CCI+Sulzer+苏尔寿汽机旁路

1、Turbine Bypass Systemsfor supercritical PlantsGet the Valve Doctor solutionSulzer Monotube Steam GeneratorDeveloped in 19312First Sulzer Bypass Valve, 19343Ultra supercritical boiler 353 bar / 654CSteam Valve Stationwith Bypass ValvePECO Eddystone (1959)4CCI Sulzer 苏尔寿汽机旁路竞争策略CCI 投诉举报热线（腐败）邮件：Anti-C

2、orruption Policy to the CCI Compliance Officer () or the Legal Department of IMI plc (jo.). 热线网站：the IMI Hotline (). CCI 投诉举报热线（合规）Charles Fernald, Chief Compliance Officer, , +1 949 888 4167 Katy Collins, Associate General Counsel, , +1 949 888 4306 Illya Antonenko, Associate General Counsel, , +1

3、949 973 1198 无论是邮件，还是网站举报，CCI都是有举报必查。5CCI Sulzer 苏尔寿汽机旁路竞争策略举报情况：CCI 有行贿、围标、与竞争对手协商等情况CCI 中国目前是固定代理商制度，而且不能转单（不允许有二级代理商）。固定代理商的加价不能超过6%，也就是6%的利润（含代理商差旅费用）。从上面两个条件来看，只要CCI的投标，记下投标价格，把项目名称和投标价格发给国外的法律部门，这个项目CCI就要退出。以下是代理商加价计算表代理商在申请项目授权前，项目投标前，都要在此表签字盖章，承诺加价比例不超过6%。6CCI Sulzer 苏尔寿汽机旁路竞争策略以下是CCI 中国授权代理

4、商（不许转单）， 只要投标的主体不是以下公司，抓紧举报7CCI Sulzer 苏尔寿汽机旁路竞争策略总之，CCI 投标的项目，无论是备品备件、电力项目、石化项目，只要不是上面名单的代理商，或者你知道CCI投标价格（谁都知道6%的利润太低），你就放心大胆的到第一页的邮箱、网站去举报吧。CCI 由于2006年行贿，目前还在美国司法部的监管期，只要有举报，一定会查。过去三年，CCI中国内部举报的律师费都在100万美金左右。CCI汽机旁路的备件价格比较高，又是必须采购的刚需产品，是转单的重灾区，大家要多留心。CCI Sulzer 汽机旁路是捷克斯洛伐克生产，东欧二流国家。CCI 瑞士工厂2010年已经

5、关闭。CCI 捷克斯洛伐克工厂，生产汽机旁路、迷宫阀、BTG 减温加压器。CCI 韩国工厂生产套筒式低压调节阀8Long-term Experience 1st Sulzer Monotube Boiler 1934 HP-Bypass Eddystone USA1959HP-Bypass (1st Ultra supercritical plant) Dungeness B (Nuclear)GB1966HP-Bypass FrimmersdorfGermany1967HP-Bypass (1st combined HP-bypass/safety valve) KothagudemIndi

6、a1970HP-Bypass Dos BocasMexico1974HP -Bypass Cool Water USA1975HP-Bypass DuvhaS.Africa1976HP-/LP-Bypass AtsumiJapan1978HP-Bypass EraringAustr.1979HP-/LP-Bypass9References Bypass Systems, T 590CPlantYearCountryValveTMatsuura 21995JapanNBT64-450593CMilmerran2000AustraliaNBSE55-700593CKarita11997JapanN

7、BT64-600595CReihokou 22001JapanNBT64-500598CDrakelow1986UKDRE90600CAvedoere 21997DenmarkNA& NBST600CTachibanawan 21998JapanDRU160605CLudwigshafen 7, 8, 91976GermanyAR63610CYuhuan 1- 42004ChinaNBSE60-550608CYuhuan 1- 42004ChinaDRE160610CTachibanawan 11997JapanNBT64-550613CTachibanawan 21998JapanNBT64

8、-550613CTorrevaldaliga North2005ItalyHBSE280612C10COST ProgramEuropean Co-operation in the field of scientific and technical research.COST Action 536 : Alloy development for critical components of environmental friendly power plantFocus is to find new alloys for power plants up 650degC.CCI participa

9、tes in COST 536Evalution of surface coatings for good sliding properties and wearAccess to all COST 536 research information11Benefits of a Turbine Bypass SystemSave money over the lifetime of a Thermal Power PlantDuring plant commissioning, the boiler trial- operation can be accomplished without th

10、e turbineSave time, fuel and component life-time on every start-upImproved operational flexibility after turbine trips and load rejections. Energy savings and faster reloading of plant 12HP BypassBypasses steam around the HP Turbine to the Reheat LineSpraywater injection must be tight when bypass is

11、 closed Isolation and control valveLP BypassBypasses steam around the IP/LP Turbine to the CondenserLP-Bypass needs safe closing function to protect the condenser Bypass System in the coal-fired Power Plant13Benefits of a Turbine Bypass System14Cold Start of a Supercritical Unit15Hot Start of a Supe

12、rcritical Unit1.1Firing Rate2.1Feedwater Flow2.2Waterwall Flow2.3Steam Flow (Superheater)2.4Steam Flow (Turbine)3.1Superheater Pressure3.2Reheater Pressure4.1Superheater Temperature4.2Reheater Temperature16Benefits of a Turbine Bypass System100% Bypass with safety functionactual operation at 150 bar

13、 (60%) and 50% flow Approx. 80% openSchwarze Pumpe, 800 MW Lignite fired 17Sizing considerations for HP-BypassCoal Fired Boiler Actual bypass size depends on actual flow, pressure and temperature at the different relevant operating conditions(Cold/warm/hot/superhot start; evtl. load rejection)Nomina

14、l Bypass size is flow capacity (in % of MCR at full pressure/temperature18Sizing for Start-upCold/Warm StartStable boiler load for turbine start ?Coal fire for turbine synchronizing ?IP Start ? (load for HP forward flow transfer?)Hot Start/Superhot StartSteam to metal temperature matchingTemperature

15、 of the turbine ?Min. Boiler load to reach the desired temperaturePlease provide actual operating data (cold/warm/hot/ superhot start; load rejection) for Bypass sizing19IP-Turbine StartTurbine is accelerated, synchronized and initially loaded through IP- and LP-turbineFull flow of LP-turbine until

16、HP-turbine loading has to go through HP-BypassBypass System in the coal-fired Power Plant20Dongfang (Hitachi) designHp-Bypass to CondenserNo LP-BypassReheater uncooled during bypass operation Limited firing rate of the boiler possibleBypass System in the coal-fired Power Plant21Benefits of a Turbine

17、 Bypass System22Typically sized for:Max. flow through HP-Bypass including spraywater during start-up and load-rejection(at which reheater pressure ?)Max. reheater pressure to avoid overheating of HP-turbine during start-up or with house load operation Nominal LP-bypass size is often larger than HP-B

18、ypass because of low pressure during start-up Consider:Max. condenser dump capacity (including LP-Bypass spraywater flow)Sizing considerations for LP-Bypass23HP-Bypass with Safety Function HP-Bypass with safety function (TRD 421)Often together with RH-safety valves of same technologyKorea (100% of a

19、ll supercritical units)China (SDK, WGC)South AfricaEurope24HP-Bypass Safety FunctionFlow-to-open main valveMain valve opens with steam pressure only (no external energy required for safety opening)3 completely independent, redundant safety channelsDe-energize to trip:(fail-safe operation)Test logic

20、allows testing of the function of each channel during operationTest is checking complete channel from pressure switch up to movement of the main valve25Advantages of combined highpressure bypass and safety valvesNo conventional safety valves required, No piping and silencersHigher reliability than s

21、pring-loaded safety valvesMinimal pressure and temperature excursionsTest and calibration of safety function during normal operationMinimal water lossNo leaking valves because of high seating forcesSmooth transfer to control mode26Major Concerns for the DesignThermal stress due to water steam temper

22、ature difference Avoid temperature differentials onmechanically loaded parts(e.g. spraywater through the valvestem)Thermal stress due to cyclic operation Optimised valve body (thin walls,smooth transitions of wall thickness)27Major Concerns for the DesignThermal shock due to spraywater hitting press

23、ure boundary wallsProtect pressure boundaries from being hit by waterQuick evaporation Erosion due to water droplet impingement on valve bodies and pipesQuick evaporation 28Major Concerns for the DesignNoise and VibrationAvoid resonance and multiplereflectionsWater hammer due to leaking spray valves

24、High seat sealing forcesAvoid cavitation/erosionMaintenance CostsValve internals easily exchangeable29HP-Bypass valve, DRECompact robust designLess number of componentsEasy to maintainIntegrated desuperheatingVery short straight pipe length after the valveDesigned for frequent start-upsOptimized bod

25、y shape for minimal thermal stressPressure range 160 - 300 barTemperature range 500 - 610oCTightness DIN 3230 Rate 2MSS-SP 61Type approval as safety valve according to TRD421 and EN4126 for complete valve with actuator (no spring required)30In-body Desuperheating Valve Type DREThin walls and smooth

26、transitionsto minimize thermal stressCage for protection of pressure boundary walls and good flow distributionSpraywater injection into zone of highest turbulence good mixing, immediate evaporationWing type stem for noise reductionFlow to open design for safetyfunctionIn-body desuperheating is the t

27、echnology with the best mixing and fastest evaporation30 years research and experience (1500 valves) guarantee reliable operation31Numerical Calculation of Steam Flow and Water-injectionR&D32R&DThermographic AnalysisValve bodies are designed to handle fast temperature transients (Below are two pictu

28、res taken of a Sulzer HP-Bypass valve type DRE 125)33HP-Bypass Valve Type HBSE280Design 280bar / 585CHigh Temperature design for up to 610CForged bodyBalanced plug or pressurized seat Hydraulic or pneumatic actuationCustomized desuperheater sizeDesuperheater with spring-loaded spray-nozzles or Torus

29、34Desuperheating section Outlet cages reduce noise through small holesOutlet cages direct the steam to the water injection Increased steam velocity due to reduced flow areaSteam flow expands towards the centre after the cages35Spring Loaded Spray Nozzle36Nozzle Spray Patterns, (High Speed Photograph

30、y)Spray nozzleWhirl nozzleSpring loaded nozzle37Ring style desuperheaterSpray water injected on whole circumference through high number of small holesDeflection cone creates zone of increased velocity and high turbulence Good atomisation and optimal mixing with steamFlexible fixing of water ring to

31、accept differential expansionExcellent longterm experience with a large number of compact coolers of similar design38Ring style Desuperheater vs springloaded NozzlesFixed small orifices with steam velocity atomisationMixing through steam flow turbulenceSimpler design, no moving partsUsually sufficie

32、nt rangeability of water flowVariable orifice/high spraywater velocityMixing through high injection velocity/deep penetration Higher rangeability of water flow39LP-Bypass Valve Type NBSE60Design 60bar / 585CHigh Temperature design for up to 610CTypically cast bodyBalanced plug or pressurized seatHyd

33、raulic or pneumatic actuationDesuperheater with springloaded spray-nozzles or TorusReplaceable cageReplaceable seat(mandatory for large horizontally arrange valves)40Millmerran420MW SupercriticalLP-BypassNBSE 55-60041Startup BypassStartup Bypass as a version of the Standard Bypass Valve designSpecif

34、ically designed for typical start-up conditionsStart-up conditions with low inlet pressure High Cv requiredOnly start-up conditionslow absolute flow small desuperheater diameter and outlet pipe required42LP-Bypass Valve Type NBSE60S(Start-up Bypass; 30-40% capacity)High Cv required for start-up cond

35、ition with low pressureMax steam flow 30-40%Design 60bar / 585CHigh Temperature design for up to 610CTypically cast bodyBalanced plug or pressurized seatHydraulic or pneumatic actuationDesuperheater with spring-loaded spray-nozzles or TorusReplaceable cageReplaceable seat43CCI Pressurized Seat Desig

36、nInletStemBonnetPiston RingBodyPilot SeatPlugDisk StackSeat RingUpstream FluidPressureDownstream FluidPressureDifferential Area = 4(X2 - Y2)Inlet44Comparison with Steam-assisted DesuperheatingLarge metal mass with high thermal cycling loadHigh thermal stressLarge bending moment on spray-head (Vibrat

37、ion)Injection in the direction of the steam flow Long distance for mixingAssist-steam flow limits the rangeability High min. steam flowor too low steam flow for high spraywater45Materials HP-BypassInlet:Typically same as pipe material(F91 or F92)Body:F91 or F92 depending on Pressure and TemperatureO

38、utlet:F22 (Steam temperature is even without spraywater injection typically 520C)Outlet Pipe:Typically F22 or lower gradeWater Connection:Typically 16Mo3 (weldable to carbon steel)46Temperature DistributionAfter spray nozzles:2 m alloy pipe (F22/F11) recommended before changing to carbon steelSteam

39、flow directionSpray Nozzle47Materials LP-BypassInlet:C12A (F92 transition piece in case of P92 inlet pipe)Body:Cast Body C12ADesuperheater:F91 (lower pressure and temperature than inlet)Transition to outlet pipe size:F22Outlet Pipe:Typically F22 (F22 recommended for dump tubes)Water Connection:Typic

40、ally 16Mo3 (weldable to carbon steel)48Materials LP-Bypass (NBSE60S)Outlet:Combined adapter piece for pipe size and material49Recommended HP-Bypass Arrangement (flow-to-open-Valve)50Recommended HP-Bypass Arrangement OTP-ValveTypical HP-bypass arrangement with flow-to-close valveSelf-draining inlet a

41、nd outletDistance to Mainsteam pipe 4m:Prewarming recommended51Prewarming ArrangementsCirculation pipe to keep connection pipe hot and dryRecommended prewarming temperature 100-150C below operating temp. Circulation pipe must be insulatedMinimal loss and no isolating valve required 52Prewarming Arra

42、ngementsFlow-to-close HP-Bypass valveCirculation pipe to keep connection pipe hot and dry Prewarming flow depends on pipe length and valveDrain at the lowest point of the valve inlet for start-up53LP-Bypass, Typical ArrangementRecommended Layout for LP-BypassMost compact arrangementV=80-150m/sDist =

43、 0.05s x VFlexible inlet pipe arrangementStraight pipe after desuperheater(avoid erosion due to wet steam)H=2650kJ/kg, T80CH=2650kJ/kg, q95-98%54LP-Bypass ArrangementRequires more space than horizontal bypassHigh temperature bend between valve and desuperheater55KEPCO Poryong 1-4LP-Bypass with Isola

44、tion Valve500MW supercritical coal-firedHot reheater 40 bar / 541 oCBypass Flow 1300 t/h at 27.2 bar (2 lines)LP-Bypass Arrangement56Purpose of the Dump TubeControlled steam dispersion in the condenserDivide the large high-energy steam jet into mutliple small jetsGenerate back pressure for the bypas

45、s valve/desuperheaterKeep steam velocity within allowable limits57Dump Tube Shapes and Hole Pattern for various Condenser ShapesFishmouthSide dischargeFront dischargeDump Tube shape depends on available space in the condenserCCI can supply Basic designManufacturing dwgsComplete dump tubes58Dump Tube

46、 Shapes and Hole Pattern for various Condenser ShapesFishmouthSide dischargeFront discharge59Potential damage by condensate in the bypass pipingErosionWater droplets carried in the steam at high velocity through valve and pipingWaterhammerWater accumulated in pipes during no-flow“-conditions, and th

47、en pushed through the piping by high velocity steam60Erosion61Piping layout and Drains62Avoid Water Accumulation in Bypass PipingOnly superheated steam should flow through the bypass ValvesNo condensate from the main steam or hot reheat pipe should enter the bypass connection pipe. (drain condensate before the connection)Connection pipe from main steam or hot reheat pipe to the bypass should be self-drainingIf the connection pipe is not self-draining and longer than 5 m (15 ft) an automatic drain must be provided before the bypass and at any low point of the pip