Pyry Energy

TWO(2) X 500MW
MONG DUONG 1 THERMAL POWER PLANT

APPROVED
Approved without exception

APPROVED WITH COMMENTS

AC

Approved Subject to Incorporation of comments

RETURNED FOR CORRECTION

RT

Insufficient Information/ Detail

Resubmit for Approval

RJ

REJECTED
Complete redesign required

RECEIVED FOR INFORMATION

Returned without comments

RECEIVED FOR INFORMATION

IC

Returned with comments

Note: Approval or comments does not relieve the Contractor of
any obligations covered under contract

FOR INFORMATION

Engineer:
Discipline:
Date:

Soumen Mitra
Senior Mec Engineer
27-Jul-12

26-04-12

Issue for information

H.D.KIM

K.T.NAM

J.W.CHOI

REV.

DATE

DESCRIPTION

DSGN

CHKD

APPD

SUB-CONTRACTORS DOCUMENT NUMBER: MD1-0-V-111-09-00008

26-04-12

Issue for information

J.A.SEO

M.K.LEE

J.Y.KIM

REV.

DATE

DESCRIPTION

DSGN

CHKD

APPD

PROJECT :

TWO(2) x 500 MW MONG DUONG 1 THERMAL POWER PLANT

EMPLOYER :

CONSULTANT :

CONTRACTOR :

SUB-CONTRACTOR :

DESIGNED BY

DATE

TITLE :

H.D.KIM

26-04-12

CHECKED BY

DATE

K.T.NAM

26-04-12

APPROVED BY

DATE

PROJECT NUMBER

DOCUMENT NUMBER

REV.

J.W.CHOI

26-04-12

ADB/MD1-TPIP/EPC150911

MD1-0-V-111-09-00008

EXTRACTION SYSTEM REQUIREMENTS

TABLE OF CONTENTS
I. GENERAL

II. BACKGROUND

III. CHECK VALVE DESIGN REQUIREMENTS

A. General Specifications of Check Valves Used for Overspeed Protection

B. Specifications for the Free Swing Portion of the Check Valve

C. Specifications for the Power Assisted Portion of the Check Valve

D. Specifications for the Performance of the Air System

IV. BASIC RULES FOR DETERMINING NUMBER AND TYPES OF CHECK VALVES

11

V. PROCEDURE TO DETERMINE THE NEED AND LOCATION OF CHECK VALVES

12

VI. OVERSPEED PROTECTION AGAINST EXTRACTION SYSTEM

AUXILIARY STEAM SUPPLIES

13

VII. TYPICAL ARRANGEMENTS

16

A. Arrangement No. 1

16

B. Arrangement No. 2

17

C. Arrangement No. 3 and 4

17

D. Arrangement No. 5

17

VIII. MISCELLANEOUS SOURCES OF OVERSPEED

17

IX. PRESSURIZATION OF FEEDWATER HEATERS

21

X. PROBLEMS OF LOWPRESSURE (LP) HEATER APPLICATION

21

XI. WET EXTRACTIONSNUCLEAR UNITS

22

XII. WATER INDUCTION

22

XIII. INFORMATION NEEDED FROM CUSTOMER

23

LIST OF FIGURES

Figure 1. Pressure Switch Activation of Non-Critical Positive Asset Cylinders

14

Figure 2. Air Relay Dump Valve Activation of Non-Critical Power Actuators

14

Figure 3. 3-Way Solenoid Valves in the Air Lines to Each Cylinder

15

Figure 4. 3-Way Solenoids in Air Lines to the Spring Side of the Air Piston

15

Arrangement No. 1

19

Arrangement No. 2

19

Arrangement No. 3

20

Arrangement No. 4

20

Arrangement No. 5

20

Figure 5. Typical Heater Shells and Internals

24

Figure 6. Baffling with Special Drip Arrangement

25

Figure 7. Baffling with Drip Arrangement

25

Figure 8. Dry Heater by Means of External Drain Receiver Section

26

Figure 9. Multiple Strings of Feedwater Heaters

26

I. GENERAL
The following describes Doosans aims and requirements pertaining to the extraction system
and should answer the majority of questions that arise on this subject. The enclosed typical data
form (ATT. #1) will aid in the study of a particular extraction system and overspeed situation. It
will also help determine the requirement for and the proper location of check valves in the
extraction system. Form (ATT. #1) issued for the specific unit must be returned to Doosan
completely filled in for the review of the overspeed potential by the responsible engineering
section. This document, together with DST00132A, Water Induction in Large Steam Turbines
Design Recommendations, should be used in designing the extraction system and controls.
II. BACKGROUND
A wellknown fact among consultants and power companies is that excessive overspeed of a
turbinegenerator shaft can be disastrous. A lesser known fact is that the energy contained in
the feedwater heaters of a steam turbinegenerator power cycle is often sufficient to contribute
significantly to the magnitude of the turbinegenerator rotating speed upon an electrical load
rejection or tripout and must be prevented from doing so by some means, the most common of
which is by the use of check valves. This energy is in the steam contained in the piping from the
turbine to the feedwater heaters and in the heater shells, in the water contained in the feedwater
heaters, as well as in the metal parts.
After a load rejection, the steam admission valves will close, causing the pressure of the steam
already in the turbine to decay. This decay allows the steam in the extraction piping and heater
shell to flow back into the turbine giving its energy to the rotor. This will cause the heater
pressure to decay so that the water which was saturated at the heater pressure under normal
operating conditions will become superheated momentarily, flash into steam, and flow through
the turbine giving up its energy to the rotor. The heat of the metal components provides some of
the necessary latent heat of vaporization.
In applications where steam volumes and water volumes are large, check valves in the
extraction piping are considered necessary to protect the turbine from this energy. The number
of check valves recommended by Doosan depends upon the steam and water volumes and
include the free swing and power assisted types. Two power assisted valves in series (with
proper maintenance and testing) are considered to afford the maximum protection necessary.
Doosan steam turbine design rules and code requirements specify that the turbine controls will
be capable of preventing the turbine speed from rising above a certain maximum value after a
full load rejection or trip. Under this condition, the speed will rise due to the delays in getting
the steam admission valves closed and due to the energy contained in the bottled up volumes of
steam within the turbine. Part of the latter is the extraction system volume. The amount of speed
increase contributed by the extraction system must be held below a certain maximum value by
4

the use of check valves or baffles.

The consequences of check valve failure are considered when determining how many and what
type check valves are needed. The turbine valve control system is made up of two separate
systems such that if the first fails, the second should operate. Each part of the control system is
extremely reliable so that this redundancy results in an exceptionally reliable protection against
excessive turbine overspeed. This philosophy of extremely reliable protection must be
employed in the selection of extraction check valves as well. For example, if the energy of a
particular extraction point is sufficient to cause a speed rise exceeding the maximum allowable
limit, then one check valve must be backed up with another in series, and both are to be the
power assisted type actuated by the turbine emergency trip system.
Therefore, it can be seen that considerable importance is attached to the protection of the
turbine rotor from experiencing excessive speed, and the cost of protecting the turbine against
the energy of the extraction system by the use of extraction check valves is minute compared to
the cost of repairing turbine or generator parts damaged by overspeed.
III. CHECK VALVE DESIGN REQUIREMENTS
With this background, it should be understandable why the design requirements of the
extraction check valves, listed below, must be adhered to.
A. GENERAL SPECIFICATIONS OF CHECK VALVES USED FOR OVERSPEED
PROTECTION
1. The valve specifications sent to valve vendors should include all, but not be limited to,
the specifications outlined below. These specifications are intended to provide an
extraction system that has reliable, adequate protection against overspeed.
2. The valve vendors recommendations as to maximum velocity through the valve should
be observed to maintain reliability. Too small a velocity will cause the valve to remain
partially open causing continuous fluttering. Too large a velocity may prevent closure of
the valve during testing. Typical ranges of maximum velocity could be between 125
ft./sec (40 m/sec) and 200 ft./sec (60 m/sec) at rated load. The valve vendor should be
supplied with the maximum design flow through each ex-traction check valve, the
maximum pressure and temperature (the maximum pressure and % moisture if the
extraction is wet) of the steam, and the system air pressure supplied to the air relay
dump valve on the turbine.
3. The check valve must be located in the extraction pipe such that allowable overspeed
criteria discussed later are met. The valve should also be located with consideration of
the vendors recommendations to minimize vibration problems on the valve. For
5

example, the vendor may recommend locating the valve in a straight run of pipe 10 pipe
diameters downstream from any elbow in the pipe and 5 pipe diameters upstream from
the next elbow.
B. SPECIFICATIONS FOR THE FREE SWING PORTION OF THE CHECK VALVE
1. The free swing portion of the check valve must be such that it will freely close with no
flow in the extraction line.
2. The pivot shaft should be a single shaft.
3. On check valves with a circular disc attached to a swing arm there should be a means of
preventing rotation of the disc.
4. On check valves with separate check valve discs and swing arms, there should be two
different positive means of assuring the disc will not come off the swing arm. Just
pinning the nut to the disc threads is not satisfactory. It is preferred that the disc and
swing arm assemblies be secured by the valve vendor such that field removal can only
take place by pulling the pivot shaft and removing the whole assembly rather than by
allowing internal removal of the disc off the swing arm.
5. Field tests have shown that on a turbine load rejection small diameter high pressure
check valves stroke from full open to closed position in 0.1 seconds. As the valves
increase in diameter and the steam pressures decrease, the stroke times increase to
approximately 0.6 seconds. The check valves should be capable of these repeated
closures without sustaining permanent deformation that would prevent shutoff of steam
on reverse flow.
6. Disc to seat sealing shall be accomplished with metal to metal seals. There shall be no
seal ring screwed into the disc, unless there are two provisions for locking the screws in
place, for example, bottoming screw torqued and staked secured in place. There shall be
no screwed in seats, unless they are seal welded in place.
7. The disc must be designed such that it will cause minimum pressure drop when open.

8. The use of a counterweight on a lever, external to the valve body, to balance the weight
of the disc for the purpose of reducing pressure drop is permissible, but only if the
following conditions are met.
a. The lever should be short enough so that it is impossible to develop more than 50% of
6

the torque required to open the valve under no flow conditions no matter where the
weight is positioned on the lever.

b. The weight should be secured positively on the lever. For example, the weight could
be pinned in place on the lever, then the pin should be staked.

c. The shaft seal should meet the criteria set forth in the next items. This will probably
lead to applications where external counterweighting would not be permitted.

9. Shaft sealing has a significant impact on the reliability of the check valve to perform
satisfactorily. Based on field experience the following restrictions are placed on the
type of shaft sealing.
a. To avoid a potential water source of water induction to the turbine, and to prevent
quenching and distortion of the valve, water sealing the shaft is not permitted.

b. To avoid binding of the free swing check valve disc due to overtightening of packing
material, the valve must be designed with shaft seals such that it is not possible to
overtighten packing to restrain free swing motion.

10. Possible means of sealing the shaft include:

a. Hardened steel bushings with gasketed end caps where the shaft does not protrude
through the valve body
b. Hardened steel bushings with an intermediate steam leak off to the turbine steam seal
system, with no soft packings

c. Packing arrangements that cannot be overtightened enough in the field to restrain

motion

d. Soft packing, but with the lost motion device internal to the valve so that the packing
does not restrict free swing motion. This implies that any counterweighting required
must be internal to the valve.

11. On check valves with double D swing plates.

a. The plates should not open to an angle of greater than 85 perpendicular to the flow,
so that re-verse flow will force the plates closed.

b. There should be 1 /2 in. (40 mm) dia. hole drilled through one plate to ensure positive
drainage.

c. The spring should be selected so that it is stressed below its endurance limit.
C. SPECIFICATIONS FOR THE POWER ASSISTED PORTION OF THE CHECK
VALVE
1. The power assisted portion of the check valve shall consist of an actuator designed such that,
on tripping the air system by the turbine air relay dump valve (ARDV), a spring will cause the
actuator to close the check valves.
2. Upon supplying air to the cylinder, the air should compress the spring and allow the check
valve to open. It must not restrict the free swing motion of the check valve disc in the closed
direction.
3. To help assure a fast response when the air system is tripped, the air cylinder and spring are to
be sized so that with the cylinder connected to the valve and with no steam flow:

a. Approximately 30 psig [206.9 kPa (gauge)] [2.1 kg/cm (gauge)] air pressure is required
to lift
the piston from its closed end stop.

b. Approximately 60 psig [413.7 kPa (gauge)] [4.3 kg/cm (gauge)] air pressure is required
to hold the piston against its open end stop. [Assuming air supply pressure to be in the 60
2

to 100 psig(413.7 to 689.5 kPa (gauge)] [4.3 to 7.1 kg/cm (gauge)] range.]

4. To help assure an adequate force level to overcome valve friction, the air cylinder and spring
are to be sized so that:
a. With the cylinder in the closed position, there must be enough spring force to exceed, by a
factor of at least four, the force required to overcome the combined normal friction levels
of the air piston, linkage and valve disc.

b. With the power assist actuator hooked up to the valve, with the check valve disc free to
move, with full steam flow down the extraction line, and with normal friction levels in the
valve and actuator, there will be enough spring force to close the disc to the point where
the disc will have closed off 10% of the cross sectional flow area. If the 10% flow point is
not known, it is accept-able to size the spring to shift the disc from 100% open to 90%
open position of angular travel against the above conditions of full resistance force. At the
90% position reverse steam flow is to be a positive closing force on the disc.
8

5. The power assist actuator should have a stroke such that it would move the check valve to the
3

point where the check valve disc would have closed off at least /4 of the cross sectional flow
area.
6. The power assist actuator should be designed with a convenient means of local daily testing
that the free swing portion of the check valve is still free to move. The testing feature should
be located such that the operator testing the valve can be sure that the valve moves freely
through stroke. Because rod end seals in the top of conventional air closing cylinders tend to
develop excessive leakage with time, testing force margin can be lost. To overcome this
maintenance problem, the heater high level solenoid can be used to accomplish the daily check
valve test. This option is shown in figure 3.
D. SPECIFICATIONS FOR THE PERFORMANCE OF THE AIR SYSTEM
1. The extraction air piping from the turbine air relay dump valve (ARDV) to the individual
power assist actuator must be designed so that the air in the cylinder will depressurize
rapidly. With full rated air pressure in the system and check valve discs in the closed
position, this rate of decay should be fast enough for the air pistons to go through full stroke
in the check valve closing direction within two seconds of tripping the air relay dump valve.
Careful attention to the size and routing of all the air piping is required to minimize the
volume of air contained in the system and yet maximize the response time of the critical air
pistons. In general the following has been used successfully in the field. The main manifold
run from a single ARDV at the turbine end standard down to the first or second tee for the
closing cylinders has worked well when sized to 1 in. (27 mm) inside diameter. Note that for
two ARDVs tied together the main header flow area could be doubled. The individual runs
1

to single air closing cylinders have worked well with the equivalent of /2 in. (13 mm)
tubing. Sub manifolding lines were sized in between the main header and individual runs.
Minimizing the number of elbows is important. Because of the variety of field installations
the above information is only intended as a guide. The architect engineer and customer are
responsible for determining their optimum station layout which will meet the two sec-ond
timing requirement.
It is common practice to provide check valves of the power assisted type even when it has
been deter-mined only a free swing check valve is required for adequate overspeed
protection. The extra air piping and volume involved can make it very difficult for those
valves requiring power assist for overspeed reasons to have a satisfactory response time. The
following two subsections describe possible alternatives for arranging the critical and non
critical power assists. Subsection a. is for a single air relay dump valve (ARDV) and
9

subsection b. is for a system with two ARDVs.

a. On units with only one air relay dump valve (ARDV), use the arrangement shown in
Figure 1. Run the air piping from the ARDV (again giving careful attention to the size
and routing) only to those critical check valves on which power assist actuators are
required for overspeed protection. Install or utilize a pressure switch (used for opening
extraction drains) in the outlet of the ARDV (again minimizing size and routing). Run
an air supply line directly to the remaining power assist actuators. This air supply will
not go through the ARDV. Dumping of the air from these cylinders will be by means of
an automatic three way valve in each individual air line. The pressure switch on the
outlet of the ARDV should provide a signal to these automatic valves so that they will
dump the air to these noncritical cylinders on activation of the ARDV. If the critical
check valves which are to be connected to the ARDV are also tripped by this pressure
switch, then a modified timing requirement is imposed. The pressure switch trip has to
meet the two second closure; and with the pressure switch trip temporarily disconnected,
the critical air cylinders are to close in less than five seconds by action of the ARDV.
b. On units with two air relay dump valves (ARDV 1 & ARDV 2) use the arrangements
shown in Figure 2 or 4. Run the air piping from ARDV 1 (again giving careful attention
to the size & routing) to only those valves in which the positive assist feature is required
for overspeed protection. Run the air piping from ARDV 2 to the remaining valves. If
the air volume in the runs of critical lines exceeds the noncritical lines, then
manifolding the lines together as shown in Figure 3 is acceptable since the trip times of
the critical valves will be reduced.
As a guide in analysis of the system response time, the turbine front standard contributes a
loss of about 7.5 velocity heads per extraction relay dump valve based on a 1.063 in. (27 mm)
ID pipe.
2. No more than twelve critical power assisted check valves should be connected to a single
ARDV. On most units shipping after 1980, two ARDVs are supplied. With two ARDVs this
rule can be easily met.
3. There must be no possibility of restricting air decay from air cylinders on power assist check
valves required for overspeed protection by the location of a valve in the air line. This means
that there must be no 2way shutoff valves in the air lines from an ARDV, which has critical
positive assist check valves hooked to it, through to the individual air cylinders on any check
valve.
4. Any 3way solenoid valves in the air lines from the ARDV to each air cylinder hooked up to
10

an ARDV with critical positive assist check valves must not pose any problems in restricting
flow on tripping the air system from the ARDV. See Figure 3 for the arrangement. Thus the
solenoid valve must be of the direct acting type, and must have been selected for fast dumping
of the cylinder through the cylinder to inlet port direction. Fast dumping through the cylinder
to vent connection is not as important as through the cylinder to inlet connection. This is
because the cylinder to vent connection is used on heater level as a protection against water
induction. Water from a leaking feed-water heater is a relatively slow process. Flow rates for
such an event have been given in ASME TDP1 for use in timing when shutoff valves have to
1

close. This has resulted in time typically in the order of /2 to 1 /2 minutes.

5. Bypassing any solenoid valve in the air lines with another solenoid valve and/or a check valve
to improve the response time in dumping the cylinders through the inlet port of the solenoid
valve via the ARDV is not permitted if that ARDV has any critical positive assist check valves
hooked up to it.
6. The above restrictions on the solenoid valve do not apply if the solenoid valve is used to
equalize pressures around the air cylinder as in figure 4. The solenoid valve is now in the air
line to the spring side of the air piston rather than the nonspring side. In this position it has no
influence at all on dumping the cylinder via the ARDV valve.
Note this is still fail safe, as loss of air still always calls for valve closure.
IV. BASIC RULES FOR DETERMINING NUMBER AND TYPES OF CHECK VALVES
The basic rules for determining the type and number of check valves in each extraction line to
guard against overspeed are as follows:
A. The omission of a check valve is permitted if the energy storage in the line and heater is
negligible.
B. One freeswing check valve is required when failure of the check valve to stop reverse flow
on loss of maximum load would result in no more than a moderate rise in speed.
C. One springclosed check valve, controlled by the emergency trip system, is required when
failure of the check valve to stop reverse flow, on loss of maximum load, would result in a
turbinegenerator speed rise approaching the maximum speed considered allowable for
repeated occurrences.
D. Two springclosed check valves in series, actuated by the emergency trip system, are
required if reverse flow, on loss of maximum load would result in a turbinegenerator speed
rise exceeding the maximum allowable limit.
11

V. PROCEDURE TO DETERMINE THE NEED AND LOCATION OF CHECK VALVES

The item numbers referred to in the following correspond to the item numbers on the enclosed
typical Extraction Data Form (ATT. #1).
Item 1 should be determined and includes all crossties and branch line volumes entering the
extraction line on the turbine side of check valves. This item should include all volumes to the
heater and heater steam volume, if and only if, no check valve is to be provided.
Item 2 should include all crossties and branch line volumes entering the extraction line after
the check valve.
This item should be omitted, if and only if, no check valve is to be provided.
Item 3 should be filled in, if and only if, a check valve is provided.
Item 4 should be filled in, if and only if, no check valve is provided.
Items 5, 6 and 7 do not apply to all extraction lines but should be filled in where applicable.
Items 8 and 9 are previously filled in by the Doosan. The quantities given are the available
energy of steam and water in each extraction line/heater combination.
Items 10, 11, 12 and 13 are determined from the previously filled in information. That is the
total volume of steam or water times its available energy. It is important here to ensure that
items 1, 2, 3 and 4 have been entered correctly, depending on check valve provisions.
Item 14 is the summation of items 10, 11, 12 and 13 and represents the total amount of
available energy per extraction. The summation of all item 15 extraction entries represents the
total unrestrained energy in the whole extraction system. This must be below the value given on
ATT. #1. If the value is above this allowable, the check valves should be relocated nearer the
turbine. Check valves if not installed should be installed.
The volume of water in heaters unprotected by reverse flow check valves has to be minimized
or the heaters run dry. If unrestrained energy is still a problem, the final alternative is to submit
data to the Doosan and we will attempt to size heater baffles which would reduce the effective
volume of water in the heater by restricting the flashing rate of the water during the time of
turbine acceleration. As the baffle flow area is reduced, significant water could collect on top of
the baffles. Sometimes relocating the cascaded drains to enter below the baffles will keep the
water volume above the baffles at an acceptable low level. Also higher pressure heaters have
more difficulty using baffles because of the large increase in available energy of a cubic foot of
water. If a suggested baffle size is issued by Doosan, the designer is to determine if the baffle
size can be installed and is to supply Doosan with the volume of water above the baffles. The
entries in the ATT. #1 form may thus require some iteration before final data is acceptable to
12

the Doosan.
Items 16 and 17 are to be filled in to show what is being done to meet the individual extraction
requirements.
Items 18 through 26 should be filled in for each different check valve that is used in the
extraction system. Note these items are not under the column headings of items 1 through 17.
The information requested is to assist in assuring that the reliability and performance of the
check valves will be satisfactory. They are grouped in four major areas.
Items 18, 19, and 20 relate to general information about the check valves.
Items 21 and 22 relate to the free swing performance of the check valve.
Items 23, 24, 25 and 26 relate to solenoid valve restriction of flow. Additional sheets may be
needed to fill in the data for all types of valves.
To eliminate late changes and corresponding higher costs the form should be returned to the
Doosan by the date shown on the top of ATT. #1 in partial satisfaction of schedule item ATT.
#1. It is appreciated the final data (to meet partial satisfaction of schedule item ATT. #1), might
not be obtained by this date, but good estimates would indicate whether a problem exists.
VI. OVERSPEED PROTECTION AGAINST EXTRACTION SYSTEM AUXILIARY
STEAM SUPPLIES
Should the unit undergo a load rejection, it is subsequently free to accelerate in speed at a rate
directly proportional to any energy input to it (minus rotation losses) and inversely
proportional to the inertia of the rotors. From the worst case point of view, it must be assumed
that no auxiliary load remains on the generator.
The form of energy input, which we are concerned with here, is due to externally unlimited or
auxiliary sup-plies of steam which enter a feedwater heater, an extraction pipe, a branch of an
extraction pipe or any auxiliary turbine or vessel equipment associated with an extraction pipe.
Interconnections between extractions on the same unit may also come under the above
category depending upon whether or not they constitute a by-pass path around normal
protective devices (i.e. main stop valves, control valves, combined valves, etc.). If such an
auxiliary supply, upon a worst case failure of regulators, reducers, various types of valves, etc.,
could have an open backflow path through the extraction piping to the main turbine wheels
and to the con-denser at full vacuum, the location of that supply must then receive special
consideration. Typically, because of the low condenser pressure, sonic flow generally would
exist somewhere in the backflow path. If the power of the resulting backflow can overcome
rotation losses, the unit will accelerate towards an unsafe speed as determined by the available
power then being equal to the losses at that speed. Any such source of supply is then defined
as being externally unlimited.
13

14

The regulators, reducers or valves mentioned above, which in an emergency would require
manual operator action, are not acceptable as turbine protective devices. Two (2) power
assisted check valves (PACV) must be situated in series in some way between the auxiliary
supply and the turbine extraction wheel space. Both PACVs must be positively closed by
action of the turbine emergency trip system through the extraction relay dump valve. This is
consistent with the two in series valves in the more common turbine flow paths (main
stop/control valves, crossover administration stop/control valves, speed matching valves and
15

combined valves) which also receive emergency trip signals.

Freeswing check valves (FSCV) may be required somewhere in the same extraction system
for other reasons, but they cannot be accepted as performing the function of one or both of the
above PACVs.
VII. TYPICAL ARRANGEMENTS
Arrangements 1 and 2 typify a popular BFP turbine design wherein the primary BFP turbine
supply is branched from a main turbine extraction pipe. An auxiliary supply, separately
admitted, enables normal operation of the BFP turbine while the main turbine is operating at
low flows. The backflow path, which must be guarded against, is through the BFP turbine
itself. It would take the path from the auxiliary supply, through the first BFP turbine stage, out
of the primary admission, through the primary supply branch and into the main turbine
extraction pipe. Depending upon the plant cycle, there are five possible arrangements as
follows.
A. ARRANGEMENT NO. 1
For the cycles in which the BFP turbine primary supply line branches from an extraction
pipe, which also supplies a closed feedwater heater, the first PACV should be installed in
the extraction pipe at some point between the main turbine and the primary supply branch
line (preferably as close to the main turbine as possible). This valve will also protect the
main turbine from the overspeed contribution of the steam and to some extent water in the
closed feedwater heater. The second PACV could be installed in the primary supply
branch, close to the primary supply stop valve. BFP turbine manufacturers generally
require a FSCV in the primary supply branch, close to the primary supply stop valves.
This FSCV would prevent backflow to the feedwater heater, while the auxiliary supply is
admitting, and loss of BFP turbine efficiency. However, since the second PACV would
provide for this function, the additional FSCV would not be required. The second PACV
would also provide the required protection of the main turbine against any other process
systems which may also have some form of auxiliary supply or contain unusually large
columns of steam.

16

B. ARRANGEMENT NO. 2
For plant cycles in which the BFP turbine primary supply branches from an extraction
pipe which also supplies a deaerator, it would not be necessary to install two additional
PACVs. These will already be provided in the extraction pipe to protect the main turbine
from the overspeed hazard presented by the large amount of water in the deaerator. The
requirement here is that the BFP turbine primary supply should branch from the
extraction pipe at some point between the PACVs and the deaerator. In this way the
same PACVs will afford the required protection of the main turbine against either the
deaerator or the BFP turbine auxiliary supply. However, for the reasons outlined under
Arrangement No. 1, the BFP turbine manufacturer may require the FSCV. Again, the two
PACVs also provide the required protection against any other process systems.
C. ARRANGEMENT NO. 3 AND 4
These arrangements are simply generalizations of 1 and 2, respectively, just discussed. It
is recognized that there may be several other types of BFP turbine cycles and designs.
There are also a number of other plant process systems which might take their primary
supply from a main turbine extraction pipe, but also require an auxiliary source of steam
into the same branch. Discounting any auxiliary supplies of steam for the moment, the
volume of a process system, such as might be in a plant heating network, could become
so large as to constitute a nearly unlimited source of steam. All such volumes should be
taken into account by the customer when filling out Form ATT. #1, shown in this bulletin.
D. ARRANGEMENT NO. 5
Upon occasion, the volume of steam and water in a closed feedwater heater will require
only a simple FSCV, or possibly no valve at all, for protection of the main turbine. In
determining and approving protective FSCV or PACV(s) requirements, for heaters and
deaerators, the Doosan will use the data supplied on Form ATT. #1. Since such
determinations could result in some liberties in choosing the numbers and sizes of FSCV
or PACVs, the customer should complete and return the Form ATT. #1 at the earliest
possible date. The PACV is generally the more costly valve with size and it is desirable to
have the optimum arrangement of valves in an extraction system, from the standpoint of
normal flow head losses, and still meet the main turbine protective requirements. Form
ATT. #1 also provides space in which to describe the auxiliary steam supplies we have
mentioned.

VIII. MISCELLANEOUS SOURCES OF OVERSPEED

17

The following list gives the possible energy sources which could result in excessive
overspeed if a load rejection occurred.
A. The deaerator and feedwater steam and water storage
B. Evaporator vapor combined with boiler feed pump turbine exhaust, or others
C. Pegging lines or startup steam connection from the boiler
D. Interconnection from the cold reheat line with some lower extraction
E. Interconnection from an extraction stage of another turbine

18

19

F. Station header fed from boilers

G. Pressurization of heaters during startup or low load operation to maintain feedwater
temperature at the inlet of the steam generator.
The overspeed potential of these energy sources can be determined by considering the available
energy storage and the maximum possible rate at which the energy can be applied to the
20

turbine rotor if reverse flow occurs. In some cases the piping may restrict the flow to such an
extent that the excessive overspeed will never be reached even though the total energy storage
is very large.
IX. PRESSURIZATION OF FEEDWATER HEATERS
On some fossil units, for example oncethru boilers of the Bensen or Universal design, it has
been deter-mined that there may be a severe overspeed problem even during the startup phases.
Consequently, it is a requirement to have two (2) PACVs between any heater receiving
pressurizing steam or pressurizzing water and the turbine. Also, it is a requirement to have two
(2) PACVs between the turbine and any heaters receiving pressurizing energy through
cascaded drains of higher point heaters.
Nuclear units are considerably more complicated in the feedwater cycle than fossil units.
Pressurizing feed-water heaters on nuclear units makes the opportunity greater for equipment
failure, control system failure and operator failure to cause excessive turbine overspeed or
water induction as compared to fossil units. Doosan Large Steam Turbine Department
recommends against pressurizing feedwater heaters on nu-clear units.
X. PROBLEMS OF LOWPRESSURE (LP) HEATER APPLICATION
Experience has shown that it is permissible, from an overspeed protection point of view, to
eliminate check valve protection in the last one or two LP stage heaters. This requires: first, the
proper location of the check valves of the other extraction lines and second, actual steam and
water volume reduction in the LP heaters by changing pipe routing, relocating heaters,
maintaining a lower water level in the heater, etc. or by the addition of a baffle plate below the
LP heater tube bundle but above the heater water volume to restrict the rate of flashing and
back flow.
In many cases, the LP heaters have been drained completely dry with the water level
maintained in separate drain receivers, standpipes, etc. A heater water level control adjusted to
hold the amount of saturated water storage at a minimum in the heater shell itself has been
possible in the majority of cases where it is necessary to do so. Such arrangements in heater
design and drain system have become increasingly important with the increasing popularity of
LP heaters located in the condenser neck where it is difficult to provide check valves in the
extraction lines.
Figures 5 through 8 show some typical methods of water volume reduction in heaters. They do
not cover all the possible methods or means of accomplishing this reduction but are
representative of some in use today.
Some gains can be made by considering the case shown in Figure 9, where there are X number
of extraction lines coming from the number Z extraction stage of LPA shell going to heater YA
21

and there are X number of extraction lines coming from the number Z extraction stage of LPB
shell going to heater YB. If these steam extraction lines or heaters are not intertied, they may
be treated as separate extractions to separate heaters. We suggest that the data requested on
DST00173A be provided for each separate heater and extraction such as YA & YB in this
example.
XI. WET EXTRACTIONSNUCLEAR UNITS
It should be recognized that the wet extraction steam associated with saturated steam cycles will
introduce variable quantities of saturated water in the extraction piping system.
The extraction lines, therefore, must be adequately pitched and drained to prevent or minimize the
accumulation of water in the extraction piping.
Where feedwater heaters are located such that the extraction line does not continuously pitch
downward or a check or isolation valve is not present between the turbine connection and the heater
shell, special attention must be given to providing adequate drainage. This could be accomplished by
use of a drain pot with a level control, high level alarm and a bypass drain dumping directly to the
condenser.
When a check or isolation valve is located in an extraction line, the extraction piping between the
turbine connection and the valve must be adequately drained. This is done to prevent accumulation of
water when the valve is closed.
For full details of the extraction drain recommendations see the Turbine Steam Drain
Recommendations.
XII. WATER INDUCTION
The introduction of water into any part of the turbine can cause serious damage to the shells, rotors,
buckets and thrust bearings. The problem has reached serious proportions. The Doosan has revised
and reissued design recommendations to prevent water induction in large steam turbines. These
recommendations are outlined in DST00132. These recommendations closely follow the
Recommended Practices for Prevention of Water Damage to Steam Turbines Used for Electric
Power Generation, issued by the American Society of Mechanical Engineers, ASME, Turbine Water
Damage prevention Committee.
Design of an extraction system consistent with the safety and reliability required of a large steam
turbine must be undertaken by reviewing the above two publications along with this publication. This
publication is now used only to consider the extraction system from an overspeed viewpoint and to
transmit the Doosans requirements to protect the unit from overspeed.

22

XIII. INFORMATION NEEDED FROM CUSTOMER

A. Forward a diagram illustrating how the emergency trip system controls the power assisted check
valves. Include high water level controls if used in conjunction with this system.
B. Forward one copy of flow diagram of steam piping and heater drain piping to assist in the review.
C. Forward a filled in copy of ATT. #1 with as many extra sheets as required.
D. The above three items should be submitted at the earliest possible time.
E. Item 3 should be resubmitted, along with any changes in items 1 and 2, in final design stages for
final engineering approval.
F. A ATT. #1 form employing Standard International (SI) units is available for use by customers
who so desire. Upon notification, Doosan will issue a form with appropriate SI units for volume. A sample
form is included in this document.

23

24

25

26

ATT. #1 EXTRACTION SYSTEM DATA

INITIAL RETURN BY CUSTOMER ___________________
REVISION # ___________________
PURCHASER ___________________ STATION ___________________ TB. NO. ___________________

TO ENSURE NO LATE CHANGES OCCUR THIS FORM SHOULD BE RETURNED TO

DOOSAN CO. BY __________________
DATE ___________________
EXTRACTION STAGE NO./ HEATER NO.
1. VOLUME OF PIPING FROM TURBINE TO CHECK VALVES (FT.3 ) OR FROM TURBINE
TO HEATER PLUS HEATER STEAM VOLUME (FT.3 ) IF THERE ARE NO CHECK
VALVES.
2. VOLUME OF PIPING FROM CHECK VALVE TO HEATER PLUS HEATER STEAM
VOLUME. ITEM 2 IS NOT TO BE ENTERED IF THERE ARE NO CHECK VALVES.
3. VOLUME OF SATURATED WATER IN HEATER SHELL OUTSIDE SUB COOLING
SECTION OR IN THE STORAGE TANK OF A DEAERATOR (FT.3 ) IF THERE ARE
CHECK VALVES.
4. VOLUME OF SATURATED WATER IN HEATER SHELL OUTSIDE OF SUB COOLING
SEC TION (FT.3 ). ITEM 4 IS NOT TO BE ENTERED IF THERE ARE CHECK VALVES.
5. VOLUME OF WATER IN HEATER SUB COOLING SECTION OR IN SEPARATE DRAIN
COOLER, OR IN SEPARATE DRAIN TANK (FT.3 ).
6. FLOW AREA (IN.2 ) OF OPENING BETWEEN SHELL AND SUBCOOLING SECTION,
OR PIPE SIZE BETWEEN HEATER SHELL AND DRAIN COOLER, OR PIPE SIZE
BETWEEN HEATER SHELL AND SEPARATE DRAIN TANK IF THERE ARE NO CHECK
VALVES.
7. AUXILIARY STEAM SUPPLY TO HEATER, IF ANY. GIVE MAXIMUM CAPACITY
(#/HR) PRES SURE, TEMPERATURE AND SOURCE. DESCRIBE SOURCE SO THAT IT
WILL BE KNOWN WHETHER OR NOT THIS SUPPLY WILL BE SHUT OFF UPON
CLOSING OF THE THROTTLE STEAM TO THE TURBINE. ALSO, INCLUDE ANY
INTERCONNECTION BETWEEN TWO EXTRACTION STAGES AS IN AUXILIARY
STEAM SUPPLY TO THE LOWER STAGE.
8. AVAILABLE ENERGY OF STEAM, BTU/PER FT.3
9. AVAILABLE ENERGY OF WATER, BTU/PER FT.3
10. TOTAL AVAILABLE ENERGY OF STEAM UNRESTRAINED BY CHECK VALVES
BTU(#1) X (#8)
11. TOTAL AVAILABLE ENERGY OF STEAM RESTRAINED BY CHECK VALVES
BTU(#2) X (#8)
12 TOTAL AVAILABLE ENERGY OF STEAM UNRESTRAINED BY CHECK VALVES
BTU(#4) X (#9)
13. TOTAL AVAILABLE ENERGY OF STEAM RESTRAINED BY CHECK VALVES
BTU(#3) X (#9)
14. TOTAL AVAILABLE ENERGY OF STEAM AND WATER, BTU (#10) + (#11) + (#12) +
(#13)
15. TOTAL AVAILABLE ENERGY OF STEAM AND WATER UNRESTRAINED BY
CHECK VALVES, BTU(#10) + (#12)
LIMITATIONS INDICATES PRELIMINARY DATA SUBJECT TO CHANGE
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE <____________ BTU, NO CHECK VALVE NECESSARY
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >____________ BTU, BUT < __________BTU, NEED ONE (1) FSCV
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >____________ BTU, BUT < __________BTU, NEED ONE (1) PACV
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >____________ BTU, NEED TWO (2) PACV
TOTAL AMOUNT OF UNTRSTRAINED ENERGY MUST NOT EXCEED____________ BTU, REFER TO DST 00132A FOR ALTERNATES:
(SUM TOTAL OF ALL AMOUNTS ENTERED IN LINE 15)
NOTE USE OF BAFFLES EFFECTIVELY REDUCES THE VOLUME OF
WATER ENTERED IN ITEM 4 & USED IN ITEMS 12 & 15. IT DOES NOT
ELIMINATE THE WATER.
16. NUMBER OF CHECK VALVES IN SERIES PER EXTRACTION LINE.
17. STATE TYPE OF CHECK VALVE, PACV OR FSCV. IF PACV, STATE WHETHER
CONTROLLED DIRECTLY BY ARDV OR HEATER HIGH LEVEL OR BOTH. STATE
BAFFLE AREA PER HEATER IF USED.

UPON RECEIPT OF THIS FORM SEE DST 00132

Doosan DATE OF INITIAL ISSUE __________________

NOTE: APPROVAL AND/OR COMMENTS OF THE SUBJECT DATA WILL BE RECEIVED BY LETTER
FROM Doosan REVISION AND REISSUANCE OF THIS FORM DOES NOT IMPLY APPROVAL.

REVISION __________________ DATE __________________

27

ATT. #1 EXTRACTION SYSTEM DATA

Purchaser ____________________ Station

Date Returned By Customer _________________________

Turbine No. ___________________

Revision No. __________________________

28

ATT. #1 EXTRACTION SYSTEM DATA

INITIAL RETURN BY CUSTOMER
PURCHASER

STATION

TB.NO.

REVISION #

TO ENSURE NO LATE CHANGES OCCUR THIS FORM SHOULD BE RETURNED

TO DOOSAN CO. BY

DATE
EXTRACTION STAGE NO./ HEATER NO.
1. VOLUME OF PIPING FROM TURBINE TO CHECK VALVES (M3 ) OR FROM TURBINE TO
HEATER PLUS HEATER STEAM VOLUME (M3 ) IF THERE ARE NO CHECK VALVES.
2. VOLUME OF PIPING FROM CHECK VALVE TO HEATER PLUS HEATER STEAM
VOLUME. ITEM 2 IS NOT TO BE ENTERED IF THERE ARE NO CHECK VALVES.
3. VOLUME OF SATURATED WATER IN HEATER SHELL OUTSIDE OF SUB COOLING
SECTION OR IN THE STORAGE TANK OF A DEAERATOR (M3 ) IF THERE ARE CHECK
VALVES.
4. VOLUME OF SATURATED WATER IN HEATER SHELL OUTSIDE OF SUB COOLING
SECTION (M3 ). ITEM 4 IS NOT TO BE ENTERED IF THERE ARE CHECK VALVES.
5. VOLUME OF WATER IN HEATER SUB COOLING SECTION OR IN SEPARATE DRAIN
COOLER, OR IN SEPARATE DRAIN TANK (M3 ).
6. FLOW AREA (CM2 ) OF OPENING BETWEEN SHELL AND SUBCOOLING SECTION, OR
PIPE SIZE BETWEEN HEATER SHELL AND DRAIN COOLER, OR PIPE SIZE BETWEEN
HEATER SHELL AND SEPARATE DRAIN TANK IF THERE ARE NO CHECK VALVES.
7. AUXILIARY STEAM SUPPLY TO HEATER, IF ANY. GIVE MAXIMUM CAPACITY
(KG/HR) PRES SURE, TEMPERATURE AND SOURCE. DESCRIBE SOURCE SO THAT IT
WILL BE KNOWN WHETHER OR NOT THIS SUPPLY WILL BE SHUT OFF UPON CLOSING
OF THE THROTTLE STEAM TO THE TURBINE. ALSO, INCLUDE ANY
INTERCONNECTION BETWEEN TWO EXTRACTION STAGES AS IN AUXILIARY STEAM
SUPPLY TO THE LOWER STAGE.
8. AVAILABLE ENERGY OF STEAM, KILOJOULES/M.3
9. AVAILABLE ENERGY OF WATER, KILOJOULES/M.3
10. TOTAL AVAILABLE ENERGY OF STEAM UNRESTRAINED BY CHECK VALVES
KILOJOULES (#1) X (#8)
11. TOTAL AVAILABLE ENERGY OF STEAM RESTRAINED BY CHECK VALVES
KILOJOULES (#2) X (#8)
12 TOTAL AVAILABLE ENERGY OF STEAM UNRESTRAINED BY CHECK VALVES
KILOJOULES (#4) X (#9)
13. TOTAL AVAILABLE ENERGY OF WATER RESTRAINED BY CHECK VALVES
KILOJOULES (#3) X (#9)
14. TOTAL AVAILABLE ENERGY OF STEAM AND WATER, KILOJOULES (#10) + (#11) +
(#12) + (#13)
15. TOTAL AVAILABLE ENERGY OF STEAM AND WATER UNRESTRAINED BY CHECK
VALVES, KILOJOULES (#10) + (#12)
LIMITATIONS INDICATES PRELIMINARY DATA SUBJECT TO CHANGE
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE <_____________ KJ, NO CHECK VALVE NECESSARY
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >_____________ KJ, BUT <_________KJ, NEED ONE (1) FSCV
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >_____________ KJ, BUT <_________KJ, NEED ONE (1) PACV
IF: TOTAL AVAILABLE ENERGY PER EXTRACTION LINE >_____________ KJ, NEED TWO (2) PACV
TOTAL AMOUNT OF UNTRSTRAINED ENERGY MUST NOT EXCEED_____________ KJ, REFER TO DST 00132A FOR ALTERNATES:
(SUM TOTAL OF ALL AMOUNTS ENTERED IN LINE 15)
NOTE USE OF BAFFLES EFFECTIVELY REDUCES THE VOLUME OF
WATER ENTERED IN ITEM 4 & USED IN ITEMS 12 & 15. IT DOES NOT
ELIMINATE THE WATER.
16. NUMBER OF CHECK VALVES IN SERIES PER EXTRACTION LINE.
17. STATE TYPE OF CHECK VALVE, PACV OR FSCV. IF PACV, STATE WHETHER
CONTROLLED DIRECTLY BY ARDV OR HEATER HIGH LEVEL OR BOTH. STATE BAFFLE
AREA PER HEATER IF USED.

UPON RECEIPT OF THIS FORM SEE DST 00132

Doosan DATE OF INITIAL ISSUE________________

NOTE: APPROVAL AND/OR COMMENTS OF THE SUBJECT DATA WILL BE RECEIVED BY LETTER
FROM Doosan REVISION AND REISSUANCE OF THIS FORM DOES NOT IMPLY APPROVAL.
REVISION __________________ DATE ___________

29