Supercritical Boiler Technology

Operation

Feb. 2007 R.Kral 1

 Operation Mode of Power Plants

Sliding pressure Sliding pressure

or constant Pressure
pressure 250
G
~ bar Constant pressure

200

150

100

Sliding pressure
50

0
0 20 40 60 80 %100
Load

Feb. 2007 Supercritical Boiler Technology R.Kral 2

Source: Siemens
 Comparison of Different Operation Modes

Variable Pressure Constant Pressure

Turbine
o
C (downstream first stage) o
C Turbine
(downstream first stage)
500 500

400 400 Separator

Separator

300 300

20 50 Load [%] 100 20 50 Load [%] 100

Maximum Load Change Rates Maximum Load Change Rates

Turbine 10 Turbine 1-3

% %
Boiler 7 min Boiler 7 min

Plant 7 Plant 1-3

Feb. 2007 Supercritical Boiler Technology 2a R.Kral 3

Source: Siemens
 Power Plant Design is Defined by the Requirements

Boiler Operation Mode

Requirement Drum Type: Once-Through: Turbine with control Turbine without

Evaporator with stage: control stage:
- natural circulation
constant sliding constant sliding
- forced circulation const. pressure const. or sliding
pressure pressure pressure pressure
supercritical pressure; sub- or
supercritical

• Base load (∼∼ 1000 Start Up) x x x x x x x

• Intermediate peaking / x x x

two-shift Operation
∼ 5000 start-up)
(∼
– many fast load changes
– short start-up times

• Large load step changes (∼∼ 10 %) x x x x 1*

• High plant efficiency x x x x x

1*: Mod. sliding pressure

Feb. 2007 Supercritical Boiler Technology 6 R.Kral 4

Source: Siemens
 Typical Power Plant Design

Preferred
used in
Drum Type Boiler, Constant Pressure Operation, Turbine with Control Stage
S.E.Asi
a
for USA
Base Load and large Load Step Changes
OT-Boiler with Supercritical Evaporator, Constant Pressure Operation,
Turbine with Control Stage USA
for
Base Load with high Efficiency

O.T. Boiler, Sliding Pressure Operation, Turbine without Control Stage Europe
for Japan
Base Load and Two-Shift-Operation with high Efficiency

Feb. 2007 Supercritical Boiler Technology 7 R.Kral 5

Source: Siemens
 Main Steam to Turbine

- +
SP Main Steam Temp.
+
+ +
- + ∆T=f(Load)
+
PI Load Index

- + ∆T=f(Load)
+
+ +
Super
+ - +
heater
PI y = f (x) y = f (x) y = f (x)
Enthalpy
Trim SPh SPFW SP∆h
+ +
I
- +
.
∆QDesign
h -
Water/Steam Enthalpy
+ TEvap
PI = f (p)
Separator Controller + dx
- d t
metal heat
+ + absorbtion
A
Eva- - MV∆h + B

y = f (x)
porator SP FFW
+ -
PI
FFW, min
Economizer M A X

- +
PI

h
SP: Set Point
FW: Feedwater
F: Mass Flow M
h: Enthalpy
T:Feb.Temperature
2007 R.Kral 6
.
Q: Heat input across evaporator
MV: Measured Value Feedwater Pump
 Comparison of Feedwater Control Concepts
Load reduction from 100% to 50%

Evaporator outlet temperature

Previous feedwater
470 control concept
°
New feedwater
460 control concept
with allowance for
450 - inlet enthalpy
- storage of thermal
energy
440

430

420

410

400
0 250 500 750 1000 1250 s 1500
Time

Feb. 2007 Supercritical Boiler Technology R.Kral 7

Source: Siemens
 Boiler Follow Mode

Main Steam Pressure

Boiler Outlet Target Load

S
Heat Balance
PID
S
Set Point Turbine
Main Steam Controls
+
Pressure
-Speed
- -Load
-Initial
Pressure
m& Feedwater
G
M

Boiler
Controls
Boiler Demand Generated
M
Power

m& Fuel / m& Combustion − Air

Feb. 2007 Supercritical Boiler Technology R.Kral 8

Source: Siemens
 Turbine Follow Mode

Main Steam Pressure

Boiler Outlet

Boiler Demand

Turbine
Controls
+
S -Speed
- -Load
Set Point -Initial
Main Steam Pressure
m& Feedwater Pressure
G
M

Boiler
Controls
Generated
M
Power

m& Fuel / m& Combustion − Air

Feb. 2007 Supercritical Boiler Technology R.Kral 9

Source: Siemens
 Coordinated Load Control

Main Steam Pressure

Boiler Outlet

Coordinated
S Control
Set Point PID Turbine
Load Controls
+
t
-Speed
Set Point - -Load
Turbine -Initial
Pressure
m& Feedwater
G
M

Boiler
Controls
Boiler Demand Generated
M
Power

m& Fuel / m& Combustion − Air

Feb. 2007 Supercritical Boiler Technology R.Kral 10

Source: Siemens
 Coordinated Initial Pressure Control

Main Steam Pressure

Boiler Outlet

Coordinated
S Control
Set Point PI
Turbine
Load Controls
+
t
-Speed
Set Point - -Load
Turbine -Initial
Pressure
m& Feedwater
G
M

Boiler
Controls
Boiler Demand Generated
M
Power

m& Fuel / m& Combustion − Air

Feb. 2007 Supercritical Boiler Technology R.Kral 11

Source: Siemens
 Start - up Systems for O.T. Boilers

Superheater Circulation
Pump IP /
HP
or LP
Separator Feedwater tank
or
Heat exchanger
Evaporator or
Flash tank
or Reheater
Economizer Atmpspheric
flash tank

Feb. 2007 Supercritical Boiler Technology R.Kral 12

Source: Siemens
 Start - up System with and without
Circulation Pump

Turbine Turbine

For Base Load For DSS

operation
operation

atm. flash atm.flash

tank tank

Feb. 2007 Supercritical Boiler Technology R.Kral 13

Source: Siemens
 Water Steam Separator / Water Collecting Vessel –

To superheaters

Water steam separator Water collecting vessel Level tap

From
evaporator From separators
Tangential inlet
nozzles

Min. flow
To flash tank

Vortex breaker

Level tap

Water injection

To water collecting vessel To circulating pump

Feb. 2007 Supercritical Boiler Technology R.Kral 14

Source: Siemens
Feb. 2007 R.Kral 15
Feb. 2007 Supercritical Boiler Technology R.Kral 16
Source: Siemens
Feb. 2007 Supercritical Boiler Technology R.Kral 17
Source: Siemens
 Start-Up Times [min] of Power Plants
with HP-and LP-Bypass Stations

300
300 -- 700
700 MW
MW
Plants with Drum Boiler Plants with BENSON Boiler
167 bar / 538°C / 538°C 250 bar / 540°C / 560°C

From ignition to: From ignition to:

After shut first steam full load first steam full load
down hours to Turbine to Turbine

<2 25 60 15 50

8 40 90 25 75

48 80 220 60 200

Cold start (150 °C) 150 370 - 450 60 280 - 360

Feb. 2007 Supercritical Boiler Technology R.Kral 18

Source: Siemens
 Requirements for the Provision of
Reserve Capacity for Frequency Control

Feb. 2007 Supercritical Boiler Technology R.Kral 19

Source: Siemens
 Actions to Implement Fast
Load Changes

1 Main steam control valves

2 no longer throttled
2 Opening of multistage valve

1 3 Shutdown of LP feed
5 heaters
4 Shutdown of feed water tank
5 Increase of spray water flow
6 Shutdown of HP feed heaters
6 (not recommended)

Actual power
Control device
for reserve Specified
capacity power
4
3

Feb. 2007 Supercritical Boiler Technology R.Kral 20

Source: Siemens
 Condensate Throttling Process

Feb. 2007 Supercritical Boiler Technology R.Kral 21

Source: Siemens
 The Inlet Stage for the Interstage Valve can be
Behind Stage 3, 4 or 5
Inlet Zone for Interstage Valve Drum Blading

Additional Control Valve for Overloads Balance Piston Ring

for sealing or
designed leakages
Interstage valves guarantee an immediate increase in output

Feb. 2007 Supercritical Boiler Technology R.Kral 22

Source: Siemens
 Activation of Reserve Capacity

Feb. 2007 Supercritical Boiler Technology R.Kral 23

Source: Siemens
 Heat Rate for the Provision of
Reserve Capavcity

Feb. 2007 Supercritical Boiler Technology R.Kral 24

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by fuel

12

10

10% Step optimized

8
Load [%]

Reihe2
10%Step
6 Reihe1
5% Step Reihe3

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 25

Source: Siemens
 Reserve Capacity for Frequency Control

Condensate stop (water, water and steam)

12

10

8
Load [%]

Reihe1
6
Reihe2

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 26

Source: Siemens
 Reserve Capacity for Frequency Control

Control Valve Throttling

12

10

8
Load [%]

Reihe1
6 Reihe2
Reihe3

4
Once through10%

2
Once through 5% Drum5%

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 27

Source: Siemens
 Reserve Capacity for Frequency Control

1 HP heater shut down

12

10

8
Load [%]

6 Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 28

Source: Siemens
 Reserve Capacity for Frequency Control

Additional spray flow: 4% HP, 6% RH

12

10

8
Load [%]

6 Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 29

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by 10% fuel step

+condensate and steam stop

14

12

10

8
Load [%]

Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 30

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by 10% fuel step

+ condensate and steam stop + 5% control valve throttling

14

12

10

8
Load [%]

Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 31

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by 10% fuel step + condensate and steam stop

+ 5% control valve throttling + additional spray flow

14

12

10

8
Load [%]

Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 32

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by 10% fuel step + condensate and steam stop

+ 5% control valve throttling (drum boiler) + additional spray flow

14

12

10

8
Load [%]

Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 33

Source: Siemens
 Reserve Capacity for Frequency Control

Load change by 10% fuel step + condensate and steam stop

+ 5% control valve throttling + additional spray flow + 1 HP heater stop

14

12

10

8
Load [%]

Reihe1

0
0 30 60 90 120 150 180 210 240
Time [sec]

Feb. 2007 Supercritical Boiler Technology R.Kral 34

Source: Siemens
 Text

Feb. 2007 Supercritical Boiler Technology R.Kral 35

Source: Siemens
 Plant Net Heat Rate Difference to Basis (1)

30.00
Heat Rate
Difference Spray control
[kJ/kWh] 20.00

Cold gas recirculation Damper control

10.00

0.00
60 Basis 80 100
-10.00
Hot gas recirculation

-20.00

-30.00

-40.00
Load [%]

Feb. 2007 Supercritical Boiler Technology R.Kral 36

Source: Siemens
 Plant Net Heat Rate Difference to Basis (2)

50.00
Spray control
Heat Rate
Difference Cold gas recirculation
[kJ/kWh]
0.00
20 40 60 80 100
Basis
Damper control

-50.00
Hot gas recirculation

-100.00

-150.00

-200.00
Load [%]

Feb. 2007 Supercritical Boiler Technology R.Kral 37

Source: Siemens
 Reheater Control

44 Reihe1
Eta net [%]
Reihe2
43,5 Reihe3
Reihe4
43 Reihe5

42,5 1 Basis (w.o.control)

2 Spray control
3 Damper control
42
4 Hot gas rec
5 Cold gas rec
41,5

41
Basis
40,5

40
20 40 60 80 100
Load [%]

Plant Net Efficiency

Feb. 2007 Supercritical Boiler Technology R.Kral 38

Source: Siemens
 Features of a One Stage Reheater

With exception of the spray control method all systems can be designed with a
One Stage or with a Two Stage Reheater. Therefore it is necessary to compare
both solutions.

Features of a One Stage

Reheater

No intermediate header: the investment costs are reduced.

No intermediate header: this leads to a smaller pressure loss and better efficiency.

Temperature imbalances are considerably larger (20K-50K): as a consequence

the material design temperatures increase. Especially in units with elevated steam
conditions this fact might be of great importance.

Orifices at the inlet of the single tubes: they are necessary to evenly distribute
the flow and to reduce the outlet temperature imbalances. The benefit of a smaller
pressure loss for the One Stage Reheater vanishes.
Feb. 2007 Supercritical Boiler Technology R.Kral 39
Source: Siemens
 Summary

Cold gas recirculation is expensive with no advantages in heat rate.

Hot gas recirculation reduces heat rate and gives some flexibility against
changing furnace heat absorption.

Damper control reduces heat rate and has the highest flexibility against changing
furnace heat absorption. References are available only in 2-pass boilers.

Spray control has higher heat rate at full load but lower heat rate at loads below
80%. The flexibility against changing furnace heat absorption is limited. It is the
only concept with high control quality and has the highest availability.

The basic version is more expensive than the boiler with spray control and in
addition it has some operational disadvantages. The high full load efficiency can
only be achieved with the design furnace heat absorption.

Feb. 2007 Supercritical Boiler Technology R.Kral 40

Source: Siemens
 Result

For base load plants and plants with changing fuel quality:

Damper control
with spray attemperators between the two stages;
without emergency spray

All other plants:

Spray control

Feb. 2007 Supercritical Boiler Technology R.Kral 41

Source: Siemens