Jindal Power Ltd

OP Jindal Super Thermal Power Plant, Tamnar

Introduction to HP/ LP
Bypass system
Presented by
V.N.Bangde
DGM (Commi)

HP LP Bypass SYSTEM

HP Bypass system in co-ordination with LP

Bypass system enables Boiler Operation and
Loading independent of Turbine
Quick raising of the steam parameters required
for turbine rolling during Start up
Turbine loading while steam flow gets
transferred to the turbine- parallel operation
with turbine on load rejection.
Allowing Boiler operation after Turbine trip out
up to 60 % of boiler load
Prevents floating of safety valves at raised
steam pressure

INTRODUCTION
HP Bypass consists of two parallel branches
that divers MS line to CRH to maintain
desire upstream pressure
The steam is Desuperheated in order to
keep steam temp in CRH line within limit

M.S ( LHS )

TT

PT

S- 109

PT

WARM UP

S -111

S -110

TO HPT

PT

TT

BP 1

TT

TT

TT

BD 4A
BPE 1
BFP
DISCHARGE BD 4

BD - 2
TO DRAIN

BD 1

TO REHEATER
BP 2
TT TT

BPE 2
S - 120

S - 121

S - 119

TT

PT

M.S ( RHS )

BD - 3
PT

TT TT

WARM UP
PT

TO DRAIN
TO HPT

TO HPFT
HRH - L

HRH-101
MS-105
FLASH VESSEL

MS - L

HRH-103

HPFT
HRH-109

LPBP
BP-1

ESV1
HPCV1

CRH

ESV3
HPCV3

CRH-101

IPCV1

TO HPFT

HPT

LPT

IPT

BP-2

IPCV2

MS-110
HPCV2
ESV2

HPCV4
ESV4

MS-106
FLASH VESSEL

HRH-110

CONDENSER

HRH - R
HPFT
HRH-102

LPBP
MS - R

ATM.

TO CONDENSER

HRH-104

TO HPFT

TITLE
.

CD-53

EX-129

EX-110

EX-107

EX-111

EX-131

CEP DISCHARGE

EX-125

EX-105

DEA.
NRV
DRAINS

FROM HPH - 5
FROM HPH - 6

EX-124
FROM GSC

1
-1
RH
H

0
-1
RH
H

DR-38

DR
-4

DR-22

AL
SE

AT
W

ER

OM
FR

ST
OC

1
-10

DR-28

-1
DR

CRH

-101

HRH-102

HRH

DR
-9

04
-1
RH
H

LP FLASH TANK

HP FLASH TANK

0
-1
RH
H

EX-112

Hydraulic Oil supply

Hydraulic Oil supply
Hydraulic Oil supply :- Provides Hydraulic
actuation energy for complete actuating system
2 Nos. Electrically driven axial flow pumps
which pumps pressurized oil through filter via
NRV into oil accumulator .
A safety valve protects the system against over
pressure.

Servo-valve
Two stage servo valve is actuated by the torque
motor which is controlled from an analogue
positioning amplifier or manual desk control
The torque motor moves the control fork of the
servo motor and operates the pilot stage which
control the position of the control pistion.

Blocking Unit
The electro hydraulically pilot operated
unit is mounted between the servo vavle
and the actuator.
It closes off both ports to the actuator if
electrically de-energized or with sufficient
oil pressure, and holda the piston of the
actuator in the last position.

Actuator
The actuator consists of double acting
cylinder with piston and the piston rod. An
intermediate yoke connects this cylinder
with the valve,and a solid coupling connect
the valve stem with the piston rod. A
feedback transmitter unit is mounted on to
the couplin yoke and is connected to the
valve stem by a linkage system

MODE OF OPERATION
HP Bypass is intended to ensure
Reheater protection
Minimum safety valve lifting uder Emergency
condition.
Adequate steam in CRH for auxiliary steam
condition

Interlock and Protection for HP Bypass system

HP bypass valve BP-1 Or BP-2 > 2 % open
automatically Open the Spray water pressure
control valve
HP bypass valve BP-1 Or BP-2 < 2 % open
automatically close the Spray water pressure
control valve.
Steam Temp D/S Bp valve >= 380 C ,BP-1 &
BP-2 close and BP controller transfer from auto
to manual.

Fast Opening Signal

1.
2.
3.
4.

HP bypass opens fully for 2 sec duration during

following abnormality to avoid sudden pressure
rise for the safety of the boilerunder following
condition
Generator breaker open.
Turbine Load shedding relay operated
On operation of fast opening push button .
Ms pressure before MS stop valve > 165
Kg/cm2

LP BYPSS SYSTEM
Provide alternate pass for dumping the stream from
Reheater outlet to condenser at suitable steam
parameters
It is Electrohydraulic operated system with 02 Nos LP
bypass stop and control valves combined in the
common body
The double shutoff arrangement separates there
Reheater from condenser during normal operation
Water injection valve is provided for Desuperheating
purpose

 LP Bypass set point

Fixed Set Point : Manually set from the
control desk.
Variable set point : derived from the
pressure Upstream of the HP blading .
The Maximum of the 02 is control the LP
Bypass.

LP BYPASS PROTECTION

Under following protection LP Bypass closes.

1. Condenser vacuum low ( -0.6 kg/cm2)
2. Condenser wall temp high > 90 C
3. Spray water flow low ( From the Curve
generated from the condensate spray water
pressure)

HP/LP Bypass charging

1.
2.
3.
4.
5.
6.
7.
8.
9.

Ensure Turbine on Barring Gear

Ensure the condensate system is charged & Vacuum more than
-0.8 Kg/cm2
Ensure condensate water spray isolating vaves are open
Ensure all MS ,CRH,HRH & LPBP line drains are open
Charge MS line up to Turbine Stop valve at 15 kg/cm2 Ms pr.
Open BP-1 & BP-2 only by 2-3 % and check HPBP
Downstream temp increases.
When HRH pressure increases to 12 Kg/cm2 put HPBP on
auto and fixed set point at 12Kg/cm2
Put BP-1 & BP-2 on auto after giving suitable set point.
Put BPE-1 & BPE-2 on auto after giving suitable set point say
340 C

Major Accidents reported During charging of

HP/LP Bypass during cold start up
Due to passing of Hp bypass spray isolating valves : Water
get accumulated in the CRH line on admission of Ms
steam heavy hammering of the MS and CRH line resulting
in the heavy damage to the CRH line even to the HP
Turbine Exhaust
Sudden opening of spray valves during charging :- Water
suddenly get accumulated in the CRH line

How to Avoid ?
Over the period of Operation HP Bypass spray isolating and
Block valve start passing
During long shutdown keep the HPBP spray isolating valve
close and keep it open just after charging the Bypass system
Religiously ensure that the MS ,CRH & HP bypass drains are
open and gradually open BP-1 & BP-2 < 5% observing the
D/S temp of HPBP valve increasing and >200C
During Cold start up avoid charging HPBP from the filedby
Manually forcing the servo valve from local.