PRESENTATION ON SETTING

OF GOVERNING SYSTEM

OF
KWU TURBINE

AND
LP BYPASS SYSTEM

INTRODUCTION

THE SETTING OF GOVERNING RACK AND LP BYPASS RACK

IS OF IMMENSE IMPORTANCE AS IT GOES A FAR WAY IN
THE SMOOTH RUNNING OF THE MACHINES DURING THE START-UP. WE SHALL DISCUSS IN DETAIL, THE PROCESS OF SETTING OF THE TWO RACKS

SETTING OF THE GOVERNING RACK
FOLLOWING CHECKS ARE TO BE CARRIED OUT BEFORE SETTING OF HYDRAULIC GOVERNING:› › › COMPLETION OF OIL PIPING VALVES, MAX 42, PT001 AND 002

OPEN.
TEST VALVES OF HP AND IP, STOP VALVES MAX 47 AA011 AND 012 AND MAX 47AA 021AND 022 CLOSED. ISOLATING VALVES OF CONTROL OIL LINE MAX 41AA 581, 582 591 592 AND SECONDARY OIL LINE MAX 45AA 511, 512, 521 AND 522ARE FULLY OPENED FOR HP AND IP CONTROL VALVES. › › EHC SECONDARY OIL FOR HP AND IP -MAX 45AA 501 AND 502

CLOSED.
CONTROL OIL PRESSURE 6 TO 7 KSC.

SETTING OF THE GOVERNING RACK › › › › › › › › › OIL TEMPERATURE 50-55 DEG.C.

CONT...

ISOLATING VALVES BEFORE INDIVIDUAL EQUIPMENTS IN THE

RACK ARE OPEN.
LOAD SHED RELAY SOLENOID MAX 46 AA 011 DE- ENERGISED MAINN TRIP VALVE MAX 51 AA005 -006 OPENED. ATRS SUPPLY OFF CONTROL OIL PRESSURE START UP OIL PRESSURE AUX. START UP OIL PR. TRIP OIL PR. 6-7 KSC 5-6 KSC 5-6 KSC 5-6 KSC

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR
1 NOTE THE INITIAL READING WHEN START UP DEVICE IN FULLY CLOSED CONDITION. OPERATE STARTING DEVICES MAX 46BY001 GRADUALLY FROM MINIMUM TO MAXIMUM POSITION AND CHECK THE FOLLOWING:2. WHETHER STARTUP AND AUX. STARTUP OF OIL PRESSURE DROPS. 3. OPERATE STARTING DEVICE SLOWLY AND INCREASE THE AUX. SECONDARY PR. 2.3 KSC AND NOTE THE HP AND IP SECONDARY OIL PRESSURE. 4. WHEN THE STARTING DEVICE IS FULLY OPEN, NOTE THE STARTING DEVICE LIFT. THE LIFT SHOULD BE 24.5MM AND AUX. PRESSURE SHOULD BE 4.2 KG/CM2.

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
5. IF AUX. SECONDARY OIL PRESSURE NOT ACHIEVED, ADJUST THE AUX. FOLLOW PISTON KA08 TO OBTAIN AUX. SEC. PR. OF 4.2 KSC AND ABOVE, WHEN THE STARTING DEVICE IS FULLY OPENED. 6. NOTE THE HP /IP SEC. OIL PRESSURE CORRESPONDING TO 4.2 KSC OF AUX. SEC. OIL PRESSURE.

7. BRING BACK THE STARTING DEVICE GRADUALLY TO CLOSE
POSITION AND CHECK THE TRIP POINT OF AUX. SEC. OIL PRESSURE THE TRIP POINT SHOULD BE AROUND 2.1 KSC

APPROX. AT LEAST UNDER 2.3 KSC
8. BRING BACK STARTING DEVICE TO CLOSE POSITION. 9. FIX DIAL GAUGE BELOW THE BELLOW AND ADJUST TO ‘0’ MM.

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
28.PLOT THE CURVE FOR THE FOLLOWING
a) HP SEC. VERSUS HP CONTROL VALVE LIFT AND IP SEC., OIL PR. VERSUS IP CONTROL VALVE LIFT. 29.IF THE LEFT OF THE CONTROL VALVES ARE NOT COMING EQUAL ADJUST THE FULCRUM POINT OF LEVER 12 FEED BACK LINKAGE 30.OPEN THE TEST VALVES OF EACH STOP VALVE AND CHECK THEIR OPERATION 31.ENSURE LEFT OF HP STOP VALVE OF 92MM AND IP STOP VALVE OF 176MM

32.DE-ENERGIES SOLENOID VALVE MAX 42AA051 OF TRIMMING
DEVICE KA10 OF HYDRAULIC AMPLIFIER MAX 45BY011 33.BRING BACK THE STARTING DEVICE TO CLOSE POSITION

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
10.NOTE THE INITIAL READING OF POWER PISTON KA08 OF HC MAX 45BY 011BY DEPTH GAUGE 11.OPERATE STARTING DEVICE GRADUALLY TO OPEN TILL AUX. SEC. OIL PR. REACHES 2.3 KSC 12..AT 2.3 KSC OF AUX. SEC. OIL PR. CHECK HP SEC. OIL PR. IS 2.5 KSC 13.IF VALUE IS NOT ACHIEVED FOLLOW THE PISTONS KA01 OF MAX45 BY011OF HP SEC. OIL PR. 14.CHECK THE LIFT OF POWER PISTON OF HC IS AROUND 6-7MM WHEN HP SEC. IS 2.5 KSC. 15.IF NOT ACHIEVED ADJUST THE START UP OPENING OF PILOT VALVE K07 OF MAX 45BY 011

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
16.INCREASE AUX SEC. OIL PR. TO 2.5 KSC AND HP SEC. OIL PR. WILL BE 2.79 KSC AND IP SEC. 2.5 KSC. 17.IF THE IP SEC. OIL PR.2.5 KSC IS NOT ACHIEVED ADJUST THE FOLLOW PISTON TO ACHIEVE THE SAME 18.NOTE DOWN THE STARTING DEVICE TRAVEL, LIFT OF THE BELLOW, POWER PISTON LIFT OF HYD CON, AUX. SEC, HP SEC., & IP SEC. OIL PR. 19.INCREASE AUX SEC. OIL PR. 4.2 KSC AND CHECK WHETHER HP SEC. OIL PR. REACHES 5 KSC. 20.IF VALUE IS NOT ACHIEVED, ADJUST THE PROPORTIONALITY ADJUSTER KA09 OF MAX 45BY011TO GET HP SEC. OIL PR OF 5 KSC WHEN AUX. SEC. IS 4.2 KSC

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
21.CHECK BY CLOSING THE ISOLATING VALVES MAX 42 BT001 AND 002 OF SPEED CONTROL BACK AND NOTE THE PRESSURE AT WHICH THE TRIPPING DEVICE MAX 51AA006 AND 05 TRIP

SUDDENLY. IT SHOULD TRIP AT 3 KSC TRIP OIL PR. IF NOT
ACHIEVED ADJUST THE SPRING TENSION TO SET THE VALVE. 22.AFTER THE ABOVE CHECK CLOSE THE STARTING DEVICE TO

ZERO AND AGAIN CHECK AT OIL PR. 2.3 KSC OF AUX. SEC. THE
HP SEC. IS 2.5 KSC AND AT 2.5 KSC OF AUX. SEC., THE HP SEC. AND IP SEC. SHOULD BE 2.79 KSC AND 2.5 KSC RESPECTIVELY 23.INCREASE THE AUX. SEC. PR. INSTEPS OF 0.2 KSC AND NOTE DOWN THE HP AND IP SEC. OIL PR., POWER PISTON LIFT OF HC AND STARTING DEVICE TRAVEL. 24.CHECK THAT OPENING AND CLOSING RESERVE OF 3.5 MM IS

AVAILABLE IN HC POWER PISTON

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
25.CHECK THE BELLOW TRAVEL OF STARTING DEVICE BETWEEN AUX SEC.
OIL PR. OF 2.3 KSC AND BELLOW LEFT. 26.INCREASE THE AUX SEC. OIL PR. BY 0.2KSC AND NOTE DOWN THE FOLLOWING:a) HP SEC OIL PR, IP SEC. OIL PR., HP CONTROL VALVE LIFT AND IP CONTROL VALVE LIFT 27.ADJUST THE START OF HP CONTROL VALVE, TO OPEN JUST AT 2.3 KSC

AND IP CONTROL VALVE AT 2.5 KSC OF IP SEC OIL PRESSURE.
28.INCREASE TH AUX SEC. OIL PR. AND NOTE THE FOLLOWING UP TO THE MAX. POSITION OF STARTING DEVICE :a) HP SEC. OIL PRESSURE, b) IP SEC. OIL PR. c) HP CONTROL VALVE LIFT Id) CONTROL VALVE LIFT.

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
34.CHECK THE DIAL GAUGE BELOW THE BELLOW IS SETTLED
ZERO 35.NOTE THE INITIAL READING OF DEVICE 36.OPEN THE STARTING DEVICE GRADUALLY AND NOTE THE FOLLOWING :a) BELLOW LIFT, AUX SEC OIL , HP SEC, IP SEC, STARTING DEVICE TRAVEL 37.PLOT THE CURVE BETWEEN BELLOW TRAVEL AND AUX. SEC. BELOW TRAVEL AND HP SEC. BELLOW TRAVEL AND IP SEC. 38.ENERGIES THE TRIMMING DEVICE SOLENOID MAX 42AA051

PROCEDURE FOR SETTING OF HYDRAULIC GOVERNOR CONTD….
39.LOAD SHED RELAY MAX 46AA011 WILL GET ENERGIES WHEN EVER GENERATOR BREAKER OPENS. THE DURATION IS ONLY 2

SECOND.
40.DURING THE EXECUTION OF LOAD SHED RELAY CHECK WHETHER AUX. SEC. OIL PR. DROPS TO ZERO AND COMES BACK TO ORIGINAL VALUE. 41.SWITCH ON THE ATRS SUPPLY 42.CHECK THE MAIN TRIP VALVES, TRIPS IMMEDIATELY AND ALL THE STOP AND CONTROL VALVES GET CLOSED 43.SWITCH OFF THE ATRS SUPPLY.

SETTING OF ELECTRO HYDRAULIC CONVERTOR
1. NORMALIZE ISOLATING VALVES MAX 45AA501 AND 502 IN SEC. OIL LINES OF EHC WHICH WAS ISOLATED WHILE SETTING HYDRAULIC CONTROLLER VALVES.

2. KEEP THE STARTING DEVICE IN MAXIMUM POSITION
3. ENSURE THAT TRIP OIL LINE ISOLATING VALVES MAX51AA511 IS OPEN. 4. ENSURE ISOLATING VALVES MAX42AA611 IS KEPT OPEN 5. ENSURE PROVISION OF PRESSURE GAUGE UPTO 8 KG RANGE BEFORE EHC MAX45BY001 IN TRIP OIL LINE. PROCEDURE :-

1. CHECK WHETHER VOLTAGE IN THE MOVING COIL MAX 45CG001T
IS( -) 1VOLT 2. THE EQUILIBRIUM VOLTAGE IS BETWEEN (-)0.8 TO( -)1.2 VOLTS

SETTING OF ELECTRO HYDRAULIC CONVERTOR CONTD...
3. IF IT IS NOT, ADJUST THE MOVING COIL BY LOOSENING THE THREE LOCK SCREWS TO SUCH A POSITION WHERE THE VOLTAGE IS AROUND -1 VOLT

4. AFTER ADJUSTING THE ABOVE FEED ZERO VOLTS THROUGH
SET POINT AND NOTE THE POWER PISTON LEFT ( MINIMUM READING ) 5. FEED 10 VOLTS THROUGH SET POINT VOLTAGE AND NOTE THE POWER PISTON LIFT (MAX. READING ) 6. THE DIFFERENCE BETWEEN MAX AND MINIMUM LIFT SHOULD BE APPROX. 50MM

7. VARY THE CONTROLLER FROM MINIMUM TO MAXIMUM POSITION
AND NOTE THE OUTPUT OF COLLINS 1 & 2 IN THE MIN. AND MAX. POSITION.

SETTING OF ELECTRO HYDRAULIC CONVERTOR CONTD...
8. THE COLLINS 1 & 2 OUTPUT VOLTAGES SHOULD BE (-) 7.5 T0 (+) 7.5
VOLTS. ADJUST THE COILLNS TO GET THE IS VOLTAGE IF THIS IS NOT ACHIEVED. 9. INCREASE THE SET POINT VOLTAGE AND HOLD THE POWER PISTON LIFT ABOUT 6 TO 7 MM AS OBTAINED IN HC. 10.CHECK HP SEC. PR. AND ADJUST FOLLOW PISTON TO GET HP SEC. OIL PR. 2.5 KSC WHEN THE PISTON LIFT IS 6 TO 7 MM AS IN

HYDRAULIC SETTING. 11. INCREASE THE SET POINT VOLTAGE AND HOLD HP SEC. OIL PR. AT 2.79 KSC ADJUST FOLLOW PISTONS OF IP TO GET 2.5 KSC OF IP

SEC. OIL PR.
12.NOTE THE POWER PISTON LIFT OF EHC 13.INCREASE THE SET POINT VOLTAGE INSTEPS OF 1 VOLT AND NOTE DOWN THE COILLENS OUTPUT 1 & 2 AND POWER PISTON LIFT.

14.CHECK WHETHER THE HP SEC. AND IP SEC. OIL PR. ARE EQUAL TO THE HYDRAULIC GOVERNOR CHARACTERISTICS . 15.ENSURE BY PLOTTING THE CURVE THAT A CLOSING AND OPENING RESERVE OF 3 TO 5 MM IS AVAILABLE FOR POWER PISTON. 16. ENSURE THAT THE START OF OPENING OF HP AND IP CONTROL VALVES REMAINS AT 2.5 KSC OF HP AND IP SEC. OIL PR.. RESPECTIVELY AS SET EARLIER. 17.CHECK THE VALVES OPEN WITH RESPECT TO HP AND IP SEC. OIL PR. AS PER THE GOVERNOR CHARACTERSTICS FROM FULL CLOSE TO FULL OPEN POSITION. 18.PLOT THE CURVES a) SET POINT VOLTAGE VERSUS COLLINS 1 & 2;

SETTING OF ELECTRO HYDRAULIC CONVERTOR CONTD...

b)SET POINT VOLTAGE VERSUS HP AND IP SEC. OIL PR; c) HP AND IP
SEC. OIL PR. AND CONTROL VALVE LIFT, d) POWER PISTON LIFT VERSUS HP AND IP SEC. OIL PR. 19.AFTER DRAWING THE CHARACTERISTICS CURVE OF EHC AND IC

COMPARE THE SLOPE OF THE CURVES.

SETTING OF NRV’S OF CRH AND EXTRACTION LINES
EXTRACTION RELAY MAX51AA001 1. ENSURE THE DRAIN VALVES CLOSED IN THE TRIP OIL LINES ARE

2. OPEN THE ISOLATING VALVE MAX51AA527 TO TEST VALVE MAX
51AA047 TO EXTRACTION NRV’S IS OPENED AND THE UNDER TEST VALVES ARE ALSO OPENED 3. SOLENOID VALVE MAX51AA027 IS DE-ENERGISED. ISOLATING VALVES MAX45AA509 OF ACCUMULATOR MAX 45BB001 IN HP SEC. OIL LINE IS OPEN. 4. ENSURE PRESSURE GAUGE IS PROVIDED IN TRIP OIL LINE

AFTER EXTRACTION VALVE RELAY.
5. ADJUST THE PILOT VALVE SPRING TENSION KA01 AND 02 TO OPEN EXTRACTION VALVE A2+A3 AND A4+ A5 AT HP SEC. OIL PR. OF 2.8 KSC.

SETTING OF NRV’S OF CRH AND EXTRACTION LINES
CONTD..

6. INCREASE THE HP SEC. OIL PR. ABOVE 2.8 KSC AND CHECK BY ENERGISING THE SOLENOID MAX 51AA027 THAT BE EXTRACTION VALVE CLOSES.

7. DE-ENERGISE SOLENOID VALVE AND CHECK OPENING OF
EXTRACTION VALVES A2 A3 A4 AND A5 OPEN BACK 8. CLOSE THE TEST VALVE MAX 51AA047 CHECK THE NRV CLOSES 9. ENSURE THE OPENING OF THE TEST VALVE IS BACK. 10.ENSURE BY REDUCING THE HP SEC. OIL, ALL THE EXTRACTION NRV’S CLOSE DOWN AND NOTE THE HP SEC. OIL PRESSURE AT THAT POSITION.

11.THE NRV’S SHOULD NOT CLOSE BELOW TO 2.5 KSC OF HP SEC.
OIL PR.

SETTING OF NRV’S OF CRH AND EXTRACTION LINES CONTD...
CRHNRV’S 1. ENSURE DRAIN VALVE IN CONTROL OIL LINES ARE CLOSED. 2. ISOLATING VALVES MAX42AA621 IN CONTROL OIL LINE TO SLIDE VALVE MAX 42AA001 IS OPEN 3. ISOLATING VALVES MAX45AA566 IN SEC. OIL LINE IS KEPT OPEN 4. ADJUST SLIDE VALVE MAX 42AA001 SPRING TENSION TO OPEN

THE NRV AT 2.9 KSC HP SEC. OIL PR.
5. CHECK BY REDUCING THE PRESSURE OF HP SEC. BELLOW 2.9 KSC WHETHER NRV IS CLOSES FULLY.

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS
1. VALVES BEFORE FILTER MAX 42BT021AND 22 IS ALL THE DRAIN VALVE IN THE CONTROL OIL LINES OF WATER INJECTION VALVES ARE CLOSED. 2. ISOLATING VALVES MAX 42AA541+ 543, 542+544, 554+ 556, 553+ 555 IN CONTROL OIL LINE TO WATER INJECTION VALVE OPEN. 3. SIGNAL OIL INLET VALVE MAX53AA521 + 522 TO SLIDE VALVE MAX52AA081 + 082 OF LP BYPASS STOP VALVES OPEN 4. CONTROL OIL INLET VALVE MAX42AA521+523 TO SLIDE VALVE MAX 53 OF BOTH STOP VALVES OPEN 5. SIGNAL OIL INLET VALVE TO SLIDE VALVE MAX53AA086 + 087 OF LP BYPASS CONTROL VALVE OPEN. 6. CONTROL OIL INLET VALVE MAX42AA522 + 524 TO SLIDE VALVE MAX 53AA086 +87 OF LP BYPASS CONTROL VALVE OPEN. 7. ISOLATING VALVE BEFORE INDIVIDUAL EQUIPMENT IN THE RACK OPEN.

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
8. CONTROL OIL PRESSURE OF 6-7 KSC IS AVAILABLE 9. CONDENSATE WATER PRESSURE OF 10KSC IS AVAILABLE BY OPENING THE VALVE MAN 11 + 12 AA511IN THE LIMIT CONTROLLER. 10. VACUUM IS AVAILABLE TO THE LIMIT PRESSURE CONTROLLER VACUUM > 0.6 BAR ABS 11.ISOLATING VALVES MAN 01AA501 IN THE DOWN STREAMS REHEAT STEAM LINE TO LIMIT PRESSURE CONTROLLER OPEN 12.ISOLATING VALVE MAX 42 AA571 IN CONTROL OIL LINE TO EHC OPEN . 13.TEST GAUGES OF 0 TO 10 KSC FIXED IN SIGNAL OIL LINE OF WATER INJECTION OF LP BYPASS VALVES

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
14.OPERATE THE HAND WHEEL OF KA09 TO MOVE THE

DIFFERENTIAL AMPLIFIER PISTON KA08 OF CONVERTOR FOR ELECTRO HYDRAULIC GOVERNOR FOR INCREASING SIGNAL OIL PR. IN LP BYPASS AND WATER INJECTION LINES 15.MEASURE THE LIFT OF KA08 WHILE OPERATING THE HAND WHEEL KA09

16.STOP THE OPERATION OF KA09 WHEN THE LIFT AT KA08 OF
DIFFERENTIAL AMPLIFIER PISTON.IS ABOUT 3.2MM. 17. SIGNAL OIL PRESSURE IN WATER INJECTION LINE SHOULD BE

ABOUT 1.5 KSC
18.IF SIGNAL OIL PRESSURE IS NOT ACHIEVED ADJUST THE FOLLOW PISTON KA03 TO GET SIGNAL OIL PRESSURE OF

1.5KSC IN THE WATER INJECTION LINE

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
19.ADJUST THE SLIDE VALVES MAX53AA031 SPRING TENSION TO OPEN WATER INJECTION VALVE 1 & 3 EXACTLY AT 1.5 KSC OF SIGNAL OIL PRESSURE. 20.ENERGIZE SOLENOID MAX53AA051 TO ADMIT OIL IN THE SLIDE VALVE MAX53AA041.

21.CHECK WATER INJECTION VALVE 2 & 4 OPENED / CLOSE.
ADJUST SLIDE VALVE SPRING TENSION TO OPEN EXACTLY AT 1.5 KSC OF SIGNAL OIL PR. IN WATER INJECTION VALVE.

22.REDUCE KA08 OF DIFFERENTIAL AMPLIFIER PISTON TO ZERO
BY OPERATING HAND WHEEL INJECTION VALVES CLOSE. KA08 AND CHECK ALL WATER

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
23.OPERATE HAND WHEEL KA09 AND INCREASE SIGNAL OIL PR. TO 1.5 KSC AND ENSURE ALL 4 WATER INJECTION VALVE OPEN AT SAME TIME AND SET LIMIT SWITCHES FOR OPEN CONDITION
24.MOVE THE DIFFERENTIAL AMPLIFIER PISTON KA08 TO 7MM BY OPERATING HAND WHEEL KA09.

25.ENSURE THE SIGNAL OIL PR. IS 1.7 KSC, ADJUST THE FOLLOW
PISTON EQUALLY TO ACHIEVE THE PRESSURE IF NECESSARY. 26.MOVE THE DIFFERENTIAL AMPLIFIER PISTON KA08 TO A POSITION OF 12MM, 36.8MM AND MAX. BY OPERATING THE HAND WHEEL KA09 AND CHECK WHETHER SIGNAL OIL PR. IS 2.2 AND 4.7 KSC AND ABOUT 5 KSC IN THE LP BYPASS LINE

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
27.IF MAXIMUM SIGNAL OIL PR. OF 5KSC IS NOT ACHIEVED FOR MAXIMUM POSITION ADJUST THE PROPORTIONALITY. 28.BRING BACK THE PISTON KA08 OF DIFFERENTIAL AMPLIFIER PISTON TO ZERO POSITION AND CHECK THE SIGNAL OIL PR. IS ZERO AND THE STOP VALVES FULLY CLOSED, SET THE CLOSED LIMIT SWITCHES OF STOP VALVES.

29.INCREASE SIGNAL OIL PR. TO ACHIEVE 1.7 KSC BY ROTATING HAND
WHEEL KA09 AND CHECK OPENING OF LP BYPASS STOP VALVES FULLY. 30.ADJUST THE FOLLOW PISTON OF MAX53AA091 + 092 TO OPEN THE STOP VALVES EXACTLY AT 1.7 KSC SIGNAL OIL PR. AND SET OPEN LIMIT SWITCHES

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
31.ENSURE CONTROL VALVES ARE FULLY CLOSED AND ADJUST THE
LPBP CONTROL VALVE POSITION TRANSMITTER TO ZERO

POSITION.

32.MOVE THE AMPLIFIER PISTON KA08 IN THE SIGNAL OIL PR. IS 2.2
KSC AND ENSURE LPBP CV SERVOMOTOR JUST OPEN. ADJUST SLIDE VALVE MAX53AA086 AND +87 IF REQUIRED. 33.INCREASE DIFF. AMPLIFIER PISTON KA08 TO ACHIEVE SIGNAL OIL PR. OF 4.7 KSC AND CHECK THAT LPBP CV OPENS FULLY. IF NECESSARY ADJUST THE FOLLOW PISTON IN THE FEED BACK OIL LINE TO GET THE FULL OPENING. IF NECESSARY ADJUST THE PROPORTIONALITY . THE FULL LIFT SHOULD BE 80MM. 34.DE-ENERGIES THE SOLENOID OF TEM. PROTECTION AND CHECK WHETHER THE SIGNAL PR. IN THE LP BP LINE GOES TO 5 KSC.

SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC AND EHC OF LP BY PASS CONTD...
35.ACTUATE LOW VACUUM PROTECTION AND WATER PR. SWITCH PROTECTION ONE BY ONE

36.BRING BACK DIFF. AMP PISTON KA08 TO A POSITION WHERE SIGNAL OIL PR. IS 1.5 KSC IN THE WATER INJECTION LINE. NOTE DOWN THE SIGNAL OIL PR. IN LP BYPASS LINE OPERATE THE HAND WHEEL KA09 AND CHECK THE OPENING OF STOP VALVE AND CONTROL VALVE AT 1.7 AND 2.2 KSC RESPECTIVELY.

37.INCREASE THE SIGNAL OIL PR. INSTEPS OF 0.2 KSC AND NOTE
THE LPBPCV LIFTS 38.PLOT THE CHARACTERISTICS CURVE OF : a) STROKE OF CONTROL SLEEVE OF FOLLOW PISTON VERSUS SIGNAL OIL PR. IN WI SYSTEM. b) STROKE OF CONTROL SLEEVE OF FOLLOW PISTON VERSUS SIGNAL OIL PR. IN LPBP SYSTEM. c) SIGNAL OIL PR. VERSUS LPBPCV LIFT

SETTING OF LP BYPASS ELECTRO HYDRAULIC CONVERTOR
1. OPEN CONTROL OIL ISOLATING VALVES MAX 42AA571 TO EHC
OF LPBP 2. ENSURE HAND WHEEL KA09 OF CONVERTOR FOR ELECTRO

HYDRAULIC IN FULLY CLOSE CONDITION AND LOCK IT.
3. ENSURE PISTON KA08 IS IN UPPER MOST POSITION AND HERE IS CLEARANCE BETWEEN KA08 TOP TO HAND WHEEL LEVER OF

KA09.
4. FEED ZERO TO 10 VOLTS TO EHC IN STEPS OF ONE VOLT. AT 10 VOLTS THE DIFF. AMP PISTON KA08 TRAVELS 40 MM APPROX.

AND POSITION CONTROLLER INDICATED 100% .
5. FEED ZERO VOLTS AND BRING DIFF. AMPLIFIER PISTON KA08 TO MIN. POSITION

6. FEED VOLTAGE GRADUALLY TO EHC AND NOTE DOWN THE
FOLLOWING

SETTING OF LP BYPASS ELECTRO HYDRAULIC CONVERTOR CONTD..

a) VOLTAGE AT WHICH WI VALVES OPEN AND CORRESPONDING SIGNAL OIL PRESSURE IN THE WI LINE IN ONE KSC . THE VOLTAGE WILL BE ABOUT 2 VOLTS b) VOLTAGE AT WHICH STOP VALVES OPEN IT SHOULD BE APPR. 2.5 VOLTS AND SIGNAL OIL PR. 1.7 KSC IN THE LP BYPASS LINE c) VOLTAGE AT WHICH LPBP CV STARTS OPEN IT SHOULD BE ABOUT APPRX. 3.5 VOLTS AND SIGNAL OIL PR. OF 2.2 KSC d) VOLTAGE AT WHICH LPBP CV OPEN FULLY IT WOULD BE 7.5 VOLTSB APPRX. AND SIGNAL OIL PR. WILL BE 4.7 KSC. 7. PLOT THE FOLLOWING CURVES : a) b) c) d) EHC VOLTAGE VERSUS SIGNAL OIL PR. IN WI LINE EHC VOLTAGE VERSUS SIGNAL OIL PR. IN LPBP LINE EHC VOLTAGE VERSUS DIFF. AMPLIFIER PISTON LIFT EHC VOLTAGE VERSES CV LIFT

DRAWING/DOCUMENT REF.

GOVERNING CHARACTERISTICS
HYDRAULIC GOVERNING GOVERNOR BELLOW STROKE vs AUXILIARY SECONDARY OIL PRESSURE Control Oil Pressure = Trip Oil Pressure = 6.8 5.5 kg/cm² kg/cm²

Governor Bellow Stroke (mm) Design 0.00 0.57 1.00 1.18 1.30 1.60 2.00 2.15 2.50 3.20 3.90 4.50 5.00 Actual 0.00 0.57 1.00 1.18 1.30 1.60 2.00 2.15 2.50 3.20 3.90 4.50 5.00

Auxiliary secondary Oil Pressure (kg/cm²) Design 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 Actual 2.30 2.50 2.70 2.80 2.85 2.95 3.10 3.15 3.30 3.55 3.80 4.05 4.25

Design reference : BHEL Drawing No. 1-11400-01004 (Rev 01)

DATE OF INSPECTION DRAWING/DOCUMENT REF.

OVERHAUL IN SEPTEMBER - OCTOBER, 2002

GOVERNING CHARACTERISTICS
A) GOVERNING OIL CHARACTERISTICS AOP Discharge Pressure Control Oil Pressure Trip Oil Pressure Aux. Sec. Oil Pressure (kg/cm²) Design 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 Actual 2.30 2.50 2.70 2.75 2.80 2.90 3.05 3.10 3.25 3.50 3.80 4.00 4.20 = = = 7.0 6.8 5.5 kg/cm² kg/cm² kg/cm² IP Sec. Oil Pressure (kg/cm²) Design 2.50 3.18 3.47 3.66 4.12 4.76 5.00 Actual 2.50 3.25 3.50 3.70 4.00 4.80 5.00

HP Sec. Oil Pressure (kg/cm²) Design 2.50 2.79 3.00 3.09 3.15 3.30 3.50 3.57 3.75 4.10 4.45 4.75 5.00 Actual 2.45 2.75 3.05 3.15 3.20 3.30 3.55 3.65 3.85 4.20 4.60 4.85 5.00

Design reference : BHEL Drawing No. 1-11400-01004 (Rev 01) B) At Auxiliary Secondary Oil Pressure Start Up Oil Pressure Auxiliary Start Up Oil Pressure At Turbine Speed Primary Oil Pressure = = = = = 0.00 6.00 4.20 3000 kg/cm² kg/cm² kg/cm² rpm kg/cm²

C)

DATE OF INSPECTION DRAWING/DOCUMENT REF.

OVERHAUL IN SEPTEMBER - OCTOBER, 2002

GOVERNING CHARACTERISTICS
HYDRAULIC GOVERNING AUXILIARY SECONDARY OIL PRESSURE vs VALVE STROKE Control Oil Pressure Trip Oil Pressure = = 6.8 5.5 kg/cm² kg/cm²

Aux. Sec. Oil Pressure (kg/cm2) 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 4.30

Design HPCV 0.0 2.5 4.5 5.0 5.5 7.0 8.8 9.5 11.8 16.4 25.5 38.8 50.0 IPCV 0.0 0.0 6.8 10.5 16.0 30.0 75.0 95.0 HPCV - 1 0.0 0.5 3.0 3.5 4.0 5.5 6.5 8.5 10.5 15.5 31.0 36.0 43.5 49.0

Actual HPCV - 2 0.0 0.5 3.0 4.0 4.5 5.5 7.0 8.5 11.0 15.0 32.0 37.0 45.0 50.0 IPCV - 1 0.0 0.0 7.0 14.0 17.5 28.5 67.0 95.0 IPCV - 2 0.0 0.0 7.0 11.0 15.0 23.0 53.0 93.5

DATE OF INSPECTION DRAWING/DOCUMENT REF.

OVERHAUL IN SEPTEMBER-OCTOBER, 2002

GOVERNING CHARACTERISTICS
LP BYPASS GOVERNING CHARACTERISTICS Control Oil Pressure A) = 6.8 kg/cm²

Uppermost Position of Limit Controller Piston W.I.Valve Signal Oil Pressure (kg/ cm²) Design 1.50 2.34 3.44 Actual 1.50 2.30 3.20 LPBP Valve Signal Oil Pressure (kg/ cm²) Design 1.32 1.70 2.20 Actual 1.35 1.70 2.20 WI Valves open LPBP Stop Valve Starts Opening LPBP Control Valve Starts Opening Remarks

Power Piston Lift in mm Design 0.80 (3.20) 1.75 (7.00) 3.00 (12.00) Actual 3.2 7.0 12.0

B)

Lowermost Position of Limit Controller Piston W.I.Valve Signal Oil Pressure (kg/ cm²) Design 1.50 > 8.00 Actual 1.5 > 6.00 LPBP Valve Signal Oil Pressure (kg/ cm²) Design 1.56 Actual 0.60 1.60 WI Valves open Remarks

Power Piston Lift in mm Design 0.80 (3.20) 10.00 (40.00) Actual 3.2 40.0

Design reference : BHEL Drawing No. 3-12300-01003 C (Rev 01)

DRAWING/DOCUMENT REF.

GOVERNING CHARACTERISTICS
LP BYPASS VALVE TRAVEL vs SIGNAL OIL PRESSURE Control Oil Pressure = 6.8 kg/cm²

LPBP Valve No. 1 Signal Oil Pressure 2.3 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 CV Opening 0 3.5 14 22 30 38 48 57 65 72 79 3.3 Feedback Pressure 0.9 Signal Oil Pressure 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2

LPBP Valve No. 2 CV Opening 0 6 15 22 30 36 44 51 57 64 70 3.2 Feedback Pressure 0.8

EHC CHARACTERISTICS
Trip Oil Pressure AOP Discharge Pressure Aux. Sec. Oil Pressure = = = kg/cm² kg/cm² kg/cm²

Coil Volts 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

HP Sec oil press design 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75 5.00 actual 2.25 2.75 3.04 3.25 3.70 3.80 4.10 4.30 4.60 4.80 5.00

IP sec oil press design 0.60 2.50 3.20 4.00 4.75 5.00 5.00 5.00 5.00 5.00 5.00 actual 1.60 2.50 3.15 3.95 4.60 5.15 5.50 5.90 5.90 5.90 5.90

HPCV design 0.0 2.5 4.0 6.0 8.0 11.0 14.0 18.0 27.0 38.0 50.0

IPCV design 0.0 0.0 6.0 25.0 75.0 94.0 94.0 94.0 94.0 94.0 94.0

HPCV actual 1 0.0 1.5 4.5 7.0 11.0 14.5 19.0 29.5 40.0 48.5 50.0 2 0.0 1.5 4.0 6.5 9.5 13.0 16.5 26.5 37.5 46.0 50.0

IPCV actual 1 0.0 0.5 11.5 33.0 85.0 95.0 2 0.0 0.0 9.5 29.0 76.0 93.5

GOVERNING CHARACTERISTICS
AUXILIARY SECONDARY OIL PRESSURE vs POWER PISTON LIFT Total Lift of Power Piston = 44.5 mm

Aux. Sec. Oil Pressure (kg/cm2) 2.0 2.3 2.5 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.3

Power Piston Lift in mm 0.8 8.1 12.1 14.5 18.0 22.3 27.1 31.3 34.8 40.7 44.5 48.2 49.5

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