Once Through Boiler
Once Through Boiler
Once Through Boiler
Figure 8 shows the temperature-enthalpy diagram and boiler mass flux needed in the higher heat flux zone of the lower fur-
state conditions for the Zimmer boiler at full load operation. nace, this multiple pass arrangement also minimizes the tem-
Note that in the first and second passes of the furnace the tem- perature upset due to heat absorption upset. The heat absorp-
perature changes very little for significant changes in enthalpy. tion profile varies around the furnace perimeter (especially be-
Therefore the first and second pass tubes operate at near the ing lower near the furnace corners) and the heat flux distribu-
same temperature making the alternating tube construction pos- tion is ever changing as a result of furnace slagging changes.
sible and, in fact, desirable as a way to make the overall fur- Thus, the design does recognize that some tubes within the fur-
nace expansion more uniform. In addition to providing the higher nace absorb greater heat than other tubes. This increased heat
absorption has a double effect on temperature within the tube furnace, as shown on the temperature enthalpy diagram. As a
since, with the high mass flux, the flow rate within the tube result of this two-phase condition steam-water separation can
also decreases, with respect to other tubes, as the heat flux in- occur so that the fluid at the inlet of some tubes of the second
creases. Thus, the mix location between the burners and fur- pass will contain a greater steam fraction than will other tubes.
nace arch is selected to hold the theoretical maximum tempera- Because of the large density difference between the steam and
ture upset among adjacent tubes to the proven design value. the water, the flow will be restricted in the tubes receiving the
Figure 9 shows this effect of heat upset on individual tube tem- greater steam fraction so that these tubes will overheat and fail.
perature as well as the function of the mix sections for enthalpy Therefore, in order to take advantage of the beneficial effects
equalization. of variable pressure turbine operation during load turndown,
As discussed earlier, the supercritical UP boiler design re- pressure control division valves are located within the boiler
quires that the fluid pressure within the furnace tubes must re- between the primary and secondary superheaters. These valves
main above the critical pressure at all times. If this provision is maintain the furnace fluid pressure above the critical point while
not met and the pressure falls into the subcritical regime a steam letting the turbine follow its most economical pressure versus
water mixture would be present entering the second pass of the load operating profiles. With partial arc admission turbine de-
2nd Pass
Outlet Header
1st Pass
3rd Pass
Outlet Header
Pressure
Figure 9 Enthalpy upset and mix.
Load
signs, the most economical operating condition is consistent pres-
sure operation to the second valve point typically at between 60
and 70% load. The resulting boiler pressure and turbine pressure
Figure 10 UP boiler variable pressure operation.
operating characteristics are shown in Figure 10. While the re-
quirement for the furnace to remain above the critical pressure
point means that the pump power reduction associated with vari-
able pressure operation is not realized, the partial arc admission
characteristic of the turbine means that there is very little pen- is operated by Cincinnati Gas & Electric) are normally operated
alty due to the pump power down to approximately 50% load. in a load cycling duty with maximum load during the middle of
In the United States, most once through boilers are normally the day and a reduction to 40% load at night. The weekly load
operated in a load cycling mode and the UP boiler design per- profile for two of the 1300 MW units is shown on Figure 11. This
forms very well in such service. For example, the six 1300 MW load cycle closely follows the American Electric Power system
boilers operated by American Electric Power (the Zimmer boiler load requirements. This load cycling operation is necessary even
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