STEAM TURBINE 500 MW ERECTION

SPECIFICATIONS FOR ERECTION OF PIPING

ERECTION OF PIPING
NOTE: These guidelines are intended to provide advice to lay and support pipings at site, especially non-prefabricated pipes < Nb 50. GENERAL These guidelines apply to turbine and generator piping forming part of the BHEL scope of supply and delivered to the site in the form of prefabricated pipe sections and straight lengths of piping. Generally Applicable Specifications Prefabricated lines > Nb 50 In case of deviation the site erection engineer to decide in alternate routing. LAYING OF PIPES WITH ROUTING SPECIFIED IN PIPING PLAN. Lay the lines as specified in the piping plans. Support them at the defined points. Cold bending method and special pipe-bending equipment should be used for bending of pipes. Care should be taken to ensure that the deformation is well within the tolerance limits. ACCOMMODATION OF MOVEMENT AND EXPANSION. Care is to be taken to ensure the movements at pipe terminals and thermal expansion of the pipes themselves are

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SPECIFICATIONS FOR ERECTION OF PIPING

accommodated by adequately long legs and expansion loops. For lines connected to emergency stop valves (main steam valve, stop valve, bypass valve ) allowance of 20 mm in all directions shall be made. Determine with the aid of the diagram (Fig. 1 & 2 ) the pipe legs required to accommodate terminal movement and thermal expansion. Ensure the valid coordinate system of that power plant (Fig 13) is adhered. If it is not possible to obtain values for movement of the terminal point taken from Fig 14, add a 50% safety margin to the thermal expansion calculated for the connecting pipe Figs 3 & 4. ASCENDING AND DESCENDING GRADIENTS Install all lines with the ascending or descending gradients appropriate to their function. Lay supply lines with a constant ascending or descending gradient at least 5 mm/m - with at the very least a 5O slope (-90 mm/m). Lay drain and vent lines with a descending gradient of a least 20 mm/m. PIPE SUPPORTS Pipe supports should not restrict pipe movements. Where spring-

loaded supports are used, the additional load or load relief exerted by spring force on the pipeline at maximum deflection from its unloaded position should not exceed 25% of the supported pipe weight. (Fig. 6). The Table (Fig. 5) gives reference values for pipe supports. Bharat Heavy Electricals Limited Rev 00, 7-98 T1-08-1010G Page No. 2 of 10

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SPECIFICATIONS FOR ERECTION OF PIPING

When fabricated pipe supports and guides, only flat steel pipe clamps and aluminum clamps serve as the pipe bearing surface. The use of round -steel shackles should be avoided in all cases. ATTENTION: Suspension supports are to be preferred to support from beneath. Friction points should be avoided.

WELD PREPARATIONS AND WELDING OF PREFABRICATED AND NON-PREFABRICATED PIPES.

WELD PREPARATIONS Ensure proper edge preparation as per drgs. Remove scale, rust, paint etc. from weld joints. WELDING Complete welding as per WPS/drgs. Nitrogen purging to be done wherever required. Complete N.D.T.

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SPECIAL SYSTEM REQUIREMENTS Lubricating Oil System Match up, weld and examine the prefabricated connecting pieces of the discharge and suction nozzles prior to the final erection of the first bearing pedestal. Other matching and welding work to be done when the bearing pedestal is full assembled. The direction of flow of the oil temperature control valve should be ensured as indicated by markings on the valve itself. Jacking Oil Lines Where possible, lay jacking oil lines so as to be protected by other lines of larger nominal diameters against being used as an aid to climbing. Once the line has been welded to the bearing pedestal, fit a protection plate to protect the line in this area. Oil Vapor extraction lines Ensure that oil vapor extraction lines are laid with a gradient descending constancy towards the main oil tank without blowers return drains to the oil tank. Fire Prevention To avoid fire hazards, do not route oil lines near lines or components at high temperature. low points. A drain loop at the lower end of this line upstream from the

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If the laying of oil lines in these areas cannot be avoided, ensure that no detachable connections or valves are erected directly above high-temperature lines or components. Control Fluid System Single Fluid Lines Signal fluid lines comprise all those lines in which some kind of signal or pulse is transmitted from one point to another (in other words, almost all fluid lines which do not lead directly from pump via filter to component). These includes : primary oil lines, secondary auxiliary secondary and bypass signal fluidlines, trip, auxiliary trip, test and return fluid lines, by[pass startup fluid lines, and water filled (condensatefilled) impulse lines. They do not include : turbine start-up and auxiliary start-up oil lines, pilot fluid line (between pressure transducer and pilot valve on Nb200 and Nb250 bypass stop valves with LP hydraulic system). To ensure correct prevent functioning of signal fluid lines, lay them A

with an adequate ascending or descending gradient to air pockets from forming and accumulating. number of different routing strategies are available for this purpose (the control medium flows from the control equipment) Fig. 7.

Version 1.

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SPECIFICATIONS FOR ERECTION OF PIPING

If a line is installed from the control equipment to the load with an ascending gradient (ascending in the direction of flow) there must be a minimum gradient of 67 mm Fig. 7. Version 2. If a line is installed from the control equipment to the load with a descending mm/m Fig. 7. If it is not possible to install the line as shown in Version 1&2, two other strategies may be adopted (Fig.8) Version 3. If local conditions make it necessary to install the line with one or more high points, each high point must be provided with permanent venting facilities (orifices with a diameter of 1.5mm). Fig.8. Version 4. If local conditions make it impossible to observe the 10OC minimum gradient in installing a line as shown in Version-2, then reduce the gradient required from 175 mm/m to 67 mm/m by introducing an external supply to reverse the direction of flow Fig.8. Installation of Damping Devices gradient (ascending gradient counter to the direction of flow) there must be a minimum gradient of 175

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SPECIFICATIONS FOR ERECTION OF PIPING

The as-installed configuration of each damping device is indicated in symbolic form on the system flow chart. As the flow is generally directed via the installed orifice plate, i.e. pressing the ball downward against the valve seat, care must be taken to interpret the symbol correctly. If the system flow chart indicates that the damping device should be installed as shown in Fig.9 the flow passes via the orifice plate (slow flow) if the damping device is to be installed the other way around the ball is lifted away from the seat and thus permits a rapid through - flow.

SEAL STEAM SYSTEM

Seal Steam Lines, valve Stem Steam Leak-Off Lines and Seal Ring Steam Leak-Off Lines. In laying these lines, provide sufficient compensation for thermal expansion. The service temperature for all lines can be assumed to be approximately 450OC. state. ATTENTION : Always include a safety margin. Leak-Off and Seal Steam Extraction Lines in the Steam Seal Casings. Insert leak-off and seal steam lines, though the pipe penetrations in the LP end walls before mounting the LP bearing pedestals. Connect the lines up when the LP steam seal casings have been fully assembled. Ensure that the lines are concentric within the penetrations to accommodate the insulation to be installed subsequently. These pipes expand by approximately 6 mm/m between the cold state (initial temperature 20 OC) and the hot

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Pressure Sensing Line Terminals for the Seal Steam Control system Erect the pulse lines to the pressure transducers in a manner which will prevent the generation of fluctuating pressure pulses. Refer Fig.12. Lay the header, with an ascending gradient from the terminal point to the pressure transducers, making sure that the pipe leg below the transducers has a gradient of 30OC. From this pipe leg, in which two Nb 25 nozzles are welded, erect two lines 500 mm long, to the pressure gauge cutoff valves of the pressure transducers. NOTE: The header should not be insulated over the last 2-3m so as to ensure that all condensation takes place below the final connection to the transducers. Fig.12.

DRAIN SYSTEM
Drain Lines All drain lines shall have as steep a gradient as possible, an all cases at least 20 mm/m. In erecting these lines, provide sufficient compensation for thermal expansion. The service temperature in plant can be assumed to be approximately 450OC. These pipes expand by approximately 6mm/m between the cold state (initial temperature 20 OC) and the hot state. Determine from the diagram (Fig.2) the minimum legs required to accommodate movement. ATTENTION : Always include a safety margin.

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On drain lines made from thick-wall piping, ensure straight pipe sections at least 500 mm long between the drain sockets (on casings and pipes) and the first bend in the pipe.

PRESSURE SENSING LINES, GENERAL

In laying these lines, observe the following: Lines under pressure must be laid with a constant descending gradient. Lines under vacuum must be laid with a constant ascending gradient. The above lines must have an adequate gradient - at least 1:15 (67 mm/m) between their connection point and the transducer rack. Lay pressure sensing lines such that the primary cutoff valve forms an anchor point, which entails laying the line between the connection point and the primary cutoff (anchor point) with the sufficient flexibility to accommodate movement of the connection point. A compensating leg extending 1 meter in each of two planes should be provided in the lubricating oil, control fluid and drains system on account of the minimal terminal movement there. (Refer Fig. 10 & 11). Locking Devices for Threaded Connections. All Fasteners should be locked using tab washers or a suitable thread lock adhesive.

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DESCRIPTION OF THE COORDINATE SYSTEM

When isometric are drawn of piping, an indication of the three orthogonal axes X, Y and Z as in Fig.3 is required. Projections of these axes in the corresponding drgs. shall be as under : X axis Y axis Z axis = view toward generator = view upward generator = view to the right

This axis designation shall be positive where no prefix is used. A minus sign prefix shall be used to indicate the opposite direction.

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