Steam Attemperation Valve and Desuperheater Driven Problems On HRSG S PDF

28 March 2005
Attemperation Frustrations
Steam Attemperation Valve and Desuperheater

Driven Problems on HRSGs
Main and Reheat Steam Attemperation

Turbine Bypass Operation
2003. CCI Control Components Inc. CCI is the Valve Doctor . All rights reserved. P102
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28 March 2005
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
Control temp
Control temp
Con
System response is slow
and can cause cycling
swings
Water carryover into the
tubing possible
Thermal cycling of tubing
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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
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Steam header and tube failures
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Cumulative failures of SH tubes
Increased superheat tube failures

with years of operation
80
60
40
20
0
0
10
Unit age, years
Downloaded from APTECH web site

28 March 2005
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
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Spray basic atomisation shape / Formen des Strahlzerfalls
1. Rayleigh Regime
v amb
2. First Wind-induced Regime
v water (Velocity)
v water - v amb 0
v water - v amb 2 m/s
Breakup way out of jet outlet

Capillary + Viscosity Forces are
dominant
Aerodynamic Resistance is small
Droplets larger than jet diameter
Breakup closer to the jet outlet

due to higher relative motion, gives
additional aerodynamic Resistance
Droplets are equal to jet diameter
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3. Flapping Jet
4. Spray Jet
Breakup closer to the jet outlet

Increasing of relative velocity
Superposition of "O-mode"(dilatation)
and "1st-mode"(sinusoidal flapping)
gives Instabilities
Droplets smaller than jet diameter
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
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10
Water droplet size distribution by different

nozzle designs
% Volume
15
10
0
19
35
63
114
205
370
668
1207
Droplet diameter, microns
28 March 2005
Spray distribution into the steam
FC 526.07
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11
Evaporation of water in steam

Steam/Water Temperature Gradient vs Time
1000
900
800
Deg. F
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
700
Steam Temp
Water Temp
600
Initial heating
Boiling
500
400
300
10
12
14
16
Time
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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
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13
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
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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
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Spray Nozzle Desuperheaters
H2 0
SH
STEAM
H2 0
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
DS STEAM
pressure drops than spray
ring.
Fixed orifice, rangeabiltiy is
limited to between 5:1 and
15:1
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Spring Loaded Spray Nozzle
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17
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.
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Nozzle Spray Patterns, High Speed

Photography
Spray nozzle
Whirl nozzle
Spring loaded nozzle

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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
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10
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Problems seen in the field on Spray Probes
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21
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.
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11
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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.
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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
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12
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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
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26
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
13
28 March 2005
Superheat water spray valve operating

pressure differentials
3500
3000
2500
~700 psid
Pressure [psig]
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
2000
~1500 psid
~2000 psid
1500
1000
HP Feedwater
Pressure
500
HP Steam
Pressure
0
10 Days of Data (10 min intervals)
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27
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, FCI70 Class V.
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14
28 March 2005
Velocity control customized

characterization
% Flow
100
90
80
Linear
70
60
Modified Linear
50
40
30
20
Modified Equal %
10
0
0
10
20
30
40
50
% Stroke
60
70
80
90
100
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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.
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15
28 March 2005
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
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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
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16
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Installation recommendations
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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
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17
28 March 2005
Turbine Bypass
Valve
Applications
Combined Cycle
Power Plant
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35
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
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28 March 2005
HRH to condenser bypass system and affect

on HRSG life
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
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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
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19
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High Integrity Bypass Systems
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Desuperheater with flow conditioning

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
20
28 March 2005
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
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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
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21
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Temperature Control
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Enthalpy Control Using Backpressure

for Flow Measurement
HRH
Trh
Prh
Fw = f(Pdump, Tw, Trh)

Tsw
Fw =f(p)
Trh = Steam Inlet Temp.

Tsw = Spray Water Inlet Temp.
Pdump = Dump Tube Press.
Fw = Water Flow
Steam
Control
Valve
Spray
Water
Valve
Pdump
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22
28 March 2005
Feed Forward Enthalpy Control Using

Valve Position for Flow Estimation
HRH
Trh
T = Temperature
P = Pressure
F = Flow
h = Enthalpy
Yst = Valve Stroke
Prh
hrh=f(p,T) Fst=f(Yst,p,T)
Fw=Fst
Fw =f(p)
Steam
Control
Valve
hrh-hdes
hdes-hw
Spray
Water
Valve
Yst
pdump
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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
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23
28 March 2005
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.
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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
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28 March 2005
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-200550108
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
3/28/2005
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25

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28 March 2005

Steam Attemperation Valve and Desuperheater

Main and Reheat Steam Attemperation

Interstage Steam Attemperation

Problems on Main and Reheat Steam

Superheat and reheat tube failures

Steam header and tube failures

Cumulative failures of SH tubes

Increased superheat tube failures

Unit age, years

Downloaded from APTECH web site

Fundamentals of steam attemperation

Fundamentals of steam attemperation

2. First Wind-induced Regime

v water - v amb 2 m/s

Breakup way out of jet outlet

Breakup closer to the jet outlet

Fundamentals of steam attemperation

v water - v amb 10 m/s

v water - v amb 50 m/s

Breakup closer to the jet outlet

Breakup near to the jet outlet

Water droplet size distribution by different

Droplet diameter, microns

Spray distribution into the steam

Evaporation of water in steam

Traditional venturi nozzle

Variable Area Probe

Typically flanged to the

Spray Ring Desuperheaters

Spray Nozzle Desuperheaters

Applied in large and small

Spring Loaded Spray Nozzle

Spring Loaded Spray Nozzles

Nozzle Spray Patterns, High Speed

Spring loaded nozzle

Problems seen on Spray Control Probes

Problems seen in the field on Spray Probes

HP and HRH Attemperator Steam Solutions

Spray Nozzle Design

Cure for poor atomization, desuperheater

Multiple Spring Loaded Nozzle Assembly

Superheat water spray valve operating

Valve Solutions to solve the spray water

Velocity control customized

Clogging and Filtration Recommendations

Water injection directly downstream of elbows

Improper Piping Design

Increase distance from the elbow to the water

Check location and size of drains

HP to CRH bypass system and adverse affects

HP spray water valve leakage and water collection

Poor HP steam bypass control results in pressure

HRH to condenser bypass system and affect

Turbine Bypass System issues

High Integrity Bypass Systems

Desuperheater with flow conditioning

Sequencing of Steam and Spray valves

Water Injection Control on Bypass Systems

Enthalpy Control Using Backpressure

Fw = f(Pdump, Tw, Trh)

Trh = Steam Inlet Temp.

Feed Forward Enthalpy Control Using