CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER

OF LP BYPASS 210 MW.
1.0.0.

Initial checks for setting the Hydraulic Converter of LP by pass.

1.1.0.

The components number indicated on the checklist is based on the

Governing scheme Drg. No. 1.1-2190-7280/1.

1.2.0.

Check whether erections of all pipelines are completed, for LP bypass

system.

1.3.0.

Check that all the drain valves in the control oil lines of water of
water injection valve are kept closed.

1.4.0.

Check whether the isolating valves before the filter MAX 42BT 021 is
kept opened.

1.5.0.

Check whether the isolating valves before the filter MAX 42 BT 022 is
kept opened.

1.6.0.

Check whether the isolating valve before the filter MAX 42 BT 081 is
kept opened.

1.7.0.

Check whether the following valves are kept opened.

1.7.1.

The isolating valves MAX 42 AA 551 + 543, MAX 42 AA 542 + 544,

MAX 42 AA 553 + 555 in the control oil line to water injection valve.

1.7.2.

Signal oil inlet valve MAX 53 AA 521 + 522 to slide valve MAX 52 AA
081 + 082 of LP by pass both stop valves.

1.7.3.

Control oil inlet valve MAX 42 AA 521 + 523 to slide valve MAX 53 AA
081 + 082 of LP by pass both stop valves.

1.7.4.

Signal oil inlet valve MAX 53 AA 086 + 087 of LP by pass control

valves.

1.7.5.

Control oil inlet valve MAX 53 AA 086 + 087 of LP by pass control

valves.

1.8.0.

Check and ensure that the isolating valve before the individual
equipment in the rack, are kept opened.

1.9.0.

Check whether ACP is running and control oil pressures of 6 to 7 bar

is available.

1.10.0.

Run the condensate pump and ensure by opening the valve MAN 11 +
2
12 AA 511, that water pressure more than 10 kg/cm is available in
the limit controller.

1.11.0.

Ensure the vacuum is available to the limit pressure controller.

Vacuum should be greater than 0.6 bar abs.

1.11.1.

Vacuum can be created by means of Portable vacuum pump, vacuum

system is not ready.

1.12.0.

Keep open the isolating valve MAN 01 AA 501, in the downstream

reheat steam line to limit pressure controller.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

1.12.1.
1.13.0.
1.14.0.

Connect a Hydraulic pump in reheat line to limit pressure controller.

Check and ensure the isolating valve MAX 42 AA 571 in the control oil
line to EHC of LP bypass is OPEN.
Ensure reheat line is not charged with steam.

1.15.0.

Ensure that the respective LP bypass Governor characteristics is used,

while setting the LP by pass Governor.

1.16.0.

Ensure two standard gauges of 0-10 kg/cm is fixed in the signal oil
line of water injection and LP by pass.

1.17.0.

NOTE: - As per the LP by pass Governor adjustment sheet the stoke of

control sleeve cannot be measured. Hence the power piston KA 08
movement is measured, which is the four times the movement of
control sleeve given in the LP by pass Governor adjustment sheet.0-10
sleeve ring = 0-40 mm power piston.

**************
2.0.0.
2.1.0.

Checking and setting of protective devices of the LP by pass.

Ensure full vacuum is available to limit pressure controller and low
vacuum protection unit.

2.1.1.

Check the vacuum gauge indicates full vacuum.

2.2.0.

Ensure water pressure more than 10 kg/cm

pressure controller and water pressure switch.

2.2.1.

Check that pressure gauge MAN 01 CP 511 indicates more than 10

2
kg/cm .

2.3.0.

Ensure the solenoid valve for temp protection is not

energized.

2.4.0.

Rotate the hand wheel KA 09, to move the piston KA 08 of Amplifier

piston of converter for Electro hydraulic LP by pass Governor, for
obtaining signal oil pressure in LP by pass valve.

2.4.1.

Rotate hand wheel KA 09, to move the piston KA 08 about 12 mm to

get a signal oil pressure more than 2.0 kg/cm2 in the by pass valves.
Signal oil pressure in water injection line also will increase.

2.5.0.

Test the condenser vacuum trip protection is healthy. The trip value
for LP by pass limit controller MAX 53 BY 011 and low vacuum
condenser protection MAG 01 AA 016 is around 0.6 bar abs by opening
a vent screw at test valve.

2.5.1.

Reduce the vacuum gradually and note down by observing the

vacuum gauge, at what value of vacuum the signal oil pressure in the
by pas line drops down.

2.5.2.

Record the trip value of vacuum.

Page 2 of 9

is available for limit

CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

2.6.0.

Increase the vacuum and check the vacuum protection gets reset and
signal oil pressure in by pass comes back to original value.

2.7.0.

Jack the low vacuum condenser protection for making it ineffective.

2.7.1.

Repeat the operation 2.5.1.

2.7.2.

Record the trip value of vacuum for LP by pass limit controller.

2.7.3.
2.8.0.
2.9.0.

2.9.1.

Remove the jack from low vacuum condenser protection, for making
it effective.
Repeat the operation 2.6.0.
Open the top cover of LP by pass limit controller, MAX 53 BY 011 and
ensure that the oil jet nozzle KA 01 is in RHS. Insert a filer gauge on
the LHS by pass limit controller, in operative.
Repeat the operation 2.5.1.

2.9.2.

Record the trip value of vacuum for low vacuum condenser

protection.

2.9.3.

Remove the filer gauge from the LP by pass limit controller, placed
during operation 3.9.0.

2.10.0.

Repeat the operation 2.6.0.

2.11.0.

Study the values obtained in 2.5.2. 2.7.2. and 2.9.2. All the three trip
values obtained should be around 0.6 bar abs.

2.11.1.

Any of the trip value obtained in 2.7.2, 2.9.2. is less or more, adjust
LP bypass limit controller/low vacuum condenser protection to obtain
trip value around 0.6 bar abs.

2.11.2.

For obtaining required value at LP by pass limit controller

increase/decrease, the spring tension provided for adjustment on
vacuum, connection to bellow, according to the value obtained in 2.7.2.

2.11.3.

For obtaining required value at low vacuum condenser protection

unit, adjust item no. 2 of component drawing 1-1-3402-0002/1 in O&
M Manual, to vary the spring (item no. 4) compression, according to
the value obtained in 2.9.2.

2.12.0.

Test the water pressure switch protection is healthy. The trip value
for limit pressure controller MAX 53 BY 011 and water pressure switch
MAN 01 AA 011 protection is around 8.5 bar.

2.12.1.

Reduce the water pressure gradually and note down by observing the
water pressure gauge, at what value of water pressure, the signal oil
pressure in the by pass line drops down suddenly.

2.12.2.

Record the trip value of water pressure.

2.13.0.

Increase the water pressure and check the water pressure protection
gets reset and signal oil pressure in the by pass comes back to original
value.

2.14.0.

By pass the hydraulic water switch protection by operating the lever

to by pass position for making it ineffective.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

2.14.1.

Repeat the operation 2.12.1.

2.14.2.

Record the trip value of water pressure, for LP limit pressure

controller.

2.14.3.

Normalise the lever of hydraulic water protection to make it effective.

2.15.0.

Repeat the operation 2.13.0.

2.16.0.

Open the top cover of LP by pass limit controller MAX 53 BY 011 and
ensure that the oil jet nozzle KA 01 is in RHS. Insert a filer gauge on
the LHS which makes the LP by pass limit controller inoperative.

2.16.1.

Repeat the operation 2.12.1.

2.16.2.

Record the trip value of hydraulic water pressure switch protection.

2.16.3.
2.17.0.

Remove the filer gauge from the LP by pass limit controller placed
during operation 2.16.0.
Repeat the operation 2.13.0.

2.18.0.

Study the values obtained in 2.12.2, 2.14.2 and 2.16.2. All the three
trip values obtained should be around 8.5 bar.

2.18.1.

Any one of the trip values obtained 2.14.2 and 2.16.2 is less/more
adjust LP by pass limit controller/water pressure switch to obtain
2
around 8.5 kg/cm .

2.18.2.

For obtaining required value of LP by pass limit controller

increase/decrease the spring tension provided for adjustment on
water pressure, according to the trip value obtained in 2.14.2.

2.18.3.

For obtaining required trip value at hydraulic pressure switch unit,

vary the compression of the string item 6 of Drg. No.1-1-3410-0009/1
in O & M Manual.

2.18.4.

Close the top cover of LP by pass limit controller MAX 53 BY 011.

2.19.0.

The trip value of temperature protection device MAX 53 AA 021 + 022

is around 90qC at down stream of LP by pass.

2.19.1.

Energise one by one solenoid by shorting the protection lead and

check the signal oil pressure in LP by pass drops suddenly.

2.19.2.

De-energise the solenoids one by one, and check that the signal oil
pressure in the LP by pass comes back to the original value.
NOTE: - During this check, when solenoid for LPBP-1 is energized the
corresponding LPBP-1 stop and control valve actually clos eand
similarly for LPBP-2.

2.20.0.

Check the reheat protection of LP by pass limit controller.

2.20.1.

Increase the pressure in down stream impulse line of LP by pass

connected to the by pass limit controller through hydraulic pump to a
value of 21.2 kg/cm2.

2.20.2.

Ensure the piston KA 07 for the LP by pass limit controller just start to
2
close, at a pressure of 21.2 kg/cm .

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

2.20.3.

Record the pressure in the down stream of LP by pass reheat line,

when the piston KA 07 for limit controller closes fully.

2.20.4.

The difference between the reheat pressure in down stream line is

about 3.5 kg/cm2 approx. when the piston KA 07 of limit controller
moves from fully open to fully closed position.

2.21.0.

After ensuring the following protections namely LP by pass limit

controller, low vacuum condenser protection, water pressure switch
and temperature and pressure protection down stream of LP by pass
proceed for further setting and checking of LP by pass.

**********

3.0.0.
3.0.1.

3.0.2.

Setting of LP by pass Hydraulic Governor.

Operate the hand wheel of KA 09 to move the differential Amplifier
piston KA 08 of Converter for Electro-hydraulic LP by pass Governor,
for increasing the signal oil pressure in LP by pass and water injestion
lines.
Measure the lift of KA 08, while operating the hand wheel KA 09.

3.0.3.

Stop the operating of KA 09 when the lift at KA 08 of differential

Amplifier piston is about 3.2 mm.

3.0.4.

Check whether signal oil pressure in water injection line, is around

1.5 kg/cm2.

3.0.5.

If the signal oil pressure is not achieved, adjust both the follow up
2
piston KA 03 equally, to get a signal oil pressure of 1.5 kg/cm , in the
water injection line.

3.1.0.

Check whether the water injection valve 1 & 3 opens at a signal oil
pressure of 1.5 kg/cm2.

3.1.1.

Check whether the water injection valve 1 and 3, opened/not opened,

adjust the slide valve MAX 53 AA 031, spring tension accordingly, to
2
open exactly at 1.5 kg/cm of signal oil pressure in water injection
line.

3.2.0.

Energise the solenoid MAX 53 AA 051, to admit signal oil to the slide
valve MAX 53 AA 041.

3.2.1.

check the water injection valve 2 & 4 opened/not opened. Adjust the
2
slide valve spring tension accordingly, to open exactly at 1.5 kg/cm of
signal oil pressure in water injection line.

3.3.0.

Bring back the piston KA 08 of differential Amplifier piston to zero

position, by operating the hand wheel KA 09, and check all the four
water injection valves, closes fully.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

3.4.0.

Set the limit switches for full closed position, for all the four water
injection valves.

3.4.1.

Check whether the lamp indication appears at control room for all the
four water injection valves closed position.

3.5.0.

Operate the hand wheel KA 09, gradually, and increase the signal oil
pressure of 1.5 kg/cm2 in water injection line.

3.5.1.

Ensure that all the four water injection valves open at signal oil
2
pressure of 1.5 kg/cm , at the same time.

3.6.0.

Adjust the limit switches for full open position for all the four water
injection valves.

3.6.1.

Check whether the lamp indication appears at control room, in full

open position and closed lamp indication disappears for all the four
water injection valves.

3.7.0.

De-energise the solenoid MAX 53 AA 051.

3.7.1.

Check water injection valves 2 and 4, closes immediately.

3.7.2.

Check whether fully closed lamp indication appears and open lamp
indication disappears at control room for valves 2 and 4.

3.8.0.

Bring back the piston KA 08, differential Amplifier piston to zeo

position.

3.8.1.

Check whether water injection valves 1 & 3 closes immediately, when

the signal oil pressure in water injection line drops down below 1.5
2
kg/cm .

3.8.2.

Check whether closed lamp indication appears at control room for

valves 1 and 3.

3.9.0.

Move the differential Amplifier piston KA 08 to 7 mm by operating the

hand wheel KA 09.

3.9.1.

Check the signal oil pressure in the LP by pass line. It should be 1.7
kg/cm2.

3.9.2.

If the signal oil pressure is not achieved, adjust both the follow up
2
pistons equally to get a signal oil pressure of 1.7 kg/cm , in the LP by
pass line.

3.10.0.

Move the differential Amplifier piston KA 08 to a position of 12 mm,

36.8 mm and maximum by operating the hand wheel KA 09, and check
2
2
whether the signal oil pressure obtained are 2.2 kg/cm ,4.7 kg/cm ,
and near about 5 kg/cm2 respectively.

3.10.1.

If the maximum signal oil pressure of about 5 kg/cm in the LP by

pass line is not achieved for the maximum position of amplifier piston,
adjust the proportionality.

3.11.0.

Bring back the piston KA 08, of differential Amplifier piston to zero

position.

3.11.1.

Check the signal oil pressure in the LP by pass line is zero.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

3.11.2.

Ensure both the LP by pass stop valves are in full closed position.

3.11.3.

Adjust the closed limit switch of both the LP by pass stop valves.

3.11.4.

Check whether the lamp indication appears at control room.

3.11.5.

Adjust both the LP by pass stop valve, mechanical scale to zero

position, when the stop valves are fully closed.

3.12.0.

Bring back the piston KA 08 to the position where signal oil pressure
2
of LP by pass line is 1.7 kg/cm .

3.13.0.

Check whether the LP by pass stop valve, servomotor opens fully at a

signal oil pressure of 1.7 kg/cm2 in the LP by pass line.

3.13.1.

If the LP by pass stop valves one and two opened/not opened, adjust
the follow up piston MAX 53 AA 091+092 accordingly, to open exactly
2
at 1.7 kg/cm , of signal oil pressure in LP by pass line.

3.13.2.

Ensure that both the LP by pass stop valves are fully opened.

3.13.3.

Adjust the limit switches for full open position, for both the LP by
pass stop valves.

3.13.4.

Check whether the lamp indication appears at control room for full
open position of both the LP by pass valves.

3.13.5.

Check that close lamp indication do not exist at the control room for
both LP by pass stop valves.

3.14.0.

Check and ensure that both the LP by pass control valves, are in full
closed position.

3.14.1.

Adjust the LP by pass control valve position transmitter at local and

control room to zero position, when both the control valves are in fully
closed condition.

3.15.0.

Move the differential Amplifier piston KA 08, till the signal oil
pressure of LP by pass line, is around 2.2 kg/cm2.

3.15.1.

Check whether both the LP by pass control valve Servomotor just

2
opens at a signal oil pressure of 2.2 kg/cm in the LP by pass line.

3.15.2.

If the LP by pass control valve just opened/not opened, adjust the

2
slide valve MAX 53 AA 086 + 087, just to open, exactly at 2.2 kg/cm ,
of signal oil pressure, in the LP by pass line.

3.16.0.

Move the differential amplifier piston on KA 08, till the signal oil
2
pressure is around 4.7 kg/cm .

3.16.1.

Check whether both the control valve of LP by pass have opened fully.

3.16.2.

If both the LP by pass control valves has opened/not opened fully,

adjust the follow up piston in feed back oil line to get the full open
position. If necessary adjust the proportionality.

3.17.0.

Ensure the full lifts of both the LP by pass control valves are 80 mm.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

3.18.0.

3.19.0.

Check and ensure that the local position transmitter reads 80 mm at

the full open position of both the LP by pass control valves and the
control room, percentage position indicator, indicates 100%.
Bring back the differential Amplifier piston to zero position.

3.19.1.

Check and ensure that the closed lamp indication appears, and open
lamp indication disappears at control room, for both stop valves of LP
by pass.

3.19.2.

Check and ensure that the closed indication at control valves of LP by

pass matches with zero position at local and at control room
respectively.

3.20.0.

Actuate the solenoid of temperature protection.

3.20.1.

Move the differential Amplifier piston KA 08 by operating hand wheel

KA 09, to the maximum position.

3.20.2.

Check and ensure that the signal oil pressure in the water injection
line is more than maximum and signal oil pressure in the LP by pass
line is less than 1.6 kg/cm2.

3.20.3.

De-energise thee solenoid of the temperature protection.

3.20.4.

Check whether the signal oil pressure in the LP by pass line goes to 5
kg/cm2.

3.21.0.

Actuate low vacuum protection and water pressure switch protection

one by one.

3.21.1.

Note, when any one of the protection is actuated, the action that
takes place is as per 3.20.2.

3.22.0.

Bring back the differential Amplifier piston KA 08, to a piston where

2
signal oil pressure is 1.5 kg/cm in the water injection line.

3.22.1.

Note down the signal oil pressure in the LP by pass line.

3.23.0.

Operate the hand wheel KA 09 of converter for Electro-hydraulic LP

by pass Governor, and increase the signal oil pressure in the LP by
pass line.

3.23.1.

Check and ensure that both the LP by pass stop valves open fully and
both the LP by pass control valves start to open, at a signal oil
pressure of 2.2 kg/cm2, on the LP by pass line.

3.24.0.

Increase the signal oil pressure in the LP by pass line in the LP by

2
pass line in steps of 0.2 kg/cm and note down both the LP by pass
control valve lifts.

3.25.0.

Plot the characteristics curve.

3.25.1.

Stroke of control sleeve of follow up piston versus signal oil pressure

in water injection.

3.25.2.

Stoke of control sleeve of follow up piston versus signal oil pressure

in the LP by pass system.

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO HYDRAULIC CONVERTER OF LP BYPASS 210 MW

3.25.3.

Signal oil pressure in the LP by pass system versus LP by pass system

versus LP by pass control valve lift.

**********

4.0.0.

Setting and checking of Electro-Hydraulic Converter of LP

by pass MAX 53 BY 001.

4.1.0.

Open the control oil-isolating valve MAX 42 AA 571 to EHC of LP by

pass.

4.2.0.

Ensure the hand wheel KA 09 of Converter for Electro-Hydraulic in full

closed condition and lock it.

4.3.0.

Ensure that piston KA is in the upper most position and there is a

clearance between piston KA 08 top to the hand wheel lever of KA 09.

4.4.0.

Feed 0-10 volts to Electro-Hydraulic converter in steps of one volt.

4.4.1.

Ensure at 10 volts, the differential amplifier piston KA 08 travels,

approximately 40 mm and piston controller at control room indicates
100%.

4.5.0.

Feed zero volts and bring differential amplifier piston KA

08 to minimum position.

4.6.0.

Feed the voltage gradually to EHC and note down the following.

4.6.1.

Check and note down the voltage at which water injection valves
opens corresponding to signal oil pressure in the water injection line of
2
1.5 kg/cm . The voltage will be approximately about 2.0 volts.

4.6.2.

Check and note down the voltage at which both the stop valves of LP
by pass opens corresponding to signal oil pressure in the LP by pass
line of 1.7 kg/cm2. The voltage will be approximately about 2.5 volts.

4.6.3.

Check and note down the voltage at which, both the control valves of
LP by pass starts to open corresponding to signal oil pressure of 2.2
2
kg/cm in the by pass line. The voltage will be approx. about 3.5 volts.

4.6.4.

Note down the voltage at which both the control valves of LP by pass
opens fully. The voltage will be approximately about 9.0 volts for a
2
signal oil pressure of 4.7 kg/cm in the LP by pass line.

4.7.0.

Plot the curve for the following.

4.7.1.

EHC voltage versus signal oil pressure in the water injection line.

4.7.2.

EHC voltage versus signal oil pressure in the LP by pass line.

4.7.3.

EHC voltage versus differential amplifier piston lift.

4.7.4.

EHC voltage versus control valve lift, of LP by pass.

Page 9 of 9