Overview

Over the years, turbine-bypass technology has advanced along with that of the power

industry. F turbine-bypass systems have grown in sophistication to enhance

operational flexibility and to protect power plant components during a variety of transient

modes. With more than 1500 bypass valves supplied over the last 40 years and a strong

worldwide service network, our leadership has been proven time and time again.

Turbine-bypass systems are 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. Turbine-bypass systems permit operation of the steam-generator independently

of the turbine during start-up, commissioning, shutdown and load disturbances. This enhances

operational flexibility during transient operating conditions. As a result, startup and reloading

times are reduced. In addition, equipment life and overall plant availability are increased.

To achieve the desired results, turbine-bypass systems must be adequately sized to meet

the needs of transient operating modes. F can effectively support plant designers
and plant operators in selecting and integrating a bypass system into an overall plant

design. In addition to providing original-equipment, we have extensive experience in

integrating bypass systems into existing plants and in retrofitting existing bypass valves that

have failed in service. Our worldwide sales and service organization and local engineering

centers are ready to support customers in their evaluation and engineering efforts.

F turbine-bypass systems meet the requirements of all governing boiler and valve
codes, including ANSI, ASME, TRD and many others.
Examples of CCI/Sulzer Bypass Systems:

1967 RWE Frimmersdorf, Germany

(combined bypass and safety function)
1975 TEAS, Elbistan A, Turkey
(once through boiler)
1982 Chubu Electric, Kawagoe 1&2, Japan
(ultra-supercritical plant)
1988 HIPDC Shidongku, China
(supercritical power plant)
1991 Korea Electric Power Corp., Korea
(twenty supercritical units, Poryong, Taean,
Hadong & others)
1993 Shanghai Municipal Electric Power Bureau,
WaiGaoQiao 1-4, China
1993 China Light and Power, Black Point, China
(eight combined cycle plants)
1993 Kansai Electric, Himeji Units 1-5/1-6, Japan
(combined cycle units)
1995 Shell Australia Ltd., Geolong Refinery, Australia
(system redesign and valve replacement)
1996 VEAG, Schwarze Pumpe, Germany
(supercritical, combined bypass and safety
function)
1965-98 Various plants, Japan
(over 40 bypass systems)
1971-98 Neyvilly Lignite 1-3, NTPC Rihand STPP, NTPC Talcher,
CESC Budge Budge and other plants, India
(over 100 bypass systems)
1972-98 Various plants, China
(over 130 bypass systems with all utilities)
1981-98 EGAT, Mae Moh 4-13, Rayong, Ratchaburi, Thailand
(drum, combined cycle, and supercritical plants)
1988 Pacific Gas & Electric, Moss Landing, USA
(supercritical, cyclic operation)
1990 New England Power Service Co., Brayton Point, USA
(supercritical, cyclic operation)

WaiGaoQiao Power Plant, China

 “ F turbine-bypass systems are recognized around
startup, preventing needless energy loss, lengthening
Heat Recovery
Steam Generator
Deaerator

HP-Bypass

Steam Turbine
Gas Turbine
GT HP IP LP G

LP-Bypass
HP-System
IP-System
LP-System

Typical combined cycle power plant schematic IP-Bypass

Purpose

Faster Start-up and Minimized Thermal Stress

A good turbine-bypass system reduces start-up time under cold, warm, and hot conditions. The turbine-
bypass system provides continuous flow through the superheater and the reheater, and allows for higher
firing rates which result in quicker boiler warm-up. It also controls superheater and reheater pressure during
the entire startup, keeping thermal transients in the boiler to a minimum. Operating experience shows that
power plants equipped with F turbine-bypass systems experience reduced start-up times and
much less solid particle erosion of the turbine blades,reducing the need for expensive repair and replacement.

Temperature Matching

A F turbine-bypass system allows optimum steam to metal temperature matching for all start-
up modes. The boiler load can be selected to reach the desired superheater and reheater conditions
for turbine start. This results in reduced start-up time and extented life for main turbine components.
the world as the best turbine-bypass systems for faster
trouble-free plant life and increasing plant reliability.”
Steam Turbine

p HP IP LP G
HP-Bypass Safety p
Controller System

Superheater Safety
System

HP-Bypass T

p
LP-Bypass
T
Controller
Safety
System Condenser
Reheater
RH-Safety Valve

Evaporator LP-Bypass

Preheater Deaerator
Economizer

Typical coal fired supercritical plant schematic

Avoid Boiler Trip after Load Rejections

A fast-acting F turbine-bypass system allows boiler operation to continue at an optimal

standby load while demand for turbine load is re-established after a load rejection. The turbine
can cover house load requirements. Pressure and temperature transients invariably associated
with boiler trip and restart are avoided.

Eliminate HP-Safety Valves

A F HP-bypass valve sized for 100% MCR capacity can serve as an HP-safety valve
when equipped with the necessary safe opening devices. This eliminates the need for separate
spring-loaded HP-Safety valves, associated piping, and silencers and can save millions of dollars
in equipment and maintenance costs. Our engineering staff is qualified to review applicable codes
and system designs.

Preventing Energy and Feedwater Loss

Even when regulations require spring-loaded safety valves, a large capacity F turbine-
bypass system with fast acting actuators can avoid lifting of the safety valves and the resulting
energy and water losses under almost all upset conditions.
Sizing of the F Turbine-Bypass System
Turbine-bypass system sizing considerations must take into account all plant operating
conditions such as the number of warm starts, hot starts and requirements for house load
operation. Later in plant life, cyclic operation may become common. Sizing of low pressure
turbine-bypass valves must take into account the desired reheater pressure for turbine
start as well as condenser capacity.

F turbine-bypass systems are custom designed to meet the specific capacity

requirements of the individual plant. Capacity can range up to 100 percent of the maximum
continuous rating (MCR) boiler steam flow for the HP-bypass as well as for the LP-bypass.

Integrating Turbine-Bypass Systems

F turbine-bypass systems can be supplied for any type of fossil-fired power plant.
The schematics on pages 4-5 show the integration of a turbine-bypass system into a
combined-cycle power plant (CCPP) and a 500 MW fossil-fuel-fired supercritical plant.

The chart to the right shows a typical hot-startup characteristic for a supercritical, fossil-
fuel-fired, 500 MW unit using a F turbine bypass system. Forty minutes after
lighting the steam generator, the steam temperature is matched to the turbine metal
temperature. The bypass system flow rate equals the difference between steam-
generator and turbine flows. In this case it is 22 percent of full flow. The corresponding
steam-generator pressure is 30 percent of full-load pressure (80 bar [1160 psig] at 40
minutes compared to 260 bar [3800 psig] at full load).

The result is a required turbine bypass system capacity of approximately 70 percent

MCR at full load (percent-steam-flow divided by percent-pressure). Because of the
large bypass system designed into this particular plant, coal firing can be initiated
earlier, thus reducing the amount and cost of oil necessary in the start-up cycle.
 Steam
temp press flow
˚C bar %

500 300
4.2
400
4.1
300
200
200

100

0 100 100
3.1

3.2
50
2.1
2.2
1.1
2.3
2.4
0
0 50 100 minutes
Light up Synchr. Full Load

Start-Up Time

Pulverizers
1.1 Firing Rate
2.1 Feedwater Flow 3.1 Superheater Pressure
2.2 Waterwall Flow 3.2 Reheater Pressure
2.3 Steam Flow (Superheater) 4.1 Superheater Temperature
2.4 Steam Flow (Turbine) 4.2 Reheater Temperature

Hot start of a supercritical 500 MW unit

 “ F has developed a wide range of technologies for
supplier of turbine-bypass systems, F supplies researched

Valves

Duty of a Turbine-Bypass System

The primary job of any turbine-bypass system is steam conditioning — high-pressure throttling

integrated with desuperheating. Bypass valves must be able to perform these functions

and achieve the desired pressures and temperatures without undue noise and vibration

and without destructive valve-trim wear. In addition, bypass valves must perform these

functions under severe temperature cycling.

Depending upon plant design, bypass systems must also perform additional functions

such as safe HP-bypass opening and LP-bypass closing for condenser protection during

transient operating periods.

F offers the advanced valve technology to meet these severe service

requirements. With its distinctive body design, F is recognized as the lasting

turbine bypass valve technology around the world.

Lower Noise and Vibration

Excessive vibration in a turbine bypass valve can break pipe hangers and shake

accessories off actuators, resulting in high maintenance costs and unscheduled downtime.

Using wave-principle theory, F developed the unique WING-type stem with

contoured cage design for use in high pressure bypass systems. Unlike conventional plug

designs, the WING-type stem has a specially contoured profile to produce wave
valves, desuperheating, actuators and controls. As the original
and proven solutions to suit the needs of any type of plant.”

F WING-type trim

interference. This effectively “cancels out” some of the aerodynamic effects as they impact

valve parts. This design incorporates specially engineered channels that divide the steam

flow into discrete paths and increase generated noise frequency. This higher frequency

noise is more easily absorbed by the adjacent piping and results in noise-level reduction

of more than 10 dBA as compared to conventional designs.

In addition, the WING-type stem with contoured cage creates a highly turbulent zone

immediately down-stream of the valve seat in drum and supercritical plants. This turbulent

zone is ideally suited for the in-body injection of desuperheating spraywater. Also, noise is

attenuated by water injection inside the valve. This valve design ensures that this turbulent

zone is removed from any valve surface to eliminate a source of vibration.

For installations requiring strict noise control, F offers a low noise DRAG ®
solution.

DRAG® solutions provide the lowest noise for any turbine-bypass available in the industry.

Noise generated by the valve can be kept to below 85 dBA throughout the entire operating

range without the use of back pressure diffusers and acoustic insulation.

CCI DRAG® Disk Stack

 F are recognized as the benchmark of
With their distinctive body design,
turbine bypass systems — Distinctive, Complete, Proud, Swiss — F
Thermally Efficient Design

F turbine bypass systems feature unique thermally efficient bodies designed to

eliminate the stresses from thermal transients associated with cycling duty. The body designs

incorporate thin-walled spherical sections to produce compact, strong valves that are

easily recognized as the distinctive F style.

Thermographic analysis of a bypass valve during start-up showing

complete water atomisation inside a F DRE valve

Isolation Valves

Specifications often call for steam-isolation valves upstream of the LP-bypass valve

for condenser protection. F supplies LP-bypass valves which combine the

control function with a safe-closing function. However, if the specification requires a
bypass system with separate control and isolation valves for reasons of a different

plant safety philosophy, we an also supply steam isolation valves.

Reheater Safety Valves
“The desuperheating function in a F turbine-bypass
and quick evaporation of the injected water without

Desuperheating

F has developed many different controls, flow range and piping

technologies for desuperheating. The arrangement can affect the quality of

primary job for any type of desuperheater atomisation. Finally, good atomisation can

is the complete evaporation of the only be achieved when the proper

injected water — this must be spraywater valve is selected. A good

accomplished without any water droplets spraywater valve will have multi-stage

hitting the pressure boundary walls of the pressure letdown to eliminate cavitation

valve or downstream piping. Key factors and trim erosion in order to maintain fine

affecting desuperheater performance are temperature control at all steam flows.

the degree of atomisation of the injected

water and the mixing with the steam, and F experience and technology
second, quick evaporation with proper ensures the optimal solution of complete

location and direction of the spray water atomisation every time.

jet. Complete evaporation must be

attained before the first pipe bend to In-Body Desuperheating

prevent any erosion caused by high-speed For HP bypass applications in a drum or

droplets contacting the pipe walls. supercritical power plant, F

recommends in-body desuperheating.

The degree of spraywater atomization In-body desuperheating makes the best

attained is determined by the relative use of the principle of water injection into

speed of steam flow to that of injection a zone of high steam-flow turbulence. The

water flow. Full atomisation is the result of spraywater is fully atomised before the

high water injection speed and injection steam exits the valve body, thereby

of the desuperheating water into a zone providing the shortest evaporation length.

of turbulent, high-speed steam flow. In In-body desuperheating provides the

addition, factors such as accuracy of best atomisation available.

must provide for excellent steam and spraywater mixing
creating thermal stress that can cause system damage.”

Proper design of in-body desuperheating

requires a detailed understanding of the

flow pattern inside the valve at all load

conditions. F has done extensive

research into these flow patterns, including

spraywater injection and atomisation with

the help of dynamic numerical calculations.

Optimum arrangement of the injection

nozzles, material selection, and shape

and hole pattern of the cage around

the injection zone is the result of this

extensive research.

F is the only turbine bypass

system supplier that has perfected in-body

desuperheating technology to provide

long lasting, fully integrated steam-

conditioning within the valve body. With

this technology, we recommend only a

ver y shor t straight length of piping

downstream of the valve. In addition,

piping material downstream of the valve

may be switched to carbon steel instead Steam conditioning valve type DRE
using inbody desuperheating technology
of alloy material.
 Spring-Loaded Injection Nozzles

Spring-loaded nozzles are typically used for LP

bypass applications, but can be used in all

types of combined cycle power plant

applications. The atomizing principle of spring-

loaded injection nozzles is based on high-

speed injection. Due to the design of the

spring-loaded nozzles, a sufficient injection

pressure and injection speed exists at minimum

load.The injection speed results not only in good

atomisation but also in a sufficient penetration

of the spraywater into the steam flow.

In addition, the F spring-loaded

nozzle incorporates a unique swirl pattern

which provides rotational energy to the

spraywater over the entire range of flow

conditions. This insures an even distribution

which produces good mixing of steam and

spraywater with extremely good rangeability.

Steam conditioning valve type NBSE

using spring loaded spray nozzles Ring-Type Desuperheater

For LP bypass applications, F

recommends separate desuperheating

downstream of pressure reduction. In a ring-

type desuperheater, which is used primarily in

drum and supercritical power plants, steam

turbulence is created by the shape of the

steam-flow. The steam velocity is increased by

a contraction of the flow path, and the

injection takes place where the flow path

abruptly expands. Mixing takes place in this

region of turbulence to produce the shortest

Ring type desuperheater EK
distance required for atomisation.
Steam-Assisted Desuperheaters

F has developed the STEAMJET

desuperheater for steam conditioning

applications requiring the best possible

atomisation outside of the body. The

STEAMJET provides significantly better

atomisation than the ring-type and spring-

loaded nozzle desuperheaters currently

available in the industr y. The design is

based on a combination of high-speed

water injection into a high-velocity , venturi

steam flow. The "compound swirl" nozzle

provides high injection speed while the

atomising steam provides a velocity which

is virtually independent of the main steam

flow. The spray pattern is centered in the

piping to produce even temperature

distribution at all flow conditions.

F STEAMJET produces the shortest

distance required for atomisation of all

downstream desuperheaters.

Sparger Tubes

F provides custom-engineered
condenser sparger (dump) tubes for the

introduction of steam from the bypass valves

to the condenser. These optional sparger

tubes are custom designed to meet the space

constraints of the specific condenser and to

protect the internals of the condenser.

As required, we will engineer the sparger tubes

F DRAG ® steam conditioning valve
using steam assisted STEAMJET desuperheating technology.

to meet low-noise requirements. The desuperheater is also available as a separate

downstream component.
 “Turbine-bypass valves and their actuators and controls

Actuators and Controls

Reliable system operation is based on the proper

selection and design of all of the system

components . Using advanced technology

developed by F over years of testing and

experience, our expertise has produced the best

pneumatic and hydraulic actuation technology

in the industry.

Pneumatic Actuators

F pneumatic actuators feature a double-

acting piston designed to meet the application

requirements for stroke, speed, actuating force, and

positional accuracy. The actuator is equipped with

quick acting components to achieve stroke speeds

for bypass applications of one second.

Pneumatic actuator

F is the only supplier in the industry to provide

high speed pneumatic actuation with stable control.

Hydraulic Actuators

Hydraulic actuators are well suited for applications

requiring high force and high stroking speeds with

precise control. F provides the complete

system consisting of hydraulic cylinders, control devices,

positioners and hydraulic power units. The hydraulic

power units meet all safety requirements and consist

of a fluid tank, pumps, filters, accumulators, and the

necessary monitoring and controls.

Hydraulic power unit for a bypass system
must be matched for optimum system performance.”

Our hydraulic actuation systems and controls are

recognized as the original, long-lasting technology

for hydraulic actuation.

Safety Systems for HP Bypass valves

In countries where regulations allow the use of HP-

bypass valves as safety valves against superheater

overpressure, F can provide bypass valves,

actuators , and the necessar y safety control

equipment. Safe trip devices can be easily mounted

on hydraulic actuators permitting the use of bypass

systems in place of safety valves. The complete safety

system has a type approval according to the

German TRD421 code.

F Turbine-bypass Controller
A well-designed bypass controller is important for

smooth plant operation, especially during plant

Hydraulic actuator
start-up, shut down, and load disturbances. We

have more than 25 years’ experience in designing

and supplying turbine-bypass controllers.

Our latest AV6 series turbine-bypass controller uses

advanced control strategies. The state controller

with observer (SCO) provides more precise control

than standard systems, thereby producing less thermal

cycling stresses on valves and pipings.

The AV6 series controllers can easily interface to any

boiler and turbine control system.

F AV6 series bypass controller

F
a product of CCI
CCI World Headquarters
Telephone: (949) 858-1877
Fax: (949) 858-1878
F are manufactured in a
state of the art facility centrally located in
22591 Avenida Empresa
Rancho Santa Margarita Switzerland. We welcome you as a visitor
California 92688 USA to our factory and beautiful country.

CCI Switzerland
formerly SULZER THERMTEC
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
P.O. Box Hegifeldstrasse 10
CH-8404 Winterthur, Switzerland

CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567
Japan

CCI Korea
Telephone: 82 341 85 9430
Fax: 82 341 85 0552
26-17, Pungmu-Ri
Kimpo-Eup, Kimpo Gun
Kyunggi-Do, South Korea

CCI UK Technology Centre

North Europe
Sharp Street
Worsley, Manchester
M2B 3NA, England

“We Solve Control Valve Problems”

Sales & Service Locations Throughout The World
E-Mail: info@ccivalve.com
Web Site: http://www.ccivalve.com

MC-310-10/98 310