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WRITE UP ON LOW PRESSURE BYPASS SYSTEM

03 02 01 00 REV

12.12.03 27.7.02 31.1.01 3.2.93 DATE

Cl. no. 2.0 modified & cl. 5.0 added. Revised as per MOM dtd. 1-2/7/02 with NTPC DOC.CONVERTED TO MS-WORD -REMARKS

VK BS RANA Sd. SS Sd./ SS Sd./ PREPARED

BSR BS RANA Sd. KBB Sd./ KBB Sd./ CHECKED

KBB KB BATRA Sd. AA Sd./ AKB Sd./ APPROVED

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1.0

GENERAL Low pressure bypass system enables to establish an alternative path for dumping the steam from reheater outlet directly into condenser at suitable steam parameters bypassing the IP and LP turbines. LP bypass controls are engineered to dump the excess steam present in the reheat circuit due to its large "time constant" during transient non-steady state. LP bypass valves get opened and dump steam to condenser to such an extent as to maintain the reheater pressure at a value derived from criteria representing the HP turbine flow conditions at any given instant during load changes. This control criterion ensures that only the requisite flow is maintained through the IP and LP turbines. The control of LP bypass system is hooked up by same control oil/ fluid, which is envisaged for the turbine governing system. LP bypass system works in conjunction with HP bypass system as and when necessitated by system requirements such as warming up stage or dumping of large quantity of steam following a heavy load rejection. Under certain operating conditions such as start-up the variable derived pressure set point is replaced by a fixed set value. The controls for LP bypass system are essentially a combination of electrical and well-proven hydraulic system. Electro-hydraulic converter provides the necessary link between hydraulic actuator and electrical system. The electronic controller acts as a maximum pressure controller and regulates the reheater pressure either to the fixed set value or suitable derived set value. If the reheater pressure exceeds this set value, the controller causes the Electro-hydraulic converter to operate and initiate bypass operations. Emergency stops and control valves of the LP bypass are combined in a common body. The double shut off arrangement separates the condenser from the reheater during normal operations. The Electro- hydraulic LP bypass control system includes the necessary safety devices for the protection of the condenser. These devices prevent the dumping of the steam into condenser if the water injection pressure is too low, if pressure in the condenser is too high or if flow of bypass steam is too large.

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2.0

AUTO OPERATION OF LP BYPASS CONTROL SYSTEM

(Rev. 3)

During Turbine generator start up and shut down the steam not accepted by IP and LP turbines are dumped to the condenser by the LP turbine bypass valves. Two set points are derived for the LPB and are gated thru MAX gate as shown in the diagram and the actual pressure is obtained by means of pressure transmitter in the reheater outlet. During startup and shutdown the variable set point is suppressed by a fixed set point. This fixed set point can be adjusted between 0 and 120 % of the maximum reheat pressure from the control room. In auto mode, which is selected from control room pressing the A/M control button in auto mode, whenever, there is a Turbine tripping, pressure in reheat circuit goes up, and a deviation signal between the actual pressure and the higher of the variable and fixed set point signals is generated and fed to the PIaction pressure controller. The deviation signal is also indicated in the control room. The output signal acts as the set point signal for the connected position controller, which gives the valve-opening signal. The command from the electro-hydraulic converter in LPBP rack actuates the follow up piston to cause opening of water injection valve and opening signal to the LPBP stop valve is given once the vacuum is OK and water injection pressure gets established. Further controller output signal opens the control valves immediately. Once the control valve is opened the position transmitter generates the feedback signal thereby reducing the deviation and reducing the controller output till the loop gets balanced. 2.1 ELECTRICAL SECTION The LP bypass control system comprises electrical and hydraulic controls. The LPBP control shall be implemented through a set of redundant controller modules, I/O modules etc. (Rev.2) 2.1.1 Measured Value Acquisition (Rev. 2)

The actual pressure is derived by means of two pressures in dual measurement configuration, the output of the transmitters are proportional to reheat pressure in the reheater outlet. 2.1.2 Set value Formation (Rev.2)

Two set values -fixed and variable are formed for the LP bypass control system and the one to be used is determined by a maximum value selector i.e. the higher value is used. The variable pressure is obtained with the help of two pressure transmitters in dual measurement configuration upstream of the HP blading and used to measure the steam pressure in HP turbine.

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2.1.3 Pressure Controller The continuously actuating electronic pressure controller consists of a linear amplifier, a feed back circuit and a power amplifier. The amplifier is of high accuracy and gain. The control deviation is formed at the inlet to the amplifier by comparing the actual value. The power amplifier controls the Electro- hydraulic converter directly.

2.1.4 Manual Control The LP bypass control system can be changed over from automatic control to manual control by means of a push button "Controller ON/ OFF". During manual control operation it is possible to operate valve manually by means of open and close push button. The condenser protection system continues to be operative through the hydraulic circuit even during manual control. 2.2 HYDRAULIC SECTION The hydraulic system comprises of components which have been described elsewhere and schematic arrangement indicated in governing scheme. 2.3 MODE OF OPERATION The controller controls the plunger coil, which has been provided on the left hand side of the Electro-hydraulic converter. With the increase in voltage the jet pipe is deflected to the right and the piston of the converter moves downwards. Through suitable linkages, the movement of the piston is transferred to the sleeves of the follow up piston. The first two follow up pistons actuate and open the first stage water injection valve. After the establishment of pressure downstream of the water injection valve and vacuum in condenser the other follow up pistons get detached and perform the duty to open emergency stop valve and control valves according to the requirement. The second stage water injection comes into operation when the quantity of steam flowing through the LP bypass valves increases more than 45%. A pressure switch tag no. MAN01CP001 downstream of LP bypass valve represents the flow of steam through LPBP and when it increases to more than 45% rated flow, the switch picks up and energises the solenoid valve tag no. MAX53AA051, which provides for second stage water injection to LP bypass. The steam pressure downstream of LP bypass automatically closes the LP bypass control valves proportionally in case it exceeds a preset value.

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As a measure of additional protections, protection devices causing the closure of bypass station in case of following eventualities have been envisaged: a) Condenser vacuum is low b) Spray water pressure is low c) Temperature of condenser body is high While a) and b) are achieved hydraulically c) is achieved electrically through binary control. The temperature on condenser body is sensed by thermocouples MAN11CT001 & MAN12CT001 and processed and operates on the condenser temperature protection valve tag no. MAX53AA021 and 22 when temperature increases to more than 90 degree C. 2.4 OPERATION THROUGH AUTO CONTROL INTERFACE (Rev.2)

During cold start & warm start-up, when actual reheat pressure is low, Automatic Control Interface is switched ON by the operator to allow flow through reheater during pressure build-up. Once the automatic control interface has been switched ON, the fixed set point is set to a value of approx. +2 Kg/cm2 above the actual reheat pressure as soon as the light up signal is available from boiler. When the reheat pressure exceeds the fixed set point the bypass control valves open. As a result of the positive control deviation the control valves rapidly reach a minimum opening of approx. 25% position. The valves are held in this position as a result of limiting the controller output in order to permit rapid pressure built-up. Simultaneously during "holding" the fixed set point is matched to the actual value. When the reheat pressure reaches to value for turbine startup (approx. 12 kg/cm2), holding signal is cancelled and the control of reheat pressure is released, the fixed set point is maintained at 12 kg/cm2. When the actual pressure exceeds the fixed set point as a result of increasing fire rate, due to which bypass control valves are further opened. When a bypass control valve position of approx. 50 % is reached, the automatic control interface for the fixed set point is switched off. Thus the fixed set point is maintained at 12 kg/cm2. When steam is admitted into the turbine, variable set point starts rising and eventually takes over from fixed set point due to Maximum selection.

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3.0

MONITORING The system is monitored for the following faults for which potential free contacts are provided to initiate alarms. a) Manual control fault b) Automatic control fault c) Transducer fault d) Control fault

4.0

CONTROLS AND DISPLAY

(Rev.2)

ALL the necessary display and control buttons for the LP bypass system are realized in MMI. Certain conventional control tiles are also provided on the back up panel for operation of system. General Arrangement drg. of conventional control tile may be referred for the same. 5.0 Actuation of Reheat safety valves (Rev. 3)

Malfunctions of the turbine bypass, i.e. failure of the bypass valves to open on demand, have to be counteracted by opening of the reheat safety valves to ensure flow through the reheater. This prevents a heat accumulation in the reheater tubes. For this purpose, the measure of flow through reheater is the magnitude of the deviation between actual and set pressure. The following conditions prevail. If the control deviation rises above a set limit value (>30%) and neither all bypass stop valves are fully open (<100%) nor all bypass control valves are at least opened around 60% position, the command for opening the reheater safety valves is given after a delay of 5 seconds. When valve position ref set point exceeds a set limit value (>25 %) and all LP bypass stop valves are fully open, the command for opening the reheater safety valves is also given on a time delay of 30 Seconds.

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