Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
b) Non-IBR piping systems:
1. |
At shop |
All piping including fabricated piping shall be hydro |
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tested at 1.5 times the design pressure. However, |
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non-destructive testing in lieu of hydro test is also |
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acceptable subject to regulation 343 (3) of IBR. |
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2. |
After |
All piping systems shall be hydro tested at 1.5 times |
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erection |
the design pressure. However, for such systems |
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where it is practically not possible to do hydro tests, |
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the tests as called for in ANSI B31.1& IBR in lieu of |
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hydro test shall also be acceptable. |
Notes:
1.Material X20 or P91 is applicable for Main Steam and HP Bypass line upto HPBP valve. However, for pipes sizes 150 NB & below in these piping systems, A335 P22 shall also be acceptable.
2.Material P22 or P91 are applicable for Hot Reheat, and LP bypass.
3.In case design temperature is above 5500C and upto 6050C, then P91 or equivalent material only shall be applicable (for 1 & 2 above).
4.EFW pipes as per ASTM A 691 2-1/4 Cr. Class 22 are acceptable for alloy steel piping of size 550 NB & above if the design pressure and design temperature are such that it calls for ASME 300 class or below.
5.EFW Pipes as per A 672 Gr. B60, Class 12/22 are acceptable for carbon steel piping of size 550 NB & above if the design pressure and design temperature are such that it calls for ASME 150 class or below.
6.The fitting for ASTM A672 piping shall correspond to ASTM A 234 with Grade corresponding to the pipe material. Welded construction fittings are also acceptable with A672 piping. However, all requirements as per ASME B31.1 including the requirements given in mandatory appendix-D, IBR & respective material code shall be fully complied with, in respect of welded fittings.
7.Pipe material for CRH piping from HPT exhaust nozzle up to CRH NRV shall be alloy steel to ASTM A335 Gr.P22/ Gr.P11. Fittings shall also be corresponding to ASTM A 234 Gr. WP22/ Gr.WP11.
8.Pipe material for HP Bypass and LP Bypass downstream piping upto the mixing length as per recommendation of valve manufacturer shall be of Alloy steel to ASTM A335 P11/ P22. Fittings shall also be corresponding to ASTM A 234 Gr. WP11/ WP22.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
9.Material P-22 is applicable for piping with temperature > 5100C and upto 5500C and P11 is applicable for all other alloy steel piping below 5100C.
10.Materials for fittings, specialties and valves shall be corresponding to piping material or equivalent.
18.1.8Specific requirements
i)Manufacturing tolerances on pipe diameter (for both ID and OD controlled pipes) and thickness shall be as per ASTM A-530/ A999M, as applicable.
ii)Bend thinning allowance shall be provided for all bends as per the recommendations of ANSI B 31.1.
iii)Maximum carbon content for ASTM A 106 Gr. B or A- 105 shall be limited to 0.30% and for ASTM A 106 Gr. C, it shall be limited to 0.35%.
iv)All drains and vent lines in piping system with design pressure 40 kg/cm2 and above shall have two valves in series.
v)Wherever mitered bends are used, the thickness of pipe from which they are fabricated shall conform to the requirements of IBR Regulations 361 (C). The angle between axes of adjoining pipe sections shall not exceed 22.5 degree.
vi)Piping system fabrication shall be in accordance with the requirement of ANSI B 31.1. However for system under purview of IBR, the requirements of IBR shall also be complied with.
vii)Where welded pipe and fittings are used the longitudinal weld seams of adjoining sections shall be staggered by 90 degree.
18.1.9Valves
i)All valves shall be full port and shall meet the requirements of ASME B 16.34. The class of the valves shall be compatible to the service requirements. All materials that are bent, forged or formed shall be subject to heat treatment after the forming operations as required by the original material specification. For alloy steel materials the preferred heat treatment process is full annealing.
ii)Valves of size 65 NB and above shall have butt welded ends as per ANSI B16.25 and valves 50 NB and below shall have socket weld ends as per ANSI B16.11. Rubber lined valves shall have flanged ends as per ANSI B16.5.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
iii)All gate and globe valves shall be with outside screw and yoke with rising stem. Gate valves below 100 NB shall be solid wedge/flexible wedge type. Valves of class 150/ 300 and size 100 NB and above shall
be of flexible wedge type. However, for sizes 100 mm NB and above for temperatures above 3000C, parallel slide valves are also acceptable.
iv)All globe valves shall be capable of being closed against the design pressure. Where globe valve has been specified for regulation purpose, the disc shall be tapered plug type and suitable for controlling throughout its lift.
v)All gate and globe valves shall have bonnet-back seating arrangement to facilitate easy replacement of packing with the valves in service.
vi)All gate, globe and check valves shall be designed for reconditioning of seating surfaces and replacement of stem and disc without removing the valve body from the line.
vii)Minimum differential hardness between seat and other disc material shall be 50 HB in case of 13% chrome hardened with heat treatment of steel.
viii)For all globe and check valves, the direction of flow shall be clearly stamped on the body of the valve.
ix)Locking arrangement, where provided shall be of non-detachable type.
x)Integrated bypass valves:
a)The requirement of integral bypass valves shall be worked out, as per process requirement.
b)Integral bypass shall be motor operated if main valve is motor operated.
c)Bypass pipe shall be of seamless construction and thickness corresponding to minimum of schedule 80 and shall be of the same material class as the main pipe.
xi)For valves of size 65 NB and above in vacuum service, water gland sealing arrangement shall be provided. Valves of size 50 NB and below shall have extra, deep gland packing without requiring water gland sealing.
18.1.10Hangers and supports
i)All hangers and supports shall be so erected that they are preferably vertical when the piping is in hot condition (rated parameters). However, in piping system connected to the turbine/turbine valve nozzles it may be required to erect the hangers/supports vertical in the
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
cold condition or as per the recommendation of TG supplier to ensure that there is no transfer of undesired pipe weight/ load on the turbine valves/nozzles.
ii)All pipes hangers and supports shall be designed to carry the weight of the piping, fitting, thermal insulation, self weight of the hanger assembly and medium transported or test medium whichever is heavier. In addition, all rigid rod hangers and variable spring shall be designed to carry the operation load in hot condition.
iii)Design and Manufacture of hangers and supports shall conform to ANSI B 31.1, MSS-SP-58, MSS-SP-89.
18.1.11Metallic expansion joints
i)The expansion joints shall be of metallic multi-bellows construction and shall be used to reduce the reactions (forces and moments) at the connected equipment terminals due to thermal expansion/contraction and/or vibration of connected equipment and piping.
ii)Expansion joints shall comply with the currently applicable requirement of EJMA, Boiler and Pressure Vessel Code Section III, ANSI B-31.1 and all statutes, regulations and safety codes.
18.1.12Chemical cleaning of piping systems and equipments
i)The following piping system shall be cleaned chemically:
a)Boiler feed discharge piping
b)Heater drains piping
c)Main condensate piping
d)Extraction steam piping
ii)The following equipments which form a part of the above system shall also be included in the cleaning operation as per OEM’s proven practice:
a)HP Heaters
b)LP Heaters
c)Deaerator
d)Gland steam condenser
e)Drain cooler
iii)Before introducing chemicals, all the piping systems and equipment listed above shall be water flushed. Water flushing will be followed by alkaline cleaning, acid cleaning and passivation or by EDTA (Ethylene Diamene Tetra Acid) and passivation.
iv)Strict safety precautions shall be exercised at all times during the chemical cleaning and during storage and handling of the chemicals. Protective clothing, apparatus and equipment alongwith necessary first aid kits as required shall be envisaged for handling the chemical and for carrying out the cleaning operation.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
18.1.13Steam blowing of piping systems
i)The following piping systems shall be cleaned through steam blowing operation:
a)Main steam, HRH, CRH, HP bypass & LP bypass piping.
b)Auxiliary steam piping including TG gland sealing lines.
c)Steam lines feeding turbines of boiler feed pumps.
ii)Steam blowing shall be carried out for removal of particles (rust, scales, weld splatter etc.) from various piping systems to avoid damage to turbine bladings. Cleanliness of system shall be checked by means of test plates made of steel, which will be installed in the centre line of the piping system.
iii)Cleaning shall be achieved by steam purging i.e. by blowing of steam through the piping such that the momentum of flow is greater than that of steam flow during normal operation of unit (at TMCR). The disturbance factor during steam blowing (ratio of momentum of flow during purge to that during TMCR) shall be more than 1.4.
18.2Control Valves
18.2.1General requirements
i)The control valves shall comply with the latest applicable requirements of code for pressure piping ANSI B 31.1, the ASME Boiler & pressure vessel code, Indian Boiler Regulation (IBR), ISA as well as in accordance with all applicable requirements of the Federal Occupational Safety and Health Standards, USA or acceptable equal standards.
ii)The control valve sizing shall be suitable for obtaining rated flow conditions with valve opening at approximately 80% of total valve stem travel and minimum flow conditions with valve stem travel not less than 10% of total valve stem travel. All the valves shall be capable of handling at least 120% of the required rated flow. Further, the valve stem travel range from minimum flow condition to rated flow condition shall not be less than 50% of the total valve stem travel. The sizing shall be in accordance with the latest edition of ISA on control valves. The valves port outlet velocity shall not exceed 8 m/sec for liquid services, 150 m/sec. for steam services and 50% of sonic velocity for flashing services.
iii)Valve body rating shall meet the process pressure and temperature requirement as per ANSI B16.34.
iv)All control valves shall have leakage rate as per leakage Class-IV.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
v)For cavitation service, only valve with anti cavitation trim shall be provided. Applications like CEP minimum recirculation valve shall have anti-cavitation trim with tight shut-off. The deaerator level control valve shall have characterized trim cages to have a cavitation protection at minimum flow as well as good rangeability.
18.3Thermal Insulation
18.3.1General requirements
i)Thermal insulation shall be provided mainly for conservation of heat and maintenance of temperature as per design cycle and personnel protection.
ii)Insulation alongwith aluminum cladding shall be provided for all the
equipments/surfaces (excluding coal pulverisers) having skin temperature more than 600C.
iii)For the piping and the equipment with surface operating temperature of 600C and above, the personnel protection insulation shall be applied such that the temperature of protective cladding is below 600C.
iv)An insulation thickness schedule shall be prepared covering both the cases of heat conservation and personnel protection based on the following design data:
a) |
Design ambient temperature |
: 400C |
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b) |
Maximum cladding temperature |
: 600C |
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c) |
Wind speed |
: 0.25m/s |
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d) |
Emissivity of cladding |
: 0.2 |
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e) |
Thermal conductivity |
: As per relevant IS |
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f) |
The minimum acceptable |
: 1. |
75 mm for Boiler & TG |
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insulation thickness |
2. |
70 mm for ESP surfaces |
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3. |
25 mm for other surfaces |
g) |
Pipe/equipment wall temperature |
: Fluid design temperature |
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v)The insulation thickness to be provided shall be calculated as per ASTM C-680 or BS- EN-ISO 12241 subject to minimum thickness values as mentioned above.
vi)The material and application of insulation material, protective cladding, wire mesh etc. shall conform to the latest edition of the following standards/ codes:
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
a) |
IS 280 |
Mild steel wires for general engineering |
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purposes. |
b) |
IS 3144 |
Methods of test for mineral wool insulation |
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materials. |
c) |
IS 3677 |
Unbonded rock and slag wool for thermal |
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insulation. |
d) |
IS 5696 |
Loose mineral wool. |
e) |
IS 8183 |
Lightly bonded mineral wool for thermal |
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insulation. |
f) |
IS 9428 |
Pre-formed calcium silicate insulation. |
g) |
IS 9742 |
Sprayed mineral wool thermal insulation. |
h) |
IS 9842 |
Preformed fibrous pipe insulation. |
i) |
IS 4164 |
Code of practice for thermal insulation on cold |
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surfaces. |
j) |
IS 15402 |
Ceramic fibre blanket insulation. |
k) |
IS 737 |
Wrought aluminum and aluminum alloy sheet |
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and strip for general engineering purposes. |
l) |
ASTM C 892 |
Standard specification for high-temperature |
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fiber blanket thermal insulation. |
m) |
ASTM B 209 |
Standard specification for aluminum and |
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aluminumalloy sheet and plate. |
18.3.2Technical requirements
i)All insulating materials, accessories and protective covering shall be non-sulphurous, incombustible, low chloride content, chemically rot proof, non-hygroscopic and shall be guaranteed to withstand continuously and without deterioration the maximum temperature to which they will be subjected under the specified conditions.
ii)Insulation materials containing asbestos in any form shall not be used.
iii)Insulation mattress/section shall be in thickness of 25, 40, 50 and 75 mm. Insulation of higher thickness shall be made up in multiple layers using these mattress/slabs. If required, the mattress/slabs in increment of 5mm thickness may be used to achieve the required thickness of insulation.
iv)Special fire protection measures shall be taken for the steam lines running in the immediate vicinity of oil lines. The sheet metal jacketing shall be made oil proof by inserting self-adhesive flexible tapes.
v)Rock wool insulation mattress shall be of long fibered rock processed into fibrous form bonded with a binder. No kind of slag wool inclusion is acceptable.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
vi)The thermal insulation for the turbine casing shall consist of sprayed insulation produced by projecting specially prepared mineral wool along with a fine liquid spray. This shall be covered with prefabricated 'blanket' type insulation. Voids around the blankets should be avoided. However, unavoidable voids shall be filled with loose mineral wool.
18.3.3Materials of insulation
i)Insulation
Type |
Type # 1 |
Type # 2 |
Type # 3 |
Type # 4 |
Type #5 |
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Material |
Lightly |
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Resin |
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Calcium |
Rock |
wool |
Ceramic |
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resin |
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bonded |
silicate pre- |
for |
spray |
fibre |
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bonded |
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mineral |
formed |
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insulation |
blankets/ |
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mineral |
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(rock) wool |
pipe |
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blocks |
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(rock) |
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pre-formed |
sections/ |
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wool |
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pipe |
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blocks |
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sections/ |
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blocks |
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Apparent |
100 |
kg/m3 |
100-150 |
200-25- |
200-250 |
128 kg/m3 |
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density |
for |
temp. |
kg/m3 |
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kg/m3 |
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kg/m3 |
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60-4000C |
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and |
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150kg/m3 |
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for |
above |
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400oC. |
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Material |
IS:8183 |
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IS:9842 |
IS:9428 |
IS:9742 |
IS:15402 |
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standard & |
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testing |
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code |
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Applicable |
Piping |
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Piping |
Piping |
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Steam |
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Steam |
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service |
system |
& |
system of |
system |
& |
turbine & |
turbine, |
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equipment |
350 |
NB |
equipment |
valves with |
boiler |
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with |
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and |
below |
with |
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operating |
surfaces & |
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operating |
with |
temp. |
operating |
temp. range |
valves |
with |
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temp. |
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range |
of |
temp. range |
of |
400- |
operating |
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range |
of |
60-4000C. |
of |
400- |
6500C. |
temp. range |
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60-6500C. |
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6500C. |
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of |
400- |
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6500C. |
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ii)Sheathing/ Cladding Material
Sheathing/ cladding material for all insulated surfaces. equipment, piping etc. confirming to ASTM B 209-1060 temper H-14 or IS-737 Gr.19000/H2 shall be provided as follows:
a) For dia. of insulated surfaces |
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0.914 mm (20 SWG) |
of 450 mm & above and for |
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flat surfaces |
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b) For dia of insulated surfaces |
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0.71 mm (22 SWG) |
less than 450 mm |
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183 |
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
c) |
For steam generator |
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1.219 mm (18 SWG) |
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outer casing |
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ribbed Aluminum |
d) |
For ESP |
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0.71 mm (22 SWG) |
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ribbed Aluminum |
iii)Binding and Lacing Wires
a) |
For temperature upto 4000C |
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20 |
SWG galvanised steel |
b) |
For temperature above 4000C |
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20 |
SWG stainless steel |
iv)Straps and Bands
a) |
For temperature upto 4000C |
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Galvanised steel |
b) |
For temperature above 4000C |
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Stainless steel |
Bands shall be 20 mm wide and 0.6 mm thick.
v)Hexagonal Wire Mesh
a) |
Upto 4000C |
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22 SWG, |
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10 to 13 mm aperture |
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galvanised steel |
b) |
Above 4000C |
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22 SWG, |
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10 to 13 mm aperture |
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stainless steel |
18.4Refractories
i)The refractory material shall comply with relevant Indian Standards. The refractory selected shall ensure perfect sealing, and shall have good thermal cycling properties allowing quick start-up/shut down of steam generators.
ii)The refractory material shall:
a)have high bulk density and minimum moisture content.
b)be capable of withstanding service temperature of 17000C.
c)be resistant to slagging products due to coal, and to impurities of oil like V2O5, Fe2O3, K2O etc. and to erosion due to fly ash.
d)be chemically inactive towards alkalies, iron, silica etc.
e)shall pose no health hazard to working personnel, and shall not have any explosive properties.
f)have sufficient strength to withstand forces generated in boiler, without any rupture or damage.
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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Units
CHAPTER - 19
STEAM TURBINE HP-LP BYPASS SYSTEM
19.1Purpose
The HP and LP turbine bypass system is envisaged to be used for the following functions:
i)To enable boiler and turbine to be operated independent of each other during start-up and shutdown.
ii)To enable in quick reloading of the unit following a turbine trip.
iii)To quickly open to relieve the system from high steam pressure in the event of generator breaker opening/ turbine tripping as well as during large load throw-off.
iv)To reduce starting and loading time of steam generator.
v)For house load operations.
19.2General Requirements
19.2.1A HP bypass system shall be provided between MS and CRH and shall have aggregate capacity not less than 60% of the main steam flow at BMCR condition considering main steam parameters at the upstream of valves & CRH steam parameters corresponding to 60% TMCR condition on the downstream side. The HP bypass system shall have minimum 2x50% capacity valves. In addition the aggregate capacity of HP Bypass valves shall be adequate to evacuate the required minimum steam flow from the boiler under various startup conditions (viz. cold/ warm/ hot start ups).
19.2.2LP bypass shall be provided between HRH and condenser and shall be designed to condition the incoming steam from re-heater corresponding to parameters resulting from operation of HP bypass as stated above, to parameters matching with those of LP Turbine exhaust steam. The valve capacity shall be commensurate with that of HP bypass system plus the spray water used in HP bypass. Number of LP Bypass valves shall be as per manufacturer’s standard practice subjected to a minimum of two (2) numbers.
19.2.3Seat tightness of the HP and LP bypass valves shall be equivalent to leakage Class V conforming to ANSI/FCI 70-2.
19.2.4HP bypass station spray water requirement shall be provided from Boiler feed pumps discharge & LP bypass spray water requirement shall be provided from condensate extraction pump discharge.
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