16

MOISTURE SEPARATOR
REHEATER (MSR)
16.1 INTRODUCTION

In PWR live steam feeding the turbine is saturated and relatively at low
pressure. After initial expansion in HP turbine the moisture content in the
cycle steam increases up to 10% to 15 % at the HP turbine exhaust. If the
expansion were continued without any external moisture removal, the
moisture content at the exhaust of LP turbine would increases upto 20% to
25%. This excessively high amount of moisture content will decrease the
turbine efficiency and as well as erosion of LP turbine blading. plant
efficiency. So to remove the moisture contents from steam exhausted from
HP turbine and improve plant thermal efficiency by reheating the cycle steam
two MSR are installed on each side of LP turbine team after moisture removal
passes through two stage reheater where it is superheated to about 254 C
The two MSR are connected with the HP turbine and LP turbine by means of
cross-under and cross-over piping respectively as shown in figure - 16.1.

16.2 COMPONENT DESCRIPTION

The MSR is in horizontal construction, consists of a separator and two stage

reheater (i.e. one low pressure tube bundle and one high pressure tube
bundle). The MSR shell are welded plate structure with elliptical heads. Cycle
steam inlet nozzle is palced on the same elliptical head near turbine governor
end, while steam outlet nozzles are placed on the top of the shell. Nozzles
are made of carbon steel plate. On the top of the MSR shell near governor
end, a relief valve is mounted preventing over pressurization of the MSR shell
and cyclee steam piping in an emergency by discharging steam to the
atmosphere. The relief valve is constructed with a pilot valve as shown in fig-
16.2 . The setting pressure of relief valve is 1.14 Mpa (gauge). During startup
and shutdown condition MSR’S shell is in vacuum condition at the inlet of
relief valve until turbine reaches 8% of full load. Air leakage to the turbine can
not exceed 3.45 x 104 m3/min.

Each MSR is supported on four spherical surface pads, it allows the MSR
shell to slide freely during change of environment temperature. To prevent the
reaction due to release of cycle steam from relief valve during earth quake,
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antiseismic anchor plate are placed on the four ends of the two supporting
feets. The lower portion of the anchor plate is welded to the foundation plate,
while the upper portion of it is on the supporting foot. Heat insulation area of
MSR is about 186 m2

16.3 CONSTRUCTION FEATURES OF MSR

The internal construction feature of MSR is shown in the fig 13.x. Main parts
of moisture seperator reheater (MSR) are:

1. Distribution header
2. Perforated plate
3. Separator
4. Reheaters
5. Shell

16.3.1 DISTRIBUTION HEADER

The cycle steam after leaving the high pressure turbine enters the end of the
MSR shell from the crossundr piping. After entering inside the elliptical head
of the MSR shell, the cycle steam divides and flows down to the two
distribution manifold pipes which are located along each side of the centerline
of MSR. With the help of the distribution header distribution and flow of the
cyclic wet steam becomes uniform before it enters to the moisture separator
as shown in fig- 16.3. Distribution manifold pipe is a cylindrical structure pipe.
Its inner diameter and wall thickness are 895 mm and 9.5 mm respectively. It
extends the entire length of the shell. 35 specially sized slots along the length
of the distribution manifold pipe are provided for uniform distribution of the
cycle steam to the chevrons type moisture separator. Size of the slots
gradually decreasing from steam inlet end to the other end. One end of the
distribution header pipe is open to the cycle steam entering to the MSR and
closed at the other end.

16.3.2 PERFORATED PLATE

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CHAPTER - 16 MOISTURE SEPERATOR AND
REHEATER

For further improving the flow and distribution of the wet steam and hence
enhancing the moisture separation effect of the separator, perforated plates
with 6.4 mm dia, small holes are installed on the upstream face of the
chevrons type moisture separator. Material of perforated plate is carbon steel.
16.3.3 SEPARATOR

Charvon type moisture separator is one of the important parts of the MSR.
The Chevron vanes remove moisture from the wet steam by forcing changes
in the direction of flow as shown in fig- 16.4. As the flow direction changes,
the moisture is then trapped in the “folds” or “hooks” and flows to the bottom
of the chevron by gravity. A trough or channel collects the liquid and directs it
to the bottom of the shell to the drain nozzles. Chevron vanes are constructed
of type AIS 430 stainless steel. Space bars on one side of the vanes maintain
a definite space for proper vane separation.

16.3.4 REHEATER

Reheater includes high pressure tube bundle(2 nd stage reheater) and low
pressure tube bundle (1 st stage reheater). Both constructions are basically the
same. Tube bundle consists of a formed hemispherical head welded to the
tube sheet, acting as an inlet and outlet chamber for heating steam and U
tubes, as shown in fig- 16.5. Hemispherical head consists of a hemispherical
dish, tube sheet, inlet nozzle, drain nozzle, vent chamber, partition plate and
manway. Hemispherical dish is constructed of SA516 (GRAD 70) carbon stl
plate and tube sheet SA350 (GRADE LF 2) carbon steel forging.

Each U-tube bundle cnsist of a horizntal array of 19.05 diameter low profile,
integrally fined (expanded surface) tube. Th fins which are formed on th
outside wall of the tubs are approximately 1.27 mm high. Thre are 27 fins per
inch of the tubing. Tubes for the HP and LP tube bundles are 1.65 mm (fig-
16.6-a) and 1.47 mm (fig- 16.6-b) thickness respectively. The tubes are
constructed of type SA286 (GRADE TPXM8) stainless steel which has been
selected for its mechanical strength, fatigue strength, and resistance to stress
corrossin cracking. The ends of the U-tubes are weldd into a tube sheet which
has been clad or faced with inconel. Vent chamber is constucted of carbon
steel weld pieces. The cantilever portion of U-tubes is fastened by wrappers
and 19 tube support plates. The fuunction of tube support plates are:

a) To put the heat exchanger tubes together into a bundle

b) To be able to avoide damage to the tube due to the change in natural
frequency of the tube material.

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The thickness of the first 17 tube supporting plate is 16 mm and diameter of

the chamfered holes 19.56 mm. The thickness of the last two tube supporting
plate is 29 mm.

Heating steam enters the upper section of the hemispherical head of the tube
bundle and flows down the top leg of outer radious U tube. Heating steam
after transferring its heat t the cycle steam flowing across the outside of the
tubes It condenses as it flows down the top leg and back the bottom leg of
these outer radius tubes. the Condensate and the excess or vent steam
which did not condense exit these tubes into the lower section of the
hemispherical head. Condensate low by gravity out a drain connection the
bottom of the hemispherical head, and then flows into the drain tank. The
heating steam remaining or vent steam and the condensate existing at the top
leg of the inside radius tubes enters the vent chamber or scavenging steam
vent condenser which is attached to the tube sheet..

16.3.5 SHELL

MSR shell is a large pressure vessel in which distribution manifold pipes,

separator and Reheater are located. It consists mainly of a cylinder, two
elliptical head and other inner parts. Shell cylinder is constructed of type
SA515 (GRADE 70) carbon steel plate, 38 mm thick, inner diameter 3810
mm; material of elliptical head is the same as that of shell plate. Wall
thickness of LP and HP hemispherical had is 36 mm and 60 mm respectively
Two distribution pipes are installed, in paroled, at both internal sides of the
shell and their two ends are welded on both end plates of the shell
respectively. liquid collected in the chevrons flows by gravity out of the MSR
though a drain connection on the bottom of the shell. There are tow cycle
steam outlet nozzles on the top of the shell, a welded flange for installing
relief valve is also on the top of the shell.

4.0 MSR AUXILIARY SYSTEM

The auxiliary system of MSR consists of mainly three system, shown in fig (6).

1. Heating steam system

2. Scavenging steam vent system
3. Drain system.

(1) Heating Steam System:

The MSR consists of two stage reheaters so there are two systems for
heating cycle steam in MSR. One for LP tube bundle (ist stage reheater) and
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REHEATER

the other for HP tube bundle (2nd stage reheater). Control system is not
require for first stage reheater. Heating steam for this LP tube bundle is
extracted from high pressure (HP) turbine, through ist stage extraction line.
Consequently the first stage heating steam pressure increases uniformly with
load, which result in a controlled thermal transient. Heating steam. For the
second stage reheater heating steam is taken from the upstream of the HP
turbine i.e. main steam common header. In order to prevent damage to the
MSR second stage tube bundles and to the low pressure (LP) turbine by rapid
cycle steam temperature increases, a reheat steam temperature control
system (i.e. RTC)is required. The reheat temperature controller (RTC) is a
kind of controller which controls the inlet steam temperature of the LP turbine.
The RTC can perform all its function automatically

(2) Scavenging Steam Vent System

The connection and components of scavenging steam vent system of HP

tube bundles and LP tube bundles are similar. The two phases mixture of
steam and condensate leaving the vent section of the HP and LP tube
bundles during plant normal operation flows to its corresponding HP
feedwater heater due to sufficient differential pressure. During plant start-up
and low load operation when the differntial pressure is not sufficient enough
an alternate path to the condenser high pressure drain flash tank is provided.

(3) Drain Systems

Drain systems of MSR include drain system for HP tube bundle, LP tube
bundle and shell. Drains normally flow from three drain tanks to the
corresponding HP feedwater heaters. Drain of HP tube bundle (ist stage
reheater) flows to the HP-7 feedwater heater, drain of LP tube bundle (2nd
stage reheater) flows to the HP-6 feedwater heater and shell side drain flows
to the dearator. The alternate paths for the three drain tanks during
emergency such as in case of high level of liquid in drain tanks or drains
failed to the feedwater heaters. are also provided. Drains from the three drain
tanks in emergency are diverted to the condensor high pressure drain flash
tank and condense. Power assisted non-return valves and non-return valves
are used to prevent the back flow of drains.

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MOISTURE SEPARATOR
AND REHEATER (MSR)

17.1 INTRODUCTION:

In PWR live steam feeding the turning is saturated at relatively low pressure 50
to 60 bar (For CHASNUPP 53. 4 bar).

After initial expansion in HP turbine the steam contains 10% to 15 % water

( 12.5% for CNPP)

If the expansion were continued without any particular precaution being taken,
the moisture content at the exhaust of LP-turbine rise to 20% to 25%.

The excessively high amount of moisture would decrease turbine efficiency

and as well as erosion of LP-turbine balding.

MSR are installed after HP-Turbine (between HP & LP turbine) for the two
basic reasons.

a) To reduce moisture contents of the cycle steam which appreciable

reduces the erosion of LP-turbine balding.
b) It increases plat efficiency by 1.9 to 2.7% (for two stage
reheater).

(It increases cycle efficiency by 1.5 to 2.1% if there is one stage of reheat & by
further 0.4 to 0.6% when second stage of reheat is added).

Steam after expansion in HP-turbine passes through moisture separator,

where it gives up its water by phase separation. The water is called drain and
is collected in the drain recovery tank (DRT).

After separator steam passes through first stage reheater and then second
stage reheater where it is superheated to about 240 to 270 (for CHASNUPP
unit about 253.7, degree of superheat is about 90).

Heating steam of Ist stage reheater is supplied from turbine Ist stage extraction
steam line.

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CHAPTER - 16 MOISTURE SEPERATOR AND
REHEATER

 W = 74715 Kg/hr. (For two MSR)

 P = 2.56 MPa
 T = 227oC

Heating steam for 2nd stage reheater is taken from main steam line.

 Heating Steam Flow = 72429 Kg/Hr. (For two MSR)

 Steam Pressure = 5.3 MPa.
 Temperature = 268.1oC

Heating steam is condensed inside the reheater tubes by transferring its

energy to the cycle steam. Water resulting from this condensation is called
condensate and is collected by gravity in the condensate recovery tank (CRT).

Condensate and Drains are routed as follows:

1. Separator Drains: from DRT to Deaerator.

2. Ist stage reheater condensate: from CRT to HP-6 heater.

3. 2nd stage reheater condensate: from CRT to HP-7 heater.

ENTHALPY PRESSURE MOISTURE

(KJ/Kg) (Mpa) (%)
HP Inlet 2784.6 5.34 0.5
HP Exhaust 2518.4 0.795 12.5
After 2765.4 0.764 < 0.5
Separator
After Reheator 2960.9 0.734 Superheated
LP Inlet 2960.9 0.719 Nearly same
LP Exhaust 2363.6 0.0057 8.5%

Enthalpy Increase

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Separator = 247.0 KJ/Kg

Reheator = 195.5 KJ/Kg
In MSR 442.5 KJ/Kg

2.0) Design Data of MSR for CHASNUPP 300MWe:

 No. of MSR =2
 Type: two stage reheater (horizontal)
 Separator: Cheveron Type

3.0 CONSTRUCTION FEATURES OF MSR:

Main parts of MSR are:

a) Distribution heater
b) Perforated Plate
c) Moisture Separator
d) Ist stage tube bundles
e) 2nd stage tube bundles
f) Heater shell

a) Distribution Header
Distribution manifold contains various cross - section holes. The size of the holes
increases continuously from the entrance point. The function of this header is to keep
a constant flow of steam.

b) Perforated Plates
These plates are installed near the separator (Cheveron type). The function of these
plates are to keep the steam flow more and more uniform. Thus the steam is quite
uniform before entering the separator.
- Material of perforated plate is Carbon steel (C.S.)

c) Moisture Separator
 The separator is of Cheveron type i.e. corrugated plate type.
 Steam when passes through corrugated plate. it continuously changes their
direction due to when moisture are separated from the steam.
 There are total of 2396 corrugated plates (QNPP & CNPP).
 Material of Cheveron is Austenitic stainless Steel SS-304 (Ni 9% Cr 18%)
 The Cheveron plates are joined with small pieces of metal

SEPARATOR TYPES
- Wire mesh
- Cheveron separator
- Centrifugal or Swirl Vane
Cheveron Separator has
- Low press. drop
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REHEATER

- Low readability
- High frontal velocity (double that of wire mesh)
- easily dismantle

During expansion in the HP-turbine. droopiest of water form within the steam itself.
 Dia. of droplets reaching the separator have a diameter greater than 10um.
 Droplet size distribution in the cross-under piping are as follows:
 All the droplets are under 1mm.
 Half of the droplet under 20 um.
 only 5% droplets under 10 um.

4.0) DRAIN AND CONDENSATE TANKS:

Drain Recovery Tank (DRT)

Separator drains are first collected in drain recovery tank (DRT)
- No. of DRT =2
- Volume of DRT = 1.8
- Pressure = 0.784 MPa.
- Temperature = 169.6°C

Condensate recovery tank (CRT) for Ist stage:

Condensate of Ist stage reheater are collected in condensate recovery tank (CRT).
- No. of DRT =2
- Volume of DRT = 1.8
- Pressure = 2.638 MPa.

CRT for 2nd stage:

Condensate of 2nd stage reheater are collected in condensate recovery tank.
- No. of DRT =2
- Volume of DRT = 1.8
- Pressure = 5.29 MPa.
(d) &(e) Ist & 2nd stage tube bundles:

 Before and upto 1980, Cupro-Nickel (Cu-Ni) is used as a material for first and
second stage reheater tubes.
 It has been observed that after a long period of operation their is a deposition of
Cu in the steam generator and causes denting of S.G. tubes.
 Cu-Ni has high value of coefficient of expansion thank SS-439, therefore, more
chances of sagging of tubes.
 Tube sheet holes are rounded and inclined to prevent cutting from tube sheet
edge when tube expansion r bends occur. First stage an second stage reheater

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bundles heat-up the cycle steam from the saturation temperature and supper heat
the cycle steam.
 Material of tubes SS-439 (Both for QNPP & CNPP)
 Cr-19%, Low Low Carbon, Ti suitable amount, (both for Ist and end stage reheater
tubes)
 Thickness of Ist stage reheater tube = 1.47 (Both for QNPP & CNPP)
 Thickness of 2nd stage reheater tubes = 1.65 mm (Both for QNPP & CNPP)
 Tube sheet material: Medium Carbon Steel
 Water box material: Carbon Steel
 Tube to tube sheet joint: Welded and expanded (roller expansion)
 The heating steam of either Ist stage or second stage reheater are not completely
condensed.
Steam condensed = 75%
uncondensed steam = 25%
 The steam which is not condensed having quality 5-8% and is scavenged from the
reheater through different piping to the HP heater.

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