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Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/10

Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 1 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES A) DRAWING Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 2 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 2.0 3.0 PLANT DETAILS: LP Bypass rack containing the following equipments. Convertor for Electro Hydraulic. LP Bypass limiting Regulator. Solenoid valves for temperature dependent 2 Nos. Slide valve for water injection valves Set of follow up pistons. Vacuum protection device. Spray water protection device. 2 Nos LP By pass valves (Stop and control valves) 2 Set of water spray valves. Connected steam and oil pipe lines. Connected Instrumentation. OBJECTIVE: To commission the LP Bypass valves. To test the protections. PROPOSAL: To adjust and test the LP Bypass governing system and also to check the protection devices. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 3 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 4.0 4.1 4.2 4.3 5.0 SERVICES REQUIRED: Oil system shall be in service. Operating man power. The following equipments and Instruments. a) Portable vaccum pump one No. b) Hydraulic pressure pump one No. c) Standard pressure gauges with an accuracy of 0.1kg/cm2 range 0-10 kg/cm2 4 Nos. “ 0 –20 kg/cm2 1 Nos. “ 0 – 40 kg/cm2 1 Nos d) Standrad vacuum gauge range 0 – 760 mm Hg. e) Dial gauge with Magnetic Base 0-10 mm one No. f) Depth gauge one No. range 0-50 mm g) Slip gauge Box one No. h) Filer gauge 0.05 to 1 mm 1 Set. i) Different sizes of spanner set ( double end) j) Ring spanner 3 mm to 27 mm one set. k) Allan Key one set 3 mm to 10 mm. l) Screw driver small to big one set. m) Voltage injection test kit one No. n) Multimeter one No. o) Digital speed indicator one No. 0-400 rpm range. SAFETY PRECAUTION: While testing and adjusting the LP Bypass governing no insulation work shall be allowed. Fire fighting equipments shall be made available. The operating personnel shall be aware of the procedure. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 4 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 6.0 7.0 7.1 7.2 7.3 7.4 7.5 7.6 EMERGENCY PROCEDURE: Refer Section 6.0 of procedure for Turbine on Barring Gear BHEL Ref.No PS-DC-186-500-100. STATE OF THE PLANT: Oil lines after oil flushing shall be normalizes. Hydrotest of oil lines completed. Instrumentation and controls made available. CEPs are commissioned and available for operation The required services are made available. L.P. Bypass system erection completed in all respect. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 5 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 8.0 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.7.1 8.1.7.2 8.1.7.3 METHOD: Initial checks for setting the Hydraulic converter of LP by pass. The components number indicated on the check list is based on the Governing scheme Drg.No.1-1-2190 – 7279/1. Check whether erection of all fluid pipe lines are completed, for LP by pass system. Check that all the drain valves in the control fluid lines of water injection valves are kept closed. Check whether the isolating valves before the filter MAX 42 BT 021 is kept opened. Check whether the isolating valves before the MAX 42 BT 022 is kept opened. Check whether the isolating valves before the filter MAX 32 BT 081 is kept opened. Check whether the following valves are kept opened. The isolating valves MAX 42 AA 541 + 543, MAX 42 AA 542 + 544, MAX 42 AA 554 + 556 and MAX 42 AA 553 + 555 in the control fluid line to water injection valves. Signal fluid inlet valve MAX 53 AA 531 + 532 to LP by pass control valves. Control fluid (32 bar) inlet valve MAX 31 AA 582, 584 of LP by pass control valve. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 6 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 8.1.7.4 8.1.8 8.1.9 8.1.10 8.1.11 8.1.11.1 8.1.12. 8.1.12.1 8.1.13 8.1.14 8.1.15 8.1.16 Control fluid inlet valve MAX 31 AA 541 + 545 to accumulator is kept opened. Check and ensure that the isolating valves before the individual equipment in the rack are kept opened. Check whether AOP is running and control fluid pressure of 6 to 7 bar is available. Run the condensate pump and ensure by opening the valve MAN 11 + 12 AA 511, that water pressure more than 10 kg/cm2 is available in the limit controller. Ensure the vacuum is available to the limit controller greater than 0.6 bar abs. Vacuum can be created by means of vacuum pump, if vacuum system is not ready. Keep open the isolating valve MAN 01 AA 501, in the reheat steam line to limit pressure controller. Connect a hydraulic pump in reheat line to limit pressure controller. Check and ensure the isolating valve MAX 42 AA 571 in the control fluid line to EHC of LP by pass is kept open. Ensure reheat line is not charged with steam. Ensure that the respective LP by pass Governor characteristics is used, while setting the LP by pass Governor. Ensure two standard gauges of 0-10kg/cm2 is fixed in the signal fluid line of water injection and LP by pass. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 7 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 8.2.0 8.2.1 8.2.1.1 8.2.2 8.2.2.1 8.2.3 8.2.4 8.2.4.1 8.2.5 Note: As per the LP by pass Governor adjustment sheet the stroke of control sleeve cannot be measured. Hence the power piston KA 08 movement is measured which is four times the movement of control sleeve given in the LP by pass Governor adjustment sheet. Checking and setting of protective devices of LP by pass. Ensure full vacuum is available to limit pressure controller and low vacuum protection unit. Check the vacuum gauge indicates full vacuum. Ensure water pressure more than 10kg/cm2 is available for limit pressure controller and water pressure switch. Check that pressure gauge MAN 01 CP 511 indicates more than 10kg/cm2 Ensure that solenoid valve for temp. protection is not energised. Rotate the handwheel KA 09, to move than the pistion KA 08 of Amplifier piston of converter for electro hydraulic LP by pass governor, for obtaining signal fluid pressure in LP by pass valve. Rotate handwheel KA 09, to move the piston KA 08 by about 12 mm to get a signal fluid pressure more than 2.0 kg/cm2 in by pass valves. Signal fluid pressure in water injection line also will increase. Test the condenser vacuum trip protection is healthy. The trip value for LP by pass limit controller MAX 53 By 011 and low vacuum condenser protection MAG 01 AA 016 is around 0.6 bar abs by opening a vent screw at test valve. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102/ Sheet 8 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 8.2.5.1 8.2.5.2 8.2.6 8.2.7 8.2.7.1 8.2.7.2 8.2.7.3 8.2.8 8.2.9 8.2.9.1 8.2.9.2 Reduce the vacuum gradually and note down by observing the vacuum gauge, at what value of vacuum the signal fluid pressure in the LP by pass line drops down suddenly. Record the trip value of vacuum. Increase the vacuum and check the vacuum protection gets reset and signal fluid pressure in LP by pass comes back to original value. Jack the low vacuum condenser protection for making it ineffective. Repeat the operation 8.2.5.1. Record the trip value of vacuum for LP by pass limit controller. Remove the jack from low vacuum condenser protection, for making it effective. Repeat the operation 8.2.6.0. Open the top cover of LP by pass limit controller MAX 53 By 011 and ensure that the oil jet nozzle KA 01 is in RHS. Insert a filer gauge on the LHS which makes the LP by pass limit controller inoperative. Repeat the operation 8.2.5.1. Record the trip value of vacuum for low vacuum condenser protection. STATUS Signatures NTPC BHEL Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-102 NTPC Ref no SIM/2/TS/1/102 Sheet 9 of 22 Plant area: TURBINE PROCEDURE FOR LP BY PASS SYSTEM SLNO 8.2.9.3 8.2.10 8.2.11 8.2.11.1 8.2.11.2 8.2.11.3 8.2.12. 8.2.12.1 Remove the filer gauge from the LP by pass limit controller placed during operation 8.2.9.0. Repeat the operation 8.2.6.0. Study the values obtained in 8.2.5.2 8.2.7.2 and 8.2.9.2. All the three trip uploads/Ingenierie_Lourd/ lpbp-commisiong-guide.pdf