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Technical Paper Once-Through Steam Generation Melvin F. Sankovich Manager PWR Design & Standards Nuclear Power Generation Department Lynchburg, Virginia B. Norval McDonald Section Manager Component Development Nuclear Power Generation Department Akron, Ohio Presented to XVI Nuclear Congress Rome, Italy, March 25-26, 1971 Babcock&Wilcox
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Page 1: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Technical PaperOnce-ThroughSteam Generation

Melvin F. SankovichManagerPWR Design & StandardsNuclear Power Generation DepartmentLynchburg, Virginia

B. Norval McDonaldSection ManagerComponent DevelopmentNuclear Power Generation DepartmentAkron, Ohio

Presented to XVI Nuclear CongressRome, I t a ly , March 25-26, 1971

Babcock&Wilcox

Page 2: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

TP-446March 1971

ONCE-THROUGH STEAM GENERATION

by

M. F. SankovichN. B. McDonald

BABCOCK & WILCOXPower Generation Division

Nuclear Power Generation DepartmentP. O. Box 1260

Lynchburg, Virginia 24505

Babcock & Wilcox

Page 3: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

CONTENTS

Page

Introduction 1

Generator Description 1

Thermal Protection of Tubesheet 3

OTSG-IEOTSG Comparison , 4

Power Level 5

Controllability , 5

Contact Feedwater Heating 6

Effects of Feedwater Solids ._ 6

Heat Transfer Data 7

Laboratory Models 8

Primary Flow Distribution . 10

Conclusions 11

List of Figures

Figure

1. Nuclear Steam System 122. Cross Section of Nuclear Once-Through

Steam Generator 133. Integral Economizer Once-Through

Steam Generator 144. Temperature Vs Load 155. Temperature Vs Load, OTSG 166. Temperature Vs Load, IEOTSG 177. Feedwater Heating Chamber Test Facility 188. Mixture Quality at DNB 199. 19-Tube Laboratory-Sized Steam Generator . . . . 20

10. OTSG Axial Temperature Distribution 2111. Axial Temperature Distribution at 100% Load . . . 2212. IEOTSG Axial Temperature Distribution 2313. OTSG and IEOTSG Axial Temperature

Comparison 2414. Comparison of Analytical Model and

Experimental Data 2515. Primary Flow Model, Schematic Diagram « 2616. Primary Flow Distribution 27

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Page 4: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Introduction

Babcock & Wilcox's position among builders of pressurized water

reactor systems is unique because B&W is the only Company that sup-

plies a once-through steam generator delivering superheated steam at

constant pressure to the turbine throttle. This paper describes the de-

sign and performance of the first units, the Once-Through Steam Gen-

erators (OTSG), and the progression of design to the most recent units,

the Integral Economizer Once-Through Steam Generators (IEOTSG).

Economic justification of the once-through concept depends on the

transfer of the bulk of the energy by nucleate boiling with its attendant

high heat transfer coefficient. When this concept was first seriously

considered, no experimental data or technical literature was available

to help establish boiling characteristics of an OTSG at the pressure,

mass velocities, and heat fluxes dictated by PWR system design.

Therefore, an extensive experimental program had to be con-

ducted, not only to establish the heat transfer characteristics of the

OTSG, but to assure its controllability under transient conditions, to

develop details of the contact feedwater heating concept, ani to provide

data on operating limits and procedures in areas of feedwater chemistry

and cleaning. A series of laboratory boilers equipped wi'.h control sys-

tems of the type proposed for commercial plants was built and operated.

These boilers contained a small number (7, 19, and 37) of full-length,

full-diameter tubes and were operated over the temperature pressure,

and mass velocity ranges required for the full-sized units.

Generator Description

Figure 1 shows a typical arrangement of B&Ws nuclear steam

system. Three plant sizes, including the maximum of approximately

3700 MWt, are offered, and all three have the same arrangement. No

steam separation and drying equipment is required; the units can be

completely shop fabricated and shipped without field assembly. The

appearance of the OTSG and the IEOTSG is very similar, as shown in

Figures 2 and 3, but the operation and performance are somewhat

different.

- 1 - Babcock & Wilcox

Page 5: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

In both the OTSG and the IEOTSG, primary coolant enters the tcp

through a 36-inch-ID nozzle, flows downward inside Inconel tubes, and

discharges through two 28-inch-ID nozzles. As shown in Figure 2,

feedwater in the OTSG is introduced through 32 spray nozzles connected

to 14-inch semicircular headers, which are located about midway along

the shell, and flows downward in an annular cham "er between the shell

and the tube bundle shroud. Steam, which is drawn from the high-qual-

ity steam region of the tube bundle just above the feedwater nozzles,

quickly heats the feedwater to saturation. The flow of steam through

the space between the upper and lower portions of the shroud is created

by condensing action of the steam as it comes into contact with feedwater

spray.

Saturated feedwater enters the tube bundle at. the bottom and be-

gins to boil immediately. The steam is boiled to dryness at approxi-

mately two-thirds of the bundle's height and is then superheated about

35 degrees to ensure dry steam to the turbine. Steam from the bundle

is diverted downward through the upper annulus and leaves the genera-

tor through two 24-inch-ID nozzles.

The upper portion of the steam generator shell is bathed in sup-

erheated steam, and most of the lower portion of the shell is bathed in

saturated water. By maintaining a high shell temperature and match-

ing coefficients of thermal expansion between the shell and the tubes,

stresses in the tubes can be minimized even in the straight-tube design.

The OTSG allows a unique method of system operation for pres-

surized water reactors. The average primary coolant temperature of

the reactor is kept constant above 15% load as shown in Figure 4.

Since the temperature difference between the primary and seconda.ry

sides is relatively constant, the length of the nucleate boiling zone is

roughly proportional to the steam flow or load. At 100% load, nucleate

boiling occurs over about 80% of the total surface; at 15% load, this is

10%. At low loads, most of the tube bundle is used for superheating,

and tne superheater outlet or steam temperature is very close to the

primary inlet temperature. Figure 4 also shows this effect. Again,

note that the average primary temperature is constant between 15 and

100% load. The primary inlet and outlet temperatures diverge as the

load increases since the primary flow is constant.

_ 2 - Babcock & Wilicox

Page 6: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

The secondary pressure is held at the full-load setpoint by the

turbine controls. Operation between zero and ,15% power minimizes

the secondary design pressure by controlling the secondary pressure

to the full-load value, and enough water is regained in the OTSG to al-

low a fast return to full power. The feedwater flow control maintains

a. minimum water level in the tube bundle. Since the -secondary tem-

perature and the amount of submerged surface are both held constant,

the primary temperature is the only remaining variable. Thus, pri-

mary temperature follows the ramp (shown in Figure 4) between the

15% load value and the zero load value (secondary saturation tempera-

ture).

The Integral Economizer Steam Generator, shown in Figure 3, is

very similar to the OTSG except that it is a true once-through steam

generator. In this unit, feedwater is admitted directly to the bottom of

the tube bundle and is heated in the bundle rather than in a direct-con-

tact feedwater heating chamber. The cold feedwater is heated to satu-

ration very quickly, and steam is boiled to dryness at about the same

elevation as in the OTSG. Once again, the superheated steam is di-

verted downward through the annulus and leaves the steam generator at

a low elevation to maintain a high shell temperature.

Thermal Protection of Tubesheet

The temperature of the feedwater in the OTSG varies directly

with load as shown in Figure 5. This is satisfactory since the feedwater

is heated to saturation by direct contact with steam before it comes into

contact with the tubesheet face. In the IEOTSG, this could cause exces-

sive temperature gradients in the tubesheet. Therefore, the feedwater

inlet temperature is modified as shown in Figure 6 by bleeding main

steam into one or two high-pressure feedwater heaters at loads below

40%. The supplemental, low-load feedwater heating reduces the fatigue

usage factor to an acceptable level and also provides adequate margin

for occasional feedwater temperature upsets.

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Page 7: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

OTSG-IEOTSG Comparison

Table 1 shows the principal differences in the performance of thetwo units. The steam flow in the IEOTSG is about 40% higher, the sup-erheat has been increased from 3 5 to 50 degrees, and the steam pres-sure has been increased from 92 5 to 107 5 psia. A substantial part ofthe increased performance may be attributed to the increased flow andtemperature of the reactor. The inlet temperature to the steam gener-ator has been increased about 25 degrees above that of the originalunits, and the flow has also besn increased. However, the performanceof the steam generator is increased by about 10%; this improvement isattributed to the change to an integral economizer concept. The sizeand weight of the steam generator have not been increased although ap-proximately 1000 additional tubes have been added by using higher-strength material to reduce the wall thickness of the shell.

Table 1. Comparison of OTSG and IEOTSG

Functional performance

Steam flow, lb/h X 106

Steam temp/SH, FSteam pressure, psiaFeedwater temp, FPrimary flow, lb/h X 106

Primary temp (inlet/outlet), F

Physical characteristics

Shell ID, in.Overall height, ftNumber of tubesWall tube size, OD, in.Effective tube length, ft

OTSG

5.3

570/35910

455

65.66602.8/555

138

73.7

15,500

0.625X0.034

52.1

IEOTSG

7.43

603/50

107 5

473

69.5

629.6/572

140

73.7

16,500

0.625X0.034

52.1

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Page 8: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Power Level

The level of water in the OTSG feedwater heating chamber rises

with increased power (increased flow) because of an increase in pres-

sure drop. This pressure drop is also increased by fouling. There-

fore, the maximum power attainable is limited when the feedwater

nozzles become flooded due to either increased flow or increased

fouling.

In The IEOTSG, the feedwater is heated in the tube bundle,

and the performance of the boiler is relatively unaffected by additional

pressure drop regardless of the cause: flow or fouling.

Controllability

Stability in two-phase systems has been widely investigated

during the past 20 years. Since the OTSG is essentially a two-phase

system, it has potential for instability. Therefore, B&W thoroughly

investigated this phenomenon using the laboratory-sized steam gener-

ators and mathematical models.

It was shown that under certain combinations of operating condi-

tions, several of the measured parameters displayed variations at

periods between 4 and 5 seconds. The amplitude of the oscillations

peaked at specific combinations of operating conditions. For example,

when all other conditions were held constant as the steam pressure

was increased, the peak in oscillations occurred at decreasing loads.

As demonstrated in the tests and proved by mathematical models, os-

cillations were eliminated by adding flow resistance in the feedwater

heating chamber . Therefore, an adjustable orifice was installed near

the bottom of the feedwater heating chamber to ensure stability in the

commercial unit. Since the IEOTSG is a true once-through design

without internal recirculation, the oscillations have been eliminated

without increasing the pressure drop.

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Page 9: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Contact Feedwater Heating

A unique feature of the OTSG design is that the feedwater is heat-

ed in a direct-contact feedwater heating chamber before it enters the

tube bundle. To justify this design feature and to develop design de-

tails, an extensive laboratory program was conducted. A model of a

test section simulating the annular feedwater heating chamber of the

OTSG was installed in a pressure vessel in which pressure could be

varied. This model—a 22-1/2 degree segment—is shown in Figure 7.

Two multiple-or if ice nozzles of B&W design were used. The

thermal gradients induced in the shell and the feedwater temperatures

in the test section were measured for a range of steam-to-feedwater

ATs from 100 to 270F and for 10 to 100% feedwater flow at steam pres-

sures of 50, 100, and 140 psia. Provisions were made to detect steam

carry-under during the tests.

The results indicated that commercially available nozzles were

unsatisfactory, so a new nozzle was designed. In tests with this noz-

zle, saturation temperatures were reached in about 8 feet of shell

length, and no carry-under was observed. The discharge pressure

drop, for 100% feedwater flow was determined to be 30 psi.

Effects of Feedwater Solids

The once-through design of the nuclear steam generator requires

high-quality feedwater. However, regardless of the purity of the feed-

water, some impurities will be transported to the steam generator.

Therefore, since the unit will have to be chemically cleaned periodi-

cally throught its lifetime, a program was initiated to investigate foul-

ing and cleaning. The objectives included a study of the effect of feed-

water impurities on the performance of the once-through steam gener-

ator.

The most significant effect of fouling was found to be an increase

in pressure drop on the secondary side; the effect on heat transfer was

very small. Forced convection (superheat) coefficients were only

slightly decreased, while the boiling heat transfer rate increased. As

a resiilt of fouling, the superheat temperature was decreased about 5F

and the boiling length to reach 100% quality was increased about 3 feet.

Similar results were revealed for either soluble or suspended solids.

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Page 10: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Heat Transfer Data

Research contributing to the development of the PWR once-through

boiler began in the middle 1950s. The results of this work are illus-

trated in the curve of DNB plotted as a function of mixture velocity in

Figure 8. DNB is defined as the condition existing when nucleate boil-

ing changes to film boiling. Nucleate boiling is boiling from a wetted

surface in which steam bubbles form around nucleation centers with a

characteristically high heat transfer coefficient. Film boiling, which

is characterized by low heat transfer, contains a film of superheated

steam that insulates most of the water from the heat transfer surface.

The abcissa of Figure 8 shows the quality of the steam at a given

location by weight percent. This quality varies from zero (all liquid)

to 100% (all steam). The ordinate shows mixture velocity. This curve

qualitatively shows the steam quality at which DNB occurs for a given

pressure, heat flux, and geometry.

The zones identified in Figure 8 represent the boiling conditions

in various types of steam generators. When B&W conceived the OTSG

for pressurized water reactors, the heat transfer characteristics in

Zone D had not been investigated. However, it was apparent that if the

quality at DNB was high for the conditions of mass velocity, tempera-

ture, and heat flux dictated by PWR operating conditions, then the size

and cost of the heat exchanger surface in the OTSG would be competitive

with those of natural-circulation PWR boilers of conventional design.

In 1963, B&W began a test program to determine whether the

OTSG concept was economically feasible. The heat transfer character-

istics of boiling water inside electrically heated tubes at low mass ve-

locities and low pressures were studied to determine the steam quality

at which nucleate boiling changes to film boiling. The results indicated

that steady-state operation under nucleate boiling conditions at steam

qualities above 95% is feasible at low mass flows, low pressures, and

low heat fluxes. It was also shown that some of the experimental nu-

cleate boiling conductances can be predicted by existing correlations.

- 7 - Babcock & Wilcox

Page 11: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Laboratory Models

The 19-tube laboratory boiler simulated the structure of the

OTSG and IEOTSG most closely. This boiler was instrumented to pro-

vide thermal-hydraulic data over the entire operating range. The tube

length, diameter, wall thickness, material, and spacing of the 19-tube

unit shown in Figure 9 duplicated those of the OTSG and IEOTSG de-

signs. Also, primary and secondary side pressures, temperatures,

arid mass flows duplicated the conditions of the commercial units. Be-

cause of the size of the 19-tube unit, the physical arrangement of its

secondary side was modified. However, the flow paths and the relative

arrangement of the functional components were closely followed. As

shown in Figure 9, the 19-tube boiler is set up to operate with the

direct-contact method of feedwater heating. By closing the steam

bleed-off valve and fully opening the feedwater heating chamber valve,

the 19-tube unit was operated in the once-through mode.

Figure 10 is a typical axial thermal profile as measured for the

19-tube OTSG. The upper curve represents the primary axial fluid

temperatures, and the lower curve represents the secondary axial

fluid temperatures. The slope of the primary temperature curve can

be used to calculate the axial heat flux distribution and the local thermo-

dynamic quality of the secondary fluid. The local slope of the primary

temperature profile can be used to determine whether the local mode

of heat transfer is controlled by single-phase forced convection, by

nucleate boiling, or by film boiling.

It appears that the axial location at which 100% thermodynamic

quality is reached can easily be detrmined from the secondary temper-

ature measurements, i. e. , the point at which"the secondary thermo-

couples rise sharply above the saturation temperature. However, this

is not the case, and it is believed that thermal nonequilibrium existed

between the vapor and the liquid phases. Experimental studies have

shown that at bulk enthalpy conditions corresponding to 100% quality,

superheated vapor co-exists with small, dispersed, saturated liquid

droplets. The saturated liquid droplets wet the thermocouple and thus

record saturation temperature. Only when the droplet supply is de-

pleted will the thermocouples indicate a temperature above the satura-

tion temperature.

- 8 - Bahcock&Wifcox

Page 12: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

If a heat balance is made for the indicated superheater region on

the primary and secondary sides using the enthalpy of saturated vapor

at the point of secondary temperature rise, it can be shown that the cal-

culated secondary enthalpy rise always exceeds the primary enthalpy

decrease. This indicates that the enthalpy of the secondary fluid at the

point at which the thermocouples first exhibit a sharp rise is already

well above saturation enthalpy. This is further illustrated by Figure

11, which compares calculated secondary temperatures with measured

temperatures.

Figure 12 shows typical axial temperature profiles for the 19-

tube laboratory boiler operating in the IEOTSG mode. The primary

inlet condition and the secondary mass flow are essentially the same

as those shown in Figure 10, where the 19-tube boiler is operating

with direct-contact feedwater heating.

The feedwater enters the bottom of the boiler at 455F (80F sub-

cooling) and is heated to saturation in approximately 8 feet. The sat-

urated fluid is then boiled to dryness and heated to approximately 608F

or 73F superheat.

The performance of the 19-tube laboratory boiler operating in the

recirculating, or feedwater heating, mode can now be compared with

the performance of the same unit operating in the pure once-through,

or IEOTSG, mode. In Figure 13, the axial primary and secondary

thermal profiles for each mode of operation aie superimposed. This

comparison shows the effect of inlet subcooling and the elimination of

secondary recirculation on the performance of the OTSG. As can be

observed from the figure, the length required to attain 40 degrees of

superheat v/ith 80F subcooling is reduced by about 8 feet. In addition,

the length in which the measured secondary temperatures correspond

to saturation temperature is decreased by about 17 feet.

The reduction in length due to operating in the IEOTSG mode re-

sults from the decrease in inlet feedwater temperature and the subse-

quent higher temperature difference between the primary and second-

ary fluids in the lower section of the boiler. As can be seen from the

curves showing operation of the 19-tube boiler with feedwater heating,

i .e. , no subcooling, boiling begins at the bottom of the boiler where

the thermodynamic quality is zero. The pinch-point temperature differ-

ence is about 15F. The relatively low heat flux continuously increases

up the boiler until nucleate-like boiling ceases.

9 Babcock & Wilcox

Page 13: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

When the secondary liquid is subcooled at the inlet, i. e. , no feed-

water heaving, a higher temperature difference between the primary

and secondary fluids exists at the bottom of the boiler. In the lower

section of the boiler, the increased temperature difference leads to

high local heat fluxes despite the absence of the boiling process. The

secondary liquid absorbs the energy from the primary liquid and reaches

saturation temperature approximately 8 feet from the bottom. This con-

dition of zero thermodynamic quality, or the pinch point, is analogous

to the inlet condition for the case without inlet subcooling. Since the

secondary liquid has absorbed some energy from the primary fluid, the

pinch-point temperature difference is higher, as is the local heat flux.

With inlet subcooling, the pinch-point temperature difference is approx-

imately 30F. The temperature difference between the two fluids re-

mains higher throughout the nucleate-like boiling region, and this con-

dition results in higher local heat fluxes. Therefore, less heat trans-

fer surface is required to attain a given thermodynamic quality. In

addition, for a given secondary exit steam flow, the flow in the bottom

portion of the boiler is less when the steam bleed-off valve is closed

than when it is opened. Hence, operation in the IEOTSG mode signifi-

cantly increases the thermal performance.

Finally, analytical models have been developed to predict the per-

formance of the IEOTSG. Figure 14 compares measured and analyti-

cally predicted axial thermal profiles for the 19-tube laboratory boiler

operating at conditions simulating those given in Table 1 for the IEOTSG.

The agreement is generally good. As explained earlier, the point at

which the temperature first deviates from saturation in the secondary

profiles results from thermal nonequilibrium temperature indications

due to droplets in the secondary flow.

Primary Flow Distribution

In addition to the thermal performance tests, flow distribution

tests of the primary side were conducted. The objectives v/ere to de-

termine the pressure drop through the 180-degree bend preceding the

primary flow nozzle and the primary flow nozzle itself and to determine

the distribution of primary fluid in the upper tubesheet.

- 10 - Babcock & Wilcox

Page 14: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

The model (Figure 15) was geometrically scaled at a ratio of 1 to

6 except for the tube bundle, which was simulated by 24 tubes, each

containing a calibrated orifice. Similarity of Euler numbers between

the model and the OTSG was maintained for the tube bundle. The ori-

fice connection to the simulated tube bundle and the control panel is

shown along with the removable 180-degree inlet bend and inlet nozzle.

As shown in Figure 16, the primary flow distribution varied

from 92 to 116% of the average flow per segment. The region of high-

est velocity is slightly off the centerline of the nozzle, and the region

of lowest velocity is near the outer edges of the tubesheet. Finally,

calculations have shown that the effect of the small primary flow distri-

bution on the performance of the OTSG is negligible.

Conclusions

The increase in thermal performance resulting from operating in

the IEOTSG mode has been demonstrated. Analytical models have been

developed to predict the performance of the IEOTSG. Comparisons

have been developed to predict the performance of the IEOTSG. Com-

parisons of analytical and experimental data have been good.

- 11 - Babcock&Wilcox

Page 15: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 1. Nuclear Steam System

- 12 - Babcock&Wiicox

Page 16: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 2. Cross Section of Nuclear Once-ThroughSteam Generator

Primary InletNozzle

I"Steam Outlet

Nozzle

•IS

Broached PlateTube Supports

OrificePlates

Primary OutletNozzles

Feedwa.ter HeaterNozzle

FeedwaterHeader

Annular FeedwaterHeating Chamber

Shell

Shroud

•Tube sheet

- 13 - Babcock&Wilcox

Page 17: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 3. Integral Economiser Once-ThroughSteam Generator

Manways

CylindricalBaffle

SteamOutlets (2)

Economizer—*Section

Reactor CoolantInlet

AuxiliaryFeedwater Inlet

Hand ho le s

FeedwaterInlets (2)

Reactor CoolantOutlets (2)

- 14 - Babcock&Wilcox

Page 18: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 4. Temperature Vs Load

600

GENERATOR OUTLET

SATURATION.TEMP 925 PSIA

- 15 - riabcock & Wilcox

Page 19: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 5. Temperature Vs Load, OTSG

650

600

550

500

tu

O)

uÎ 450u0)

SO)

400

350

300

250

Saturation Temp — 925 psia

4

4

e

Reactor Outlet

Average

Generator Outlet

Reactor Inlet

Feedwater Temp

25 50

Load, %

15 100

- 16 - Babcock&Wilcox

Page 20: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 6. Temperature Vs Load, IEOTSG

650

600

550

500

u

î 450uo>aSa>H

400

350

250

Saturation Temp — 92 5 psia

Reactor Outlet

Average

Generator Outlet

Reactor Inlet

Feedwater Temp

25 50

Load, %

75 160

- 17 - Babcock&Wilcox

Page 21: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 7. Feedwater Heating Chamber Test Facility-

Steam .

Feedwater »r

Thermocouples

Water in TestSection

SimulatedShell

Water in PressureVessel

PressureVessel

22.5°

Nozzles

ObservationPorts

(M

4.5-ftDiameter

Drains

- 18 - Babcock & Wilcox

Page 22: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 8. Mixture Quality at DNB

Zone COnce-Through Boilers

High-Temp Heat Source

uo

a>u

4->

X

s

Zone B (Recirc. Boiler)

Zone DOnce-Through BoilersLow-Temp Heat Source

20 40 60 80

Mixture Quality at DNB, %

Zone APot-Type

Boiler

- 19 - Babcock & Wilcox

Page 23: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 9. 19-Tube Laboratory-Sized Steam Generator

OOOOO

OOOOOOOO

Section A-A

Top of LowerTubesheet

Bottom of UpperTube sheet

Tube Supports

Bleed SteamValve

FeedwaterInlet

FeedwaterNozzle

Bleed SteamLine

FeedwaterHeating

Chamber

Z-1/2-in.Sch 80 Pipe

FeedwaterHeating

ChamberValve

Primary Outlet

- 20 - Babcock&Wilcox

Page 24: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 10. OTSG Axial Temperature Distribution

t—'

i

00

1

610

590

570

19-TUBE BOILER• PRIMARY• SECONDARY

550 * » '

530 Ii_«__i_«__B_.i_B_i_i.

0 20 30 40 5Q 60

DISTANCE FROM BOTTOM, FT

Page 25: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 11. Axial Temperature Distribution at 100% Load

613

fifin

590

h 580

ire,

H 570a>

S£ 560

550

540

530

520

i i i19-Tube OTSG

yPrir

easurenary F

3luid—#i

S

/

/

——=

•Calculated BulkSecondary Fluid-*»-/

/

k /I

. *

//; J

/ f

/ /

f

/ 'Measured£•—Secondary Fluid

Upper Tubesheetat 52.1 ft

i i

mmi

- * •

10 20 30 40Distance Above Lower Tubesheet, ft

50

- 22 - Babcock & Wilcox

Page 26: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 12. IEOTSG Axial Temperature Distribution

620

600 -

570

540

510

480

4500 10 20 30 40 50 60

DISTANCE FROM BOTTOM, FT

- 23 - Babcock&Wilcox

Page 27: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 13. OTSG and IEOTSG Axial Temperature Comparison

620 i

600 -

u- 570 -

540

510

480

450 L

Lkl 19-TUBE BOILER

— IEOTSG- x - OTSG

• PRIMARY• SECONDARY

) 20 30 40 50 60

DISTANCE FROM BOTTOM, FT

- 24 - Babcock & Wilcox

Page 28: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 14. Comparison of Analytical Model andExperimental Data

• 19 TUBE lEOTSG DATA— EXPERIMENTAL DATA

— ANALYTICAL MODEL

20 40ELEVATION, FT

- 25 - Babcock & Wilcox

Page 29: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 15. Primary Flow Model, Schematic Diagram

- 26 - BabcocktWikox

Page 30: Once-Through Steam Generation...ONCE-THROUGH STEAM GENERATION by M. F. Sankovich N. B. McDonald BABCOCK & WILCOX Power Generation Division Nuclear Power Generation Department P. O.

Figure 16. Primary Flow Distribution

95°/.

Centerline of Inlet Nozzle

- 27 - Babcock & Wilcox


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