HP/LP

BYPASS
SYSTEM
PREPARED BY:CHARANPREET SINGH
C&I ( SR. ENGG.)

CONTENTS

HP/LP BYPASS ANIMATED OVERVIEW & OBJECTIVE

SERVO OIL SKID & LOGIC
SERVO VALVE COMPONENTS
ON/OFF SOLENOID VALVE OPERATION
PROPORTIONAL SOLENOID VALVE OPERATION
HPBP CONTROL MODES
HPBP PRESSURE CONTROLLER
HPBP TEMPRATURE CONTROLLER
LPBP CONTROL MODES
LPBP PRESSURE CONTROLLER
LPBP TEMPRATURE CONTROLLER
BLOCK VALVE ,FAST OPEN & FAST CLOSE OPERATION

HP BYPASS ANIMATED OVERVIEW

STRAINER
SH OUTLET (L)

TV1 /
GV1

PRESSURE
CONTROLLER

BP-1

TEMP
CONTROLLER
BPE1
BD

DRAIN

HP
TURBINE

TO CRH INLET
HEADER

FROM BFP
BPE2
TEMP
CONTROLLER

DRAIN

BP-2

TV2 /
GV2
SH OUTLET (R)
STRAINER

LP BYPASS SYSTEM
RH OUTLET
LP BYPASS SPRAY
FROM CEP

STRAINER

RSV 1 /
IV1

LPCV 1

CONDENSER

IPT
LPCV 2

LP BYPASS SPRAY
FROM CEP
RH OUTLET

STRAINER

RSV 2 /
IV2

HP & LP BYPASS
OBJECTIVE OF HP BYPASS :i) To operate the boiler and the turbine virtually independent of each other by bypassing
the Main steam to Cold Reheat line during STARTUP, SHUTDOWN, LARGE DISTURBANCES.
ii) It also performs the De superheating function to keep the steam temp in CRH within 380 degC.

The HPBP valve can handle a maximum of 60% of the full load turbine steam flow(2200TPH).
OBJECTIVE OF LP BYPASS :i) To operate the boiler and the turbine virtually independent of each other by bypassing
the HRH to CONDENSER during STARTUP, SHUTDOWN, LARGE DISTURBANCES.
ii) It also performs the De superheating function to keep the condenser temp within 90 degC.

SERVO OIL SKID

COMPONENTS
PUMP:-consists of two pump with its
individual accumulator charging
valve.
If the Pr. In the accumulator increases
the accumulator valve switches the
pump into recirculation.
Filter pump can also be used to fill
and empty the tank by switching over
a multi way cock.
3 no. of PT, 01 no. of LT, 01 no of TT
and 01 DP switch are used.

N2

PT

HDR

ACC.
CHRGNG VLV

F
FILTER & FAN

P
FILTER PMP

LT

TT

i)
ii)
iii)

PMP START PORMISSIVE

No Pressure Fault.
No Level Fault.
No Temperature Fault.
PUMP AUTO LOGIC

1.Pump1 Primary .
OR
2.Pump1 Standby AND Pump2 Selected
OR
3. Pr. < 201 KG/CM2 AND Pump1
main selected.

PUMP2 MAIN SEL SET

If any one of the conditions set
TRUE
i)
Pump1 Primary for 3 Days.
ii)
Pump1 Primary AND Pressure
> 250kg/cm2.
iii) Pump1 Power Switch OFF
from the skid.
iv)
Accumulator charging valve1
Power switch OFF from the
skid.
v)
Pump1 DP HI.

i)

ii)
iii)
iv)

PUMP STNDBY SET

Oil System
Healthy(LVL>170mm,120<DIS
CH Pr <250,Oil Tmp<70 degC).
AND
Discharge Pr. <201 kg/cm2 AND
Pump2 ON feedback AND
Pump2 Main Selection SET.
PUMP STNDBY RESET

1. Oil System NOT health.

OR
2. Pressure > 216 kg/cm2.

PUMP PRIMARY SELECTION

AUTO SELECTION AND Pump2 NOT
main selected AND (Level not <170mm
OR Pressure Not
< 120 Kg/cm2 OR
Pressure Not > 250 Kg/cm OR
Temperature Not >70 Deg C.
ACC CHARGING VLV
1. AUTO ON:- Pump ON AND Pr.<216
kg/cm2.
2. AUTO OFF:-Pump ON AND Pr.>
240 kg/cm2.

PUMP 2 MAIN SEL RESET

If any one of the conditions set
TRUE
i)
Pump2 Primary for 3 Days.
ii)
Pump2 Primary AND Pressure
> 250kg/cm2.
iii) Pump2 Power Switch OFF
from the skid.
iv)
Accumulator charging valve2
Power switch OFF from the
skid.
v)
Pump2 DP HI.
vi)
Pump1Standby selected.

FILTER PUMP
1. MANUALLY TURN ON/OFF.
2. TO TURN ON TANK LVL NOT <
170 MM.
COOLING FAN
1. MANUALLY TURN ON/OFF.
2. AUTO ON if Filter Pump is
Running AND Temp>70 deg C.

SERVO VLAVE COMPONENTS

1. Power supply cabinet PVN11(Supply A & B):-230V/50Hz/4.3A/ Fuse 20A/ UPS Supply.
2. CCI Positioner Cabinet PVR10eP-5(for PCV):- 24VDC/3.9A/ Fuse 10A.
3. CCI Positioner Cabinet PVR11eP-1(for spray Block Valve & CV):-24VDC/5.1A/ Fuse 10A.
4. Pressure Control Valve:-Proportional Valve PVA & PVB for OPEN & CLOSE
(24VDC),Blocking unit(24VDC) (De- Energize to Block) ,Solenoid Valve for FAST OPEN
(Energize to Open) & for FAST CLOSE (De- Energize to Close) .
5. Spray Control Valve:- :-Proportional Valve PVA & PVB for OPEN & CLOSE
(24VDC),Blocking unit(24VDC) (De- Energize to Block).
6. . Spray Block Valve:- Solenoid valve for OPEN & CLOSE (24VDC) and Blocking unit(24VDC)
(De- Energize to Block).
7. RSG16+ 2K:- Position transmitter(24 V DC/ 4-20 mA) with 4 Limit Switches for Open & Close
feedback.

ON/OFF VALVE SOLENOID OPERATION

P
Pp

PT
Qk

Q1

QP

QP

PT QT T
Qk

Q1

P1
1

P2
2

4/3
SOLENOID
SOLENOID
VALVE
VALVE
SYMBOL
SYMBOL
SOLENOID
VALVE
SYMBOL
BLW
BLW
PISTON
PISTON

ABV
ABV
PISTON
PISTON

CLOSE
CLOSE

OPEN
OPEN

100%

PROPORTIONAL VALVE OPERATION.

P
Pp

PT
PT

QPQ QP
P
QP
Qk

Q2

PPT QQ
T
T T
T
Qk

Q1

Q2

QQ1 1

P2
2

PP11
1

4/3 WAY PROPORTIONAL VALVE

SYMBOL

25%
50%
75%
100%

10

HPBP & LPBP CONTROL MODES

BLR FLM ON
OR

MS HDR PR > 0.5MPA /

HRR HDR PR > 0.01MPA

MIN. POSITION MODE

AND

MIN. POSITION MODE

MS HDR PR > 1MPA /
HRH HDR PR > 0.22MPA

AND
OR

MIN. PR. CNTRL MODE

MIN. PR. CNTRL MODE

AND

HPCV POS>50% /
LPCV POS>40%

S
OR

PRESSURE RAISE MODE

MS HDR PR > 5.9MPA /
HRH HDR PR > 0.5MPA

PRESSURE RAISE MODE

AND

S
OR

FIXED PRESSURE
CONTROL MODE

N
FIXED PRESSURE CONTROL
MODE
GEN MW>20%
TMC IN AUTO
BLR IN AUTO

OR

AND

S
R

PRESSURE FOLLOW MODE

11

LPBP

HPBP & LPBP PRESSURE CONTROLLER

1.

FIXED PR. CONTROL MODE

2.

MIN. PR. CONTROL MODE

3.

PR. FOLLOW MODE

5.9MPa

0.55MPa

1MPa

0.22MPa

MS HDR
PR.
SP

MS HDR Pr.+ fixed SP

HRH HDR Pr.+ fixed SP

HPBP

PV

P I
MIN. POS.
MODE

N
Y

15

60

30

80

140

PR. RAISE
MODE

120

100
80

MSTR
DMD

60
40
20
0

MIN.
POS
VLV POS
MS HDR PR.

MIN. PR.

PR.
RAIS E

FIXED
C NTR
L

PR.
FOLLOW

HP CV
LEFT

HP CV
RIGHT

12

HPBP SPRAY CONTROL VALVE LOGIC

MSTR DMD

POS FDBK

HPBP I/L STM ENTHALPY

HPBP O/L STM ENTHALPY

BFP DISCH
ENTHALPY

F(x)

D
CNTRLR

BLOCK VLV LOGIC

FEEDFORWARD
SIGNAL

PV

PI
SP

HPBP
O/L TMP
SET
POINT

AUTO OPEN:- PCV>2% OPENS

AUTO CLOSE:- PCV<2% OR
ABNORMAL CONDITION

HEAT LOST BY STM = HEAT GAIN BY WTR

STM QTY* NET ENTHLPY=WTR QTY*NET ENTHLPY

MSTR DMD

WTR REQ= STM QTY* (I/L STM ENTH - O/L STM ENTH)
(I/L WTR ENTH - O/L WTR ENTH)

SPRAY CV
LEFT

SPRAY CV
RIGHT

13

LPBP SPRAY CONTROL VALVE

MSTR DMD

POS FDBK

LPBP I/L STM ENTHALPY

LPBP O/L STM ENTHALPY

ENTHALPY SP

N
D

F(x)

LPBP
O/L TMP
CNTRLR

TCV
F
LOW SP

PI

PV

MSTR DMD

SPRAY CV
LEFT

SPRAY CV
RIGHT

14

BLOCK VALVE OPERATION

BLOCK VALVE

FAST OPEN

FAST CLOSE

PROPORTIONAL
VALVE

OPEN

CLOSE

HPBP FAST OPEN

BOILER FLAME ON AND NO QUICK
CLOSING
BLOCKING
COND AND
CONDITIONS
(TURBINE TRIPS
IN NORMAL
CONDITION
OR MS HDR
PR >17.5 Mpa.
WHEN BLOCK VLV DE-ENERGISE.
BLOCK
SOLENOID:DUE TO
OIL PR.
TOO LOWENERGISED
OR POWER
FAST
OPEN
SOL:-DE-ENERGISED
SUPPLY NOT HEALTHY
IT PERFORMS
FAST LPBP
CLOSING
FASTSOL:-ENERGISED
OPEN
THE BLOCKING
ACTION.
BOILER FLAME ON AND NO QUICK
CLOSING COND AND (TURBINE TRIPS
OR HRh PR >3.7Mpa.

15

FAST OPEN OPERATION

BLOCK VALVE

FAST OPEN

FAST CLOSE

FAST
OPENED

3.
4.
5.

HPBP FAST CLOSE

HPBP O/L TEMP HI HI >390 DEGC.
HPBP IN
SUPERHEAT
TMP
<50 DEGC
FAST OPEN
COND.
AND MS PR >5.9 Mpa.
OIL
TANK SOLENOID:LVL < 170mm.
BLOCK
ENERGISED
Pr.FAST
TOO OPEN
LOW SOL:-ENERGISED
< 120Kg/cm2.
FAST
CLOSING
SOL:-ENERGISED
OIL
TEMP
TOO HI>
70 DEGC.

1.
2.
3.
4.
5.

LPBP FAST CLOSE

CNSR VAC HI.
CNSR TMP HI.
OIL TANK LVL < 170mm.
Pr. TOO LOW < 120Kg/cm2.
OIL TEMP TOO HI> 70 DEGC.

1.
2.

16

FAST CLOSING OPERATION

BLOCK VALVE

FAST OPEN

FAST CLOSE

CLOSED

IN FAST CLOSE COND.

BLOCK SOLENOID:- ENERGISED
FAST OPEN SOL:-DE-ENERGISED
FAST CLOSING SOL:-DE-ENERGISED

17

THANK YOU
18