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The Contribution of Valves in Maximum Power Plant Performance

By Sanjay V. Sherikar, Ph. D. P Manager, Plant Betterment .E. Presented at COAL -GEN Chicago, IL July 25-27 2001 ,

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Contribution of Valves in Maximizing Power Plant Performance

n Sanjay V. Sherikar, Ph. D., Control Components Incorporated, Rancho Santa Margarita, California, USA. Abstract Proper functioning of control valves is critical in maximizing the performance of a power station. Non-optimum control valve operation affects plant operation and all the important measures of plant performance. Misapplication, with regards to design and selection, is a leading cause of control valve problems. Severe service applications cause most of the performance penalty that is attributable to valves, even though they are a small minority in the valve population. The performance of power stations can be improved by 2% to 5%, very economically, by eliminating such valve-related penalties. Such improvement can be achieved without affecting other major plant equipment such as turbine, boiler etc., or their respective processes. When upgrading controls system, it is necessary to ensure peak performance of valves to realize the full benefit of the new system. Introduction The Forgotten Valve. Industry experience suggests that eliminating valve problems actually offers one of the quickest and most effective ways of improving plant efficiency. This is evident in classic text books [Reference 1] on steam cycle performance as well as, more importantly, through plant experiences [Reference 2-7]. Table 1 shows results of studies done at some sites. Power plants that overlook valve problems experience poor reliability and more frequent Unit trips, a loss in maximum dependable capacity, higher heat rates and increases in operating and maintenance costs.

Influence of Control Valves on Plant Operation & Heat Rate Final Control Elements - Valves. Figure 1 shows a simplified diagram for process control. The weakest links in such control loops are the valves. The accuracy of modern digital control systems (DCS) can be better than 0.1% and that for modern sensors is typically better than 0.25%, whereas it is poorer than 2% for most valves. The control system itself cannot make up for the limitations in the performance of a control valve.

CONTROL SYSTEM Control Signal

Feedback Loop Sensor PROCESS

Figure 1: Simplified diagram of process control.

As the final control elements, control valve performance directly affects plant operation - in terms of maximum MW-capability, heat rate, ramp rate (MW/min.), minimum sustainable load and/or in terms of reliability and availability. Inefficiency Attributed to Valves. There are three basic modes through which valve-related penalties occur in a power station: n n n Loss of production (MW-hours) due to their unavailability/ unreliability. Loss of production (MW-hours) due to leakage and/or poor control. Penalty in heat rate, and/or MW-capacity, due to leakage and/or poor control.

Table 1: Potential for Performance Improvement by Eliminating Valve-related Losses STATION TYPE POTENTIAL IMPROVEMENT (MWe) Supercritical, 915 MW Subcritical once-through, 705 MW Subcritical once-through, 330 MW Drum boiler, 305 MW Drum boiler, 235 MW Combined Cycle, 658 MW (230 MW in the steam cycle) 18 MW 35 MW 11 MW 13 MW 8 MW 6 MW Valves for the Startup system, BFP recirculation and spraywater Valves for the Startup system, BFP recirculation and spraywater LP bypass, sky vents, steam drains, spraywater Startup bypass, steam drains and heater emergency drains Startup bypass, spraywater, steam drains and heater emergency drains Turbine bypass, spraywater, steam drains MAJOR VALVE CONTRIBUTORS

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Figure 2: Typical Control Valves in Power Stations

In addition, other components have to work harder to compensate for such losses, which affects their life-cycle. While contributions to plant efficiency loss from individual valve applications may be small, together they can sum together to significant levels. When the invisible effects of the valve problems are taken into account, the net impact is even greater. Valve Considerations Valve Types. Figure 2 shows different types of control valves commonly used in power stations and Figure 3 shows different types of trims, or throttling elements, that are possible in just the globe type valves [Reference 8]. With so many combinations, it is not surprising that valves are misapplied in services where they are not suitable. Problems in severe service applications, and poor system performance, are bound to occur because of misapplication of valves in such duty [Reference 9]. Severe Service Valves versus General Service Valves. Of the hundreds of control valves in any power plant, some valves experience particularly tough operating conditions either at all times or under some operating conditions. The severity of operating conditions may be in terms of high-pressure drop, two-phase flashing flow, high turndown requirement, tight shutoff requirement or in ways that an off-the-shelf general service valve is not suitable. These are known as severe service valves. Although few in number, they pose challenges to maintenance and operation. Examples of severe service applications include those for boiler feed pumps minimum flow control, feedwater flow control, spraywater control, main drainage, heater emergency drainage, auxiliary steam pressure reduction, turbine bypass and startup valves.
2001 CCI. All rights reserved.

Valve Problems. Indicators of inadequate valve performance may be one or one or more of the following: n n n n Leakage when shut. High vibration and/or noise. Poor process control. Premature mechanical damage to valve components or to the piping in the vicinity. These are merely symptoms. Their root causes must be understood from solutions perspective. Perhaps more importantly, their impact on the power station performance needs to be quantified from operations perspective. Root Cause of Poor Valve Performance. When a valve does not perform up to expectations, it is important to understand why that is happening. Having to repair a valve every outage is a sure sign that the root cause of problem is not being addressed. There are two, broad valve-problem categories [Reference 9]: n Related to design and/or selection: It is essential that the valve design features, or capability, match the specific application requirements. If this is not so, then there is little hope that corrective actions after installation will be able to overcome the initial errors. This is strictly a technology issue. n Related to maintenance and/or operation: Operation and maintenance aspect of valves includes issues such as correct assembly, actuator supports, system debris and flushing procedures, calibration and air supply - all require careful attention and personnel training. Distinguishing the problem category as identified above is half the battle in arriving at a reliable solution.
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Figure 3: Typical Valve Trim Designs

In a majority of the cases of poorly performing valves in severe service applications, the problem can be traced to high fluid velocities along the flowpath. The typical velocity profile when the pressure drop is achieved in a single stage in a valve, as with trim designs in Figure 3 a-c, is shown in Figure 4. Higher pressure drop results in higher peak velocity, which causes premature trim erosion, mechanical damage, poor control, high vibration and poor reliability.

If the pressure drop is absorbed in many small steps, then the peak velocity can be controlled below a safe limit as shown in Figure 5. More pressure reducing steps means lower velocity along the flow path. Figure 3 (g) represents a trim design with many steps, or stages, of pressure drop within a valve.

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The cost and effort of frequent maintenance of valves is only the tip of the iceberg in power plant economics. The operational cost of poor performance of valves needs to be computed. Lowest maintenance cost is not necessarily the most economic solution. The correct solution will minimize the overall cost, and will perform reliably over long term. Reliability should be evaluated on technical merits of the design and past experience, not on commercial terms. Recovering Plant Capability in Existing Units A Plant Betterment Program Focussing on Valves. Power
Figure 4: Velocity Along the Flowpath Inside Conventional Valves for Liquid Flow.

stations do give attention to valves in crisis mode, and sometimes on a as needed basis. A systematic approach can avoid such crisis situations. In addition, it can help achieve reliable peak performance capability by eliminating losses as shown in Table 1 for different power stations. There are some major advantages in focussing on valves early for performance improvement [Reference 5, 6]: n Valve operation can be improved without adversely affecting other plant systems - control system tuning, combustion, steam cycle, structure etc. Changes in efficiency, emissions, MW and all such performance parameters are on the positive side. n Valve improvements can be implemented quickly and reliably. Typical lead time is three to six months; implementing changes in the plant is a matter of days. In most cases, valve modifications do not require major structural modifications. n There is a quick payback for valve modifications that will recover most of the potential. A return on investment period of 1 year or less is typical. Experience at several power stations shows that these benefits can be realized with a systematic program focussing on valves. Execution of such a program can be divided roughly into three broad phases: n n n A study to identify valves which affect plant performance and solutions for the same. Implementation of recommended solutions. Follow-up, or monitoring, to ensure that the desired results are achieved. The first phase is a study to identify the loss in unit performance due to control valves, to diagnose the root cause of these valve problems, determine solutions to eliminate these root causes and to establish priorities for implementation. Expertise to quantify valverelated performance penalty is available in the industry. In addition, involving the technical staff at the power station in this effort is crucial for success. Implementing changes requires definition of timetable and scope, within the operating limits of the subject unit(s). It provides a good opportunity to re-write equipment specification to current standards of

Figure 5: Velocity Along the Flowpath Inside a Valve with Velocity Control Trim (liquid flow). Fluid Velocity is Controlled to Eliminate Cavitation.

Full discussion on this subject, and on other commonly experienced root causes of valve problems, can be found in [Reference 8-11]. Solutions to Valve Problems. The common approaches to improving valve performance are: n Repair, or upgrade, is usually the first reaction. It assumes that the basic selection and design of the existing valve is correct. It is a good idea to challenge such an assumption, at least to ensure that all the issues are understood correctly and fully. n Replacement is the approach taken when all efforts at repair and upgrade of the existing valve fail to yield satisfactory results. Generally, it is an acceptance of the fact that the basic selection and design of the original/existing valve is incorrect. In such cases, it is a good idea to verify through quantifiable means that the solution addresses the root cause of problems being addressed. Again, this should strictly be a technology issue - not a brand name issue. n Retrofitting valves is a possibility in many cases [Reference 12]. In retrofits, the original valve body is retained without any modifications; the retrofit solution consists of changes to the valve trim and/or the actuation system to address the root cause of the problems. Retrofit solutions have proven successful, especially in the nuclear power industry because they eliminate cutting and re-welding of valves from the pipelines.

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485 | Contribution of Valves in Maximum Power Plant Performance

excellence to make sure that the performance is as expected. Provision can be made for any anticipated changes in the operating parameters. The focus at any stage needs to be on long-term reliable performance. The third phase in this program is the follow-up, or monitoring to ensure that the valves performed as expected. Integration of this activity with performance monitoring systems raises awareness among the operators and helps limit such controllable losses. Focus on Valves as Part of Control Systems Upgrade. Power stations have undertaken modernization of control systems, from old analog systems to DCS or upgrade of early DCS systems, to improve reliability and for better control of the Unit. In the spirit of earlier discussion with Figure 1, it is important to pay as much attention to the performance of control valves. There is a common interface between the control system and the valves. However, the nature of issues with valves and valve-related systems tends to be very different from the controls side. The scope of controls side includes electronics hardware, optimizing process loops, control algorithms, tuning etc. but does not get into mechanical issues such as valve design, leakage when shut, eliminating high vibration or cavitation, two-phase flow, valve dynamic response etc. Therefore, it is logical to de-couple these two elements and focus on valves independently within the whole project. The required valve characteristics can then be defined to meet the controls requirement as well as those for reliability and long-term mechanical performance. In order to get the full benefit of any control system upgrade, the valves have to be at peak performance - focussing on valves independently, and necessarily, helps ensure that [Reference 13, 14]. A bonus of enhancing valve performance is that the direct losses, such as those due to leakage, can be eliminated resulting in improved heat rate and/or increased MW capability. Conclusions Eliminating valve problems offers one of the quickest means of improving reliability and performance of existing power stations. A systematic Plant Betterment approach, focussed on eliminating valve-related losses, is necessary for achieving the potential benefits fully. The initial system-wide study and the follow-up in monitoring performance are key components for such a program. Ease of implementation, quick payback and low risk all combine to make this approach very attractive for heat rate improvement. It is necessary to upgrade control valves for their peak performance when upgrading controls system in order to realize the full benefit of the new controls.

References 1. 2. Cotton, K.C., Evaluating and Improving Steam Turbine Performance, 2nd edition, p. 296, pp. 305-313, (1998). Sherikar, S.V., Sterud, C.G., Bhate, B.H. and Strother, J., Modernization of the Startup System at Paradise Power Plant, Report for TVA Contract #99-PYN-247276 (1999). 3. Sherikar, S.V. and Puri, A., Importance of Startup System Isolation in Recovering MW-Loss and Heat Rate in Power Plants, International Conference on Power Plant Operation, Efficiency and Environmental Protection, New Delhi, India, 8-11 February, 2000. 4. Sherikar, S.V. and Kaegi, U., Modernization of the Startup System at Bull Run Steam Station, Report for TVA Contract #99-PYN-247276 (1999). 5. Byrne, L. and Sherikar, S.V., Improving Efficiency at Moneypoint Power Station: Focus On Control Valves, January 2000. 6. Bayini, A., Sherikar, S.V., Basu, S. and Bhate, B.H., Improving the Performance of Jorf Lasfar Power Station: Focus on Control Valves, Unit 1&2, December 2000. 7. 8. Weeks, Ed, (Navajo Generating Station), Personal Communication, (May 2000). Control Valve Applications, Chapter 12, Control Valves - ISA Practical Guides for Measurement and Control, ed. Borden, Guy, Jr., and Friedmann, Paul G., Instrument Society of America, Research Triangle Park, N.C., 1998 9. Miller, H.L., Frequent Control Valve Problems, Seventh EPRI Valve technology Symposium, Incline Village, NV, May 26-28, 1999. 10. Miller, H.L., and Stratton, L., Fluid Kinetic Energy As A Selection Criteria For Control Valves, ASME Paper FEDSM97-3464. 11. Sherikar, S.V., Technology In Severe Service Control Valves, 15-th Annual Air-Operated Valve Users Group (AUG) Meeting, Tucson, AZ, June 9-12, 1998. 12. Yost, P. and Sherikar, S.V., Retrofit - An Option to Eliminate Root Cause of Control Valve Problems, 17-th Annual AirOperated Valve Users Group (AUG) Meeting, New Orleans, LA, June 7-11, 1999. 13. 14. Musmeci, N., (Ninemile Generating Station, Entergy), Personal Communication, (October 1999). Redlington, D.E. and Romano, J.M., (Sioux Generating Station, AmerenUE), Personal Communication, (December 2000).

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