WRITE UP ON LPBP

DRG.NO. 4-18000-90-440

1 As per agreed MOM dtd 06.01.2011 Nirbhay/CI NIRBHAY B.S.RANA 05.02.11

REV. STATUS TYPE REASON PRPD. CHKD. APPD. DATE

CUSTOMER : INDIABULLS POWER LIMITED.

AMRAVATI 5X270 MW TPP
PROJECT:
AMRAVATI, MAHARASTRA

CONSULTANT : TATA CONSULTING ENGINEERS LTD. MUMBAI.

DRN NAME SIGN DATE

PRPD. NIRBHAY Sd/- 14.09.10

14.09.10
BHARAT HEAVY ELECTRICALS LTD., DEPT: CIE
CHKD. NIRBHAY Sd/- . .
14.09.10
HARDWAR CODE: 4180 APPD. B.S.RANA Sd/- 19.09.10
14.09.10
TITLE : WRITE UP ON LPBP REV.NO.
DRG.NO. 4-18000-90-440
0
Inventory No. Sign & Date Ref. Drg. No. The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. SHEET NO. 1 OF 9
It must not be used directly or indirectly in anyway detrimental to the interest of the company.

VR_C15.FR
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1.0 GENERAL

In certain operating conditions, the IP-turbine cannot accommodate the

steam produced by the boiler. The LP Bypass system enables to establish
an alternative path for dumping this excess steam from the reheater
outlet directly into the condenser at suitable steam parameters, bypassing
the IP and LP turbine.

For this purpose, the bypass valve combinations (i.e. LPBP SV & CV) open
in relationship to the pressure in the reheat line, by a pressure controller.
The pressure regulator feeds the positioner, such that,

a) there is sufficient flow through the reheater, and

b) the response of the reheater safety valves is avoided during load
shedding and during turbine emergency trip.

Each LP-bypass Stop Valve (SV) and Control Valve (CV) is provided with
its own Electro-Hydraulic Actuator (EHA) which operates with high
pressure control fluid supplied by a centralized Hydraulic Power Supply
Unit (HPSU).

The EHA of each LPBP-SV is provided with a pilot valve (solenoid valve)
and 2 Trip Solenoid Valves (TSV) for redundancy. On receiving a trip
signal, one of the coils of TSV must de-energise to cause trip. The
opening of bypass SV is done over the pilot valve, which is controlled in
relationship to the pressure controller output signal.

The EHA of each LPBP-CV is provided with a servo/proportional-valve and

an interlocking solenoid valve. For opening & closing of the LP-Bypass-CV,
the pressure controller controls the servo/proportional-valve over a
positioner (one for each CV). The proportional-valve positions the EHA,
which in turn operates the LPBP-CV. The position of the CV is fed back
over an analog position transmitter, to the positioner.

2.0 FUNCTIONAL SPECIFICATIONS:

The LPBP control system consists of a pressure controller, subordinated

by positioner (one for each LPBP CV).

2.1 Pressure Control Circuit.

The pressure controller features different transfer functions, one applies

for opening & closing of the LPBP stop valves and the other for opening &
closing of the LPBP control valves.

2.1.1 Set point Formation

The pressure set point is formed over a MAX selection of the Fixed
setpoint & Variable setpoint.

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For startup and coast-down, a fixed setpoint value is fed to the pressure
controller. This can be manually set to the desired value from the control
room. It can also be set from the `Automatic Setpoint Matching’ (ASM)
to have a proper balance between the reheater flow and buildup of
reheater pressure during a cold start. The ASM can be switched ON/OFF
from the control room.

Formation of Variable setpoint depends on load, which is achieved by

acquisition of pressure before HP-blading by means of a pressure
transmitter. An upper pressure limit is also provided by means of which
the setpoint is limited to a value below the setting of the reheat safety
valves.

2.1.2 Pressure Actual Value

The reheat pressure is measured by means of a pressure transmitter to

form the pressure actual value.

2.2 Flow Limit Control

For the reduction of steam temperature, water is injected into the bypass
steam before steam enters into the condenser.

In case of partial bypass, the designed steam flow is exceeded for the
shedding of loads of turbine emergency trip with high super heater
pressure. This may lead to the condition of insufficient injection water and
overloading of condensate pumps. To avoid this , a flow limit controller is
provided which restricts the opening of the LPBP-CV depending on
pressure after the bypass valves. For this, the output of the pressure
controller or manual control is coupled with the output of the flow limit
controller in a MIN selection.

2.2.1 Set point

This is a pre-selectable constant signal which corresponds to the

maximum allowable steam pressure after LPBP valves.

2.2.2 Actual Value

This is the pressure after the LPBP CV. A pressure transmitter measures
the pressure in the pipeline downstream each bypass valve combination
and the maximum pressure is derived from a MAX selection of the two
transmitters. This pressure gives the actual value of pressure after the
LPBP CV.

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2.3 Control of each bypass valve combination (i.e. SV + CV) :

2.3.1 Bypass SV

The opening of each BPSV is done over a pilot valve (solenoid valve)
which is controlled by the effective position setpoint (hs) .
Pilot valve ON (energised) = SV open.

The pilot valve is switched ON when the position setpoint is > -20% and
LPBP trip has not responded.

2.3.2 Bypass CV

The pressure controller output acts on a minimum value selection along

with the output signal of the flow limit controller, for the opening and
closing of the BP CV . The output signal of this MIN-gate forms the
position setpoint (hs) for the position controller.

2.3.3 Water Injection Valve (WIV)

Water is injected into the bypassed steam before it passes into the
condenser. This is done by a controlled-type Water Injection Valve (WIV).
There is one Water Injection Valve for both LP-bypass valve combinations,
which is controlled over a controller.

(For operation of the controlled-WIV, refer separate write-up no. 4-

18000-90-441)

2.4 Control of Reheater Safety Valves

Malfunctions of the turbine bypass, i.e. failure to open the bypass valves,
have to be counteracted by opening of the reheater safety valves to
ensure flow through the reheater. This prevents heat accumulation in the
reheater tubes. For this purpose, the measure of flow through reheater is
the magnitude of the control deviation between actual and set pressure.

The following limit signals are generated from the pressure controller, for
control of the reheater safety valves :
• Control deviation of the pressure controller (xd) > 30%
• Position setpoint >25%

The reheater control valves are opened under the following conditions :

¾ The control deviation rises above the value given above AND
neither the bypass stop valves are open (<100%) nor all bypass
control valves are at least about 60% open, the command for
opening the reheater safety valves is given after a delay of 5 sec.

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¾ The position setpoint exceeds 25% AND the LPBP stop valves are
not open (<100%), the command for opening the reheater safety
valves is given after a time delay of 30s.

2.5 Valve Positioner

The valve positioner performs the function of positioning the EHA of the
LPBP-CV according to the position setpoint. An individual positioner is
allotted to each EHA. Each positioner gets its setpoint as described above
in pt. 2.3.2.The positioner is mounted in control cabinet located near
Actuator. The positioner controls the. Proportional-valve The proportional-
valve in turn, positions the EHA to operate the corresponding LPBP-CV.

2.5.1 Position actual value (ha)

The position of the piston in the operating cylinder of the EHA is recorded
by means of an analog position transmitter, thereby giving the position
actual value.

2.5.2 Blocking of actuation of BPCV

An interlocking valve (solenoid valve) is provided in the LPBP CV actuator

to prevent the proportional-valve from acting on the power cylinder,
thereby holding the CV in the last position, when HPSU system header
pressure becomes very low.

Under normal conditions, the interlocking valve remains energised and

the CV is opened / closed directly through the servo/proportional-valve.
When system header pressure goes very low , the Interlocking Valve is
deenergized and causes the intermediate check valves to close, thereby
blocking the servo/proportional-valve from the cylinder. Thus the CV is
held in its last position.

2.6 Manual control (Fig.2.)

Switching over to manual control can be done from the control room
by the control display ‘LPBP Controller ON/OFF’. The switching ON is
stored (OFF has preference to ON). In addition, in case of disturbances in
the electrical part of the controller, switching over to manual control is
done.

The following disturbances cause switching over to manual control:

- Fault in positioner 1
- Fault in positioner 2
- Fault in pressure transducer measuring pressure before HP-blading
(output signal < 3mA) – refer point 2.1.1.
- Fault in pressure transmitter measuring actual reheat pressure
(output signal < 3mA) – refer point 2.1.2
- Internal voltage supply failure.

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The pressure controller output can be controlled by the open / close

control displays. Thus the LPBP-CV can be positioned manually as desired.

2.6.1 Tracking

In order to facilitate the switching ON and OFF of the control during

normal turbine operation, a constant tracking of the control parameter not
in operation is done (i.e. manual control signal or pressure controller
signal).

As long as the pressure actual value and the pressure setpoint conform,
switching over is bump less. If the set-value and the actual value do not
conform, the position of the LPBP-CV varies according to the existing
control deviation.

3.0 Automatic Setpoint Matching

During startup, the fixed setpoint of the LPBP controller is automatically

compensated to the actual value when boiler is fired. The reheat pressure
rises and when it exceeds the fixed setpoint, the LPBP CV opens. Due to
increasing positive control deviation, the LPBP CV opens further as
required, for the sufficient flushing of the reheater. At this position, the
CV is kept ‘fixed’ automatically by the signal ‘keep fixed’, to quickly
produce a pressure buildup. At the same time, the actual value is tracked
by the signal ‘Keep Fixed’. If the reheater pressure attains a value which
corresponds to the startup of the turbine (approx. 12 bars), the ‘keep
fixed’ signal is removed and the FSP no longer tracks the actual value and
the control of the reheat pressure is released. The variable setpoint, now
rising fast (refer point 2.1.1.2) releases the fixed setpoint over the MAX
selection. With the attainment of pressure actual value > 15 bar or with
LPBP controller switched off, the Automatic Setpoint Matching is tripped
automatically.

The Automatic Setpoint Matching can be switched ON/OFF from the

control room.

4.0 Control Room Signals

4.1 The following status indications are provided in the control room:

- LPBP controller ON/OFF

- Automatic Setpoint Matching ON/OFF
- LPBP SV1 OPEN/CLOSED
- LPBP SV2 OPEN/CLOSED

4.2 The following indications are provided in the control room :

- Position of LPBP CV1

- Position of LPBP CV2

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- Fixed Setpoint
- Variable Setpoint
- Effective pressure setpoint
- Control Deviation
- Reheater Pressure (HRH steam press before LPBP Valves)

4.3 Alarms :

An alarm ‘LPBP Control Faulty’ is generated from the response of any of

the following signals (refer point 2.6) :

- Fault in Pressure Transmitter measuring pressure before HP blading.

- Fault in Pressure Transmitter measuring actual reheat pressure.
- Fault in Positioner 1
- Fault in Positioner 2
- Internal Voltage Supply failure.

An alarm ‘Flow Limit Signal Disturbed’ is generated from the response of

any the two signals as below (refer point 2.2.2):

- Fault in Pressure Transmitter measuring pressure in the pipeline

downstream LPBP CV1
- Fault in Pressure Transmitter measuring pressure in the pipeline
downstream LPBP CV2

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