Hp by Pass System-modified

8/18/2019 Hp by Pass System-modified

1/21

Station: NTPC –

RAMAGU

NDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A

NTPC Ref No. : C!S-C!MM-R-Co""#.-PR!$01%

S&eet 1 of 1%

P'ant A(ea: B!)LER

Te*tin# S+&e,'e: HP BPASS SSTEM

SL. N!.

1.

2.

/.

%.

5.

.

.

.

.

10.

L)ST !3 C!NTENTS

PLANT DETA)LS

!B4ECT)ES

PR!P!SALS

SER)CES RE6U)RED

SA3ET PRECAUT)!NS

EMERGENC PR!CEDURES

STATE !3 THE PLANT

METH!D

C!MPLET)!N CR)TER)A

APPEND)CES

a7 DRA8)NG

Si#nat(e*

NTPC BHEL


2/21

Station: NTPC –

RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 2 of 1%

P'ant A(ea: B!)LER

Te*tin# S+&e,'e: : HP BPASS SSTEM

1.0 PLANT DETA)LS STATUS

HP BP System work in conjunction with LP BP System as and when

necessitated by the system requirements such warming up stage or

dumping a large quantity of steam following a heavy load rejection.

urbine ! "enerator trip.

#.# HP BP System basically consists of the following items. $%efer to theenclosed drawings&.

♦ 'il Supply (nit $with motor and pump&.

♦ )ccumulator

♦ *uick opening device

♦ +onnection manifold

♦ Blocking element

♦ Servo valve

♦ hrottle valve

♦ ,solating ball valve

♦ Hp -ilter

♦ Spray +ontrol valve

♦ By pass control valve

♦ ,solation alve

♦ Break down orifice

♦ 'ther piping accessories.

#./ he System is provided with series of pressure switches for automatic

on!off of motor and for annunciation.

Si#nat(e

NTPC BHEL


3/21

Station: NTPC –

RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet / of 1%

P'ant A(ea: B!)LER


#.0 he oil supply unit and the By pass and spray valves are connected

through pipe lines and hose pipes.

#.1 HP BP System is an important item of the Power Plant and it requires

e2treme precaution in commissioning the system as given in Section 3.4

$%efer to '56 6anual for echnical Specification of HP BP System.&

2.0 !B4ECT)E

he objective of this esting Schedule is to commission the HP BP

System and make it available for (nit 'peration.

/.0 PR!P!SAL

+ommissioning of HP BP System is proposed to be carried out through

following proposals.

0.# )cid +leaning of Pipe lines. $"enerally7 pipe lines are not subjected to

acid cleaning. By visual inspection7 if the internal surface of the pipe

lines are rusted heavily and pitted7 then the pipe lines are subjected to

acid cleaning.&

0./

0.0

0.1

+ommissioning of the HP BP System oil supply units $minus BP and

Spray alves& and setting up of pressure switches.

'il -lushing of the HP BP System as per following stages

Stage , 88 Pressure line $P& and %eturn line $&

Stage ,, 88 Pressure line $P& and Leakage line $L&

Stage ,,, 88 Lines of *uick 'pening 9evice

+ommissioning of HPBP System

Si#nat(e

NTPC BHEL


4/21

Station: NTPC –

RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet % of 1%

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STATUS

%.0 SER)CES RE6U)RED

1.# )vailability of L.. Power Supply.

1./ )vailability of lighting7 communication and clear access in the test area.

1.0 )vailability of recommended oil $ S:%'. +';)L 1

1.>.#

1.>./

1.>.0

1.>.1

1.>.=

)vailability of chemicals for acid cleaning.

88 H+L

88 %odine

88 Sodium ;itrate

88 Liquor )mmonia

88 Lime Powder

;ote? *uantities of above chemical to be worked out at site.

5.0 SA3ET PRECAUT)!NS


5/21

=.#

=./

=.0

=.1

=.=

)vailability of -irst aid bo2 containing dilute ammonium hydro2ide7

=4@ sodium bicarbonate solution7 :ye lotion7 Bandage7 incture

,odine7 +otton7 Burnol etc should be ensured.

)vailability of suitable type portable fire e2tinguishers should be

ensured.

)vailability of following should be ensured?

"um boots 8 0 Pairs

%ubber "loves 8 = Pairs

)pron 8 0 ;os.

ransparent -ace 6ask 8 0 ;os.

)vailability of running service water near the activity area is ensured.

Suitable and safe place for draining and neutraliAation of used chemicals

should be kept identified.


6/21

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAGUNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


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7/21


.0 EMERGENC PRECAUT)!NS STATUS

./ )ctuators of BP and Spray alves and : 1=s are serviced $if

necessary& and fitted back in position.

>.0 )ll joints are properly tightened and pipe line clamped with proper

supports.

>.1 'il tank of 'S( thoroughly cleaned and ready for oil filling.

>.= )ll the local ,!c inputs and remote ,!c inputs7 control panel and

console insert and the required control and power cabling completed

and ready of charging.

.0 METH!D

.1 A+i, C'eanin# in 9i9e 'ine*

3.#.#

3.#./

3.#.0

3.#.1

he disassembled pipeline pieces are filled with 96 water and flushed

few times. )lso ensure that there is no leakage through the wooden plug

provided at one end of the pipe.

=@ Hydrochloric acid with 4./@ inhibitor $%odine /#0 spl& is filled in

the pipes. :fficiency test of the inhibitor is to be done prior to its use as

per ;)+: procedure.

he solution is allowed to soak in the pipes for 1 $four& hours and then

drained in a safe place and neutraliAed. his is then disposed off with

plenty of service water.

he pipes are flushed with 96 water for =8#4 minutes.

he pipes are again filled with / @ sodium nitrite and =.4 @ liquor


8/21

3.#.=

3.#.<

3.#.>

ammonia solution. he solution is allowed to soak for 04 minutes.

)nd then drained.

he pipe is rinsed ! flushed with 96 water till pH is >.=

$appro2imately&.

he internal surface of pipes is dried with dry compressed air.

he lines are filled with lube oil and uniform oil film is achieved

through out the internal surface of the pipes.

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAG

UNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet of 1%

P'ant A(ea: B!)LER


STATUS

.2 Co""i**ionin# of HP BP S*te"; !i' S99' Unit*.

3./.# -illing the oil tank with hydraulic fluid.

3./.#.#

3./.#./

:nsure that the entire system is clean and also connections are tight.

-ill the tank upto the level 6a2C $on the dip stick& with

recommended "rade of oil $-ig. /& through 0 micron filter. PresentlyServo +onval81< of ,'+ used or as per the recommendation given in

the '56 manual.

3././ +heck the ,% value using =44 megger for power cables and for

motor of 'S( is :nsure the healthiness and record the value.

3./.0 :2tend power supply to both incomers of the control panel up to the

breakers and check the correctness. +heck the voltage in the respective

B and also ensure proper polarity.

3./.1 :2tend supply to +P by switching ';C the incomer breakers.

:nergise the +P by switching '; the power supply modules one by


9/21

one and check the correctness.

3./.= ,solate all the outgoing leads and charge each rack by switch on the

respective breakers and check all the out going voltages are as per the

requirement.

3./.< :nsure availability of all cards and are placed in respective position.

3./.> (sing test kit7 calibrate the cards and set the valves as per the

recommendation wherever possible $)nne2 B&

3./.3 ,solate the power supply to 'S(86otors. :nergise the 6odule for

+ontrol and 6onitoring of 'S( and check power contactor packing

and also drops when local stop PB pressed.

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 2 of 1%

P'ant A(ea: B!)LER


STATUS

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAG

UNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet of 1%

P'ant A(ea: B!)LER


10/21


3./.D :nsure the readiness of 'S(7 switch on the motor and check whether

the oil pressure is developed as per the requirement by keeping thecock valve of EPF line closed. ,f pressure is not developing7 slowly

open the drain screw provided on the manifold and on seeing the

pressure building up close the drain screw.

3./.#4 Geep the ball8valve of pressure line $P& in closed condition and

pressurise the accumulator appro2. /4 bar above the stamped gas

filling pressure. Switch off the pump motor. %educe the pressure

from the accumulator via the drain screw in the supply manifold .

he oil pressure drop to Aero as soon as the gas pressure reached.

"as pressure $;/& can be checked with ;/ charging device7 which is

supplied along with the system.

3./.## +harging with accumulator with ;itrogen

-i2 the special charging device and verify the gas pressure in the

)ccumulator bladder. ,f the pressure is less than the recommended

value7 i.e. 34 kg ! sq.cm.7 recharge the bladder using commercial

quality ;itrogen storage bottle at high pressure.

3./.#/ +heck the tripping pressure of safety relief valve

he tripping pressure of the safety relief valve is set at higher pressure than that of Switch off pressureC for oil pump and also the

Pressure too highC alarm. he set pressure can be rechecked as

follows?

3./.#/.#

3./.#/./

3./.#/.0

3./.#/.1

88 +lose the ball valve in pressure line $P& in 'S(.

88 +heck the oil level in tank and lower the level to /4 cm below the

maintenance opening in the tank.

88 %emove the cover of the maintenance opening

88 Bridge the micro switch for Pump motor offC

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAGUNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet of 1%

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11/21


3./.#/.=

3./.#/.<

3./.#/.>

88 Start the oil pump and switch off as soon as relief valve trips. ;otethe tripping pressure. )djust the tripping pressure if necessary by

adjusting the set screw on the valve.

88 %epeat the checking until the tripping pressure is correct. he

tripping pressure of safety relief valve should be set at #34 kg !

sq.cm.

88 Set the tripping pressure of the second 'S( also as described

above.

3./.#0 +heck the accumulator operating pressure

he accumulator operating pressure is set with four pressure switches

provided in the bo2 . he pressure at any instant can be read

provided on the manifold from the manometer which is provided

before the pressure reducing valve in the manifold. he set pressure

of the individual micro switches should be checked and resetting is to

be done if necessary by adjusting the screws. urning the set screw in

clockwise results in a lower value. he purpose of each micro switch

setting is as follows?

Switch ;o. #? Pump motor offC. he ma2. operating pressure in

accumulator at which the pump motor is switched off $i.e.&

#4 kg ! sq.cm. and also used to stop

the pump in case of failure of switch ;o. #.

)fter the setting7 the individual setting must be rechecked for its

correctness.

Si#nat(e

NTPC BHEL


12/21

Station: NTPC –

RAMAG

UNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet of 1%

P'ant A(ea: B!)LER

Te*tin# S+&e,'e : HP BPASS SSTEM

3. 0

3.0.#

'il -lushing

he oil flushing operation is to be carried out to clean the complete

system of pipe work. -or the normal operating system7 the flushing is

to be done in two stages. -irst stage includes the pressure line $P& and

the return line $& and second stage includes pressure line $P& and the

leakage line $L&.

./.2 Sta#e ) 3'*&in#

3.0./.#

3.0././

3.0./.0

3.0./.1

3.0./.=

+onnect the pressure line $P& and the return line $& with high

pressure hose at actuator $-ig. 0& for all valves.

%emove the 0 micron -ilter in EPF lines near all the actuators

he filtering elements for suction strainer in 'S(7 air filter and the

pressure filter must remain in place.

,nstall the flushing filter in return line between supply manifold

and the ball cock

,nstall /= micron filter element into the flushing filter.

3.0./.<

3.0./.>

Geep open all ball cocks in EPF and EF lines near the actuators and

EF line near 'S(.

Start the oil pump. hen the pressure in accumulator reached the

motor offC limit the ball valve is opened $while charging the linefor the first time the valve is to be opened slowly and watched

for any oil leakage& and then closed when the pressure reduced

to Pump motor onC limit.

Si#nat(e

NTPC BHEL


13/21

Station: NTPC –

RAMAGU

NDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 10 of 1%

P'ant A(ea: B!)LER


STATUS

3.0.0 his process of flushing is to be continued for not less than 04

minutes per loop or till such time no dirt or iron filling is observed in

the bowl of flushing filter. ,f observed7 the filter and the bowl should

be cleaned with petrol and the filter is blown with instrument air and

flushing should be continued till the filter and the bowl is clean.

3.0.1 ,f more than one 'S( feed the same system we can install flushingfilter in the return line of each unit. his will enable us to use the

'S( alternatively for flushing purpose.

3.0.= %emove the /= micron filter element and install 0 micron filter

element in flushing filter. +ontinue the flushing operation as

described above for minimum 04 minutes per loop or till such time

no dirt or iron filling is observed in the howl of flushing filter. ,f

observed7 cleaning of the flushing bowl and filter as e2plained in the

case of /= micron flushing should be repeated till such time the oil

in the flushing bowl is clean.

./. Sta#e )) 3'*&in#

3.0.


14/21

Station: NTPC –

RAMAGU

NDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 11 of 1%

P'ant A(ea: B!)LER


./.

3.0.>.#

3.0.>./

3.0.>.0

3.0.>.1

3.0.>.=

3.0.>.<

3.0.>.>

3.0.>.3

!i' f'*&in# fo( 'ine* of i+e ?SSB nit7

+lose the isolating ball valves in the pressure and return line near

'S(.

)dditional accumulator connection block $S)B& should be

isolated from the flushing circuit.

%emove the filter elements fitted in pressure line before the

additional accumulators.

,nstall the flushing device in oil return line of SSB unit near 'S(.

+onnect the supply line and return line as shown in -ig. = 5 <

respectively using suitable fittings7 hoses7 etc.

+arry out the flushing operation as described in 3.0./. he

isolating valve in pressure line to additional accumulator near

'S( is to be used to carry out flushing operation.

)fter completing the flushing7 connect the oil line as shown in

-ig. #4 for flushing the additional accumulator drain line to tank.

+arry out the flushing as per the procedure in 3.0

%emove the flushing device and restore the oil pipe line

connections after declaring the completion of flushing operation

to carry out flushing operation.

Si#nat(e

NTPC BHEL


15/21

Station: NTPC –

RAMAGU

NDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 12 of 1%

P'ant A(ea: B!)LER


./.

3.0.3.#

3.0.3./

3.0.3.1

3.0.3.=

3.0.3.<

.%

3.1.#

3.1./

3.1.0

3.1.1

3.1.=

Re*to(ation

%emove the flushing filter unit from the oil supply unit $'S(&.

%estore all piping connection in the original condition.

,nstall 0 micron filter elements.

%emove the pressure filter in both the pump discharge lines and clean

them7 remove the dirty oil remaining in the filter bowl. Put the filter

back in position and put back the cover of these filters.

he oil in the tanks should be drained and the man hole cover of the

tanks should be opened. he suction filter in both the oil tanks are to be

removed and cleaned. he tanks should be cleaned and visually

inspected for its cleaniness. he suction filter and the man holes covers

are put back in position and properly tightened . Both the oil tanks are

to be filled with clean S:%' +';)L 1< oil to the ma2 level and

keep open the isolating valve in the interconnection line. he drum of

Servo +onval 1< shall be kept vertical for allowing any setteliment to

settle for a certain period$at least a week& before oil flushing in to the

tank.

C!MM)SS)!N)NG

+heck the operation of bypass valves $BP&7 emperature control valves

$BP:& and the ,solation valve :1= S from control desk $(+B&.

)djust the stroke locally for full open!close $1 to /4 m)&.

+alibrate the position feedback transmitters $BP& bypass valves as wellas $BP:& temperature control valves

Set for valve opening time of BP 5 BP: valves at #4 seconds for full

open by adjusting the throttle valve located in EF line near the actuator

of each valve.

+harge the oil in fast opening system. +heck the operation of BP valves

from (+B8+ontrol desk -ast openC push button.

Si#nat(eNTPC BHEL


16/21

Station: NTPC –

RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


S&eet 1/ of 1%

P'ant A(ea: B!)LER


+heck the timing for full open when the -ast 'penC PB actuated.

Set 0 seconds for full open by adjusting the throttle valve in the fast

opening device.

3.1.< :nsure calibration of pressure and temperature transmitters. :2tend

supply and adjust for Aero of the span .

3.1.> +heck for the availability and proper termination of cable for fastopening criteria like $,& "+B open $ii& urbine load shedding relay

operating $iii& urbine trip $iv& Pressure deviation too high7 etc. and

also for closing criteria like condenser vacuum low7 etc.

3.1.3 +heck the over rides and interlocks for the following important

functions.

.%. 3!R BP ALES

3.1.D.#

3.1.D./

3.1.D.0

3.1.D.1

3.1.D.=

3.1.D.<

.%.10

- BP closing over ride

-B9 closing over ride

- B9 opening interlock

- BP: auto interlock

- -ast opening

- Protection over ride.

3!R BPE ALES

3.1.#4.#

3.1.#4./

3.1.#4.0

-)uto interlock

- 'pening signal

- +losing interlock

Geep the HP bypass system on )uto operation when the unit is in

service and check adjust the autoloops for $,& pressure master

controller $ii& temperature controller and $iii& fast opening system?


17/21

Si#nat(e

NTPC BHEL

Station: NTPC –

RAMAGUNDAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A


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D.4 C!MPLET)!N CR)TER)A

+ommissioning of HPBP system completed by carrying out the

proposals successfully and acceptable manner as mentioned in section0.4.


18/21

Si#nat(e

NTPC BHEL

Station: NTPC –RAMAGUN

DAM

BHEL Ref No. : PS - DC - 202 – 500 – 001A NTPC Ref No. : C!S-C!MM-R-Co""#.-PR!$01% S&eet 2 of 1%

P'ant A(ea: B!)LER


1.0

#.#

#./

STATUS

Si#nat(e

NTPC BHEL


19/21

HP BPASS SSTEM

PROJECT M/S RAMAGUNDAM, UNIT- 7, 500 MW

PROCEDURE HP BY PASS SYSTEM

PURPOSE OF

DOCUMETFOR EXECUTION / INFORMATION

DOCUMENT PS:TSX:178:00:0


20/21

Copy No:

Issued to :

00 KJ MKS KB 08.09.2003

Rev.No. Prepared by Revieed by !pproved by "ate

B#!R!$ #%!&' %(%C$RIC!(S (IMI$%"PSSR)$%C#NIC!( S%R&IC%S

*+*, !--a Saai, Na-da-a/,C&ennai – 00 0/5.

!)L P)P)NG 3!R HP B PASS

SSTEM ?TP)CAL7

RAMAGUNDAM UN)T- 500M8




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