+ economic + + flexible + + innovative +

BENSON Boiler

Research & Development at the BENSON Test Rig by Siemens AG Power Generation (PG)

designs and constructs fossil fired power plants

manufactures steam and gas turbines, generators, electrical equipment and I&C

is licenser for BENSON boilers

develops an improved concept with vertically tubed water walls for BENSON boilers

This booklet should remind you of the exhibition in the monitoring room of the BENSON test rig in Erlangen, Germany, where the fundamental research and development of Siemens/PG is performed on:

heat transfer in boiler tubes smooth vertical, inclined, horizontal rifled pressure loss in boiler tubes thermoelastic design of water walls feedwater treatment erosion corrosion

The BENSON know-how allows for reliable design and ensures customers benefit via validated codes based on extensive investigations.

Siemens AG Power Generation PG

BENSON license
Department PG W7 Freyeslebenstrae 1 D-91058 Erlangen Germany Tel: Fax: +49 9131 18-6234 +49 9131 18-6214

BENSON test rig

Framatome ANP GmbH (A Framatome and Siemens company) Department FANP NT31 Freyeslebenstrae 1 D-91058 Erlangen Germany Tel: Fax: +49 9131 18-93718 +49 9131 18-92851

email: joachim.franke@erl11.siemens.de

email: holger.schmidt@framatome-anp.de

Evaporator systems for boilers by Siemens/PG

Principle

Natural circulation (drum)

BENSON with superposed circulation

BENSON (once-through)

Superheater

Evaporator

Economizer

Operating pressure Water wall tubing

10 180 bar vertical

20 180 bar vertical

20 400 bar spiral or vertical

BENSON Boilers
are the world-wide most often built once-through boilers with approx. 1000 units:
steam pressure up to 310 bar steam temperatures up to 650 C steam capacities up to 1232 kg/s (4435 t/h)

Advantages of BENSON boilers

Highest efficiency of power plants

Enthalpy Critical point Modes of operation Pressure (load)

Use of worldwide and difficult coals

Suitable for subcritical and supercritical pressure Economical and low-stress operation
Temperature 545 C

Wide scope in design (oversized combustion chamber, slag tap furnace) Flexible operation mode
Load 4-6 %/min

Load

Time

Main steam temperature independent of fuel and degree of fouling . Low-stress start-up

Rapid load changes with sliding pressure operation

Improved concept with vertical tubed water walls based on R&D by Siemens/PG with additional advantages:
Simple design and easy maintenance of water walls similar to drum boilers

Low part-load of 20% with high steam temperatures

Simple start-up system without recirculation pump

Optimized flow chracteristic of water wall tubes (see next page)

Advantages of BENSON boilers with vertically tubed water walls

Once-through characteristic at high mass flux (approx. 1800 kg/m2s)

Pressure drop at constant mass flux

Friction

Due to equal pressure drop in all parallel tubes:

System of parallel tubes

Hydrostatic Hydrostatic

Mass flow decreases in the excessively heated tube

Nominal heated tube

Excessively heated tube

Optimized flow characteristic in case of excessive heat input of water wall tubes due to low mass flux

Natural circulation characteristic at low mass flux (approx. 1000 kg/m2s)

Pressure drop at constant mass flux

Friction

Due to equal pressure drop in all parallel tubes:

System of parallel tubes Hydrostatic

Mass flow increases in the excessively heated tube

Nominal heated tube

Excessively heated tube

Milestones in the field of BENSON boilers

1924 Siemens buys the BENSON Patent from Mark Benson 1926 Siemens manufactures to three BENSON boilers 1929 (30 t/h to 125 t/h) 1933 Siemens introduces variablepressure operation 1933 Siemens awards licences to several boiler manufacturers 1949 The worlds first once-through boiler with high steam conditions (175 bar/610 C) 1954 The first BENSON boiler with supercritical pressure (300 bar/605 C) 1963 The worlds first spiral-tubed water walls in membrane design 1987 First hard-coal-fired boiler >900 MW with spiral-tubed water walls 2000 About 1000 BENSON boilers with >700.000 t/h sold in total 2000 First order of a BENSON boiler with vertical tubed water walls in low mass flux design

BENSON boilers licence since state: 2001 1937 Steinmller 1939 Austrian Energy 1950 Deutsche Babcock 1951 Mitsui Babcock 1954 Babcock & Wilcox 1954 Burmeister & Wain 1954 Kawasaki 1960 Babcock-Hitachi 1995 Ansaldo 1996 Foster Wheeler 1999 Bharat Heavy Electricals Ltd. (BHEL)

BENSON boiler activities by Siemens/PG Boiler

Boiler concepts Arrangement of heating surfaces Thermal hydraulic design Start-up systems

New water wall/evaporator design

Vertical tubed water walls with optimized rifled tubes BENSON Boiler with superposed circulation Horizontal evaporator tubes for advanced power plants with fluidized bed combustion or coal gasification

Increase of availability Control concepts Water chemistry Interaction of boiler and turbine R&D Computer programs
Reliable design based on extensive knowledge of heat transfer and flow stability Material preservation by thermal elastic component design Prevention of pipe wall thinning and resulting failures

Reduction of operating cost

Low pressure loss and steady-state flow condition in evaporator zones and separators Optimized feedwater chemistry

BENSON test rig and range of parameters investigated

Test section

Pressurizer

Spray condenser

Main heater Circulation pump Trickle cooler

Feedwater tank Preheater Dosing pump Piston pump

Technical data: System pressure Temperature Mass flow Heat capacity

330 600 28 2000

bar C kg/s kW

Reduction valve

Main cooler

Tube Geometry Number of measurements Heating

uniform vertical one-side uniform one-side

> 100.000

> 160.000

Tube orientation

inclined

horizontal

Test parameter

Pressure Mass flux Heat flux

25 p 280 bar 100 m 2500 kg/m2 s 0 q 950 kW/m2 8d 50 mm

Test matrix for heat tansfer and pressure drop investigations

8

Tube inner diameter

Heat transfer and pressure drop in boiler tubes

Schematic course of wall temperature and pressure loss in an uniformly heated vertical smooth evaporator tube

Heat transfer region

Convective heat transfer to steam flow Steam quality 1.0

Steam

Post -CHF region/ Post-dryout region Boiling crisis

0.8

p L
Convective heat transfer through water film 0.6

Wall temperature

Fluid temperature
0.4

0.2 Saturated nucleate boiling 0

Subcooled boiling Convective heat transfer to water flow Pressure loss gradient

Temperature

Water

Heat transfer in boiler tubes

Effect of gravity on heat transfer in inclined and horizontal smooth tubes

Inner wall temperature (C) 600 500 400 300 200 0.40 0.45 0.50 Steam quality 0.55 0.60

Calculation with WATHUN

Inclined tube
Pressure 50 Mass flux 1000 Heat flux 400 Tube inner diameter 24.3 bar kg/m2s kW/m2 mm

15

Inner wall temperature (C)

600 500 400 300

Horizontal tube
Pressure 100 bar Mass flux 500 kg/m2s Heat flux 300 kW/m2 Tube inner diameter 24.3 mm

Fluid
200 0 0.2 0.4 0.6 0.8 1.0

Steam quality

10

Heat transfer in boiler tubes

Improvement in heat transfer by rifled tubes

Wall temperature in smooth and rifled tubes

Pressure Mass flux Heat flux

150 bar 500 kg/m2s 300 kW/m2

Steam quality Fluid

1.0 Rifled tube

0.8

Smooth tube

0.6

0.4

10 0 Rifled tube

20 0

30 0

40 0

50 0

60 0 Smooth tube

Inner wall temperature (C)

11

Heat transfer in boiler tubes

Wall temperatures in vertical rifled tubes at different loads

Inner wall temperature (C) High load Pressure Mass flux Peak heat flux 400 212 bar 770 kg/m2s 310 kW/m2

375 Fluid

Calculation with WATHUN

350 Pressure Mass flux Peak heat flux 100 bar 250 kg/m2s 200 kW/m2

Low load 325

Fluid 300 1600 1800 2000 2200 2400 2600 2800

Fluid enthalpy (kJ/kg)

12

Heat transfer in boiler tubes

Optimized rifled tubes reduce wall temperatures or allow mass flux reduction
Inner wall temperature (C) Smooth tube Mass flux 1000 kg/m2s Standard rifled tube Mass flux 1000 kg/m2s

440

420

400

380

Optimized rifled tube Mass flux 1000kg/m2s

360

Calculation with Pressure WATHUN

212 bar Peak heat flux 310 kW/m2

440 Standard rifled tube Mass flux 1000 kg/m2s 420

Optimized rifled tube Mass flux 770 kg/m2s

400

380 Smooth tube Mass flux 1500 kg/m2s 360 1800 2000 2200 2400 Fluid enthalpy (kJ/kg)

13

Pressure loss in smooth and rifled boiler tubes

Pressure Mass flux Heat flux Tube inner diameter

100 bar 1000 kg/m2s 100 kW/m2 ca.13 mm

Related pressure loss 20

Location of boiling crisis

p wet steam p water

16

12 Rifled tube 8

Calculation with DRUBEN

4 Wetted surface 0 0 0.2 0.4 0.6 0.8 Steam quality Smooth tube 1 Smooth tube Unwetted surface

Water

Rifled tube

Steam

14

Thermoelastic design of water walls increases flexibility (1)

Rack plate

1 1
177 176,5 13,8

2 2

178 183 181

9,37

4,91 182 184 186 188 190 192 191 194 4,01 8,44 12,9 0,45 -4,01 8,47

193 4,01

-8,47

Temperature field [C]

Stress field [N/mm2]

Measured values
Temperature and stress fields in a rack plate at a gradient of 10 K/min, quasi-steady-state conditions

15

Thermoelastic design of water walls increases flexibility (2)

Firing 500 C

Stress analysis with WATHAN based on R&D increases reliability of water walls
380 C

WATHAN
Input data: pressure, temperature, mass flux, steam quality, heat flux, geometry WATHUN-calculation (heat transfer coefficients) Stress analysis
FEM-calculation Temperature field Thermal stress Mechanical stress Stress assessment Primary stress < Sm Primary and secondary stress < 3 Sm

Fatigue analysis

(for p/pk < 1)

FEM-calculation Temperature field Thermal stress differences (Wetted and unwetted tube) Service life assessment Thermal stress Permissible differences range of stress

Height [m] 60 50 . q 40 30 20 10 0 100 300 Heat flux [kW/m2] 400 500 Temperature [C] 0 400 500 Stress [N/mm2] qmax TW

ax,T+P ax,W
TF

Position

al
Nomenclature . q Average heat flux . qmax Max. loc. heat flux Fluid temperature TF TW Wall temperature

ef

ef ax,T+P 1,T+P 2,T+P ax,W al

Effective stress Axial stress (T+P) Princ. stress1 (T+P) Princ. stress2 (T+P) Axial stress (weight) Allowable stress

1,T+P

2,T+P

16

Feedwater treatment . Erosion-corrosion (1)

Appearance

Parameters of influence
Material (Cr-, Mo-, Cu-contents) Geometry (pipe, bend, etc.) Fluid velocity Temperature Steam quality Feedwater chemistry (pH, O2) Exposure time

Mechanism

Fe3 O4

Oxide layer (magnetite) protects against erosion-corrosion

Fe OH+

Metal loss caused by erosion-corrosion (mass transfer)

Fe (OH)2

Velocity profile Steel Wall adjacent turbulent layer Flow core

17

Feedwater treatment . Erosion-corrosion (2)

Effect of material composition

pH = 7; O2 = < 5 ppb pH = 7; O2 = 500ppb

pH = 9,5; O2 = < 5ppb

Wall thinning mm/a 10 St 37.2 5 15 Mo3 2 1 5 13 CrMo 4 4 2 10 CrMo 9 10 0.1 X10CrNiTi 18 9 5 St 37.2+5m-Metco 33-coating 2 0.01 5 2 0.001 T = 180 v = 20 t = 200 C m/s h Austenitic steel 15 NiCuMoNb 5 Ferritic steel

18

Feedwater treatment . Erosion-corrosion (3)

Effect of thermal hydraulic and water chemistry parameters

Measurement T = 180 C pH = 7 O2 5 ppb t = 200 h Carbon steel

Measurement v = 35 m/s pH = 7 O2 5 ppb t = 200 h Carbon steel

Measurement T = 180 C v = 39 m/s O2 5 ppb t = 200-400h Carbon steel

Measurement T = 120 C v = 35 m/s pH 5 ppb t = 200 h Carbon steel

Wall thinning mm/a 10 5 2 1 5 2 0,1 5 2 0,01 5

Calculation with WATHEC

2 0,001 0 20 40 0 100 200 6 8 10 pH 0 200 400

Fluid velocity (m/s)

Water temperature (C)

Oxygen concentration (ppb)

19

Research & development by Siemens/PG allows reliable design of BENSON boilers based on computer programs as:

WATHUN DRUBEN STADE DEFA/DEFOS DYNASTAB WATHAN WATHEC/COMSY

Heat transfer

Pressure drop

Flow distribution in parallel tube systems Design of boilers

Dynamic stability

Material strength

Erosion-corrosion

Printed by and copyright (2001): Siemens Power Generation Freyeslebenstae 1 D-91058 Erlangen Germany

Siemens Aktiengesellschaft

Subject to change without prior notice