HP - LP BYPASS AND

APRDS SYSTEM
HP BYPASS SYSTEM
LP BYPASS SYSTEM
AUXILIARY PRDS SYSTEM
INTRODUCTION
The HP bypass system in co-ordination with LP
bypass system enables boiler operation and
loading independent of turbine.
This allows quick raising of steam parameters to
a level acceptable to turbine for rolling during
start-up.
Steam is bypassed from the main steam line to
CRH line through HP bypass and from the Hot
Reheat line to Condenser through LP bypass.
The HP bypass valve can handle a maximum of
60% of the full load turbine steam flow (i.e. 408
tph steam flow).
SINGLE LINE SCHEMATIC
LP TURBINE IP TURBINE HP TURBINE
HP BYPASS
LP BYPASS
CRH to
BOILER
HRH from
BOILER
TO CONDENSER
MAIN STEAM from BOILER
HP BYPASS
The possible phases of operation of HP bypass
station can broadly be classified as follows :-
Boiler start up with T.G. set at standstill.
Raising of steam parameters to a level
acceptable for TG rolling at a relatively faster
rate than otherwise is possible.
Turbine loading while steam flow gets
transferred to the turbine.
Parallel operation with turbine on load rejection.
Allowing boiler operation following turbine trip-
out provided boiler load is less than 60%.
Preventing safety valve opening at raised steam
pressure.
SYSTEM DESCRIPTION
The HP bypass system consists of two parallel
branches that divert steam flow from MS line to
CRH line. The steam pressure on the valve
upstream side can be maintained at the desired
level. The steam is de-superheated in order to
keep the steam temp. in CRH line within limits,
below 325 degC.
The MS pressure ahead of turbine is maintained
by two nos. of pressure reducing valves BP1 &
BP2 with valve mounted electro-hydraulic
actuator.
SYSTEM DESCRIPTION Contd..
The steam temperature downstream of the HP
bypass station is maintained by two nos. of
spray water temp. control valves BPE1 & BPE2
They have valve mounted electro-hydraulic
actuators.
The spray water is available from the BFP
discharge line.
There is also one spray water pressure control
valve (BD) with valve mounted electro-hydraulic
actuator.

CONSTRUCTION - HPBP
HP Bypass station consists of the following
element per unit :-
Two combined pressure reducing and
desuperheating valves (BP1 & BP2) complete
with valve mounted electro-hydraulic actuators.
Each valve has been sized to pass 204 TPH of
steam at inlet condition of 150 kg/cm2 & 5370C.
Two breakdown orifices (OP4 & OP5).
One spray water isolating valve (BD1) complete
with valve mounted electro-hydraulic actuator.
Two spray water control valves (BPE1 & BPE2)
with valve mounted electro-hydraulic actuators
for temperature control.
Two oil supply systems
OIL SUPPLY UNIT
The oil supply unit provides the hydraulic actuation
energy for the complete actuation system.
An electric motor driven 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 supplies the system with
pressurized oil and covers all the peak supply
requirement.
OIL SUPPLY UNIT Contd..
The oil pump 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 is set and controlled.

OIL SUPPLY UNIT Contd..
The pressure switch monitors the oil pressure in the
accumulator and provides the signals to switch on 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.
Four micro switches (pressure switches) are mounted on
the OSU :-
Pump motor ON
Pump motor OFF
Pressure too low
Pressure too high

SERVO VALVE
Servo valve ST is the part of the SULZER electro
hydraulic actuator system. It converts the electrical
signals of the control electronics into hydraulic signals
and uses these to control the actuator.
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 operate the pilot stage (1st 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.
SERVO VALVE
Servo valve ST is produced for three flow ratings :-
ST10-4 & ST10-05 for low flow rates
ST10-63 & ST10-65 for medium flow rates
ST20 & ST20-200 for high flow rate

BLOCKING UNIT
The electro hydraulically pilot operated blocking unit is
mounted between the servo valve and the actuator. It
closes off both ports to the actuator if electrically de-
energized or with insufficient oil pressure, and holds the
piston of the actuator in its last position. A mechanical
override on the blocking unit permits also local manual
de-blocking.
Blocking Unit BL .2 is produced in two versions :-
BL10-2 for low flow rates
BL20-2 for high flow rates
PRESSURE & TEMP. CONTROL
The operation of HP bypass station is manipulated by
the pressure and temperature set points and is
independent of LP bypass operation.
The control system is designed to maintain the steam
pressure ahead of bypass valve to the given set value.
The steam temperature at downstream of the valve is
automatically controlled to the given set value.
The pressure set point and temperature set point can be
adjusted from remote manually.
Pressure control
The pressure signal is sensed from the main steam line
by pressure transmitters
Depending upon the initial pressure condition at the time
of boiler firing, the pressure set point is to be adjusted to
a value equal to steam pressure ahead of bypass valve
plus a negative bias pressure.
This would result in opening the valves. The pressure
controller will then try to maintain the set pressure by
allowing a flow matching with the firing rate.
As the firing rate increases, the set point needs to be
manipulated in the same manner to allow matching
flows. This however shall be possible till the maximum
flow capacity of the valves are reached.

Pressure control Contd..
Upon reaching the target steam parameters for turbine
rolling, the boiler firing rate can be maintained at that
level.
Consequent upon steam admission into the turbine, the
pressure ahead of bypass valves shall tend to fall in view
of constant firing rate.
This will result in closing of bypass valves due to
pressure controller action. The process will continue till
the HP bypass valves are fully closed
Pressure control Contd..
After this further loading of the turbine, HPBP pressure
set point can be increased to a value equal to rated
turbine throttle pressure plus a bias of pressure 5 ata
This maximum limit of set point should be below the
safety valve set pressure for super heater.
With this pressure set point, the HPBP station will
automatically open to balance the discrepancy between
steam generation and consumption arising out of load
rejection under constant pressure operation.
Temperature Control
The temperature measuring signal for the HPBP station
is sensed by temperature transmitters at the down
stream of BP1, and BP2 and spray control valves are
modulated.
The control loop for the steam temperature at the
downstream of HPBP valves can be operated by
incorporating a fixed set point which is slightly higher
than the rated cold reheat steam temperature (i.e. rated
temp. plus bias temp.).
Should this be not acceptable by the boiler, the
temperature set point needs to be manipulated
accordingly.
Priority Valve Open Cmds.
During large load rejections, the bypass station will open in
about 3 seconds after initiation of signal from the
followings :-

Generator Circuit Breaker open
Turbine Trip
Turbine load Shedding Relay (LSR) operates
Rapid opening of the HPBP valves under above
conditions is achieved by activating a fast opening
device (SSB Unit) which is incorporated in the bypass
valve actuators.
Basic Interlocks
HP Bypass valves can be opened at a vacuum > 400
mm Hg
Opening of the main Control valves >2%, The
corresponding Attemperation Valves will move to force
auto and will start opening.
The BD valve will open after getting open feedback of >
2% of any control valve.
Down stream Temperature V. High trip will initiate
closing of corresponding Control valve and its
Attemperation Valve.
Alarm is generated for deviation from set pressure and
temperature.
Quick Acting Device
The quick stroking device SSB is mounted directly on the
actuator of BP1 & BP2. This device may be used for two
purposes :-
Fast operation of the actuator faster than normal control
path.
Emergency function, such as fail to open or close by
electric power, acting independently of control operation
system.
Quick Acting Device Contd..
Quick stroking device gets its emergency oil from an
additional accumulator which is always fully charged
from the OSU during normal operation.
This accumulator is positioned near to the actuator to
reduce the pressure losses caused by friction which
provides a safe function of at least one stroke even after
failure of the OSU.
A check valve in the charging line of the accumulator
prevents the oil from flowing back.
During operation with the normal control path, a pilot
operated check valve in the SSB unit prevents the oil
from flowing out of the accumulator into the actuator.

Quick Acting Device Contd..
A solenoid operated 3/2 way poppet valve is used as
pilot valve.
Because the pilot valve is of poppet construction, the
accumulator can be kept charged over a long period
after the failure of the OSU. The SSB units are operated
by this pilot valve which can be selected to trip de-
energized or energized.
Simultaneously with the tripping of the SSB unit, the
normal control path becomes de-energized i.e. the
blocking unit closes or the solenoid valve moves to
central position t prevent any unwanted oil circulation.
LP BYPASS
The Purpose of operation of LP Bypass valves are
similar to that of operation of HP Bypass valves.
Low pressure bypass system enables to establish an
alternative pass for dumping the steam from the
Reheater outlet directly into condenser at suitable steam
parameters.

LP BP System Description
LPBP system consists of two parallel branches
Each branches consists of a Stop Valve with valve
mounted electro-hydraulic actuator, a pressure reducing
control valve and a temperature control valve with valve
mounted electro-hydraulic actuator.
Steam pressure at valve upstream side can be
maintained as desired level.
HP turbine chamber pressure or hot reheat
steam pressure before intercept valves is the
controlling variable for the LPBP control system.
LP BP System Description
The steam is de-superheated in order to keep the
downstream steam temperature within allowable limits
(i.e. hotwell temp.) by the spray control valve and spray
nozzles (STD) in de-superheater.
This spray water is taken from CEP discharge line.
The double shut off arrangement of LPBP system
separates the reheater from the condenser during
normal operation.
Controlling of these parameters can be done by
Manual or Auto mode. So, LPBP system maintains
the upstream pressure (HRH pressure) and downstream
temperature (condenser temperature).


Oil Supply Unit
The hydraulic power unit supplies the hydraulic energy
necessary for the actuators. One single unit can supply
several actuators.
The hydraulic power unit consists mainly of two internal
gear pump (1W + 1S) which draws the hydraulic fluid
from the tank and pumps it into the accumulators.
There are several control and safety equipments to
guarantee the supply of hydraulic fluid from the
accumulator. As soon as the pressure in the
accumulators rises to 18 Mpa, the accumulator charging
valve switches the pump over to circulation,
Oil Supply Unit Contd..
Each Oil Unit has the following Instruments:
1. Pressure Switches: 3 Nos.: 90Kg, 110 Kg and 190 Kg
2. Temperature Switches: 2 Nos.: 50 deg and 55 deg C
3. Flow Switch: 2 Nos.
4. Level Switch: 1 No. (common for both)

Oil Supply Unit Contd..
Interlocks:
Man Mode:
1. Individual pump selection> Start
2. It will run for 2 mins.
3. If by this time the flow switch resets, the system runs
otherwise it goes to shut down.
Auto Mode:
1. Power On> both pumps take starts
2. It will run for 2 mins.
3. If the 110 Kg pressure switch resets it runs, otherwise
goes to shut down.

Oil Supply Unit Contd..
Interlocks Contd.:
Auto Mode:
1. If the pressure switch resets, the pump not selected
will stop.
2. In case of pressure low<110 Kg, Second pump takes
start.
3. This pump runs until stopped manually.
4. In case of pressure V. low< 90 kg, the system trips.
5. Pump Cut off at pressure. 190 Kg.
6. Pressure relief valve setting at 170 Kg pressure.
7. These pumps are continuous running.


Oil Supply Unit Contd..
Interlocks Contd.:
1. At temperature 50 deg C, the Fan takes start. The Fan
stops at a temperature 45 deg C.
2. At temperature 55 deg C the system trips.
3. At tank Level low, the system trips.
4. There are some common alarms, which are for anti
coincident happenings.
LP Bypass Interlocks
Conditions for Emergency Trip Commands:
1. Hotwell Level Very High.
2. Hotwell temperature High
3. Vacuum Low (-304 mmHg)
4. LP Bypass Attemperation Flow Deviation (Demand-
Actual) > 17 %
5. Turbine Axial Shift V. Hi/V.Lo (+1.1 and -1.1)
6. Turbine Lube oil Pressure low (1.2)
7. All CW Pump Trip

LP Bypass Valves
LP Bypass valves in Bakreswar are of CCI make PV
model valves.
The control unit converts the electrical signals of the
control system into hydraulic fluid flow. It is mounted on
the actuator of the LPBP control valves.
It controls intake and discharge of hydraulic fluid to and
form the piston chambers of the actuator at a continuous
control mode, thus permitting highly precise positioning
of the actuator.
Positioning times of less than three seconds can be
dynamically achieved without difficulties, and this in
connection with high response sensitivity and stability.
LP Bypass Valves
The blocking function of the control unit ensures that the
actuator is held more or less drift-free in its position at
manual mode or at the event of malfunctions.
Furthermore, the blocking function is taken care of by
two electro-hydraulically pilot controlled check valves. In
the event of power failure or loss of hydraulic pressure,
the check valve close the ducts of the actuator.
The solenoid of the control unit is excited by a current
signal being proportional to the deviation of set value to
actual value. With higher current at the solenoids the
flow through the directional valve increases.
Control units are produced in different versions :- such
as PV4, PV6, PV10/1 & PV10/2.
LP Bypass Stop Valve
This is a Solenoid operated On-Off Valve.
One single demand is generated to the LP Bypass Stop
Valve along with the LP Bypass Control Valves.
When there is no Emergency trip condition, this valve
can be operated any time.
Normally the Stop Valve remains in open condition.
If the Valve is in closed condition, then with 1% opening
of any LP Bypass Control Valve, this valve opens
LP Bypass Pressure Control Valve
Unlike HP Bypass, in case of LP Bypass, Demand is
Unique for both the Control Valves.
The Control Valves maintain the pressure of HRH line.
In Manual Mode:
The Maximum Pressure Set Point is 38 Kg
The Minimum Pressure Set Point is 3 Kg
In Auto Mode:
The Pressure Set Point starts with 3 Kg
It integrates in every 5 seconds for new set point
It goes up to 11 Kg
Upto Control Valve Position f/B 25 %, this set point will remain.
This is called Fixed pressure set Point


LPBP Pressure Control Valve Contd..
Beyond that, a sliding pressure Set Point is generated
depending on the HP Chamber Pressure.
The pressure set point is generated as per a
functional relationship between the HPT Chamber
pressure and HRH Pressure.
The Set point generation Logic is as follows:
MAX
Fixed Pressure Set Point
Sliding Pressure Set Point
LPBP Pressure Set Point
Max 38 Kg
LPBP Pressure Control Valve Contd..
In case of Stop Valve Emergency trip command, the LP
Bypass pressure controller demand goes to zero through
a switching.
In case the Load Shedding relay (LSR) operates, the
control valve demand goes to 100 %.
LSR operating time is typically 800 m secs. But the
control valve opening time is approx. 10 secs.
In case the valves are gone out of control (such as LSR
operation), they will come into control as below:
Attemp. v/v < 1% open, Pr. Cont. v/v will track from 25%
Attemp. v/v >1% open, Pr. Cont. v/v will track from 63%
Emergency trip overrides the Opening interlocks.

LPBP Temperature Control Valve
The spray water is taken from CEP discharge.
The Attemperation valves in LPBP system get demand
from down stream pressure transmitters of individual
pressure control valves.
The Pressure transmitters generate a pressure
feedback.
This pressure feedback is converted to an attemperation
flow demand through a function generation card.
Flow transmitters are mounted in the CEP Discharge
line.
The demand of flow and the flow feedback is always
calculated.
In case the deviation.17 %, the LPBP system trips
Auxiliary PRDS System
Auxiliary PRDS system consists of a Turbine PRDS
control system as well as Boiler PRDS control system.
The controller of these system are pneumatically
controlled. Both the systems are identical in nature.
Auxiliary steam is tapped from the main steam line and
its pressure is reduced and de-superheated to the
required temperature and pressure.
The spray water for de-superheating is supplied from the
CEP discharge header.
In order to obtain better operational flexibility and
controllability range, both the system have been split into
two identical PRDS system such as low capacity PRDS
and high capacity PRDS.
Auxiliary PRDS System Contd..
The low capacity is of 30% of that of the high capacity
line.
Each system comprises of the pressure controller, one
desuperheater and one spray water flow controller.
We shall henceforth call the Turbine PRDS system as
TAS and the Boiler PRDS system as BAS.
System Description- High Capacity
High capacity PRDS comprises of steam pressure
reducing control valve, motorized upstream isolating
valve, downstream manual isolating valve, one spray
water temperature control valve and one desuperheater.
A motorized regulating globe valve is provided in bypass
line of, which can be operated remote manually in case
of mal-operation of the pressure control valve.
A motorized bypass globe valve is provided for spray
water control valve , which can be operated remote
manually in case of mal-operation of spray water control
valve.
System Description- Low Capacity
Low capacity PRDS comprises of steam pressure
reducing control valve, motorized upstream isolating
valve, downstream manual isolating valve, one spray
water temperature control valve and one desuperheater.
A motorized regulating globe valve is provided in bypass
line of, which can be operated remote manually in case
of mal-operation of pressure reducing control valve.
A motorized bypass globe valve is provided for spray
water control valve, which can be operated remote
manually in case of mal-operation of spray water control
valve.
TAS/BAS Pressure/ Temperature
Control
The auxiliary steam pressure control valve supplies
steam to TAS/BAS header by maintaining TAS/BAS line
pressure constant at the set point (11 kg/cm
2
).
Downstream pressure of PRDS valve is taken as
controlled pressure.
The auxiliary PRDS spray water flow control valve (CD)
maintains the TAS / BAS line temperature constant at
the set point (260
0
C for TAS & 220
0
C for BAS). The
downstream temperature of PRDS valve is taken as
controlled temperature.
Selection of HC & LC TAS PRDS
During unit start up auxiliary steam for turbine is supplied to the
Starting & Main Ejectors, Deaerator initial heating & pegging,
Turbine Gland Sealing. To meet this high demand of auxiliary steam
HC PRDS should be put into service.
After required condenser vacuum reached, starting
ejector is withdrawn, so the aux. steam supply to starting
ejector is cut off.
After unit synchronization and at about 30 to 40% of unit
load deaerator pegging is supplied from CRH / turbine
extraction line (CAP) and pegging from TRDS is cut out.
At about 40% unit load also, turbine gland sealing supply
valve from TPRDS closes as turbine becomes self-
sealing condition.
Selection of HC & LC TAS PRDS
At that position, auxiliary steam from PRDS is supplied
to main ejector only. To meet this very low demand of
auxiliary steam , LC PRDS should be put into service,
because it will be very difficult to control TPRDS steam
pressure by HC PRDS valve which may cause of safety
valve popping of TPRDS header.
Good Bye