STANDARD OPERATING PROCEDURE FOR HY-LP BYPASS SYSTEM

OBJECTIVE: the HP-LP pass system by passes the high pressure steam to the low
pressure steam circuit & then dumps to condenser after suitable depressurization &
tempration. This way actually the turbine is bypassed from the steam circuit.

SCOPE: This SOP is applicable HP and LP bypass system

INTRODUCTION: The major equipments in a Thermal Plant are Boiler, Turbine Generator &
Power Transmission ,equipments .For the stable operation of the plant, Boiler outlet parameters
should be matched with the condition of Turbine. But due to difference in boiler & turbine
dynamic characteristics, the flexibility of operation suffers. This problem can be overcome by
employing HP-LP by pass system in the steam cycle

PRE CHECKS:
HP LP BY-PASS SYTEM TECHNICAL DATA:-
1. HIGH PRESSURE BYPASS VALVE

Make CCI Switzerland Quantity ---

Type HBSE 280-250-1 Normal inlet pressure 16.67 Mpa

Normal outlet pressure 4.133Mpa Normal inlet temperature 538 ℃

Normal outlet temperature 335 ℃ Flow 716.27 t/h

Valve travel 110 mm Full travel time < 10s

2. HP BYPASS SPRAY-WATER REGULATING VALVE

Make CCI Switzerland Quantity ---

Type 100DSV Normal inlet pressure 22.73 Mpa

Normal outlet pressure 4.67 Mpa Normal temperature 185.2 ℃

Normal outlet temperature ---- Flow 95.57 t/h

Valve travel 63.5mm Full travel time < 10s

 3. HP BYPASS SPRAY WATER ISOLATION VALVE

Make CCI Switzerland Quantity ---

Type 840G Normal inlet pressure 24.25 Mpa

Normal outlet pressure 22.73 Mpa Normal temperature 185.2 ℃

Normal outlet temperature ---- Flow 95.57 t/h

Valve travel 40 mm Full travel time < 2s

4. LOW PRESSURE BYPASS VALVE

Make CCI Switzerland Quantity ---

Type NBSE 60-600-3 Normal inlet pressure 3.72 Mpa

Normal outlet pressure 0.8 Mpa Normal inlet temperature 538 ℃

Normal outlet temperature 180 ℃ Flow 716.27 t/h

Valve travel 252 mm Full travel time < 10 S

5. LP BYPASS SPRAY- WATER ISOLATION VALVE

Make CCI Switzerland Quantity ---

Type 840G Normal inlet pressure 3. 1 Mpa

Normal outlet pressure 2.63 Mpa Normal temperature 46.7℃

Normal outlet temperature ---- Flow 205.17 t/h

Valve travel 40 mm Full travel time < 2s

 6. LP BYPASS SPRAY-WATER REGULATING VALVE

Make CCI Switzerland Quantity ---

Type 840H Normal inlet pressure 2.63 Mpa

Normal outlet pressure 1.34 Mpa Normal temperature 46.7℃

Normal outlet temperature ---- Flow 205.17 t/h

Valve travel 50 mm Full travel time < 10s

PRECHECKS AND ACTION BY FIELD ENGINEER

S No Description Ok Not Ok Remarks

BYPASS CONTROL SYSTEM  

1 All permits and cross permits have been returned.  

2 Area is clear of any other materials.  

3 1. The permanent system of BPC has been restored, with  

the permanent valve plugs fitted.
 
2. Actuators have been installed up to standard.
3. Control cabinets (Local and Remote) are wired and  
Cabling Complete and are operating normally.
4. The installation and wiring of measuring elements and  
Transmitters is complete and have been checked up to  
standard.
 

Adjustment the hydraulic power unit has been complete.

4

PRECHECKS AND ACTION BY DESK ENGINEER

S No Description Ok Not Ok Remarks

Valves and measuring points transmission test and interlock,

1 protection test for high pressure bypass system  

Valves and measuring points transmission test and interlock,

2 protection test for low pressure bypass system.  

3 Pressure and temperature control of high pressure bypass  

 4 Pressure and temperature control of low pressure bypass  

RESPONSIBILITY: Unit Control Engineer, Field Engineer and Desk Engineer.

SAFTEY PRECAUTIONS:
1. Ensure no permit to work is pending on regarding this system by checking with
EE/MRSE.

SAFTEY PPE’s: Ear Plugs, Safety Goggles, Hand Gloves, etc.

SPECIAL TOOLS/ EQUIPMENTS: NIL

OPERATING PROCEDURE -
Sr. RESPONSIBILITY
Description
No. UCE DE FE EE
PRE- START CHECKS:
1 All permits and cross permits have been returned. √ √ √ √
2 Power supply and control power supply available. √ √
3 Adjustment the hydraulic power unit has been complete. √ √
4 Valve action test and on/off time measurement √
√ √

5 Inspection of interlocks, protections, and alarms √ √

6 Switch on the power supply of HP and LP bypass system √ √
Pre-start conditions for charging of HP-LP Bypass
1 Turbine oil system is started & turbine is running on barring gear. √ √

2 Condensate extraction pumps are started & condensate discharge √ √

header pressure is normal.
3 CW system is established. √ √

4 Vacuum in the condenser is greater than 0.85 kg/cm2 √ √

5 Boiler feed pump is started & supplying adequate discharge header √ √

pressure
CONDITION BEFORE COMMISSIONING

1 The permanent system of BPC has been restored, with the permanent √
√
valve plugs fitted.

2 Actuators have been installed up to standard. √ √

3 Control cabinets (Local & Remote) are wired, Cabling Complete, √
√
Checked and operating normally.

4 The installation and wiring of measuring elements and Transmitters √

have been checked up to standard.

5 Before the start of the test, ensure that the OIL System is ready √ √

6 Check that HP and LP bypass valves, HP and LP bypass spray-water √

regulating valves act normally and the associated interlock and
protection is tested capable of functioning

7 Ensure that the services such as circulating water, cooling water, and
√
control oil system are running normally. √

8 Ensure that condensate water system and feed water system are √
running normally.
9 Ensure that vacuum inside the condenser is attained as require and √
the low vacuum protection is put into operation.

Operation of bypass
1 Warming of main steam line & HP bypass valves √ √

1.1 During cold startup the warming up of main steam line can be started √ √
after boiler blow down at 10 kg/cm2 pressure
1.2 Ensure that drain valves of main steam lines ,CRH & HRH line are open √ √

1.3 Charge the main steam line by opening integral bypass valves √ √

1.4 Open the warm up valves of HP bypass valves locally √ √

1.5 The warming up operation of MS line is completed when steam √ √

temperature before HP bypass is more than the mid-wall temperature
of MSV
1.6 Open the main boiler outlet valves √ √

2 Preparation of LP bypass system

2.1 Open the warm up valves of LPBP1 &LPBP2 √ √

2.2 Open drains of LP bypass line √ √

2.3 Put the LP bypass valve controller on “ AUTO “ √ √

3 Select the HP and LP bypass pressure valves and spray water regulating √
valves to ‘Manual’
4 After the furnace is lit up, when the main steam pressure increases √
gradually to 0.2 MPa, open the isolating valve of LP bypass tertiary
desuperheater
5 open the desuperheater regulating valve, properly open the LP bypass √
valve when the opening of desuperheater water regulating valve is
above 5％.
6 Control the pressure of reheater in relation to the boiler condition. √
Ensure that no severe vibration occurs on the pipes after the LP bypass
√
pressure valve opened.

7 After the LP bypass has been put into operation, manually open HP √
bypass valve to 5％, open the HP bypass spray water isolation valve
8 when HP bypass valve opens to 5%, adjust the opening of
desuperheater regulating valve based on the outlet temperature of HP √
bypass pressure valve. Be sure to open HP and LP bypass slowly.
9 Regulation of HP and LP bypass valve is achieved for the required main
steam , reheat steam parameters. √ √

10 During bypass system operation, closely observe all components in

system and make following adjustment timely as parameters deviate
from the normal value to keep system running in good condition

a Pressure adjustment √
√

b Pressure adjustment √ √

c Flow adjustment √ √

9 Maintain the following parameters normally in operation √ √

a HP bypass outlet temperature √ √

b HP bypass desuperheater pressure √ √

c LP bypass outlet temperature and tertiary attemperator outlet √ √

 temperature

d LP bypass desuperheater pressure √ √

Turbine bypass system in integral unit commissioning √ √

1 HP and LP bypass should be operating in “Auto” mode during √ √

integral unit commissioning

Make record of the following parameter readings, both local and

computer displayed

1 HP bypass inlet and outlet pressure √ √

2 HP bypass inlet and outlet temperature √ √
3 HP bypass spray pressure √ √
4 LP bypass inlet and outlet pressure √ √
5 LP bypass inlet and outlet temperature √
√

6 LP bypass spray pressure √ √

INTERLOCKS :

1 Fast close allowable condition

1. HP bypass valve after temperature ＞390℃

2. LP bypass fast close condition

2 Fast open allowable condition

Turbine trip or generator switch trip

3 HP bypass spray-water regulating valve

1. The position of HP bypass valve ＞3％, auto put in the automatic condition

2. The position of HP bypass valve≤3%，auto close.

3. The open permit of HP bypass valve desurperheater control valve: he back

 temperature of HP bypass valve＞230℃

4 HP bypass spray water isolation valve

1. The position of HP bypass valve ＞3％, auto open

2. The position of HP bypass valve≤3％, auto close

5 LP bypass valve

Fast close allowable condition(OR)

1. Condenser press is High

2. Condenser temperature is H(＞80℃)
3. Condenser water level is H（＞1200mm）
4. The LP bypass spray water pressure is L(＜1.5Mpa)
5. The back temperature of LP bypass valve＞120℃

6 LP bypass spray-water regulating valve

1. The position of LP bypass valve ＞3％, auto put in the automatic condition

7 LP bypass spray water isolation valve

1. The position of LP bypass valve ＞3％, auto open

2. The position of LP bypass valve≤3％, auto close

ABRIVIATIONS / NOTATIONS:-
o SOP: Standard Operating Procedure
o UCE: Unit Control Engineer
o DE: Desk Engineer
o FE: Field Engineer
o EE: Electrical Shift Engineer

Note:- During operation of the valve all records should be maintain