Steam Attemperation Valve and Desuperheater Driven Problems On HRSG's

28 March 2005
1
Attemperation Frustrations
3/28/2005 2003. CCI Control Components Inc. CCI is the Valve Doctor . All rights reserved. P102 2
Steam Attemperation Valve and Desuperheater
Driven Problems on HRSGs
Main and Reheat Steam Attemperation
Turbine Bypass Operation
28 March 2005
2
Interstage Steam Attemperation
Process is controlled by inlet
steam temperature to turbine
Pro
Decreases potential for
moisture content at turbine
inlet
Decreases temperature in
superheat/reheat tubing
Con
System response is slow
and can cause cycling
swings
Water carryover into the
tubing possible
Thermal cycling of tubing
Control temp
Control temp
Problems on Main and Reheat Steam
Attemperation
Superheat and reheat tube failures
Main/Reheat steam header failures
Poor spray water control and thermal cycling
Failure of spray probe components
Plugging and blockage on spray valve and nozzle
Leaking spray valves
Steam leakage from flanged connections on main
steam line
Broken liners
28 March 2005
3
Steam header and tube failures
Increased superheat tube failures
with years of operation
Downloaded from APTECH web site
0
20
40
60
80
0 2 4 6 8 10
Unit age, years
C
u
m
u
l
a
t
i
v
e

f
a
i
l
u
r
e
s

o
f

S
H

t
u
b
e
s
28 March 2005
4
Fundamentals of steam attemperation
The smaller the water droplets, the greater the
surface area of the liquid and the faster the
droplets evaporate.
Spray nozzles generate a distribution of droplets
with different sizes (Sauter number)
Both primary and secondary atomization break
water droplets apart
Aerodynamic forces exceed surface tension forces
break apart water droplets (Weber number)
Distribution of the water into the steam
Time for steam to evaporate
Spray basic atomisation shape / Formen des Strahlzerfalls
1. Rayleigh Regime
v
water
(Velocity)
v
amb
v
water
- v
amb
0
Breakup way out of jet outlet
Capillary + Viscosity Forces are
dominant
Aerodynamic Resistance is small
Droplets larger than jet diameter
2. First Wind-induced Regime
v
water
- v
amb
2 m/s
Breakup closer to the jet outlet
due to higher relative motion, gives
additional aerodynamic Resistance
Droplets are equal to jet diameter
Spray basic atomisation shape / Formen des Strahlzerfalls
1. Rayleigh Regime
v
water
(Velocity)
v
amb
v
water
- v
amb
0
dominant
1. Rayleigh Regime
v
water
(Velocity)
v
amb
v
water
(Velocity)
v
amb
v
water
- v
amb
0
dominant
v
water
- v
amb
2 m/s
v
water
- v
amb
2 m/s
28 March 2005
5
3. Flapping Jet 4. Spray Jet
v
water
- v
amb
10 m/s
Increasing of relative velocity
Superposition of "O-mode"(dilatation)
and "1st-mode"(sinusoidal flapping)
gives Instabilities
Droplets smaller than jet diameter
v
water
- v
amb
50 m/s
Breakup near to the jet outlet
High relative velocity
Increasing of shortwaving disturbance on
the surface due to the aerodynamic forces
Droplets very much smaller than jet
diameter
3. Flapping Jet 4. Spray Jet
v
water
- v
amb
10 m/s
Increasing of relative velocity
Superposition of "O-mode"(dilatation)
and "1st-mode"(sinusoidal flapping)
gives Instabilities
Droplets smaller than jet diameter
v
water
- v
amb
50 m/s
Breakup near to the jet outlet
High relative velocity
Increasing of shortwaving disturbance on
the surface due to the aerodynamic forces
Droplets very much smaller than jet
diameter
Water droplet size distribution by different
nozzle designs
0
5
10
15
19 35 63 114 205 370 668 1207
Droplet diameter, microns
%

V
o
l
u
m
e
28 March 2005
6
FC 526.07
Spray distribution into the steam
Evaporation of water in steam
Finite amounts of
time are required to
heat the water and
boil the water off
As the water
evaporates, steam
temperature
decreases, reducing
driving forces
The largest water
droplets will be the
last to evaporate,
and an exponential
increase in
evaporation time
can occur
Steam/Water Temperature Gradient vs Time
300
400
500
600
700
800
900
1000
0 2 4 6 8 10 12 14 16
Time
D
e
g
.

F
Steam Temp
Water Temp
Initial heating Boiling
28 March 2005
7
Traditional venturi nozzle
Fixed orifice
nozzle
Venturi tube
for mixing and
thermal
sleeve
protection
Used on base
load drum
boiler and
supercritical
units
Variable Area Probe
Style Desuperheaters
Typically flanged to the
main steam piping.
Multiple nozzles are
exposed as the valve
plug opens
Spray water nozzles
and valve are immersed
in the steam line
Nozzles face
downstream and inject
water with the steam
flow
Most common
desuperheater in CCPP
steam attemperation
28 March 2005
8
Spray Ring Desuperheaters
Normally applied in
large mass flow
systems
Individual streams
break into small
droplets
Liners are often
used when steam is
attemperated close
to saturation.
Fixed orifice,
rangeabiltiy is
limited to between
3:1 and 5:1
Spray Nozzle Desuperheaters
Applied in large and small
mass flow systems
Liners are often used because
of directed water jets.
Nozzles can be designed to be
serviceable.
Nozzle can take higher
pressure drops than spray
ring.
Fixed orifice, rangeabiltiy is
limited to between 5:1 and
15:1
DS STEAM
H
2
0
H
2
0
SH
STEAM
28 March 2005
9
Spring Loaded Spray Nozzle
Spring Loaded Spray Nozzles
Spring loading increases the minimum discharge
pressure before injecting water into the steam
Provides a higher water velocity discharge into the
steam flow
Provide a very thin sheet injection at low flow rates
Can be provided in multiple point entry injection or
single point middle injection
Places the critical control valve outside the steam
flow environment.
28 March 2005
10
Nozzle Spray Patterns, High Speed
Photography
Spray nozzle
Whirl nozzle Spring loaded nozzle
Problems seen on Spray Control Probes
Lack of throttling control, stair step
flow response
Cracked extension pipes
Missing and damaged nozzles
Fracture of tack weld and loosening of
lower housing
Wear on the valve trim
Sticking/galling with trash sensitivity
Leakage in the closed position
Damaged upstream Spray water
Block Valves
28 March 2005
11
Problems seen in the field on Spray Probes
HP and HRH Attemperator Steam Solutions
Separate spray water control and spray water
injection functions
Location is the Key to low thermal stresses
Simplify components in high temperature transition
zones.
Use high temperature components in high thermal
shock zones.
Provide thermal isolation for spray water headers to
steam headers.
28 March 2005
12
Spray Nozzle Design
Thermally isolated spray
water housing and header
Spring loaded spray nozzles
for fine atomization
High temperature spring and
nozzle materials
No welding to retain
threaded components.
Cure for poor atomization, desuperheater
design
Variable orifice nozzle for best
primary atomization
Increase steam velocity with
liner to increase velocity at
water injection and protect
steam piping
Spray nozzles create back
pressure to spray water valve
Over-travel nozzles for
passing contamination
28 March 2005
13
Multiple Spring Loaded Nozzle Assembly
Multi-nozzle design
Variable geometry spring
loaded nozzles
High capacity
Nozzle rangeability 50:1
or more.
System rangeability
limited water control
valve and steam flows
Used for superheater &
reheater applications,
turbine bypass, aux.
steam applications
Direct Probe
Replacement
Remove the
water control
valve from the
high temp. steam
Multiple spring
loaded nozzles
No piping
modifications
required
Multistage
characterized
water control
valve
28 March 2005
14
Superheat water spray valve operating
pressure differentials
2 x 500 MW units
Fixed speed
motor driven
feedpump
Operation in 1x1
and 2x1 results in
variable steam
turbine pressure
with fixed water
pressures 0
500
1000
1500
2000
2500
3000
3500
10 Days of Data (10 min intervals)
P
r
e
s
s
u
r
e

[
p
s
i
g
]
HP Feedwater
Pressure
HP Steam
Pressure
~1500 psid
~700 psid
~2000 psid
Valve Solutions to solve the spray water
control problem
High Rangeability
Multistage design
Highly characterized
for spray
applications,
generally modified
equal percentage
Provide a tight
shutoff design, FCI-
70 Class V.
28 March 2005
15
Velocity control customized
characterization
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60 70 80 90 100
% Flow
% Stroke
Modified Linear
Linear
Modified Equal %
Clogging and Filtration Recommendations
Temporary filters may be needed during plant
commissioning
100 micron filtration recommended on many
designs
Separate strainers for at least several months of
commissioning
Use spray water valve trims as back-up protection
devices
Partial clogging of nozzles can cause directed water
flow at steam pipe walls.
28 March 2005
16
Water injection directly downstream of elbows
or valves
Non-uniform
steam velocity
profile
generated
Water
distribution is not
uniform
Water is carried
into pipe wall
and drops out
Pipe cracking
can occur
Overall steam
velocity an issue
Improper Piping Design
Increase distance from the elbow to the water
injection point
Add flow straighteners to the piping to obtain a
more uniform flow regime
28 March 2005
17
Installation recommendations
Drain issues
Improper draining causes:
Water hammer
Thermal shocks and gradients
Check location and size of drains
Use the drains more aggressively during start-up
Sizing drains for not only condensate formation but
also for leaking spray valves
Drains cant be sized for open spray valves
28 March 2005
18
Turbine Bypass
Valve
Applications
Combined Cycle
Power Plant
HP to CRH bypass system and adverse affects
on HRSG life
HP steam valve leakage and overheating of CRH
headers
Operation of the water valve without steam flow
Isolation of the bypass steam valve
Continual operation of the bypass system
HP spray water valve leakage and water collection
in the downstream pipe.
Water carryover into the HRH tubing
Water-hammer
Poor HP steam bypass control results in pressure
fluctuations causing drum level changes and alarms
28 March 2005
19
Poor HRH steam bypass control results in pressure
fluctuations causing drum level changes and alarms
Poor HRH bypass operation can cause unit trips
Operation/leakage of the water valve without steam
flow can cause water-hammer
Operation near saturation during desuperheating can
cause loss of spray water control
High condenser enthalpy can cause unit trips system
HRH to condenser bypass system and affect
on HRSG life
Turbine Bypass System issues
Use high integrity turbine bypass systems
Use same high integrity desuperheating systems as
used on HP and HRH steam attemperation
Use proper sequencing of steam and water valves
to prevent water hammer and thermal shock issues
Use feedforward control logic for both unit trips and
for spray water desuperheating control
Proper design of piping systems for distances for
desuperheating
Proper draining of the turbine bypass system
downstream of the bypass valve
28 March 2005
20
High Integrity Bypass Systems
Desuperheater with flow conditioning Desuperheater with flow conditioning
and pressure reduction and pressure reduction
Variable area Nozzle
Desuperheating after
Pressure Reduction
Nozzles configured to
give even cross section
distribution
Water injection at high
velocity and turbulence
points in steam flow
Steam flow acts as
thermal Shield
Quick Change Nozzle
Assy
28 March 2005
21
Sequencing of Steam and Spray valves
Water valves need to be interlocked to prevent
opening if the steam valve is closed.
Opening
Open steam valve
Once steam valve closed limit switch has cleared,
signal water valve to open
Review systems for minimum recommended flow
Closing
Bring steam valve to recommended minimum lift and
hold
Close water valve
Close steam valve
Water Injection Control on Bypass Systems
Temperature Control
Temperature measurement and feedback controls
amount of water injected.
Feedforward Control
P1/T1 and Valve Position Control for estimating
steam flow
P1/T1/P2 measurement for estimation of steam flow
using the dump tube as a flow meter
28 March 2005
22
Temperature Control
Enthalpy Control Using Backpressure
for Flow Measurement
Spray
Water
Valve
T
rh
F
w
=f(p)
Pdump
Steam
Control
Valve
HRH
Trh = Steam Inlet Temp.
Tsw = Spray Water Inlet Temp.
Pdump = Dump Tube Press.
Fw = Water Flow
T
sw
Fw = f(Pdump, Tw, Trh)
Prh
28 March 2005
23
Feed Forward Enthalpy Control Using
Valve Position for Flow Estimation
h
rh
=f(p,T)
F
w
=F
st
Spray
Water
Valve
T
rh
h
des
-h
w
h
rh
-h
des
F
w
=f(
p)
Y
st
F
st
=f(Y
st
,p,T)
p
dump
P
rh
Steam
Control
Valve
HRH
T = Temperature
P = Pressure
F = Flow
h = Enthalpy
Yst = Valve Stroke
Temperature vs Enthalpy Control
Longer straight
distances and
distances to
condenser on
temperature control
More potential for
oscillation with
temperature control
Lower steam
discharge enthalpy to
condenser with
enthalpy control
28 March 2005
24
Desuperheating Distances,
Recommendations (rules of thumb)
Distance to first elbow
0.1 seconds at maximum steam velocity for most
desuperheaters
0.05 seconds for steam assist
Distance to Pipe Spec Change
16 ft (5 m)
Distance to Temperature Sensor
0.2 seconds at maximum steam velocity for < 15% water
injection
0.3 seconds at maximum steam velocity for > 15% water
injection.
Temperature set point 18 F (10 C) above saturation
The above values can change based on steam SH, water
steam ratios, required accuracy, and desuperheater type.
HRSG and Plant Upgrades
Most HRSG and CCPP plants were designed for
base load operation
Most CCPP are in high cycle operation due to the
high cost of fuel and cycling load demands
Replacement and upgrades of attemperation
hardware can reduce thermal cycling and other
problems seen at plants
Separation of the water control function from high
temperature steam will improve service life
Steam attemperation and turbine bypass systems
are integrated units that need to be designed to fit
specific piping systems
28 March 2005
25
Publications/Helpful References
Attemperators, Combined Cycle Journal, 1Q 2005
Advances in Desuperheating Technology for
Reliable Performance of Combined Cycle Power
Plants, Proceedings of PWR2005, PWR-2005-
50108
Polished Performance, Refined HRSG Designs and
O&M Practices Boost Plant Performance, Power
Engineering, February 2005.
Avoid Desuperheater Problems with Quality
Equipment, Proper Installation, Tight Process
Control, Combined Cycle Journal, Fall 2004

Steam Attemperation Valve and Desuperheater Driven Problems On HRSG's

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Steam Attemperation Valve and Desuperheater Driven Problems On HRSG's

Hochgeladen von

Copyright:

Verfügbare Formate

28 March 2005

Das könnte Ihnen auch gefallen