PROBLEM FACED DURING COMMISSIONING OF LPBP SYSTEM IN UNIT 2 PROJECT : SIMHADRI 2 X 500 MW ,

PROBLEM : At Simhadri Unit-II, 500 MW LPBP system characteristics adjustment was carried out during last week of July 2002. While adjusting LPBP stop valve 1, open/close characteristics with respect to LPBP signal fluid pressures were not able to get consistent values. Few occasions the stop valve did not open even at 5.0 kg/Sq.cm signal oil pressure instead of normal opening pressure of 2.88 Kg/Sq.cm. Some time the stop valve opened full while closing the signal oil pressure isolating valve completely.(Ref. Fig. in page 11) OBSERVATION: The pilot valve was removed and serviced and put back. Still behaviour of the valve did not change. After that the liner (Item No.25) was removed. It was found that three number 'O' rings (Item No.40) located between supply and drain ports were not available. Moreover the liner secured pin (Item No.27) was also found in shorter length (19 mm against the required length of 25 mm). Hence the liner was not secured fully in position and was moving in up and down along with the pilot valve. Normally the liner should not move. Because of these problems, the servomotor characteristics behaved erratically.

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RECTIFICATION: The main servomotor is opened by control fluid against the spring force. A pilot valve item, No.24, will admit the control fluid to open or close side of servomotor. This pilot valve will be normally in downward position because of the spring compression (Item No.6). When the signal fluid pressure raises at the bottom of the pilot valve then the pilot valve moves upwards against the spring force and admits control fluid into the open side of the servomotor and servomotor opens full. When the signal fluid pressure reduces, then the pilot valve will move down from upside position because of self weight and spring force then the control fluid will be admitted into the close chamber of servomotor and at the same time open side oil will get drained into the drain header. New "O rings, three numbers and correct length cylindrical pin Item No.27 (12 x 25mm) was machined at workshop and liner was assembled. As per design characteristics when the LPBP signal fluid pressure of stop / control valve reaches around 2.88 Kg/Sq.cm, stop valve will full open and when the signal fluid pressure drops below 2.80 kg/sq.cm, the stop valve will close. If the isolating valve of the signal fluid is closed then the stop valve will get closed fully. Then valve characteristics were checked repeatedly and consistent value of open / close found and thus the: problem was resolved.

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