Dbplgoverning System Final

STATION: NTPC- RIHAND NTPC ref:RH/Stg-II/TS/B/05 SHEET
Unit # 3: stage –II (2x500 MW) BHEL ref:PW/TSX/RIT/TUR/TS/001/Rev00 OF
PLANT AREA: TURBINE
TESTING SCHEDULE: procedure for commissioning of Governing System
ITEM LIST OF CONTENT
1.0 Plant details & technical specification
2.0 Testing objectives & Proposals
3.0 Services required.
4.0 Safety.
5.0 Emergency procedures.
6.0 State of the plant.
7.0 Test method
8.0 Reinstatement & preservation.
9.0 Staffing
10.0 Responsibilities & communications.
11.0 Appendices:
12.0 Safety clearance certificate.

12.1 Mechanical plant item completion list.
12.2 Electrical plant item completion list
12.3 C & I plant item completion list.
12.4 Alarm, Interlocks & protections.
12.5 Check sheets.
12.6 Log sheet.
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NTPC BHEL
PLANT AREA: TURBINE
ITEM 1 PLANT DETAILS REMARK
Governing Rack Consisting of following.

i) Emergency trip valve
ii) Tripping Device
iii) Change over valve
iv) Filters in control oil
v) Accumulator.
vi) Starting Device
vii) Hydraulic Amplifier with set of follow up
pistons (HP&IP)
viii) Load shedding relay
ix) Trimming Device
x) Electro Hydraulic converter with set of
follow up pistons (HP & IP)
xi) Extraction Relay
xii) Oil injection Test Device
xiii) Vacuum protection Device.
xiv) Set of solenoids for ATT operation.
HP Front Pedestal consisting of following.
i) Impeller for primary oil

ii) Over speed trip governor
HP Rear Pedestal Consisting of following.
i) Thrust protection Device.

ii) For brief description of above items,
refer to O&M manual
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NTPC BHEL
PLANT AREA: TURBINE
ITEM 2 TESTING OBJECTIVES & PROPOSALS REMARK
2.1 OBJECTIVE:
To commission the Governing control system for

controlling speed and load of the machine
2.2 PROPOSAL:
Proposed to set the Hydraulic, Electro Hydraulic

converters, to set the characteristics of HP and IP
governing valves and to check the operation of
emergency stop valves of HP and IP.
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ITEM 3 SERVICES REQUIRED REMARK
3.1 Control fluid system shall be in service.
3.2 Operating manpower.
3.3 The following equipments and Instruments.
 Portable vacuum pump one No.

 Hydraulic pressure pump one No.
 Standard pressure gauges with an accuracy
of 0.1kg/cm2
Range 0-10 kg/cm2 4 Nos.
2
“ 0 –20 kg/cm 1 Nos.
“ 0 – 40 kg/cm2 1 Nos
 Standard vacuum gauge range 0 – 760 mm
Hg.
 Dial gauge with Magnetic Base 0-10 mm
one No.
 Depth gauge one No. range 0-50 mm
 Slip gauges Box one No.
 Feeler gauge 0.05 to 1 mm 1 Set.
 Different sizes of spanner set (double end)
 Ring spanner 3 mm to 27 mm one set.
 Allen Key one set 3 mm to 10 mm.
 Screwdriver small to big one set.
 Voltage injection test kit one No.
 Multimeter one No.
 Digital speed indicator one No. 0-4000 rpm
range
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ITEM 4 SAFETY REMARK

4.1 All members of the test team and all other
persons involved in the testing /commissioning
schedule must be maid familiar with the contents
of the testing /commissioning schedule.
4.2 Safe access to and adequate escape routes from

the confined areas must be maintained.
4.3 The test area must be effectively defined.
4.4 Access to the test area will be restricted where

necessary by use of barriers and /or warning
notices
4.5 The test area will be clear of obstructions.
4.6 Permanent lighting, supplemented by temporary

lighting where necessary, must be availed to give
adequate lighting to all equipments.
4.7 All hand rails access stairs, ladders, guards and

trench covers must be permanently fitted unless
specified exempted by the test method.
4.8 Safety clearance certificate will be in force
4.9 The operation deptt must be informed on daily

basis of the programmed being carried out.
4.10 No person would be allowed to work on fed pump

and associated piping including Deaerator, during
the test.
4.11 Fire fighting equipment suitable for electrical and

oil fire will be available
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PLANT AREA: TURBINE
ITEM 5 EMERGENCY PROCEDURE
5.1 The test team should be aware of the procedure to

be adopted in case of damage to machinery /
injury of any personnel connected to the activity
and oil / water leakages.
5.2 The test team should be well aware of the

procedures to be adopted in case of any
abnormality in the activity
5.3 Fire extinguishers to be used for the quenching

minor or major fires.
5.4 The testing team should be aware of the

procedure to be followed in case of accident
involving personnel injury
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PLANT AREA: TURBINE
ITEM 6 STATE OF PLANT REMARK
6.1 Mechanical PICL completed
6.2 Electrical PICL completed
6.3 C&I PICL completed
6.4 Safety clearance certificate available.
6.5 All service must be available.
6.6 Erection completion must be ascertained.
6.7 AOPs and control fluid pumps are available for

running.
6.8 Control oil, Trip oil & Test oil lines are erected &
Hydro tested after oil flushing.
6.9 HP & IP Governing valves are erected.
6.10 Connected Instrumentation and controls are

made ready.
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PLANT AREA: TURBINE
ITEM 7 TEST METHOD REMARK

7.1 Initial checks to be carried out before setting
of Hydraulic governor.
7.1.1 The components number indicated on the

checklist is based on Governing Scheme
Drg.No.1.1-2192-7279/1 of KWU / 0-11400-
25000 BHEL.
7.1.2 Check whether the isolation valves before the

filter MAX 42 BT 001 – 003 is kept opened for
speed control rack.
7.1.3 Check whether the test valves of HP and IP for

stop valve MAX 47 AA 011 – 012 and MAX 47 AA
021 – 022 respectively are kept closed fully.
7.1.4 Ensure that the isolating valves before the 32 bar

control fluid filters MAX 32 BT 011-012 for HP
control valves and filters MAX 32 BT 021 – 022
for IP control valves are kept opened fully.
7.1.5 Ensure whether the isolating valves in control

fluid lines MAX 32 AA 511,512, and MAX 32 AA
521,522, and secondary oil lines MAX 45 AA 511-
512 and MAX 45 AA 521-522 are kept fully
opened for HP and IP control valves.
7.1.6 Check whether the isolating valves in EHC circuit

in HP secondary fluid MAX 45 AA 501 and IP
Secondary fluid MAX 45 AA 502 is closed, while
setting the hydraulic controller.
7.1.7 Close the control fluid line isolating valve MAX 42

AA 621 and Secondary fluid line isolating valve
MAX 45 AA 566 of CRH NRV slide valve MAX 42
AA 001.
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PLANT AREA: TURBINE

7.1.8 Ensure closing of the trip fluid line isolating valve
MAX 51 AA 527 and MAX 51 AA 530 of extraction
NRV slide valve MAX 51 AA 048 and MAX 51 AA
051.
7.1.9 Fix a dial gauge 0-10 mm underneath bellow KA

09 in the hydraulic speed Governor MAX 46 BY
001.
7.1.10 Fix three standard gauges in Auxiliary secondary
fluid HP secondary oil and IP secondary fluid
lines at the governing rack.
(0-8 kg/cm2 to read up to 0.1-kg/cm2 accuracy).
7.1.11 Open the top cover of Hydraulic amplifier MAX 45

BY 011 to measure the power piston KA 08 lift
with the help of depth gauge.
7.1.12 Ensure that the Boiler stop valves are fully closed
and the main steam line is not charged with
steam.
7.1.13 Check whether solenoid MAX 42 AA 051 of the

trimming device KA 10 is in energized condition.
7.1.14 Check that the trip solenoids MAX 51 AA 202 and

MAX 51 AA 201 are in the de-energised condition
and ensure that the change over valve MAX 51 AA
211 is in normal position and not in Test position.
7.1.15 Ensure starting device MAX 47 BY 001 in closed

condition.
7.1.16 Keep the speeder gear in maximum set positions.
7.1.17 Check whether control fluid pump is running and

a control fluid pressure of 32 kg/cm 2 and 8
kg/cm2 is available.
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PLANT AREA: TURBINE

7.1.18 Maintain fluid temperature in control fluid tank
around 500 C / 550 C.
7.1.19 Check the load shed relay solenoid MAX 46 AA

011 is in de-energised condition and aux.
Secondary fluid doesn’t drain through the load
shed relay solenoid.
7.1.20 Ensure that the main trip valve MAX 51 AA 005-

006 is in reset conditions.
7.1.21 Switch off ATRS panel supply, so that hydraulic

governor can be checked when boiler is not in
service.
7.1.22 Check the following pressure in the rack.
Control fluid pressure - 8 kg/cm2
Start up fluid pressure - 7 kg/cm2
Aux. Start up fluid pressure - 7 kg/cm2
Trip fluid pressure - 7-7.5 kg/cm2
Aux. Trip fluid pressure - 7-7.5 kg/cm2
Control fluid pressure to

control valve - 32 kg/cm2
Grid frequency 49 to 50.5 hz (desirable).
7.1.23 Ensure that the respective governor

characteristics is used while setting the governor
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7.2 Procedure for checking and setting of
Hydraulic Governor.
7.2.1 Note down the initial reading of starting device

when the starting device is in full closed
condition.
7.2.2 Operate starting device MAX 46 By 001 gradually

from Minimum to Maximum position and carry
out the following checks.
7.2.3 Check whether the start up and Auxiliary start up

fluid pressure drops.
7.2.4 Operate the starting device gradually and

increase the Auxiliary secondary fluid pressure to
2.3 kg/cm2 and note down HP and IP secondary
fluid pressure.
7.2.5 Check when starting device is fully opened, note

down the starting device lift. The lift should be
24.5mm and auxiliary secondary fluid pressure
should be 4.4 kg/cm2 or above.
7.2.6 If the aux. Secondary fluid pressure is not

obtained, adjust Auxiliary follow up piston KA 08
which is in service of MAX 46 By 001 to obtain
aux. Secondary fluid pressure of 4.4 kg/cm2 and
above, when starting device is fully opened
condition.
7.2.7 Note down the HP and IP secondary fluid

pressure corresponding to 4.4 kg/cm 2 of Auxiliary
secondary fluid pressure.
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7.2.8 Bring back the starting device gradually towards

the closing position and check the trip point of
aux. Secondary fluid pressure. The trip point
should be around 2.1 kg/cm2 approximately. At
least under 2.3 kg/cm2.
Note: Trip point of Auxiliary follow up piston is

the pressure at which auxiliary secondary fluid
pressure suddenly falls to zero.
7.2.9 Bring back the starting device to fully closed

position.
7.2.10 Ensure the starting device is in closed condition.
7.2.11 Fix the dial gauge (0 – 10 mm) below the bellow

and adjust it to read zero mm.
7.2.12 Note down the initial reading of power piston KA

08 of MAX 45 BY 011 by a depth gauge.
7.2.13 Note down the starting device initial readings.
7.2.14 Operate the starting device gradually to open

position till the auxiliary secondary fluid pressure
increases to 2.3 kg/cm2.
7.2.15 At 2.3 kg/cm2 of Auxiliary secondary oil pressure

check whether the HP secondary fluid pressure is
3.0 kg/cm2.
7.2.16 If the value is not achieved, adjust the two follow

up pistons KA 01 of MAX 45 BY 011 of HP
secondary fluid pressure equally
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7.2.17 Check the lift of power piston KA 08 of MAX 45
By 011 is around 6 to 7 mm (approx.), when the
HP secondary fluid pressure is around 3.0
kg/cm2.
7.2.18 If the value is not achieved, adjust the start up
opening of pilot valve KA 07 of MAX 45 BY 011.
7.2.19 Increase the aux. Secondary fluid pressure to

2.55 kg/cm2 HP secondary fluid pressure will be
3.24 kg/cm2. The IP secondary fluid pressure
should be 3.5 kg/cm2.
7.2.20 If the IP secondary fluid pressure value is not

achieved, adjust the two follow up pistons KA 02
of MAX 45 BY 011 equally to get 3.5 kg/cm 2 of IP
secondary oil pressure.
7.2.21 Note down the values of followings:-
 Starting device travel.

 Lift of the bellow.
 Power piston lift of Hydraulic controller.
 Aux. Secondary fluid pressure, HP
secondary fluid pressure and IP secondary
fluid pressure.
7.2.22 Increase the Auxiliary secondary fluid pressure to

4.4 kg/cm2 and check whether HP secondary
fluid pressure reaches 5.0 kg/cm2.
7.2.23 If the value is not achieved, adjust the

proportionality adjuster KA 09 of MAX 45 BY 011
to get HP secondary fluid pressure of 5.0 kg/cm 2
when auxiliary secondary fluid pressure is
around 4.4 kg/cm2.
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NTPC BHEL
PLANT AREA: TURBINE
7.2.24 Check by closing the isolating valve MAX 42 BT

001 and MAX 42 BT 002 and MAX 42 BT 001 of
speed (governing) control rack and note at what
pressure of trip fluid, Tripping device MAX 51 AA
006, MAX 51 AA 005 and emergency trip valve
MAX 52 AA 005 trips suddenly.
7.2.25 Trip devices and emergency trip valve should trip

at 3 bar of trip fluid pressure. If it is not achieved,
adjust the spring tension to get the set value.
7.2.26 After checking and ensuring that trip devices and

emergency trip valve trips at 3 bar, bring down
starting device from open position to closed
position.
7.2.27 Operate the starting device from closed position

and once again check at 2.3 kg/cm 2 of Auxiliary
secondary fluid pressure, the HP secondary fluid
pressure is 3.0 kg/cm2 .
7.2.28 Increase the auxiliary secondary fluid pressure in

steps of 0.2 kg/cm2 and note down the following.
 HP secondary fluid pressure.

 IP secondary fluid pressure.
 Power Piston lift of Hydraulic converter.
7.2.29 Check that a closing and opening reserve of 3.5

mm, is available for power piston KA 08 of
Hydraulic Amplifier MAX 45 By 011
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NTPC BHEL
PLANT AREA: TURBINE
7.2.30 Check the bellow travel KA 09 of MAX 46 BY 001

between auxiliary secondary fluid pressure of 2.3
to 4.4 kg/cm2 , should be approx. 5 mm.
7.2.31 Check the total travel of Amplifier power piston. It

should be 50 mm approximately, from fully closed
position to fully open condition of starting device
MAX 47 BY 001.
7.2.32 Plot the following curve.
 Power piston lift versus Auxiliary secondary

fluid pressure.
 Bellow lift versus auxiliary secondary fluid
pressure
 Bellow lift versus HP secondary fluid
pressure.
 Bellow lift versus IP secondary fluid
pressure.
7.2.33 Bring the starting device to minimum position, to

set HP and IP control valves.
7.2.34 Adjust the local position transmitter to indicate

zero mm for both HP and IP control valves.
7.2.35 Bring the starting device to a position where HP

secondary fluid pressure is 3.0 kg/cm2.
7.2.36 Adjust the start of opening of HP control valves 1

& 2, just to open at 3.0 kg/cm 2 of HP secondary
fluid pressure.
7.2.37 Bring the starting device to a position where IP

secondary fluid pressure is 3.5 kg/cm2
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PLANT AREA: TURBINE
7.2.38 Adjust the start of opening of IP control valves 1

& 2, just to open at 3.5 kg/cm 2 of IP secondary
fluid pressure.
7.2.39 Increase the Auxiliary secondary fluid pressure in

steps of 0.2 kg/cm2 and note down the following
up to the maximum position of starting device.

 HP control valve lift.
 IP control valve lift.
7.2.40 Plot the curve for the following.
 HP secondary fluid pressure versus HP

control valve lift 1 & 2.
 IP secondary oil pressure versus IP control
valve lift 1 & 2.
7.2.41 If the lifts of control valves are not coming equal

adjust the fulcrum point of lever 12 feed back
linkage as shown in O&M manual KWU Drg.1.1-
2321-0006/1.
7.2.42 Open the test valve of HP stop valve number one

fully and check whether stop valve opens fully.
Ensure that oil pressure above the piston is
showing zero.
7.2.43 Repeat the same test 7.2.41 and 7.2.42 for HP

stop valve number Two, and IP stop valve number
One, and Two.
7.2.44 Ensure full lift of HP stop valve about 92 mm and

IP stop valve about 176 mm which are the design
values.
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7.2.45 Fully close the test valves of HP stop valve

number one and check whether the stop valve
closes fully.
7.2.46 Now open HP stop valve number one by opening

the test valve fully and ensure that the stop valve
has opened fully.
7.2.47 Energise solenoid valve MAX 48 AA 201 and MAX

48 AA 202, to admit auxiliary start up fluid to
Main trip valves MAX 51 AA 005 and MAX 51 AA
006.
Note: Do not energise longer than 30 minutes.

Check by closing the isolating valve MAX 42 BT
001 MAX 42 BT 002, and MAX 42 BT 003 in
control fluid system to speed control rack.
7.2.48 Note down at what trip fluid pressure HP stop

valve number one suddenly closes.
7.2.49 Repeat the operation 7.2.47 for HP stop valve

number Two, and IP stop valve number one and
two. Note down the trip fluid pressure at which
stop valve closes.
7.2.50 De-energise the solenoid MAX 48 AA 201 and

MAX 48 AA 202 after completing the test on stop
valves.
7.2.51 Bring back the starting device to full close

condition.
7.2.52 Operate the starting device gradually from

minimum to maximum position
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7.2.53 Check whether HP stop valve opens first, and IP

stop valves opens later as per the indications
marked on the starting device scale and note
down the start up fluid pressure for opening of
HP and IP stop valves.
7.2.54 De-energise solenoid MAX 42 AA 051 of the

trimming device KA 10 of Hydraulic Amplifier
MAX 45 BY 011.
7.2.55 Bring back the starting device to closed position.
7.2.56 Check the dial gauge below the bellow is set at

zero.
7.2.57 Note down the initial reading of starting device.
7.2.58 Open gradually the starting device from fully

closed position to fully open position and note
down the following.
 Bellow lift.
 Auxiliary secondary fluid pressure.

7.2.59 Plot the following curve
 Bellow travel versus Auxiliary secondary

fluid pressure.
 Bellow travel versus HP secondary fluid
pressure.
 Bellow travel versus IP secondary fluid
pressure
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7.2.60 Energise the trimming device solenoid MAX 42 AA

051.
7.2.61 Load shed relay MAX 46 AA 011 gets energized

whenever generator breaker trips on fault. The
duration of operation is only two seconds.
7.2.62 During the actuation of load shed relay check

whether Aux. Secondary fluid pressure drops
down to zero and comes back, to the value at
which the load shedding relay was actuated.
7.2.63 Operate the starting device to maximum.
7.2.64 Check whether all stop and control valves are full
open and Auxiliary secondary fluid pressure, HP
secondary fluid pressure, IP secondary fluid
pressure, trip fluid pressure, and Auxiliary trips
fluid pressure reads maximum
7.2.65 Switch on the ATRS supply.
7.2.66 Check the Main trip valve trips immediately and

all the stop valves and control valves closes
immediately.
7.2.67 Check the Auxiliary secondary fluid pressure, HP

secondary fluid pressure, IP secondary fluid
pressure, trip fluid pressure, and Auxiliary trips
fluid pressure reads zero.
7.2.68 Switch off ATRS panel supply.
7.2.69 Ensure and check it is as per step number

7.2.64.
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7.3 Initial checks to be carried out before setting

of Electro-Hydraulic Converter.
7.3.1 Normalise the isolating valves MAX 45 AA 501 in
HP secondary fluid line and MAX 45 AA 502 in IP
secondary fluid line from EHC, which was kept
closed while checking the hydraulic controller.
7.3.2 Keep the starting device MAX 47 BY 001 in

maximum position.
7.3.3 Ensure that the trip fluid line isolating valves

MAX 51 AA 511 is kept opened.
7.3.4 Ensure that control fluid line isolating valve MAX

42 AA 611 is kept opened.
7.3.5 Ensure a pressure gauge 0 to 8 kg/cm2 in the

pressure gauge point provided before EHC MAX
45 BY 001 in trip fluid line.
7.4 Procedure for checking and setting of EHC

7.4.1 Feed through set point voltage, a fixed voltage in
co-ordination with C & I Engineer.
7.4.2 Check whether the voltage in moving coil MAX 45

CG 001 T is around minus volts.
7.4.3 The Equilibrium voltage should be between

minus8 volts to minus 1.2 volts.
7.4.4 If it is not, adjust the moving coil by loosening the

three locking screws to such a position where the
equilibrium voltage is around minus 1 volt.
7.4.5 After adjusting as said in 7.4.4 feed zero volt

through set point and note down the power piston
lift. (Minimum reading)
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7.4.6 Feed 10 volts through set point voltage and note

down the power piston lift. (Max. reading)
7.4.7 The difference in lift between maximum and

minimum lift should be approximately 50mm.
7.4.8 Vary the controller from minimum to maximum

position and note down the output of Collins II
and I in the minimum and maximum position.
7.4.9 The Collins I and II out put should be –7.5V to

+7.5V. Adjust the Collins MAX 45 CG 001B, MAX
45 CG 001C to get this voltage, if it is not
achieved.
7.4.10 Increase the set point voltage and hold the power
piston lift KA 08 of EHC MAX 45 BY 001 about 6
to 7mm as obtained in Hydraulic Governor
setting.
7.4.11 Check the HP secondary fluid pressure, and

adjust the two follow up pistons KA 01 of EHC
MAX 45 BY 001 equally to get HP secondary fluid
pressure of 3.0 kg/cm2 when power piston lift is 6
to 7mm as obtained in Hydraulic Governor
setting.
7.4.12 Increase set point voltage and hold the HP

secondary fluid pressure at 3.24 kg/cm2.
7.4.13 At 3.24 kg/cm2 of HP secondary fluid pressure

adjust, follow up pistons KA 02 of EHC MAX 45
BY 001 equally to get 3.5 kg/cm 2 of IP secondary
fluid pressure.
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PLANT AREA: TURBINE
7.4.14 Note down the power piston lift of EHC.
7.4.15 Increase the set point voltage in steps on one volt

and note down Collins out put II and I and power
piston lift.
7.4.16 Check whether the HP secondary fluid pressure

versus IP secondary fluid pressure obtained is
equal to the hydraulic governor characteristics set
earlier.
7.4.17 Ensure by plotting the curve, that a closing and

opening reserve of 3 to 5 mm is available for
power piston KA 08 of EHC MAX 45 BY 001.
7.4.18 Ensure the start up opening of HP and IP control

valves remains at 3.0 kg/cm2 of HP and 3.5
kg/cm2 IP secondary fluid pressures respectively,
as set earlier during hydraulic controller
adjustment.
7.4.19 Check and ensure that the HP and IP control

valves open with respect to HP and IP secondary
fluid pressure as per the governor characteristics,
from full close to full open position.
7.4.20 Plot the following curves.
 Set point voltage versus Collins I and II

voltage.
 Set point voltage versus HP and IP
 HP and IP secondary fluid pressure versus
control valve lift.
 Power piston lift versus HP and IP
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After drawing the characteristic curves of EHC

7.4.21 and Hydraulic compare the slope of these curves.
Both should be equal.
7.5 Checking and setting of non-return valves on

extraction and cold reheat
7.5.1
(Extraction Relay MAX 51 AA 011)
7.5.1.1 Check and ensure that all the drain valves in trip
fluid lines are kept closed.
7.5.1.2 Open isolating valve MAX 51 AA 527 and MAX 51

AA 530 to test valve MAX 51 AA 048 and MAX 51
051 to extraction NRV is opened.
7.5.1.3 Check whether test valve MAX 51 AA 048 and

MAX 51 AA 051 are in open condition.
7.5.1.4 Check whether solenoid valve MAX 51 AA 028

and MAX 51 AA 031 are in de-energised
condition.
7.5.1.5 Check whether isolating valve MAX 45 AA 509

accumulator MAX 45 BB 001 in HP secondary
fluid line is opened.
7.5.1.6 Ensure a pressure gauge is provided on the trip

fluid line after the extraction valve relay.
7.5.1.7 Adjust at HP secondary fluid pressure of 3.25

kg/cm2 the pilot valve spring tension of KA 01
and KA 02 to open the extraction valve A2, A3, A4
and A5.
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PLANT AREA: TURBINE
7.5.1.8 Increase the HP secondary fluid pressure above

3.25 kg/cm2 .
7.5.1.9 Check by energizing the solenoid MAX 51 AA 028

and MAX 51 AA 031 the NRV’s A2. A3. A4 and A5
close.
7.5.1.10 De-energise the solenoids and check the NRV’s

A2, A3, A4 and A5 opens back.
7.5.11 Check by closing the test valve MAX 51 AA 048

and MAX 51 AA 031 the NRV’s A2, A3, A4 and A5
closes.
7.5.1.12 Ensure by opening the test valve, the NRV’s A2,

A3, A4 and A5 opens back.
7.5.1.13 Ensure by reducing the HP secondary fluid, all

the extraction NRV’s closes and note down the HP
secondary fluid pressure at that position.
7.5.1.14 All the extraction NRV’s should close not later

than (before) 3.0 kg/cm2 of HP secondary fluid
pressure.
7.5.2 Cold Reheat Non-Return valve

7.5.2.1 Check and ensure that all the drain valves in
control fluid lines are kept closed.
7.5.2.2 Check the isolating valve MAX 42 AA 621 in

control fluid line of slide valve MAX 42 AA 001 is
kept opened.
7.5.2.3 Check the isolating valve MAX 45 AA 566 in

secondary fluid lines is kept opened
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7.5.2.4 Adjust the slide valve MAX 42 AA 001 spring

tension to open the NRV at 3.3 kg/cm 2, of HP
7.5.2.5 Check by reducing the pressure of HP secondary

fluid below 3.3 kg/cm2 and ensure whether NRV
is closed fully.
7.6 Ensure the following settings in coordination

with C&I Engineers.
7.6.1 Ensure the starting device percentage position at
control room indication from 0 to 100% matches
with full close to full open position.
7.6.2 Adjust the four number of limit switches provided

on the starting device for 1%, 42%, 56% and
100% respectively of starting device opening.
7.6.3 Ensure the speeder gear percentage position at

control from indication, from 0 to 100% matches
with full close to full open position.
7.6.4 Adjust the limit switches in full open direction

and full close direction for two numbers of HP
stop valves and two numbers of IP stop valves.
7.6.5 Ensure the open and close indication is appearing

for the entire stop valve at control room.
Adjust the percentages position of the two control
valves of HP and a two-control valve of IP
indicates at control room the full open and full
close directions.
7.6.6 Ensure the local scale indicator mounted on the

body of two numbers of HP control valve and two
numbers of IP control valve in the fully open and
fully closed directions.
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NTPC BHEL
PLANT AREA: TURBINE
7.6.7 Adjust the limit switch of cold reheat NRV in the

fully open and fully closed direction and check
the open and closed indication is appearing at
control room.
7.6.8 Ensure that the potentiometer for extraction

valves A2, A3, A4 and A5 indicating the valve
opening position is calibrated.
7.6.9 Ensure the extraction NRV solenoid MAX 51 AA

028 and MAX 51 AA 031 for A2, A3, A4 and A5
indication at control room for energized and de-
energised condition.
7.7 Testing of overspeed Bolts by injecting oil
through over speed test device MAX 62 AA
001.
7.7.1 Conduct the following checks at 3000 rpm

7.7.1.1 Release the lock of pilot valve KA 02 and KA 03 of
MAX 62 AA 001.
7.7.1.2 Check whether the turbine speed is exactly 3000

rpm.
7.7.1.3 Press the pilot valve KA 03 fully, to isolate the

Auxiliary trip fluid from main trip valve to
overspeed trip test device and keep in pressed
down.
7.7.1.4 Note down the Auxiliary trip fluid pressure
7.7.1.5 Rotate the hand wheel KA 01 of overspeed trip

test device in clockwise direction for admitting the
test oil (mineral oil) to the overspeed Bolts
7.7.1.6 Check at what pressure of test oil, the overspeed

Bolts 1 & 2 act.
Signature
NTPC BHEL
PLANT AREA: TURBINE
7.7.1.7 The actuation of overspeed bolt is indicated on

the test rack by lamps and can be observed by
the actuation of limit switches MAX 10 CG 001 +
002, provided on the LHS of HP front bearing
pedestal.
7.7.1.8 Check whether Auxiliary trip fluid pressure goes

to zero.
7.7.1.9 Note down the test oil pressure at which

overspeed, bolt number one comes out and
overspeed bolt number Two comes out.
7.7.1.10 Rotate the hand wheel KA 01 of overspeed test

unit in the anticlockwise direction where the test
oil gets cut off, to the overspeed bolts.
7.7.1.11 Press the Pilot valve KA 02 of overspeed test

device, to reset overspeed bolts One and Two.
7.7.1.12 Check whether Auxiliary trip fluid pressure builds

up and it is as per the recorded value at 8.8.3.
7.7.1.13 Release Pilot valve KA 02, of overspeed test

device.
7.7.1.14 After ensuring auxiliary trip fluid pressure is

steady, release the knob of pilot valve KA 03, of
overspeed test device.
7.7.1.15 Repeat the test two to three times as per the steps
7.7.1.1 to 7.7.1.14 and check whether test oil
pressure comes to a steady valve
7.7.1.16 Lock the Pilot valves KA 02 and KA 03 of

overspeed testing device, after completing the
test.
Signature
NTPC BHEL
PLANT AREA: TURBINE
7.7.2 Testing of 7% regulation of Hydraulic

Governor.
7.7.2.1 Check the machine is running on electro
hydraulic or Hydraulic.
7.7.2.2 If it is running on Electro Hydraulic change over

to Hydraulic.
7.7.2.3 Ensure after changing over to hydraulic, the

isolating valves MAX 45 AA 501 and MAX 45 AA
502 in secondary Fluid lines of Electro Hydraulic
converter is kept closed.
7.7.2.4 Ensure the starting device in maximum position.
7.7.2.5 Increase the speeder gear to full open condition

and check the speed increases to 3210 rpm at
fully open condition.
7.7.2.6 If the speed is not achieved, loosen the lock nut

and increase the compression of spring item
No.13 of component drawing in O&M manual,
Drg. No. 1.1-2210-0004/1, of hydraulic speed
governor, to get the required speed.
7.7.2.7 After starting 7% of rated speed, at speeder gear

and starting device in maximum position, lock,
the lock nut, if Hydraulic speed governor
monitoring group.
7.7.3 Actual overspeed Test 10 to 12% of rated

speed.
7.7.3.1 Ensure before carrying out actual overspeed test,
the both overspeed bolts are operative by
conducting oil injection test.
Signature
NTPC BHEL
PLANT AREA: TURBINE
7.7.3.2 Ensure that all speed indicators and recorders

are indicating the same speed when the machine
is at 3000 rpm and at 3210 rpm cross check the
actual speed with the help of condition
7.7.3.3 Ensure that turbine is running at a speed of

3210 rpm with starting device and speeder gear
in maximum position.
7.7.3.4 Press continuously the overspeed-testing lever KA

07 provided in the start and load-limiting device
MAX 46 BY 001, by watching the speed
indication.
7.7.3.5 Ensure the speed raise is steady and the machine

trips at 3300 rpm (approx.) by the actuation of
overspeed governors.
7.7.3.6 Both the overspeed bolts should operate between

10 to 12% of rated speed.
Note: Release the lever if the overspeed governor

is not acting at 12% of the rated speed. Adjust the
overspeed governor bolt to act 10-12% of rated
speed.
7.7.3.7 Record the speed at which overspeed bolts 1 and

2 acts.
7.7.3.8 After trip out when machine reaches 3000 rpm,.
7.7.3.9 Note down the coasting down time from 3000

rpm, to turning gear speed at 100-rpm interval.
Signature
NTPC BHEL
PLANT AREA: TURBINE
7.8 Testing of Hydraulic low vacuum trip MAG 01

AA 011 at 3000rpm.
7.8.1 Ensure that the control fluid and Auxiliary trip

fluid are available to the low vacuum trip unit.
7.8.2 Ensure whether primary oil pressure is available

in the low vacuum trip unit.
7.8.3 Ensure a calibrated vacuum gauge is fixed in

between the solenoid valve MAG 01 AA 201 and
low vacuum trip unit, on the vacuum impulse
line.
7.8.4 Energise the solenoid MAG 01 AA 201 and

observe the vacuum gauge, for drop of vacuum.
7.8.5 Record at what value of vacuum, the low vacuum

trip acts.
7.8.6 The low vacuum trip should act at 0.3 bar.
7.8.7 If low vacuum trip has not acted at 0.3 bar,

adjust the spring tension number 7, by means of
adjusting screw number 5 as shown in
component drawing in O&M Manual Draing
number 1-1-3400-009/1.
7.8.9 Lock the adjusting screw.
7.8.10 Bring back the machine to the rated speed and

release for carrying out generator dry out.
7.8.11 Note:- Hydraulic low vacuum trip can be test even

on turning gear by jacking the disc No.2 O&M
Manual Drg No.1.1-3400-0009/1 with the help of
locking screw.
ITEM 10 REMARK
STAFFING
Signature
NTPC BHEL
PLANT AREA: TURBINE
The test team, which has been approved by the

Boiler /Turbine commissioning panel will consist
of: -
Test team leader _________________
Erection –Mechanical _________________
Erection –Electric _________________
Erection – C & I ________________
Commissioning- Mechanical _______________
Commissioning – Electrical: ______________
Commissioning – C & I _________________
Commissioning – Chemist: ________________
Commissioning BHEL: __________________
ITEM 11 REMARK
RESPONSIBILITY & COMMUNICATION
Signature
NTPC BHEL
PLANT AREA: TURBINE
11.1 Test team leader responsibilities are: -
11.1.1 To ensure that all the items within the

testing/commissioning Schedules are compiled.
11.1.2 He has the authority to delegate some of the

functions and checking contained within the
schedule.
11.1.3 To ensure that the effective communications link

has been set up and the other affected operating
plant.
11.1.4 To ensure that the detailed log of all events has

been kept.
11.1.5 All test team members have responsibility of

carrying out the test method in a manner that will
safe guard both plant and personnel
11.2 Communications:
11.2.1 A reliable communication system must be

established between the unit control board and
equipment floor.
11.2.2 The test team should have a clear understanding

of how they should communicate with other at
the test bed when they are positioned at
remote places
ITEM 12.1 REMARK

SAFETY CLEARANCE CERTIFICATE
Signature
NTPC BHEL
PLANT AREA: TURBINE
This is to certify that the plant item to be tested

is complete in all respect necessary for the
above testing and clearance is hereby accorded
for its test run.
BHEL
Mechanical erection ____________________
Electrical erection ____________________
C & I erection ____________________
Commissioning team: __________________
RhSTPP
Mechanical erection ____________________
Electrical erection ______________________
C & I erection ____________________
Commissioning–mechanical ________________
Commissioning–electrical __________________
Commissioning–C & I____________________
ITEM 12.3 MECHANICAL PLANT ITEM COMPLETION LIST

Signature
NTPC BHEL
PLANT AREA: TURBINE
Valve schedule
Valve no DISCRIPTION TYPE MODE OF REMARK
OPERATION
Signature
NTPC BHEL
PLANT AREA: TURBINE
Valve no DISCRIPTION TYPE MODE OF REMARK

OPERATION
Signature
NTPC BHEL
PLANT AREA: TURBINE
Valve DISCRIPTION TYPE MODE OF REMARK

no OPERATION
Signature
NTPC BHEL
PLANT AREA: TURBINE
Signature
NTPC BHEL

Dbplgoverning System Final

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STATION: NTPC- RIHAND NTPC ref:RH/Stg-II/TS/B/05 SHEET

Unit # 3: stage –II (2x500 MW) BHEL ref:PW/TSX/RIT/TUR/TS/001/Rev00 OF

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM LIST OF CONTENT

1.0 Plant details & technical specification

2.0 Testing objectives & Proposals

3.0 Services required.

5.0 Emergency procedures.

6.0 State of the plant.

7.0 Test method

8.0 Reinstatement & preservation.

10.0 Responsibilities & communications.

12.0 Safety clearance certificate.

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 1 PLANT DETAILS REMARK

Governing Rack Consisting of following.

HP Front Pedestal consisting of following.

i) Impeller for primary oil

HP Rear Pedestal Consisting of following.

i) Thrust protection Device.

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 2 TESTING OBJECTIVES & PROPOSALS REMARK

To commission the Governing control system for

Proposed to set the Hydraulic, Electro Hydraulic

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 3 SERVICES REQUIRED REMARK

3.1 Control fluid system shall be in service.

3.2 Operating manpower.

3.3 The following equipments and Instruments.

 Portable vacuum pump one No.

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 4 SAFETY REMARK

4.2 Safe access to and adequate escape routes from

4.3 The test area must be effectively defined.

4.4 Access to the test area will be restricted where

4.5 The test area will be clear of obstructions.

4.6 Permanent lighting, supplemented by temporary

4.7 All hand rails access stairs, ladders, guards and

4.8 Safety clearance certificate will be in force

4.9 The operation deptt must be informed on daily

4.10 No person would be allowed to work on fed pump

4.11 Fire fighting equipment suitable for electrical and

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 5 EMERGENCY PROCEDURE

5.1 The test team should be aware of the procedure to

5.2 The test team should be well aware of the

5.3 Fire extinguishers to be used for the quenching

5.4 The testing team should be aware of the

PLANT AREA: TURBINE

TESTING SCHEDULE: procedure for commissioning of Governing System

ITEM 6 STATE OF PLANT REMARK

6.1 Mechanical PICL completed

6.2 Electrical PICL completed

6.3 C&I PICL completed

6.4 Safety clearance certificate available.

6.5 All service must be available.

6.6 Erection completion must be ascertained.