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Desuperheating
Superheated steam is steam that is at a temperature higher than the saturation temperature for the steam
pressure. For example, steam at a pressure of 3 bar g has a saturation temperature of 143.762C. If
further heat was to be added to this steam and the pressure remained at 3 bar g, it would become
superheated. This extra heat results in steam which:
The relationships between these three properties are well documented and can be found in most texts
relating to the thermodynamic properties of steam.
Wet steam within a turbine would result in water droplets and erosion of the turbine blades, as
well as increased friction.
Higher pipeline velocities (up to 100 m / s) can be used. This means that smaller distribution
pipelines can be used (provided that the pressure drop is not excessive).
For continuously running plants, superheated steam means there is no condensation in the
pipework, therefore, there is only a requirement for steam trapping during start-up.
Although superheated steam contains a large amount of heat energy, this energy is in three
forms; enthalpy of water, enthalpy of evaporation (latent heat) and enthalpy of superheat. The
bulk of the energy is in the enthalpy of evaporation, and the energy in the superheat represents a
smaller proportion.
For example, take superheated steam at 10 bar a and 300C, then:
Enthalpy of water = 763 kJ / kg
Enthalpy of evaporation = 2 015 kJ / kg
Enthalpy of superheat = 274 kJ / kg
Fig. 15.1.2
Enthalpy in superheated steam
The coefficient of heat transfer when using superheated steam as the heating medium is variable,
low and difficult to quantify accurately. This makes accurate sizing and control of heat transfer
equipment difficult, and will also result in a larger and more expensive heat exchanger.
Once the superheated steam is cooled to saturation temperature, the heat transfer coefficient
increases dramatically, and the temperature at which the steam condenses back into water is
constant. This greatly assists accurate sizing and control of heat transfer equipment.
The presence of high heat transfer coefficients associated with saturated steam leads to smaller
and cheaper heat exchangers than those which utilise superheated steam.
Some processes (for example, distillation columns) perform less efficiently when supplied with
superheated steam.
The higher temperatures of superheated steam may mean that higher rated, and hence more
expensive equipment is required.
These disadvantages mean that superheated steam is generally undesirable for thermal process
applications. However, sites exist where superheated steam is raised for power generation, and it makes
economic sense to desuperheat some of this steam from some point in the power generation cycle, and
then use it for process applications. (More information on superheated steam can be found in Tutorial 2.3).
Sites also exist where large quantities of waste are used as fuel for the boiler. If the quantity of waste is
sufficiently large, then superheated steam may be produced for power generation. Examples of this type of
plant can be found in the papermaking and sugar refining industries.
In plants that have superheated steam available for process use, it makes sense to distribute the
superheated steam to remote points in the plant, as this will ensure that the steam remains dry. This
becomes significant if there are long lengths of pipe separating the point of generation and the point of
use.
Indirect contact type - The medium used to cool the superheated steam does not come into
direct contact with it. A cooler liquid or gas may be employed as the cooling medium, for
example, the surrounding air. Examples of this type of desuperheater are shell and tube heat
exchangers. Here the superheated steam is supplied to one side of the heat exchanger and a
cooler medium is supplied to the other side. As the superheated steam passes through the heat
exchanger, heat is lost from the steam, and gained by the cooling medium.
The temperature of the desuperheated steam could be controlled by either the inlet superheated
steam pressure or the flowrate of the cooling water. Control of the superheated steam flow for
this purpose is not normally practical and most systems adjust the flow of the cooling medium.
Direct contact type - The medium used to cool the superheated steam comes into direct contact
with it. In most cases, the cooling medium is the same fluid as the vapour to be desuperheated,
but in the liquid state. For example, in the case of steam desuperheaters, water is used. A typical
direct contact desuperheating station is shown in Figure 15.1.3.
When the desuperheater is operational, a measured amount of water is added to the
superheated steam via a mixing arrangement within the desuperheater. As it enters the
desuperheater, the cooling water evaporates by absorbing heat from the superheated steam.
Consequently, the temperature of the steam is reduced.
Control of the amount of water to be added is usually achieved by measuring the temperature of
the steam downstream of the desuperheater. The set temperature of the desuperheated steam
would typically be 3C above that at saturation. Therefore, in such arrangements the inlet
pressure of the superheated steam should be kept constant.
Desuperheating calculations
The amount of water added must be sufficient to cool the steam to the desired temperature; too little water
and the steam will not have been cooled enough, too much and wet saturated steam will be produced
which will require drying through a separator.
Using Equation 15.1.1, which is based on the conservation of energy, the cooling liquid requirement can
be easily and quickly determined:
Equation 15.1.1
Where:
cw = Mass flowrate of cooling water (kg / h)
s = Mass flowrate of superheated steam (kg / h)
hs = Enthalpy at superheat condition (kJ / kg)
hd = Enthalpy at desuperheated condition (kJ / kg)
hcw = Enthalpy of cooling water at inlet connection (kJ / kg)
Example 15.1.1
Determine the required cooling water flowrate for the conditions in the following Table:
Solution:
The necessary information can be obtained or interpolated from hard copy steam tables; the relevant
extracts are shown in Table 15.1.1 and Table 15.1.2. Alternatively, the Spirax Sarco online steam tables
can be used.
Table 15.1.1 Extract from steam tables - Saturated water and steam
Equation 15.1.1
Fonte:
http://www.spiraxsarco.com/resources/steam-engineeringtutorials/desuperheating/basic-desuperheating-theory.asp
acesso em 30/12/2009
Desuperheaters
The simplest type of desuperheater is an unlagged section of pipe, where heat can be radiated to the
environment. However, apart from the obvious risk of injury to personnel from such a hot item of plant, and
the expensive energy wastage, this approach does not adjust to compensate for changes in the
environmental conditions, steam temperature or steam flowrate.
Turndown ratio - 'turndown' is used to describe the range of flowrates over which the
desuperheater will operate, as shown in Equation 4.2.1.
Equation 4.2.1
This is an important parameter, as any variation in inlet pressure, temperature or flowrate will cause a
variation in the requirement of cooling liquid.
In general, the two turndown values may be specified for a particular desuperheater:
Steam turndown ratio - This reflects the range of steam flowrates that the device can effectively
desuperheat.
Cooling water turndown ratio - This reflects the range of cooling flowrates that can be used. Although
this directly affects the steam turndown ratio, the relationship depends on the temperatures of the
superheated steam, the cooling water and the resulting desuperheated steam.
Equation 15.1.1 is the mass/heat balance equation for this application:
Equation 15.1.1
Where:
mcw = Mass flowrate of cooling water (kg/h)
ms = Mass flowrate of superheated steam (kg/h)
hi = Enthalpy at superheat condition (kJ/kg)
hd = Enthalpy at desuperheated condition (kJ/kg)
hcw = Enthalpy of cooling water at inlet connection (kJ/kg)
It should be noted that the steam and water flowrates are directly proportional to each other; the constant
of proportionality 'k' depends on the enthalpies of the superheated steam, the cooling water and the
required desuperheated steam. Mathematically:
cw
If the required turndown cannot be achieved using a single desuperheater, two desuperheaters can be
installed in parallel, with operation switching from one to another; or both can be in operation depending on
steam demand.
It should be noted that the desuperheater itself is only one part of a desuperheating station, which will
include the necessary control system for correct operation.
Amount of superheat before, and amount of desuperheated steam required after, the process.
In the case of in-line desuperheaters, the distance travelled by the steam before complete
desuperheating has occurred is also an important consideration. This is referred to as the
absorption length.
The following Sections include descriptions of the common types of desuperheater available, their
limitations and typical applications.
Advantages:
1.
2.
3.
4.
Disadvantages:
1.
2.
3.
Bulky - because there are now a number of in-line devices available, they have been largely
superseded.
Cost.
An important concern with this type of desuperheater is the efficiency of the heat exchange
process. The build up of air or scale films on the heat exchange surface can act as an extremely
effective barrier to heat transfer.
Applications:
1.
Applications:
1.
2.
3.
4.
Simple
Steam is produced at saturation temperature.
Steam with a dryness fraction of 0.98 can be produced.
Turndown is only limited by the controls that are fitted.
Disadvantages:
1.
2.
Bulky.
Not practical for high temperatures.
Applications:
1.
2.
Particle size - The smaller the water particle size, the greater the ratio of surface area to mass,
and the higher the rates of heat transfer. Since the water is being directly injected into the moving
superheated steam, the smaller the particle size, the shorter the distance required for heat
exchange to take place.
The water is broken into small particles using either a mechanical device (such as a variable or
fixed orifice nozzle) or steam atomising nozzles.
Turbulence - As the flow within the pipeline becomes more turbulent, the individual entrained
water particles reside longer in the desuperheater, allowing for greater heat transfer. In addition,
turbulence encourages the mixing of the cooling water and the superheated steam. Increased
turbulence results in a shorter distance being required for complete desuperheating to occur.
Turbulence can be created in two ways:
Pressure drop across the nozzle - Subjecting the cooling water to a higher pressure drop will
increase its velocity and induce greater turbulence.
Velocity - By increasing the overall velocity of the water and steam mixture, the amount of
turbulence is inherently increased. The increase in velocity is usually achieved by creating a
restriction in the steam path, which further generates turbulence by vortex shedding.
In addition to these high velocities, if poor piping design practices are used, the speed of the
superheated steam could in theory approach Mach 1. At such speeds a number of problems
would occur (including the generation of shock waves). However, this would be far in excess of
the velocities used in good piping design. Typical velocities of steam entering a desuperheater
should be around 40 to 60 m/s.
Cooling water flowrate - The rate at which cooling water can be added to the superheated
steam is affected by a number of factors, which are related by Equation 4.2.11:
Equation 4.2.11
Where:
3
qv = Cooling water volumetric flowrate (m /s)
C = Coefficient of discharge for the nozzle
2
A = Area of the nozzle (m )
2
g = Gravitational constant (9.81 m/s )
h = Pressure drop over the orifice (m head)
Bearing in mind that C and g are constants, reviewing Equation 4.2.11 shows that only two factors can be
manipulated to alter the cooling water flowrate, q v:
Changing the pressure drop over the orifice (nozzle), h - Expressing flowrate as a function of pressure
drop over the nozzle:
This means that if, for example, flow is increased by a factor of 5, the available pressure must increase by
2
a factor of 5 = 25. The effect of this relationship is to severely hamper the turndown ratio.
In addition to affecting the cooling water flowrate, there are two other important considerations when
determining the required cooling water pressure:
1.
2.
The cooling water pressure must be greater than the superheated steam pressure at the point of
injection.
The greater the pressure drop across the nozzle, the better the atomisation of the cooling water.
Changing the area of the orifice, A - Expressing flowrate as a function of the area of the orifice:
This direct relationship means that if, for example, flow is to be increased by a factor of 5, the available
area must also increase by a factor of 5. This change may simply be achieved by an orifice, which has the
ability to change in area (see Figure 15.2.4), or alternatively by altering the number of orifices passing the
coolant.
Thermal sleeves - Careful control of the spray is required to ensure that the water does not fall
out of suspension as this can result in thermal stresses being generated in the pipeline and
cracking may occur. However, in some cases, an inner thermal sleeve can be used to provide
protection from this.
Advantages:
1.
2.
3.
Simple in operation.
Cost effective.
Minimum steam pressure drop.
Disadvantages:
1.
2.
3.
4.
5.
Low turndown ratio, typically a maximum of 3:1 on both steam and cooling water flow.
Desuperheated steam temperature can only be reduced to 10C above saturation temperature.
Longer absorption length than the steam atomising type.
Most prone to cause erosion damage to the internal pipework. This can be overcome by the use
of a thermal sleeve.
Limited pipe sizes.
Applications:
1.
2.
3.
Advantages:
1.
2.
The pressure of the cooling liquid is less than that in the single point version; therefore, it is not
necessary to use a thermal sleeve.
The absorption length is shorter compared with that of the single point version due to better
mixing of the water and the superheated steam. The absorption length is still significantly longer
than other types of water spray desuperheater.
Other advantages, disadvantages and applications are similar to those of single point radial
injection spray desuperheaters.
Axial injection of the cooling water improves the mixing of the water and the superheated steam by two
methods:
1.
2.
As the water is injected along the centre of the pipeline, it will be more evenly distributed
throughout the superheated steam.
The cooling water delivery pipe that is inserted in the pipeline acts as an obstruction, creating
additional turbulence at the point of water injection due to vortex shedding.
Fig. 15.2.9 Vortex shedding around the cooling water delivery pipe
A modification of this basic arrangement involves turning the nozzle so that the cooling water is sprayed
upstream, against the steam flow. The high velocity of the superheated steam reverses the spray water
flow pattern and sends it back through a mixing chamber. This achieves more efficient mixing of the water
and steam over a short absorption length.
Advantages:
1.
2.
3.
4.
Simple in operation.
No moving parts.
Cost effective across the entire range of sizes.
Minimal steam pressure drop.
Disadvantages:
1.
2.
3.
4.
Low turndown ratio, typically a maximum of 3:1 on both steam and cooling water flow.
Desuperheated steam temperature can only be reduced to 10C above saturation temperature.
Longer absorption length than the steam atomising type, but less than the radial type
desuperheaters.
Most prone to cause erosion damage to the internal pipework. This can be overcome by the use
of a thermal sleeve.
Applications:
1. Constant steam load.
2. Constant steam temperature.
3. Constant coolant temperature.
All of which mean a relatively constant cooling water requirement.
Fixed area type - All the nozzles are open when the desuperheater is operating, and the cooling
water is regulated by a spray water control valve.
Variable spray type - The downstream temperature determines the number of exposed nozzles.
Cooling water enters the desuperheater through the water jacket to the sealing area above the
disc (see Figure 15.2.12). When an increase in the downstream steam temperature is detected
by the associated temperature control system, the actuator moves the stem down, progressively
exposing more nozzles. When the demand for the cooling water changes, the stem and disc
arrangement moves up and down as required. This has the effect of changing the overall orifice
area.
3.
Spring-assisted type - This is essentially a combination of the two previous types. Instead of the
stem and disc arrangement being controlled by an actuator, the spring-assisted type contains a
spring-loaded flow plug, which moves in response to a change in the differential pressure
between the coolant and the superheated steam. The moving plug changes the number of open
nozzles, thereby adjusting the flow into the main pipeline. In addition, the cooling water is
regulated by a spray water control valve.
Being able to control both the pressure and flow of the cooling water enables accurate control
over the amount of water injected into the superheated steam. This type does, however, require a
high cooling water pressure.
Advantages:
1.
2.
3.
Turndown ratios of up to 8:1 are possible with the fixed area type, up to 9:1 with the spring
assisted type and 12:1 for the variable area type.
Better dispersion of the water droplets means that the absorption length is less than that of single
nozzle devices.
Minimal steam pressure drop.
Disadvantages:
1.
2.
3.
4.
5.
6.
Applications:
1.
Applications with a requirement for a higher turndown ratio than that offered by single nozzle
devices, but where the expense of more sophisticated devices is not justified.
2. Constant steam load.
3. Constant steam temperature.
4. Constant coolant temperature.
All of which require a relatively constant desuperheating load.
Fonte:
http://www.spiraxsarco.com/resources/steam-engineering-tutorials/desuperheating/basicdesuperheater-types.asp
acesso em 30/12/2009
2.
The first stage of desuperheating occurs in the internal diffuser. A portion of the steam is
accelerated in the internal nozzle and the velocity is used to atomise the incoming water. The
cooling water is injected into the diffuser through a number of small jets, which helps to further
atomise the water.
In the second stage of desuperheating, a saturated mist or fog emerges from the internal diffuser
into the main diffuser where it mixes with the remainder of the steam.
The main diffuser itself creates a restriction to the remainder of the steam thereby increasing its velocity in
this region. Thus, there is a region of turbulence where the second stage of desuperheating occurs. This
mechanism minimises cooling water contact with the sidewalls, combining maximum desuperheating
effectiveness with minimum pipe wear.
The steam flow turndown ratio does vary depending on the actual conditions, but 4:1 is typical. In
applications where there is a dedicated pressure reducing station upstream of the desuperheater, the
available steam turndown can be improved to over 5:1.
The cooling water turndown is usually satisfactory for most plant applications, with 20:1 possible
depending on the actual operating conditions. At cooling water turndowns beyond 20:1, the need for a
cooling water booster pump also increases.
Venturi type desuperheaters can be installed either horizontally or vertically with the steam flow upwards.
When installed vertically, better mixing occurs which can result in an improved turndown ratio of over 5:1.
The main problem with this is ensuring that there is enough vertical space to install the desuperheater, as
it will be more than several metres long.
A modification to the standard venturi type desuperheater is the attemperator desuperheater. This
essentially uses the same method of injecting the coolant into the superheated steam, but does not utilise
the venturi shaped mixing section. Attemperator desuperheaters are used in place of the venturi type
where there is sufficient space available to install a long absorption pipe, especially where slightly higher
turndown is required, but where the additional cost of a steam atomising type cannot be justified.
The term attemperator is also generally used to refer to a desuperheater that is installed after a boiler or
superheater to give accurate control over temperature and pressure.
Advantages:
1.
2.
3.
4.
5.
6.
Steam turndown ratios of up to 5:1 and cooling water turndowns of over 20:1.
Simple operating principle (although more complex than the spray type).
No moving parts.
Accurate control of desuperheated steam temperature; typically within 3C of the saturation
temperature.
Suitable for operation under steady or variable steam conditions.
There is reduced wear in the downstream pipework compared to a spray type desuperheater, as
the cooling water emerges as a mist rather than as a spray.
Disadvantages:
1.
2.
3.
Pressure drop is incurred (although this is generally small and within acceptable limits).
The absorption length is still longer than the steam atomising type; so more space is required for
installation.
A minimum cooling water flow rate is required.
Applications:
1.
Suitable for most general plant applications, except where high turndowns on steam flowrate are
required.
2.
The first stage occurs in the diffuser, where the cooling water is atomised by the high velocity
atomising steam. The auxiliary steam pressure needs to be at least 1.5 times the desuperheater
inlet pressure, typically with a minimum pressure of 4 bar a. The flowrate of atomising steam is
normally between 2% and 5% of the mainline flow. The use of atomising steam means that the
cooling water can be introduced into the diffuser at lower pressures. In general, the only
requirement is that the pressure must be greater than that of the superheated steam.
In the second stage, a wet mist or fog emerges from the diffuser where it mixes with the mainline
steam in the pipeline. Evaporation occurs in the pipework immediately downstream of the
desuperheater, where the remaining water droplets remain suspended in the steam and
gradually evaporate.
Using steam to atomize the cooling water produces finely atomized water particles, which ensures efficient
heat transfer and evaporation.
This arrangement allows for high steam turndown ratios; ratios of up to 50:1 are possible. It should
however be noted that at turndowns greater than 20:1, low pipeline velocities may result in the 'settling out'
of water, caused by the decreasing momentum of the water droplets. In this case, a drainage and recycle
arrangement is required (see Figure 15.3.3). If such a recycle arrangement cannot be fitted, the turndown
ratio will be reduced.
The typical installation of a steam atomising desuperheater is illustrated in Figure 15.3.3.
Advantages:
1.
2.
3.
4.
5.
Good turndown - steam turndown of up to 50:1 is possible, but operation and control is most
efficient for a turndown of around 20:1.
Very compact - with a short absorption length relative to the other types.
Pressure drop is negligible.
The cooling water used can be cold, as the atomising steam will preheat it.
Low approach to saturation temperature - typically to within 6C of saturation temperature.
Disadvantages:
1.
2.
Applications:
1.
Suitable for applications where the steam flowrates will vary widely, for example in combined
pressure reducing and desuperheating stations.
The plug is typically fitted with a spring-loaded plunger, which increases the friction between the plug and
the cage, effectively damping the plug's movement. Given a fixed pressure drop across the valve this
effectively enables the amount of cooling water to be varied when mixing with the flow of superheated
steam.
The plunger also provides stability under light load conditions.
The fact that the coolant is not sprayed into the desuperheater, and that virtually all the desuperheating
occurs in the body of the device, means that there is little wear of associated pipework or the
desuperheater itself. Therefore, thermal sleeves are unnecessary.
A typical installation of a variable orifice desuperheater is illustrated in Figure 15.3.6
Advantages:
1.
2.
3.
4.
5.
The turndown is only limited by the cooling water control valve, and steam turndown ratios of up
to 100:1 can be readily achieved.
Low approach to saturation temperature - typically to within 2.5C of saturation temperature.
Short absorption length.
The cooling water pressure need only be 0.4 bar superior to the superheated stem pressure.
Superheated steam velocities may be very low.
Disadvantages:
1.
2.
3.
Applications:
1.
2.
Suitable for applications where the steam flowrate will vary widely and a relatively high pressure
drop is not critical.
Where the steam velocity is likely to be very low.
Fig. 15.3.7 Combined pressure control valve and desuperheater (cut section)
The pressure reducing aspect is similar to a standard pressure reducing valve. Although a number of
different designs of pressure reducing valve could be used, angle or globe configurations are most
commonly used. In addition, the valve is typically of the balanced type (with either a balancing plug or a
balanced bellows arrangement) to reduce the required actuator force.
As accurate pressure control is usually important in desuperheater applications, pneumatic actuation of the
valve is virtually universal, and so is the use of positioners. In addition, because quite substantial pressure
drops may be involved, the manufacturer will often offer a noise reduction trim for the pressure control
valve (see Figure 15.3.8).
In some combined pressure control and desuperheating stations, there are a number of baffle plates
installed immediately after the desuperheating station. These plates induce further pressure drop and
improve mixing of the steam and coolant.
Combined pressure control valve and desuperheating stations are commonly used in turbine bypasses,
where the valve dumps the flow directly to the condenser or to 'cold reheat'.
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4.Typical Installations
A number of important considerations need to be taken into account when installing
desuperheaters. This tutorial covers issues such as water quality and pressure control. A
desuperheater selection chart and a list of applications are also included.
Installation
There are a number of important considerations to take into account when installing a desuperheater,
namely:
The control valves used on the cooling water line and the superheated steam line.
Temperature - The most effective desuperheating will be achieved using cooling water that is
hot, preferably as close to the saturation temperature as possible. However, cooling water
temperatures as low as 5C could be used if absolutely necessary.
The use of hot water has the following advantages:
o
o
o
It minimises the time period for which water particles are suspended in the steam.
It evaporates more quickly.
It minimises the amount of water falling to the inside walls of the pipework.
There are however, two disadvantages to using high temperature cooling water:
4. The higher the temperature of the cooling water, the greater the required flowrate due to
its lower cooling effect.
5. Unless a supply of the water at the required temperature is available, additional heating
mechanisms may have to be incorporated.
Due to the benefits of using hot water, it is logical to insulate the hot water supply pipes to
minimise heat loss, and to protect personnel.
Quality - The quality of the injected water is important. The Total Dissolved Solids (TDS)
content of the injection water should be as low as possible, as any solids that come out of
solution will be deposited on:
o
o
o
In addition to reducing the TDS levels, all cooling water should be passed through a suitable
strainer installed before the water control valve.
Pressure and flowrate - As mentioned in Tutorial 15.2, the pressure of the cooling water,
along with the area of the nozzles, determines the flow of cooling water into the desuperheater.
Table 15.3.1 shows the typical minimum pressures (above the superheated steam pressure)
required for each type of desuperheater. It should be noted that these might vary between
manufacturers and for different steam pressures.
If a booster pump is used, a 'spill back line' will be required to ensure that there is always
sufficient flow through the pump at times of low cooling water demand.
Control - A pressure drop will inevitably be required over the water control valve. When using
cooling water close to saturation temperature, care is needed to ensure that the pressure drop is
not large enough to cause the water to flash into steam.
An equal percentage characteristic plug in the water control valve may be selected, which will
usually complement the pump characteristic.
Source - The availability of water at high pressure and temperature may be difficult. There are
a number of possible sources of the cooling water; and options include:
Water from the pressure side of the boiler feedpump (providing the boiler uses
modulating level control).
o
o
o
De-mineralised water.
Condensate.
Town water. This however may require treatment to improve the quality, otherwise salts
may be deposited on the inside of the desuperheater downstream pipework.
Desuperheater installation
The total installed length of a desuperheater station will vary with size and type, but it is typically about
7.5 m.
Most desuperheaters can be installed in any direction (the variable orifice type is a notable exception), but
if installed vertically, the flow should be upwards. The venturi type is best installed in a vertical pipe with
the flow in the upward direction, as this aids mixing of the water and the steam. However, such
installations are not usually possible due to the vertical space required.
If the sensor is too close to the water injection point, the mixing of the steam and the water will
not have been completed, and the temperature sensor will give a false output.
If the sensor is too far away, it will make the installation unnecessarily long.
The minimum installation distance will vary between different types of desuperheater and with different
manufacturers. It is usually specified as a function of the temperature difference between the required
outlet temperature and either the inlet temperature or the coolant temperature. Figure 15.4.2 shows a
typical manufacturer's sensor positioning chart.
Separator station
Efficient drainage of the pipework following the desuperheater is essential. To ensure that water cannot
accumulate at any point, the pipe should be arranged to fall approximately 20 mm per metre in the
direction of flow, and should be provided with a separator station.
The steam trap used to drain the separator should be carefully selected to prevent air binding, and the
discharge pipe from the steam trap should have ample capacity to deal with the drainage and it should be
fixed as near to vertical as possible. In addition, there must be sufficient space in the drainage pipe for the
water to flow down and air to pass up the pipe. The steam trap must also be able to withstand superheat
conditions.
On critical applications, for example, prior to a turbine, a separator is even more important; the separator
station will remove entrained water in the case of control failure, and prevent too much water being added
to the steam.
Isolation valves
To allow maintenance to be safely carried out, isolation valves are recommended upstream of:
The desuperheater.
Typically, these should be installed approximately, but no less than 10 pipe diameters from the item they
are isolating.
Safety valve
A safety valve may be required to protect equipment downstream of the desuperheating station from
overpressure, in the event of failure of the pressure control station.
It is necessary to ensure discharge pipework from the safety valve is led away to a safe area. This is of
particular importance as high temperature superheated steam may be discharged.
Figure 15.4.3 depicts typical pressure/temperature gradients for PN16, PN25 and PN40 rated products on
a non-specific material. It is important to note that different materials will, by specification, produce
variations in the temperature gradient.
In addition, components such as gaskets, fasteners and internal components may have a further limiting
effect on the maximum temperature and pressure.
Controls
The selection and installation of the control devices to be used in a desuperheater station are an important
consideration, as they can affect the overall turndown of the desuperheater. If the controls installed have a
lower turndown ratio than the desuperheater itself, the turndown of the desuperheater station will be
reduced (refer to Tutorial 15.2)
Further information on basic control theory and practice can be found in Blocks 5 to 8 inclusive.
Selection
When selecting a suitable type of desuperheater for a particular application, the following factors need to
be considered:
Separator station - This is probably one of the most important considerations, as the
different types of desuperheater vary significantly in the range of superheated steam flowrates
that can be effectively desuperheated.
It is important to note here that, although ensuring that the device will have sufficient turndown for
the flow likely to be encountered, it is important not to specify more turndown capability than is
really needed. This predominantly affects cost, but it can also lead to poor system performance.
Poor performance is often aggravated by the fact that most desuperheaters tend to perform
better at the higher end of the specified flowrates and a system designer would tend to allow for
increases in capacity due to expansion. As an extreme example, if the maximum flow specified
was ten times the current requirement (in order to take into account future growth), the
desuperheater will operate between 1 and 10% of its full flowrate instead of the 10% to 100% it is
designed for.
Generally, where some degree of residual superheat can be tolerated, the desuperheated
steam temperature should be as high above saturation as possible.
This is beneficial for several reasons:
1.
2.
3.
4.
The lower temperature difference also reduces the heat transfer rate between the water
and the steam, and therefore the water droplets have to stay in suspension for longer to
be evaporated. This increases the likelihood that the water particles will fall out of
suspension in the pipe. In order to prevent this from occurring, as the temperature
approaches TS, the velocity of the steam needs to be increased in order to create more
turbulence.
Available coolant supply pressure - The choice of desuperheater type will also depend
on the availability of cooling water at the necessary pressure. It would provide a cost advantage
to use cooling water that is already available, for example, from the pressure side of a boiler
feedwater pump.
If the available pressure were not sufficient for a particular type of desuperheater, additional
pumping arrangements would have to be made.
A typical manufacturer's selection chart is shown in Figure 15.4.4. It is based on the typical performance
and installation characteristics, which can be found in Table 15.3.1.
The method used to size a desuperheater will vary depending on the particular manufacturer and the type
of desuperheater, and therefore it is outside the scope of this publication.
Typical applications
Desuperheaters are mainly applied in two areas:
1.
Power generation - Desuperheaters are mainly used to reduce the temperature of steam
2.
emitted from turbine bypass systems to an efficient level for operation on other parts of the plant
requiring saturated steam for heat transfer purposes.
Process industry - In process industries, desuperheaters are used as part of a system for
reducing the temperature and pressure of steam from boilers to economical levels of operation.
Table 15.4.1 shows some common application examples in particular industries.
Table 15.4.1 Typical applications for desuperheaters in process industries
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acesso em 30/12/2009