW100FeedwaterRegulator
n BW501SecondarySuperheaterStop
& Bypass Valve
n BW502PrimarySuperheaterBypass
Valve
n BW518MainSteamAttemperator
n BW519ReheatOutletSteam
Attemperator
n BW510TurbineBypass
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
attemporation 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.
It should be obvious that the five valves we provide for this system are
crucial to the successful operation of the system.
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.
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. The customer would like the system to have an inherent
linear characteristics, i.e., valve stroke linear, with load increase. This
requires that we plot the C v required for each position of the valve for
load required.
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.
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This CCI valve for sootblower header control has been designed to meet
the above requirements. The disk stack is characterized with 14-turn and
eight-turn expanding disks with Pressure Equalizing Ring (PER) grooves for
minimum fluid velocities and high rangeability. The flow is over the plug
to protect the seat from trash damage. The plug is unbalanced with high
actuator load for good shutoff.
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There are two sets of heater systems in a normal power plant. The low-
pressure heaters heat the condensate coming from the condensate pump so it
is near saturation when it gets to the deaereator. The other set, called high-
pressure heater, heats the feedwater coming from the boiler feedwater pump
so that it is near saturation when it enters the boiler. Both systems work
with same way, 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 best system
efficiency, so the drain system is fairly elaborate. There are emergency heater
drain valves which bypass the fluid to the condensor. There are heater drain
valves between each other. Each heater is at a lower pressure than the
preceeding 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.
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 distributer integral
with the seat ring to limit velocity will also combat erosion. In addition, the
body material should be A217C5, or A182F5.
Globe DRAG Heater Drain Valve
with Flow Distributer Integral
with the Seat Ring
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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 startup bypass system.
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Many variations exist when comparing the startup systems provided by each
of the boiler manufacturers. Functionally, they all have a common purpose
as elaborated below. Notice in Figures 1, 2 and 3, the physical differences
illustrated for each of the once-through boiler manufacturers. Combustion
Engineering, Inc., (Figure 3 on Page 52) provides circulation pumps to
recirculate fluid through the furnace pumps and convection walls and, in
this way, protect the tubes from overheating. (Figure 3 on Page 52) Babcock
& Wilcox Company and Foster Wheeler Corporation (Figure 2 on Page 52)
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 startup
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 startup and initially load
the unit as follows:
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.
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 startup 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.
Bailey valves was owned by B&W. B&W aquired CCI in 1971 to utilize the
advantages of the DRAG valve in the severe service applications in the
steam generation units. At the same time, the manufacturing of the Bailey
valve was moved to CCI in California.
So, CCI supports the startup system valves of old or new B&W units,
whether Bailey or CCI drag valves are used.
The following diagrams show typical B&W units with Bailey valves in an
older plant, and CCI DRAG valves in a plant after 1974.
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For startup, 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.
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.
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 startup 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
attemporation
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 once-through operation at lowload generator.
3. The 202 valve is eliminated from the cycle and the 207 valve is used for all
functions formerly done by the 202 and 207 valves.
4. The key valve(s) for sliding pressure is the 401 valve. This valve is the turbine pressure
control valve. The valve must control load from as low as 10% at 2500 PSI pressure
drop to 100% at approx. 50 PSI pressure drop with a linear installed stroke vs. load
characteristic.
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401 Valve
Disk Stack
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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.
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W VALVE
Pressure reduction. This valve is usually sized for approximately 25%
boiler flow at 300 psi differential pressure with an equal percentage
characterized disk stack.
P VALVE
Superheater bypass valve. This valve discharges to the flash tank. During
start up the valve is used in series with W valve to control boiler pressure
as temperature is raised. When the unit is on line the P valve is closed
and functions as a pressure relief valve for the boiler. The valve must have
good shutoff. The pressurized seat valve, like the 207 valve in the B&W once
through system (Figure 4A), should be used here. The disk stack can be MS
2000 16 turn type with linear characteristics.
D VALVE
Flash tank level. This valve is the same as the B&W 241 valve.
E VALVE
Flash tank level (along with D valve). This valve is the same as the B&W
221 valve.
C VALVE
Flash tank to H.P. heater. This valve is the same as the B&W 220 valve.
B VALVE
Flash tank to deaereator. This valve is the same as the B&W 231 valve.
A VALVE
Flash tank to overpressure control valve. This valve is the same as the B&W
240 valve.
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W VALVE
Pressure reducing station. This valve is usually sized for approximately
70% boiler flow at 300 psi differential pressure with an equal percentage
characterized disk stack.
P VALVE
Superheater bypass valve. During startup, this valve is used in series with
the W valve to control boiler pressure and level in the separators. The
P valve discharges to the heaters, deaereators, and condenser through the
E, F, and D valves.
D VALVE
Separator to condenser. This valve is the same as the B&W 241 valve.
E VALVE
Separator to heater. This valve is the same as the B&W 220 valve.
F VALVE
Separator to deaereator. This valve is the same as the B&W 231 valve.
MX VALVE
Auxiliary steam to BFPT (attemperator at low flow). This valve is used to
inject saturated steam into the steam exiting the platen superheater during
system low flow operation.
PR VALVE
Auxiliary steam to BFPT. This valve takes steam from the platen superheater
outlet during system low flow operation.
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Combustion Engineering,
Once-Through Unit Base Loaded
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BT Valve
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Combustion Engineering
Supercritical Once-Through Type Unit
SUBJECT: Startup valve modification to The CE unit incorporates a Combined Circulation system.
allow frequent turbine load changes without
affecting the turbine life. In a drum unit, circulation of water within the unit provides a cooling
flow in the furnace tubes to prevent overheating. In a once-through steam
BACKGROUND: The unit shown is a
generator, a turbine bypass system is used during startup and low load
Combustion Engineeringdesigned once-
through critical pressure 565 MW system. operation to handle the minimum flow required for furnace wall cooling.
The startup system incorporates Sulzer This flow is usually 30% of max flow.
valves. The schematic is shown below:
The startup 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 startup system.
To reduce load down to the low load is a reverse of the startup. 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 startup 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 startup system for low load down to
approximately 7%. However, transfer from once-through to the startup
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.
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 startup
and once-through ranges of the Sulzer valves:
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The system could be configured with only the BT valves. However the BTB
capacity addition at 100% load is of benefit for minimizing parasitic power.
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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.
These critical valves for the three major once-through boiler manufacturers
are shown below:
The flash tank subloop controls include the following valves in the three
boiler designs:
w 52
Figures 1 Through 3
Base-Loaded Configurations
Figure 1
Babcox & Wilcox
Once Thru Unit
Figure 2
Foster Wheeler
Once Thru Unit
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Figures 3 Through 4
Base-Loaded Configurations
Figure 3
Combustion Engineering
Once Thru Unit
Figure 2
Riley Stroker
Once Thru Unit
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Figures 4 Through 6
Sliding Pressure Configurations
Figure 4
Babcox & Wilcox
Once-Through Unit
Figure 2
Foster Wheeler
Once-Through Unit
Figure 3
Combustion Engineering
Once-Through Unit
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Stein Boiler
w 57
Throughout the world, companies rely on CCI to
solve their severe service control valve problems.
CCI has provided custom solutions for these, and
other industry applications for more than 30 years.
CCI Switzerland
formerly Sulzer Thermtec
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
Hegifeldstrasse 10, P.O. Box 65
CH-8404 Winterthur, Switzerland
CCI Korea
Telephone: 82 31 985 9430
Fax: 82 31 985 0552/3
26-17, Pungmu-Dong
Kimpo City
Kyunggi-Do 415-070
South Korea
CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567-0051
Japan
Contact us at:
info@ccivalve.com
Visit us online at:
www.ccivalve.com