A PRESENTATION

ON
HP-LP BYPASS

HP BYPASS SYSTEM OVERVIEW

HP Bypass system alongwith LP Bypass enables the boiler
operation &
loading independent of turbine. Its a part of Boiler control.

During start-up, it helps to raise the steam parameters quickly thus

fulfilling various criteria required for turbine rolling.

HP Bypass system is a combination of :

~BP (Bypass) Valve
~BD (Spray Block) Valve
~BPE (Spray Control) Valve

The steam is desuperheated by applying spray (taken from Boiler

Feed Pump
discharge) to keep CRH steam temperature within limit.

BP Valve Capacity : 60% of BMCR.

A separate oil supply unit (OSU) is installed for HPBP operation.

HP BYPASS OVERVIEW
MS LINE

BPE VALVE
BFD
BP VALVE

BD VALVE

HPBP WARM-UP I/L V/V

CRH LINE
TO REHEATER

HPT

IPT

PHASES OF OPERATION

1.Boiler start-up while turbine is on turning

gear.
2.Increasing steam parameters to achieve
criteria for turbine rolling.
3.Loading of turbine as steam gets admitted
to it.
4.Parallel boiler operation with turbine on load
rejection.
5.Ensure boiler operation in case of a turbine
trip.
6.Preventing superheater safety valve pop at
raised MS pressure.
7.Ensure reheater (RH) protection.

REHEATER PROTECTION
In normal boiler operation, adequate steam flow must be
ensured through reheater to prevent reheater material from
overheating due to flue gas. The path of steam from reheater to
condenser should always be through by any means to avoid the
occurrence of reheater protection trip.

In case of a turbine trip, BP valve should fast open in order to

divert the steam flow through reheater & in turn boiler will
survive.

RH Protection Logic:
RH protection is armed when any coal feeder is on.
Case 1: GCB open (During rolling)

HPBP & LPBP open <2%

Case 2: GCB close
Any coal feeder on
and

MODES OF OPERATION

* Two modes of operation:

~ Sliding Setpoint Mode
~ Fixed Setpoint Mode
Sliding Setpoint tracks the MS pressure by +2.5%.
* Pre-Start-up Checks:
1.Boiler is in light-up condition, turbine on turning gear.
2.APRDS & Gland sealing are charged.
3.Vacuum pumps are in service & vacuum pulling is done.
(vacuum => - 0.8 kg/cm2). Then, HPBP trip is reset.
4.Line warm-up is done by opening HPBP warm-up & its
drain
isolation valves.
* Emergency Operation:
1.Load throw-off due to high frequency (Load Shedding
Relay

PROTECTION & INTERLOCKS

1.If BP valve opening becomes <2%, it will auto close.
2.If BP valve opening becomes <2%, BD valve will auto
close.
3.HPBP will trip on low vacuum ( -0.7kg/cm2).
4.HPBP will trip on high downstream temperature (380
C).
5.HPBP fast opens during following cases:
(a) Generator circuit breaker (GCB) is open.
(b) Load shedding relay operated.
(c) Deviation in pressure controller is + 10 kg/cm2 w.r.t

A MODIFICATION
HPBP throttle pressure setpoint always remains in tracking mode.
~Previous Status:
When LSR operates, HPBP throttle pressure setpoint keeps on
tracking
the MS pressure & actually never opens untill the mode is manually
changed
over to Fixed Setpoint. So, chances of occurring of RH protection &
boiler
tripping were more.
~Current Status:
Unit 2: Tracking is off when:
(i) Fast open occurs (including LSR).
(ii) Turbine inlet steam pressure >134 kg/cm2
Unit 3: Tracking is off when:
(i) Fast open occurs (including LSR).
(ii) Turbine inlet steam pressure >127 kg/cm2

LP BYAPSS SYSTEM OVERVIEW

~LPBP system enables the dumping of steam from
reheater
outlet to the condenser directly through a couple of control
valves. Its a part of turbine control.
~LPBP capacity: 100% of TMCR.
~Unlike HPBP system, theres no separate OSU for LPBP.
LPBP control & stop valves are operated by control oil.
~Spray water required for desuperheating the reheater
outlet
steam is taken from CEP discharge. LPBP spray injection is
kept in
auto. If required the standby CEP can be taken into service

LP BYPASS OVERVIEW

LPBP
SV2

LPBP
CV2
TO LP TURBINE

HRH LINE

HPT

LPT

IPT

WARM-UP V/V

TO LP TURBINE

LPBP
SV1

LPBP
CV1

WARM-UP DRN.

CEP
DISCHARGE

LPBP SPRAY CV

LPBP BODY DRN.

TO HP FLASH TANK

CONDENSER

MODES OF OPERATION
~LPBP operation can be done in two modes,viz.,
1.Fixed Setpoint Mode: This can be set manually from CRT.
It can
also be regulated in auto by Automatic Control Interface
(ACI)
during start-up & is normally used to set the lower limit of
pressure
setpoint.
2.Variable Setpoint Mode: This is a function of turbine 1st
stage
pressure.
The maximum of these two act as the effective setpoint
under any
operating condition.

AUTOMATIC CONTROL INTERFACE (ACI)

In order to avoid a high setpoint during start-up, ACI is

introduced.
Firstly, it is ensured that LPBP control is in auto mode &
then ACI
PB is switched on. when the actual RH pressure is <3
kg/cm2, it
brings the fixed SP to 3kg/ cm2. If actual RH pressure is
>3kg/cm2,
then ACI opens the LPBP CVs upto 10% & they remain
locked at
that position upto a RH Pressure of 8 kg/cm2. During this
period,
ACI tracks the actual reheat pressure & increases the fixed
setpoint
as the RH pressure increases instead of opening LPBP
(beyond
10%). Once this fixed SP is reached, ACI Is switched Off in

PROTECTION & INTERLOCKS

LPBP CVs will auto close during following cases:
1.Condenser vacuum is low (-0.5kg/cm2) to avoid
condenser
to get pressurised.
2.Spray water protection:
Spray Water Flow <10 kg/sec
or
Both CEPs are off.
In both cases, LPBP will trip & boiler will trip on RH
protection.

THANK YOU !