HP-LP Bypass System

HP/LP Bypass System HP-LP Bypass System

HP Bypass Valve
HP Bypass Spray Valve
LP Bypass Valve
LP Bypass Spray Valve
Electro Hydraulic Actuating System
 HP-LP Bypass System

HP-LP Bypass System

High pressure (HP) and Low pressure (LP) bypass systems are
used for quick start-up of the unit as well as during trip-out, where
load rejection at the turbine does not automatically lead to a boiler
trip. With a bypass system, start-up is quicker. The system diverts
the steam generated by the boiler to the Re-heater/Condenser, at
the same time reducing the pressure and temperature of steam,
thus maintaining a minimum circulation of steam through the boiler.
This enables running the boiler without the turbine in service,
ensuring flow through re-heater coils.

BHEL HP-LP bypass system has the following advantages :

The prolonged venting of safety valves to atmosphere is avoided,

thereby reducing DM water loss and cutting noise emission.

Contd...
 HP-LP Bypass System

HP-LP Bypass System

Sustained flow through the boiler heating surfaces is

assured, ensuring Re-heater protection during start-up of
units.

If the grid cannot accept power, the unit can be kept

running on house load.

Almost all power plants are provided with HP-LP bypass

systems for technical and economical reasons. The
technology has been obtained from SULZER
THERMTEC, Switzerland and we manufacture all the
components in-house.

BHEL has supplied bypass systems to

over 150 power plants of 120/210/250/500 MW rating with
a total installed capacity of over 32,000 MW.
 HP-LP Bypass System

HP-LP Bypass System

LEGEND
BP - HP BYPASS VALVE
BD - SPRAY WATER ISOLATION VALVE
HRH
BPE - SPRAY WATER FLOW CONTROL VALVE
MSL
LBP - LP BYPASS VALVE
LPC - LP COOLER
BP LBPE - LP BYPASS SPRAY VALVE
BOILER HPT MPT LPT HPT - HIGH PRESSURE TURBINE
MPT - MEDIUM PRESSURE TURBINE
CRHNRV LPT - LOW PRESSURE TURBINE
CRH LPC
LBP CON CRHNRV - CRH NON RETURN VALVE
BFP - BOILER FEED PUMP
BPE
LBPE CON - CONDENSER
BD MSL - MAIN STEAM LINE
HRH - HOT REHEAT LINE
BFP CRH - COLD REHEAT LINE
 HP-LP Bypass System

HP Bypass Valve
l Combined pressure reducing and
de-superheating valve.
l Steam pressure reduction by throttling and
temperature reduction by spray water injection
l To suit varying high pressure and temperature,
the valve body is made from forged material of
2¼ Cr 1 Mo steel (A182 F22 Cl.3).
l To keep the stresses in optimum level, valve
body is made of spherical shape.
l Leak tight seat. (HS 25)
l Stem is made from high chrome alloy steel
11 Cr 1 Mo (X19CrMoVNbN111).
l Design pressure : 200 kg/sq.cm
l Design temperature : 545°C

Model Nos: ARS 45, ARS 50, ARS 63,

ARS 72, ARS 80, ARS 90, ARS 100,
ARS 112, ARS 140 & ARS 140A
 HP-LP Bypass System

HP Bypass Spray Valve

l For spray water flow control to HP Bypass

Valve.
l Pressure reduction & flow control achieved
in three stages to avoid erosion due to high
pressure drop.
l Valve body is of "Z" configuration made from
forged carbon steel A 105.
l Stem is made from high chrome alloy steel
11Cr 1Mo (X19CrMoVNbN111)
l Leak Tight Stellite Seat.
l Design pressure : 350 kg/sq.cm
l Design temperature : 300°C

Model No : E22S, E32S, E45S

 HP-LP Bypass System

LP Bypass Valve

l Pressure reducing valve.

l Steam pressure reduction by throttling.
l Valve body is made from forged material
of 2¼ Cr 1 Mo steel (A 182 F 22 Cl.3)
l Stem is made from High Chrome alloy
steel 11Cr 1 Mo (X19CrMoVNbN111)
l To keep the stresses at optimum level,
valve body is spherical in shape.
l Leak tight seat.
l Design Pressure : 64 kg/sq. cm
l Design Temperature : 540°C

Model No : NR 64-500 EK
 HP-LP Bypass System

LP Bypass Spray Valve

l For spray water flow control to LP

Bypass valve
l Valve body is made from forged Carbon
steel A 105.
l Stem is made from High Chrome alloy
steel 11Cr 1 Mo (X19CrMoVNbN111)
l Leak tight seat.
l Design Pressure : 50 kg/sq. cm
l Design Temperature : 300°C
 HP-LP Bypass System

Electro Hydraulic Actuating System

Electro hydraulic actuating system is a complete modular unit

7 with a wide range of actuator cylinders (type ASM) having a
force of about 100 tonnes and large stroke.

8 It consists of an Actuator cylinder (type ASM), Oil supply unit

(type OV 32B), Servo valve (type ST), Blocking unit (type BL),
3

44 Step control unit (type APL), Quick stroking device (type SSB).
Each actuator is equipped either with one Servo valve and
1
5 6 Blocking unit or a step control unit.

Servo valve and blocking element control the open/close and

stay-put function of the valves.
1. Actuator cylinder, type ASM Hydraulic oil required under
2 2. Oil supply unit, type OV 32B
high pressure for the
3. Servo valve, type ST
4. Blocking unit, type BL operation of the valves under
5. Step control unit, type APL high steam pressure is
6. Connection plate
supplied by the Oil supply unit.
7. Additional accumulator
8. Quick stroking device, type SSB