HP - LP

BYPASS
T.V.V.SIVA RAMA KUMAR
ADE/E&P/Dr.NTTPS
 INTRODUCTION

The major equipment in Thermal Power Stations are

 Boiler,
 Turbine,
 Generator,
 Power transmission and Equipment

In Boiler, fuel is fired ,steam is generated and

superheated under high Pressure. This superheated
steam under high pressure is supplied to High
Pressure Cylinder of steam turbine and expanded.
The Low Pressure exhaust steam from H.P cylinder is
taken again to the boiler and reheated.
 TRANSMISSION &
SUPER HP IP &LP DISTRIBUTION
TURBINE GEN SYSTEM
HEATERS TURBINE

BOILER REHEATER

CONDENSER
ECONOMISER

MAKE UP
HP HEATERS
DEMINERALISATION
PLANT
FEED LP COND
DEAERATORS PUMP
PUMP HEATERS

The reheated steam is used in the intermediate pressure and Low pressure
cylinders of the turbine for expansion and finally steam is dumped into the
condenser. The condensate from the condenser is extracted by a condensate
extraction pump (CEP) and flows to the dearator through a series of Low
pressure heaters. The feed water from the dearator is pumped back to the
boiler by the boiler feed pump through a set of high pressure heaters.
Function of Re-heater:-
Re-heater is used to increase degree of superheat of exhaust
steam from HP turbine.
If we consider the Rankine cycle without reheating, the nos.
of stages handling the steam below the saturation line, are
more. The blades of these stages are subjected to heavy
erosion caused by water droplets.
To minimize the erosion, steam is taken from HP exhaust to
re-heater where the heat is added to increase the temperature
of the steam.
Total nos. of stages handling wet steam is reduced.
Reheating makes it possible to achieve higher thermal
efficiency, and larger power output.
The LP Bypass protects the re-heater from overheating
and pressurization by allowing extra steam to condenser.
 HP-LP BYPASS SYSTEM
HP stop &
Control valve
HP Bypass
valve

Steam
Generator HP IP LP G
HPT PX
IP stop &
HRH PX
Control valve

LPBP stop &

REHEATER Bypass Control valve
Safety valve CONDENSER
CONSOLE
The Bypass system will be in operation
during the following conditions

Warm start
Hot start
Load rejection
House load operation
Quick shut down of turbine
Turbine trip
 OIL SUPPLY UNIT

The oil supply unit provides the hydraulic actuation energy for the
complete actuating system, and functions as follows:
 
An electric motor driven axial-piston oil pump sucks the hydraulic fluid
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 the system with
pressurized oil and covers all the peak supply requirements. The oil pump is
therefore sized only for the mean supply requirements 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
switch.
With the pressure reducing valve the system pressure is set and
controlled. The pressure switch monitors the oil pressure in the accumulator and
provides the signals to switch the oil pump motor. From the supply manifold the
oil is fed through the pipe work and the 3-micron pressure filters to the
appropriate control valves and the actuators.
1. OIL SUPPLY UNIT
2. SERVO VALVE
3. BLOCKING UNIT
4. HYDRAULIC SERVO MOTOR
5. FEED BACK TRANSMITTER
6. CONTROL VALVE
7. CONTROL UNIT
8. OTHER POSSIBLE
CONNECTIONS
 SERVO-VALVE

The Electro-Hydraulic servo valve transforms the

control signals coming from the electronic amplifiers into
hydraulic pressures.
  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 (1 st 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

It is part of the Electro-Hydraulic actuating system, situated in the oil

circuit between the servo-valve and actuator.
 
The blocking unit has the function of freezing the actuator and the
valve, ( electrically de-energized or with insufficient oil pressure ) in its last
held position. A mechanical override on the blocking unit permits also local manual
de-blocking.
 
PRESSURE SWITCH:
 4 Micro switches for set point.
 
Pump motor ON.------ pressure set 100 Kg/Cm 2.
 Pump motor OFF------- Pressure set 140 Kg/Cm 2.
 Pressure TOO LOW---Pressure set 90 Kg/Cm 2.
(HP BP Control failure annunciation flashed in UCB).
 Pressure TOO HIGH—Pressure set 150 Kg/Cm 2.
(HP BP Control failure annunciation flashed in UCB)
 
FAST OPENING DEVICE:
 
It consists of a solenoid valve, pilot
operated check valves and flow control /
throttle valves. Whenever the solenoid valve is
energized it will open the HP Bypass valve in 3
secs. Normally with the use of servo valve and
blocking element the valve can be opened in 10
or 12 secs. This quick opening device is
provided to avoid sudden pressure rise in the
main steam line at certain specified operating
conditions.
PRESSURE CONTROL LOOP :

The pressure control loop measures and compares the actual value and the
set value and it issues commands to the B.P. valves either to open/close depending on
the deviation being POSITIVE/NEGATIVE. The B.P.valves are to be kept in auto so as
to be ready to control the steam to the present pressure and temperature.

Actual pressure before HPT inlet is measured by two transmitters. One

measurement and one regulation. Regulation transmitter output is used in auto control.

  HP BYPASS set point can be selected to either in Auto or Manual.

 
AUTO SET POINT: - Here set point is taken from Boiler Master. Auto set point
deviation has two modes of operation.
 
1.    Relief Mode: - In this mode a fixed bias ( 5 Kg/Cm2 ) is added to the set value.
 
2.      Control Mode: - In this mode the MSP set point is directly taken as set point for
control.
 
HP BYPASS SPRAY SYSTEM:

The spray system consists of two numbers spray water flow control
valves and one number spray water isolation valve (BD valve).

When any BP valves opens more than 2%(>2%) an open command

given to BD valve for full open.

When any HPBP valves (BP valves) close less than 2%(<2%) closing
signal given to the isolating valve (BD valve) to close it fully.

BP valves open more than 2%(>2%) an auto command is given to

BPE(SPRAY VALVES) to open with an interlock of downstream temp > 340 deg c .

A close signal is given to that particular BPE valve when the

corresponding BP valve closes to less than 2%(<2%).

ALARMS: HPBP down steam temperature high : 380oc

HPBP down steam temperature very high : 420 oc

HPBP pressure deviation exceeded(CRT): More than 10 kg/cm2(>10kg/cm2 ).

 HP & LP BYPASS CONSOLES IN UCB
100 100
150 150 300 300
200 200 450 450 % %
200
0 BYPASS CTRL V1 0 BYPASS CTRL V2
0 kg/cm² 0 kg/cm² 0 °C 0 °C
BYPASS STP V1 OPEN BYPASS STP V2 OPEN
M S L PRESSURE M S L PRESSURE B P E 1 TEMP ACTUAL B P E 2 TEMP ACTUAL
BYPASS STP V1 CLSD BYPASS STP V2 CLSD
ACTUAL ACTUAL (REGULATION) (REGULATION)
(MEASUREMENT) (REGULATION) INJ WATER V1 OPEN INJ WATER V3 OPEN
300 450 INJ WATER V1 CLSD INJ WATER V3 CLSD

160 200 INJ WATER V2 CLSD INJ WATER V4 OPEN

0 °C INJ WATER V2 CLSD INJ WATER V4 CLSD

0 kg/cm²
MASTER TEMP SETTER
FOR BPE- 1 & BPE- 2
60 100
MSL PR. SETTER BD VALVE OPEN
FOR BPE1 AND BPE2 BD VALVE FAULT TEMP. SET %

MAN
PR.SET

F AUTO
PR. MODE BD VALVE CLOSE
OPEN - + 0HR/HKg/ sq cm
STM BEF LPBP
0
RLF CONTR
EL HYDR CONV. LPBP
FAULT
CLOSE
0 + 30 REH SAF V 100%

Δp REH SAF V 0%
300 300
10 450 450
EMERGENCY FAST
OPEN
0 100 200 -30 KG/SQ.CM
%
-10 CNTRL DEVTN
0 °C 0 °C
0 0 KG/SQ.CM 60
B P E 1 TEMP ACTUAL B P E 2 TEMP ACTUAL REH SAFETY V OPEN
DEMAND / DEVIATION SLIDING SET POINT
(MEASUREMENT) (MEASUREMENT)
FOR BP 1 & BP 2
0 KG/SQ.CM 60
CONSOLE FIXED SET POINT
10 10 10 10
ENABLED 100 100 100 100
0 % 0 % 0 % 0 %
CONSOLE -10 -10 -10 -10 FIXED SET POINT RESET BYPASS TRIP SV1
DISABLED
0 0 0 0
LP BYPASS CNTRL
LAMP TEST BP 1 POSITION / BP 2 POSITION / BPE 1 POSITION / BPE 2 POSITION /
CONTROL DEVIATION CONTROL DEVIATION CONTROL DEVIATION CONTROL DEVIATION
BP - 1 BP - 2 BPE - 1 BPE - 2
AUTOM. CONT. INTERE RESET BYPASS TRIP SV2
A / M ENABLE MAN F AUTO MAN F AUTO MAN F AUTO MAN F AUTO
 100 100
% %
0 BYPASS CTRL V1 0 BYPASS CTRL V2
BYPASS STP V1 OPEN BYPASS STP V2 OPEN

BYPASS STP V1 CLSD BYPASS STP V2 CLSD

INJ WATER V1 OPEN INJ WATER V3 OPEN

INJ WATER V1 CLSD INJ WATER V3 CLSD

INJ WATER V2 CLSD INJ WATER V4 OPEN

INJ WATER V2 CLSD INJ WATER V4 CLSD

60 100
%
0HR/HKg/ sq cm
STM BEF LPBP
0
EL HYDR CONV. LPBP

0 + 30 REH SAF V 100%

Δp REH SAF V 0%

-30 KG/SQ.CM
CNTRL DEVTN

0 KG/SQ.CM 60
SLIDING SET POINT REH SAFETY V OPEN

0 KG/SQ.CM 60
FIXED SET POINT

FIXED SET POINT RESET BYPASS TRIP SV1

FIXED SET POINT

AUTOM. CONT. INTERE RESET BYPASS TRIP SV2

Check before charging HP-LP Bypass :
 HP Bypass valve (BP1&BP2) start opening if M.S Pressure
is more than set point.
 Boiler stop valves are open.
 Cold re-heat and hot re-heat steam line drains are open.
 Vacuum in the condenser is 0.650Kg/cm².
 HP Bypass oil units oil level normal, its pump is running
and oil pressure is adequate.
 HP Bypass down stream temperature set point is at 200˚ C .
 Transfer LP Bypass control to auto and switch on the
automatic control interface device.
 Transfer HP Bypass control to auto.
 Reduce HP Bypass upstream pressure set point.
Advantages of HP/LP Bypass system:

to enable house load operation of the machine.

to achieve quick start up and faster loading.
to reduce start up and shut down losses.
to minimise loss of DM water.
to enable quicker warming up of steam lines.
to minimize operation of safety valves.
to improve boiler stability under transient conditions.
to enable boiler to be kept in operation after a load rejection.
to enable the independent operation boiler and turbine.
to maintain the steam flow through the re-heater and boiler.
 RH PROTECTION
TURBINE TRIP

GCB OPEN OR
ANY MILL ON
& TP
HPBP-1< 2%
&
HPBP-2 <2%
OR 5 SEC
LP BP-1 <2%
LP BP-2 <2% &

& TP >
LOAD
SHEDDING S
RELAY
10 SEC
R TP RH PROTECTION
TURBINE
WORKING
11 SEC
HPBP-1 S.T.
FLOW >50T & TP
HPBP-2 S.T.
FLOW >50T OR S
ANY MILL ON
5 SEC
MFR
R
BOILER ON
 If a reheat is needed after shut down interval on “ts”, the boiler
steam temperature “Tb” is much lower than the turbine metal
temperature “Tm” as can be seen in figure:

Tm
Tb

ts

Hence, it will be necessary to rise the boiler steam temperature to a value higher than the Turbine
metal temperature before any steam could be admitted into the Turbine
this is necessary to avoid thermal stresses due to temperature change in the thick walled
component like the Turbine. This rise is shown by the dotted line.
 SLIDING SET POINT
ACTUAL VALUE FIXED SET POINT
HRH Press. (bar) 12
10
8
6 RELATIONSHIP
4 BETWEEN
PRESSURE CONTROL
2
&
0 VALVE POSITION
Bypass Valve Pos. (%)

MATCHING FREEZE TRACKING

OPENING RANGE OF

100 WATER INJECTION VALVES

AND REHEAT SAFETY VALVES

80
60
40 AUTOMATIC SWITCH OFF
OF AUTOMATIC CONTROL
INTERFACE
20
0 2 4 6 8 10 12 14 16 18 20 22 24