ENERGY, ENVIRONMENT, ECOSYSTEMS, DEVELOPMENT and LANDSCAPE ARCHITECTURE

Impact of the HP Preheater Bypass on the Economizer Inlet Header

Abstract: In the case of high pressure preheater tube leakages feed water can ow to the turbine and cause damages. To protect the turbine a hp (high pressure) preheater bypass is installed. When this bypass opens the feed-water inlet temperature will drop by approximately 120K in modern super-critical steam generators causing fatigue due to additional thermal stresses in the economizer inlet header. To get a better understanding of the impact and the numbers of the possible load cycles the results of a transient power plant-simulation by the program ENBIPRO are used as input for the simplied method for calculating fatigue of the EN 12952. Tubes, pipes and heat exchangers are simulated dynamically by using FVM (Finite Volume Method) and solving the resulting equation system by the SIMPLERAlgorithm (Semi Implicit Momentum and Pressure Linked Equations Revised). The FVM calculates all data needed for calculating the temperature distribution over a thick walled pipe like a header. This includes information like uid temperatures and heat transfer coecients. The temperature distribution in the pipe wall itself is calculated in a post processing by using the numerical method of Crank and Nicolson. Based on the transient temperature distribution in the wall pipe the thermal stresses and the fatigue is estimated by using the EN 12952. KeyWords: FVM, SIMPLER, Fatigue, High pressure preheater bypass, EN 12952, Crank and Nicolson

Introduction

In the case that a high pressure preheater tube has a leakage, e.g., a weld fails, feed water of high pressure ows through the leakage to the extraction line of the turbine. If the damper in the extraction line also fails the turbine can be ooded and damaged. For safety reasons a HP preheater bypass is installed to protect the turbine. A ow diagram with the bypass is shown in gure 1. When opening the HP preheater bypass the feed water inlet temperature will drop by approximately 120 K. This temperature dierence is much higher in modern super-critical steam generators than in older ones with lower pressure. Therefore, the thermal stresses in the thick walled components especially in the economizer inlet header have to be checked more accurately. The question is raised how often the HP preheater bypass can be opened before the life time of the economizer inlet header is consumed by fatigue.

Figure 1: HP Preheater Bypass

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Approach

The energy balance of the pipe wall at a certain cross section is: 0 = cR R dR Q0 Qin + dt AR

A fatigue analysis can be performed by either using FEM (Finite Element Method) analysis or by a simplied method like it is described in the EN 12952. In both cases simulation data of uid temperatures and heat uxes to the pipe wall are needed. This data can be generated by transient simulation programs like ENBIPRO that is developed at the Institute for Heat and Fuel Technology at the TU Braunschweig. ENBIPRO is described in [1], [2] and [3] and based on [4], [5] and [6]. ENBIPRO doesnt calculate the temperature distribution in the wall of the pipes. Therefore, in a post processing the uid temperatures and the heat transfer coecients calculated by ENBIPRO are used as input data for a CrankNicolson-Algorithm as described in [7] that solves the transient energy balance inside the pipe wall. The result is the transient temperature distribution in the pipe wall. Based on the temperature distribution a simplied fatigue analysis is performed as described in the EN 12952.

(7)

ENBIPRO discretizes the partial dierential equations system by using a FVM described in [5]. The FVM is solved by using the SIMPLER algorithm described in [4]. The ability of ENBIPRO to couple partial and ordinary dierential equation systems is described in [1].

3.2

Calculation of the Temperature Distribution in the Pipe Wall

The heat ux in the pipe wall of each volume element is modelled by cR R t = 1 R r r r r (8)

Figure 2 shows a discretised pipe wall.

3
3.1

Mathematical Model
ENBIPRO

ri dr

For calculating the water and steam ow inside the tubes and pipes ENBIPRO uses the following numerical models for the momentum, mass and energy balance: p w w2 + Sw t x x w + t x h hw Qin + t x Ast

ra

0 = 0 = 0 =

(1) (2) (3)

Figure 2: Discretizised pipe wall of a thick walled component is regarded as constant. The boundary conditions at the inner side and outer side of the pipe are modelled as dR dr = (R u ) (9)

The mathematical model of the momentum, mass and energy balance of the ue gas side is simplied to: 1 2 dp + R w dx d2 dm dx dmh Q0 dx

0 = 0 = 0 =
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(4) (5) (6)

The discretization of the partial dierential equation is done by using the implicit nite difference method of Crank and Nicolson described in [7]. The algorithm becomes implicit by discretising the storage term over the half time step: t i,k+1 i,k t (10)

1 i,k+ 2

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For all other terms arithmetic mean values of time step k and k + 1 have to be calculated. The result is an implicit equation system for each time step of a tridiagonal structure that can be solved easily by using the TDM-algorithm as it is described in [4].

3.3

Fatigue Analysis

The fatigue analysis is performed for a bore hole in the rst (inner) discretised volume element of the pipe wall by using EN12952 [8] part three chapter thirteen and appendix B and D.

Simulated System and Boundary Conditions

The simulated system is shown in gure 1. It shows the feed water pump, the HP preheater, the bypass, the three way valve, the non return valve and the economizer inlet header. The HP preheater is simulated by only one heat exchanger. The bypass is kept warm by a small mass ow. The temperature distribution and the fatigue is calculated in the rst cross section of the economizer inlet header because the thermal stresses are highest due to the fastest temperature change

and highest mass ow. The economizer inlet header is overown by ue gas like in current two pass boiler designs. During the simulation the three way valve stops the mass ow through the HP preheater within ve seconds. The geometries of the components of the original design have been slightly modied. During the simulation the feed water temperature upstream of the economizer will drop by 117 K. The mass ow of 325 kg/s is constant, the inner diameter of the economizer is 114 mm and the wall thickness 55 mm. The connected economizer heat exchanger tubes have an outer diameter of 44.5 mm and a wall thickness of 6.3 mm. The pipe material is 13CrMo45. The feed water has an inlet temperature of 315 C at the beginning and a constant pressure of 320 bar. The ue gas has an inlet temperature of 357 C and a mass ow of 296.7 kg/s.

Results

Figure 3 shows the temperature distribution over the time and the wall of the rst cross section of the header wall. It can be seen that the temperature drops very fast at the inner surface of the header.

Temperature in C over the Header Wall and Time

330 320 310 300 290 280 270 260 250 240 230 0.17 0.16 0.15 0.14 Radius in m 0.13 0.12 10 12 14 16 0.11

330 320 310 300 290 280 270 260 250 240 230

4 6 8 Time in s

Figure 3: Temperature distribution in the pipe wall

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Figure 4 shows the most important temperature curves over the time. For calculating the fatigue the temperature of the inner surface and

the integral average pipe wall temperature are needed.

Temperature over the pipe wall 450 400 Temperature in C 350 300 250 200 0 2 4 6 8 Time in s Figure 4: Wall and Fluid Temperatures The integral average temperature is dened by 2 2 2 ro rin
N

Water Temperatur Inner Header Wall Temperature Integral Header Temperature Outer Header Wall Temperatur Flue Gas Temperature

in in in in in

C C C C C

10

12

14

m =

ri ri
i=1

(11)

destroy the magetite lm. This will have an impact on the wall thickness and the life time of the turbine. But it should not be necessary to have an emergency shut down of the boiler because the frequency of a failure of a HP preheater is very low.

To protect the magnetite lm the maximum thermal tension at the inner side of the bore hole N has to be less than 200 mm2 . The protection of the magnetite lm stipulates the maximum temperature dierences in the pipe wall. In the simulated case the maximum temperature dierence as dened by EN 12952 is 39K and the maximum temperature decrease velocity is 0,35 K/s. The simulated maximum temperature dierence is 63 K and the simulated maximum temperature transient is 12 K/s. The number of allowable cycles till the starting of crack is approx. 5000.

Conclusion and Outlook

That means that even with new super-critical boilers and high temperature rise in the HP preheaters the bypass can be used, but each use will
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Symbols
Symbol A c d h l m p Q r Sw t w x R Unit m2 J/(kgK) m J/kg m kg/s Pa W/m m N/m3 s m/s m W/(m2 K) W/(mK) kg/m3 Description Cross section area Specic heat capacity Diameter Enthalpy Pipe length Mass ow Pressure Heat ux per unit length Radius Source term Time Velocity Axial coordinate Heat transfer coecient Friction coecient Heat conductivity Density

References: [1] H. Zindler, Dynamische Kraftwerkssimulation durch Kopplung von FVM und PECE Verfahren mit Hilfe von Adjungiertenverfahren, Fortschritt-Berichte VDI Reihe 6 Energietechnik, Nr. 573 [2] G. Stamatelopoulos, Berechnung und Optimierung von Kraftwerkskreislufen, a Fortschritt-Berichte VDI Reihe 6 Energietechnik, Nr. 340 [3] Epple; Leithner; Linzer; Walter; Simulation von Kraftwerken und wrmetechnischen Ana lagen, 2009, ISBN 978-3-211-29695-0 [4] S. Patankar, Numerical Heat Transfer and Fluid Flow, Hemisphere Publishing Corporation, 1980 [5] H. Walter, Modellbildung und numerische Simulation von Naturumlaufdampferzeugern, Fortschritt-Berichte VDI Reihe 6 Energietechnik Nr.: 457, Wien 2001 [6] K. Brenan, S. Campbell, L. Petzold, Numerical Solutions of Initial-Value Problems in Dierential-Algebraic Equations, siam, 1995 [7] Stephan/Bhr, Wrme- und Sto bertraa a u gung, Springer Verlag [8] EN 12952 Wasserrohrkessel genkomponenten und Anla-

Index in i, k m N o u R st w

Description Inside Counting indices Mean Maximum number Outside Fluid Tube Steam Wall

[9] J. Bausa, Dynamische Optimierung energie- und verfahrentechnischer Prozesse, Fortschritt-Berichte VDI

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ISBN: 978-960-474-125-0