Advanced Steam Turbine Bypass Valve Design for Flexible Power Plants

The authors company has had extensive experience providing steam turbines including auxiliary systems as a turn key contractor for more than 40 years. Bypass systems are an integrated part of modern Combined Cycle Power Plants (CCPP) [1]. Bypass systems contribute a major part for operational flexibility. They allow the shortest start-up times by minimising mismatches between boiler/HRSG and turbine. Bypass systems also lead to predictable and repeatable start-up times, as well as reducing solid particle erosion of component, to a great extent. The functional requirements for bypass valves are: • Control mode for an accurate control of the IP and LP bypass steam flow during the unit start-up and shut-down, as well as during normal operating transients. • Fast closing mode for bypass-trip (supported by spring force) when required for condenser protection. • Combined mode for fast reaction on pressure increase to a define set point and further action in control mode. In the past, a combined stop and control valve design, each with a separate stem, was common. The challenging objective for the bypass valve design was to integrate the control function and the trip function with a single stem design. The authors company has developed this advanced steam turbine bypass valve that incorporates hydraulic actuator with a single stem design. The valve bodies have noise reduction fittings and are equipped with large extensions on the outlet side to reduce vibration throughout the bypass system. The bypass valve body has an integrated steam strainer which protects both valve parts and the condenser from external debris. The bypass design is prepared for Power Plants with elevated temperatures which allow for the highest plant efficiencies [2]. Surface coating protect moving components against oxidation and reduce friction by means of a surface coating. Steam at high temperature passes through the bypass to the condenser. An incorporated water attemporating flow control system reduces the steam temperatures before entering the condenser. Condensate water is injected through an orifice in the bypass system. The orifice is located down stream in the pipe between the bypass valve and condenser. Electro-hydraulic supply units deliver the control fluid to the bypass valves. An optimized bypass system has to provide: • Long service life with low maintenance costs; • High stroke speed; • Pressure control by unit set point; • High actuation forces; • Accurate positioning; • Very short trip time into closed position. By means of bypass station, one can get highest flexibility of power plants use of the new valve one will get highest control performance and shortest reaction time.