Design of High Energy Bypass Systems in Combined-Cycle

Power Plants
The main purpose of the steam turbine bypass system is to virtually duplicate the expansion and heat transfer normally
undertaken in the operating steam turbine. By doing so, the steam turbine bypass system enables faster plant startups, continued
operation of the gas turbine generators (GTGs) and heat recovery steam generators (HRSGs) following a steam turbine generator
(STG) trip, and simple-cycle operation (if designed with the condenser for this service) of the GTGs with the STG out of service.
Bypass systems in a combined-cycle power plant
Steam Turbine (ST) bypass systems may be categorized into cascading and parallel (non-cascading) type. For a three pressure
level steam system, ST bypass is usually cascading type with the cascade flow going from high pressure (HP) steam to cold reheat (CRH) steam line, through the HRSG re-heat section, exiting with hot re-heat (HRH) steam bypass to the condenser. Low
pressure (LP) steam from the HRSG bypasses directly to the condenser.
In the parallel bypass arrangement, HP steam bypasses directly to the condenser through the HP bypass valve. Steam generated
by the IP drum is either admitted to the cold reheat section (CRH) or bypassed directly to the condenser. IP admission to the CRH
is only allowed when the generator breaker is closed. With this system, there is no flow through the re-heater when the ST is not
in operation. Boiler feed for any configuration typically relies on condensate collected from the condenser hotwell, with boiler
feedwater make up made through the condenser.
Throttling devices are used to reduce the pressure from inlet throttle pressures to the desired output conditions. The throttling
process is isenthalpic since no work is accomplished and little or no heat transfer occurs across the system boundaries, therefore
the outlet enthalpy is virtually the same as the inlet enthalpy. Without some additional conditioning, the discharging steam would
most likely exceed the thermal limits of the downstream piping and system equipment. To prevent this from occurring, the bypass
system is normally supplied with a water spray system that injects a controlled quantity of water into the steam flow. The actual
volume of water injected is dependent on the actual operating conditions being exhibited and a simple heat balance. This water
then mixes with the steam, absorbs heat via various heat and mass transfer processes, evaporates, and cools the steam to an
enthalpy level that is more representative of the actual turbine discharge and acceptable to the plant equipment. This is in the
range of less than 1,200 BTU/lbm, or as otherwise determined by the condenser manufacturer.
Steam bypass systems are employed in many ways. The two most prevalent operating modes are between the Main Steam and the
Cold Reheat Line, when the plant design incorporates a reheat steam cycle, and the hot reheat and low-pressure steam bypass(es)
to condenser. See Figure 1 for a basic steam cycle flow diagram, which illustrates the HP, hot reheat, and LP bypasses for a 2 x 1
or 3 x 1 configuration. The diagram illustrates a triple pressure reheat unit since that is the most common combined-cycle
commercially used today. There is a separate set of bypass valves per HRSG-in normal practice-to assist with individual
CTG/HRSG startup.

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Figure 1: Condenser Bypass Diagram. Note: Bypass may be configured in one condenser admission line or up to three per
service, depending on configuration (2x1 vs. 3x1) and control philosophy.

The HP bypass has fairly simple design and implementation requirements. The pressure drop, flow requirements, rangeability,

and quantity of spray water injected are minimal by valve engineering standards. The hot reheat bypass to the condenser, on the
other hand, is far more complex due to a number of factors, including:

Large quantity of water injected

Minimal distance for vaporization and thermal equilibrium

High-pressure drop ratios due to condenser vacuum conditions

High rangeability and turndown requirements

Speed of operation

Noise limits

Protection of the condenser (operating permissives in place)

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Turbine bypass system design criteria
From a valve sizing and pipe sizing point of view, the criteria needs to be established with the owner on pressure, temperature,
and flow rates during the startup phase through all modes of operation, as well as percent of bypass (based on contract
requirements) at full pressure and temperature from a steam turbine trip scenario. Turbine bypass modes of operation are
established for all equipment, and the bypass systems consider:

Commissioning start-up and check-out

Normal start-up (cold condition)

Warm / hot start-up

Steam turbine trip

Gas turbine trip

HRSG high drum-level trip

Extended bypass operation

The owner's business plan integrated with the plant heat balances will establish the criteria for bypass design. In an organized
approach, this will be solidified early in the project, prior to detail design and equipment selection.
Turbine bypass system configuration
As with the design and layout of a combined-cycle power station, there is no one specific configuration for a turbine bypass
system. The number of components, how and where they are installed, will all be determined based on the mode of operation and
the physical constraints mandated by the plant logistics. In some cases, these factors will have little or no effect on the
performance of the system; however, in other cases they will directly affect the end result and may create problems. For example,
the steam bypass valve is physically placed in the line to allow for complete zone mixing to reach the pre-determined enthalpy or
temperature for the exit condition. Failure to drain the pipeline upstream or downstream of the valve or to allow for necessary
residence time for complete mixing could result in impingement damage to the condenser tubes. Meeting the required entrance

conditions to the condenser must be considered in the overall layout of the condenser and piping with the plant's physical
constraints. The two most basic component configurations can be seen in Figures 2 and 3.

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Figure 2: Combined Bypass System

Both Figures illustrate the basic components needed in most all bypass systems. They include a pressure-reducing device, a water
injection system including a spray water control valve, and a backpressure element. The spray control valve and water injection
points are diagrammatically shown and are located much further away from the condenser. The bypass installations are shown
penetrating the condenser wall at the neck in the vicinity of the turbine discharge; however, the exact location will be determined
by the condenser manufacturer based on the condensers design, spatial and structural limits, and the steam flows' proximity to
sensitive heat transfer surfaces.

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Figure 3: Separate Bypass System

Figure 1 illustrates a system layout utilizing a combined pressure-reducing and attemperating valve. This arrangement has an
advantage in that the conditioning of the bypass steam is accomplished in a minimum of space, and the number of components,
as well as associated installation costs, is reduced. However, flexibility in the layout of the system is constrained by the
installation requirements and limitations of the valve, i.e., weight, orientation, support, etc.
Figure 2 is similar to the combined system except that the pressure-reducing component is separated from the cooling section.
This arrangement provides greater flexibility in terms of component placement in the plant and may provide significant benefits
for inspection and maintenance. By separating the valve from the cooler section, it is much easier to orient the valve with the
stem in the preferred vertical direction, especially if the design utilizes an angle configuration, thus reducing side loads, sliding
friction, and wear on the valve trim. However, the arrangement may not be capable of achieving the same degree of turndown

that the combined unit affords. Turndown is defined as the ratio of maximum to minimum controllable steam flowing through the
system. When considering just the valve, the turndown would be equivalent to the unit's rangeability, or the ratio of maximum to
minimum controllable flow coefficients, i.e., Cv. However, since we are also adding the attemperating function into this equation,
the system must consider the valve's contribution and assistance in the mass, momentum, and energy transfer to the injected
water particles. In a combined system, the proximity of valve discharge, and its resultant turbulence and high kinetic energy, to
the water injection system enhances the mixing and heat transfer between the steam and water. While this localized region of high
velocity and turbulence is relatively short lived, its benefit to the process is greatly utilized. If the separate cooler section, having
been placed some distance downstream of the valve, does not provide a means to produce a similar flow stream conditioning, the
same degree of mass, momentum, and energy will not be accomplished and thus the expected turndown could be considerably
less. The result would be in the form of water fallout and pooling on the bottom of the outlet pipe. This condition will result in
overspray scenarios and quenching, which will promote low cycle fatigue failures. To reduce this problem, many manufacturers

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will include a diffuser plate, or some other means of geometrically enhancing the flow, to produce localized turbulence and high
velocities in the vicinity of the water injection.
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Another consideration for the separate configuration is the fact that an intermediate pressure class pipe section is added to the
system. This is the pipe length that communicates the valve outlet with the cooler inlet. Since no desuperheating has been
introduced, the steam temperature is still relatively high even though the pressure has been greatly reduced. Thus, some form of
high temperature grade piping may still be required and the pipe diameter will be increased.
Bypass valve and desuperheating section
The bypass valve and desuperheating section comprise at least two-thirds of the major system components and some comments
on design differences/considerations are worthwhile to maximize longevity.
The bypass valve should be constructed for the intended severe service of a bypass system. This should include materials of
construction, both body and hardened trim parts, control trim style, pressure reduction staging, seat integrity, accessibility of
wearable components, noise and vibration resistance, and a solid, well-supported structural design, especially if the valve will be
installed with the stem in the horizontal plane. A partial listing of typical main steam to condenser bypass valve specifications can
be found in Table 1.

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The desuperheating sections may actually be more difficult to specify than the bypass valve or pressure reduction device. One of
the difficulties with any desuperheating device is the fact that it is a secondary control device as compared to the bypass valve
being a primary control device. The functional differences of these two devices can be seen in Table 2.
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On condenser bypass applications, we are usually dealing with a considerable spray water flow. On a mass basis, it can exceed
40 percent of the total steam mass flow through the system. In order to achieve good mixing and distribution, as well as rapid
vaporization, the cooler section has to be designed properly. To this end, most manufacturers utilize multi-point injection systems.
By multi-point, we are describing the distribution of the total water flow through multiple injection ports or nozzles. Research has
shown that the smaller the nozzle, the smaller the spray particle it can produce. With ever-smaller particle sizes, the total surface
area for interaction and heat transfer with the flowing steam improves, thus increasing the vaporization rate. It should also be
noted that as nozzles become smaller, their susceptibility to clogging or debris interference increases. Even moderately sized
nozzles, when contaminated with pipeline debris, will lose efficiency in forming the desired spray pattern, particle size, and
distribution. To eliminate this problem, it is always recommended that strainers be used in the spray water system and located as
close as possible to the nozzles themselves. The size of the mesh should be carefully considered both from a pressure drop and
nozzle passage viewpoint. If the mesh is selected too large, debris that could be damaging to the nozzles may pass. If the mesh is
too small, the added restriction to flow may consume too much pressure drop for the system. This will restrict the necessary
quantity of water from reaching the system and prevent the spray water from attaining the correct pressure required for
atomization by the spray nozzles.
At the present time, there are two types of nozzles used for cooler sections, fixed and variable geometry. Generally speaking, the
variable geometry styles will provide greater rangeability and more consistency in the spray pattern created. This translates
directly to improved turndown and more efficiency in the process.
The available water pressure is also a factor in terms of performance. Besides reducing the size of the nozzle, increasing the
pressure differential also produces smaller spray particle sizes. In a similar manner, the water temperature also improves nozzle
performance. With increased water temperature, the surface tension of the water is reduced. This allows greater efficiency in the
formation of droplets with a smaller diameter. Additionally, these smaller and hotter droplets interact better with the flowing
steam. Their latent heat of vaporization is reduced, as is their resistance to shear by momentum transfer. This results in further
droplet size reduction and more rapid vaporization even though the fluid particles are hotter, an idea that is contrary to
discussions on cooling processes.
Unfortunately, the source of water selected by most users for this process is from the low-pressure condensate system. Water
temperatures are normally in the 100 F-150 F range and pressures in the 150 psi to 250 psi range. Besides being relatively cool
and with low pressure potential, this water source also affects another component in the system, the backpressure device.
Backpressure device
The backpressure device, also referred to as a sparger, is utilized to create an elevated pressure downstream of the valve. Without
this device, the vacuum conditions of the condenser would exist in the discharge piping. At these extremely low pressures, the
velocity of the steam exiting the valve would reach sonic or choked conditions almost immediately unless the outlet pipe size and
resultant cross-sectional flow area, were sized to accommodate the large specific volume of the free expanding steam. As this is
normally not economically feasible, nor logistically possible, the backpressure device is installed to provide a fixed resistance to
the flow entering the condenser. This translates to an intermediate pressure that is variable based on the valve inlet conditions and
the mass flow through the system. Ideally, we would prefer that this variable intermediate pressure be as large as possible to keep
the outlet pipe size to a minimum. In most condenser bypass applications, the desired outlet flow velocity from the valve is in the
200 FPS-300 FPS range. As mentioned previously, the available water pressure has a direct affect on the sizing of the
backpressure device. Within the design and layout of the spray water circuit, we have multiple orifices or restrictions that require
pressure differentials to operate, i.e., strainer, spray water valve, nozzles. If the backpressure is selected too high, we may not
have sufficient pressure energy remaining to get the spray water to the discharge pipe. Thus, a compromise must be made relative

to the distribution of water pressure as compared to the desired backpressure for the maximum flowing steam conditions.
Normally, backpressures of 50 psi to 100 psi are utilized, but under certain conditions this could rise to as much as 200 psi.
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The backpressure device also has an affect on the performance of the desuperheating system. Unlike most steam applications
where steam velocity is proportional to the mass flow of steam, the flow discharging from the conditioned valve outlet will
remain constant at all mass flow as long as the inlet conditions of pressure and temperature stay the same. This is due to the
thermodynamic relationship between the pressure, temperature, and specific volume. Since we are dealing with an isenthalpic
throttling process, the temperature will remain nearly constant at a given backpressure. The backpressure device is sized to
operate within a given flow range, and once the upper flow range is set, maximum backpressure is set for the fixed openings in
the backpressure device. Thus, the pressure and specific volume will vary in an inversely proportionate manner as mass flow
changes. Therefore, once an outlet pressure is selected and the resultant velocity calculated, that velocity will remain the same for
all mass flows into the condenser.
The backpressure device also provides protection for the condenser. Its construction is usually that of a series of orifices, sized for
a particular pressure differential and mass flow, machined in rows, both axially and radially, along the device circumference. The
conditioned steam is then admitted to the condenser through this pattern of orifices. Based on guidance and direction from the
condenser manufacturer, who in normal practice supplies the backpressure device within his own scope, the orifices are placed to
direct the high-energy jets of steam away from critical and sensitive heat transfer surfaces, such as tube bundles and structural
members. The potential to steam cut tubes, structural members or induce damaging vibration harmonics exist if the backpressure
device is not designed or coordinated within the condenser.
Piping system
Both the inlet and outlet piping associated with the bypass system are important for proper function. Two key areas of interest are
the excess fluid drain system and valve/piping preheating. The draining of excess fluid from both the inlet and outlet of the
bypass system are essential for proper operation and maintenance. Depending on the mode of operation, the bypass may stand
idle for long periods of time. Steam trapped upstream of the valve inlet will begin to cool and eventually condense on the bottom
of the pipe. This excess condensate must be trapped and removed prior to the initiation of bypass system operation. If it is left in
the pipeline, momentum forces of the incoming steam flow could carry the fluid into the valve trim creating a two-phase flow
scenario with resultant damaging erosion and thermal shock problems. Sloping the pipe away from the inlet valve inlet and
installing a drip-leg or water separator system just upstream of the valve inlet can easily eliminate this situation.
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Similarly, the outlet has to be protected from the collection of excess fluids from desuperheating or condensation. The valve
outlet and condenser feed pipe normally has greater quantities of fluid to be removed than the inlet and the flow energy is greater,
thus compounding the situation. The elimination of excess fluid can be handled in several ways. The first is to make sure that
only the correct amount of spray is injected into the discharge pipe. Thus, if all is evaporated effectively, there will be no excess
fluid fall-out. The second is to make sure that the backpressure device is equipped with a drain connection near its termination
point to continuously drain excess fluid build-up to the hotwell or some other low-pressure collection location. This is normally
the case in that the backpressure device orifices point radially out and away from the condenser tube bundle, leaving a natural
collection point at the end of the header.
Preheating is used not only to keep the valve warm and to prevent thermal shock when the system is commanded to operate, but
also to keep the piping warm so that excess fluid condensation is minimized, reducing the cyclic thermal stresses which can lead
to thermal fatigue. The quantity and method of preheating are dependent on the piping layout of the system, the design of the
valve, and the mode of operation of the system, i.e., long term stand-by vs. daily start and stop. In many situations, little or
nothing is done to assist in preheating beyond considerations for conduction through the pipe and valve walls. This will certainly
have a long-term affect on the reliability and longevity of the equipment. In other situations, a small bypass line is installed
between the upstream and downstream piping. A small needle valve is placed in the line and used to control the quantity of steam
being bypassed around the main valve. Temperature readings are monitored until the desired thermal conditions are achieved.
The system can be set up as automatic with temperature controls included or as a manual system requiring monitoring by the
operators. Table 3 indicates recommended temperatures maintained through pre-heating of the valve dependent on temperature
service.

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It is also important that the slope of the discharge piping be pitched, negative, with drainage towards the condenser. This forces
the entrapped fluid to move towards the internal condenser drain and discharges into the hotwell. If the fluid is not adequately
removed from the system prior to bypass valve operation, the resultant momentum transfer could create a water hammer-like
situation that could be seriously damaging to both the backpressure device and the condenser.
In some installations, use of isolation valves upstream of both the attemperator spraywater control valve and upstream of the
bypass valves is utilized. Though an added expense, some owner/operators perceive that the use of a motor-operated block-valve
upstream of the spraywater valve reduces the chance for a constant leak of spraywater through the bypass. The use of a motoroperated block valve upstream of the bypass valve is less common, but is sometimes used to eliminate steam leaks through
bypass valves, which can cause significant MW losses that are "hidden" in many cases. A metal-to-metal seat valve is at best
good for Class IV shutoff, which means a small amount of steam will leak by at all times. By definition, leakage allowed for this
type of valve is 0.01 percent of rated valve Cv capacity at ANSI test conditions. Under actual service conditions, the leakage is
more significant due to the high system pressure.
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SUMMARY
In examining all aspects of the design and layout of a bypass system for a combined cycle power plant, it is readily apparent how
important defining the operating conditions, condenser, bypass valve, and supporting systems are to the overall performance and
life of the condenser. Definition of commercial objectives on how the combined cycle plant should operate must be well defined
in order for the equipment to support the plant's performance criteria. The frequency of starts and stops, ramp rate during startup, duration of start-up, extended bypass operation at full or partial load for various reasons, and even the decision to run in
simple cycle mode for short periods of time all affect the plant reliability and working life.
The bypass system must be fully integrated into the operating logic of the plant such that its operation is nearly transparent when
put into service. Flow, pressure, and temperature fluctuations or oscillations cannot be tolerated, as they will affect the input and
performance of other systems. On the other hand, the bypass system has another important function, the conditioning of the
bypass steam for entrance into the condenser. It is imperative that the conditioning is done correctly so as to prevent thermal or
vibration damage to the sensitive heat transfer surfaces and structures within the condenser itself.
Tightened condenser spaces (modern day combined cycle plants as compared to older fossil units) which handle high energy
dumps, pose greater challenges for dissipation of energy into the condenser. Established guidelines may not be achievable in this
case and the condenser designer is faced with challenges, which require designs to evolve, to address some of the issues
described in this paper.
Conclusions
To have a properly operating bypass system requires a concerted engineering effort as well as extensive communication between
all parties involved in its design and implementation, i.e., plant operations, bypass supplier, condenser supplier. The key to proper

and efficient bypass system operation is the understanding of all possible facets of operation, the control interfaces with the
equipment involved, and the physical match-up of all the mechanical components required. E-TECH
References
Eaton, R.H.; Blessman, E.R.; Schoonover, K.G., Paper no. PWR2004-52057 "Design Considerations and Operation of Condenser
Bypass Systems in Combined Cycle Power Plants - Part 2;" Proc. ASME Power 2004; Baltimore, MD; March 30 to April 1,
2004.
Eaton, R.H.; Blessman, E.R.; Schoonover, K.G., Paper no. PWR2004-52056 "Design Considerations and Operation of Condenser
Bypass Systems in Combined Cycle Power Plants - Part 1;" Proc. ASME Power 2004; Baltimore, MD.; March 30 to April 1,
2004.
ASME TDP-1-1998 - "Recommended Practices for the Prevention of Water Damage to Steam Turbines Used for Electric Power
Generation;" 1998.
EPRI CS2251 - "Recommended Guidelines for the Admission of High Energy Fluids to Steam Surface Condensers;" February
1982.
HEI - "Standards for Steam Surface Condensers;" Heat Exchange Institute, 9th edition, Cleveland, OH, USA, 1995.
General Electric Co. GEK 107538, "Basic Combined Cycle Start-up Procedure from a Turbine Controls Point of View;"
November 2000.
Yao, G.F., Ghiaasiann, S.M., Abdel-Khalik, S.I., and Schoonover, K.G., "Computational Modeling of Spray Cooling in Vapor
Conditioning Equipment;" Proc. 2nd Int. Symp. on Computational Technologies for Fluid/ Thermal/ Chemical/ Systems with
Industrial Applications, Vol. 2, pp.107-116, Boston, MA., USA, 1999.
Yao, G.F., Abdel-Khalik, S.I., and Schoonover, K.G., "Progress Towards Development of a Robust CFD Code for Simulation of
Spray Cooling in Steam Conditioning Devices;" Proc. 3rd Int. Symposium on Computational Technologies for Fluid/ Thermal/
Chemical/ Systems with Industrial Applications, Atlanta, GA., USA, 2001.
Schoonover, K.G., "An Experimental and Numerical Investigation of Evaporating Water Sprays Injected into Flowing
Superheated Steam;" Masters Thesis, Georgia Institute of Technology, Atlanta, GA., USA, 2001.</P< div>
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