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Document type

STIM-03.006
Revision/Date: 14 2009-09-25
No.:

Steam Turbine Information Manual

Issued by:

P11P14

Title

Control Fluid Piping Design


Proj Code

UA

Content Code
UNID-Nr

Document Status:

Preliminary

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Final

ISO 9001 Clause & Title:

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Fluid Piping Design

Document No.:
Revision/Date:
Page:

STIM-03.006
14
2009-09-25
2 of 17

Released by:

Andreas Logar

E F PR SU EN R&D 14

signed Logar

2009-09-29

Reviewed by:

Jrgen
Havemann

E F PR SU EN NA

signedHavemann

2009-09-29

Prepared by:

Heinz Ltters

E F PR SU EN R&D 14

signed Ltters

2009-09-25

Name

Org. Unit

Signature

Date

REVISION SHEET
REVISION

REISSUE

SECTION

DESCRIPTION OF CHANGE

DATE
010

011

2007-05-31

2008-02-29

4.1

Valve actuators added


Paragraphs added
PED note deleted
3.3.2: table with data for pressure surge added
4.1 max. allowable pressure drop and viscosity added
Drawings added

6
3.2

Design and test pressure changed

4.1

Butt weld requirement added

2.2
3.1
3.2.1
3.3

012

2008-07-04

4.3

Functional safety requirements added

013

2009-02-02

3.3

Closing times of bypass valves for driving in open


position changed, see report R&D1-09-006.

014

2009-09-25

4.1
3.3.2

Requirement for seamless piping added


Table with data for pressure surge: variant for partial
stroke testing added

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This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Control Fluid Piping Design

Steam Turbine Information Manual

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2009-09-25
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TABLE OF CONTENTS
SECTION

PAGE

1.

SCOPE .......................................................................................................................................................5
1.1 Responsibilities of the pipe designer:.................................................................................................... 5

2.

GENERAL ..................................................................................................................................................5
2.1 National Standards ................................................................................................................................ 5
2.2 Piping Interfaces .................................................................................................................................... 6

3.

DESIGN REQUIREMENTS FOR CONTROL FLUID SYSTEM.................................................................6


3.1 General Design Requirements .............................................................................................................. 6
3.2 Load case steady state.......................................................................................................................... 7

3.2.1
3.2.2
3.2.3

Operating pressure:..................................................................................................... 7
Design pressure (set pressure of pressure relief valve downstream main pumps):.... 7
Test pressure (1.5 x Design pressure): ....................................................................... 7

3.3 Load case pressure surge ..................................................................................................................... 7

3.3.1
3.3.2

Pressure surge (operating pressure + pressure increase): ......................................... 7


Table with data for pressure surge calculation............................................................ 8

3.4 Load case pressure variation .............................................................................................................. 10


3.5 Load case with temperature variation ................................................................................................. 10
3.6 Other Load cases ................................................................................................................................ 10
4.

PIPING DESIGN REQUIREMENTS.........................................................................................................11


4.1 General requirements.......................................................................................................................... 11
4.2 Insulation and trace heating ................................................................................................................ 12
4.3 I&C measures for steam turbines ........................................................................................................ 12

4.3.1
Steam turbine with two or more valve combinations (stop and control valve) per
expansion range ...................................................................................................................... 12
4.3.2
Steam turbines with one valve combination (stop and control valve) per expansion
range
.................................................................................................................................. 15
5.

PIPING SYSTEM FABRICATION REQUIREMENTS..............................................................................18


5.1 General ................................................................................................................................................ 18
5.2 Welding ................................................................................................................................................ 18
5.3 Non Destructive Test ........................................................................................................................... 18
5.4 Testing ................................................................................................................................................. 18

6.

INFORMATION PROVIDED BY SPG......................................................................................................18


6.1 Thermal Expansion.............................................................................................................................. 18
6.2 Volume flows for pressure drop and pressure surge calculation ........................................................ 18
6.3 Purity after oil flushing ......................................................................................................................... 18
6.4 P&ID..................................................................................................................................................... 18

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This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
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Control Fluid Piping Design

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1. SCOPE
This document covers the general requirements for the design of interconnecting piping for the
Turbine Control Fluid Systems. The associated project specific document is drawing xxxxx980294. The specific scope of interconnecting piping is indicated on the Turbine Control Fluid
System Diagrams.
If required, the scope of the piping must be including the scope of the insulation, trace heating,
trace heating related I&C.
1.1 Responsibilities of the pipe designer:
The pipe designer is responsible for the design, analysis and specification of the
interconnecting piping systems per the requirements of ASME B31.1 or VGB R503 M, VGB
R510 L and DIN EN13480-3 and this specification. This includes also the calculation of
strength against pressure/pressure surges and pipeline flexibility for valve movement due to
thermal expansion. The information, examples and remarks submitted do not relieve the
designer of responsibility for the system.

2. GENERAL
2.1 National Standards
Specific standards issued by the following organizations must be applied where referenced in
this specification. It is the Designer's responsibility to obtain copies of all referenced documents
and drawings.
ANSI
ASME
ASTM

American National Standards Institute


American Society of Mechanical Engineers
American Society of Testing Materials

or where required
DIN EN Deutsches Institut fr Normung / European Norm
ISO
International Standard Organisation
EG Machine Directive 98/37/EG
Pressure Equipment Directive (PED) 97/23/EG
VGB R503 M, VGB R510 L

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It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Fluid Piping Design

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2.2 Piping Interfaces


Piping Interfaces are located at the following equipment, depending on turbine type.:

Main Steam Valve Actuator

Hot Reheat Steam Valve Actuator

LP Induction Valve Actuator

Intercept Valve Actuator

Overload Valve Actuator

Heat Extraction Control Valve Actuator

Start-Up and Safety Valve Actuator

Bypass Valve Actuator

Hydraulic Supply Unit

3. DESIGN REQUIREMENTS FOR CONTROL FLUID SYSTEM


3.1 General Design Requirements
The electro-hydraulic valve actuators are provided with control fluid via one or more hydraulic
supply units (the quantity of units is depending on type of plant and quantity of valve actuators).
Valve vibrations must not affect the hydraulic supply unit. The control fluid is either mineral oil
or fire-resistant fluid (FRF).
The control fluid lines represent a very high risk potential due to the high operating pressure
and the additional pressure surges. Any leakages could lead to an oil fire in the potentially hot
surroundings. The control fluid line design must therefore be calculated with regard to strength
and restrained thermal expansion as well as the configuration of pipe supports such as fixed
points, guides and vibration dampeners.
Suitability of the pipeline wall thickness and pipe routing must be verified for the following load
cases given in chapter 3.2, 3.3 and 3.4.

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It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Fluid Piping Design

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3.2 Load case steady state


3.2.1

Operating pressure:
p = 160 bar (2320 PSI)

3.2.2

Design pressure (set pressure of pressure relief valve downstream main pumps):
p = 180 bar (2611 PSI)

3.2.3

Temperature: = 60C (140F)

Temperature: = 70C (158F)

Test pressure (1.5 x Design pressure):


p = 270 bar (3916 PSI)

Temperature: = 20C (68F)

3.3 Load case pressure surge


3.3.1

Pressure surge (operating pressure + pressure increase):


p = 160 + p bar (2320 PSI + p PSI)

Temperature: = 60C (140F)

The pressure increase p on a sudden change in mass flow is based on the Joukowsky
pressure surge equation, the main equation from pressure surge theory. This provides
information on the possible pressure increase p on a sudden change in mass flow.
p = a . . w / 105 bar
where a = sound velocity,

mineral oil and FRF : a = 1500 m/s (4921 ft/s)

w = change of velocity due to a sudden change of the mass flow


w = V& / A (m/s)

V& = flow rate (m3/s)


A = inner cross-sectional area (m2)
A= /4 . di
di = inner pipe diameter (m)
and

= fluid density,

mineral oil :

= 900 kg/m3 (56.2 lb/ft3)

FRF :

= 1250 kg/m3 (78.0 lb/ft3).

This pressure increase propagates at the velocity of sound against the direction of flow of
the medium. The resulting shock forces on the piping system have to be used for specifying
the locations of guides, fixed points and vibration dampeners. The determination of the
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and returned upon request. This document and such information is not to be
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Control Fluid Piping Design

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2009-09-25
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shock forces must be performed in accordance with standard industry analytical


techniques.
Note:
The following Siemens standard for calculation of the shock forces can be used for
comparison purposes.
Determination of the shock forces is a function of critical pipe length Lcrit .
Lcrit = a . ts

where ts = servo or solenoid valve closing time

& / ts if L < Lcrit


Fsurge = L . m

where L = pipeline section length

& = mass flow rate


m
&
Fsurge = a . m

if L > Lcrit

Verification of suitability of the pipework against stresses must be performed in accordance


with ASME B31.1 or DIN EN13480-3.

3.3.2

Table with data for pressure surge calculation

The pressure surge in the control fluid system is caused either by rapid shutting off the
short circuit volume flow by servo respectively solenoid valve or by sudden stop of the
control fluid column through driving valve or actuator against the end position.
Explanation of Short circuit volume flow: This is the maximum possible volume flow
through pressure and return lines occurring after Steam turbine trip until servo respectively
solenoid valve switch back. This happens, if a turbine trip is released during opening of
valve (servo/solenoid valve and trip solenoid valves are connected to different control
systems). All actuators with solenoid trip valves are affected by this.

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and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Fluid Piping Design

Valve Type
Main Steam
Main Steam
Main Steam

7)

Actuator
Type
Control Valve
Stop Valve
Stop Valve

Document No.:
Revision/Date:
Page:

200

Occurrence
per
1)
lifetime
10000

25
200

10000
10000

200

10000

25

10000

Closing time solenoid valve

200

10000

200

10000

Closing time servo valve


Closing time servo valve failure
mode
Closing time servo valve
Closing time servo valve failure
mode

25

10000

Closing time solenoid valve

200

10000

25
200

10000
10000

Closing time servo valve


Closing time servo valve failure
mode
Closing time solenoid valve
Closing time servo valve

Closing time servo valve failure


mode

Closing Time
ts [ms]

Reason of pressure surge


Closing time servo valve
Closing time servo valve failure
mode
Closing time solenoid valve
Closing time servo valve
Closing time servo valve failure
mode
Closing time servo valve
Closing time servo valve failure
mode

STIM-03.006
14
2009-09-25
8 of 17

Volume flow to be considered


[l/min]
See xxxxx-980294 chapter 3.4
25
See xxxxx-980294 chapter 3.4

Hot Reheat
Steam

Control Valve

Hot Reheat
Steam

Stop Valve

Hot Reheat
7)
Steam

Stop Valve

LP Induction
Steam

Control Valve

LP Induction
Steam

Stop Valve

Intercept

Control Valve

Intercept

Stop Valve

Overload

Control Valve

Heat Extraction
Control

Control Valve

No pressure surge expected

Start-Up and
Safety

Stop Valve

40

10000

Closing time solenoid valve

20

Hot Reheat
Bypass
Single Stem

Control Valve

100

300

Supply Steam
Bypass
Single Stem

Control Valve

Hot Reheat
Bypass
Double Stem

Control Valve

(2 welded angle
valves /Boxberg
Design)

Hot Reheat
Bypass
Double Stem
(2 welded angle
valves /Boxberg
Design)

Hot Reheat
Bypass
Double Stem
(2 welded angle
valves /Boxberg
Design)

Hot Reheat
Bypass
Double Stem
(Z-valve design)

Hot Reheat
Bypass
Double Stem

25
See xxxxx-980294 chapter 3.4

See xxxxx-980294 chapter 3.4


25
See xxxxx-980294 chapter 3.4
25
See xxxxx-980294 chapter 3.4

2)

Valve will be driven into full open


3)
end position
2)
Closing time servo valve
Valve will be driven into full open
3)
end position

See xxxxx-980294 chapter 3.4

100

300

100

300

Valve will be driven into full open


3)
end position

25

100

Closing time solenoid valve

See xxxxx-980294 chapter 3.4

Actuator with
spring

10000

Valve will be driven into full open


end position

See xxxxx-980294 chapter 3.4

Control and
Stop Valve

Failure mode volume flow to stop


and control valve added

See xxxxx-980294 chapter 3.4

400

Valve will be driven into full end


2)3)4)5)
position

See xxxxx-980294 chapter 3.4

25

100

Closing time solenoid valve

See xxxxx-980294 chapter 3.4

10000

Valve will be driven into full open


end position

See xxxxx-980294 chapter 3.4

Failure mode volume flow to stop


6)
and control valve added

See xxxxx-980294 chapter 3.4

Actuator with
spring

Stop Valve

Control Valve
Actuator without
spring

Stop Valve

(Z-valve design)

Hot Reheat
Bypass

Closing time servo valve

See xxxxx-980294 chapter 3.4

Control and
Stop Valve

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Closing time servo valve

See xxxxx-980294 chapter 3.4

2)

See xxxxx-980294 chapter 3.4

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Fluid Piping Design

Actuator
Type

Valve Type

Closing Time
ts [ms]

Occurrence
per
1)
lifetime

Document No.:
Revision/Date:
Page:

Reason of pressure surge

STIM-03.006
14
2009-09-25
9 of 17

Volume flow to be considered


[l/min]

Double Stem
(Z-valve design)

Supply Steam
Bypass
Double Stem (Zvalve design)

Supply Steam
Bypass
Double Stem (Z-

See xxxxx-980294 chapter 3.4


Control Valve
Actuator without
spring

Stop Valve

400

25

100

Control and
Stop Valve

Closing time solenoid valve

2)

10000

Valve will be driven into full open


end position

Failure mode volume flow to stop


6)
and control valve added

valve design)

Supply Steam
Bypass
Double Stem (Z-

Valve will be driven into full end


2)3)4)5)
position
See xxxxx-980294 chapter 3.4
See xxxxx-980294 chapter 3.4

See xxxxx-980294 chapter 3.4

valve design)

Notes:

1) Maximum expected loading combinations.


2) Bypass Trip (e.g. due to loss of injection water or increasing condenser pressure).
3) Full opening of bypass valve (e.g. load rejection and turbine trip under high loads).
4) For bypass double stem control valves (Z-design, actuator without spring) there is no short circuit flow due to
design without trip valves.
5) 400 loads = 300 loads full open + 100 loads full closed end position.
6) Trip actuation during opening of control valve causes switching of servo valve.
7) Only for valves with partial stroke testing.

3.4 Load case pressure variation


Pressure variation between

Load cycles

130bar (1885 PSI) and 160bar (2320 PSI)

The fatigue-strength under


pulsating (oscillating,
fluctuating) compressive
stress must be guaranteed.

115bar (1668 PSI) and 160bar (2320 PSI)

The load cycle of 10000 has


to be considered.

0 bar (0 PSI) and 160bar (2320 PSI)

The load cycle of 400 has to


be considered.

3.5 Load case with temperature variation


Temperature Load cycle of 7000 has to be considered (for temperature delta of 50 Kelvin).
All other temperature cycles below 50K must be guaranteed for life time of the piping.
3.6 Other Load cases
For additional loads caused by vibration of electro-hydraulic actuators, working platforms,
earthquakes, etc.

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and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

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4. PIPING DESIGN REQUIREMENTS

4.1 General requirements

Movement of the valves due to thermal expansion


Due to the high forces and the large movement of the valves, especial care must be taken,
when designing the first support of the control fluid pipe after the valve. The small control
fluid pipes must have a short span between the valve and the first support due to the high
forces of the pressure surge. However, due to the large movement of the valves there must
be a certain distance between valve and first support to reduce the stress in the pipe. To
fulfill both requirements vibration dampeners are necessary. This must be calculated in
every case.

The following must be taken into consideration where calculating the thermal expansion of
the connection points at the actuators:

Main steam valve, Hot Reheat, Overload- and Intercept Steam Valve and Heat
Extraction Control valve
The thermal expansion of the turbine, the steam valves itself and the adjoining pipes
must be considered.

Bypass Valves
The movement of the adjoining pipe and the movement of the condenser must be
considered as well as the thermal expansion of the bypass valve itself.

LP Induction Valve
If the valve is flanged at the turbine the thermal expansion of the turbine must be
considered. If it part of the pipe, the movement of the pipe must be considered.

Start-Up and Safety Valve


The movement of the adjoining pipe as well as the thermal expansion of the valve itself
must be considered.

The pipes are pressure sensitive lines. Therefore the allowable pipe pressure drop is
limited. The maximum allowable pressure drop values are:
5 bar for pressure pipes
2,5 bar for return pipes.
Pressure drop must be calculated with a fluid viscosity of 46 cSt. [Note: For ISO VG46 (either
mineral oil or FRF) fluid this is corresponding to a fluid temperature of 40C which is a reasonable
temperature when MAX system is in operation and bigger control valve movements may occur.]
The associated volume flow is given in xxxxx-980294, chapter 3.3.

The pipes must be routed with a constant pitch of 1 back to the hydraulic supply unit.

Vibrations can have several causes such as rotating machines like turbines and motors,
flows through piping, valves and fittings etc. To avoid serious damage of welds and
material, the piping must be supported by means of dampers and guides wherever there is
a hazard that vibrations can arise.

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and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Control Fluid Piping Design

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Since it is not possible to anticipate if vibrations occur during the piping design, it is
required that the piping will be checked during commissioning. Special attention must be
paid to high-frequency vibrations, because they quickly reduce the fatigue strength.

The pipe material must be stainless steel.


All welding seams of the pressure line must to be performed as butt weld.

Only seamless pipes are allowed

4.2 Insulation and trace heating


For outdoor units where the ambient temperature and for indoor units where the temperature in
the turbine building is expected to be at or below 5C (41F), the piping and the actuators must
be provided with insulation and trace heating. Installation of trace heating systems is specified
for the following:
-

Supply lines for control fluid system connecting tank to actuators


Actuators for turbine valves (main-, reheat-, LP induction steam)
Return lines connecting actuators to tank

Solenoid valves, servo valves on the control block and position transmitters must be installed
without thermal insulation
When trace heating is used, the max. pipe and actuator temperature must not exceed 25C
(77F ). During operation with trace heating the control fluid temperature cycle must not
exceed 20 Kelvin.
The temperature limits are valid for fluids according to STIM-05.002.
In the event that a trace heating system is not activated when needed or has failed of a trace
heating system, the closing function is then no longer assured for turbine valve actuators. Load
rejection may then result in turbine overspeed with consequential catastrophic failure of the
rotor.
To reduce the hazard potential commensurately, appropriate protection circuits must be
installed. These serve to close the affected valves before temperatures have fallen below safe
temperature levels.
4.3 I&C measures for steam turbines
In case standards on Functional Safety apply (IEC61508, IEC61511, ISA S84.01, ....) the
following description of I&C measures has to be completed by analysis, specification and
validation measures as described in these standards.
4.3.1 Steam turbine with two or more valve combinations (stop and control valve) per
expansion range
A 1-out-of-2 temperature protection circuit (with monitoring of the trace heating)must be
installed for the return line of each HP steam, IP steam and LP (induction) steam valve
combination. Failure of the trace heating for the associated valve combination causes
response of this circuit and closure of this valve combination by initiation of individual trip in
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and returned upon request. This document and such information is not to be
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Control Fluid Piping Design

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good time (before control fluid temperature in the return line falls below a safe level: alarm
signal issue at temperature below/equal to 10C (below/equal to 50F), trip signal issue at
temperature below/equal to 8C (below/equal to 46F ) ).
Temperature measurement (clamping strap elements) for this temperature protection
circuit must be implemented by means of instrumentation installed under the thermal
insulation slightly ahead (about 0.5 m) of the tank for the control fluid supply system.
The temperature protection circuit must be implemented such as to give a safe failure
percentage of better than 60%.
In the case of the LP (induction) steam valve combination, a temperature protection circuit
for the return line must be supplemented by installation of an additional 1-out-of-2
temperature protection circuit on both the stop valve actuator and the control valve actuator
for configurations that feature two separate trace heating systems (for the stop valve and
for the control valve). The associated temperature instrumentation must be installed on the
operating cylinder (see diagram 1). In the event that a common trace heating system is
implemented for the two actuators, a common additional 1-out-of-2 temperature protection
circuit for the two actuators is then adequate. The associated temperature instrumentation
must be installed on the operating stop valve cylinder (see diagram 1).
In the event that a common trace heating system is implemented for the return line and the
two LP (induction) steam valve actuators, a common additional 1-out-of-2 temperature
protection circuit on the return line is then adequate. Temperature measurement for this
temperature protection circuit must be implemented by means of instrumentation installed
under the thermal insulation slightly ahead (about 0.5 m) of the tank for the control fluid
supply system.
To rule out control fluid degradation in the event of excess temperatures, alarms are
derived from the separate temperature measurements in response to T> 70C (158F) in
the case of mineral oil and in response to T>65C (149F) in the case of FRF.
A trip signal must be formed for each steam valve combination. This must be implemented
in the form of binary, redundant signals routed along break-current circuitry (deenergize to
trip) to the Siemens PG automation system scope of supply (see schematic).

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confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Oil Piping Design

Document No.:
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2009-02-02
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CONCEPT TEMPERATURE PROTECTION TRACE HEATING SYSTEM


Turbine with two valve combinations (stop and control valve) per expansion range
2 out of 2 TRIP SIGNALS
MP 6

PT100 resistance
thermometer
surface mounted

PT100 resistance
thermometer
surface mounted

PT100 resistance
thermometer
surface mounted

MP 3

MP 1

MP 4

MP 2

MP 5

Temperature
Protection
From outside scope
of supply
not PG S

sensor 2
sensor 1

MP 2

MP 1

MP 7

protection circle MP3, MP6


and MP7 depending from
trace heating line

P
MP 6

PT100 resistance
thermometer
surface mounted
MP 6 and 7 depending from
trace heating line

1 oo 2

UPDATE: S32M3
Havemann
17.07.2004

1 oo 2

1 oo 2

1 oo 2

1 oo 2

1 oo 2

1 oo 2

>=1

MP 7

2 Trip-Signals for each protection circle


normally energized

Warning
temperature
protection circle

O.K.-Signals

Freeze Protection Units

Steam Turbine Protection


Scope of PG S
2 out of 2
for each protection circle with
noncoincidence monitoring
P

PT100 resistance
thermometer
surface mounted
MP 4

individual control of the


5 valve combinations

MP 5
T

Legend:
MP

noncoincidence
warning
CentralControlRoom

PT100 resistance
thermometer
surface mounted

measuring-point

Siemens Power Generation

trip of
low pressure
valve
combination

trip of
intermediate
pressure
valve
combination 1

trip of
high pressure
valve
combination 1

trip of
high pressure
valve
combination 2

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

trip of
intermediate
pressure
valve
combination 2

Control Oil Piping Design

Steam Turbine Information Manual

Document No.:
Revision/Date:
Page:

STIM-03.006
13
2009-02-02
14 of 17

4.3.2 Steam turbines with one valve combination (stop and control valve) per expansion
range
A 1-out-of-2 temperature protection circuit (with monitoring of the trace heating) must be
installed for the return line of each HP steam, IP steam and LP (induction) steam valve
combination. Failure of the trace heating for the associated valve combination causes
response of this circuit (before control fluid temperature in the return line falls below a safe
level: alarm signal issue at temperature below/equal to 10C (below/equal to 50F), trip
signal issue at temperature below/equal to 8C (below/equal to 46F ) ).
Temperature measurement (clamping strap elements) for this temperature protection circuit
must be implemented by means of instrumentation installed under the thermal insulation
slightly ahead (about 0.5 m) of the tank for the control fluid supply system.
The temperature protection circuit must be implemented such as to give a safe failure
percentage of better than 60%.
In the case of the LP (induction) steam valve combination, a temperature protection circuit
for the return line must be supplemented by installation of an additional 1-out-of-2
temperature protection circuit on both the stop valve actuator and the control valve actuator
for configurations that feature two separate trace heating systems (for the stop valve and
for the control valve). The associated temperature instrumentation must be installed on the
operating cylinder (see diagram 1). In the event that a common trace heating system is
implemented for the two actuators, a common additional 1-out-of-2 temperature protection
circuit for the two actuators is then adequate. The associated temperature instrumentation
must be installed on the operating stop valve cylinder (see diagram 1).
In the event that a common trace heating system is implemented for the return line and the
two LP (induction) steam valve actuators, a common additional 1-out-of-2 temperature
protection circuit on the return line is then adequate.
To rule out control fluid degradation in the event of excess temperatures, alarms are
derived from the separate temperature measurements in response to T> 70C (158F) in
the case of mineral oil and in response to T>65C (149F) in the case of FRF.
A common trip signal must be formed for the HP steam and IP steam valve combinations.
This must be implemented in the form of binary, redundant signals routed along breakcurrent circuitry (deenergize to trip) to the Siemens PG automation system scope of supply
(see schematic).
A common trip signal must be formed for the two actuators of the LP (induction) steam
valve combination. This must be implemented in the form of binary, redundant signals
routed along break-current circuitry (deenergize to trip) to the Siemens PG automation
system scope of supply.

Siemens Power Generation

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Control Fluid Piping Design

Steam Turbine Information Manual

Document No.:
Revision/Date:
Page:

STIM-03.006
14
2009-09-25
15 of 17

Diagram 1

Siemens Power Generation

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It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

Steam Turbine Information Manual

Control Oil Piping Design

Document No.:
Revision/Date:
Page:

STIM-03.006
13
2009-02-02
16 of 17

CONCEPT TEMPERATURE PROTECTION TRACE HEATING SYSTEM


Turbine with 1 valve combination (stop and control valve) per expansion range
2 out of 2 TRIP SIGNALS

UPDATE: PG S32M3
Havemann
17.07.2004
MP 4

PT100 resistance
thermometer
surface mounted

MP 5

MP 1

MP 2

protection circle MP3, MP4


and MP5 depending from
trace heating line

PT100 resistance
thermometer
surface mounted

Temperature
Protection
From outside scope
of supply
not PG S

sensor 2
sensor 1

MP 1
MP 3

P
MP 4

PT100 resistance thermometer


surface mounted
MP4 and 5 depending from
trace heating line

1 oo 2

1 oo 2

1 oo 2

1 oo 2

>=1

1 oo 2

Warning
temperature
protection circle

>=1

MP 5
2 Trip-Signals for each protection circle
normally energized

O.K.-Signals

Freeze Protection Units

Steam Turbine Protection


Scope of PG S
2 out of 2
for each protection circle with
noncoincidence monitoring
noncoincidence
warning
CentralControlRoom

PT100 resistance
thermometer
surface mounted
individual control of the
3 valve combinations

MP 2
T

Legend:
MP

trip of
low pressure
valve combination

measuring-point

Siemens Power Generation

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.

trip of
steam turbine

Control Oil Piping Design

Steam Turbine Information Manual

Document No.:
Revision/Date:
Page:

STIM-03.006
13
2009-02-02
17 of 17

5. PIPING SYSTEM FABRICATION REQUIREMENTS


5.1 General
The fabrication, inspection and testing of the piping system must be per the requirements of
ASME B31.1 or where required according VGB R503 M + VGB R510L, STIMs and
Transmittal Drawings.
5.2 Welding
All welding must be per the requirements of ASME B31.1 or where required according VGB
R503 M + VGB R510L and STIM-03.002.
5.3 Non Destructive Test
Siemens requires a non-destructive test for all lines within the control fluid system (MAX).
The requirements are specified in the STIM-03.009.
5.4 Testing
The Control Fluid Pipes must be hydrostatic tested. The pressure of the hydrostatic
pressure test must be 1.5 x design pressure.
6. INFORMATION PROVIDED BY SPG
6.1 Thermal Expansion
xxxxx-980255 MAIN STEAM VALVE
xxxxx-980256 REHEAT STEAM VALVE/INTERCEPT VALVE
xxxxx-980258 OVERLOAD VALVE
xxxxx-980321 HOT REHEAT BYPASS VALVE
xxxxx-980322 SUPPLY STEAM BYPASS VALVE
xxxxx-980360 LP INDUCTION VALVE
xxxxx-980332 HEAT EXTRACTION CONTROL VALVE
xxxxx-980355 START-UP AND SAFETY VALVE
6.2 Volume flows for pressure drop and pressure surge calculation
xxxxx-980294 REQUIREMENTS ON CONTROL FLUID SYSTEM
6.3 Purity after oil flushing
STIM-11.009 CONTROL FLUID SYSTEM FLUSHING AND CLEANING PROCEDURE
6.4 P&ID
xxxxx-983130 SYSTEM DIAGRAM CONTROL FLUID
xxxxx-983131 SYSTEM DIAGRAM CONTROL FLUID (BYPASS)

Siemens Power Generation

This document contains proprietary information.


It is submitted in
confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.