Document No. QNI-SEC-G-03-71.K156-7E01 Rev No.:0
Vietnam Quang Ninh Thermal Power Plant
Phase I: 2x300MW Project
\
CONTROL AND PROTECT
SYSTEM INSTRUCTION
EME Ha AU CREA) A AY
Shanghai Electric (Group) Corporation
2007.09 Index No.: 71.K156-7EO1
@D src raare cout 1 DOCUMENT CONTROL SHEET
PROJECT: VIETNAM QUANG NINH THERMAL POWER
PLANT
PHASE |: 2X300MW PROJECT
CLIENT: VIETNAM QUANG NINH THERMAL POWER JOINT
STOCK COMPANY
DOCUMENT TITLE: CONTROL & PROTECT
SYSTEM INSTRUCTION
DOCUMENT NO.: QNI-SEC-G-03-71.K156-7E01
REV. NO.: 0
ENDORSEMENTS
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Index
General Instructions... a a 5
EH Fluid Supply System... : 1
2.1 System Structure and Principle. esastniennnninememannenneT
2.2 System Equipment.
2.2.1 Fire-resistant hydraulic fluid.
22.2 Fluid reservoir. se
223 Polishing filter. es
2.24 High pressure accumulators. 18
225 Drain accumulators. 18
2.3 System Operation..... 18
EH Actuator and Emergency Protect System... ee
3.1. Principle Of System... 22
3.1.1 Actuator eee)
3.12 Emergency Trip Control Unit... 24
3.1.3. EH Pressure Low Testing Block o.oo ee 25
3.1.4 Diaphitagm Valve ee ee 26
3.15 Air Pilot Valve ie
3.2 System Equipments. eee 26
3.21 Throttle Valve Actuator. senne 26
3.2.2 Governor Valve Actuator (GV). 31
3.2.3 Reheat Stop Valve actuator (RSV). see 32
3.24 Intercept Valve actuator (IV)eornnunnnnnn ae 3
3.2.5 Emergency Trip Control BlOCk snes soe
3.2.6 Test block of low EH pressure... sen 36
3.2.7 Diaphragm valve. = : 36
328 Airpilot valve... eee 38
Overspeed mechanical trip system. 39
4.1 System configuration... p39.
4.2 Overspeed trip mechanism eee 39)
42.1 Overspeed tip t6St rennin — 4
4.22 Injection test. ae}
4.3 Overspeed trip valve remote reset device ieneaiaca 42
4.4 Overspeed trip mechanism check device eas
4.5 Integrative safety device......... oe 44
Maintenance guidance of control system
5.1 General principle eel ee
5.2. The treatment, usage and intentions of the EH fluid 46
5.3. Prevent the fluid from deteriorating. 47
5.4 Fluid container and transport tool 48
5.5. Typical characteristics of new liquids... 49 in) Shanghai Turbine Co. Index. No.; 71.K156-7EO1
2 General Instructions
DEH, whose hydraulic system (EH) is high pressure fire-resistant fluid
system, is applied in the adjusting and safety system of K156 steam
turbine. I/A’ $ of Foxboro and OVATION of Siemens-Westinghouse , etc.
is applied to assure the incorporation of DEH hardware and DCS, it has a
better affect on resource sharing and communication,
The whole adjusting and safety system includes DEH, EH fluid supply
system, EH hydraulic actuators, emergency safety activator, TSI and ETS,
etc.
The DEH equipment, software characteristic and configuration method
can be found in the documents that supplied by corresponding hardware
suppliers. The functions detail and manual are given in specific
instructions, not mentioned in this document.
The control command signals, which control the steam valve of steam
turbine to adjust the steam flow, of DEH are given to EH system. EH
system contains the EH fluid supply system, hydraulic actuator and
emergency safety activator.
The main functions of the EH fluid supply system, which uses the high
pressure fire-resistant fluid, is to supply the power for activators and
safety components, and is to assure quality of the fluid.
Steam valves are controlled by EH oil activators that 2 for main steam
stop valve, 4 for high pressure governor valve, 2 for reheat steam stop
valve, 2 for reheat intercept valve. The activation, shutdown or opening
degree of the actuator is controlled by the electrical signals of DEH. And
it is closed quickly when the ETS trip signal is received. The structures,
functions, operation manual, maintenance of all actuators are specified in
this document.
The emergency safety executor has emergency trip control block,
diaphragm-operated valve, overspeed trip device and integrate safety 4-47
6 High pressure EH fluid system polishing directions
6.1
6.2
6.3
6.4
6.5
Index. No.: 71.K156-7EOL
Preparation for system polishing
Charge the EH fluid...
Polishing.
Measurement of the system cleanliness.
Systems recovery.
case getty fees eS Shanghai Turbine Co. Index No. TI.K1S6-TEO1
equipments. It provides the functions of overspeed protect and emergency
trip, ete.
TSI and ETS monitor steam turbin
, operate all the trip signals in the
PLC logic and deliver the trip signal. For safety reason, online test has
been implemented in all channels. Other documents will be introduced in
TSI and ETS, not here.
Furthermore, the “Maintenance Guide of Control System” and “Cleaning
instructions of High-pressure EH fluid System” also included in this
document.
7. 9.2) an) Shanghai Turbine Co. Index No.: 71.K156-7EO1
74M)
3 EH Fluid Supply System
3.1 System Structure and Principle
Refer to Fig.2-1 “Principle of EH fluid Supply System”.
Electrical heater, which is controlled by temperature switch (23/HER), is
equipped under oil tank to control the fluid temperature. The cooler,
which is automatically controlled by temperature controller (23/TCD) and
solenoid valve (20/CW) or manually controlled by operating the water
outlet stop valve of cooler, cooperate with cooling circulating pump. The
pump will be activated if fluid temperature higher than the well-balanced
situation.
Level indicator and level switch, which are in the fluid tank, are used to
recognize the actual fluid level and make an alarm when level is higher
than well-balanced situation or stop the pump when the level is too low.
Some field stick plug into the fluid from the top of oil tank is to adsorb
the grain in the fluid.
There are two same parallel main pumps, which has pressure control
valve that can adjust system oil pressure, and they are commutatively
standby. The out flow of pump is automatically adjusted by the system
requirements. Inlet filter and outlet filter are equipped on each pump, and
the alarm signal will deliver when differential pressure of the outlet filter,
which is monitored by differential pressure switch (63/MPF-I, 2), is
higher than setting value. The flow gauge of outlet monitors the out flow
of the fluid pump, and the outlet check valve is used to protect the
standby oil pump from the reversing impulsion of the high pressure fluid.
Disconnecting valve, which is equipped on each pump, is used to online
maintenance, and it is opened in normal condition.
The relief valve, of which the setting value should be 2MPa higher than
the outlet pressure, is a dump valve. It can protect the system from high S Shanghai Turbine Co. Pee
2.4.4
pressure impulsion when the failure of pressure adjusting of the pump,
and it’s closed in normal condition. There is some high pressure fluid will
return to the tank via dump valve if the pressure setting value of dump
valve approaches to system oil pressure. This makes the energy loss and
the fluid temperature higher.
cuits
Fig.2-1 diagram of EH supply system
ater
com
There are three pressure gauge (GA4080, 4090 4100), which can show
the outlet pressure of pump, the system pressure and differential pressure
of outlet filter for system. S Shanghai Turbine Co. Index No: 71.K156-7EO]
The EH system fluid pressure, which is sent to power station control desk
to provide the monitoring signals, is transformed by pressure transmitter
(XD/EHP).
The outlet pressure of pump is stabilized by the accumulators.
The signal hardware of pressure switch (63/MP) will be equipped into
automatic activating loop of the EH main pump, to start the standby
pump automatically if the system pressure is lower than setting value. A
throttling orifice is equipped at the upstream of pressure switch, and a
manual stop valve and a solenoid valve (20/MPT) are at its downstream.
These two are used to test the standby pump regularly. The pressure
switch (63/MP) will get a signal of low system pressure, if the solenoid
valve is energized or the stop valve is opened manually. This signal will
start the standby pump and the system pressure will not be affected
because of the throttling orifice. Renew the valve to resume the pressure
of the switch, then stop the standby pump manually, because the EH main
pump can’t be stopped automatically otherwise the fluid level is too low.
Alternating current motor and pump of the EH cooling system will start,
if the fluid temperature still higher than normal in the condition of oil
cooler’s running, to cool the fluid in EH reservoir further.
Alternating current motor and pump of oil filter system has two loops,
one is for polishing filter to improve the moisture content, acid value and
resistivity, etc. And another is for filter (With differential pressure switch
63/MPF3) to clean the impurity particle. The polishing filter is also called
regenerating unit, which consist an in series corrugated cellulose filer and
a fuller’s earth filter. It is bypassed when the filter pump is not equipped
in early time. The absorption capacity of fuller's earth is limited and it
will be exhausted if fluid is seriously deteriorated. So it must be
frequently changed. Ion exchange resin, whose filter has two kind, cation
and anion, is used for ion contaminant. But it not only can’t absorb the
moisture, but also release moisture in ion exchange process. So the
additional dewater must be equipped with ion exchange resin. 71.K136-TE01
Index. No,
S Shanghai Turbine Co.
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7.4.9 S Shanghai Turbine Co. Index No.: 71.K156-7E01
3.2 System Equipment
3.2.1 Fire-resistant hydraulic fluid
A synthetic fluid of the tri-aryl phosphate ester type must be used in the
high pressure fluid supply system. It is recommended that the fluid
manufacturer’s instructions covering its use, storage, handling, and
compatibility with other materials should be carefully followed.
3.2.2 Fluid reservoir
Refer to the figure 2-3 EH “EH fluid reservoir”. It contains:
Fig. EH reservoir | SEHRE Sj] ome
7.4%) 0-49
a) Shanghai Turbine Co. Index No.: 71.K156-7E0L
1. One fluid tank with sufficient capacity constructed of stainless steel.
A bolted personal cover plate is fitted on the tank top. There is a
manually-operated drain valve at the bottom of tank. And there are many
drain and suction ports
2. Two main fluid pumps of identical capacity.
Each pump, which can operate continuously, is coupled through flexible
couplings to individual motor. All pumps suction is below the fluid level
to ensure positive suction pressure.
Fig. 2-4 EH pump
The structure of fluid pump is shown on Fig 2-4. Main fluid pump, which
has pressure regulator and the outlet pressure can be set, is a constant
pressure updated flow plunger pump. Flow is regulated automatically to
follow the fluid flow of system. The screw (28-11) is used to adjust outlet
fluid pressure, which works on sleeve (21) that withstand the pivot board
(9), to balance the spring force. The pivot board will turn to a bigger
angle under the spring force with the pressure decreasing. This makes the a) Shanghai Turbine Co. Index No: 71.K156-7E01
fluid flow increasing because the axial displacement for every piston will
increase, and the system reaches to a new balance point. Otherwise, the
pivot board will turn to a smaller angle. This is a differential adjustment
that the pressure is a little lower when the flow is bigger. The biggest
journey of sleeve is limited by screw, so the biggest flow can be adjusted
by it. The friction between the slipper and pressure plate is proportional
with the outlet pressure of pump when the pump is working, and the lube
fluid leak into pump casing, so there must be a return pipe to reservoir.
3. Circulation Pump
The circulation pump is blade pump; it is to be used for cooling cycle and
filtering cycle. It is not running in usual. The pump suction, which can get
fluid via hose from the tank, is equipped on pump.
4, Strainer is fitted in each pumps suction pipe. Main fluid pumps filter
cartridge can be on-line replaced through reverse pump processing,
circulation pumps filter cartridge can be replaced after pump is off.
5. One control block, mounted on the reservoir top, is machined for the
assembly of the following:
a. Two 3-micron metal mash filters, two filters separated. These filter
cartridges of filters can be cleaned and reused, but it must be operated
according to special cleaning technology.
b. Two check valves (Fig. 2-5), which are at the downstream of the filter
of control block, installed in the high pressure fluid circuit on the
discharge side of each pump
c. One relief valve located in the high pressure fluid circuit in the line
downstream the check valves. Fluid pressure is monitored by it and any
fluid at pressure above the designed requirements will be returned to the
reservoir properly.
d. Two shutoff valve, normally open. Closing these valves manually can
isolate the control block from the high pressure fluid header to permit
"7-44 S Shanghai Turbine Co. Index. No,: 71.K156-7EO1
7.4.4
maintenance check valves, filter and pump. By closing only one of these
valves, only one side of the redundant system is isolated, and operation of
the turbine is not hindered.
Fig. 2-5 check vlv
spring needle
HP relief viv
press adj
(normal
close)
anil “glide viv
AST of OPC.
check viv for
HP orifice
Fig 2-6 relief valve
6. Four hollow stainless steel rods containing magnets are fully immersed
in the reservoir fluid. Individually, each rod may be removed for cleaning.
7. One magnetic level gauge is installed at the side of fluid reservoir, and
fluid level can be displayed visibly. Level switch, which used for alarm S Shanghai Turbine Co. Index No.: 71.K156-7E01
and trip control, installed on the level gauge, concretion are following:
a. When level is too low, low alarm and low-low trip valve linking stops
the pumps.
b. Level high and level low-low alarm.
8. One needle valve and one solenoid valve installed in parallel in the
fluid circuit adjacent to the fluid pump pressure switch. This arrangement
allows the standby fluid pump start-up to be test manually and remote
control.
9. One digital temperature controller, which is on the side of reservoir,
displays and controls the fluid temperature
10. One in-line, spring-loaded, check valve installed on the bypass of
pressure drain fluid. This allows the drain fluid to bypass the fluid cooler
and drain strainer if drain pressure is too high because the drain strainer
plugged or drain flow is over size, and the pressure avoid in drain main
pipe too high.
11. Two fluid coolers are mounted on the side of the reservoir. The system
fluid is circulated within the shell around the tube bundle while the
cooling water passes through the tubes. Cooling water flow can be
controlled manually or controlled by the solenoid valve automatically,
whose control command is delivered from temperature controller.
12. A drain strainer is at the upstream of the cooler to improve fluid
condition.
13. A cabinet encloses the electrical terminal board and the following
assembly of pressure switches.
a. Two high pressure differential pressure switches, 63-1/MPF, 63-2/MPF.
Each measures pressure differential with the inlet and outlet sides of the
corresponding filter. If the pressure differential reaches ultimate value, the
switches will cause an alarm to sound, indicating that the filter is clogged
and needs to be cleaned or replaced. The drain differential pressure switch
(63-3/MPF) and drain strainer differential pressure switch (63/ORF), of 2-4-4
S Shanghai Turbine Co. Index No.: 71,K156-7E01
which the setting value is 0.21MPa, are equipped in new product.
b. One pressure switch 63/MP senses the low pressure of fluid system and
is set to close contact to start the fluid standby pump on decreasing
pressure at 10.4~11.13MPa.
c. One pressure switch 63/HP senses the high pressure of fluid system and
is set to close contact to send an alarm on increasing pressure at
16.1~16.4MPa.
d. One pressure switch 63/LP senses the low pressure of fluid system and
is set to close contact to send an alarm on decreasing pressure at
9.31~10.2MPa.
e. One drain pressure high pressure switch 63/PR, used for when drain
pressure is as high as 0.21~0.27MPa, will give alarm. This switch is
cancelled in some old products.
14. One gas-liquid high pressure accumulator, with a butyl bladder
mounted on the side of the reservoir, to maintain system’s pressure to
reduce pressure surge.
The accumulator pre-charge pressure of nitrogen on one side opposes the
system’s fluid pressure on other. The accumulator is connected to the
fluid system through an accumulator block which includes a shutoff valve
which enables the accumulator to be isolated from the system for testing,
recharging, or servicing. The accumulator has a pressure gauge on the
nitrogen side to enable checking the nitrogen pressure. There isn’t a
pressure gauge on some accumulators and a pressure measure tool will be
supplied with it.
3.2.3. Polishing filter
One polishing filter assembly (Fig 2-7), which locates on the downstream
of throttling orifice of the main pipe line, consisting of an in series
corrugated cellulose filer and a fuller’s earth filter. The EH fluid crosses
the throttling orifice and filter with the flow of 3.8L/min, and returns to
the EH reservoir. = Shanghai Turbine Co. Index No.: 71.K156-7E01
.4Y)
The fuller's earth filter can be bypassed and the fluid passed only through
the corrugated cellulose filer. This happens (about 3~4 hours) only at the
first time usage of corrugated cellulose filer to let it be sufficiently
moistened. The bypass line passes the throttling orifice with a
normally-closed valve. Each filter is also equipped a pressure gauge
which indicates abnormally high pressure (higher than 0.21MPa) when
the filter needs to be replaced.
The fuller's earth and corrugated cellulose filters are both of the
replaceable cartridge type. With the line valve closed, the filter covers
may be removed and cartridges can be replaced. The cover-shell joints are
provided with a gasket to ensure against fluid leakage. If the pressure in
either of the filters increases to 0.21MPa with fluid temperature between
43.3-54.4°C the filter cartridge needs to be replaced.
Ion exchange resin, which is used to replace the components of polishing
filter, is used in new products. The cation or anion filter can be chosen
according to the fluid condition. And the additional dewater device must
7 S Shanghai Turbine Co. Index No.: 71.K156-7EOL
be equipped with it.
3.2.4 High pressure accumulators
Additional gas- liquid high pressure accumulators are mounted in two
supporting racks, which has two accumulators independently, and they
are located at each throttle valve-steam chest assembly. The individual
accumulators, each provided with a gas pressure gauge (replaced by
pressure-measurement devices in some import products), are connected to
a manifold block. The manifold block can isolate any of the accumulators
through valve so the accumulators may be isolated for testing, recharging,
or servicing.
3.2.5 Drain accumulators
Four rubber bladder low pressure accumulators installed in the
pressurized drain return pipe to the fluid reservoir serve as a surge
chamber to displace fluid in the drain system during a load pump. The
accumulators consist of a steel shell enclosing a synthetic rubber bladder
charged with dry nitrogen gas at 0.21MPa, which provides a separation
between the gas and fluid chambers. The shell is fitted with a charging
valve connected to the bladder for the nitrogen gas charge.
3.3 System Operation
The initial pressure requirements for the high pressure system is supplied
by the NO.1 or NO.2 motor-driven pump under the EH reservoir during
normal operation. The pumps are of equal pressure variable and outlet
pressure can be adjusted through an adjusting bolt located on pumps. The
stand-by pump will start automatically if the system pressure is lower
than the setting value. The pumps all can be started manually with control
switch. Any of pumps can self-start through pressure switch, connected to
outlet line, which starts standby pump through a relay.
Heaters are required if the fluid supply system is operated in low ambient
temperature. Prolonged operation below 21°C is not recommended, S Shanghai Turbine Co. Index No.: 71.K136-TEOL
operation below 10°C is prohibited under any circumstances.
If fluid temperature is below 21°C but not less than 10°C, the following
emergency procedure may be implemented:
Turn the HP relief valve screw adjustment to the minimum pressure
position and start heater and one pump. Turn the adjustment screw in to
maintain 3.5MPa discharge pressure. Operate the pump for a period of
time, and when the temperature increases to 15.6°C, increases pressure
gradually to 7.1MPa. In order to increases the rate of temperature rises,
the second pump may be started to increase the rate of heating.
CAUTION
/f pump noise and vibration level increase considerably,
reduce discharge pressure by reducing the relief valve
setting.
Once the fluid temperature reaches 21°C the stand-by pump may be shut
down and the relief valve can be reset to the original setting. See
transitive diagram “Turbine control settings” for this setting.
To reset relief valve
4k Reset relief valve to the original setting.
%& Lock the adjustment screws.
NOTE
The above procedure may be used only under emergency
conditions. Start-ups under these conditions are not
recommended.
Once either pump was running, it must be stopped manually by turning
its control switch to the “Off” position. The control switches are spring
loaded to return to the “Auto” position to place the pump once again i) Shanghai Turbine Co. Index No.; 71.K156-7E0
under control of the pressure switch. There is a solenoid valve and a
manual valve that are used to test the stopped standby pump by release
the oil pressure on pressure switch.
The fluid pumps take suction from the bottom of reservoir through a
suction strainer. The fluid is then discharged to a control block on the top
of the reservoir, where it passes through the 3-micron cartridge filters.
Connected across the filter is a differential pressure switch, which
actuated means the filter becomes dirty.
CAUTION
Once the filter differential pressure switch is actuated,
immediate step must be taken to change the contaminated
filter cartridges.
If the header pressure of main pipe decrease to 10.7~11.8, a pressure
switch will be turned on and send an alarm. And the standby pump will
start when the pressure decrease to 10.4~11.1.
After filter, fluid passes through a check valve and a relief valve. Relief
valve, which common to both the NO.1 and NO.2 pumps, protects the
system against excess pressure. The relief valve drains the excess back to
the reservoir if the pressure increases to 16.2MPa.
Above the high pressure accumulators have the leather bag charged with
dry nitrogen gas at a pressure of 9.3MPa. The system fluid pressure is
stored on the outside of the leather bag for normal or instantaneous
system fluid demands. This gas pressure should be checked periodically
and recharged if necessary. Checking the gas pressure in each
accumulator should be done individually by following the special
instructions included in this leaflet under “accumulator recharging”
instructions. The gas pressure may be read on the gauge mounted on the
top of the accumulator or via measure tool. Since the temperature
surrounding the gas will affect this pressure, pressure checks should be
made after the surrounding temperature is stabilized. 14y
eS Shanghai Turbine Co. Index No.: 71.K1S6-7EO1
Connected in the drain system are the low pressure accumulators, The gas
charge pressure in these accumulators should be checked and recharged if
necessary by following the special instructions included in this
description under “accumulator recharging” instruction.
The water to the cooler should be regulated to maintain a system fluid
temperature of 35°C to 45°C. Cooling water flow must be regulated
manually or by solenoid which controlled through temperature
automatically in order to maintain the fluid temperature within the range
mentioned above. A digital temperature meter, on the EH fluid reservoir
terminal box, constantly indicates the fluid temperature in the reservoir.
The filtering circulating system is used to improve the condition of the
fluid (maintains neutralization, remove moisture. etc.). Start circulating
pump, the fluid passes through polishing filter or drain strainer and
returns to reservoir. The polishing filter should be operated for 8 hours
constantly per week during the first month when turbine goes into
operation. Thereafter, analysis according to the fluid contaminant and
chemical (acidity content), and operate polishing filter if necessary.
Analysis should be in accordance with rules of “care, handling, and
application of control system fluid”.
To further protect against fluid contamination, magnetic rods are installed
in the top of the reservoir. These rods should be removed periodically and
cleaned. During the time the rods are out of the reservoir, the open port
they leave should be adequately covered to prevent contaminants from
entering the reservoir.
Adequate fluid should be maintained in the reservoir so that with the unit
in full operation, the fluid level is at the normal operating level. If
additional fluid is required, it is to be added in accordance with the “care,
handling, and application of control system fluid” instruction. The
reservoir capacity is 200 gallon
a 7.94
> Shanghai Turbine Co. Index No.: 71.K136-7EO!
4. EH Actuator and Emergency Protect System
4.1 Principle of System
Refer to Fig 2-2 to get the basic principle of the system
4.1.1 Actuator
There are three pipes between each servomotor and system. One is for
transporting high pressure fluid that is the driving power of the
servomotor, which has a stop valve at the entry. If components on the
servomotor need online replacing, the stop valve will closed and the
pump needs no stop. A drain pipe of servomotor connects to drain header.
A non-return valve, which avoids the leakage of return fluid when online
repairing, is equiped. A safety header with a non-return valve can separate
the servomotor without affect when it releases the safe pressure to stop
the servomotor quickly. The safety header of throttle valve actuator (TV)
and reheat stop valve actuators will be connected to header of emergency
(AST). And the safety header of governor valve (GV) and intercept valve
(IV) actuators should be connected to OPC header. The headers of AST
and OPC link to emergency trip control block, in which there are two
parallel non-return valves, which let the fluid can flow to AST from OPC
but closed with the inverse direction, between header of AST and OPC.
This can only release the OPC pressure but keep the AST pressure when
overspeed protection. And OPC pressure automatically released without
relevant OPC solenoid valve when releasing AST pressure.
The servomotor, which is shown in Fig 2-2, are opened via pressure and
closed by spring force. The servomotor of RSV is an on/off actuator, and
the others are all adjustable.
After turbine latch and resetting, high pressure fluid flows into the high
pressure part of the cylinder, which is connected the high pressure part of
unloading valve, via stop valve and throttling orifice of the RSV. The high
pressure fluid flows to AST header, via throttling orifice that is on the
2 eS Shanghai Turbine Co. Index No.: 71.K156-7E01
unloading valve and non-return valve, to open RSV by the increasing
pressure approaching to HP pressure.
There are three ways to close the RSV. First, you can release the pressure
of AST (equal to turbine stop). The second way is open the overflow
valve by loosing the pressure adjusting handle of unloading valve. In this
way, the other servomotors will not be affected because the AST
non-return valve keeps the pressure of AST header. So it’s necessary in
handle and servomotor test. The last way, which has the same effect of
loosing the pressure adjusting handle of unloading valve, is to make the
test solenoid energized. It can be carried out in test of remote control
handle.
Fig 2-2 shows TV operation principle. HP flows to servo valve via stop
valve and filter, and it also flows to a two-position three-way solenoid
valve via throttling orifice to establish the AST pressure. Servo valve, one
of whose outlet is blocked when it used as a single-side servomotor, is
equal to a three-position three-way solenoid valve, although it is a
three-position four-way valve. It is controlled by electrical signal of the
servo amplifier. The servo valve equals to a stop valve and the flow is
blocked to keep the statues of servomotor, when the input current is zero.
If it is energized, the high pressure fluid connects to hydraulic cylinder
and the flows to unloading valve. Solenoid valve 20/TV is the same with
RSV test valve and it is used as a direction controller. AST inlet and
outlet are connected when it is not energized. The outlet and return flow
is connected when it is energized, and the inlet is blocked. The 20/AST
and diaphragm valve will close when the unit is latched, so the unloading
valve is closed and the piston of hydraulic cylinder move to the top
(move downward when it is energized by inverse current). The pulling
servomotors are applied if the piston rod directly connects to valve rod.
‘And the servomotors, which applies on RSV, are called pushing
servomotor. The LVDT (linear variable differential transformer) is an
electromechanical transducer which produces an electrical output signal
proportional to the position of actuator. It consists of three coils
distributed round coil form. The alternating current that is 1kHz and 18V
AC is in the primal coil.
2B S Shanghai Turbine Co. Index No.: 71.K156-7EO1
a4y
Arod shaped magnetic, which set in coils assembly axial orientation and
form a passage connected into magnetic line of force, core fixed actuator
connecting rod. Median coil is primary and is energized alternating
current. So that, voltage will be inducted in the outside two coils which
are secondary coils and in series oppositely, therefore, voltage phase of
the secondary coils is converse and the net output of the transmitter is the
difference of these two voltages. The iron core is located in medial
position and its output is null, it is called zero position. Zero position is
the mid-point of actuator mechanical stroke. The output of LVDT is
alternating signal, which must be rectified by a modem in order to
summaries with actuator position signal required from DEH. The
command voltage of DEH and feedback voltage of LVDT will be
compared and send to servo amplifier. If the feedback voltage of LVDT is
lower than DEH command voltage, the servo amplifier will give the plus
current to move the piston upwards until the feedback voltage is equal to
DEH command voltage.
The operation principle of GV is similar with TV, and the only difference
is that the AST header to TV and the OPC header to GV. The unloading
valve of GV is the same with RSV’s,
The operation principle of IV is similar with GY, the only difference is
the unloading valve of IV is the same with TV.
4.1.2 Emergency Trip Control Unit
The main components of emergency trip control unit are the two OPC
solenoid valves, four AST solenoids, and two check valves.
Two OPC solenoids (20/OPC) are responsive to OPC signal. In the event
of a complete loss of load (over 30%) or if the unit should overspeed to
103% of rated speed, the DEH will give impulse signals to solenoid valve.
So, all the OPC fluid in the governor valve actuator will be released and
the governor valve will close quickly.
The check valve will hold the AST fluid pressure and make throttle valve
open when OPC pressure is released
4 S Shanghai Turbine Co. Index No.: 71.K156-7EOL
When the OPC signal comes from DEH, the OPC solenoids act and all
GV and IV will close. Turbine speed will decrease after remainder steam
inflates in the turbine. When turbine speed decrease a little the OPC
solenoid power will cut off and the solenoid closed. DEH controller uses
GV to adjust turbine speed and make it near synchronous speed. And the
IV will open with a controlled speed. Then, unit synchrony and load on in
order to prevent turbine cooled rapidly.
Two OPC solenoids are provided in system as redundant protection and
prevent accident occur when one solenoid lose effectiveness.
The control block is internally separated into two channels. Channel 1
consists of 20-1/AST and 20-3/AST, and channel 2 consists of 20-2/AST
and 20-4/AST. Each channel is kept energized from separate relay in the
emergency trip system (ETS) cabinet. The purpose of the ETS is to trip
the unit by opening all of the AST solenoids when sensors indicate that a
turbine variable is at a trip level. The system is designed to minimize the
chance of a malfunction due to a single component failure. This is the
reason for the two identical independent channels as previously note
above. Each channel has its own relays and power supplies and monitors
all of the turbine trip variables. The operation of both channels is required
to trip the turbine. If a trip contingency should occur, at least one AST
valve in each channel must be functional to trip the turbine. Each channel
can be tested separately while the turbine is still on the line without
causing or preventing a valid trip. During testing the channels are isolated
electrically so that only one channel can be tested at same time.
4.1.3 EH Pressure Low Testing Block
This block is the sampling source of EH pressure low switch. And the
pressure is shown on pressure gauge.
The EH high pressure fluid is imported from inlet and becomes two
parallel pipelines, which link to pressure gauge and switch after throttling
orifice, after it cross the inlet stop valve.
The two solenoids are interlocked when testing, so they will not open in) Shanghai Turbine Co. Index No: 71,K1S6-7E01
simultaneously. And it should be noticed that the two hand control valves
can not simultaneously open when starting the turbine to avoid trip.
The throttling orifice will not affect the pressure except in testing. And
the pressure gauge and pressure switch measure the system pressure.
4.1.4 Diaphragm Valve
Diaphragm valve is the bridge between low pressure oil emergency
protection system and EH system. Its inlet connects to AST header and
outlet connects to drain. It is closed by the low safety oil pressure and
opened by spring force. The trip signal of low pressure oil emergency
protection system can be sent to EH system by the usage of diaphragm
valve.
4.1.5 Air Pilot Valve
Air Pilot valve is the bridge between extraction non-return valve and EH
system. All the extraction non-return valves, whose compress air is
controlled by air pilot valve, are pneumatic. The air pilot valve is opened
by OPC pressure and closed by spring force. The air pilot valve is opened
by OPC pressure to send the compress air to the extraction non-return
valve which is controlled by solenoid valve, when the unit operates in
normal condition. The air pilot valve is closed by spring force to close the
compress air and open the air outlet, and the extraction non-return valves
are all closed.
4.2. System Equipments
4.2.1 Throttle Valve Actuator
The throttle valve will be controlled by throttle valve actuator
(TV)(Fig3-1). Its piston rod is connected to the throttle valve rod directly.
It is so arranged that outward movement opens the valve. The actuator is
single acting and provides the force for opening the valve and closing
spring provide the force to close the valve.
6 S Shanghai Turbine Co. Index No.: 71.K156-7EO1
97.4.)
(ety
. ft
ZZ
Fig.3-1 TV actuator
The main components of the actuator are hydraulic cylinder, control
block, electro hydraulic servo valve, relief valve, LVDT (linear variable
differential transformer), shutoff valve, two check valves, filter and
throttling orifice board.
The designing of diameter of the cylinder bases on the required spring
force and open force of valve. And its stroke is longer than steam valve.
The control block is the place to install and connect all the components.
Since the hydraulic cylinder diameter of TV is too big to close quickly, its
unloading valve structure is specifically produced, As shown in Fig 3-2,
the unloading valve body will be up to open by spring force when the
OPC pressure is released. When OPC pressure increasing, the pressure
a AAD
S Shanghai Turbine Co. Index No.: 71.K156-7E01
will act on the top of body in a small cylinder to push it downward until
the up seal ring is sealed (at that time, the down seal ring should remain
some clearance because it is difficulty to make both seal ring sealed at
same time in machining, on the other hand, the clearance in the down seal
ring can be used to discharge the pressure from HP cylinder to prevent the
valve body is moved up to make up seal ring couldn’t seal totally), then
OPC pressure fluid can flow into large chamber through orifice to force
valve body move down further until the clearance in down seal ring is
eliminated.
check valv
to AST
header
Fie 12 chm wee
Stop valve is used to cutoff the high pressure fluid to flow into
servomotor cylinder while maintenance the servomotor online.
Two check valves are on the drain header and AST header respectively.
The one that on the drain is used to prevent drain fluid flow back from the
pressurized drain header during maintenance on the actuator. Another
check valve is used in the AST header, with it permitted to close of any
actuator without affecting the position of other actuators wherever for test
or maintenance.
All high pressure fluid passes through the 3-micron filter. This ensures
clean fluid at all times for the operation of the servo valve. The filter is
designed as a metal mesh and should be replaced at least once a year. It
28 S Shanghai Turbine Co. Index No.: 71.K156-7EO1
may be cleaned and reused if special cleaning equipment is used.
The structure of electro hydraulic servo valve is shown in Fig 3-3, and
Fig 3-4 shows its principle.
electric
/ plug
hydraulic Seal ring
amplifier
otdle
Fig.3-3 BH servo valve
magnetic loop
soft tube
flaper
coil lever -
inject hole E = N
Saal x) _—~ feedback
WANs ezzrar
slide vlv
orifice
inlet
filter orifice
drain HP
Fig. 3-4 principle of servo vlv
The servo valve consists of an electrical torque motor with permanent
magnet and two stages of hydraulic power amplification with mechanical
feedback. The first stage consists of a dual nozzle and single flapper. The
flapper is attached to the mid point of the armature and passes between
the two nozzles, creating two variable orifices between the nozzle tips
and the flapper. The pressure controlled by the flapper and nozzle is fed
»
9.4.9) S Shanghai Turbine Co. Index No.: 71.K156-7E01
to the ends of the second stage spool. The second stage spool is a
four-way sliding spool in which output flow from the valve, at a constant
pressure drop, is proportional to the spool displacement from null. A
cantilever feedback spring is fixed to the flapper and engages a slot in the
center of the spool. In the null position, the flapper imposes an equal
restriction to flow through both nozzles and no differential pressure exists
to cause spool displacement. Upon application of a signal to the torque
motor, the armature and flapper are displaced toward one nozzle or the
other, creating a pressure differential across the spool resulting in spool
displacement. The spool will continue to move until the counteracting
force transmitted through the feedback spring equals the force developed
by the torque motor. At this point, the flapper has returned to neutral and
the pressure differential across the spool is zero. The spool remains in its
new position until another differential current is applied.
The LVDT is an electromechanical transducer which produces an
electrical output signal proportional to the position of actuator. It consists
of three coils distributed round coil form. A rod shaped magnetic, which
set in coils assembly axial orientation and form a passage connected into
magnetic line of force, core fixed actuator connecting rod. Median coil is
primary and is energized alternating current. So that, voltage will be
inducted in the outside two secondary coils and in series oppositely,
therefore, voltage phase of the secondary coils is converse and the net
output of the transmitter is the difference of these two voltages. The iron
core is located in medial position and its output is null, it is called zero
position. Zero position is the mid-point of actuator mechanical travel. The
output of LVDT is alternating signal, which must be rectified by a modem
in order to summaries with actuator position signal required from DEH.
The solenoid and throttling orifice have two functions. First, when the
solenoid valve is not energized, the high pressure fluid flows to AST
header and unloading valve, and it has nothing to do with the status of
electro hydraulic servo valve. Second, the AST pressure will be released
and servomotor will be closed quickly when solenoid valve is energized,
but this takes no effects on AST header pressure because of the non-return
valve on AST.
n.4y S Shanghai Turbine Co. Index. No,: 71.K156-7EO1
4.2.2 Governor Valve Actuator (GV)
The governor valve is controlled by GV actuator (Fig 3-5). The actuator
is single action, dragging type, and it uses high pressure fluid to open the
governor valve quickly and accurately to the position corresponds with
signal from electrical controller. The actuator is located on the upward
side of GV spring box, and its piston rod is connected with GV rod
through coupling. This rod upward movement opens and downward
movement closes. Heavy-duty spring makes the GV maintain close
position, and actuator can overcome the spring force to push GV up to
position required.
mid
Fig. 3-5 GV actuator
The main components functions of the actuator are similar with the
throttle valve actuator, the only differences are: the stroke is shorter, the
unloading valve is purchased in market and controlled by OPC pressure.
The relief valves of GV and EH reservoir are the same type, and it is used
as the unloading valve on actuator only. It is consist of main valve body S Shanghai Turbine Co. Index No.: 71.K156-7EO1
and pilot valve, which is controlled by OPC pressure. If releasing OPC
pressure, the actuator will be closed quickly to have nothing to do with
electronic system. The unloading valve will return all the HP fluid to
drain header and up chamber of actuator cylinder, so the drain header will
not be overload when actuator is closed quickly.
Unloading valve is connected with pipeline of actuator. The top of slide
valve of it is pressurized by OPC and the bottom of it is by HP. They are
balance in normal and the slide valve will be closed according to spring
action. The high pressure will open slide valve to put all HP fluid into
drain header when OPC pressure is released.
Unloading valve also can be used to close the actuator manually, and the
isolating valve should be closed before it to avoid too much flow
releasing. Turn the handle screw out, the actuator will be closed quickly
when the handle screw reach some special position. When reopen the
actuator, turn the handle screw in totally then open the isolating valve
slowly, the actuator will be open.
4.2.3. Reheat Stop Valve actuator (RSV)
fil=—
ele
2
Ue
Fig. 3-6 RSV actuator
The RSV controlled by servomotor (Fig. 3-6), which is mounted on the S Shanghai Turbine Co. Index No.: 71.K156-7E01
7.4.7)
RSV spring-box, and the piston rods of them are directly connected. The
piston moves up to open the valve and moves down to close it. The valve
only can full open or full close. It is single acting and the force for
opening the valve is applied by fluid pressure and springs provide the
force to close the valve.
The main components are consist of cylinder, control block, solenoid
valve, relief valve, isolating valve and two check valves, etc.
Solenoid valve, which is a two position two way valve, is used to
remotely close the valve to testing the valve rod movement periodically.
The AST pressure of RSV will be released quickly when the solenoid is
energized and then the unloading valve will act to close the RSV. After
cut off the current on solenoid, the RSV will reopen
Notice: When the trip signal is present, the servomotor will be closed.
This has nothing to do with the status of solenoid valve.
4.2.4 Intercept Valve actuator (IV)
Fig. 3-7 IV actuator S Shanghai Turbine Co. Index No.: 71.K156-7E01
‘The actuator (Fig. 3-7), whose piston rod directly connects to [V's rod, is
on the top of IV. It is opened by hydraulic pressure and closed by spring
force. The piston moves up to open the valve.
The structure and main components of IV is the same with TV. And the
only difference is that OPC pressure will act on the dump valve, but not
AST.
4.2.5 Emergency Trip Control Block
The emergency trip control block, which is illustrated in Figure 3-8, is
mounted by side of the turbine fore-bearing pedestal. Its main function is
to provide an interface between the emergency trip system cabinet and the
AST fluid header, and between DEH and OPC fluid header.
to HP header
with orifice
ope block
ieataaan to AST header
‘to HP header
with orifice
/ sty
<0 br. Gy colencia
to OPC header” a: air
pilateslve to AST header
Fig, 3-8 emergency trip block
The main components are the control block, two OPC (overspeed protect
uM
"4 in) Shanghai Turbine Co. Index No. 71.K156-7E01
controller) solenoid valves, four AST (auto stop trip) solenoids, and two
check valves. All the solenoids are installed on the control block, which
provides the necessary internally machine passage in order to connect the
various components. The ports of openings or drilled passages, which
were necessary to connect internal holes are permanently plugged. Each
of these plugs has an “O” ring for sealing purposes. In all case, new “O”
ring should be used when the plug is replaced.
WB
OPC principle
Fig. 3-9 OPC, AST solenoid
The solenoids are illustrated in Figure 3-9. The OPC solenoids differ from
AST solenoids in that the “OPC” are piloted internally fluid supply,
normally closed, DC power-off close while the “AST” solenoids are
piloted externally from the HP header, normally open, AC power-off open.
Function and number on Figure 2-2 identify each of the solenoids, AST
solenoids are 63-1~4/AST, and OPC solenoids are 63-1~2/OPC.
Four AST solenoids (20/AST) are two stage action valves with the first
stage normally energized closed. The orifice fluid enters the second valve.
The solenoid valve, being energized closed blocks the path of the fluid to
drain. It will block the fluid flow of the AST header to drain and safe
fluid pressure can be build up under the various valve actuators. When the
solenoid opens, the high-pressure fluid providing the unbalanced force
33 a) Shanghai Turbine Co. Index No.: 71.K156-7EO1
behind the second stage poppet valve is released to drain and the poppet
valve opens.
4.2.6 Test block of low EH pressure
solenoid
press gauge press gauge
shutoff vlv
test vlv
channel 1 t) channel 2
Fig. 3-10 low BH press test block
As shown in Fig 3-10, The test block of low EH pressure is the local
equipment of ETS channel experiment, as part of safe equipment. It has
the control block, one inlet needle valve, two outlet needle valves, two
solenoid valves, two pressure gauge and pipe conjunction, etc. There are
two orifices in block with channels and two tube connectors to pressure
gauges. The detail refer to “4.5 Integrative Safety Device”.
4.2.7 Diaphragm valve
The diaphragm valve, which is shown on Figure 3-11, is associated with
the lubricating oil and EH fluid system. The function of the valve is trip
turbine through diaphragm valve send the AST fluid to drain when
o4n 7.4.4
S Shanghai Turbine Co. Index. No.: 71-K156-7E01
overspeed trip lubricating oil pressure decreases to a impermissible level.
See EH fluid system, lubricating oil system transitive diagram and Figure
2-2,
mechanical & manual trip header
‘diaphram seat
push lever
‘adjusting screw
DP ——_
EAC header
‘head of valve
Pig. 3-11 diaphram valve
The diaphragm valve is mounted at the right side of the front bearing
housing. When turbine operated normally, overspeed trip lubricating oil
pressure enters the chamber at the upside of the diaphragm mounted in
the valve cover. The pressure that acts on the diaphragm overcomes the
force of spring, blocks up the AST header drain passage and makes EH
system function put into work. Pay attention with the direction of valve
while installation, if the direction is reverse, the acting pressure will be
changed. Adjusting the reset force of springs, the acting pressure can be
changed.
The single or cooperative actions of overspeed trip mechanism or manual S Shanghai Turbine Co. Index No.: 71.K1S6-7E01
overspeed test lever will cause a loss or decay of the lubricating oil
pressure and allow the compression spring to open the valve and release
the AST fluid to drain. The loss of the AST fluid will cause all steam inlet
valves and extraction valves to close and all bypass valves and drain
valves to open.
4.2.8 Air pilot valve
ee ene
to extraction check vlv | L cylinder
TD otis —|
oar { °! Q
i a eee from OPC
beck
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