500mw Checking and Setting of Hydraulic and Electro

8/10/2019 500mw Checking and Setting of Hydraulic and Electro

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CHECKING AND SETTING OF HYDRAULIC AND ELECTRO-

HYDRAULIC CONVERTER OF LP BY-PASS 500 MW.

1.0.0. Initial checks for setting the Hydraulicconverter of LP by pass.

1.1.0. The components number indicated on the check list is basedon the governing scheme Drg. No. 1-1-2190-7279/1.

1.2.0. Check whether erection of all fluid pipe lines are completed, forLP by pass system.

1.3.0. Check that all the drain valves in the control fluid lines of waterinjection valves are kept closed.

1.4.0. Check whether the isolating valves before the filter MAX 42 BT021 is kept opened.



1.7.0. Check whether the isolating valves are kept opened.

1.7.1. The isolating valves MAX 42 AA 541+543, MAX 42 AA 542+544,MAX 42 AA 554+556 and MAX 42 AA 553+555 in the control fluidline to water injection valves.

1.7.2. Signal fluid inlet valve MAX 53 AA 531+532 to LP by pass controlvalves.

1.7.3. Control fluid (32 bar) inlet valve MAX 31 AA 582, 584 of LP bypass control valve.

1.7.4. Control fluid inlet valve MAX 31 AA 541 + 545 to accumulator is

kept opened.

1.8.0. Check and ensure that the isolating valves before the individualequipment in the rack are kept opened.

1.9.0. Check whether AOP is running and control fluid pressure of 6 to 7bar is available.

1.10.0. Run the condensate pump and ensure by opening the valve MAN11+12 AA 511, that water pressure more than 10 kg/cm2isavailable in the limit controller.

1.11.0. Ensure the vacuum is available to the limit controller greater than0.6 bar abs.


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2.5.0. Test the condenser vacuum trip protection is healthy. The valuefor LP by pass limit controller MAX 53 By 011 and low vacuumcondenser protection MAG 01 AA 016 is around 0.6 bar abs byopening a vent screw at test valve.

2.5.1. Reduce the vacuum gradually and note down by observing thevacuum gauge, at what value of vacuum the signal fluid pressurein the LP by pass line drops down suddenly.

2.5.2. Record the trip value of vacuum.

2.6.0. Increase the vacuum and check the vacuum protection gets resetand signal fluid pressure in LP by pass comes back to originalvalue.

2.7.0. Jack the low vacuum condenser protection for making itineffective.

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. Remove the jack from low vacuum condenser protection, formaking it effective.


2.9.0. Open the top cover of LP by pass limit controller MAX 53 BY 011and ensure that the oil jet nozzle KA 01 is in RHS. Insert a filler

gauge on the LHS, which makes the LP by pass limit controllerinoperative.


2.9.2. Record the trip value of vacuum for low vacuum condenserprotection.

2.9.3. Remove the filler gauge from the LP by pass limit controllerplaced during operation 2.9.0.


2.11.0. Study the values obtained in 2.5.2, 2.7.2 and 2.9.2. All the threetrip values obtained should be around 0.6 bar abs.

2.11.1. Any one of the trip value obtained in 2.7.2, 2.9.2. is less or more,

adjust LP by pass limit controller/low vacuum condenserprotection to obtain trip value around 0.6 bar abs.

2.11.2. For obtaining required value at LP by pass controller/decrease,the spring tension on vacuum, connection to bellow according tothe value obtained in 2.7.2.


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2.11.3. For obtaining required value at low vacuum condenser protectionunit, adjust item No. 2 of component drg. 1.1-3402-002/1 in O & Mmanual to vary the spring (item No. 4) compression, according tothe value obtained in 2.9.2.

2.12.0. Test the water pressure switch protection is healthy. The tripvalue for limit pressure controller MAX 53 BY 011 and waterpressure switch MAN 01 AA 011 protection is around 9.5 bar.

2.12.1. Reduce the water pressure gradually and note down by observing

the water pressure gauge, at what value of water pressure, thesignal fluid pressure in the LP by pass line drops down gradually.

2.12.2. Record the trip value of water pressure.

2.13.0. Increase the water pressure and check the water pressureprotection gets reset and signal fluid pressure in LP by pass comes

back to original value.

2.14.0. By pass the hydraulic water switch protection by operating thelever to by pass position for making it ineffective.


2.14.2. Record the trip of water pressure, for LP by pass limit pressurecontroller.

2.14.3. Normalize the lever of hydraulic water protection to make iteffective.


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


2.16.2. Record the trip value of hydraulic water pressure switchprotection.

2.16.3. Remove the filler gauge from the LP by pass limit controllerplaced during operation 2.16.0.


2.18.0. Study the values obtained in 2.12.2. 2.14.2 and 2.16.2. All thethree trip values obtained should be around 9.5 bar.

2.18.1. Any one of the trip values obtained 2.14.2. and 2.16.2. isless/more adjust LP by pass limit controller/water pressure switch

to obtain around 9.5 kg/cm2

.


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2.18.2. For obtaining required value of LP by pass limit controllerincrease/decrease the spring tension provided for adjustment onwater pressure, according to the trip value obtained in 2.14.2.

2.18.3. For obtaining required trip value at Hydraulic pressure switchunit increase/decrease the compression of spring item 6 of Drg.No. 1-1-3410-0009/1 in O & M manual, according to the trip valueobtained in 2.16.2.

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 AA021+022 is around 90

C at down stream of LP by pass value.

2.19.1. Energize the solenoid one by one by shorting the protection lead

and check the signal fluid pressure in the LP by pass drops downsuddenly.

2.19.2. De-energize the solenoid one by one and check that the signalfluid pressure in the LP by pass comes back to original value.

NOTE: - During this check, when solenoid for LP BP 1 is energized,the corresponding LP BBP 1 stop and control valve actually closeand similarly for LPBP 2.

2.20.0. Check the reheat protection of LP by pass limitcontroller.

2.20.1. Increase the pressure in down stream impulseline of LP by pass connected to the LP by passlimit controller through hydraulic pump to a

value of 25.1 kg/cm2.

2.20.2. Ensure the piston KA 07 for the LP by passlimit controller just starts to close, at a pressure

of 25.1 kg/cm2.

2.20.3.

Record the pressures in the down streamimpulse line of LP by pass reheat line, when thepiston KA 07 for limit controller closes fully.

2.20.4. The difference between the reheat pressures

in down streamline is about 3.5kg/cm2approximately when the piston KA 07 oflimit controller moves from fully open to fully

closed position.


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2.21.0. After ensuring the following protections

namely LP by pass limit controller, low vacuumcondenser protection, water pressure switch andtemperature and pressure protection down

stream of LP by pass proceed for further settingand checking of LP by pass.

***********

3.0.0. Setting of LP by pass Hydraulic Governor.

3.0.1. Operate the hand wheel of KA 09 to move the

differential Amplifier piston KA 08 of Converterfor Electro hydraulic LP by pass Governor, forincreasing the signal fluid pressure in LP by pass

and water injection lines.

3.0.2. Measure the lift of KA 08, while operating thehand wheel KA 09.

3.0.3. Stop the operation of KA 09 when the lift at KA

08 of differential Amplifier piston is about 3.2mm.

3.0.4. Check whether signal fluid pressure in water

injection line is around 1.5 kg/cm2.

3.0.5. If the signal fluid pressure is not achieved,adjust both the follow up piston KA 03 equally to

get a signal fluid pressure of 1.5 kg/cm2, in the

water injection line.

3.1.0. 3.1.0. Check whether the water injection valve1 & 3 opens at a signal fluid pressure of 1.5

kg/cm2.

3.1.1. If the water injection valve 1 & 3 opened/notopened adjust the slide valve MAX 53 AA 031,spring tension accordingly to open exactly at 1.5

kg/cm2of signal fluid pressure in water injection

line.


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3.2.0. Energise the solenoid MAX 53 AA 051, to admit

signal fluid to the slide valve MAX 53 AA 041.

3.2.1. Check the water injection valve 2 and 4

opened/not opened, adjust the slide valve springtension accordingly, to open exactly at 1.5kg/cm2of signal fluid pressure in water injectionline.

3.3.0. Bring back the piston KA 08 of differential

Amplifier/piston to zero position, by operatingthe hand wheel KA 09, and check all the four

water injection valves, closes fully.

3.4.0. Set the limit switches for full closed positions

for all the four water injection valves.

3.4.1. Check whether the lamp indication appears atcontrol room for all the four water injection

valves closed position.

3.5.0. Operate the hand wheel KA 09, gradually andincrease the signal fluid pressure to 1.5

kg/cm2in water injection line.

3.5.1. Ensure that all the four water injection valvesopen at a signal fluid pressure of 1.5 kg/cm2atthe same time.

3.6.0. Adjust the limit switches for full open positionand closed lamp indication disappears for all thefour water injection valves.

3.6.1. Check whether the lamp indication appears at

control room, in full open position and closedlamp 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 & 4, closes

immediately.


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3.7.2. Check whether fully closed lamp indication

appears and open lamp indication disappears atcontrol room for valves 2 & 4.

3.8.0.

Bring back the piston KA 08, differentialAmplifier piston to zero position.

3.8.1. Check whether water injection valves 1 & 3

closes immediately when the signal fluidpressure in water injection line drops down

below 1.5 kg/cm2.

3.8.2. Check whether closed lamp indicating appearsat control room for valves 1 & 3.

3.9.0. Move the differential Amplifier piston KA 08 to7 mm by operating the hand wheel KA 09.

3.9.1. Check the signal fluid pressure in the LP bypass line. It should be 1.7 kg/cm2.

3.9.2. If the signal fluid pressure is not achieved,adjust both the follow up pistons equally to get a

signal fluid pressure of 1.7 kg/cm2

in the LP bypass line.

3.10.0. Move the differential Amplifier piston KA 08 to

a position of 12 mm, 36.8 mm and maximum byoperating the hand wheel KA 09, and check

whether the signal fluid pressure obtained are2.2 kg/cm2, 4.7 kg/cm2and near about 5kg/cm2respectively, in the LP by pass line.

3.10.1. If the maximum signal fluid pressure of about

5 kg/cm2 in the LP by pass line is not achievedfor 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 fluid pressure in the LP by

pass line is zero.


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3.11.2. Ensure both the LP by pass stop valves are in

fully closed position.

3.11.3. Adjust the closed limit switch of both the IP 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 valves,

mechanical scale to zero position, when the stopvalves are fully closed.

3.12.0. Bring back the piston KA 08 to the position

where signal fluid pressure of LP by pass line is1.7 kg/cm2in the LP by pass line.

3.13.0. If the LP by pass stop valves one and two

opened/not opened, adjust the follow up pistonMAX 53 AA 091+092 accordingly, to open exactlyat 1.7 kg/cm2of signal fluid pressure in LP by

pass line.

3.13.1. Ensure that both the LP by pass stop valvesare fully opened.

3.13.2. Adjust the limit switches for full open position,

for both the LP by pass stop valves.

3.13.3. Check whether the lamp indication appears atcontrol room, for full open position of both the LP

by pass valves.

3.13.4. Check that close lamp indication do not exist,

at the control room for both the LP by pass stopvalves.

3.14.0. Check and ensure that both the LP by pass

control valves are in fully closed position.

3.14.1. Adjust the LP by pass control valve positiontransmitter at local and control room to zero

position, when both the control valves are in fullyclosed condition.


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3.15.0. Move the differential Amplifier piston KA 08,

till the signal fluid pressure of LP by pass line isaround 2.2 kg/cm2.

3.15.1.

Check whether both the LP by pass controlvalve servomotor just opens at a signal fluidpressure of 2.2 kg/cm2in the LP by pass line.

3.15.2. If the LP by pass control valve just opened/notopened, adjust the slide valve MAX 53 AA 086 +

087, just open exactly at 2.2 kg/cm2of signalfluid pressure in the LP by pass line.

3.16.0. Move the differential Amplifier piston KA 08,till the signal fluid pressure is around 4.7 kg/cm2.

3.16.1. Check whether both the control valves of LP by

pass have opened fully.

3.16.2. If both the LP by pass control valves hasopened/not opened fully, adjust the follow up

piston in feedback to fluid line to get the fullopen position. If necessary adjust the

proportionality.

3.17.0. Ensure the full lift of both the LP by passcontrol valves are 120 mm.

3.18.0. Check and ensure that the local position

transmitter reads 120 mm at the full openposition of both the LP by pass control valves andthe control room percentage position indicator

indicates 100%.

3.19.0. Bring back the differential amplifier piston tozero position.

3.19.1. Check and ensure that the closed lampindication appears and open lamp indication

disappears at control room for both stop valvesof LP by pass.


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3.19.2. Check and ensure that the closed indication at

control valves of LP by pass matches with zeroposition at local and at control room respectively.

3.20.0.

Actuate the solenoid of temperatureprotection.

3.20.1. Move the differential Amplifier piston KA 08 by

operating hand wheel KA 09, to the maximumposition.

3.20.2. Check and ensure the signal fluid pressure.

3.20.3. De-energise the solenoid of the temperature

protection.

3.20.4. Check whether the signal fluid pressure in theLP 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

actuate, the action taken place is as per 3.20.2.

3.22.0. Bring back the differential Amplifier piston KA08, to a position where signal fluid pressure is

1.5 kg/cm2in the water injection line.

3.22.1. Note down the signal fluid pressure in the LPby pass line.

3.23.0. Operate the hand wheel KA 09 of converter for

Electro hydraulic LP by pass Governor, andincrease the signal fluid 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 passcontrol valves starts to open at a signal fluidpressure of 1.7 kg/cm2and 2.2kg/cm2respectively, on the LP by pass line.


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3.24.0. Increase the signal fluid pressure in the LP by

pass line in steps of 0.2 kg/cm2and note downboth the LP by pass control valve lifts.

3.25.0.

Plot the characteristic curve.

3.25.1. Stroke of control sleeve of follow up piston

versus signal fluid pressure in water injection

system.

3.25.2. Stroke of control sleeve follow up pistonversus signal fluid pressure in the LP by pass

system.

3.25.3. Signal fluid pressure in the LP by pass systemversus LP by pass control valve lift.

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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 forElectro Hydraulic in full closed condition and lock

it.

4.3.0. Ensure that piston KA 08 is in the upper mostposition and there is a clearance between piston

KA 08 top to the hand wheel lever of KA 09.

4.4.0. Feed 0 to 10 volts to Electro Hydraulicconverter in steps of one volt.

4.4.1. Ensure at 10 volts, the differential Amplifier

piston KA 08 travels, approximately 40 mm and

position controller at control room indicates100%.

4.5.0. Feed zero volt and bring differential Amplifier

piston KA 08 to minimum position.


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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 tosignal fluid pressure in water injection line of 1.5kg/cm2. The voltage will be approximately about2.0 volts.

4.6.2. Check and note down the voltage at which

both the stop valves of LP by pass openscorrespondingly to signal fluid pressure in the LP

by pass line of 1.7 kg/cm2. The voltage will beapproximately about 2.5 volts.

4.6.3. Check and note down the voltage at which boththe control valves of LP by pass starts to open

corresponding to signal fluid pressure of 2.2kg/cm2in the by pass line. The voltage will be

approximately about 3.5 volts.

4.6.4. Note down the voltage at which both thecontrol valves of LP by pass open fully. The

voltage will be approximately about 7.5 volts fora signal fluid pressure of 4.7 kg/cm2in the LP bypass line.

4.7.0. Plot the curve for the following.

4.7.1. EHC voltage versus signal fluid pressure in thewater injection line.

4.7.2.

EHC voltage versus signal fluid pressure in theLP 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.

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LIST OF INSTRUMENTS AND TOOLS REQUIRED FOR

CHECKING AND SETTING HYDRAULIC/ELECTRO-HYDRAULIC L.P. BY PASS OF 210/500 MW KWU SETS.

1.1.0. Portable VacuumPump.

0 to 760 mm of Hg. 1 No.

1.2.0. Hydraulic PressurePump.

0 to 40 kg/cm2. 1 No.

1.3.0. Standard Pressuregauges with accuracyof 0.1 kg/cm2.

0 to 10 kg/cm2.

0 to 20 kg/cm2.

0 to 40 kg/cm2.

4 Nos.

1.4.0. Standard VacuumGauge.

0 to 760 mm of Hg. 1 No.

1.5.0. Dial gauge withMagnetic base.

0 to 10 mm. 1 No.

1.6.0 Depth gauge. 0 to 50 mm. 1 No.

1.7.0. Slip gauge. Complete Box. 1 set.

1.8.0. Filer gauge. 0, 0.5 to 1 mm. 1 No.

1.9.0. Spanner set (doubleend).

1 set.

1.10.0.

Ring Spanner.

3 mm to 27 mm.

1 set.

1.11.0. Allan screw. 3 mm to 10 mm. 1 set.

1.12.0. Screw driver. Small - Big. 1 set.

1.13.0. Voltage injection testkit.

- 1 No.

1.14.0. Multimeter. - 1 No.

1.15.0. Digital Speed Indicator. 0 to 4000 RPM. 1 No.

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500mw Checking and Setting of Hydraulic and Electro

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Transcript of 500mw Checking and Setting of Hydraulic and Electro