Bypass Systems

Designed to
Enhance the
Flexibility of
Plant Operations
...................................................
By Ulrich Kägi

22591 Avenida Empresa

Rancho Santa Margarita, CA 92688
949.858.1877 ! Fax 949.858.1878 ! ccivalve.com
391 | 06/00 ! ©2000 CCI ! DRAG is a registered trademark of CCI.

Bypass Systems Designed
to Enhance the Flexibility
of Plant Operations
" By Ulrich Kägi, CCI AG (Switzerland)
Presented at the 12th CEPSI Thailand, from Nov. 2–6, 1998
Abstract
T urbine bypass valves were first used in the early 1930s with
the newly developed once-through steam generators. Bypass
systems are today not only essential for the flexible operation of
large coal-fired power plants, but play an equally important role
in advanced combined-cycle power plants. Bypass systems permit
the boiler and steam-turbine operation to be separated during
startup, shutdown and load disturbances. The possible separation
enhances operational flexibility during those transient operating
modes. Startup and reloading time—and consequently fuel
costs—are reduced, due to the improved flexibility. Other
advantages are reduced lifetime consumption of major plant
components, and a higher overall availability of the plant. In
order to achieve the desired results, the bypass system must be
adequately sized for the different operating modes. The bypass
system must closely fit into the overall plant design. Therefore
the supplier of the bypass system requires a high degree of
system and plant operation know-how to assist the plant designer
effectively. Sizing and system design aspects for various operating
modes are also discussed in this paper.
HP IP LP
PT
PT
1 Turbine bypass systems can contribute to flexible plant operation
3 2
TT
C " Repeatedly attainable fast startups with the greatest possible
CL
PT
6
TT
C 8
1 HP-Bypass valve 6 LP-Bypass Control Valve
2 Spraywater Control Valve 7 Desuperheater
3 Spraywater Isolation Valve 8 Spraywater Control Valve
Figure 1—Single Reheat Plant with HP- and LP-Bypass
2 Bypass Systems Designed to Enhance the Flexibility of Plant Operations | 391
1. Introduction
Turbine bypass valves were first used in the early 1930’s with the
newly developed Sulzer monotube steam generators. This type of
steam generator was started with the evaporator and superheater
full of water and the boiler already under pressure. This required
a new startup arrangement with automatically controlled valves
to control the boiler pressure immediately after light-off when
the water expanded and steam was produced. In order to operate
the newly developed boiler successfully, Sulzer had to, besides
the boiler, develop the necessary control valves as well as a
hydraulic boiler control system.
With the development of boilers with reheaters, bypass systems
as we know them today, with HP- and LP-bypasses, were
introduced. Fig. 1 shows the water/steam cycle of a single-reheat
power plant with HP- and LP-bypasses. In the effort to increase
efficiency and reduce cost per installed megawatt, unit sizes
were increased, along with higher temperatures and pressures at
superheater as well as reheater outlets. In the 1960s the first
plants were operated in sliding pressure mode. In continental
Europe it became customary to utilize the HP-bypass valves as
safety valves to protect the superheater against excessive pressure.
The design of the bypass valves had to follow the trend of ever-
increasing steam flow in conjunction with higher temperature
and pressure. In the 1970s, bypass systems were also applied in
increasing numbers to enhance the flexibility of large drum-type
boiler units.
Today’s modern power stations need not only high efficiency,
but also high operational flexibility (e.g., cyclic operation), high
reliability and availability, together with a high life expectancy
of all the major components. Well-designed bypass systems can
contribute to fulfill these initially contradictory requirements.
G
2. Function of Turbine Bypass Systems
mainly by supporting:
regard to the lifetime of heavy-walled components.
" Quickest possible restoration of power supply to the grid after

any disturbance
Therefore, bypass systems contribute to the overall target of safe
and efficient supply of electric power at minimum total cost.
2.1 Plant startup
During unit startup, the bypass system essentially allows the
separation of boiler and turbine operations by diverting all
the steam, which cannot be accepted by the turbine or other
consumers, through the bypass. This allows the boiler to reach
the desired steam qualities as quickly as possible to start the
turbine.
©2000 CCI. All rights reserved.
Without a bypass it is difficult to control two output variables o
C bar
of the boiler (pressure and temperature) with only one input 500 300
4.2
variable, the firing rate. If there is no steam flow through the
400
reheater and almost no steam flow through the superheater, the 4.1

firing rate is limited to very low values. Such low firing rates 300
200
do not allow a quick warm-up of the boiler. Increased slagging 200

and fouling of the boiler can be, besides high fuel consumption, %
100
the result of slow warm-up. Because of the low boiler load, the
attainable superheater outlet temperature is limited. Changes 0 100 100
3.1
in the firing rate will always affect pressure and superheater
outlet temperature. Fast pressure transients during startup are not
3.2
desirable because of the change of the saturation temperature 50
in heavy-walled parts, such as the boiler drum or the startup 2.1 2.2 2.3

separator. Bypass 

Operation
2.4
2.1.1 The HP-Bypass During Hot Start 0
0 50 100 min
The hot start characteristics of a coal-fired 500 MW unit (Fig. Light-up Synchr. Full Load
2) shows how a bypass system can contribute to a quick and
Pulverizers
lifetime-saving startup. The boiler is a once-through design with
1.1 Firing Rate
nominal superheater outlet conditions at full load of 254 bar 3.1 Superheater Pressure
(3683 psig) and 541oC (1000oF). After an overnight shutdown the 2.1 Feedwater Flow 3.2 Reheater Pressure
2.2 Waterwall Flow 4.1 Superheater Temperature
unit is restarted at a superheater pressure of approx. 80 bar (1160 2.3 Steam Flow (Superheater) 4.2 Reheater Temperature
2.4 Steam Flow (Turbine)
psig). This is, at the same time, the pressure for turbine start,
so no large pressure transients are to be expected. Immediately Figure 2—Hot start of a coal-fired supercritical 500 MW unit
after light-up, the bypass opens and starts to control constant
pressure. The firing rate is quickly increased in order to match pulverizers are started before the turbine is started. This keeps
the superheater outlet temperature with the turbine metal temperature transients, invariably associated with the start of the
temperature. For this unit, the desired steam temperature after first pulverizers, away from the heavy wall turbine parts. The
an overnight shutdown is approximately 450oC (842oF). Two bypass compensates for load swings originating from pulverizer
Time to
start. The reheater pressure is quickly increased to approx. 12 bar
full load
Bypass
Minutes size (175 psig) which allows auxiliary steam to be supplied from the
140 70% Steam pressure for startup
reheater.
67%
120 60%
32%
=80bar
50% 2.1.2 Sizing the HP-Bypass for Temperature Matching
100 50% =125bar

80 40% The ultimate goal of steam-to-metal temperature matching is to

60
Cyclic life expenditure 30% reduce cyclic life expenditure of the turbine for any startup. Fig.
40 0.01% 20% 3 shows the required considerations to size an HP-bypass to
0.02%
20 10% achieve that goal for a typical coal fired supercritical unit.
0.03%

–150 –100 –50 0 +50 +100 10% 20% 30% 40% 50% 60%
The first diagram (top left) shows characteristics of cyclic life
Metal Temp. Mismatch Steam Flow
expenditure for the turbine, depending on startup time and
SH-outlet SH-outlet
temp. temp. temperature mismatch. For a desired turbine startup time of 45
600 600 Gas temp. Steam temp.
minutes, from synchronizing to full load, and a maximum cyclic
550 550
life expenditure of 0.01%, the steam metal temperature mismatch
500 500
must be +20oC.
450 450
SH-outlet temp.
400 400 The second diagram (bottom left) gives a required boiler outlet
350 350 temperature of 470oC (880oF), assuming a metal temperature of
throttling loss turbine first stage steam
o
temp. (400 C metal temp.
300
after 8 h)
300 400oC (750oF) and taking into account temperature reduction
due to throttling at the turbine control valves.
      10% 20% 30% 40% 50% 60%
Metal Temp. Mismatch Steam Flow
The third diagram (bottom right) shows that the necessary
Figure 3—HP-Bypass sizing for temperature matching boiler load to reach this superheater outlet temperature is 22%.

©2000 CCI. All rights reserved. 391 | Bypass Systems Designed to Enhance the Flexibility of Plant Operations 3
At this load the boiler has already o
C bar

reached a stable superheater outlet 500 300

4.2
temperature, which is desirable for 400

turbine start. 300 4.1

200
Diagram 4 (top right of Figure 3 on 200
%
previous page) shows the required 100

bypass capacity for a required boiler

0 100 100
3.1
load of 22% at a superheater
pressure of 80 bar (1160 psig). The
3.2
resulting bypass size for this startup 50
case is 67%, which means a flow 2.2
capacity of 67% MCR at nominal 2.1
1.1
2.3
boiler pressure. A higher turbine 0
2.4

metal temperature requires an even 0 50 100 150 200 250 300 min
Light up Synchr. Full Load
larger bypass flow.
1.1 Firing Rate
3.1 Superheater Pressure
2.1.3 The HP-Bypass During 2.1 Feedwater Flow 3.2 Reheater Pressure Pulverizers
Cold/Warm Start 2.2 Waterwall Flow
2.3 Steam Flow (Superheater) 4.1 Superheater Temperature
2.4 Steam Flow (Turbine) 4.2 Reheater Temperature
Cold and warm start require some
different considerations. Fig. 4 shows
Figure 4—Cold start of a coal-fired supercritical 500 MW unit
a typical cold start. The boiler is no
longer under pressure before light-off. An HP-bypass with capacity of 100% MCR can, in case of a load
The boiler pressure is brought into a controlled mode as quickly rejection or a turbine trip, immediately take over all excess steam.
as possible, but with due regard to the temperature transients of This has the following advantages for the plant operation:
heavy-walled boiler parts, up to the desired pressure for turbine
" The boiler can remain in operation and immediate restart is
rolling. An early start of the pulverizers can save considerable possible
costs due to reduced oil consumption during startup. The startup
" Superheater and reheater are continuously cooled.
characteristic shows a bypass steam flow (the difference between
Unnecessary pressure and temperature transients are avoided
steam flow at the superheater outlet and steam flow through the
turbine) of about 10–12% at a superheater pressure of 80 bar " The boiler can run back to a stable minimum load in a
controlled manner
(1160 psig), which corresponds to a bypass size of about 30–40%
MCR. " No immediate pulverizer trips are necessary

2.1.4 The LP-Bypass During Startup " House load operation is possible
The LP-bypass is diverting the hot reheated steam directly to the " Reheat steam is available as auxiliary steam
condenser. The LP-bypass should have at least a capacity which
" Part load trip in sliding pressure mode without unnecessary
is equal to the HP-bypass flow during startup, including the
pressure transients
HP-bypass spraywater flow. The reheater pressure during startup
is determined by various considerations: 2.2.2 LP-Bypass

Due to limited capacity of the condenser, the LP-bypass usually

" Use of reheat steam as auxiliary steam
cannot dump 100% MCR flow into the condenser. When
" Desired reheat pressure for turbine warming determining the maximum allowable LP-bypass flow, the high
" Desired HP-turbine pressure for startup LP-bypass spraywater flow of approx. 25% of steam flow has to
be taken into account. On the other hand, it is desirable from
The reheat pressure during startup is kept at 12 bar (175 psig).
a turbine operating point of view, to have for house load and
This keeps the exhaust pressure of the HP-Turbine low enough to
reloading an HP-Turbine exhaust pressure as low as possible. A
avoid overheating of the last turbine stages through ventilation
reduced pressure ratio across the HP-Turbine results in less energy
losses. The LP-bypass must therefore be sized for the startup flow
consumed and therefore an increased exhaust temperature. At
at this reduced pressure.
very low pressure ratios the steam is not expanding anymore in
2.2 Load rejection the last stages, resulting in additional ventilation losses. The
steam will even be heated up again in the last stages. If the
2.2.1 HP-Bypass
4 Bypass Systems Designed to Enhance the Flexibility of Plant Operations | 391 ©2000 CCI. All rights reserved.
LP-bypass is not sized to dump the required steam amount at a of the valve. The safety equipment does not need any external
pressure low enough, these effects could lead to overheating of energy for safely opening the valve.
the last stages of the HP-turbine.
The safety equipment includes test circuitry for regular testing of
The result of the two contradictory requirements is very often a the safety function. This testing takes place while the unit is in
LP Bypass with a 100% MCR capacity at full reheat pressure but a operation and does check the proper function of all elements in
flow limitation introduced in the control system. Fig. 5 illustrates the safety paths. The bypass valve actually lifts during the test,
house load operation with an LP-bypass. but a limitation of the valve stroke during this functional
test ensures that the power operation of the plant is not
The operating conditions are assumed as follows:
affected. Recalibration of safety valves during outages becomes
" Minimum stable boiler load approx. 35% unnecessary.
" Required steamflow for house load approx. 10% Additionally the safety control usually provides inputs to activate
" LP-bypass flow (including HP-bypass spraywater) approx. 25% the safety path from the control room and from the bypass
MCR controls. This allows the quick-opening function to also be
activated during a part-load trip, to ensure a quick transfer of
" Max. reheat
pressure of bar Pressure
steam flow from the turbine to the HP-bypass.
10 bar (145
psig) at
40 Investigations of the German TÜV have shown that the reliability
house load of pilot-operated hydraulic safety valves is considerably higher
(25% of full than that of spring-loaded safety valves. Moreover, safety valves,
load
which are kept closed hydraulically, are absolutely tight, even
pressure)
20 after a valve lift.
As Fig. 5 shows,
As easily understood, the smooth transfer from safety valve lift to
the resulting 10 bar pressure control is much easier to achieve if the safety function
size of the
Flow is combined with the control function in one valve. The bypass
LP-bypass
controller has only to take over control of the already-open
valves is 100% Bypass Flow 25% 50 100 %
valve. Since there are separate safety valves, this transfer involves
MCR at full Boiler Flow 35%
different valves with different stroking speeds and no direct
reheater Turbine House Load Flow 10%
pressure. Manual Trip
Figure 5—LP-Bypass after load rejection
If the maximum allowable flow through the LP-bypass is less
than 100%, the reheat safety valves will have to open in the initial
Control
phase of a load rejection from full load. The reheat safety valves System
have to dump the excess steam to atmosphere until the boiler Test
Logic
has been run back to a load corresponding to the capacity of
the LP-bypass. KC KB KA

&
2.2.3 HP-Bypass as Safety Valves
ZC ZB ZA
Regulations in various countries allow the use of HP-bypass Safety
Cabinet
valves as safety valves against overpressure in the superheater. SX ..

Conventional safety valves can be eliminated altogether. With a To parallel

100% HP-bypass, with flow to open valves, a few additional safety Safety
Blocking Valves
Unit
control devices can convert the bypass valves into combined
MC MB MA
bypass and safety valves. Fig. 6 illustrates the required safety
Servo
equipment. It comprises three identical, independent safety paths, Valve
SBE SBE SBE

which operate in fail-safe mode. The pressure in the HP pipe is

PSA PSB PSC
HP-Bypass Valve
monitored with three individual pressure switches. Tripping of to Reheater with Safety
any of the pressure switches results in deenergizing the hydraulic Function
IVA IVB IVC
solenoid valve in the corresponding path. The de-energized
Main Steam Pipe
solenoid valve opens a bypass in the hydraulic actuator between
the upper and the lower piston chamber, and the valve will be
Figure 6—HP-Bypass safety system
opened by the steam pressure, acting in the opening direction
©2000 CCI. All rights reserved. 391 | Bypass Systems Designed to Enhance the Flexibility of Plant Operations 5
coordination, which will ultimately lead to much higher pressure Fig. 7 shows the bypass system of an advanced Combined-Cycle
fluctuations during an already critical plant operating situation. Power Plant (CCPP) with a three-pressure Heat Recovery Steam
Generator (HRSG).
2.2.4 Safety Functions of LP-Bypass

Because the LP-bypass needs a safe closing function for The purpose of the bypass system in this type of power plant
protection of the condenser, it can never be used as an is in principle the same as in the coal-fired plants. It has to
overpressure safety valve for the reheater. Reheater safety valves, compensate for the differences in the startup sequence between
dumping to the atmosphere, are therefore always required. the steam generator and the steam turbine. The steam production
For countries which allow power-operated safety relief valves, of the boiler is determined primarily by the gas turbine operation
reheater safety valves are available with the same advantages as and therefore the available thermal energy at the outlet of
the above-described HP-bypass valves with safety function. the gas turbine. By controlling the steam flow of the HRSG,
it is possible to
The LP-bypass needs a condenser protection function, which
reach steam
closes the LP-bypass safely in any case, where the condenser
conditions
cannot accept steam. The safe closing function can be achieved
desired for a
in two ways:
smooth and
" By a separate isolation valve upstream of the LP-bypass control lifetime-saving
valve start of the
" By adding a safe closing function, similar to the safe opening of steam turbine.
the HP-bypass, to the LP-bypass control valve Sizing
An LP-bypass control valve, with a completely independent safe considerations
closing function, can have the same reliability as a separate are similar to
isolation valve. Tightness of the bypass control valve is in this those for a coal
case essential. fired power
plant. Criteria
3. Turbine Bypass Systems
in Combined-Cycle Power Plants for the different
bypass systems
Bypass systems are not only essential for flexible operation of
(of the different
large coal-fired power plants, elaborate bypass systems are also
pressure levels)
part of any of today’s advanced combined cycle power plants.
can be
determined
Figure 8—HP-Bypass valve with integrated
by
desuperheating
evaluating the
differences in the startup characteristics of the HRSG and the
steam turbine. The possible separation of steam generator
and steam turbine during disturbances plays an even more
important role in the CCPP because the steam generator
operation is directly coupled with the gas turbine. The
separation therefore allows independent operation of gas-
and steam turbines.

4. Design Considerations
1
GT HP IP LP G
Bypass systems are installed to enhance the flexibility of
power plant operation. They have to be designed so that
they are not by themselves a flexibility limitation. This is, on
3 one hand, the responsibility of the valve supplier, but it also
1 HP-Bypass requires from the plant designer a good knowledge of the
2 IP-Bypass features and the benefits of bypass systems and operation.
3 LP-Bypass
2 4.1 Valve Design

Fig 8 is a sectional drawing of a HP-bypass valve. Since

Figure 7—Bypass system in a combined-cycle power plant

6 Bypass Systems Designed to Enhance the Flexibility of Plant Operations | 391 ©2000 CCI. All rights reserved.
this valve is designed to be used as a combined bypass and
safety valve, the steam flow is in the opening direction of the
valve. Because the high pressure- (thick walled-) part of the
valve consists essentially only of the inlet nozzle, this design
minimizes stress due to thermal cycling. The valve body must
on one side be designed for the specified design pressure and
temperature and be stiff enough to accept forces from the piping
without undue deformation. On the other hand, it must be
resistant to temperature cycles caused by startup, shutdown and
any other plant transients. The following design criteria apply to
reach a high cyclic life time of the valve:
" Use of forged material
" Application of spherical shapes, which result in the thinnest
possible wall thickness
" Avoiding unnecessary material accumulation, sharp edges and
sudden changes in wall thickness
" Good surface finish to avoid initiation of cracks
The HP-bypass valve in Fig. 8 features integrated spraywater
injection. Proper design of an integrated injection requires a
detailed understanding of the flow pattern inside the valve during
all load conditions. Analysis of these flow patterns, including
spraywater atomization and evaporation, is today possible with
dynamic numerical calculation.
The spray water is injected through a high number of small
injection nozzles directly into the zone of highest turbulence of
the steam flow. This ensures a good atomization of the injected
water, and due to the small droplet size, a very fast evaporation
of the injected water. The cage around the desuperheating area
prevents the pressure-retaining walls from being hit by water
droplets, which would cause high local thermal stress. Hole
pattern, shape, and material selection of the cage are the result of
long experience with integrated injections.
Due to the optimal atomization and evaporation of the
spraywater, the water is essentially evaporated at the outlet of
the valve which gives maximum freedom in placing the valve in
the plant.
4.2 System Design
Good system design is essential for operating flexibility and
lifetime of the bypass. System design involves the arrangement of
components, prewarming of valves, spraywater prewarming, etc.
Fig. 9 shows an arrangement of an HP-bypass which addresses
these issues. For cyclic operation, the bypass valve should
be prewarmed to a temperature of approx. 100oC below the
mainsteam temperature. This is automatically attained if the
valve can be arranged 1–2 m above the main steam line. If such
an arrangement is not possible, prewarming must be attained
through a permanent prewarming steam flow. Bypass valves must
be continuously prewarmed, because they are in permanent
©2000 CCI. All rights reserved.
readiness to take over steam flow in case of a plant disturbance.
For cyclic operation the spraywater should also be prewarmed.
In order to avoid a large amount of cold water being injected
immediately after opening the bypass, the spraywater should be
prewarmed up to the inlet of the spraywater isolation valve. The
distance and therefore the volume of cold water between the
spraywater isolation valve and the bypass valve should be kept
as small as possible.
The final responsibility for the system design is the architect/
engineer. The bypass valve supplier can contribute by clearly
defining the requirements for the bypass valves under the given
operating conditions and making his recommendations as to
how to fulfill these requirements
4.3 Turbine Bypass Controller
The HP-bypass controller consists of a pressure controller,
controlling superheater pressure through the position of
the steam valve, and a temperature controller, controlling
downstream temperature through the position of the spray
control valve. The most important part of the pressure controller
is the setpoint generator. It has to produce the correct setpoint for
all the different operating modes during startup, load operation,
load rejection and shutdown. Core of the setpoint generator is
a rate limiter, which limits the gradient of any pressure increase
during all operating modes, therefore protecting heavy-walled
parts from pressure/temperature transients. Operating modes are
mainly determined by process signals, namely the superheater
pressure and the valve position. The bypass controller therefore
does not depend on many signals from the boiler or turbine
controller.
The HP-spraywater controller, although at first glance a very
simple controller, has to deal with large variations in process
gain, time delay, and disturbances. The use of an advanced
control strategy, i.e., a state controller with observer (SCO), can
considerably improve accurate control under different operating
approx. 1 m
Straight Length
5–10 × DI
Valves below
connecting Flange
min. 3–4 m
Without Temp. Measurement
Prewarming
prewarming
Recirculation
5–7 × DI
Continously
falling
Main Steam Pipe
Cold Reheat Pipe
Figure 9—HP-Bypass arrangement
391 | Bypass Systems Designed to Enhance the Flexibility of Plant Operations 7
conditions, and is therefore an important life-conserving factor
for the heavily stressed walls of valves and piping.
The LP-bypass pressure controller controls the reheat pressure
during startup and load rejections. Similar to the HP-pressure
controller, it requires a setpoint generator producing the correct
pressure setpoint during all operating modes. In the case
of power-operated reheater safety valves, it is the LP-bypass
controller which generates the signals to keep the reheater safety
valves open as long as the reheat stem flow is too large to be
dumped through the LP-bypass only.
Because the steam conditions after the LP-bypass desuperheating
are at or near saturation conditions, the temperature after
injection cannot be used as a control signal. The necessary
injection water flow and corresponding injection valve position
must be calculated on basis of the steam flow and desired
conditions after desuperheating.
As mentioned above, the actual signal interchange between the
HP-/LP-bypass controller and other control systems is small, and
required functions for startup and other operating conditions
can be clearly defined. It can therefore be advantageous to
procure the bypass system, including controls, as one package.
The bypass supplier is best suited to implement all required
8 Bypass Systems Designed to Enhance the Flexibility of Plant Operations | 391
control functions for a smooth operation of the bypass system.
This is certainly the case if safety functions and coordination with
power operated reheater safety valves are involved.
5. Conclusion
The main reason for installing turbine bypass systems is gaining
flexibility in plant operation, especially during startup, shutdown
and disturbances of plant operation. Benefits of this enhanced
flexibility are faster startup times, reduced downtime and higher
availability of the plant, resulting in less fuel costs and lower
overall plant operating costs. The highest flexibility can be
reached with a 100 % HP-bypass system and an LP-bypass as
large as the condenser allows. If the HP-bypass is equipped with a
safety function, provided regulations allow, considerable savings
in equipment and installation costs can be made.
6. References
1. Assessment of Fossil Steam Bypass Stations
EPRI CS-3717, Final Report, 1984
2. R. Rohner, Sulzer Bypass-Systems for Fossil Power Stations
I Mech E Power Conference 1988
3. W. Bung and B. Föllmer, Controlled Safety Valves in Power
Plants in Accordance with the German Standards
VGB Kraftwerkstechnik 75 (1995) Number 9
©2000 CCI. All rights reserved.