AMERICAN NATIONAL STANDARD

ANSI/ISA–77.13.01–1999
Formerly ANSI/ISA–S77.13.01–1999

Fossil Fuel Power Plant

Steam Turbine Bypass System

Approved 15 December 1999

ANSI/ISA–77.13.01–1999
Fossil Fuel Power Plant Steam Turbine Bypass System

ISBN: 1-55617-711-9

Copyright  1999 by the Instrument Society of America. All rights reserved. Not for resale. Printed
in the United States of America. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means (electronic, mechanical, photocopying,
recording, or otherwise), without the prior written permission of the Publisher.

ISA
67 Alexander Drive
P.O. Box 12277
Research Triangle Park, North Carolina 27709
 —3— ANSI/ISA–S77.13.01–1999

Preface

This preface, as well as all footnotes and annexes, is included for information purposes and is not part of
ANSI/ISA–77.13.01-1999.

This document has been prepared as part of the service of ISA, the international society for measurement
and control, toward a goal of uniformity in the field of instrumentation. To be of real value, this document
should not be static but should be subject to periodic review. Toward this end, the Society welcomes all
comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices
Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919)
549-8411; Fax (919) 549-8288; E-mail: standards@isa.org.

The ISA Standards and Practices Department is aware of the growing need for attention to the metric
system of units in general, and the International System of Units (SI) in particular, in the preparation of
instrumentation standards. The Department is further aware of the benefits to USA users of ISA standards
of incorporating suitable references to the SI (and the metric system) in their business and professional
dealings with other countries. Toward this end, this Department will endeavor to introduce SI-acceptable
metric units in all new and revised standards, recommended practices, and technical reports to the
greatest extent possible. Standard for Use of the International System of Units (SI): The Modern Metric
System, published by the American Society for Testing & Materials as IEEE/ASTM SI 10-97, and future
revisions, will be the reference guide for definitions, symbols, abbreviations, and conversion factors.

It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests
in the development of ISA standards, recommended practices, and technical reports. Participation in the
ISA standards-making process by an individual in no way constitutes endorsement by the employer of that
individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA
develops.

CAUTION — ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS

INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS
REQUIRED FOR USE OF THE STANDARD, IT WILL REQUIRE THE OWNER OF THE PATENT TO
EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING
WITH THE STANDARD OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE
FREE FROM UNFAIR DISCRIMINATION.

EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS STANDARD, THE USER IS
CAUTIONED THAT IMPLEMENTATION OF THE STANDARD MAY REQUIRE USE OF TECHNIQUES,
PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE
EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING
THE STANDARD. ISA IS NOT RESPONSIBLE FOR IDENTIFYING ALL PATENTS THAT MAY
REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE STANDARD OR FOR INVESTIGATING
THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD
CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE STANDARD FOR THE
USER’S INTENDED APPLICATION.

HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS STANDARD WHO IS AWARE OF ANY
PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE STANDARD NOTIFY THE ISA
STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER.

ADDITIONALLY, THE USE OF THIS STANDARD MAY INVOLVE HAZARDOUS MATERIALS,

OPERATIONS OR EQUIPMENT. THE STANDARD CANNOT ANTICIPATE ALL POSSIBLE
APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN
HAZARDOUS CONDITIONS. THE USER OF THIS STANDARD MUST EXERCISE SOUND
ANSI/ISA–S77.13.01–1999 —4—

PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USER’S
PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY
GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH
PRACTICES BEFORE IMPLEMENTING THIS STANDARD.

The following people served as members of ISA Subcommittee SP77.13:

NAME COMPANY

L. Broeker, Chairman Consultant

W. Holland, Managing Director Southern Company
C. Fernandez-Varela Comision Federal de Electricidad
H. Foreman Brown and Root Energy Services
M. Kuffer NEOTECHA AG
D. Lee ABB Automation Inc.
G. Mookerjee U.S. Department of Energy
K. Schoonover Con-Tek Valves, Inc.
D. Tennant International Applied Engineering
T. Zuvlis Woodward Governor Company

The following people served as members of ISA Committee SP77:

NAME COMPANY

W. Holland, Managing Director Southern Company

L. Altcheh Israel Electric Corporation
S. Alvarez Compania Inspeccion Mexicana
J. Batug PP&L Inc.
L. Broeker Consultant
Q. Chou Consultant
D. Christopher Reliant Energy
D. Crow TXU
G. Davis Duke Power Company
H. Foreman Brown & Root Energy Services
W. Fryman Illinois Power Company
A. Gile Potomac Electric Power Company
R. Hicks* Black & Veatch
R. Hubby Consultant
R. Johnson Sargent & Lundy Engineers
J. Kennard Ontario Hydro
D. Lee ABB Automation Inc.
W. Matz Foxboro Company
G. McFarland* Honeywell Inc.
G. Mookerjee U.S. Department of Energy
N. Obleton* Honeywell, Inc.
R. Papilla Southern California Edison Company
G. Ramachandran Cytek Industries, Inc.
L. Rawlings, II Babcock & Wilcox
D. Roney Raytheon Engineers & Constructors
R. Roop Hoosier Energy Inc.

______
* One vote per company.
 —5— ANSI/ISA–S77.13.01–1999

T. Russell* Honeywell Inc.

A. Schager Vitec, Inc.
C. Skidmore Consultant
T. Stevenson Baltimore Gas & Electric Company
C. Taft* Electric Power Research Institute
D. Tennant International Applied Engineering
B. Traylor GE ICS
J. Weiss* Electric Power Research Institute
T. Zuvlis Woodward Governor Company

This Standard was approved for publication by the ISA Standards and Practices Board on 1 August 1998.

NAME COMPANY

R. Webb, Vice President Altran Corporation

H. Baumann H. D. Baumann Inc.
D. Bishop David N. Bishop Consultant
P. Brett Honeywell, Inc.
W. Calder III Calder Enterprises
M. Cohen Senior Flexonics, Inc.
H. Dammeyer The Ohio State University
W. Holland Southern Company
H. Hopkins Consultant
A. Iverson Ivy Optiks
K. Lindner Endress + Hauser GmbH and Company
V. Maggioli Feltronics Corporation
T. McAvinew Instrumentation and Control Engineering LLC
A. McCauley, Jr. Chagrin Valley Controls, Inc.
G. McFarland Honeywell, Inc.
E. Montgomery Consultant
D. Rapley VECO Rocky Mountain Region Inc.
R. Reimer Rockwell Automation
J. Rennie Factory Mutual Research Corporation
W. Weidman Parsons Energy & Chemicals Group
J. Weiss EPRI
J. Whetstone National Institute of Standards & Technology
M. Widmeyer EG & G
R. Wiegle CANUS Corporation
C. Williams Eastman Kodak Company
G. Wood Graeme Wood Consulting
M. Zielinski Fisher-Rosemount Systems, Inc.

______
* One vote per company.
This page intentionally left blank.
 —7— ANSI/ISA–S77.13.01–1999

CONTENTS

Preface .................................................................................................................................................. 3
1 Scope ............................................................................................................................................... 9
2 Purpose ............................................................................................................................................ 9
3 Definitions......................................................................................................................................... 9
4 Bypass systems.............................................................................................................................. 11
4.1 General requirements ........................................................................................................... 11
4.2 Elements ............................................................................................................................... 12
4.3 Capacity ................................................................................................................................ 13
4.4 Design requirements ............................................................................................................. 13
4.5 Turbine bypass instrumentation ............................................................................................ 22
4.6 Control and logic requirements ............................................................................................. 24
4.7 Alarm requirements............................................................................................................... 27
4.8 Operator interface ................................................................................................................. 27
Annex A — References ....................................................................................................................... 29
Annex B — The use of bypass systems.............................................................................................. 31
Annex C — Valve life expectancy ....................................................................................................... 33
Annex D — Some typical high- and low-pressure turbine bypass valve size and material
specifications .................................................................................................................... 35
Annex E — Figures ............................................................................................................................. 37
This page intentionally left blank.
 —9— ANSI/ISA–S77.13.01–1999

1 Scope
This Standard covers the design requirements and operator interface for steam turbine bypass systems for
drum and once-through steam generators and combined cycle plants. Hardware configurations are
suggested to obtain the minimum design requirements to obtain a safe and operable system. Both fixed
percentage bypass and variable pressure systems are covered.

It is applicable to boilers with steam capacities of 200,000 lb/hr (25 kg/s) or greater.

2 Purpose
This Standard establishes the minimum requirements for design specifications to implement steam turbine
bypass systems and hardware configurations for drum and once-through, fossil fuel power plant boilers.

The turbine bypass system should provide for cold start-up, warm start, hot restart, load rejection, turbine
shutdowns, and unit trips. The system shall be designed to provide pressure, temperature, and flow
control of steam around and through the turbine by controlling each bypass valve, isolation valve, and
associated desuperheater. The desuperheating function may be integral with the bypass valve. The
turbine bypass system does not interface with the turbine control and supervisory system. The turbine
bypass system is set to maintain steam pressure, and any coordination with the turbine is through
interaction with the process as the turbine demands more or less steam. There is no direct interconnection
of control systems.

3 Definitions
The following definitions are included to clarify their use in this Standard and may not correspond to the
use of the word in other texts. For other definitions, see ISA-S51.1-1979 (R1993), Process
Instrumentation Terminology.

3.1 alarm:
an indication used to alert an operator about an abnormal operating condition.

3.2 automatic tracking:

the action of a control system to automatically track a setpoint or the process variable without any other
corrective mechanisms.

3.3 boiler:
the entire vessel in which steam or other vapor is generated for use external to itself, including the furnace,
consisting of waterwall tubes; the firebox area, including burners and dampers; the convection area,
consisting of any superheater, reheater, and/or economizer sections as well as drums, generating tubes,
and headers.

3.4 condenser backpressure elements:

a multiple breakdown diffuser, normally installed in the steam condenser neck, used to generate a positive
back pressure upstream of the condenser vacuum and to reduce the kinematic energy of steam from an
external source other than the turbine exhaust.

3.5 controller:
any automatic, semi-automatic, or manual device or system of devices used to regulate the boiler turbine,
or any other equipment within defined parameters. If automatic, the device or system responds to
variations in temperature, pressure, water level, flow, or other control variables.
ANSI/ISA–S77.13.01–1999 — 10 —

3.6 differential producer:

a measuring element that is inserted in a process flow path and used to create a pressure drop that is
proportional to the square of the volumetric flow rate.

3.7 fail safe:

the capability to go to a predetermined safe state in the event of a specific malfunction.

3.8 fault tolerant:

built-in capability of a system to provide continued, correct execution of its assigned function in the
presence of a hardware and/or software fault.

3.9 integral windup:

the saturation of the integral controller output, in the presence of a continuous error, which may cause
unacceptable response in returning the process to its setpoint within acceptable limits of time and
overshoot.

3.10 load:
a device that receives power or that power which is delivered to such a device, as in the rate of output,
lb/hr (kg/s) of steam or megawatts (kilowatts) of electrical generations.

3.11 logic system:

decision-making logic equipment with its associated power supplies, I/O hardware, and sensing devices.

3.12 mode (submode):

a particular operating condition of a control system, such as manual, automatic, remote, or coordinated.

3.13 redundant (redundancy):

the duplication or repetition of elements in electrical or mechanical equipment to provide alternative
functional channels in case of failure of one channel.

3.14 severe duty valve:

a mission-critical valve, typically seeing high-pressure drop service, which may see cavitating or flashing
fluids, or if not properly designed, may see early trim erosion, vibration, or excess noise.

3.15 shall, should, and may:

the word “SHALL” is to be understood as a REQUIREMENT; the word “SHOULD” as a
RECOMMENDATION; the word “MAY” as a PERMISSIVE, neither mandatory nor recommended.

3.16 steam quality:

the ratio of the vapor’s mass to the mixture’s mass.

3.17 turbine:
a machine that converts energy from a moving fluid into rotating mechanical energy that drives a load. In
a power plant, a turbine converts energy in the steam into mechanical energy to drive an electric generator
(the mechanical load).

3.18 turbine governor valves:

the primary control valves used to regulate the flow of steam through the turbine during normal operation.

3.19 turn-down ratio:

the ratio from maximum operating to minimum operating conditions, providing a controllable or measurable
span. The device must perform over this range.
 — 11 — ANSI/ISA–S77.13.01–1999

4 Bypass systems
4.1 General requirements

The steam turbine bypass system requirements are defined for those components and logic systems
necessary to handle steam to and around the turbine.

The design of systems to prevent water damage to steam turbines is covered by the American Society of
Mechanical Engineers (ASME) standard TDP-1-1985.

The steam should be of a minimum quality of 92 percent to avoid impingement and corrosion.

Figures E.1 and E.2 show a typical turbine steam bypass system to assist in explaining the design
requirements of this clause. Other figures show specific areas to help clarify the text materials.

This Standard will cover the following functions:

a) Matching with an acceptable difference the metal to steam temperatures before steam is admitted to
the turbine

b) Handling the difference between the generated and consumed steam flows during transient conditions

4.1.1 High-pressure (HP) bypass system

The HP bypass system shall fulfill the following requirements:

a) Control the pressure of the steam bypassing the HP turbine

b) Control the pressure of the main steam from the boiler

c) Control the flow and temperature of steam through the cold reheat line to cool the boiler reheater
tubing

d) Control the flow of steam through the main steam line to cool the boiler final superheater in case of
sliding pressure operation

e) Prevent lifting of main steam and hot reheat safety valves during transient operations

4.1.2 Intermediate-pressure (IP) and low-pressure (LP) bypass system

The IP and LP bypass system shall fulfill the following requirements:

a) Control the pressure of the steam bypassing the IP and LP turbines

b) Control the pressure and temperature of the hot reheat steam from the boiler

c) Prevent the lifting of hot reheat safety valves during transient operations

d) Protect the condenser against excessive pressure, temperature, and steam kinematic energy
ANSI/ISA–S77.13.01–1999 — 12 —

4.2 Elements

The elements that make up the steam turbine bypass system are those added over the elements required
for a system without the ability to bypass steam around the HP, IP, and LP turbines. Therefore, those
elements that are added due to the bypass are shown in figures E.1 and E.2.

4.2.1 HP bypass elements

a) HP bypass control valve (HPB) (see notes 1 and 3)

b) Before HP bypass control valve, block valve (B) (see note 3)

c) HP bypass desuperheater (DES) (see note 1)

d) HP bypass desuperheater spray water control valve (SPV) (see notes 2 and 3)

e) HP bypass desuperheater spray water block valve (B) (see note 3)

f) HP turbine cold reheat, non-return valve (NRV)

g) HP turbine bypass control system

h) HP turbine bypass instrumentation

i) HP turbine reverse flow valve (see note 4)

NOTE 1 — The pressure control valve and desuperheater may be combined into one HP turbine mainstream bypass pressure control
and desuperheating valve as shown in figure E.2.

NOTE 2 — The desuperheater may have an integral spray water control valve.

NOTE 3 — Block valves are usually required to assure that leakage does not occur through the control valve. This function could be
integrated in a composite control valve, provided the block valve’s purpose is not compromised.

NOTE 4 — The reverse flow valve may be necessary to prevent excessive windage heating of the HP turbine blades during a hot
restart if initial loading is accomplished using the LP/IP sections.

4.2.2 IP and LP elements

a) IP/LP bypass control valve (IP/LPB) (see notes 1 and 3)

b) Before IP/LP bypass control valve, block valve (B) (see note 3)

c) IP/LP bypass desuperheater (DES) (see note 1)

d) IP/LP bypass desuperheater spray water control valve (SPV) (see notes 2 and 3)

e) IP/LP bypass desuperheater spray water block valve (B) (see note 3)

f) Condenser back pressure elements (I)

g) IP/LP pressure bypass control system

h) IP/LP bypass instrumentation

 — 13 — ANSI/ISA–S77.13.01–1999

NOTE 1 — The pressure control valve and desuperheater may be combined into one IP and LP turbine hot reheat bypass pressure
control and desuperheating valve as shown in figure E.2.

NOTE 2 — The desuperheater may have an integral spray water control valve.

NOTE 3 — Block valves are usually required to assure that leakage does not occur through the control valve. This function could be
integrated in a composite control valve, provided the block valve’s purpose is not compromised.

4.3 Capacity

The steam flow capacity of the bypass system is governed by a number of other variables in the overall
steam system. These are

a) heat distribution in the boiler;

b) turbine rotor diameter;

c) condenser internals;

d) startup, loading, unloading, and shutdown practices and requirements for the unit;

e) safety considerations; and

f) economics.

4.3.1 System size

There are a number of possibilities to size the bypass system. In this document the bypass system size or
capacity to fulfill the two functions previously defined in 4.1 are as follows:

a) A bypass system that matches the steam-to-turbine metal temperatures should be sized for 15 percent
of maximum continuous rated (MCR) flow at valves wide open. This system reduces the startup time
by about 30 minutes.

b) A bypass system that handles the difference between the generated and consumed steam flows
during upset or transient conditions should handle 40 percent of MCR flow at valves wide open or
should have a greater size range.

c) A bypass system that keeps the steam generator running at full load without blowing the safety valves
in case of a turbine or generator trip at full load should handle 100 percent of MCR flow at valves wide
open.

4.4 Design requirements

The design requirements for each of the elements are as follows.

4.4.1 HP and IP/LP turbine bypass control valve

a) Design criteria

The design criteria for the bypass system valves shall be specified as shown in tables 4.4.1(a) and
4.4.1(b).
ANSI/ISA–S77.13.01–1999 — 14 —

Table 4.4.1(a) — HP turbine bypass control valve

Severe duty, pressure type or pressure- and temperature-reducing type (see note 2)

The coordinated inlet and outlet pressure, temperature, and flow conditions for all distinct
Operating Conditions
service situations

Inlet and Outlet

The maximum design pressure for the inlet and outlet
Design Pressure

Inlet and Outlet The maximum design temperature for the inlet and outlet
Design Temperature

Inlet Pipe Size

(Internal Diameter [ID]) and The same as the piping just before the valve
Material

Outlet Pipe Size

(Internal Diameter [ID]) and The same as the piping just after the valve
Material

The desired maximum noise level at 1.0 meter (3.28 feet) from the valve
Noise Level
(see ISA-S75.07-1997)

Shutoff Leakage Class The desired shutoff class at the design pressure and temperature rating of the valve — usually
Class V of ANSI/FCI 70.2

Travel Time The desired minimum travel time from any position including fully closed at the maximum
operating pressure

Fail State The HP bypass valve is normally a fail-closed valve (see note 1.)

Modulating Time The maximum time for full stroke operation

Turndown Ratio The full range of coordinated operating parameters of flow, pressure, and temperature

Quick Opening Time The travel time for a valve that is provided with quick opening devices

NOTE 1 — If the code permits, this valve can also be used as a fail-open safety relief. An “HP to condenser” valve is preferably fail-
closed.

NOTE 2 — If the control valve has an integral water injection system, the average droplet size and distribution and the evaporation
length (90% of total droplet mass) shall be provided by the manufacturer.
 — 15 — ANSI/ISA–S77.13.01–1999

Table 4.4.1(b) — IP and LP turbines hot reheat bypass control valve

Severe duty, pressure type or pressure- and temperature-reducing type with stem sealing for condenser vacuum if
required (see note 2 from previous page)

The coordinated inlet and outlet pressure, temperature, and flow conditions for all distinct
Operating Conditions
service situations

Inlet and Outlet

The maximum design pressure for the inlet and outlet
Design Pressure

Inlet and Outlet

The maximum design temperature for the inlet and outlet
Design Temperature

Inlet Pipe Size

(Internal Diameter [ID]) and The same as the hot reheat piping just before the valve
Material

Outlet Pipe Size

(Internal Diameter [ID]) and The same as the hot reheat piping just after the valve
Material

The desired maximum noise level at 1.0 meter (3.28 feet) from the valve
Noise Level
(see ISA-S75.07-1997)

The desired shutoff class at the desired design pressure and temperature rating of the
Shutoff Leakage Class valve — usually Class V of ANSI/FCI 70.2

Travel Time The desired minimum travel time from any position, including fully open, at the maximum
operating pressure

Fail State The IP and LP turbines bypass valve is preferably a fail-closed design.

Modulating Time The maximum time for full-stroke operation

Turndown Ratio The full range of coordinated operating parameters of flow, pressure, and temperature

Condenser Back Pressure The maximum back pressure for valve operation at a specified pressure, temperature, and
flow

NOTE — If the code permits, this valve can also be used as a fail-open safety relief. An “HP to condenser” valve is preferably fail-
closed.

b) Control valve actuator

The type, motive power, material, function, and design of the actuator desired to meet the
requirements of the specific control valve should be either specified or left to the manufacturer.

c) Control valve position indication

The number, type, and operation of position switches and transmitters should be specified.

d) Stem, trim, packing, and seat

The material and design of the stem, trim, packing, and seat shall be specified or left to the
manufacturer. The design and materials shall be suitable to resist mechanical, thermal, and fluid-
induced wear.

e) Valve stem vacuum sealing connection (applies to IP and LP bypass control valve if required by
specific design)
ANSI/ISA–S77.13.01–1999 — 16 —

The size, type, and materials for the connection should be specified or left to the manufacturer.

f) End-connection preparation

The end preparation for the valves should be specified with the weld-end or flange details.

g) Cycles

The number of cycles per month and modes of operation along with the temperature gradients should
be specified.

h) Trim and valve outlet kinematic energy

Trim and valve outlet velocities shall be specified to reduce noise, vibrations, and erosion.

4.4.2 HP and IP/LP bypass block valve

a) Design criteria

The design criteria for the HP and IP/LP bypass block valves shall be specified as shown in
table 4.4.2.

Table 4.4.2 — Bypass block valves

These are non-pressure-reducing type valves (see note 1).

Operating Pressure Same as control valve

Operating Temperature Same as control valve

Design Pressure Same as control valve

Design Temperature Same as control valve

Before Block Valve Inlet and Outlet

Pipe Size (Internal Diameter [ID]) Same as or larger than the inlet of the control valve
and Material

Shutoff Leakage Class Shall be per MSS SP-61, Class V

Required minimum and maximum travel time from one end to the other shall be
Travel Time
specified.

Fail State Follow control valve fail state

NOTE — Block valves are usually required to assure that leakage does not occur through the control valve. This function could be
integrated in a composite control valve provided the block valve’s purpose is not compromised.

b) Actuator

The type, motive power, material, and design of the actuator desired to meet the opening and closing
time should be specified or left to the manufacturer.
 — 17 — ANSI/ISA–S77.13.01–1999

c) Block valve position indication

The number, type, and operation of position limit switches and transmitters should be specified.

d) Stem, disk, packing, and seat

The material and design of the stem, disk, packing, and seat should be specified or left to the
manufacturer. The design and materials shall be suitable to resist mechanical, thermal, and fluid-
induced wear.

e) Stem vacuum sealing connection (intermediate and low pressure bypass block valves only, if required)

The size, type, and materials for the connection to the valves should be specified for vacuum sealing
or left to the manufacturer.

f) End-connection preparation

The end preparation should be specified with the weld-end or flange details.

g) Pressure loss

The bypass block valves should be specified to have a low pressure loss and minimum flow
disturbance to minimize operational instability of the downstream piping and valves.

4.4.3 Desuperheater

The design criteria for the main steam and hot reheat steam desuperheaters shall be specified as shown in
table 4.4.3. The desuperheater may have an integral spray water control valve. The design parameters
that affect the time/distance required for evaporation of the water spray include

a) the nozzle design and associated droplet size distribution;

b) the relative location of associated nozzles and their direction of spray into the superheated steam flow
path;

c) the amount of initial and final superheat available in the steam/water mixture;

d) the steam and droplet velocity and degree of turbulence in the mixing region;

e) the amount and temperature of the injected water; and

f) the water surface tension and viscosity.

ANSI/ISA–S77.13.01–1999 — 18 —

Table 4.4.3 — Desuperheater

Body Material The body material shall be specified for each desuperheater.

Internal Components The material for the internal components shall be specified or left to the manufacturer.

Type The type of desuperheater shall be specified.

Mounting The position in the bypass piping shall be specified.

Operating Conditions The operating, design, and boiler hydro test pressures and temperatures shall be specified.

The temperature reduction differential at various steam flow and pressure conditions shall
Temperature Control Range
be specified.

Average Droplet Size and The average droplet size and distribution shall be provided by the manufacturer for each
Distribution set of operating conditions.

Evaporation Length The evaporation length shall be provided by the manufacturer for each set of operating
(90% of Total Droplet Mass) conditions.

End Connection Preparation The end preparation shall be specified, along with the weld-end or flange details.

4.4.4 Desuperheater spray water control valve

a) Design criteria

The design criteria for the desuperheater spray water control valve shall be specified as shown in
table 4.4.4.
 — 19 — ANSI/ISA–S77.13.01–1999

Table 4.4.4 — Desuperheater spray water control valve

This is a pressure-reducing-type valve.

The coordinated inlet and outlet pressure, temperature, and flow conditions for all distinct
Operating Conditions
service conditions

Design Pressure The maximum design pressure for the system

Design Temperature The maximum design temperature for the system

Inlet Pipe Size

(Internal Diameter [ID]) and The same as the piping just before the valve
Material

Outlet Pipe Size (Internal

The same as the piping just after the valve
Diameter [ID]) and Material

The desired maximum noise level at 1.0 meter (3 feet) from the valve
Noise Level
(see ISA-S75.07-1997)

The desired shutoff class at the desired design pressure and temperature rating of the
Shutoff Leakage Class valve—usually Class V of ANSI/FCI 70.2

The desired minimum travel time from any position, including fully open, at the maximum
Travel Time
operating pressure

The valve shall be coordinated with the fail state of the HP bypass and IP/LB bypass
Fail State valves.

Modulating Time The maximum time for full-stroke operation

Turndown Ratio The full range of coordinated operating parameters of flow, pressure, and temperature

b) Control valve actuator

The type, motive power, material, function, and design desired to meet the requirements of the control
valve should be either specified or left to the manufacturer.

c) Control valve position indication

The number and type of position limit switches and transmitters should be specified.

d) Stem, trim, packing, and seat

The material and design of the stem, trim, packing, and seat shall be specified or left to the
manufacturer. The design and materials shall be suitable to resist mechanical, thermal, and fluid-
induced wear.

e) End-connection preparation

The end preparation for the valves should be specified along with the weld-end or flange details.
ANSI/ISA–S77.13.01–1999 — 20 —

4.4.5 Desuperheater spray water block valve

a) Design criteria

The design criteria for the desuperheater spray water block valve shall be specified as shown in
table 4.4.5.

Table 4.4.5 — Desuperheater spray water block valve

These valves are non-pressure-reducing type (see note 1).

Operating Pressure Same as control valve

Operating Temperature Same as control valve

Design Pressure Same as control valve

Design Temperature Same as control valve

Before Block Valve Inlet and

Outlet Pipe Size (Internal Same as for the inlet of the control valve
Diameter [ID]) and Material

Noise Level Same as control valve

Shutoff Leakage Class Shall be per MSS SP-61

Travel Time Required minimum and maximum from one end to the other shall be specified.

Fail State Follow control valve fail state.

NOTE — The desuperheater spray water block valve is required for water induction prevention. This isolation function may be
integrated into a composite control valve provided that the block valve’s protection function is not compromised.

b) Actuator

The type, motive power, material, and design of the actuator desired to meet the opening and closing
time should be specified or left to the manufacturer.

c) Block valve position indication

The number, type, and operation of position limit switches and transmitters should be specified.

d) Stem, disk, packing, and seat

The material and design of the stem, disk, packing, and seat should be specified or left to the
manufacturer. The design and materials shall be suitable to resist mechanical, thermal, and fluid-
induced wear.

e) End-connection preparation

The end preparation should be specified, along with the weld-end or flange details.
 — 21 — ANSI/ISA–S77.13.01–1999

f) Pressure loss

The bypass block valves should be specified to have a low pressure loss and minimum flow
disturbance to minimize operational instability of downstream piping and valves.

4.4.6 Cold reheat non-return valve

a) Design criteria

The design criteria for the cold reheat non-return valve shall be specified as shown in table 4.4.6.

Table 4.4.6 — Cold reheat non-return valve

This is a non-pressure-reducing-type valve.

Operating Pressure Same as HP bypass control valve

Operating Temperature Same as HP bypass control valve

Design Pressure Same as HP bypass control valve

Design Temperature Same as HP bypass control valve

Internal Diameter Same as for cold reheat piping

Noise Level Same as for HP bypass control valve

Shutoff Leakage Class Shall be per MSS SP-61

Travel Time Required minimum from one end to the other shall be specified.

Material Required materials shall be specified.

b) Actuator

The type, motive power, material, and design of the actuator desired to meet the opening and closing
time should be specified or left to the manufacturer.

c) Non-return position indication

The number, type, and operation of position limit switches should be specified.

d) Shaft, disk, packing, and seat

The material and design of the shaft, disk, packing, and seat should be specified or left to the
manufacturer. The design and materials shall be suitable for the mechanical, thermal, and fluid-
induced wear.

e) Counterweight

The size, type, and materials for the counterweights should be specified or left to the manufacturer.
ANSI/ISA–S77.13.01–1999 — 22 —

f) End-connection preparation

The end preparation should be specified along with the weld-end or flange details.

g) Pressure loss

The valve should be specified to have a very low pressure loss and minimum flow disturbance to
minimize operational instability of the downstream piping and valves.

4.4.7 Desuperheater spray water filter

If the desuperheater spray water control valve does not include filtering, a dual element, full flow filter
should be specified. Differential pressure detection, measurement, and alarm should be included.

4.4.8 Condenser element

The design criteria for the condenser pressure element to withstand impingement and erosion from the wet
steam should be specified as follows (see EPRI Report CS-2251):

a) Steam quality (The minimum expected quality of the steam should be specified.)

b) Steam dump condenser entry (The preferred location for the bypass steam should be left to the
condenser manufacturer.)

c) The desired level of backpressure to be generated at a specific pressure, temperature, and flow
condition

4.5 Turbine bypass instrumentation

The design criteria for the turbine bypass high, intermediate, and low pressure instrumentation should be
specified as follows.

4.5.1 Instrumentation components

Instrumentation components furnished with the equipment shall be in accordance with the following
articles and shall be constructed to withstand high vibration and high temperatures encountered in the
actual service. Explosion-proof construction shall be furnished where required by applicable code.

4.5.1.1 Limit switches

Limit switches, except those integrally mounted on motor-operated valves, shall be specified.

4.5.1.2 Pressure elements

Pressure elements shall be specified.

4.5.1.3 Temperature elements

Temperature elements shall be specified.

4.5.1.4 Solenoid valves

Solenoid valves shall be specified. Valves shall be selected based on body construction, trim materials,
packing, and internal arrangements suitable to the application. Solenoid enclosures shall be NEMA 4
 — 23 — ANSI/ISA–S77.13.01–1999

unless otherwise required. Solenoid coils shall be Class H, high-temperature construction or Class F, as
applicable, and shall be suitable for continuous duty.

4.5.1.5 Pressure gauges

Gauges for control air supply and signal pressures integral to the instrument shall be in accordance with
the manufacturer’s standards. All other gauges shall be specified as needed.

4.5.1.6 Thermometers

Thermometers for local mounting shall be specified as needed.

4.5.1.7 Thermowells

Fluid system temperature sensors shall be equipped with thermowells. The thermowell’s design shall be
certified acceptable for the maximum conditions of temperature, pressure, type of fluid, and fluid velocity
by methods described in ASME Performance Test Code 19.3. Thermowells shall be welded or threaded
and, if threaded, constructed to allow seal welding after installation. Threaded thermowells shall be a
minimum of 3/4 inch NPT. Thermowell insertion length shall be specified.

4.5.1.8 Test wells

Test wells shall meet all the criteria for material, design, construction, and certification stipulated for
thermowells.

4.5.1.9 Vibration transducers

A non-contact, vibration pick-up system for monitoring valves, steam lines, and the condenser inlet should
be considered.

4.5.1.10 Position transmitters

Position transmitters have to be able to withstand the high vibration, high temperatures, and humidity.

4.5.2 Instrument installation

Instruments should be installed as close as is practical to the source of the measurement, with
consideration given to excessive vibration, temperature, and accessibility for periodic maintenance.

Recommendations for the location of instrument and control equipment connections can be found in the
joint publication, Recommendations for Location of Instrument and Control Connections for the Operations
and Control of Watertube Boilers, by Scientific Apparatus Makers Association (SAMA) and American
Boiler Manufacturers Association (ABMA).

Thermowell installation for temperature measurements shall meet the requirements of ANSI/ASME B31.1,
ASME Code for Pressure Piping.

Thermowell installation shall consider location, mounting, and velocity criteria in making a proper interface
with the process.

4.5.3 Process measurements

Process measurements for steam turbine bypass controls are listed. For location of these measurements,
refer to figures E.1 and E.2.
ANSI/ISA–S77.13.01–1999 — 24 —

4.5.3.1 Main steam pressure

A pressure measurement taken at the turbine inlet is required for HP turbine steam bypass control.

4.5.3.2 Main steam temperature

A temperature measurement taken at the turbine inlet is required for operator information.

4.5.3.3 First stage pressure

A pressure measurement taken at the turbine first stage (impulse chamber) is required for IP/LP turbine
steam bypass control.

4.5.3.4 First stage inner metal temperature

A temperature measurement taken as near as possible to the inner metal surface of the first stage is
required for operator information.

4.5.3.5 Reheat outlet temperature

A temperature measurement taken at the outlet of the reheater superheater section is required for IP/LP
turbine steam bypass control.

4.5.3.6 Reheat innerbowl temperature

A temperature measurement taken as near as possible to the inner metal surface of the turbine reheat
bowl is required for operator information.

4.5.3.7 HP bypass steam temperature

A temperature measurement taken downstream of the HP bypass desuperheater is required for HP turbine
steam bypass control.

4.5.3.8 Reheat outlet pressure

A pressure measurement taken at the outlet of the reheater superheater section is required for IP/LP
turbine steam bypass control.

4.5.3.9 LP bypass steam temperature

A temperature measurement taken downstream of the LP bypass desuperheater is required for IP/LP
turbine steam bypass control.

4.5.3.10 Condenser pressure

A pressure measurement taken in the condenser is required for IP/LP turbine steam bypass control.

4.5.3.11 Condenser temperature

A temperature measurement taken in the condenser is required for IP/LP turbine steam bypass control.
 — 25 — ANSI/ISA–S77.13.01–1999

4.6 Control and logic requirements

The function of the turbine bypass system is to take the boiler energy output and generate the demand for
pressure and temperature reduction to simulate the high pressure, intermediate pressure, and low
pressure stages of the turbine in an efficient and stable manner. This subclause addresses the means for
controlling the difference between the generated and consumed steam flow and steam temperature for HP
bypass control and IP and LP bypass control.

4.6.1 System design requirements

The turbine bypass control’s logic system design shall be fault tolerant. The designer shall recognize the
failure behavior of components when designing a fail-safe system.

The logic system design shall include diagnostics to monitor and alarm any microprocessor component
failures, including processor, data transfer, I/O, and power supplies.

Control access to the turbine bypass’s decision-making logic shall be (1) prohibited while fuel is being fired
in the boiler and (2) protected from unauthorized changes. Decision-making logic includes, but is not
limited to, maintenance interface, test and bypass functions, alarms, and I/O configuration.

Pneumatic and single loop controllers may be used in the control system design.

4.6.2 HP bypass controls

4.6.2.1 HP bypass control valve

Single-element, high-pressure bypass control is the minimum control strategy required to regulate the
steam pressure leaving the boiler. Referring to figure E.3, main steam pressure is measured and
compared to a setpoint, with the results used to regulate the high-pressure control valve. The steam
pressure setpoint is limited within a minimum and maximum value and ramped smoothly to prevent
process upsets. The valve is not permitted to open if the desuperheater spray water pressure is
insufficient, if no water is present, or if the block valve is not fully open.

For redundancy and added safety, a two-out-of-three or one-out-of-three pressure-monitoring safety

system should be used.

4.6.2.2 HP bypass desuperheater spray water valve

Single-element, HP bypass steam temperature control is the minimum control strategy required to regulate
the steam temperature leaving the HP turbine bypass. Referring to figure E.3, HP bypass steam
temperature is measured and compared to a setpoint. The results are used to regulate the HP
desuperheater spray water control valve.

4.6.2.3 HP bypass and desuperheater spray water block valve(s) logic

Provisions shall be made to override the HP bypass demand and block valve sequence logic and to open
the control and block valve in the event of

a) a turbine trip;

b) a generator breaker open; or

c) an operator open request.

ANSI/ISA–S77.13.01–1999 — 26 —

Provisions shall be made to override the HP bypass demand and block valve sequence logic and to close
the control and block valve in the event of an operator close request.

A sequence control logic shall be provided for the block valve(s) operation to preserve its tight shutoff
ability. The block-valve logic shall open the block valve to its fully open position prior to the initial opening
of its modulating control valve. The block-valve logic shall close the block valve after its modulating valve
is fully closed.

4.6.3 IP and LP bypass controls

4.6.3.1 IP and LP bypass control valve

Single-element IP and LP bypass control is the minimum control strategy required to regulate the steam
pressure leaving the boiler’s reheater section. Referring to figure E.4, reheat outlet steam pressure is
measured and compared to a setpoint with the results used to regulate the IP and LP pressure control
valve. The steam pressure setpoint is programmed based on the turbine’s first stage pressure and is
limited within a minimum and maximum value. The valve is not permitted to open if the desuperheater
spray water pressure is insufficient, if no water is present, or if the block valve is not fully open.

4.6.3.2 IP and LP bypass desuperheater spray water valve

Single-element, IP and LP bypass steam temperature control is the minimum control strategy required to
regulate the steam temperature leaving the LP turbine bypass. Referring to figure E.4, LP bypass steam
temperature is measured and compared to a setpoint with the results used to regulate the IP and LP
desuperheater spray water control valve. The LP setpoint is derived from the IP and LP bypass control
valve position, the reheater outlet pressure, and the reheater outlet temperature.

If the distance between the spray water injection and temperature measurement device is too short to
evaporate the water, a heat balance calculation can be carried out to position the water valve.

A one-out-of-three or a two-out-of-three pressure-monitoring safety system should be used for redundancy

and safety.

4.6.3.3 IP and LP bypass control and block valve(s) logic

Provision shall be made to override the IP and LP pressure bypass demand and block valve sequence
logic and to close the control and block valve in the event of

a) condenser high pressure;

b) condenser high temperature;

c) hotwell high level; or

d) desuperheater spray water low pressure.

A sequence control logic shall be provided for block valve(s) operation to preserve its tight shutoff ability.
The block valve logic shall open the block valve to its fully open position prior to the initial opening of its
modulating control valve. The block valve logic shall close the block valve after its modulating valve is fully
closed.
 — 27 — ANSI/ISA–S77.13.01–1999

4.6.4 Automatic tracking

Automatic tracking shall be provided such that any control mode transfer is accomplished without process
upset.

4.6.5 Integral windup prevention

Means shall be provided with the HP and IP/LP bypass flow and temperature control strategy to prevent
integral windup of the feedback controller when the primary regulating device is at a limit (fully open or fully
closed).

4.7 Alarm requirements

Minimum alarm requirements shall include the following information:

a) High condenser pressure

b) High condenser temperature

c) High condenser level

d) Low HP spray water pressure

e) Low LP spray water pressure

f) Loss of control power

g) Loss of final drive power

h) Control loop trip-to-manual

i) Control and bypass valve open/close abnormal status

j) High HP outlet temperature

k) High LP outlet temperature

4.8 Operator interface

4.8.1 Operator information

The following information used in the HP and LP/IP bypass control system shall be made available to the
operator:

a) Main steam pressure

b) Main steam temperature

c) First stage pressure

d) First stage inner metal temperature

e) Reheat outlet temperature

ANSI/ISA–S77.13.01–1999 — 28 —

f) Reheat inner bowl temperature

g) HP bypass steam temperature

h) RH outlet pressure

i) LP bypass steam temperature

j) Main steam pressure setpoint

k) HP bypass steam temperature setpoint

l) LP bypass steam pressure setpoint

m) LP bypass steam temperature setpoint

n) All alarms

o) Automatic/manual control loop status

p) Reheat outlet minimum pressure setpoint

q) Control and bypass valve (open/closed status)

In addition to the above, valve position(s) should be made available to the operator.

4.8.2 Operator control functions

The control system shall include capabilities for the automatic/manual control of each individual, final
device.

The control system shall include capabilities for the operator to control/adjust the main steam pressure
setpoint, main steam pressure rate-of-change, and the HP bypass steam temperature setpoint.
Consideration should be given to setpoint limits that would be accessible to the operator.

The control room operator shall receive indications and have control functions for the bypass system and
process interfaces.
 — 29 — ANSI/ISA–S77.13.01–1999

Annex A — References

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/FCI 70-2 Control Valve Seat Leakage, 1991

Available from: ANSI

11 W. 42nd Street
New York, NY 10036
Tel.: (212) 642-4900

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Performance Test Code 19.3

ANSI/ASME B31.1 ASME Code for Pressure Piping

ANSI/ASME TDP-1-1985 Recommended Practice for the Prevention of Water Damage to Steam
Turbines Used for Electric Power Generation, Fossil Fueled Plants

Available from: ASME International

Three Park Avenue
New York, NY 10016-5990
Tel.: (800) 843-2763

ELECTRIC POWER RESEARCH INSTITUTE (EPRI)

Research Project 1184-3 Turbine and Superheater Bypass Evaluation (Final Report CS-4810
dated October 1986)

Report CS-2251 Recommended Guidelines for the Admission of High-Energy Fluids to

Steam Surface Condensers (dated February 1982)

Available from: EPRI

3412 Hillview Ave
P.O. Box 10412
Palo Alto, CA 94304-1395
Tel: (800) 313-3774

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC Directives, Part 3 Drafting and Presentation of International Standards from the
International Electrotechnical Commission

Available from: IEC

P.O. Box 131
3, rue de Varembe
CH-1211 Geneva 20
Switzerland
Tel: 41 22 919 0211
ANSI/ISA–S77.13.01–1999 — 30 —

ISA

ANSI/ISA-S5.1-1984 (R1992) Instrumentation Symbols and Identification

ANSI/ISA-S51.1-1979 (R1993) Process Instrumentation Terminology

Available from: ISA

67 Alexander Drive
P.O. Box 12277
Research Triangle Park, NC 27709
Tel: (919) 549-8411

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY, INC.

(MSS)

MSS SP-61, 1992 Edition Manufacturers Standardization Society  Valve and Fitting Industry
Pressure Testing of Steel Valves

Available from: MSS

127 Park St. NE
Vienna, VA 22180
Tel.: (703) 281-6613

SCIENTIFIC APPARATUS MAKERS ASSOCIATION (SAMA)

Recommendations for Location of Instrument and Control Connections for the Operation and Control of
Watertube Boilers, SAMA/ABMA/IGIC’s Recommended Standard: Instrument Connections Manual; jointly
published by the Scientific Apparatus Makers Association, the American Boiler Manufacturers Association,
and the Industrial Gas Cleaning Institute, Inc., 1981.

Available from: American Boiler Manufacturers Association

950 North Glebe Rd. Suite 160
Arlington, VA 22203-1824
Tel: (703) 522-7350

or

Industrial Gas Cleaning Institute

700 North Fairfax St. Suite 304
Alexandria, VA 22314
Tel: (202) 457-0911
 — 31 — ANSI/ISA–S77.13.01–1999

Annex B — The use of bypass systems

The steam generator output can be run down in ten minutes or less to a house load value of approximately
10 to 20 percent without creating excessive temperature gradients when bypass systems are used.

The pressure setpoint must follow the actual steam pressure value at the superheater outlet during
variable pressure operation. This setpoint can be changed automatically or manually.

The quick opening signal for the HP bypass valve can be initiated as a function of the control position of
the turbine stop valve(s) or the generator trip signal.

Bypass steam flow is used as a feedforward signal for the temperature control system. The bypass valve
position indexed by the steam pressure is indicative of this steam flow. For 40-percent bypass systems
and larger, an HP bypass steam flow measurement may be needed for the control strategy that regulates
the boiler’s feedwater demand. If steam flow is measured by the turbine’s first stage pressure (steam flow
index), then an HP bypass flow nozzle is required to measure the bypass steam flow, or a characterized
bypass valve position indication may be used. If steam flow is measured before the main steam stop
valve, then an HP bypass flow nozzle is not required.

The European Boiler Codes allow omitting the conventional safety valves and operating the system with
the HP bypass valves only. The American Boiler Codes require conventional safety valves even with the
bypass valves.

All valves in the bypass system are usually equipped with a control system, power unit, and actuators that
permit operating valves of any size full stroke in two seconds or less.

The following list highlights some particular advantages of correctly sized and designed bypass valves:

a) Cold start

For the boiler, especially in supercritical units, the bypass system allows enhanced operation of the
furnace, primary and secondary superheaters, flash tank, and main and reheater steam lines in the
early steam water cycle.

This improves the system’s steam purity before starting the turbine. It further reduces the start-up
times drastically. The turbine can be started from the turning gear and can reach the rated speed in
15 to 30 minutes, provided the turbine rotor temperature is above the fracture appearances transition
temperature. The bypass operation may take approximately 2.5 to 3.5 hours.

The steam flow through the superheater and reheater enhances the tube cooling effect and may allow
the steam generator to operate with a higher increased furnace firing rate.

Rotor bore temperatures should follow the turbine manufacturer’s temperature gradients.

b) Warm start

The advantages of the bypass system mentioned under cold start also apply to this mode, where the
casing temperature of the HP turbine is usually above 212°F (100°C). The bypass valves allow the
operator to optimally match the steam to the metal temperatures under all speed conditions.
ANSI/ISA–S77.13.01–1999 — 32 —

c) Hot start

Minor disturbances that caused the unit to trip will usually involve a hot restart. Many of the
advantages mentioned earlier apply to this mode of operation. The bypass has the ability to closely
match the metal temperature of the heavy turbine parts, and this makes it unnecessary to go through
tedious cool down and rewarming procedures.

d) Partial- or full-load rejection and quick restart

In the case of a partial- or full-load rejection, the bypass valves have to open immediately. The bypass
control system opens the bypass valves to the same degree the turbine control valves were before
they closed.

The turbine can shut down slowly and prepare to restart.

Protective systems should be provided to trip the boiler when HP bypass or LP bypass valves fail to
open and when insufficient cooling steam flow passes through the superheater or reheater.

The European Boiler codes require variable pressure safety valves on the reheater outlet and
omission of the safety valves on the reheater inlet.
 — 33 — ANSI/ISA–S77.13.01–1999

Annex C — Valve life expectancy

There are basically two major valve design standards in use: ANSI B-16.34 in the Americas and DIN 3840
(German) in Europe. The first takes the “cookbook approach” by providing easy-to-use tables for
determining the required wall thicknesses. The latter requires the engineer to perform an accurate stress
analysis by using the so called “pressure area comparison method” (the flow area versus the pressure
containing section area). This approach is similar to ASME Section 3, Nuclear Valves.

DIN 3840 requires the designer to select the correct material strength value and apply a safety factor as a
function of the material characteristics (type and condition) and the “expected lifetime.” In turbine bypass
valves, this is often a P22 Chrome-Molybdenum Alloy Steel (CrMo) forging with certification 3.1A or 3.1B,
according to DIN 50049, and the creep rupture value at the design temperature (example 1000°F) for an
expected lifetime of 100,000 or 200,000 hours. Please note that the safety factor is 1.0 in case of 200,000
hours.

A designer knows much better where the products’ limits are when using DIN 3840. DIN results in thinner
walls. Thus steady state thermal stresses will be lower. However, the maximum thermal stress, which
impacts the cycle life of the valve, will occur during the thermal transient as the valve heats up on opening.
These maximum thermal transient stresses are essentially independent of the wall thickness for the range
of metal thicknesses used in Steam Turbine Bypass valves. The presence of water spray inside the valve
body would significantly increase the maximum thermal stresses present and would result in a reduced
cyclic life.

DIN penalizes the use of cast bodies instead of forgings by a higher safety factor, not only for the design
but also for the testing. Paragraph 7.5 of DIN 3840 briefly mentions “Additional Stresses” that must be
considered. The German TRD (and AD [non-fired piping]) Boiler rules provide the guidelines to calculate
those. ASME Section 1, in turn, requires loadings other than pressure and static head. But no rules for
this have been set.

The advantage of using DIN 3840 is the implicit time element that goes into the analysis and makes a
statement about the expected lifetime.

ASME Code Case 1331 provides guidelines for the calculations of the cyclic lifetime of, for example,
turbine bypass valve bodies (low cycle fatigue). These values have been used extensively over many
years and are particularly important for the design of HP bypass and trip valves with very short stroking
times.

Utility people generally expect a turbine bypass to last 20 to 25 years. This typically is used to translate
into 10,000 to 12,000 total cycles. Today, bypass systems in combined cycle plants can be exposed to a
much more cyclic service, but, generally, they also are operating at lower pressures and temperatures,
although recent developments have design temperatures up to 1100°F.
This page intentionally left blank.
 — 35 — ANSI/ISA–S77.13.01–1999

Annex D — Some typical high- and low-pressure turbine bypass valve

size and material specifications

High Pressure Turbine Bypass Valve

Life Expectancy: 20 - 25 Years

Size and ANSI Class: 12" x 18" ANSI 1500 - 4500#

Maximum Design Pressure: 6812 PSIG @ 100°F (38°C) (cold working)

Body Material: ASTM/ASME SA182-F22 or SA217-WC9

Disk Material: Hardened heat resistant

Maximum Temperature: 1050°F (566°C)

Stem Material: Hardened heat resistant

Seat Material: Hardened heat resistant

Packing and Trim Materials: Service conditions of valve

Seat Leakage: ANSI/FCI 70-2 (see reference in annex A)

Low Pressure Turbine Bypass Valve

Life Expectancy: 20 - 35 Years

Size and ANSI Class: 20" x 30" ANSI 900#

Maximum Design Pressure: 2250 PSIG @ 100°F (38°C) (cold working)

Body Material: A217-WC6/WC9 or SA182-F11/F22

Disk Material: Hardened heat resistant

Maximum Temperature: 932 – 968°F (500 – 520°C)

Stem Material: Hardened heat resistant

Seat Material: Hardened heat resistant

Packing and Trim Materials: Service condition of the valve

Seat leakage: ANSI/FCI 70-2 (see reference in annex A)

This page intentionally left blank.
 — 37 — ANSI/ISA–S77.13.01–1999

Annex E— Figures

Figure E.1 — Turbine steam bypass system with separate pressure reducing
valves and desuperheaters
ANSI/ISA–S77.13.01–1999 — 38 —

Figure E.2 — Turbine steam bypass system with combined pressure reducing and
desuperheating valves
 — 39 — ANSI/ISA–S77.13.01–1999

Figure E.3 — HP turbine steam bypass control

ANSI/ISA–S77.13.01–1999 — 40 —

Figure E.4  IP/LP turbine steam bypass control

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Attn: Standards Department
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