KOSO Turbine Bypass Systems

KOSO Turbine Bypass Systems
Agenda
Turbine bypass systems

KOSO experience
Components/ hardware
FAQs
Sep 22, 201

5
2009 - KOSO. All rights reserved.
Typical turbine bypass problems
Pipe/ components cracking

Water hammer
Stuck valve
High vibration
High noise
Trim erosion
.
.
.
The combination of high pressure drop and

desuperheating requires special attention in
turbine bypass systems
Sep 22, 201
5
Kosos experience in turbine bypass and

steam conditioning systems
Kosos strengths:
Experience of over 25 years
in desuperheaters
turbine bypass systems
PRDS
process steam
The most cost effective

solutions resulting from a
unique combination of:
knowledge of systems,
engineering expertise, and,
customer support.
Sep 22, 201
5
Turbine bypass Schematic (typical)
Current projects
(recently completed or under construction - partial)
Turbine bypass systems for

600 MW supercritical units - Mo Chin
Sep 22, 201

5
Scope of supply for 600 MW supercritical x 2

Units:
2 HP bypass systems
steam PRV - 8 x 16, 2795# SPCL, F91
body
Spray ring & probe desuperheaters
Fast-acting pneumatic actuator (< 2s
trip)
4 LP bypass systems
steam PRV - 10 x 18, 600# SPCL, F91
body
Spray ring desuperheater
7
Fast-acting pneumatic actuator (< 2s
HP bypass system (Mo Chin)
Steam PRV: 8 x 24
Flow-to-Open
285 barA/ 546 deg C
700 t/hr
Class V shutoff
Desuperheater:
Spray Ring + Probe
Actuation: Pneumatic
Sep 22, 201

5
LP bypass to condenser (Mo Chin)
Steam PRV: 16 x 34
Flow-to-Open
53 barA/ 574 deg C
375 t/hr
Class V shutoff
Desuperheater:
Spray Ring
Actuation: Pneumatic
Sep 22, 201

5
LP bypass to condenser (Mo Chin)
Sep 22, 2015
10
Turbine bypass systems for

Sredneuralskaya (Ekaterinberg), Russia
Scope of supply:
1 HP bypass system
2 inlets (6) for steam PRV,
24 outlet
Job-Rated 270 bar-a/ 545 C
inlet, F91 body
Fast-stroking electric actuator
Sep 22, 201

5
11

Kharanorskaya, Russia
Scope of supply (bypass to condenser):
1 HP bypass system
2 inlets (175 mm) for steam PRV, 630 mm
outlet
Job-Rated 14 MPa-a/ 570 C inlet, F91 body
1 PRDS system (bypass to condenser)
Globe steam PRV, (175 mm), 630 mm outlet
Job-Rated 14 MPa-a/ 570 C inlet, A216 C12A
body
Sep 22, 201
5
12
Turbine bypass system for Iberdrola,

Spain (400 MW Elektrenai CCGT, Lithuania)
Scope of supply:
1 HP bypass system (bypass to Cold Reheat)
Job-Rated 142 barA/ 575 C inlet, F91 body
Multi-Nozzle Ring desuperheater
Fast-stroking pneumatic actuator
1 IP bypass system (bypass to condenser)
Job-Rated 31 barA/ 575 C inlet, F91 body
Multi-Nozzle Ring desuperheater
Fast-stroking pneumatic actuator
1 LP bypass system (bypass to condenser)
Job-Rated 7.5 barA/ 320 C inlet, A105 body
PED certified
Sep 22, 201
5
13
Size relationship:
Plant MW & turbine bypass
Power plant size has a major influence on
sizing of major equipment in the station
turbine, boiler etc
Sizing of turbine bypass systems depends on
the design %-bypass and number of lines:
1000 MW plant with 30% bypass through 1 line will
be same size as for a 1000 MW plant with 60%
bypass through 2 lines
(and same as a 60% bypass through 1 line for 500
MW unit)
Sep 22, 201

5
14
HP bypass experience
3 x 1 CCGT
184 MW (ACC)
LithuaniaElektranai
CCGT
Pulau
Seraya
Mo Chin
Riau Pulp
& Paper
Job-rated
Job-Rated
2500#
2795#
SPCL
1500#
Inlet size
10
10"
ID 210 x
38
10"
Outlet size
12
20
12"
OD 584 x
19
12"
Body Material
WC9/F22
F91
WC9
F91
WC9
Inlet pressure
(barA)
60 bar
(873 psi )
142
185
285
186
440 C
(860 deg F)
575
544
546
544
187 (420 kpph)
317
126
678
125
ANSI
Temperature (oC)
Flow rate (T/H)
Sep 22, 201
5
15
LP bypass experience
Example
3 x 1 CCGT
280 MW
LithuaniaElektranai
CCGT
Poryong
Mo Chin
WKC
Heineken
(ABB)
Job-Rated
Job-Rated
300#
600# SPCL
900#
Inlet size
24
24
200 mm
ID 432 x 20
150 mm
Outlet size
30
32
1200 mm
OD 863.6 x
12
900 mm
Body Material
C12A/ F91
F91
Inlet pressure (barA)
51 (791 psi)
30.5
23.5
52.5
59
594 (1102 deg F)
575
320
574
511
385 (862 kpph)
408
85
373
39
ANSI
Temperature (oC)
Flow rate (T/H)
Sep 22, 201

5
16
F91
Sizing & Selection of Turbine Bypass

Systems
Sizing & Selection of Turbine

Bypass System
Turbine bypass system components:
High Pressure (HP) bypass to Cold Reheat
Sometimes HP bypass to condenser
Hot Reheat (HRH) bypass (to condenser)

also in the same general category
Intermediate Pressure (IP) bypass (to condenser)

Low Pressure (LP) bypass (to condenser)
IP/LP bypass (to condenser)
LLP bypass
Sep 22, 2015
18
Turbine Bypass System

Components
Each system consists of:
Steam Pressure Reducing Valve
Spraywater Control Valve
Desuperheater
Additional equipment:
Spraywater isolation valve (for HP Bypass system)
Steam isolation valves (sometimes)
Dump device
Only for bypass to condenser
Sep 22, 2015
19
9-pack of China
Standard configuration for coal-fired power stations
in China:
1 HP bypass line + 2 LP bypass lines
HP system HP steam valve
HP spray control valve
HP spray isolation valve
(qty 1)
(qty 1)
(qty 1)
LP system
LP steam isolation valve

LP steam valve
LP spray control valve
(qty 2)
(qty 2)
(qty 2)
TOTAL number of valves = 9

Sep 22, 2015
20
Steam Bypass Valve selection

Trim exit kinetic energy rules:
Maximum 70 psi (480 kPa)
General VectorTM applications
Continuous operation
Maximum 150 psi (1030 kPa)
VectorTM Turbine bypass ONLY
Normal turbine bypass ONLY
o Start-up, shutdown and Unit trip
o Base-loaded plant - only few start-up per year
None (2 cages)
VectorATM based on Cv,required ONLY
Sep 22, 2015
21
About the Flow Distributor
Failures like this must be, and can be, avoided!
Sep 22, 201

5
22
Turbine bypass steam valve Flow-toClose

Flow-to-close design
Cage trim for pressure reduction
VectorTM is an option
Downstream flow distributor for

noise control
Spray Ring desuperheater
downstream
Actuation
Pneumatic
Electro-hydraulic
Design can be customized to

meet specific system
requirements
Sep 22, 201
5
23
Turbine bypass steam valve Flow-toOpen

Flow-to-open design
Balanced trim
More compact
Less heavy
Less structural support
requirements
Lower cost
Meets all performance
requirements
Design can be customized to

meet specific system
requirements
Sep 22, 201
5
24
Spray valves for bypass systems
HP bypass spraywater valves - VectorTM

LP bypass cage-guided/ top-guided
Isolation valves cage-guided/ top-guided
CalcCv is used for sizing
General service rules apply
Sep 22, 2015
25
Sizing spraywater valves
Sep 22, 201

5
26
Turbine bypass noise
Noise is a major issue for plants near population centers

Requires correct specification and selection of turbine
bypass system
Sep 22, 201
5
27
Desuperheating problems
Broken pipe supports

Cracked pipes and joints
Broken/cracked internals
Poor temperature control
Drain valves open too long
Plant trip due to condenser
temperature
May 11, 2010
28
Desuperheating in turbine bypass

systems
Challenging
Large amounts of spraywater injection
15 20% of steam flow rate for HP bypass to Cold Reheat
30 35% of steam flow rate for bypass to condenser
Sep 22, 201

5
29
Solutions small droplets

Spraywater atomization is
critical
There is no industry
standard for desuperheating
applications
Standard adopted by KOSO:
Droplet size < 250
microns
Derived from physics-based
analysis
Confirmed by field
experience
Sep 22, 201

5
30
Size range
microns
Type
<0.001
Molecular
0.001 0.1
Smoke
0.01 40
Fog
50-200
Mist
500-2000
Rain
Primary atomization
Primary break-up of a liquid jet
Primary atomization is initiated by shear between the liquid and

gas streams
The liquid stream to be unstable and eventually breaks up into
droplets of different sizes
Mean droplet size after primary break-up from typical high
capacity desuperheating nozzles is typically in 200 - 800 micron
May 11, 2010
range.
31
Secondary atomization
U 2 d
We
We Weber number
Small droplets (less than 250 microns):
Faster evaporation,
Faster mixing,
Easily stay suspended in the steam flow,
Less likely to impinge on (hot) metal pipe
Solution - Cold water not hitting hot

metal
No in-body desuperheating
Spray not hitting pipe walls
Spray penetration 18-85%
Solution - Correct control logic

The fact that the control
loop delays typically 30
seconds to 1 minute
needs to be recognized
Correct interlocks are
required to ensure
simultaneous flow of steam
and spraywater
Feed-forward control based
on enthalpy calculation is
required when the final
temperature set point is
close to saturation
Solution - Stream pipe drains

Steam piping
layout should allow
natural drainage of
any condensate in
the line
Drain lines must
have sufficient
capacity
Desuperheater selection rules

RULE #0: AVOID IN-BODY DESUPERHEATING
The risk is high cold water coming in contact with hot
metallic valve body will lead to cracking at the pressure boundary.
RULE #1: Average droplet size should be less than 250 m.
Fixed area orifices/nozzles
Spring loaded nozzles, variable area
Steam assisted
RULE #2: Eliminate direct spraywater hit on hot metal

Spray penetration should be between 15% and 85%
RULE #3: For control near saturation, feed-forward control logic

RULE #4: Provide sufficient distances to bends & temp sensors
May 11,
2010
36
Spring-loaded, multi-nozzle spray ring

(HP bypass to Cold Reheat)
Spring-loaded, variable area spray nozzles
Sep 22, 201

5
37
Spray ring desuperheater layout

(typical for turbine bypass to
condenser)
Simple, fixed-area spray
nozzles
Relies on energy of the steam
flow for atomization
Sep 22, 201

5
38
Dump tubes
For safe discharge of high energy steam into the
condenser
Selection of dump tube pressure is very important
Bypass steam
Sep 22, 201

5
39
Control logic for bypass to

condenser
KOSO has the expertise to provide guidance in critical areas

necessary for correct operation of turbine bypass systems.
Sep 22, 201
5
40
Actuation for turbine bypass

service
Actuation for turbine bypass

service
Pneumatic
Electro-hydraulic
Electric
Choice is dictated by customer preference
Functional requirements must be met
Reliability must be high
KOSO can provide any of the actuation

systems specified
Sep 22, 201
5
42
Functional requirements
Stroke speed
Modulation 10 s (typical)
Trip .. 2 s (typical)
Thrust
Modulation
Shutoff (seating)
Failure modes
Signal failure
Power failure
Controllability
Positioning accuracy to control upstream pressure
All these requirements are met in modern turbine

bypass systems by pneumatic actuators
Sep 22, 201
5
43
Double-acting, low-volume
pneumatic actuator
Meets ALL functional requirements
Benefits
Proven, mature technology
Very high reliability
(simple construction)
Maintenance is easy
Significantly lower cost
Very common for turbine bypass

service
Sep 22, 201
5
44
Typical control logic for fast action

- pneumatic actuator
Sep 22, 201

5
45
Control logic for HP bypass steam

PRV (pneumatic actuator) at Mo
Chin
Sep 22, 201

5
46
Electro-Hydraulic actuation systems
Self-contained electro-hydraulic
actuation
Sep 22, 201

5
47
Electro-Hydraulic actuation systems
Comparison of actuator options

Pneumatic
Attribute
(Double-acting,
ElectroHydraulic
Electric
Low-volume,
Piston)
Stroke time
< 2 seconds
< 1 second
Positioning
accuracy
Step change
response
Reliability
< 2%
< 0.5%
< 10
seconds
< 2%
<1%
overshoot
VERY HIGH
Low
No
overshoot
MODERATE
to HIGH
HIGH
No
overshoot
MODERATE
to HIGH
Moderate
High
Moderate
Moderate
Maintenance
requirement
Harsh
environment
Sep 22, 201
5
49
Summary
Summary
In summary:
KOSO has a wide experience in turbine bypass
systems for steam power plants.
KOSO can meet turbine bypass system
requirements for the Power industry with reliable
equipment which is also economical
KOSO can provide strong follow-on engineering
support this is critical in the proper
commissioning of engineered systems
KOSO team is uniquely qualified to help their
customers be competitive in markets of their
interest.
Sep 22, 201
5
51
Turbine bypass:
FAQs Frequently Asked

Questions

Frequently Asked Questions
Body type (steam PRV) - globe or angle valve?

Body material (steam PRV) - forging or casting?
Under-the-plug vs. over-the-plug geometry?
Balanced plug or unbalanced plug?
Desuperheater selection? Distances
downstream?
Actuator selection?
- Pneumatic vs. Electro-Hydraulic vs. Electric.
Piping layout, pre-warming requirements?
Dump tube sizing and design?
Sep 22, 201
5
53

Frequently Asked Questions
Allowable load on nozzles for By pass
Method for atomization
Temperature Control Loop. Location of
temperature sensor.
Turndown
Actuator sizing and speed. Step change
positioning / accuracy
Turbine trip without losing boiler
CV Sizing
Sep 22, 201

5
54
FAQs - 1
Body type (for steam PRV) globe or
angle?
Both will work
Ultimately, it is the designers design as to
what best fits the piping system
Angle body is more economical
o Angle body has higher capacity so it
results in a smaller valve less weight, less
cost, less demanding support requirements
(all good)
Sep 22, 201
5
55
FAQs - 2
Body material (for steam PRV) forged or

cast?
Both work equally well (ASME code allows
both)
Stringent QA is necessary in either case
Castings are more economical
Sep 22, 201

5
56
FAQs 3
Under-the-plug (FTO) vs. over-the-plug (FTC)
geometry?
Both work equally well
FTO means higher steam density at the seat ring
smaller trim size is required
smaller valve
less weight, less cost, less demanding support
requirements (all good)
(FTC means opposite of the above)

FTC keeps the body gallery warmer
FTO results in thinner sections (for body gallery),
which react better to thermal transients
Sep 22, 201
5
57
FAQs 4
Balanced plug or unbalanced plug?
Both will work; both can give tight shut-off
Unbalanced plug in turbine bypass means
Very high actuator forces are required electrohydraulic actuator is a MUST (old thinking)
More susceptible to vibration (no damping)
Balanced plug in turbine bypass means

Actuator forces required are moderate high
performance pneumatic actuator works very well
(used in most modern turbine bypass systems)
Pressurized seat trim is an option

Only Flow-to-Close (FTC) configuration.
Sep 22, 201
5
58
FAQs 5
Actuator selection?
Pneumatic vs. Electro-Hydraulic vs. Electric.
Any of the above is technically acceptable if it
meets technical requirements
In the old days, only Electro-hydraulic actuators
met the system requirements but they also
had significant maintenance problems
Pneumatic actuator technology (double-acting,
low-volume piston type) has now advanced to
meet turbine bypass requirements
It is highly reliable, low-cost and low
maintenance
Sep 22, 201
5
59
Comparison of actuator options

Pneumatic
Attribute
(Double-acting,
ElectroHydraulic
Electric
Low-volume,
Piston)
Stroke time
< 2 seconds
< 1 second
Positioning
accuracy
Step change
response
Reliability
< 2%
< 0.5%
< 10
seconds
< 2%
<1%
overshoot
VERY HIGH
Low
No
overshoot
MODERATE
to HIGH
HIGH
No
overshoot
MODERATE
to HIGH
Moderate
High
Moderate
Moderate
Maintenance
requirement
Harsh
environment
Sep 22, 201
5
60
FAQs 6
Desuperheater selection?
Key objectives are: (1) Small droplets, (2) no
spray impingement on the pipe walls
Multi-Nozzle spray Ring DSH for HP bypass
to CRH
Spray Ring DSH for bypass to condenser
Sep 22, 201

5
61
Fixed area Spray ring desuperheater

layout
(typical for turbine bypass to
condenser)
Simple, fixed-area spray nozzles
Relies on energy of the steam
flow for atomization
Better than 10:1 rangeability for
good atomization for dump to
condenser is possible
Sep 22, 201

5
62
Spring-loaded, multi-nozzle spray ring

typical for HP bypass to CRH
Spring-loaded, variable area spray nozzles

Rangeability for spray nozzles > 20:1
Rangeability for steam flow rate > 10:1
Commonly used for PRDS and process
steam applications where pipe > 12 (300
mm)
Sep 22, 201

5
63
FAQs 7
Distances downstream?
HP bypass to Cold Reheat:
Distance to the first elbow > 6 meters
Temperature probe > 15 meters
Bypass to condenser:
a) when desuperheating is within a few metersto condenser
with no tight bends in between:
Enthalpy control only (Saturated steam, with small excess water)
Temperature probe for alarm only
Pressure 7-15 barA at full flow (depending on available water pressure)
b) when desuperheater is far from condenser:

Temp control, 25 OC superheat,
Distance to the first elbow > 6 meters,
Temperature probe > 20 meters,
Pressure 7-15 barA at full flow (depending on available water pressure)
Sep 22, 201

5
64
FAQs - 8
Piping layout? Pre-warming requirement?
Steam PRV take-off should be located near, and
above, the main steam line.
Long radius elbows downstream of DSH are
preferred
Steam PRVs should be well-insulated.
Pre-warming is required when there is a risk of
(steam) valve bodies cooling excessively below
the main steam temperatures
Pre-warming may be through a small continuous
flow or via a natural convection line in the piping
Sep 22, 201
5
65
Example of long radius elbow

downstream of DSH
Sep 22, 201

5
66
FAQs - 9
Dump tube sizing and design?
Selection of dump tube pressure at maximum flow
condition is important
Determines the size of the upstream pipe & the dump tube
Correct dump tube design is important for ensuring

proper dispersal of steam into the condenser and to
eliminate the potential for erosion
Must be designed to fit in available space
Sep 22, 201

5
67
FAQs 10
Bolted bonnet or pressure seal bonnet?
Both will work
Bolted bonnet
Well-suited for compressed trim design
Quick-change trim easier valve maintenance
(desirable)
Pressure seal bonnet

Well-suited for hung cage or top-guided designs only
Generally characterized by seat rings which are
welded-in or screwed into the valve body
difficult for maintenance of seats (not desirable)
Smaller bonnet bolting requirement
more economical than bolted bonnet in this respect
Pressure seal bonnet with compressed trim design drives
up the overall cost
Sep 22, 201
5
68
Air Cooled
Condensers
(ACCs)
Special requirements for ACCs

Turbine bypass systems for plants with
ACC require additional protection against:
Excessive vibration
Excessive noise
The requirements are special because of:

thin duct downstream, and,
lack of vibration/ noise attenuation as in
the case of water-cooled condenser
Sep 22, 201

5
70
Differences in noise considerations:

Traditional versus ACC application
(1/2)
Traditional condenser (water cooled):

ONLY CONTROL VALVE NOISE NEEDS TO BE ADDRESSED.
Although valve aerodynamic noise prediction is complex, it is
understood well enough to have an industry standard.
Dump tube noise is not an issue.
Dump tube is inside the condenser itself, which has thick
concrete wall so very little of the noise from the dump tube
transmits to the outside.
Turbine bypass steam lines to the condenser is smaller dia
and thick so noise transmission loss to outside is HIGH.
The pipe resonant frequencies are high so the low frequency
noise from valves is attenuated more effectively.
Bypass lines to condenser have insulation which attenuates
noise.
Sep 22, 201
5
71
Differences in noise considerations:

Traditional versus ACC application
(2/2)
Air Cooled Condenser:

DUMP TUBE IS ALSO A MAJOR NOISE SOURCE IN BYPASS
SYSTEMS (IN ADDITION TO THE CONTROL VALVE).
Dump tube noise is not well understood in the industry.
Steam bypass lines to the condenser are HUGE and thin
so noise is transmission loss to outside is LOW,
i.e. noise is easily transmitted to the outside.
The pipe resonant frequencies are low so significant
part of the low frequency noise from valve AND the
steam dump element leaks through to the outside. In
addition, the duct wall can get excited and vibrate.
Steam dump element is inside the thin ACC duct which is
outside of the condenser itself. So the noise is
transmitted by the entire length of the ACC duct.
Sep 22, 201
5
72
ACC source of high noise

Large flow rates and high energy jets can be very
noisy
Strong shock waves and combination of high energy
jets are additional sources
Jet spacing-to-dia ratio = 1.44, Pressure ratio
=8
Source: Noise Characteristics and Shock Structures of Under-expanded Jet Array

Configurations, S. V. Sherikar, ASME FEDSM 2007-37290
Sep 22, 201
5
73
Interaction of jets
The noise contribution due to interaction of
neighboring jets depends strongly on jet spacingto-diameter ratio and pressure ratio across the jets
Conventional dump
tube
Source: Noise Characteristics and Shock

Structures of Under-expanded Jet Array
Configurations, S. V. Sherikar, ASME
FEDSM 2007-37290
Sep 22, 201

5
74
Control of fluid energy and

turbulence is key
Sep 22, 201

5
(This paper can be made available upon

request.)
75
ACC solution for low noise

Control of fluid kinetic energy and turbulence is
required for steam PRVs in the bypass systems
Dump tube has to be designed for low noise
Eliminate/ minimize shock wave noise
Minimize noise contribution of recombining jets
Optimization of upstream pressure for
economical size
All drains and vents must be checked for noise

contribution
Attention to all details flow discontinuities,
elbows etc
Sep 22, 201
5
76
Pictorials of technologies for low

noise Steam PRV: Multi-stage pressure letdown
valve
Sep 22, 201

5
77
Thank you !
Questions?
Sep 22, 201
5
78

KOSO Turbine Bypass Systems - (Sales Training, March 10 2011) - Rev A

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Turbine bypass systems

Sep 22, 201

2009 - KOSO. All rights reserved.

Typical turbine bypass problems

Pipe/ components cracking

The combination of high pressure drop and

2007 - KOSO. All rights reserved.

Kosos experience in turbine bypass and

The most cost effective

2007 - KOSO. All rights reserved.

Turbine bypass Schematic (typical)

Turbine bypass systems for

Sep 22, 201

2007 - KOSO. All rights reserved.

Scope of supply for 600 MW supercritical x 2

HP bypass system (Mo Chin)

Sep 22, 201

2007 - KOSO. All rights reserved.

LP bypass to condenser (Mo Chin)

Sep 22, 201

2007 - KOSO. All rights reserved.

LP bypass to condenser (Mo Chin)

Sep 22, 2015

Turbine bypass systems for

Sep 22, 201

2007 - KOSO. All rights reserved.

Turbine bypass systems

2007 - KOSO. All rights reserved.

Turbine bypass system for Iberdrola,

2007 - KOSO. All rights reserved.

Sep 22, 201

2007 - KOSO. All rights reserved.

187 (420 kpph)

2007 - KOSO. All rights reserved.

Inlet pressure (barA)

594 (1102 deg F)

385 (862 kpph)

Sep 22, 201

2007 - KOSO. All rights reserved.

Sizing & Selection of Turbine Bypass

Sizing & Selection of Turbine

Hot Reheat (HRH) bypass (to condenser)

Intermediate Pressure (IP) bypass (to condenser)

Turbine Bypass System

LP steam isolation valve

TOTAL number of valves = 9

Steam Bypass Valve selection

About the Flow Distributor

Failures like this must be, and can be, avoided!

Sep 22, 201

2007 - KOSO. All rights reserved.

Turbine bypass steam valve Flow-toClose

Downstream flow distributor for

Design can be customized to

2007 - KOSO. All rights reserved.

Turbine bypass steam valve Flow-toOpen

Design can be customized to

2007 - KOSO. All rights reserved.

Spray valves for bypass systems

HP bypass spraywater valves - VectorTM

Sizing spraywater valves