Guidance of piping design

1. Scope of Application

This standard compiled as piping design guidance for conventional thermal power plant and
combined cycle power plant.

2. Contents

This guidance include abundant experience in piping design field which based on our engineer’s
know how.

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 Contents

Page

1. General 1-1

1.1 Preface 1-1

1.2 Outline of thermal power plant system 1-1

2. Main Piping 2-1

2.1 Definition of main piping 2-1

2.2 Summary of main piping 2-1
2.3 Arrangement of main piping 2-4

3. Guideline of Main Piping MNS No. 3-1

3.1 Main steam pipe (LBA**) 3-2

3.2 Cold reheat pipe (LBB**) 3-23
3.3 Hot reheat pipe (LBC**) 3-32
3.4 Main steam blow down pipe (LBA**) 3-37
3.5 Cold reheat blow down pipe (LBB**) 3-42
3.6 Hot reheat blow down pipe (LBC**) 3-45
3.7 High pressure turbine bypass pipe (MAN**) 3-46
3.8 Low pressure turbine bypass pipe (MAP**) 3-64
3.9 Turbine bypass DeSH spray water pipe (MAN**/ MAP**) 3-66
3.10 Boiler start-up extraction steam pipe (LBH**) 3-70
3.11 Water separator drain tank drain pipe (HAG**) 3-73
3.12 HP feed water pipe(BEF outlet) (LAB**) 3-77

4. Guideline of circulating water Piping MNS No 4-1

4.1 Circulating water pipe (PAB**) 4-2

4.2 Sea water pipe (PAB**) 4-45

5. Guideline of Boiler Plant piping MNS No 5-1

5.1 Auxiliary steam pipe (QLB11/LBD**/LBG**) 5-2

5.2 Economized recirculation pipe (HAC**) 5-9
5.3 SHDeSH spray water pipe (LAE01) 5-10
5.4 RHDeSH spray water pipe (LAF01) 5-13
5.5 Steam drum continuous blow down pipe (LCQ**) 5-16)
5.6 Boiler drain and vent pipe 5-18
5.7 Steam drum water level gauge pipe 5-35
5.8 Boiler water filling pipe (GHC01) 5-42
5.9 Sootblower steam and drain pipe (HCB**) 5-44
5.10 Steam air heater drain pipe (HLC**) 5-54
5.11 Seal air pipe (HWA**) 5-59
5.12 Aspirate air pipe (QEB**) 5-63
5.13 Boiler blow down tank exhaust and drain pipe (LCQ**) 5-65
5.14 Safety valve exhaust pipe 5-81
5.15 Safety valve drain pipe 5-85
5.16 Boiler washing water and blowing pipe (SDD**) 5-87
5.17Chemical cleaning water pipe 5-91
5.18 Blowing pipe 5-94

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6. Guideline of Turbine plant Piping MNS No. 6-1

6.1 Condensate water pipe (Condensor – CP) (LCA11) 6-2

6.2 Condensate pump balance pipe (LCB**) 6-6
6.3 Condensate water pipe (CP outlet) (LCA12) 6-7
6.4 Condensate water recirculation pipe (LCA**) 6-20
6.5Condensor makeup water and spill over pipe (GHC01) 6-22
6.6 Condensor curtain spray water pipe (LBE01) 6-27
6.7 LP turbine spray water pipe (LBE01) 6-29
6.8 Feed water pipe (Deaerator- BFP booster pump) (LAB11) 6-31
6.9 BFP minimum flow pipe (LAB12) 6-35
6.10 BFP warming pipe (LAB**) 6-39
6.11 Feed water pipe (BFP booster pump outlet) (LAB11) 6-41
6.12 Extraction steam pipe (LBQ**) 6-43
6.13 HP heater drain pipe (LCH**) 6-53
6.14 LP heater drain pipe (LCJ**) 6-60
6.15 Heater and deaerator air vent pipe (LAD**/LCC**/LAA**) 6-63
6.16 Turbine gland steam pipe (MAW**) 6-67
6.17 Turbine gland steam leakage pipe (MAW**) 6-73
6.18 Gland condensor exhaust and drain pipe (MAW**) 6-77
6.19 BFPT steam supply pipe (LBG16) 6-82
6.20 BFPT exhaust pipe (LBE11) 6-86
6.21 Deaerator heating steam pipe (LBS**) 6-89
6.22 Deaerator recirculation pipe (LAB09) 6-92
6.23 Deaerator over flow pipe (LP clean up pipe) (LAA**) 6-95
6.24 HP clean up pipe (LAB**) 6-99
6.25 Condensor air extraction pipe (MAJ01) 6-102
6.26 Condensor water box air extraction pipe (MAJ11) 6-105
6.27 BFP seal water pipe (LCA**/LCE**) 6-108
6.28 Condensate return water pipe (LCM01) 6-112
6.29 Condensor blowing pipe (MAG**) 6-114
6.30 Seal water pipe (LCW01) 6-121

7. Guideline of Combined Cycle Plant Piping MNS No. 7-1

7.1 GT fuel gas pipe (MBP**/QEF**) 7-2

7.2 GT fuel oil pipe (MBN**) 7-21
7.3 GT water injection pipe (MBU**) 7-27
7.4 GT vapor extractor exhaust pipe 7-29
7.5 GT starting steam pipe 7-31
7.6 LP turbine cooling steam pipe 7-33
7.7 Piping around deaerator for CC 7-35

8. Guideline of Common Piping MNS No. 8-1

8.1 Closed cooling water pipe (PGA**) 8-2

8.2 Chemical dosing pipe (LFN**) 8-9
8.3 Sampling pipe (QUA**) 8-12
8.4 Control air pipe (QFB**) 8-19
8.5 Service air pipe (QEB01) 8-22
8.6 Nitrogen supply pipe (QJA01) 8-25
8.7 Fire fighting water pipe (SGA**) 8-29
- Fire water supply system
- Ring main
- Fire water spray system
- Air foam system for fuel oil tank

8.8 Floor drain pipe (GMA**) 8-43

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1. General

1.1 Preface

There are many piping systems in thermal power plant.

The piping design shall be considered purpose of system, operation requirements (start-operation-
stop), installation, maintenance and repair procedure.
Attention items for piping design are shown in Table 1-1.

1.2 Outline of thermal power plant system

Outline of thermal power plant system are shown in Fig 1-1.

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File draw .doc

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 Table 1-1 Attention items for piping design

No. Attention Items System name Remarks

1. No interference between For all piping systems The required insulation
structure, equipment, cable thickness shall be
and pipe( including considered.
insulation)
2. Steam hammer and water . Main steam pipe Special attention shall be
hammer shall not allow at . Cold reheat pipe paid to the following
starting, operation time and . Hot reheat pipe case.
stopping. . Condensate water recirculation pipe
. BFP suction pipe/minimum flow pipe 1.Pipe for saturated
. SAH drain pump suction pipe water.
. Low pressure drain tank suction pipe 2.Pipe with ON-OFF
. SH spray pipe valve ( with pressure
. RH spray pipe reducing orifice at down
. Condensor curtain spray pipe stream side.
. Subsidiary steam pipe 3. Feed water pipe for
. Heater drain pipe drum inlet port (for
. Boiler starting system pipe. combined plant).
3. Pipe vibration shall not . Suction pipe for boiler feed water pump
allow at starting, operation . Feed water pipe, discharge pipe for feed
time and stopping. water booter pump.
. Minimum flow pipe for boiler feed
water pump.
. Pipe around condensate water flow
control valve, condensate water
recirculation pipe.
. Heating steam pipe for deaerator
Air pipe for plant use/control
(reciprocating air compressor)
. Air vent pipe, pressure detection pipe,
sampling pipe, flow meter pipe (connect
to main pipe).
. Drain pipe around drum (For long
vertical piping system).
. Spray water pipe.
. BCP inlet pipe.
. Continuous blow off pipe.
. Main steam blow off pipe.

4. Air and drain pocket shall be . BFP seal water return pipe(BFP-condensate
avoided as possible. water gathering tank).
. BFP gland leak off pipe.
. Condensor air vent pipe.
. Control air pipe.
. Seal air pipe.
. Turbine gland steam pipe.
. Drain pipe for main pipe(MS, HTR,LTR)
. SAH drain pipe.
. Extraction pipe.
. Others.
5. Opposite slope by thermal . Main steam pipe
elongation in piping shall be . Cold reheat pipe
avoided. . Hot reheat pipe
. Drain pipe around drum.
. Other steam pipe and steam drain pipe.
6. No interference allow between For all piping system. Operation pattern shall be

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 insulation of each pipe. considered.
7. Temperature indicator and . Main steam pipe (set at upstream side of
pressure gauge shall be set at drain pipe)
correct position. . Cold reheat pipe ( set at downstream
side of heat exchanger).
. Others (downstream side of heat
exchanger).

8. Keep thermal stress in pipe . For all high temperature pipe.

within allowable value.
9. Keep thermal reaction moments .Main piping system. Referring item is pipe
for equipment . For all heat elongation piping system. support.
( boiler,turbine,pump etc.)
within allowable value.
10. Erosion shall not be allow in . Downstream side of pressure reduction Grade up for pipe material
pipe line. valve which 20K and over pressure. by applying rubber lining
. Drain pipe for main pipe (downstream side etc.
of the valve, downstream side of trap).
. BFP warning pipe (downstream side of
orifice).
. BFP minimum flow pipe (downstream
side of control valve).
. Heater drain pipe (downstream side of
control valve).
. Drain pipe around drum (systems which
used at starting).
. Circulation water pipe (downstream
side for discharge valve of condenser).
. Others, downstream side for reducing
valve and orifice etc.

11. Corrosion shall not be allow in . All embeded pipe (outer surface). Following shall be
pipe line. . Sea water pipe (inside surface) considered.
. Lost way electric current.
. Different kind of
materials (prevention of
electric corrosion).
. Outside electric source
system.
. Anode (Zn plate etc)
12. No problem required for . Feed water pipe, cooling water pipe around
overhaul space (for equipment), BFP
operation, handling, passing . Condensate water pipe (around gland
through space (expansion joint condensor)
for T-BFP, monorail etc). . Air pipe, condensate water pipe around
condensor chamber.
. Cooling sea water pipe, cooling fresh water
pipe around cooling water cooler.

13. Easy carry in and installation. . Circulating water pipe.

. Main pipe.
. Suction pipe for condensate water pump.

14. Allow, for irregular sink. . Circulating water pipe.

. Other embedded pipe.
. Pipe around outside tank.

15. Allow, for error of installation. . Circulating water pipe. . Expansion joint.
. Sea water pipe. . Loose allowance.
. Exhaust pipe for BFPT.

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16. Electrical items (such as motor 1. Pipe which installed near explosion Explosion proof
valve etc.) shall not be install in proof area. specification shall be
explosion proof areas. . Drain pipe around drum. applied for electric items
. Air vent pipe around drum (specially, which installed inside of
natural gas operation) explosion proof area
. Starting valve (starting system pipe). unavoidably.

2. Pipe which installed inside explosion

proof area.
. Bent pipe for fuel gas piping system.
. H2 pipe around valve station.
. Bend pipe for H2 piping system.

17. Enough to noise regulation. . Turbine by-pass pipe (arrangement of

starting valve).
. Drain pipe for water separator drain tank.
. Safety valve and exhaust pipe.
. Downstream pipe of flow reducing valve.
. Around fuel gas pressure reducing valve
station.
18. Proof of fluid freezing (special Drain or water staying line at boiler stop Insulation, steam heating,
attention shall be paid for plant condition (plant water, feed water, discharge Electrical heating, drainage
which installed in cold region). water, sea water etc.) line.

19. Keep, pressure loss within . Main steam pipe

allowable value. . Cold reheat pipe
. Hot reheat pipe
. Extraction pipe.
. Gland steam leak pipe.
. All exhaust steam pipe.
20. No dangerous factor recognized . Exhaust pipe for safety valve. Exhaust end shall be keep
at discharge port. . Bend pipe for deaerator. + 0.5m above 2.3m gland
. Exhaust pipe for heater relief valve. level.
. Exhaust pipe for vacuum pump.
21. Draw attention to scattering of . Exhaust pipe for turbine main tank vapor
water and oil at discharge port. extractor.
. Exhaust pipe for blow tank.

22. No water injection allow into . Cold reheat pipe Entrance of drain or cooled
the turbine. . Hot reheat pipe steam into the turbine cold
. Extraction pipe. water injection. It causes
. Turbine gland steam pipe. vibration and serious
. Drain pipes. accidents on the turbine.
23. Confirm, pipe dismantling . Condensate water pipe (around gland
request at equipment overhaul. condensor, condensate water pump).
. High pressure feed water pipe (around
BFPM, BFPT).
. Low pressure feed water pipe (around
BFPM, BFPT).
. Cooling sea water pipe (around sea
water cooler).

24. Only vertical shaft shall be For all pipes.

allowed for large size valve.

25. Coincide with waste water For all pipes.

discharge limits.

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26. Economical effect shall be For all pipes.
considered.

27. Satisfy to customer’s spec. For all pipes.

28. Piping shall be as shorten as For all pipes.

possible and bend pipe used
mostly.

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2. Main Piping

Main piping has an important influence upon cost, performance and arrangement of thermal plant. It must be
arranged firstly refer to follows:

2.1 Definition of main piping

Main piping is include follows;

- Main Steam Pipe.

- Hot Reheat Pipe.
- Cold Reheat Pipe.
- HP Feed Water Pipe.
- High Pressure Turbine Bypass Pipe.
- Low Pressure Turbine Bypass Pipe.
- Boiler Start-up Extraction Steam Pipe.
- Water Separator Drain Tank Drain Pipe.
Above piping are very important line in the plant system, and it has large bore and heavy thickness against
high temperature and high pressure.

2.2 Summary of main Piping.

1) Very high cost than another line pipes because it constructed by high class materials. [ ASTM P22, ASTM
P91, ASTM A106C etc.] against for high temperature and high pressure operation condition.

Main pipe takes large portion (weight, cost) in thermal power plant piping system. As for the sample (exclude fuel
system), weight and cost for main piping system (Main Steam Pipe. Hot Reheat Pipe, Cold Reheat Pipe) are
shown in Fig 2-1,2-2.

2) Main piping give large impact to thermal power plant performance and its design are required suitable
investigation of function and economical side.

Total plant construction and operation cast must be minimum.

HOT REHEAT PIPE HOT REHEAT PIPE

Main Steam
Pipe 176 Main Steam
TON 288 TON
(13.4%) (12.9%)

162 TON
383 TON
(12.3%)
(17.2%)
416 TON 810 TON
(31.7%) 78 TON
(6%)
(36.3%)
139 TON
(6.2%)

1,314 TON 2,230 TON

Others 898 TON Others 1,420 TON

(68.3%) (63.7%)
COLD REHEAT PIPE
COLD REHEAT PIPE
a. AKO 1B
b. MATSUURA 1B
Output : 600 MW
Steam : 1900 T/H Output : 700 MW
Steam : 2300 T/H

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 Hot Reheat Pipe Hot Reheat Pipe

Main Steam Main Steam

150 TON 442 TON
(14.7%) (12%)
171 TON
(16.8%) 291 TON
(8%)
383 TON
62 TON 891 TON
(37.6%) (24.3%
(6.1%) 158 TON
(4.3%)
1,020 TON 3676 TON

Others (Turbine)
Others (Boiler)
1853 TON
Others 637 TON 932 TON
(50.4%)
(62.4%) (25.3%)

Cold Reheat Pipe Cold Reheat Pipe

c. SHIN KOKURA 5B d. MISUMI 1B-T

Output : 600 MW Output : 1000MW

Steam : 1950T/H Steam : 2900T/H

FIG 2-1 Ratio of main pipe weight in boiler plant pipe weight.

(MISUMI plant include boiler and turbine plant)

Note : This figure shows pipe only, Not include fittings etc.

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 Others Main Steam Others Main Steam
55.2% Pipe 57.4% 19.7%
25.1%

44.8% of Total 42.6% of Total

boiler piping boiler piping 15.5%
system 12.9% system

6.8% 7.4%

Cold Reheat Pipe Hot Reheat Pipe Cold Reheat Pipe Hot Reheat Pipe

a. AKO 1B b. MATSURA 1B
Output : 600 MW Output : 700 MW
Steam : 1900T/H Steam : 2300T/H

Hot Reheat Pipe

Turbine Main Steam

Others Main Steam plant pipe 18%
45.4% 28.5% 52.8%

7.2%
28.2% of Total
54.6% of boiler &
Total boiler 17.7% turbine piping 3.0%
piping system system

8.4%
Others (Boiler)
19%

Cold Reheat Pipe Cold Reheat Pipe

Hot Reheat Pipe
d. MISUMI 1B-T
c. SHINKOKURA 5B
Output : 1000 MW
Output : 600 MW Steam : 2900T/H
Steam : 1950T/H
FIG 2-2 Ratio of main pipe weight in boiler plant pipe weight.

(MISUMI plant include boiler and turbine plant)

Note : This figure shows pipe only, Not include fittings etc.

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2.3 Arrangement of main Piping.

2.3.1 Flow chart of main Piping Design.

Confirm Design Condition

Check Lead Number

Planning Pipe Route

Check pipe dia, thickness, material, pressure loss

NO
Check Cost

YES

Fix Base Specification

Checking
Piping Route

Support and fixed point design

NO
Thermal stress (include Support
Calculation Design)

YES

NO
YES or NO for anti-earthquake
design

YE

NO
Calculate earthquake force, Wind
force and Steam hammer

YE

Finalized Piping Route

Load Calculation

Arrangement drawings of main pipe

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Outline of arrangement for Main Pipes are as follows which according to previously mentioned flow chart.
Detail design shall be refer to Item3.

1) Confirm design condition

Design condition shall be confirmed before arrangement of main piping.

1. Design pressure/Design temperature.

2. Flow rate.
3. Flow velocity.
4. Allowable pressure loss.
5. Treminal condition and termial point on the boiler and turbine (position and allowable reaction
force, moment, displacement).

2) Check Lead Number

Usually, main Steam Pipe and Reheat Steam Pipe designed as 1lead or 2 lead. The lead number
decided by considering with total cost (material cost, manufacturing cost, insulation cost,
transportation cost, hanger/support etc etc.), thermal stress and raw material manufacturing limit (max.
pipe dimension and weight).

3) Planning of Piping Route

Outline route shall be arranged in consideration with Item 3 for piping systems which include pipe
diameter, thickness, material, boiler termial point and pressure loss.

4) Study of Pipe diameter, thickness, material and pressure loss.

Pipe diameter, thickness, material and pressure loss shall be studied under consideration with item (1)
~ (3).
1. Examination of Pipe Diameter.

Pipe diameter shall be decided as enough to allowable velocity and allowable pressure loss.
( detail is shown in item (5)).
Pressure loss will be calculated by using equations as shown in Item 3.1.2.2.5(3).

2. Decision of Pipe material.

Several allowable materials can be select by considering design temperature for Main pipe.
Generally speaking, using high class materials such as 9Cr steel, 12cr steel etc.brings high
allowable stress, thin thickness, low material cost, high manufacturing cost,low transportation
cost and low installation cost. That’s read to total cost minimum, but finally fitting item cost
and delivery time shall be considered.
Guidance for material selection are shown in following data. KPM-99-004 Selection of piping
specification ( material, diameter, thickness ). Customer’s requirements shall be checked for
seamless pipe or seamed pipe which relate to the cost.(generally, seamed pipe is cheaper than
seamless pipe for 450A and over size). Deviation offer shall be examined when customer
required seamless pipe for Hot reheat pipe and Cold reheat pipe.

3. Decision of Pipe Thickness.

Pipe thickness are calculated by using equations in the domestic engineering standard for
thermal power plant and/or ASME B31.1 cosidered with pipe size, material and design
pressure, temperature. And furthermore, manufacturing errorand reducing ratio of thickness at
pipe bending process shall be counted.

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4. Decision of pipe specification.

Pipe specification ( pipe size, thickness , material) related to above mentioned item (1)~(3), pipe
size and thickness are selected according to each materials. These specification related to pipe BQ
data.

5.Fluid Velocity in Pipe.

1) Selection of fluid velocity in pipe (no customer’s requirements). According to MHI standard
MS01-511 [ Standard fluid velocity in pipe]. Select, most high and within existing similar
plant value. High velocity and small pipe size produce low cost. But, uneasonable high
velocity brings vibration, noise and erosion on pipe.

2) Fluid velocity in main Steam Pipe, High/cold reheat pipe and HP Feed Water Pipe are
standardized as follows:

Pipe size for Main Steam Pipe and High/Cold reheat pipe are decided by taking into account
pressure loss.
a. Main Steam Pipe : 45~65m/sec
b. Hot reheat pipe : 60~80m/sec
c.Cold reheat pipe : 30~50m/sec
d. High Pressure Feed Water Pipe :4~7m/sec
( inside diameter 300mm and over)

Temporary pipe size and routing are set by using above standard velocity when proceeding
case study. Correction shall be made by referring approximate conditions existing plant. rEfer
to above 1) for HP Feed Water Pipe size because the standard velocity for HP Feed Water Pipe
are different to each pipe inside diameter.

3) Combined Cycle Plant

At each HRSG Main Steam Pipe discharge port (up stream side of confluence), fluid velocity
on 1G/T UNIT operation is faster than total G/T UNITS operating condition. Steam condition
change as follows:
- Pressure Low
- Temperature & volume Nearly the same.
- Velocity Fast.

Pipe size shall be decided by taking into account vibration, noise and erosion condition on
1G/T UNIT operation.
Fluid velocity in the pipe under total G/T UNITS operation condition is slower than that
selected for 1G/T UNIT operation by referring [ Standard fluid velocity in pipe] MS01-511,
and brings high cost.
We recommend as follows: Pipe size shall be select by referring [ Standard fluid velocity in
pipe] MS01-511 under total G?T UNITS operation condition.
Fluid velocity in pipe shall be confirmed under 90m/s (NOTE1) at 1G/T UNIT operation
condition.
(NOTE 1)
We have no experienceover 90m/s steam in Main Steam Pipe.

4) Generally customer’s specification for export thermal power plant have velocity limit. We
recommend high velocity that when fluid velocity limitation are lower than calculation results
which getting from 1).

(NOTE)
Surplus design required for pipe thickness error and difference of elbow/bend pipe thickness,
especially for export thermal power plant to GULF.

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6) Checking Piping Route

Piping route shall be incarnated after set piping outline and base specification. Check follows:

1) Interference between piping and equipment/builiding (include brace).

2) Position of safety valve (refer to item, 3.1.3.4)
3) YES or NO bending pipe adoption (refer to item 3.1.3.7)
4) Others (refer to item 3).

7) Planning of Support point anf Fixed Point

Piping support span follows to ASME B31.1 recommendation and confirmed its stress which
described as below. Fixed point are planned for restrain or control of random thermal expansion of pipe,
and consider follows :

1) Suitably balanced fixed point shall be designed as under allowable reaction force and
moments to the boiler and turbine. Usually, very small reaction force and moments are
allowed to the turbine.
It is very difficult that to set under allowable reaction force and moment on the pipe. Suitable
check shall be carried out for reaction force and moment on the turbine.
Fix vertical direction of turbine shaft on turbine center line, or fix up and down direction on
turbine center line level for reducing reaction force and moment basically. (refer to Fig
3.1.3.3)
2) Fixed point shall be set as much as possible to reduce complicated action and vibration of pipe
under operation condition. Many fixed points recommend at under low stressed condition, but
it brings flexibility reducing of piping systems. Fixed point include anchor which completely
fixed a point on the pipe and stopper or guide that restraint one direction movement of the
pipe.
3) Suitable much fixed point shall be select for restrain pipe swing or vibration from earthquake
and pipe stress which produced by inertia force.From another point of view, suitable
flexibility are required on piping system for displacement between boiler structure and turbine
building at earthquake break out.
4) Minimum application of high cost constant hanger, spring hanger anti-vibration equipment
shall be considered. Much fixed point produce cost minimum. Upper and down fixed point on
vertical pipe of boiler front pipe are save vertical load on constant hanger and spring hanger.

8) Thermal Stress Calculations.

Thermal Stress Calculations are carried out for confirmation of the thermal stress lower than
allowable stress which introduced by thermal elongation of pipe. By this technique, calculate reaction force
on terminal point of boiler and turbine which described above, moment value, load on support or fixed
point, displacement of pipe etc.

9) Calculation of anti-seismic load.

Calculation of anti-seismic load shall be carried out by using [ Regulation for calculation of anti-
seismic load on thermal power plant].
The above results applied to evaluation of
- Pipe stress which brings by inertia force under seismic condition.
- Pipe stress which brings by relative displacement between boiler structure and turbine
building.
( For the combined plant, relative displacement between pipe rack shall be checked ).

10) Calculation of Steam Hammer and anti-wind force.

No calculation carried for steam hammer and anti-wind force unless specified in the customer’s
specification. Under rare case calculation are carried for shock load by pressure rise with turbine trip and

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wind load by storm. Anti-vibration equipment shall be set as shock absorber at turbine trip on flouting type
MSV side.

11) Loading Data.

Loading data shall be submit to the our civil engineer or customer for confirming boiler and
turbine column base load after decision of pipe route, fixed point and load calculation. To put in correctly,
hanger point load or water filling load which calculated by considering thermal calculation anti-seismic
calculation act on boiler structure and turbine building shall be include.

12) Planning of Main Piping System.

Planning of main piping system shall be produced after completion of calculation and check.

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 3. Guideline of Main Piping System

Purpose of piping system application, operation requirements are important point on proceeding piping arrangement.
And this section include followings:
1) Constitutions of systems.
2) Purpose of piping system application.
3) Planning procedure of piping system.

This section compiled as piping design guidance for thermal power plant and mainly applied to conventional thermal
power plant. Furthermore, this guidance include several technique for combined cycle power plant.

2.4 Main Steam Pipe

2.4.1 Constitution of Systems.

a. 156MW ~ 450 MW class. 1 lead

MSV/GV

HP Turbine

SH outlet header

b. 500 MW ~ 700 MW class. 2 leads

Cross-over pipe

MSV/GV

HP Turbine

SH outlet header
2 leads
Cross-over pipe
c. ~ 1000 MW class.

SH outlet header MSV/GV

HP Turbine

2.4.2 Purpose of Piping System Application.

This piping system lead steam which generated in the boiler to the turbine.
3.1.2.1 Number Of lead

Main Steam Pipe are constructed as 1 lead or 2 lead. Almost existing plant has 2 leads for 500 MW and over
capacity, 1 lead for under 450 MW respectively.

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(NOTE 1) Plant cost ( material cost, manufacturing cost, insulation cost, installation cost, transportation
cost, and hanger cost etc.), thermal stress and limit of manufacturing (pipe dimensions & weight )
shall be considered.

(NOTE 2) For a few export plant, 1 series required by customer for over 500 MW plant. Large pipe dia
system brings drastic cost up. Customer’s requirement for lead number shall be confirmed at
estimation period.

3.1.2.2 Application Of System and valve Operation

3.1.2.2.1 Cross over Pipe

MSV operation test carried 1/week. Cross-Over Pipe are provided for reducing differential pressure at front of MSV,
and prevent metal temperature rise by unbalanced flow of boilwe SH. Diameter of Cross-Over Pipe select as
follows :

1) No operation allowed for safety valve under pressure rise.

2) Confirm, SH metal temperature rise by unbalanced flow are under allowable value.

At the case that heater by-pass line branch off from Cross-Over Pipe, large flow shall be select either by-pass valve
capacity or above calculated value.

(Additional Explanations 1) Cross-Over Pipe has a purpose of boiler balance pipe as described above. In
domestic rule, balance pipe discharge port considered as boiler discharge port.

(Additional Explanations 2) Attention shall be paid to MSV steam flow difference on right side and left
side which caused from GV sequence under partial load operation. We
designed 2 series MSV-GV line, so 1 lead power output at MSV test on our
conventional type turbine controlled as 70~8-%. But, different type turbine
which provide steam chest and/or junction pipe can generate nearly 100%
output.

3.1.2.2.2 Installation of Main stop valve.

MITI and ASME required as a rule installation of Main Stop Valve at boiler discharge. But the case that turbine MSV
can resist to hydro pressur test on boiler, Main Stop Valve can be omit. ( refer to note 1.2 ). We are standardized no
Main Stop Valve installation when no customer’s request confirmed.

( NOTE 1 ) : Stop valve function are: Steam shut off. Turbine MSV can resist to hydro pressure test on
boiler. Shut off at inlet port of steam supply equipment.

( NOTE 2 ) : Attention shall be paid for combination with boiler which designed by German Regulation
(TRD) because hydro pressure test valve are different. (TRD : 1.2 times of design pressure) (
ASME : 1.5 times of design pressure).

22
3.1.2.2.3 Design Pressure

Design pressure obtained as follows :

SH outlet header MSV
Stop Valve 2
1

 
Circulating With stop valve Max working pressure of boiler. Turbine inlet rated pressure X
boiler 1.05
Without stop  Turbine inlet related pressure X 1.05 Whichever
valve  Drum safety valve min. blow off pressure X 0.85 large.
Through flow boiler Turbine inlet rated pressure X 1.05 ( + main steam pipe loss ).

( NOTE 1) ASME required that count of Main steam Pipe loss but not required in domestic regulation.

( NOTE 2) Maximum pressure which brings by pressure control equipment are regulated in German
Regulation. In that case working pressure comes higher.

( NOTE 3) Generally SH outlet port safety valve is installed on Main Steam Pipe. Setting pressure of SH
outlet port safety valve for flow through boiler is about 19% high of design pressure of Main
Steam Pipe, because it brings from Design pressure of boiler outlet. This pressure is lower than
short time allowable value 20%. Timely confirmation required when setting of SH outlet safety
valve pressure as under 1.2 times of Design pressure of Main Steam Pipe. Attention shall be paid
to higher working pressure setting on boiler outlet for FCB function attached flow through
boiler. ( refer to next page NOTE 1 ).

Pressure setting of SH outlet valve

Following are samples for flow through type boiler ( Turbine inlet rated pressure 246K )

Set pressure ( blow off pressure ) Boiler safety valve SH outlet safety valve

Pbsv ( 320 k )

Blow stop pressure Pshsv ( 308 k ) 1.5k X Boiler no

 of safety valve.
16%  
At M.F.T (292 k )
Maximum working Final super
pressure of boiler 6% ( 276 k ) Required less than
outlet. 20%

NOTE 1 Main working pressure.

MCR operation pressure
5% 1.05Pth (259k) main steam pipe.

MCR operation 5% (12.3k)

Pmp (9 k) Pth ( 246k )

SH Main Steam Pipe

MSV

23
1. Legend

Pth : Turbine inlet pressure.

Pmsp : Pressure loss of main steam pipe.
Pbsv: Setting pressure of boiler safety valve (usually install at outlet of water seperator ).
Pshsv : Setting pressure of SH outlet safety valve ( usually install on Main ).

2. Pressure setting procedure of SH outlet safety valve

 Setting pressure of Boiler Safety Valve is 1.16 times of boiler outlet Design pressure ( NOTE 1 ).
 Setting pressure of SH outlet safety valve numbers of safety valve is calculated by required
blow
off volume. 1.5K pressure shall be plus on each setting pressure of safety valve. Confirm setting
pressure of SH outlet safety valve is less than 1.2 times of Main Steam Pipe Design pressure.

( NOTE 1 ) Generally, boiler outlet Design pressure are given as shown  marks in the figure.
Special attention shall be paid for the plant which has FCB function on flow through boiler,
because pressure expected at turbine by-pass operation condition, so the pressure set as inlet side
pressure of final super heater.

3.1.2.2.4 Setting of design Pressure.

(1) In the case of conventional plant.

Maximum working temperature are set as based on super heater outlet design temperature
(Ts) plus following  ~  addition. German Regulation ( TRD ) required that design
temperatue are set as boiler outlet working temperature plus 5oC.

 Margin 3oC for control error.

 Margin 5oC for unbalbance of right and left.
 Margin 0oC for submission data to authorities.
CUSTOMER’S GENERAL RULE DOMESTIC THERMAL PLANT
CLASSIFICATION EXCEPT TEC,CEC.
Applying class Max. working Calculated Max. working Calculated
press, temp, for pipe press, temp, for pipe
thick thick
Steam Temp Pipe.

Case of From Ts + 8oC Ts + 8oC Ts + 0oC Ts + 8oC

mean steam boiler
temp, control outlet to
end point
for 2 or more
of mixing
No of pipe (NOTE 3)
( NOTE 2) From end Ts + 3oC Ts + 3oC Ts + 0oC Ts + 3oC
point of
mixing to
Main Stop
Valve
(NOTE3)
Case of steam temp, control for Ts + 3oC Ts + 3oC Ts + 0oC Ts + 3oC
the pipe

( NOTE 1 ) Over temperature operation than maximum working temperature is no problem from the point
of stress.

( NOTE 2 ) Apply to conventional thermal power plant if required.

24
( NOTE 3 ) Mixing point are as follows:

SH/RH outlet header

End of mixing area

Main steam pipe

Hot Reheat Pipe
Mixing

Actually this is equal to max manufacturing pipe length.

(2) In the case of Combined Plant.

Maximum working temperature ( HP2SH outlet etc. ) are set as working temperature plus 3 oC ( NOTE 1 )
when the temperaturecontrolled at HRSG outlet pipe.

(ex )  Turbine inlet design temperature : 538oC

 HP2S outlet working temperature : 541oC (+3oC for consideration of thermal radiation)
 HP Main Steam Pipe Max, working
temperature: 544oC ( + 3oC for consideration of control error).

( NOTE 1 ) There are few thermal power plants exist that working temperature are set + 8 oC by customer’s
request.

3.1.2.2.5 Design temperature st Super Heater Outlet.

Design temperature st Super Heater Outlet are set by considering turbine inlet rated steam temperature and
following items :

 Temperature drop caused by pressure loss ( Equal enthalpy change ).

 Temperature drop caused by thermal radiation from the pipe.
Typical samples are shown as follows :

Main Steam Press/ Turbine inlet rated Temperature drop Temperature drop Super Heater outlet
MS Press Loss temperature caused by press caused by thermal design temperature
loss radiation (Ts)
246k/9k 538 oC 3.3 oC 0.1 oC 542 oC
169k/7k 538 oC 2.8 oC 0.1 oC 541 oC
169k/7k 566 oC 2.5 oC 0.1 oC 569 oC

3.1.2.2.6 Pressure Loss

1) Main piping system give large impact to thermal power plant performance, and its design required
suitable investigation of function and economical side.
2) Total plant construction and operation cost must be minimum.
3) Pressure loss calculateby using following equation learned by experience

 Main Steam Pipe : Darcy’s equation

25
 Hot Reheat Pipe/Cold Reheat Pipe : Darcy’s equation + (Fritzshe equation)/2
 Low presssue Steam Pipe : Fritzshe equation

Circumstances of applying above equat ions are follows and after actual measurement, check and
evaluation are necessary for cost down.

4) Pipe dia are selected by considering above total evaluation and apply lower value for main steam
pressure loss which shown in the following table.

Semi critical pressure plant Super critical pressure plant

Output Pressure loss Output Pressure loss
75 MW 3 kg/cm2 300 MW 9 kg/cm2
125 MW 4 kg/cm2 325 MW
156 MW 5 kg/cm2 375 MW
200 MW 6 kg/cm2 410 MW
220 MW 6 kg/cm2 450 MW
250 MW 7 kg/cm2 500 MW
300 MW 7 kg/cm2 600 MW
500 MW 7 kg/cm2 700 MW
900 MW
1000 MW 9 kg/cm2

3.1.3 Piping system planning procedure

3.1.3.1 Arrangement of equipment

Investigation shall be required to give shortest piping route between each equipment at planning step of
plant arrangement.

B B

T T

As shown above, generally to say shortest piping route are obtained by arranging on the same center line of
boiler and condensor which considering each thermal stresses of the boiler and turbine condensor.

3.1.3.2 Pipe Connection Point

Two style pipe connection point are shown as following figurefor Main Steam Pipe connection of
end pipe chest on boiler final super heater.

TEE STYLE END STYLE

(1) Tee style

26
 One or plural tee attached at center of pipe chest and drawing the steam attached angle of the tee are
45o ~ 90 o upside from center line. In the case of element hanging type, Main Steam Pipe through into
the housing , and require adjustment against hanging bar or connection pipe in the housing. For,
reducing the height of boiler structure, recently many cases recognized the Main Steam Pipe put
outside the housing. Suitable space for installation of safety valve shall be considered in the case of
pipe route designed in front of drum.

(2) End style

Main steam draw from the end of pipe chest. Main steam draw from the end of pipe chest, different
and reducer required for adjustment ( reducer on pipe chest is better judge from cost side ). In the case
of two lead type, piping route designed right and left side. Pressure investigation shall be done for
settling safety valve silencer numbers.

(3) Decide tee type or end type after consideration with the following as brings cost minimum.

 Cost of boiler side ( boiler side plant cost for down stream of 1st super heater ).
 Cost of Main Steam Pipe ( BQ check for different pipe route and figure ).
( Supplement )

Two tee style which have 1tee for 1 pipe chest gives cost minimum for 1000MW class thermal power plant
aas shown in the table. Cost of Main Steam Pipe for end style and 2 tee style are nearly equal. In the case of
under 600mm ( 700 MW class or smaller ) final SH outlet pipe chest dia recommend end style, for over
600mm ( 800 ~ 1000MW class or larger ) dia 2 teestyle is profitable.

Case Pipe arrangement style Cost boiler side Cost of side Total cost
1
1 End style 411 390 801
(100) (100) (100)
2

2 2 tee style 309 380 689

(75) (97) (86)
2 Cost minimum

3 4 tee style 282 449 731

(69) (115) (91)
3

 1: Cost of boiler side include both pipe chest on downstream side of 1 st super heater and connection pipe
cost.
 2 : Pipe chest size for end style are  2 times of two tee style.
 3 : Tee will be required on the Main Steam Pipe for 4 tee style, BQ and pipe size.

27
3.1.3.3 Piping Route

Pipe chest for final super heater outlet

Main steam pipe Boiler

Turbine room

UP/DOWN : fixed

3FL
To MSV

left/right : fixed

(1) The figure shows generally adopted design, Main Steam Pipe start at pipe chest for final super heater
outlet and go down in front of boiler then turn to MSV. ( this route gives minimum cost from a point of
thermal stress, installation, pressure loss and hanger cost ).
(2) In case of 2 lead type, equal pressure loss shall be designed for each other. Shortest cross-over pipe
shall be planned by consideration with thermal elongation of mother pipe.
(3) Decide the level of piping route by consideration with keeping spaces for head clearance and one point
hanger. Two point hanger brings high cost ( special attention shall be paid for turbine room because the
room has less spaces).
(4) In the case of large reaction force and moment obtained by thermal stress calculation, fix the pipe at
suitable points and reduce the reaction and moment for insure operation stability. Basic method of
reducing reaction force and moment are as follows: Fix on right angle direction of turbine shaft at
turbine center concentrate condensor and boiler center. Fix up and down side on same position of
turbine shaft center. ( refer to Fig 3.1.3.3 ). Investigate reducing of hanger cost ( application of
manufacturer’s special specification shall be avoided for both hanger travel and hanger load ).
(5) Following shall be considered at planning :
 Prevention of vibration.
 Through hole, rain seal.
 Cold sprig.
 Reaction force under blowing of safety valve.
 Thickness of insulation.

3.1.3.4 Installation position of safety valve

(1) In general, pipe chest of SH outlet has no space for safety valve because the pipe chest designed inside
of boiler casing, so the SH outlet safety valve are installed on Main Steam Pipe. Unsuitable
arrangement of safety valve brings vibration and unsuitable pressure on safety valve caused by sonic
vibration. At that time following counter plan required.

28
  Safety valve shall be installed at the point that keep 8di straight length on up stream side.
 There shall not provide boss, well, joint ( tee, reducer etc ) in the 8di range.
 In the case of 3 or more safety valve installation required at a point unequal spaces shall be kept
between each other.
 For prevention of resonance and sympathy, edge of hole which cut off on the mother pipe shall be
chamfered.

In the case, ASME application required by customer’s specification, refer to to ASME B31.1.
NONMANDATORY for keeping straight pipe down stream side (NOTE 1)
( NOTE 1 ) Following planning recommended in ASME B31.1- 1995 APPENDIX II 5.2

a. In the case, safety valve installed on the pipe which designed same plane, keep 8di straight length
on up stream side.
b. In the case, safety valve installed on the pipe which designed three-dimensionally, keep 8di
straight length on both up and down stream side.

Pipe chest of super heater

Pipe chest of super heater

Min. 8 di

No limitation Min .8 di

Min. 8 di

To Turbine

To turbine

a. Same plane piping b. Three-dimensional piping

There are no special regulations in German Rules (TRD 421 6.1 ) for arrangement of safety valve.

(2) Planning of safety valve arrangement shall include the following : Government witness for safety valve
shut off test ( for domestic thermal plant ). Floor plan for overhaul and adjusting works ( include
temporally parts store spaces ). Exhaust route of safety valve ( refer to section 5.14 ).

3.1.3.5 Slope of pipe.

(1) In general, horizontally arranged pipe shall have a slope to down stream direction. Slope angle shall be
set so avoid as reverse slope appear under operation condition. Set MSV inlet port at most lowest level
and attach drain pipe and blow time for warming.

29
(2) Attention shall be paid for customer’s specification of export plant which described pipe slope
requirements.

3.1.3.6 Other calculations

(1) Following calculations shall be carried.

 Thermal stress.
 Loading.
 Anti-seismic.
 Steam hammer.
 Wind load.
 Stress ( carried on detail design ).
(2) Above    calculation shall be carried without fail for domestic commercial plant.
(3) Above  ~  calculation will be omit for export plant when no regulation applied in the customer’s
specification.  shall be carefully checked for regulation in customer’s specification.

3.1.3.7 Pipe/joint parts

(1) According to design condition, high cost material 2 1/4Cr ~ 12 Cr are used for Main Steam Pipe and
especially joint parts ( elbow, tee etc ) are 4 ~ 6 times high cost than pipe. Avoid using finished elbow
and tee for cost saving, bending pipe and welded bosses are recommended. In the case of adopting
welded bosses, consider stress concentration function on thermal stress calculation.
(2) Following shall be previously confirmed for bending pipe . Bending pipe length ( including holding
space ) are kept within manufacture dimension. Finish radius.
(3) Inside machining and outside maching forged steel pipe are used. Out side maching pipe is cheaper
than inside maching pipe. Select cost minimum pipe after total evaluation including thermal stress,
transportation, installation, hanger cost etc. Recently, 400A and under size pipe can produce by hot
draw method which brings low cost than outside maching pipe.
(4) In the case of using forged joint parts for DSS plant, uniform thickness joint parts shall be adopted for
reducing thermal stress caused by temperature difference at the start and stop condition.

3.1.3.8 Attached points of instruments and bosses.

(1) Pressure gauge

 Install up stream side from thermal gauge.
 Boss for safety valve test pressure gauge installed as near as possible to the safety valve for easy
measurement.

(2) Thermal gauge.

Keep pull out space for thermal element, specially for 2 lead Main Steam Pipe design plant.

(3) Sampling.
Sampling points for Main Steam Pipe are select at 10Di ( Di : mother pipe dia ) down stream side
from bending point which produce turbulent flow. Detail are shown in item 8.3.3(3).

(4) Flow meter ( if required ).

 Straight length of pipe ( about 25 ~ 30Di ) shall be kept both up and downstream side of the flow
meter. Flow meter installed as flat position as possible.
 Drain port shall be given on both side of the flow meter for pressure test and stop condition.

(5) Button for detection of yearly deterioration.

30
 Button ( inconel ) installation procedure on main pipe outside for yearly deterioration checking of the
pipe after plant operation started. The button attached usually on Main Steam Pipe and High
Temperature Reheat Steam Pipe, confirm customer’s specification and regulation.
 Checking Time
1st : at plant construction. 2nd and future : periodically according to plan.
 Attached position
 Field weilding position.
 Comparatively high stress position on horizontal and vertical piping.
 Position that checking works can proceed easily.
 Fifure of attached position.

Field welding

C ( 8 Places ) B ( 4 Places ) A ( 4 Places )

Flow direction

1000 100

100

3.1.3.9 Support items

(1) Refer to item 3.1.3.3 fixing procedure for reducing of turbine reaction force and moments.
(2) Hanger setting level shall be selected as can reading easily from nearest passage.
(3) Access for hanger point at hydraulic pressure test are proceed by using temporally floor. Only beam
for handling shall be provided.
(4) 100% load on each hanger point shall be considered for 2 point rigid hanger at vertical piping because
load unbalance caused by thermal movement.

3.1.3.10 Valve installation position

(1) Main Stop Valve installed for the unit of conventional plant which has connection to another unit.
Usually the valves are installed on vertical pipe in front of the boiler and proceed planning for over—
haul floor and valve operation. Sometimes, manufacturer’s recommendation ( install on horizontal pipe
and draw valve spindle to up side ) shall be considered. Drain port on upstream side and air vent line
on down stream side shall be put for the Stop Valve.
(2) In the case of 2on 1 or 3 on 1 combined plant floor for valve operation and over-haul space shall be
designed for Stop Valve and Check Valve which installed on the upstream side confluence point of
each UNIT and near the turbine inlet. Drain port shall be provided both side of the valve. Same as to
Low Pressure Steam Pipe, High/Low Temperature Reheat Steam Pipeand HP/IP/LP Turbine By-Pass
Pipe for another line.

3.1.3.11 Free blow ( refer to item 5.18 )

Confirm, temporally piping space around MSV for exclusive MSV adaptor at free blow.

3.2 Low Temperatue Reheat Steam Pipe

31
3.2.1 Constitution of system

a. With check valve ( HP/LP by-pass system, refer to item 3.7.2.1 )

From main steam pipe

High pressure turbine

Superheat reducing TB valve

equipment
Boiler

NOTE 1

NOTE 2

Superheat reducing equipment

b. Without check valve (HP by-pass system, refer to item 3.7.2.2).

Boiler
Superheat reducing
equipment

NOTE 1

Take off short pipe under free blow condition

Superheat reducing equipment

( NOTE 1 ) Decide weilding line position on the plant side Turbine

pipe after confirmed longitudinal welding line on
the turbine side pipe. RT ( radiographic examination ) Longitudi
nal
32 welding
line
 required for the case that the dimension 5t and over
can not keep.
5t and over

( NOTE 2 ) Drain port installation shall be on both sides of the all LTR Plant pipe
check valves for the case that application of ASME TDP-1
required. Select the drain port position near to the High
Pressure Turbine and on lowest level pipe.

3.2.2 Purpose of system installation.

High pressure turbine exhaust steam feed to re-heater by this system.

3.2.2.1 Number of lead

1 lead standardized for mother pipe.

3.2.2.2 System and valve operation

3.2.2.2.1 Installation of High Pressure Turbine outlet check valve

(1) Install constraint check valve ( NOTE 1 ) for HP/LP by-pass balance system. This system prevent
reverse flow of the steam from Low Temperature Reheat Steam Pipe to High Pressure Turbine during
by-pass operation.
( NOTE 1 ) Constraint stop function are not required for LTR check valve from the point of water
injection and over speed for combined plant. On the combined plant, High Pressure Turbine by-pass
system connect to LTR, and brings 100% turbine by-pass operation for single operation. For
prevention, reverse flow of turbine by-pass to the turbine, following items are account for decision of
constant function.
 2 on 1 or 3 on 1 case
Constraint function are not required for check valve because motor valve provided between
confluence point of High Pressure Turbine by-pass and the turbine for intend to separate each other.
 1 on 1 case
Constraint function are required for check valve because there is no motor valve provided and
expect more reliability for shut off facility.

(2) No check valve installed for HP by-pass system

( Supplement ) Usually, the check valve installed at High Pressure Turbine outlet for prevention over speed
on the turbine which has HP-IP combined casing manufactured at our works.

3.2.2.2.2 Design Pressure

Design pressure are calculated by using the following equations.

 ( Po – 1.03 ) X 1.10 ( NOTE 1 )

 ( Po – 1.03 ) + 75 psi ( 5.27kg/cm2 ) whichever gives higher pressure

Po : High pressure Turbine outlet pressure (ata)

( NOTE ) 1.10 was 1.15

3.2.2.2.3 Maximum working temperature

33
 Total investigation proceed and decide with consideration of maximum steam flow,  maximum
temperature for specified portion  and expansion temperature under maximum design pressure. Note that
in German Regulation (TRD) no SH safety valve installed. Full volume through the TB valve spray water
zero at plant black ( full failure ) condition. Design temperature becomes as boiler outlet maximum
operation temperature at 5oC.

 Maximum steam flow

High Pressure Turbine exhaust temperature that obtained by flowing steam to the turbine.
 B-MCR : Maximum steam volume of continuous boiler generation.
 Capa : Maximum steam flow under operation condition.
 V.W.O : Maximum swallow volume of the turbine.

 Maximum temperature for specified portion ( example )

In the case of adopted HP/LP by-pass system few volume steam which flow to High Pressure
Turbine are closed because down stream of High Pressure Turbine becomes high back pressure ( 9 ~ 10
ata ) when by-pass operation in HP/LP by-pass system. ( for prevention of this high back pressure, install
ventilation valve).
Maximum working temperature between High Pressure Turbine outlet and confluence point of high
pressure turbine by-pass are set higher because exhaust temperature of High Pressure Turbine comes up by
rotor running loss. ( NOTE 1).
No consideration will be required for effect of High Pressure Turbine exhaust temperature high under
turbine by-pass operation which installed ventilation valve ( NOTE 2 ).

( NOTE 1) Rotor running loss means that brings by friction temperature rise of rotor rotation in closed
condition.

( NOTE 2 ) Ventillation valve

600MW and over output turbine ( super critical ) which manufactured in our works has ventilation valve for
both case with or without high pressure turbine outlet check valve.
a. Without check valve
Pressure turbine over heat by rotor running loss at load rejection condition. In that case,
turbine inside pressure kept by reverse steam flow from re-heater.
b. Common for with/without check valve.
Prevent high pressure exhaust temperature over heat under turbine by-pass operation
condition. ( plant only, operation etc.)
For 600MW and less output plant the valve are not always installed.

High pressure turbine

Low temperature
reheat steam pipe Condenser
Ventilation valve

Actuator space shall be considered bacause the valve

required at high speed operation.

3.2.2.2.4 Pressure loss

34
(1) Total loss of re-heater and re-heater steam pipe are 6 ~ 10% of High Pressure turbine outlet pressure
( at MCR condition ). Attention shall be paid for coal fired thermal plant which required large reheat
surface and basically select minimum cost of construction and operation. Check valve resistance
coefficient shall be fully investigated for loss calculations bacause the check valve installed at High
Pressure Turbine outlet. For KEC GOBO plant, resistance coefficient is 2.5 by actual measurement.
Usually the check valve scope belongs to turbine manufacturer and gurantee of pressure loss which
include the valve are impossible by boiler side. Terminal point between boiler and turbine shall be set
at the check valve outlet and control pressure loss by each other. When only the check valve included
in the scope of turbine manufacture, check valve resistance coefficient shall be received for total
pressure loss calculation between High Pressure Turbine outlet and re-heater.
(2) Distribution of pressure loss.
a. Total pressure loss of reheat steam system Po X 0.08 ---------- 
b. Pressure loss of re-heater  X 0.5
c. Pressure loss of Low Temperature Reheat Steam Pipe ( X 0.5)X 0.4
( include : check valve pressure loss)
d. Pressure loss of High Temperature Reheat Steam Pipe ( X 0.5)X 0.6

Basically loss distribution are shown above and adjustment are put on re-heater and re-heater steam pipe
design. Co-operation works shall be required for total cost evaluation. Regarding to pressure loss of RH
system piping, low pressure loss design for low temperature side brings small size High Temperature
Reheat Steam Pipe and also low cost.

3.2.3 Piping Planning Procedure.

Basically, same as Main Steam Pipe except noted.

3.2.3.1 Arrangement of equipment’s.

3.2.3.2 Connection point of pipe.

Connection point of pipe are put on the turbine and at the re-heater inlet pipe chest end, usually.

3.2.3.3 Route of Piping

(1) Branch the pipe at the front center of the boiler drum for uniform pressure loss obtained on
down stream side of the branch.
(2) Usually, on floor arrangement are given for the pipe which installed between turbine outlet
and near the check valve ( or short pipe with flange ). Suitable space shall be kept between
floor and pipe with considered drain port of the mother pipe and drain valve installation.

3.2.3.4 Install position of safety valve

3.2.3.5 Slope of pipe.

3.2.3.6 Calculations.

3.2.2.7 Pipe/joint items.

Refer to the item for High Temperature Reheat Steam Pipe.

3.2.2.8 Install position of boss for instruments.

3.2.3.9 Support.

3.2.3.10 Install position of valve.

In principle, the check valve arranged as near as possible to the turbine for prevention of turbine
over speed by reverse flow which hold between turbine and the check valve. Temporary piping route shall
be considered for free blow.
3.2.3.11 Free blow ( refer to item 5.18 )
(1) With check valve

35
 Temporary piping ( 400 ~ 500A ) space shall be considered for installation od adaptor after
take off the bonnet of the check valve. Provide lifting up piece for check valve bonnet, and
openings for temporary piping on buliding structure.

(2) Without check valve

Attention shall be paid for arrangement of short flanged pipe ( NOTE 1 ) on Low Temperature
Reheat Steam Pipe to lead temporary pipe at free blow. Flange rating shall be decided
considering both inner pressure and bolt selting force at construction.
 Dimensions between face to face shall be kept for temporary piping connection.
 For easy installation and take off, horizontal and straight portion shall be selected.
( vertical pipe are not recommended ). Upside floor of the short pipe shall be removable
(and/or opening ) for short pipe handling or lifting.
 Avoid the short pipe installation at thermal stress concentration position. ( ex bend part
etc ).

Cause of leakage

~
Bad sample Better sample

( NOTE 1 ) In the case of flange loss short pipe, weld part shall be checked by non-destructive
examination. Avoid blind plate application between the flange for leakage. Attention shall be drawn to
above  ~ .

3.2.3.12 Super heat reducing equipment

(1) Super heat reducing equipment are installed on reheat steam system. This equipment keeps re-heater
outlet steam temperature as regulated level at over regulation temperature appeared.

(2) Installation position are on Low Temperature Reheat Steam Pipe and/or on connection pipe for boiler
re-heater.

(3) Tee style arrangement are recommended for spray nozzle, ( refer to UBSP 3.5.5-03 Rev 1 [ Nozzle
design standard for super heat reducing equipment]).

(4) Following investigation shall be carried for prevention of thermal stress crack on spray pipe, brake out
by vibration, thermal stress crack on down stream side pipe, leakage and so on.
 Structure and arrangement as match to operation condition. ( check spray pipe structure, keep down
stream side straight pipe, provide enough strength for thermal stress on down stream side side pipe and
vibration.
 Resonance calculation at spray nozzle installation part.
 Attach thermometer after one bend of super heater reducing equipment.

(5) Other details are refer to applied regulations ASME TDP-1 etc.

36
3.3 High Temperature Reheat Steam Pipe

3.3.1 Arrangement of system

a. 156 MW ~ 400 MW class ( NOTE 1 )

Head

RSV/GV
Re-heater outlet pipe chest
Intermediate press turbine

b. 450 MW ( NOTE 1 ) ~ 1000 MW class.

2 lead Cross-over pipe

RSV/GV
Re-heater outlet pipe chest
Intermediate press turbine

( NOTE 1 ) Above output class shows our actual experience. Final decision are put after cost check of pipe
chest and connecting pipe ( reducer, elbow ).

3.3.2 Purpose of system installation

Lead reheat steam to Intermittent Pressure Turbine.

3.3.2.1 Number of lead

Lead number selected as follows :
a. 400MW and less 1 lead
b. 450MW and over 2 lead
Final decision are put after examination of plant cost ( material cost, manufacturing cost,
installation cost, insulation cost, transportation cost and hanger cost etc ), thermal stress and manufacturing
limit. For latest large capacity single furnace boiler provide 1 lead for reduce thermal effect to the turbine
caused by temperature unbalance. Instead of ball joint, lateral type shall be applied except for DSS thermal
plant ( NOTE 1 ).

( NOTE 1) Ball joint are applied for DSS thermal plant after evaluation for stress and fatigue. ( refer to
following figure ).

Ball joint

Pipe chest of re-heater

37
 RSV/GV
Intermediate press turbine.

3.3.2.2 System and valve operation.

3.3.2.2.1Cross-over pipe
(1) Pipe size ( required 60% and over cross sectional area of main pipe ) shall be selected as reducing
unbalance flow which brings RSV, ICV test operation for 2 lead cross-over pipe.
(2) Refer to item 3.1.2.2.1 for others. At that time, MSV read as RSV ( reheat stop valve ) and SH as RH
(re-heater).

3.3.2.2.2Design pressure.
Design pressure are calculated by referring domestic government regulations. There are two ways that first
follow to customer’s requirement, 2nd offer deviations.
 Adopt minimum blow off pressure of re-heater outlet safety valve.
 Minimum blow off pressure of re-heater outlet safety valve are settled as a pressure that minus re-heater
pressure loss at boiler MCR fro re-heater max. working pressure.
Attention shall be paid for German Regulation (TRD) which brings higher working pressure than domestic
rule.

3.3.2.2.3Maximum working temperature

Maximum working temperature are defined as plus margin as main steam pipe on re-heater outlet
operation temperature. There are two ways that first follow to customer’s requirement, 2 nd offer deviations.
Attention shall be drawn to the plant which regulated by German Rules (TRD) that gives design
temperature become boiler outlet maximum operation temperature plus 5oC.
(1) Re-heater outlet operation temperature
Re-heater outlet operation temperature defined by considering the turbine inlet rated temperature as
follows:
 Temperature down by pressure loss ( equal enthalpy change ).
 Temperature down by radiation from pipe.
(NOTE) 1oC temperature margin of total  +  are enough for turbine inlet steam condition 30 ~ 50 atg,
538 ~ 566oC unit. Actually 2 ~ 5oC applied.

3.3.2.2.4Pressure loss
(1) Refer to item 3.2.2.2.4 for pressure loss of Low Temperature Reheat Steam Pipe.
(2) No unbalance flow between LTR ~ Re-heater ~ HTR are allowed for 2 lead plant and arrange pipe
suitably. Temperature unbalance of reheat steam require temperature control of RH by spray water
injection and brings boiler efficiency down. BQ reducing of reheat steam pipe brings economical pipe
planning. Most suitable distribution of total pressure loss that allowed in re-heater system give cost
minimum in plant.

3.3.3 Piping planning procedure

Basically same as main pipe except noted.

3.3.3.1 Arrangement of equipment.

3.3.3.2 Connection point of pipe.

End style is better for High Temperature Steam Pipe after evaluated from cost side.

3.3.3.3 Piping route

Within +- 3oC temperature unbalane required for reheat steam pipe route on 2 lead plant.

3.3.3.4 Install position of safety valve

3.3.3.5 Slope of pipe.

3.3.3.6 Calculations.

38
3.3.3.7 Pipe/joint items.
(1) Basically same as Main Steam Pipe.
(2) Two kind of steel pipe are used, such as seamless pipe and welding pipe. Welding pipe is cheaper in
domestic but must check in overseas.
(3) Selection standard for seamless pipe or welding pipe.
Usually welding pipe are used for domestic thermal power plant. In the case of export plant, basically
follow to the customer’s specification ( almost customer require seamless pipe ). Welding pipe and
seamless pipe shall be compared on commercial point of manufacturing and transportation for plant which
has no requirement in the customer’s specification (at the contract).

(4) Drain pot shall be attached at lowest position of High Temperature Reheat Steam Pipe for requirement
of ASME TDP-1 which prevent water injection.

(5) Pipe slope shall be kept as ordinary when both pipe hot and cold condition. In the case of no cold
spring gives to Reheat Steam Pipe (LTR,HTR), investigate pipe slope by referring thermal calculation
results.

(6) When pipe installed on elevator support structure, attention shall be paid for pipe vibration effect on
elevator.

(7) Valve shall be arranged within 10D (D: branch pipe inside diameter) as following figure for branch
pipe which operate as “normally close” (like as air vent pipe to atmosphere).(unsuitable long distance
from the mother pipe,same drain generate by thermal radiation in the branch pipe and give leakage
caused by thermal shock). In the case that there are no 10D distance for the valve, warming line shall
be provided.
Reference data MM01-2502
Trouble sample for piping design (for thermal power plant).

10D within

Air vent pipe to atmosphere

High temperature reheat steam pipe

3.3.3.8 Boss and instruments position.

3.3.3.9 Support items.

3.3.3.10 Valve install position.

39
40
41
42
43
44
45
46
47
48
3.7 High Pressure Turbine By-Pass Pipe

3.7.1 Arrangement of system

a. Introduce to condensor (HP by-pass system)

TB valve (NOTE1)

(NOTE2)

Cross-over pipe

Temperature
Condensor
Main steam pipe reducing equp.

EC valve
M
Boiler

Extraction pipe for boiler starting ( refer to item 3.10)

( This system bilated by rationalization )

b. Introduce to Low Temperature Rehaet Steam Pipe (HP/LP by-pass system).

HP TP
TB valve (NOTE1)

Cross-over pipe

Temperature
reducing equp.
Main Steam Pipe

To Reheater

Low temperature reheater steam pipe.

(NOTE1) TB valve style and direction of flow are different by

manufacturer and design condition (refer to item 3.7.3.12)

3.7.2 Purpose of System installation

3.7.2.1 HP by-pass system (Introduce style to the condenser)

This system called HP by-pass system and applied for starting by-pass system of super critical and variable
pressure through flow boiler. Combined with extraction valve for boiler starting and keep required main
steam temperature at starting process also blow off main steam system pressure for FCB operation.
Capacity of turbine by-pass valve and extraction valve for boiler starting are usually selected as 25 ~ 30%
MCR capacity at rated pressure. This capacity defined by following function under condition of no LP by-
pass installed. Furnace outlet gas temperature is under allowable temperature of reheater tube.

49
Corresponding steam volume to injectable fuel flow (about 12%). Ejectable capacity by TB valve + Main
Stream Drain Valve and/or Starting Extraction Valve + Super Heater Drain Valve.

3.7.2.2 Introduce style to the Low Temperature Rehaet Steam Pipe.

This system called HP/LP by-pass system and applied for Main Steam Pipe warming and blow off of main
steam steam line pressure as the same of condenser. This system applied for the following cases.
a. Rapid starting required, LP by-pass required for protection of reheater under much fuel firing
condition.
b. Coal firing and FCB operation (plant only operation) or normal stop operation required at system
failure.
c. Boiler single operation required.

[FCB operation]

In the of that the thermal unit separate from system by accident, generator covers only plant demand
and boiler firing are continued. After recovering the system, generator feed stabilized rated power.
This operation function called as FCB (Fast Cut Back and/or Fuel Cut Back).

3.7.3 Piping planning procedure

3.7.3.1 Arrangement of temperature reducing equipment.

Short
Flange for nozzle
overhaul. TC

TB valve

Temperature
reducing equp. Condenser

Spray water
Main steam pipe

Confirm the dimension which required by manufacture of temp

reducing equipment.

Required straight pipe length shall be kept at down stream side of temperature reducing equipment for
suitable mixing spray water and steam. (refer to item 3.7.3.1)
Piping shall have down slope to the condenser and planned as no spray water drain remained in the pipe.
(prevention of steam hammer).In the case that reducer installed at temperature reducing equipment outlet,
drain port shall be designed at upstream side of reducer.

3.7.3.2 Prevention of erosion

Suitable straight length pipe shall be provided at down stream side of TB valve for prevention of erosion by
fluid. Bending portion shall be applied bending pipe. (refer to item 3.7.3.11).

50
 <Better sample> <Bad sample>
Not enough
TB valve TB valve straight pipe
Keep suitable length length
Erosion

Temperature
reducing equp. Temperature
reducing equp.
Bending pipe
Elbow

3.7.3.3 Main Steam Pipe warming function

This line provided for main steam pipe warming at starting operation. Branch point for the main pipe shall
be defined as nearest to the turbine.

Branch at nearest point to the turbine

MSV

HP IP
Boiler

TB valve Temperature
reducing equp.

Condenser

(Reference) In the case of following figure, High pressure turbine by-pass placed on HRSG side. In this
Raytheon plan, main stream pipe warming can able by drain valve (about 40A) which installed in front of
MSV. In this case high pressure turbine by-pass are not count for warming.

MHI Raytheon

High pressure steam pipe Raytheon

HRSG
HP turbine MSV
by-pass pipe. Drain HP MHI

Low temperature
reheat steam pipe Raytheon

51
3.7.3.4 Countermeasure for TB valve drain attack.

TB valve shall be arranged at highest point of the system and piping planned as no drain holed at both up
and downstream side of the valve.

TB valve
Slope Slope

Main steam pipe

Condenser
( Low temperature reheat steam pipe ).

TB valve

Slope

Main steam pipe Slope

Condenser
(Low temperature reheat steam pipe)

Same existing plant has different arrangement by considering TB valve noise, easy operation and
maintainability. But, above arrangement shall be adopted as first priority.

3.7.3.5 TB valve and countermeasure for warming.

As short as possible (within 7d)

TB valve
(NOTE) Sometiomes warming stop
valve are not provided.

(NOTE)

Warming lineCondenser
(Low temperature reheat steam pipe)
Main steam pipe
(In case of 2 lead)

52
In the above figures TB valve is fully closed under normal operation condition. Unsuitable long dimension
between main steam pipe and TB valve brings TB valve inlet temperature go down to saturated temperature
of main steam pipe. Opening TB valve under this condition gives abruptly temperature rise to the valve and
finally check valve function by strain. Crack appeared at pipe inside by repeated thermal stress cause
reverse drain flow which produced by thermal radiation of TB valve and connection pipe. TB valve shall be
arranged at near to the main steam pipe. In the case that some distance exist, warming line shall be installed
from main steam pipe to near the TB valve inlet. (CCI recommended, hold TB valve temperature as main
steam temperature minus 100 ~ 150oC). Warming line shall be installed that the distance between main
steam pipe and TB valve are over 10d. (d : pipe inside diameter ). Refer to item 3.7.3.6.1 for turbine by-
pass valve warming procedure.

3.7.3.5.1 Turbine by-pass valve warming procedure.

Turbine by-pass valve warming procedure are shown as  ~  case from our experience. Most
economical and effective case shall be adopted after adjustment with plant side. Case  is mostly not
applied for described reasons.

HTR

MS

   
RH SH

 
HP-TB LP-TB Turbine
valve valve
LTR

To Condenser

Case Warming Procedure Advantages Problems

 Take out warming steam from Under any load condition (1) Large thermal caused by
just up stream side of TB enough differential pressure for low pressure ( and/or
valve inlet and throw in down orifice can keep including intermediate pressure)
stream line of TB valve. starting and stopping condition. TB valve warming
Usually required warming flow steam lead to condenser.
can keep High reliability. (2) At the time when Low
pressure ( and/or
intermediate pressure)
TB valve full opening,
warming steam throw in
down stream side of the
valve as high
temperature condition.
Usually dispatch alarm
at downstream side of
the valve.
(3) Countermeasure for
above (2) are required
by customer and is
risky.
 Take out warming steam from (1) No thermal loss. (1) Keeping of required
just upstream side of TB (2) Cost saving type because warming volume are

53
 valve, and throw in no orifice installation. hardly enough because
downstream line of main (3) Cost saving type because only few differential
pipe. up and downside guard pressure exist between
valve for the orifice are not main pipe pressure loss and
required. (only shut off warming pipe pressure
valve required for TB loss.
valve maintenance). (2) In the case of long
warming pipe arrangement,
warming pipe size comes
large and complexity
arrangement.
 Take out warming steam from (1) No thermal loss. This system applied to the case
upstream main pipe of by- (2) Orifice installation are not that only few differential press
pass steam branch point, and required. cal be available.
throw in by-pass steam pipe (3) Cost saving type because
just before the TB valve inlet. up and downside guard
valve for the orifice are not
required. (only shut off
valve required for TB
valve maintenance).

 Take out warming steam from (1) Taking the volume of A little low temperature
by-pass steam pipe just required warming steam appeared for high pressure
before the high pressure TB are easy because enough warming steam by pressure
valve inlet, and throw in by- differential pressure exist reducing on orifice. Warming
pass steam pipe just before under all loading steam volume are slightly
low pressure (and/or condition which include increased than case ,.
intermediate pressure) TB start and stop operation.
valve inlet. High reliability.
(2) Cost saving type because
warming pipe total length
are shorter than case
,.
(3) Orifice for low pressure,
(and/or intermediate
pressure) TB valve are not
required.

3.7.3.6 TB valve overhaul

Lifting piece

Draw out space for valve

3FL

54
Main steam pipe Low temperature reheat
Operation and maintenance floor steam pipe.

Usually the valve installed on the turbine 2FL for prevention of noise. For the case of overhaul, it required
both operation and maintenance floor, common hutch on the 3FL for the valve overhaul. Also lifting piece
are provided.

3.7.3.7 Piping arrangement

This pipe material is same to the main steam pipe and high cost. Pipe route shall be designed as short as
possible and bending pipe shall be adopted at point. Pipe route shall be arranged as no drain holed in the
pipe, upstream side of the TB valve designed up slope and downstream are down slope. No reverse slope
by thermal elongation are allowed.

3.7.3.8 Thermal stress of pipe

This pipe branched from mainsteam pipe and connect to Low temperature Reheat steam Pipe. Thermal
stress calculation shall be proceed under connected condition by consideration with operation pattern.

3.7.3.9 Countermeasure of TB valve noise

Excessive noise appeared under the valve operation condition at down stream pipe and the valve body,
prevent pass through noise from pipe by using thick pipe and straight pipe as shown. Some manufacturer
request that anti-noise hood on the valve and noise saving plate (lead plate) on the pipe.

TB valve

Temp. reducing equp.

Main steam Valve confirm : manufactures recommendation Condenser

Pipe (refer to item 3.7.3.12)

2FL (under 3FL) arrangement are recommended for prevention of noise at turbine operation floor 3FL.

3.7.3.10 Countermeasure of temperature reduction

This line used for both pressure and temperature reduction with considered downstream side requirements.
Spray water injection required for temperature reducer (both separate type and exchange type). Straight
pipe arrangement shall be required at up and downstream side of temperature reducer and the valve to
promote mixing spray water and steam. Confirm, straight pipe dimension to the valve manufacturer
standard at piping system planning. (refer to item 3.3.3.12).Pipe material at downstream side shall be
selected considering equal enthalpy change (after pressure reducing) temperature.

3.7.3.11xxxx

xxxx

xxxx

xxxxx

55
xxxxx
xxx

xxxx

xxxx

xxxx

TABLE 1 Required straight pipe length for up and down stream of the TB valve ( )

xxx Straight pipe Straight pipe length on valve Straight pipe YES or NO for
length on valve outlet length for valve outlet
inlet (L1) Temperature Exchange type separate type diffuser
reducer (L2) temperature
separate reducer
type(L2) outlet(L3)
CCI 5 – D1 D1: 5 – D2 Min 2m xxx xxx YES
valve inlet dia D2 valve outlet
dia
A 6 ~ 7 D1 D1: 4 ~ 6 D4 D4 : Set as required Set as required YES
valve inlet dia diffuser outer
dia
B 2 – D1 D1: 6 - D2 D2: 5 ~ 8 – D2 D2: Set as required YES
valve inlet dia valve outlet dia valve outlet dia ( Min. 5m )
C 5 – D1 D1: 5 ~ 7 – D2 D2: --- Whichever NO
valve inlet di valve outlet dia short 3m or
7D3

[ Outline ]

Temperatrure reducer separate type ( Pressure reducing valve + Temperatrure reducer)

Pressure reducing valve

L1 L2 Temperature L3
reducing equp.

Steam
Diffuser
Spray water

56
Exchange type ( Pressure reducing + Temperatrure reducing)

Exchange valve
L1

(NOTE) Relation between the TB valve type

and flow direction are different for
each valve manufacture and plan
condition

Steam Diffuser

L2
Spray water

Xxxxx – 2 CCI xxxxxx xxxx xxx xxx xxxx

Xxxx “Desuper Heating length” xxxx xxx xxx xxx

Xxx xxx Xxx xxx 15oC xxxx xxxx 80oC xxx xxxx
Xxxx Xxx Xxxxx Xxxx Xxx Xxx
(m) (m) (m) (m) (m) (m)
In Body < 450 mm N/A N/A N/A 0.5 0.5 3.6
> 900 mm N/A N/A N/A 1.2 1.2 7.5
Steam Jet < 450 mm 1.0 1.6 4.1 1.0 1.0 3.5
> 900 mm 2.0 2.6 7.6 2.0 2.0 7.0
Spring < 450 mm 1.1 2.3 5.4 1.1 1.7 4.8
nozzle > 900 mm 2.4 3.6 10.0 2.4 3.0 9.3
Spray < 450 mm 1.5 4.0 7.2 1.5 3.5 6.6
Probe > 900 mm 3.0 5.5 12.0 3.0 5.0 11.3
Fixed area < 450 mm 1.8 5.3 8.4 1.8 4.8 8.0
nozzles > 900 mm 3.6 7.1 13.5 3.6 6.6 13.0
Spray < 450 mm 2.2 6.2 9.3 2.2 5.2 8.4
Ring > 900 mm 4.5 8.5 14.8 4.5 7.5 13.8

xxx

xxx

xxxx

57
xxx
xxx – 3 CCI xxx xxxx xxx xxxx

Xxx xxx xxx Xxx xxx xxx xxxx

xxx Xxx xxx In Body Multi- Spring Venturi Probe
TB nozzle Loaded Steam Style
Ring Nozzles Atomisation ( Spray
( Fixed ( Spring ( Steam Probe)
area Nozzles ) Jet)
nozzles)
Xxx xxx HP < 100dBA xxx xxx
< 90dBA xxx xxx
< 85dBA
LP < 100dBA ( High
capacity )
< 90dBA
< 85dBA
Xxx xxx HP < 100dBA xxx xxx
< 90dBA xxx xxx
< 85dBA
LP < 100dBA
< 90dBA
< 85dBA
Xxx xxx HP < 100dBA
< 90dBA
< 85dBA ( Under ( Over
the plug the plug
flow ) flow )
IP < 100dBA
< 90dBA
< 85dBA
LP < 100dBA
< 90dBA
< 85dBA

xxxx

xxxx

xxxx

xxxx

xxx

xxxx

58
xxx

xxx

xxxx

x
xx

xxxxxx

xxxx

xxx
xxxx

xxxx

xx
x
x

x
x
x
x
x

59
- 5CCIxxxx xxx xxxxx

Xxx xxxx Xxx xxxx Xxx xxx

xxx Xx TB xxxx xxx xxx
Xxx xxx xxx HP < 100dBA A A DRAG
(xxx)/DRE
(xxx)
< 90dBA A A DRAG
(xxx)/DRE
(xxx)
< 85dBA A A DRAG
LP < 100dBA A/B (High A/B (High NBSE/NBE
capccity) capccity) Cage : High
Capacity
< 90dBA A A DHC
< 85dBA A A DHC LOW
NOISE
Xxx xxx HP < 100dBA A A DRAG
(xxx)/DRE
(xxx)
< 90dBA A A DRAG
(xxx)/DRE
(xxx)
< 85dBA A A DRAG
LP < 100dBA B B NBSE(xxx)
NBE (xxx)
< 90dBA A B DHC
(xxx)/NBSE(xx
x)
< 85dBA A B DHC LOW
NOISE(xxx)
NBSE (xxx)
C/C xxx xxx HP < 100dBA B B HBSE
< 90dBA A/B (xxx3) A/B (xxx3) DRAG/HBSE
< 85dBA A/B (xxx3) A/B (xxx3) DRAG/STEAM
JET
IP < 100dBA B B DHC
< 90dBA A A DHC
< 85dBA A A DHC LOW
NOISE
LP < 100dBA C C 840 G
< 90dBA B B 840 TBS
< 85dBA B B 840 TBS

xxx

xxx
xxx

60
xxxx

xxxxx

xxxxxxxxxx

xxxx

x
x
x

x
xx

61
3.8 LP turbine by-pass pipe

( NOTE1)

TB valve (NOTE2)
Temp reducing equp.

M
(NOTE1)
TB valve

Condenser
Install if required (generally no
installation)
High temp
reheat steam pipe To intermittent pressure turbine

Cross-over pipe (NOTE1) xxxxxx xxxx

Xxxxxxxxx

3.8.2 Purpose of system installation

(1) This system installed with High Pressure turbine by-pass foe HP/LP by-pass system. Starting time
reduced by using over heating prevention function of the Reheater. Abrupt operation condition change
avoided by using this system which exchange from coal firing FCB operation to the plant installed
operation. FCB operation technique has been established for oil/gas firing boiler unit under no LP by-
pass operation. Therfore no LP by-pass system required usually, but for FCB operation coal firing unit
LP by-pass required because rapid fuel squeeze are difficult owing to mill characteristics and can not
reduce minimum load to plant only demand.
(2) HP/LP by-pass system capacity are decided by considering the following :

 Achivement of required starting time

Capacity check by starting simulation.
 Prevention of over pressure rise at FCB operation
Keep under MFT (Master fuel Trip, Main Fuel Trip) or safety valve blow off.
 Plant island operation
Dispose of unbalance between boiler minimum load and plant demand for coal fired unit.
 Partial load shut off by system requirement
(Complement 1) Domestic experience
Several domestic commercial thermal power plants has HP/LP by-pass system after adopted Super
Variable Pressure through floe boiler mainly. It brings short starting time and reduction of life consumption
(Countermeasure for DSS).

(Complement 2) Export experience

There are many different capacity such as 30 ~ 100% for above  ~ . In the case of oil/gas firing 30 ~
70%, coal firing 100 ~ 120%. Capacity means the ratio under rated pressure for main steam flow.

3.8.3 Piping planning procedure

Same as HP turbine by-pass pipe.

62
3.9 Turbine by-pass temperature reducer spray water pipe.

3.9.1 Arrangement of system

3.9.1.1 HP turbine by-pass

a. Temperature reducer combined type.

Main Steam Pipe

TB valve ( temperature reducer combined type)

Condenser

High Pressure
Feed Water
pipe
b. Temperature reducer separate type

Main Steam Pipe

TB valve ( temperature reducer seperate type)

Temperature reducer

Condenser

Condensate water pump

discharge pipe.

63
3.9.1.2. LP turbine by-pass

a. Temperature reducer combined type

b.
High Temperature Reheat Steam Pipe

Condenser

Condensate water pump discharge

pipe.

b.Temperature reducer separate type

High temperature reheat steam pipe

TB valve ( temperature reducer separate type)

Condenser

Condensate water pump discharge pipe

64
3.9.2 Purpose of system installation

Super Heater by-pass, HP turbine by-pass and LP turbine by-pass etc are installed for PCB operation at
boiler starting. Temperature reducer and spray water pipe are provided for temperature reducing till
allowable enthalpy by condenser.

3.9.2.1 System and valve operation

In the case of steam exchange system include common valve body and temperature reducer at the Turbine
by-pass, usually temperature reducing water feed from high pressure feed water line because condensate
water pump discharge pressure are not enough.

3.9.3 Piping planning procedure.

Minimum

Shut off valve

Control valve

Temperature
reducer

Minimum

Xxx xxx (cc 1m)

(1) Piping shall have up slide slope, are not allowed on piping.
(2) Control valve and Shut off valve shall be arranged as near as possible for prevention of water hammer.
(3) Control valve and Shut off valve shall be installed under than temperature reducer.
(4) Temperature reducer inlet valve shall be designed as short as possible.
Xxx xxxx xxxx
Xxxx xxxx
(5) xxxxx xxxxxxxxxxxx
[ Recommendations for the installation of an HP-by pass to Cold reheater ]
(6) In the case of the reduced connection part exist at temperature reducer and spray water pipe joint, the
joint shall be designed as same as sectional area by reinforcement or stress concentration.
(7) Vibration countermeasure shall be applied for flow direction at Control Valve down stream side.
(8) Xxxxxxxx

65
3.10 Extraction pipe for boiler starting

3.10.1 Arrangement of system

Inlet port pipe chest Outlet port pipe chest

Final Super Heater

Main Steam Pipe

To
Heater

Warming pipe Turbine by-pass pipe

M TB valve

Temperature reducer

EC valve Extraction pipe for boiler starting Condenser

(*1) Min 2m

(*1) EC valve : Extraction Steam Control valve (xxx xxxx)

3.10.2 Purpose of steam installation

At the beginning of very hot/hot starting time: Boiler is colder than Main Steam Pipe. In the case of that no
EC system provided, Main Steam Pipe cooled by cold boiler steam. Then starting time turn no longer. For
preventing above trouble, Final SH and Main Steam Pipe are by-passed by EC system. Steam shall be
introduced to the Main Steam Pipe after warming the boiler to steam shall be introduced to the Main Steam
Pipe after warming the boiler to starting time turn to shorter. Main steam pressure control are processed by
using EC valve when the boiler starting extraction system used. The system will be omitted for less
economical merit of short time starting which used for few number of very hot/hot start base load unit.

3.10.2.1 System and valve operation

(1) EC valve is used for pressure control at boiler starting, and forcibly closed at normal operation.
(2) EC valve capacity decided by considering with starting time, and set min 8% MCR after referring
simulation result and actual result of existing plants. Valve capacity selection point are decided by
considering with guranteed starting time at very hot/hot starting mode.
(3) Usually steam exchange type are not used for EC valve because high capacity and low reliability.
(4) There are two cases as follows for front valve of the EC valve. MHI standard is .
 Front valve of the EC valve is motor operated and normally closed for prevention burnout of final
Super Heater at EC valve mis-operation.
  Front valve of the EC valve is not provided because its used for pressure reducer at MFT
operation.
(5) Common temperature reducer capacity for EC/TB line is decided as same to the capacity at TB
pressure released condition, because the line are not used in a same time under normal operation.

66
3.10.3 Piping planning procedure
(1) Thermal stress calculation shall be carried for high temperature/pressure line.
(2) Following shall be considered for EC valve inlet piping.
 Up slope design shall be adopted between terminal point and EC valve as for prevention of
drain. Also, up slope design shall be applied between terminal point of final Super Heater inlet
pipe chest and boiler housing through port.
 EC xxxx xxxxx xxxx xxxxx xxxxx
xxxxxxxxxx
xxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxx
 Straight pipe which longs 5 times of valve inner dia shall be designed at EC valve inlet for
prevention of noise and vibration. ( refer to item 3.7.3.11/EC xxxxxx xxxxxxxx )
(3) Attention shall be paid for EC valve outlet port pipe planning as follows:
 Down slope shall be applied for all pipe.
 Straight pipe which longs 5 times (min 2m and over) of valve inner dia shall be designed at
EC valve outlet for prevention of noise and vibration. The valve dia and pipe dia shall be
designed as same as possible by using thick wall valve. If required bend part, bend after
enlarging the pipe dia by using diffuser. Enlarged ratio of diffuser shall be within 1:3 by 1
chance and enlarged angle less than 7o.
(4) EC valve and EC front valve shall be arranged by consideration with operationability,
maintenability and also floor planning. Lifting book for maintenance shall be provided.
(5) EC xxxx xxxxx xxxxx xxxx xxxx
xxxx xxxxx
Xxxxxxx xxxxxxxx xxxxxxx xxxxxxx
Xxxxxxxxxxxxxxxx xxxxxxxxxxxx xxxxxxxxxxx
xxxxxxxxx xxxxxx
(6) Temperature reducer and piping planning procedure for after confluence of turbine by-pass
pipe shall be refered to High Pressure Turbine by-pass pipe. (item 3.7)

67
3.11 Drain pipe for water seperator drain tank

3.11.1 Arrangement of system.

~ ~

1 set
super

Water separator

Evaporator

~ ~
Water separator drain
tank
Economiqer outlet pipe chest
(*1)
Warming pipe
Drain pipe for water
drain tank
WDC valve (*3)

Boiler circulating pump

M
( *2 ) High pressure
feed water pipe C
To economiqer O
M N
D
E
N
S
M E
R

Blow pipe for out of system

( to blow tank )

(*1) Vertical pipe shall be designed as long as possible and keep enough static head for prevention of fluid
flash. Slanting down direction connection shall be provided for branch portion of BPC suction pipe.
(*2) There are no BPC plant exist.

68
(*3) WDC valve : Water Separator Drain Control Valve.
3.11.2 Purpose of system installation.

Water separator and/or its drain tank level risen temporarily at boiler starting time by swelling
phenmenon. (NOTE 1). At that time, WDC valve open and release surplus boiler water to the
condenser and reduce extreme high water level.

(NOTE 1) Swelling phenmenon: At the boiler starting (after firing start), boiler water changes
from saturated to boiled condition and the water blow out by sudden volume up. Sudden change of
Water Seperator level at boiler starting caused by swelling phenmenon which brings volume
change of fluid under low pressure condition.

3.11.2.1 System and valve operation

(1) WDC valve are arranged for controlling of Water Separator drain level at boiler clean up,
starting and stopping. Operation case are as follows :
 For very hot start swell. For water feed at before fired (5% MCR).
 For hot start swell (very hot, hot, warm, cold)
 For warm start swell. Mis-open operation under semi-critical range.
 For cold start swell
(2) WDC valve shall be installed 2 sets for cover abnormal condition each other. Capacity of
plural numbers valve shall be decided as given cost minimum.
(3) Afterside valve shall be installed on the down stream side of WDC valve and fully closed at
super critical pressure condition. The valve provided for :
 Blow to out of steam, exchange of circulation at clean up condition.
 Condenser protection at WDC valve mis-opening operation.
 Super Heater burn out protection at WDC valve mis-opening operation.
(4) There shall be installed orifice at WDC valve outlet for prevention of vibration and noise,
because WDC valve outlet is vacuum and flush over. ( for angle type valve, there are no
problems under 15 ~ 18% flush ratio, but can not keep this condition without orifice).
(5) Warming line for WDC valve will be required after investigation of the valve lifewhen there
are large temperature difference exist on WDC valve. At that time, warming line take from
economizer outlet and connect to WDC valve inlet as same as BOP warming line. Minimum
warmable flow required.
(6) BCP xxxx xxxx xxxxx xxxxx

3.11.3 Piping planning procedure.

(1) Thermal stress calculation shall be proceeded. Confirm reaction force and moment at the
terminal point of the Condenser.
(2) Water Seperator drain tank outlet pipe shall be designed as vertically downside direction as
posiible for countermeasure of flush by saturated drain. Piping route shall be select as
minimum number of bend, large radius bend and kept down slope to WDC valve.
(3) In the case of the Water Seperator drain tank installed at behind of the boiler, horixontal pipe
route which required after drain tank outlet vertical pipe shall be designed as hold spaces for
draw out of ammonia injection nozzle and gas analyzer.
(4) Straight pipe which have 5 times length of valve inner dia shall be installed at WDC valve
inlet for prevention of noise and vibration. Also, straight pipe which have 10 times length
(min 2m and over) of valve inner dia shall be installed at WDC valve outlet.
(5) Install target plate at WDC valve outlet.
(6) WDC valve installed as near as possible to the Condenser and desired straight pipe after
portion of valve outlet. Orifice shall be arranged at just front of the Condenser.
(7) WDC valve and WDC after valve shall be arranged by consideration with operationability,
maintenability and also floor planning. Lifting hook for maintenance shall be provided.
(8) Plant arrangement and piping planning shall be proceeded by consideration with WDC valve
type which different by manufacturer and with/without oil supply unit. When required the oil

69
 supply unit, its installed at lower 1 ~ 1.5m position than WDC valve actuator, and about 20m
pipe length, down slope.
(9) Enlarged ratio for after orifice pipe dia shall be about 1:2 on area.
(10) Blow pipe connect to the out of system from in front of after valve, this line shall be
considered at piping planning.

3.12 High Pressure Feed Water Pipe

3.12.1 Arrangement of system

3.12.1.1 Feed Water Pump ~ HP Heater

a. Motor Feed Water Pump

To HP2 heater

HP1 heater

Minimun flow

Deaerater M
Feed water control valve

BFP
B/P M BFP
~

b. Motor Feed Water Pump + Torque Converter

To HP2 heater

HP1 heater

Minimum flow
Feed water control valve
Deaerater M

BFP
B/P M BFP
~ BFP
Torque converter

70
 c. Turbine Drive Feed Water Pump

To HP2 heater

HP1 heater
Minimum flow

Deaerate
M

BFPT
B/P BFP
BFP

~ BFP
xxxx xxxx xxxx xxxxx

3.12.1.2 HP heater ~ Economizer inlet

SH spray water (BHP xxxx xxxxx xxxxx)

Fx

Economiquer inlet
pipe chest
HP3 heater

HP2 heater

HP1 heater

BFP
3.12.2 Purpose of system installation

71
 This system installed for water feed to Economizer through High Pressure Heater which pressure
risen by Feed Water Pump flowed from Deaerator tank through Booster Pump.
3.12.2.1 System and valve operation

3.12.2.1.1 Feed Water Control

Feed Water discharge are controled by boiler loading condition. Many control systems exist and generally
shown as follows :
 In the case of driven by constant speed motor, water flow controlled by feed water control valve that
provided at discharge side. (some times feed water control valve designed as double valve type).
 Feed water flow controlled by using constant speed motor which connect to torque converter, and control
pump speed.
 Feed water flow controlled by using steam turbine as driver and turbine speed controlled.
For each above systems, requirements of flow control are different by boiler type. Usually boiler type, feed
water type and control system are shown in the following table.

Boiler type Feed water pump type Control system

A

Discharge control valve

M BFP control (NOTE 1)

B
1. Drum type constant Number of revolution
pressure operation control (NOTE2)
M HC BFP
B/P M

C Number of revolution
control (NOTE3)
BFPT M
B/P BFP

B/P

2. Drum type variable B Number of revolution

pressure operation control
C
Number of revolution
control

3. Super critical constant Discharge valve control

pressure operation A + C + number of revolution
control

72
4. Super critical constant
pressure operation B + C ( C xxxxxxx) Number of revolution
control

A + C ( M xxxxxxxxx

NOTE : Above tables are changed by cost evaluation.

(NOTE1) After investigation of rangeability of CV value, inner valve arranged if required.

(NOTE2) Number of revolution control by torque converter Control valve are provided for about 100 ~
300% low discharge outer range pressure and low flow range, because number of revolution control are
difficult.

(NOTE3) Number of revolution control in the case of boiler pressure has less operation, control valve shall
be provided as by-pass for operation at over BFPT min rpm.(1st critical speed ).

3.12.2.2 Design of heater by-pass

There are many designing applied for heater by-pass. Usually following systems are used.
a. Attach by-pass on each heater.
b. Attach common by-pass ( nowadays, this system much used ).
c. Top heater (HP3 heater) and other heater seperated, and have each by-pass.
d. HP2.3 heaterand other heater seperated, and have each by-pass.
e. No by-pass attached (only 2 line heater).

Choice of above system are as follows :

 Common by-pass systemwhich shown above b. will be applied for cost down of valueand piping in the
case of no customer’s requirements exist.
 Above c. applied for turbine overload operation condition by top heater cut. ( When HP1.2 heater or
other heater leaked, load regulation shall be arised from top heater and load becomes larger).
 In the case that above b. system brings over cooling boiler inlet feed water temperature, above d. system
applied for which can by-pass only HP1 heaterwith easy inlet attack in high pressure system. Boiler feed
water over cooling brings boiler fuel flow rise, furnace outlet gas temperature high, SH metal temperature
high. In the case of using high sulphur contained fuel brings [low temperature feed water acid corrosion
on economizer].

3.12.3 Piping planning procedure

(1) Reaction force and moment caused by pipe thermal elongation appeared at pipe connection part of
feed water pump and heater. Confirm the reaction force and moment are under allowable value of the
equipment, and also established reaction force and moment on economizer to theboiler.
Xxxx xxxxx xxxxxxx xxxxxxxxxx xxxxx
xxxxxx
(2) Thermal stress calculation shall be proceed after confirmation of operation pattern.
(3) Sometimes, reaction force and moment from pipe side to heater nozzle becomes over 10 ton, because
this line is used for high pressure with large thickness of pipe wall. This reaction force and moments
are translated to the building through heater base.
(4) This line brings high cost by applying large thickness of pipe. Pipe route from pump to economizer
shall be designed as short as possible, and bending pipe applied for corner.(large cost impact).
Recently, face to face diameter of bending pipe becomes nearly equal to elbow’s.
(5) Crane and/or mono-rail are used for overhaul or carry in/out. Piping planning shall be proceed as not
diasturb above works.(usually, whole pump lifting up are not required at feed water pump overhaul.
But if required flanged connection for pipe shall be considered).
(6) Generally, valve spindle shall be set as vertical for large valve maintainability.

73
(7) Feed water pump outlet check valve shall be installed at horizontal pipe for prevention of chattering
on low load and low speed range.
(8) Piping shall be arranged as up slope as possible to economizer and avoid piping in the system.
(prevent for drain or air port). In the case that unavoidable pipe are exist as shown below in
the system, drain port and air vent shall be provided.
 The case that both level of final heater and economizer are nearly equal.
Requirement
 For precendence operationability and maintainability of the valve by customer’s requirement and
vertical pipe route applied.
(9) Reducer stretch angle at both pump outlet and control valve outlet shall be set as one side 7o for
prevention of erosion.

(10) It is recommended that 5D (D: inside dia) straight pipe arrangement at heater inlet as shown below for
prevention of heater inlet attack.
,  are MHI standard.
Attention shall be paid for export plant because recommended that 10D distance and over arrangement
of reducer in HEI-1998.2.8

Larger 5D Heater
(include heater inlet boss)
3.83

Floor

(11) Confirm, heater and inlet pipe connection are set above the floor opening (including floor sleeve) for
field welding works.

(12) Feed water flow meter installed at economizer inlet, front and rear side straight pipe length shall be
confirmed to flow meter manufacturer, and keep up side space for overhaul.

(13) Terminal point of economizer recirculation pipe (item 5.2) shall be put as near as possible to the
economizer.(prevention of by-metal action).

(14) Sometimes common header system of BFP outlet request by customer (especially for domestic
commercial plant) for operationability point.

(15) Branch position of SH water pipe shall be kept 3D (D: feed water main pipe inner dia) or more awat
from T joint center as shown below.(prevention for erosion and corrosion)
[reference data] , are MHI report.

SH spray water

Feed water main pipe

Over 3D

74
4. Planning procedure of Circulating Water Pipe

Following items include in this guidance for planning by consideration with installation purpose and
operation procedure of several piping systems.
 Constitution of system.
 Purpose of system installation.
 Piping planning procedure.
This section described for commercial conventional plant, and also useable for industrial conventional plant
and combined plant. Most suitable piping planning shall be proceeded by consideration with total plant and
equipment design because there many cases exist for plant design condition.

4.1 Circulating Water Pipe.

Xxxx xxxx xxxxx xxxxxxx xxxxx

4.1.1 Constitution of system

Several combination are applied for constitution of Circulating Water Piping. Typical sample are as follows:
(1) Pass number of condenser……1 pass or double pass (refer to item 4.1.2.1 for detail).
(2) Condenser parallel flow/against flow……parallel or against flow (refer to 4.1.2.2 for detail).
(3) Several equipment for protection of condenser (refer to 4.1.2.4 for detail).
 Various reverse flow wash system…… inside reverse flow wash type or outside reverse flow wash
type or four reverse flow wash.
 Debris filter……with or without.
 Ball cleaning equipment…… with or without.
 Injection of FeSo4……Yes or No.
(only for aluminium brass tube)

Condenser

75
Circulating water Ball collecter
pump

Drain Water

xample of double pass + parallel flow + ball creaning system

76
 Condenser

(B)

( A)

Ball collecter Ball collecter

Circulating water
pump

Drain water

1pass + against flow + outside reverse cleaning + ball cleaning system

4.1.2 Purpose of the system installation

Large quantity cooling water shall be required at Steam Condenser for condense the steam after worked on Low Pressure Turbione. This line arranged for feed
the cooling water to the Condenser and discharge heat exchanged cooling water to out side of the system.

77
.1.2.1 Pass number

There are 2 styles in Condenser pass number, 1 pass system has 1 direction of cooling water flow, 2 pass
has return flow cooling water in the Condenser. Generally, to say, large condenser designed as 1 pass type
and middle/small capacity Condenser sre 2 pass. The reasons are as follows:
(1) Large capacity Condenser
*2 pass design required large & deep foundation for Condenser by limitation of bearing span for LP
Turbine (limitation of Turbine support foot position). *2 pass design brings cost expensive.
(2) Middle/small capacity Condenser
*2 pass design required not so deep foundation as large capacity, and horizontal compact 2 pass type brings
cost saving system.

4.1.2.2 Parallel flow and against flow.

LP turbine exhaust port LP turbine exhaust port

Turbine
shaft
A B A B

Turbine shaft

Parallel flow Against flow

Parallel and against flow systems are shown in above figure.

Application of each system are as follows:

(1) Usually, parallel flow type are adopted for merit of Circulating water Pipe arrangement.
(2) In the case that single shell and cooling water flow through in half block separately. High vacuum
appear in the cooling water inlet side by same direction flow. Unbalanced Turbine exhaust pressure
A.B are influenced to thrust force. After confirmation of the thrust force there are no problems to 700
MW class domestic thermal plant, parallel flow type are adopted for merit of Circulating water Pipe
arrangement.Refer to KPM –98-007 for detail.

4.1.2.3 Parallel and vertical arrangement to the Turbine Shaft

Pass number and Condenser flow direction are related to piping planning.
LP turbine
LP turbine exhaust exhaust
LP turbine exhaust
Turbine shaft
A B A B
Turbine shaft

Parallel arrangement to the turbine shaft

Vertical arrangement to the turbine shaft

Parallel and vertical arrangement are shown in the above figure, and relations of each items are in the
following table. Refer to KPM-98-007 for detail.

General arrangement ( evaluation result of total cost)

78
 No of LP casing Shaft parallel arrangement Shaft vertical arrangement
1 pass 2 pass 1 pass 2 pass
Single casing O
Double casing
O

O : Often used : Sometimes used : Not used

4.1.2.4 Equipment for Condenser protection

Cooling water temperature rise and tube inner contamination are large factor of vacuum drop,
contamination brings bu accumulation of sea glows. Cooling water shortage by sea glows in the Condenser
Tube will be caused as time goes. For prevention of above described problems, following are applied by
combined.
a. Reverse flow system…… Wash by reverse flow in the tube (NOTE1).
 Inside reverse flow (valve turn over style)
 Outside reverse flow (valve turn over style)
 Four way reverse wash valve style
b. Ball cleaning style……Cleaning tube inside by sponge ball injection.
c. Debris filter style……Prevent trespass of shell and sea glows.
Outline of above each styles are as follows:

(NOTE1) Attention shall be paid for open/close time of reverse wash flow valve, because momentary
cooling water stopped and Condenser vaccum seriously down at single shell Condenser which installed for
C/C plant.

4.1.2.4.1 Outside reverse flow type

Peal off foreign matter in the tube by changing flow direction A.B side which produced by 8 set butterfly
valves open/close around the Condenser as following figure

Condenser
( A)

(B)

Cooling water inlet Cooling water outlet Cooling water inlet

Flow direction of normal operation ( xxxx xxxx )
Condenser Condenser

79
 ( A) ( A)

(B) (B)

Cooling water outlet Cooling water Cooling water Cooling water outlet
Cooling Inlet inlet Cooling
water inlet water
inlet
4.1.2.4.2 Inside reverse flow type

Peal off foreign matter in the tube by changing flow direction A.B side which produced by butterfly valves
open/close ( in the  case, change feed and return each other in A.B side) around the Condenser as shown
in figure  ~ .

 1 pass and connection valve installed at inlet/outlet chamber.

Condenser
Cooling
Cooling (A) water inlet
water outlet

Cooling (B) Cooling

water inlet water outlet

Water chamber connection valve

Flow direction of normal operation ( xxx xxxx)

Cooling water (A) Cooling water

Outlet inlet
(B)

B side reverse flow wash

Cooling water (A) Cooling water

Inlet outlet
(B)

A side reverse flow wash

 1 pass and connection valve installed at only outlet chamber.

80
 Condenser

(A)
Cooling
water Cooling water
outlet inlet

(B)

Water chamber connection valve

Flow direction of normal operation ( xxxx xx)

(A)
Cooling water Cooling water
Outlet (B) inlet

B side reverse flow wash

Cooling water (A)

Outlet Cooling water
(B) inlet

A side reverse flow wash

 Case for double pass

81
Cooling water inlet

Condenser

(A) Feed Side

Cooling water outlet Return Side

Cooling water outlet (B) Return Side

Feed Side

Cooling water inlet

Flow direction of normal operation ( xxx xxx )

Cooling water inlet

(A) Feed Side

Cooling water outlet Return Side (A) Feed side reverse
wash
(B) Return side reverse
Cooling water outlet (B) Return Side wash
Feed Side

Cooling water inlet

Cooling water inlet

(C) Feed Side

Cooling water outlet Return Side (A) Return side reverse
wash
(B) Feed side reverse
Cooling water outlet (D) Return Side wash
Feed Side

Cooling water inlet

4.1.2.4.3 Four way reverse flow wash style

82
Peal off foreign matter in the tube by changing flow direction A.B side which produced by change vane
position of four way reverse flow valve as shown.

Condenser
(A)

(B)

Four
way
reverse flow
wash valve

Cooling water inlet Cooling water outlet Cooling water inlet

Flow direction of normal operation ( xxx x)

Condenser

(A)

(B)

A side reverse
Four way flow wash
reverse flow
wash valve

Cooling water inlet Cooling water outlet Cooling water inlet

Condenser
(A)
83
(B)
Four way reverse
flow wash valve
Cooling water inlet Cooling water outlet Cooling water inlet

B side reverse flow wash

4.1.2.4.4 Debris filter arranged style

Blow out trespassed foreign matter to out of the system by using blow line which designed with
debris filter at Condenser inlet cooling water pipe as following figure. Refer to KPM-98-004 for detail of
debris filter.

Condenser
(A)

(B)

Debris filter

Blow to out of Cooling water Blow to out of

System (drainage outlet System (drainage
Cooling water canal or cooling canal or cooling Cooling water
inlet water outlet) water outlet) inlet

4.1.2.4.5 Ball cleaning equipment

84
 Peal off foreign matter as following process. Inject much piece of special sponge ball with cooling
water into the tube. Catch the ball at cooling water outlet by the ball collecter. Again inject the ball into the
Condenser by ball circulating pump comtinuously. Refer to KPM-98-004 for detail of ball cleaning
equipment. Refer to item 4.1.3.6 for ball circulating piping plan.

Condenser
Tube

Sponge
ball

Ball collecter

Cooling water inlet

Cooling
Ball circulation pipe Ball circulation pipe water outlet

Ball catcher Ball circulation pump

4.1.2.5 Protection countermeasure of Condenser Tube

Usually,Condenser tube materials are alumi-brass or titanium.Typical cause of Condenser tube

erosion and les\akage are as follows:

4.1.2.5.1 Inside erosion of the Condenser alumi-brass tube

(1) Inlet attack

Peel off of protection layer and tube thickness reducing by cooling water disorder flow near
the tube inlet edge.

(2) Deposit attack

Tube thickness reducing by down stream side vortex (CARMAN vortex) of the foreign materials
in the tube. (Disorder flow caused by trespass of concrete piece, wooden piece, sea glows).

(3) Sand erosion

Tube thickness reduced by sand erosion which included in cooling water and flow through tube.

(4) Abnormal corrosion

85
 In the case that cooling sea water draw from estuary much volume sand draw into the tube. Direct
erosion caused by sand . Peel off protection layer on the tube surface. These are lead to corrosion.
Collodial MnO2 etc are produced by oxidization of Mn2 + in sea water and attach to the tube inner
surface. MnO2 has catodic reaction and if recognized protection layerdamage on the cooling tube,
corrosion brings by anodic reaction of the tube.
Cavity portion appeared under high speed disorder flow condition and brings cavitation erosion
for very worst results.

(5) Contaminated sea water corrosion

Plenty of sea glows corpse, city drainage and industrial drainage are gathered as contamination south at
sea bottom, and include many sulfured material and Su. These items are given corrosion on the tube.

(6) Electolytic corrosion

Water chamber side electolytic corrosion brings by electric potential difference between Condenser
chamber and tube which caused by peel off the Condenser chamber rubber lining. Reliable isolation
required for titanium Condenser tube because at that case electric potential difference are larger than
other materials. MHI TAKASAGO Works applied rubber lining on the near Condenser circilating
water pipe about 1D range.
(Isolation method of around Condenser chamber)

 MHI NAGASAKI Works

Basic electolytic corrosion countermeasure are installation of sacrficed anode plate in the
Condenser chamber. No rubber lining applied on circulating water pipe because electric potential of
titanium tube are low.
 MHI TAKASAGO Works
Different kind of materials exposed at ball collecter. Installation of sacrificed anode plate on
Circulating water Pipe at Condenser chamber outlet are standardized. Rubber lining applied on near
Condenser water chamber circulating water pipe (about 1D range).

4.1.2.5.2 Outer surface corrosion of Condenser alumi-brass tube

Ammonia appeared by resolution of hydrazing etc in the cycle used for feed water treatment. This
ammonia gas extracted to the out of system by Condenser Vacuum Pump as non condensate gas from
Condenser air cooling part. Air cooling part and near around tube outer surface are usually exposed
ammonia which soluble in condensed water, especially support plate are corroded by drip drain (ammonia
attack). At the air cooling part, nickel plated alumi-brass tube are 70/30 cuplonickel, and titanium tube are
used for prevention of ammonia attack. For prvention of erosion by Turbine exhaust condensation, nickel
plated tube or 70/30 cuplonickel tube are used on several line of tube nest upper portion.

4.1.2.5.3 Protection countermeasure for Condenser tube erosion leakage (countermeasure for inner surface
erosion).

(1) In the case of Cu alloy tube (NOTE 1)

Erosion from Protection countermeasure

Inlet attack  Electrical anti-corrosion protection equipment
 Bell mouth formation at tube inlet end.
Deposit attack  Build up protection layer by injection of Fe ion.
 Chlorination system.
 Reverse flow wash system.
 Check water intake.
Sand erosion  Check water intake.
 Build up protection layer by injection of Fe ion.

86
 Abnormal erosion  Build up protection layer by injection of Fe ion.
 Ball cleaning system.
 Debris filter.
 Check water intake.
Corrosion by contaminated sea  Build up protection layer by injection of Fe ion.
water  Check water intake.
 Change tube material (applied, alumi-brass tube with protection
layer, titanium tube).

Enviornmental protection problems are considered for applying FeSO4 injection of Fe ion injection.

(NOTE1) Cu-alloy tube materials

Cu-alloy tube materials are shown as follows and applied mainly alumi-brass for Condenser tube.

Application
Admiralty For fresh water (not used for sea water)
Arsenical Copper Used rarely
Aluminium Brass Used rarely
Aluminium Bronze Used rarely
90/10Cu - Ni Useable to air clean zone.

(2) For titanium tube

Corrosion type Protection countermeasure

Electrical corrosion Electrical corrosion are prevented by complete rubber lining to the water chamber
and using titanium tube plate (solid titanium or titanium clad). Complete isolation
shall be done between titanium tube. Complete isolation shall be done between
titanium tube chamber etc.
Hydrogen brittleness In the case of electrical corrosion prevention applied, over prevention brings
hydrogen by sea water resolution. Titanium tube absorbed hydrogen and brittled.
For keeping of suitable electric potential, fixed electrical potential, system for outer
electrical source type and titanium only (susaranode etc) anode plate for sacrifice
anode system are applied.

4.1.2.5.4 Application of anti-fouling countermeasure for Condenser tube (different by water contamination
condition)

(1) For Cu-alloy tube

Protection countermeasure Application

Ball cleaning system (Circulation 60min+ball collection 30 min) X 2
In summer times/week/chamber
Reverse flow wash system 30 min/1 time/day/chamber apply before ball cleaning system
operation.
Debris filter 1/day and/or blow at different pressure comes over regulation
level.
Ball cleaning system (Circulation 60min+ball collection 30 min) X 1
In winter times/week/chamber
Reverse flow wash system 30 min/1 time/day/chamber apply before ball cleaning system
operation.
Debris filter 1/day and/or blow at different pressure comes over regulation
level.
(2) For titanium tube

87
 Protection countermeasure Application
Ball cleaning system (Circulation 60min+ball collection 30 min) X 1
In summer times/every/day/chamber
Reverse flow wash system 30 min/chamber : apply before ball cleaning system operation.
Debris filter 1/day and/or blow at differential pressure comes over
regulation level.
Ball cleaning system (Circulation 60min+ball collection 30 min) X 1
In winter times/day/chamber
Reverse flow wash system 30 min/chamber : apply before ball cleaning system operation.
Debris filter 1/day and/or blow at differential pressure comes over
regulation level.

4.1.2.6 System and valve operation (start and stop procedure)

Fixed vane type and variable pitch vane type are applied for Circulating Water Pump. Variable
pitch type pump installed for frequently load change plant to reduce auxiliary’s HP. Start ans stop procedure
are as follows:

Circulating water pump (NOTE 1) Circulating water pump

start (NOTE 1) shall be started before high temp’
steam drain comes into the
Condenser.

For fixed vane for variable pitch

Pump started under pump The pump started at pump outlet butterfly
outlet butterfly valve  valve  fully closed condition. At that
open condition. time, pump vane opening shall be as 0%
(Condenser outlet for reducing pump starting torque.
butterfly valve  (Condenser outlet butterfly valve 
slightly) --- --- slightly open).

Pump outlet butterfly valve Pump outlet butterfly valve  open,

 open bit by bit pump vane shall be open bit by bit.

Condenser
chamber air
extraction pump


Confirm air in the Condenser chamber
and Circulating Water Pipe are
completely vent and filled by water then Circulating
Condenser outlet chamber air vent valve Water pump
 fully closed. Condenser Discharge
  canal

Valve opening in the above figure shown

before starting. Condenser outlet valve 
Pump outlet butterfly valve  fully open. are slightly open for keeping minimum
flow.

88
 Open bit by bit Condenser outlet butterfly valve  till rated flow

Start Condenser chamber air extraction pump

For fixed vane for variable pitch

In the case of load change In the case of load change under
Reverse procedure
under normal operation, normal operation, pump vane applied for stop
Condenser outlet butterfly opening controlled. action
valve controlled.

4.1.2.7 Painting for Circulation Water Pipe.

Circulation Water Pipe inner surface shall be protected by anti-corrosion countermeasure because mainly
sea water used for Condenser cooling water (Circulation Water). Also outer surface of the pipe which
embedded under ground shall be protected. Generally, protection method are shown as follows, at selection
of method customer’s requirements, installation and transportation condition shall be considered and lead to
cost minimum.

(1) Anti- corrosion countermeasure for inner surface

Usually applied to anti- corrosion countermeasure for pipe inner surface are shown as follows:
 Tar epoxy coating.
 Polyethylene lining (Up to 650A outer dia).
 Rubber lining (Reducing portion) MHI TAKASAGO works applied rubber lining for ID range of
Condenser outlet pipe inner surface (Several plants applied 2D range rubber lining). (Refer to item
4.1.2.5.1(6) for detail).
 Concrete lining.
 Electricity corrosion protection.
 Others (Glass flake coat,cast iron pipe,FRP pipe).
(2) Anti- corrosion countermeasure for pipe outer surface.(Following countermeasure shall be select as
meet to the result of site agronomic survey). Usually applied to anti- corrosion countermeasure for pipe
outer surface are shown as follows :
 Electrical anti- corrosion protection.
 Jute wound (Coal tar enamel + glass cloth double wound.(Nowadays this protection can not be
applied in domestic plant from enviornmental point of view).
 Tar epoxy coating.
 Concrete
 Special anti-corrosion tape (Experienced for 200mm dia pipe).
 Others (Polyulethane sleeve… mainly used for ductile iron pipe).( Polyulethane coat).
NOTE : In the case of applying electrical anti- corrosion protection, embedded part and non- embedded
part shall be completely insulated. Therefore flange required at joint of embedded /non- embedded part and
insulated. Following shall be considered for stopping of electrical current going to outer objections.
 Insulation rubber installed on the band which used for prevention of embedded part float up.
 Over 75mm clearance shall be given at concrete through hole for insulation between pipe and
reinforcing bar.

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 Pipe support shall not be installed for anti-corrosion protection pipe, if it be required unavoidably
insulate the support fully.
 For all branch pipe which comes from embedded pipe, complete insulation applied at stick out part
from the ground.
 Suitable space shall be kept for insulation of butterfly valve and expansion joint which installed at near
to the ground.
If there is long distance between the ground level and flange, add one more flange. ( It recommended that
the flange installed as near as possible to the embedded part from the view point of insulation).

4.1.2.8 Flow velocity in the Circulation Water Pipe.

Usually 3m/s flow velocity applied for Circulation Water Pipe except customer’s requirement exist, reasons
are as follows:
(1) Fluid velocity limit for peel off anti-corrosion painting.
Usually tar epoxy resin which has small adhesive paint are applied for anti-corrosion painting of
Circulation Water Piping for low cost. From our test result which carry out in 1962 for anti-corrosion paint
characteristics, fluid velocity limit for tar epoxy resin paint are 20m/s by loop test in flowing water. In the
case of flow velocity set as 5m/s, safety factor becomes 4 and no problems. Flow velocity 2 ~ 3.5m/s
applied for almost domestic thermal plant, for few plants has over 5m/s velocity. We recommend up to 5m/s
flow velocity limit for prevention of anti-corrosion paint peel off. Usually rubber lining are applied at
reducing part for countermeasure of anti-corrosion paint peel off by cavitation (refer to item 4.1.2.7).
(Reference data)
 MHI experienced for fluid velocity and anti-corrosion painting of Circulation Water Pipe.
 Experience data for sea glows at thermal power plant.

(2) Flow velocity limit for adhesive prevention of sea glows

More high velocity brings more better result for sea glows adhesive prevention. 3m/s flow velocity
are effective for prevention of shells adhesive by TEC test result. But many thermal plant operated
under 3m/s velocity.
(Reference data)
 Technical report (May 1993) by TEC
Fluid velocity of existing thermal power plant.
2.0 ~ 3.0m/s ……212 units (72%)
Upto 1.8m/s …… 19 units
3.1m/s and over …… 18 units.

(3) Economical design.

Pipe and valves cost are down by reducing pipe dia and flow velocity rise, but Circulation Water
Pump motor cost risen for pressure loss and the Pump motor HP up. The Pump motor HP up effect
to auxiliary equipment HP evaluation. From our experience at ELBISTAN 350MW, MAP TA
PHUT 700 MW thermal plant, less than 3m/s velocity are more economical, but sea glows are
attacked at low velocity plant as mentioned abobe item (2). Most suitable flow velocity shall be
selected by considering with length of Circulation Water Pipe, auxiliary equipment’s HP, and
Circulation Water System arrangement etc.
(Reference data)
Economical investigation results for ELBISTAN 350MW, MAP TA PHUT 700 MW thermal
power plant.

(4) Conclusion
As for above mentioned, most suitable selection of flow velocity are proceed by consideration with
Circulation Water System arrangement for each project, usually about 3m/s are appli

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 .1.3 Piping planning procedure

4.1.3.1 General

From Circulation Water Pump to discharge canal outline route are shown in the following figure. This pipe line have an important effect upon piping
arrangement, cost and progress of the works because it’s required transport a lot of cooling water (mainly sea water used) by large dia and very long length pipe.Also
effect to arrangement of equipment and pole span of Turbine room. Route planning and support point for the pipe shall be decided by consideration with embedded
setting or set up in trench. Followings are actual planning sample.

Turbine room Siphon limit 7.9m less than

Tube top high

Condenser
Circulation water
Pump
M Discharge canal

Intake Seal pit

pit Debris filter Ball filter Discharge out by
Static head
Submerge into seal pit

(NOTE : Refer to item (11) for seal pit requirement)

(1) It’s recommended that Condenser top set as highest level and no in the system for prevention of eater hammer by air staining in the pipe, In the case of the
pipe line arranged partially on ground level and have , confirmation required for water hammer by transitional stage calculation of the Circulation Water Pipe
System.
(2)Generally Circulation Water Pipe has a large diameter, and the system planning are proceeded by consideration with easy passing in the yard, thermal deformation
of
(3) Most shortest route shall be selected to the Circulation Water Piping because it’s very large BQ. For embedded route, recommend straight arrangement by less

91
 .thermal deformation.
(4) Interference between building and under ground foundation of equipment shall be avoided for
embedded piping system.
(5) For embedded pipe basically embedded pipe level shall be kept as equal to Circulation Water Pump
discharge level at intake pit. Reinforcement (NOTE1) shall be applied for the pipe which embedded just
under passing road for prevention of brake. Keep pipe strength by using reinforcement ring instead of
thick wall pipe which give large cost impact. Pitch and size of reinforcement ring shall be decided by
consideration with raw pipe length.
(NOTE 1) Reinforcement procedure for Circulation Water Pipe (example)
 Rise the pipe side stiffness by using numbers of reinforcement ring for Circulation Water Pipe.
 Avoid over load to the pipe by applying inside tunnel arrangement.
 Rise the pipe side stiffness by using thick wall pipe.
(6) Horixontal bend and vertical bend shall be arranged at a portion as reduce as possible of cost and
pressure loss.

Better sample
Bad Sample

(7) Usually Circulation Water Pump hold water by using siphon mechanism as shown in figure of front
page except Cooling Tower applied plant. Condenser outlet ~ discharge end ( to seal pit in figure front
page) are arranged absolutely under Condenser top level for prevention of siphon break appearance.
(8) Embedded pipe level kept as shown and shall be decided by considering with excavation volume and
countermeasure for gush out of water.
 Complication between piping,cable and trench.
 Condition of solid (drainage).
 Underground water level.
 Reinforcement at road crossing.
 Freezing depth at chill district.
Usually 1.5m ~ 2m depth are kept from ground level to Circulation Water Pipe top.

Road

Circulation water pipe 1.5m ~ 2m

45o and over

Min 500mm Min 600 mm

(working space) (working space)

(9) Vertical straight pipe length for Condenser chamber shall be designed as short as possible for less
excavation depth of Turbine room.

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(10) For large sink of turbine building, require expansion joint at the portion which through the pipe into the
building for countermeasure of irregular sinking both through the Pit for expansion joint will be
arranged for prevention of water entrance to the Turbine building directly. Refer to item 4.1.3.4 for
other notice of expansion joint arrangement.

(11) In the case that the Circulation Water Pipe discharge connect to seal pit (NOTE1), the pipe shall be
connected to under water level in the seal pit for prevention of air entrance into the pipe under operation
condition. (The pipe top shall be set as 0.5m lower than weir level). Seal pit weir level are given by
number of pump operation and designed as shown in figure above item(1). The level are lower than
Condenser siphon limit (Usually about 7.9m). Seal pit are not required for the case that discharge level
kept between Condenser tube top and siphon limit at minimum number (Usually 1 set) pump operation.

(NOTE 1) Seal pit: One of the style of discharge canal dam.Up part installed in plant yard. Small water
level control pond. Discharge canal lead to ocean by and useable siphon effect. Refer to KPM-99-004
for detail.

(12) In the case of Circulation Water Pipe discharge connect to seal pit the pipe which arranged between seal
pit ~ discharge canal shall not rise up for static pressure flow.

(13) Refer to item 4.1.3.2 for planning procedure around Circulation Water Pump.

(14) Maintenance manhole shall be arranged on the pipe. Distance between each manhole settled as 50 ~
100m.

(15) In the case of the pipe arranged both feed and return line are set at one route.(adopted by cooling tower
system). Two line shall be designed as near as possible and parallel for reduction of B/Q and case of
civil and architectural works. Working space shall be kept as mentioned above in item (8).

(16) No interference confirmed to near road because channel of Circulation Water Pipe are excavated by 45 o
slope as shown in item (8). When applied less slope than 45 o from yard limitation, use seat pile and
brings cost up.

(17) Civil and architectural cost are sharply increased than embedded style when applied pit style to
Circulation Water Pipe for turbine room. Site delivery time of the embedded pipe required as advanced
Turbine building foundation works, it’s critical for progress of project works to short delivery time
plant. Generally embedded style shall be adopted from cost minimum view of point, and arrange
minimum length embedded pipe in Turbine room. Pit style shall be considered for short time delivery
plant.(especially for full turn key project).

(18) Inner pit piping fixed point arranged at necessary point. Pipe elongation start point set as to 2 ~ 3 and
controlled. Minimize of affection to terminal points.

(19) This pipe line has large bore: Very large piping load Vertical load (pipe and water weight) and
horizontal load (friction force at under operation condition/thrust force at pressure test) are very large
for support point (pump discharge, before/after of expansion joint, before/after of socket welding joint,
around the Condenser) foundation. Reflect calibaration load to foundation design. Filter, reverse flow
wash valve, motor valve are also big weight items.

(20) Attention shall be paid for nominal pipe dia (inside or outside) for calculation of fluid velocity and
pressure loss. Interference shall be checked for outer dia standard (for Circulation Water Pipe) and inner
dia standard (for valve). If interference find out at plant site, liner shall be applied for adjustment.

94
4.1.3.2 Piping around Circulation Water Pump.

M Rubber expansion joint

Outlet valve

O O O O

Thrust force Thrust force

Damper base damper base

(1) Usual pump outlet pipe arrangement shown in above figure.

Purpose of rubber expansion joint installation at pump outlet are as follows:
 Adjustment of piping installation error.
 Adjustment of piping irregular sinking.
 Easy overhaul of valve maintanance.
 Prevention of vibration.
(2) Thrust force brings by installation of rubber expansion joint, therefore thrust force damper base shall be
installed for prevention of the force effect to the pump. (refer to figure of previous page).
(3) Pump outlet rubber expansion joint and butterfly valve shall be arranged as can lifting and carry in/out
by pump lifting crane.
(4) In the case of plural pump units operated and one of them stopped: Pipe inner pressure rise because
Circulation Water flow into stopped unit line. Countermeasure for this action, check valve type
butterfly valve will be installed. In this case, rubber expansion joint shall be installed at pump ~ valve
portion for prevention of over pressure in rubber expansion. In this case of check valve type butterfly
valve are not installed, expansion joint installed at opposide side as for avoid inner pressure act on
rubber expansion joint at pump shutt off operation. For irregular sinking expansion joint arranged near
intake pool.
(5) In the case of using pressure oil actuator for Circulation Water Pump outlet valve,installation space for
large counter weight of the valve shall be considered. (Many cases are recognized as for prevention of
pump reverse rotation at pump trip that the plant applying cooling tower).

95
(6) There is vibration possibility for butterfly valve which installed at Circulation Water Pump outlet by
disordered flow. Followings shall be considered and co-operate with valve manufacturer.
 We experienced above vibration at WANG NOI, COSTANERA plant by applying AMRI valve.
 8D (D: Circulation Water Pipe dia) straight length required from Circulation Water Pump outlet in
AMRI investigation report, but such long straight pipe can not arrange for actual design.
 Countermeasure for valve vibration
a. Butterfly valve full opening set as 70o
Butterfly valve full opening shall be set as 70 o and prevent vibration by given differential pressure to
the valve vane. (Applied to GHAZLAN, WANG NOI, COSTANERA) AMRI valve vane are made of
sus steel and no problems, but some countermeasure shall be considered for rubber lining valve vane.
Also, rubber lining required to valve down stream side Circulation Water Pipe for countermeasure of
disordered flow. There are problems for little pressure loss arise.
b. Neck extension butterfly valve shall not be applied.
By our experience,vibration occurred at neck extension butterfly only. Therfore shall not apply
that type valve for Circulation Water Pump outlet valve.
(7) Arrangement planning for butterfly valves except Circulation Water Pump outlet shall be referred to the
item 8.1.3(5).
(8) Pump suction piping for horizontal shaft double suction vortex pump (double suction type inner
structure pump) shall be reoceed by referring to item 4.2.3(13).

4.1.3.3 Piping around Condenser

4.1.3.3.1 Connection direction of Condenser inlet pipe.

Following attention shall be paid for connection direction of Condenser inlet pipe. Circulation
Water flow through in cooling tube after turn smoothly in the Condenser chamber. There is a possibility of
damage on alumi-brass tube which connect the Circulation Water Pipe to the Condenser chamber with
unsuitable angle. Unsuitable connection of the pipe brings abnormal distribution of the cleaning ball.

I Figure ( better sample )

II Figure ( bad sample ) a portion

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As shown in fig II a, Circulation Water Pipe connect to the Condenser inlet at 90 o ( angle), cooling water
flow into the tube after turn 90o flow direction in the chamber. There is a possibility of air inclusion because
cooling water flow turned in the chamber and wrap in chamber air. Tube (for alumi-brass) inner surface
damaged as corrosion by included air for incompleted Fe skin cover. Possibility of unbalanced cleaning ball
distribution. It’s recommend that The Condenser inlet side Circulation Water Pipe connect as parallel
direction as possible to the tube arrangement and the chamber as shown in fig I (if it is possible, 22.5 o shall
be applied). Random direction for Condenser outlet connection allowed, but recommend small flow out of
angle for the plant which used flow wash frequently. Following 2 items shall be considered for troublesome
arrangement (ex, required large building).

(1) Damage prevention of Condenser Tube

In the case of alumi-brass tube, connection angle shall be set within exist plant. Following are example
of large inlet angle ( fig II a ) plant.

MATSUURA : 75o ( NOTE 1)

NANKO : 75o

AKO : 65o

GOBO : 45o

SODEGAURA : 45o

(NOTE 1) We experienced at MATSUURA plant, abnormal tube erosion by inclusion air.

(Complement)

Following shall be checked for Fe protection skin of tube inner surface which installed as large angle
inlet arrangement.

 Check density FeSO4.

 Check Condenser chamber form (flow condition in the chamber, ball distribution).
 Requirement of flow regulation plate (flow condition in the chamber, ball distribution)
Refer to item 4.1.3.7 for FeSO4 injection point.

(2) Prevention of unbalanced ball distribution in Condenser tube.

Inlet angle of the Circulation Water Pipe shall be set within existing plant setting. (We have experienced
that 90o angle applied for single shaft train combined plant). When keeping straight pipe length at under
the Condenser as shown in item 4.1.3.3.2(1), 0o ~ 65o and 180o flow in angle (4.1.3.3.1 fig II a) of
Condenser inlet are effect only slightly. For domestic commercial thermal power plant, flow condition
calculation and model test are carried out for Condenser chamber form of countermeasure of prejudiced
flow prevention.

97
4.1.3.3.2 Condenser inlet/outlet pipe

Chamber Condenser Chamber

No interference on valve
Ball collecter
0.4 ~0.5D
and over

3 ~ 4D and over
(including elbow ID)
Ball injection nozzle
Debris filter
As separate as possible
1.5D and over
(recommend 5D and
over)

Condenser Chamber

3 ~ 4D and over

Ball collecter

Ball collecter set at just under condenser

Inlet/outlet pipe of Condenser chamber shall be designed as short as possible for given minimum excavation
depth of the Turbine room. As shown in previous figure, followings shall be considered.

A. In the case that ball cleaning equipment installed

(1) Condenser inlet side

 Ball injection nozzle shall be attached at normal flow range. (Not recommended at disorder flow range).
Ball injection nozzle shall be attached at 1.5D distance from debris filter outlet. (D: Circulation Water pipe
dia).

98
  For consideration of ball distribution, keep 0.4 ~ 0.5D between Condenser bottom to bend end. (D:
Circulation Water pipe dia).
(2) Condenser outlet side

 Ball collecter shall be apart 3 ~ 4D (include bending part1D) or over form elbow or Condenser bottom.
(D : Circulation Water Pipe dia) Possibility of ball staying by vortex at the pipe wall which brings from
close arrangement of ball collecter, elbow and Condenser. Close arrangement will be affect to ball collection
factor. Manufacture’s recommendation and existing plant arrangement shall be considered for final decision.
 Following arrangement shall be applied by consideration with eccentric flow elbow when ball collecter
installed at near outlet elbow of the Condenser chamber.

Condenser
chamber

Ball outlet

Ball collecter shaft

 Usually outlet valve are operated at half opening condition, and caused eccentric flow that effect ball
collection factor. Followings shall be considered:
a. Ball collecter ~ Butterfly valve distance : 5D and over.
b. Relation of ball collecter shaft and butterfly valve shaft position : refer to the figure.

Ball outlet Ball collecter

Butterfly valve

B. Installation of debris filter

99
 Confirm debris filter type (install at straight pipe or bend part).
 MASSEL filter will be supplied by debris filter manufacturer because flow vortex required by Condenser
inlet valve. (debris filter inlet valve).Face to face dimension of this filter and installation place are restricted
by manufacturer’s requirements.

 Attention shall be paid to interference between Condenser inlet valve vane and debris filter. Usually
0.5D straight pipe required from valve center,

C. Others

 In the case of Condenser inlet/outlet valve installed at just under of Condenser chamber: As shown in
figure section A-A, falling prevention lattice shall be installed in the chamber and adjust no intereference
between valve vane and lattice. Some times the lattice used both as prevention of eccentric flow.

Lattice

A-A section

A A

No interference between valve and lattice

 Thermowell strength shall be confirmed as enough to Circulation Water flow vibration.

 Against corrosion investigation required for Circulation Water Pipe and drain pipe etc which applied to
sea water. Especially when stainless steel pipe applied to drain pipe, lining pipe or alma-pipe shall be
required for prevention of clearance corrosion by foreign matter accumulation.

 Packing installation attachment flange shall be provided for insulation between Embedded part and over
ground part when installed electrical corrosion protection on Embedded pipe. For detail of electrical
corrosion protection, refer to item 4.1.2.7(2) NOTE.

 For prevention of welding strain, flange hub required for large dia Circulation Water Pipe.

4.1.3.4 Installation of expansion joint.

(1) Installation of rubber expansion joint on Circulation Water Pipe intend to follows:
a. Condenser inlet : Adjustment of installation error.
b. Circulation Water Pipe outlet : Adjustment of installation error + adjustment irregular sinking +
prevention of vibration + easy take out at valve maintenance.
c. Intermittent of pipe : Absorption of reaction force.
d. Adjustment of installation error + adjustment of irregular sinking.

100
 Turbine room

Condenser

b
M
d
a a

Circulating water pump

(NOTE) Thrust force generated surely by expansion joint installation. Thrust block for the thrust force
shall be provided to the pipe. Generally, tie-rod for expansion joint shall be arranged because the thrust
force is very large.

Thrust
force Tie rod

4.1.3.5 Condenser support system and Circulation Water Pipe planning

Rigid support and spring support are used for Condenser support as shown below. In domestic commercial
plant, rigid support used mainly,and spring support applied in most of USA & EUROPE plant. Condenser
movement shall be surely absorbed by Condenser expansion joint for spring style support.

101
 LP turbine outlet

Expansion joint

Condenser

Expansion joint

Rigid support

Rigid support type

LP turbine outlet
(No expansion joint)

Expansion joint

Spring

Spring support type

4.1.3.6 Ball circulation pipe

Arrangement and installation purpose are referred to item 4.1.1.4.5

(1) Avoid air pocket

102
 Cleaning ball float up in the water by breathing air and brings low ball collection rate. Air vent line
installed unavoidably, punching metal plate shall be provided for prevention of ball flow out.

Air pocket

(2) Equal piping route shall be arranged at ball collecter and ball injection point.

Distributer

Ball collecter Ball injection nozzle

Pipe route shall be decided as suck out and flow out the ball uniformly as possible to/from nozzles.

4.1.3.7 FeSO4 injection point

Protection skin shall be spread uniformly to Condenser tube and tube plate by completely mixing FeSO4
and Circulation Water at the space of injection point and Condenser chamber. (related item 4.1.3.1).
Following attention shall be drawn:
(1) 1 bend pipe and/or 5D or over 9m straight pipe length shall be kept after FeSO4 injection point as
mixing zone.
(2) Condenser inlet Circulation Water Pipe arrangement are different for 2 pass Condenser which related to
plant capacity.
 For large/middle capacity plant, injection boss shall be attached for each Circulation Water Pipe
because long pipe arranged to each Condenser pass and under ground pit.
 For small capacity plant:
Circulation Water Pipe are installed by single route till to the Condenser. The pipe will be installed in the pit
near the Condenser. The pipe branched at just under the Condenser inlet. There are no space in front of the
branch for injection points and enough mixing zone. Suitable number of injection boss shall be provided for
prevention of eccentric flow of FeSO4 by considering pipe arrangement between the branch point and the
Condenser inlet.
 FeSO4 injection nozzle shall be installed 2 or more as much as to the pipe arrangement and bore.

103
  FeSO4 injection pipe shall be introduced at side or top portion of Circulation Water Pipe. Under side
introduction of injection pipe brings FeSO4 drain pot and mass of it.
 Injection nozzle shall be kept at suitable strength for vibration which caused by Circulation Water flow.
4.2 Sea cooling water pipe

4.2.1 Arrangement of the system

Sea water booster pump Sea water strainer

Bearing cooling Bearing cooling Bearing cooling

Water water water

Circulation pump discharge pipe

Supply Return Supply Return Supply Return

(Stand-by)

4.2.3 (12) Refer to

M

Condenser outlet circulating water pipe

4.2.2 Purpose of the system installation

Closed cycle bearing cooling water system are provided for equipment bearing cooling. This system
arranged for cooling water by sea water. Cooling sea water brings by branching from Circulation Water Pipe
and pressure up by booster pump and feed to Cooling Water Cooler, then again lead to the Circulation Water
Pipe and discharge.

4.2.2.1 System and valve operation.

(1) Generally, Sea Water Booster Pump are provided as 50% X 2Unit. One set of Booster Pump will be
started at Turbine low load condition and 2nd pump operated under normal operation condition.

104
(2) Discharge valve opening shall be controlled for prevention of over flowing to the Circulation Water
Pipe at the Sea Water Booster Pump one set operation condition. And then, large valve opening for
2Unit operation and small valve opening for 1Unit operation are applied. (Rubber linings are applied on
valve downstream side)

(3) Unit number of Cooling Water Cooler which pass through sea water adjusted as Sea Water Booster
Pump operation number.

(4) Adhere os sea growth to pipe inner surface or wall reduced by applying flow velocity 3.5 ~ 4m/s at
downstream of Sea Water Booster Pump outlet pipe.

(5) Sea Water Booster Pump suction will be related to Circulation Water Pipe branch position, and high
level installation of the Pump brings no margin of NPSH. Adjustment of pressure loss required against
plant total designing.

4.2.3 Piping planning procedure

(1) Sea water used as cooling water for the Circulation Water Pipe. Corrosion countermeasure required on
pipe inner surface because the original pipe (carbon steel pipe) has only low corrosion property.
Usually, tarepoxy coating or polyethylene lining are applied for corrosion countermeasure.
(2) Tarepoxy coating connection can be joined by welding and touch up required for field welding joint.
This connection will be applied for large bore (650A and over) pipe because worker proceed the works
in pipe inside.
(3) This coating can not be applied to small dia pipe (up to 650A), and polyethylene lining are used.
Polyethylene lining pipe are expensive than tarepoxy coating pipe because by manufacturing limitation
of dimension and need of connection flange.
(4) Trench inside arrangement are used for the pipe for keeping pass way around IFL installed Cooling
Water Cooler. Flanged joint applied for polyethylene lining pipe. Trench width shall be decided by
considering space for flange bolt tightening works. Over ground arrangement of the pipe are applied
occasionally for full turn key plant including civil and construction works from cost saving view point.
(5) Piping arrangement shall be decided as problems for Cooling Water Cooler draw out works from both
shell and chamber side.
(6) Avoid air pocket on Circulation Water Pipe arrangement and air vent pipe shall be provided for
unavoidable air pocket.
(7) Middle bore pipe arrangement shall be decided by considering with inside cleaning of it. (Flanged joint
shall be provided around the pipe for cooler and pump).
(8) Maintenance mono-rail shall be provided for pump and stainer (Bucket-type). Another strainer type
shall be selected as the element can draw out without cutting the pipe (Cone type which directly
attached to the pipe. Y type strainer etc).
(9) Expansion joint shall be provided for adjustment of thermal expansion and installation error on pipe
and cooler connection part.
(10) Insulated bolts and nuts shall be provided for corrosion prevention of pipe and embedded pipe
connection.
(11) Short pipe shall be provided for easy valve open/close and overhaul, for the type of wafer type flange
butterfly valve. Wafer type butterfly valve shall not be applied for connection part which related to
maintenance equipment.
(12) The valve installation position shall be decided as prevention of sea water stopping under nornal
operation condition for the plant which has spare Sea Water Cooler. (Sea water stopping caused shell
growth in the Sea Water Pipe and the shell flow into the cooler at spare cooler starting, then brings
corrosion *1) *1 : Refer to item 4.1.2.5.1(4) for corrosion.
(13) Double suction vortex pump eccentric flow appeared to the pump which has horizontal bend at just
front of the pump suction as shown in figure a. Eccentric flow effect to the pump efficiency and
characteristics. Also eccentric flow brings noise and over heat of the bearings by thrust force. We
recommend vertical bend for just front pump suction as shown in figure b. Concrete planning procedure
are described in following pages.

105
 Suction bend
Suction bend

Figure a horizontal bend Figure b vertical bend

(Undesirable design : right side dense, left side thin) (Desirable design : right and left or uniform)

Pump suction piping shall be designed according to H.I.S at least which internationally recognized
regulation.
 Reducer (if required) shall be installed at just front of the pump suction. (Reducer shall be installed
downstream side of elbow because the reducer brings well regulated flow).
 Down or upper direction bend shall be provided for pump suction. Unavoidably horizontal bend used,
2D length (including reducer) shall be kept as shown in figure B.
 Long elbow shall be applied for pump inlet elbow.

Reducer

Long elbow

Reducer ) 2D and over (include reducer)

Figure A Long elbow

(Up or down side bent)
Figure B
(Horizontal bend)

106
(Additional explanations)

Another MHI standard or pump manufacture’s recommendation for pump inlet piping arrangement and
required straight pipe length are prepared instead of H.I.S regulation.
 MHI standard : Centrifugal pump applcation manual generally, 4 ~ 6D straight part required. 6 ~ 8D
straight pipe required for 90o bend type strainer down stream side.
 Pump manufacture’s recommendation
4D or more straight pipe required for horizontal bend used. About 2D straight pipe allowed for up/down
side bend used.
From the above description, following are found. 4 ~ 6D for horizontal bend. 2D for up/down side bend. 6 ~
8D (including strainer) for 90o bend type strainer down stream side. But we applied H.I.S as minimum
regulation by following reasons:
 We experienced using up side bend instead of horizontal bend by customer’s requirement of applying
H.I.S regulation. ( SAUDI ARABIA)
 There are many existing thermal power plant which not conformed required straight pipe length at
pump suction piping. (but no trouble experienced for each plant).
 Large space required around the pump when planned to meet pump manufacture’s recommendation.
Almost of the same arrangement allowed for new plant as existing plant by only considering H.I.S
regulation.
 From above described view point of regulation and experience, only internationally recognized H.I.S
regulation applied for our designing.

(14) Refer to item 8.1.3(5) for planning of butterfly valve arrangement.

107
5. Planning Procedure of Boiler General Piping

As expressed in the beginning , planning of piping shall be done by well considering of procedure of system
installation, operation procedure, etc. in this book, piping planning procedure of each system is conform in
items written below:

 Construction of system.
 Purpose of system installation.
 Piping planning procedure.

This system mainly described for Commercial Conventional Plants, and also useable for Industrial
Conventional Plants and Combined Cycle Plants, but more suitable piping shall be proceed by co-operation
with plant engineering and component design section, because many cases exist for plant design condition.

5.1 Auxiliary Steam Line

5.1.1 Composition of line ( Outline systematic )

See next page.

108
LP Steam Extraction
Pipe LP4, Deaerator

installed for Oil Firing

Converter is mainly
Note 1 : Steam
Heating

SAH

Plant

L-11 Desulfurization System Trace

Cold Reheat Steam Pipe

H-8 BFPT Drive

L-10 Desulfurization System Seal Air
H-7 AH Cleaning Heater Trace
L – 9 EP
Low Pressure ( about 8 k ) Auxiliary Steam Main Pipe

H-6 GGH Heating and Soot Blower

High Pressure (about 15 k) Auxiliary Steam Main Pipe

H-5 CW Desalination
L – 8 Ash Handling System
H-4 FW Heater seal
H-3 Deaerator Heater L – 7 NH3 Generator
H-2 BFPT Grand Seal
L – 6 Heating
Other Units

109
H-1 Turbine Grand Seal
L – 5 Mineralizer
Converter

L – 4 Auxiliary Boiler Heating

Steam

Note 1
L – 3 Heavy Oil Heater
House Boiler

Spray
L – 2 Trace for Heavy Oil Line
L – 1 Heavy Oil Tank
DSH
Atomizing
Burner Atomazize
Steam DSH
SH Intermediate Stage

Spray

Boiler, AH Soot
Blower
Auxiliary Steam Line (Outline)

Mitsubishi Heavy Industries

110
5.1.2 Purpose of Line

(1) As shown in outline systematic in previous page, source of auxiliary steam is classified to
 House Boiler
 Other Units
 SH intermediate stage (Note 1)
 Cold reheat steam pipe
 LP extraction pipe (LP4, Deaerator heating extraction pipe)
Above steam sources are switched by plant condition, stopped, start-up, on-load (NOTE 1). SH intermediate
stage generally points the SH header inlet, or connecting pipe inlet.

(2) Auxiliary steam is served to lines shown in previous page, and pressure and temperature are reduced to
correspond the requested steam condition.

5.1.2.1 Operation Condition and Planning Purpose of Auxiliary Steam Source

5.1.2.1.1House Boiler
One – through boiler needs auxiliary steam to keep the water quality before main boiler start up to
establish condenser vacuum and deaerator heating, and to establish the vacuum, steam for grand
seal is required.
So, if auxiliary steam can not served from other units, house boiler is required to ensure the
auxiliary steam source.
On the other hand, drum boiler is operated by process of boiler start-up – vacuum up – load up,
auxiliary steam from house boiler is not required for boiler start-up.
However in many drum boiler plants, auxiliary steam is required for fuel line heating, air
conditioning etc., and house boiler is prepared.

5.1.2.1.2SH intermediate stage

Step of supplying auxiliary steam is, before ignition, auxiliary steam can not be supplied from
boiler itself, it is supplied from other units or house boiler.
After ignition, when boiler extraction pressure exceeds the supplying pressure (15kg/cm 2), and
become stabilized (30~80 kg/ cm 2), steam are supplied from SH intermediate stages (stages differs
by supplying condition), and operation hours of house boiler is shorted.
When plant load becomes higher, and auxiliary steam from cold reheat pipe becomes able to
supply stabilized, in many cases the electric motor operated valve of extraction point is closed.
( In some plant the electric motor operated valve remains open for backup, and in this case the
capacity of auxiliary steam safety valve increases).

5.1.2.1.3Cold reheat steam pipe

Boiler is started up by house boiler or other unit, and after the boiler pressure has reached 30kg/
cm2, it is switched to SH intermediate stage, and when supply condition is achieved , steam from
house boiler/other unit is stopped. After boiler load has exceeded 50%, steam from cold reheat pipe
is supplied. (steam from SH intermediate stage is stopped).

5.1.2.1.4LP extraction pipe (LP4, Deaerator Heating Extraction Pipe)

LP extraction, (LP4, Deaerator Heating Extraction Pipe), is heating source for SAH, to keep the
plant efficiency, steam from LP extraction should be supplied as much as possible.
Namely, extraction steam pressure rises with load, when the satisfied steam condition of SAH side
is achieved, auxiliary steam from other equipment is switched to extraction steam, first, steam from
deaerator is served, and the rise of LP4 extraction steam is waited, and it is switched to LP4
extraction steam.
(Auxiliary steam source extraction point shall be chosen by totally consideration of operation,
economy etc. extraction may not be as written in this book).

112
 5.1.3 Piping planning procedure
FX


Soot Blower Steam
SH Intermediate Stage 


(Note)
Boiler Room
3 or 4 FL

15 k Auxiliary Steam Header

Other
Units

(Note ) Auxiliary Steam Header is
installed in turbine room in
Cold reheat steam pipe some plant.
LP4
Deaerator Heating
Extraction
Extraction

DSH
(Note)
Turbine room
Boiler Room
2 FL
3FL
Spray
 8 k Auxiliary Steam

Steam Converter

1 FL
House Boiler
1 FL
SAH 1 FL

(1) Above shows the relationship of installed floor level of equipment.

(2) Auxiliary steam is switched in order shown as  ~ , drain dispenser shall be installed as also
consideration about certainly dispensable pipe arrangemnt, to dispense the drain appeared by switching
the lines. (prevention of drain hammer)

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5.1.3.1 SH Intermediate Stage

Boiler Housing

Target Plate

(1) When the line is not in operation, drain will collect both side of pressure reducing valve, erosion of
pressure reducing valve and drain hammer are afraid. So, as shown above, pressure reducing valve and
both side valves shall be installed at highest level, so that drain flush to up and down stream.

(2) As stream from SH intermediate stage is high temperature/pressure, costly materials are used, line shall
be short as possible.

(3) Target plates is installed to prevent erosion of pressure reducing valve in some cases. In this case
pressure reducing valve down stream valve must be installed on branched line to avoid erosion of the
valve. (In case of causes over 30kg/cm2 difference pressure, target plate is installed).

(4) Under the safety valve attachment, to catch the reaction of safety valve blowout, fixed up and down
direction support must be installed.

5.1.3.2 Cold Reheat Auxiliary Steam

From SH intermediate stage

Cold reheat steam

(1) Pressure reducing valve and related equipment shall be installed at highest position to flash the drain to
up and down stream. To avoid drain down stream of check valve, line shall be downspout just behind
the check valve, and the pipe between check valve and junction of auxiliary steam line from SH
intermediate stage, shall be as short as possible.

5.1.3.3 Other Auxiliary Steam Line

(1) Line shall be designed to flush the drain certainly, and drain flushout shall be installed.

(2) To prevent vibration, point around control valve shall be fixed.

114
5.2 ECO Recirculation Pipe

5.2.1 Constitution of Syatem

ECO Inlet Header

Water Wall Lower Header

M M

HP Feed Water Pipe

5.2.2 Purpose of system installation

When the boiler is stopped (Hot Banking), without feed water, water remained in economizer is heated by
remain heat of boiler, and vapourization occurs at economizer outlet. To prevent this, water from wall lower
header is circulated to economizer with this line.

5.2.3 Piping planning Procedure

(1) In this line, water circulation occurs by deference of stored water density. So, piping shall be considered
to minimize pressure loss and elbow minimized simplified.

(2) In this line, air accumulation is not allowed.

(3) Economizer and unction point of feed water pipe shall be as short as possible. ( To refuse Bi – metal
phenomenon).

115
 5.3 SH Spray Pipe

5.3.1 Construction of System

a. Super Critical Pressure Plant
1st SH 2nd SH 3rd SH 4th SH
Inlet Header Inlet Header Inlet Header Inlet Header

DSH DSH DSH

Steam Seperator 1st SH 2nd SH 3rd SH

Outlet Header Outlet Header Outlet Header Outlet Header

Fx

Blow Back Pipe Blow Back Pipe

Fx (To Blow Tank) (To Blow Tank)
Steam Separator
Drain Tank

Fx

~ HP Feed Water Pipe

Steam Separator Drain Tank Spray Pipe

b. Sub Critical Pressure Plant

1st SH 2nd SH 3rd SH
Inlet Header DSH Inlet Header Inlet Header

1st SH 2nd SH 3rd SH

Outlet Header Outlet Header Outlet Header

Fx
Blow back Pipe
(To Blow Tank)

HP Feed Water Pipe 116

5.3.2 Purpose of System Installation

SH outlet steam temperature varies by boiler load, to keep the stipulated temperature, control is required.
When steam steam temperature is too high, the strength of the SH pipe will be reduced, and worthiest case,
it will be broken. So, to control the steam temperature, water is sprayed to desuperheater (DSH), in middle
of SH.

5.3.2.1 Operation of System valve

(1) Reducing temperature water for steam temperature control is supplied either from,
 BFP outlet pipe.
 HP heater outlet feedwater pipe.
 Economizer outlet.

is,compared with ,, SH spray line effective difference pressure (SH spray supply pressure – SH
pressure) can keep high, even plant load is low, but plant efficiency decreases, because of regenerative cycle
efficiency decreases.
So, in case of , can not be selected (Specially difference pressure shortage),  is selected. (However,
by using movable orifice on , pressure deference can be secure).
(2) Proper steam temperature control is achieved by proper rate balance of feedwater and fuel, by
measuring the each side SH outlet steam temperature, if temperature deflection exist compared with set
point, each spray volume is controlled. By the way, on regular operation, volume of splay is kept 4% of
main steam inflow to get better plant control, and load change is followed by splay volume varying.
With this control, feedwater – fuel rate becomes further more correct, and finally splay volume is
control to restore to set point.
(3) As feed forward signal of steam temperature,temperature of DSH inlet is used for control.

5.3.3 Piping Planning Procedure

(1) To prevent splay water nozzle choke, blowback is done from DSP side.Therefore, pipe material from
DSP to check valve shall be selected by condition of steam side.
(2) To do blowback written above, not to remain debris down stream of check valve, browback piping
layout shall be as shown below:
DSH

Splay Pipe

This horizontally piping shall be as short as possible

( Not to remain debris)

Blowback Pipe
( To Blow Tank )

(3) Piping shall be up incline to DSP, air accumulation shall not exist.
(4) As this line is operated under high pressure, coastlines thick founded steal pipe is used. So, line shall be
connected as short as possible, bended pipes shall be used, instead of elbows.
(5) Junction point from HP feed water pipe shall be as written in section 3.12.3 (15).

117
5.4 RH Splay Line

5.4.1 Constitution of System RH DSH

(Note 3)

Fx

M M M

( (Note 3)

Blow Back Line (Note 2)

(To Blow Tank)

Note Note Note Note 1 : Extracted from intermediate stage of BFP ( In

Case of subcritical, extraction from outlet
BFP exists)
Note 2 : For prevention of splay nozzle choke, steam
M-BFP T-BFP T-BFP is blowbaced and dust is rejected.
Note 3 : Installed for leak-check of valve. (In ASME-
TDP, installation is provided).
5.4.2 Purpose of System Installation

(1) Lines for turbine, SH,RH, and all system connected to those are designed by it’s operating pressure and
temperature, over temperature and pressure will cause strength weakness, and will cause bursting of
pipe and worthiest case, accident of turbine destruction will happen. The other hand, when main steam
and reheat temperature decrease, plant efficiency will decrease. So to control the steam temperature,
water will be sprayed to DSH in middle of RH ( In some case, in installed on cold reheat steam pipe).
(2) Types of RH steam temperature control are shown below, on rapid load rise of plant, fuel will relativity
exceed follow-up control by damper operation will be delayed, it temporary breakaway from the design
point, RH is overheated. To follow this phenomenon, temperature control with splay will be done.
[ Types of RH steam control ]
 GRF dumper
 Back-path dumper (parallel gas dumper) for daily use
 Burner tilt
 RH spray For emergency
Up to recently, some plant don’t have , or ,.

118
 5.4.2.1 Operation of System Valve

(1) Supplying over-pressured spray water to RH spray will cause elution and control distribution of spray
control valve.
In supercritical plants, spray water is supplied from intermediate stage of feed water pump, because
outlet pressure is too high. In supercritical plants, there exists two cases to supply splay water from feed
water pump, from intermediate stage and from outlet of feed water pump.
This comes from that RH pressure of supercritical and subcritical plants don’t have so much difference.
(2) Check valve of pump outlet is installed for every lines, to prevent back flow to low head and stopped
pumps.
(3) To prevent turbine water injection caused by leak of RH spray water, spray shut valve is installed, and
when spray control valve is closed, this shut valve is also closed, and also, to prevent steam back flow
to RH, check valve is installed.

5.4.3 Piping Planning Procedure

(1) Piping shall have rising gradient without any unevenness.

(2) To prevent vibration, around junction point from feedwater line, and shut-off valve should be fixed
supported from floor.
(3) Normally, shut-off valve, control valve are closed, the temperature of water closed between both valve
decreases. The line between the two valves becomes vacuumed, because the volume of closed water
decreases. If splay start in this condition, spray water will flow into vacuumed line at once, and strong
water-hammer will exist.
Therefore, thw two valves should be installed as near as possible to decrease the water volume closed
between the two valves. ( see figure below ).
(4) Line shall be risen up to DSH after the spray valve set.
Control Shut off
Valve Valve

As short as possible
Top Housing
Top Housing

Control Shut off

Valve Valve
DSH

Boiler

Fixed Blow-back pipe

(To blow tank)

Blow-back pipe
(To blow tank)

(good case) (bad case)

(5) Heat stress calculation shall be done under consideration of DSH side mother-pipe thermal transfer,
support point of spray pipe insode the boiler housing, and way of housing trunk ( in case DSH is installed in
Boiler housing), etc.

119
 Steam Drum
5.5 Boiler Continuously Blow Pipe

Note 1
Blow Tank
Up to 10D
Outline
Up to 3D

Note 1 : This reducer shall direct

Connect with 2nd valve.
5.5.2 Purpose of System Installation
In circulation boiler, it is installed for continuously blow out, not to exceed the limit of density of the
enriched silica inside the pressurized drum.

5.5.2.1 Operation of Lines and Valves

Blowing large quantity of drum water causes hindrance of drum water circulation, and steam pressure and
vapourize volume will vary, continuously drum water blow out is pre-designed. Min/Max flow rate 2 nd valve
shall be checked beforehand, negotiation shall be done with the valve supplying vendor, so that the valve
has the performance of nearly 100% opening rate at max flow rate, and about 5 to 10% opening rate at min.
flow rate. ( In case of capacity of valve is huge, operation will be under bit-opening, erosion will exist
around the blow valve).

5.5.3 Piping Planning Procedure

(1) This line is for blowing out high pressured drum water, and down stream of 2 nd valve, flush will occur
and fluid will be acclerated.
So, piping planning for down stream of 2nd valve shall be considered about prevention of erosion
caused by high velocity fluid, as written below:
 2nd valve shall be installed as near as possible from blow tank.
 Even if the 2nd valve is under 50A, short pipe shall not be installed between the reducer. And this
reducer shall be a special one which has some gradient with the valve of 7 o one side. ( To prevent
erosion to the pipe wall just behind the valve).
 Behind the reducer, straight pipe shall be connected ( outline is shown in fig 5.5.1), and target plate
shall be installed. On the other hand, large diameter bended pipe (4 ~ 5 di) and direct connect to blow
tank method is also used, instead of target plate. To use bended pipes, consideration such as gain
thickness of pipe shall be done.
 Piping material shall be Cr-Mo or stainless steel, which is superior against erosion.
(Supplement)
It is confirmed by test that if the straight pipe length is more than 900 times of the one side crevice of
valve sheet (‘a” of below figure), problem will not occur.

disk

a
seat

7o

(2) Vibration prevention shall be installed to apprpriate point..

120
5.6 Drain/Air Vent Pipe around Boiler

5.6.1 Constitution of System

(1) Drain pipe and air vent pipe around boiler, depends on boiler type whether it is needed or not, so it can
not explain the hole line of boiler in one diagram.
(2) For forced circulation boiler, because it differs by types (SH,RH) types, it can not explain the hole line
in one diagram. So, in this section instead of showing diagrams, most popular names of lines are
written. (SH and RH are assumed as pendant type).
(3) Lines explained in this section shall be considered for every plant seperately.

1. Boiler water filling pipe.

2. ECO inlet pipe drain pipe.
3. ECO outlet pipe air vent pipe.
4. Saturated steam pipe air vent pipe.
5. Steam drum air vent pipe.
6. Steam drum continuous blow pipe.
7. Steam drum level control and silica drain pipe.
8. Roof SH inlet header drain pipe.
9. Panel SH outlet pipe air vent pipe. ( Secondary SH outlet )
10. Platen SH inlet pipe air vent pipe. ( Primary SH inlet )
11. Platen SH outlet pipe air vent pipe. ( Primary SH outlet )
12. Final SH outlet header drain pipe. ( Tretiary SH outlet )
13. Main steam pipe air vent pipe.
14. Main steam pipe drain pipe. ( turbine inlet )
15. Cold reheat steam pipe drain pipe. ( to condenser )
16. Cold reheat steam pipe drain pipe. ( to blow out tank )
17. Primary RH outlet pipe air vent pipe ( Primary RH outlet )
18. Final RH outlet header drain pipe. ( Secondary RH output )
19. Hot reheat steam pipe air vent pipe.
20. Hot reheat steam pipe drain pipe. ( to condenser )
21. Hot reheat steam pipe drain pipe. ( to blow out tank )

5.6.2 Purpose of System Installation

(1) The aforesaid lines ( 1 ~ 21 ) are used for plant operation, the purpose of every line installation is
many-sided, so purpose of installation is put in order as listed below :

( O : operated , X : not operated)

No.
WarmStart (with filling water)

Boiler stop ( Normal + Forced

Cold Start (with filling water)

Lay up ( full N2 filled )

Boiler stop (banking)

Repair and checking

Chemical cleaning

Safety valve test

Hydraulic test
Cooling )

1. Boiler water filling valve O X X X X X O X X

2. ECO inlet water pipe drain valve X X X X X X O O X
3. ECO outlet pipe air vent valve O.2 X X X O.1 O O*4 O X
4. Steam drum outlet saturation steam O X O X O*1 O O*5 O X
pipe air vent valve

121
 5. Steam drum air vent valve O X X X O*1 O O O X
6. Steam drum continuous blow valve O O X X X X O O X
7. Steam drum water level control and O O X X X X O O O
silica blow valve
8. Roof SH (steam cooled wall) inlet O O O X X X X O X
header drain valve
9. Panel SH outlet pipe air vent valve ( 2nd X X X X O*1 O O O X
SH outlets )
10. Platen SH inlet pipe air vent valve. ( 1st X X X X O*1 O O O X
SH inlet )
11. Platen SH outlet pipe air vent valve. X X X X X O O O X
( 1st SH outlet )

12. Final SH outlet header drain valve. ( 3rd O O X X X O* X O O

2
SH outlets )
13. Main steam pipe air vent valve. X X X X X O O O X

14. Main steam pipe drain valve. ( turbine O O X X X X O O O

inlet )
15. Cold reheat steam pipe drain valve. ( to O*3 O*3 X X X X X O X
condenser )
16. Cold reheat steam pipe drain valve. ( to X X X X X X X O O
blow tank )
17 Primary RH outlet pipe air vent valve X X X X O O X O O
( 1st RH outlet )
18 Final RH outlet header drain valve. X X X X X X X O O
( 2nd SH output )
19 Hot reheat steam pipe air vent valve. X X X X O O X X X

20 Hot reheat steam pipe drain valve. ( to O O O O X X X X X

condenser )
21 Hot reheat steam pipe drain valve. ( to X X X X X X X X O
blow tank )

*1 In case of air vent valves are installed both side of drum as drum air vent during hydraulic test.
*2 Opened only by water filling
*3 Opened only after condenser vacuum is established
*4 Opened only by water filling, water extraction, N2 extraction
*5 Opened only by water filling, water extraction.

5.6.2.1 Operation of line valve

The lines described in this section, includes lines which are used under warm condition, as also under cold
condition.
 Cold condition

 Hydraulic test (Water filling, water extraction, air vent)

 Full lay up, N2 injected (Water filling, water extraction, air vent)
 Chemical cleaning (Water filling, water extraction)
 Boiler repair, checking (water extraction, air vent)

 Warm condition
 Cold start
 Warm condition start
 Normal operation

122
  Boiler stop ( Normal stop,emergency stop, forced cooling, Hot banking )
So, piping planning shall be done by considering the strictest condition of operation written above. (Refer
section 5.6.3.2 –(12),(18) )
And normally, manual operation valve is selected for only cold condition written above operated valve, and
electric motor operated valve is selected for also warm condition operated valve.

(1) Boiler water filling pipe.

This line is used for water filling before BCP starting, when water is filled before cold condition start, it is
not used during usual operation. (5.8 clause references)
(2) ECO inlet water pipe drain pipe.
It is used as the water extraction during repair and blow out during chemical cleaning, it is not used during
usual operation.
(3) ECO outlet pipe air vent pipe.
It is used for the air ventilation during hydraulic test, air ventilation during full lay up and N2 filling, and
also used for air ventilation during repair and chemical washing, and it is not used during usual operation.
(4)

123