Integrated Solutions

Plant|Flexibility
Start-Up Boost

Changing market requirements and energy demands have increased the need for plant flexibility and efficiency to meet the relevant market and economics. Whether this be generation hours, output capability, efficiency or plant operating flexibility a Power Plants economic status depends on its ability to match the market. Alstom Powers Plant|Flexibility can add considerably to both flexibility and efficiency with the installation of a Turbine Bypass System, allowing power plants to be optimized in todays market conditions.
Customer Benefits Reduced start-up times Cost savings Improved unit behavior at load rejection (turbine trip) Reduced CO2 and SO2 emissions

Background
To remain competitive in the electricity market, many aged coal fired power plants have been forced to change operational mode from design base-load to twoshifting or cycling. As there is a fundamental difference in baseand shift load design, some components become more stressed and limitations are then necessary for operation and sustaining performance. This leads to problems such as: Sub optimal start up times and generation capability to allow for temperature management Decreased turbine efficiency due to prolonged Turbine solid particle erosion
Figure 1: Water-Steam-Cycle with new Turbine Bypass Interconnections

Decreased availability due to increased boiler tube leaks from inadequate cooling Leakages at boiler safety valves impacting performance and maintenance High repeated thermal stresses Additionally these inherent designs also limit overall management capability for: High number of start-ups Instability in grid frequency and turbine short term trip fault conditions Matching main steam to turbine metal temperature

Proposed Solution
Installation of a Turbine Bypass System to an existing fossil fired steam power plant, consisting of a high pressure bypass valve and a low pressure bypass valve with steam dump device (see Figure 1). With this arrangement, the boiler can, to a certain degree, be operated independently from the turbine. A turbine bypass system provides the opportunity to improve startup flexibility and ensure cooling steam flow through the superheater and reheater during starts and load rejections.

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Integrated Solutions

HP Bypass System The HP bypass system connects the live steam pipe through the HP bypass valve with the cold reheat pipe. Inside the HP bypass valve, temperature and pressure of the live steam are reduced to cold reheat conditions. The HP Bypass Valve is a steamconditioning valve with a pressure drop (e. g. 160 bar 40 bar) combined with in-body desuperheating through spray-water injection.

LP Bypass System The LP bypass system transfers steam from the hot reheat pipes via LP bypass valve and steam dump device to the condenser. Hot reheat pressure and hot reheat temperature are converted to condenser conditions. The LP bypass valve is designed as a pressure-reducing control valve with an integrated stop valve. This stop valve also protects the condenser and the LP turbine.

Further pressure is reduced in steam dump device. Inside the steam dump device steam is desuperheated spraywater injection prior admission to condenser.

the the by to

Figure 5: Example of steam dump device

Stop Valve

Spray Water Inlet Reheat Steam Outlet

Hot Reheat Steam Inlet

Pressure-reduced Steam Outlet to Dump Tube Control Valve

Live Steam Inlet

Bypass Capacity Variants Depending on Individual power plant load characteristics Grid demands Economical aspects Environmental regulations Alstom has determined three optimised bypass capacity configurations: 1. Start-Up Enhancement 2. Economically Optimal 3. Zero Noise Full Capacity

Figure 2: Example of HP Bypass Valve

Figure 3: Example of LP Bypass Valve

Required Instrumentation and Control for HP and LP Bypass Valves and Steam Dump Device
SG

PC

HP
3

G
IP LP LP

Start-Up Enhancement Capacity HP: 30 % - 60 % mass flow and pressure of MCR Capacity LP: 30 % - 60 % mass flow and pressure of MCR The 30 % (60 %) / 30 % (60 %) capacity for this option is derived from steam flow required to achieve steam conditions mandatory for the start of turbine rotation.

TC

RH
2 Water Supply

PC

4 5 6

1 2 3 4

HP Bypass Control Valve Water Injection Valve HP-Exhaust Check Valve LP Bypass Stop Valve

5 6

LP Bypass Control Valve Steam Dump Device

TC

PC Pressure Control TC Temperature Control

Figure 4: LP Bypass Control

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Integrated Solutions

Economically Optimal Capacity HP: 100 % mass flow and pressure of MCR Capacity LP: 60 % mass flow and pressure of MCR With a 100 % HP bypass, the blowing of main steam safety valves can be avoided and the reheater can be optimally cooled during load rejection. With 60 % LP bypass capacity, the maximum design steam capacity of the condenser will not be exceeded at turbine trip. Reheater safety valves or boiler vent valves will release the excess steam. This configuration will ensure that the capacity of the installed components is adequate for warm and hot starts. Furthermore, the boiler can remain in operation at reduced load (after load rejection) and be ready for further grid demand. Zero Noise Full Capacity Capacity HP: 100 % mass flow and pressure of MCR Capacity LP: 100 % mass flow and pressure of MCR

Figure 6: Example for start-up curve of a hot start (8h shut-down)

If load rejection or turbine trip from full load is required without the blowing of safety valves, then a 100 % capacity HP/LP bypass system is necessary.

This configuration is very attractive for regions where there are stringent noise level requirements.

Benefits
Start-Up
Reduction of start-up time Reduction of start-up fuel and auxiliary power consumption Reduction of solid particle erosion Reduction of thermal stress Water Savings during start-up Higher availability because of faster start-up times Reduction of emissions because of overnight shut-down instead of low-load operation

Option 1 Start-Up Enhancement

Option 2 Economically Optimal

Option 3 Zero Noise Full Capacity

X X X X X X

X X X X X X

X X X X X X

Turbine Trip

Synchronisation

Turbine Speed Turbine Load

Bypass in operation
Turbine Trip Synchronisation

Operation / Trip
Capability of rapid load reduction without blowing of safety valves (% of MCR) Constant reheater cooling capacity (% of MCR) Water savings during turbine trip (% of MCR) Prevention of boiler trip after load rejection Prevention of HP safety valves blowing Reduction of time between load rejection and resynchronization No noise emission at turbine trip 30 % (60 %) 30 % (60 %) 60 % 60 % 60 % X X X 100 % 100 % 100 % X X X X

Turbine Speed Turbine Load

Boiler Trip

Figure 7: Turbine Trip and Resynchronization

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Integrated Solutions

Customer Benefits
Reducing steam path erosion Reduction of thermal stress Reduction of start-up fuel and auxiliary power consumption Reducing steam loss Higher availability because of faster start-up times Reduction of time between load rejection and resynchronization Elimination of minimum offtime between shutdown and restart Reduction of emissions due to overnight shut-down instead of low-load operation

Solution Approach
Feasibility Check-Up Depending on customers operational conditions, Alstom will determine the most suitable bypass configuration. The Feasibility Check-Up includes: Analysis of operation conditions Check of impact on affected components Turbine Trip Calculation Determination of new start-up / shut-down times Layout recommendation Cost estimate Implementation Schedule

Turnkey Bypass Implementation The delivery and construction of a complete bypass solution would include: HP bypass system including water injection and control system LP bypass system and steam dump device including water injection and control system HP exhaust non-return valve (if not already installed) Electronic control and protection system Construction and Commissioning Delivery of technical documentation In addition, Alstom can Improve the level of turbine automation Improve the level of boiler automation Determine the most efficient boiler operation mode (modified sliding pressure operation instead of fixed pressure operation)

Figure 9: LP Bypass Valve and Steam Dump into Condenser

References
The first Alstom reheat turbine with HP / LP bypass system commenced operation in 1954. Since then, Alstom has installed over 300 units with turbine bypass systems. Turbine Bypass System design and operation is a well proven and effective system fitted to most European and new generating steam plant. Alstom is experienced in all the design and operational requirements. Currently, a new build power plant with drum boiler is also built with a turbine bypass system.

Your local service partner:

Figure 8: HP Bypass Valve

ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties without ALSTOMs express written authority is strictly prohibited.

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