MP BYPASS SYSTEM

PRESSURE
AND
TEMPERATURE CONTROL
S K SAMANTA
cn=S K SAMANTA, c=IN,
o=NTPC LTD,
ou=NTPCEOC,
email=sksamanta@ntpceo
c.co.in
CAT - I
2008.09.08 16:22:48
+05'30'

CORRESPONDING APPROVED SCHEME

FOR KORBA STAGE-III(lX500MW)
NTPC DOC NO. 6130-108-110-03PE-PVI-F-086

DADRI-STAGE-11, 2x490 MW

PROJECTS ENGl

I I
SHEET 01 OF 16 00
 DOCUMENT

FORM No. PEM - 6100 -0

PROJECT : DADRI-STAGE-II, 2x490 MW, TG PACKAGE NUMBER PE-DG-259-145-I 005
REVISION
DOCUMENT TITLE
NUMBER
00 DATE 16.02.07
HP BYPASS PRESSURE AND TEMPERATURE SHEET 13 OF 16
CONTROL WRITE-UP

1.0 HP BYPASS CONTROL SYSTEM

1.1 PURPOSE
The Purpose of the HP Bypass station is to allow the steam pressure at the HP Turbine
inlet to be controlled before and during Turbine start-up as well as during trip and shut-
down conditions, by the BP valves. In addition, the dump steam is attemparated through
the BPE valves, to the temperature in accordance with the cold re-heater inlet. It is
designed for constant/sliding/modified sliding pressure modes of operation.
1.2 CONTROL LOOPS
- Pressure master controller
- Temperature controller
- Spray water isolation valve
- Fast opening system
1.3 OPERATION
All the control loops are to be left on AUTO continuously, the only manipulation needed is
the desk operated Pressure Setpoint during start-up and shut-down. The pressure
controller also receives setpoint from turbine throttle pressure (4-20 mA signal) and the
manual setpoint station according to the throttle pressure, if it is selected on auto.
Normal operation is defined as 100% MCR operation of the main turbo-generator set
during which all valves of bypass station are tightly closed with their controllers on auto,
ready to control the preset pressure and temperature.
2.0 MASTER PRESSURE CONTROLLER - BP VALVES
2.1 OPERATING MODE
The control system is designed to maintain the steam pressure ahead of bypass valve to a
given set value.
The HP bypass control receives set point either from the throttle pressure with a positive
bias, when it is in auto or from VPC when it is in manual mode.
When the deviation between the measured pressure signal and the set point is more than
the preset value, an override signal is given to the fast opening device to open the BP
valve quickly. After synchronization and taking over of steam by the turbine, the bypass
station only serves for keeping the live steam pressure of the system.
2.2 LOOP DESCRIPTION
The actual pressure is sensed by two pressure transmitters . Normally the mean value
generated is used for controls. If one transmitter fails, the second transmitter is
automatically selected. However operator can select mean value or any transmitter value
for controls through VPC. MVS also monitors the deviation between the two transmitters
and in the event of high deviation, the control loops is changed to manual. The same set
point is fed to both valve controls. The alarms for transmitter fail and control deviation high
shall be given to the CRT.

A PI controller drives the electro-hydraulic actuators to modulate the BP valves, in order to

maintain the live steam pressure at the pre-selected value.
 DOCUMENT

FORM No. PEM - 6100 -0

PROJECT : DADRI-STAGE-II, 2x490 MW, TG PACKAGE NUMBER PE-DG-259-145-I 005
REVISION
DOCUMENT TITLE
NUMBER
00 DATE 16.02.07
HP BYPASS PRESSURE AND TEMPERATURE SHEET 14 OF 16
CONTROL WRITE-UP

The pressure signal is compared at the input of the PI controller with the signal coming
from the set point station. The throttle pressure signal after the bias addition and the set
point at the output of the memory module is indicated on CRT.

The deviation, following the PI modification, produces a valve position demand signal
which drives the positioner modules of the BP valve control loops. The demand signal is
indicated on CRT. This demand signal will exist, until they are balanced by the BP valves
position feedback signals. The positions of the BP valves and the deviation w.r.t. the
demand signal are indicated in the console indicator. The output of the positioner is fed to
the input of analog power amplifier module. The combination of the positioner and the
analog power amplifier is represented by a block called “K” controller or slave controller.
This controller gives a modulating signal to the servo valves and DC signal to the blocking
unit. The VPC facilitates remote manual operation of the BP valves and auto/manual
transfer.
2.3 OVER-RIDES AND INTERLOCKS
The PI output and the BP valve position signals are monitored by limit valve monitors,
which initiates the following functions.
a) BP CLOSING OVER-RIDE
When BP valves are less than 2% opened, a Force Close (FC) signal interlock is
given to prevent the BPE valves from drift open.
b) FAST OPENING
Besides the normal control channels, an additional element is mounted on the
actuators of BP valves called quick opening device.
When this devices are activated, the valves will open quickly. The signals that activate the
fast opening devices under boiler ‘ON’ condition (From FSSS to be added with other fast
opening signals) are the following:
- Generator circuit breaker open.
- Turbine load shedding relay activated.
- Turbine trip.
- Pressure deviation too high.
- Emergency fast open push button from control desk.
- Reheater Protection Active.
The fast opening signals change the positioning loop of the BP valves to auto mode and
block the control signals from the output module. Once the valves are fully opened in
about 3 seconds (adjustable), the fast opening signal will be cut off by the timer or
through the check back signals of fully open derived from position transmitter output.
c) PROTECTION OVER-RIDES
Any one of the following protection signals will select the BP positioning loops to
manual mode and close the BP valves fully whereby the manual opening signals
and the fast opening signals from the control desk are inoperative.
- Steam temperature downstream of BP is too high.
- Condenser vacuum low < 0.6 ata.
 DOCUMENT

FORM No. PEM - 6100 -0

PROJECT : DADRI-STAGE-II, 2x490 MW, TG PACKAGE NUMBER PE-DG-259-145-I 005
REVISION
DOCUMENT TITLE
NUMBER
00 DATE 16.02.07
HP BYPASS PRESSURE AND TEMPERATURE SHEET 15 OF 16
CONTROL WRITE-UP

3.0 SPRAY SYSTEM

The spray system consists of two spray water flow control valves (BPE-1 & BPE-2) and
one spray water isolation valve (BD). By injecting water into the downstream of BP
valves, the downstream steam temperature is cooled to the temperature required at the
reheater inlet. The spray water system does the following requirements:

a) The spray flow has to correspond statically as well as dynamically under all
operating conditions to the steam flow as closely as possible.

b) An absolute stable flow has to be maintained even at very low steam flow rates.

c) The anticipatory control must not lead in any way to; a transcient over travel of
the spray control. The anticipatory control action has to be adopted to the actual
operating conditions.

4.0 TEMPERATURE CONTROLLER - BPE VALVES

The actual temperature signal sensed by the redundant thermocouples and fed to the
Mean Value Selector. Normally the mean value generated from MVS is used for controls .
If one thermocouple fails, the second one is automatically selected.However the operator
can select mean value or any transmitter for controls through VPC. MVS also monitors
the deviation between the two thermocouples outputs and in the event of high deviation,
the control loop is changed to manual and the necessary alarms shall be given to the
CRT.

The PI controllers drive the electro-hydraulic actuators to maintain the down stream steam
temperature of the BP valve at the preset value.

The temperature signal after MVS is compared at the input of the PID controller with the
setpoint signal generated from the setpoint station from the control desk. The error
between setpoint and actual process values and valve positions are indicated on CRT.
The control deviation, following the PID modifications produces a demand signal, which is
sent to the positioning loops of the temperature spray control valves BPE valves. These
positioning loop input compares the actual value position feedback signal and the PID
demand signal and send the output signal to; the servo valve and the blocking element.
The same set point is given to both temperature control circuits.

A variable gain controller is provided at the output of the PID controller to regulate the
spray water flow according to the steam flow through the bypass valves. This is achieved
by adopting the amplification of the PI controller by means of multiplying the controller
output signal with the steam flow signal. This signal has the simultaneous effect of
generating an anticipatory positioning signal for the spray control valve. The gain between
steam flow rate and position of the spray control valve (controller output signal) is
automatically adjusted to the actual operating conditions.

The steam flow signal is the product of steam pressure multiplied by the actual bypass
valve area whereby the valve is represented by a non-linear function of the valve stroke.
 DOCUMENT

FORM No. PEM - 6100 -0

PROJECT : DADRI-STAGE-II, 2x490 MW, TG PACKAGE NUMBER PE-DG-259-145-I 005
REVISION
DOCUMENT TITLE
NUMBER
00 DATE 16.02.07
HP BYPASS PRESSURE AND TEMPERATURE SHEET 16 OF 16
CONTROL WRITE-UP
4.1 OVER-RIDES AND INTERLOCKS

a) Auto Interlock

As the BP valves open more than 2% switch to auto signal is given to the BPE
control loop.

b) Opening Signal

As the BP valves open more than 2%, the BPE valves open to a preset minimum
value, to ensure that certain amount of water is immediately injected into; the
steam flowing through BP valves. This is to give an advance spray before a
meaningful signal reaches from the temperature measuring system.

c) Closing Interlock

When the downstream steam temperature raises to a preset high limit, a closing
signal is given to the BP valves, followed by an alarm.

5.0 SPRAY WATER ISOLATION BLOCK VALVE

The spray water line ahead of BPE valve is provided with an electro-hydraulic actuator
operated isolation valve.

5.1 INTERLOCKS AND OVER-RIDES

a) When any one of the bypass valves open more than 2% or demand to valve BP is >
2% an opening signal is given to; the isolating valve for full open.

b) When both HP bypass valve (BP-1 & BP-2)are less than 2% opened and the
controller demand is not > 2%, a closing signal is given to the isolation valve to close
fully.

6.0 HP Bypass station operates independent of LP Bypass system, any mal-operation of the
same during load rejection would result in disturbance of re-heater flow to a dangerous
level with fire on in boiler. For taking care of such conditions it would be necessary to
generate a signal indicating that bypass has not opened in spite of demand signal
prevalent for the same to open. Also signal should be available when HP bypass is stuck
up are not opening during startup. These Alarms will be generated from the HP Bypass
Valves.