FOSTER WHEELER POWER GROUP, INC.

FWPG BENSON VT BOILER PROCESS AND OPERATIONAL DESCRIPTION

1.0 1.1 1.1.1 PROCESS DESCRIPTION BENSON Vertical Boiler Description General

The Foster Wheeler-BENSON Vertical Tube (VT) once-through, supercritical steam generating unit consists of a vertical tube water wall furnace, primary superheater, platen superheater, finishing superheater, convection reheater, and economizer. Main steam temperature is controlled by a combination of two (2) spray water attemperators and fuel/feedwater flow control. Reheat steam temperature is controlled by gas flow proportioning through the parallel pass heat recovery area (HRA). Therefore Foster Wheeler can guarantee absolutely zero RH spray flow under steady state conditions. An emergency spray water attemperator is provided in the reheat inlet piping for transient operation only. The unit fires pulverized coal through Foster Wheeler Low-NOx burners. Each burner will incorporate a light oil ignitor, and the corresponding flame detectors. Secondary air flow control to each level of burners served by a single pulverizer is independently controlled for finer combustion control. The patented Foster Wheeler ECT PC online coal measurement system provides optimized burner air flow adjustment as a function of coal distribution. Each of multiple Foster Wheeler MBF medium speed, vertical shaft, roller type coal pulverizers feeds a row of four (4) burners. The boiler will have the capability to achieve full load operation with one (1) pulverizer out of service. Combustion air will be provided by axial flow type forced draft fan(s), and centrifugal type primary air fan(s). The furnace draft system will included axial flow type Induced draft fan(s), as well as tri-sector regenerative airheater(s) and electrostatic precipitator.

1.1.2

BENSON Vertical OTU Technology. Critical to the design of a supercritical oncethrough boiler is the design of the furnace steam/water evaporator circuitry, the associated startup system, and how they are integrated with the firing and heat recovery area (HRA) systems. The boiler offers the latest advancements in once-through supercritical boiler technology by integrating the BENSON Vertical OTU technology into the Foster Wheeler OTU boiler system.

To provide safe and reliable operation of a once-through supercritical boiler requires minimizing peak tube metal temperatures and limiting the temperature differential between adjacent enclosure tubes. The BENSON Vertical boiler addresses these issues in the following unique and effective ways:

Natural Circulation Flow Characteristic. In a once-through boiler which operates at supercritical pressure, there is no distinction between liquid and vapor phases, and there is a continual increase in fluid temperature. With radial unbalances in heat absorption (caused by tube geometric position, burner heat release pattern, and furnace cleanliness), and variations in flow rate (caused by to hydraulic resistance differences from tube-to-tube), variations in tube temperatures occur. High differential temperatures induce high thermal stresses which, if not limited, can result in tube failure. Historically, this issue has been addressed in two different ways:

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In units with multiple passes in the furnace evaporator, the differential temperature is limited by the fact that each pass picks up a fraction of the total evaporator duty which limits the magnitude of the unbalance and intermediate mixing occurs before the fluid is distributed to the next downstream pass. However, with multiple passes, the furnace must operate at supercritical pressure to avoid the difficulties of uniformly distributing a steam-water mixture to the down stream passes. In units with a spiral tube configuration, the unbalance issue is addressed by having each inclined tube pass through the varying heat absorption zones so that each tube absorbs approximately the same amount of heat. With a single up-flow pass, the spiral design can operate with variable pressure steam which minimizes part load auxiliary power requirements and allows matching of steam and turbine metal temperature for extended steam turbine life. However, the spiral tube evaporator configuration requires a special support system for the inclined tubes which are not self-supporting.

In the FW BENSON Vertical design, the furnace enclosure is formed from a single, upflow pass of vertical tubes (rifled in the lower furnace, smooth-bore in the upper furnace) as illustrated in Figure 1-1. The tube size and spacing is selected to provide a low fluid mass flow rate of approximately 1000 kg/m2-s. As illustrated in Figure 1-2, with this low mass flow rate, the frictional pressure loss is low compared to the gravitational head, and as a result, a tube that is heated strongly, i.e., absorbs more heat, draws more flow. With an increase in flow to the strongly heated tube, the temperature rise at the outlet of the tube is limited which limits the differential temperature between adjacent tubes.

Figure 1-1 BENSON Vertical OTU

Optimized Rifled Tubes. To minimize peak tube metal temperatures, multiple pass and spiral types designs use high fluid mass flow rates to achieve good tube cooling. However, high fluid mass flow rates results in high pressure losses as well as a oncethrough flow characteristic which, as illustrated in Figure 1-3, means that strongly heated tubes have a reduction in fluid mass flow and a correspondingly high increase in fluid and therefore metal temperature which can result in excessive tube-to-tube temperature differentials.

Figure 1-2 Natural Circulation Characteristic

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Figure 1-3 Once-Through Characteristic

As noted above, the BENSON Vertical technology is characterized by low fluid mass flow rates. Normally, low fluid mass flow rates do not provide adequate tube cooling when used with smooth tubing. However, unique to the BENSON Vertical technology is the use of optimized rifled tubes to Figure 1-4 Optimized vs. Standard Rifling eliminate this concern. The greatest concern for tube overheating occurs when the evaporator operating pressure approaches the critical pressure. In the 210 to 220 bar (3055 3200 psig) pressure range the tube wall temperature required to cause film boiling (departure from nucleate boiling DNB) quickly approaches the fluid saturation pressure. DNB will occur in this region and a high fluid film heat transfer coefficient is required to suppress the increase in tube wall temperature. As shown in the example in Figure 1-4, standard rifled tubing will provide an improvement in heat transfer. However, full load mass flow rate of approximately 1500 kg/m2-s would be required at full load to have a sufficiently high heat transfer coefficient at reduced loads when passing through the critical pressure. This mass flow rate would be would be too high to achieve a natural circulation flow characteristic as described above. What permits the use of the a lower full mass flow rate is an optimized rifled tube rib configuration that will improve tube cooling as illustrated in Figure 1-4. Extensive laboratory and field testing has been conducted to define the optimum rib geometry (lead angle, rib height, corner/ edge rounding, etc.) that will provide the best enhancement to heat transfer. The benefits of the low mass flow rate FW-BENSON Vertical evaporator design can be summarized as follows: Self compensating to accommodate heat absorption variations Excellent tube cooling with optimized rifled tubes
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Simple, self-supporting vertical tubes with standard support system Low pressure loss for improved plant efficiency Full variable furnace/superheater pressure for cycling or two-shift operation Low minimum once-through load (BENSON load); not limited by min. mass flux

1.1.3 Steam/Water Circuitry. The steam and water flow circuitry is schematically illustrated in Figure 1-5.

Figure 1-4 Steam/Water Circuitry Diagram

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1.1.4 Economizer. Feedwater is introduced into the unit through the economizer inlet header. It flows through the economizer tube elements, and from each end of the outlet header to a common, external, unheated transfer pipe to the furnace to ensure a uniform entrance conditions into the furnace evaporator. Feeder pipes uniformly distribute subcooled feedwater to the furnace wall panel lower headers. 1.1.5 Evaporator. The furnace circuitry consists of a lower section with optimized, vertical rifled tubes that extend up to a transition header located at an elevation below the furnace nose. Above this location, vertical smooth bore tubes extend up to the furnace roof, and also form the furnace exit screen and part of the vestibule side walls. The tube panels that form the furnace enclosure are of Monowall type construction. Risers pipes extend from the furnace enclosure upper headers and are routed to a collection header from which the flow is directed to a final evaporator pass that forms the furnace nose, vestibule floor and approximately half of the vestibule sidewalls. The furnace enclosure tube size and spacing were selected to provide a low mass flux (nominally 1000 kg/m2-s at full load) to provide a natural circulation flow characteristic (as described above) to accommodate radial heat absorption variations around the perimeter of the furnace. Tube sizes and spacing, membrane fin sizes, and materials are all selected to provide a long-term, trouble-free life in cycling and base load service. The final evaporator pass that forms the furnace nose, vestibule floor, and part of the vestibule sidewalls is provided to act as buffer circuit to minimize tube temperature differentials between the furnace evaporator walls and the adjacent HRA enclosure superheater panels during start-up and transient conditions. The interface between evaporator and superheater tubes is positioned near the center of the vestibule to avoid structure discontinuities such as enclosure corners where stress concentrations are the greatest. From the vestibule enclosure, steam is directed to three (3) in-line steam/water separators connected in parallel, which are part of the start-up system which is described below in a subsequent section. 1.1.6 Superheaters. From the in-line steam/water separators the fluid passes through the superheater circuitry which includes the furnace roof, half of the vestibule sidewalls and heat recovery area (HRA) enclosure, the primary superheater located in the outboard pass of the parallel pass HRA, the furnace platen superheaters, and the pendant finishing superheater at the furnace exit. Spray water attemperators are positioned upstream of the furnace platen superheaters, and the pendant finishing superheaters for initial rapid final main steam temperature control which is coordinated with the feedwater and firing rate controls. 1.1.7 Reheater. Reheat steam is first heated in the inboard pass of the Heat Recovery Area (HRA). The reheater tubes then extend into the vestibule area to achieve the final reheat steam temperature. Reheat steam temperature is controlled by gas flow proportioning through the parallel pass HRA. A spray water attemperator is provided in the inlet piping for transient conditions. 1.1.8 HP/LP Turbine Bypass. A complete and comprehensive turbine bypass system can be comprised of many interlinked and coordinated components. The bypass system incorporates a dual operating function, i.e., controlled reduction of both pressure and temperature. These valves incorporate the latest technology in pressure
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reducing/low noise trim designs to handle the flow and reduction of pressure energy to acceptable levels. However, since steam throttling in a control valves are an isenthalpic process, desuperheating is required to control the discharge temperature and enthalpy levels. As a result, the valves are equipped with a special spraywater injection system that produces a finely atomized and evenly distributed water interface for rapid vaporization and steam temperature control. The bypass system is supplied with two control inputs due to its role in the unit control scheme. Besides use during start-up and shutdown of the unit the valve must also act to relieve pressure during a turbine trip or load rejection. An additional discrete input is included that will rapidly ramp the valve open, to a predetermined position, before reverting to a modulating configuration in accordance with the boiler control requirements. Actuation of the turbine bypass valves is critical, in a trip situation, to maintain system stability and limit the release of costly steam and condensate to the atmosphere. The turbine stop valves normally close in 0.2-0.3 seconds. To compensate for this, the bypass valves are usually equipped with electro-hydraulic actuation and positioning equipment. This provides the necessary positioning speed, and resultant alternate flow path, to counteract the pressure buildup resulting from the isolation of the boiler piping circuit when the turbine valves close. Where codes allow the HP/LP bypass system is sized to replace the function of boiler superheater safety valves.

1.2

Operation

1.2.1 Start-Up System. Before fuel can be fired in a once-through boiler, a minimum fluid mass flow rate must be established within the evaporator tubes that form the furnace enclosure to protect the tubes from overheating. This minimum flow can be provided by the feedwater pump or preferably, by a recirculation pump that returns the heated water back to the boiler in a closed loop for maximum heat recovery. During this start-up phase the boiler is controlled similar to a drum type unit by having in-line steam/water separators (Figure 1-6) downstream of the evaporator (refer to Figure 1-5) to separate liquid and vapor phases. The load at which boiler control is switched from drum type control to a once-through mode is called the BENSON load (typically 25% load ). Separated water is drained to a water collecting Figure 1-6 Steam/Water Separator vessel from which the water is pumped back to back to the economizer. To ensure that subcooled water enters the pump, a small amount of cold feedwater is piped to the pump inlet line. The design includes three (3) tangential type separators with the water collecting vessel integrated with the center separator. The separator design is an optimized configuration developed to minimize pressure loss and also, vessel size. During initial firing, the inventory of water within the evaporator expands. Excess water is drained from the water collecting vessel to a flash tank to maintain an acceptable water level within the water collecting vessel.
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1.2.2 Start-Up Modes of Operation. The unit is capable of being quickly started, synchronized, ramped to full load. For reference, typical BENSON boiler start-up curves for cold, warm, hot, and very hot conditions are included in Figures 1.7, 1.8, 1.9, and 1.10. The curves show steam pressure, temperature and flow with respect to time during the start-up period, matching conditions for steam temperature and metal temperatures of turbine HP and IP rotors and casing, as well as time from boiler light-off to turbine rolling, from turbine rolling to synchronization, and loading up to fuel load. Actual values for this project will vary based on the finalized steam parameters, selected BENSON load, and steam turbine requirements. 1.2.3 Cold Start-Up Procedure. Referring to Figure 1-11, the typical sequence of events for start-up of a BENSON once-through boiler is as follows: Main steam header mean temperature <200 C 1. 2. 3. 4. 5. Raise the temperature of the feedwater in the feedwater tank to at least 248F (120C). Set the drain regulating valve (V-1) behind the water collecting vessel to Regulate. Open the H.P. & L.P. Bypass Valves and switch on their temperature control. Start the boiler feed pump and fill the economizer and evaporator until the water level in the water collecting vessel rises and the drain regulating valve (V-1) begins to lift. Reduce the feedwater flow rate (down to about 5% MCR).

Establish minimum flow in evaporator 6. 7. 8. 9. 10. 11. 12. Start the recirculating pump. (P-1) Slowly open the recirculation regulating valve (V-2) to about 50% and switch on the pump minimum recirculation control (V-3). Open the subcooling valve (V-4). Reduce the feedwater flow to the minimum fluid mass flow rate adjusting the feedwater regulating valve (V-2). Set the feedwater to automatic control when the evaporator minimum flow set value deviation is zero. The drain regulating valve (V-1) will close until only the subcooling flow is being taken from the recirculation loop. Start the ID & FD fans; purge the air and flue gas systems.

Commence firing 13. When the feedwater chemistry improves to a maximum conductivity of 1.0 S/cm2 commence firing and increase the firing rate to about 5%, limiting the water/steam separator outlet temperature to 500F (260C).

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Figure 1-7 Typical Cold Start-Up

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Figure 1-8 Typical Warm Start-Up

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Figure 1-9 Typical Hot Start-Up

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Figure 1-10 Typical Very Hot Start-Up

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Figure 1-11 Steam/Water Circuitry Design

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14. 15. 16. 17. 18. 19.

Steam formation in the furnace tubes causes a small amount of water to be expelled from the evaporator shortly after firing commences. Excess water in the water collecting vessel is discharged from the recirculation loop via the drain regulating valve (V-1). As steam generation increases, the quantity of water deposited in the water collecting vessel falls and the recirculation flow reduces. Simultaneously the feedwater control increases the flow rate to maintain the evaporator minimum flow constant. Set the pressure set value for the L.P. Bypass Station and place it on automatic pressure control. The L.P. Bypass Station will regulate the proper pressure in the reheater.

Raise firing rate 20. 21. When the flow and cooling of the reheater is adequate and the feedwater conductivity is no greater than 0.5 S/cm2, increase the firing rate to 10%. Switch on the main steam and reheat steam temperature control systems before the temperatures reach the set values.

Warm steam lines and turbine 22. 23. 24. In the meantime, warming-up of the main steam line and the turbine admission section and subsequently starting of the turbine can begin. Match the steam pressure to the requirements of the turbine by throttling at the H.P. Bypass Station; switch on the pressure control for the H.P. Bypass Station if necessary. Match the superheater outlet temperatures to the requirements of the turbine by varying the temperature control set values according to the permissible gradients and increasing the firing rate if necessary. As the turbine steam demand increases, the HP and LP bypass stations close. When the flow rate of generated steam equals the minimum fluid mass flow value through the evaporating section, the recirculation regulating valve will be dosed.

25. 26.

The Boiler is now in once-through operation 27. 28. 29. 30. Switch off the evaporator minimum flow control and switch on the feedwater control for once-through operation. Switch off the recirculation control. Stop the the recirculating pump (P-1). Close the subcooling valve.

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Raise load 31. 32. Raise the unit firing rate and output according to the permissible pressure and temperature gradients. By using the HP/LP turbine bypass system the boiler steaming rate can be raised independently and in anticipation of turbine loading.

1.2.4 Steam Temperature Control. In general terms, when operating a once-through boiler below the BENSON load, the boiler is controlled similar to a drum type unit with firing rate used to control steam flow rate and spray water attemperation used to control steam temperature. Above the BENSON load when the boiler control system is in the once-through mode, the coordinated control of feedwater flow rate and fuel firing rate are used to control final main steam temperature with the boiler feedpump establishing the required steam flow rate. In both cases, reheat steam temperature is controlled by gas flow proportioning through the parallel pass heat recovery area with spray water attemperation used for emergency conditions. Of note are the following: 1.2.5 Main Steam Temperature. As shown in Figure 1-12, two (2) main steam attemperators are provided with a total spray water flow rate of 5% divided between both spray stations over the once-through operating load range (25-100% MCR). The first attemperator is located between the primary and platen superheaters; the second is upstream of the finishing superheater. The second attemperator is used for quick response to control final steam temperature. The first attemperator is used to control the temperature differential across the second attemperator. If the control span of the first attemperator is exceeded, the set point for the evaporator outlet enthalpy is adjusted by varying the feedwater flow rate which is turn requires adjustment to the fuel firing rate. Close monitoring of the evaporator outlet enthalpy, as well as the enthalpy differential across the evaporator are used to anticipate adjustments required to the feedwater and fuel flow firing rates. Appropriate time delays, feed forward signals, and decoupling features are incorporated in the control system logic to closely control final steam Figure 1-12 BENSON Boiler Control temperature. 1.2.6 Reheat Steam Temperature. Final reheat steam temperature is controlled by gas flow proportioning through the parallel pass heat recovery area (HRA) and is the standard arrangement used by Foster Wheeler since the early 1960s on all large scale, suspension fired utility boilers. The basic concept is schematically illustrate in Figure 1-13 Multi-louvered
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dampers, such as illustrated in Figure 1-14, are positioned at the outlet of each pass to push more or less flue gas over the reheater elements to achieve the required reheat steam temperature.

Figure 1-13 Reheat Steam Temperature Control in Parallel Pass HRA

Figure 1-14 Reheat Steam Temperature Control Dampers

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Advantages of this arrangement include: No reheat spray is required and therefore no cycle efficiency lost Fast control response Elimination of spray avoids water contaminants to turbine Reheat surface not in high heat flux furnace zone Gas recirculation is not required Responds to but does not drive excess air and combustion

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