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FEEDBACK:1
PROJECT: JSL, DUBURI, 2 X 120 MW PROBLEMS: 1. CLOSING OF HP BYPASS MAIN BP AND BPE VALVES WAS VEY SLOW FROM 2.0% TO 0%. 2. DRIFTING OF VALVE FROM 0 % TO 0.5 % AND TO 0.8 % DURING MANUAL OPERATION AND AUTO OPERATION. ACTION TAKEN: During commissioning of HP Bypass valves, the above problems were observed at 120 MW JSL Duburi site. Servo valves were serviced and calibration of position feedback was checked. No improvement was observed. But operation of valves with blocking element at local, it was found closing faster and also no drifting was noticed. Hence problem was suspected in valve positioner card. After thorough checking, it was observed that the principle of operation of HP Bypass from PROMAX module is different from original card/ Pro-control card. Refer the enclosed scheme of valve positioner card of PROMAX. Both manual operation and auto operation of valve is carried through position demand and Position controller by keeping the blocking element in always released position. In max control, the operator window (pop up) for analog drive for HP Bypass does not provide any binary output for raise/lower. It gives directly variable analog signal of 0 to 100% for raise /lower command. The manual operation through console from HMI or back up panel was only varying the position demand to the positioner. Hence for HP Bypass the PROMAX positioner card is always kept on auto and positioner manual operation is blocked. Whereas in earlier condition, operation on auto

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mode was through position demand and position controller with blocking element released and operation on manual mode was through blocking element via logic circuit by external binary input command for open and close. Due to this difference in operation, tight closure command (through binary input to the close command of logic circuit) for the valve on feed back less than 2 % was not taking place with the PROMAX module. Closure of the valve through positioner was causing slow closing and drifting of the control valves.

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ORIGINAL BINARY INPUT LOGIC TO PROMAX MODULE

BP AUTO binary input to A N D
FAST OPEN ING

BP FD BK >98%

RESOLUTION: After studying the above problem the logics have been modified such that the blocking element is enabled during tight shut off command on feed back less than 2% and same will be released after opening command more than 2 %. By this no drifting of the valve and also fast closing during closing from 2.0 % to 0 % was ensured. The modified logic for auto binary bit to logic circuit is as below. This problem was observed in BPE valve also and similarly modified. HP BY PASS AUTO LOGIC MODIFIED AT JSL DUBURI 2
A N D S
FAS T OPE FD BK (BP) > 98%

BP AUTO binary input to logic

A N D

GT >2% DEM AND

TPUL SE =1.2 SEC

BP close binary input to the logic

LT 2% POS T FBK