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Last time we learned how the condenser recycles steam from the turbine exhaust by condensing it back into water for its reuse within the power plant steam-water cycle. This water is known as condensate, and after leaving the boiler feed pump at high pressure, it’s known as boiler feed water. Today we’ll introduce a special valve into the system, whose job it is to perform the important function of compensating for lost water. It’s known as the make-up valve.
The illustration shows the flow of steam and water within the cycle. Tracing the path of orange arrows will reveal it as a closed system. Under ideal operating conditions recycled condensate from the condenser would provide enough water to keep the boiler indefinitely supplied. In reality water and steam leaks are a chronic problem within power plants, even when well maintained. Leaks typically occur due to worn parts on equipment, a condition which is commonly present due to the demanding operating conditions they must endure. First, there is the strain of continuous operation, then there are the high temperatures, typically greater than 1000°F, and high pressures that pipes, valves, pumps, and the boiler itself must endure. We’re talking about pressure higher than 2000 psi, that is, pounds per square inch. As a result, water levels within the boiler must periodically be replenished. While tracing the arrows through the diagram, you would have come across the new make-up valve under discussion. It’s located on the pipe leading from the power plant’s water treatment system to the boiler feed pump. It’s normally kept closed, except under two circumstances, when the boiler is initially filled at startup, or when water replenishment needs to take place. Due to water loss and difficult operating conditions, maintenance within the water-to-steam system of a power plant is a never ending task. There are miles of pipe connected to hundreds of pieces of equipment, all of which are distributed through a huge power plant structure. So the reality is that power plants operate with a continuous eye on leakage. To contend with the leaks, human intervention is often required in the way of a boiler operator. Their job is to manually open the make-up valve to admit a fresh supply of water from the treatment plant to the boiler via the boiler feed pump. Once the system’s water requirements are replenished, the valve is once again closed. Next time we’ll continue this series by discussing how the condenser enables the steam turbine to run more efficiently by creating a vacuum at the turbine’s exhaust.
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Posts Tagged ‘electric utility power plant’
The Make-up Valve in the Power Plant Steam to Water Cycle
Monday, October 28th, 2013
How A Power Plant Condenser Works, Part 3
Monday, October 14th, 2013|
We’ve been discussing various aspects of a power plant’s water-to-steam cycle, from machinery specifics to identifying inefficiencies, and today we’ll do more of the same by introducing the condenser hot well and discussing its importance as a key contributor to the conservation of energy, specifically heat energy. Let’s start by returning our attention to the steam inside the condenser vessel. Last week we traced the path of the condenser’s tubes and learned that the cool water contained within them serve to regulate the steam’s temperature surrounding them so that temperatures don’t rise dangerously high. To fully understand the important result of this dynamic we have to revisit the concept of latent heat energy explored in a previous article. More specifically, how this energy factors into the transformation of water into steam and vice versa. Steam entering the condenser from the steam turbine contains latent heat energy that was added earlier in the water/steam cycle by the boiler. This steam enters the condenser just above the boiling point of water, and it will give up all of its latent heat energy due to its attraction to the cool water inside the condenser tubes. This initiates the process of condensation, and water droplets form on the exterior surfaces of the tubes.
The water droplets fall like rain from the tube surfaces into the hot well situated at the bottom of the condenser. This hot well is essentially a large basin that serves as a collection point for the condensed water, otherwise known as condensate. It’s important to collect the condensate in the hot well and not just empty it back into the lake, because condensate is water that has already undergone the process of purification. It’s been made to pass through a water treatment plant prior to being put to use in the boiler, and that purified water took both time and energy to create. The purified condensate also contains a lot of sensible heat energy which was added by the boiler to raise the water temperature to boiling point, as we learned in another previous article. This heat energy was produced by the burning of expensive fuels, such as coal, oil, or natural gas. So it’s clear that the condensate collecting in the hot well has already had a lot of energy put into it, energy we don’t want to lose, and that’s why its an integral part of the water-to-steam setup. It acts as a reservoir, and the drain in its bottom allows the condensate to flow from the condenser, then follow a path to the boiler, where it will be recycled and put to renewed use within the power plant. Next week we’ll follow that path to see how the condensate’s residual heat energy is put to good use. ________________________________________ |
Superheater Construction and Function
Sunday, September 15th, 2013|
Power plants produce electrical energy for consumers to use, whether at home or for business, that’s obvious enough, but did you know that in order to produce that electrical energy they must first be supplied with heat energy? The heat energy that power plants crave comes from a fuel source, such as coal, oil, or natural gas, by way of a burning process. Once the heat energy is released from the coal through burning, it’s transported into a steam turbine by way of superheated steam, which is supplied to it by a piece of equipment named, appropriately enough, a superheater. So what is a superheater and how does it function? Take a look at the illustration below.
The superheater looks like a W. It’s actually a cascading array of bent steam pipe, situated above a source of open flames which are produced by the burning of a fuel source. A photo of an actual superheater is shown below.
So how many bends are in a superheater? Enough to fill the needs of the particular power plant it is supplying energy to. Since all power plants are designed differently, we’ll keep things in general terms. The many bends in the superheater’s pipes form a circuitous path for steam to flow as it follows a path from the boiler to the steam turbine. The superheater’s unique construction gives the steam flowing through it maximum exposure to heat. In other words, the bends increase the time it takes for the steam to flow through the superheater. The more bends that are present, the longer the steam will be exposed to the flame’s heat energy, and the longer that exposure, the more heat energy that is absorbed by the steam. Superheating routinely results in temperatures in excess of 1000°F. This superheated steam is laden with abundant heat energy which will keep the steam turbine spinning and the generator operating. The net result is millions of watts of electrical power. As we learned in a previous blog, the superheater is designed to provide the turbine with sensible heat energy to prevent steam from completely desuperheating, which would result in dangerous condensation inside the turbine. The newly added superheater is a major improvement to a power plant’s water-to-steam cycle, but there’s still plenty of waste and inefficiency in the system, which we’ll discuss next week.
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Desuperheating in the Steam Turbine
Monday, September 2nd, 2013|
Last time we learned that the addition of a superheater to the electric utility power plant steam cycle provides a ready supply of high temperature steam, laden with heat energy, to the turbine, which in turn powers the generator. But this isn’t its only job. One of the superheater’s most important functions is to regulate the ongoing process of desuperheating that takes place as the turbine consumes heat energy. To understand this, let’s see what takes place if the superheater were to be removed from its position between the boiler and turbine.
Figure 1
Without the superheater, the only available remaining source of sensible heat energy to the turbine would come from the meager amount present in phase C steam as shown in Figure 1. If you’ll recall from a past blog, the sensible heat energy contained in superheated steam is the best source of energy for a steam turbine, because it’s able to keep it operating most efficiently. As the turbine consumes the heat energy in phase C, starting at point 3 and continuing to point 2, the steam it’s consuming is in the process of desuperheating, as evidenced by the downward slope between the two points. Desuperheating is an engineering term which means that as sensible heat energy is removed from the steam due to its use by the turbine, there will be a resulting drop in steam temperature. And if this process were to continue without the compensatory function provided by the addition of a superheater to the steam cycle, the steam’s temperature would eventually return to mere boiling point, at point 2. This is an undesirable thing. With the steam’s temperature at boiling point, the only remaining source of heat energy to the turbine is the latent heat energy of phase B. This heat energy will lead to an undesirable circumstance for the operation of our power hungry turbine as we will see next week. ________________________________________ |
Heat Energy Within the Power Plant—The Power Behind the Turbines
Monday, July 29th, 2013|
Last time we discovered that the boiling point of water varies. It’s dependent upon the amount of pressure exerted on its surface, which varies due to a variety of reasons, including where it is in relation to sea level. Before we see what happens under higher than atmospheric pressures, such as exist in an electric utility power plant boiler, let’s cover some basics. In the power plant, water is heated in a boiler specifically to produce steam, unlike our tea kettle where the primary purpose is to produce hot water. The steam produced is used to spin turbine generators, which in turn generate electricity, as I explained in a previous blog on steam turbines. Unlike a tea kettle, which is open to the atmosphere on your kitchen stove, the boiler in a power plant is an enclosed, reinforced steel vessel. See illustration below.
The reinforced steel boiler vessel is designed to withstand great internal pressure as temperatures rise within. In addition to providing a safety feature, the enclosed space provides a sheltered environment for collecting steam so it can later be put to use spinning power generating turbines down the line. In other words, surface water inside the boiler is closed off from the surrounding atmosphere, allowing its internal pressure to build for our specific purposes. As heat energy is added to water within the boiler, the water boils and steam bubbles break out from its surface, filling the empty space above the surface with pressurized steam. This steam will try to expand here, but it can’t, because it’s being constrained by the reinforced steel vessel within which it is enclosed. Instead, steam pressure builds up on the surface of the water inside the boiler until it is high enough to be released through an attached pipe which is connected to a nearby turbine. We’ll talk more about this pent-up energy and how it is put to use within the power plant in next week’s blog. ___________________________________________
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Forms of Heat Energy – Boiling Water and Atmospheric Pressure
Sunday, July 21st, 2013|
If you’ve ever baked from a pre-packaged cake or cookie mix, you’ve probably noticed the warning that baking times will vary. That’s because the elevation of the area in which you’re doing the baking makes a difference in the baking time required. Living in New Orleans? Then you’re at or below sea level. In Colorado? Then you’re above sea level. Your cake will be in the oven more or less time at the prescribed temp, depending on your location. Last time we learned how the heat energy absorbed by water determines whether it exists in one of the three states of matter, gas, liquid, or solid. We also learned that at the atmospheric pressure present at sea level, which is about 14.7 pounds per square inch (PSI), the boiling point of water is 212°F. At sea level there are 14.7 pounds of air pressure bearing down on every square inch of water surface. Again, I said sea level for a reason. The boiling point of water, just like cake batter baking times, is dependent upon the amount of pressure that’s being exerted on its surface from the surrounding atmosphere. When heat energy is absorbed, it causes the water or cake batter molecules to move around. In fact, the temperature measured is a reflection of this molecular movement. As more heat energy is absorbed, the molecules move more and more rapidly, causing temperature to increase. When the water temperature in our tea kettle reaches its boiling point of 212°F at sea level, the steam molecules in the bubbles that form have enough energy to overcome the atmospheric pressure on the surface of the water. They become airborne and escape in the form of steam.
If we’re up in the Rockies at say an altitude of 7000 feet above sea level, the atmospheric pressure is only about 10.8 PSI. There’s just less air up there. That means there’s less air pressure resting upon the surface of the water, so it’s far easier for steam molecules to form into bubbles and leave the surface. As a result the boiling point is much lower in the Rockies than it is at sea level, 196°F versus 212°F.
So what if the water was boiling in an environment that had even higher pressures exerted upon it than just atmospheric? We’ll see how to put this pent-up energy to good use next week, when we begin our discussion on how steam is used within electric utility power plants.
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