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final superheater SH3. This heat exchanger accessories are defined according to the boiler
operates in a cross-flow regime (vertical gas manufacturer estimations [2]. The calculations
flow - horizontal tubes). The superheater is are performed using Matlab and it is therefore
composed of 34 vertical sections (tube banks convenient to work with the equivalent length
parallel to the plane of fig. 1). Each section is coefficients in the corresponding matrices. The
composed of ten tubes which in their way expressions for the hydraulic computation are:
upwards undergo a series of eight horizontal
folds. Steam is supplied from two different m- p A v
2
headers to two groups of 17 sections each. The &p= Rm (2)
headers locations for the two groups are
different. Two typical hydraulic paths arise
then in this analysis as steam flows from all where p denotes the density Of steam, A the
tubes into the outlet header. The influence of cross sectional area, v the velocity, / the
changes in the internal diameter and length of friction coefficient, D the internal diameter, ^?
some of the tubes was examined. the hydraulic resistance and Ap the pressure
loss. The length L is given below with lMb as a
from HP loss coefficient.:
turbine
\Lluhi, for straight tubes,
= \ NhD (3)
for bends and other accesories.
f
The resistance for elements in series is:
toLP
turbine (4)
545
Esl Alur€ rtormalizftd to Ih6 3't<
stands for the mass flow rate per unit area 0 84
a«ttft
heat transfer coefficient: 0.76
i3 0 74'
,,0.61 7K°- k0.61 s
G«
0.287- H 0.39 ,,0.28 (7) 0 72*1-
fl*
D, 0.7
10 20 30
lube number
where D" stands for the outer tube diameter.
Fig. 2: Normalized wall temperatures.
The relations for convection heat transfer from
the gas to the tube and from the tube to the Heat transfer coefficients estimation
steam are:
A different approach must be used when the
correlations for the heat transfer coefficients
are not provided ( 72 MW unit). The solution
(8a,b,c) would require a detailed CFD simulation of the
flow and heat transfer. However, the size and
o//|
rri Ci/tul m
geometry of the superheater made a full CFD
T1 —
treatment too large for practical purposes. The
steam flow in the 168 tubes was controlled by
Qi denotes the heat flow transferred to the i* orifices of different diameters, which makes the
control volume and TWs the external wall geometry of the pipe not relevant for pressure
temperature. Conservation of energy for gas drop (mass flow rate) calculations. The heat
and steam is formulated as: flow was calculated for a typical single tube
using a CFD code. The superheater was
modeled using an equivalent geometry which
(9a,9b) allowed for fully developed flow (equivalent
pipe length) and both the pressure drop and the
heat transfer were introduced as localized
sources (lumped parameters within the CFD
H denotes the enthalpy and rh§H?i the part of
code). Heat balances were checked by
the gas mass flow rate which transfers heat to
calculating for each seven tubes panel (24 of
the superheater (recall that it is in parallel with them).
the steam generator on the wall), given by:
Qsm Conclusions
mSH3 + mwall (10)
iwall Modern computational means enable the
building of combined engineering models, in
The heat flows are obtained from the integral the whole range of detail, from integral
heat balance. Finally heat conduction through balance, through lumped parameter to full field
the wall yields: CFD simulation. In this work, some of these
2/r k L, options were used. The model used for the
Qi = - T\ w 00 large unit allows for a detailed mapping of the
heat flux, steam, gas and metal temperatures
under steady state conditions operation.
The above constitutes a system of five
Superheater wall temperatures were below the
nonlinear equations with five unknowns,
allowable limit for both designs. Failure was
namely, & , T*"'",Kml T,Kml, T?s, T** foreach attributed to the graphytization tendency of the
tube. In the upper (outlet) bank, the elementary steel used for the tubes in question found in the
control volume is split and the number of specimens extracted from the failed tubes. The
unknowns raises to ten. The overall heat influence of design changes can be evaluated
balance is checked once the solution is as shown in the work.
obtained. Some of the results will be displayed
to illustrate the model capabilities. The References
estimated maximum tube temperatures [1] Burmeister, L. C , 1983. "Connective Heat
normalized to the maximum allowable value Transfer". John Wiley & Sons, Inc.
are shown in fig. 2 for two different tube
thickness series of data. [2] Babcock & Wilcox, 1992. "Steam, its
Generation and Use", 401'1 edition.
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