Actuator lifting test of Unit-1

 Start AOP as per procedure & make overhead tank normal.

 Start COP as per procedure & put the stand by pump in manual mode.
 If both Boilers are in shut down condition, then ask C&I people to put FD fan of any
Boiler in simulation mode.
 Reset all heavy faults displayed in DCS.
 Press Governor clear & then reset button provided in Governor Panel.
 Ensure ESV is opened both in field & DCS.
 Then operate shut down button provided in key pad of Governor Panel.
 Press Actuator (no.2) button.
 Scroll 2 times down ward & see in the display panel that Steam must be cut off.
 Then press Yes (no.1) & again scroll 2 times down ward, check manual lifting of
Actuator will come in Display panel.
 Press yes (no.1).
 Press Enter & give open command (% wise) to Actuator.

Actuator lifting test on 18.04.2014

Opening command from Governor Panel Opening in field(mm)

10 2
20 6
30 11
40 17
50 23
60 30
70 36
80 42
90 48
100 55

Events happened
1. While giving opening command from 20 to 40 % or from 40 to 60 %, stand by COP got
auto started.
2. During giving command from 0 to 100 %, COP got auto started but still ESV closed.

Actuator lifting test on 27.04.2015

Opening command from Governor Panel Opening in field(mm)

 10 0
20 6
30 11
40 17
50 23
60 29
70 36
80 42
90 48
100 55

Note:- No abnormality found.

Actuator lifting test on 13.06.2015

Opening command from Governor Panel Opening in field(mm)

10 0
13 0
15 4
20 5
30 10
40 15
50 22
60 28
70 35
80 40
90 48
100 55

Note:- No abnormality found.

Actuator lifting test on 21.08.2015

Opening command from Governor Panel Opening in field(mm)

10 0
 20 4
30 10
40 15
50 20
60 29
70 35
80 42
90 48
100 55

Note:- No abnormality found.

Actuator lifting test on 01.03.2016

Opening command from Governor Panel Opening in field(mm)

10 0
20 4
30 10
40 14
50 20
60 28
70 32
80 40
90 46
100 52

Note:- No abnormality found.

Actuator lifting test with the existing amplifier

Date: - 01.06.2016

Opening command from Governor Panel Opening in field (mm)

0 0
10 0
20 5
30 11
 40 17
50 24
60 28
70 35
80 41
90 47
100 54

Note: The same readings observed in both coupled and decoupled condition

Actuator lifting test with the replaced amplifier

Opening command from Governor Panel Opening in field (mm)

0 0
10 5
20 12
30 18
40 24
50 30
60 37
70 44
80 50
90 56
100 62

Note: The same readings observed in both coupled and decoupled condition

Actuator lifting test on DT. 24.10.2016

Opening command from Governor Panel Opening in field (mm)

0 0
10 5
20 10
30 20
40 25
50 30
60 37
70 45
80 50
 90 56
100 64

Remarks:-

1. When command given from 0% to 25% directly, the standby COP auto started as control
oil pr low. Pr switch acted.

2. When command given from 75% to 100%, both COP-1&2 were in service, still then
control oil pr low. Pr switch acted.

Actuator lifting test on DT. 03.02.2017

10% interval command

Opening command from COP Pr (kg/cm²) Drop

Opening in field (mm)
Governor Panel w.r.t. Actuator Command
0 0
10 6
20 12
30 18
40 24 Control oil pressure was
50 30 dropping from 14.00 kg /
60 37 cm2 to 13.87 kg/ cm2
70 44
80 50
90 56
100 62

25% interval command

Opening command from COP Pr (kg/cm²) Drop

Opening in field (mm)
Governor Panel w.r.t. Actuator Command
0 0
25 16 Control oil pressure was
50 30 dropping from 14.00 kg /
75 46 cm2 to 13.60 kg/ cm2
100 62
50% interval command

Opening command from COP Pr (kg/cm²) Drop

Opening in field (mm)
Governor Panel w.r.t. Actuator Command
0 0 Control oil pressure was
50 30 dropping from 14.00 kg /
100 62 cm2 to 13.40 kg/ cm2

100% command

Opening command from COP Pr (kg/cm²) Drop

Opening in field (mm)
Governor Panel w.r.t. Actuator Command
0 0 Control oil pressure was
dropping from 14.00 kg /
100 62 cm2 to 11.25 kg/ cm2

Remarks:- In all above cases Control Oil Pump was not getting started in auto.

Actuator lifting test on 29.01.2019

Opening command from Governor Panel Opening in field(mm)

10 6
20 12
30 18
40 24
50 32
60 38
70 44
80 50
90 58
100 62
90 58
50 32
25 16
25 14
 50 30
80 48
100 62
0 0
50 30
100 62
0 0
75 46
0 0
100 62
0 0
Remarks:-

1. When command given from 0% to 100% directly, the standby COP auto started as
control oil pr low(12.75ksc DCS value. Pr switch acted

Actuator lifting test on 26.02.2019

Opening command from Governor Panel Opening in field(mm)

10 6
20 12
30 18
40 24
50 32
60 38
70 44
80 50
90 56
100 62
75 46
50 32
25 14
0 0
50 32
100 62
Remarks:-

1. When command given from 0% to 100% directly, the standby COP auto started as
control oil pr low& ESV closed.
 Actuator lifting test on 30.05.2019

Opening command from Governor Panel Opening in field(mm)

10 6
20 12
30 18
40 24
50 30
60 36
70 44
80 50
90 56
100 62
20 12
40 25
20 12
0 0
Remarks:-

1. When command given from 0% to 20% directly, Control oil pr. was dropping from 13.88
ksc. to 13.65 ksc. and normalized.
 Actuator lifting test on 26.06.2019

Opening command from Governor Panel Opening in field(mm)

10 5
20 10
30 15
40 22
50 30
60 35
70 42
80 50
90 55
100 62
90 55
80 55
70 45
60 37
50 30
40 25
30 20
20 12
10 5
0 0
20 12
40 22
20 12
0 0
50 30
100 62
0 0
75 46
0 0
100 62
Remarks:-

1. When command given from 0% to 100% directly, Control oil pr. was dropping from
13.90 ksc. to 11.32 ksc. and Turbine trip ,COP-02 auto start.