MAR

26

COMMISSIONING CHECK LIST FOR HP BYPASS SYSTEM

COMMISSIONING CHECK LIST
FOR HP BYPASS SYSTEM
1.0.0      MECHANICAL
1.1.0     Preliminary checks
1.1.1     Check that all the valves, piping, oil supply units, etc. are erected as per the layout.
1.1.2.0  Ensure that the following are serviced, if necessary, according to the condition of
equipments and fitted back properly.
1.1.2.1       Bypass control valve (BP) actuators.
1.1.2.2  Spray water control valve (BPE) actuators.
1.1.2.3  Accumulators.
1.1.3               Ensure all joints are properly tightened and the pipelines are clamped with
proper supports.
1.1.4               Ensure cleanliness of oil tank in oil supply units.
1.2.0     Acid cleaning of pipelines
1.2.1               The oil pipe line system (fig. 1) has to be subjected to chemical cleaning in
order to avert plugging of servo valves, filters, etc. Visual inspection of pipes before erection
reveals the condition. If rusted heavily and pitted, the pipes are to be chemically cleaned,
preferably before erection. If the piping erection is completed, suitable arrangements for
filling, draining and venting, are to be made at appropriate levels. Soaking method is
recommended if circulation method is not practicable.

1.2.2     Alkaline water wash

            The oil pipelines are to be flushed with water to remove loose debris before
subjecting it to acid cleaning. Fill the pipeline with 1% solution containing sodium carbonate
and trisodium phosphate. (5 gms of sodium carbonate and 5 gms. Of Trisodium phosphate
per litre of water). Soak the lines in alkaline solution for four to six hours. Drain and rinse
the pipelines with clear filtered water or demineralised water to free them from any remnant
alkali.
1.2.3     Acid cleaning
            Fill the oil pipelines, with 6% hydrochloric acid mixed with 0.2% Rodine 213 special
inhibitor for 6 hrs. (200 CC of HCL and 2 CC of Rodine per lit. of water). Drain the pipeline,
flush it with clear filtered water or demineralised water to ward off remnant acidity. Test it
with litmus paper. If the litmus paper does not turn red no acidity.

1.2.4     Neutralisation and passivation

            Fill the pipelines with solution containing 0.5% sodium hydroxide of PH 13 and
0.5% sodium nitrite for 6 to 8 hrs. (10 gms. Of sodium hydroxide of PH 13 and 10 gms. Of
sodium nitrite per lit. of water). Drain and flush the lines with clear filtered water or
demineralised water. Dry the pipelines by blowing hot air. Preserve the pipe lines by filling
with recommended oil and cover the ends.
1.3.0     Precommissioning
1.3.1     Filling the oil tank with Hydraulic fluid.
            Ensure that the entire system is clean and also connections are tight.
             Fill the tank upto the level “Max” (on the dip stick) with recommended Grade of oil
(Fig. 2). Presently Servo prime 311 of IOC used or as per the recommendation given by the
manufacturer to the project.
1.3.2     Check the gas pressure in Accumulator
            Keep the ball – valve of pressure line (P) in closed condition and pressurise the
accumulator appx. 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. (Fig. 3) The oil pressure drop to zero as soon as the gas pressure reached.

1.3.3     Charging the accumulator with Nitrogen

            Fix the special charging device (Fig. 4) 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.

1.3.4     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 presssure” for oil pump and also the “Pressure too high” alarm. The set pressure
can be rechecked as follows :
-                                 Close the ball valve in pressure line (P) in OSU.

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

-                                 Remove the cover

-                                 Bridge the micro switch for “Pump motor off” (switch no.1).

-                                 Start the oil pump and switch off as soon as relief valve trips. Note
the tripping pressure. Reset 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.
1.3.5     Check the accumulator operating pressure
            The accumulator operating pressure is set with four pressure switches provided in
one box. (Fig. 5). The pressure at any instant can be read from the manometer which is
provided between accumulator and supply manifold. The set pressure of the individual micro
switches should be checked and resetting is to be done if necessary by adjusting the set
screws. Turning the set screw in clockwise results in a lower value. The purpose of each
micro switch setting is as follows :
o. 1 : -   “Pump motor off”. The max. operating pressure in accumulator at which the pump motor is
switched off (i.e.) 160 kg/sq.cm.
o. 2 : -   “Pump motor on”. The min. operating pressure in accumulator at which the pump motor is
switched on. (i.e.) 110 Kg/sq.cm.
o. 3 : -   “Pressure too low” alarm. The oil pressure is below the min. operating pressure (i.e.) 70
Kg/sq.cm.
o. 4 :-    “Pressure too high” alarm. The oil pressure is higher than the operating pressure (i.e.) 170
Kg/sq.cm.
            After the setting, the individual settings must be rechecked for its correctness.
1.3.6     Oil Flushing
             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)
1.3.7     Stage I Flushing
            -   Connect the pressure line (P) and the return line (T) with high pressure hose at actuator (Fig.
6) for all valves.
            -   The filtering elements for suction strainer in OSU, air filter and the pressure filter must remain
in place.
            -   The 3 micron filter elements in the pressure line (P) filters before the actuator must be
removed.
            -   Instal the flushing filter in the return line between supply manifold and ball cock (Fig. 7).
            -   Instal 25 micron filter element into the flushing filter.
            -   Keep open all ball cocks in ‘P’ and ‘T’ lines near the actuators and ‘T’ line near OSU.
            -   Close ball valve in pressure line (P) near OSU.
            -   Start the oil pump. When the pressure in accumulator reached the “Pump 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.
            This processes of flushing is to be continued for not less than 30 minutes per loop.
During the flushing operation, the fluid temp. has to reach minimum of 40 deg.C. and also
the maximum temp. should not exceed 70 deg. C or as specified in O & M manual.
            -   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 alternately for flushing purpose. If number of
flushing filter are not available, then the leakage lines must be closed off on all the OSU
which is not used for the flushing purpose.
            -   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.
1.3.8     Stage II Flushing
            -   Connect the pressure line (P) and leakage line (L) with high pressure hose at the actuator for
all the valves (Fig.8)
            -   The flexible hose in return line (T) at OSU is to be changed to leakage line (L)
            -   Flushing operation as described in 1.3.7 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.
1.3.9     Restoration
            -   Remove the flushing filter unit from the oil supply unit (OSU).
            -   Restore all piping connections in the original condition.
            -   Install 3 micron filter elements. 

1.3.10   Oil flushing for lines of quick opening device (SSB Unit)

            -   Close the isolating ball valves in the pressure and return line near OSU.
            -   Additional accumulator connection block (SAB) should be isolated from the flushing circuit.
            -   Remove the filter elements fitted in pressure line before the additional accumulators.
            -   Install the flushing device in oil return line of SSB Unit near OSU.
            -   Connect the supply line and return line as shown in Fig. 9, using suitable fittings, hoses, etc.
            -   Carry out the flushing operation as described in 1.3.7 The isolating valve in pressure line to
additional accumulator near OSU is to be used to carry out flushing operation.
            -   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 1.3.7.
            -   Remove the flushing device and restore the oil pipe line connections after declaring the
completion of flushing operation.
2.0.0     ELECTRICAL
2.1.0     Preliminary checks
2.1.1     Ensure completion of erection of all components like control panel (CP), pressure
transmitter, Temp. transmitter, etc. as per the bill of material.
2.1.2     Ensure cabling for various points like MCC to OSU-motor, Incomer cable CP, CP to
field equipments, CP to UCB insert and termination of the same.
2.1.3     Identify the cables and ensure proper termination
2.1.4     Ensure proper fixing of fabricated cable from CP to UCB console insert.
2.1.5     Ensure proper earthing of CP (i.e.) CP earthing should be connected to the common
earth bar.
2.2.0     Pre-commissioning
2.2.1     Check the IR value using 500V megger for power cables and for motor of OSU.
Ensure the healthiness and record the value.
2.2.2     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.
2.2.3     Extend supply to CP by switching ‘ON’ the incomer breakers. Energise the CP by
switching ON the power supply modules (NER 30) one by one and check the correctness.
2.2.4     Isolate all the out going leads and charge each rack by pressing the respective
breakers and check all the out going voltages are as per the requirement.
2.2.5     Ensure availability of all cards and placed in respective position.
2.2.6     Using test kit, calibrate the cards and set the valves as per the recommendation
wherever possible (Annex. B)
2.2.7     Isolate the power supply to OSU-Motors. Energise the Module for control and
monitoring of OSU (SOL 10) and check power contractor picking and also drops when local
stop PB pressed.
2.2.8     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.
2.2.9     Set the accumulator operating pressure as described in 1.3.5.
2.2.10   Charge the oil lines and keep OSUs on auto operation. Check the auto operation of
OSU-motors to maintain the operating pressure as per the requirement (1.3.5).
3.0.0     Commissioning
3.1.0     Check the operation of bypass valves (BP), Temperature control valves (BPE) and
the Isolation valve (BD) from control desk (UCB). Adjust the stroke locally for full
open/close (4 to 20 mA).
3.2.0     Calibrate the position feed back transmitters for (BP) bypass valves as well as
(BPE) temperature control valves (5-15 mA).
3.3.0     Set for valve opening time of BP & BPE valves at 8 to 10 seconds for full open by
adjusting the throttle valve located in ‘P’ line near the actuator of each valve.
3.4.0     Charge the oil in fast opening system. Check the operation of BP valves from UCB-
Control desk “Fast open” push button.
3.5.0     Check the timing for full open when the “Fast open” PB actuated. Set 3 seconds for
full open by adjusting the throttle valve in ‘P’ line of fast opening system.
3.6.0     Ensure calibration of pressure and temperature transmitters. Extend supply and
adjust for zero of the span of each one (4 mA)
3.7.0     Check for the availability and proper termination of cable for fast opening criteria
like (i) GCB open (ii) Turbine load shedding relay operated (iii) Turbine trip (iv) Pressure
deviation too high etc. and also for closing criteria like condenser vacuum low, etc.
3.8.0     Check the over rides and interlocks for the following important functions.
3.8.1     For BP valves
            -   BP closing over ride
            -   BD closing over ride
             -   BD opening interlock
            -   BPE auto interlock
            -   Fast opening
            -   Protection over ride
3.8.2     For BPE valves
            -   Auto interlock
            -   Opening signal
            -   Closing interlock
3.9.0     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.
4.0.0     General
4.1.0     The respective O & M manual should be made available before start to
commissioning activities.
4.2.0     A format on “Check list for commissioning of HP bypass system” prepared taking
into account of all commissioning aspects enclosed as Annex. A. This format will be very
much useful for commissioning engineers to carry out the commissioning activities
systematically.
4.3.0     A typical set values for 210 MW HP bypass system used in various cards and also in
OSU is enclosed as annex B for information. However, the set values as specified in the
respective O & M manual of a particular project/unit capacity should be considered while
commissioning the HP bypass system.

ANNEX A
BHARAT HEAVY ELECTRICALS LIMITED
PS SR < TECHNICAL SERVICES
CHECK LIST FOR COMMISSIONING
OF HP BYPASS SYSTEM

PROJECT                                         UNIT NO.       CAP :               MW

Checks                                                  Remarks
01.  Completion of erection
      a) Mech. System                           :
b) Electrical                                  :
02.  All components as per bill of
material installed
      a) Mechanical                               :
b) Electrical                                  :
03.  Acid cleaning of oil pipelines           :
04.  Ensure tightness of all joints          :
and proper supprot
05.  Cleanliness of oil tank                   :
06.  Filling the hydraulic fluid in             :
oil tank.
07.  Serving of valve actuators,             :
accumulator, etc.
08.  Cable identification and proper        :
termination.
09.  IR value using 500V megger in (Mm)
      -   Motor of OSU                            :
      -   Cable                                      :
      -   Control panel                            :
10.  Extend both power supply to           :
CP (Incomers) upto breakers and
check for its correctness
(Polarity and voltage)
11.  Energise CP by switching ON the     :
breaker in power supply module
(NER – 30) and ensure healthiness
12.  Energise CP and check all outputs    :
and inputs are as per the
requirement
13.  Ensure availability of all cards         :
and also fixed in proper locations
14.  Ensure isolation of power to motor
of OSU and energise the modules
SOL-10 (Control & Monitoring module)
Check the following
      -   Power contactors picking            :
      -   Dropping of power contractors when
    local stop P.B. pressed.
15.  Close the Ball valve in ‘P’ line         :
of supply manifold. Switch on
the motors and check whether the
pressure is developed to the
required value.
16.  Check the operating pressures and  :
reset if required.
17.  Ensure no oil leakage                     :
18.  Carry out oil flushing
      -   Normal operating system            :
      -   Fast opening system                  :
19.  Calibration of cards using               :   (Values are set
test kit.                                           As per Annex A1)
20.  Operate all valves (BP, BPE & BD)   :
from UCB control desk and carry
out the stroke adjustment for full
close/open for all valves (4-20 mA)
21.  Calibrate the position feed back
transmitter for BP & BPE valves
(5 – 15 mA)
22.  Check/Set the opening time for BP &    :
BPE valves (8-10 seconds)
23.  Check fast opening of BP valves      :
when fast opening P.B. actuated from
control desk.
24.  Set the opening time 3 seconds for  :
full open when fast opening P.B.
actuated
25.  Put pressure & temp. transmitters   :
in service and set for zero span
(4 mA)
26.  Check over rides and interlock for    :
BP, BPE and BD valves and correct
if necessary.
27.  Check auto operation of control
loops for
      -   Pressure master controller          :
      -   Temperature controller               :
      -   Fast opening system                  :
28.  Remarks                                      :

ANNEX A1
HP BYPASS SYSTEM
(Enclosure to Annex A)
Project       :
Unit No.     :
CAP                                                   :
I     Using test kit, the following cards were tested and values are set as noted against each :
Sl. No.       Card location                      Card      Setting          Set
                                                  type      on                 value 

II              The following settings were made on OSU

Sl. No.       Description                             Unit          Set        Value
1.   Switch No.1 Pump off   Pa (1)              Kg/sq.cm
2.   Switch No. 2 Pump on  Pe (2)              Kg/sq.cm.
3.   Switch No. 3 Pr. too low Dt (3)            Kg/sq.cm.
4.   Switch No. 4 Pr. too high Ph (4)           Kg/sq.cm.
5.   Accumulator bladder pr.                      Kg/sq.cm.
6.   System oil pressure                           Kg/sq.cm.
7.   Standby Accumulator bladder pr.          Kg/sq.cm.
ANNEX B
Typical setting values of 210 MW HP Bypass system
(For guidance only)
I     For cards
 

Sl.     Location                   Card            Setting on          Set Value

No.
 

01     B/021                      RPV-10        U                      0.25 V
02     B/055                      RPV-10        U                      0.25 V
03     B/071                      RUM-20        U1                    0.2 V
04     B/087                      RUM-20        U1                    0.5 V
05     B/095                      RUM-20        U1                    0.5 V
                                                                                U2    1.0 V
06     B/119                      RUM-20        U2                    0.25 V
07     C/021                      RUM-20        U1                    0.2 V
08     C/029                      RUM-20        U1                    9.8 V
                                                                                U2    0.2 V
09     C/037                      RUM-20        U1                    1.0 V
10     D/021                      RUM-20        U1                    0.2 V
                                                                                U2    0.2 V
11     D/029                      RUM-20        U1                    9.8 V
                                                                                U2    0.2 V
12     D/037                      RUM-20        U1                    1.0 V
13     E/021                      RUM-20        U1                    8.0 V
                                                                                U2    8.6 V
14     F/021                      RUM-20        U1                    8.0 V
                                                                                U2    8.6 V

II      For Oil supply unit

Sl.     Description                                 Operating value Set value

No.                                                   (kg/sq.cm)         (kg/sq.cm)
  

01     Pump off pa (1)         (Switch no.1)      -                 160

02     Pump off Pe (2)         (Switch no.2)      -                 110
03     Pressure too low dt (e) (Switch no.3)   -                 70
04     Pressure too high Ph (4) (Switch no.4)  -                 170
05     Accumulator bladder pressure              80               -
06     System oil pressure                           -                 100
07     Standby accumulator bladder pressure  80               80
08     Blow off pressure of relief valve          -                 18