Document No. Rev. No.

SIEMENS LTD.
62OP42654_U1_643010112 -
Responsible Department Take over Department Doc type Folder No. :
IST COE IND TPE IST OPS VAD P BOP TI
Prepared : Checked : Approved : Language :
MS 28.12.2020 BMK 28.12.2020 MP 28.12.2020 EN
Valid for : Derived from : Replaces : E file no.
GP PG IST 643010112.doc

Technical Requirements & Recommendations

Project Name :
1 x 14MW MARWAR MUNDHWA WHRS PROJECT

Customer :
THYSSENKRUPP INDUSTRIES INDIA PVT. LTD.

End Customer :
LAFARGE HOLCIM LTD.

- 28.12.2020 First Release MS BMK MP

Revision Date Description Prepared Checked Approved
We reserve the rights in this document and in the information contained therein reproduction, use or disclosure to third parties without
express authority is strictly forbidden. © Siemens Ltd
Format No.: IP-Q-F-3021/C
Rev.Date : 27.01.2015
Restricted Page 1 of 1
 Page Document Rev. No.
Siemens Ltd. 2 of 2 62OP42654_U1_643010112 -

INDEX
Turbine Requirements
S. No. Document Title Document No. Rev
1.0 Steam Condition
1.1 Steam Purity for Turbine Operation STIM-11.002 F
1.2 Main Steam Parameters Variation 1CYJ470056 -
2.0 Auxiliray System "Lube Oil"
2.1 Turbine Oil Cleaning and Flushing 1CYJ464025 D
2.2 Inservice Monitoring of Mineral Turbine oils for Steam Turbines 1CYJ470058 -
2.3 Lubrication Oil TLV 9013 05 A
3.0 Steam Blowing
3.1 Steam Blowing procedure 2CWN002896 G
4.0 Non Return Valves
4.1 Installation of QCNRV in Steam Line 1CYJ470057 A
5.0 Safety
5.1 Saftey Precautions 1CYJ470059 -
6.0 Piping
6.1 Turbine Piping Guidelines 1CYJ470060 B
6.2 Heater's Drain Piping 1CYJ470061 -
Flushing and Chemical Cleaning of TG Steam, Condensate and Feedwater
6.3 1CYJ464026 A
piping.

7.0 Turbine Preservation

7.1 Conservation of Steam Turbine During Stand Still 1CYJ470064 -
8.0 Instrument Air quality requirement
8.1 Instrument Air Quality for valves equipped with pneumatic actuator 1CYJ470068 -
Recommendations
1.0 Fire Protection of TG Hall 1CYJ470065 -
2.0 Job Site Storage of Goods 1CYJ470066 -
3.0 Grouting Material Specification 1CYJ470067 B

Format No.: IP-Q-F-3021/B

Rev. Date : 30.03.2010

Unrestricted
 Document type
No.: STIM-11.002
Steam Turbine Information Manual
Revision/Date: F 2014-08-29

Issued by: E F PR SU R&D SV 1

Title Protection Class: Restricted

Turbine Steam Purity

EXPORT CONTROLLED
Technology specified in the CCL, AL or ECL

Technical Classification: ECCN: EAR99 AL: N ECL: N US-Content: N

This document is subject to U.S. and/or national export regulations. Unauthorized diversion may be prohibited. In cases of
doubt contact your Export Compliance Department.
Dieses Dokument unterliegt nationalen und/oder U.S. Ausfuhrvorschriften. Die Verbreitung kann eine Genehmigung
benötigen. Im Zweifel wenden Sie sich an Ihre ECC Abteilung.

This document contains the turbine steam purity specification for main and auxiliary steam
condensate from the steam turbine manual, document number 1.1.3-42100-00003.

Siemens “This document contains proprietary information. It is submitted in

Energy Sector confidence and is to be used solely for the purpose for which it is furnished
and returned upon request. This document and such information is not to be
reproduced, transmitted, disclosed, or used otherwise in whole or in part
without written authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 2 of 7

Edwin Gobrecht E P SU JF UST

Released by:
Walter David E P SU R&D TEC MAT
Reviewed by:
Andrei Ghicov E P SU R&D TEC MAT 1
Reviewed by:
Michael Rziha E P ES EC COMM
Reviewed by:
Anke Soellner E P ES EN PTEC PE 4
Reviewed by:
Ludger Quick E P GT PI T M 2
Prepared by:
Name Org. Unit Signature Date

REVISION SHEET

REVISION REISSUE SECTION DESCRIPTION OF CHANGE

DATE

F 2014-08-29 Table 1 modified:

Column 4 removed, Footnotes adapted.
Table 2 modified:
“Degassed Conductivity” established, Footnotes adapted.

E 2013-05-17 All Index: Number replaced by letter

3 2008-04-23 Table 1 and Table 1 modified:
2
Limit values for silica and total copper changed.
Table 2 modified:
Action Level 1 extended to 0,5 µS/cm, if increased
conductivity is caused by CO2.
Limit values for silica, total iron, total copper in AL2, AL3
and AL4 deleted.
Footnote 5 added.
2 2001-07-25 All Merging with SWPC specification CT23977:
Text completely modified, no change in limit values

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 3 of 7

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 4 of 7

start-up

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 5 of 7

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 6 of 7

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
Steam Purity Steam Turbine Information Manual Document No.: STIM-11.002
Revision/Date: F/ 2014-08-29
Page: 7 of 7

Siemens AG “This document contains proprietary information. It is submitted in confidence

Energy Sector and is to be used solely for the purpose for which it is furnished and returned
upon request. This document and such information is not to be reproduced,
transmitted, disclosed, or used otherwise in whole or in part without written
authorization.”
 Document No. Rev.No.

SIEMENS Energy Sector 1CYJ470056 -

Responsible Department: Take over Department: Document Type: Folder No.
E O IP CE E O IP PM / PE TI
Prepared: Checked: Approved: Language Page:
SV/MT (27.03.2013) RK/MP(27.03.2013) RK/MP(27.03.2013) EN 1 of 3
Valid for: Derived from: Replaces: E File no.:
E O IP - Baroda.

Technical Instruction:
Main steam parameters variation
(As per EN ISO 60045-1, formerly IEC45-1)

- 27.03.2013 FIRST ISSUE SV / MT RK / MP RK / MP

Rev. No Date Description Prepared: Checked: Approved:

_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

SIEMENS Oil & Gas - Industrial Power 2 1CYJ470056 -

1.6 Main steam parameters variation

This guideline defines the permissible variation in the main steam parameters (at turbine inlet)
with respect to rated parameters in approved contractual HMBD as per EN ISO 60045-1
(formerly IEC45-1) – as direct extract from standard.

The steam conditions at inlet to the ESV. The limitations placed on variations of initial pressure
and initial temperature in 6.2 a) and 6.2 b) respectively are appropriate for a turbine supplied
with steam from a fossil-fired boiler or other high temperature source.

For a turbine supplied with steam at or near saturated conditions, for example from a nuclear
reactor, waste-heat recovery steam generators, non fossil-fired boilers the limitations to be
placed on initial steam conditions shall be agreed between the purchaser, the reactor supplier
and the turbine supplier.

a) Initial pressure

The average initial pressure at the turbine inlet over any 12 months of operation shall not
exceed the rated pressure. In maintaining this average, the pressure shall not exceed 105% of
the rated pressure. Further accidental swings not exceeding 120 % of the rated pressure are
permitted, provided that the aggregate duration of such swings over any 12 months of
operation does not exceed 12 h (but see note at the end of 6.2). Pressure limits on lower side
from rated value shall be applicable as per SIEMENS recommendation.

b) Initial temperature and where applicable, reheat temperature

The average steam temperature at any inlet to the turbine over any 12 months of operation
shall not exceed the rated temperature.

In maintaining this average, the temperature shall not normally exceed the rated temperature
by more than 8K. if, exceptionally, the temperature exceeds the rated temperature by more
than 8K, the instantaneous value of the temperature may vary between this figure and a value
of 14K in excess of the rated temperature, provided that the total operating time between these
two limits does not exceed 400 h during any 12 months operating period.

Operation between limits of 14K and 28K in excess of the rated temperature may be permitted,
for brief swings of 15 min or less, provided that the total operating time between these two
limits does not exceed 80 h during any 12 months operating period.

In no case shall the temperature exceed the rated temperature by more than 28K.
Temperature limits on lower side from rated value shall be applicable as per SIEMENS
recommendation.

c) Exhaust (Back) pressure

The average exhaust pressure shall not exceed the specified exhaust pressure over any 12
months operating period. In maintaining this average, the exhaust absolute pressure shall not
exceed the rated pressure by more than 10 % nor drop more than 20 % below it.
Exhaust pressure limits (Vacuum) for condensing turbines as per Siemens guidelines.

_________________________________________________________________________________________________________________________________
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Rev.Date : 31.03.2010
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SIEMENS Oil & Gas - Industrial Power 3 1CYJ470056 -

d) Abnormal operation

The purchaser shall clearly specify his requirements if operation is required in any of the
following categories, as a part of contract.

1. Part of the condenser cooling section isolated

2. Some or all of the feed water heaters out of service;
3. Overload, and how it shall be achieved;
4. Any other operating mode which imposes unusual conditions.

Siemens Steam Turbine

Live steam pressure Limits Time period / Tripping

Rated 100% Normal

Overpressure > 105% Only alarm
Main steam Pressure & Temp limits as per IEC45

Accidental swings up to 120% 12 hours for every 12 month

Accidental swings >105% Trip-Beyond 12 hours
Siemens
Under pressure Siemens Guideline
Guideline
(At Turbine Inlet)

Live steam temp Limits Time period / Tripping

Rated 100% Normal

Over temp > +8 °C Only alarm
400 hours for every 12
Accidental swings +8 °C to +14 °C
month
Accidental swings of
+14 °C to +28 °C 80 hours for every 12 month
15 minute or less
Accidental swings of
+14 °C to +28 °C Trip
> 15 minute
Trip-Beyond permissible
Accidental swings > +8 °C
hours as above
Siemens
Under temp Siemens Guideline
guideline

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ464025 D

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MP/07.01.1997 NGD/07.01.1997 NGD/07.01.1997 Eng. 1 of 9
Valid for: Derived from: Replaces: E File no.:
EO IP 464025.doc

Flushing of turbine oil systems

Contents:

Scope and range of application

1 Cleaning of the pipes
1.1 Cleaning of the pipes
1.1.1 Prefabricated pipes
1.1.2 Pipes which are adjusted and welded on site
1.2 Cleaning of the oil system components
1.2.1 Oil tank
1.2.2 Oil Filter
1.2.3 Bearing housing
2 Flushing circuit
2.1 Flushing circuit of the Lube oil system
2.2 Flushing circuit of the control oil system
3 Preparations for flushing the oil system
3.1 Preparation of the oil system
3.1.1 General
3.1.2 Inlet pipe of the jacking oil pump
3.1.3 Oil cooler
3.1.4 Flushing oil
4 Flushing procedure, Criteria for the duration of flushing
4.1 General
4.1.1 High flow velocity
4.1.2 Temperature changes during flushing
4.1.3 Hammering of the pipes
4.2 Flushing procedure
4.2.1 Emergency oil pump
4.2.2 Flushing of Oil System
4.2.3 Flushing of the Control oil system
4.2.4 Jacking oil & Turning oil gear pipes
4.3 Evaluation of system cleanliness
5 Getting the system ready for operation (After Flushing)
6 Check list

D 13.05.2019 Clause 4.2.2 & 4.3 updated BMK BMK MP

C 30.08.2018 Clause 3.1.1 updated TV BMK KS
B 27.08.2012 GENERALLY REVISED PP MP MP
A 04.08.2008 GENERALLY REVISED PP MP MP
- 07.01.1997 FIRST ISSUE MP NGD NGD
Rev. No Date Description Prepared: Checked: Approved:

_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.
2
1CYJ464025 D

Scope and range of application

These flushing specifications describe the flushing conditions and cleanliness criteria for Industrial
Turbines demanded by SIEMENS to ensure trouble-free operation of the turbo set.
In spite of installed oil filters, heavy bearing damage may be caused by foreign matter if the system has
not been flushed properly.

As a general rule it shall be observed that no turbo set must ever be started before the oil system has
been flushed in accordance with the present standard.

1. Cleaning of the pipes

Successful cleaning of the oil system including bearing housing and cooler from scale, rust, sand and
other foreign matter is only ensured if the following preconditions are complied with.

1.1. Cleaning of the pipes

1.1.1. Prefabricated pipes

All prefabricated pipes supplied shall have been as far as possible cleaned and treated with a
preservation agent according to specification (1CYJ464027). If the pipes have not been flushed, they
shall be tagged accordingly and flushed at site.

If the pipes cannot be mounted immediately, they shall be suitably stored to avoid new contamination
(Pipe ends to be covered with a plastic lid; storage not in the vicinity of sand blasting or grinding work).

Pipes, which need not be adjusted or welded any more on site, shall be thoroughly checked for
cleanliness and be cleaned if necessary prior to their installation. Care shall be taken that no dirt particles
are retained due to the preservation agent. Removal of the preservation and dirt shall be done with a cold
cleansing agent followed by blowing out with air (the regulations governing the use of hazardous material
must be observed).

1.1.2. Pipes which are adjusted and welded on site

Before starting the work to be done, the areas to be welded of the pipes prepared for welding shall be
cleaned from the preservation by means of a solvent (mind the regulations governing the use of
hazardous material). Inert-gas-shielded welding shall be used for all welds.

1.2. Cleaning of the oil system components

1.2.1. Oil Tank

Prior to starting oil flushing the oil tank shall be checked for contamination and if required to be cleaned
properly. Same is applicable for Overhead Oil Tank (if applicable), Drain Oil Tank (if applicable) &
Collecting Oil Tank (if applicable) also. Before filling the oil tank with turbine oil for the first time, the oil
tank shall be subjected to an acceptance test and a corresponding report issued. The same procedure
shall be carried out before refilling the turbine oil after flushing.

1.2.2. Oil Filter

Oil Filter cartridges to be removed and filter casing to be checked for contamination and if required to be
cleaned properly.

1.2.3. Bearing housing

Independent of the flushing procedure, the bearing housings shall be subsequently checked and
thoroughly cleaned.

Remarks!

· Cotton waste or fluffing rags must not be used for cleaning.

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1CYJ464025 D
· Diesel fuel and silicone type sealing compound will destroy the oil and must not under any circumstances be
used.

2. Flushing circuit

2.1. Flushing circuit of the Lube oil system (Refer to Flushing PID)

The flushing oil is bypassed at the bearings by means of bypass connection between bearing inlets and
outlets. The flushing oil is also bypassed around the oil-containing equipment which is susceptible to
functional disturbances in the case of minor oil contaminations.

The Bypassed equipment includes the following systems:

- Hydraulic shaft turning device (if applicable)

- Manually operated pump for the hydraulic shaft turning device (if applicable)
- Jacking Oil Pump (if applicable)
- Hydraulic flow control valve and non-return flap valve
- Main Oil Pump – Gearbox Shaft Driven (if applicable)
- Overhead Oil Tank
- Temperature control valve (if applicable)

For flushing the suction and pressure pipes of a shaft driven Main oil pump, the pressure-side non-return
flap valve will be removed and replaced by a spool piece. As the main oil pump is removed, there will be
sufficient space for placing a bypass between the suction pipe and the discharge pipe.

Damage of the auxiliary or emergency oil pump due to dirt particles carried into the tank by the flushing oil
need not be expected. The strainer screens will retain the dirt particles.

The pressure pipes of the emergency oil pump are cleaned by means of the emergency oil pump.

The non-return valve flaps of the Auxiliary and Emergency oil pumps are not dismantled for the flushing
procedure.

Temperature control valve (if applicable) shall be isolated and bypass with the help of the valve provided
with the system.

The Lube oil header pressure regulating valve (if applicable) shall be removed and replaced by a spool
piece.

Remarks!

All necessary bypass connection(s), loop(s), hose(s), spool(s), Screen(s), flanges with necessary
hardware, fittings etc. required for oil flushing shall be provided by “Erection Contractor”

2.2. Flushing circuit of the Control oil system (Refer to Flushing PID)

The bypass of the following components is part of the preparatory work for flushing the Control oil circuit:

- Servomotor(s)
- Current to Pressure convertor / I to H converter
- Safety Block
- Valve Actuator for Emergency Stop Valve

For flushing the orifice provided in the inlet of servomoters shall be removed.

3. Preparations for flushing the oil system

The lube oil system shall not be flushed before it is completely assembled. Erection work of the turbo set
should be completed as much as possible, any temporary solutions shall be avoided and all
arrangements interfering with the system shall be limited to a minimum.

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1CYJ464025 D
In order to avoid that any blind flanges and other flushing facilities remain in place by mistake after
flushing, all modifications made to the system for the purpose of flushing shall be noted down on a special
list. After completion of the flushing procedure, the operating conditions of the system shall be restored
with the help of this list.

3.1. Preparation of the oil system

3.1.1. General

· The system will be flushed with the help of the auxiliary oil pump(s). If two 3-ph A.C driven pumps are
available, they shall be operated together to increase the effectiveness - Higher flow velocity. The
pump drive motors must be equipped with the normal protection equipment. Care shall be taken not
to exceed the admissible power input indicated on the maker’s name and rating plates of the motors.

· Monitoring of the oil level in the tank must be ensured. (For this purpose, the suction basket length
from the oil tank cover is to be measured and the oil quantity suitably determined to ensure an oil
level, at least 50 – 60% tank level to be maintained during normal flushing operation).

· All adjustable orifices in the oil supply piping shall be fully open to allow maximum flow in the system.

· The oil vapor extraction fan must be in operation during flushing.

· Setting of the maximum possible oil flow is accomplished by closing the pressure control valve
(tightening the setting screw). Care shall be taken that the oil pressure does not exceed 2.5 Bar (g).

· To fulfill this requirement, pressure switch at oil supply header to be installed at the time of oil
flushing. An interlock also to be provided with the pump in order to avoid pressure beyond specified
limit.

· MCC protection scheme to avoid over pressure of the pump is given in Annexure I.

· All filter inserts / cartridges must be removed.

· A throttling plate with an open cross section of 10 % to 15 % of the inner pipe cross section or
Butterfly valve shall be installed in drain header at the last flange upstream of the oil tank. If the
throttling plate is used, opening must be situated in the bottom area of the pipe. Because of this
throttling plate entire inner cross section of the pipe will be filled with oil during flushing.

· The suction and pressure sides of the main oil pump shall be connected by means of a bypass.

· The non-return flap valve in the pressure pipe shall be removed. After the flushing procedure, the oil
channels shall be cleaned manually and by blowing out with air.

· High point vents to be provided in flushing circuit to ensure proper venting of the trapped air during
flushing startup.

3.1.2. Inlet pipe of the Jacking oil pump (If applicable)

The inlet pipe of the jacking oil pump shall be led direct to the oil tank by means of a bypass connected
upstream of the pump.

3.1.3. Oil cooler

Both coolers are completely mounted and connected on their oil and water sides. The oil temperature is
increased by admitting hot water to the cooling water side. The oil can also be heated using the heating
coil in the tank and by using the heating coil of the oil purifier, while the pump is in operation for more than
8 hours.

· The maximum water temperature in case of water heating shall not increase 80 °C. Heating of the
water shall be done carefully and slowly to avoid a temperature shock inside the cooler. The heating

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1CYJ464025 D
water circuit shall incorporate one cooler only so that quick cooling down of the oil is possible
through the second cooler.
· An oil temperature between 60- 70 Deg. C must be maintained while flushing.

3.1.4. Flushing oil

· Only new flushing oil shall be used (ISOVG32 or ISOVG46) depending on which oil shall be used
during normal operation. The oil shall be delivered in accordance with Siemens specification &
Technical delivery terms (TLV 9013-05) and amount of oil required shall be as per specification
provided by SIEMENS.
· The flushing oil can be reused as first fill lubrication oil as per technical instruction provided by
SIEMENS (Refer document no. 1CYJ461103E43)

4. Flushing procedure, Criteria for the duration of flushing

4.1. General

Pipes which are properly ground and pickled are free from scale and weld splatter. Oil flushing is primarily
intended to remove from the oil system any loose foreign particles that are lying in the pipes or dirt
sticking to the wall.

· Efficient oil flushing is only possible if the following requirements are fulfilled:

4.1.1. High flow velocity

The oil must flow through the pipes at the highest velocity possible.
Before starting the oil pumps for the first time, the pressure control valve is fully opened. As soon as the
Auxiliary pump is in operation, the control valve is slowly closed while observing the oil flow as well as the
pump capacity (take care that the power consumption of the oil pumps is in accordance with the
admissible rating data of the motors, i.e. that the pumps are not overloaded), in order to achieve
maximum flow velocity in the oil pipes.

· High flow velocities will be achieved if the overall oil system is divided into partial systems. (Please
refer point no. 4.2 for further details)

4.1.2. Temperature changes during flushing

Particles which are sticking to the inside walls of the pipe are to be loosened by the effect of thermal
shocks (differential expansion).

The Thermal shocks can be created in two different ways:

a) Heating of the oil.

Subsequently, the heating source is disconnected and the second oil cooler with the cold cooling
water is connected instead so that now cold lube oil can flow through the previously hot pipes.

b) After heating of the oil system and oil pipes, cooling down is achieved by stopping the lube oil pump.
This abbreviates the duration of the flushing procedure and saves time.

Remarks!

· The heating and cooling method described under a) should always be used because this type of
temperature change has the greatest effect.

4.1.3. Hammering of the Pipes

During flushing, the pipes shall be hammered with a high-frequency pneumatic vibrator fitted with a
copper or hard-rubber top, so that any dirt sticking to the walls is loosened and can be carried more easily
by the lube oil flow to the oil tank strainer. If a pneumatic vibrator is not available, the pipes shall be
hammered by hand with the help of a plastic hammer.

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1CYJ464025 D
Remarks!

· During this, care shall be taken to avoid any damage to the pipes and pipe supports.

4.2. Flushing Procedure

The oil is cleaned with the filters or strainers or screens / flushing oil filter installed in the drain header.

· Flushing should be carried out for each lines as per below steps to achieve high flow velocities in oil
lines.

Flushing Lines Step 1 Step 2 Step 3

Flushing for Turbine Front & Rear Bearings inlet & outlet Not Not
Connected
bypass loop Connected Connected
Not Not
Flushing for Gearbox Bearings inlet & outlet bypass loop Connected
Connected Connected
Not Not
Flushing for Alternator Bearings inlet & outlet bypass loop Connected
Connected Connected
Overhead Oil Tank supply & overflow bypass loop Connected Connected Connected
Not Not Not
Control oil system piping’s / tubing bypass loop
Connected Connected Connected

Remarks!

· During the flushing procedure, the flushing oil is circulated by means of the Auxiliary oil pump. In the
oil return line to the tank, screen of 200 microns mesh size has to be installed. Gradually reduce the
screen size to 150, 100, 50 & 30 microns as contamination reduces. Same procedure to be followed
for Step 1, Step 2 & Step 3.

4.2.1. Emergency Oil Pump

After step 3 when the 30 micron screen in the return oil line is clear, the relatively short pressure pipe of
the Emergency Oil Pump shall be flushed. For this purpose, the pump shall be operated for 2 - 3 hours.
After that 30 micron screen shall be remain in clean condition, if not continue flushing for emergency oil
line until system is clean.

Remarks!

· All other oil pumps shall be shut down during that time.
· All Connections / loops prepared for Step 3 should remain as it is for flushing Emergency oil pump
lines.

4.2.2. Flushing of the oil system

After the above cycle & when 30 micron screen in the return line is clear remove the bypass connection to
the bearings of Turbine, Gear unit & driven machine and install lube oil filter elements.

Ensure the level of the oil tank is to 50 - 60 % of the operating oil quantity. Now lube oil is circulated in the
lube oil system with main oil filters.

Start the flushing of system and run for a minimum of 2 hours & ensure that main filter elements are in
clean condition. If the filter differential pressure reaches the value of contamination, clean/replace the
filter elements.

The flushing shall be considered complete when the filter differential pressure remains essentially
unchanged for 4 hours and the solid contamination code conforms to the 19/17/14 contamination code
outlined in ISO 4406.

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1CYJ464025 D
4.2.3. Flushing of the Control oil system

Before terminating the flushing procedure of the lube oil system, the control oil system shall be
incorporated into the flushing circuit. Flushing of the control oil system is completed when the differential
pressure remains essentially unchanged and the service life of the control oil filters (if applicable)
exceeds 24 hours.

4.2.4. Jacking Oil & Turning gear pipes (If applicable)

Connect the jacking oil supply line(s) to the jacking oil pump(s). All jacking oil pressure lines to be
connected to lube oil return lines with hoses.

Start the lube oil pump and than jacking oil pump. Keep them in operation for at least 4 hours. Shut down
the first jacking oil pump and start the second one (if applicable) and keep them in operation for at least 4
hours.

Reinstall jacking oil piping / tubing and repeat the procedure for turning gear tubing (if applicable)

Remarks!

A strong stream of jacking oil shall be discharged from each pipe.

4.3. Evaluation of System Cleanliness

A high degree of oil purity in the turbine oil system is required in order to prevent damage to bearings (or
jamming), gear transmission and all other oil supplied components, and also for operation of turbine
control system.

The worldwide accepted and up-to-date standard for classifying the oil purity is ISO 4406:1999. According
to this standard, the number of particles of the sizes > 4 µm, > 6 µm and > 14 µm is determined that exist
in a sample of 100 ml of the liquid to be examined. The particles can be counted either microscopically or
with the help of an automatic particle counting device.

ISO class 19 / 17 / 14 says that the following are found in 100 ml of analyzed sample:
250000 - 500000 particle > 4 µm (c)
64000 - 130000 particle > 6 µm (c)
8000 - 16000 particle > 14 µm (c)

5. Getting the system ready for operation (After Flushing)

· All flushing pipes, bypasses, screens, blind flanges and orifices installed or attached for the purpose
of flushing shall be removed and the "dead ends“ resulting thereof or the fittings and pipe sections
dismantled shall be manually cleaned and re-installed.

· The bearings and oil channels of the bearing housings which are part of the flushing circuit shall be
manually cleaned and mounted together with the upper part of the bearing ready for operation.

· The oil pans of the bearing housings shall be cleaned.

· The bypasses at the main oil pumps shall be removed and the “dead ends” resulting thereof or fittings
shall be manually cleaned and re-installed.

· The suction filter of the main oil pump, auxiliary oil pump & emergency oil pump shall be cleaned
internally and re-installed.

· The non-return flap valves in the pressure pipe of the main oil pump shall be re-installed.

Important: Be careful to install the non-return flap valve for operation in the correct direction.

· All filter elements must be checked for cleanliness and thoroughly cleaned prior to assembly. Also
check and clean the filter housing carefully.

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Rev.Date : 31.03.2010
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8
1CYJ464025 D
· After termination of the flushing procedure, the oil tank shall be drained and cleaned. In case the
same lube oil is to be used for later operation, it shall be purified, filtered and returned to the oil tank
via an oil purification system.

Remarks!
· The oil shall be drained in warm condition. Make sure that the heaters are switched off before the oil is
drained. Make also sure that all oil has been drained from pipes, coolers, components low points, etc.

· Before draining the oil tank, it is advisable to allow for a certain settling time of about one day so that
all dirt particles can settle on the oil tank floor.

· Before filling in the filtered turbine oil, the oil tank shall be checked and a corresponding report be
issued.

· All non-return flap valves installed in the oil systems shall be checked for correct installation and
trouble-free operation.

· Any expansion joints (rubber or metal) incorporated in the piping system shall be dismantled and
cleaned.

· By installing pressure gauges at the measuring points downstream of the inlet orifices, it is possible to
check the lube oil flow to the bearing.

6. Check list
For the flushing of the oil system a check list shall be completed which comprises the following pages:

CHECK LIST – FLUSHING OF TURBINE OIL SYSTEMS

This check list is to demonstrate that the individual points under this factory standard have been properly
complied with.

The check list is allocated to the documentation of new equipment, provided with a corresponding
document number and documented accordingly.

The individual items on the check list will be checked one by one and either be ticked off or completed
with additional information (remarks), as applicable.

The person who has attended to the individual point shall confirm the proper execution of the work by
signing with his name and date at the corresponding place on the check list.

· Reference Documents :

Sr. No Description Document no. Rev.

1 Flushing Circuit of Lube Oil System 1CYJ247967P656 -
2 Flushing Circuit of Control Oil System 1CYJ247967P657 -
3 Technical Instruction : Reusing flushing oil as first fill 1CYJ461103E43 -
4 Cleaning Procedure: Carbon steel & Stainless Steel piping 1CYJ464027 B
5 Check List - Flushing of Turbine Oil Systems 1CYJ470046 -
6 Turbine Oils TLV 9013 05 May 2012

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Annexure I

In TGMCC ( either in Siemens or customer scope) , the lub oil

pressure switch NC contact ( 1 = health and 0 = pressure high )
need to be wired in feeder STOP control circuit
during oil flushing condition .
This contact need to be removed after oil flushing process .

Auxiliary / Main
oil Pump Motor

Temporary connection of Lub oil pressure switch during oil flushing

process to avoid over pressure by automatically tripping Motor Feeder .

Note : The above circuit represents conceptual view and same need to be followed
in project specific MCC circuit.
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470046 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
PP / 07.09.2012 SB / 07.09.2012 MP / 07.09.2012 Eng. 1 of 4
Valid for: Derived from: Replaces: E File no.:
EO IP 470046.doc

Check List - Flushing of Turbine Oil Systems

- 07.09.12 FIRST ISSUE PP SB MP

Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470046 -
1. Flushing Turbine Oil Systems : Check List

Project Name: Customer :

Machine Type :

Step 1 :
Remarks Date Name

Piping System

Before installing any of the pipes listed

below, blow them through with
compressed air first:

1) Supply and return oil pipes

2) Instrument line
3) Impulse line

All pipes clear at the locations listed

below?:

1) Branches
2) Tapers
3) Gauge connections

All seal plugs removed before assembly ?

Insides of the piping visually checked

1) For Dirt ?
2) Weld seams ?

Piping system acid-treated and then

neutralized ?

Step 2 :

Before Filling with Oil for the First Time

Main oil Tank cleaned ?

All electrical connections available ?

Temperature control valve isolated and

bypassed ? (If Applicable)
Oil Centrifure ready for operation ?

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Rev.Date : 31.03.2010
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3 1CYJ470046 -
Step 3 :

Remarks Date Name

Flushing

Oil level monitored in oil container ?

Oil low level interlock for pump ?

Checking of direction of rotation of :

1) Auxiliary oil pump

2) Emergency oil pump
3) Jacking oil pump (If applicable)
4) Oil vapour extractor
5) Control oil pumps (If applicable)

Current consumption of Auxiliary oil

pump ?

Oil vapour extractor ready for operation ?

Flushing loop prepared ?

1) For Turbine bearings

2) For Gearbox bearings
3) For Alternator bearings
4) For Overhead oil tank
5) For Control oil system pipings
6) For Main oil pump
7) For Jacking oil & Turning Gear

Adjustable orifices fully opened ?

Flushing filter / return line screens

installed ?

Pressure of lubricating oil not above 2.5

bar

Oil temperature (60 - 70° C)

Piping tapped during flushing ?

Have all piping sections been flushed ?

Pressure line of emergency oil pump

flushed ?

Control oil line flushed ?

Jacking oil & Turning gear (if applicable)

lines flushed ?

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

4 1CYJ470046 -
Step 4 :

Remarks Date Name

Oil Tank

Oil tank drained through cenrifuge ?

Has all of the flushing oil been drained ?

All oil pump suction filter has been

cleaned?
Final lube oil test report avalable ?

Step 5 :

Making Ready for Operation

Has the bearing casing been checked for

dirt and cleaned

Have any pipes been cleaned that may

not have been flushed. ("dead sections")

Temperarory flushing loop has been

removed ?

Have the blank flanges been removed

All filters cleaned ?

All non-return valves installed in correct

direction

All bearings are supplied with oil with the

auxiliary oil pump running

Blocking equipment on temperature

control valve disengaged ?

Lube oil header pressure regulating valve

/ pressure control valve installed ?

Date Name
Checked

Released

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ464027 B

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MP/07.01.1997 NGD/07.01.1997 NGD/07.01.1997 Eng. 1 of 4
Valid for: Derived from: Replaces: E File no.:
EO IP 464027.doc

Cleaning Procedure:

Carbon steel & Stainless Steel piping

Oil tanks & Oil coolers for Oil system.

B 07.09.12 GENERALLY REVISED PP MP MP

A 04.08.2008 GENERALLY REVISED PP MP MP
- 07.01.1997 FIRST ISSUE MP NGD NGD
Rev. Date Description Prepared Reviewed Released
_________________________________________________________________________________________________________________________________
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forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ464025 B
This specification aims at the cleaning procedure for carbon steel, stainless steel piping, oil tanks and oil
coolers for oil system.

A. Cleaning Procedure for Carbon Steel Oil piping

The following procedure to be strictly followed for cleaning of carbon steel oil piping

1) Deburring:

Remove scale and corrosive layer by a wire brush or by sand-blasting method. For smaller sizes
of pipes pull method of wire brush can be adopted.

2) Cleaning :

1. After deburring the pipes, degrease them with detergent water.

2. Acid clean the pipes in Hydrochloric Acid Bath solution. This solution contains Hydrochloric Acid
with 30 – 35% concentration and water in the ratio of 1: 10. Keep the pipes in the solution for
about 8 hrs and then wash them in clean and normal water.
3. Now the pipes are to be kept in Neutralising solution for about 2 hrs. This solution is prepared by
mixing 3 kgs of Caustic Soda with 100 ltrs of water. Since the reaction is exothermic, the
temperature of the solution may reach up to 90 degrees. Again wash the pipes with clean and
normal water.

3) Pressure Testing :

The pressure test of the pipes shall be carried out as mentioned below:

1. All Control Oil pipes to be pressure tested at 12 barg.

2. All Lube Oil pipes to be pressure tested at 4 barg.
3. All Return Oil (Drain) pipes to be pressure tested at 2 barg.

4) Anticorrosive Treatment :

After caring out pressure testing of the pipes, blow hot air through the pipes to remove water
particles.
Apply “RUSTOP-274” or “TECTYL-511” on the inner as well as outer surface of the pipes and blow
compressed air to spread it thoroughly.
All Holes / Openings in the pipes shall be plugged by Plastic / Wooden plugs.

B. Cleaning procedure for Stainless Steel Oil Piping

The following procedure to be strictly followed for cleaning of carbon steel oil piping

1) Cleaning :

Clean the pipes by a wire brush. For smaller sizes of pipes pull method of wire brush can be
adopted.

2) Wiping :

Clean the interior of the pipes with linen cloth drawn through the pipes.
Prior to cleaning, excessively dirty pipes should be degreased in Neutralising solution which is
prepared by mixing 3 kgs of Caustic Soda with 100 ltrs of water.

_________________________________________________________________________________________________________________________________
_____
Format No.: DDIT3009
REV./Date : A/08.12.2005
 Page: Document No. Rev.No.

3 1CYJ464025 B
3) Pressure Testing :

The pressure test of the pipes shall be carried out as mentioned below:
1. All Control Oil pipes to be pressure tested at 12 barg.
2. All Lube Oil pipes to be pressure tested at 4 barg.
3. All Return Oil (Drain) pipes to be pressure tested at 2 barg.

Note
Brush, steel wool and wire rope should not be of Carbon steel material.

C. Clearing Procedure of Oil Tank

1) Deburring :

Remove scale, corrosion, burrs, metal / weld lumps from tank as well as nozzles & fitment of the
tank.
1. Clean properly weld areas &remove all weld spatters.
2. Perform sand /shot blasting.

2) Cleaning :

1. Degrease tank with detergent water.

2. Cleaning: take hydrochloric acid of 30-35% concentration; mix with water in the ratio of 1: 7 fill up
the tank with this solution & keep it for 8 hrs duration approx.
3. Washing: Rinses the tanks with plain normal water & ensure no trace of HCL remains inside.
4. Neutralising: Neutralising solution is made from caustic soda and water, Take 3kgs of caustic
soda and mixes it with 100 ltrs of water fill up the tank with this solution. Solution temperature
may reach 90 degree C due exothermic reaction. Keep the solution for 2 hrs duration approx.

PRESSURE TEST & ANTICORROSIVE TREATMENT:

1. Pressure test tank with water as per requirement.

2. Keep the tank dry with hot air and apply “Rustop- 274” inside & outside surface of tank to
protect from rust.

CLOSE THE TANK AND NOZZLES IMMEDIATELY TO AVOID DUST TO GO IN.

D. Cleaning Procedure of Oil Cooler :

1) Deburring:

1. Remove scales, corrosion, burrs, metal lumps etc. from shell as well as holes provided for fitment
of nozzles.
2. Remove scales, corrosion, burrs, metal lumps etc. from both dished ends as well as holes
provided for fitment of nozzles.
3. Clean properly weld area of shell & dished ends & remove all weld spatters.
4. Sand blast shell & dished ends.

CLEANING OF SHELL & DISHED ENDS AFTER WELDING OF FITMENTS BUT BEFORE WELDING
OF TUBE SHEETS WITH SHELL.

1. DEGREASING: Degrease and clean shell and dished ends with detergent water.

2. CLEANING: Take hydrochloric acid of 30-35 % concentration. Mix with water in the ration of 1:10.
Put shell & dished ends in the above solution.

_________________________________________________________________________________________________________________________________
_____
Format No.: DDIT3009
REV./Date : A/08.12.2005
 Page: Document No. Rev.No.

4 1CYJ464025 B
Duration – 8 hours approx.

3. WASHING: Wash shell & dished ends with plain normal water. Ensure no trace of HCL is left out.

4. NEUTRALING: Neutraling solution is made from caustic soda and water.

Take 3 kg of caustic soda and mix it with 100 litres of water. Put shell and dished ends in the
solution. Solution temperature may reach 90 deg. c due to exothermic reaction.

Duration - 2 hours approx.

CLOSE OIL INLET& OUT LET NOZZLES WITH DUMMUY FLANGE & GASKET IMMEDIATELY AFTER
WELDING OF TUBE SHEETS WITH SHELL.

ENSURE ALL FUMES ARE EXHAUSED GENERATED DURING WELDING.

PRESSSURE TESTING & RUST PREVENTIVE TREATMENT:

1. Pressure test cooler with water as per requirement.

2. Dry with hot air. Ensure no water particles are left out inside the cooler.

3. Apply rustop-274 inside & out side surface of cooler as rust preventive. Ensure application of
RUSTOP on inside surface of shell & dished end of the cooler.

4. Close all the nozzles with dummy flange and gasket to avoid dust getting inside.

_________________________________________________________________________________________________________________________________
_____
Format No.: DDIT3009
REV./Date : A/08.12.2005
 Document No. Rev.No.

SIEMENS LTD. 1CYJ461103E43 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
PP / 10.04.2012 SB / 10.04.2012 MP / 10.04.2012 Eng. 1 of 2
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E43.doc

Technical Instruction:
Reusing flushing oil as first fill

- 10.04.12 FIRST ISSUE PP SB MP

Rev. No Date Description Prepared: Checked: Approved:

_________________________________________________________________________________________________________________________________
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forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ461103E43 -
General:

Lube Oil System shall be flushed before first turbine start as per Flushing of Turbine Systems
(1CYJ464025)

Draining of Flushed oil:

Draining of flushed oil shall be done through centrifuge only. Flushed oil shall be collected
to empty oil drums / drain oil tank (If provided) only.
Centrifuge suction line to be connected to Main oil tank drain line provided at tank bottom &
centrifuge discharge line pipe to be connected to empty oil drum / drain oil tank (If provided)
Before draining the oil tank, it is advisable to allow for a certain settling time of about one
day so that all dirt particles can settle on the oil tank floor.
The oil shall be drained in warm condition. Make sure that the heaters are switched off
before the oil is drained.
Make also sure that all oil has been drained from all pipes, both coolers & filters,
components low points, etc.
Temporary piping / hose pipe to be used for draining oil form all pipes, both coolers & filters,
components low points, etc.

All components to be cleaned after draining of flushed oil as per Flushing of Turbine Systems (1CYJ464025)

Refilling of Flushed oil:

Refilling of flushed oil shall be done through centrifuge only, collected in empty oil drums /
drain oil tank (If provided).
Centrifuge suction line to be connected to empty oil drum / drain oil tank (If provided) and
centrifuge discharge line pipe to be connected to main oil tank oil filling line or centrifuge
return line.

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470058 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
PP / 26.03.2013 SB/ 26.03.2013 MP / 26.03.2013 Eng. 1 of 7
Valid for: Derived from: Replaces: E File no.:
EO IP 461103EXX.doc

Technical Instruction:
In-Service Monitoring of Lube Oil for Steam
Turbines

- 29.03.2013 FIRST ISSUE PP SB MP

Rev. No Date Description Prepared: Checked: Approved:

_______________________________________________________________________________________________________________________________
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strictly forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Document No. Rev.
No.

1CYJ470058 -

1. General:

The guidelines in this document are based on practical experience from SIEMENS Ltd. and
international standards for condition monitoring of lubricating oils.

This document is intended to assist the user to maintain effective lubrication of all parts of the turbine
generator set. It includes information and recommendations regarding lubricating oil quality, sampling
and testing schedules and actions that must be taken if the quality of the lubricating oil is not within
given recommendations.

The document is not universal and cannot be expected to cover all issues that may be connected to
lubricating oil.

2. Properties of turbine oil:

Turbine oil is usually paraffin based mineral oil consisting of a mixture of saturated hydrocarbons and
different additives. Additives are added depending on the requirements on the lubricating oil, for
example oxidation inhibitors, rust inhibitors and anti wear agents.

While new turbine oil should exhibit properties fulfilling the material specification, these properties
cannot be expected to remain unchanged during the life of the oil. Lubricating oil experience thermal
and oxidative stresses which gradually deplete the oil’s additive package and also degrade the
chemical composition of the oil’s base stock.

Some deterioration can be tolerated without consequences to the safety or efficiency of the system,
but good monitoring procedures are necessary to determine when and how the properties of the oil
have changed. This helps the user to judge the condition of the oil and decide when actions are
required.

3. Why turbine oils degrade:

Regardless of the initial quality of the oil, the turbine oil will deteriorate in service. Air, elevated
temperature, metals and water are always present to some extent in turbine oil systems. These
elements promote oil degradation. Deterioration occurs by one or a combination of the processes
mentioned below.

Oxidative degradation – Presence of oxygen causes the oil to degrade chemically in a constant
chain reaction. Additives are added to all modern lubrication oils to act as a buffer against
oxidation and protect the base oil from degradation.

Thermal/oxidative degradation – At elevated temperatures, hydrocarbons are subject to thermal

cracking, forming unstable compounds. These unstable compounds are easily oxidized and do
also tend to polymerize, forming resins and sludge.

Water accumulation in system – Water promotes degradation as well as additive depletion,

corrosion, reduced lubricating film thickness and microbial growth.

Loss of additives – This can result in more rapid oxidation, premature rusting and formation of
deposits and sludge.

System impurities – Remains of rust protection fluids and cleaning agents can influence the
properties of the turbine oil.

Contaminants – Contaminants arising within the system (for example additive-, corrosion- and
wear products) or entering the system (for example dirt and fluids) can cause lubrication and wear
problems.

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Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.
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1CYJ470058 -
The deterioration process cannot be stopped but it can be delayed. This can be achieved by using
high quality Lubrication oil, by making sure the system is clean before filling and by minimizing the
possibilities of contamination. Proper maintenance and adequate monitoring of the oil is necessary in
order to achieve a high reliability of the lubricating system.

4. Monitoring of turbine oil:

The main purpose of a monitoring is to ensure a long trouble-free operation of the turbine generator
set. This can be achieved by taking prompt and proper action steps. Such action steps should be
based on correct interpretation of test results and operation experience gathered over a period of
time. Siemens Ltd. developed an oil condition monitoring program for our turbines based on years of
experience and international standards for condition monitoring.

4.1 Analysis of oil after flushing

A sample shall be taken after flushing in order to verify the delivered oil quality. The results shall be
used to establish a baseline of oil properties for complete use of a condition monitoring program. The
sample after flushing should be analyzed according to table 1. See table 4 for analysis methods and
standards.

Table 1: Recommended analyses after flushing

Oil properties
Chemical elements
Viscosity
Total acid number
Water content
Cleanliness
Anti-oxidation additives
Air release
Demulsibility
Foaming (at 50°C)
Oxidation stability

4.2 Analysis of oil in normal operation

The condition of the oil should be monitored according to the schedule in table 2. See table 3 for
warning levels and actions if these are exceeded and table 4 for analysis methods and standards.
Depending on analysis results it may be necessary to change the frequency of analysis for certain
properties.

Table 2: Recommended analysis frequency during normal operation. See table 4 for analysis methods
and standards.

Oil property Frequency of analysis

th
Chemical elements Every 6 month
th
Viscosity Every 6 month
th
Total acid number Every 6 month
th
Water content Every 6 month
th
Cleanliness Every 6 month
th
Oxidation product content Every 6 month
th
Anti-oxidation additives Every 6 month
th
Air release Every 12 month
th
Demulsibility Every 12 month
th
Foaming (at 50°C) Every 12 month
th
Oxidation stability Every 12 month

4.3 Monitoring and supervision of the oil system

_______________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.
No.

1CYJ470058 -

Continuous supervision of the oil system ensures optimum efficiency and high availability. The
following actions will help greatly to keep the oil in serviceable condition and to notice coming issues
beforehand.

Change, or if possible clean, filters regularly.

Make sure that openings in the tank and pipes are only uncovered for a short time and only if
absolutely necessary.
Note any disturbances and external influence on the lubricating system for future reference in case
of sudden oil deterioration.
Take a small oil sample every week. Check if the color suddenly changes between samples. Also
check if any sludge or deposits can be seen in the oil. If anything is noticed samples of
deposits/sludge and oil should be sent for analysis.
Take a small oil sample from the bottom of the tank monthly. Check if the oil is hazy, this indicates
that it contains water. Analyze water content of the sample. If the sample contains water, actions
must be taken in order to reduce the water in the oil (see section 6).
Check for accumulation of sludge or deposits in any part of the turbine oil system. If sludge or
deposits are found, samples of the deposits/sludge as well as a sample of the oil should be taken
for analysis.
Check for foaming and recognize problems due to foam in the system. An oil sample should be
sent for analysis if an excessive amount of foam is seen.
When refilling the whole tank volume it is recommended that the tank is cleaned according to
applicable routines before filling.

4.4 Sampling of turbine oils:

Samples submitted for examination must be representative of the complete oil volume. To obtain a
representative sample from the lubricating system the sample should be taken from a free flowing line
during oil circulation. If this is impossible the sample can be taken from an agitated tank.

4.5 Lubrication oil properties:

The properties of turbine oil cannot be expected to remain unchanged during the life of the oil. Some
deterioration can be tolerated without consequences to the safety or efficiency of the system but it is
important to know when certain limits have been reached. Recommended warning levels and actions
for certain properties of oil in operation are given in table 3. Actions must be taken in order to restore
the quality of the oil if these warning levels are exceeded.

_______________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.
No.

1CYJ470058 -

Table 3: Warning levels, possible causes & consequences and recommended actions for deviating analysis
results.

Possible
Property Warning level Possible causes Recommended actions
Consequences
Appearance Hazy, Sudden Contamination of Check water content and
change in color water or dirt. solid impurities.
between samples Deterioration of oil.
Water content Max. 200 mg/kg Water or steam Decreased lubricity. Drain water from bottom of
(ppm) leakage. Increased oil tank if possible. Reduce
deterioration. water by centrifugation.
Damaged pumps, Check Demulsibility.
gears and bearings.
Viscosity ± 10% from initial Contamination or Decreased lubricity. Consider oil change.
value severe oxidation of oil. Increased filter
exchange rate.
Solid impurities
Sediment Max. 10 mg / 100 ml Organic sediment: Increased filter Check type of impurities.
The oil may be exchange rate. Investigate and remedy
deteriorated or Decreased lubricity. sources of contamination if
chemically Increased oil possible.
contaminated. deterioration.
Dirt: Dirt left in the Formation of Check function of filters.
system or entering the deposits in the oil Clean oil by centrifugation
system during system. or filtration.
operation.
Cleanliness Max. 20 / 16 / 13 Wear particles: Damaged pumps,
Defective lubrication. gears and bearings.
Rust particles: Decreased lubricity.
Corrosion of oil Increased oil
system, from for deterioration.
example water in the
system.
Dirt: Dirt left in the
system or entering the
system during
operation.

Chemical elements
Wear metals Continuous or Defective lubrication Damaged gears Check for solid impurities.
Contaminants sudden change. or contamination. and bearings. Check physical properties.
Additives Decreased filter Decreased lubricity.
efficiency. Increased oil
Depletion or deterioration.
deterioration of
additives.
Total Acid Max. increase 0.3- Severe deterioration of Decreased lubricity. Look for signs of increased
Number 0.4 mg KOH/g over oil. Formation of sediments on filters.
(TAN) new oil deposits in the oil
system.
Air release Max. 7 minutes Contamination or Decreased lubricity. Resample and retest. If
deterioration of oil. Increased oil same result, consider oil
deterioration. change.
Foaming Tendency: Contamination or Decreased lubricity. Resample and retest. If
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Rev.Date : 31.03.2010
 Document No. Rev.
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1CYJ470058 -
(at 24°C) max.450 ml deterioration of oil. Increased oil same result, consider oil
Stability: 0 ml deterioration. change.
Demulsibility 40/37/3 in 30 Contamination or Decreased lubricity. Resample and retest. If
minutes deterioration of oil. Increased oil same result, consider oil
deterioration. change.
Oxidation >3000 h Deterioration of oil. Decreased lubricity. Perform RPVOT test
stability Formation of (Result 750 min)
deposits and Resample and retest. If
sludge same result, consider oil
in the oil system. change.

Table 4: Test methods, standards and general information regarding oil properties and analyses.

Property Test method Standards General information

ASTM D ISO
Appearance Visual The appearance of new turbine oil
examination should be clear and bright. Colour of
new oil can vary from bright yellow to
bright orange. As the oil ages it
gradually turns darker.
Water content Karl Fischer 760 High water content can decrease
lubricity. Water can be separated from
the oil as long as the demulsibility is
good.
Solid impurities
Sediment 4898 Sediment is the amount of particles and
sludge collected on a small pore filter.
Cleanliness 4406 Cleanliness describes the particle count
in the oil. It is stated as a code showing
the particle size distribution
( 4µm/ 6µm/ 12µm).
Viscosity 445 3104 The viscosity is important both for
lubricity and for the functionality of
pumps and valves in the system.
Chemical elements
Wear metals ICP-AES 5185 Metals in the oil can indicate wear in
bearings and/or gears. Typical wear
metals are Fe, Cr, Sn, Cu and Ni.
Contaminants ICP-AES 5185 Foreign contaminants may enter the oil
through open hatches or failing seals.
Typical contaminants are Ba, Ca, Na, Si
and Zn.
Additives ICP-AES 5185 Extreme pressure additives are added
to improve the oils lubricity at high
pressures.
Phosphorus (P) is a typical additive.
Total Acid 974 6618 Acidic compounds form as the oil ages,
Number (TAN) forming deposits at peak
concentrations. This process can be
tracked with TAN.
Air release 3427 9120 Air release describes the oils ability to
release air from the oil. High air release
can cause operating problems. Foaming
describes the oils tendency to form
foam. Too high foaming or persistent
foam can
cause operating problems.
Foaming (at 892 6247 Foaming describes the oils tendency to
_______________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.
No.

1CYJ470058 -
24°C) form foam. Too high foaming or
persistent foam can cause operating
problems.
Demulsibility 1401 6614 Describes the oils ability to separate
water. An important parameter
especially for steam turbines where
there is a higher risk for water entering
the oil system.
Oxidation RPVOT 2272 RPVOT (Rotating Pressurized Vessel
stability Oxidation Test) estimates the working
life of the oil.
The higher the RPVOT the longer the oil
can normally be used

_______________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 2015-07-03; Varma Murali Krishna; Siemens AG, PG SU AP IN EN PEN MECH
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Technische Liefervorschrift September 2010
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Turbinenöle TLV 9013 05

mit erhöhter thermischer Stabilität SAP Doc. No.
DSTLV901305\DE\A

Technical Purchasing Specification: Ersatz für Ausgabe: Erstausgabe

Turbine oils with higher thermal stability Replacement for issue: First issue

TLV-Exportkennzeichnung: TLV-Export-Identification:
AL = N AL = N
ECCN = N ECCN = N

Weitergabe
sowie Verviel- Vertragsverbindlich ist immer die deutsch- The German version of this TLV shall be consid-
fältigung
dieser Unter- sprachige Fassung dieser TLV. ered as the only binding one. The English ver-
lage, Ver- sion is for reference only.
wertung und
Mitteilung
ihres Inhaltes
nicht gestattet
soweit nicht
ausdrücklich 1. Geltungsbereich 1. Scope of Application
zugestanden.
Zuwiderhand- Diese Liefervorschrift (TLV) gilt für die Beschaffung This specification (TPS) is valid for procuring turbine
lungen ver-
pflichten zu von Turbinenölen, die zur Schmierung und teilweise oils used as lubricating oils and particulary as con-
Schadener-
satz. auch zur Steuerung und Regelung von Siemens- trol and governor oils for Siemens steam and gas
Alle Rechte
für den Fall
Dampf- und Gasturbosätzen mit und ohne Getriebe turbosets with and without gearbox.
der Patent- verwendet werden.
erteilung oder
GM-Ein-
tragung
vorbehalten.
2. Mitgeltende Dokumente 2. Referenced Documents
DIN 51 562-1, DIN EN ISO 3104, DIN ISO 2909, DIN 51 562-1, DIN EN ISO 3104, DIN ISO 2909,
DIN ISO 9120, DIN 51 558-1, DIN EN ISO 12937, DIN ISO 9120, DIN 51 558-1, DIN EN ISO 12937,
ISO 6247, DIN 51 589-1, DIN ISO 6614, ISO 6247, DIN 51 589-1, DIN ISO 6614,
___ DIN 51 757, DIN ISO 2592, DIN ISO 3016, DIN 51 757, DIN ISO 2592, DIN ISO 3016,
ISO 4406, DIN EN ISO 2160, DIN ISO 7120, ISO 4406, DIN EN ISO 2160, DIN ISO 7120,
Copying of
this docu-
DIN EN ISO 4263-1, DIN ISO 14635-1, DIN EN ISO 4263-1, DIN ISO 14635-1,
ment, and ASTM D 445, ASTM D 2270, ASTM D 3427, ASTM D 445, ASTM D 2270, ASTM D 3427,
giving it to
others and ASTM D 974, ASTM D 1744, ASTM D 892, ASTM D 974, ASTM D 1744, ASTM D 892,
the use or
commu-
ASTM D 1401, ASTM D 1298, ASTM D 92, ASTM D 1401, ASTM D 1298, ASTM D 92,
nication of ASTM D 97, ASTM D 130, ASTM D 665, ASTM D 97, ASTM D 130, ASTM D 665,
the contents
thereof, are ASTM D 943, ASTM D 5182, ASTM D 2272 ASTM D 943, ASTM D 5182, ASTM D 2272
forbidden
without ex-
press author-
ity.
Offenders 3. Allgemeine Forderungen 3. General Requirements
are liable to
the payment
of damages.
Unter Turbinenöl nach dieser TLV ist ein Mineralöl According to this TPS turbine oil is a mineral oil or a
All rights are oder ein synthetisches Öl mit Wirkstoffen zur Erhö- synthetic oil containing additives to increase corro-
reserved in
the event of hung des Korrosionsschutzes und der Alterungsbe- sion protection and ageing stability.
the grant of a
patent or the ständigkeit zu verstehen.
registration of
utility model
Turbinenöle, die zur Getriebeschmierung eingesetzt Turbine oils used for gear lubrication may additional
or design. werden, können zusätzlich Wirkstoffe zur Erhöhung contain additives to increase the load capacity and
der Belastbarkeit und zur Herabsetzung des Ver- to decrease wear.
schleißes enthalten.

Sector Energy Fortsetzung Seite 2 bis 5

Fossil Power Generation Continued page 2 to 5
erstellt: E F PR PI T M 2 geprüft: E F PR SU R&D SV 1 freigegeben: 2010-05-19
Siemens AG prepared: 2010-05-12 gez. Quick checked: 2010-05-19 gez. Böhm released: gez. Logar

Schutzklasse: Nur für internen Gebrauch / Protection class: For internal use only Copyright © Siemens AG All Rights Reserved
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TLV 9013 05: 2 0 1 0 -09

4. Eigenschaften 4. Properties
4.1 Chemische Zusammensetzung 4.1 Chemical Composition
Bei Turbinenöl handelt es sich in der Regel um pa- Usually turbine oil is a paraffin based mineral oil
raffinbasisches Mineralöl, bestehend aus einem consisting of a mixture of saturated hydrocarbons. A
Gemisch gesättigter Kohlenwasserstoffe. Eine defi- defined composition cannot be given on account of
nierte Zusammensetzung kann wegen der Vielzahl the quantity of different components. The criterion of
unterschiedlicher Bestandteile nicht gegeben wer- selection for use as turbine oil is the physical condi-
den. Auswahlkriterium für die Verwendung als Tur- tion.
binenöl ist die physikalische Beschaffenheit.
Die zugemischten Wirkstoffe (Additive) dürfen keine The admixed additives must not have any negative
nachteiligen Auswirkungen auf Werkstoffe des Öl- effects on the materials of the oil system. They must
systems haben. Sie dürfen keine metallorganischen not contain organometallic compounds (e.g. organic
Verbindungen (z.B. organische Zinkverbindungen) zinc compounds).
enthalten.

4.2 Thermische Belastbarkeit 4.2 Thermal stability

Das Turbinenöl muß so beschaffen sein, daß durch The turbine oil must be capable of withstanding
Temperaturen von max. 130°C in Maschinenkom- temperatures in turboset components (e.g. bearings,
ponenten (z.B. Lager, Kupplung, Getriebe) und von couplings, gearboxes) of max. 130°C and oil tank
max. 80°C im Ölbehälter keine negativen Verände- temperatures of max. 80°C without physical or
rungen der Öleigenschaften auftreten. chemical degradation of the oil properties.
4.3 Verträglichkeit 4.2 Compatibility
Das Turbinenöl muß mit Restmengen (max. 4 Vol.- The turbine oil must be miscible with remaining
%) eines anderen Turbinenöles mischbar sein, ohne quantities (max. 4% by volume) of turbine oil.
daß negative Änderungen der Öleigenschaften ein- There should be no deterioration of the turbine oil
treten. properties in presence of such small quantities.

4.4 Physikalische und chemische Eigenschaften 4.4 Physical and chemical properties

Eigenschaft Zahlenwert Einheit Prüfverfahren / test method

property value unit DIN / ISO ASTM
1)
Kinematische Viskosität bei 40°C DIN 51 562-1 / ASTM D 445
kinematic viscosity at 40°C 1) DIN EN ISO 3104
ISO VG 32 28.8 - 35.2 mm2/s
ISO VG 46 41.4 - 50.6 mm2/s
Viskositätsindex
≥ 90 - DIN ISO 2909 ASTM D 2270
viscosity index
Luftabscheidevermögen bei 50°C
air release value at 50°C ≤4 min DIN ISO 9120 ASTM D 3427

Neutralisationszahl
total acid number ≤ 0.30 mg KOH/g DIN 51 558-1 ASTM D 974

Wassergehalt
water content ≤ 200 mg/kg DIN EN ISO 12937 ASTM D 1744

Schaumverhalten bei 24°C ISO 6247 ASTM D 892

foaming at 24°C: ≤ 450 / 0 ml / ml
(Seq. 1) (Seq. 1)
Wasserabscheidevermögen
water separability ≤ 300 s DIN 51 589-1 -

Demulgiervermögen
demulsibility ≤ 30 min DIN ISO 6614 ASTM D 1401
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TLV 9013 05: 2 0 1 0 -09

4.4 Physikalische und chemische Eigenschaften 4.4 Physical and chemical properties
(Fortsetzung) (continued)

Eigenschaft Zahlenwert Einheit Prüfverfahren / test method

property value unit DIN / ISO ASTM
Dichte bei 15°C anzugeben
- DIN 51 757 ASTM D 1298
density at 15°C report
Flammpunkt
> 200 °C DIN ISO 2592 ASTM D 92
flash point
Pourpoint
pourpoint ≤-6 °C DIN ISO 3016 ASTM D 97

Reinheitsgrad 2)
cleanliness level 2) ≤ 20/17/14 - ISO 4406 -

Korrosionswirkung auf Kupfer,

3h bei 100°C, Korrosionsgrad DIN EN ISO 2160
Copper strip corrosion, ≤2 - ASTM D 130
3h at 100°C, corrosion class
Korrosionsschutz gegenüber
Stahl, Verfahren B bestanden -
DIN ISO 7120 ASTM D 665
Rust-preventing characteristics, pass
Procedure B
Alterungsverhalten:
Zeit bis zur Zunahme der NZ um
≥ 3000 h DIN EN ISO 4263-1 ASTM D 943
2,0 mg KOH/g
Oxidation stability:
time to an increase of total acid
number of 2 mg KOH/g
Oxidationsstabilität (RPVOT3))
≥ 750 min - ASTM D 2272
Oxidation stability (RPVOT)

1) Die Viskositätsklasse wird von der zuständigen Konstruktionsabteilung festgelegt.

The viscosity class is determined by the responsible design department.

2) Der Reinheitsgrad des Öles bezieht sich auf den Anlieferungszustand. Die geforderte Reinheit im System wird sys-
temspezifisch festgelegt und muß durch geeignete Maßnahmen (z.B. Filtrierung, Separierung) sichergestellt werden.
The cleanliness level refers to the oil condition on delivery. The required system cleanliness is dependent upon the
system design. Suitable measures (e.g. filtration, separation) have to be taken to guarantee this cleanliness level.

3) RPVOT: Rotating Pressure Vessel Oxidation Test

4.5 Zusätzliche Anforderung an Getriebe- 4.5 Additional requirement on turbine oils for use
turbinenöle in gearboxes

Eigenschaft Zahlenwert Einheit Prüfverfahren / test method

Property value Unit DIN / ISO ASTM
FZG-Test; A/8,3/90
Schadenskraftstufe
failure load stage ≥8 - DIN ISO 14635-1 ASTM D 5182
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TLV 9013 05: 2 0 1 0 -09

5. Musterprüfung und Freigabe 5. Pattern test and approval

Für die Freigabe eines Turbinenöls nach dieser TLV To gain approval for a turbine oil the following pro-
ist folgender Verfahrensablauf vorgesehen: cedure is provided:
a) Diese TLV wird dem Hersteller bzw. Lieferanten a) This specification is placed at the manufacturer's
zur Verfügung gestellt. or supplier's disposal.
b) An Siemens AG Energy Sector ist ein Erstmuster b) An initial sample (3liter) must be delivered to
(3 Liter) zu liefern. Das Gebinde muß eine ein- Siemens AG Energy Sector. The container must
deutige Produktbezeichnung sowie den Namen show a clearly indicated product name and also
des Herstellers bzw. Lieferanten aufweisen. the name of the manufacturer or supplier. The
Der Hersteller oder Lieferant muss einen Erst- manufacturer or supplier must supply an initial
musterprüfbericht des Musters nach Pkt. 4.4 und sample inspection report of the supplied sample
ggf. Pkt. 4.5 dieser TLV liefern. Der Lieferung ist according to subitem 4.4 and 4.5 of this specifi-
ein Sicherheitsdatenblatt beizulegen. cation. A safety data sheet must be attached
c) An dem Erstmuster führt Siemens AG Energy c) The initial sample will be tested by Siemens AG
Sector auf Grundlage dieser TLV Prüfungen Energy Sector according to this specification.
durch. Nach positivem Prüfergebnis erfolgt die Providing that the specification is met, the turbine
Freigabe des Turbinenöls. Das Produkt wird in oil will be approved. The product will be pub-
die Freigabeliste für Turbinenöle nach dieser TLV lished in the list of approved turbine oils accord-
aufgenommen. ing to this specification.
d) Die Freigabe entbindet den Lieferanten nicht von d) The approval does not release the supplier from
der Verantwortung für die Qualität seines Pro- his responsibility for the quality of the product.
duktes. Jede Änderung des Produktes ist Sie- Siemens AG Energy Sector must be informed in
mens AG Energy Sector mitzuteilen. In der Regel case of any alteration of the product. In this case
wird in solchen Fällen ein neues Freigabeverfah- generally a new approval procedure will be car-
ren durchgeführt. ried out.

6. Lieferung und Dokumentation 6. Delivery and documentation

Rechtzeitig vor jeder Lieferung teilt der Lieferant In good time prior to delivery the supplier has to
dem Besteller die Prüfergebnisse jeder für die Liefe- inform the purchaser in writing of the test results of
rung verwendeten Charge schriftlich mit. the batches proposed for delivery.
Für jede Charge sind mindestens die Prüfergebnis- For each batch at least the test results of the follow-
se folgender Parameter vorzulegen: ing parameters have to be submitted:
• Kinematische Viskosität • Kinematic viscosity
• Luftabscheidevermögen • Air release value
• Neutralisationszahl • Total acid number
• Wassergehalt • Water content
• Schaumverhalten • Foaming
• Wasserabscheidevermögen • Demulsibility
Die Lieferung des Turbinenöls erfolgt in gereinigten The turbine oil must be delivered in cleaned con-
Gebinden, die mit einer eindeutigen Produkt- und tainers. They must show a clearly indicated product
Chargen-Kennzeichnung versehen sind. Andere name and batch number. Other forms of delivery
Lieferarten (z.B. im Tankwagen) sind schriftlich zu (e.g. road tanker) must be stipulated.
vereinbaren.

7. Befüllen 7. Filling
Serviceleistungen zur Befüllung sind vom Besteller Services for filling must be stipulated between pur-
mit dem Lieferanten schriftlich zu vereinbaren und chaser and supplier.
im Vertrag festzuhalten.

8. Sondervereinbarungen 8. Special agreements

Sondervereinbarungen, die Abweichungen von den Special agreements concerning variations from the
Anforderungen dieser TLV beinhalten, bedürfen der requirements of this specification need authorization
Genehmigung durch den Besteller. Sie sind schrift- by the purchaser. They must be stipulated.
lich festzulegen.
List of approved turbine oils according to TLV 9013 05 page 1 of 4
Liste der freigegebenen Turbinenöle nach TLV 9013 05 Seite 1 von 4
Issue: February 2016 / Ausgabe: February 2016

Technical purchasing specification TLV 9013 05 Die Technische Liefervorschrift TLV 9013 05
is valid for purchasing turbine oils with higher gilt für die Beschaffung von Turbinenölen
thermal stability for Siemens steam and gas mit erhöhter thermischer Stabilität für
turbosets. Siemens Dampf- und Gasturbosätze.
Turbine oils that were tested and approved Turbinenöle, die nach TLV 9013 05 untersucht
according to TLV 9013 05 are shown in the und freigegeben wurden, sind in der folgenden
following approval list. The approval does not Freigabeliste aufgeführt. Die Freigabe entbindet
release the supplier from his responsibility for den Lieferanten nicht von der Verantwortung für
the quality of the product. die Qualität seines Produktes.
Attention: The selection must be made Achtung: Bei der Auswahl eines Öls muss
in consideration of the viscosity class die für den jeweiligen Turbosatz festgelegte
determined for the turbo set. Turbo sets with Viskositätsklasse beachtet werden. Bei
gearboxes need special turbine oils suitable Turbosätzen mit Getriebe muss ein
for gearbox lubrication. Getriebeturbinenöl ausgewählt werden.
Dates about the viscosity class and the suitabi- Die jeweilige Viskositätsklasse und die Angabe,
lity for gearbox turbosets can be found in the ob es sich um ein Getriebeturbinenöl handelt,
following table. Turbine oils for use in turbines finden sich in der folgenden Tabelle. Getriebe-
with gearboxes may also be used for turbosets turbinenöle können auch in Turbinen ohne Ge-
without a gearbox. triebe eingesetzt werden.

manufacturer / supplier product name ISO VG for turbosets

Hersteller / Lieferant Produktbezeichnung class with gearbox
ISO VG- für Turbosätze
Klasse mit Getriebe
Addinol Addinol Turbine Oil MT 46 46 x
Adnoc Adnoc GII Turbine Oil 32 32
Adnoc Adnoc GII Turbine Oil 46 46
Apar Industries Ltd. Power Turbo Super AW 32 32 x
Apar Industries Ltd. Power Turbo Super AW 46 46 x
Bharat Petroleum MAK Turbol 32 32
Bharat Petroleum MAK Turbol 46 46
Bharat Petroleum MAK Turbol EP 32 32 x
Bharat Petroleum MAK Turbol EP 46 46 x
Caltex Caltex Regal Premium EP 32 32 x
Caltex Caltex Regal Premium EP 46 46 x
Castrol Castrol Product HS 0009 46 x
Castrol Perfecto XPG 32 32 x
Castrol Perfecto XPG 46 46 x
Castrol Perfecto X 32 32
Castrol Perfecto X 46 46
Castrol Perfecto XEP 32 32 x
Castrol Perfecto XEP 46 46 x
Cepsa Turbinas EP 32 32 x
Cepsa Turbinas EP 46 46 x
Chevron GST Oil ISO 32 32
Chevron GST Oil ISO 46 46
Chevron GST EP Oil ISO 32 32 x
Chevron GST EP Oil ISO 46 46 x
Chevron GST Premium 32 32
Chevron GST 2300 ISO 32 32 x
Chevron GST 2300 ISO 46 46 x
Eni eni OTE 32 GT 32 x
Eni eni OTE 46 GT 46 x

Siemens AG . Power and Gas Restricted / Intern

List of approved turbine oils according to TLV 9013 05 page 2 of 4
Liste der freigegebenen Turbinenöle nach TLV 9013 05 Seite 2 von 4
Issue: February 2016 / Ausgabe: February 2016

manufacturer / supplier product name ISO VG for turbosets

Hersteller / Lieferant Produktbezeichnung class with gearbox
ISO VG- für Turbosätze
Klasse mit Getriebe
ENOC Vortex GT-2 32 32
ENOC Vortex GT-2 46 46
ExxonMobil Mobil DTE 732 32
ExxonMobil Mobil DTE 746 46
ExxonMobil Mobil DTE 832 32 x
ExxonMobil Mobil DTE 846 46 x
ExxonMobil Mobil SHC 824 32 x
ExxonMobil Mobil SHC 825 46 x
Fuchs Europe Schmierstoff GmbH Renolin Eterna 32 32 x
Fuchs Europe Schmierstoff GmbH Renolin Eterna 46 46 x
Fuchs Europe Schmierstoff GmbH Renolin Eterna 32 SGV 32
Fuchs Europe Schmierstoff GmbH Renolin Eterna 46 SGV 46 x
Gazpromneft Lubricants Gazpromneft Turbine Oil 32 32
GS Caltex Corporation GS Turbine Oil 32 32
GS Caltex Corporation GS Turbine Oil 46 46
Gulf Oil International Gulf Crest EP 32 32 x
Gulf Oil International Gulf Crest EP 46 46 x
Gulf Oil International Gulf Crest 46 46
Hitecrun Speciality Hitecrun GT Gas Turbine Oil ISO 32 32 x
Hitecrun Speciality Hitecrun GT Gas Turbine Oil ISO 46 46 x
HPC (Hindustian Petroleum Corp.) Turbinol 32 32
HPC (Hindustian Petroleum Corp.) Turbinol 46 46
HPC (Hindustian Petroleum Corp.) Turbinol XT 32 32 x
HPC (Hindustian Petroleum Corp.) Turbinol XT 46 46 x
Idemitsu Daphne Super Turbine ME32 32 x
Idemitsu Daphne Super Turbine MG32 32
Idemitsu Daphne Super Turbine MG46 46
Indian Oil Corp. (IOC) Servoprime 32G 32 x
Indian Oil Corp. (IOC) Servoprime 46G 46 x
Interlub Turbo RO H 32 32
Interlub Turbo RO H 46 46
Kuwait Petroleum Q8 van Gogh 32 32
Kuwait Petroleum Q8 van Gogh 46 46
Kuwait Petroleum Q8 van Gogh EP 32 32 x
Kuwait Petroleum Q8 van Gogh EP 46 46 x
Kuwait Petroleum Q8 Volta 32 32
Kuwait Petroleum Q8 Volta 46 46
Kuwait Petroleum Q8 Volta EP 32 32 x
Kuwait Petroleum Q8 Volta EP 46 46 x
Lubrication Engineers 6461 MONOLEC Turbine Oil 32 x
Lubrication Engineers 6462 MONOLEC Turbine Oil 46 x
Lukoil Tornado T 32 32 x
Lukoil Tornado T 46 46 x
Lukoil Lubricants OMV power turb 32 32
Lukoil Lubricants OMV power turb 46 46
Lukoil Lubricants OMV power turb EP 32 32 x
Lukoil Lubricants OMV power turb EP 46 46 x
Orlen Oil Turbinex TG 32 32 x
Orlen Oil Turbinex TG 46 46 x

Siemens AG . Power and Gas Restricted / Intern

List of approved turbine oils according to TLV 9013 05 page 3 of 4
Liste der freigegebenen Turbinenöle nach TLV 9013 05 Seite 3 von 4
Issue: February 2016 / Ausgabe: February 2016

manufacturer / supplier product name ISO VG for turbosets

Hersteller / Lieferant Produktbezeichnung class with gearbox
ISO VG- für Turbosätze
Klasse mit Getriebe
Orlen Oil Turbinex TG Premium 32 32 x
Orlen Oil Turbinex TG Premium 46 46 x
Paz Lubricants & Chemicals PAZ Perfect HPT 46 46 x
Pertamina Pertamina Turbolube 32 32 x
Pertamina Pertamina Turbolube 46 46 x
Petro-Canada Lubricants Turboflo 32 32
Petro-Canada Lubricants Turboflo 46 46
Petro-Canada Lubricants Turboflo XL 32 32
Petro-Canada Lubricants Turboflo XL 46 46
Petro-Canada Lubricants Turboflo EP 32 32 x
Petro-Canada Lubricants Turboflo EP 46 46 x
Petrochina KunLun KTL Turbine Oil 32 32
Petrochina KunLun KTL Turbine Oil 46 46
Petrochina KunLun KTL EP 32 32 x
Petrochina KunLun KTL EP 46 46 x
Petrochina Turbine Oil KTG/S 32 32 x
Petrochina Turbine Oil KTG/S 46 46 x
Petrol Ofisi Turbine Oil TX 32 32
Petrol Ofisi Turbine Oil TX 46 46
Petrol Ofisi Turbine Oil TX-P 32 32 x
Petrol Ofisi Turbine Oil TX-P 46 46 x
Petromin Corporation Turbocompressor Oil 32 32 x
Petromin Corporation Turbocompressor Oil 46 46 x
Petronas Petronas Jenteram HC Extra 32 32
Petronas Petronas Jenteram HC Extra 46 46 x
Phillips 66 Diamond Class™ Turbine Oil 32 32
Phillips 66 Diamond Class™ ÁW Turbine Oil 32 32 x
Phillips 66 Turbine Oil 32 32
Phillips 66 Turbine Oil 46 46
Phillips 66 Ultra Clean Turbine Oil 32 32
Phillips 66 Ultra Clean Turbine Oil 46 46
Prista Oil Prista tps-32 32
Prista Oil Prista tps-46 46
Raj Petro Specialities Kyros Super Turbo S 32 32 x
Raj Petro Specialities Kyros Super Turbo S 46 46 x
Royal Mfg Co Cirro XS Turbine Oil 32 32
Royal Mfg Co Cirro XS Turbine Oil 46 46
Savita Oil Technologies Ltd. Savsol Super Turbine Fluid AW 32 32 x
Savita Oil Technologies Ltd. Savsol Super Turbine Fluid AW 46 46 x
Sinopec Corp. Sinopec Greatwall Gas Turbine Oil 32 32 x
Sinopec Corp. Sinopec Greatwall Gas Turbine Oil 46 46 x
Sinopec Corp. Sinopec Greatwall Turbine Oil TSA/LF 32 32
Sinopec Corp. Sinopec Greatwall Turbine Oil TSA/LF 46 46
Sinopec Corp. Sinopec Greatwall Turbine Oil TSE/LF 32 32 x
Sinopec Corp. Sinopec Greatwall Turbine Oil TSE/LF 46 46 x
Shell Shell Turbo Oil CC 32 32 x
Shell Shell Turbo Oil CC 46 46 x
Shell Shell Turbo Oil T 32 32
Shell Shell Turbo Oil T 46 46

Siemens AG . Power and Gas Restricted / Intern

List of approved turbine oils according to TLV 9013 05 page 4 of 4
Liste der freigegebenen Turbinenöle nach TLV 9013 05 Seite 4 von 4
Issue: February 2016 / Ausgabe: February 2016

manufacturer / supplier product name ISO VG for turbosets

Hersteller / Lieferant Produktbezeichnung class with gearbox
ISO VG- für Turbosätze
Klasse mit Getriebe
Shell Shell Turbo Oil GT 32 32
Shell Shell Turbo S4 X 32 32
Shell Shell Turbo S4 GX 32 32 x
Shell Shell Turbo S4 GX 46 46 x
SK Lubricants SK Turbine Oil 32 32
SK Lubricants SK Turbine Oil 46 46
SK Lubricants SK Turbine Oil GT 32 32
SRS Schmierstoff Vertrieb SRS Wiolan GT 32 32
SRS Schmierstoff Vertrieb SRS Wiolan GT 46 46
Statoil TurbWay GT 32 32 x
Statoil TurbWay GT 46 46 x
Strub Strub STE ISO 46 46
Teboil Teboil Turbine Oil XOR 46 46
Texaco Texaco Regal Premium EP 32 32 x
Texaco Texaco Regal Premium EP 46 46 x
TongYi Petroleum Chemical Co. TongYi Remoto EP 32 Turbine Oil 32 x
TongYi Petroleum Chemical Co. TongYi Remoto EP 46 Turbine Oil 46 x
TongYi Petroleum Chemical Co. TongYi Remoto L-TSA 32 32
TongYi Petroleum Chemical Co. TongYi Remoto L-TSA 46 46
Total Preslia 32 32 x
Total Preslia 46 46 x
Total Preslia GT 32 32 x
Total Preslia GT 46 46 x
YPF Turbina EP 46 46 x

Siemens AG . Power and Gas Restricted / Intern

 2CWN002896
Responsible department: Take over department: Revision: Doc.-type: File no.:

ST G WN TUB 051-05-010
Prepared: Checked: Released: Language: Page:

07-06-27 Absenger Anton 08- s. PDMSystem 08- s. PDMSystem en 1/7

Valid for: location: Derived from: Replaces: Classify no.: Datei:

PG I Nbg. / Essen

Factory Standard For internal use only translated: 00-02-29

SYSTEC GmbH
Up-to-date version at SAP; PDM or LN-database

Blowing Out Steam Piping

Contents
1. General ............................................................................................................................... 1
1.1 Danger of Accidents/Noise Prevention ................................................................................ 1
2. Blowing Circulations ............................................................................................................ 2
3. Conditions for Blowing Out .................................................................................................. 2
3.1 Dynamic Pressure Conditions.............................................................................................. 2
3.2 Rating the Blow Out Piping.................................................................................................. 3
3.3 Blowing Gate Valve ............................................................................................................. 4
4. Blowing Out Operation ........................................................................................................ 4
4.1 Duration of a Blast............................................................................................................... 4
4.2 Number of Blasts ................................................................................................................. 4
4.3 Sudden Temperature Drop .................................................................................................. 4
4.4 Procedure When Blowing Out.............................................................................................. 4
5. Cleanliness of the System ................................................................................................... 4
5.1 Assessing the Cleanliness of the System ............................................................................ 4

1. General
This recommendation describes the blowing-out conditions and purity criteria that are required by
manufacturer.

Blowing-out has the purpose of removing rust, scale, coatings dirt and foreign bodies from the inner
surfaces of steam piping to avoid blockages of the steam filter at the turbine inlet or damage to the turbine.

You must never start up a turbine before the boiler and the steam piping to the turbine have been cleaned.

Failure to follow this recommendation and starting the system even though it has not been properly cleaned
is at the customer's own risk. Any damage that occurs due to incorrect blowing out is excluded from the
warranty.
The manufacturer exclusively retains the right to inspect the turbine before acceptance testing the turbo
generator to determine the current status and, if necessary, to take into account corrections to the
guarantee values. Any additional costs that result from this shall be borne by the customer.

If blowing out was not carried out in accordance with this guideline, the customer must be informed in
writing of the facts and the corresponding results.

1.1 Danger of Accidents/Noise Prevention

Before starting blowing out, you must insulate all the steam lines that are to be blown out. This is to reduce
the danger of accidents (burns) or of fire (cables, oil, etc.)
Clearly identify danger areas by means of tapes and ensure that security staff cordon off the area before
starting blowing out. Before each blow out, check the danger area to ensure that no unauthorized
personnel is present.

Official regulations dictate that you must provide noise prevention measures.

Copyright DIN ISO 16016 shall be observed ! The reproduction, distribution and utilization of this document as well as the communication of
its contents to others without explicid authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved
in the event of the grant of a patent, utility model or design. © Siemens AG

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To reduce noise pollution due to blowing-out, you can use two procedures:

- utilize a silencer
- divert the steam under water

The supplier of the boiler or the piping must guarantee the provision of noise prevention measures.

2. Blowing Circulations
Blowing out is intended above all to clean the boiler's piping system. In the same way, you must clean all
the steam piping (live steam piping, secondary steam piping) that supplies steam to the turbine. In addition,
the supply lines of by-pass and reduction stations are blown out as well as those of the seal-steam system
and the steam-jet air ejector units.

Normally, you blow out all of the piping until directly in front of the valve casing or close to it.
The provisional blow out pipe is connected to the connection flange of the steam pipe to the quick-action
valve or to a pipe flange close to it.
If you carry out blowing via the quick-action valve, you must dismount it. If constructional reasons dictate
that it is not possible to connect the blow-out line in front of the quick-action valve and the quick-action
valve is welded to the control valve casing, you must carry out blowing via the quick-action valve by means
of a deployment ordered from the manufacturer.
Dismount the provisional blow out pipe and mount the definitive steam piping under conditions that are as
clean as possible.
It is advisable to remove from the blowing circulation sensitive objects such as valve seats, valve shafts,
flow-measuring orifices, etc.

3. Conditions for Blowing Out

3.1 Dynamic Pressure Conditions

Adequate dynamic pressure is the most important factor for achieving high velocity of flow and, with this,
good levels of steam piping cleaning by blowing out. When carrying out blowing out, the dynamic pressure
in the entire boiler and piping system must be greater than the subsequent maximum in full-load operation.

Below, we will use index A for the maximum throughflow in full-load operation and index B for blowing out:

c = Steam velocity [ m/s ]

v = Specific volume [ m³/kg ]
m = Mass flow rate [ kg/s ]
p = Pressure [ Bar ]
T = Temperature [ °C ]

⎛ c2 ⎞ ⎛ c2 ⎞
⎜ ⎟ >⎜ ⎟
⎝ 2v ⎠ B ⎝ 2v ⎠ A

( m²xy v )B > ( m² y v )A

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vA
mB > m A ⋅
vB

Calculation example:

pA = 61 bara mA = 33 kg/s
TA = 450° C vA = 0.051189 m³/kg

vA
mB > m A ⋅
vB

pB = 30 bara vB = 0.090526 m³/kg

TB = 350° C

0,051189
mB > 33 ×
0,090526

mB > 24.8 kg/s

To ensure that the desired parameters of the mass flow rate are achieved, you should carry out an
estimate of the mass flow rate, if possible, by means of the operational measurement.
If possible, you should measure the pressure and the temperature for the calculation directly by the boiler
outlet.

You should aim to achieve high steam conditions, since experience has shown that steam piping is not
correctly cleaned until high temperatures have been reached.
The following empirical values are used to specify the pressure and temperature for blowing out:

Pressure: pB > 50% of the rated pressure pA

Temperature: TB = minimum of 50 K overheating relative to the rated pressure, pA

3.2 Rating the Blow Out Piping

The provisional blow out piping must have approximately the same cross-section as the final piping.
When rating the piping suspension of the steam pipe and the provisional blow out piping which are to be
blown-out, you must observe the special conditions relating to blowing out, e.g. increased dynamic
pressure.
In addition, with welded quick-action valves, you must comply with the permissible forces and torques on
the turbine flanges.
The piping or boiler supplier will pay for the design, supply and assembly of the blow-out piping and the
piping suspension and take responsibility for it.

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3.3 Blowing Gate Valve
It is absolutely vital to install a blowing gate valve with a low (30-second) opening time. You should install
the gate valve in the area of the blow-out pipe in front of the mirrors. This gate valve makes it possible to
achieve a reduction in the blow-out time, due to warming of the steam line via water drains, and an
improvement in the level of cleaning.
The supplier of the boiler or the piping will provide the blowing gate valve.

4. Blowing Out Operation

4.1 Duration of a Blast

Depending on the capacity of the boiler, you should aim at achieving a duration of 1 - 2 minutes per blast.
Note that with long blowing gate valve run times (greater than 30 seconds), you must extend the blowing
out duration by the run time of the blowing gate valve.

4.2 Number of Blasts

Continue blowing out until you achieve satisfactory levels of cleanliness in the steam piping. The necessary
level of cleanliness is specified in Section 5.1, Assessing the Cleanliness of the System.

4.3 Sudden Temperature Drop

Large temperature differences between the blow-out and cool-down stages lead to oxide layers being
detached. This means that after blowing out at high steam temperatures there should be a cooling down
period to bring the temperature of the piping down to as close as possible to the ambient temperature. To
ensure adequate cooling, it is advisable for this period to last five to six hours with insulated piping.

4.4 Procedure When Blowing Out

After warming the piping, carry out initial blowing at moderate steam temperatures to allow you to detect
possible faults in the piping or the suspension.

Blowing out is started by running up the boiler to the previously specified blowing parameters and by
warming to piping that is to be blown out.
After this, carry out blowing using the steam data that is necessary to achieve the dynamic pressure
conditions and the temperature. While doing this, you should keep open the blowing gate valve for 1-2
minutes. Carry out blowing two to three times according to this method.
After this, blow down to low pressure and empty the boiler to clean the evaporator.
After this, use the fans to cool down the boiler.
On the day after this, run at full blowing pressure and full temperature.

With the first two or three blasts, no steel mirrors are installed to check cleanliness due to the high levels of
contamination that can be expected.

5. Cleanliness of the System

5.1 Assessing the Cleanliness of the System

You use steel mirrors to assess the cleanliness of the system. The boiler supplier provides these mirrors in
accordance with the material specification stated below.
You must install the mirrors directly at the end of the piping that is to be blown out after the blowing gate
valve into the provisional blow out pipe.
An undisturbed section of piping, which is at least ten times the diameter of the piping, must be available in
front of the steel mirror's installation position.

You must install a mirror at least after every cooling down period of the boiler to allow you to determine the
effectivity of the blowing out operation.

A recommendation for the blowing mirror's material, dimensions and installation

(refer to drawing 1 CWK 027 472 s. page 7) is shown below

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Material: St 37
ASTM A36
ASTM A516Gr70
Hardness: approximately 110 -120 HB

Installation position of the mirror:

Blowing Gate Valve Mirror

>10 D

Dimensions depending on the diameter of the piping

DN L [ mm ] B [ mm ]
100 90 15
150 135 20
200 180 25
250 225 30
300 270 35
350 315 40
400 360 45

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Adequate cleanliness of the steam piping was achieved by complying with the conditions below:

a) Two successive blasts must result in mirror surfaces that have no strikes that are outside the
assessment limits stated below.

b) After a cooling-down period of at least 12 hours, two more successive blasts must result in mirror
surfaces that have strikes that comply with the stated assessment limits.

The entire surface is considered for assessing a blowing mirror.

The assessment limits for an acceptable mirror are as follows:

y No strikes with diameters greater than 0.8 mm

y Not more than 2 strikes with diameters greater than 0.4 mm per 2500 mm²

y Not more than 10 strikes with diameters greater than 0.2 mm per 2500 mm²

y Strikes with diameters of less than 0.2 mm must be uniformly distributed.

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 Document No. Rev.No.

SIEMENS LTD. 1CYJ470057 A

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 27.03.2013 BMK/ 27.03.2013 MP / 27.03.2013 Eng. 1 of 4
Valid for: Derived from: Replaces: E File no.:
EO IP 1CYJ470057.doc

Technical Instruction:
INSTALLATION OF QCNRV IN STEAM LINE

A 11.03.2013 QCNRV DRAIN ARRANGEMENT UPDATED MT BMK MP

- 27.03.2013 FIRST ISSUE MT BMK MP
Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470057 A

INSTALLATION OF QCNRV IN STEAM LINE

Non-Return Valves in Steam Turbine Extractions, Bleeds and Backpressure Exhausts.
1.0 General
The non-return valves in the steam turbine extractions and bleeds are primarily
installed to protect the turbine rotor from unacceptable over speed.
Failure to follow this recommendation and starting the system is at the customer's own
risk, Customer will be solely responsible for any damage due to the non adherence to
this document.
If the extraction or bleed is connected to a steam system which can produce steam of
higher pressure than the existing turbine exhaust pressure, there is a risk of turbine
rotor over speed. It is therefore very important for the safety of the turbine to install the
non-return valves.
In the exhaust line from a back pressure turbine the non-return valves are installed to
protect the turbine.

2.0 Type of Non Return Valves

The non return valves are of tilting disc or free swinging disc type. Each non return
valve is also fitted with a single acting, spring closing pneumatic actuator.
During normal operation the valve disc is free to move from fully open to fully closed
position.
The disc closes automatically by its own weight when steam flow stops and/or changes
direction. Thus reverse steam flow into the turbine is prevented.
The disc is also pushed down into closed position by the spring in the actuator in the
event of a failure in power supply, instrument air supply or at an emergency trip of the
turbine(s).
Part stroke test is possible during operation.

3.0 Installation Requirements

The first non return valve shall be positioned in accordance with the following:
Extraction and bleed lines: In order to prevent functional impairment of the non-
return valve, it shall preferably be positioned 5-7 times the pipe diameter after
the pipe bends or similar flow disruptions.
HP-turbine exhaust line (cold reheat): The distance between the HP-turbine
exhaust flange and the non-return valve, shall be a straight portion of between
5-7 times the pipe diameters.
The second non-return valve (if provided) shall be located between 7-10 times the pipe
diameter from the first one.
The straight length of piping downstream the second non-return valve (if provided) shall
preferably be 5-7 times the pipe diameter.
No external steam connection is acceptable between the turbine flange and the non-
return valve, or between the non-return valves.
Depending on pipe layout, drains upstream and downstream of valves have to be
installed.
All non-return valves must be installed in a straight and horizontal line (only drain
slope).

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3 1CYJ470057 A
In case of non conformance to the above distances, Customer suppose to brought the
actual upstream and downstream length of QCNRV to Siemens notice for final
concurrence.

Below Diagrams Indicate Typical Installation of the QCNRV. How ever the Actuator Side (Right
side/Left side) shall be project specific.

Figure 1: Assisted Non return Valve (Armatury)

Figure 2: Assisted Non Return Valve (WEIR)

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4 1CYJ470057 A

Inlet Outlet

Figure 3: Assisted Non Return Valve (ADAMS)

QCNRV when provided with an internal drain, same must be continuously drained to
atmosphere by means of steam trap assembly as shown is fig 4.

The following instructions shall be followed when planning and implementing non-return valve
drains.

The drain shall be implemented with an orifice and valve in the main line and a drain
trap in the bypass as per fig 4
The drain trap shall be selected under consideration of the pressure parameters in
accordance with Section 3.5 of steam trap and 3.6 of orifice from Turbine drain
guideline, doc no 1CYJ470060.
Unhindered draining of the condensate shall be ensured, although this may be either to
a header or to the atmosphere
Under all circumstances, it must be ensured that there is a pressure gradient of at least
1 bar to the main steam line, where the main steam line has the higher pressure level

Figure 4: Draining of assisted non return valve

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470059 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 26.03.2013 SB/ 26.03.2013 MP / 26.03.2013 Eng. 1 of 7
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E59.doc

Technical Instruction:
SAFETY PRECAUTIONS

- 27.03.2013 FIRST ISSUE MT SB MP

Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470059 -
Safety precautions

General

This section covers the general safety precautions which must be observed during
operation and periodic maintenance of the Siemens Ltd. Supplied steam turbines.

It includes the most important precautions which, if neglected, can cause personal injury or
death. In addition to this general safety information, there are also some additional safety
information in the operating and maintenance instructions that has to be considered as well,
but which only concerns a specific action or component.

Safety information

There are two different levels of safety information:

Warning
Indicates the presence of danger. Ignoring the sign may lead to
Personal injury or death and/or damage to the equipment.

Caution
Informs you of situations or conditions which, if not adhered to,
may damage machinery or cause additional wear to the equipment.

Note
Additional important information—that should be observed by the operating
or maintenance personnel—are labeled as notes.

Note!
Notes provide you with additional and useful information.
Although less urgent than cautions and warnings, notes are
Important and should not be ignored.

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3 1CYJ470059 -

Warning

General

Follow the instructions given in the operating and maintenance

Manuals.

Prior to Switch on the CEP, the condenser has to be filled with demin water
until the level indication shows a level of approximately 50 % of the range.

In the control room

Only authorized personnel is permitted to operate the Steam

Turbine.

Never block automatic shutdown devices anywhere in the

circuit. Manual override of signals is only allowed by authorised
personnel who are fully aware of the consequences and takes
responsibility for any possible dangerous conditions that may
arise.

Programming is only allowed by personnel authorised by Siemens Ltd. It is

recommended that Siemens Ltd. is consulted before any alterations in
the control program are implemented. Any modifications of the
control program must be documented, including date of
modification (logbook).

The authority-key for the Operator Station keyboard must be

kept in a safe place and may not be available to unauthorised
personnel.

Be observant of control system fault alarms. Make sure that the

Reason for the alarm is investigated and that the fault is rectified
Without delay.

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4 1CYJ470059 -
Manual synchronizing must only be carried out by authorised
Personnel. The utmost care must be taken to avoid out of phase
Synchronization.

Before start up, make sure that the unit is ready for start-up after
Any maintenance work.

Ensure that operation of switches and valves cannot endanger

Personnel and/or equipment.

At the turbine unit

Caution! If there is still power or speed after a turbine trip, close the main
steam line.

Never open the generator breaker manually!

Always wear eye protection, ear protectors and hard hat.

Beware of oil spillage at the oil tank, which could cause

slipping. Avoid direct contact with lubricating oil or
hydraulic fluid and avoid inhalation of oil mist.

The use of solvents as cleaning agents and the use of

Lubricants can involve health and/or safety hazards. The manufacturers
of the solvents and lubricants should be contacted for safety data.

Do not step on electrical conduit or junction boxes or use

them as supports.

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5 1CYJ470059 -

The precautions and procedures recommended by the

Manufacturers must be followed.

Avoid direct contact with hot, uninsulated parts of the turbine.

Always bring a flashlight when entering the sound

Enclosure, in case of loss of light.

Check for zero system pressure before disconnecting any

System lines.

Stand clear of all pressure lines and fittings during start.

Vessel and main steam lines have to be blown out before first start-up
and after repair works. Loose particles can lead to damages at valves,
blading or labyrinths.

In this case SIEMENS doesn’t take liability!

Never run the sealing steam while the turbine rotor is not running.
In case of malfunction of the turning gear device the sealing steam
system must be shut off immediately.

Too high sealing steam pressure can damage the labyrinth packings!
The sealing steam pressure must not be higher than 1.1 ata.

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6 1CYJ470059 -

Lube Oil System / Control Oil System

Caution! Danger of fire by oil leakage.

To prevent damage occurring (burning, corrosion, etc.) and to ensure

regular operation, it is important to repair leakages (oil, steam, water,
condensation) immediately in its initial stage or to label plainly, that
cannot be repaired during operation, but only during standstill.

The auxiliary oil pumps may only be switched off after standstill of the
turbines, otherwise it might damage the bearings.

Only use oil of the quality and type as in the specification indicated.
Damages which can be put down to the use of unspecified oil evade our
liability.

The disposal of leak and used oil has to be done in accordance with
local regulations and laws.

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7 1CYJ470059 -

Turning Gear Device

Prior to the start up of the steam turbine the turning gear is operating for
at least 24 hours.

While the turbines are hot / flange centre temperature is greater than
recommended hot start temperature , the rotor should not be stopped
for longer than 10 minutes. If necessary, turn the turbine rotor each 10
minutes for 90°.

If the turbine rotor was not turned in time and is stuck, in no case use
violence, but let the turbine completely cool down. Before the restart of
the cold turbine try, whether the turbine rotor can be turned free for at
least two turns (no scraping sounds).

After a standstill of the turbine more than one week the turbine rotor
must be turned by hand for at least two turns (no scraping sounds)
before starting the turbine again.

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD 1CYJ470060 B

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
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PG / 14.02.2013 MN/ 14.02.2013 MP / 14.02.2013 Eng. 1 of 22
Valid for: Derived from: Replaces: E File no.:
EO IP 1CYJ470060.doc

Technical Instruction:
Turbine Piping Guidelines

Turbine preheating requirement and piping

B 25.04.2016 TP KS MP
requirements added
A 28.02.2013 Revision MRT/BMK SB MP
- 14.02.2013 First Issue PG MN MP
Rev. No. Date Revision Prepared Checked Approved

Unrestricted
_______________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is
strictly forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page Document No. Rev. No.

2 1CYJ470060 B

Sr.
Contents Page
No.
1.0 Scope of Application 3
2.0 Type of Drains 3
2.1 External Drains 3
2.2 Internal Drains 4
2.3 Function of Drains 5
3.0 General Information on Drain System 6
3.1 Design Notes 6
3.2 Typical Design 7
3.3 Dimensioning 10
3.4 Condensate collection nozzle (Drip leg) 10
3.5 Application of ANSI/ASME TDP-1 standard 11
3.6 Steam Traps 12
3.7 Orifice 12
3.8 Drain Headers 12
3.9 Drain Collecting Tank 13
4.0 Draining of condensing turbine with upward facing exhaust and axial 15
exhaust
5.0 Drainage of condensing turbine with installation at ground floor 15
6.0 Perfect Closure 15
7.0 Live Steam 16
8.0 Extraction Steam 18
9.0 Admission Steam 20
10.0 Exhaust Steam Backpressure 22
11.0 Oil System 22

Unrestricted
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3 1CYJ470060 B

1.0 Scope of Application:

This guideline applies to piping systems not included in the SIEMENS scope of services and
supply.

This guideline defines the requirements that SIEMENS AG specifies to the company performing
the work for planning, production and installation of piping systems (e.g. non-automatic
extraction). Adherence to this guideline will help prevent damage to components delivered
by Siemens, thus making a contribution to ensuring smooth,fault-free operation of the turbine
plant.

The document contains essential information about piping arrangement that can strongly
influence safe and reliable operation of steam turbine. Therefore, fulfillment from Customer’s
side has to be verified by Siemens staff on site and is condition for validity of Guarantees.

This design standard is derived to establish piping design criteria for the turbine (SST 150, SST
200, SST 300, and SST 600 (G&V)). Among other benefits, this ensures operating reliability of the
turbine generator unit.

An inadequately designed drain system can result in the following damage or faults in the turbine
unit:
· Uneven cooling of the turbine casing and shaft due to condensate in the lower section of
the casing, with resulting deformation.
· Water hammer in the turbine – damage to blades
· Chugging in piping with consequential damage to piping hangers.
· Accumulation of condensate in the seal and leak-off steam system, with faults in pressure
regulation of the valves
· Corrosion due to condensate.

2.0 Type of Drain:

The drains are categorized by their location (external / internal) and their function (start-Up /
continuous). The differentiation between internal & external drains of the turbine and its steam
piping is to make it possible with the turbine deactivated to completely separate the drains of the
deactivated turbine and the plant system. This means that designer must always strictly separate
the external drains from the internal drains.

If there is a possible link between the external drains & the internal drains, e.g. By means of a
common flash tank, the steam from the external piping systems could flow into the turbine and the
condenser and locally heat them, which would lead to damage.

In addition, designer must not route the internal drains into the atmosphere when there is a
vacuum in the turbine and the condenser, since this would result in air being sucked into the
internal system.

2.1 External Drains

External drains are those of closed steam systems that can carry steam in the case of a turbine
standstill. The condensate that results is discharged into the outside air or to the external
atmospheric flash tank. (See Fig 1 & 2)
The system carries out external drainage of the following steam piping (viewed in the direction of
flow):
· Main steam pipe before turbine emergency stop valve.
Unrestricted
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4 1CYJ470060 B

· High or low pressure turbine bypass pipes with condensing plant before the bypass
valve.
· Extraction / Bleed lines after the first non-return valve.
· Back pressure line (exhaust steam) after QCNRV

2.2 Internal Drains

Internal drains are drains of the turbine and the piping systems that are connected to it, which do
not carry steam at a turbine standstill or which can be under a vacuum at start-up.
The system discharges the occurring drainage condensate to the internal flash box (separate
atmospheric tank / drain trench with back pressure machines or vacuum flash box with condensing
machines). (See Fig 1 & 2)

The system carries out internal drainage of the Turbine and the following steam lines (viewed in
the direction of flow):
· Turbine casing and balance piston line drains.
· Lines between the ESV and turbine governing valves.
· Lines after the turbine governing valves.
· Seal steam pipe after the regulating valve.
· Extraction / bleed lines before the first non-return valve.
· Ejector and GSC drains.
· Cross-over or cross-under pipes between various turbine casings.
· Back pressure line (exhaust steam) before QCNRV.
· high or low pressure turbine bypass pipes with condensing plant after the bypass valve

Fig.1: Separation of the drain system with condensing turbine

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2.3 Function of Drains:

2.3.1 Start up drain:
Start up drains must be provided as per figure 4 when plant sections normal operating
temperature range, from idling to full load (except for start-up) are clearly above the
associated saturated steam temperature (degree of super heat greater than 30 K). The start-
up drain consists of shut off valve with down-stream orifice. The orifice is welded horizontally
in the vertical pipe section of the drain. The diameter of the orifice shall be as mentioned in
3.6.

2.3.2 Continuous drain:

Continuous drain must be provided as per figure 3 and 5 if the turbines or piping sections to
0
be drained are to be flowed through with steam superheated less than 30 K ( in the design
point). This also applies to bleed and extraction lines that can be shut off, steam lines in
which flow can be interrupted by means of isolation valves.
The continuous drain consists of a steam trap, a shut off valve upstream and downstream of
it and a parallel valve with orifice. The orifice is welded horizontally in the vertical pipe section
of the drain. The diameter of the orifice shall be as mentioned in 3.6.

Fig 2. : Separation of the drain system with back-pressure turbine

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Fig.3: Continuous drain Fig.4: Start Up drain

Fig.5: Continuous drain acceptable arrangement

3.0 General Information on Drain System:

3.1 Design Notes:
Drain lines must be implemented so as to ensure reliable draining under all turbine generator unit
operating conditions.
· The piping gradient must be at least 2‰ for all load cases in the direction of flow, taking
into account any thermal expansion that may be present. The same applies to blow-
off piping (safety valves) and to drain lines.
· Drains shall be provided at least every 50 m in long steam supply lines (e.g.main
steam).
· Non-return valves must also be installed in the extraction and bleed lines. The number of
required non-return valves shall be as per P&I diagrams. These non-return valves
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must be installed at a maximum of 5 m downstream of the turbine nozzles in the

direction of flow, but upstream of the isolating elements.
· Long steam lines shall be implemented in several sloped sections with individual
drains.
· Pockets and loops shall be prevented due to the potential for condensate
accumulation.
· A drain is required at every low point in lines and valves
· No condensate return shall occur in the main lines
· Multiple valves shall be separated by drain equipment
· Valves in steam lines shall not be bypassed by drains (Fig 6.)
· All drain lines should be terminated to drain header(s) as indicated in figure 19 & 20.
· The drains shall be arranged according to increasing pressure, i.e. the line with the lowest
pressure shall be arranged as close as possible to flash box and the line with the highest
pressure as far as possible from the flash box.
· The material of the drainage pipe from the connection point to the last fitting (valve / orifice)
before drain header shall be same.

Fig. 6 Correct and incorrect implementation of drains on isolation elements

3.2 Typical Design:

· Legend

Fig. 7 Routing and draining of main steam pipes (I)

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Fig. 8 Routing and draining of main steam pipes (ii)

Fig. 9 Routing and draining of exhaust steam lines with valves, self draining

Fig. 10 Routing and draining of exhaust steam lines with valves, via drain line (I)

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Fig. 11 Routing and drainage of purging lines (I)

Fig. 12 Routing and drainage of purging lines (II)

Fig. 13 Routing and draining of steam lines with expansion joint and orifice

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3.3 Dimensioning
The dimensions and number of drains are determined by the nominal diameter, length, steam
conditions and steam mass flow rate in the piping section to be drained.

Table 1 presents minimum diameters of drain lines recommended by Siemens.

The cross sections of the drain lines shall be compared with the quantities of condensate
occurring in operating conditions.

Nominal pipe diameter Nominal pipe diameter

Remarks
(steam) (drain)
< 250 25
1 drain per 10 m of line
DN
≥250 50 to be drained

Table 1: Dimensions of drain lines

3.4 Condensate collection nozzles (Drip Leg)

Automatic and non-automatic extraction lines as well as connecting steam lines between the
turbine and to condensers shall be drained with condensate collection nozzles. The condensate
collection nozzle shall be implemented so as to enable draining and cleaning at the bottom. The
drain nozzle shall be located as close as possible to the bottom of the condensate collection
nozzle.
The size of the condensate collection nozzle is indicated in Table 2.

Fig 15 Drain pot (example with implementation)

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3.5 Application of ANSI/ASME TDP-1 Standard

Drainage of internal (vacuum) parts of turbine according ANSI/ASME TDP-1 as described
below is not allowed.

Fig 16 Drainage concept according to ANSI/ASME TDP-1

Water accumulated in drain pots is on saturation temperature according pressure in individual

line and this pressure is driven by turbine flow (alternatively turbine load). Incase of sudden
turbine unload (turbine trip, load rejection, etc.) condenser pressure (usually vacuum pressure)
in whole turbine area in several seconds is present. This effect cause sudden evaporation of the
remaining water. Evaporated water is passing through blading into turbine exhaust and
condenser. This mixture is entering blades and can cause blade failure or rotor seizure due to
thermal shock. Target is to avoid these issues in future.

Fig 17 Modified drainage concept according to ANSI/ASME TDP-1 acceptable to turbine internal
drainage
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3.6 Steam Traps

Steam traps shall be installed in condensate discharge line in parallel bypass of the main drain
valves. The following guide line to be used for selecting the type of steam trap.

pv : Upstream pressure of the trap

pn : Downstream pressure of the trap
∆ p = p v - pn

∆ p <= 10 bar: Use Ball float type steam trap

∆ p >= 10 bar: Use Thermodynamic type steam trap

Fig. 18 Pressure ratio on condensate discharge lines.

3.7 Orifice
The diameter of orifice should be selected based on upstream operating pressure at full load,
according to the table below. Orifice in drain lines should be installed after first rolling of
turbine.

3.8 Drain Headers

Drain headers receive and remove the accumulating condensate. These shall be configured with
their valve assemblies below the lowest point to be drained.

The drains shall be implemented in sequence on the header as a function of pressure, starting with
the highest pressure. The drain at the highest pressure shall be configured the furthest from the
flash box. This prevents drains at higher pressure from compromising the functioning of drains at
lower pressure (isolation processes). Drain lines to be connected to header from top. Connection to
the header at centerline or below is not recommended.

The drain header shall be connected to flash box for water cooled condenser and to drain boot for
air cooled condenser at least 250mm above the maximum condensate level. The Drain Header
must be of minimum possible length and sloped towards terminal point / flash box. (Figure 19 & 20)

A split in the drain header may be necessary depending on the engineering implementation and
local/spatial conditions (Figure 19). The separate sections shall be divided by pressure ranges (HP,
LP), where the pressure-dependent configuration shall also be observed.

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3.9 Drain Collecting Tank

Drain collecting tanks shall be configured below the lowest point to be drained. If necessary, the
customer shall provide a pit for installation of the drain collecting tank.

These provide for separation and discharge of the condensate/steam mixture from the drain
headers. Additional spray attemperation ensures cooling/condensation.

The exhaust steam line for the drain collecting tank shall be dimensioned so as to prevent any
pressure build-up in the tank.

Implementation is atmospheric for backpressure turbines.

In condensing plants, the collecting tank is connected to the condenser on the steam side (main
condenser, heating condenser or air-cooled condenser).

Fig. 19 HP and LP Drain headers individually connected to condenser flash box

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Fig. 20 Combined HP + LP Drain header connected to condenser flash box

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4.0 Draining of condensing turbines with upward facing exhaust and axial exhaust

In turbines with upward-facing exhaust steam nozzles and axial exhaust, the condenser is usually
configured next to or above the turbine. The drain header shall be located at a hydrostatic level
which ensures reliable draining at all times.

Fig 21: Draining of condensing turbine with upward facing and axial exhaust

5.0 Draining of condensing turbines with installation at ground floor

The elevations of the following components shall be checked to determine the location of the drain
header:
· Lowest point of turbine casing or piping drain
· Drain headers
· Minimum condensate level in flash tank

The minimum distance between the lowest drain connection (e.g. turbine casing) and the drain
header is at least 1000 mm. The drain valves shall be configured horizontally if necessary. The
connection to the drain header is vertically upwards.
The minimum height difference between the drain header and the maximum condensate level is
250 mm (Figure 21).

6.0 Perfect Closure

- A perfect closure (in addition to blinding the piping with a blind flange) consists of two closing
Valves with deaeration and clearance between them (Standstill drain) This arrangement prevents
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steam leaking from the pressurized piping into the turbine; which is inadmissible for reasons of
safe work on the equipment of the consecutive pressure piping; in case of a long-term outing this
closure eliminates steam penetration into the turbine which would be the reason of either corrosion
of the turbine or local heating of some parts of the turbine and later their deformation.

Fig. 22 Perfect Closure (standstill drain)

7.0 Live Steam

MSIV - Main Steam Isolating Valve of turbine live steam line
ESV –Emergency Stop Valve of Turbine
CV – Control Valve of Turbine

Fig. 23 Live Steam line (Example)

- Turbine Live steam temperature and pressure measurements have to be located as close as
possible to ESV, maximally 3 m upstream of ESV. If this requirement cannot be met, Siemens
has to be requested for approval
- Dimension of MSIV bypass need to be designed with regard to requirements of live steam line
preheating. Live steam line needs to be preheated by speed 4 °C/min to minimum start-up
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temperature (usually min. 50 °C superheated).

-Live steam need to be superheated (usually higher than 50 °C above saturation temperature)
before turbine start-up. In order to ensure minimal steam superheating, installation of vent for
preheating line is strongly recommended. If a preheating vent is not installed, preheating is
provided only by installed drainage and there is a risk than required steam superheating
will not be possible.
- No other steam source can be connected to live steam line between MSIV and ESV.

7.1 Preheating of Live Steam Line

-The Main steam isolating valve installed upstream of the turbine shall be fitted with a bypass with
a control valve. The bypass control valve serves for heating of the steam pipeline upstream of
the turbine and for heating of the turbine control valve chest. Dimension of bypass control valve is
according to length and diameter of the steam pipeline between the main isolating valve and
emergency stop valve, and also quantity and diameter of corresponding drains. 2" dimension of
the bypass line and the control valve are usually sufficient for correct inlet steam line preheating.

Fig. 24 Live Steam line

- Main steam isolation valve (MSIV):

The Main steam isolation valve is valve for isolation of turbine from steam part of plant. The
Main steam isolation valve is usually gate valve with el. Motor operated actuator or
manually operated. Choosing of manually operated or remote operated valves are
according to plant operation philosophy (and numbers of expected start per year).

- Bypass of Main steam isolation valve – control valve

The Bypass of Main steam isolation valve – control valve is valve for inlet steam line preheating
by required ramp. This valve is usually globe valve with el. Motor operated actuator or with
pneumatic actuator operated actuator (failure to close actuator) or manually operated.
Choosing of manually operated or remote operated valves are according to plant
operation philosophy (and numbers of expected start per year).

- Bypass of Main steam isolation valve – closing valve

The Bypass of Main steam isolation valve - closing valve - is valve for isolation of turbine from
steam part of plant (for bypass line tight from the control valve potential leak). This valve
is manually operated usually globe valve.

- Preheating rate is controlled according to the temperature of the inlet steam,

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optimal temperature increasing trend is 4 °C/minute (or increasing of pressure by

same steam saturation curve).

- Inlet steam line is preheated via open Emergency stop valve to closed turbine control valve.

7.2 Reason of the Main steam isolation valve and its bypass Necessity
- The emergency stop valve cannot be used as isolation valve for long time (more than 1 hour) if
turbine is not operated by corrosion reason. This means – in this case (missing MSIV) steam
system cannot be operated without turbine operation (for example steam heaters, steam
technology consumers, bypass valves, test of boilers etc.)

8.0 Extraction Steam

8.1 With External Source of Steam
- First non-return valve has to be located less than 5 m of piping length from turbine
nozzles. If this requirement cannot be met, Siemens has to be requested for approval. Risk of
turbine overspeed.
- Drain and vent lines have to be installed between two MSIVs to ensure safe isolating of
steam turbine unit against steam ingress.

Fig. 25 Extraction steam line connection to turbine top

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Fig. 26 Extraction steam line connection to turbine bottom

8.2 Without External Source of Steam

- First non-return valve has to be located less than 5 m of piping length from turbine
nozzles. If this requirement cannot be met, Siemens has to be requested for approval. Risk of
turbine overspeed.
- If extraction pressure is 1.5 bar below turbine exhaust steam pressure, than extraction line
can be designed without non-return valves. Nevertheless, this solution is subject of Siemens
additional approval.

Fig. 27 Extraction steam line connection to turbine top

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Fig. 28 Extraction steam line connection to turbine bottom

9.0 Admission Steam

- Control valve has to be located less than 5 m of piping length from turbine nozzles. If
this requirement cannot be met, Siemens has to be requested for approval. Risk of turbine
overspeed.
- Turbine admission steam temperature and pressure measurements have to be located as close
as possible to ESV, maximally 3 m upstream of ESV.
- Position of MSIV is recommended as close as possible to ESV.
- Dimension of MSIV bypass need to be designed with regard to requirements of admission
steam
line preheating. Admission steam line needs to be preheated by speed 4 °C/min to minimum
start-up temperature. Bypass of MSIV is not required, if no of admission steam parameters
exceed 10 bar(a) or 250 °C.
- No other steam source can be connected to admission steam line between MSIV and
ESV.
- Steam blowing of admission steam pipeline to be ensured according to 2CWN002896 up
to ESV.

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Fig. 29 Admission steam line- connection to turbine top

Fig. 30 Admission steam line- connection to turbine bottom

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10.0 Exhaust Steam Backpressure:

-Reverse initial heating of the turbine may be required for backpressure turbines. This is
illustrated as appropriate in the P&I diagram. The bypass around the exhaust steam valve MSIV 1
is used for reverse heating. The condensate that accumulates is removed through the turbine
casing internal drains.

Fig. 31 Exhaust steam of back pressure turbine (example)

11.0 Oil System

- If routing of oil lines over steam systems cannot be avoided, shield plates shall be
provided beneath the oil lines (e.g. as troughs or channels). These items are part of the
customer's scope of supply and services.

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SIEMENS LTD. 1CYJ470061 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
PG / 14.02.2013 MN/ 14.02.2013 MP / 14.02.2013 Eng. 1 of 7
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E61.doc

Piping Guidelines:

Heaters Drain Piping

- 14.02.2013 FIRST ISSUE PG MN MP

Rev. No Date Description Prepared: Checked: Approved:

_______________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is
strictly forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Document No. Rev.
No.
1CYJ470061 -

INDEX
1.0 Guidelines for design of LP heater normal / emergency drain Piping
2.0 Guidelines for design of HP heater normal drain Piping
3.0 Guidelines for design of HP heater emergency drain Piping

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1.0 LP Heater Normal / Emergency Drain to Condeser Flash Box

Piping Guidelines for Termination of heaters drain’s near to Condenser Flash Box
Pipline after Control valve should be connect straight at nozzle elevation of
flash box to avoid accumulation of water inside the pipe. ( Refer Fig.1.1 &
Fig.1.2)
There should not be any riser nor any bends after Control Valve
Line Size after Control Valve should be designed as per Volumetric flow of
fluid ( Mixture of Steam + Water) Refer Calculations below
Fluid downstream of control valve will be “Flash Steam” having very high
velocity & energy, so it is recommended to keep the control valve nearrer &
strainght inline with flash box nozzle
There should not be any bend after control valve to avoid fluid hammering
Do Not Provide Rigid Support near to flash box nozzle, Prefrable to provide
spring support.

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1CYJ470061 -

Fig. 1.1 Piping sketch for control valve outlet to condenser flash box

Fig. 1.2 Piping sketch for control valve outlet to condenser flash box

What is flash steam? When hot condensate or heater water, under pressure, is
released to a lower pressure, part of it gets re-evaporated and become flash
steam.

How is it formed? When water is heated at atmospheric pressure, its

temperature rises until it reaches 212°F, the highest temperature at which water
can exist at this pressure. Additional heat does not raise the temperature, but
converts the water to steam. The heat absorbed by the water in raising its
temperature to boiling point is called “sensible heat” or heat of saturated liquid.
The heat required to convert water at boiling point to steam at the same
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temperature is called “latent heat.” which is the amount of heat required to raise
the temperature of one pound of water 1°F at atmospheric pressure.
If water is heated under pressure, however, the boiling point is higher than 212°F,
so the sensible heat required is greater. The higher the pressure, the higher the
boiling temperature and the higher the heat content. If pressure is reduced, a
certain amount of sensible heat is released. This excess heat will be absorbed in
the form of latent heat, causing part of the water to “flash” into steam.

% flash steam = (SH – SL) / H x 100

SH = Sensible heat in the cond. at the higher pressure before discharge.

SL = Sensible heat in the cond. at the lower pressure to which discharge takes
place.

H = Latent heat in the steam at the lower pressure to which the cond. has been
discharged.

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2.0 HP Heater Normal Drain to Deaerator

Piping Guidelines for Termination of heaters drain’s near to Condenser Flash Box
Pipline after Control valve should be connect straight at nozzle elevation of
flash box to avoid accumulation of water inside the pipe. ( Refer Fig.1.1 &
Fig.1.2)
There should not be any riser nor any bends after Control Valve
Line Size after Control Valve should be designed as per Volumetric flow of
fluid ( Mixture of Steam + Water) Refer Calculations below
Fluid downstream of control valve will be “Flash Steam” having very high
velocity & energy, so it is recommended to keep the control valve nearrer &
strainght inline with flash box nozzle
There should not be any bend after control valve to avoid fluid hammering
Do Not Provide Rigid Support near to flash box nozzle, Prefrable to provide
spring support

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Fig. 2.1 Piping sketch for control valve outlet to Deaerator

(Recommended Practice)

Fig. 2.2 Piping sketch for control valve outlet to Deaerator

(Wrong practice)

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SIEMENS LTD. 1CYJ464026 A
Responsible Department Take over Departm ent Doc- type Folder No. :
Pro jec t Engine ering\BOP\Gene ral\Ere ction do cs\
E P SU PEN E S FS TI Sta ndard doc uments
Prepared : Checked : Released : Language : Page :
-- -- -- Eng 1 of 5
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E P SU VAD 464026.doc

TECHNICAL SPECIFICATION FOR FLUSHING & CHEMICAL CLEANING OF

TG STEAM, CONDENSATE & FEEDWATER PIPING

1.0 Scope & Range of application

The specification describes the cleaning procedure for the following piping:
- Steam piping
- PRS piping
- Gland sealing piping
- Condensate & Feed water piping including recirculation piping
- Heaters drain piping.

The objective is to remove dirt, oil, grease, welding slag and mill scale adhering to
the internal surfaces of piping by cold water flushing, hot water flushing & alkali
flushing and preservation of pipes, fittings, valves & pumps to ensure flow of clean
condensate and feed water to the boiler.

2.0 Preparation of Temporary Circuits

Hydraulic test of the system as applicable shall be completed. All flow measurement
devices and pneumatic operated control valves in the circuit shall be installed after
completion of flushing operation and wherever required spool pieces shall be used
at these locations.

The cleaning may be carried out by circulating the specified chemical solutions in the
specified sequence and conditions. Temporary piping, pumps of suitable capacity,
fittings, flanges, tanks, gaskets, heating arrangement, hydrometers, valves, test
coupons, spares, laboratory facilities with all accessories required for conducting
tests during cleaning operation, chemicals and safety accessories for operation per-
sonnel etc., shall be made available at site prior to cleaning operation. Quantity of
chemicals required should be calculated based on the hold-up volume of the circuit.

A 03.01.2014 First issue BMK/KS SB/PI MP

- 01.03.2013 First issue MM ND ND
Rev Date Description Prepared Reviewed Approved

We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden. © SIEMENS Ltd.
Format No.: IP-Q-F-3009
Rev./Date : C / 31.03.2010
 Page Document No. Rev

SIEMENS LTD. 2 of 5 1CYJ464026 A

Customer has to provide DM water & Construcion power and same will be tapped by
contractor by making necessary arrangements. All other activites, processes and
Loop diagram showing details for cleaning shall be done by Erection contractor and
submitted to Owner for review before starting the work. For making the loops refer to
the PID’s for the project.

3.0 Procedure
Preferably each of the steam, condensate, feed water and heater drain systems
shall be flushed separately. It consists of cold water flushing, hot water flushing fol-
lowed by alkali flushing using Trisodium Phosphate, Caustic Soda and Lissopol. Af-
ter Alkali flushing, the system is flushed well with DM water and then preserved
using Hydrazine Hydrate with Ammonia to maintain Ph 10.

3.1 Cold Water Flushing:

Piping loops are filled with DM water and flushing of the same is carried out using
circulating pumps till the effluent water in the system is visibly clean.

3.2 Hot Water Flushing:

The loops are again filled with DM water and its temperature increased to around
0
70 C and circulated for 2 hours or more till till the effluent water in the system is visi-
bly clean

3.3 Hot Alkali Flushing:

The system is again filled with DM water, its temperature increased to 85 0C circula-
tion continued. Trisodium Phosphate, Caustic Soda are added to achieve required
concentration and also Lissopol is added to produce sufficient foaming. The solution
is circulated for 6 hours or more. During this time, Alkalinity is tested at intervals till
stability of the reading is achieved. After achieving stability, the system is drained.

System is again filled with DM water and circulated for half an hour in each loop and
drained. Now rinse the system with DM water by continuous filling and draining while
keeping pumps running till effluent is visibly clean and conductivity and oil parame-
ters meet as per completion criteria.

3.4 Preservation:

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SIEMENS LTD. 3 of 5 1CYJ464026 A

After completion of alkali flushing, Add Hydrazine and Ammonia to get 200 PPM Hy-
drazine and pH of the water to 10.0. Raise the temp of the solution to 80 deg C by
steam admission in mixing tank. Circulation is maintained for 8 Hrs. at this temp. The
system is completely drained hot. All air vent valves and feed storage tank man-
holes are opened to aerate the system. The system is ready to take into service
within 15 days to complete post flushing operation.

4.0 Post Flushing operation:

Remove all the temporary connections from the permanent scheme. Check that all
the pipelines and connections are as per the final PID’s of the project. After welding
of flow nozzle and pneumatic operated control valves, flush the piping with DM wa-
ter.

5.0 Completion Criteria:

DM water mixing after chemical flushing shall be considered complete once drained
water conductivity is less than 10 micro mhos / cm, and oil content is NIL.

6.0 Chemical Composition:

The chemical composition and the concentration of the chemicals to be used during
Alkali Flushing and Preservation are given below:

# Description Concentration
1. Trisodium Phosphate Na 3PO4.12H2O 0.5% by wt.
2. Caustic soda Sodium Hydroxide NaOH 0.3% by wt.
3. Lissopol Patented Chemical 0.02% (200ppm)
4. Hydrazine Hydrate N2H4H2O 200 ppm
5. Ammonia for Ph 10

7.0 Safety Precautions

The alkali and acid solutions involved for chemical cleaning are corrosive for the skin
and proper care shall be taken in the handling of the chemicals.

Format No.: IP-Q-F-3009

Rev./Date : C / 31.03.2010
 Page Document No. Rev

SIEMENS LTD. 4 of 5 1CYJ464026 A

RECORD SHEET 1

PROJECT:

ACTIVITY: Detergent Flushing of ………………… system

NAME & QUANTITY OF CHEMICALS ADDED FOR FLUSHING:

NAME & QUANTITY OF CHEMICALS ADDED FOR PRESERVATION:

Start Finish
S No. Activity Remarks
Date Time Date Time

REMARKS:

..................................... .....................................
Signature Signature
(Siemens Limited, Vadodara, India) (Customer :______________ )

Format No.: IP-Q-F-3009

Rev./Date : C / 31.03.2010
 Page Document No. Rev

SIEMENS LTD. 5 of 5 1CYJ464026 A

RECORD SHEET 2

PROJECT:

UNIT:

ACTIVITY: Alkali Flushing of ………………….. system

DM Water Rinsing after Alkali Flushing

Conductiv-
Oil content
S No Date Time ity Micro Remarks
PPM
S/Cm

Preservation

Hydrazine
S No Date Time pH Remarks
PPM

REMARKS :

..................................... .....................................
Signature Signature
(Siemens Limited, Vadodara, India) (Customer :______________ )

Format No.: IP-Q-F-3009

Rev./Date : C / 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470064 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP CE EO IP PM TI
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SV (27.03.2013) RK (27.03.2013) RK (27.03.2013) Eng. 1 of 6
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E64.doc

Technical Instruction:
Preservation of the Shut-down Turbine plant
(Extract from Turbine O&M Manual )

- 27.03.2013 FIRST ISSUE SV RK RK

Rev. No Date Description Prepared: Checked: Approved:

_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ461103EXX -
Preservation of the Shut-down Turbine plant
Shut-down turbine plants are exposed to corrosion. Mostly an electro-chemical process is
involved in which iron is converted to rust by the presence of water and air (oxygen). Also the
most disadvantageous, forming of pitting may occur.

Stand still periods can cause damage by corrosion and later consequent faults due to corroded
components. After a stand still period of only a few days with high humidity damage of blading
components is possible. The combination of moisture and salt deposits in the cold turbine
increases the risk of pitting, which may reduce the endurance strength and increase the risk
for high cycle fatigue.

The recommendations as mentioned in this section are for Turbine point of view only.
Customer to refer respective equipment manuals for other plant systems / auxiliaries.

Corrosion of metals in air

The presence of free water on the surface of metal is necessary for atmospheric,
electrochemical, corrosion to take place. In the air, there is always some amount of water in
steam form. The moisture causes a thin water film to occur on the metal surface. The
thickness of this film depends on the relative humidity of the air.

The higher the relative humidity, the thicker the water film and the faster the corrosion will be.
The relation between relative humidity and relative corrosion velocity is shown in the diagram.
This relation has three important zones.

Below 30 % relative humidity, no corrosion at all

At 30 - 50 % relative humidity, negligible corrosion which increases very slowly with

increased relative humidity

Above 50 % relative humidity, the corrosion velocity increases rapidly with increased
relative humidity

It is common practice to keep the relative humidity below 40 % to prevent corrosion.

If the relative humidity of the environment is higher than 40 %, the recommend precautions
must be taken immediately in order to prevent corrosion damage. If the stand still period is
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Rev.Date : 31.03.2010
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3 1CYJ461103EXX -
expected to exceed 9 - 12 months, or if the environment is extremely aggressive, a more
extensive conservation procedure than described here in should be considered.

This process begins immediately after the turbine is shut-down and has subsequently cooled-
down. Air temperatures below dew point cause condensation of air moisture on internal
surfaces.

The relative humidity can be reduced by hot-air injection, dry-air injection or inert gas
injection (for example nitrogen). We recommend dry-air injection with dehumidifiers
because it is more reliable and economic than the other methods.

The described measures are to be understood as recommendations and must be decided

upon on site according to actual operating conditions, shut-down period, costs, plant location
and plant size.

Leak steam, steam back flows and condensate penetration to protected sections should be
prevented first of all.

SHORT SHUT-DOWN (UP TO 4 DAYS)

The shut-down period counts from complete cooling-down up to ambient temp.

Special preventive measures are not required.

For short stand still periods, such as a night or a weekend, we recommend that the
gland steam system is left in operation and the main condenser is kept under vacuum.
(Rotor on barring speed)

If there is no possibility to get gland steam during the stand still period, Maintain the
condenser cooling water circulation in order to direct the condensation to the condenser
instead of the turbine.

For frequent weekend standstills, connect dry air dehumidification system.

SHUT-DOWN (LONGER THAN 4 DAYS UP TO 6 - 8 MONTHS)

Turbine

For longer stand still periods the condenser should be drained and a dehumidifier be
connected.
Drain the turbine, and related pipes.
In any case no steam or condensate may leak to the turbine system, because the
conservation would fail and the dehumidifiers would accelerate corrosion.

Connect a dehumidifier to the turbine; optionally it can also be connected

through bleed lines or any connections available on turbine casing / condenser.

Maintain RH < 30 % to ensure better preservation inside turbine

Open the valves in the drainpipes slightly

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Rev.Date : 31.03.2010
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4 1CYJ461103EXX -
Check that there is airflow from the turbine shaft glands. This airflow is very important in
order to prevent corrosion in the glands.
Clean the strainers in the steam traps and check the drain pipes for clogging
Check that there is airflow through turbine and condenser.

Protect turbine against possible entering of leak steam. Do not use the emergency stop
valve as a component of steam lock. It is not protected against corrosion.

Casing and rotor temperatures are kept above dew and freezing point.

Protect against entering steam by fitting blank plates between inlet connecting flanges
(main steam, bleed steam, sealing steam).

Remove measuring instruments and electrical equipment, mark carefully and store
wrapped in oil paper.

Oil System

Every 2 weeks put oil pumps for 1 hour into operation; during this period all control
devices shall be moved once from "completely closed" to "completely open" position.

Turn turbine rotor with turning gear shortly. Most of the commercial turbine oil brands
contain corrosion inhibitors which provide good protection against rusting. Take oil
samples as accustomed.

A slow cooling water flow should be maintained in the coolers all the time. (Both sides
of oil cooler)

SHUT-DOWN FOR INDEFINITE PERIOD

(LONGER THAN 6 TO 8 MONTHS)

To protect turbine plants against corrosion for indefinite periods is rather extensive and
expensive. All measures for preservation should be carried out in connection with an
immediate overall overhaul of the complete turbo set after shut-down. All components are
preserved, packed and stored in dismantled condition. Check the preservation in 2 years
intervals and renew if required. Prior to recommissioning the corrosion inhibitors must be
removed with steam or paraffin.

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Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
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5 1CYJ461103EXX -
Turbine
Dismantle turbine not later than 4 days after shut down and remove rotor. Check and
clean internals.
The relative humidity in the storage environment must be kept below 40%, below 30%
is recommended.
Protective coatings with anti corrosion protection agents can be applied. Checks at
regular intervals are necessary to ensure protection.
Mark carefully the components. Apply TECTYL 506 to all internals, bearings, joints,
auxiliary drives, flange bolts, etc. Bearings and joint surfaces should be additionally
wrapped in oil paper. Apply TECTYL 511M to all inner casing surfaces. Dismantled
components shall be wrapped in foils and stored indoors or stored next to the turbine in
cases.
Lift upper turbine casing, bearing cover, valve block by about 100 mm from the
horizontal joint by means of hardwood distance pieces. Wrap these in oil paper. Plug all
turbine ports with plastic covers well visible for everybody.
Clean and apply TECTYL 506 to all dismantled components like steam strainers,
control and emergency stop valves, valve chests, control components etc. Dismantled
components shall be wrapped in foils and stored indoors or stored next to the turbine in
cases.
Apply TECTYL 506 and preserve base plates, sliding surfaces, keys, guide pins.
Remove measuring instruments and electrical equipment and store them carefully
marked and wrapped in oil paper. Check external coatings, renew if required. Remove
piping and clean, dry the individual sections, seal air-tight and apply a new external
coating. Order and keep on store one set of new sealing rings and gaskets for
recommissioning.

TECTYL 511-M

Properties
TECTYL 511-M is a fluid rust-preventive. The resulting film is light-brown, nearly transparent
and soft. Coverage amounts to 35-45 m2 per litre. TECTYL 511-M is an especially water
displacing and creepable product. The film does not attack any metal surfaces.
This product is very suitable for temporary storage and short time dispatch (metals being
protected by TECTYL 511-M must be covered so that neither rain water nor sunshine can
affect them). It forms a barrier between metals and aggressive mediums protecting steel from
rust and aluminium-magnesium-alloys from efflorescence.

Protection Period on Clean Steel Surfaces (Film Thickness Approx. 15 Microns):

Inside storage (uncovered): approx. 18 months

Application

TECTYL 511-M can be applied by spraying, painting or dipping of the parts to be protected.

Removal

TECTYL 511-M can be removed without any difficulties by benzine, petroleum, Diesel oil, wax
solvents and alkali cleaner and steam.

Spec. gravity DIN 51757 0.865

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Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
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6 1CYJ461103EXX -
Flash point DIN 51755 approx. 40°C

Class of danger as per VbF A II

TECTYL 506

TECTYL 506 is a rust-preventive especially suitable for export of machines of various types.
When being supplied, product is liquid. The resulting wax film is not affecting any metal
surfaces and does not attack lacquer, plastics and rubber materials. This brown rust-
preventive is resistant against temperatures occurring in packing, which amount to 70-90°C in
some countries. The wax film furthermore has an outstanding adhesion with minus
temperatures. TECTYL 506 with its flexible protective film being tight and adhesive forms a
good barrier between metal surface to be protected and corrosive influences. Coverage
amounts to 6-8 m2 per litre - depending on the film thickness.

Protection Period on Clean Steel Surfaces (Film Thickness Approx. 100 Microns):

Inside storage Uncovered: 4-5 years

More if covered

Outside storage Uncovered: 18 months to years

More if covered

Application
TECTYL 506 can be applied by painting or spraying or airless to the parts to be protected

Removal
TECTYL 506 can be removed without difficulties by means of benzine, petroleum, Diesel oil or
wax solvents. In case of big surfaces steam jet cleaning device with special additives can be
used (prior to this use wax remover and wait for its reaction).

Spec. gravity DIN 51757 0.88

Flash point DIN 51755 approx. 40°C

Class of danger as per VbF A II

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470068 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 27.03.2013 SB/ 27.03.2013 MP / 27.03.2013 Eng. 1 of 2
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E68.doc

Technical Instruction:

INSTRUMENT AIR QUALITY FOR VALVES

EQUIPPED WITH PNEUMATIC ACTUATOR

- 27.03.2013 FIRST ISSUE MT SB MP

Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470068 -

INSTRUMENT AIR QUALITY FOR VALVES EQUIPPED WITH

PNEUMATIC ACTUATOR

In order to get a safe and trouble-free operation with pneumatic actuators, the
instrument
air shall fulfil the demands in either ISO 8573-1 or ANSI/ISA-7.0.01-1996.

- If ISO 8573-1 is used, the following demands shall be fulfilled:

Solid particles: Class 1.
Humidity: Class 3 shall be fulfilled for indoor installations. For outdoor installations, the
guidelines in ISO 8573-1 shall be followed in order to find out which class shall be
chosen.
Oil: Class 1.

-Minimum allowable instrument air pressure: 4 bar (g) /58 psig.

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470065 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 27.03.2013 SB/ 27.03.2013 MP / 27.03.2013 Eng. 1 of 3
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E65.doc

Technical Instruction:
FIRE PROTECTION OF TG HALL

- 27.03.2013 FIRST ISSUE MT SB MP

Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470065 -

Fire Protection of Industrial Steam Turbines

General

It is essential to design the turbine and equipment to minimize the risk for fire. Based on our
experience passive protection has reduced the risk to an acceptable level.

Design rules/features for steam turbines supplied from Siemens LTD.

• Welded couplings are used for the high-pressure oil tubing to avoid leakage.

• Shielding Plates are provided near front and rear bearing pads in order to avoid the
exposure to High temperature region of Turbine casing.

• Steam pipes and oil pipes shall be separated on each side of the turbo set in order to
avoid mixture of hot steam pipes and oil pipes. If separation is not possible, separating
plates shall be mounted between the oil- and steam containing parts.

• All lube oil piping/oil tubing is hydrostatic tested at site.

• The use of flange joints in the lube oil pipes is minimized.

• Sub-atmospheric pressure is present in the lube oil supply unit, return lube oil piping and
part of the bearing bracket in order to reduce the risk for leakage.

• All lube oil piping/oil tubing are routed in such a way that the risk for rupture of
piping/tubing due to mechanical damage is minimized.

Active fire protection

If the customer requires or insurance company demands active fire protection, we recommend
the customer to install a water-spray protection.

This kind of fire protection has the following advantages:

• High cooling effect.
• The evaporating fire-fighting water very quickly displaces the oxygen thus smothering the
fire.
• High efficiency with low water consumption.

For detection of a fire we recommend the use of smoke detectors.

Protection is recommended in the following areas:

Protection beneath turbine operating floor

• Under the operating floor – protection should extend beyond all oil systems.
• Over basement – protection should extend to all areas where oil may spread including
areas between pedestals.
• Oil System Protection In TG Hall (Refer fig. 1)
• A fixed, automatically actuated water-spray system with directional-spray nozzles.
_________________________________________________________________________________________________________________________________
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Rev.Date : 31.03.2010
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3 1CYJ470065 -
• The protection should be provided for the following.
Bearing housings
Shaft-driven oil pumps
Control oil systems using mineral oil
Main supply and return oil piping

When there is a sound enclosure on the turbine operating floor, the turbine foundation must be
equipped with necessary floor drainages. This in order to be able to drain the water inside the
sound enclosure if the water-spray system have been activated.

Other recommended basic safeguards

• Operator training to secure the unit so that lube oils pumps can be shut off as quickly and
safely as possible.

• Protection of control rooms, located in turbine buildings in order to provide operators the
opportunity to take action during emergency.

• Protection of critical cable to minimize the possibility of loss of more than one unit and
reduce the chance of uncontrolled loss of lubrication system.

• The steam piping insulation must be proof against oil splashes.

Figure. 1

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470066 -

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 27.03.2013 SB/ 27.03.2013 MP / 27.03.2013 Eng. 1 of 3
Valid for: Derived from: Replaces: E File no.:
EO IP 461103E66.doc

Technical Instruction:
JOB SITE STORAGE OF GOODS

- 27.03.2013 FIRST ISSUE MT BMK MP

Rev. No Date Description Prepared: Checked: Approved:
_________________________________________________________________________________________________________________________________
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly
forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470066 -

JOB SITE STORAGE OF GOODS

General

During storage before and during erection and first start certain precautions must be taken
in order to prevent corrosion damage to the plant equipment.

This instruction primarily covers the equipment leaving Siemens Ltd. workshop in India.

All equipment shall be preserved and stored according to supplier requirements.

Special attention must be given to the generator, where, for instance, all the heaters must
be connected and activated upon arrival at site. Additional information will be made
available before shipping.

If the relative humidity of the environment is higher than 50 %, the recommended

Precautions must be taken immediately in order to prevent corrosion damage.

If the standstill period is expected to exceed 9 - 12 months, or if the environment is

Extremely demanding, a more extensive conservation procedure should be considered.

Recommended precautions during storage

All machinery, electrical and other sensitive parts shall be stored indoors. If the storage
time exceeds 2 - 3 months, the packages shall be opened and a dehumidifier unit
Connected to the storage room in order to keep the relative humidity below 50 %.

Other equipment, such as piping and less sensitive materials, need not to be stored dry
indoors. Instead, rust protection by use of rust preventive agents e.g. Tectyl TM, water-
soluble oils and silica gel inside sealed-off space can be used. Weather protection and
periodic inspections are recommended.

Arrival at site

General parts

Place the crates and boxes, so that they will not be exposed to water (rain, flooding etc.)
and/or physical damage.

Do not open any box or crate until the equipment in that specific box or crate is to be used.
If an opened box or crate is to be stored further, it must be carefully closed and resealed.
At the opening of the different boxes an inventory must take place using the packing list
for each box, in the presence of a Siemens Ltd. representative.

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Rev.Date : 31.03.2010
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3 1CYJ470066 -
Spare parts

Spare parts are to be placed indoors in a ventilated space in normal room temperature
and preferably low humidity. Rust inhibitors should not be removed until each spare part is
intended to be used.

Control cubicles

Do not remove or damage the plastic film that covers each cubicle.

If an inspection of the cubicles has to be made the moisture absorbent (silica gel) must not
be removed from inside the cubicles. The plastic film should then be hermetically resealed
by welding as soon as possible.

Do not place the cubicles in their final space until the conditions are such that no
Condensation will take place inside the cubicles.

_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010
 Document No. Rev.No.

SIEMENS LTD. 1CYJ470067 B

Responsible Department: Take over Department: Document Type: Folder No.
EO IP PEN EO IP PM TI
Prepared: Checked: Approved: Language Page:
MT / 29.05.2014 BMK/ 29.05.2014 MP / 29.05.2014 Eng. 1 of 2
Valid for: Derived from: Replaces: E File no.:
EO IP 1CYJ470067.doc

Technical Instruction:
GROUTING MATERIAL SPECIFICATION

B 11.09.2015 Suggestive Make updated as per vendor feedback MT BMK KS

GROUTING MATERIAL SPECIFICATION FOR GEARBOX

A 27.03.2014 MT BMK MP
AND ALTERNATOR INCLUDED
- 27.03.2013 FIRST ISSUE MT BMK MP
Rev. No Date Description Prepared: Checked: Approved:

Unrestricted
_________________________________________________________________________________________________________________________________
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forbidden. © SIEMENS Ltd.

Format No.: IP-Q-F-3009/C

Rev.Date : 31.03.2010
 Page: Document No. Rev.No.

2 1CYJ470067 B
GROUTING MATERIAL SPECIFICATION

General
Grouting Material:

Generally any grouting material having expansive characteristics is preferred. The Grout
expands while drying and is non-shrink with high early strength. Providing and laying High
Strength Non-shrink free flow grout below the base-Frame of the turbine, gear box,
alternator, condenser etc. as per the drawing, manufacturer’s specification and instruction of
Engineer in charge.
Volume / Quantity to be decided as per respective equipment drawings.
Table :1 Indicates minimum required Properties of Grouting material.

Sr No Siemens Turbine SST300 SST200 SS SST800 Reheat

Models T60
0
2
1 Compressive Age Flowable Pourable 1Day-90 N/mm
(Day Consistency Consistency 2
Strength 2 2Days-95N/mm
s) (W/P=0.165N/mm
) 7Days-104N/mm 2
1 24 27
3 45 54
7 55 66
28 65 78

2 Flextural Strength Age Flexural Strength 7 Days – 26 N/mm²

2
(Days) (W/P=0.18) N/mm
1 2.5
3 7.0
7 9.0
28 10.0
3 Tensile Strength 3.5 N/mm² @ 28 days (W/P=0.18) 7 Days – 14 N/mm²
4 Time for Expansion Start : 20 minutes -
(After mixing) Finish : 150 minutes
5 Modulus of Young’s Modulus 28 Compressive Modulus of Elasticity : 14,600
Elasticity kN/mm² Kg/cm²
Flexural Modulus of Elasticity: 1,40,600 Kg/cm²
6 Coefficient of 11 X 10-4/°C 28.1 X 10-6/°C
Thermal Expansion
0
7 Flow Max Flow Distance in mm at 30 C Max Flow Distance for a head of 100mm at 20
Characteristics Gap 50mm 100m 250m °C
Width head m m
(mm) head head
35mm Gap – 2000mm
20 200 950 1600 70mm Gap – 3500mm
30 350 1500 2300
40 600 2200 3000
50 900 3000 3000+
8 Suggested Make Fosroc : Conbextra GP 1 Chock Fast Red
for Grouting Conbextra GP 2 Masterflow 410 (Rev B)
Material Sika : Sikagrout 214 Conbextra EP75
Fairmate : Flowgrout 40
Flowgrout 60
ACC : Shrinkkomp

Unrestricted
_________________________________________________________________________________________________________________________________
Format No.: IP-Q-F-3009/C
Rev.Date : 31.03.2010