June 2, 1964 W. W.

SCHROEDTER
METHOD OF‘ AND APPARATUS FOR OPERATING AT STARTUP AND
3,135,096
LOW LOAD A ONC E-THROUGH VAPOR GENERATING SYSTEM
Filed July 27, 1961

PRESSURE 'sENsoR 46 45 __ 47

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V
VALVE
REGULATOR
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FINISHING 50 V
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__ _ | LEVEL SENSOR
SUPERHEATER \ 52‘ E; ‘ : 2-,
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49 '
A _ E’: 29 TURBINE
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20 \J
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PRIMARY ‘mm/u. _3o
su PE R HEATER REHEATER

FINISHING
REHEATER “ 3'

32
FURNACE
WALL 34
TUBES T

T T

36

ECONOMIZER l6 3.,
/

CONDENSER
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39

HEATER / '2
/ /
I4 40
@F
as
INVENTOR.
WILLBURT w. SCHROEDTER

ATTORNEYS
 3,l35,®%
United States Patent 0 "ice Patented June 2, 1954

1 2
the tubes and thereby reduces the ?ow through the super
3,135,096 heater to the turbine section to less than 10 percent full
METHOD OF AND APPARATUS F013 OPERATRNG load flow. In accordance with the invention, the turbine
AT STARTUP AND LOW LOAD A ONtZE bypass is greatly reduced in size, and is also employed
THRQUGH VAPQR GENERATING SYSTEM to supply vapor for preliminary heating and deaerating
Willburt W. Schroedter, West Hartford, Coma, assiguor purposes. Further, during low load operations, the use
to Combustion Engineering, Inc, Windsor, Conn, a of the turbine bypass is eliminated, since no excess ?ow
corporation of Delaware is produced above that permitted to pass to the turbine.
Filed July 27, 1961, Ser. No. 127,291
17 Claims. (Cl. 6?-1tl6) The superheater bypass is eliminated, since, with recircu
10 lation, the amount of ?uid passed to the superheater to
This invention generally relates to vapor generating produce a given superheater outlet temperature during
systems that operate in either the subcritical or super an initial startup need not be less than the thru flow (not
critical pressure ranges. More particularly, it relates to "' including the quantity recirculated) that leaves the fur
vapor generating systems of the forced-?ow, once-through nace Wall tubes. During a restarting operation, the
type, and is directed toward changing the bypass and 15 amount of ?uid circulated remains low enough to avoid
spillover sections normally associated with such systems. sudden cooling of the already hot superheater. Finally,
. Although vapor generating systems of the once-through the spillover associated with the turbine reheating sec
type are widely used, such systems generally contain a tions during startup operations is eliminated, since, with
number of drawbacks that tend to become more and more recirculation and the consequent reduction in furnace
objectionable as the capacity of a given system increases, 20 ?ring, the danger of overheating the reheater tubes is
To elaborate, a vapor generating system of the forced removed.
?ow, once-through type requires a special section to by Although recirculation of a portion of the working ?uid
pass the working ?uid around the turbine section of the through a section of a once-through vapor generating
system during startup to prevent liquid damage to the system is a well known technique, it has been employed
turbine, since at this time the Working ?uid is not in the 25 heretofore almost exclusively to aid in cooling certain
form of a vapor. Furthermore, such a bypass is generally ?uid carrying tubes of the system and to reduce furnace
needed during low load operation of the turbine to bypass ?ring. Recirculation is employed in this invention, how
an excess amount of working ?uid that is circulated ever, to effect drastic changes in other sections of the
through the tubes in the furnace, such excess amount being system.
required for the cooling of these furnace tubes. The Although the invention has been described generally
total ?ow in the tubes to provide proper cooling is typi above, a better understanding of it may be obtained by
cally 30 percent of full load ?ow. consulting the following detailed description of a vapor
Such systems also generally require a superheater by generating system that embodies the principles of the in
pass to compensate for startup conditions when a. rela vention. Further reference should be made to the ap
tively large ?ow of working ?uid, again approximately 35 pended drawing which contains a single ?gure show
30 percent of full load ?ow, is circulated to cool the tubes ing in block diagram form such a system.
in the furnace. To reduce the heat necessary to produce Referring to the ?gure, a storage tank 11, contain
a. given superheater outlet temperature, a superheater ing a working ?uid, is coupled to a feed pump 12 which
bypass is employed to circumvent most of the ?ow around pumps the working ?uid at a predetermined pressure to a
the superheater. Further, during restarting operations 40 preliminary heater 14. After being heated in the heater,
when the superheater is at or near its operating tempera the working ?uid passes through a control valve 15 to an
ture, a superheater bypass is utilized‘to prevent sudden economizer 16. Within the economizer, the ?uid is
cooling of the superheater due to the circulation of the heated by hot gases from a furnace (not shown), and
colder working ?uid therethrough. ' then passes to a mixing vessel 17. The output of the
Also generally required in systems of this type is an 45 mixing vessel is coupled to tubular furnace walls 19 Where
auxiliary ?uid feeding line, or “spillover,” that is coupled in the working ?uid is heated by appropriate ?ring of
to the reheating sections of the bypassed turbine appa the furnace to raise the temperature thereof. In the case
ratus during startup operations to cool the sections, there of heating a working ?uid at a supercritical pressure, an
by to prevent overheating. apparent vapor is generated while the ?uid remains in
This invention involves the recognition that startup the single phase state, in contrast to the heating of a work
and low load operations of a forced ?ow, once-through ing ?uid at subcritical pressure when the ?uid passes from
type of vapor generating system may be accomplished the liquid state to the vapor state.
without utilizing superheater bypassing and reheater spill The output of the furnace walls 159 is connected to a
over equipment and without endangering any sections of primary superheater 20 and to a stop valve 21. It the
the system, by providing for recirculation of a portion system is operating at subcritical pressures, a separator
of the working ?uid through at least a portion of the tubes (not shown) may be used to separate the liquid from the
in the furnace in combination with a unique form of ?uid ?owing from the furnace walls to be applied to the
turbine bypass in which bypassed ?uid is utilized for de stop valve 21. The stop valve is in turn connected to a
aerating and then for ?uid preheating. If desired, such recirculating pump 22 which pumps a portion of the
bypassed ?uid may also advantageously be utilized for 60 working ?uid ?owing out of the vapor generator through
other purposes, such as in turbine seals, etc., with any a stop and check valve 24 to the mixing vessel 17. With
excess ?ow being discharged by way of an outlet line to in the mixing vessel, the ?uid withdrawn for recirculation
a condenser. ' by the pump 22 is mixed with the ?uid from the econo
Pursuant to the present invention, the turbine bypass mizer 16, and the mixture is circulated to the furnace
system described above as modi?ed‘, and the superheater 65 Wall tubes 19.
bypass and the spillover to the turbine reheating sections ' In the primary superheater 2.0, the working ?uid not
are altogether eliminated, thereby substantially reducing withdrawn for recirculation is now superheated and is
installation and operating expenses. In particular, during passed to a ?nishing superheater 25 which superheats the
startup and low load operations, a portion of the Working ?uid to the required operating temperature.
?uid passing through at least a portion of the tubes in 70 The output of the ?nishing superheater 25 is coupled
the furnace is withdrawn and recirculated therethrough. through a turbine stop and governor valve 26 to a high
This provides the necessary excess ?ow of ?uid to cool pressure turbine 27. The vapor actuates the turbine, and
 3,135,0ee
as A
is exhausted therefrom through a valve 29 to an initial pressure in the line 52, the excess vapor valve 54 opens
reheater 3t) and a ?nishing reheater 31, wherein the under the action of the pressure sensing device 61 and
vapor is reheated. From the reheater 31, the vapor passes the regulating mechanism 57 , and passes to the condenser
through a valve 32 to an intermediate pressure turbine 37 any vapor, at the fourth pressure and higher pressures,
36 which is actuated thereby. The vapor then passes that is not used in the heater 14 and the deaerator 41. As
through a valve 35 to low pressure turbines 36, and is may be seen, then, the bypass system supplies vapor for
exhausted therefrom into a condenser 37 wherein the deaerating and heating, in that order and at two different
vapor is condensed to a liquid. pressures, respectively, during startup operations, and any
The liquid in the condenser 37 is pumped by a feed excess flow is passed to the condenser 37.
pump 39 to a heater 4% for preliminary heating. It 10 Since, with recirculation, the startup ?ow of Working
then flows to a deaerator 41 for the removal of air or ?uid is greatly reduced over that which it would be with
other gases therein, and ?nally passes to the storage tank out recirculation, the size of the turbine bypass system
11 to commence another cycle in the vapor generating is greatly reduced, and a superheater bypass is elimi
process. nated altogether. Further, because of furnace ?ring re
The turbine bypass apparatus, to be used during start 15 ductions that come about as a result of the smaller start
up operations, comprises a bypass valve 42 which couples up ?ow of working ?uid, a spillover line to the reheaters
the output of the ?nishing superheater 25 to a liquid and is also eliminated.
vapor separator 44. The valve 42, which is adjusted by a Operation of the system during a startup is as follows.
regulating mechanism 45 that is under the control of The turbine valve 26 is completely closed, thereby effec
either one of a pair of pressure sensing devices 46 and 47, tively removing the turbines 27, 34, and 36 and the re
throttles the vapor passing therethrough. If the system heaters 30 and 31 from the ?uid system. Next, the by~
is being operated at a supercritical pressure, the Working pass valve 42 is set to automatically open at a given
?uid is throttled to a subcritical pressure. pressure and to maintain such pressure. The feed pumps
Liquid from the separator 44 ?ows through an adjust 39 and 12 are energized, and the valve 15 is opened
able valve 49 to the condenser 37 where it is added to the to circulate less than 30 percent, and preferably less than
liquid condensed from any vapor which may be passing 10 percent, of full load ?ow of working ?uid through
from the low pressure turbines 3d. The liquid level in the system. The bypass valve 42 will now open and pass
the separator 44 is regulated by adjusting the valve 49, the flow established by valve 15. The recirculating pump
which is done automatically by a level sensing device 5@ 22 is energized, and the working ?uid is recirculated
that actuates a regulating mechanism 51 coupled to the through the furnace wall tubes 19. The bypass valve 42,
valve 49. presently under the control of the pressure sensing de
Vapor from the separator 44 is withdrawn in a line 52 vice 47, provides a predetermined pressure at the outlet
and applied to an excess vapor valve 54, a deaerator valve of the ?nishing superheater 25.
55, and a heater valve 56. Each of these valves is ad At this time, the furnace (not shown) is ?red to pro
justed by associated regulating mechanisms 5'7, 59, and 63, vide a heat input that is less than 30 percent, and prefer
respectively, which are in turn controlled by pressure ably less than 10 percent, of full load ?ring. As the
sensing devices 61, 62, and 64, respectively. ?uid reaches the desired temperature, at the outlet of
Vapor passing through the heater valve 56 is applied the ?nishing superheater 25, the working ?uid is throttled
to the heater 14 and serves to heat the working ?uid that in the bypass valve 42 and passes to the liquid and vapor
is pumped through the heater coils. The vapor is con 40 separator 44. As described above, vapor ?rst passes
densed to a liquid and is pumped out of the heater by a to the deaerator 41 to deaerate at a constant pressure the
pump 65 which returns the ?uid to the deaerator 41. working ?uid. As the vapor pressure in the line 52 in
The vapor passing through the deaerator valve 55 is ap creases, the valve 55 begins to close while at the same
plied to the deaerator 41 to be used for deaerating the time the valve 56 is opened and the excess vapor is ap
working ?uid applied from the heater 4% and the pump plied to the heater 14. Finally, as the pressure increases
65.
still further, the additional excess vapor in line 52 passes
The vapor passing through the excess vapor valve 54 through the valve 54 to the condenser 37.
is applied to a de-superheater 66. Liquid from a source When the temperature of the ?uid ?owing from the
(not shown) is applied through an injection valve 67 ?nishing superheater 25 becomes high enough to ensure
to the de-superheater 66 wherein it is sprayed into the 50 that no liquid is formed as the vapor passes through the
vapor from the excess vapor valve 54, thereby cooling turbines 27, 34, and 36, the turbine valve 26 is opened.
the vapor. The amount of liquid sprayed into the de Vapor now ?ows to the turbines and to the reheaters 30
superheater is controlled by a regulating mechanism 69 and 31. When this occurs, control of the bypass valve 42
that is, in turn, controlled by a temperature responsive is transferred to the pressure sensitive device 46 which
device '70 which measures the temperature of the vapor operates to reduce the vapor pressure in the line 52 suf
passing out of the de-superheater 66. This cooled vapor ?ciently to close the excess vapor valve 54 under the
is applied to the condenser 37 to be added to the liquid action of the pressure sensitive device 61; however, the
condensed from the vapor exhausted from the low pres pressure is retained at a high enough level to retain the
sure turbines 36.
valves 55 and 56 open, thereby supplying enough vapor
The three pressure sensing devices 61, 62 and 64 are to the deaerator 41 and to the heater 14 to satisfy their
so set that, at a ?rst vapor pressure in the line 52, the respective needs. As may be seen, then, at this time the
deaerator valve 55 opens, under the action of the pres bypass system is supplying only vapor useful for deaerat
sure sensing device 62 and the regulating mechanism 59, ing and ?uid heating; none is exhausted through the ex~
admitting vapor to the deaerator 41. As the vapor pres cess ?ow circuit.
sure in the line 52 increases, the sensing device 62 and 65 Next, the supply of working fluid is increased through
the mechanism 59 cause the valve 55 partially to close an appropriate adjustment of the pumps 39 and 12 and
to maintain the pressure in the deaerator at the ?rst pres the valve 15, and the ?ring rate of the furnace is in
sure. At the same time as valve 55 begins to close, or creased to preheat the turbines, to actuate the turbines,
at a second, higher pressure in the vapor line 52, the valve and then to synchronize them at some predetermined
56 opens in response to impulses received from valve 55 70 load. At this point, the bypass system is shut down com
to admit the excess vapor to the heater 14. As the vapor
pletely by closing the bypass valve 42. Thereafter, vapor
pressure in the line 52 increases, the sensing device 64 is applied to the heater 14 and to the deaerator 41 for
and the mechanism 69 may desirably regulate the valve heating and deaeration, respectively, from turbine ex
56 so that the pressure in the heater 14 rises to, but does
traction lines (not shown) that Withdraw vapor from
not exceed, a third pressure. At a fourth, even higher 75 the turbines for this purpose.
 3,135,096“
6
After closing o? the bypass system, the recirculating working ?uid of the system, comprising ?rst means cou
pump 22 is retained in operation until a suf?cient amount pling the bypass system to one of the deaerating and pre—
of working ?uid passes through the furnace wall tubes liminary heating means when the pressure in the bypass
19 to the superheaters 20 and 25 to cool the ?uid carry system is at least as great as a ?rst pressure, and second
ing tubes (not shown) that are exposed to the hot fur ’ means coupling the bypass system to the other of the
nace gases. This occurs when a given load in the system deaerating and preliminary heating means when the
is reached, and atlthis point the valve 21 may be closed. pressure in the bypass system is at least as great as a
From the description of the invention above, it is ap second pressure, said second presure being greater than
parent that modi?cations and changes may be made with said ?rst pressure.
out departing from the spirit of the invention. Such 6. In combination with apparatus as recited in claim
modi?cations and changes should be deemed to be en 5, means coupling the bypass system to the condensing
compassed by the following claims, which are set forth means when the vapor pressure in the bypass system is
as follows to de?ne the invention. . greater than a third pressure, said third pressure being
I claim: greater than said ?rst and second pressures.
1. In combination with a vapor generating-turbine sys 7. The method of operating at startup a vapor generat
tem that has in series relationship a source of working ing-turbine system that has a furnace and, in series rela
?uid, pumping means for circulating the working ?uid, tionship, a tubular section of a furnace wall, a vapor heat
furnace wall heating tubes, a superheating section, tur ing section, turbine apparatus, and condensing means;
bine apparatus, and condensing apparatus; means for comprising the steps of bypassing only the turbine ap
facilitating startup and load operations comprising re 20 paratus, circulating substantially less than 30 percent full
circulating apparatus for recirculating a portion of the load ?ow of working ?uid through the system, recirculat
working ?uid through at least a portion of the furnace ing a portion of the working ?uid through at least a part
wall heatingtubes to maintain a minimum velocity of of the tubular furnace wall section by returning said work
the working ?uid therein, and bypass means connected ing ?uid portion directly to said tubular furnace wall sec
in parallel relationship with only the turbine apparatus 25 tion from a point downstream of said part and directly
and having a capacity of substantially less than 30 per to a point upstream of said part so as to maintain a mini
cent full load ?ow for bypassing the turbine apparatus. mum velocity of the working ?uid therein, and ?ring the
2. Apparatus as recited in claim 1 in which the bypass furnace at substantially less than 30 percent of full load
means has a capacity of less than 10 percent full load ?ring.
?ow capacity. 8. The method of operating at startup a vapor generat
3. A vapor generating system for operation in the ing system that has a furnace and, in series relationship,
supercritical pressure range during startup and low load a source of working ?uid, pumping means for circulating
operations, comprising furnace wall heating means, super the working ?uid throughout the system, a tubular fur
heating means, turbine means, condensing means, the nace Wall section, a superheating section, turbine appara
four last-named means being connected in closed series 35 tus that has at least one re-heating section, and a con
relationship to form a vapor generating unit, pumping denser; comprising the steps of bypassing only the turbine
means for circulating a Working ?uid at supercritical apparatus, circulating substantially less than 30 percent
pressures through the unit, means for recirculating a por full load ?ow of working ?uid throughout the system at
tion of the working ?uid through at least a portion of a ?rst predetermined pressure, recirculating a portion of
the furnace wall heating means to maintain a minimum 4:0 the working ?uid through at least a portion of the tubular
velocity of the working ?uid therein, and bypass means furnace wall section, ?ring the furnace at substantially less
connected in parallel relationship with only the turbine than 30 percent full load ?ring, regulating the pressure
means and having a capacity of substantially less than 30 at the superheater outlet at a desired working pressure,
percent full load ?ow for bypassing the turbine means. admitting vapor to the turbine apparatus at a predeter
4. In combination with a vapor generating-turbine mined vapor temperature, increasing the ?ring of the fur
system that has in series relationship a source of Work 45 nace and synchronizing the turbine apparatus at a pre
ing ?uid, pumping means for circulating the working determined load, and discontinuing the bypassing of the
?uid, heating means having a vapor input for prelimi turbine apparatus at a preestablished turbine load.
narily heating the working ?uid, a furnace wall heating 9. The method as recited in claim 8 in which the
section, a superheating section, turbine apparatus, con amount of ?uid initially circulated is less than 10 per
densing apparatus, and deaerating means having a vapor 50 cent of full load ?ow and the initial ?ring rate is less
input for deaerating the working ?uid; means comprising than 10 percent full load ?ring.
recirculating apparatus for recirculating a portion of the 10. The method as recited in claim 8 wherein the de
working ?uid through at least a portion of the furnace sired working pressure is within the supercritical pressure
wall heating section to maintain a minimum velocity of range.
the working ?uid therein, bypass means connected in 55 11. The method of operating at startup a vapor generat
parallel relationship with only the turbine apparatus and ing-turbine system that has a furnace and, in series rela
having a capacity of substantially less than 30 percent tionship, a tubular furnace wall section, a vapor heat
full load ?ow for bypassing the turbine apparatus, ?rst ing section, turbine apparaus that has at least one reheat
means coupling the bypass means to the vapor input of section, condensing means, and a plurality of heat ex
the deaerating means when the pressure in the bypass 60 changers; comprising the steps of bypassing the turbine
means is at least as great as a ?rst pressure, second means apparatus, circulating substantially less than 30 percent
coupling the bypass means to the vapor input of the heat full load ?ow of working ?uid through the system, re
ing means when the pressure in the bypass means is at circulating a portion of the working ?uid through at least
least as great as a second pressure, said second pressure a portion of the tubular furnace wall section, ?ring the
being greater than said ?rst pressure, and means coupling 65 furnace at substantially less than 30 percent of full load
the bypass means to the condensing apparatus when the ?ring, and sequentially applying ?uid bypassed around
pressure in the bypass means is at least as great as a the turbine apparaus to different ones of the plurality of
third pressure, said third pressure being greater than the heat exchangers to add heat to the working ?uid passing
?rst and second pressures. through the heat exchangers.
5. In combination with a bypass system that bypasses 70 12. In combination with the method as recited in claim
the turbine section of a vapor generating system, the vapor 11, the steps comprising admitting vapor at a predeter
generating system having working ?uid preliminary heat mined vapor temperature to the turbine apparatus from
ing means, working ?uid deaerating means, and vapor
condensing means; means for utilizing vapor from the the vapor heating section, and, after vapor is admitted
bypass system to deaerate and preliminarily heat the 75 to the turbine apparatus, discontinuing the application of
 3,135,096
8
?uid bypassed around the turbine apparatus to the con 16. ‘Apparatus as recited in claim 5, wherein the ?rst
densing means. means includes means for retaining substantially constant
13. The method of operating a bypass system that by the pressure at which the ?uid is applied to one of the
passes the turbine section of a vapor generating system, deaerating and preliminary, heating means from the bypass
the vapor generating system having working fluid pre system. i i
liminary heating means, Working ?uid deaerating means, 17. The method as recited in claim 11, wherein the
and vapor condensing means; comprising the steps of ap fluid bypassed around the turbine apparatus is applied to
plying to one of the deaerating and preliminary heating the condensing means after 'all the heat exchangers are
means vapor separated from the ?uid in the bypass sys being supplied with ?uid bypassed around the turbine
tern when the pressure in the bypass system is at least 10 apparatus. '
as great as a ?rst pressure, and applying to the other one
of the deaerating and preliminary heating means vapor References Cited in the ?le of this patent
separated from the ?uid in the bypass system when the
pressure in the bypass system is at least as great as a sec UNITED'STATES PATENTS
ond pressure, the second pressure being greater than the 15' 1,934,667 Hatter ______________ __ Nov. 7, 1933
?rst pressure. 2,900,792 Buri ________________ __ Aug. 25, 1959
14. In combination with the method as recited in claim 2,989,038 Schwarz _____________ __ June 20, 1961
13, the steps comprising applying vapor separated from' 3,009,325 Pirsh ________________ __ Nov. 21, 1961
the ?uid in the bypass system to the condensing appara 3,019,774 Beyerlein ____________ __ Feb. 6, 1962
tus when the pressure in the bypass system is at least 20 3,038,453 Armacost ____________ __ June 12, 1962
as great as a third pressure, the third pressure being
greater than the ?rst and second pressures. FOREIGN PATENTS
15. Apparatus as recited in claim 1, including a plu 709,888 Great Britain _________ __ June 2, 1954
rality of heat exchangers through which the working ?uid 1,064,869 France ______________ __ Dec. 30, 1953
passes, and means for sequentially applying ?uid from 25
the bypass means to di?ferent ones of the plurality of heat OTHER REFERENCES
exchangers to add heat to the working ?uid passing The Breed Plant Story, pp. 47-78, January 16, 1961,
through the heat exchangers. Electrical World.
 UNITED STATES PATENT OFFICE
CERTIFICATE OF CORRECTION
Patent No, 3, 1358096 _ June 21 1964
Willburt W0 Schroedter
It is hereby certified that error appears in the above numbered pat
ent requiring correction and that the said Letters Patent should read as
corrected below.

Column 59 line 2Oq before "load‘" insert —— 10w ——; column

6v line 8‘? for "'presure‘" read —- pressure ——; lines 58- and
6% for "'apparaus"it each occurrence‘I read —- apparatus ——.

Signed and sealed this 29th day of September 1964o

(SEAL)
Attest:

ERNEST W; SWIDER EDWARD J. BRENNER

Attesting Officer Commissioner of Patents