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Rev 03

WRITE UP

ON

LOW PRESSURE BYPASS SYSTEM

Cl. no. 2.0

03 12.12.03 modified & cl.
5.0 added. VK BSR KBB
Revised as per
02 27.7.02 MOM dtd. 1-2/7/02
with NTPC BS RANA Sd. BS RANA Sd. KB BATRA Sd.
DOC.CONVERTED
01 31.1.01 TO MS-WORD SS Sd./ KBB Sd./ AA Sd./

00 3.2.93 -- SS Sd./ KBB Sd./ AKB Sd./

REV DATE REMARKS PREPARED CHECKED APPROVED

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Rev 03

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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Rev 03

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 PI-
action 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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Rev 03

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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Rev 03

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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Rev 03

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.

¾ 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.

¾ 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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STE, BHEL, HARDWAR