HP - LP

BYPASS
T. V. V. SIVA RAMA KUMAR
DEE /SIMULATOR/TRG.INST
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 Deaerator through a series of Low pressure
heaters. The feed water from the Deaerator 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.
 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.
 OIL SUPPLY UNIT
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.

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.
 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/Cm2.
Pump motor OFF------- Pressure set 140 Kg/Cm2.
Pressure TOO LOW---Pressure set 90 Kg/Cm2.
(HP BP Control failure annunciation flash in UCB ).
Pressure TOO HIGH—Pressure set 150 Kg/Cm2.
(HP BP Control failure annunciation flash in UCB).
1. OIL SUPPLY UNIT 2.SERVO VALVE 3.BLOCKING UNIT 4.HYD. SERVO MOTOR
5.FEED BACK TRANSMITTER 6.CONTROL VALVE 7.CONTROL UNIT
8.OTHER POSSIBLE CONNECTIONS
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.
PRESSURE CONTROL LOOP :
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 ).

Advantages of HP/LP Bypass system
enable house load operation of the machine.
achieve quick start - up and faster loading.
reduce start - up and shut - down losses.
minimize loss of DM water.
enable quicker warming up of steam lines.
minimize operation of safety valves.
improve boiler stability under transient
conditions.
enable boiler to be kept in operation after
a load rejection.
enable the independent operation of boiler
and turbine.
maintain the steam flow through the
re-heater and boiler.
Check before charging HP-LP Bypass :
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 unit’s oil level is normal, its
pump is running & oil pressure is adequate.
HP Bypass down stream temperature set
point is at 200˚ C .
HP Bypass valves(BP1&BP2) start opening if
M.S Pressure is more than set point.
Transfer LP Bypass control to auto and switch
on the automatic control interface device.
T. V. V. SIVA RAMA KUMAR
DEE /SIMULATOR/ TRG.INST
Dr.NTTPS