Station: NTPC

RAMAGU
NDAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 1 of 14

Plant Area: BOILER

Testing Schedule: HP BYPASS SYSTEM
SL. NO.

LIST OF CONTENTS

1.

PLANT DETAILS

2.

OBJECTIVES

3.

PROPOSALS

4.

SERVICES REQUIRED

5.

SAFETY PRECAUTIONS

6.

EMERGENCY PROCEDURES

7.

STATE OF THE PLANT

8.

METHOD

9.

COMPLETION CRITERIA

10.

APPENDICES
a) DRAWING

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RAMAGUN
DAM

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Sheet 2 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
1.0

PLANT DETAILS

STATUS

HP BP System work in conjunction with LP BP System as and when

necessitated by the system requirements such warming up stage or
dumping a large quantity of steam following a heavy load rejection.
Turbine / Generator trip.
1.1

1.2

HP BP System basically consists of the following items. (Refer to the

enclosed drawings).

Oil Supply Unit (with motor and pump).

Accumulator

Quick opening device

Connection manifold

Blocking element

Servo valve

Throttle valve

Isolating ball valve

Hp Filter

Spray Control valve

By pass control valve

Isolation Valve

Break down orifice

Other piping accessories.

The System is provided with series of pressure switches for automatic

on/off of motor and for annunciation.

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RAMAGUN
DAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 3 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
1.3

The oil supply unit and the By pass and spray valves are connected
through pipe lines and hose pipes.

1.4

HP BP System is an important item of the Power Plant and it requires

extreme precaution in commissioning the system as given in Section 8.0
(Refer to O&M Manual for Technical Specification of HP BP System.)

2.0

OBJECTIVE
The objective of this Testing Schedule is to commission the HP BP
System and make it available for Unit Operation.

3.0

PROPOSAL
Commissioning of HP BP System is proposed to be carried out through
following proposals.

3.1

Acid Cleaning of Pipe lines. (Generally, pipe lines are not subjected to
acid cleaning. By visual inspection, if the internal surface of the pipe
lines are rusted heavily and pitted, then the pipe lines are subjected to
acid cleaning.)

3.2

Commissioning of the HP BP System oil supply units (minus BP and

Spray Valves) and setting up of pressure switches.

3.3

Oil Flushing of the HP BP System as per following stages

Stage I

--

Pressure line (P) and Return line (T)

Stage II

--

Pressure line (P) and Leakage line (L)

Stage III -3.4

Lines of Quick Opening Device

Commissioning of HPBP System

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Station: NTPC
RAMAGUN
DAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 4 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
STATUS
4.0

SERVICES REQUIRED

4.1

Availability of L.T. Power Supply.

4.2

Availability of lighting, communication and clear access in the test area.

4.3

Availability of recommended oil ( SERVO. CONVAL 46).

4.4

Availability of sand buckets for use in case of oil spillage.

4.5

Availability of work force for the activity.

4.6

Availability of DM water / Service water / Compressed Air.

4.7

Availability of chemicals for acid cleaning.

4.7.1

-- HCL

4.7.2

-- Rodine

4.7.3

-- Sodium Nitrate

4.7.4

-- Liquor Ammonia

4.7.5

-- Lime Powder
Note: Quantities of above chemical to be worked out at site.

5.0

SAFETY PRECAUTIONS

5.1

Availability of First aid box containing dilute ammonium hydroxide,

50% sodium bicarbonate solution, Eye lotion, Bandage, Tincture
Iodine, Cotton, Burnol etc should be ensured.

5.2

Availability of suitable type portable fire extinguishers should be

ensured.

5.3

Availability of following should be ensured:

Gum boots
Rubber Gloves
Apron
Transparent Face Mask

5.4
5.5

3 Pairs
5 Pairs
3 Nos.

3 Nos.

Availability of running service water near the activity area is ensured.

Suitable and safe place for draining and neutralization of used chemicals
should be kept identified.

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NTPC
Station: NTPC
RAMAGU
NDAM
Plant Area: BOILER

BHEL
BHEL Ref No. : PS - DC - 202 500 0017A
NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 5 of 14

Testing Schedule: : HP BYPASS SYSTEM

6.0
6.1

6.2

EMERGENCY PRECAUTIONS

STATUS

The members of the testing team should be aware of the procedures to be

followed in case of accident involving injury to personnel.
The team conducting the flushing activity should be aware of the
operating procedures of fire extinguishers to be used for quenching fire.

7.0

STATE OF THE PLANT

7.1

The entire HP BP System erected as per recommended lay-out and

released for carrying out the activities given in this Testing Schedule.

7.2

Actuators of BP and Spray Valves

necessary) and fitted back in position.

7.3

All joints are properly tightened and pipe line clamped with proper
supports.

7.4

Oil tank of OSU thoroughly cleaned and ready for oil filling.

7.5

All the local I/c inputs and remote I/c inputs, control panel and
console insert and the required control and power cabling completed
and ready of charging.

8.0

METHOD

8.1

Acid Cleaning in pipe lines

8.1.1

and E 45s are serviced (if

The disassembled pipeline pieces are filled with DM water and flushed
few times. Also ensure that there is no leakage through the wooden plug
provided at one end of the pipe.

8.1.2

5% Hydrochloric acid with 0.2% inhibitor (Rodine 213 spl) is filled in

the pipes. Efficiency test of the inhibitor is to be done prior to its use as
per NACE procedure.

8.1.3

The solution is allowed to soak in the pipes for 4 (four) hours and then
drained in a safe place and neutralized. This is then disposed off with
plenty of service water.
The pipes are flushed with DM water for 5-10 minutes.

8.1.4

The pipes are again filled with 2 % sodium nitrite and 5.0 % liquor

8.1.5

8.1.6
8.1.7

ammonia solution. The solution is allowed to soak for 30 minutes.

And then drained.
The pipe is rinsed / flushed with
(approximately).

DM water till pH is 7.5

The internal surface of pipes is dried with dry compressed air.

The lines are filled with lube oil and uniform oil film is achieved
through out the internal surface of the pipes.

Signature
NTPC
Station: NTPC
RAMAG
UNDAM

BHEL
BHEL Ref No. : PS - DC - 202 500 0017A
NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 6 of 14

Plant Area: BOILER

Testing Schedule: HP BYPASS SYSTEM
STATUS
8.2
8.2.1

Commissioning of HP BP System, Oil Supply Units.

Filling the oil tank with hydraulic fluid.

8.2.1.1

Ensure that the entire system is clean and also connections are tight.

8.2.1.2

Fill the tank upto the level Max (on the dip stick) with
recommended Grade of oil (Fig. 2) through 3 micron filter. Presently
Servo Conval-46 of IOC used or as per the recommendation given in
the O&M manual.

8.2.2

Check the IR value using 500V megger for power cables and for
motor of OSU is Ensure the healthiness and record the value.

8.2.3

Extend power supply to both incomers of the control panel up to the

breakers and check the correctness. Check the voltage in the respective
TB and also ensure proper polarity.

8.2.4

Extend supply to CP by switching ON the incomer breakers.

Energise the CP by switching ON the power supply modules one by

one and check the correctness.

8.2.5

Isolate all the outgoing leads and charge each rack by switch on the
respective breakers and check all the out going voltages are as per the
requirement.

8.2.6

Ensure availability of all cards and are placed in respective position.

8.2.7

Using test kit, calibrate the cards and set the valves as per the
recommendation wherever possible (Annex B)

8.2.8

Isolate the power supply to OSU-Motors. Energise the Module for

Control and Monitoring of OSU and check power contactor packing
and also drops when local stop PB pressed.

Signature
NTPC

Station: NTPC
RAMAGUN
DAM

BHEL

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 2 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
STATUS

Signature
NTPC

Station: NTPC
RAMAG
UNDAM
Plant Area: BOILER

BHEL

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 7 of 14

Testing Schedule: HP BYPASS SYSTEM

8.2.9

Ensure the readiness of OSU, switch on the motor and check whether
the oil pressure is developed as per the requirement by keeping the
cock valve of P line closed. If pressure is not developing, slowly
open the drain screw provided on the manifold and on seeing the
pressure building up close the drain screw.

8.2.10

Keep the ball-valve of pressure line (P) in closed condition and

pressurise the accumulator approx. 20 bar above the stamped gas
filling pressure. Switch off the pump motor. Reduce the pressure
from the accumulator via the drain screw in the supply manifold .
The oil pressure drop to zero as soon as the gas pressure reached.
Gas pressure (N2) can be checked with N2 charging device, which is
supplied along with the system.

8.2.11

Charging with accumulator with Nitrogen

Fix the special charging device and verify the gas pressure in the
Accumulator bladder. If the pressure is less than the recommended
value, i.e. 80 kg / sq.cm., recharge the bladder using commercial
quality Nitrogen storage bottle at high pressure.

8.2.12

Check the tripping pressure of safety relief valve

The tripping pressure of the safety relief valve is set at higher
pressure than that of Switch off pressure for oil pump and also the
Pressure too high alarm. The set pressure can be rechecked as
follows:

8.2.12.1

-- Close the ball valve in pressure line (P) in OSU.

8.2.12.2

-- Check the oil level in tank and lower the level to 20 cm below the
maintenance opening in the tank.

8.2.12.3 -- Remove the cover of the maintenance opening

8.2.12.4 -- Bridge the micro switch for Pump motor off

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RAMAGU
NDAM
Plant Area: BOILER

BHEL

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NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 8 of 14

Testing Schedule: HP BYPASS SYSTEM

8.2.12.5 -8.2.12.6 -8.2.12.7 -8.2.13

Start the oil pump and switch off as soon as relief valve trips. Note
the tripping pressure. Adjust the tripping pressure if necessary by
adjusting the set screw on the valve.
Repeat the checking until the tripping pressure is correct. The
tripping pressure of safety relief valve should be set at 180 kg /
sq.cm.
Set the tripping pressure of the second OSU also as described
above.
Check the accumulator operating pressure
The accumulator operating pressure is set with four pressure switches
provided in the box . The pressure at any instant can be read
provided on the manifold from the manometer which is provided
before the pressure reducing valve in the manifold. The set pressure
of the individual micro switches should be checked and resetting is to
be done if necessary by adjusting the screws. Turning the set screw in
clockwise results in a lower value. The purpose of each micro switch
setting is as follows:
Switch No. 1: Pump motor off. The max. operating pressure in
accumulator at which the pump motor is switched off (i.e.)
160 kg/sq. cm
Switch No. 2: Pump motor on. The min. operating pressure in
accumulator at which the pump motor is switched on. (i.e.) 110
kg/sq. cm.
Switch No. 3: Pressure too low alarm. The oil pressure is below the
min. operating pressure (i.e.) 90 kg/sq. cm and also used to start
pump in case of failure of switch no. 2.
Switch No. 4: Pressure too high alarm. The oil pressure is higher
than the operating pressure (i.e.) 170 kg / sq.cm. and also used to stop
the pump in case of failure of switch No. 1.
After the setting, the individual setting must be rechecked for its
correctness.

Signature
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RAMAG
UNDAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 9 of 14

Plant Area: BOILER

Testing Schedule : HP BYPASS SYSTEM

8. 3

Oil Flushing

8.3.1

The oil flushing operation is to be carried out to clean the complete

system of pipe work. For the normal operating system, the flushing is
to be done in two stages. First stage includes the pressure line (P) and
the return line (T) and second stage includes pressure line (P) and the
leakage line (L).

8.3.2

Stage I Flushing

8.3.2.1

Connect the pressure line (P) and the return line (T) with high
pressure hose at actuator (Fig. 3) for all valves.

8.3.2.2

Remove the 3 micron Filter in P lines near all the actuators

8.3.2.3

The filtering elements for suction strainer in OSU, air filter and the
pressure filter must remain in place.

8.3.2.4

Install the flushing filter in return line between supply manifold

and the ball cock

8.3.2.5

Install 25 micron filter element into the flushing filter.

8.3.2.6
8.3.2.7

Keep open all ball cocks in P and T lines near the actuators and
T line near OSU.
Start the oil pump. When the pressure in accumulator reached the
motor off limit the ball valve is opened (while charging the line
for the first time the valve is to be opened slowly and watched
for any oil leakage) and then closed when the pressure reduced
to Pump motor on limit.

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Station: NTPC
RAMAGU
NDAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 10 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
STATUS
8.3.3

This process of flushing is to be continued for not less than 30

minutes per loop or till such time no dirt or iron filling is observed in
the bowl of flushing filter. If observed, the filter and the bowl should
be cleaned with petrol and the filter is blown with instrument air and
flushing should be continued till the filter and the bowl is clean.

8.3.4

If more than one OSU feed the same system we can install flushing
filter in the return line of each unit. This will enable us to use the
OSU alternatively for flushing purpose.

8.3.5

Remove the 25 micron filter element and install 3 micron filter

element in flushing filter. Continue the flushing operation as
described above for minimum 30 minutes per loop or till such time
no dirt or iron filling is observed in the howl of flushing filter. If
observed, cleaning of the flushing bowl and filter as explained in the
case of 25 micron flushing should be repeated till such time the oil
in the flushing bowl is clean.

8.3.6

Stage II Flushing

8.3.6.1

Connect the pressure line (P) and leakage line (L) with high
pressure hose at the actuator for all the valves (Fig.4).

8.3.6.2

The flexible hose in return line (T) at OSU is to be changed to

leakage line (L).

8.3.6.3

Flushing operation as described in 8.3.2 is to be followed for

flushing of leakage line (L). The flushing is to be done for 30 mts
with 25 micron filter and then for 30 mts. with 3 micron filter for
each loop as explained in stage I flushing.

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RAMAGU
NDAM

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NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 11 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
8.3.7

Oil flushing for lines of quick opening device (SSB unit)

8.3.7.1

Close the isolating ball valves in the pressure and return line near
OSU.

8.3.7.2

Additional accumulator connection block (SAB) should be

isolated from the flushing circuit.

8.3.7.3

Remove the filter elements fitted in pressure line before the

additional accumulators.

8.3.7.4

Install the flushing device in oil return line of SSB unit near OSU.

8.3.7.5

Connect the supply line and return line as shown in Fig. 5 & 6
respectively using suitable fittings, hoses, etc.

8.3.7.6

Carry out the flushing operation as described in 8.3.2. The

isolating valve in pressure line to additional accumulator near
OSU is to be used to carry out flushing operation.

8.3.7.7

After completing the flushing, connect the oil line as shown in

Fig. 10 for flushing the additional accumulator drain line to tank.
Carry out the flushing as per the procedure in 8.3

8.3.7.8

Remove the flushing device and restore the oil pipe line
connections after declaring the completion of flushing operation
to carry out flushing operation.

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RAMAGU
NDAM

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NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 12 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
8.3.8
8.3.8.1
8.3.8.2
8.3.8.4
8.3.8.5

Restoration
Remove the flushing filter unit from the oil supply unit (OSU).
Restore all piping connection in the original condition.
Install 3 micron filter elements.
Remove the pressure filter in both the pump discharge lines and clean
them, remove the dirty oil remaining in the filter bowl. Put the filter
back in position and put back the cover of these filters.

8.3.8.6

The oil in the tanks should be drained and the man hole cover of the
tanks should be opened. The suction filter in both the oil tanks are to be
removed and cleaned. The tanks should be cleaned and visually
inspected for its cleaniness. The suction filter and the man holes covers
are put back in position and properly tightened . Both the oil tanks are
to be filled with clean SERVO CONVAL 46 oil to the max level and
keep open the isolating valve in the interconnection line. The drum of
Servo Conval 46 shall be kept vertical for allowing any setteliment to
settle for a certain period(at least a week) before oil flushing in to the
tank.

8.4

COMMISSIONING

8.4.1

Check the operation of bypass valves (BP), Temperature control valves

(BPE) and the Isolation valve E45 S from control desk (UCB).

8.4.2

Adjust the stroke locally for full open/close (4 to 20 mA).

8.4.3

Calibrate the position feedback transmitters (BP) bypass valves as well

as (BPE) temperature control valves

8.4.4

Set for valve opening time of BP & BPE valves at 10 seconds for full
open by adjusting the throttle valve located in T line near the actuator
of each valve.

8.4.5

Charge the oil in fast opening system. Check the operation of BP valves
from UCB-Control desk Fast open push button.

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BHEL

Station: NTPC
RAMAGUN
DAM

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
Check the timing for full open when the Fast Open PB actuated.
Set 3 seconds for full open by adjusting the throttle valve in the fast
opening device.
8.4.6

Ensure calibration of pressure and temperature transmitters. Extend

supply and adjust for zero of the span .

8.4.7

Check for the availability and proper termination of cable for fast
opening criteria like (I) GCB open (ii) Turbine load shedding relay
operating (iii) Turbine trip (iv) Pressure deviation too high, etc. and
also for closing criteria like condenser vacuum low, etc.

8.4.8

Check the over rides and interlocks for the following important
functions.

8.4.9

FOR BP VALVES

8.4.9.1

BP closing over ride

8.4.9.2

BD closing over ride

8.4.9.3

BD opening interlock

8.4.9.4

BPE auto interlock

8.4.9.5

Fast opening

8.4.9.6

Protection over ride.

8.4.10 FOR BPE VALVES

8.4.10.1

Auto interlock

8.4.10.2

Opening signal

8.4.10.3

Closing interlock

Keep the HP bypass system on Auto operation when the unit is in

service and check adjust the autoloops for (I) pressure master
controller (ii) temperature controller and (iii) fast opening system:

Sheet 13 of 14

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NTPC
Station: NTPC
RAMAG
UNDAM

BHEL
BHEL Ref No. : PS - DC - 202 500 0017A
NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Plant Area: BOILER

Testing Schedule: HP BYPASS SYSTEM

9.0

COMPLETION CRITERIA
Commissioning of HPBP system completed by carrying out the
proposals successfully and acceptable manner as mentioned in section
3.0.

Sheet 14 of 14

Signature
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RAMAGUN
DAM

BHEL

BHEL Ref No. : PS - DC - 202 500 0017A

NTPC Ref No. : COS-COMM-R-Commg.-PRO/014

Sheet 2 of 14

Plant Area: BOILER

Testing Schedule: : HP BYPASS SYSTEM
1.0

STATUS

1.1
1.2

Signature
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BHEL

HP BYPASS SYSTEM

PROJECT

M/S RAMAGUNDAM, UNIT- 7, 500 MW

PROCEDURE

HP BY PASS SYSTEM

PURPOSE OF
DOCUMET

FOR EXECUTION / INFORMATION

DOCUMENT

PS:TSX:178:00:03

Copy No:
Issued to :

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KJ

MKS

KB

08.09.2003

Rev.No.

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

PSSR/TECHNICAL SERVICES
474, Anna Salai, Nandanam,
Chennai 600 035.

OIL PIPING FOR HP BY PASS

SYSTEM (TYPICAL)
RAMAGUNDAM UNIT-7 500MW

RAMAGUNDAM UNIT-7 500MW

RAMAGUNDAM UNIT-7 500MW

RAMAGUNDAM UNIT-7 500MW

RAMAGUNDAM UNIT-7 500MW

RAMAGUNDAM UNIT-7 500MW