Procedure For Governing Oil System PDF

Station: NTPC- Simhadri BHEL Ref No.
PS-DC-186-500-103
Sheet 1 of 28
NTPC Ref no SIM/1/TS/2/103
Plant area: TURBINE
PROCEDURE FOR GOVERNING OIL SYSTEM
SLNO
1.0 PLANT DETAILS
2.0 OBJECTIVE
3.0 PROPOSAL
4.0 SERVICES REQUIRED
5.0 SAFETY PERECAUTIONS
6.0 EMERGENCY PROCEDURE
7.0 STAE OF THE PLANT
8.0 TEST METHOD
9.0 COMPLETION CRITERIA
10.0 APPENDICES
a. TECHNICAL SPECIFICATION
b. DRAWINGS
i) Governing System Drawing
ii) Governing Characteristic curves

Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-103
Sheet 2 of 28
Plant area: TURBINE
SLNO STATUS
1.0 PLANT DETAILS:
Governing Rack Consisting of following.
i) Emergency trip valve

ii) Tripping Device
iii) Change over valve
iv) Filters in control oil
v) Accumulator.
vi) Starting Device
vii) Hydraulic Amplifier with set of follow up pistons
(HP&IP)
viii) Load shedding relay
ix) Trimming Device
x) Electro Hydraulic converter with set of follow up pistons
(HP & IP)
xi) Extraction Relay
xii) Oil injection Test Device
xiii) Vacuum protection Device.
xiv) Set of solenoids for ATT operation.
HP Front Pedestal consisting of following.
i) Impeller for primary oil

ii) Over speed trip governor
HP Rear Pedestal Consisting of following.
i) Thrust protection Device.

ii) For brief description of above items, refer to O&M
manual
2.0 iii) HP and IP governing valves.
OBJECTIVE:
To commission the Governing control system for controlling

speed and load of the machine.
Signatures
NTPC BHEL
Sheet 3 of 28
Plant area: TURBINE
SLNO STATUS
3.0 PROPOSAL:
Proposed to set the Hydraulic, Electro Hydraulic convertors, to

set the characteristics of HP and LP governing valves and to
check the operation of emergency stop valves of HP and IP.
4.0 SERVICES REQUIRED:
4.1 Oil system shall be in service.
4.2 Operating man power.
4.3 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) Diffent sizes of spanner set ( double end)
j) Ring spanner 3 mm to 27 mm one set.
k) Allen 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. 0-4000 rpm range.
Signatures
NTPC BHEL
Sheet 4 of 28
Plant area: TURBINE
SLNO STATUS
5.0 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.
6.0 EMERGENCY PROCEDURE:
Refer to Section 6.0 of LP Bypass System.
(BHEL Ref.No.PS-DC-186-500-102
NTPC Ref No. SIM/1/TS/2/102)
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NTPC BHEL
Sheet 5 of 28
Plant area: TURBINE
SLNO STATUS
7.0 STATE OF THE PLANT:
7.1 AOPs are available for running.
7.2 Control oil, Trip oil & Test oil lines are erected & Hydrotested after
oil flushing.
7.3 HP & IP Governing valves are erected.
7.4 Connected Instrumentation and controls are made ready.
Signatures
NTPC BHEL
Sheet 6 of 28
Plant area: TURBINE
SLNO STATUS
8.0 METHOD:
8.1.1 Initial checks to be carried out before setting of Hydraulic

governor.
8.1.2 The components number indicated on the check list is based on

Governing Scheme Drg.No.1.1-2192-7279/1 of KWU.
8.1.3 Check whether erection of all fluid pipe lines are completed.
8.1.4 Check whether the isolation valves before the filter MAX 42 BT
001 – 003 is kept opened for speed control rack.
8.1.5 Check whether the test valves of HP and IP for stop valve MAX
47 AA 001 – 014 and MAX 47 AA 021 – 024 respectively are kept
closed fully.
8.1.6 Ensure that the isolating valves before the 32 bar control fluid
filters MAX 32 BT 011-012 for HP control valves and filters MAX
32 BT 021 – 022 for IP control valves are kept opened fully.
8.1.7 Ensure whether the isolating valves in control fluid lines MAX 32
AA 511,512,516,517 and MAX 32 AA 521,522,526,527 and
secondary oil lines MAX 45 AA 511-514 band MAX 45 AA 521-
524 are kept fully opened for HP and IP control valves.
8.1.8 Check whether the isolating valves in EHC circuit in HP

secondary fluid MAX 45 AA 501 and IP Secondary fluid MAX 45
AA 502 is closed, while setting the hydraulic controller.
8.1.9 Close the control fluid line isolating valve MAX 42 AA 621 and
Secondary fluid line isolating valve MAX 45 AA 566 of CRH NRV
slide valve MAX 42 AA 001.
Signatures
NTPC BHEL
Sheet 7 of 28
Plant area: TURBINE
SLNO STATUS
8.1.10 Ensure closing of the trip fluid line isolating valve MAX 51 AA 527
and MAX 51 AA 530 of extraction NRV slide valve MAX 51 AA
048 and MAX 51 AA 051.
8.1.11 Fix a dial gauge 0-10 mm underneath bellow KA 09 in the

hydraulic speed Governor MAX 46 By 001.
8.1.12 Fix three standard gauges in Auxiliary secondary fluid HP

secondary oil and IP secondary fluid lines.
(0-8 kg/cm2 to read upto 0.1 kg/cm2 accuracy).
8.1.13 Open the top cover of Hydraulic amplifier MAX 45 By 011 to

measure the power piston KA 08 lift.
8.1.14 Ensure that the Boiler stop valve is fully closed and the main
steam line is not charged with steam.
8.1.15 Check whether solenoid MAX 42 AA 051 of the trimming device

KA 10 is in energized condition.
8.1.16 Check that the solenoids MAX 51 AA 202 and MAX 51 AA 201
are in the de-energised condition and ensure that the change
over valve MAX 51 AA 211 is in normal position and not in Test
position.
8.1.17 Ensure starting device MAX 47 By 001 in closed condition.
8.1.18 Keep the speeder gear in maximum set positions.
8.1.19 Check whether control fluid pump is running and a control fluid
pressure of 32 kg/cm2 and 8 kg/cm2 is available.
Signatures
NTPC BHEL
Sheet 8 of 28
Plant area: TURBINE
SLNO STATUS
8.1.20 Maintain fluid temperature in control fluid tank around

500 C / 550 C.
8.1.21 Check the load shed relay solenoid MAX 46 AA 011 is in de-
energised condition and aux. Secondary fluid doesn’t drain
through the load shed relay solenoid.
8.1.22 Ensure that the main trip valve MAX 51 AA 005-006 is in reset
conditions.
8.1.23 Switch off ATRS panel supply, so that hydraulic governor can be
checked when boiler is not in service.
8.1.24 Check the following pressure in the rack.
8.1.25 Control fluid pressure - 8 kg/cm2
8.1.26 Start up fluid pressure - 7 kg/cm2
8.1.27 Aux. Start up fluid pressure - 7 kg/cm2
8.1.28 Trip fluid pressure - 7-7.5 kg/cm2
8.1.29 Aux. Trip fluid pressure - 7-7.5 kg/cm2
8.1.30 Control fluid pressure to

control valve - 32 kg/cm2
8.1.31 Ensure that the respective governor characteristics is used while

setting the governor.
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NTPC BHEL
Sheet 9 of 28
Plant area: TURBINE
SLNO STATUS
8.2 Procedure for checking and setting of Hydraulic Governor.
8.2.1 Note down the initial reading of starting device when the starting
device is in full closed condition.
8.2.2 Operate starting device MAX 46 By 001 gradually from Minimum

to Maximum position and carry out the following checks.
8.2.3 Check whether the start up and Auxiliary start up fluid pressure
drops.
8.2.4 Operate the starting device gradually and increase the Auxiliary
secondary fluid pressure to 2.3 kg/cm2 and note down HP and IP
secondary fluid pressure.
8.2.5 Check when starting device is fully opened, note down the
starting device lift. The lift should be 24.5mm and auxiliary
secondary fluid pressure should be 4.4 kg/cm2 or above.
8.2.6 If the aux. Secondary fluid pressure is not obtained, adjust

Auxiliary follow up piston KA 08 which is in service of MAX 46 By
001 to obtain aux. Secondary fluid pressure of 4.4 kg/cm2 and
above, when starting device is fully opened conditior.
8.2.7 Note down the HP and IP secondary fluid pressure corresponding

to 4.4 kg/cm2 of Auxiliary secondary fluid pressure.
8.2.8 Bring back the starting device gradually towards the closing
position and check the trip point of aux. Secondary fluid pressure.
The trip point should be around 2.1 kg/cm 2 approximately. At
least under 2.3 kg/cm2 .
Note: Trip point of Auxiliary follow up piston is the pressure at

which auxiliary secondary fluid pressure suddenly falls to zero.
Signatures
NTPC BHEL
Sheet 10 of 28
Plant area: TURBINE
SLNO STATUS
8.2.9 Bring back the starting device to fully closed position.
8.2.10 Ensure the starting device is in closed condition.
8.2.11 Fix the dial gauge below the bellow and adjust it to read zero mm.
8.2.12 Note down the initial reading of power piston KA 08 of MAX 45 By

011 by a depth gauge.
8.2.13 Note down the starting device initial readings.
8.2.14 Operate the starting device gradually to open position till the
auxiliary secondary fluid pressure increases to 2.3 kg/cm 2 .
8.2.15 At 2.3 kg/cm2 of Auxiliary secondary oil pressure check whether

the HP secondary fluid pressure is 3.0 kg/cm2 .
8.2.16 If the value is not achieved, adjust the three follow up pistons KA
01 of MAX 45 By 011 of HP secondary fluid pressure equally.
8.2.17 Check the lift of power piston KA 08 of MAX 45 By 011 is around

6 to 7 mm (approx.), when the HP secondary fluid pressure is
around 3.0 kg/cm2 .
8.2.18 If the value is not achieved, adjust the start up opening of pilot
valve KA 07 of MAX 45 By 011.
8.2.19 Increase the aux. Secondary fluid pressure to 2.55 kg/cm 2 HP

secondary fluid pressure will be 3.24 kg/cm 2 . The IP secondary
fluid pressure should be 3.5 kg/cm2 .
8.2.20 If the IP secondary fluid pressure value is not achieved, adjust

the three follow up pistons KA 02 of MAX 45 By 011 equally to
get 3.5 kg/cm2 of IP secondary oil pressure.
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NTPC BHEL
Sheet 11 of 28
Plant area: TURBINE
SLNO STATUS
8.2.21 Note down the values of followings:-
8.2.22 Starting device travel.
8.2.23 Lift of the bellow.
8.2.24 Power piston lift of Hydraulic controller.
8.2.25 Aux. Secondary fluid pressure, HP secondary fluid pressure and

IP secondary fluid pressure.
8.2.26 Increase the Auxiliary secondary fluid pressure to 4.4 kg/cm 2 and
check whether HP secondary fluid pressure reaches 5.0 kg/cm 2 .
8.2.27 If the value is not achieved, adjust the proportionality adjuster KA

09 of MAX 45 By 011 to get HP secondary fluid pressure of
5.0 kg/cm2 when auxiliary secondary fluid pressure is around
4.4 kg/cm2 .
8.2.28 Check by closing the isolating valve MAX 42 BT 001 and MAX 42
BT 002 and MAX 42 BT 001 of speed control rack and note at
what pressure of trip fluid, Tripping device MAX 51 AA 006, MAX
51 AA 005 and emergency trip valve MAX 52 AA 005 trips
suddenly.
8.2.29 Trip device sand emergency trip valve should trip at 3 bar of trip
fluid pressure. If it is not achieved, adjust the spring tension to get
the set value.
8.2.30 After checking and ensuring that trip devices and emergency trip
valve trips at 3 bar, bring down starting device from open position
to closed position.
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NTPC BHEL
Sheet 12 of 28
Plant area: TURBINE
SLNO STATUS
8.2.31 Operate the starting device from closed position and once again
check at 2.3 kg/cm2 of Auxiliary secondary fluid pressure, the HP
secondary fluid pressure is 3.0 kg/cm2 .
8.2.32 Increase the auxiliary secondary fluid pressure in steps of

0.2 kg/cm2 and note down the following.
8.2.33 HP secondary fluid pressure.
8.2.34 IP secondary fluid pressure.
8.2.35 Power Piston lift of Hydraulic converter.
8.2.37 Check that a closing and opening reserve of 3.5 mm, is available
for power piston KA 08 Hydraulic Amplifier MAX 45 By 011.
8.2.38 Check the bellow travel KA 09 of MAX 46 By 001 between

auxiliary secondary fluid pressure of 2.3 to 4.4 kg/cm2 , should be
approx. 5 mm.
8.2.39 Check the total travel of Amplifier power piston. It should be 50

mm approximately, from fully closed position to fully open
condition of starting device MAX 47 By 001.
8.2.40 Plot the following curve.
8.2.41 Power piston lift versus Auxiliary secondary fluid pressure.
8.2.42 Bellow lift versus auxiliary secondary fluid pressure.
Signatures
NTPC BHEL
Sheet 13 of 28
Plant area: TURBINE
SLNO STATUS
8.2.43 Bellow lift versus HP secondary fluid pressure.
8.2.44 Bellow lift versus IP secondary fluid pressure.
8.2.45 Bring the starting device to minimum position, to set HP and IP

control valves.
8.2.46 Adjust the local position transmitter to indicate zero mm for both
HP and IP control valves.
8.2.47 Bring the starting device to a position where HP secondary fluid

pressure is 3.0 kg/cm2 .
8.2.48 Adjust the start of opening of HP control valves 1-4, just to open
at 3.0 kg/cm2 of HP secondary fluid pressure.
8.2.49 Bring the starting device to a position where IP secondary fluid

pressure is 3.5 kg/cm2 .
8.2.50 Adjust the start of opening of IP control valves 1-4, just to open at
3.5 kg/cm2 of IP secondary fluid pressure.
8.2.51 Increase the Auxiliary fluid pressure in steps of 0.2 kg/cm 2 and
note down the following upto the maximum position of starting
device.
8.2.54 HP control valve lift.
Signatures
NTPC BHEL
Sheet 14 of 28
Plant area: TURBINE
SLNO STATUS
8.2.55 IP control valve lift.
8.2.56 Plot the curve for the following.
8.2.57 HP secondary fluid pressure versus HP control valve lift 1-4.
8.2.58 IP secondary oil pressure versus IP control valve lift 1-4.
8.2.59 If the lifts of control valves are not coming equal adjust the
fulcrum point of lever 12 feed back linkage as shown in O&M
manual KWU Drg.1.1-2321-0006/1.
8.2.60 Open the test valve of HP stop valve number one fully and check
whether stop valve opens fully.
8.2.61 Fully close the test valves of HP stop valve number one and
check whether the stop valve closes fully.
8.2.62 Repeat the same test 2.24.0. and 2.24.1 for HP stop valve
number Two, Three & Four and IP stop valve number One, Two,
Three and Four.
8.2.63 Ensure full lift of HP stop valve about 92 mm and IP stop valve
about 176 mm which are the design values.
8.2.64 Now open HP stop valve number one by opening the test valve
fully and ensure that the stop valve has opened fully.
8.2.65 Energise solenoid valve MAX 48 AA 201 and MAX 48 AA 202, to

admit auxiliary start up fluid to Main trip valve MAX 51 AA 005
and Main trip valve MAX 51 AA 005 and MAX 51 AA 006.
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NTPC BHEL
Sheet 15 of 28
Plant area: TURBINE
SLNO STATUS
Note: Do not energise longer than 30 minutes.
8.2.66 Check by closing the isolating valve MAX 42 BT 001 MAX 42 BT

002, and MAX 42 BT 003 in control fluid system to speed control
rack.
8.2.67 Note down at what trip fluid pressure HP stop valve number one
suddenly closes.
8.2.68 Repeat the operation 2.27.0. for HP stop valve number Two,
three and Four and IP stop valve number one and two, three and
four. Note down the trip fluid pressure at which stop valve closes.
8.2.69 De-energise the solenoid MAX 48 AA 201 and MAX 48 AA 202

after completing the test on stop valves.
8.2.70 Bring back the starting device to full close condition.
8.2.71 Operate the starting device gradually from minimum to maximum

position.
8.2.72 Check whether HP stop valve opens first, and IP stop valves
opens later as per the indications marked on the starting device
scale and note down the start up fluid pressure for opening of HP
and IP stop valves.
8.2.73 De-energise solenoid MAX 42 AA 051 of the trimming device KA

10 of Hydraulic Amplifier MAX 45 By 011.
8.2.74 Bring back the starting device to closed position.
8.2.75 Check the dial gauge below the bellow is set at zero.
Signatures
NTPC BHEL
Sheet 16 of 28
Plant area: TURBINE
SLNO STATUS
8.2.76 Note down the intial reading of starting device.
8.2.77 Open gradually the starting device from fully closed position to
fully open position and note down the following.
8.2.78 Bellow lift.
8.2.79 Auxiliary secondary fluid pressure.
8.2.83 Plot the following curve
Bellow travel versus Auxiliary secondary fluid pressure.
Bellow travel versus HP secondary fluid pressure.
Bellow travel versus IP secondary fluid pressure.
8.2.84 Energise the trimming device solenoid MAX 42 AA 051.
8.2.85 Load shed relay MAX 46 AA 011 get energized whenever

generator breaker trips on fault. The duration of operation is only
two seconds.
8.2.86 During the actuation of load shed relay check whether Aux.
Secondary fluid pressure drops down to zero and comes back, to
the value at which the load shedding relay was actuated.
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NTPC BHEL
Sheet 17 of 28
Plant area: TURBINE
SLNO STATUS
8.2.87 Switch on the ATRS supply.
8.2.88 Check the Main trip valve trips immediately and all the stop
valves and control valves closes immediately.
8.2.89 Check the Auxiliary secondary fluid pressure, HP secondary fluid

pressure, IP secondary fluid pressure, trip fluid pressure, trip fluid
pressure and Auxiliary trips fluid pressure reads zero.
8.2.90 Switch off ATRS panel supply.
8.2.91 Ensure and check it is as per step number 2.38.2.
8.3 Initial checks to be carried out before setting of Electro-

Hydraulic Converter.
8.3.1 Normalise the isolating valves MAX 45 AA 501 in HP secondary

fluid line and MAX 45 AA 502 in IP secondary fluid line from EHC,
which was kept closed while checking the hydraulic controller.
8.3.2 Keep the starting device MAX 47 By 001 in maximum position.
8.3.3 Ensure that the trip fluid line isolating valves MAX 51 AA 511 is
kept opened.
8.3.4 Ensure that control fluid line isolating valve MAX 42 AA 611 is
kept opened.
8.3.5 Ensure a pressure gauge 0 to 8 kg/cm 2 in the pressure gauge

point provided before EHC MAX 45 By 001 in trip fluid line.
8.4 Procedure for checking and setting of EHC
8.4.1 Feed through set point voltage, a fixed voltage in co-ordination

with C & I Engineer.
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NTPC BHEL
Sheet 18 of 28
Plant area: TURBINE
SLNO STATUS
8.4.2 Check whether the voltage in moving coil MAX 45 CG 001 T is

around minus volts.
8.4.3 The Equilibrium voltage should be between minus 8 volts to

minus 1.2 volts.
8.4.4 If it is not, adjust the moving coil by loosening the three locking
screws to such a position where the equilibrium voltage is around
minus 1 volt.
8.4.5 After adjusting as said in 4.1.3. feed zero volt through set point
and note down the power piston lift. (minimum reading)
8.4.6 Feed 10 volts through set point voltage and note down the power
piston lift. (Max. reading)
8.4.7 The difference in lift between maximum and minimum lift should
be approximately 50mm.
8.4.8 Vary the controller from minimum to maximum position and note
down the out put of Collins I and II in the minimum and maximum
position.
8.4.9 The Collins I and II out put should be –7.5V to +7.5V. adjust the
Collins MAX 45 CG 001A, MAX 45 CG 001K to get this voltage, if
it is not achieved.
8.4.10 Increase the set point voltage and hold the power piston lift KA 08
of EHC MAX 45 By 001 about 6 to 7mm as obtained in Hydraulic
Governor setting.
8.4.11 Check the HP secondary fluid pressure, and adjust the three
follow up pistons KA 01 of EHC MAX 45 By 001 equally to get HP
secondary fluid pressure of 3.0 kg/cm2 when power piston lift is 6
to 7mm as obtained in Hydraulic Governing setting.
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NTPC BHEL
Sheet 19 of 28
Plant area: TURBINE
SLNO STATUS
8.4.12 Increase set point voltage and hold the HP secondary fluid
pressure at 3.24 kg/cm2 .
8.4.13 At 3.24 kg/cm2 of HP secondary fluid pressure adjust, follow up

pistons KA 02 of EHC MAX 45 By 001 equally to get 3.5 kg/cm 2
of IP secondary fluid pressure.
8.4.14 Note down the power piston lift of EHC.
8.4.15 Increase the set point voltage in steps on one volt and note down
Collins out put I and II and power piston lift.
8.4.16 Check whether the HP secondary fluid pressure and IP

secondary fluid pressure obtained are equal to the hydraulic
governor characteristics set earlier.
8.4.17 Ensure by plotting the curve, that a closing and opening reserve
of 3 to 5 mm is available for power piston KA 08 of EHC MAX 45
By 001.
8.4.18 Ensure the start of opening of HP and IP control valves remains

at 3.0 kg/cm2 of HP and 3.5 kg/cm2 IP secondary fluid pressures
respectively, as set earlier during hydraulic controller
adjustement.
8.4.19 Check and ensure that the HP and IP control valves open with
respect to HP and IP secondary fluid pressure as per the
governor characteristics, from full close to full open position.
8.4.20 Plot the following curves.
8.4.21 Set point voltage versus Collins I and II voltage.
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NTPC BHEL
Sheet 20 of 28
Plant area: TURBINE
SLNO STATUS
8.4.22 Set point voltage versus HP and IP secondary fluid pressure.
8.4.23 HP and IP secondary fluid pressure versus control valve lift.
8.4.24 Power piston lift versus HP and IP secondary fluid pressure.
8.4.25 After drawing the charecteristic curves of EHC and Hydraulic

compare the slope of these curves. Both should be equal.
8.5 CHECKING AND SETTING OF NON-RETURN VALVES ON

EXTRACTION AND COLD REHEAT.
Extraction Relay MAX 51 AA 001
8.5.1 Check and ensure that all the drain valves in trip fluid lines are
kept closed.
8.5.2 Open isolating valve MAX 51 AA 527 and MAX 51 AA 530 to test
valve MAX 51 AA 048 and MAX 51 051 to extraction NRV is
opened.
8.5.3 Check whether test valve MAX 51 AA 048 and MAX 51 AA 051
are in open condition.
8.5.4 Check whether solenoid valve MAX 51 AA 028 and MAX 51 AA

028 and MAX 51 AA 031 are in de-energised condition.
8.5.5 Check whether isolating valve MAX 45 AA 509 accumulator MAX

45 BB 001 in HP secondary fluid line is opened.
8.5.6 Ensure a pressure gauge is provided on the trip fluid lien after the
extraction valve relay.
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NTPC BHEL
Sheet 21 of 28
Plant area: TURBINE
SLNO STATUS
8.5.7 Adjust at HP secondary fluid pressure of 3.25 kg/cm 2 the pilot

valve spring tension of KA 01 and KA 02 to open the extraction
valve A2, A3, A4 and A5.
8.5.8 Increase the HP secondary fluid pressure above 3.25 kg/cm 2 and
check the following.
8.5.9 Check by energizing the solenoid MAX 51 AA 028 and MAX 51

AA 031 the NRV’s A2. A3. A4 and A5 closes.
8.5.10 De-energise the solenoids and check the NRV’s A2, A3, A4 and
A5 opens back.
8.5.11 Check by closing the test valve MAX 51 AA 048 and MAX 51 AA
031 the NRV’s A2, A3, A4 and a5 closes.
8.5.12 Ensure by opening the test valve, the NRV’s A2, A3, A4 and A5
opens back.
8.5.13 Ensure by reducing the HP secondary fluid, all the extraction

NRV’s closes and note down the HP secondary fluid pressure at
that position.
8.5.14 All the extraction NRV’s should close not later than 3.0 kg/cm 2 of
HP secondary fluid pressure.
8.6 Cold Reheat Non-Return valve
8.6.1 Check and ensure that all the drain valves in control fluid lines
are kept closed.
8.6.2 Check the isolating valve MAX 42 AA 621 in control fluid line to
slide valve MAX 42 AA 001 is kept opened.
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NTPC BHEL
Sheet 22 of 28
Plant area: TURBINE
SLNO STATUS
8.6.3 Check the isolating valve MAX 45 AA 566 in secondary fluid lines
is kept opened.
8.6.4 Adjust the slide valve MAX 42 AA 001 spring tension to open the
NRV at 3.3 kg/cm2 , HP secondary fluid pressure.
8.6.5 Check by reducing the pressure of HP secondary fluid below 3.3

kg/cm2 and ensure whether NRV is closed fully.
NOTE: - The opening of CRH NRV and extraction NRV had to be

set as per the customer consultants requirements. If it is
not given, it can be set in the above said value.
8.7 Ensure the following settings in coordination with C&I /

electrical Engineers.
8.7.1 Ensure the starting device percentage position at control room

indication from 0 to 100% matches with full close to full open
position.
8.7.2 Adjust the four number of limit switches provided on the starting
device for 1%, 42%, 56% and 100% respectively of starting
device opening.
8.7.3 Ensure the speeder gear percentage position at control from

indication, crom 0 to 100% matches with full close to full open
position.
8.7.4 Adjust the limit switches in full open direction and full close
direction for four number of HP stop valves and four numbers of
IP stop valves.
8.7.5 Ensure the open and close indication is appearing for all the stop
valve at control room.
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NTPC BHEL
Sheet 23 of 28
Plant area: TURBINE
SLNO STATUS
8.7.6 Adjust the percentages position of the Four control valves of HP

and Four control valves of IP indicates at control room the full
open and full close directions.
8.7.7 Ensure the local scale indicator mounted on the body of Four
numbers of HP control valve and Four numbers of IP control
valve in the fully open and fully closed directions.
8.7.8 Adjust the limit switch of cold reheat NRV in the fully open and
fully closed direction and check the open and closed indication is
appearing at control room.
8.7.9 Ensure that the potentiometer for extraction valves A2,A3,A4 and
A5 indicating the valve opening position is calibrated.
8.7.10 Ensure the extraction NRV solenoid MAX 51 AA 028 and MAX 51
AA 031 for A2, A3, A4 and A5 indication at control room for
energized and de-energised condition.
8.8 Testing of overspeed Bolts by injecting oil through

overspeed test device MAX 62 AA 001.
CONDUCT THE FOLLOWING CHEKS AT 300 RPM
8.8.1 Release the lock of pilot valve KA 02 and KA 03 of MAX 62 AA

001.
8.8.2 Check whether the turbine speed is exactly 3000 rpm.
8.8.3 Press the pilot valve KA 03 fully, to isolate the Auxiliary trip fluid
from main trip valve to overspeed trip test device and keep in
pressed down.
Note down the Auxiliary trip fluid pressure.
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NTPC BHEL
Sheet 24 of 28
Plant area: TURBINE
SLNO STATUS
8.8.4 Rotate the handwheel KA 01 of overspeed trip test device in

clockwise direction for aditting the test oil (mineral oil) to the
overspeed Bolts.
8.8.5 Check at what pressure of test oil, the overspeed Bolts act.
8.8.6 The actuation of overspeed bolt is indicated on the test rack by

lamps and can be observed by the actuation of limit switches
MAX 10 CG 001 + 002, provided on the LHS of front bearing
pedestal.
8.8.7 Check whether Auxiliary trip fluid pressure goes to zero.
8.8.8 Note down the test oil pressure at which overspeed, bolt number
one comes out and overspeed bolt number Two comes out.
8.8.9 Rotate the handwheel KA 01 of overspeed test unit in the

anticlockwise direction where the test oil gets cut off, to the
overspeed bolts.
8.8.10 Press the Pilot valve KA 02 of overspeed test device, to reset

overspeed bolts One and Two.
8.8.11 Check whether Auxiliary trip fluid pressure builds up and it is as

per the recorded value at 8.3.0.
8.8.12 Release Pilot valve KA 02, of overspeed test device.
8.8.13 After ensuring auxiliary trip fluid pressure is steady, release the
knob of pilot valve KA 03, of overspeed test device.
8.8.14 Repeat the test two to three times as per the steps 8.2.0 to 8.9.0
and check whether test oil pressure comes to a steady valve.
Signatures
NTPC BHEL
Sheet 25 of 28
Plant area: TURBINE
SLNO STATUS
8.8.15 Lock the Pilot valves KA 02 and KA 03 of overspeed testing

device, after completing the test.
8.9 Testing of 7% regulation of Hydraulic Governor.
8.9.1 Check the machine is running on electro hydraulic or Hydraulic.
8.9.2 If it is running on Electro Hydraulic change over to Hydraulic.
8.9.3 Ensure after changing over to hydraulic, the isolating valves MAX
51 AA 501 and MAX 51 AA 502 in secondary Fluid lines of
Electro Hydraulic converter is kept closed.
8.9.4 Ensure the starting device in maximum position.
8.9.5 Increase the speeder gear to full open condition and check the
speed increases to 3210 rpm at fully open condition.
8.9.6 If the speed is not achieved, loosen the lock nut and increase the
compression of spring item No.13 of component compression of
spring item No. 13 of component drawing in O&M manual, Drg.
No. 1.1-2210-0004/1, of hydraulic speed governor, to get the
required speed.
8.9.7 After starting 7% of rated speed, at speeder gear and starting

device in maximum position, lock, the lock nut, if Hydraulic speed
governor.
8.10 Actual overspeed Test 10 to 12% of rated speed.
8.10.1 Ensure before carrying out actual overspeed test, the both
overspeed governors are operative by conducting oil injection test
as explained in 8.0.0
Signatures
NTPC BHEL
Sheet 26 of 28
Plant area: TURBINE
SLNO STATUS
8.10.2 Ensure that all speed indicators and recorders are indicating the
samespeed when the machine is at 3000 rpm and at 3210 rpm.
8.10.3 Ensure that turbine is running at a speed of 3210 rpm with

starting device and speeder gear in maximum position.
8.10.4 Press continuously the overspeed testing lever KA 07 provided in

the start and load limiting device MAX 46 by 001, by watching the
speed indication.
8.10.5 Ensure the speed raise is steady and the machine trips at 3300
rpm (approx.) by the actuation of overspeed governors.
8.10.6 Both the overspeed governors should operate between 10 to

12% of rated speed.
Note: Release the lever if the overspeed governor is not acting at

12% of the rated speed. Adjust the overspeed governor bolt to
act 10-12% of rated speed.
8.10.7 Record the speed at which overspeed governors 1 and 2 acts.
8.10.8 After trip out when machine reaches 3000 rpm, note down the
coasting down time from 3000 rpm, to turning gear speed at 100
rpm interval.
8.10.9 Bring back the machine to the rated speed for further checks.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-
Sheet 27 of 28
NTPC Ref no SIM/
Plant area: TURBINE
SLNO STATUS
8.11 Testing of Hydraulic low vacuum trip MAG 01 AA 011 at

3000rpm.
8.11.1 Ensure that the control fluid and Auxiliary trip fluid are available to
the low vacuum trip unit.
8.11.2 Ensure whether primary oil pressure is available in the low

vacuum trip unit.
8.11.3 Ensure a calibrated vacuum gauge is fixed in between the

solenoid valve MAG 01 AA 201 and low vacuum trip unit, on the
vacuum impulse line.
8.11.4 Energise the solenoid MAG 01 AA 201 and what the vacuum
gauge, for drop of vacuum.
8.11.5 Record at what value of vacuum, the low vacuum trip acts.
8.11.6 The low vacuum trip should act at 0.3 bar.
8.11.7 If low vacuum trip has not acted at 0.3 bar, adjust the spring
tension number 7, by means of adjusting screw number 5 as
shown in component drawing in O&M Manual Draing number 1-1-
3400-009/1.
8.11.8 Lock the adjusting screw.
8.11.9 Bring back the machine to the rated speed and release for
carrying out generator dryout.
Note:- Hydraulic low vacuum trip can be test even on turning gear
by jacking the disc No.2 O&M Manual Drg No.1.1-3400-0009/1
with the help of locking screw.
Signatures
NTPC BHEL
Sheet 28 of 28
Plant area: TURBINE
SLNO STATUS
9.0 COMPLTION CRITERIA:
The characteristic of governing valves shall match with design

valves closely.
10.0 APPENDICES:
a) Technical Specification
b) Drawing
i) Governing System Drawing.
ii) Governing Characteristic Curves.
Note: O&M Manual of Turbine to be referred for 10. 0 a) & b)
Signatures
NTPC BHEL

Procedure For Governing Oil System PDF

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Station: NTPC- Simhadri BHEL Ref No.

1.0 PLANT DETAILS

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STAE OF THE PLANT

8.0 TEST METHOD

9.0 COMPLETION CRITERIA

i) Governing System Drawing

ii) Governing Characteristic curves

1.0 PLANT DETAILS:

Governing Rack Consisting of following.

i) Emergency trip valve

HP Front Pedestal consisting of following.

i) Impeller for primary oil

HP Rear Pedestal Consisting of following.

i) Thrust protection Device.

To commission the Governing control system for controlling

Proposed to set the Hydraulic, Electro Hydraulic convertors, to

4.0 SERVICES REQUIRED:

4.1 Oil system shall be in service.

4.2 Operating man power.

4.3 The following equipments and Instruments.

a) Portable vaccum pump one No.

5.0 SAFETY PRECAUTION:

While testing and adjusting the LP Bypass governing no

Fire fighting equipments shall be made available.

The operating personnel shall be aware of the procedure.

6.0 EMERGENCY PROCEDURE:

Refer to Section 6.0 of LP Bypass System.

7.0 STATE OF THE PLANT:

7.1 AOPs are available for running.

7.3 HP & IP Governing valves are erected.

7.4 Connected Instrumentation and controls are made ready.

8.1.1 Initial checks to be carried out before setting of Hydraulic

8.1.2 The components number indicated on the check list is based on

8.1.8 Check whether the isolating valves in EHC circuit in HP

8.1.11 Fix a dial gauge 0-10 mm underneath bellow KA 09 in the

8.1.12 Fix three standard gauges in Auxiliary secondary fluid HP

8.1.13 Open the top cover of Hydraulic amplifier MAX 45 By 011 to

8.1.15 Check whether solenoid MAX 42 AA 051 of the trimming device

8.1.17 Ensure starting device MAX 47 By 001 in closed condition.

8.1.18 Keep the speeder gear in maximum set positions.

8.1.20 Maintain fluid temperature in control fluid tank around

8.1.24 Check the following pressure in the rack.

8.1.25 Control fluid pressure - 8 kg/cm2

8.1.26 Start up fluid pressure - 7 kg/cm2

8.1.27 Aux. Start up fluid pressure - 7 kg/cm2

8.1.28 Trip fluid pressure - 7-7.5 kg/cm2

8.1.29 Aux. Trip fluid pressure - 7-7.5 kg/cm2

8.1.30 Control fluid pressure to

8.1.31 Ensure that the respective governor characteristics is used while

8.2 Procedure for checking and setting of Hydraulic Governor.

8.2.2 Operate starting device MAX 46 By 001 gradually from Minimum

8.2.6 If the aux. Secondary fluid pressure is not obtained, adjust

8.2.7 Note down the HP and IP secondary fluid pressure corresponding

Note: Trip point of Auxiliary follow up piston is the pressure at

8.2.9 Bring back the starting device to fully closed position.

8.2.10 Ensure the starting device is in closed condition.

8.2.12 Note down the initial reading of power piston KA 08 of MAX 45 By

8.2.13 Note down the starting device initial readings.

8.2.15 At 2.3 kg/cm2 of Auxiliary secondary oil pressure check whether

8.2.17 Check the lift of power piston KA 08 of MAX 45 By 011 is around