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INTRODUCTION
The HP bypass system in co-ordination with LP bypass system enables boiler operation and loading independent of turbine. This allows quick raising of steam parameters to a level acceptable to turbine for rolling during start-up. Steam is bypassed from the main steam line to CRH line through HP bypass and from the Hot Reheat line to Condenser through LP bypass. The HP bypass valve can handle a maximum of 60% of the full load turbine steam flow (i.e. 408 tph steam flow).
HP TURBINE
HP BYPASS
IP TURBINE
LP TURBINE
HP BYPASS
The possible phases of operation of HP bypass station can broadly be classified as follows : Boiler start up with T.G. set at standstill. Raising of steam parameters to a level acceptable for TG rolling at a relatively faster rate than otherwise is possible. Turbine loading while steam flow gets transferred to the turbine. Parallel operation with turbine on load rejection. Allowing boiler operation following turbine tripout provided boiler load is less than 60%. Preventing safety valve opening at raised steam pressure.
SYSTEM DESCRIPTION
The HP bypass system consists of two parallel branches that divert steam flow from MS line to CRH line. The steam pressure on the valve upstream side can be maintained at the desired level. The steam is de-superheated in order to keep the steam temp. in CRH line within limits, below 325 degC. The MS pressure ahead of turbine is maintained by two nos. of pressure reducing valves BP1 & BP2 with valve mounted electro-hydraulic actuator.
CONSTRUCTION - HPBP
HP Bypass station consists of the following element per unit : Two combined pressure reducing and desuperheating valves (BP1 & BP2) complete with valve mounted electro-hydraulic actuators. Each valve has been sized to pass 204 TPH of steam at inlet condition of 150 kg/cm2 & 5370C. Two breakdown orifices (OP4 & OP5). One spray water isolating valve (BD1) complete with valve mounted electro-hydraulic actuator. Two spray water control valves (BPE1 & BPE2) with valve mounted electro-hydraulic actuators for temperature control. Two oil supply systems
SERVO VALVE
Servo valve ST is the part of the SULZER electro hydraulic actuator system. It converts the electrical signals of the control electronics into hydraulic signals and uses these to control the actuator. The two stage servo valve is actuated by the torque motor which is controlled from an analogue positioning amplifier or from a manual desk control. The torque motor moves the control fork of the servo valve and operate the pilot stage (1st stage) which controls the position of the control piston (2nd stage). A mechanical override acting directly on the control piston permits local manual operation of the valve.
SERVO VALVE
Servo valve ST is produced for three flow ratings :ST10-4 & ST10-05 for low flow rates ST10-63 & ST10-65 for medium flow rates ST20 & ST20-200 for high flow rate
BLOCKING UNIT
The electro hydraulically pilot operated blocking unit is mounted between the servo valve and the actuator. It closes off both ports to the actuator if electrically deenergized or with insufficient oil pressure, and holds the piston of the actuator in its last position. A mechanical override on the blocking unit permits also local manual de-blocking. Blocking Unit BL .2 is produced in two versions : BL10-2 for low flow rates BL20-2 for high flow rates
Pressure control
The pressure signal is sensed from the main steam line by pressure transmitters Depending upon the initial pressure condition at the time of boiler firing, the pressure set point is to be adjusted to a value equal to steam pressure ahead of bypass valve plus a negative bias pressure. This would result in opening the valves. The pressure controller will then try to maintain the set pressure by allowing a flow matching with the firing rate. As the firing rate increases, the set point needs to be manipulated in the same manner to allow matching flows. This however shall be possible till the maximum flow capacity of the valves are reached.
Temperature Control
The temperature measuring signal for the HPBP station is sensed by temperature transmitters at the down stream of BP1, and BP2 and spray control valves are modulated. The control loop for the steam temperature at the downstream of HPBP valves can be operated by incorporating a fixed set point which is slightly higher than the rated cold reheat steam temperature (i.e. rated temp. plus bias temp.). Should this be not acceptable by the boiler, the temperature set point needs to be manipulated accordingly.
Basic Interlocks
HP Bypass valves can be opened at a vacuum > 400 mm Hg Opening of the main Control valves >2%, The corresponding Attemperation Valves will move to force auto and will start opening. The BD valve will open after getting open feedback of > 2% of any control valve. Down stream Temperature V. High trip will initiate closing of corresponding Control valve and its Attemperation Valve. Alarm is generated for deviation from set pressure and temperature.
LP BYPASS
The Purpose of operation of LP Bypass valves are similar to that of operation of HP Bypass valves. Low pressure bypass system enables to establish an alternative pass for dumping the steam from the Reheater outlet directly into condenser at suitable steam parameters.
LP BP System Description
LPBP system consists of two parallel branches Each branches consists of a Stop Valve with valve mounted electro-hydraulic actuator, a pressure reducing control valve and a temperature control valve with valve mounted electro-hydraulic actuator. Steam pressure at valve upstream side can be maintained as desired level.
HP turbine chamber pressure or hot reheat steam pressure before intercept valves is the controlling variable for the LPBP control system.
LP BP System Description
The steam is de-superheated in order to keep the downstream steam temperature within allowable limits (i.e. hotwell temp.) by the spray control valve and spray nozzles (STD) in de-superheater. This spray water is taken from CEP discharge line. The double shut off arrangement of LPBP system separates the reheater from the condenser during normal operation. Controlling of these parameters can be done by Manual or Auto mode. So, LPBP system maintains the upstream pressure (HRH pressure) and downstream temperature (condenser temperature).
LP Bypass Interlocks
Conditions for Emergency Trip Commands:
1. 2. 3. 4.
5. 6. 7.
Hotwell Level Very High. Hotwell temperature High Vacuum Low (-304 mmHg) LP Bypass Attemperation Flow Deviation (DemandActual) > 17 % Turbine Axial Shift V. Hi/V.Lo (+1.1 and -1.1) Turbine Lube oil Pressure low (1.2) All CW Pump Trip
LP Bypass Valves
LP Bypass valves in Bakreswar are of CCI make PV model valves.
The control unit converts the electrical signals of the control system into hydraulic fluid flow. It is mounted on the actuator of the LPBP control valves. It controls intake and discharge of hydraulic fluid to and form the piston chambers of the actuator at a continuous control mode, thus permitting highly precise positioning
of the actuator.
Positioning times of less than three seconds can be dynamically achieved without difficulties, and this in connection with high response sensitivity and stability.
LP Bypass Valves
The blocking function of the control unit ensures that the actuator is held more or less drift-free in its position at manual mode or at the event of malfunctions. Furthermore, the blocking function is taken care of by two electro-hydraulically pilot controlled check valves. In the event of power failure or loss of hydraulic pressure, the check valve close the ducts of the actuator. The solenoid of the control unit is excited by a current signal being proportional to the deviation of set value to actual value. With higher current at the solenoids the flow through the directional valve increases. Control units are produced in different versions :- such as PV4, PV6, PV10/1 & PV10/2.
In Auto Mode:
The Pressure Set Point starts with 3 Kg It integrates in every 5 seconds for new set point It goes up to 11 Kg Upto Control Valve Position f/B 25 %, this set point will remain. This is called Fixed pressure set Point
The auxiliary steam pressure control valve supplies steam to TAS/BAS header by maintaining TAS/BAS line pressure constant at the set point (11 kg/cm2). Downstream pressure of PRDS valve is taken as controlled pressure. The auxiliary PRDS spray water flow control valve (CD) maintains the TAS / BAS line temperature constant at the set point (2600C for TAS & 2200C for BAS). The downstream temperature of PRDS valve is taken as controlled temperature.
After required condenser vacuum reached, starting ejector is withdrawn, so the aux. steam supply to starting ejector is cut off. After unit synchronization and at about 30 to 40% of unit load deaerator pegging is supplied from CRH / turbine extraction line (CAP) and pegging from TRDS is cut out. At about 40% unit load also, turbine gland sealing supply valve from TPRDS closes as turbine becomes selfsealing condition.
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