STANDARD PROCEDURE FOR REGENERATIVE SYSTEM CHEMICAL CLEANING 210 MW

INTRODUCTION It is important that entire feed, condensate drip and regenerative system in the system are thoroughly cleaned to remove the dirt, rust, oil grease, weld slag, loose materials from inside the pipes. Presence of any undesirable material in the system contaminates the feed/condensate system and adversely affects commissioning and operation of the power plant. The various valves in the system also pose problems like passing and seat damage due to entrapment of foreign material on the valve seats. Cleaning of the system is considered adequate by alkali flushing and subsequent rinsing and DM water flushing through the system and no acid cleaning of piping after alkali flushing will be carried out. PREPARATION AND PRECAUTIONS TO BE TAKEN: Ensure that the system is erected fully and hydro test of the system is complete. Ensure that proper supports, preferably permanent are installed. Ensure that Mixing tank as per specification is installed. Ensure that circulating pumps as per specification are available for operation and the temporary connections are made as per scheme. Ensure that required chemicals, laboratory reagents and apparatus are available. All cutting and welding works on heaters for gauge glass and level switches etc. are to be completed. Deaerator and condenser are to be mechanically cleaned to the extent possible. All orifices and flow nozzles are to be removed and replaced with spool pieces. Regulating valves are to be mounted only after completion of chemical cleaning and spool pieces are to be mounted in place of the valves. All the instrument tapings in the system are to be completed and instruments are to be isolated before the flushing process. All check valves falling in flow circuit should be installed after flushing. Otherwise their flaps/discs to be kept removed. All the NRVs in extraction lines are to be erected in position. All gate valves in turbine extraction lines are to be tightly closed.

Ensure that suction and discharge end of BFPs are blanked off. RH spray, SH spray, HP Bypass spray and LP Bypass spray lines, TAS/BAS spray lines should be included in flushing operation to the extent possible.

Alkali should be passed through tube of heat exchangers. It should be ensured that alkali solution does not enter turbine, condenser, heaters, main ejectors, BFP, CEP etc. For this, isolation valves for equipments should be judged properly for any passing and accordingly suitable corrective action to be taken either by attending the valve or by putting dummy plate.

Booster pumps should be taken out and spool piece to be used. Booster pump suction strainer elements to be removed. Flow disperser and the built in orifice in BFP recirculation lines to be welded only after flushing completion.

Final connection of BFP discharge lines and recirculation line to be made after flushing completion.

BFP suction pipe to be slightly titled form its counter flange at BFP for connecting temporary line for alkali entry. BFP suction flange to be kept protected against any foreign material entry.

Portion of pipe lines which are not covered under flushing operation shall be mechanically cleaned.

Depending upon local conditions and facilities, minor modification in the scheme can always be done at site. The left over spray lines should be water flushed after running of BFP.

INPUTS REQUIRED BHEL Mixing tank as per specification 1 No. Temporary drain line from mixing tank to neutralizing pit. Chemical circulating pumps: 3 Nos. (150 T/hr. 12 Kg/sq. cm) minimum Temporary pipes, flanges, dummies etc. Pressure gauges 5 Nos. (0-25 kg/sq. cm) Thermometers 4 Nos. (0-200 Deg.C.) Steam source 8 to 10 kg/sq. cm (150-200 Deg C) Sampling water 12 Nos. Chemicals

TPS NAOH LISSOPL CUSTOMER

1500 kg 1000 kg 60 Lt.

5 fills of each 250 T of DM water (feed line) 500 T clarified / filtered water (condensate & drip lines) 500 T clarified / filtered water for mass flushing Neutralizing pit. Lab equipment for testing PH valve, alkalinity.

SAFETY AND PRE-CAUTIONS Alkaline solution may cause skin burning and as its fumes are injurious to eyes, all safety precautions must be taken during alkaline flushing. 1. The operators and workers must use rubber gloves, eye protecting glasses, Aprons, Gum boots, Masks etc. while flushing is going on and they are working on the job. 2. Due precautions must be taken while tightening the flanges of temporary pipe joints of the loops so that they do not leak when the pump is started and thereby a spray of alkali leaks through these joints. 3. Ensure the handy availability of first aid boxes, eye drops, neutralizing bottles, cotton rolls etc. 4. Before a person enters the deaerator for inspection, its manhole may be kept opened for 8-10 hours and air may be forced in the deaerator during period of working. PROCEDURE: The flushing of the system can be carried out in the following steps: 1. 2. 3. 4. 1. a. Mass flushing Alkali flushing Rinsing Final flushing MASS FLUSHING With Cold Water

Firstly mass flushing is done with cold filtered water. The mixing tank is to be cleaned properly and filled with filtered water and then the system is to be completely filled be running circulating pump. The system is thereafter kept on circulation for about 45 min and the entire water is then drained. This filling and draining should be continued till the effluent is clear. Samples at inlet and outlet should be taken and compared before declaring completion of mass flushing. b. With Hot Water The system should be filled up with filtered water and kept on circulation for 8 hrs. Maintaining water temperature at about 80 Deg. C. The process is declared completed when turbidity and conductivity of water at inlet and outlet are same. 2. ALKALI FLUSHING: Mixing tank is filled with DM water and steam is admitted to raise the temperature at 50 Deg. C. The system is filled up and kept on circulation till the temperature of water in the entire system comes to 50 Deg. C. Chemicals are then added in the mixing tank in the following quantities: a) Tri sodium phosphate b) Sodium hydroxide 5 kg/Ton of water i.e. 5000 ppm. 3 kg/Ton of water i.e. 3000 ppm. 0.2 /kg/Ton of water

c) Lissopal D

Lissopal D should be added carefully so as to avoid excess foaming. After achieving the required concentration of chemicals, the temperature of the solution is raised to 80 Deg. C. and the system is kept on circulation for 6-8 hours for each loop. Samples are to be taken from inlet and outlet ends of the loop hourly and analyzed for mechanical impurities, iron content, and PH value. The process is declared complete when the inlet and outlet sample values are identical. The entire system is to be drained completely.

3.

RINSING:

Immediately after completion of the alkaline flushing operation, the system is rinsed with DM water to remove the alkalinity left over on surfaces. Fill the tank with DM water and run the pump for 30 minutes through system. Then open the make up and drain in controlled way keeping the level constant. Try to drain maximum quantity of water from the system continuously throughout the operation. Hourly samples are taken and analyzed for phosphate, alkaline content and conductivity. The conductivity and PH value of DM water used is to be measured. Rinsing operation is cleared completed when conductivity and PH value are same at inlet and outlet. The system is then drained completely. 4. FINAL FLUSHING WITH DM WATER

After rinsing operation, final mass flushing is to be done with cold DM water and DM water at a temperature of 80 Deg. C. The system is kept on circulation for some time and drained completely. All drain lines in the circuitry should be charged to ensure thoroughness. Any line found cold should be attended. STAGE-I (FEED LINES): Temporary connections are made as per the scheme shown in sketch. The Booster pump is to be replaced with a spool piece and filter elements of booster pump suction strainers is to be taken out. Mass flushing is carried out. After mass flushing, alkaline flushing is to be done. No alkaline flushing is to be done through the tubes of the heaters. Rinsing and final mass flushing operations are to be done. STAGE-II (CONDENSATE LINES): Temporary connections are made as per scheme in the sketch. Mass flushing with cold and hot water is to be carried out. After flushing alkaline flushing is to be carried out. No alkaline flushing is to be done through the tubes. After alkaline flushing, Rinsing operation is to be carried out. Final DM water flushing is to be done after this.

STAGE-III (DRIP LINES): Temporary connections are to be made as per scheme Mass flushing with cold and hot water is to be done. Final Dm water flushing is to be done if filtered water is used during mass flushing. Criteria for completion of flushing activity 1. a) b) Mass Flushing Turbidity Conductivity

Process is declared complete when both turbidity and conductivity of water at inlet and outlet is approx. same 2. a) b) c) d) Alkali Flushing Conductivity PH value Phosphate Mechanical impurity

Samples are taken at every hours and the analyzed for the above and process declared completed when the inlet and outlet sample values approx same. 3. Rinsing Process is declared competed when conductivity is approx. same at inlet and outlet. POST FLUSHING OPERATION: A. Following temporary lines are to be removed. 1. 2. 3. B. C. D. All temporary lines of the loop Temporary lines from the system to Mixing Tank. Temporary line from Alkaline Pump discharge to system.

Blanks provided in the system are to be removed Stubs used for Alkali Flushing are to be normalized. Any choked drain line, as identified during flushing operation, should be attended either by opening the valve bonnet or by cutting the line.

E.

After draining the deaerator, it should be thoroughly inspected from inside and cleaned properly (The Deaerator manhole doors should be kept open for 8-10 hours prior to entry for expelling chemical gasses).

F.

Install the control valves, flow nozzles, orifices in the system permanently after taking due care so that no foreign matter enters the system again.

G.

In case of BFP suction flow nozzles after its welding it is always advisable to flush the line again before entering water to the pump. Suction pipe at BFP flange may be lifted slightly and some sheet may be kept at pump flange for this purpose.

PREBOILER ALKALI FLUSHING / HOT WATER FLUSHING OF DRIP LINES 210 MW Sr. No. 1 2 3 4 5 List of Valves PUMP SUCTION VALVES PUMP DISCHARGE NRVs PUMP DISCH. VALVES MIXING TANK DRAIN V/v SYSTEM INLET/OUTLET V/vs Nb 200 Nb 100/150 Nb 100/150 Nb 200 Nb 250 Nb 200 Nb 150 Nb 100 6 7 8 9 10 11 DRAIN TO NEUTRALIZING PIT PUMP RC VALVE ROOT VALVES SAMPLE VALVES LINE DRAINS DMW & STM V/v Nb 250 Nb 150 Nb 25 Nb 40 Nb 80 Nb 40 Nb 150 12 FLOW METER IN SYSTEM INLET (0-600 T/Hr) 3 NOS. 3 NOS. 3 NOS. 1 NO. 7 NOS. 1 NO. 2 NOS. 1 NO. 1 NO. 1 NO. 8 NOS. 4 NOS. 3 NOS. 5 NOS. 2 NOS.

PIPING: 1 2 3 4 5 6 7 BENDS 1 2 3 4 5 DIA 273 X 7.5 CS 90 DEG DIA 219 X 6.3 CS 90 DEG. DIA 199 X 6.3 CS 90 DEG. DIA 133 X 6.5 CS 90 DEG DIA 108 X 4.5 CS 90 DEG. = = = = = 15 NOS. 5 NOS. 5 NOS 10 NOS. 12 NOS. DIA 323.9 X 7.5 MM DIA 273 X 7.5 MM DIA 219 X 6.3 MM DIA 159 X 6.3 MM DIA 133 X 4.0 MM DIA 44.5 X 2.5 MM DIA 21.3 X 2.6 MM 15 MTRS 200 MTRS 110 MTRS 80 MTRS 60 MTRS 50 MTRS 50 MTRS

REDUCESS 1 2 3 4 5 300-250 MM CS 250-200 MM CS 200-150 MM CS 250-150 MM CS 150-100 MM CS = = = = = 2 NOS. 2 NOS. 4 NOS. 8 NOS. 4 NOS.

STANDARD PROCEDURE FOR OIL FLUSHING OF TURBINE OIL SYSTEM 210 MW

1.0 OBJECTIVE

Oil flushing is done to clean the oil piping system by removing dirt, welding slag etc., after completion of piping erection. This is ensured by creating conditions similar to the machine in operation, by adopting thermal shock process. For conducting the oil flushing effectively, the oil system is flushed in loops viz.: a) b) c) d) 2.0 Lub oil system flushing Jacking oil system flushing Control oil system flushing Seal oil system flushing INITIAL PREPARATION 2.1 The temporary pipes, which are included in this process, should be cleaned prior to installation. 2.2 Prior to oil flushing the cleanliness of the main oil tank and bearing pedestals must be ensured. Only marking cloth is to be used for cleaning purpose of oil system. Use of cotton waste is prohibited.

2.3

After cleaning the bearing pedestals and the oil tank they must undergo a visual inspection jointly by erection and commissioning engineers.

2.4

Before starting the oil pump for checking of its direction of rotation the oil must be filled in MOT and a short start / stop command is to be given. The trial run of the pump is to be taken up with the oil flushing process.

2.5

Ensure that pipeline erection has been done, as per the drawing s. seal oil system flushing will be taken up along with turbine oil flushing.

2.6 a) Throttles in the line injector as well as MOT injector are not to be removed. b) Oil throttle internals in oil supply line to bearings are to be removed and provided dummy plates on top of the throttle body. These dummy plates are provided with oil flushing material. c) Oil throttle before oil coolers need not to be removed also provide a temporary pipeline between inlet and outlet of the cooler. d) Duplex filter elements provided in the supply line to thrust bearing are to be removed. These elements are to be put back in position during the final stage of flushing. e) 2.7 Remove O-rings from COV seats of duplex filter. The regular adaptors in the bearing pedestals for supply are submitted with flushing device so that oil is deflected to bearing-tobearing pedestal instead of going to the bearings. 2.8 MOP is to be completely removed and a flushing device is to be placed in position. 2.9 2.10 Dummy is to be provided at flange 3 as indicated in the scheme. The jacking oil pumps are disconnected at the discharge flanges of the pumps and rotates as required and oil supply pipe to be connected through a temporary valve (of high pressure duty) to the dummy flange in the AOP discharge header. 2.11 The header of the jacking oil supply line has a dummy flange at the exciter side. From this a temporary connection is run to the oil return pipe blank flanges (D) of flushing, with an isolating valve.

2.12

Pressure regulating valve of JOP discharge line to be removed and spool piece to be erected for connecting JOP discharge header and relief drains is to be blanked.

2.13

The hose connections of JOP lines inside the bearing pedestals are removed at the bearing end and left in the pedestals it.

2.14

The internals of non-return valves provided in individuals jacking oil line of the bearings may be removed. Internals of combined discharge and non-return valve in the JOP discharge line is to be removed.

2.15

Remove the tuning gear nozzle box and provide a flushing device in its place before boxing up the pedestal.

2.16

Suitable steam heating arrangements for oil as per temperature requirements must be made at site. Process of thermal shocks will be used, as oil flushing is very effective at changing oil temperatures.

2.17

Adequate quantity of cooling water must be available for oil coolers to reduce oil temperature during the process of thermal shocks.

2.18

The necessary permanent drain tank must be made available for accepting the full charge of oil.

2.19

Arrangement for analysis of oil sample after the flushing must be made. The sample may be taken for checking mechanical impulses.

2.20

The Governing Rack & LP bypass racks are to be excluded from flushing. The stop valves servomotors of ESV, IV & LPBP and water injection valve to be bypassed.

2.21

Suitable piping connections to be provided as per drawing for bearing pedestal, overspeed trip device, thrust bearing trip device etc.

2.22

By pass connections as per drawing for CRH-NRV and all extraction NRVs. The solenoid valves must be replaced with suitable adopters.

3.0 a) b)

PRECAUTIONS Leak points must be attended immediately. Provision has to be made for emergency stopping of the pumps from local as well as UCB. c) d) e) Fire fighting equipment must be available. Means to remove spilled oil must be available. AOP current should not exceed the rated valve.

4.0 4.1

OIL FLUSHING Before starting oil filling, ensure the followings: a) b) c) d) Adequate nos. of oil drums are available (approx. 200 drums). Completion of erection of oil system. Quality oil as recommended (Turbine Oil 46) Install all dummy flanges and close drains and vents in the main drain header

4.2 4.3 4.4 4.5 5.0

Oil filling is to be done using centrifuge. During filling MOT filters are to be cleaned as and when required. About 80% of normal service oil is filled in for flushing. Keep a constant watch on MOT level to ensure that the tank does not overflow. FLUSHING LUB OIL LINES Trial run of vapour extraction fans should be completed. First charging of oil system is to be done by running the DC EOP in order to avoid any excessive oil spillage during first charging as discharge pressure of DC EOP is lower than that of AOP. Ensure proper venting from all available vents in the system.

5.1.1 5.1.2

5.1.3

For initial oil flushing the lub oil cooler should be bypassed connection provided for this purpose to be used. This will prevent the dirt of lines from entering in the cooler. The duration of oil flushing can be decided observing, the main oil tank filter. Normally 2-3 days flushing should be sufficient, after these connections to be normalized and oil flushing with thermal shock method is to be carried out.

5.1.4

Once oil system in completely filled up and all leakages are attended, AOP is to be run further flushing operations.

5.1.5 a)

During flushing operations ensure the followings: Thermal shocks as describes below are given regularly. During the process of thermal shocks, oil temperature 70-75C. (oil temp. after coolers). After this heating is to be stopped and oil cooled by opening the cooling water to the coolers till the oil temperature goes down to minimum possible (oil temp. before coolers). Ensure that oil temperature does not exceed 80C. during

heating process. As soon as oil temp. drops to the minimum possible again start heating up raise temperature. b) Manual tapping / hammering of oil lines to be done continuously during the heating / cooling periods. Hammering to be done on the complete length of the pipes. c) d) 5.1.6 Filters in MOT are to be cleaned regularly, during the oil flushing. Centrifuge is to be run continuously with heaters on. After initial cleaning of oil lines, throttles in the oil supply line to bearings are to be put in position. Oil flushing should then be continued for some bearing at a time (keeping the throttles full open condition and closing the throttles of the remaining bearings), therefore, ensuring flushing with maximum possible flow in the oil return lines. 5.1.7 The flushing operation is to be continued by undertaking the above exercise in rotation so that bearing oil supply lines are thoroughly flushed. 5.1.8 After flushing for sometime the injector throttle may be throttled and kept in minimum flow position so that the oil flushing is done through tank injector time. 5.1.9 Turning gear line is to be flushed by opening the gate-gearing valve in such a way that AOP motor does not get overloaded. This should be done daily once for hour with thermal shock. 5.2 5.2.1 JACKING OIL LINES The jacking oil system flushing can be started after initial dirt / muck of lub oil system is cleared. The flushing is done by using the temporary connection from AOP discharge header. 5.2.3 Initially the jacking oil header is to be flushed by using the connection C to D i.e. from header dead end to drain header. 5.2.4 After using above circuit for about sometimes the above connection is to be closed and then the lines to the individual bearing are to be flushed, say 2 or 3 lines at a time for effective flushing. 5.3 5.3.1 FLUSHING OF CONTROL OIL LINES After ensuring flushing ckt as per scheme. Keep all the valves of control oil ckt close, and open only such small lines, which are at end of system and will act as vent lines.

5.2.2

5.3.2

Open the emergency shut off valve gradually observing for leakages in the system.

5.3.3

To achieve maximum velocity through pipeline the circuit of control oil lines should be divided into 4 to 5 groups and circulation of oil should be rotated in these groups.

6.0 a)

CRITERIA FOR COMPLETION OF FLUSHING The oil analysis of sample drawn from centrifuge inlet should not have any mechanical impurities and moisture. Main oil tank filter should be in clean condition over a period of 24 hours. Duplex filter element should be free from impurities such that no chocking of filter should be experienced in duration of 24 hours. d) Line filters are to be installed and flushing carried out for 24 hours and no accumulation of dirt should be observed. e) All criteria to be met for declaring the oil flushing completion. RESTORATION OF THE SYSTEM 7.1 On completion of flushing, hydraulic test of the system is to be done. Then the system is normalized (lub oil lines 8 bar, C.O. lines 20 bar). When the oil is drained into the drain tanks provided, the drain tank, which accepts oil, must be clean. The oil contained in the system, main oil tank and oil coolers is to be completely drained. 7.3 The MOT is carefully cleaned and inspected as done earlier before flushing. The root valve in the oil injector must be dismantled and sludge deposits must be removed. The plugs provided in the oil throttle vent holes must be removed. Throttles in oil inlet line of injectors are to be normalized. 7.4 7.5 Jacking oil lines are to be normalized. The cooler tube nest should be withdrawn for inspection and cleaning of the coolers should be done with steam. Taking care so that O-rings are protected. 7.6 All bearing pedestals are to be cleaned thoroughly before boxing up the pedestals. 7.7 7.8 All temporary arrangements must be removed / normalized. All bearing pedestal connections should be normalized. Turbine bearings should be normalized. 7.9 Remove the vent hole plug of oil tank injector float.

b) c)

7.0

7.2

CHECK LIST FOR OIL FLUSHING 1. 2. Check condition of oil pipelines. Check erection of piping is complete.

3.

Bypasses, looping dummies etc. are as per the oil-flushing scheme. NRV flaps of J.O.P. line to be removed.

4. 5. 6. 7. 8.

Main oil tank has been cleaned and inspected. Tank filter and cover is fitted with profile gasket. Power supply to D.C. & A.C. oil pumps is available. Sufficient lights / illumination in the area is available. Arrangements for giving thermal shock have been made and steam is available.

9.

Flushing devices have been fixed at all bearings.

10. Turbovisory calibration has been completed. 11. The bearing pedestals are cleaned and then boxed up. 12. Check tightness of flanges, sockets and nipples job. 13. Check all drains / vents in atmosphere are closed. 14. Check pressure gauges for pumps and temperature gauges for oil water before and after cooler are installed. 15. Check sufficient manpower is available for tapping the lines thermal shock and other operations for conducting oil flushing. 16. Check vent holes in MOT ejector float have been plugged. 17. Check / Ensure that all the keys of pedestal and casing have been finalized and fixed properly in their respective locations. A) JACKING OIL LINES 1. 2. 3. Check NRV flaps are back in position. Normalize the pipe lines with the jacking oil pump discharge Check pressure-regulating valves has been serviced and it is in low-pressure position. B) LUB OIL & CONTROL OIL SYSTEM 1. Put plugs in the relief holes of oil throttles and put the throttles in full close position. 2. Provide dummy at the last flange joint available in the permanent piping, before it is connected to the drain.

3.

Make a connection from jacking oil header supply line to the lub oil ckt. As marked in the drawing.

4. A)

Close the valves wherever the valves are located at the end of pipeline. JACKING OIL LINES Duration 10 Minutes

Test Pressure 225 kg/Sq. Cm. B) LUB OIL LINES

Test Pressure 12 kg/Sq. Cm. C) CONTROL OIL LINES

Duration 10 Minutes

Test Pressure 12 kg/Sq. Cm.

Duration 10 Minutes

STANDARD PROCEDURE FOR STEAM BLOWING (210 MW)

PURPOSE The purpose of steam blowing is to descale and remove foreign material from steam pipelines leading to turbine in order to avoid damage to turbine from such material in the course of normal operation. PRINCIPLE Steam blowing is carried out by puffing method. a. b. Dislodge rust/scales from pipe work by thermal shocks. High momentum of expanding steam in the pipe work purges out loosened material. It is required to create a higher momentum during steam blowing than possible during operation of the unit including valves wide open (VWO) condition of the turbine. This is applicable for all steam piping leading to turbine. Disturbance factor is the measure of ratio of momentum during steam blowing to the momentum at TMCR condition.

Disturbance Factor = MSB X VSB / MMCR X VMCR Where: MSB VSB MMCR VMCR Mass flow of steam during blowing Specific Volume of steam during blowing Mass Flow of steam of MCR condition Specific volume of steam of MCR parameters.

In case of HP and LP bypass system blowing is carried out to avoid any damage later to valve intervals due to foreign material. Sharp elbows, miter bends and tees are to be avoided as these contribute to increased pressure loss, under steam blowing conditions. Also care to be taken in piping and contour to avoid critical velocities within the piping. Procedure The boiler is to be started in normal manner following start up procedure. All normal recommendations and limitations with respect to fuel firing equipments, draft plant, drains and vents, instrumentation, interlocks, protections etc. should be taken care of as if the unit is started to synchronise the generator with the grid. The procedure is to raise the boiler pressure to 40 kg/cm2, shut of firing and same time open temporary valve/boiler stop valve (blow off valve). The steam lines which are blown should be warmed up prior to blowing. The opening of blow off valve allows steam to escape to atmosphere at high velocity carrying with it loose and dislodged debris. To prevent thermal stresses in the thick walled shell like drum and headers the saturation temp. Change in drum is limited to 40 deg C maximum. Hence, for the purpose steam blowing of all critical piping the blow off valve will be opened at 40 kg/cm and closed at 19kg/cm-drum pressure. The water level in the drum swings beyond visible limits at the start, during and at the end of steam blowing. There are chances of water droplets to get carried over to the saturated steam pipes and low temp. superheater. This can possibly be minimized by keeping the water level in the drum at the lowest port (visible limit) before the start of each steam blow off. All the steam lines are purged in parallel and it is standard practice to limit number of blows per day to 8 with an interval 1-1/2 hrs. For cooling in addition to overnight cooling.

Stage I Stages II A Stage II B Stage III A Stage III B

SH MS lines ESV Out SH MS lines ESV CRH Out at Blr. End. SH MS lines HPBP CRH Out at Blr. End. SH MS lines ESV CRH RH HRH IV Out SH MS lines ESV CRH RH HRH LPBP Out at cond. End.

Preparation Estimated quantity of DM water requirement for steam blowing is about 5000 M3. Fuel oil requirement for the same has been estimated as 2000 MT. Target plate assemblies are to be located in the temporary exhaust pipes, nearest possible to the permanent pipe work. Sufficient quantity of carbon steel and stainless steel polished target plates are to be kept ready. Boiler should be ready in all respects including interlocks, protections, chemical dozing system, instruments etc, as if the unit is started to synchronise the generator with grid.

Precautions The temporary discharge piping should be well supported to withstand reaction forces during blowing. The steam must be exhausted to atmosphere outside the turbine hall building and so directed that personnel and equipment are not damaged or endangered. The area should be cordoned off and notices displayed prominently. For thermal expansion of the pipe, proper allowances must be given. First steam blow in every stage should be given at a lower pressure, say 25 kg/cm at boiler drum and the pipe lines including temporary piping is surveyed for proper expansion and supports. All the permanent and temporary piping must be insulated before the beginning of steam blowing operations. The furnace exist gas temperature should be limited to 540C to safeguard superheaters and reheaters. Sufficient storage of DM water should be ensured and the rate of make up water to feed tank is to be matched taking into account the capacity of feed tank. Internal Boiler water treatment to be carried out with liquid Ammonia and Hydrazene Hydrate only, to maintain a pH value of 10.0 in Boiler water and 5 to 25 ppm of N2H4 in feed water. Total dissolved solids in boiler water should not exceed 10.0 ppm before going in for steam blowing. If it is more, rinse the boiler till it comes down to less than 10 ppm. Hot tightening of flanges, studs/bolts is to be done wherever such connections have been made. Drain going to any vessel should be left open to atmosphere suitably outside TG Hall. Before normalizing, the drain pots should be inspected. It should be ensured that all permanent hangers of the various lines should be erected as per drawing and all values set accordingly to the design figures. Also ensure that he locking of all hangers is removed, which would have been done for hydraulic test before steam blowing. Remove all strainer elements before start of steam blowing. Down stream lines of ESV, IV and LP bypass valves are to be manually cleaned. Ensure no loose debris / extraneous materials are left inside the permanent / temporary pipe work.

Flow nozzles, Control Valves, NRV flaps and attemperators are not to be erected before steam blowing of lines for cleanliness. Any loops coming in the system which is steam blown should be checked after steam blowing. Spool pieces are to be erected in its place wherever applicable. Steam blowing of steam lines are to be started after hydraulic test of respective lines / pressure parts. Steam blowing of Auxiliary steam lines. a) These lines are to be blown by continuous blowing for about 20 to 30 minutes at a pressure of 50% of their normal operating pressure. b) Precaution to be taken of control valves etc; as mentioned in item 13 above. c) Lines, which are to be made ready before boiler first light up should be blown with external steam source. Note: Boiler and main steam valves will be inspected for tightness during drum and superheater safety valve floating. Tightness is to be checked by keeping MSSV closed, raising the SH pressure to MCR conditions and opening the drain lines downstream of MSSV. Valves will be serviced if passing is established. Completion Criteria Indications for the result of each blowing period is the number of pitting found on the target plate. The highest velocity of steam is in the center of the pipe. Hence judgement should be made for the end point of steam blowing in this area. The area for the above is 3/4th the discharge pipe diameter at the center. It is recommended to install the target plate after completing few blows in each stage. For evaluating the cleanliness and termination point of the steam-blowing, target plate of stainless steel are to be used. For initial stages, target plate of carbon steel is to be used. The results of the blowing operations can be judged by the absolute number of pitting on the target plate in the central zone. The piping is considered clean if there are not more than five pitting and shall not have any deformed edges. Besides there shall be no pitting in the rim zone.

STEAM BLOWING BOM VALVES 1. 2. 3. 4. 5. 6. 7. 10 NOS-GV / Nb 400 / NP 64 / BW 4 NOS-GV / Nb 50 / NP 64 / BW Nb 2 1500 Class 4 nos Nb 2 800 Class 2 NOS Nb 1 800 Class 2 NOS Nb 800 Class 4 NOS Quick closing electrically optd. Valves 2 Nos., Time full stroke 30 s 1 min. Nb 400 / NP 64 / BW

PIPES: 1. 2. 3. 4. f 406.4 x 12.7 = 105 M f 273 x 9.27 = 20 M Nb 2 = 125 M Nb 1 = 15 M

REDUCERS 1. 2. 3. f 406.4 x f 323.9 x 12.5 4 NOS f 406.4 x 219.1 x 10 4 NOS f 457.2 x f 406.4 x 12.7 4 NOS

BENDS: 1. 2. 3. 4. 5. 6. 7. LR ELBOW 90 f 406.4 x 12.5 = 10 NOS (45 = 7 NOS, 90 = 6 NOS) LR ELBOW 90 f 323.4 x 9.53 = 5 NOS. (45 = 4 + 90 = 6 NOS) LR ELBOW 90 f 406.4 x 12.5 = 10 NOS. (45 = 7 NOS, 90 = 6 NOS) f 406 45 = 7 NOS f 406 90 = 8 NOS f 323 45 = 6 NOS f 273 45 = 6 NOS + 4 NOS = 10 NOS.

SUPPORTING STRUCTURE: 15 MB 450 18 M 15 MB 400 24.5 M 15 MB 200 2.2 M 15 MB 125 5.8 M 15 MB 300 7.5 M 15 MC 150 6.7 M 15 MC 100 74.6 M 15 MB 250 8 M 298.4 Kg

POSITION OF ISOLATION VALVES DURING STEAM BLOWING Sequence of Blowing 1&2 Main steam line Cold reheat line Hot reheat line HP bypass line LP bypass line O C C C C 3&4 C O O C O 5&6 C C C O C 7&8 C C O C O 9&10 C O C O C 11&12 C C O C C 13&14 C C C C O Isolation Valves

O Open C Close

SETTING AND CHECKING OF HYDRAULIC AND ELECTRO-HYDRAULIC GOVERNING SYSTEM OF 200/210 MW.
1.0.0. Initial checks to be carried out before setting of hydraulic governor. The components number indicated on the checklist is based on Governing Scheme Drg. No. 1.1-2190-7280/1. Check whether erection of all oil pipeline are completed.

1.1.0.

1.1.1.

1.2.0.

Check whether the isolation valves before the filter MAX42 BT 002 is kept opened for speed control rack. Check whether the test valves of HP and IP for stop valves MAX47 AA 011 and MAX47 AA 021 + 022 respectively are kept closed fully. Ensure whether the isolating valves in control oil lines MAX41 AA581 + 582 and MAX41 AA 591 + 592 and secondary oil lines MAX45 AA 511 + 512 and MAX45 AA 521 + 522 are kept fully opened for HP and IP control valves. Check whether the isolating valves in EHC Circuit in HP secondary oil MAX45 AA 501 and IP secondary oil MAX45 AA 502 is closed, while setting the hydraulic controller. Close the control oil line isolating valve MAX42 AA 621 and secondary oil line isolating valve MAX45 AA 566 of CRH NRV slide valve MAX42 001. Ensure closing of the trip oil line-isolating valve MAX51 AA 047. Fix a dial gauge 0-10mm underneath bellow KA09 in the hydraulic speed Governor MAX 46 By 001. Fix three standard gauges in Auxiliary secondary oil, HP secondary oil and IP secondary oil lines. (0-8 kg/cm2 to read up to 0.1 kg/cm2 accuracy). Open the top cover of Hydraulic Amplifier MAX45 By 011 to measure the power position KA 08 lift. Ensure that the boiler stop valve is fully closed and the main steam line is not charged with steam. Check whether solenoid MAX42 AA 051 of the trimming device KA 10, is in energized condition. Check that the solenoids MAX51 AA 202 and MAX 51 AA 201 are in the de-energized condition and ensure that the change over valve MAX 51 AA 211 is in normal position and not in Test position. Ensure starting device MAX47 By 001 in closed condition. Keep the speeder gear in maximum set positions. Check whether Auxiliary oil pump is running and a control oil pressure of 6 to 7 kg/cm2 is available. Maintain oil temperature in Main oil tank around 50/55C, which can be ensured before oil cooler. Check and ensure that the isolating valves before individual equipment in the rack are kept opened.

1.3.0.

1.4.0.

1.5.0.

1.6.0.

1.7.0. 1.8.0.

1.9.0.

1.10.0.

1.11.0.

1.12.0.

1.13.0.

1.14.0. 1.15.0. 1.16.0.

1.17.0.

1.18.0.

1.19.0.

Check the load shed relay solenoid MAX 46 AA 011 is in deenergized condition and auxiliary Secondary oil doesnt drain through the load shed relay solenoid. Ensure that the main trip valve MAX 51 AA 005-006 is in reset conditions. Switch off ATRS panel supply, so that hydraulic governor can be checked when boiler is not in service. Check the following pressures in the rack. Control oil pressure Start up oil pressure 6 to 7 kg/cm2. 5 to 6 kg/cm2. 5 to 6 kg/cm2.

1.20.0.

1.21.0.

1.22.0. 1.22.1. 1.22.2. 1.22.3. 1.22.4. 1.22.5.

Aux. Start up oil pressure Trip oil pressure

5 to 6 kg/cm2. 5 to 6 kg/cm2.

Aux. Trip oil pressure

1.23.0.

Ensure that the respective governor characteristic is used while setting the governor. **********

2.0.0. 2.1.0.

Procedure for Checking and Setting of Hydraulic Governor. Note down the initial reading of starting device when the starting device is in full close condition. Operate starting device MAX 46 BY 001 gradually from Minimum to Maximum position and carry out the following checks. Check whether the start up and Auxiliary start up oil pressure drops. Operate the starting device gradually and increase the Auxiliary secondary oil pressure to kg/cm2 and note down HP and IP secondary oil pressure. Check when starting device is fully opened, note down the starting device lift. The lift should be 24.5mm and Auxiliary secondary oil pressure should be 4.2 kg/cm2 or above.

2.2.0.

2.3.0.

2.4.0.

2.5.0.

2.5.1.

If the aux. Secondary oil pressure is not obtained, adjust Auxiliary follow up piston KA 08 which is in service of MAX 46 BY 001 to

obtain aux. Secondary oil pressure of 4.2 kg/cm2 and above, when starting device is in fully opened condition. 2.5.2. Note down the HP and IP secondary oil pressure corresponding to 4.2 kg/cm2 of Auxiliary secondary oil pressure. Bring back the starting device gradually towards the closing position and check the trip point of aux. Secondary oil pressure. The trip point should be around 2.1 kg/cm2approximately. At lean under 2.3 kg/cm2. NOTE: Trip point of Auxiliary follow up piston is the pressure at which auxiliary secondary oil pressure suddenly falls to zero. Bring back the starting device at the fully closed position. Ensure the starting device is in closed condition. Fix the dial gauge below the bellow and adjust it to read zero mm. Note down the initial reading of power piston KA 08 of MAX 45 BY 011 by a depth gauge. Note down the starting device initial readings. Operate the starting device gradually to open position till the auxiliary secondary oil pressure increases to 2.3 kg/cm 2. At 2.3 kg/cm2 of auxiliary secondary oil pressure check whether the HP secondary oil pressure is 2.5 kg/cm2. If the value is not achieved, adjust the three follow up pistons KA 01 of MAX 45 BY 011 of HP secondary oil pressure equally. Check the lift of Power Piston KA 08 of MAX 45 BY 011 is around 6 to 7mm (approx), when the HP secondary oil pressure is around 2.5 kg/cm2. If the value is not achieved, adjust the start of opening of pilot valve KA 07 of MAX 45 By 011. Increase the aux. Secondary oil pressure to 2.48 kg/cm 2 HP secondary oil pressure will be 2.79 kg/cm2. The IP secondary oil pressure should be 2.5 kg/cm2. If the IP secondary oil pressure value is not achieved, adjust the three follow up pistons KA-02 of MAX 45 BY 011 equally to get 2.5 kg/cm2 of IP secondary oil pressure.

2.6.0.

2.7.0. 2.8.0. 2.8.1. 2.8.2.

2.8.3. 2.9.0.

2.9.1.

2.9.2.

2.9.3.

2.9.4.

2.10.0.

2.10.1.

2.11.0. Note down the values of following: 2.11.1. 2.11.2. Starting device travel. Lift of the bellow.

2.11.3. 2.11.4.

Power Piston lift of Hydraulic Controller. Aux. Secondary oil pressure, HP secondary oil pressure and IP secondary oil pressure. Increase the aux. Secondary oil pressure to 4.2 kg/cm 2 and check whether HP secondary oil pressure reaches 5.0 kg/cm2. If the value is not achieved, adjust the proportionality adjuster KA 09 of MAX 45 BY 011 to get HP secondary oil pressure of 5.0 kg/cm2 when auxiliary secondary oil pressure is around 4.2 kg/cm2.

2.12.0.

2.12.1.

2.13.0.

Check by closing the isolating valve MAX 42 BT 002 of speed control rack and note at what pressure of trip oil, main trip valve MAX 51 AA 005 trips suddenly. Both main Trip valve should trip at 3 bar of trip oil pressure. If it is not achieved, adjust the spring tension to get the set value. After checking and ensuring the Main trip valve trips at 3 bar, bring down starting device from open position to closed position. Operate the starting device from closed position and once again check at 2.3 kg/cm2. Similarly note down at 2.79
kg/cm2 of HP secondary

2.13.1.

2.14.0.

2.15.0. 2.15.1. 2.16.0. 2.16.1. 2.16.2. 2.16.3. 2.16.4. 2.17.0.

oil pressure, the IP secondary oil pressure is around

2.5

kg/cm2.

Increase the Auxiliary secondary oil pressure in steps of 0.2 kg/cm2 and note down the following.
HP secondary oil pressure. IP secondary oil pressure. Power piston lift of Hydraulic converter. Starting device travel. Check that a closing and opening reserve of 3.5mm is available for power piston KA Hydraulic Amplifier MAX 45 By 011.

2.18.0.

Check the bellow travel KA 09 MAX 47 By 001 between auxiliary secondary oil pressure of 2.3 kg/cm2 to 4.2 kg/cm2, should be approx. 5mm. Check the total travel of Amplifier power piston. It should be 50mm approximately, from fully closed position to fully open condition of starting device MAX 47 By 001. Plot the following curves. Power piston lift versus Aux. Secondary oil pressure. Bellow lift versus Aux. Secondary oil pressure. Bellow lift versus HP secondary oil pressure. Bellow lift versus IP secondary oil pressure. Bring the starting device to minimum position, to set HP and IP control valves. Adjust the local position transmitter to indicate zero mm for both HP and IP control valves. Bring the starting device to a position where HP secondary oil pressure is 2.5 kg/cm2. Adjust the start of opening of HP control valve one or two, just to open at 2.5 kg/cm2 of HP secondary oil pressure. Bring the starting device to a position where IP secondary oil pressure is 2.5 kg/cm2. Adjust the start of opening of IP control valve one or two, just to open at 2.5 kg/cm2 of IP secondary oil pressure. Increase the aux. Oil pressure in steps of 0.2 kg/cm 2 and note down the following upto the maximum position of starting device. HP secondary oil pressure. IP secondary oil pressure. HP control valve lift. IP control valve lift. Plot the curves for the following.

2.19.0.

2.20.0. 2.20.1. 2.20.2. 2.20.3. 2.20.4. 2.21.0. 2.21.1. 2.21.2. 2.21.3. 2.21.4. 2.21.5. 2.22.0. 2.22.1. 2.22.2. 2.22.3. 2.22.4. 2.23.0.

2.23.1. 2.23.2. 2.24.0. 2.24.1. 2.24.2.

HP secondary oil pressure versus HP control valve lift 1 & 2. IP secondary oil pressure versus IP control valve lift 1 & 2. Open the test valve of HP stop valve number one fully and check whether stop valve opens fully. Fully close the test valves of HP stop number one and check whether the stop valve closes fully. Repeat the same test 2.24.0. and 2.24.1. for HP stop valve number Two, IP stop valve number one, and IP stop valve number Two. Ensure full lift of HP stop valve about 70mm and IP stop valve about 140mm which are the design values. Now open HP stop valve no. one by opening the test valve fully and ensure that the stop valve has opened fully. Energise solenoid valve MAX 45 AA 201 and MAX 48 AA 208, to admit aux. Start up oil to Main trip valve MAX 51 AA 005 and MAX 51 AA 006. NOTE: - Do not energise longer than half hour, Solenoid may get burnt.

2.24.3. 2.25.0. 2.26.0.

2.27.0. 2.27.1. 2.27.2.

Check by closing the isolating valve MAX 42 BT 001 and MAX 42 BT 002 in control oil system to speed control rack. Note down at what trip oil pressure HP stop valve number One suddenly closes. Repeat the operation 2.27.0. for HP stop valve number Two, IP stop valve number One and Two and note down the trip oil pressure at which stop valve closes. De-energise the solenoid MAX 48 AA 201 and MAX 48 AA 202 after completing the test on stop valves. Bring back the starting device to full close condition. Operate the starting maximum position. device gradually from minimum to

2.28.0. 2.29.0. 2.30.0. 2.31.0.

Check whether the HP stop valve opens first, and IP stop valves opens later as per the indications marked on the starting device scale and note down the start up oil pressure for opening of HP and IP stop valves.

2.32.0. 2.33.0. 2.33.1. 2.33.2. 2.34.0. 2.34.1. 2.34.2. 2.34.3. 2.34.4. 2.34.5. 2.35.0. 2.35.1. 2.35.2. 2.35.3. 2.36.0. 2.37.0.

De-energise solenoid MAX 42 AA 051 of the trimming device KA 10 of Hydraulic Amplifier MAX 45 By 011. Bring back the starting device to closed position. Check the dial gauge below the bellow is set at zero. Note down the initial reading of starting device. Open gradually the starting device from fully closed position and note down the following. Bellow lift Auxiliary secondary oil pressure. HP secondary oil pressure. IP secondary oil pressure. Starting device travel. Plot the following curves. Bellow travel versus Auxiliary secondary oil pressure. Bellow travel versus HP secondary oil pressure. Bellow travel versus IP secondary oil pressure. Energise the trimming device solenoid MAX 42 AA 051. Load shed relay MAX 46 AA 011 will get energized whenever generator breaker trips on fault. The duration of operation is only two seconds. During the actuation of load shed relay check whether Aux. Secondary oil pressure drops down to zero and comes back to the value at which the load shedding relay was actuated. Switch on the ATRS supply. Check the main trip valve trips immediately and all the stop valves and control valves closes immediately.

2.37.1.

2.38.0. 2.38.1.

2.38.2.

Check the Aux. Secondary oil pressure, HP secondary oil pressure, IP secondary oil pressure, trip oil pressure and Aux. Trip oil pressure reads zero. Switch off the ATRS panel supply. Ensure and check it as per step no. 2.38.2.

2.39.0. 2.39.1.

*********

3.0.0.

Initial checks to be carried out before setting of Electro-Hydraulic Converter.

3.1.0.

Normalise the isolating valves MAX 45 AA 501 in HP secondary oil line and MAX 45 AA 502 in IP secondary oil line from EHC, which was kept closed while checking hydraulic controller. Keep the starting device MAX 47 By 001 in Maximum position. Ensure that the trip oil line isolating valves MAX 51 AA 511 is kept opened. Ensure that control oil line isolating valve MAX 42 AA 611 is kept opened. Ensure a pressure gauge 0 to 8 kg/cm2 in the pressure gauge point provided before EHC MAX 45 By 001 in trip oil line.

3.2.0. 3.3.0.

3.4.0.

3.5.0.

**********

4.0.0.
4.1.0.

Procedure for checking and Setting of EHC.

Feed the rough set point voltage, a fixed voltage in co-ordination with C & I Engineer. Check whether the voltage in moving coil MAX 45 CG 001T is around-1 volts. The equilibrium voltage should be between (-) 0.8 to (-) 1.2 volts. There will be six hexagonal head and bolts. Out of them three will have screw cut in the head of bolts and locking nut. Loosen only those screw headed bolts. After adjusting balance volt. Ensure with plunger coil off. EHC goes to max. for making plunger coil off, take out the plug in connections on the side of EHC box. EHC max. will be manifested by full rise of HP/IP secondary oil pressure (provided HC is in max.). If it is not happening readjust coil. Take out supply to plunger coil slowly unscrew the plunger coil. Keep plunger coil at the point where suddenly HP/IP secondary oil pressure will go to max. Now again try for balance voltage by feeding any voltage to plunger coil & checking its balance voltage. If it is not, adjust the moving coil by loosening the three locking screws to such a position where the equilibrium voltage is around 1 volts. After adjusting as said in in 4.1.3., feed zero volts through set point and note down the power piston lift (Minimum reading). Feed zero volts through set point voltage, and note down the power piston lift (Maximum reading). The difference in lift between maximum and minimum lift should be approximately 50 mm. Vary the controller from minimum to maximum position and note down the output of Collins I and II in the minimum and maximum positions. The Collins I and II output should be +7.5V. Adjust the Collins MAX 45 CG 001A, MAX 45 CG 001K to get this voltage, if it is not achieved. Increase the set point voltage and hold the power piston lift KA 08 of EHC MAX 45 By 001 about 6 to 7 mm as obtained in Hydraulic Governor setting. Check the HP secondary oil pressure, and adjust the three follow up pistons KA 01 of EHC MAX 45 BY 001 equally to get HP secondary oil pressure of 2.5 kg/cm 2 when power piston lift is 6 to 7mm as obtained in Hydraulic Governor setting. Increase set point voltage and hold the HP secondary oil pressure at 2.79 kg/cm2.

4.1.1.

4.1.2. 4.1.3.

4.1.4.

4.1.5.

4.1.6.

4.2.0.

4.3.0.

4.4.0.

4.5.0.

4.6.0.

4.7.0.

At 2.79 kg/cm2 of HP secondary oil pressure adjust, follow up pistons KA 02 of EHC MAX 45 By 001 equally to get 2.5 kg/cm 2 of IP secondary oil pressure. Note down the power piston lift of EHC. Increase the set point voltage in steps of one volt and note down Collins output I and II and power piston lift. Check whether the HP secondary oil pressure obtained is equal to the hydraulic governor characteristics set earlier. Ensure by plotting the curve, that a closing and opening reserve of 3 to 5mm is available for power piston KA 08of EHC MAX BY 001. Ensure the start of opening of HP and IP control valve remains at 2.5 kg/cm2 of HP and IP secondary oil pressure respectively, as set earlier during hydraulic controller adjustment. Check and ensure that the HP and IP control valves open with respect to HP and IP secondary oil pressure as per the governor characteristics, from full close to full open position. Plot the following curves. Set point voltage versus Collins I and II voltage.

4.8.0. 4.9.0.

4.10.0.

4.11.0.

4.12.0.

4.13.0.

4.14.0. 4.14.1.

4.14.2.

Set point voltage versus HP and IP secondary oil pressure.

4.14.3. 4.14.4. 4.14.5.

HP and IP secondary oil pressure versus control valve lift. Power piston lift versus HP and IP secondary oil pressure. After drawing the characteristic curve of EHC & compare the slope of the curves. They should be equal. Hydraulic

********** CHECKING AND SETTING OF NON-RETURN VALVES ON EXTRACTION AND COLD REHEAT.

5.0.0.

Extraction Relay MAX 51 AA 001.

5.1.0.

Check and ensure that all the drain valves in trip oil lines are kept closed. Open isolating valve MAX 51 AA 527 to test valve MAX 51 AA 047 to extraction NRV is opened. Check whether test valve MAX 51 AA 047 is in open condition. Check whether solenoid valve MAX 51 AA 027 is in de- energized condition. Check whether isolating valve MAX 45 AA 509 accumulator MAX 45 BB 001 in HP secondary oil line is opened. Ensure a pressure gauge is provided on the trip oil line after the extraction valve relay. Adjust at HP secondary oil pressure of 2.8 kg/cm2 the pilot valve spring tension of KA 01 and KA 02 to open the extraction valve A2 + A3 and A4 + A5. Increase the HP secondary oil pressure above 2.8 kg/cm 2 and check the following. Check by energizing the solenoid MAX 51 AA 027 the NRVs A2 + A3 and A4 + A5 closes. De-energise the solenoid and check the NRVs A2, A3, A4 + A5 opens back. Check by closing the test valve MAX 51 AA 047, the NRVs A2, A3, A4 + A5 opens back. Ensure by opening the test valve, the NRVs A2, and A4 + A5 opens back. Ensure by reducing the HP secondary oil, all the extraction NRVs closes and note down the HP secondary oil pressure at that position. All the extraction NRVs should close not later than 2.5 kg/cm 2 of HP secondary oil pressure.

5.2.0.

5.3.0. 5.4.0.

5.5.0.

5.6.0.

5.7.0.

5.8.0.

5.8.1.

5.8.2.

5.8.3.

5.8.4.

5.9.0.

5.9.1.

**********

6.0.0. 6.1.0.

Cold Reheat Non-Return Valve.

Check and ensure that all the drain valves in control oil lines are kept closed. Check the isolating valve MAX 42 AA 621 in control oil line to slide valve MAX 42 AA 001 is kept opened. Check the isolating valve MAX 45 AA 566 in secondary oil lines is kept opened. Adjust the slide valve MAX 42 AA 001 spring tension to open the NRV at 2.9 kg/cm2 at HP secondary oil pressure. Check by reducing the pressure of HP secondary oil below 2.9 kg/cm2 and ensure whether NRV is closed fully.

6.2.0.

6.3.0.

6.4.0.

6.5.0.

NOTE: -The opening of CRH NRV and extraction NRV has to be set as per the customer consultants requirements. If it is not given, it can be set in the above said value.

********** Ensuring of connected C & I/Electrical works pertaining to governing system.

7.0.0.

Ensure the following I/Electrical Engineers.

settings

in

co-ordination

with

&

7.1.0.

Ensure the starting device percentage position at control room indication from 0 to 100% matches with full close to full open position. Adjust the four number of limit switches provided on the starting device for 0%, 42%, 56% and 100% respectively of starting device opening. Ensure the speeder gear percentage position at control from indication, from 0 to 100 % matches with full close to open position. Adjust the limit switches in full open direction and full close direction for Two number of HP stop valves and Two numbers of IP stop valves. Ensure the open and close indication is appearing for all the stop valves at control room.

7.2.0.

7.3.0.

7.4.0.

7.5.0.

7.6.0.

Adjust the percentages position of the Two control valve of HP and Two control valves of IP indicates at control room the full open and full close directions. Ensure the local scale indicator mounted on the body of Two numbers of HP control valve and Two numbers of IP control valve in the fully open and fully closed directions. Adjust the limit switch of cold reheat NRV in the fully open and fully closed direction and check the open and closed indication is appearing at control room. Ensure that the potentiometer for extraction valves A2, A3, A4 and A5 indicating the valve opening position is calibrated. Ensure that extraction NRV solenoid MAX 51 AA 027 for A2, A3, A4 and A5 indication at control room for energized and de-energised condition. ********** CONDUCT THE FOLLOWING CHECKS AT 3000 RPM.

7.7.0.

7.8.0.

7.9.0.

7.10.0.

8.0.0.

Testing of overspeed bolts by injecting oil through overspeed test device MAX 62 AA 001.

8.1.0. 8.2.0. 8.3.0.

Release the lock of pilot valve KA 02 and KA 03 of MAX 62 AA 001. Check whether the turbine speed is exactly 3000 rpm. Press the Pilot valve KA 03 fully, to isolate the Aux. trip oil from main trip valve to overspeed trip test device, and keep it pressed down. NOTE: - The Auxiliary trip oil pressure.

8.4.0.

Rotate the hand wheel KA 01 of overspeed trip test device in clockwise direction for admitting the test oil to the overspeed pins.

8.5.0. 8.5.1.

Check at what pressure of test oil, the overspeed bolts act. The actuation of overspeed bolts is indicated on the test rack by lamps and can be observed by the actuation of limit switches MAX 10 CG 001 + 002, provide on the LHS of front bearing pedestal.

8.5.2. 8.5.3.

Check whether Auxiliary trip oil pressure goes to zero. Note down the test oil pressure at which overspeed, bolt number one comes out and overspeed bolt number Two comes out. Rotate the hand wheel KA 01 of overspeed test unit in the anticlockwise direction where the test oil gets cut off, to the overspeed bolt. Press the pilot valve KA 02 of overspeed test device, to reset overspeed bolts One and Two. Check whether Aux. trip oil pressure builds up and it is as per the value recorded in 8.3.0.

8.6.0.

8.7.0.

8.7.1.

8.8.0.

Release pilot valve KA 02, of overspeed test device.

8.9.0.

After ensuring auxiliary trip oil pressure is steady, release the knob of Pilot valve KA 03, of overspeed test device. Lock the pilot valves KA 02 and KA 03 of overspeed testing device, after completing the test. *********** 9.0.0. Testing of 7% regulation of Hydraulic Governor.

8.10.0.

9.1.0. 9.2.0. 9.3.0.

Check the machine is running on Electro-Hydraulic or Hydraulic. If it i8s running on Electro-Hydraulic change over to Hydraulic. Ensure after changing over to hydraulic, the isolating valves MAX 51 AA 501 and MAX 51 AA 502 in secondary oil lines of ElectroHydraulic converter is kept closed. Ensure the starting device in maximum position. Increase the speeder gear to full open condition and check the speed increases to 3210 rpm at fully open condition.

9.4.0. 9.5.0.

9.5.1.

If the speed is not achieved, loosen the lock nut and increase the compression of spring item no.4 of component drawing in Drg No. 1-1-

2210-0001/1, of Hydraulic speed governor, to get the required speed.

9.5.2. After attaining 7% of rated speed, at speeder gear and starting device in maximum position, lock the locknut, of Hydraulic speed governor.

*********** 10.0.0. 10.1.0. Actual overspeed Test 10 to 12 % of rated speed.

Ensure before carrying out actual overspeed test, the both overspeed governors are operative by conducting oil injection test as explained in 8.0.0. Ensure that all speed indicators and recorders are indicating the same speed when the machine is at 3000 rpm and at3210 rpm.

10.1.1.

10.2.0.

Ensure that turbine is running at a speed of 3210 rpm with starting device and speeder gear in maximum position.

10.3.0.

Press continuously the overspeed testing lever KA 07 provided in the start and load limiting device MAX 46 By 001, by watching the speed indication. Ensure the speed raise is steady and the machine trips at 3300 rpm (approx.) by the actuation of overspeed governors. Both the overspeed governors should operate between 10% to 12% of rated speed.

10.3.1.

10.3.2.

NOTE: - Release the lever, if the overspeed governor is not acting at 12% of the rated speed. Adjust the overspeed governor bolt to act at 10% to 12% of rated speed. 10.4.0. Record the speed at which overspeed

governors 1 and 2 acts.

10.5.0.

After trip out when machine reaches 3000 rpm, note down the coasting down time from 3000 rpm to turning gear speed at 100 rpm interval. Bring back the machine to the rated speed for further checks.

10.6.0.

***********

11.0.0.

Testing of Hydraulic low vacuum trip MAG 01 AA 011 at 3000 rpm. Ensure that the control oil Auxiliary trip oil are available to the low vacuum trip unit. Ensure whether primary oil pressure is available in the low vacuum trip unit. Ensure a calibrated vacuum gauge is fixed in between the solenoid valve MAG 01 AA 201 and low vacuum trip unit, on the vacuum impulse line. Energise the solenoid MAG 01 AA 201 and watch the vacuum gauge, for drop of vacuum. Record at what value of vacuum, the low vacuum trip acts. The low vacuum trip should act at angle 0.3 bar abs. If the low vacuum trip has not acted at angle 0.3 bar, adjust the spring tension number 6, by means of adjusting screw number 5 as shown in component drawing in O & M Manual Drawing number 1-1-3400-003/1. Lock the adjusting screw. Bring back the machine to the rated speed and release for carrying out generator dry out. NOTE: -Hydraulic low vacuum trip can be tested even on turning gear by jacking the disc no. 2, of O & M Manual Drg. No. 1.1-3400003/1 with the help of locking screw.

11.1.0.

11.2.0.

11.3.0.

11.4.0.

11.5.0. 11.5.1. 11.5.2.

11.5.3. 11.6.0.

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. Check whether erections of all pipelines are completed, for LP bypass system. Check that all the drain valves in the control oil lines of water of water injection valve are kept closed. Check whether the isolating valves before the filter MAX 42BT 021 is kept opened. Check whether the isolating valves before the filter MAX 42 BT 022 is kept opened. Check whether the isolating valve before the filter MAX 42 BT 081 is kept opened. Check whether the following valves are kept opened. 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. Signal oil inlet valve MAX 53 AA 521 + 522 to slide valve MAX 52 AA 081 + 082 of LP by pass both stop valves. Control oil inlet valve MAX 42 AA 521 + 523 to slide valve MAX 53 AA 081 + 082 of LP by pass both stop valves. Signal oil inlet valve MAX 53 AA 086 + 087 of LP by pass control valves. Control oil inlet valve MAX 53 AA 086 + 087 of LP by pass control valves. Check and ensure that the isolating valve before the individual equipment in the rack, are kept opened. Check whether ACP is running and control oil pressures of 6 to 7 bar is available. Run the condensate pump and ensure by opening the valve MAN 11 + 12 AA 511, that water pressure more than 10 kg/cm2 is available in the limit controller. Ensure the vacuum is available to the limit pressure controller. Vacuum should be greater than 0.6 bar abs. Vacuum can be created by means of Portable vacuum pump, vacuum system is not ready. Keep open the isolating valve MAN 01 AA 501, in the downstream reheat steam line to limit pressure controller.

1.2.0.

1.3.0.

1.4.0.

1.5.0.

1.6.0.

1.7.0. 1.7.1.

1.7.2.

1.7.3.

1.7.4.

1.7.5.

1.8.0.

1.9.0.

1.10.0.

1.11.0.

1.11.1.

1.12.0.

1.12.1.

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. Ensure that the respective LP bypass Governor characteristics is used, while setting the LP by pass Governor. Ensure two standard gauges of 0-10 kg/cm2 is fixed in the signal oil line of water injection and LP by pass. 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.

1.13.0.

1.14.0. 1.15.0.

1.16.0.

1.17.0.

************** 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. Check the vacuum gauge indicates full vacuum. Ensure water pressure more than 10 kg/cm 2 is available for limit pressure controller and water pressure switch. Check that pressure gauge MAN 01 CP 511 indicates more than 10 kg/cm2.

2.1.1. 2.2.0.

2.2.1.

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. 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/cm 2 in the by pass valves. Signal oil pressure in water injection line also will increase. Test the condenser vacuum trip protection is healthy. The trip value for LP by pass limit controller MAX 53 BY 011 and low

2.4.1.

2.5.0.

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. Record the trip value of vacuum. Increase the vacuum and check the vacuum protection gets reset and signal oil pressure in by pass comes back to original value. Jack the low ineffective. vacuum condenser protection for making it

2.5.2. 2.6.0.

2.7.0.

2.7.1. 2.7.2. 2.7.3.

Repeat the operation 2.5.1. Record the trip value of vacuum for LP by pass limit controller. 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. Record the trip value of vacuum for low vacuum condenser protection. Remove the filer gauge from the LP by pass limit controller, placed during operation 3.9.0. Repeat the operation 2.6.0. 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. 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. 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. 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.

2.8.0. 2.9.0.

2.9.1. 2.9.2.

2.9.3.

2.10.0. 2.11.0.

2.11.1.

2.11.2.

2.11.3.

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. 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. Record the trip value of water pressure. 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. By pass the hydraulic water switch protection by operating the lever to by pass position for making it ineffective. Repeat the operation 2.12.1. Record the trip value of water pressure, for LP limit pressure controller. Normalise the lever of hydraulic water protection to make it effective. Repeat the operation 2.13.0. 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. Repeat the operation 2.12.1. Record the protection. trip value of hydraulic water pressure switch

2.12.1.

2.12.2. 2.13.0.

2.14.0.

2.14.1. 2.14.2.

2.14.3.

2.15.0. 2.16.0.

2.16.1. 2.16.2.

2.16.3.

Remove the filer gauge from the LP by pass limit controller placed during operation 2.16.0. Repeat the operation 2.13.0. 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. 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 around 8.5 kg/cm2. 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.

2.17.0. 2.18.0.

2.18.1.

2.18.2.

2.18.3.

For obtaining required trip value at hydraulic pressure switch unit, vary the compression of the string item 6 of Drg. No.1-13410-0009/1 in O & M Manual. Close the top cover of LP by pass limit controller MAX 53 BY 011. The trip value of temperature protection device MAX 53 AA 021 + 022 is around 90C at down stream of LP by pass. Energise one by one solenoid by shorting the protection lead and check the signal oil pressure in LP by pass drops suddenly. 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.

2.18.4. 2.19.0.

2.19.1.

2.19.2.

2.20.0. 2.20.1.

Check the reheat protection of LP by pass limit controller. 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. Ensure the piston KA 07 for the LP by pass limit controller just start to close, at a pressure of 21.2 kg/cm2. Record the pressure in the down stream of LP by pass reheat line, when the piston KA 07 for limit controller closes fully. 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. 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.

2.20.2.

2.20.3.

2.20.4.

2.21.0.

**********

3.0.0. 3.0.1.

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.

3.0.2. 3.0.3.

Measure the lift of KA 08, while operating the hand wheel KA 09. Stop the operating of KA 09 when the lift at KA 08 of differential Amplifier piston is about 3.2 mm. Check whether signal oil pressure in water injection line, is around 1.5 kg/cm2. If the signal oil pressure is not achieved, adjust both the follow up piston KA 03 equally, to get a signal oil pressure of 1.5 kg/cm 2, in the water injection line. Check whether the water injection valve 1 & 3 opens at a signal oil pressure of 1.5 kg/cm2. Check whether the water injection valve 1 and 3, opened/not opened, adjust the slide valve MAX 53 AA 031, spring tension accordingly, to open exactly at 1.5 kg/cm 2 of signal oil pressure in water injection line. Energise the solenoid MAX 53 AA 051, to admit signal oil to the slide valve MAX 53 AA 041. check the water injection valve 2 & 4 opened/not opened. Adjust the slide valve spring tension accordingly, to open exactly at 1.5 kg/cm2 of signal oil pressure in water injection line. 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. Set the limit switches for full closed position, for all the four water injection valves. Check whether the lamp indication appears at control room for all the four water injection valves closed position. Operate the hand wheel KA 09, gradually, and increase the signal oil pressure of 1.5 kg/cm2 in water injection line. Ensure that all the four water injection valves open at signal oil pressure of 1.5 kg/cm2, at the same time. Adjust the limit switches for full open position for all the four water injection valves. 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. De-energise the solenoid MAX 53 AA 051. Check water injection valves 2 and 4, closes immediately.

3.0.4.

3.0.5.

3.1.0.

3.1.1.

3.2.0.

3.2.1.

3.3.0.

3.4.0.

3.4.1.

3.5.0.

3.5.1.

3.6.0.

3.6.1.

3.7.0. 3.7.1.

3.7.2.

Check whether fully closed lamp indication appears and open lamp indication disappears at control room for valves 2 and 4. Bring back the piston KA 08, differential Amplifier piston to zeo position. Check whether water injection valves 1 & 3 closes immediately, when the signal oil pressure in water injection line drops down below 1.5 kg/cm2. Check whether closed lamp indication appears at control room for valves 1 and 3. Move the differential Amplifier piston KA 08 to 7 mm by operating the hand wheel KA 09. Check the signal oil pressure in the LP by pass line. It should be 1.7 kg/cm2. If the signal oil pressure is not achieved, adjust both the follow up pistons equally to get a signal oil pressure of 1.7 kg/cm 2, in the LP by pass line. 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 whether the signal oil pressure obtained are 2.2 kg/cm2,4.7 kg/cm2, and near about 5 kg/cm2 respectively. If the maximum signal oil pressure of about 5 kg/cm 2in the LP by pass line is not achieved for the maximum position of amplifier piston, adjust the proportionality. Bring back the piston KA 08, of differential Amplifier piston to zero position. Check the signal oil pressure in the LP by pass line is zero. Ensure both the LP by pass stop valves are in full closed position. Adjust the closed limit switch of both the LP by pass stop valves. Check whether the lamp indication appears at control room. Adjust both the LP by pass stop valve, mechanical scale to zero position, when the stop valves are fully closed. Bring back the piston KA 08 to the position where signal oil pressure of LP by pass line is 1.7 kg/cm 2. 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. 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

3.8.0.

3.8.1.

3.8.2.

3.9.0.

3.9.1.

3.9.2.

3.10.0.

3.10.1.

3.11.0.

3.11.1. 3.11.2. 3.11.3. 3.11.4. 3.11.5.

3.12.0.

3.13.0.

3.13.1.

open exactly at 1.7 kg/cm2, of signal oil pressure in LP by pass line. 3.13.2. 3.13.3. Ensure that both the LP by pass stop valves are fully opened. Adjust the limit switches for full open position, for both the LP by pass stop valves. Check whether the lamp indication appears at control room for full open position of both the LP by pass valves. Check that close lamp indication do not exist at the control room for both LP by pass stop valves. Check and ensure that both the LP by pass control valves, are in full closed position. 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. Move the differential Amplifier piston KA 08, till the signal oil pressure of LP by pass line, is around 2.2 kg/cm2. Check whether both the LP by pass control valve Servomotor just opens at a signal oil pressure of 2.2 kg/cm2 in the LP by pass line. If the LP by pass control valve just opened/not opened, adjust the slide valve MAX 53 AA 086 + 087, just to open, exactly at 2.2 kg/cm2, of signal oil pressure, in the LP by pass line. Move the differential amplifier piston on KA 08, till the signal oil pressure is around 4.7 kg/cm2. Check whether both the control valve of LP by pass have opened fully. 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. Ensure the full lifts of both the LP by pass control valves are 80 mm. 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. 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.

3.13.4.

3.13.5.

3.14.0.

3.14.1.

3.15.0.

3.15.1.

3.15.2.

3.16.0.

3.16.1.

3.16.2.

3.17.0.

3.18.0.

3.19.0. 3.19.1.

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. Actuate the solenoid of temperature protection. Move the differential Amplifier piston KA 08 by operating hand wheel KA 09, to the maximum position. 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/cm 2. De-energise thee solenoid of the temperature protection. Check whether the signal oil pressure in the LP by pass line goes to 5 kg/cm2. Actuate low vacuum protection one by one. protection and water pressure switch

3.20.0. 3.20.1.

3.20.2.

3.20.3. 3.20.4.

3.21.0.

3.21.1.

Note, when any one of the protection is actuated, the action that takes place is as per 3.20.2. Bring back the differential Amplifier piston KA 08, to a piston where signal oil pressure is 1.5 kg/cm2 in the water injection line. Note down the signal oil pressure in the LP by pass line. 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. 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. Increase the signal oil pressure in the LP by pass line in the LP by pass line in steps of 0.2 kg/cm2 and note down both the LP by pass control valve lifts. Plot the characteristics curve. Stroke of control sleeve of follow up piston versus signal oil pressure in water injection. Stoke of control sleeve of follow up piston versus signal oil pressure in the LP by pass system. Signal oil pressure in the LP by pass system versus LP by pass system versus LP by pass control valve lift.

3.22.0.

3.22.1. 3.23.0.

3.23.1.

3.24.0.

3.25.0. 3.25.1.

3.25.2.

3.25.3.

**********

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. Ensure the hand wheel KA 09 of Converter for Electro-Hydraulic in full closed condition and lock it. 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. Feed 0-10 volts to Electro-Hydraulic converter in steps of one volt. Ensure at 10 volts, the differential amplifier piston KA 08 travels, approximately 40 mm and piston controller at control room indicates 100%.

4.2.0.

4.3.0.

4.4.0. 4.4.1.

4.5.0.

Feed zero volts and bring differential amplifier piston KA 08 to minimum position.

4.6.0. 4.6.1.

Feed the voltage gradually to EHC and note down the following. Check and note down the voltage at which water injection valves opens corresponding to signal oil pressure in the water injection line of 1.5 kg/cm2. The voltage will be approximately about 2.0 volts. 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. 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 kg/cm2 in the by pass line. The voltage will be approx. about 3.5 volts. 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 signal oil pressure of 4.7 kg/cm 2in the LP by pass line. Plot the curve for the following. EHC voltage versus signal oil pressure in the water injection line.

4.6.2.

4.6.3.

4.6.4.

4.7.0. 4.7.1.

4.7.2. 4.7.3. 4.7.4.

EHC voltage versus signal oil pressure in the LP by pass line. EHC voltage versus differential amplifier piston lift. EHC voltage versus control valve lift, of LP by pass.

BOILER COMMISSIONING.

OBJECTIVE: It is a systematic procedure used after completion of erection in making the Boiler and its auxiliaries available for safe, smooth and reliable Operation.

Major events in Boiler Commissioning

01. Air leakage test. 02. Hydro testing of boiler. 03. Readiness of Boiler auxiliaries. 04. Gas distribution test. 05. Boiler light up 06. Alkali boil-out and first stage passivation. 07. Acid cleaning and second stage passivation. 08. Steam blowing of critical piping. 09. Safety valve floating. 10. Coal firing.