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OF GOVERNING SYSTEM
OF
KWU TURBINE
AND
LP BYPASS SYSTEM
INTRODUCTION
OPEN.
TEST VALVES OF HP AND IP, STOP VALVES MAX 47 AA011 AND 012 AND MAX 47AA 021AND 022 CLOSED. ISOLATING VALVES OF CONTROL OIL LINE MAX 41AA 581, 582 591 592 AND SECONDARY OIL LINE MAX 45AA 511, 512, 521 AND 522ARE FULLY OPENED FOR HP AND IP CONTROL VALVES. EHC SECONDARY OIL FOR HP AND IP -MAX 45AA 501 AND 502
CLOSED.
CONTROL OIL PRESSURE 6 TO 7 KSC.
CONT...
OPENED.
6. NOTE THE HP /IP SEC. OIL PRESSURE CORRESPONDING TO 4.2 KSC OF AUX. SEC. OIL PRESSURE. 7. BRING BACK THE STARTING DEVICE GRADUALLY TO CLOSE POSITION AND CHECK THE TRIP POINT OF AUX. SEC. OIL PRESSURE THE TRIP POINT SHOULD BE AROUND 2.1 KSC APPROX. AT LEAST UNDER 2.3 KSC 8. BRING BACK STARTING DEVICE TO CLOSE POSITION. 9. FIX DIAL GAUGE BELOW THE BELLOW AND ADJUST TO 0 MM.
9. INCREASE THE AUX. SEC OIL PR TO 2.5 KSC & CHECK IF THE IP& HP SEC OIL
PR IS 2.5 KSC & 2.79 KSC RESPECTIVELY IF NOT ADJUST THE IP FOLLOW UP PISTONS.
ZERO AND AGAIN CHECK AT OIL PR. 2.3 KSC OF AUX. SEC. THE
HP SEC. IS 2.5 KSC AND AT 2.5 KSC OF AUX. SEC., THE HP SEC. AND IP SEC. SHOULD BE 2.79 KSC AND 2.5 KSC RESPECTIVELY 23.INCREASE THE AUX. SEC. PR. INSTEPS OF 0.2 KSC AND NOTE DOWN THE HP AND IP SEC. OIL PR., POWER PISTON LIFT OF HC AND STARTING DEVICE TRAVEL. 24.CHECK THAT OPENING AND CLOSING RESERVE OF 3.5 MM IS
SECOND.
40.DURING THE EXECUTION OF LOAD SHED RELAY CHECK WHETHER AUX. SEC. OIL PR. DROPS TO ZERO AND COMES BACK TO ORIGINAL VALUE. 41.SWITCH ON THE ATRS SUPPLY 42.CHECK THE MAIN TRIP VALVES, TRIPS IMMEDIATELY AND ALL THE STOP AND CONTROL VALVES GET CLOSED 43.SWITCH OFF THE ATRS SUPPLY.
HYDRAULIC SETTING. 11. INCREASE THE SET POINT VOLTAGE AND HOLD HP SEC. OIL PR. AT 2.79 KSC ADJUST FOLLOW PISTONS OF IP TO GET 2.5 KSC OF IP
14.CHECK WHETHER THE HP SEC. AND IP SEC. OIL PR. ARE EQUAL TO THE HYDRAULIC GOVERNOR CHARACTERISTICS . 15.ENSURE BY PLOTTING THE CURVE THAT A CLOSING AND OPENING RESERVE OF 3 TO 5 MM IS AVAILABLE FOR POWER PISTON. 16. ENSURE THAT THE START OF OPENING OF HP AND IP CONTROL VALVES REMAINS AT 2.5 KSC OF HP AND IP SEC. OIL PR.. RESPECTIVELY AS SET EARLIER. 17.CHECK THE VALVES OPEN WITH RESPECT TO HP AND IP SEC. OIL PR. AS PER THE GOVERNOR CHARACTERSTICS FROM FULL CLOSE TO FULL OPEN POSITION. 18.PLOT THE CURVES a) SET POINT VOLTAGE VERSUS COLLINS 1 & 2;
6. INCREASE THE HP SEC. OIL PR. ABOVE 2.8 KSC AND CHECK BY ENERGISING THE SOLENOID MAX 51AA027 THAT BE EXTRACTION VALVE CLOSES.
DIFFERENTIAL AMPLIFIER PISTON KA08 OF CONVERTOR FOR ELECTRO HYDRAULIC GOVERNOR FOR INCREASING SIGNAL OIL PR. IN LP BYPASS AND WATER INJECTION LINES 15.MEASURE THE LIFT OF KA08 WHILE OPERATING THE HAND WHEEL KA09
25.ENSURE THE SIGNAL OIL PR. IS 1.7 KSC, ADJUST THE FOLLOW
PISTON EQUALLY TO ACHIEVE THE PRESSURE IF NECESSARY. 26.MOVE THE DIFFERENTIAL AMPLIFIER PISTON KA08 TO A POSITION OF 12MM, 36.8MM AND MAX. BY OPERATING THE HAND WHEEL KA09 AND CHECK WHETHER SIGNAL OIL PR. IS 2.2 AND 4.7 KSC AND ABOUT 5 KSC IN THE LP BYPASS LINE
POSITION.
32.MOVE THE AMPLIFIER PISTON KA08 IN THE SIGNAL OIL PR. IS 2.2
KSC AND ENSURE LPBP CV SERVOMOTOR JUST OPEN. ADJUST SLIDE VALVE MAX53AA086 AND +87 IF REQUIRED. 33.INCREASE DIFF. AMPLIFIER PISTON KA08 TO ACHIEVE SIGNAL OIL PR. OF 4.7 KSC AND CHECK THAT LPBP CV OPENS FULLY. IF NECESSARY ADJUST THE FOLLOW PISTON IN THE FEED BACK OIL LINE TO GET THE FULL OPENING. IF NECESSARY ADJUST THE PROPORTIONALITY . THE FULL LIFT SHOULD BE 80MM. 34.DE-ENERGIES THE SOLENOID OF TEM. PROTECTION AND CHECK WHETHER THE SIGNAL PR. IN THE LP BP LINE GOES TO 5 KSC.
36.BRING BACK DIFF. AMP PISTON KA08 TO A POSITION WHERE SIGNAL OIL PR. IS 1.5 KSC IN THE WATER INJECTION LINE. NOTE DOWN THE SIGNAL OIL PR. IN LP BYPASS LINE OPERATE THE HAND WHEEL KA09 AND CHECK THE OPENING OF STOP VALVE AND CONTROL VALVE AT 1.7 AND 2.2 KSC RESPECTIVELY.
37.INCREASE THE SIGNAL OIL PR. INSTEPS OF 0.2 KSC AND NOTE
THE LPBPCV LIFTS 38.PLOT THE CHARACTERISTICS CURVE OF : a) STROKE OF CONTROL SLEEVE OF FOLLOW PISTON VERSUS SIGNAL OIL PR. IN WI SYSTEM. b) STROKE OF CONTROL SLEEVE OF FOLLOW PISTON VERSUS SIGNAL OIL PR. IN LPBP SYSTEM. c) SIGNAL OIL PR. VERSUS LPBPCV LIFT
KA09.
4. FEED ZERO TO 10 VOLTS TO EHC IN STEPS OF ONE VOLT. AT 10 VOLTS THE DIFF. AMP PISTON KA08 TRAVELS 40 MM APPROX.
a) VOLTAGE AT WHICH WI VALVES OPEN AND CORRESPONDING SIGNAL OIL PRESSURE IN THE WI LINE IN ONE KSC . THE VOLTAGE WILL BE ABOUT 2 VOLTS b) VOLTAGE AT WHICH STOP VALVES OPEN IT SHOULD BE APPR. 2.5 VOLTS AND SIGNAL OIL PR. 1.7 KSC IN THE LP BYPASS LINE c) VOLTAGE AT WHICH LPBP CV STARTS OPEN IT SHOULD BE ABOUT APPRX. 3.5 VOLTS AND SIGNAL OIL PR. OF 2.2 KSC d) VOLTAGE AT WHICH LPBP CV OPEN FULLY IT WOULD BE 7.5 VOLTSB APPRX. AND SIGNAL OIL PR. WILL BE 4.7 KSC. 7. PLOT THE FOLLOWING CURVES : a) b) c) d) EHC VOLTAGE VERSUS SIGNAL OIL PR. IN WI LINE EHC VOLTAGE VERSUS SIGNAL OIL PR. IN LPBP LINE EHC VOLTAGE VERSUS DIFF. AMPLIFIER PISTON LIFT EHC VOLTAGE VERSES CV LIFT
DRAWING/DOCUMENT REF.
GOVERNING CHARACTERISTICS
HYDRAULIC GOVERNING GOVERNOR BELLOW STROKE vs AUXILIARY SECONDARY OIL PRESSURE Control Oil Pressure = Trip Oil Pressure = 6.8 5.5 kg/cm kg/cm
Governor Bellow Stroke (mm) Design 0.00 0.57 1.00 1.18 1.30 1.60 2.00 2.15 2.50 3.20 3.90 4.50 5.00 Actual 0.00 0.57 1.00 1.18 1.30 1.60 2.00 2.15 2.50 3.20 3.90 4.50 5.00
Auxiliary secondary Oil Pressure (kg/cm) Design 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 Actual 2.30 2.50 2.70 2.80 2.85 2.95 3.10 3.15 3.30 3.55 3.80 4.05 4.25
GOVERNING CHARACTERISTICS
A) GOVERNING OIL CHARACTERISTICS AOP Discharge Pressure Control Oil Pressure Trip Oil Pressure Aux. Sec. Oil Pressure (kg/cm) Design 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 Actual 2.30 2.50 2.70 2.75 2.80 2.90 3.05 3.10 3.25 3.50 3.80 4.00 4.20 = = = 7.0 6.8 5.5 kg/cm kg/cm kg/cm IP Sec. Oil Pressure (kg/cm) Design 2.50 3.18 3.47 3.66 4.12 4.76 5.00 Actual 2.50 3.25 3.50 3.70 4.00 4.80 5.00
HP Sec. Oil Pressure (kg/cm) Design 2.50 2.79 3.00 3.09 3.15 3.30 3.50 3.57 3.75 4.10 4.45 4.75 5.00 Actual 2.45 2.75 3.05 3.15 3.20 3.30 3.55 3.65 3.85 4.20 4.60 4.85 5.00
Design reference : BHEL Drawing No. 1-11400-01004 (Rev 01) B) At Auxiliary Secondary Oil Pressure Start Up Oil Pressure Auxiliary Start Up Oil Pressure At Turbine Speed Primary Oil Pressure = = = = = 0.00 6.00 4.20 3000 kg/cm kg/cm kg/cm rpm kg/cm
C)
GOVERNING CHARACTERISTICS
HYDRAULIC GOVERNING AUXILIARY SECONDARY OIL PRESSURE vs VALVE STROKE Control Oil Pressure Trip Oil Pressure = = 6.8 5.5 kg/cm kg/cm
Aux. Sec. Oil Pressure (kg/cm2) 2.30 2.52 2.68 2.75 2.79 2.91 3.06 3.12 3.25 3.52 3.78 4.01 4.20 4.30
Design HPCV 0.0 2.5 4.5 5.0 5.5 7.0 8.8 9.5 11.8 16.4 25.5 38.8 50.0 IPCV 0.0 0.0 6.8 10.5 16.0 30.0 75.0 95.0 HPCV - 1 0.0 0.5 3.0 3.5 4.0 5.5 6.5 8.5 10.5 15.5 31.0 36.0 43.5 49.0
Actual HPCV - 2 0.0 0.5 3.0 4.0 4.5 5.5 7.0 8.5 11.0 15.0 32.0 37.0 45.0 50.0 IPCV - 1 0.0 0.0 7.0 14.0 17.5 28.5 67.0 95.0 IPCV - 2 0.0 0.0 7.0 11.0 15.0 23.0 53.0 93.5
GOVERNING CHARACTERISTICS
LP BYPASS GOVERNING CHARACTERISTICS Control Oil Pressure A) = 6.8 kg/cm
Uppermost Position of Limit Controller Piston W.I.Valve Signal Oil Pressure (kg/ cm) Design 1.50 2.34 3.44 Actual 1.50 2.30 3.20 LPBP Valve Signal Oil Pressure (kg/ cm) Design 1.32 1.70 2.20 Actual 1.35 1.70 2.20 WI Valves open LPBP Stop Valve Starts Opening LPBP Control Valve Starts Opening Remarks
Power Piston Lift in mm Design 0.80 (3.20) 1.75 (7.00) 3.00 (12.00) Actual 3.2 7.0 12.0
B)
Lowermost Position of Limit Controller Piston W.I.Valve Signal Oil Pressure (kg/ cm) Design 1.50 > 8.00 Actual 1.5 > 6.00 LPBP Valve Signal Oil Pressure (kg/ cm) Design 1.56 Actual 0.60 1.60 WI Valves open Remarks
Power Piston Lift in mm Design 0.80 (3.20) 10.00 (40.00) Actual 3.2 40.0
DRAWING/DOCUMENT REF.
GOVERNING CHARACTERISTICS
LP BYPASS VALVE TRAVEL vs SIGNAL OIL PRESSURE Control Oil Pressure = 6.8 kg/cm
LPBP Valve No. 1 Signal Oil Pressure 2.3 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 CV Opening 0 3.5 14 22 30 38 48 57 65 72 79 3.3 Feedback Pressure 0.9 Signal Oil Pressure 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2
EHC CHARACTERISTICS
Trip Oil Pressure AOP Discharge Pressure Aux. Sec. Oil Pressure = = = kg/cm kg/cm kg/cm
Coil Volts 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
HP Sec oil press design 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75 5.00 actual 2.25 2.75 3.04 3.25 3.70 3.80 4.10 4.30 4.60 4.80 5.00
IP sec oil press design 0.60 2.50 3.20 4.00 4.75 5.00 5.00 5.00 5.00 5.00 5.00 actual 1.60 2.50 3.15 3.95 4.60 5.15 5.50 5.90 5.90 5.90 5.90
HPCV design 0.0 2.5 4.0 6.0 8.0 11.0 14.0 18.0 27.0 38.0 50.0
IPCV design 0.0 0.0 6.0 25.0 75.0 94.0 94.0 94.0 94.0 94.0 94.0
HPCV actual 1 0.0 1.5 4.5 7.0 11.0 14.5 19.0 29.5 40.0 48.5 50.0 2 0.0 1.5 4.0 6.5 9.5 13.0 16.5 26.5 37.5 46.0 50.0
IPCV actual 1 0.0 0.5 11.5 33.0 85.0 95.0 2 0.0 0.0 9.5 29.0 76.0 93.5
GOVERNING CHARACTERISTICS
AUXILIARY SECONDARY OIL PRESSURE vs POWER PISTON LIFT Total Lift of Power Piston = 44.5 mm
Aux. Sec. Oil Pressure (kg/cm2) 2.0 2.3 2.5 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.3
Power Piston Lift in mm 0.8 8.1 12.1 14.5 18.0 22.3 27.1 31.3 34.8 40.7 44.5 48.2 49.5