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TAPP-3&4 COMMISSIONING

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PROCEDURE NO: 3&4-

COMMISSIONING PROCEDURE FOR


GOVERNING SYSTEM

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NUCLEAR POWER CORPORATION OF INDIA LIMITED


(A Govt.of India Enterprise)
TARAPUR ATOMIC POWER PROJECT-3&4

COMMISSIONING PROCEDURE FOR


GOVERNING SYSTEM

Concurred BY

Name & design.


NPC Design Group

PREPARED
BY

CHECKED BY

REVIEWED
BY

APPROVED
BY

ISSUED BY

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COMMISSIONING PROCEDURE FOR


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REVISION LOG
Revision Details
Issue No.

Rev.No.

Details

Date

Page
No.

Preparation Details
Prepared by
Concurred by
Checked by
Approved by
Reviewed by

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TAPP-3&4 COMMISSIONING
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CONTENTS
SL
TITLE CLAUSE

PAGE NO.

NO.
Cover sheet
Revision log
Contents
1.

Purpose

1
3
5
6

Pre-requisites

2.

3.
4.
5.
6.
7.
8.
9.
10.

2.1 Status of other systems


2.2 System Requirements
2.3 Manpower requirements
2.4 Requirement of special Equipments
2.5 Requirement of outside agencies
2.6 Hazards & precautions
General method
Design intents
Expected process parameters
Work plan
Test report format
Reference
Verification process
COMMISSIONING PROCEDURE ACCEPTANCE NOTE

8
19
20
20
21
23
24
25

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Purpose:
The purpose of this procedure is to provide guidelines for
commissioning of the governing system.

2.0

Pre-requisites:

2.1

Status of other systems:


a
b
c
d
e
f
g
h
i

All erection activities should be completed.


Oil flushing of the system should be completed.
System should be available with fresh oil.
Pipes should be normalized in all respects.
Temporary supports should be removed.
AOPs are available for running.
Oil Purification System should be in operation.
Service air should be available near filters for cleaning.
Cooling water at oil cooler should be available.

2.2 System Requirements


The following equipments and Instruments shall be made available.
a) Portable vacuum pump one No.
b) Hydraulic pressure pump one No.
c) Standard pressure gauges with an accuracy of 0.1kg/cm 2
10 kg/cm2
4 Nos.

0 20 kg/cm2 1 Nos.

0 40 kg/cm2 1 Nos
d) Standard vacuum gauge range 0 760 mm Hg.
e) Dial gauge with Magnetic Base 0-10 mm one No.
f) Depth gauge one No. range 0-50 mm
g) Slip gauges Box one No.
h) Filer gauge 0.05 to 1 mm 1 Set.
i) Diffent sizes of spanner set (double end)
j) Ring spanner 3 mm to 27 mm one set.
k) Allen Key one set 3 mm to 10 mm.
l) Screwdriver small to big one set.
m)Voltage injection test kit one No.
n) Multimeter- one No.

range 0-

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o) Digital speed indicator- one No. 0-4000 rpm range.


2.3 Manpower requirements:
Commissioning team of mechanical, electrical & C&I engineers &
supporting manpower.
2.4 Requirement of special Equipments:
A.
b.
c.
d.

1000V MEGGER
Digital Multimeter
Clamp-on meter
Milli-ampere source

2.5 Requirement of outside agencies


Nil
2.6 Hazards & precautions
The hydraulic systems of governing system are equipped with oil
storing accumulators. Loosening or tightening of any mechanical
item should be done after depressurization & draining of the
system.
A telephone should be available near by and the telephone numbers
of hospital, ambulance and fire brigade is displayed.
While testing and adjusting the LP Bypass & governing systems no
insulation work shall be allowed.
Fire fighting equipments shall be made available.
The operating personnel shall be aware of the procedure.
Debris in and around oil systems and MOT floor to be removed.
Approach/Stair Case/Platform wherever required are made
available.
Sign boards to be displayed at strategic location to indicate that Oil
System is charged and oil pumps are ON.

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General method

Check the completion of erection as per the design flow sheets and
drawings. Check the completion of equipments and supports in all oil pipe
systems.
Check the N2 pressure in the accumulators. Make up N2 if required.
(N2 pressure=3.0 bar.-Hyd rack for CSDV controller.HP system=bar, LP
system pr=4.5 bar)
Check whether the test valves of HP stop valves MAX 47 AA 211 212 are
kept opened fully.
Check whether the isolating valve in EHC circuit in HP secondary oil is
closed MAX 45 AA 502 & MAX 45 AA501 is open while setting the
hydraulic controller.
Close the trip oil line-isolating valve MAX 51 AA 521, 522, 524, 525, 527,
528, 530, 531,536,538 of extraction NRV test valves MAX 51 AA 041, and
042,044,045,047,048,050,051,056,058.
Fix a dial gauge 0-10 mm underneath bellow KA 09 in the hydraulic speed
Governor MAX 46 By 001.
Fix three standard gauges in Auxiliary secondary oil & HP secondary oil
lines.
(0-8 kg/cm2 to read upto 0.1 kg/cm2 accuracy).
Open the top cover of Hydraulic amplifier MAX 45 By 011 to measure the
power piston KA 08 lift.
Ensure that the Boiler stop valve is fully closed and the main steam line is
not charged with steam.
Ensure starting device is in closed condition & limit switch 47CG001C is
operated.
Keep the speeder gear in maximum set positions,(not mandatory).
Check whether oil pump is running.

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Maintain oil temperature in oil tank around 50 0 C / 550 C.


Ensure that the main trip valve is in reset conditions.
Switch off ATRS panel supply, so that hydraulic governor can be checked
when boiler is not in service.
Record the following pressure in the rack.
Control oil pressure
Start up oil pressure
Aux. Start up oil pressure
Trip oil pressure
Aux. Trip oil pressure
Ensure that the respective governor characteristics are used while setting
the governor.
(Drg No.1-11400-09200 & 1-1280009300)
Procedure for checking and setting of Hydraulic Governor.
Note down the initial reading of starting device when the starting device is
in full closed 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 2.3 kg/cm2 and note down HP secondary oil pressure.
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.

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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/cm 2 and above, when starting device is
fully opened condition.
Note down the HP secondary oil pressure corresponding to 4.2 kg/cm 2 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/cm2 approximately. At least under 2.3 kg/cm2.
Note: Trip point of Auxiliary follow up piston is the pressure at which
auxiliary secondary oil pressure suddenly falls.
Bring back the starting device to 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/cm2.
At 2.3 kg/cm2 of Auxiliary secondary oil pressure check whether the HP
secondary oil pressure is 3.0 kg/cm2.
If the value is not achieved, adjust the 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 7
mm (approx.), when the HP secondary oil pressure is around 3.0 kg/cm 2.
If the value is not achieved, adjust the start up opening of pilot valve KA
07 of MAX 45 By 011.
Note down the values of followings: -

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Starting device travel.


Lift of the bellow.
Power piston lift of Hydraulic controller.
Aux. Secondary oil pressure, HP secondary oil pressure
Increase the Auxiliary 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/cm 2 when
auxiliary secondary oil pressure is around 4.2 kg/cm 2.
Check by closing the isolating valve MAX 41 AA 501,502 &515 of speed
control rack and note at what pressure of trip oil, Tripping device MAX 51
AA 006, MAX 51 AA 005 and emergency trip valve MAX 52 AA 005 trips
suddenly.
Trip device and emergency trip valve should trip at 3 (2.9 + 0.1) bar of
trip oil pressure.
After checking and ensuring that trip devices and emergency trip valve
trips at 3 bars, 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 of Auxiliary secondary oil pressure, the HP secondary oil
pressure is 3.0 kg/cm2.
Increase the auxiliary secondary oil pressure in steps of
and note down the following.

0.2 kg/cm 2

HP secondary oil pressure.


Power Piston lift of Hydraulic converter.
Starting device travel.
Check that a closing and opening reserve of 3.5 mm, is available for
power piston KA 08 Hydraulic Amplifier MAX 45 By 011.

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Check the bellow travel KA 09 of MAX 46 By 001 between auxiliary


secondary oil pressure of 2.3 to 4.2 kg/cm2, should be approx. 5 mm.
Check the total travel of Amplifier power piston. It should be 50 mm
approximately, from fully closed position to fully open condition of starting
device MAX 47 By 001.
Plot the following curve.
Power piston lift versus Auxiliary secondary oil pressure.
Bellow lift versus auxiliary secondary oil pressure.
Bellow lift versus HP secondary oil pressure.
Bring the starting device to minimum position, to calibrate HP control
valves.
Adjust the local position transmitter to indicate zero mm for HP control
valves.
Bring the starting device to a position where HP secondary oil pressure is
3.0 kg/cm2.
Adjust the start of opening of HP control valves, just to open at 3.0
kg/cm2 of HP secondary oil pressure.
Increase the Auxiliary oil pressures in steps of 0.2 kg/cm 2 and note down
the following upto the maximum position of starting device.
HP secondary oil pressure.
HP control valve lift.
Plot the curve for the following.
HP secondary oil pressure versus HP control valve lift.
If the lifts of control valves are not coming equal adjust the fulcrum point
of lever feed back linkage as shown in O&M manual.

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Open the test valve of HP stop valve fully and check whether stop valve
opens fully.
Fully close the test valves of HP stop valve and check whether the stop
valve closes fully.
Ensure full lift of HP stop valves & compare with the design values.
Now open HP stop valve by opening the test valve fully and ensure that
the stop valve has opened fully.
Note down at what trip oil pressure HP stop valve suddenly closes.
Bring back the starting device to full close condition.
Bring back the starting device to closed position.
Check the dial gauge below the bellow is set at zero.
Note down the intial reading of starting device.
Open gradually the starting device from fully closed position to fully open
position and note down the following.
Bellow lift.
Auxiliary secondary oil pressure.
HP secondary oil pressure.
Starting device travel.
Plot the following curve
Bellow travel versus Auxiliary secondary oil pressure.
Bellow travel versus HP secondary oil pressure.
During the actuation of load shed relays MAX 46 AA011 & 012 check
whether Aux. Secondary oil pressure drops down to zero and comes back,
to the value at which the load shedding relay was actuated.

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Switch on the ATRS supply.


Check the Main trip valve trips immediately and all the stop valves and
control valves closes immediately.
Check the Auxiliary secondary oil pressure, HP secondary oil pressure,
trip oil pressure and Auxiliary trips oil pressure reads zero.
Switch off ATRS panel supply.
Initial checks to be carried out before setting of Electro-Hydraulic
Converter.
Open the isolating valves MAX 45 AA 502 in HP secondary oil line from
EHC, which was kept, closed while checking the hydraulic controller.
Keep the starting device MAX 47 By 001 in maximum position & close
MAX 45AA501.
Ensure that the control oil line isolating valves MAX 42 AA 612 is kept
opened.
Ensure that aux secondary oil line-isolating valve MAX 46 AA 502 is kept
opened.
Ensure a pressure gauge 0 to 8 kg/cm 2 in the pressure gauge point
provided before EHC MAX 45 By 001 in aux sec oil line.
Procedure for checking and setting of EHC
Feed through set point voltage, a fixed voltage in co-ordination with C & I
Engineer.
Check whether the voltage in moving coil MAX 45 CG 001 T is around
minus 1 volts.
The Equilibrium voltage should be between minus 8 volts to minus 1.2
volts.

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If it is not, adjust the moving coil by loosening the three locking screws to
such a position where the equilibrium voltage is around minus 1 volt.
After adjusting, feed zero volt through set point and note down the power
piston lift. (Minimum reading)
Feed 10 volts through set point voltage and note down the power piston
lift. (Max. reading)
The difference in lift between maximum and minimum lift should be
approximately 50mm.
Vary the controller from minimum to maximum position and note down
the output of Collins II and I in the minimum and maximum position.
The Collins I and II out put should be 7.5V to +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 7mm as obtained in Hydraulic Governor
setting.
Check the HP secondary oil pressure, and adjust the four follow up pistons
KA 01 of EHC MAX 45 By 001 equally to get HP secondary oil pressure of
3.0 kg/cm2 when power piston lift is 6 to 7mm as obtained in Hydraulic
Governing setting.
Increase set point voltage and hold the HP secondary oil pressure at 3.24
kg/cm2.
Increase the set point voltage in steps on one volt and note down Collins
out put 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 5
mm is available for power piston KA 08 of EHC MAX 45 By 001.

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Ensure the start of opening of HP control valves remains at 3.0 kg/cm 2 of


HP secondary oil pressures, as set earlier during hydraulic controller
adjustment.
Check and ensure that the HP control valves open with respect to HP
secondary oil pressure as per the governor characteristics, from full close
to full open position. (Drg No. 1-11400-09200)
Plot the following curves.
Set point voltage versus Collins I and II voltage
Electrical calibration job shall be taken up.
Ensure the following settings in coordination with C&I / electrical
Engineers.
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 1%, 42%, 58% and 100% MAX 47 CG001C,1D,1F & 1B respectively
of starting device opening.
Ensure the speeder gear percentage position at control from indication,
from 0 to 100% matches with full close to full open position.
Adjust the limit switches in full open direction and full close direction for
of HP stop valves and IP stop valves.
Ensure the open and close indication is appearing for all the stop valve at
control room.
Adjust the percentages position of the control valves of HP in their
respective position indicators.
Ensure the local scale indicator mounted on the body of
valves in the fully open and fully closed directions.
Correct the scale if required

of HP control

Ensure that the potentiometer for extraction valves are indicating the
valve opening position is calibrated.

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Ensure the extraction NRV solenoid MAX 51 AA 021, 022, 024, 025, 027,
028, 030,031,036 & 038 indication at control room for energized and deenergised condition.
CONDUCT THE FOLLOWING CHEKS AT 3000 RPM
Check whether the turbine speed is exactly 3000 rpm.
Carry out oil injection tests
The actuation of over speed bolt is indicated on the test rack by lamps
and can be observed by the actuation of limit switches MAX 10 CG 001 +
002, provided on the LHS of front bearing pedestal.
Note down the test oil pressure at which over speed, bolt number one
comes out and over speed bolt number two comes out.
Repeat the test two to three times and check whether test oil pressure
comes to a steady valve.
Testing of 7% regulation of Hydraulic Governor.
Check the machine is running on electro hydraulic or Hydraulic.
If it is running on Electro Hydraulic change over to Hydraulic by closing
the isolating valve (in the secondary line to EHC-MAX 45 AA 502).
Ensure the starting device in maximum position & control on speeder
gear.
Increase the speeder gear to full open condition and check the speed
increases to 3210 rpm at fully open condition.
If the speed is not achieved, loosen the lock nut and increase the
compression of spring of hydraulic speed governor, to get the required
speed.
After getting 7% of rated speed, at speeder gear and starting device in
maximum position, lock, the lock nut, of Hydraulic speed governor.
Actual over speed Test 115 +0.5 % of rated speed.

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Ensure before carrying out actual over speed test, the both over speed
governors are operative by conducting oil injection test as explained
above
Ensure that all speed indicators and recorders are indicating the same
speed when the machine is at 3000 rpm and at 3210 rpm.
Ensure that turbine is running at a speed of 3210 rpm with starting device
and speeder gear in maximum position.
Press continuously the over speed testing lever 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 (approx. 115
+0.5 % of rated speed) by the actuation of over speed governors.
Note: Release the lever if the over speed governor is not acting at 115
+0.5 % of rated speed. Adjust the over speed governor bolt to act 115
+0.5 % of rated speed.
Record the speed at which over speed governors 1 or 2 acts.
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.

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Design intents:

Design orifices:
MAX
MAX
MAX
MAX
MAX
MAX
MAX
MAX
MAX
MAX
MAX

45
45
45
45
46
46
46
46
48
48
42

BP
BP
BP
BP
BP
BP
BP
BP
BP
BP
BP

001
002
003
004
004
005
001
002
001
022
001

MAX 44 BP 001

Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia
Dia

4.5
4.5
4.5
4.5
3.5
3.5
4.0
4.0
5.5
5.5
2.5

Dia 1.5

SUPPLY FOLLOW UP PISTON BLOCK


SUPPLY FOLLOW UP PISTON BLOCK
SUPPLY FOLLOW UP PISTON BLOCK
SUPPLY FOLLOW UP PISTON BLOCK
SUPPLY ELECT.HYDR CONVERTER
SUPPLY ELECT.HYDR CONVERTER
SUPPLY AUX SECONDARY OIL
SUPPLY AUX SECONDARY OIL
DRAIN TRIP DEVICE
DRAIN TRIP DEVICE
SUPPLY BEFORE SOLENOID VALVE
START UP OIL
VENT PRIMARY OIL

Proportional range=5+0.2 %
HPCVSM lift=195 mm
ESV trip pressure=3 + 0.3 bar
Trip pressure for Trip devices=2.9+ 0.1 bar
OS bolts optd=115%+0.5%
Accumulators-HP system charging pressure=24 bar at 20 deg
Accumulators-LP system charging pressure=4.5 bar at 20 deg
Adjustments of LT.Switches:
MAX 47 CG 001B = 100%=24.5 mm
MAX 47 CG 001C = 0%=0 mm
MAX 47 CG 001D = 42%=10.94 mm
MAX 47 CG 001F = 58%=14.21 mm
SPEEDER GEAR OUT=7%

AUX

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Expected process parameters

Design requirements for setting Hyd. governor


SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
6.0

Bellow Lift
0
0.518
1
1.53
2.0
2.5
3.0
3.28
3.5
3.7
4.1

Aux Sec. Oil


Pressure
2.3
2.54
2.76
3.01
3.22
3.46
3.69
3.82
3.92
4.02
4.2

Secondary oil
pressure
3.0
3.25
3.5
3.74
3.98
4.22
4.46
4.60
4.7
4.8
5.0

Work plan:
a
b
c

Commissioning of hydraulic governor


Commissioning of electro-hydraulic governor
Commissioning of system in dynamic conditions.

Control valve
lift
0
11.5
23
35
45
59
76
91
112
140
195

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Test report format

(A) For Hyd. Governor:


Hydraulic conveyor

Below lift

ST Device

HP

Measured Calculated Measured Calculated Measured Calculated SOP

(B) For Electro Hyd. Governor:

Volt

0
1
2
3
4
5
6
7

Collins

Collins

SOP

II

HP

EHC %

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8
9
10
3.446
6.157
7.370

(C) For valves:


SN

Bellow Lift

Aux Sec. Oil


Pressure

Secondary oil
pressure

Control valve
lift

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Reference
a. Turbine O&M manual
b. Drawing no. 1-11400-09200

9.0 Verification process


Verification points are included in 4.0 general methods
Verification requirements- all functional requirements have been
listed in general method. Also please refer Drawing no. 1-1140009200.
10.0 List of annexure
Drawing no. 1-11400-09200(Please refer supplied drg)

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APPENDIX
VERIFICATION TABLE
COMMISSIONING PROCEDURE FOR GOVERNING SYSTEM

COMMISSIONING PROCEDURE NO._________________________________

SL.
NO

ACTIVITY
VERIFIED

ACCEPTANCE
CRITERIA

VERIFYING
AGENCY

CERTIFICATION BY VERIFYING AGENCY


PROCEDURE
VERIFICATION

Pl refer
4.0

Pl refer 4.0

INSPECTION
WITNESS

FUNCTION
-AL TEST

RESULT
VERIFICA
-TION

GENERAL
REMARKS

TAPP-3&4 COMMISSIONING
PROCEDURE

PROCEDURE NO: 3&4-

COMMISSIONING PROCEDURE FOR


GOVERNING SYSTEM

ISSUE
REV NO:0
NO:01
Page 25 of 25
DATE OF ISSUE:

ANNEXURE
NUCLEAR POWER CORPORATION OF INDIA LIMITED
(A Govt. of India Enterprise)
TARAPUR ATOMIC POWER PROJECT3&4
COMMISSIONING PROCEDURE ACCEPTANCE NOTE
Contractor commissioning procedure number ___________________________ for
the commissioning of GOVERNING SYSTEM submitted by BHEL under the
contract number ______________ is received and found conforming to the
requirement of NPCIL specifications & Norms & hence accepted.

Commissioning procedure number:

_____________________________________

Commissioning procedure title:

COMMISSIONING PROCEDURE FOR


GOVERNING SYSTEM

NAME & DESIGNATION


Reviewed by:
Concerned Commg. Engs./
Sr.Commg. Engs/
SMEs
Concerned
ENCs/Suptds.
Concurred
by:

Approved by:

NPC Design
Group

SIGNATURE