-

DOCUMENT SUBMISSION STATUS: FOR INFORMATION

2 31.03.2017 FOR INFORMATION W.H.LEE Y.D.KIM D.S.HEO

1 12.01.2017 FOR INFORMATION I.H.SONG Y.D.KIM D.S.KIM

0 08.11.2016 FOR INFORMATION I.H.SONG Y.D.KIM D.S.KIM
REV DATE DESCRIPTION PREPARED CHECKED APPROVED

PROJECT TITLE

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR

DATE NAME SIGN DOCUMENT TITLE

PREPARED 31.03.2017 W.H.LEE

NOTES OF HIGH PRESSURE

CHECKED 31.03.2017 Y.D.KIM CONTROL SYSTEM
APPROVED 31.03.2017 D.S.HEO

DOCUMENT NO. REV.

SH1-DHI-P1MAA-M-M01-SPC-3060 2
-

1. GENERAL

Figure 1 shows a typical tubing arrangement for a High Pressure (HP) control system which uses phosphate ester as the
working fluid. The high pressure hydraulic fluid piping drawing (PIPING OF HP HYDRAULIC FLUID SYSTEM,
SH1-DHI-P1MAA-M-M01-DGA-3062) is basically a diagrammatic drawing showing the interconnecting tubing
between the components of the HP hydraulic fluid system. It does not represent the exact routing of tubing.

The tubing is to be routed to suit the station conditions, consistent with the following guidelines. Tubing lines should be
routed to provide the necessary flexibility to allow for expansion of the Turbine and components. These lines must be
supported without restraining this flexibility. Care must also be taken to respect all space requirements necessary for
hydraulic cylinder removal below all valve components. Refer to valve outline drawings for these requirements.

The tubing lines are normally at 53°C or less. Table 1 gives information on tubing sizes, wall thickness and weights.
Supply and trip lines are full of fluid, drain lines approximately half full of fluid; vent lines are empty. The hydraulic
fluid weighs approximately 4.35 kg per liter.

DOOSAN supplies the tubing, fittings and flushing valves for the high pressure hydraulic system. DOOSAN provides
the mounting brackets and hangers, as necessary, to properly install the tubing system. The installation Supervisor
supervises the location of equipment, assemblies, hangers, supports and routing of this tubing to suit the Customer's
Turbine/Generator foundation and station equipment.

Tubing should be arranged to present a neat and workmanlike appearance. The number of fittings and joints should be
kept to a minimum by using bends where possible (the number and types of fittings furnished have been based on
routing, as shown on PIPING OF HP HYDRAULIC FLUID SYSTEM - SH1-DHI-P1MAA-M-M01-DGA-3062)

The total length of any individual line from origin at the Hydraulic Power Unit to termination ends at actuators
(Examples: ETS to Stop Valve(s) ; FAS to stop valves) should be minimized whenever possible, but still be provided
with adequate support and flexibility.

2. TUBING AND FITTING MATERIALS

Stainless steel tubing (Type 304) and stainless steel fittings (Type 316) are used exclusively in all lines furnished by the
factory. Fittings are socket weld tube type. Threaded connections are of the straight thread o- ring type. Normally, all
tubing of any one size and wall thickness is furnished in 3 meter lengths. Tubing is furnished in the wall thickness listed
in Table 1. The radii listed are the minimum to be used for tube bending; larger radii are preferable.
-

TABLE 1. TUBING WALL THICKNESS, WEIGHT,

VOLUME AND BEND RADIUS

WALL APPROX. VOLUME. MIN. CONTERLINE

O.D THICKNESS WEIGHT KG/M. LITER/METER BEND RADIUS
mm[inch] millimeter [lb/ft] [gal/ft] [mm/inch]
9.5[3/8] 1.25 0.25[1.07] 0.0385[0.0032] 24[0.94]
12.7[1/2] 1.65 0.45[0.3] 0.0694[0.0065] 30[1.18]
19.1[3/4] 1.65 0.71[0.48] 0.1961[0.0157] 4 ⅹTubing O.D
22.2[7/8] 1.82 0.92[0.62] 0.2705[0.0221] 4 ⅹTubing O.D
25.4[1] 2.11 1.22[0.82] 0.3523[0.0284] 4 ⅹTubing O.D
31.8[1 1/4] 2.41 1.74[1.17] 0.5717[0.0459] 4 ⅹTubing O.D
38.1[1 1/2] 3.40 2.90[1.95] 0.7694[0.0620] 4 ⅹTubing O.D
50.8[2] 3.4 3.97[2.67] 1.5205[0.1225] 4 ⅹTubing O.D
(If req. will be provided pre-fabricated by factory)
50.8[2] 2.41 3.97[2.67] 1.5205[0.1225] 4 ⅹTubing O.D
B

B
(used in drain lines only)

3. FLEXIBILITY

The hydraulic tubing must be installed to provide flexibility for expansion of the Turbine parts but still be adequately
supported and restrained so that hydraulic flow changes in the tubing do not cause excessive motion or noise.

The supply, drain, trip and vent lines are connected at one end to the Hydraulic Power Unit Which is fixed. At the other
end, these lines are connected to the steam valve actuators, which move with the Turbine and steam lines as they heat
and cool. These lines must be free to move the same amount as the end connections.

For the expansion of the Turbine and steam valves, consult the estimated expansions given in "Foundation and piping
Design Data". The ends of lines connected to the steam valve actuators move, while the ends connected to the hydraulic
power unit do not move appreciably. At any intermediate point, the movement is between these extremes. Spring
hangers permitting vertical movement may be required at the steam valves and perhaps for the entire line. Where there
is an unusually long horizontal run from the steam valve to the Power Unit, some solid rod hangers can be used at the
Power Unit which restrict vertical movement but still permit horizontal movement.

RECOMMENDATIONS

A. Tubing connected to main Stop Valves, control Valves, overload Valve, intercept valves and reheat stop valves
actuators should allow for Valve expansion motions of up to 76.2mm. The tubing arrangement should have runs in the
three principle directions (vertical and two horizontal directions at right angles) between the actuator connections and
the first tubing anchor point. The total length of tubing between the actuator and the first anchor point is shown as "L"
in Table 2. The tubing run in each of the three principle directions should be approximately 1/3 of the "L" length in
Table 2.

TABLE 2. TUBE O.D VS TOTAL TUBE LENGTH

Tube O.D. MM 10 15 20 25 30 40
Length “L” METERS 4.5 5.5 7.5 6.5 9.0 10

B. Tubing connected to the steam turbine, steam valves(On-shell Control valve) actuators supported from the Turbine
-

casing should have tubing lengths between the actuator and the nearest anchor point for the tubing equal to 1/2 of the
value of "L" given in the Table 2. The tubing should be arranged with runs in two directions at right angles to each other.

NOTE
Tubing may be supported by hangers closer to components than the figures tabulated above, where necessary; but
supports must be of the type which do not restrict tubing motion due to expansion.

C. Figure 1 shows a typical arrangement of tubing with typical anchor points and tie- together arrangements. The tie-
together points minimize noise and motion of the tubing during transient flow conditions.

4. INSTALLATION GUIDELINES

All lines must pitch continuously downward a minimum of 3.2 MM per 0.3 METER from connection on hot position of
steam valve actuators to point of connection on the Hydraulic Power Unit, With no low points in the line.

Additional recommendations for the high pressure tubing assembly are as follows:

A. Where tubing passes through clearance holes in the floor or walls, the tubing must be located so that maximum
tubing motion due to the Turbine expansion does not result in interference between the tubing and the side of the hole.

B. Air relay dump valve connection should be made as close as possible to front end ETS connection (if Power Unit
is equipped with an air relay dump valve).

C. All field connections are stamped or tagged to agree with connection symbols shown on "Arrangement of
hydraulic fluid piping_ SH1-DHI-P1MAA-M-M01-DGA-3062".

D. For installation in corrosive atmospheres such as that found in paper mills and chemical plants, all exposed
hydraulic tubing should be painted with epoxy paint.

E. All vent lines (if any) should be installed such that air flow is not blocked by fluid pockets.

F. On outdoor units, DOOSAN must provide protection and insulation for all pipes runs exposed to the elements to
avoid chilling the H.P. fluid.

5. O-RING MATERIALS

The phosphate-ester hydraulic fluid is not compatible with seal materials usually supplied for petroleum fluid use. O-
ring material and acceptable substitutes approved for use are shown in Table 3.

TABLE 3. RECOMMENDED SEAL MATERIALS

Seal Material Substitute Material

o-rings Viton Butyl rubber, Silicone
-

Caution: Some commercial bulletins and catalogues list standard seals only, and make no reference to seal materials for
phosphate-ester fluids. If there is any doubt concerning replacement seals for the hydraulic system, consult DOOSAN.
Use of incorrect seal materials can cause turbine shut-down.

6. O-RING INSTALLATION

Lubrication of the o-ring with the hydraulic fluid is recommended. Recommended thread lubricant, not Teflon tape,
should be used at assembly of fitting.
A visual inspection of the sealing face area should be made to ensure there are no rough machining marks, ridges, etc,
present, which will make sealing difficult.
O-Ring Replacement: Do not push O-ring over threads of fitting. This practice can damage the O-ring surface. A
damaged O-ring can lead to leakage trouble. Use plastic or metal thimble (such as a thread protector) to install O-ring
on fitting. Push thimble over threads, then push resilients O-ring over thimble and into groove of fitting. A properly
installed O-ring will assure a leakproof seal.

7. STAINLESS STEEL TUBING: CUT, BEND AND WELD

Do-All, pipe or tubing cutters. Do not cut stainless-steel tubing with an abrasive Wheel, as abrasive particles are
difficult to remove from the tubing and may not be completely removed during the flushing operation.

Tube ends should be cut square, and only lightly de-burred. Failure to adequately square the tube-ends will result in
uneven contact between tube and fitting in the socket weld with the possibility of leaving open areas for dirt entrapment.

For forming required curves in stainless-steel tubing, it is recommended that a heavy duty tube-bender be used. For wall
thickness and minimum bend radii of the tubing specified, see Table 1.

It has been determined that the Shielded Metal-Arc welding process gives a clean, sound weld connection with no burn
through in this application. Specifications and materials to be used for this process are given in the Process Instruction
"Instruction for Welding Stainless Steel Tube and Fittings for Electrohydraulic Control Systems."

8. SOCKET WELD TO TUBE FITTING & SAE FLANGE

It Is Necessary That:

A. The O-rings be temporarily removed prior to welding, to prevent the assembled O-ring from being subjected to
welding heat.

B. The fit-up of tubing to fittings must be such that proper axial alignment is obtained. If the fittings and tube are not
concentric and parallel (e.g., if the tubing must be pulled over to the fitting), the fittings will not seal, even if very high
torques are applied.
-

9. FLUSHING THE TUBES

Since the tubing carries fluid to the servo valves and other precision assemblies. It is absolutely essential that all foreign
material be kept out of the tubing and fittings during and after assembly.

After each piece of tubing has been cut, welded or bent, flush each length of tubing thoroughly with a non-chlorinated
solvent to remove all material which may have entered before installing the section in the hydraulic system.

Tubing which has been fabricated and assembled at the factory and removed for shipment should also be thoroughly
flushed before reassembling.

Drain thoroughly after flushing and blow clean with air. All open connections (including tubing) should be capped or
plugged at all times. Caps and plugs should be removed only immediately prior to making a connection.

For flushing of the complete Hydraulic System, refer to "HP CONTROL SYSTEM FLUSHING PROCEDURE_ SH1-
DHI-P1MAA-M-M01-OTP-3032".

10. VIBRATION DAMPING

Vibration in the tubing can be effectively dampened by using recommended clamping methods, which give adequate
support. Table 4 can be used as a guide to the distance recommended between supports in long tubing runs. Figure 2
shows the recommended type of clamp which has proven satisfactory in the field. Supports and clamping devices are
supplied by DOOSAN.

NOTE

When various size tubing is grouped together, the maximum hanger spacing must still be met for all the tube sizes in the
group.
TABLE 4. TUBE O. D. VERSUS MAXIMUM DISTANCE BETWEEN SUPPORTS
-

MAXIMUM
TUBE O/D mm(inch) DISTANCE BETWEEN SUPPORTS M
6.4(1/4), 7.9(5/16), 9.7(3/8), 12.7(1/2) 1.0
15.87(5/8), 19.05(3/4), 22.22(7/8) 1.2
25.4(1) 1.5
31.75(1 1/4), 38.1(1 1/2) 2.0
50.8(2) 2.5

11. INSTALLATION CHECKLIST

As a final check on the installation of the field run EHC tubing, hangers, clamps etc., the system should be fully
reviewed for vibration and expansion. The review should be made before the unit goes into commercial operation, and
should consist of the following:

A. Vibration Due to Unit Trip

Tubing supports should be such that vibration caused by a unit trip is dampened immediately, or within a maximum of
three (3) oscillations. These checks can be made during check-out of the steam valves.

B. Vibration Due to Full-Load Operation

Tubing supports should be such that there is no excessive vibration in the tubing when the unit is operating at full load.

Should excessive vibration be noted, a review of tubing supports may be necessary. Check type of support, placement /
or need for additional supports in the area.

C. Expansion Due to Full-Load Operation

With unit at full-load and expansions at maximum, a check should be made to determine that there is no interference
between the tubing system and any stationary members.
Particular attention should be given to the tubing and supports in the vicinity of the steam valves, as these areas will
experience the maximum expansions and vibrations
-

Figure 1 . Typical Tubing Arrangement

Figure 2. Recommended Clamping Method for Vibration Damping in Tubing.