CONSTRUCTION AND OPERATION OF BOILER FEED PUMP

General : The high-pressure boiler feed pump is a very expensive machine, which can comply with in operation and efficiency of the feed pump does not only depend on the correct design and careful manufacturing in the works, but also on the reliable operation and maintenance. Therefore, it is important that the operating and maintenance staffs are acquainted with these instructions properly in time. They should know perfectly the operation of the boiler feed pump to be able to find out the cause of defect. The causes of any adverse running of the feed pump found in the beginning may be easily removed without endangering the operation of the power plant and also without the expensive dismantling. Any damage resulting due to the ignorance of the operating instructions will not be the responsibility of the manufacturer even if it occurs during the guarantee period. 1.0 Description of the feed pump : The high pressure feed pumps of barrel type satisfy in all respects the latest developments the stated requirements, only with a careful and skilled maintenance. The safety

achieved for the design and operation of the feed pumps. It consists of the pump barrel, into which is mounted the inside stator together with the rotor. The high-pressure cover along with the balancing device closes the hydraulic part. The suction side of the barrel and the space in the high-pressure cover behind the balancing device are closed along with the balancing device and with the stuffing box casings. The bracket of the radial bearing of the suction side and the bracket of the radial and thrust bearings of the discharge side are fixed to the lowpressure covers. The entire pump is mounted on a foundation frame. The hydraulic coupling and two couplings with coupling guards are also delivered along with the pump. The watercooling and oil lubricating connections are provided with their accessories. All the instruments necessary for observing the performance of the feed pump are mounted on the pump, on local panel and on the piping. 1.01 Rotor: The rotor of boiler feed pump consists of the shaft, impellers, distance bushes, throttle bush, balancing disc, supporting rings, stuffing box bushes, nuts for holding the stuffing box bushes, the disc of axial bearing with the lock nut, nuts for securing the coupling, shaft keys and lubricating rings. For obtaining shrunk fitting of the impellers on the shaft, the impellers are first heated and then assembled. For this purpose, stepped diameters are provided on the shaft. On each stepped diameter two impellers are mounted. The axial thrust of the rotor is taken up by the balancing disc, which is keyed, to the shaft. The axial expansion of the rotor part is limited to the extent of dilation gap that exists between the throttle bush and the supporting ring. This dilation gap should diameters, the throttle bush and stuffing box bushings is up to be within the limit of 0.2 to 0.3 mm. The maximum run out of the assembled rotor, at the sealing impeller 0.06 mm. The impellers are statically balanced and the rotor as a whole is dynamically balanced within the permissible
253

unbalance according to the standards of the works. Prior to dynamic balancing of the rotor, the deflection of the rotor due to its self weight is also measured. The deflection of the rotor due to self weight moves in the limits of 0.04 to 0.12 mm. All the measurements carried out on the rotor including the actual clearances at the sealing rings are entered in passports delivered with every feed pump. The rotor is supported on The necessary centering of rotor is done with the perfect concentricity of the stuffing box gland bush the throttle bush in the throttle space, a suitable change is made on the set of shims below the centering keys of the low pressure cover. In order to maintain the concentricity of the centering diameter diagonally opposite to each other, by removing from one place and positioning at the other. 1.01 Inside stator : The inside stator consists of stage bodies, the diffusers and rotor. The diffusers are centrally mounted in the stage bodies. They are secured against rotation, by locating pins. Stage bodies are fitted with wearing rings at the place where it is likely to come into contact with the wearing rings of impeller, and the wearing rings are secured to the stage bodies with the help of screws. The entire inside stator is connected to the barrel. The nuts at the ends of these bolts are tightened in order to pre stress the bolts to suit the working pressure and they are secured with the help of locking washers. During the operation of the pump and especially while putting the pump into operation, shocks are developed in the pump which effect the connecting bolts and the connecting bolts being as discharge side. On the suction side, a key fitted and screwed on to the inlet stage a key is provided which is fitted by a screw. This key will slide along the key way in barrel. On the discharge side also, the outlet stage is supported on the barrel by key and keyway arrangement on the supporting block welded to the barrel. The the suction side of the barrel and by aligning the high pressure cover to the end diffuser. While the pump is in operation, the inside stator will get heated earlier than the pump barrel together with the high pressure cover. This means that the expansion of the inside stator owing to temperature will be more that the expansion of the barrel and of the high pressure cover. A dilation gap of 6 mm is therefore maintained between the end diffuser an the high pressure cover. The sealing surfaces of the individual stages are accurately lapped using a fixture, and they seal metal. Therefore it is important that the sealing surfaces should not be damaged especially while dismantling the pump. If they are damaged, they must be relapped in order to obtain the perfect mating surfaces. 1.02 Mechanical seal : The design of the feed pump incorporates Mechanical seal. The mechanical seal eliminates the losses of feed water in stuffing box. Working ability of the feed pump increases. With the mechanical seal, cooling of stuffing box space should be perfect.
254

two

part

bearing

shells.

The

brackets

are

connected

to

the

low

pressure

covers.

with

the

bore

of

the

stuffing

box

casing

and

for

obtaining

the

concentricity

of

on

the

keys,

shims

are

replaced

from

the

centering

keys,

which are

subjected

to

torsion,

the

inside

stator is

secured

from

the

suction

side

as

well

centering

of

the

inside

stator

is

carried

out

by

aligning

the

inlet

stage

to

Cooling is carried out by the circulation of water by means of a pumping ring through a cooler. Cooling of the stuffing box space is different from the seal cooler. Even after stopping of the pump stuffing box cooling should be continued. Coolers are designed to keep the stuffing box space temp. below 80 0C. Pump need not be removed from base frame to replace mechanical seal. To replace mechanical seal on discharge side, dissemble thrust bearing, and bearing brackets along with bearing shells. To replace mechanical seal on the suction side, dissemble the coupling along with intermediate piece and bearing brackets along with the shells. Follow the seal disassembly and assembly instructions strictly. 2.0 Function of the feed pump : The water with the given operating temperature should flow continuously to the pump

under a required head. It passes through the suction branch into the intake spiral and from there it is directed into the first impeller. After leaving the impeller it passes through the diffusing passages of the diffuser, where the kinetic energy is converted into potential energy. Afterwards if flows over to the guide vanes to the inlet of the next impeller eye. This procedure repeats from one stage to the other till it passes through the last impeller and the end diffuser. Thus the feed water at the outlet of the last stage attains the required discharge head. A small part of the feed water, i.e. about 5% which is not calculated to the guaranteed delivery capacity, is taken off from the space behind the last impeller for the operation of the automatic balancing device to balance the hydraulic axial thrust of the pump rotor. The feed water passes through the balancing device and comes into the space behind the balancing disc. Feed water is taken from this space to the feed water tank. It is evident from the function of the balancing disc, as it disturbs the hydraulic equilibrium. Therefore the equalizing piping must have sufficient flow capacity. For a safe operation of the balancing device the pressure difference between the suction and balancing leak off should not exceed more than 5 atmospheres. 3.0 Balancing device : Balancing system of the pump takes up the entire axial thrust of the rotor, by means of

the balancing disc. Balancing device is an important aspect of the pump as far as the design and material selection is concerned. Balancing disc fitted to the high pressure cover by mans of the tightening flange and bolts with nuts which are locked by washers. Axial sealing gap is formed between the bearing disc and the balancing disc. Contact surfaces of bearing disc and balancing disc are mutually lapped against each other. Sealing of the individual parts is metal to metal. Full pressure developed by the last impeller is not carried on to the balancing device but throttled by means of the taper bush mounted on the shaft before the balancing disc.
255

device

consists

of

balancing

disc,

secured

to

the

shaft

and

bearing

The feed water passes through the taper bush, through the axial sealing gap. The axial sealing gap is approximately 0.10 mm. Balancing disc can be dismantled without extensive dismantling of the pump in case of damage to the balancing device. 2.0 Lubrication system : The feed pump consists of two radial sleeve bearings and one thrust bearing. All the

bearings are force lubricated by the main oil pump or the auxiliary oil pump or the hydraulic coupling. The thrust bearing is located at the free end of the pump. The feed pump drive motor consists of two sleeve radial bearings. The hydraulic coupling consists of four radial bearings and two tilting pad thrust bearings. Before the start of the pump main motor, lubrication to the various bearings is supplied through the auxiliary oil pump. Once the main motor attains a particular speed after start, the main oil pump of the hydraulic coupling takes over and the auxiliary oil pump is tripped automatically. The details of the switching 'ON' and switching 'OFF' of the oil pumps are dealt in the hydraulic coupling operating instructions and to be followed strictly. Two coolers are provided in the oil system. One for the working oil and the other for lubricating oil. The pressure of oil before the radial bearing should be a minimum of 0.8 atg to 1.0 atg and for the thrust bearing 0.5 atg. Before putting the lubrication system into operation all the oil lines and bearings should be clean. The following instructions should be followed for flushing of the oil system. 2.01 1) 2) 3) 4) 5) 6) Flusing of oil system : The oil pipes are cleaned thoroughly by means of wire brush. After mechanical cleaning the pipes are steam washed with steam of pressure 8 atg and 250
0

A coating of lubricating oil is given to the pipes after steam washed with steam washing against corrosion. After cleaning, the pipes are assembled in position. Fill Servo Fluid - 10" oil upto the mark indicated, through a 50 micron filter. Remove the top halves of the bearings, tilt the bottom half bearings, such that the oil hole in the bearing housing will allow free flow of oil through the system and protect the journal by covering with cloth and thin sheet of metal.

7) 8) 9)

Oil filter and bearings housings are to be cleaned. Mount all the instruments in the oil system. Heating of the oil during flushing is done by inserting steam coil or by heating elements. The oil flushing can be started by switching on the auxiliary oil pump. After the first 4

hrs of flushing the filters should be checked and put back. The choking of filters in the initial stages will be more and it should be cleaned from time to time and put back. The oil temperature during flushing is maintained at about 50-60 oil flushing is stopped. After flushing is completed, the oil tank and coolers are drained cleaned and fresh oil is filled.
256
0

. After ensuring that filters are not getting choked

2.02 1) 2)

Thrust bearing of feed pump : Quantity of oil required for each radial bearing - 7.5 lts/min Quantity of oil required for thrust bearing - 42 lts/min. For kingsbury thrust bearing. 12 lts/min. for Mitchell thrust bearing.

257

CONDENSATE EXTRACTION PUMP

GENERAL: The WKT centrifugal pump is a hydrodynamic machine. It is characterized by the fact that pressure is generated by a continuous flow of fluid through the pump. Mechanical work is imparted to the fluid by a rotating impeller (109) : The impeller, diffuser and stage casing (104) together form one stage of the pump. The suction created by the fluid discharged from the impeller causes an equal volume of fresh fluid to flow into the suction casing (102 b) of the pump. The vertical barrel-type centrifugal pump consists of the pump casing, the motor stool and the barrel. Depending on the suction head available, one column pipe is provided in addition, if required. The pump rotor assembly and the intermediate shafts are guided in metal bearings of bronze, liquid-lubricated, and in case of higher temperatures, in bearings of special carbon. Under temperature conditions exceeding 100 with a thermal barrier. IMPELLERS,DIFFUSERS,STAGECASING: The impellers are designed with a neck at the entry and discharge ends. Sealing is effected at both ends by means of renewable wear rings (122), which are press-fitted into the stage casing (104) and into the diffuser respectively. The first stage (i.e. suction) impeller (202a) is specially designed to prevent cavitation, and the results in a lower NPSH requirement of the pump. The wear ring at the suction end of the first stage impeller is pressed into the suction casing. The backplates of the impellers are drilled to obtain a balanced pressure on both sides of the impeller, and the residual axial thrust of the rotating assembly is consequently very small. This residual thrust is bsorbed by an anti-friction bearing in the drive frame. The casings are sealed by O-rings on the standard pump models, but on high temperature and pressure pumps (cast steel casings), the sealing is effected by metal-to-metal contact of the precision ground mating faces of the casing flanges. SHAFTSEALING: A pacing - type stuffing box is used as a shaft seal. During the operation of the pump it reduces the leakage flow at the gap between the shaft and the casing. In case of a suction pressure < than 1 atm. Abs., the ingress of air during standstill of the pump will be prevented by admitting sealing liquid. Under higher temperature conditions, the stuffing box will be cooled The suction and discharge piping have to be laid in such a fashion that no external stresses are transmitted to the pump. Any sudden or abrupt change of direction or crosssection has to be avoided. Flat gaskets should not protrude inside the pipe. Where welded pipe lines are used, all sharp edges, welding beads and scale are to be removed before commissioning. The suction piping and vessels have to be thoroughly clean out and flushed through before commissioning. The suction piping and vessels have to be thoroughly cleaned out and flushed through before commissioning of te plant. Experience shows that welding beads, scale and other impurities often become detached from the pipe walls only after a
258
0

C (212

F) the distribution header is fitted

considerable period of operation, especially when the liquied pumped is hot, it is necessary, therefore, to incorporate a strainer in the suction line to retain this foreign matter.

This strainer is to have a free flow area equal at least to 3 to 4 times the pipe crosssection area, in order to prevent too great a pressure drop when it becomes partially clogged with foreign matter. Cone-shaped strainers as illustrated in fig.2 have proved themselves well in service, they should be made of corrosion-resistant material. The suction pressure is to be carefully watched during operation. If there is a drop in pressure, the strainer is to be removed and cleaned. After several weeks of operation, when the presence of foreign matter is no longer anticipated, the strainer can be removed.

The vent line connects the suction compartment of the distribution header with the apex of the suction vessel. The connection for this line, on the distribution header, is arranged in such a fashion that any vapour or gas tending to form in the header, and which might cause the pump to splutter, will escape through the vent line to the suction vessel. COOLINGWATER: According to the temperature prevailing, i.e. when he liquid being pumped has a high temperature, the drive frame is cooled. The flow of cooling water is approx. 0.5-1 m3/h. It is useful to have throttling means in the supply line. The discharge is to be provided to the open, to facilitate observation of the rate of flow. In some designs of these pumps, the bearing bracket or the packing-type stuffing-box
259

in the drive frame are cooled. The system is similar to that for the frame itself. Max. cooling water inlet emperature: approx. 20 0C (68 0F). A temperature difference of 10 0C (50 0F) between the inlet and the outlet temperature of the cooling water is allowable. SEALINGWATER: To prevent air from entering the system when the pump is not working, the stuffingbox is supplied with sealing liquid. It is recommended that his be drawn from the discharge side of the main condensate pumps. The sealing water piping is to be fitted with a check-valve to prevent the pump from discharging into this piping during its operation. LEAKAGELIQUID: There is a tapped connection provided on the motor stool to drain off any leakage. Any leaks should be allowed to drain off freely. FOUNDATION: A foundation support frame consisting of steel sections is the most appropriate foundation for the pumping set. The foundation support frame which has a machined contact face will be leveled up to a true horizontal position, then grouted in. if this is done, the pump itself will not require leveling up. The concrete should be allowed to set and dry out completely before the pump is placed on its foundation. We can supply exact measurements for the foundation support frame on request. ERECTION OF THE PUMP : The WKT pump is usually delivered assembled as a unit. It can be placed immediately on to the foundation and bolted down. Then, the true position of the pupmping set is to be verified again. If the barrel is mounted separately from the pump, care is to be taken to ensure a proper sealing between the barrel and the drive frame (O-ring, 542). If the set is supplied completely assembled, the rotating assembly of the pump need only be re-aligned after previous dismantling . CAUTION1: When delivered, the pumps have no oil in the bearing bracket. After the test run at our works, the bearings are drained of oil washed, as there is no means of knowing when the pump will be commissioned, and the oil might oxidize if left in the bearings too long para 1.82 gives indications about lubricants. PACKING OF THE STUFFING - BOX : The pup are delivered without packing in the stuffing-box. The straight lengths of the packing rings cut off smoothly by means of a jig (see fig3) are to be of such a length that, when fitted round the shaft sleeve, the sectional areas are in slight tough. Before insertion in the packing area, the packing must be thoroughly soaked in oil. Together with the stuffing-box gland, the first packing ring is inserted in the packing area and pushed to the bottom. The butt
260

joints are to be taken to observe the proper sequence of packing rings and seal cage ring/ lantern ring. The nuts of the stuffing-box bolts are slightly tightened by hand. A newlyh packed stuffing-box is to leak appreciably at first. If this leakage does not cese of its own accord after some time. The nuts are to be tightened slowely ad evenly during operation, until the stuffing-box only drips slightly; this indicates that the packing is functioning correctly slightly again. Every newly packed stuffing-box needs a certain running-in period and it is to be kept under frequent observation during this period. After settling down, it needs only to be checked occasionally. If the existing packing has been compressed by approx. the width of one packing ring, the packing is to be renewed. Check also the condition of the shaft sleeve on this occasion. It is to be replace if its surface shows signs of grooving or roughness.

STARTINGUPAND: Always check the following points before starting up the pump for later on. After a prolonged shutdown: a) b) c) d) e) f) g) The bearing and stuffing-box housings must be filled with oil and the soft packing fitted in the stuffing-box respectively. Close the pump discharge valve: open the suction valve. Make sure that the pump is completely primed with the liquied pumped. Vent the pump (see para 1.42) If applicable, turn on the cooling water and check the free flow of the cooling water. Switch on the driver and check direction of rotation (anti-clockwise, when viewed from above, looking down onto the pump). Slowly, open the discharge valve. Do not exceed the current intensity (Amps) on the motor rating plate. SHUTTINGDOWNTHEPUMP: The following operations should be carried out when shutting down the pump: a) b) c) d) Close discharge valve. Switch off driver and check that the pump runs down to a standstill smoothly and evenly. Turn off cooling water, if applicable. Leave suction valve open.
261

the first time and

LUBRICATIONOFTHEPUMP: The pump bearings and the column pipe bearings are lubricated by the product pumped and require no supervision. On no account let the pump run dry 1 The top shaft (bearing shaft) is guided within the bearing bracket. For the lubrication of the anti-function bearings incorporated, please. If the set is fitted with oil-lubricated selfaligning bearings or with a segmental thrust bearing. The appropriated special directions must be followed. The pump, the shaft and the riser piping required no attention if there are normal working conditions. The stuffing box must leak slightly whilst the pump is running. The drive must be maintained in accordance with the special instructions given on this subject. LUBRICATION: The top shaft (bearing shaft) is guided within the motor stolol. A good-quality wellrefined mineral oil should be used only to lubricate the grooved ball bearings. As a lube oil we recommend a brand oil having the following specification: Flash point Pour point Viscosity Ash contents Spec. gravity : 200-220
0

C (390-430
0

F)

: below - 15 : 4-6
0

C (+5 0F)
0

E at 50

C (30-45 c St. at 122

F)

: below 0.05% : 0.9 kp/dma (56 Ibs/cuft)

The oil should be changed approximately once every 2000 operating hours: in any event however, at least once a year. The oil quantities required for one initial oil fill of the bearing bracket (including the constant-level oiler and the fill piping) are given in table below : Bearing size no. Oil fill, in dm3 Fluid ounces in brackets 6311 0.3 (100) 6312 0.4 (13.5) 6315 0.5 (17) 6317 0.6 (20)

262

H.P. - L.P.
I) INTRODUCTION: a)

BY

PASS

SYSTEM

For matching of live steam and turbine metal temperatures for a quick start up, bypass stations have been provided, which dump the steam to the condenser through pressure reducing station and desuperheaters, during the period, steam parameters at the boiler are being raised. These stations in additions to the quick start D.M. water. With the use of turbine by pass station, it is possible to build up the matching steam parameters at the boiler outlet during any regime of starting, independent of the steam flow through turbine. The steam generated by boiler, and not utilised by the turbine during start up or shutdown, is conserved within the power cycle and thus losses of steam into the atmosphere is cut down to the barest minimum. By of turbine and low noise level, also economises the consumption of

b)

pass system enables to shorten the start-up time. HP/LP bypass system can be broadly classified in the two groups : 1) i) ii) iii) iv) v) HP bypass stations : This is utilised for the following tasks. To establish flow at the outlet of superheater (SH) for raising boiler parameters during start-up. To maintain or control steam pressure at pre-set value in main steam line during start-up. To warm up the steam lines. To control steam temperature down stream of HP bypass at the preset value. To dump steam from boiler into condenser, in case the generator circuit breaker opens. 2) i) ii) iii) LP bypass station : The same is utilised for the following tasks. Control of steam pressure after reheater. Establish flow of steam from reheat lines to condenser by its opening, proportional to the opening of HP bypass valves. Release of steam entrapped in HPT and reheater circuit in case generator circuit breaker opens.

Description Upstream steam Connection Down stream Connection The interconnections of the above stations with the turbine power cycle are as under: HP bypass Main steam lines Cold reheat line. Station. LP bypass Station. Ahead of MSV Hot reheat lines Ahead of IV Steam throw off device built in condenser.

263

c)

Feed water is used as cooling water for H.P. bypass station and condensate from condensate extraction pump is used as cooling water for LP bypass station.

II.

H. P. BYPASS STATION a) The main elements of HP bypass station are as follows, i) 2 Nos. 127 x 160 mm. size combined pressure reducing and desuperheating valves complete with valve mounted electro hydraulic actuator. Each valve has been sized to pass 100 T/hr steam at 140 ata and 540 0 C on upstream side. ii) iii) iv) v) 2 Nos. Throttling device One number after each HP bypass valve. 1 Nos. - 70 mm size spray water pressure control valve complete with valve mounted electrohydraulic actuator. 2 Nos. - 34 mm size spray water temperature control valve complete with valve mounted electrohydraulic actuator. 1 No. - Automatic pressure control loop consisting of the following elements. 1 No. Pressure master controller with proportional integrated (PI) characteristics. 2 No. Positioning loops for bypass valves. 1 No. Common set point setter. vi) 2 Nos. - Automatic temperature control loops consisting of the elements. 2 Nos. PI controllers and positioning loops for spray water temperature control. 1 No. PI controller for spray water pressure reducing valve . 1 No. Common set point setter. b) GENERALDESCRIPTION The control components are located in a control cabinet in unit control board (UCB). Each positioning loop may be controlled separately from the central control desk. For supervision of the control loops, the position and Control deviation are indicated on mosaic insert of the control desk. c) OILSUPPLYUNIT The oil supply units for the high - pressure bypass and the low - pressure bypass are connected in parallel. Manostats control the oil pressure in the accumulators and signal alarm "PRESSURE TOO HIGH" or "PRESSURE TOO LOW" appears in UCB if the pressure is not in order. If the oil pressure should fall below the minimum in both accumulators, positioning actuators will be blocked, and thereon the signal "ACTUATOR BLOCKED" shall appear in UCB which simultaneously changes the operation of each positioning loops from automatic to manual. d) STARTUPPROCEDURE&SLIDINGPRESSUREOPERATION. With the start-up of the boiler, the pressure set point has to be adjusted manually. If too large a deviation between the measured pressure and the set point shall occur, the alarms will be given. The deviation will be given for a positive as well as a negative difference.
264

The HP bypass station controls and maintains the upstream pressure at the desired preset value when in operation. As soon as the entire steam available from the SH outlet is swallowed by HP turbine, the HP bypass station shall get closed under automatic controller action. The HP bypass, once closed, shall cut in under pressured impulse only if the generator circuit breaker opens.

e)

TEMPERATURECONTROL: By injecting water into the HP - bypass valves, the steam is cooled to the temperature in accordance with the preset value. To over-bridge the measuring delay of the thermoelements, the spray temperature control valve controller is supplied with an opening impulse at the moment when the HP - bypass valve starts to open. To achieve favorable conditions for the bypass injection, the spray - water pressure is reduced and adjusted to a constant value before the spray water temperature control valves. In addition spray water pressure reducing valve remains closed under interlock action when the HP - bypass valves are closed.

f)

PRESSUREMEASUREMENT: The pressure signal of HP bypass system will be taken from the main steam line.

g)

PRESSURESETPOINTVALUE: With sliding pressure operation, the desired pressure value has to be adjusted manually to the actual pressure value (main steam pressure before turbine), by adhering to a certain threshold, 5 to 8% on higher side. This follow up is effected in such a way that the gradient of the desired pressure value is limited to the maximum permissible pressure gradients on the boiler side. This set point can be varied from the desk by the push button.

h)

PRESSUREMASTER-CONTROLLER: In accordance with the pressure control deviation the master controller works with PI behaviour of and forms the positioning If the signal deviation which is between given the to the slave positioners the bypass valves. actual pressure

signal and the set point value exceeds either a positive or a negative limit, the monitors produce alarms. For a positive deviation alarm "AL 1" and for a negative one alarm "AL 2" appears. These alarms do not influence the controllers, but they will appear visually and audibly in the unit control room. With the appearing of the those alarms, the operator has to correct the pressure set point. The changeover from "MANUAL" to "AUTOMATIC" mode of the pressure master controller is linked up with the adequate changeover of the HP bypass positioning circuits. If both of these slave positioners are in "MANUAL" mode, the master controller's output is switched on to the larger opening (feedback) signal from one of the bypass systems. This maximum selection will be performed by the MIN/MAX - selector.
265

Furthermore,

it's output signal gives the basic condition for the bumpless transfer if one of the slaves will by switched into "AUTOMATIC" mode. i) HP BYPASS - VALVE POSITIONER : With the positioners the HP - bypass valves are operated in accordance with the output signal of the pressure master controller. Individual control of each HP - bypass valve is possible with the push button. The monitor transmits a continuous closing - signal to the positioner if the stroke of valve is smaller than 2% and if the positioner is in "MANUAL" mode. In this way the valve remains definitely closed. j) SPRAYWATERTEMPERATURECONTROLVALVECONTROLLER: The control positioners for the bypass spray temperature valves are designed in the same way as those for the HP - bypass valves. In addition, PI - controllers are also connected up to the control positioners. The temperature-measuring signal from transmitter is compared at the input of the PI controller with the common set point signal. According to the particular control deviation, the PI controller forms a rated signal for the control positioner of the associated spray temperature valve. Due to the hydraulic drive it is possible to attain also for the spray temperature valves or short positioning time. This is necessary to allow the temperature control to intervene fast enough in the event of any fast - opening of the HP - bypass valves. To offset the time delays of the temperature measurement and to achieve favourable conditions when switching on the spray water cooling system (rapid adjustment to temperature set - point), a positive reference voltage is given to the proportional input of the injection - valve controller, by the associated bypass - valves positioning monitor. In this way independent of the temperature-measuring signal a certain amount of water is simultaneously injected at the opening of the bypass valve. Manual operation of the bypass spray water temperature valve is effected by means of the push button. The valve position and the control deviation are indicated on the desk with indicators. With the combined PI - control positioner which influences the pressure control valves, the spray water pressure is regulated at a preset value before the spray water temperature control valves. The manual control of the pressure control valve is effected with the push button. Valve is kept closed by an interlock if the HP - bypass valves are closed. Additionally, if the positioning loop was in "MANUAL" operation - mode, it will be brought into "AUTOMATIC" - state, if any one of the HP - bypass valves opens. k) SPRAYWATERPRESSURECONTROLLER: The spray water pressure before the spray water temperature valves, will be measured by the transmitter.

266

Normally the valve is closed and the positioner is in "AUTOMATIC" mode. If one or both bypass - valves open, the "CLOSE" interlock disappears and the positioner will be brought into "AUTOMATIC" mode regardless of which mode dominated before. However, this loop can be operated by the push button at the mosaic - desk insert. The actual position and the control - deviation are shown by the instrument at the mosaic - desk insert. III) INTERLOCKS: a) The HP bypass system are influenced by the following interlocks. i) ii) Generator circuit - breaker. Condenser vacuum too low / b > 2%

iii) HP - valve - position a < 2% iv)

Temperature too high at down stream of LP bypass station.

Following interlocks are produced by the bypass system and given to the other positioning loops. v) vi) b) HP valve position more than 2%. "Close" - signal for spray water pressure control valve.

GENERATORCIRCUITBREAKER: The HP bypass station shall come into operation at the moment the logic signal "GENERATOR CIRCUIT BREAKER CLOSED" disappears. However this does not imply that the HP bypass station shall be out of service if the logic signal "GENERATOR CIRCUIT BREAKER CLOSED". appears.

c)

CONDENSERVACUUMTOOLOW: The HP bypass station shall close immediately in case of too low condenser vacuum (500 mm Hg-Col). This interlock holds a first priority for the controller.

d)

HP BYPASS VALVE POSITION LESS THAN 2% : i) When turbine is running or not running and the control of HP bypass valve is on manual, the memory will get closing signal through AND logic, if the valve position is less than 2%. ii) iii) When turbine is running and control of HP bypass valve is on auto, the memory will get closing signal through AND logic, if valve position is less than 2% When turbine is not running and control of HP bypass valves are on auto, there is no closing signal to memory whatever is the position of the valve and thus pressure control loop will actuate the valve.

e)

TEMPERATURETOOHIGH: If the temperature after the outlet of the HP or LP bypass station becomes "TOO HIGH", the closing signal to HP bypass Valves is forwarded and simultaneously

267

positioning loops change from automatic to manual mode. The interlock for this case will be provided by the temperature supervising monitor respectively. f) HP BYPASS VALVE POSITION MORE THAN 2% If any of the HP bypass valves are opened more than 2% (which is initiated by a part of voltage monitor) or if the position demand signal is equivalent to more than 2%, valve opening (which is initiated by a voltage monitor), a signal is available through used to OR logic to indicate the valve is open and the same signal is

change the control of valves BPE and BD from manual to auto if their control was on manual. g) CLOSING INTERLOCK FOR SPRAY WATER PRESSURE CONTROL VALVE CONTROLLER: To ensure the tight closure of spray water pressure valve so that the spray water temperature valve are not subjected to high water pressure, during the period they are not in operation, a tight closure signal is initiated to the valve, when HP bypass valve opening is less than 2% IV) : L. P. BYPASS STATION a) Functionally the LP bypass control system can be divided into two parts. 1) Pressure control. 2) b) Temperature control.

The main elements of LP bypass stations are as follows. i) 2 Nos. 367x370 mm size pressure control valves complete with electrohydraulic actuator. Each valve has been sized to pass 112 Ton/hr. steam at 6 ata. and 540 ii) iii) iv)
0

C.

2 Nos. LP desuperheaters. 2 Nos. 44 mm. size spray water temperature control valves complete with electrohydraulic actuator. 2 Nos. Automatic temperature control loop each comprising one number PI controller and one number-positioning loop with common set point setter for spray water temperature control valve.

v) vi)

Automatic pressure control loop with a sliding, load dependent set point formation, along with one number PI controller and two number slave positioner. Automatic valve position control loop with a master signal formed as on average HP bypass valve position with "proportional" function.

vii) A selector unit to select any one of loop under (e) & (f) mentioned above. c) GENERALDESCRIPTION: The control components are located in a control cabinet in UCB. Each positioning loop may be controlled separately from the central control desk. For supervision of

268

the control loops, the position and control deviations are indicated on mosaic insert of the control desk. d) OPERATINGMETHOD: The system enables generally the manual selection of two operational modes with the selector station.

Pressure control with a sliding, load - dependent set point formation with 'PI' function. Valve position control with a master signal formed as an average HP bypass valve position with proportional 'P' function.

During the pressure control the selector relay is energized by means of selector station and analogue memory and the contact turns-over into position marked "R". In this case the master pressure controller controls the valves in accordance with the formed sliding set-point The set-point formation is load dependent and is derived from the steam pressure after regulating stage of the turbine, measured by transmitter. The intensity of the signal measured by this transmitter is reduced to approx 30% of its value by the summing amplifier. A limitation to a minimum value is realized by means of the maximum selector and motorized set-point setter. For selecting the LP bypass valves operation, proportional to the average actual position of HP bypass valves, the selector relay is made de-energised with the help of push button. Thus the contact of this relay stays in the position marked 'S'. The manual operation of LP by pass valve is possible from UCB with the help of push button modules. For achieving bumpless transfer of operation of LP bypass valves from proportional to pressure mode of control, a signal U M is always fed to PI controller, to keep the controller always charged. In addition to this, for achieving bumpless transfer during pressure mode of operation, from 'manual' to 'auto' mode, the position of LP bypass valve is fed to PI controller, through a max. selector unit. Thus the output of PI controller is switched over to the higher valve-opening signal of any of the LP bypass system. e) TEMPERATURECONTROL&OPERATINGMETHOD: The task of the loop is to control the steam temperature after the LP bypass valves and before the condenser. The controlled variable is the steam temperature after the LP bypass valves, the manipulated variable is the spray water flow. The system receives the actual steam temperature signal from transmitter compares it with the set-point and controls the position of the spray water valves in accordance with the control deviation. A feed-forward signal (actual LP bypass valve position) is introduced to the second, P-action channel of the controller to improve the control results similar bypass system.
269

to

HP

To safeguard the condenser from high temperature steam, if the actual temperature after any of the LP bypass system exceeds the permissible limit i.e. 5% above the set value, an alarm is given through voltage monitor. Simultaneously the same signal is fed to the slave positioners of HP bypass valves and LP bypass valves for closing of HP/LP bypass station, and at the same time control of positioning loops of HP/LP bypass valves change from 'auto' to 'manual' operation. III. a) b) c) d) e) OPERATIONOFHP/LPBYPASSSTATIONS: Before HP/LP bypass stations are brought into operation check the following. ESVS & IVS are closed. Oil system of the by pass station is put into operation by switching on its motor. Vacuum in the condenser is more than 540 mm of HgC. Condensate flow to steam throw off devices in the condenser is established by opening motor operated valves MC-39 & MC-57. Interlocks for NRVS in cold reheat lines at HP turbine exhaust. When HP by pass is opened CR1 & CR2 remain closed for 60 sec. and then will be ready to open position closing in by power cylinder through solenoid operation.

270

271

TG LUBRICATING OIL SYSTEM

272

VARIOUS
1.0 Introduction :

TYPES

OF

VALVES

Valves are used for different purposes. Mainly as follows: i) ii) To stop or allow the flow of fluid in a pipe line To act as a safety device. a) b) iii) iv) To prevent excess pressure generation in a pipeline or vessel (safety valve, To prevent back flow of fluid into up stream side of equipment which might get Pressure Relief valve) damaged due to the back flow (non-return valve, flap valve) To regulate the quantity or pressure of the flowing fluid. Special valves for specific service conditions like Christmas tree valve for oil well, quick operating blow down valves for boiler blow down lines.

2.0

Classification of Valves : Valves can be broadly classified into following two types based on the relative motion of the closing element with the direction of fluid flow or pressure. i) ii) The closing element moves in the same axis in which the fluid flows. (eg. Globe valve, Safety valve non return valve etc.) The closing element moves in the perpendicular direction in which the fluid flows. In other words the closing element cut across the flow of the fluid. (eg. Gate valves, cocks, ball valves etc.)

3.0

Construction of the valves : The valves are fabricated from different materials such as cast iron, steel, gun metal, stainless steel etc. in order to suit the fluid they carry. The valves are classified according to pressure class as per the relevant BSS, ASA, DIN or ISI specification. Similar type of valves have different types of ends connection i.e. flanged, welded, socket, screwed etc for connecting them with the pipe lines. Valves components can be grouped mainly as. i) ii) iii) iv) v) vi) i) Body Yoke, bonnet and cover. Disk, wedge Stem Gland Other parts. Body : The body of the valve serves the following functions. a) b) c) d) The inlet and outlet connections are accommodated. Fluid flow passage is provided in the body. One part of the sealing seat is accommodated. Connection to other valve parts and gasket are provided in the third flange.

273

e) ii) a) b) c) d) iii)

Wherever necessary bypass arrangement is provided on the body. Yoke Bonnet and Cover : The function is to connect with the body of the third flange. Houses gland and stem nut. Vent plug for deaeration is located in the yoke. In case of motor operated valves the motors are mounted on the yoke. Disk Wedge :

This is a moving part inside the body operated by the stem and this is the control element to stop or regulate the flow of the medium. This contains i) ii) iii) iv) high stresses and different conditions of temperature, contact media etc. the following functions are performed by the stem. i) ii) iii) It connects with the disk or wedge. It slides against the gland packing. It has operating screw threads, which converts the torque applied at the hand wheel to vertical thrust with the stem nut. v) Glands: The glands consist of the gland packings one piece or two pieces, gland cover, gland tightening bolts and nuts. The gland tightening bolts are supported on the yoke or bonnet. The main function of this gland is to provide sealing around the stem and smooth sliding operation to the stem. The gland packings are generally of knitted asbestos yarn with some solid lubricants like graphite or mica flakes. When sufficient pressure on the stem to prevent leakage. vi) wheel, gasket etc. fasteners are made from high carbon steel and hand wheels are made i) 4.0 from Cast steel. In a globe valve full flow area around the periphery is obtained by a lift of d/4 where 'd' is the nominal bore of the valve. Where as in gate valve the gate Comparison between Globe and Gate valves: to completely travel across the bore of the valve and hence the valve must have a lift of slightly more than 'd' which is about 4-times that of a globe valve. Hence the
274

The control element seat which mates with the body seat. The body which can isolate the fluid from upstream to downstream side. Connection to the stem.

Stem : This is also a moving part and most important part as it is subjected to

the

gland

covers

are

tightened

they

should

be

able

to

create

Other parts: Other parts are the fasteners, used for body bonnet connection, hand

has

total height headroom required, time required to complete opening and weight of a gate valve are comparatively more than a globe valve. ii) The manufacture and maintenance of a gate valve is more difficult compared to globe valve as the two tapered seats in the wedge have to perfectly match with that of the seats in the body. iii) iv) In the globe valve the disc has to function against the full medium pressure and hence the stem load is quite high compared to a gate valve. Due to the flow directional changes and possible turbulence in a globe valve the flow loss is more than a gate valve in which flow is straight and with least turbulence. 5.0 Operation of Valve : Valves can be chosen with manual hand wheel operation. In case the valves are located away from the floor level, apart from the manual operation pneumatic, hydraulic or electric motor operation can also be chosen. 6.0 Valve Actuators (Electrical) : Valve actuators are of two types: a) Rotary actuator b) Linear actuator

Rotary actuators are available in different torque capacities and different output speed. These actuators can be fitted on gate and globe valve. Linear actuators have a reciprocating movement and therefore have a restriction in the operating stroke or lift of the valve. These are used in gate valve & globe valve of smaller size. The hand wheel is normally used for opening & closing of valve. The size of the hand wheel is such a way selected that the torque required is sufficient to open or close the valve. Valves which require greater force for opening and closing and can not be provided with larger size hand wheel, due to space limitations, are provided with actuator with a worm drive, with chain pulley block type. In some cases electrically motor operated gear train is mounted on the valve with reversible motor for opening and closing of valve Enclosed figures show the various types of valves used in power station.

275

276

277

278