LS-TSZD-_- QJ005 Turbine Bypass System Commissioning Procedure

7/29/2019 LS-TSZD-_- QJ005 Turbine Bypass System Commissioning Procedure

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RPSCLROSA POWER SUPPLY COMPANY LIMITED

LUCKNOW, UTTAR PRADESH

2 x 300 MW - Stage - I

Rosa Thermal Power Project

Rosa, Shahjahanpur (U.P.)

DOCUMENT TITLE

Turbine Bypass System Commissioning Procedure

DOCUMENT NO:

LS-TSZD-- QJ 005

UEEPL

Utility Energytech and Engineers Pvt. Ltd.

Ground Floor, H-146/147

Sector-63

Noida 201 307

Uttar Pradesh

DEVELOPMENT CONSULTANTS PRIVATE

LIMITED CONSULTING ENGINEERS

24B, PARK STREET, KOLKATA - 700 016, INDIA

TPSC (INDIA) PRIVATE LIMITED

A-1 Module, D-Quadrant, 2nd Floor

Cyber Towers, Hi-Tec City, Hyderabad-81

Shanghai Electric Group Co. Ltd.

No. 8 , Xingyi Road.

Shanghai

China - 200336

Tianjin Electric Power Construction Company

The 26th floor, Harbor Centre ,No. 240

Zhangzizhong Road, Heping district, Tianjin

P.R.China p.c:300041


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Turbine Bypass SystemCommissioning Procedure

2300 MW Rosa ThermalPower Project

DOCUMENT NO. : LS-TSZD-- QJ005 Page 1 of 23

DOCUMENT CONTROL SHEET

PROJECT : 2300 MW ROSA THERMAL POWER PROJECT

CLIENT : ROSA POWER SUPPLY COMPANY LIMITED

DOCUMENT TITLE : TURBINE BYPASS SYSTEM COMMISSIONING PROCEDURE

DOCUMENT NO. : LS-TSZD-- QJ005

REV. NO. : 3

ENDORSEMENTS :

3

Initials Sgn. Initials Sgn. Initials Sgn. Initials Sgn.RevNo

Date DescriptionPrepared by Reviewed by Approved by

IssueAuthorization


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Technical training list for commissioning measure

Number:Project name

Technical training list

Unit name

Specialty System Date

Training contents:

Complementarily and modification

Trained person

Training person Project in charge person

Remarks


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Contents

1. Project overview and work quantity ...........................................................................................4

1.1 Project overview ............................................................................................................................4

1.2 Commissioning schedule ...............................................................................................................7

2 .System function introduction...........................................................................................................7

3. Compiling basis ...............................................................................................................................7

4. Required conditions before turbine bypass system commissioning ................................................8

4.1 Organization and division of work ................................................................................................8

4.2 Required conditions before system commissioning ......................................................................8

4.3 Commissioning person deployment and qualification.................................................................10

4.4 Equipment and instruments for commissioning.......................................................................10

5. Commissioning procedure and method......................................................................................10

5. Flow chart...................................................................................................................................10

5.2 Commissioning procedure and methods ..................................................................................12

6. Commissioning quality checking standard ................................................................................17

6.1 key control point setting...........................................................................................................17

6.2 Quality standard .......................................................................................................................18

6.3 Recording content ....................................................................................................................18

7. Safety requirement and environment condition during commissioning ....................................18

7.1 Danger factors identification and control.................................................................................18

7.2 Commissioning environment condition ...................................................................................19

8. Appendix ....................................................................................................................................19


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This document is only for technical direction, is not the site construction and

commissioning execution document.1. Project overview and work quantity

1.1 Project overview

The boiler for India ROSA project 2300MW is of SG1025/17.5-M type designed and

made by Shanghai Boiler Works. It is of subcritical pressure parameter, natural circulation

drum, single furnace, once through reheating. Boiler continuous steam output is 1025t/h,

rated superheating steam temperature is 541, and pressure is 17.57Mpa. Turbine is of

N300-16.67/538/538 type made by Shanghai Turbine Company, Ltd. It is reversed

operation, single shaft, once reheat, two casings and two steam exhausts, pure

condensate type. Its rated power is 300MW. Generator is of QFSN-300-2 type made by

Shanghai Turbine Generator Co., Ltd, its rated power is 300MW, and cooling method is

water-hydrogen-hydrogen. Boiler makeup water is DM water.

The bypass system is supplied by Shanghai XIXIAI energy control equipment

company which is the hydraulic control system, and the type is the HLP secondary class

series hydraulic bypass. The design capability of HP bypass is 60% BMCR, and the LP is

60% BMCR plus desuperheating water quantity of HP bypass. HP bypass system includes

bypass valve and desuperheating water spray governing valve and isolation valve. And the

LP bypass system includes LP bypass valve and dusuperheating water spray governing

valve. The bypass control system adopts the hydraulic actuator, and the main equipments

are as following:

1) HP bypass valve (1 set)

2) HP bypass desuperheating spray valve (1 set)

3) HP bypass desuperheating isolation valve (1 set)

4) LP bypass valve (2 sets )

5) LP bypass desuperheating spray valve (2 sets)


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Bypass system hydraulic oil station is made up by 2 nos oil pump and the

corresponding system that supply the high pressure oil to the system as the power

resource for hydraulic parts. Meanwhile, there has a accumulator installed on the oil supply

pipe to stabilize the system work pressure.

This bypass hydraulic control system includes the oil supply device, HP bypass

actuator, LP bypass actuator, HP accumulator parts, LP accumulator parts and pipe

fittings.

The working medium for the bypass hydraulic system is adopted the phosphate

burning resistance oil which has the good burning resistance and stability. And the oil is

supplied by the single oil supply device. The system work pressure range is 15-13.5 MPa.

And the oil temperature range is 40-55 deg C. While operation, the cleanness of the work

medium shall reach NAS 6 Class or higher Class.

Oil supply device has been set the regeneration device, circulation cooling device;

main pump, standby pump is designed as redundancy. This is supplying the power

resource for the actuator of the valve.

The valve actuator has two types, one is regulation type, and the other is switch type,

the HP & LP desuperheating valve actuator, HP & LP bypass spray governing valve

actuator is regulation type, and the HP bypass spray valve actuator is switch type. There

are two control methods for the regulation type valve, viz. normal regulating control and

fast control, this two methods are parallel, while the operation, this two control methods

are interlocked, and controlled by DCS.

In order to open or close the valve quickly, there is set the 40L HP accumulator and

40L LP accumulator for the HP bypass valve and LP bypass valve actuator respectively to

guarantee the valve can active quickly and guarantee the oil device supply oil or discharge

oil in time.

H P

b y p a s s

C o l d

s e c t i o n o f r e h e a t e r

M a i n

s t e a m R e h e a t e r

H e a t

s e c t i o n o f

r e h e a t e r

L P

b y p a s s

C o n d e n s e

r


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Technical parameter of bypass system rating work condition

Valve name Model Inlet Rating flux(t/h)

Inlet workingparameter

Discharge

working

parameter

HP bypass

valveC7z61Y-P5519.2V 615

16.67

MPa/538

3.663

MPa/318.5

HP bypass

desuperheating

spray valve

Tp7z63Y-32.01

HP bypass

desuperheating

isolation valve

Tp764Y-32.01

LP bypass

valveC7z61Y-P554.6V 716.3

3.296

MPa/5380.598MPa/160

LP bypass

desuperheating

spray valve

Tp7z64Y-4.01

bypass valve regulating factor

Valve name Qty.Driving

methodActuator

Switch on/off

time

Design

capability

HP Bypass

valve1

Hydraulic

drivenBP-300

Switch off 3s

quickly, 3s

quick

60%BMCR

HP bypass

desuperheating

spray valve

2Hydraulic

drivenLBP-300

Switch off 3s

quickly, 3s

quick

70%BMCR

HP bypass

desuperheating

isolating valve

1Hydraulic

drivenBPE-300

Switch off 3s

quickly, 3s

quick

LP bypass 1 Hydraulic BD-300 Switch off 3s


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valve driven quickly, 3s

quick

LP bypass

desuperheating

spray valve

2Hydraulic

drivenLBPE-300

Switch off 3s

quickly, 3s

quick

1.2 Commissioning schedule

The absolute commissioning schedule is 8 days.

2 .System function introduction

Bypass control system (BPS) is the important part to realize the unit auto control, it

plays a very important role while unit start up, normal stop and emergency stop. The

function of this system is to make the operation parameter in a controlled range, to

guarantee the unit safety and economic operation. Desuperheating water of HP bypass is

from the feeder water system, and the desuperheating water of LP bypass is from the

condensate water system.

HP & LP bypass valve is the angle type bypass valve with the throttle spray valve.This bypass valve can lead the main steam going through the bypass to the cold section of

reheater and also lead the reheater heat section steam going through LP bypass to the

condenser while the unit start-up, stop or at other conditions. Through TG setting, this

system can make the unit on load operation with the auxiliary power. While the turbine

tipping or generator breaker switch on, it can make the HP & LP bypass open

automatically. The valve leakage glass is the minimum V glass, and the spray valve

outlet flow speed shall not exceed 30M/S.

3. Compiling basis

3.1 Indian ROSA 2 x 300MW unit commissioning outline

3.2 Indian ROSA project equipment erection instruction

3.3 Indian ROSA project China-Indian general contract

3.4 The relevant drawings from GEDI

3.5 Equipment instruction, drawings, and data documents for Indian ROSA project


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generator bypass system

4. Required conditions before turbine bypass system commissioning

4.1 Organization and division of work

NO. Organization and division of work Confirmation

4.1.1

Under organized and directed by sub-system commissioning

group, the person in charge of commissioning should carry out

commissioning of system and make out commissioning

measures of such system.

4.1.2

Commissioning person should be responsible for transmission

of related valve, C&I signal and interlock in the system. Before

the trial, shall give the technical and safety training, Meanwhile,

measure and record necessary data.

4.1.3

Operation person is in charge of the operating and operation

monitoring, making the safety isolation for the trial run

equipments.

4.1.4

Construction unit should be responsible for finishing

commissioning of related individual units in the system and

maintaining, overhauling and eliminating the defects in

commissioning of system. Organize and coordinate safety,

fire fighting and safeguard works on commissioning site

4.1.5

The commissioning direction unit shall be in charge of

compiling the commission measure and directing the site

commissioning. And shall make the technical training before

trial run.

4.1.6

Supervision unit shall be in charge of coordinating and

attending the system acceptance, coordinating the equipment

and system storage problem, and coordinating the problems

disposal which happened in the commissioning. Quality

supervising and checking before/ after trial run.

4.2 Required conditions before system commissioning


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NO. Required conditions before commissioning Confirmation

4.2.1

Site is flat without debris, the scaffolding shall be removed, the

handrail of stairways shall be installed completely, and

adequate light is prepared. Fire fighting device is ready. There

shall have the clear dividing line around the trial run site. The

warning board or enclosure shall be set around the danger

area

4.2.2Covers of ditch and holes are complete; ladders, paths,

handrails are available for platform.

4.2.3 Enough firefighting facilities are available at site;

4.2.4Adequate light is ready for using at the trail run site. And the

emergency light can operate automatically.

4.2.5 Good ventilation establishment

4.2.6 Good communication system.

4.2.7 Equipments, pipes, valves shall be hanged the nameplate

4.2.8

Equipment and system are installed as per the requirement

and accepted. The installation recording is complete. And the

relevant equipment individual trial run is finished.

4.2.9The instrument calibration is accepted, and the warning and

showing is correct.

4.2.10The person deployment is clear, and the commissioning work

training is finished.

4.2.11

Equipment and system are installed as per the requirement

and accepted. The installation recording is complete. And therelevant equipment individual trial run is finished. And the unit

is ready for starting.

4.2.12

The entire pipes and equipment in the bypass system shall be

installed complete. The oil circu8lation is finished, oil quality is

accepted, the oil pressure test for hydraulic pipe is accepted,

the bypass oil station commissioning is accepted.

4.2.13 The pressure filling to accumulator is finished.


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4.2.14

Calibration, erection and wire connection for C & I and

electrical equipment is finished, and the bypass system C & I

commissioning is finished and accepted.

4.2.15

The steam blowing for HP bypass system is accepted, and the

cleaning for LP bypass system is accepted, flushing for HP, LP

bypass desuperheating piping is accepted.

4.2.16

Commissioning instrument is ready, the calibration for the

instrument is accepted, and the precision of the test instrument

meets the requirement.

4.3 Commissioning person deployment and qualification

Sn. Person Qty Quality Responsibility

1Commissioning

person2 Commissioning

In charge of executing the

measure and operation

direction

2Erection

person4

Technical person in

charge and person on

duty

Maintenance and overhaul

3Operation

person

So

manyOperator Each operation during test

4.4 Equipment and instruments for commissioning

S.N. Items Model Precision Qty Remarks

1 Infrared thermal meter 1

5. Commissioning procedure and method

5. Flow chart


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5.2 Commissioning procedure and methods

5.2.1 System commission plan

S.N. Items Content Result Time Remarks

1Systeminspection

Inspect the mainsteam ,reheating steam/

bypass system piping as perthe scheme

Main steam and reheatingsteam bypass pipe system

blowing

HP & LP bypass

desuperheating water pipeflushing

Control oil system circulation

2Systemblowing

Cleanness checking

Main steam pipe hydraulictest

Main steam reheating steampipe steam tightness test

Governing valve, spray valveleakage test

3Systemtightness

Electrical motoroperation

commissioning

Measurement and C & Isignal

Interlock protection loop

Function groupcommissioning

4C & I

commissioning

Auto regulation loop

Control oil system

HP & LP bypass governingvalve

HP & LP desuperheatingspray valve

Close LP bypass governingvalve

5Componentcommissioning

Discharge valve

6 C & I systemtest

Signal, interlock andprotection test


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Function group test

Control system factor test

7Static state

regulation test Regulation functionsimulation test

Operation at any condition

8System

operationBypass system

operation

Operation characteristicchecking

Parameter optimizing setting 9 Test regulation

after operationDynamic characteristic

inspection on the loadrejection condition andother working condition

5.2.2 System commissioning items

5.2.2.1 Inspect the complete bypass system.

5.2.2.2Transmission test, switch on/off test shall be done for the valve to check

whether it is flexible and reliable.

5.2.2.3 DAS measurement point and local instrument checking

5.2.2.4 Interlock protection and C & I signal test

5.2.2.5 Bypass system, static state function test

5.2.3 Main commissioning procedure

5.2.3.1 bypass system static state commissioning

A Bypass valve static state characteristic test

1HP & LP bypass governing valve switch feedback calibration, fast switch on/ off

time measurement

2HP bypass spray governing valve switch feedback calibration, fast switch on/off

time measurement

3LP bypass spray governing valve switch feedback calibration, fast switch on/off

time measurement

B Bypass system control function and interlock protection test

1 HP bypass protection test

HP bypass protection function, the HP bypass is forced to close in the following status


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a) manual HP valve close quickly

b) HP spray valve pressure is lower

c) reheater pressure is higher

The HP bypass desuperheating water control: HP bypass desuperheating water control

subsystem to control HP bypass outlet temperature in the suitable temperature around the

setting value.

HP decompression control: the HP bypass decompression control subsystem to

control the main steam pressure as per the pressure setting value. Before the HP cylinder

starting to stably the main steam pressure till the unit parameter reaches to the turbine

rolling parameter, and then the HP bypass valve is switch to the heating standby status.

While the HP cylinder starting, in order to avoid affecting the reheater pressure and HP

cylinder steam discharge stop valve action caused by HP bypass switch on/off quickly, the

auto control of the bypass shall be changed into manual control. In addition, while the unit

operated as load rejection model, the HP bypass can be operation in time.

2 LP bypass control function

LP bypass protection function, the LP bypass is forced to close as the following status:

a) condenser vacuum pressure is low

b) condenser temperature is high

c) LP desuperheating spray water pressure is low

d) three-class desuperheating water pressure is low

e) condenser water level is high

The LP bypass is open as the following status:

a) reheating steam pressure is high

b) open the LP bypass by manual methodLP bypass desuperheating water control: LP bypass desuperheating water control

subsystem to control the LP bypass outlet temperature in the suitable value around the

setting value. .

LP bypass keeps closed while the HP cylinder starting. Before the turbine rolling, the

LP bypass valve switch to heat standby status, in addition, while the unit is operated as the

load rejection model, the LP bypass can operate immediately.


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3 Reheating steam over-pressure protection

While the unit operation, if the deviation between reheating steam pressure and the

setting value is more than___ MPa (refer to the setting value from GEDI) or the reheating

steam pressure exceeds ___ MPa (refer to the setting value from GEDI), the LP bypass

open immediately, and the LP desuperheating valve is also open.

4 condenser protection test

While the condenser vacuum is lower, and the condenser water level or the high

temperature protection at the downstream of the LP are active, LP decompression valve

shall be close, meanwhile, the LP desuperheating valve is also close,

5.2.3.2 bypass control system dynamic commissioning

ARegulate the dynamic control parameter of each control subsystem at the

different load, and setting the corresponding PID parameter.

B

After the bypass control system operation and the control parameter regulated,

the setting valve dynamic perturbation test for this control system shall be done

to precisely regulate the control parameter and improve the regulation quality of

control system while the controlled heating power system is operated stably.

5.2.3.3 bypass system operation

A operation condition

1 Bypass system static state commissioning work is finished.

2water discharge system commissioning for main steam, reheating steam is

finished, and this system is ready for operation

3 The staring preparation work of the main unit is finished.

B system operation

1Open the water discharge valve of the bypass system, HP & LP bypass are

operated automatically.

2

After the boiler lighting and the pressure generation, HP bypass is switch to the

minimum opening, and the LP bypass is opening gradually, go along with the

main steam parameter rising, warm the HP & LP bypass piping. Control the

temperature rising speed to 2 deg C per min. While the main steam pressure

rising to the setting value, control the HP bypass valve to maintenance the main


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steam valve at the setting value.

3Control the LP bypass opening as per the main steam pressure changing to

maintenance the main steam setting valve.

4During operation, monitor the desuperheating water governing valve following

status, checking the pipe expansion, and discharge is normal.

5.2.3.4 test after bypass system operation

The test after bypass system operation shall be finished before the turbine rolling.

Because the HP cylinder is operating, before the turbine rolling, first, secondary class

bypass system shall be removed.

1 bypass system characteristic test

A test goal

1Measure the relationship between HP & LP bypass governing valve pressure

and flux characteristic

2 Check the spray desuperheating system working characteristic

B Test condition

1 Unit bypass is operation, and the main body is in the barring gear status

2 Bypass operation is normal

3 Boiler operation is normal

4 Condenser vacuum is normal

5 Circulation water system is operation

C test procedure

1 HP bypass characteristic test

a) Under the different opening of the governing valve, change the boiler working rate,

doing the test till the bypass system valve is full open and the main steam parameter

reaches to the rating valve

b) During test, the LP bypass is in the following model, the HP bypass desuperheating

water is operated automatically.

c) Record the relative data

d) Calculate the characteristic relationship

2 LP bypass characteristic test


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a) Under the different opening of the governing valve, change the boiler working rate

and the HP bypass opening, doing the test till the LP bypass governing valve is full open

and the main steam parameter reaches to the rating valve

b) During test, the LP desuperheating water can operate automatically, and the HP

bypass can be operated by manual method.

c) Record the relative data

d) Calculate the characteristic relationship

2 dynamic characteristic test

Before the load rejection operation model, the warming and water discharge shall be done

for the bypass system, while the unit load rejection operation starting, the HP & LP bypass

valve open immediately, in order to estimate the HP & LP spray desuperheating water

refection characteristic, record the valve open time, steam pressure, temperature stability

valve, peak value and its time.

6. Commissioning quality checking standard

6.1 key control point setting

Inspection unit

Sn. Work controlpoint Constru

ction

Commissionin

g

Development

unit

Produce unit

Supervisionunit

Witness method

1

Bypass oilstation

control oilpressure andtemperature

* * * R

2

Bypass oilstation oil

flushing andoil cleanness

* * * * * R

3

Bypasssysteminterlock

protectiontest

* * * * * R

4

Fast opentime forbypasssystem

* * * * * R


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R- record confirmed point W- witness point Hhold for inspection point Ssupervise

continually6.2 Quality standard

Sn. Items Inspection standard

1 Interlock and signalItem completely, and the action

is correct

2 Fast open time of Bypass system 3S

6.3 Recording content

1 HP & LP bypass system valve transmission recording list

2 HP & LP bypass system subsection trial run recording list

3 HP & LP bypass system logical transmission recording list

7. Safety requirement and environment condition during commissioning

7.1 Danger factors identification and control

Danger factors identification and control list

Sn. Description Control and strategy

Executive

person in

charge

Signature

person

1

lose control of

temperature and

pressure

Operation person and

erection person to check the

equipment operation status

periodically

Operation

person,

erection

person

Commissioning

person in

charge

2Injured by the

system leakage




periodically

Operation

person,

erection

person

Commissioning

person in

charge

3Leakage in the

steam valve


erection person monitor the

pressure and temperature on

the downstream of bypass

Operation

person,

erection

person

Commissioning

person in

charge


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valve periodically, and

dispose the leakage once the

leakage appeared.

4

LP bypass

desuperheating

water pressure is

lower, the LP

bypass will be

open by

interlocked

Maintenance the CEP normal

operation to avoid the low

pressure at the CEP outlet

Operation

person,

erection

person

Commissioning

person in

charge

7.2 Commissioning environment condition

Sn. Description Control strategy

Executive

person in

charge

Signature

person

1 Steam leakage




periodically

Operation

person,

erection

person

Commissioning

person incharge

8. Appendix

NO. Content

1 HP & LP bypass system subsection trial run recording list

2 HP & LP bypass system logical transmission recording list

3 HP & LP bypass system valve transmission recording list

4 HP & LP bypass system subsection trial run acceptance and signature card


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Number Unit subsystem commissioning recording list

Specialty Turbine HP & LP bypass system

Motor bearing vibration Oil pump bearing vibration

Time Leveldirection

Axialdirection

Verticaldirection

Leveldirection

Axialdirection

Verticaldirection

Motorbearingtemperature

Oil pumpbearingtemperature

Outletpressure ofpump

Commissioning in charge person : Commissioning recording person:

Date:


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Specialty TurbineHP & LP bypass system logical transmission

recording

Sn. Items Result Signature


Date:


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Specialty Turbine HP & LP bypass system valve transmission recording

Valve name Fast open times Fast close

timesOpen times Close times Remarks


Date:


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Subsection trial run acceptance and signature card

Specialty: turbine Item name: turbine bypass system

Turbine specialty HP & LP bypass system Date

EvaluationSn. Inspection Content

Acceptance Non-acceptanceRemarks

1System interlock protection and signal itemcomplete, and action is correct

2System C & I instrument is complete, andthe show is correct

3System pressure, temperature parameter

is conformed to the design regulation4

System trial run, each valve is flexible, andcan be operated normally

5 Piping is tightness without leakage

Evaluation:

The subsection trial run of this equipment/system has been completed between _____

(Day) _____ (Month), _____ (Year) and _____ (Day) _____ (Month), _____ (Year).

Through acceptance inspection according to the Criteria for Acceptance Inspection and

Assessment of Adjustment Commissioning Quality of Thermal Power Projects by former

Ministry of Electric Power, this equipment/system is rated as qualified ( ) / good ( )

and has achieved conditions required for operation. We hereby agree to enter the whole-set

startup stage.

Construction unit signature : Date:

Commissioning unit signature Date:

Commissioning direction unit signature Date:

Production unit signature Date:

Development unit signature Date:

Supervision unit signature Date:

Documents

LS-TSZD-_- QJ005 Turbine Bypass System Commissioning Procedure