97-98 PROJECT RE-ENGINEERING ALL UTILITIES HP BYPASS WARM UP LINES ARE RE-ENGINEERED TO AVOID ACCUMULATION OF CONDENSATE ESPECIALLY DURING

START UP. HISTORY: HP bypass valves, after few months of operation were found passing in some sites. On inspection of internals of the valves, it was observed that there was erosion in valve stem. On close monitoring and study it was identified that condensate attack on valve stem, during cold and warm start up may be the probable cause for the damage. Since original warm up system is found to be not effective, during cold/warm up start up. RE-ENGINEERING ADOPTED: To avoid accumulation of condensate in the upstream of valve during cold start up and to ensure proper warming up, the following design modifications in the warm up line system have been adopted after thorough discussion held between design engineers from BHEUTIRUCHY, PIPING CENTRE-MADRAS, PEM-DELHI, TECHNICAL SERVICESDELHI, TECHNICAL SERVICES-PSSR on 20/21.2.98. The warm up line tapping shall be from the bottom of the upstream line of the valve. The stub size may be of dia 60.3 mm. The tapping also shall be as close as to the valve may be around 200 mm from valve inlet weld end. The warm up line shall be connected either to down stream of MS strainer or to the HPBP downstream line. In case of warm up line connection to HPBP downstream, it shall be after the temperature measurement point at a distance of not less than 5 mtr. Two temperature measurement provisions are to be given in the HP bypass fine, one at the upstream of the valve and the other at the warm up line. The warm up line also shall be connected to flash tank through drain piping with two valves, one manual and the other of motor operated. The revised engineering scheme is given in the sketches.

PERFORMANCE OBSERVATIONS:

In Kothagudam TPS Unit-10, the warm up line tapping was shifted to bottom and the warm up line was connected to flash tank through drain pipe with 2 manual valves. After carrying out the above modifications, it was observed that the steam temp, before HPBP valve is about 480 deg C when the unit is running with main steam temperature around 540 deg C. This establishing that the warm up iine system is satisfactory while valve is on standby condition. Two numbers thermocouples are being provided for temperature measurement before HP bypass valve and on the warm up drain line. The performance during cold/warm start up will be assessed after collecting feed back on steam temperature during cold start ups in the near future.

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