HP AND LP

BYPASS SYSTEM

KORBA SIMULATOR 71
KORBA SIMULATOR 72
HIGH PRESSURE (HP) BYPASS SYSTEM
The HP Bypass system in coordination with LP Bypass enables boiler operation and
loading independent of the turbine. This allows quick raising of steam parameters to
a level acceptable to turbine for rolling during start up. Steam is bypassed from main
steam line to cold reheat line through HP-Bypass and from hot reheat line to
condenser through LP bypass. The HP bypass valve can handle a maximum of 60%
of the full load turbine steam flow.

The possible phases of operation of HP bypass station can broadly be classified as

follows:

• Boiler start-up with TG set at standstill.

• Raising of steam parameters to a level acceptable for TG rolling at a relatively
faster rate than otherwise is possible.
• Turbine loading while steam flow gets transferred to the turbine.
• Parallel operation with turbine on load rejection.
• Allowing boiler operation following turbine trip, provided boiler load < 60%.
• Preventing safety valves opening at raised steam pressures.

Description

The HP Bypass system consists of two parallel branches that divert steam from the
M.S. line to CRH line. The steam pressure on the valve upstream side can be
maintained at the desired level. The steam is de-superheated in order to keep the
steam temperatures in cold reheat line within limits, below 345 oC.

The M.S. pressure ahead of the turbine is maintained by two nos. of pressure
reducing valves BP-1 and BP-2 with valve mounted electro-hydraulic actuator. The
steam temperatures downstream of the HP-Bypass station is maintained by 2 nos.
of spray water temperatures control valves BPE-I and BPE-2 with valve
mounted electro-hydraulic actuators. The spray water is available from the BFP
discharge line. There is also a spray water pressure control valve with valve mounted
electro-hydraulic actuator.

HP Bypass System (Hydraulics)

Oil Supply unit

The oil supply unit provides the hydraulic actuation energy for the complete
actuating system, and functions as follows:

An axial-piston oil pump draws the oil through a suction strainer and pumps it
through a pressure filter and via a non-return valve into the accumulator. A safety
relief valve protects the system against over pressure. The accumulator is of the
bladder type and consists of a steel pressure vessel containing a nitrogen filled
rubber bladder, which separates the oil from the gas. The accumulator supplies
pressurised oil to the system and covers the entire peak supply requirement. The oil

KORBA SIMULATOR 73
pump therefore, is sized only for the mean supply requirement and it is switched off
when the accumulator is fully charged. From the accumulator the oil is fed through
the supply manifold with the pressure reducing valve and the pressure is set and
controlled. The pressure switch monitors the oil pressure in the accumulator and
provides the signals to switch on the oil pump.

HP BYPASS SYSTEM
Servo valve

The two-stage servo valve is actuated by the torque motor, which is controlled from
an analogue-positioning amplifier or from a manual desk control. The torque motor
moves the control fork (of the servo valve) and operates the pilot stage (1st stage),
which controls the position of the control piston (2nd stage). A mechanical override
acting directly on the control piston permits local manual operation of the valve.

Blocking Unit
The electro hydraulically pilot-operated blocking unit is mounted between the servo
valve and the actuator. It closes off both ports to the actuator if electrically de-
energized or with insufficient oil pressure, and holds the piston of the actuator
(disregarding some leakage drift) in its last position. A mechanical override on the
blocking unit permits local manual de-blocking.

KORBA SIMULATOR 74
Actuator

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

Technical Data

Oil Pump (Type) OV 16 OV 32

Oil Supply 12 24 Litre/min

Speed 1500 1500 RPM
Motor
Power 4 7.5 KW
Voltage 380 380 V
Frequency 50 50 Hz
Phase 3 3
No load speed 1500 1500 RPM
Oil Tank
Oil Tank volume 45 70 Litres
Useable volume 20 50 Litres
Hydraulic Accumulator (Standard)
Nominal volume 10 lit
Pressure rating approx. 200 bar
Ambient temperature
min. 15 oC
max. 65 oC
Operating gas Nitrogen
Bladder material Perbunan (Synthetic Rubber)
Available Oil Pressures
The controlled system pressure (set with the 25 to 120 bar
pressure reducing
The maximum valve)
oil pressure (limited with the 50 to 180 bar
pressure relief valve)
Pressure Switch
4 micro-switches for the set points:
Pump motor - on
Pump motor - off
Pressure too low
Pressure too high

KORBA SIMULATOR 75
 Electrical Rating:
20 Amp at 488 V AC
10 Amp at 125 V AC
0.25 Amp at 250 V DC
0.5 Amp at 125 V DC

Mode of Operation

The HP bypass system is intended to ensure reheater protection, minimum super

heater safety valve lifting under emergency conditions, adequate steam in CRH for
auxiliary steam consumers, if taken from CRH, to retain the boiler under fire in case
of turbine load rejections and to follow boiler control system during certain operation.

The control system is designed to maintain the steam pressure ahead of bypass valve
to the given set value. The pressure set point can be adjusted from UCB. The steam
temperatures at the downstream of valves are automatically controlled to the given
set value. The temperature set point can be adjusted from UCB.

Operation of the HP bypass station is manipulated by the pressure and temperature

set points and is independent of LP bypass operation. Depending upon the initial
pressure condition at the time of boiler firing, the pressure set point is to be adjusted
to a value equal to the steam pressure ahead of bypass valve minus a bias pressure.
This will result in opening of the valves. The pressure controller would then maintain
the set pressure by allowing a flow matching with the steam flow. As the firing rate
increases, the set point needs to be manipulated in the same manner to allow flow
sufficient through RH. This however, shall be possible till the maximum flow
capability of the valve is reached at any particular pressure and temperature at
upstream. Upon reaching the target steam parameter for turbine rolling, the boiler-
firing rate will be maintained at that level.

Before admission of steam into turbine, the HP bypass shall be set to maintain the
relevant steam pressure ahead of valves plus a bias pressure. Consequent upon
steam admission in the turbine, the pressure ahead of bypass valve would tend to
fall in view of constant firing rate.

This would result in proportional closing of bypass valve during pressure controller
action. The process shall continue till the set pressure up stream is reached. After
this, further loading of the set can be achieved by increasing the firing rate.
Thereafter, the bypass set point shall be raised to live steam pressure plus a bias
pressure of 2-5 ata. With this, the HP bypass station would automatically open and
balance the discrepancy between steam generation and consumption, acting out of
load rejection under normal operation of the unit.

KORBA SIMULATOR 76
 HP BYPASS: ELECTRO HYDRAULIC SERVO SYSTEM
The control loop for the steam temperature at downstream of HP bypass valve can be
operated by modulating set point as required for different mode of start-ups governed
by boiler/turbine characteristic as well as warm-up requirements of steam piping.

Pressure Control

The signal for the HP bypass station is sensed from the main steam and converted to
proportional current signal by transmitters. The actual pressure is displayed at the
desk by indicators. The set point can be varied from the desk by a push button
module and is indicated on the console itself.

KORBA SIMULATOR 77
Temperature Control

The control positioners for the spray valves are designed in the same way as those for
the steam valves. In addition PI controllers are connected up to the control
positioners. The temperature signal from transmitters is compared at the PI
controllers with the common temp. set point. According to particular control
deviation the PI controller forms a rated signal for the control positioners of the
associated spray control valves.

The electro-hydraulic actuators make it possible to attain short positioning time for
the spray water control valves and then allow the temperature control to intervene
fast enough in the event of quick opening of the HP bypass valves. To offset the time
delay of temp measurement and to achieve favourable conditions when reaching on
the spray water-cooling system rapid adjustment to temp input of the injection valve
controller by the associated bypass valves positioning monitor. Thus, independent of
the temperature signal, a certain amount of water is injected during the opening of
the bypass valve. Manual operation of the bypass spray water temperature control
valve is effected by means of push button modules. The valve position and the
control deviation are indicated on the desk. In order to ensure proper spray cooling
on BP-1 and BP-2 (under different steam flow rates), the spray water control valves
BPE-1 and BPE-2 are reset to a constant pressure feed water supply through the BD
Valve.

Interlocks for the HP Bypass System

ƒ HP Bypass valve BP-1 or BP-2 opening less than 2% will automatically close the
spray water pressure control valve (BD valve).

ƒ If opening of either of the bypass valves BP-1 or BP-2 is above 2%, the control of
spray water pressure control valves and temperature control valves BPE1 &
BPE2 shall be changed to 'AUTO' mode irrespective of their initial conditions.

ƒ If BP valve position drops < 2% open, it will receive auto close command to
ensure positive shut-off.

ƒ If the steam temperature downstream of the BP valves becomes 380oC, the

closing signal for these valves are initiated accompanied with an alarm. In this
case, the BP controller will transfer itself from AUTO to MANUAL.

The following will activate the 'Fast Opening' Signal:

• Generator Circuit Breaker Open.

• Turbine Load Shedding Relay operated.
• HP BP Pressure controller deviation more than (+) 10%.
• Depressing of the 'FAST OPEN' push button.

KORBA SIMULATOR 78
LOW PRESSURE (LP) BYPASS SYSTEM
Low Pressure bypass system enables to establish an alternative pass for dumping the
steam from reheater outlet directly into condenser at suitable steam parameters.

The controls for LP BYPASS system are essentially a combination of electrical and
hydraulic system. Electro-hydraulic converter provides the necessary link between
hydraulic actuators and the electrical system. The control of LP bypass system is
hooked up by the same control, which is used for turbine governing system. The LP
bypass valves are two in number. The double shut-off arrangement separates the
reheater from the condenser during normal operation. In addition to these, two steam
pressure control valves, four injection water valves are provided for de-superheating
purposes. This injection water is taken from condensate extraction pump discharge.

LP BYPASS SYSTEM

Set Point Formation

Two set points, the fixed set point and the variable set point are formed for the LP
Bypass controller, the effective set point under any set of operating conditions being
the greater of the two.

The fixed set point can be set manually from the control panel to a point between 0 -
120 % of the maximum LP Bypass pressure with the aid of a motorised set point
adjuster. It can also be regulated automatically by means of the 'Automatic Control

KORBA SIMULATOR 79
Interface' during the start-up phase and is normally used to set the lower limit for
pressure set point. The pressure upstream of the H.P. blading, required for reference
variable set point formation, is measured by a pressure transducer and transmitted to
a matching amplifier which sets the characteristic for the reference variable as a
function of the pressure upstream of H.P. blading i.e. throttle pressure.

LPBP EHC POSITION Vs VARIOUS VALVE OPENING

PRESSURE CONTROL FOR LP BYPASS SYSTEM

The reheat steam pressure before interceptor valve is the controlling variable for the
LP bypass system. Control of this parameter can be done in the 'MANUAL' mode by
changing the electro-hydraulic controller (EHC) output as required by means of the
OPEN/CLOSE push buttons located on the control module. In the 'auto' mode, the
controller matches the hot reheat pressure with the effective set point (either FIXED
or VARIABLE) by modulating the LP Bypass control valves as necessary. A tracking
controller is provided so that the control mode (manual or auto) not in service
automatically follows the effective controller. This facilitates bump less changeover,
between the modes. But when charging over from 'MANUAL' to 'AUTO' care must be
taken for matching the set point and actual value, otherwise, a jerk in the system will
be felt due to the error present (which the AUTO controller tries to bring to zero).

KORBA SIMULATOR 80
 LP BYPASS CONTROLLER

AUTOMATIC CONTROL INTERFACE DEVICE (ACI)

During the start-up, it is intended to avoid a very high level of set point. For this
purpose, the Automatic Control Interface Device has been introduced. For the
Automatic Control Interface to come in action, it must be switched on by means of the
ON/OFF push button provided on the control panel. Also the Bypass controller must
be in auto mode. When the Automatic Control Interface is switched ON, it brings the
fixed set point down to 3 Kg/cm2, in case the actual reheat pressure is below 3
Kg/cm2. When the actual reheat pressure exceeds 3 Kg/cm2 the ACI opens the LP
Bypass control valves + 25% and they remain locked in 25% position up to a reheat
pressure of 12 Kg/cm2. During this time, the fixed set point tracks the actual reheat
pressure so that the output of LP Bypass "auto" Controller is zero. Once the ACI has
brought the fixed set point 12 Kg/cm2, it gets automatically switched off. The fixed set
point remains static at 12 Kg/cm2 and the LP Bypass controller modulates the control
valve to maintain this set pressure. Any change in the reheat pressure can now be
brought only by manually varying the fixed set point to the desired value.

Two Stage Water Injection

To prevent undue overloading of condensate pumps under normal shutdown/start-up

conditions, the injection water demanded from CEPs is staggered in two stages. This
arrangement opens the injection valves (INV-2, 4) via the pressure switch (LPPS),
solenoid valve (SVV) & slide valve SV-2/4 when the steam pressure upstream at the
expansion orifice exceeds value corresponding to 45% of maximum bypass flow.

KORBA SIMULATOR 81
Protective Closing of LP Bypass System (Condenser Back-up Protection)

The LP Bypass valves will close automatically under the following conditions to
prevent damage to the condenser.

• Condenser vacuum is low (> 0.4 Kg/cm2 abs)

• Spray water pressure is low (< 10 Kg/cm2 or both condensate pumps off).

• Condenser wall temperature is high (> 90oC).

• The steam pressure downstream of LP BP is greater than 19 Kg/cm2.
High exhaust hood temperature will automatically switch on the exhaust hood spray
water. In case of condenser wall temperature protection operation, the 'RESET
BYPASS TRIP'-Pushbutton for solenoids SV-1 and SV-2 are to be depressed to reset
the TRIP command.

LP Bypass Control (Hydraulic)

Due to difference between set and actual HRH pressure the electro-hydraulic LP
bypass governor generates a proportional signal voltage in the moving coil of the
converter (EHC). With increasing signal voltage, the jet pipe of the converter moves
towards right and the amplifier piston (KA-08) moves down. A feedback mechanism
stabilises the amplifier piston for a given voltage change. The sleeves (KA04) of follow-
up piston valves (KA02/KA03) also move down increasing the signal oil Pressure of
water injection Valves, there by opening them, in the beginning of control operation.

LP BYPASS CONTROL SYSTEM

KORBA SIMULATOR 82
LP bypass stop valves (LPSV-1, 2) open up with a slight time delay after injection
valves are opened; due to rising oil pressure in follow-up pistons KA02 (assuming
piston KA07 of bypass limiting regulator is in upper position). LPBP Steam control
valves (LPCV-1, 2) open up due to hydraulic feedback between actuator pistons and
pilot valves (PV-1, 2).

1. Electric LP bypass governor

2. Plunger coil measuring system
3. Jet pipe
4. Adjusting spring
5. Adjusting screw
6. Jet pipe regulator

a. Control fluid
a1. Control fluid under control piston of differential
pressure relay
a2. Control fluid above control piston of differential
pressure relay

Electro Hydraulic Converter for LP Bypass

LP bypass limiting regulator (LPLR) has priority over (EHC). As soon as condensate at
required pressure is available with sufficient vacuum in condenser, its jet pipe swings
to right and its piston KA07 moves to upper position. This increases the signal oil
pressure in KA02 (follow-up pistons), releasing steam Stop Valves and Control Valves
to open. In case of condensate water pressure low and condenser pressure high the
reverse action takes place and the spring of KA02 is de-tensioned to such an extent
that LP bypass valves are unable to open, Refer to Figure.

1. Jet pipe
2. Jet pipe regulator
3. Adjusting spring
4. Adjusting screw
5. Corrugated measuring system
6. Adjusting spring
7. Corrugated measuring
8. Corrugated measuring
9. Adjusting spring

a. Control fluid
a1. Control fluid above control piston
of limit pressure amplifier
a2. Control fluidunder control piston
of limit pressure amplifier
k. Condensate from hydraulic
pressure switch of injection water
pressure monitor
l. Vacuum signal from bypass steam
piping behind bypass control
valve

LP Byapss Limiting Regulator

KORBA SIMULATOR 83
LP BYPASS PROTECTIONS

Low Vacuum Safety Device

1. Capnut
2. Adjusting csrew
3. Cover
4. Compression spring
5. Diaphragm
6. Valve
7. Valve sleeve
8. Casting
9. Can
10. Lever

a Bypass signal oil from converter

a1 Signal oil to bypass valve
c Oil drain
l Vacuum from condenser

A low vacuum safety device is installed in the signal oil line from follow-up piston
KA02 to bypass valves' pilots (PV-1, 2) and (PV-3,4) If vacuum drops below a preset
value; the valve of the safety device moves downwards due to increasing pressure
above it. The valve thus blocks off the signal oil line and opens the oil between itself
and PV-1, 2 & 3, 4 to drain, closing the LP bypass stop and control valves. As vacuum
increases, bypass operation is restored in reverse sequence when the preset vacuum
has built up.

Low Injection Water Pressure Protection

A pressure switch (WPS) is installed in the signal oil line from KA02 to PV-1, 2 & PV-
3,4 of bypass valves, to protect the condenser in the event of water injection failing. If
the injection water pressure drops below a preset value, the valve of the pressure
switch (WPS) moves down, blocking off the signal oil line and de-pressuring the oil
between itself and PV-1, 2 & PV 3, 4. The LP bypass valves are thus closed, due to low
condensate water pressure. Bypass operation is restored in the reverse sequence
when injection water pressure becomes normal.

KORBA SIMULATOR 84
 1. Hood
2. Bellos
3. Pushrod
4. Knife edge lever
5. Cam shaft
6. Compression spring
7. Fitted key
8. Shaft
9. Scale
10. Cylindrical pin
11. Nozzle
12. Slide valve
13. Valve bushing
14. Compression spring
15. Bearing bushing
16. Torsion spring
17. Lever

a Control oil
a1 Control oil
a2 Control oil to pilot valve of
bypass valve
c Return flow
l Injection water pressure

Low Injection Water Pressure Protection

High Condenser Wall Temperature Protection

At a preset condenser wall temperature the two thermocouples mounted in steam

dome opposite bypass steam inlet transmit a switching pulse to the associated
solenoid valves (SOLV-1, 2).

1. Solenoid
2. Compression spring
3. Solenoid valve
4. Compression spring
5. Solenoid
6. Compression spring
7. Main valve
8. Compression spring
9. Limit switch for injection

a Control oil
b Signal oil to Stop and Control valve
operator of bypass SV/CV
c Drain

The solenoid valves block off the depressive signal oil and close bypass valves in the
event of high condenser wall temperatures. The bypass valves can be opened from the
control room manually only after the solenoids are manually reset after the
temperature has become normal.

KORBA SIMULATOR 85
KORBA SIMULATOR 86