Extraction Steam System Design Description

DAWG./REF. NO.
60-F5691C J3401 11 ENGINEERING STAGE

REV.NO. A
PROJECT NAME LANCO ANPARA C 2600MW THERMAL POWER PROJECT
Extraction Steam System Design Description
NORTHWEST ELECTRIC POWER DESIGN INSTITUTE

04/2008 XIAN
PROJECT
LANCO ANPARA C 2 x 600 MW THERMAL POWER

PROJECT
ANPARA, SONEBHADRA DISTRICT, UTTAR PRADESH, INDIA
OWNER
LANCO ANPARA POWER PRIVATE LIMITED
HARYANA - INDIA
PRINCIPAL CONTRACTOR
LANCO INFRATECH LIMITED
GURGAON - INDIA
Document No. : 60F5691C J3401 11 Rev : A
Document Title :
EXTRACTION STEAM SYSTEM DESIGN DESCRIPTION
Date Revision Prepared by Reviewed by Released by
04/2008 A
BTG Supplier Originator

Dongfang Electric Corporation NWEPDI
Project : LANCO ANPARA C 2600MW THERMAL POWER PROJECT
ANPARA, SONEBHDRA, UTTAR PRADESH - INDIA
Document Title : EXTRACTION STEAM SYSTEM DESIGN DESCRIPTION
Document Number : 60-F5691C-J3401-11 Rev : A
TABLE OF CONTENTS
1.0 SYSTEM FUNCTION & SCOPE OF SYSTEM DESION
2.0 SYSTEM DESIGN CRITERIA
3.0 SYSTEM DESIGN DISCRIPTION
4.0 SYSTEM OPERATION INTERLOCKING & PROTECTION

1.0 SYSTEM FUNCTION & SCOPE OF SYSTEM DESION
1.1 System Function
The turbine has eight (8) stages of non-regulating extraction steam. The
No.1,2&3 extraction steam supply steam to three (3) HP heaters
respectively. The No.4 extraction steam stage supply steam to auxiliary
steam header and deaerator. The No. 5, 6,7&8 extraction steam supply
steam to four (4) LP heaters respectively. The system functions are:
a To heat feed water, and increase plant thermal efficiency accordingly
b To minimize thermal shock to steam generator metals by reducing the

differential in feedwater and boiler tube metal temperature;
c To remove entrained oxygen and other non-condensible gases from

feedwater by heating the feedwater in the deaerator;
d To supply steam to auxiliary steam system..
1.2 Scope of System Design
1.2.1 The No.1 Stage extraction steam includes the extraction steam piping
from No.1 stage extraction steam outlet of HP turbine to No.1 HP heater,
and the fittings on the piping and the drain system of various points.
1.2.2 The No.2 stage extraction steam includes the extraction steam piping
from CR piping to No.2 HP heater, and the fittings on the piping and the
drain system of various points..
from the No.3 stage extraction steam outlet of IP turbine to No.3 HP
heater and the fittings on the piping and the drain system of the various
points.
1.2.4 The No.4 stage extraction steam includes the main extraction steam from
No.4 stage extraction steam outlet of IP turbine and the three (3)
branches, connecting to the deaerator, the boiler feed pump turbines and
the auxiliary steam header respectively; also includes the fittings of the
system and the drain systems of the various points.
File No. BTG Supplier Sheet No.
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60-F5691C- J3401-11 Dongfang Electric Corporation NWEPDI 1
from the No.5 stage extraction steam outlet of LP turbine passing
through the condenser to the No.5 LP heater, and the fittings on the
piping and the drain systems of the various points.
from the No.6 stage extraction steam outlet of LP turbine passing
through the condenser to the No.6 LP heater, and the fittings on the
piping and the drain systems of the various points.
1.2.7 The No.7 & No.8 stage extraction steam includes the extraction steam
piping from the extraction steam outlets of LP turbine to the LP heaters
No.7A(B)& No.8A(B) inside the condenser which are the responsibility
of the manufacturer.
1.2.8 The No.4 stage extraction steam to the boiler feed water steam driven
turbine during normal operation. During low load operation, the turbines
shall be fed through CR steam line. The auxiliary steam provides steam
for the boiler feed pump turbine drives testing. The exhaust of the boiler
feed water steam driven turbines shall be connected to the main
condense.
2.0 SYSTEM DESIGN CRITERIA
The system is designed in accordance with the requirements of the

bidding document and the design criteria of ASME.
2.1 Design Parameters
The design parameters are defined according to the requirement of the

bidding document and the regulation of ASME.
2.1.1 Design Pressure
The design pressure shall be 1.1 times the extraction steam pressure from
the heat balance diagram under VWO condition.
2.2 Range of Flow Velocity
The recommended velocity in the piping shall be as follows.

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for saturated steam 30m/s
for superheated steam 60m/s
2.3 Calculated Pressure Drop
The pressure drop of various stages extraction steam piping are

calculated according to the VWO condition and are controlled in the
range of 3~5% of the extraction point steam pressure.
2.4 Piping Material Selection Criteria
According to the bidding document, power cycle piping system material

generally shall be carbon steel for design temperature up to 410 and
alloy steel for design temperature above 410.
The design temp of No.1 stage a No.3 stage extraction steam piping is
415.4 & 484.9 respectively, they shall adopt the low alloy steel
12Cr1MoVG.
For extraction steam piping with design temperature lower than 400,
#20 and Q235A carbon steel will be selected
3.0 SYSTEM DESIGN DESCRIPTION
3.1 The System Main Equipment & Its Arrangement
All the three (3) horizontal HP heaters are arranged on the 13.7m
operation floor of the deaerator bay.
The deaerator is located on the 24m floor of the deaerator bay. The No.5
LP heater is located on the 12.6m operation floor. No.6 LP heater is
arranged on the 6.3m mezzanine floor in the deaerator bay.
The No.7 A(B) &No.8 A(B) LP heaters are of compound heater sharing
one shell and arranged horizontally in the neck of the condensers.
3.2 Extraction steam Piping

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3.2.1 No.l, No. 2&No.3 Extraction Steam Piping
In the No.1 & No.3 extraction steam piping a pneumatic check valve & a
motor operated isolating valve are installed nearby the turbine.
The pneumatic check valve are located upstream the isolating valve. The
pneumatic check valve are acting as the over speed protection of the
turbine and also as the first step to protect the turbine against water
induction., The isolating valves are acting as the second step to protect
the turbine against water induction.
In the No.2 extraction steam piping nearby the CR steam piping

connection, the pneumatic check and isolating valve are installed.
3.2.2 No.4 Extraction steam piping
The No.4 extraction steam piping supply steam to the deaerator the
boiler feed pump turbines ,and the auxiliary steam header respectively, In
the No.4 extraction steam manifold nearby the turbine extraction steam
outlet two (2) series connected pneumatic check valves and a
motor-operated isolating valve are provided. The reason for installing
two (2) pneumatic check valves is that there are several equipments
connecting to the No.4 extraction steam piping, and these equipment are
connected with auxiliary steam supply also, during unit startup, low load
operation, load tripping or unit shut-down, the other steam supply may
rush into the No.4 extraction steam piping and inducing the risk of
turbine overspeed.
The two series connected pneumatic check valve will provide double
protection.
In the No.4 extraction steam piping to the deaerator a motor operated

isolating valve and a check valve are installed.
3.2.3 No.5, 6 & 7, 8 Extraction Steam Piping
The No.5, 6 extraction steam outlets are located inside the condenser
shell, so the No.5, 6 extraction steam piping pass out through the
condenser shell, and pneumatic check valve,and the motor operated
isolating valve, are arranged closed to condenser.
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The No.7A(B), 8 A(B) LP heater are arranged in the condenser neck. All
the No .7 & 8 extraction steam piping are designed & supplied by the
Turbine Manufacturer.
3.3 Turbine Overspeed Protection
The turbine various extraction steam piping is connected to the various

pressure heaters and deaerator with large amount of saturated water.
Once the turbine is tripped, its internal pressure will decrease and the
flash steam of the saturated water in the various heaters or deaerator will
go back to the turbine. Besides, an aux. steam supply is connected to the
No.4 extraction steam branch, under operating condition, the outside
steam will enter the turbine through the No.4 extraction steam piping, in
addition to the retention steam in the various extraction steam piping, it
can also come back into the turbine because of the press dropping inside
the turbine, and the turbine may be overspeed.
All stages of extraction steam piping, except the No.7& 8 extraction

steam piping are equipped with pneumatic check valve and motor
operated isolating valve in series respectively. Once the turbine is tripped
both the pneumatic check valve and the motor operated isolating valve
are closed. The function of the motor operated isolating valves is to
protect the turbine against water induction.
Due to the fact that the No.4 extraction steam piping is connected with
the deaerator with large amount of water and arranged on high elevation,
and the various steam supply branches are connected with aux. steam
supplies, its dangerous to the turbine is the greatest. Therefore, two series
connected pneumatic check valves are installed nearby the No.4
extraction steam outlet to provide the double protection. Besides, before
the aux. steam connection of various steam supply branches, check valve
and a motor operated isolating valve are installed. The check valve and
the isolating valve will be closed automatically during the steam supply
switching over to prevent the aux. steam from coming back to the turbine
through the No.4 extraction steam piping during changing of operation
condition.
3.4 Protection for Water Induction

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Because of the many extraction steam outlets existing on the turbine,

which are located near the places where water existing, in addition, water
vessels such as heaters and deaerator are connected to various extraction
steam piping, there are many possibilities of water induction in the
extraction steam piping due to sudden change of turbine load, equipment
troubles, maloperation and improper consideration of system design, etc.
Therefore, turbine water induction failure happens most frequently by
water induction in the extraction steam system
For preventing against turbine water induction, the design of extraction

steam system shaft meet the requirements stipulated in the ASME
TDP-I-1980 "Technical Measures for Turbine Water Induction
Prevention"
3.4.1 Extraction Steam Piping
One pneumatic check valve and one motor operated isolating valve are
equipped in various extraction steam piping respectively, close to the
extraction steam outlet (for No.2 extraction steam close to the CR steam
pipe connection) except in the No. 7&8 extraction steam piping located
in the condenser neck where no isolating valve can be installed. In the
No.4 extraction steam piping manifold, two (2) series connected
pneumatic check valves are provided upstream the isolating valve for
double protection because of the too much equipment connected and the
other steam supply connected which may intrude into the No.4 extraction
steam piping. In addition, another set of motor operated isolating valve
and pneumatic check valve are provided in each branch supplying steam
to various equipment (or system) to enhance once more the protection
against water induction and overspeed.
The check valves, on the protection against turbine water induction point
of view, although it can afford a certain degree of protective action, its
closing are not tight enough due to the strain of the valve seat and valve
disc surface. Therefore the check valve cannot act as isolating valve
independently, it can only act as the protection against turbine overspeed
by its quick action to prevent the reverse flow of steam from extraction
piping into the turbine, and act as a primary protection against turbine
water induction as well. The motor operated isolating valve act as the
secondary primary protection against turbine water induction.
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3.4.2 Arrangement Requirements of Extraction Steam Piping Drain & Drain

Piping
During unit start-up, shut-down and operation under various abnormal

conditions, the extraction steam piping has the potential danger of
accumulating water, if accumulated water were not discharged in time,
turbine water induction may be caused, therefore drain pipe shall be
provided in the extraction steam piping.
In the extraction steam piping, drain points are provided before the
pneumatic check valve, after the motor operated isolating valve and they
are connected to the condenser separately.
The drain valve will be pneumatic operated. The drain valve at a point in
between the check valve and isolating valve will be manual operated for
discharge water when unit shut down.
Each drain pipe shall be connected to the condenser separately. In the

automatic drain piping, no other isolating valve is allowed near the
condenser to prevent mistake operation and to cause the drain system
ineffective.
The isolating valve at upstream of motor operated drain valve shall be

locked at open position during startup and normal operation periods.
The diameter of all the drain line after the motor operated drain valve
shall be larger than that before the drain valve to prevent flow choking
due to evaporation of drain in the drain line after the valve.
All these pneumatic operated drain valves are designed to keep position
when power failure. For the emergency situation need to open drain
valves when power failure, these valves have to be manual operated.
Each drain line shall be led to the heater mounted on the drain flash tank
separately, two or several drain lines of different elevation in the same
piping should not be combined together before connecting to the heater
mounted on the drain flash tank, otherwise the drain of higher elevation
will plug the drain of lower elevation. Drain lines of different piping and
pipes with different pressures should not be combined before leading the
heater mounted on the drain flash tank.
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The arrangement of various drain valves shall be as close to the

discharge end of the drain header on the condenser as possible, so that
the drain valves may be arranged together to facilitate operation and
maintenance.
3.4.3 Monitoring of Turbine Water Induction
The above mentioned countermeasures against turbine water induction

may not be so complete that shaft is never fail or is absolutely reliable.
Turbine water induction potential still exists due to maloperation or
failure of equipment (including control equipment), therefore
thermocouples shall be equipped at the location specified by the turbine
manufacturer or at the extraction steam outlet on the turbine to assist the
operator to discover and define the turbine induction water source.
A pair of monitoring thermocouples shall be equipped in the first

horizontal piping section after the check valve of various extraction
steam piping except the No.7&8 extraction. One of the thermocouples is
mounted on the top of the pipe, the other on the bottom to detect the
accumulated water in the pipe. During normal conditions, the temp. of
the upper and lower monitoring thermocouples shall be basically the
same. If there is water accumulated in the pipe, the temp. of the lower
thermocouple will be decreased while that of the upper one remains
constant, a differential temp. signal will be produced and an alarm will
be initiated in the control room to indicate the position where water is
accumulated, so that the operator will discover the water induction in
advance and take countermeasures to prevent water entering into the
turbine.
4.0 SYSTEM OPERATION INTERLOCKING & PROTECTION
4.1 Unit start-up
a. Extraction Steam Piping
If the heaters are start-up along with the unit start-up, the motor operated
isolating valves and pneumatic check valves and drain valves in the
various extraction steam piping should be in the opened position before
the unit is start-up.
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If the heaters are not start-up along with the unit start-up but is putting
into operation one by one after the unit carrying certain load, the motor
operated isolating valve shall be closed and the drain valve before the
isolating valve be opened before the unit start-up.
When the unit load reaches ~15% (detail see turbine manufacturer
description), the drain valves in the HP heater extraction steam lines will
be closed automatically. When the unit load reaches 20-30%, the drain
valves in the MP & LP heater extraction steam lines will be closed
automatically.
b. Deaerator Start-up
Before the unit start-up, the motor operated isolating valve in the
extraction steam supply line from No. 4 extraction steam manifold to
deaerator shall be closed and the auto-drain valve after the check valve
shall be opened, and the deaerator is steam supplied by aux steam system.
The feedwater in the deaerator feedwater storage tank is heated to the
saturated temp. under 1.47 bar (a). The deaerator pressure is kept stable
under 1.47bar(a) to feed water to the boiler by the pressure control valve
in the aux. steam supply pipe line. Along with the increase of unit load,
when the pressure of No.4 extraction steam reaches 1.47 bar(a)
(meanwhile the corresponding unit load is about 15-18%), the motor
operated isolating valve in the steam supply line from No.4 extraction
steam to deaerator opens automatically and the aux. steam pressure
control valve closed automatically. The steam supply to deaerator is
switched from aux steam system to the No.4 extraction steam
automatically. Along with the increasing of unit load the deaerator steam
pressure increases gradually, and the deaerator begin to operate under
sliding pressure.
c. Heater Start-up
Fill water in the heater water side and pay attention to control the temp
increasing rate. If the heater start-up individually, the drain valve before
and after the pneumatic check valve shall be opened, and the extraction
steam piping fully drained. The steam supply amount to the heater shall
be controlled and the temp. raise rate of the level protection switched in.

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4.2 Normal Operation
a The Unit Carrying Rated Load
The motor operated isolating valves and pneumatic check valves in all
the extraction steam Lines are in the opening status, the drain valves in
all the extraction steam Lines are in closing status, but the automatic
drain valve are in connected status with its relevant interlocking signal
system.
b. Variable Load Operation
When the pressure of the No.4 extraction steam is lower than 0.8MPa,
the motor operated isolating valve in the No. 4 extraction steam line
supplying steam to aux. steam is closed and the corresponding motor
operated valve in the aux. steam supply piping is opened , steam is
supplied by the aux. steam system. When the pressure of No.4 extraction
steam resumes 0.8MPa, switch to the reverse operating process by
remote manual operation.
The ventilation valve of HP cylinder exhaust is in closed status during

unit normal operation
4.3 Abnormal Operation
a Unit shut-down due to heater failure
When a heater is under hi-hi water level, and automatically close the
motor operated isolating valve and valve in the corresponding extraction
steam line and open the motor operated drain valve in the extraction
steam line by interlocking. Open the manual operated drain valve
in-between the isolating valve and check valve manually to discharge the
accumulated water in the extraction steam line, and after confirming that
the accumulated water is totally discharged and no more accumulation
will be made, then close the above mentioned manual drain valve, but
the motor operated drain valve downstream the motor operated isolating
valve of extraction steam piping and nearby the extraction steam outlet
shall still remain in the opening position.
b. Turbine Tripping
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When the turbine is tripped, the motor operated isolating valves and
pneumatic check valves in all the extraction steam lines shall be closed
by interlocking (including the motor operated isolating valves in the
No.4 extraction steam branches). And the motor operated drain valves in
all the extraction steam line are opened automatically, and the manual
operated globe valve are opened manually at the same time.
4. 4 Unit Normal Shut-down
During unit normal shut-down, if the heating steam supply from the No.4
extraction steam manifold will still be used for the various system, then
the auxiliary steam supply will be automatically switch in when the
pressure of No.4 extraction steam drops below 0.8MPa. The procedure of
switching is the same as described in Normal Operation and Variable
Load Operation.
When turbine load reduces to lower than 20-30%, the motor operated
drain valves in the extraction steam line for various LP heaters are
opened automatically. When turbine load reduces to less than ~15 %, the
motor operated drain valves in the extraction steam lines for various HP
heaters are opened automatically till the unit stop operation, and when it
is confirmed that all the accumulated water in the various extraction
steam lines are totally cleared out, the various drain valves shall be
closed.

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DAWG./REF. NO.

60-F5691C J3401 11 ENGINEERING STAGE

Extraction Steam System Design Description

NORTHWEST ELECTRIC POWER DESIGN INSTITUTE

LANCO ANPARA C 2 x 600 MW THERMAL POWER

ANPARA, SONEBHADRA DISTRICT, UTTAR PRADESH, INDIA

Document No. : 60F5691C J3401 11 Rev : A

EXTRACTION STEAM SYSTEM DESIGN DESCRIPTION

Date Revision Prepared by Reviewed by Released by

BTG Supplier Originator

1.0 SYSTEM FUNCTION & SCOPE OF SYSTEM DESION

2.0 SYSTEM DESIGN CRITERIA

3.0 SYSTEM DESIGN DISCRIPTION

4.0 SYSTEM OPERATION INTERLOCKING & PROTECTION

1.0 SYSTEM FUNCTION & SCOPE OF SYSTEM DESION

1.1 System Function

a To heat feed water, and increase plant thermal efficiency accordingly

b To minimize thermal shock to steam generator metals by reducing the

c To remove entrained oxygen and other non-condensible gases from

d To supply steam to auxiliary steam system..

1.2 Scope of System Design

2.0 SYSTEM DESIGN CRITERIA

The system is designed in accordance with the requirements of the

2.1 Design Parameters

The design parameters are defined according to the requirement of the

2.1.1 Design Pressure

2.2 Range of Flow Velocity

The recommended velocity in the piping shall be as follows.

for saturated steam 30m/s

for superheated steam 60m/s

2.3 Calculated Pressure Drop

The pressure drop of various stages extraction steam piping are

2.4 Piping Material Selection Criteria

According to the bidding document, power cycle piping system material

3.0 SYSTEM DESIGN DESCRIPTION

3.1 The System Main Equipment & Its Arrangement

3.2 Extraction steam Piping

File No. BTG Supplier Sheet No.

3.2.1 No.l, No. 2&No.3 Extraction Steam Piping

In the No.2 extraction steam piping nearby the CR steam piping

3.2.2 No.4 Extraction steam piping

In the No.4 extraction steam piping to the deaerator a motor operated

3.2.3 No.5, 6 & 7, 8 Extraction Steam Piping

3.3 Turbine Overspeed Protection

The turbine various extraction steam piping is connected to the various

All stages of extraction steam piping, except the No.7& 8 extraction

3.4 Protection for Water Induction

File No. BTG Supplier Sheet No.

Because of the many extraction steam outlets existing on the turbine,

For preventing against turbine water induction, the design of extraction

3.4.1 Extraction Steam Piping

3.4.2 Arrangement Requirements of Extraction Steam Piping Drain & Drain

During unit start-up, shut-down and operation under various abnormal

Each drain pipe shall be connected to the condenser separately. In the

The isolating valve at upstream of motor operated drain valve shall be

The arrangement of various drain valves shall be as close to the

3.4.3 Monitoring of Turbine Water Induction

The above mentioned countermeasures against turbine water induction

A pair of monitoring thermocouples shall be equipped in the first

4.0 SYSTEM OPERATION INTERLOCKING & PROTECTION

4.1 Unit start-up

a. Extraction Steam Piping

File No. BTG Supplier Sheet No.