DEH control system overview 71.D195-01E调节保安系统说明-英文
DEH control system overview 71.D195-01E调节保安系统说明-英文
DEH control system overview 71.D195-01E调节保安系统说明-英文
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Document No.:71.D195-01E
Factor of
Units Used Transformation Units Available
1.00E-03 liter(L)
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
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Document No.:71.D195-01E
CONTENT
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subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use
otherwise without written consent.
Prepared:Man Can 2020.04
Control System
2020.04
Overview Checked:Wei Yuan
IC.Z10.60001.01-E00 Reviewed:
Approved:Chidingnan 2020.04
CONTENTS
CONTROL SYSTEM OVERVIEW ..................................................................1
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Turbine speed and load are determined by adjusting the position of emergency stop
valve and control valve. DEH send the valve position signal to servo electro-hydraulic
actuator, then control the steam intake by servo electro-hydraulic actuator. DEH
receive the feedback signal (speed, load, main steam pressure and so on.) and operator
command, then derive the flow rate to servo electro-hydraulic actuator. DEH is
mainly consist of DEH cabinet, human machine interface, servo electro-hydraulic
actuator and so on.
The digital Steam Turbine Controller (STC) regulates the steam flow that is passed
through the control valves to the turbine. Depending on the operational requirements,
the steam turbine can be operated under speed, load, or pressure control.
The load controller controls the turbine load with the allowable variable load
gradient. The maximum variable load factor depends not only on the boiler's capacity,
but also on the turbine thermal stress evaluator (TSE). Turbine control valves are
throttled by the pressure limit controller when boiler fault or the frequently load
change, thus main steam pressure surges.
The load can be set either manually by the operator using the manual setpoint, or
automatically by an external setpoint issued by a superordinate unit coordinator or a
load dispatch controller. In order to improve the dynamic stability, an adjustable
proportion of the load setpoint is directly carried to the output of the load controller.
As long as the generator is isolated from the grid, the controller acts as a speed
controller. With the synchronization being performed, i.e. main breaker ON (MBO),
the parameters are switched over and the controller becomes a load controller.
If, during start-up, the acceleration of the turbine generator tends to become too low
in the critical speed ranges, the speed-gradient monitoring will respond, and
automatically return the turbine generator to a lower holding speed (warm-up speed).
An automatic synchronizer automatically matches the turbine speed with the grid
frequency(The synchronizer is not part of the turbine generator I&C scope of supply).
The speed controller acts as a P-controller
During the shutdown of the turbine generator, the load setpoint is switched off
when the generator is separated from the grid, and the control returns automatically to
P-speed control.
While the unit is carrying load, it is possible to switch from load control operation
to speed control operation. The corresponding set points are tracked automatically
according to the actual values to ensure a bumpless transfer.
During synchronization.
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The limit frequency influence: The limit frequency influence ensures that the
turbine generator remains frequency-controlled within a predefined dead band when
operating in a grid with a varying frequency (e.g. island grid). The limit frequency
influence is always effective and cannot be deactivated.
The frequency influence is to support the grid frequency. If the grid frequency is
too low, the power generated is increased. If the grid frequency is too high, the power
generated is reduced. The frequency influence can be activated and deactivated by the
OM system.
The limit pressure mode is actived in load operation. The limit pressure controller
itself acts as a limit controller; it supports the boiler pressure control during
fault-related HP pressure drops. If the HP pressure falls below an adjustable limit
value, e.g. 10 bar below the nominal operating pressure, the turbine control valves
will throttle to counteract any further HP pressure reduction. In this way, the pressure
will recover to nominal as quickly as possible.
When switching over from limit pressure mode to initial pressure mode, the speed /
load controller is replaced by the pressure controller. In initial pressure mode, the HP
pressure is maintained at a specified value by the turbine control valves. load changes
in the steam generator will result in corresponding changes of the valve position.
A valve position setpoint limitation is provided for each valve position controller.
This permits the position of each control valve to be changed individually within the
range below its setpoint. This can be by manual intervention from the control room or
by intervention from the automatic turbine tester (ATT) in conjunction with the valve
testing.
The start-up device provides an analog signal to gate in a MIN selection function
with the outputs from the speed/load controller and main steam pressure controller.
before turbine start-up.
While the turbine is being started-up, the position of the start-up device is raised.
This in turn causes the speed controller to assume the control. When the turbine has
reached its nominal speed and the generator has been synchronized, the start-up
device will be placed in its 100% position, so that the master controller signals will no
longer be limited.
The turbine stress evaluator (TSE) functions are calculating and monitoring the
operational heat stresses of the turbine during every operational phase. The TSE
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The steam turbine can be started up safely and within an optimum time with the aid
of an automatic startup system. This meets economic requirements which prescribe
the shortest possible startup time and high plant availability.
The task of the turbine master control program is to bring the turbine and all the
auxiliary systems required for startup into a state which allows safe and reliable
transition of the steam turbine from the shutdown state to power operation.
(3) Control fluid supply for turbine valves and brings the steam turbine and the
bypass system into a state which allows turning gear operation of the steam turbine
and bypass operation.
After the auxiliary systems have been started up and brought into a steady state,
which can either be achieved using "Automatic startup control for auxiliary systems"
or by starting the auxiliary systems manually, the "Automatic startup control for
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After Turbine changed over to load operation, the auto startup procedure is
completed.
The automatic startup includes the sequence program from turbine warm up to load
on the grid. During shutdown process, the program gives the set up speed and
determines the rate of speed and load based on the calculated thermal stresses of the
valve, casing and shaft.
Meanwhile, during the process of startup and shutdown, the turbine master control
program controls the drain valve, HP exhaust none return valve, HP non-return valve,
LP water injection system and seal steam system by turbine operation status.
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IC.Z10.60104.01-E00 Reviewed:
CONTENTS
DEH GRAPHIC AND OPERATION SPECIFICATION ................................1
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1. Turbine Controller
Turbine controller graphic contains three primary modules: S / UP DEVICE, SPD / LOAD
CTRL and HP PRES CTRL. These modules are applied to generate the flow rate from three
calculation loops. The overall flow rate is derived by the low selector function. After modified by
both HP EXH TEMP CTRL and HP BLAD PRES CTRL functions, the POSN LIMIT function
separate the final overall flow rate to 5 independent branches. Each dominates the corresponding
valve position.
TAB acts on the turbine start-up phase only. The command output value (0~100%) is
calculated automatically. When TAB value reaches a certain limit, it stops changing and waits for
essential action. After receiving a valid feedback, TAB keeps working again. Under some special
conditions, TAB is able to switch to manual input to modify the overall flow rate value. TAB is
primly used for equipment reset, inspection and so on.
SPEED SETP configure is used to set turbine speed, the value can be generated by closed-loop
controller while turbine start-up. After warm-up phase the operator should confirm to ramp up
turbine speed to nominal synchronize speed. Operators are able to input the target speed value
only if the speed set point manual function is unlocked.
Notes:
Nominal turning gear speed: 50-60 rev/min
Nominal warm up speed: 360 rev/min
Nominal synchronize speed: 3009 rev/min
The turbine speed (ST SPEED) ramps up to the target speed at a rate limited which determined
by the TSE. TSE INFL function requires to be active manually before starting-up process. If this
function fails to work, the start-up procedure is forbidden while TSE fault shows up. When the
deviation of speed set point and the actual speed is too high, the set point function (STOP) is
locked, and the set value decrease automatically. If the acceleration is too low (ACCL <MIN),
the speed tracking mode is on. The target speed is going to decrease at the rate of 60r / min until
the manual reset (RELS SETP-CTRL).
LOAD SETP configuration is to set the turbine load, the initial value is automatically
generated as minimum set value after synchronization (the initial load is generally 15% of the
nominal load, which can also be modified in logic diagram). During load ramping up, the LOAD
GRAD SETP is affected by both TSE and manual input. When EXT LOAD SP mode is ON, the
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IC.Z10.60104.01-E00 Page 2 of 11
target load value receive the CCS external load communication (EXTERN LOAD SETP). The
delayed load set value is also adjust by maximum load set point (MAX LOAD SETP).
The SPD/LOAD CTRL derive the overall flow rate by input the deviation of actual speed and
speed set point or the actual load and load set point. Once the primary frequency modulation
function (FREQU INFL) is active by the operator, the according value is displayed up on the
button.
DEH receives pressure set point (HP SETP) from DCS and controlls the main steam pressure.
The LIMIT PRES mode and the INITIAL PRES mode are selected by the operator. During the
start-up process, it should be in the limited pressure mode; after turbine on load, due to pressure
fluctuation at the moment of bypass shutting down, HP SETP should be switch to the INITIAL
PRES mode. Deviation of the actual pressure value and the pressure set point is sent to the
pressure controller for closed-loop operation. When the deviation is greater than 15 bar which is
regard as the critical value, the turbine switch to pressure control from load control.
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When the steam quality meet the requirement, the operator confirms and starts STM PURITY
function at SGC step 11. If the steam quality does not satisfy the requirement in step 11 and 50%
of HP CV temperature is lower than 350 Celsius degrees, the start-up sequence pauses till decent
steam quality, then skip back to step 11.
After turbine warm-up phase, the operator should set the nominal speed by active REL
NOMINAL SPEED function; the latch procedure (RESET O / S TRIP) is automatically
completed by TAB. The high-temperature controller and high-pressure blade controller is active
automatically.
The valve position limit is set manually, the range is from -5% to 105%, operators set the
value for all valves as 105% before start-up process;
As long as the high-exhaust temperature hits the limit value, the high-pressure cylinder stops
taking in more steam. When the load is more than 100MW and the high-pressure exhaust
temperature drops to nominal value, SGC OPEN HP-TURB is active. If the temperature
continues to rise to trip value, the unit shuts down.
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IC.Z10.60104.01-E00 Page 4 of 11
LAW_GPLSPQU
CONTORLLER NOT OK
HATRIE
NTRIE
PRIE
FDPRIE
TABIE
STPSWF
SPSWF
HBDRIE
WTS
NTGRKL
NSNF
DNTGR
DCS REQ INET MODE
DCS REQ REMOTE LOAD CTRL
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3. Warm Up Valves/TSE
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Stress calculation and X criterion graphic is used to monitor the temperature of cylinder, rotor,
valve and other components of the steam turbine during start-up process. The way is to record
the deviation of the corresponding components temperature then derive thermal stress by
physical equation. The thermal stress should be maintained in an allowable range. Compare the
measured temperature difference and the allowable temperature difference to gain the allowable
temperature rise rate. All measured temperature and calculated temperature margin are indicated
and recorded, the temperature margin determines the speed rate of change and the load rate of
change. In the lower right corner of the screen, "TSE-MARGINS" influences the minimum stress
margin of five parts of the thermal stress, they are ESV, CV, high pressure cylinder, high pressure
rotor and medium pressure rotor. If any part of the calculated stress margin is not satisfied during
the start-up process, a negative stress occurs, then the fault alarm is triggered.
X-Criterion (X-CRIT), a variable temperature standard, is used to ensure that the main steam
and reheat steam parameters meet the requirements during the start-up process. As a condition of
turbine start-up, the program decides whether the unit can endure the thermal stress. The
X-Criterion is used to determine if the turbine start-up process is able to carry on. When the X
criterion is satisfied, the rectangle on the top of the bar turns "red" and "Green" indicates X
criterion unsatisfied. X1, X2 are used before opening the main steam door; X4, X5, X6 are used
before the steam turbine turned; X7A, X7B are used before the nominal speed released; X8 is
used before the unit synchronized.
This is the list of abbreviations appeared in this graphic:
MIN UPPER TEMP MARGIN
MIN LOWER TEMP MARGIN
HP ESV
HP CV
HP CSG
HPS
IPS
OPT HP ST TEMP
OPT IP ST TEMP
Z-CRIT
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6. First Out
When trip occurs, the turbine first out graphic is used for instantaneously recording the first
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protection point so as to analyze the trip reason. Green Square on the graph indicates normal
status on, red indicates the trip action on.
7. Turbine Overview
Turbine overview graphic is primarily used for monitoring the steam turbine valves status,
solenoid valve status and critical parameters value of the intake and exhaust. Each fast closing
solenoid adopt double redundant, charged latch, loss of power protection design. The direction
control valve losses power during operation. When it is charged, the EH oil rapidly flows to the
drain back tank. The green sign of the valve represents valve off-mode and the red sign of the
valve represents valve on-mode; Hydraulic servo-motor lacquer tray monitor (LEAKAGE)
Green indicates normal mode, red indicates alarm status. In the process of starting the steam
turbine, the solenoid valves are automatically latched by the TAB without manual work. Low
Pressure Cylinder Spray Solenoid Valves (CNDS) operate at low temperatures as a cooler. High
exhaust ventilation valve automatically opens after trip.
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Book : Page 19 of 152
Prepared:Man Can 2020.04
Automatic Startup
2020.04
Control For Steam
Turbine And Auxiliary Checked:Wei Yuan
Systems
Reviewed:Li Gang 2020.04
IC.Z10.62102.01-E00 Reviewed:
Approved:Chi Dingnan 2020.04
CONTENTS
1. Introduction ..................................................................................................... 1
2.2 Criteria Effective Prior to Opening of HP & IP Steam Control Valves ... 2
2.3 Criteria Effective Prior to Acceleration to Rated Speed and for Loading
3. Design ............................................................................................................... 3
............................................................................................................................. 16
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Page M160 .......................................................................................................... 29
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1. Introduction
The steam turbine can be started up safely and within an optimum time with the aid of an
automatic startup system. This meets economic requirements which prescribe the shortest
possible startup time and high plant availability.
The task of the turbine master control program is to bring the turbine and all the auxiliary
systems required for startup into a state which allows safe and reliable transition of the steam
turbine from the shutdown state to power operation.
The turbine master control program comprises the following submodules:
(1) Automatic startup control for auxiliary systems:
This automatically starts up the following systems: Steam turbine turbine lube supply, Seal
steam system and evacuation pumps, Control fluid supply for turbine valves and bypass valves
and brings the steam turbine and the bypass system into a state which allows turning gear
operation of the steam turbine and bypass operation.
(2) Automatic startup control for turbine-generator
After the auxiliary systems have been started up and brought into a steady state, which can
either be achieved using "Automatic startup control for auxiliary systems" or by starting the
auxiliary systems manually, the "Automatic startup control for turbine-generator" transfers the
steam turbine from turning gear operation to power operation. The startup program is complete
as soon as the turbine controller has been changed over to load control. The automatic
SHUTDOWN program brings the turbine-generator from power operation or initial pressure
mode to a defined state in which the turbine valves are completely closed. In the course of this, it
also takes all the actions required to allow the turbine to coast down to turning gear operation.
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without violation of the set wall temperature limits.
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ϑm HPS is calculated within the TSE/TSC
ϑm HPT CSG is measured and gated with ϑm HPS in a MAX logic
Note: The throttling effects in the HP control valve are taken into consideration.
Temperature criterion X6 :ϑRH > ϑm IPTS+ X6
Task: IP turbine To avoid cooling of the turbine shaft.
Measuring point:
ϑRH - Reheat temperature directly upstream of IP steam valves
ϑm HPS is calculated within the TSE/TSC
Note: The throttling effects in the IP steam control valve are taken into consideration.
2.3 Criteria Effective Prior to Acceleration to Rated Speed and for Loading
Following Synchronization/Clutch Engagement
Temperature criterion X7 :ϑMS < ϑm HPS+ X7a
ϑMS < ϑm HPT CSG+ X7b
Task: Adequate degree of heat soak for HP turbine shaft/casing
Measuring point:
ϑMS - main steam temperature upstream of HP bypass station(s)
ϑm HPS is the calculated integral mean shaft temperature
ϑm HPT CSG is measured
Note: The criterion is interrogated at warmup speed. It ensures that the permitted thermal
stress limits are not exhausted on acceleration to rated speed.
Temperature criterion X8: ϑRH < ϑm IPS+ X8
Task: Adequate degree of heat soak for IP turbine shaft
Measuring point:
ϑRH - reheat temperature upstream of IP bypass station(s)
ϑm IPS is the calculated integral mean shaft temperature
Note: The criterion is interrogated at rated speed. It ensures that the permitted thermal stress
limits are not exhausted on synchronization and during subsequent loading.
3. Design
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Description of sheet L010
The turbine master control program forms the link to the unit control level. The "STARTUP"
and "SHUTDOWN" step programs are started by the unit control level and process the steps
described in Sections 3.1.2 "STARTUP Step Program" and 3.1.3 "SHUTDOWN Step Program".
Provision is made for manual starting of the step programs.
STARTUP step program.
The STARTUP step program obtains its enable signal from logic L040.
SHUTDOWN step program.
The SHUTDOWN program can also be started up by the protection input (logic L070).
3.1.1.2 Logic 2: Group Signal for Emergency Stop Valve (ESV) and Extraction Check Valve
(EXTN CHK-V) Position
Description of sheet L020
Signal formation: ESVs open
This signal detects whether the turbine emergency stop valves are open.
Interrogation: at least one HP STM ESV OPEN.
Interrogation: at least one IP STM ESV OPEN.
Signal formation: All ESVs closed
This signal detects whether all turbine emergency stop valves are closed.
Interrogation: All HP STM ESVs CLOSED
Interrogation: All IP STM ESVs CLOSED
Signal formation: All extraction check valves closed
This signal detects whether all extraction check valves are closed.
Interrogation: Position of all extraction check valves < 5%.
3.1.1.3 Logic 3: Checkback Signals following Execution of Step Programs
Description of sheet L030
Signal formation: Abort valve test
Command: ATT Valves ABORT
If a valve test is being performed by the automatic turbine tester, it must be aborted before the
SHUTDOWN step program can be executed. The checkback signal from the SHUTDOWN step
program is used for this purpose.
Checkback: SHUTDOWN step program RUNNING
Signal formation: Execute "STARTUP" step program
The "STARTUP" step program has been executed when
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(1) The last step of the sequence has been reached
(2) The steam turbine is in power operation. For this purpose, all the emergency stop valves
(ESV) must be open, the generator must be synchronized and the turbine controller must be
changed over from limit pressure mode to power operation.
Interrogations
Interrogation: Last step of "STARTUP" executed.
Interrogation: All ESVs open (logic L020).
Interrogation: Generator SYNCHRONIZED.
Interrogation: Turbine-generator at rated speed > 95%.
Interrogation: Turbine controller power operation IS ON.
Signal formation: Execute "SHUTDOWN" step program
The "SHUTDOWN" step program has been executed when
(1) The last step of the sequence has been reached.
(2) All the emergency stop valves are closed and the turbine-generator speed has fallen below
the critical speed band.
Interrogations
Interrogation: Last step of "SHUTDOWN" executed.
Interrogation: All ESVs closed (logic L020).
Interrogation: Turbine-generator speed < 9 rev/s.
3.1.1.4 Logic 4: Enable for "STARTUP" Step Program
Description of sheet L040
Before the "STARTUP" step program is enabled, a check is performed to ensure that turbine
shutdown was performed as specified. This is the case if the admission controller output has been
reduced to 0%.
Signal formation: Enable for "STARTUP" step program
Interrogation: Valve opening limited by speed/load controller
The speed/load controller in the turbine controller limits valve opening by setting the
speed/load setpoint to 0%. This setpoint is set to this value for the turbine controller during
shutdown or in turning gear operation. It prevents unwanted opening of the CV when increasing
the the turbine startup and lift limiter later on (see logic 9).
Interrogation: Turbine controller speed/load setpoint =0%
Bypass criterion: Emergency stop valves are open
If the turbine master control program is restarted during operation, the emergency stop valves
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are open and the limit setting for the turbine startup and lift limiter is above 62%.
Interrogation: All ESVs open (logic L020)
Interrogation: TAB > 62%
Interrogation: TAB in operation, trip solenoid valves reset and ESVs closed
The "STARTUP" step program is enabled as soon as the trip solenoid valves have been reset
with the emergency stop valves still closed.
Interrogation: TAB < 35%
Bypass criterion: Emergency stop valves are open
Interrogation: All emergency stop valves open (logic L020)
Interrogation: Turbine trip not initiated
If a turbine trip has been initiated, the SHUTDOWN program is called up after the emergency
stop valves are closed. This brings the turbine-generator into a defined state.
When a turbine trip is initiated, the turbine startup and lift limiter (TAB) is not ramped down
in the usual way. Its limit setting is abruptly set to 0%.
Interrogation: TAB = 0%
Bypass criterion: Turbine-generator speed has entered the critical speed band
Interrogation: Turbine trip NOT INITIATED
Interrogation: Automatic valve test not running (automatic turbine tester)
If the automatic turbine tester is performing a valve test, it is not possible to execute the
"STARTUP" step program.
Interrogation: ATT Valves NOT IN OPERATION
Interrogation: Electrical unit protection unfaulted (optional)
Redundant auxiliary voltage supply to electrical unit protection from batteries present. This is
a prerequisite for proper operation of the electrical unit protection system.
Interrogation: Electrical unit protection UNFAULTED.
Interrogation: Exciter not disabled (optional)
Interrogation: Exciter NOT DISABLED
Interrogation: Paralleling unit not in operation (optional)
Interrogation: Paralleling unit NOT IN OPERATION
Interrogation: Synchronizer not disabled (optional)
Interrogation: Synchronizer NOT DISABLED
Interrogation: Grid tie breaker not selected (optional)
Interrogation: Grid tie breaker NOT SELECTED
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Interrogation: Pointer set for load controller
After the generator has been synchronized, a changeover to the load controller is effected.
Interrogation: Load controller ACTIVE
Interrogation: TSE/TSC influence on STC active
Interrogation: TSE/TSC influence on STC NOT OFF
3.1.1.5 Logic 5: Faults in Steam Generator and WT Sensor
Description of sheet L050
Faults in the SG can give rise to steam parameter conflicts with criterion X4, degree of
superheat for the hot reheat steam and to an insufficient temperature margin. If a fault occurs
while the "STARTUP" step program is being executed, an appropriate alarm is displayed
provided the sequence has already opened the control valves and the turbine has been rolled off
under steam. (logic L060).
Signal formation: Steam generator fault
(1) Turbine-generator rolled off
Interrogation: Speed/load controller > 0.5 %
Interrogation: Speed setpoint defined > 6.5 rev/s
A steam generator fault is assumed in the following cases:
(2) Degree of superheat for the main steam, measured upstream of the HP steam emergency
stop valves (variable temperature criteria X4 - 15K) is too low.
Interrogation: MS superheat < X4 15K
(3) Degree of superheat for hot reheat steam is too low.
Interrogation: Hot reheat superheat upstream of IP STM ESVs (Z4 criterion) < 15K
(4) The turbine is heated on startup. Only limited initial cooling takes place during proper
operation of the plant. In any case, this will not exhaust the permitted limits for the inlet. If the
lower margin is exhausted, a steam generator-related drop in steam temperature can thus be
assumed.
Interrogation: Lower temperature margin (HP steam valve) < 0K
Signal formation: Fault due to closed HP STM ESV
An 80 s switch-on delay is defined for this criterion, so as to prevent deactivation of the SGC
in response to closure of ESVs when the automatic turbine tester is performing a valve test.
Interrogation: HP STM ESV CLOSED
Interrogation: HP STM ESV NOT OPEN
Enable: "STARTUP" step program running
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IC.Z10.62102.01-E00 Page 8 of 55
Interrogation: "STARTUP" step program running (see logic L010)
3.1.1.6 Logic 6: Stop Setpoint Control of Speed/Load Controller
Description of sheet L060
If faults occur during automatic startup, the "STARTUP" step program is stopped (automatic
control "OFF"/manual operation).
Signal formation: Fault ⇒ "STARTUP" step program: Automatic control OFF
Command: "Automatic control OFF" for "STARTUP" step program (logic L010)
Interrogation: Monitoring of speed transient
The acceleration rate (speed transient) is monitored by the turbine controller in order to ensure
as rapid as possible passage through critical speed bands. If the monitoring circuit responds, the
startup process is aborted and the step program is set to "Automatic control OFF".
Interrogation: Speed transient TOO LOW
Interrogation: Logic L070 (shutdown due to protection) NOT ON
Interrogation: Faults in Steam Generator
Interrogation: Logic L050
Interrogation: Faults in turbine controller and TSE
Fault-free operation of the turbine controller are prerequisites for automatic operation of the
turbine-generator. The sequence is therefore set to "Automatic control OFF" when
(1) The turbine controller is faulted
(2) TSE NOT O.K.
(3) The stress assessment of the steam turbine does not respond to the response of the set value
control of the steam turbine controller.
Interrogation: The turbine controller NOT OK
Interrogation: Response of steam turbine stress assessment to control of set value of steam
turbine controller TURN OFF
Interrogation: X criterion NOT OK
Interrogation: Z criterion NOT OK
Signal formation: Fault ⇒ Stop speed/load setpoint (turbine controller)
If the turbine is at rated speed, speed/load setpoint control is stopped in the turbine controller.
The duration of this signal is limited to 2s.
Command: Speed/load setpoint STOP
Interrogation: Turbine at rated speed
Interrogation: Speed > 95%
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IC.Z10.62102.01-E00 Page 9 of 55
Interrogation: Reset criteria for command "Speed/load setpoint STOP"
The load setpoint is re-enabled by the following OR-gated signals.
Interrogation: "SHUTDOWN" step program LAST STEP EXECUTED
Interrogation: Reset signal from turbine controller (pushbutton) ENABLED
3.1.1.7 Logic 7: Initiate "SHUTDOWN" program via Protection
Description of sheet L070
Signal formation: Initiate "SHUTDOWN" program via protection input, turbine trip
during execution of "STARTUP" program
If a turbine trip occurs when the turbine is being started up by the "STARTUP" step program
or during steady-state turbine operation, the "SHUTDOWN" step program is initiated via the
protection input accompanied by Automatic control ON. The initiation of the "SHUTDOWN"
program is blocked by steps 9 and 10 so that testing the trip system does not result in turbine
shutdown. The initiation signal for protection OFF is limited to a duration of 15 seconds to rule
out the presence of a static signal when the turbine is at a standstill. In addition to the turbine trip
signal, the system waits until the emergency stop valves are closed before initiating the
"SHUTDOWN" program.
Command: "Automatic control ON" for "SHUTDOWN" step program (logic L010)
Interrogation: "STARTUP" step program started
Interrogation: "STARTUP" step program started (logic L010)
Interrogation: Turbine trip initiated
Interrogation: Turbine trip INITIATED
Interrogation: Emergency stop valves closed
Interrogation: All ESVs closed (logic L020)
Signal formation: Initiate "SHUTDOWN" program via protection input, control valves
not closed before opening of ESVs
All control valves must be closed before the emergency stop valves are opened.
Command: "Protection ON command" for "SHUTDOWN" step program (logic L010)
Interrogation: Control valves not closed before opening emergency stop valves
Interrogation: TAB NOT > 62%
Interrogation: HP STM CTRL-V N.CLSD
Interrogation: IP HP STM CTRL-V N.CLSD
Interrogation: Step 15: Admission controller not in operation. The control valves are kept
closed by the speed controller
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IC.Z10.62102.01-E00 Page 10 of 55
Interrogation: Generator NOT SYNCHRONIZED
Interrogation: Turbine-generator not at rated speed < 90%
3.1.1.8 Logic 8: Close emergency stop valves if Steam Purity is Inadequate, Enable emergency
stop valves if Steam Purity is Adequate
Description of sheet L080
Steam purity - Cold start
In the case of a cold start, the emergency stop valves are opened in order to warm up the
control valves. The limit setting for the turbine startup and lift limiter is increased for this
purpose.
When the main steam pressure is under 20 bar, the difference between the saturated steam
temperature and the mean casing temperature at the control valve is so small that the emergency
stop valves remain open initially. This makes it possible to warm up the main steam line and the
valve chambers simultaneously.
The opened emergency stop valves are closed after a set delay when the main steam
pressure is over 20 bar. When the pressure is between 20 bar and 30 bar, the HP steam control
valves can then be warmed up for a period of 30 minutes. When the pressure is between 30 bar
and 40 bar, the HP steam control valves can then be warmed up for a period of 15 minutes. It
can be assumed that the steam turbine can only be contaminated slightly by unconditioned steam
in this pressure range even on postulated steam leakage through the control valves.
The emergency stop valves are closed immediately when the main steam pressure rises
above 40 bar.
Leakage through the control valves can accelerate the steam turbine to speeds within the
critical speed band. In this case, the emergency stop valves must be closed. The critical speed
band is order-specific.
Steam purity - Hot start
The emergency stop valves are closed again until such time as an adequate level of steam
purity is reached. This serves to rule out turbine cooling in the case of a hot start (high startup
pressure, possible leakage through the control valves).
The emergency stop valves are closed by decreasing the limit setting for the turbine startup
and lift limiter to 35% (see logic 090).
Signal formation: Adequate steam purity reached
Interrogation: Adequate steam purity reached (5-second switch-on delay)
The turbine speed must be under the critical speed band when specified steam purity is
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IC.Z10.62102.01-E00 Page 11 of 55
reached.
Interrogation: Steam purity ENABLE
Interrogation: Speed < 18%
Signal formation: Inadequate steam purity - close ESVs
Interrogation: Adequate steam purity on cold start (30-minute switch-on delay)
Interrogation: Steam purity NO ENABLE
Interrogation: Mean wall temperature of HP STM CTRL-V < 150°C
Interrogation: MS pressure (limit 1 after set delay) > 20 bar
Interrogation: Adequate steam purity for main steam pressure over 30 bar (15-minute
switch-on delay)
Interrogation: Steam purity NO ENABLE
Interrogation: Mean wall temperature of HP STM CTRL-V < 150°C
Interrogation: MS pressure (limit 2) > 30 bar
Interrogation: Adequate steam purity for main steam pressure over 40 bar
Interrogation: Steam purity NO ENABLE
Interrogation: MS pressure (limit 3) > 40 bar
Interrogation: Adequate steam purity on hot start
Interrogation: Steam purity NO ENABLE
Interrogation: Mean wall temperature of HP STM CTRL-V > 150°C
Interrogation: Main steam pressure > 20 bar
Interrogation: Adequate steam purity
The steam purity is determined manually for the steam generator prior to opening the control
valves. This action serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam. The test for steam purity
a) Determines the chemical steam purity
b) Tests the electrical conductivity
Interrogation: Steam purity ENABLE
Interrogation: Duration of ESV opening limited to 60 min
If the steam purity is not adequate, the emergency stop valves must not remain open longer
than 60 min with the control valves closed. If the sequence has not executed Step 16 to Step 20
within 60 min, the emergency stop valves are closed as the result of reset of the turbine startup
and lift limiter.
Interrogation: Step 16: Interrogation for Emergency Stop Valves Open
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IC.Z10.62102.01-E00 Page 12 of 55
Interrogation: Step 17: < Idle Step >
Interrogation: Step 18: Interrogation for Adequate Steam Mass Flow prior to Opening of
Control Valves
Interrogation: Step 19: < Idle Step >
Interrogation: Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System
Conditions prior to Opening Control Valves
Bypass criterion: Turbine accelerates to speed within critical speed band
During the wait for adequate steam purity prior to opening control valves, the ESVs are open.
Under these conditions, postulated steam leakage through the control valves can accelerate the
turbine-generator to the lower region of the critical speed band. A speed monitoring function is
implemented to prevent this. If this type of acceleration occurs, the ESVs are automatically
closed. To allow the steam turbine to be decelerated only to warmup speed in the case of a
program restart following a trip during the startup process, this monitoring circuit is only enabled
under the following conditions: Speed not above warmup speed AND speed setpoint not set to
warmup speed.
Interrogation: Speed > 18%
Interrogation: Speed NOT > 16 Hz (project-specific)
Interrogation: Speed setpoint NOT > 16 Hz (project-specific)
Logic
3.1.1.9 Logic9: Open and Close Valves via Turbine Startup and Lift Limiter TAB, Acceleration
to Rated Speed
Description of sheet L090
Signal formation: Raise startup and lift limiter
When an adequate level of steam purity is reached, the turbine startup and lift limiter opens
the emergency stop valves. The limit setting for the turbine startup and lift limiter is increased to
62% (this value would allow to accelerate to minimum load).
Interrogation: Open emergency stop valves
Interrogation: Step15:Open emergency stop valves.: Admission controller not active The
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IC.Z10.62102.01-E00 Page 13 of 55
The command for decreasing the limit setting for the turbine startup and lift limiter remains
active until 35% is reached. This results in the emergency stop valves being "CLOSED". This is
implemented into the logic using a memory block which is reset when the startup device reaches
a value below 35%.
The speed transient monitoring function closes the ESVs to ensure safe coastdown of the
steam turbine even in the event of postulated steam leakage through the control valves.
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IC.Z10.62102.01-E00 Page 14 of 55
Interrogation: SLC Cold Reheat Line Drain ON
Interrogation: Turbine drains
Interrogation is performed to determine whether all turbine drains were opened within a
defined period of time.
The air supply for pneumatic valves and fittings (valves in cold reheat line and extraction
line, injection water valves, LP bypass steam or seal steam system) must be operational. Proper
functioning of the control air supply is tested on the basis of the following process criteria:
The oil cooler in the turbine oil system is cooled by a dedicated cooling water system. This
comprises clean but not deaerated water which is cooled by a heat exchanger in the condensate
cycle. The check is based on the pressure difference which has built up between the pump inlet
and outlet.
Condenser evacuation has already been initiated by starting the ELMO vacuum pumps.
Evacuation is facilitated by starting up the seal steam system and sealing the turbine. A pressure
of at least 4 bar must have built up upstream of the control valve in the seal steam header.
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IC.Z10.62102.01-E00 Page 15 of 55
Interrogation: Main condensate system in operation
Only one group signal is supplied by the associated I&C for the water-steam cycle for the
operating state of the main condensate pump, regardless of the total number of main condensate
pumps.
Interrogation:The input for confirming adequate steam purity is flashing on the OM display.
Interrogation: Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System
Conditions prior to Opening Control Valves
Interrogation: The input for confirming release for rated speed is flashing on the OM
display.
Prior to opening the control valves, it must be ensured that no moisture is present in the
main steam line.
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IC.Z10.62102.01-E00 Page 16 of 55
Bypass criterion: No moisture present in main steam line
If steam flow has been in force through this line for at least 5 minutes AND the drain
upstream of the associated ESV is open, it is likewise assumed that no moisture is present in the
main steam line.
Prior to opening the control valves, it must be ensured that no moisture is present in the
reheat steam line.
If steam flow has been in force through this line for at least 5 minutes AND the drain
upstream of the associated ESV is open, it is likewise assumed that no moisture is present in the
reheat steam line.
Page M010
Monitoring time -
Wait time -
Commands: -
Checkback signals
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IC.Z10.62102.01-E00 Page 17 of 55
3.1.2.2 Step 2: Interrogate Valve Position and Activate SLC Extraction Check Valves
Page M020
Monitoring time -
Wait time -
Before startup it must be ensured that SGC open turbine control valves, which is employed
for preservation of the turbine on outages (see module MAA01), is not active. This automatic
control is therefore switched off at this point in the sequence.
Checkback signals
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IC.Z10.62102.01-E00 Page 18 of 55
Interrogation: SLC overload valve IS ON
The control valves leave the "IS CLOSED" position if the turbine startup and lift limiter
permits them to be opened and if the turbine controller specifies a position setpoint > 0%.
Page M030
Monitoring time 5 s
Wait time -
Checkback signals
The HP blading limit pressure controller is deactivated here when speed is above 33 rev/s.
This bypass criterion is necessary to allow immediate restart even when speed is already at this
level
Page M040
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IC.Z10.62102.01-E00 Page 20 of 55
Monitoring time -
Wait time 5 s
Condensate can accumulate throughout the entire steam turbine system in the course of a
prolonged shutdown phase. This is removed at the beginning of the startup process.
The SLC Turbine Drains is activated. Warmup drains and lowest point drains are
implemented. They are only required during the startup process.
Checkback signals
Page M050
Wait time 90 s
Condensate can accumulate throughout the entire steam turbine system in the course of a
prolonged shutdown phase. This is removed at the beginning of the startup process (see above
for wait time).
In the course of the shutdown process for the steam turbine, the drain valves upstream of the
control valves are opened when the temperature falls below the defined limit. For safety reasons
the isolation valves are opened again at the start of the "STARTUP" program and a check is
performed to ensure that they are open.
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IC.Z10.62102.01-E00 Page 21 of 55
Command: Drain valve upstream of HP STM CTRL-V OPEN
Checkback signals
Bypass criteria: All ESVs are open -control valve opening is limited
The emergency stop valves are open. The control valves leave the "IS CLOSED" position if
the turbine startup and lift limiter permits them to be opened and if the turbine controller
specifies a position setpoint > 0%.
Page M060
Monitoring time -
Wait time
Commands: -
Checkback signals
Page M070
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IC.Z10.62102.01-E00 Page 22 of 55
Monitoring time -
Wait time -
Checkback: Commands:
Checkback signals
Page M080
Monitoring time 10 s
Wait time -
Checkback signals
Restart of the turbine following a trip during the startup process is possible without having
to wait for coastdown of the turbine-generator. For this, the oil pump test normally performed in
this step is bypassed. As this test entails deactivation of the main oil pump, it is only permissible
to perform this at turning gear speed.
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IC.Z10.62102.01-E00 Page 23 of 55
Interrogation: Turbine-generator not in critical speed band < 18%
Page M090
Monitoring time -
Wait time
Commands:
Checkback signals
Page M100
Monitoring time -
Wait time
Commands:
Checkback signals
3.1.2.11 Step 11: Wait for Adequate Steam Conditions prior to Opening ESV, Activate SLC
"Generator Shutdown Dryer"
Page M110
Monitoring time -
Wait time -
Step 11and Step 20 are the start and end points of a loop which is passed through several
times when steam purity is inadequate. If an adequate level of steam purity is not reached, the
emergency stop valves which are open initially, are closed. The emergency stop valves remain
closed until an enable signal is issued for steam purity. The signal ESVOPND (logic L020) acts
as a bypass criterion.
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IC.Z10.62102.01-E00 Page 24 of 55
Commands: Activate SLC "Generator Shutdown Dryer"
The steam purity is determined manually for the steam generator prior to opening the
control valves. This serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam. During warm and hot starts steam purity is to be released
already prior to opening the ESV (usually prior to opening the CV). That prevents the logic from
jumping back from Step 20 to Step 11.
Checkback signals
The main steam line and the main steam valve body are warmed up together with the steam
generator in the case of an absolute cold start when a temperature of less than 150°C is measured
at the reference measuring points in HP steam emergency stop valves and HP steam control
valves.
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IC.Z10.62102.01-E00 Page 25 of 55
Interrogation: Mean casing temp. at HP STM CTRL-V < 150 °C
In the event of a hot start (mean temperature of HP shaft > 400°C), a minimum main steam
flow of 15% is required from the SG. If the mean temperature of the HP shaft is < 400°C, a
minimum main steam flow of 10% is adequate. The minimum main steam flow can be defined
order-specifically if required.
To avoid inadmissible loadings on the HP steam control valves due to a step temperature
increase for saturated steam
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IC.Z10.62102.01-E00 Page 26 of 55
Bypass criterion: no warm or hot start
Page M120
Monitoring time -
Wait time -
Commands:
Checkback signals
3.1.2.13 Step 13: Warmup of HP and Reheat Line upstream of Turbine Complete
Page M130
Monitoring time -
Wait time -
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IC.Z10.62102.01-E00 Page 27 of 55
Wait loop until adequate steam purity is reached
Commands:
Checkback signals
The main steam and hot reheat lines are warmed up by the water-steam cycle. A check is
performed to ensure that warmup valve(s) upstream of ESV(s) are open and that steam flow is in
force for these OR that the steam turbine is at rated speed. OR steam flow is in force at all
temperature measuring points in the main steam and hot reheat lines up to the ESVs. A minimum
degree of superheat (>10K) is likewise in force at all temperature measuring points (i.e. at all
low points and upstream of the steam turbine ESVs) in the main steam and hot reheat lines,
meaning that no moisture is present at these locations. Signal formation is active under all
operating conditions.
Page M140
Wait time 90 s
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IC.Z10.62102.01-E00 Page 28 of 55
The drains upstream of ESV(s) are not opened until warmup of the main steam and hot
reheat lines has been performed. This serves to prevent possible cooling of the steam lines by
reverse flow via the drains in the event of startup with MS isolation valve open and early
activation of the automatic startup control (before the steam generator is in operation).
Checkback signals
Checkback signals to command: Drains upstream of HP STM ESV and IP STM ESV
"OPEN"
Bypass criteria: All ESVs are open - control valve opening is limited
The emergency stop valves are open. The control valves leave the "IS CLOSED" position if
the turbine startup and lift limiter permits them to be opened and if the turbine controller
specifies a position setpoint > 0%.
Page M150
Monitoring time 90 s
Wait time -
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IC.Z10.62102.01-E00 Page 29 of 55
See Step11 for description.
In the event of a hot or warm start, the turbine can be accelerated to rated speed and loaded
immediately after startup. To rule out unnecessary no-load or low-load operation with the
associated risk of windage in the HP turbine and to ensure reliable synchronization, a check is
performed prior to startup to determine whether the enable signal for loading to an appropriate
level has been issued.
Command: Enable "TAB (L090)" and "SHUTDOWN step program via protection
(L070)"
The emergency stop valves are opened initially when the turbine startup and lift limiter
(TAB) is started up. The TAB is ramped on up to 62%. This makes limited opening of the
control valves possible. This lift limit allows runup of the steam turbine to rated speed and
synchronization of the generator.
If a valve position setpoint > 1% is defined due to a malfunction, turbine rolloff under steam
is performed by the TAB which opens the emergency stop valves. This spurious startup initiates
the "SHUTDOWN" step program via the protection input.
Checkback signals
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IC.Z10.62102.01-E00 Page 30 of 55
In loop between Step11 and Step 20
Monitoring time 30 s
Wait time -
The emergency stop valves are closed again in the event that the steam purity is inadequate
or the speed is too high.
Commands: -
Checkback signals
To allow the steam turbine to be decelerated only to warmup speed in the case of a program
restart following a trip during the startup process, a bypass must be provided at this point in the
sequence. This disables the interrogation criterion for HP evacuation valve closed under the
above conditions when turbine speed is above 33 Hz.
Page M170
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IC.Z10.62102.01-E00 Page 31 of 55
Monitoring time -
Wait time
The emergency stop valves are closed in the event that the steam purity is inadequate or the
speed is too high.
Commands: -
Checkback signals
3.1.2.18 Step 18: Interrogation for Adequate Steam Mass Flow prior to Opening of Control
Valves
Page M180
Monitoring time -
Wait time -
The emergency stop valves are closed again in the event that the steam purity is inadequate
or the speed is too high.
Commands: -
Checkback signals
In the event of a hot start (mean temperature of HP shaft > 400°C), a minimum main steam
flow of 15% is required from the SG. If the mean temperature of the HP shaft is < 400°C, a
minimum main steam flow of 10% is adequate. The minimum main steam flow can be defined
order-specifically if required.
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IC.Z10.62102.01-E00 Page 32 of 55
Interrogation: MS mass flow if ϑHP shaft > 400°C > 15%
Page M190
Monitoring time 60 s
Wait time -
The emergency stop valves are closed again in the event that the steam purity is inadequate
or the speed is too high.
Commands: -
Checkback signals
3.1.2.20 Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System Conditions
prior to Opening Control Valves
In loop between Fehler! Verweisquelle konnte nicht gefunden werden and Step 20
Monitoring time -
Wait time -
The sequence waits for adequate steam purity in Step 20. Adequate steam purity is
confirmed manually by operating a pushbutton. The emergency stop valves are not opened until
adequate steam purity is in force.
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IC.Z10.62102.01-E00 Page 33 of 55
Command: Release OM button for steam purity
Checkback signals
The steam purity is determined manually for the steam generator prior to opening the
control valves. This serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam.
Steam purity is assumed when restarting. Bypassing the release prevents delays.
Interrogating condenser pressure ensures that the condenser low vacuum trip does not
respond when the speed is increased.
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IC.Z10.62102.01-E00 Page 34 of 55
Interrogation: Temperature margins
For opening of the control valves to be admissible, the lowest of the temperature margins
must amount to at least 30K for all components. The turbine controller is not expected to limit
the acceleration rate when accelerating to rated speed in this case.
The main steam and hot reheat steam conditions are checked on the basis of the following X
criteria:
It must also be ensured that the degree of steam superheat is at least 30K.
A check is performed to ensure that the main steam and hot reheat temperatures are within a
permitted tolerance band. For this purpose, the system checks whether the warning limits for
main steam and hot reheat temperature have been exceeded.
A check is performed to ensure that the discrepancy between the pressure setpoint of the
turbine controller and the actual pressure of the main steam is not too high. This is designed to
avoid a situation whereby the turbine controller has to compensate for an excessive control
deviation at the time when the control valves are opened.
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Book : Page 55 of 152
IC.Z10.62102.01-E00 Page 35 of 55
Interrogation: MS pressure: Setpoint - Actual value > ε NOT REACHED
The limit setting for the turbine startup and lift limiter has been increased to 62%. The TAB
therefore acts as a lift limiter. The control valves are kept closed until the speed setpoint is
increased.
This interrogation is necessary to allow the steam turbine to be decelerated only to warmup
speed in the case of a program restart following a trip during the startup process. This ensures
that reversal of the speed gradient in the subsequent step does not coincide with speed being
within the critical speed band.
The auxiliary systems are tested again before the control valves are opened (see Section
1.3.1.1.10).
The system waits for adequate steam purity with the emergency stop valves closed (Step
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IC.Z10.62102.01-E00 Page 36 of 55
20). Steam purity is determined by means of a chemical analysis. Adequate steam purity must be
confirmed manually (logic L110). The sequence makes a return jump to Step 11. In the steps
which follow, the emergency stop valves are then opened again and all the criteria are
interrogated in order to accelerate the turbine to warmup speed by opening the control valves.
The limit setting for the turbine startup and lift limiter is reduced if steam purity is
inadequate. This closes the emergency stop valves.
Interrogation: All ESVs closed and wait for adequate steam purity complete
The sequence does not go into the wait loop until all the emergency stop valves are closed
and the startup program has reached Step 20.
Interrogation: Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System
Conditions prior to Opening Control Valves
Page M210
Monitoring time 5 s
Wait time -
The turbine is accelerated to warmup speed. The speed setpoint is increased. This causes the
control valves to be opened. All the turbine sections, but primarily the HP turbine, are warmed
up at warmup speed. The TSE/TSC monitors the warmup process.
To allow the steam turbine to be decelerated only to warmup speed in the case of a program
restart following a trip during the startup process, the alarm for speed gradient too small stored in
the steam turbine controller must be reset. This takes place when turbine speed is within the
permissible operating window.
Checkback signals
Page M220
Monitoring time -
Wait time -
Checkback: None
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IC.Z10.62102.01-E00 Page 38 of 55
The SLC Steam Purity is also deactivated due to turbine trip (signal with 2 s delay).
Checkback signals
3.1.2.23 Step 23: Maintain at Warmup Speed: Increase Degree of Heat Soak for HP Turbine
Page M230
Monitoring time -
Commands: -
Checkback signals
The system ensures that the position controller in the turbine controller does not have a
limiting effect when the turbine startup and lift limiter opens the control valves.
In the event of extremely low ambient temperatures, it must be ensured that IP shaft
centerline temperature is at least 20°C.
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Book : Page 59 of 152
IC.Z10.62102.01-E00 Page 39 of 55
Interrogation: Temperature criterion X7, margins, superheat
(2) In addition to testing for the X criteria, a check is performed to determine whether the
temperature margins exceed the minimum value of 30K.
A degree of superheat of at least 30K must be in force for the steam upstream of the HP and
IP turbines.
Interrogation: Hot reheat temp. upstream of IPT (Z4 crit.) Superheat to > +30K
A minimum main steam flow of 15% is required from the SG prior to opening the control
valves. The minimum main steam flow can be defined order-specifically if required.
The evacuation pumps (ELMO vacuum pumps) give rise to a condenser vacuum. The
following limit applies for condenser vacuum:
√ p < 0.13 bar abs Limit for "Condenser pressure protection" reached
Page M240
Monitoring time -
Wait time -
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IC.Z10.62102.01-E00 Page 40 of 55
Commands: -
Checkback signals
Page M250
Monitoring time 5 s
Wait time -
Increasing the speed setpoint causes the turbine to accelerate to above rated speed (rated
speed + 0.25 rev/s). The generator can be synchronized at this speed. The turbine startup and lift
limiter is set to limit setting 62% to limit valve opening.
Checkback signals
Page M260
Monitoring time 60 s
Wait time -
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IC.Z10.62102.01-E00 Page 41 of 55
These drains are closed before the TAB reaches a limit setting > 99%.
Checkback signals
Checkback signals to command: Close drain upstream of HP STM ESV & HP STM
CTRL-V
Checkback signals to command: Close drain upstream of IP STM ESV & IP STM
CTRL-V
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IC.Z10.62102.01-E00 Page 42 of 55
3.1.2.27 Step 27: Deactivate SLC Speed Enable
Page M270
Monitoring time -
Wait time -
The SLC Speed Enable is also deactivated due to turbine trip (signal with 2 s delay).
Checkback signals
Page M280
Monitoring time -
Wait time -
Checkback signals
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IC.Z10.62102.01-E00 Page 43 of 55
Checkback signal to command: Activate voltage regulator
Page M290
Monitoring time -
Wait time -
Commands: -
Checkback signals: -
(2) In addition to testing for the X criteria, a check is performed to determine whether the
temperature margins exceed the minimum value of 30K.
Comment: This value was used prior to implementation of the X criteria. It is still
implemented today in cases where thick-walled valves are used, in order to ensure an adequate
temperature margin.
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Book : Page 64 of 152
IC.Z10.62102.01-E00 Page 44 of 55
3.1.2.30 Step 30: Prepare Synchronization
Page M300
Monitoring time 5s
Wait time -
Commands: Activate exciter system & preselect grid tie breaker (optional)
It is possible to close the grid tie breaker in the next step having preselected it here.
Checkback signals
Page M310
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IC.Z10.62102.01-E00 Page 45 of 55
Wait time -
Commands: Synchronize
Checkback signals
3.1.2.32 Step 32: Open Control Valves by Increasing Limit Setting for Turbine Startup and Lift
Limiter
Page M320
Monitoring time 30 s
Wait time -
After the generator has been synchronized, the position of the control valves is only limited
via the turbine controller by the limit pressure, and by the limit setting for the turbine startup and
lift limiter. The limiting effect of the turbine startup and lift limiter is cancelled during this
step.The speed controller does not act to limit valve opening following synchronization. The
control valves are opened by means of the load controller. The bypass controller closes the
bypass valves. The limit pressure controller can intervene where appropriate whenever the
pressure of the SG falls below the limit value. The control valves are throttled in this case.
Checkback signals
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Book : Page 66 of 152
IC.Z10.62102.01-E00 Page 46 of 55
Checkback: TAB > 99%
Page M330
Monitoring time -
Wait time -
Commands: -
The startup process is complete when the following conditions are met.
(1)Generator synchronized
(4) Pressure upstream of HP blading > 25 bar .The steam turbine is supplying power.
Page M340
Monitoring time 5 s
Wait time -
Commands:
Checkback signals
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Book : Page 67 of 152
IC.Z10.62102.01-E00 Page 47 of 55
The load controller in the turbine controller is activated following synchronization. The
turbine controller remains in power operation after the bypass stations have been closed.
Page M350
Monitoring time -
Wait time -
Commands: -
Checkback signals: -
3.1.3 Automatic Steam Turbine Shutdown Control (STPP) - SHUTDOWN Step Program
The "SHUTDOWN" step program is started from the unit control level. The SHUTDOWN
program can also be activated by means of a protection input if a turbine trip occurs or if
problems occur during execution of the STARTUP program. This brings the turbine-generator
into a defined state.
Page N010
Monitoring time 5 s
Wait time 10 s
The cold reheat check valves are released before the turbine power output is run down. This
ensures that the pressure in the HP turbine can be decreased as required.
Checkback signals
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Book : Page 68 of 152
IC.Z10.62102.01-E00 Page 48 of 55
The cold reheat check valves must have moved from the OPEN position within 10 s.
Page N020
Monitoring time -
Wait time -
The power contribution of the steam turbine is reduced by closing the control valves.
Checkback: (None)
Command: Disable the influence of lower temperature margins on the unloading rate
Experience shows that the standard limitation of load gradients imposed by the minimum
temperature margins is not necessary for rundown. This is due to the fact that the lower margins
normally remain above zero even at maximum loading gradient. As the lower WT limits are
often very restrictive for high mean shaft temperatures (e.g. 15K), these basically limit the
unloading gradient under these conditions. This command sets the minimum lower WT margin
in the turbine controller to a fixed value of 30K. As a result, the maximum load gradient is
effective under these conditions, without limitation by the TSE/TSC.
Checkback signals
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Book : Page 69 of 152
IC.Z10.62102.01-E00 Page 49 of 55
Checkback signal: Command "DECREASE" load setpoint
The turbine-generator is run down by means of the speed controller in the event of load
rejection.
The turbine-generator is run down by means of the speed controller in the event of load
rejection.
The turbine controller must be changed over to "LIMIT PRESSURE" right at the start of the
"SHUTDOWN" program in order to prevent spurious opening of the HP bypass stations.
3.1.3.3 Step 53: Valve Leak Test / Wait for Grid Tie Breaker to Open
Page N030
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Book : Page 70 of 152
IC.Z10.62102.01-E00 Page 50 of 55
Monitoring time 45 s
Wait time 60 s
Commands: -
Checkback signals
The system waits for 60 s for the generator breaker to open before closing the valves as the
result of a turbine trip. Motoring of the generator is limited to this time period provided the HP
evacuation line is open with the HP steam valves closed.
As soon as the speed controller is activated, the valve leak test is aborted.
As soon as the HP exhaust steam temperature controller initiates valve position trimming,
the valve leak test is aborted.
Page N040
Monitoring time 5 s
Wait time -
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Book : Page 71 of 152
IC.Z10.62102.01-E00 Page 51 of 55
Commands: Close emergency stop valves
Checkback signals
Page N050
Monitoring time 60 s
Wait time -
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Book : Page 72 of 152
IC.Z10.62102.01-E00 Page 52 of 55
Command: SLC Turbine Drains "ON"
Checkback signals
Page N060
Monitoring time -
Wait time -
Commands:
Checkback signals
The jacking oil pumps must be ready for operation and the turbine-generator in turning gear
operation before the oil pump test program is started.
Page N070
Monitoring time -
Wait time -
Checkback signals
SGC Oil Pump Test is only started on shutdown of the turbine if a 30-day interval has
expired since the last test was performed. If the lube oil pressure protection is actuated in the
course of testing, an appropriate alarm is then generated. If this occurs, the lube oil system must
then be checked and SGC Oil Pump Test activated again manually following this.
Page N080
Monitoring time -
Wait time -
Commands: -
Checkback signals
Page N090
Monitoring time
Wait time
Commands: -
Checkback signals:
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Book : Page 74 of 152
IC.Z10.62102.01-E00 Page 54 of 55
The warmup drains are not opened until the temperature of the HP steam control valves
falls below 200°C.
Interrogation: HP STM CTRL-V temperature (at 50% wall depth) < 200°C
Page N100
Monitoring time 60 s
Wait time -
Checkback signals:
Page N110
Monitoring time -
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Book : Page 75 of 152
IC.Z10.62102.01-E00 Page 55 of 55
Wait time -
Commands: -
Checkback signals:-
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Book : Page 76 of 152
Prepared:Man Can 2020.04
Emergency Trip
2020.04
System Checked:Wei Yuan
IC.Z10.60302.01-E00 Reviewed:
Approved:Chi Dingnan 2020.04
CONTENTS
1. Overview ..................................................................................................... 1
MKD12CY121,MKD21CY121 .................................................................. 6
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Book : Page 77 of 152
5.10 Other Protection .................................................................................... 8
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Book : Page 78 of 152
IC.Z10.60302.01-E00 Page 1 of 9
1. Overview
Turbine emergency trip system is used to monitor important turbine operation parameters,
when these value exceed the allowable limit, the trip signal will be occurred to close the steam
inlet rapidly, and these sequences of action avoid the further damage of the turbine.
ETS is mainly consist of Overspeed protection device, data acquisition process system and EH
trip system.
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Book : Page 79 of 152
IC.Z10.60302.01-E00 Page 2 of 9
To match up with E16 series overspeed protection device, A5S contactless series Hall speed
transmitter is picked to measure the turbine speed.
A5S series speed probe is active device, which power is supplied by DEH cabinet. The output
is nominal square wave. Installation gap is recommended as 2-2.5mm, further installation
information will be showed on probe specification.
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Book : Page 80 of 152
IC.Z10.60302.01-E00 Page 3 of 9
used in dual modules.
速度传感器1
速度传感器2
三取二
切断电磁阀供电电源 速度传感器3
处理器 2
处理器 1
通道 1
汽轮机遮断按钮
通道 2
通道 1
通道 2 发电机保护信号
I/O通道 3
超速保护#2
I/O通道 2 I/O通道2
速度传感器4
故障安全卡件
I/O通道 1 I/O通道1
速度传感器5
三取二
速度传感器6
保护条件1
保护条件2
保护条件3 主汽门/调门油动机
再热主汽门/再热调门油动机
#1关闭电磁阀 #2关闭电磁阀 补汽阀油动机
冷再热逆止阀
高排通风阀
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Book : Page 81 of 152
IC.Z10.60302.01-E00 Page 4 of 9
Standard protection strategy is 2 out of 3 logic configuration (except bearing vibration signal
is 2 out of 2). The loop consists of data acquisition device, data processor, limiter, trip signal
producer and output device. Turbine protection adapts analog measurement and signals are
continuously monitored and compared. Signal processing is performed through a digital
automatic system. With this design, all turbine protection loop can be accuratly completed
without additional testing equipment. The protection conditions of steam turbine unit are
determined by the safe operation of steam turbine unit. If protection loop are not on ,the unit will
not be allowed to operate. After the signals are summed up, the turbine protection trip
signal is sent to the TTS system (Turbine Trip System) for processing.
TTS system receive digital signal, including Overspeed protection, generator protection, boiler
MFT, emergency trip button and turbine protection signals, through relative input modules to
DPU, then the data will be processed in DPU as trip signal, through the redundant output module
to rapid close solenoid valve on EH motor, the signal will be sent to close the valve immediately.
TTS logic should be in one independent DPU.
4. EH Shutdown System
For the shutdown system of this turbine unit, every EH motor is individually to act. Two
series-wound rapid close solenoid valve is installed on each EH motor. If one of the solenoid
valve act, the valve will close rapidly. Every solenoid valve receive ETS trip signal individually,
then close the valve. The solenoid valve is nominal charged, acts when power off. The power
supply is 24VDC, from ETS DO card.
单向阀 快关电磁阀
电液伺服阀
过滤器
P 压力油 T 回油
5. Protection Specification
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Book : Page 83 of 152
IC.Z10.60302.01-E00 Page 6 of 9
MKD12CY121,MKD21CY121
This turbine unit adapt bearing landing structure design, turbine adapt flexible design, thus,
bearing protection use bearing pedestal (absolute vibration) protection, and bearing vibration
( relative vibration) is only used for alarm. If the vibration value exceed the recommend trip
value, operators trip the turbine manually.
Two bearing pedestal vibration probe installs at 45 degree horizontally close to each other.
These two signals send to ETS protection system through TSI as 4-20 mA analog signal, after 2
out of 3 deal, turbine will be tripped if the measurement value exceed the trip value.
Also, TSI send channel alarm signals after vibration channel fault. Trip value signal and
channel fault signal combined together then trip the turbine.
Probe from X, Y direction will send the vibration signal to TSI, after composition the signal
will be sent to DEH for alarm.
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Book : Page 84 of 152
IC.Z10.60302.01-E00 Page 7 of 9
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Book : Page 85 of 152
IC.Z10.60302.01-E00 Page 8 of 9
temperature exceed the alarm value, HP temp controller will be active to cut off the HP exhaust
temperature by increasing HP inlet flow; when the temperature exceed the protection value. The
turbine will be tripped.
MAC20CT171A/172A/173A
To prevent the last stage blade not exceeding the nominal working temperature, add three
thermocouple at the end of the LP cylinder to monitor the temperature. When the temperature
reach a high value, DEH will open the LP water injection to cut down the temperature, if the
temperature keep raising, the turbine will be tripped.
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Book : Page 86 of 152
IC.Z10.60302.01-E00 Page 9 of 9
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subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use otherwise
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Book : Page 87 of 152
Prepared:Man Can 2020.04
Servomotor
2020.04
Specification Checked:Wei Yuan
IC.Z10.61201.01-E00 Reviewed:
Approved:Chi Dingnan 2020.04
CONTENTS
SERVOMOTOR SPECIFICATION ................................................................. 1
1. General ............................................................................................................. 1
4. Specification ..................................................................................................... 3
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Book : Page 88 of 152
IC.Z10.61201.01-E00 Page 1 of 4
SERVOMOTOR SPECIFICATION
1. General
EH oil actuator is single side acting, that is, opens by the pressure of the EH supply system
and closes by the spring force.
The actuator is mounted directly on the valve. Closing spring chamber is between valves and
oil actuator, which also can play the role of insulation. When the actuator in the fully closed
position, the spring has a certain amount of pre-compression, this can provide pre-pressure. The
high pressure oil acts on the piston of the cylinder to overcome the force of the spring, so as to
open the oil actuator.
The actuators, depending on the control mode, divided into the main valve actuator and
control valve actuator. The main valve actuator is fully closed and fully open type, only the fully
open and fully closed two positions. The control valve actuator can keep under control
requirements in different valve position.
The number of actuator, depends on unit design. One unit contains 2 stop valve actuator(SV),
2 governor valve actuator(GV), 2 reheat stop valve actuator(RSV), 2 intercept valve actuator(IV)
and maybe1 overload valve actuator(OLV).
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Book : Page 90 of 152
IC.Z10.61201.01-E00 Page 3 of 4
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subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use otherwise
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Book : Page 91 of 152
IC.Z10.61201.01-E00 Page 4 of 4
amplifier, used to control the mainstream volume second (4).Pilot control is nozzle baffle type
amplifier. When the torque motor (2) is not running, the tube keep straight (5) so that the baffle
(6) and the armature (7) in the middle position. Baffle (6) moves (9) in intermediate position of
the nozzle, that results pressure difference on the side of control valve core (10). Due to this
pressure difference, the feedback rod change the position. The feedback rod (11) fixed to the
armature (7) is inserted in the control valve core groove. Control valve (10) changes its position
until the feedback torque and torque electric motor phase equilibrium, the pressure is reduced to
zero. Thus, the control spool (10) trip is proportional to input signal. The actual flow rate from
the valve to the actuator of depends on the valve differential pressure. External electronic
amplifier (servo amplifier), is used to control the valve. The analog input signal (a given signal)
magnified, mading output signal from control electronic amplifier can be used to control servo
valve.
Displacement transducer uses the type of magnetostriction, built inside withnoncontact
structure. It is characterized by high precision, high reliability, and is not easy to damage. The
device is mainly composed of a rod, an electronic storehouse and sheathed on the rod of
non-contact magnetic ring, magnetic ring fixed in the actuator piston rod, moves with the piston
together. By measuring time differences between the magnetic pulse electronic cabin and the ring,
the displacement can be precisely measured. The output signal is 4-20mA, and the signal is sent
to the control system as feedback. When the transmitter is break down, the actuator will close
gradually.Principle of overload valve actuator is the same as governor valve actuator, the only
difference is the number of check valve, overload valve actuator just have one tier check valve.
3. Stop Valve
The main valve actuator is fully closed and fully open type, only the fully open and fully
closed two positions.
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IC.Z10.61201.01-E00 Page 5 of 4
4. Specification
Electrical junction box on the cylinder block, all electrical signals ( valve, electro-hydraulic
converter, liquid level switch, and displacement sensor) connects to junction box, then to control
cabinet.
Return oil directly back to the tank through a return pipe.
The actuator assembled in factory must be clean, without any impurities. In the power plant
after installation, there is no need to flush again.
The main stop valve and control valve share one pressure pipe and a return pipe. Tank outlet
for the pressure oil is equipped with isolation valve, actuator failure needs no shutting down of
the unit for maintenance. Close the isolation valve, the corresponding main stop valve and
control valve can be isolated from system, and process the equipment.
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Book : Page 93 of 152
Prepared:Man Can 2020.04
Fire-Resistant
Hydraulic Oil
Checked:Wei Yuan 2020.04
System Operation
And Maintenance
Countersign:Li Gang 2020.04
IC.Z10.62202.01-E00 Countersign:
CONTENTS
FIRE-RESISTANT HYDRAULIC OIL SYSTEM OPERATION
3. Maintenance .....................................................................................................9
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
3.3 Motor..................................................................................................... 11
5. Maintenance .................................................................................................. 13
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MAINTENANCE
1.1 Introduction
In order to skillfully operate this hydraulic system, operator should follow these instructions
and familiar with its contents.
This specification provides the normal guidelines and maintenance of hydraulic system for
operators. Lacking of knowledge of the oil system, may lead to misuse of the facilities, which
will lead to dangerous to some extent. Or cannot develop the system function sufficiently.
After reading this specification does not mean that the operators can ensure the safe operation
of the hydraulic system. Instead, the operators should pay attention to the relevant part, and well
aware of security matters within its scope of work.
Pay attention to the following normal operation, maintenance and debugging security matters:
1. Before activating the system, pay attention to the surrounding environment, particularly
other people or sundries in the working area.
2. Before activating the motor, check and make sure all control elements (such as valves,
buttons etc.) are in work-off state.
3. During the operation of the system, be aware of other people not entering non-secure or
dangerous areas. Once find, stop the system immediately.
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the motor stopped, the cause of the pipeline pressure, one of which may be the system has a
regular load (such as crane system), when these assemblies need repairing or changing, without
proper treatment or system pressure release, will probably pose a danger.
1.2.2 Warning:
Before removing the seal, components or pipes on the systems, must be aware of the following
four points:
1. The motor power must be switched off (an electrical engineer in charge of power-off work).
2. When the power is switched off, it should be in a secure location for operation, if necessary,
can use safety belts or other safety equipment.
3. Use mechanical bracket or support tools to support the load of all actions components (such
as cylinder, motor etc.), then start repair or adjustment work. In addition, we also need to cut off
the supply of the oil.
4. Release residual pressure of system, piping and components.
1.2.3 Notes:
Even if the reading of pressure gauges are zero, this cannot fully guarantee the hydraulic
system has released all the residual pressure in the pipes. Check all pressure relief points and
measurement points while reopen if necessary. Make sure that all residual pressure has been
released before work.
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Dilute stored waste oil with pure water before disposal.
1.3.1 Transportation
Hydraulic oil tank can be transported with lifting equipment. Only suitable lifting attachments
can be used.
The general safety guidelines must be complied during transportation. Exhaust the oil in tank
before transporting.
Make sure Hydraulic oil tank is clean and no oil in it. But the hydraulic oil may still in the
tank after leave-factory check and acceptance (see 3.2.1 "Factory corrosion protection").
Transport with lifting equipment
Members (parts, pipes, etc.) on the tank must not be in contact with the lifting device.
- Install appropriate eyebolts on the box.
- lifting carefully, keeping the center of gravity stable.
Note: hanging loads
1.3.2 Storage
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1.3.2.1 Anticorrosion in plant
The residual oil film after the test may provide short-term protection against internal
corrosion.
On the other hand, if the tank tends to be stored for a long time, we can choose
corrosion-resistant hydraulic fluid.
Further internal anticorrosion can be accomplished by oiling (internal chamber refilling
corrosion-resistant hydraulic fluid).
1.3.2.2 Internal protection
Provide protection to achieve internal storage time shown in Table 3 through the tank test or
refilling protective liquid to equipment and tank.
Refill protective liquid to tank, start briefly then let the liquid out. All pipe connections should
be sealed through plugs.
If the protection is taken by refilling oil as shown in Table 1, we can use appropriate protective
liquid to test the tank. Protective liquid will remain in the equipment and components.
The connecting tubes are sealed via plug screws or flanges. There is no need to full fill the
tank with oil. Injecting suitable anticorrosion oil through any device components, such as pumps,
control devices and filters, is enough.
Table 1
Storage conditions Package anticorrosion storage time (months)
oil 3 6 9 12 24
| | | | |
storage at a constant seaworthy A
temperature, dry site not seaworthy A
B
Outdoor storage (to seaworthy A
prevent damage and B
moisture from not seaworthy A
entering) B
Use preservative fluid test A= Mineral oil / phosphate oil
If storage time is longer than the time shown in table 1, some of the equipment, especially the
hydraulic pump must be disassembled, cleaned with suitable cleaning to remove the residual oil
inside the device and replace the seal.
1.3.2.3 External protection information
Suitable paint is used to provide external protection (anticorrosion).
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If stored in dry, constant temperature environment, and storage time no more than six months,
then use basic paint protection.
If stored for longer than six months, it is necessary to use an appropriate topcoat.
1.3.2.4 packaged hydraulic equipment and information systems
If open the package for check, it is necessary to reseal the unit carefully. For shipping
packaging, it is necessary to add new desiccant.
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Also attention the following points:
- Solid foundation (to avoid vibrations)
- Convenient for maintenance and repair
- Proper protection from weather, fog, heavy pollution and radiation
- Ensure adequate air flow, so that the motor can work very well.
- As short as possible of the pipe.
2.4.1Before Start
Cleanliness requirements:
- Hydraulic system must be thoroughly flushed to ensure that the internal system is
absolutely clean.
- check the cleanliness of the system before filling hydraulic oil.
Inspect the Pipeline system:
- Joints are tightened?
- Piping system is already clean?
- Are there any presence of stress in the the piping system after installation?
- Whether all the pipes are well arranged according to the installation plan or piping
arrangement diagram?
Check electronic control components:
- Check the voltage of the motor, control system and other electrical components?
- Check the function of electrical components and monitoring system manually. If the element
not working, check the wiring weather is correct or not, the possibility of manual operation.
When oiling the tank, check the fluid level switch and level gauge.
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original state.
- Check abnormal noise and vibration.
- According to the technical documentation that came with the hydraulic system of the values
indicated in the figure, inspect EH tank pressure value that has been previously set-normally at
the factory.
- Check the leakage.
Debugging Problem: The device installed in the system, under certain operating conditions
(weight, speed, control, different set points), the same tank will play different performance (may
also have a different error message). Overall, during the pre-debugging and debugging, it is
necessary to test and analysis the oil.
Refer to the "cause of the malfunction and impacts on the fuel tank" to diagnose system faults
and limitations.
Stop motor
- Correct all deficiencies found in the above.
- Check all connections, bolts, etc., if necessary, re-tighten.
- Restart when finished.
Step 4 load for hydraulic system
When the hydraulic system functions under no-load conditions has reached all the technical
parameters, the system can be loaded.
- Gradually increasing the load until a satisfactory operation.
- In this process, it is possible to adjust output flow of the pump.
- Make the system work cycle until the system has reached normal operating temperature.
Step 5 checks
- Check unusual noises or vibrations.
- Check functional of safety equipment.
- Check the cooler control is stable.
- Check the leak.
- Check the pump pressure set point.
3. Maintenance
Planned hydraulic system maintenance can prevent the failure of the hydraulic system, while
the system can operate effectively as required. This particular maintenance procedures depends
on the characteristics of the device, the environment and work cycle, as well as the importance of
the systems. In order to maintain the life cycle economically, lifetime cycle cost (LCC) analysis
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IC.Z10.62202.01-E00 page 10 of 25
is recommended.
Routine inspections after the first week of operation
- Oil Leakage
- Tank level
- Operating temperature
- System pressure
- System performance and overall state
- Unusual noise
- Contamination indication of the filter
Check before each starting
- Oil Leak
- Tank level
- Suction valves open or not
- Contamination indication of the filter
Always check
- Abnormal vibration
- Unusual noise
- Oil Leak
- Tank level
- EH tank clean? Airflow duct patency?
- The usual pressure value is stable?
- Operating temperature
- Contamination indication of the filter
Scheduled maintenance
There are plans to maintain within a specific period, include the following checks and actions:
- Always check all the points
- Check all pressure values
- Check a fixed temperature value around the system
- Release water and mud from EH tank vent valve
- Check the motor
- Check function of monitoring equipment / switches and other components
- Clean dirt area
- Check wiring
- Check drain line flows and oil condition
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IC.Z10.62202.01-E00 page 11 of 25
- Check the hoses, connections and pumps, pay attention to whether there are cracks, leaks
happened
- Check coupling through inspection hole
3.3 Motor
Check whether the motor vents are blocked by trash and whether the air is easy to enter the
motor.
3.5 Cooler
The temperature is below 0℃, and the cooler does not work, so the water must be exhausted
in order to avoid cracking.
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IC.Z10.62202.01-E00 page 12 of 25
pressure, if you follow the outline described below, operation of the unit will not be affected.
The HP oil connected to the accumulator through the safety valve, safety valve contains an
isolation valve, a drain valve and a pressure relief valve. Accumulator can be isolated from the
system through isolation valve. Drain valve connect accumulator side oil with the drain oil.
When the system pressure exceeds setting of the safety relief valve, the relief valve opens, the
pressure oil return to the drain oil.
If necessary, it can be isolated an accumulator to refilling. It is not allowed once cut off more
than one pressure accumulator while the unit in run.
Re-aeration step:
3.6.2 Open The Discharge Valve (MAX01AA261), And Let The Hydraulic
3.6.3 Read Out Accumulator Barometer Readings And Record For Future
Reference.
Normal inflation pressure is 93bar. When the pressure gauge reading is less than 82.7bar,
indicating that the accumulator should be re-inflated with dry nitrogen.
Valve.
3.6.5 Connect The Nitrogen Hose And Pressure Accumulator Valve Hose.
Hexagonal nut located top of the pressure accumulator valve loose a circle, so that check valve
released and can be inflated. Open the valve on the nitrogen bottle, till the accumulator pressure
gauge indicates 93bar.
3.6.6 When Charge To The Desired Pressure, Close The Valve On The
Nitrogen Bottle, Tighten Hexagonal Nut On The Top Of The Pressure Control
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IC.Z10.62202.01-E00 page 13 of 25
Open Position.
Repeat the above steps, one by one for other accumulators.
4. Correct Maintenance
Before removing hydraulic or electrical components, first disconnect the connection of EH
tank. Ensure that the system and the motor is safe at present.
Before disassembling
- do fault diagnosis and proper test for EH tank.
- Clean all assemblies and components, bearing in mind the warnings to avoid dirt into the
system.
- Demolition work can only be done by qualified personnel.
Disassembly
- Mark all components, and protect the finished surface or mechanical surface.
- Inspect all parts during disassembly for wear or damage.
- If the hydraulic oil discharged need to be put into use again, then oil containers must be clean,
and should be sealed when not use.
- Before reassembling, using suitable solvent to clean all the metal parts and then use clean
linen to absorb the oil.
Reassemble
- With hydraulic oil to lubricate.
- Replace all seals, gaskets and O-ring with new and the same size spare.
- Make sure the pipe connection completely sealed.
- Refill the hydraulic oil in accordance with the requirements of the refueling system.
5. Maintenance
Maintenance includes prevention and recovery.
Maintenance work is divided into three parts:
- Preventive maintenance: measures to maintain device-specific operating conditions.
- Check: take measures to establish and assess the actual condition of equipment.
- Repair: Measures to restore the specific conditions.
By these means, it can use the most economical way to ensure the reliability of fire resistant
tank.
Fire resistant tank design ensures the most excellent reliability (operation reliability, service
life). They only require little maintenance, but for the device stability was essential.
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Experience has shown that 70% faults and damage of the fire resistant tank are indirectly
caused by fire resistant oil. So most of the inspection and preventive maintenance is concentrated
to checking and taking measures to ensure that fire resistant oil properties (physical and chemical
properties, cleanliness, etc.).
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darker than when the oil has just added to the fuel tank, and precipitate, etc.).
Hydraulic oil requires laboratory analysis. Take appropriate measures based on results of the
analysis:
-Replacement of aging or the formation sludge of fire resistant oil.
-For impurity fire resistant oil (cleanliness cannot be maintained), use independent filter
cartridge.
In order to remove sludge and water, we suggest remove capacity of about 90% fire resistant
oil, to clean the tank with an outside filter device. The residual oil containing dirt and water
should be discarded. (Important: All waste should be disposed in accordance with the relevant
provisions).
5.1.2.3 Change Oil
According to oil analysis results determine oil change.
Usually, oil analysis before debugging and during debugging process.
Thereafter, the same analysis required annually.
It is recommend every 3 months to conduct a qualitative analysis of the oil.
Take oil samples from the specialized sampling port.
By taking appropriate measures to deal with the oil and the test method, fire resistant oil
change cycle can be significantly extended. (See 5.1.5 “regeneration apparatus")
Warning: Check the fuel tank level is necessary, if necessary, then add the oil, because the oil
level is below the minimum level scale may cause malfunction.
Note: ensure that refueling with fire resistant oil products from the same company, and have
the same cleanliness.
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accordance with environmental performance, replace if necessary.
5.1.4 Accumulator
Accumulator is pressure vessel that required to meet the valid local safety regulations (see
"Product-specific operation guidance").
Before the disintegration of the accumulator, the accumulator oil measure necessary relief.
Warning Important: Only use nitrogen (nitrogen volume purity of 99.99% ).
When the accumulator installation must be careful, because improper operation may lead to
serious consequences.
Do not allow welding or machining operations to the accumulator housing.
See also "product-specific operation guidance".
5.1.6 Setting
Pressure and flow control valve and pump controller also signal components such as: pressure
switch, filter blockage indicators, etc. are set during debugging. During operation needs to check
these settings do not change.
Setting of pressure valve (e.g. variable pump pressure controller) has a great influence, if the
setting is not accurate, such as: pressure relief valve and pressure valve set difference is small,
during the process of the operation, the safety valve will open, and cause increased power losses
and a sharp rise of the oil temperature.
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inlet of electrical Remove all dirt
motor
accumulator Inspect nitrogen
pressure
Accumulator group, periodically check
safety valve of
accumulator
cooler periodically check
Level of tank Visually inspect
Recommended: Recommended: analysis Recommended: sampling
resistant oil
pressure of gauge Visually inspect
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indicator If necessary check the
operation
5.2 Maintenance
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6 flow control valve 1. Pressure changes lead to changes flow rate of throttle valve
7 check valve See A7-2
8 hydraulic oil oil hydraulic oil has not decomposed air (see I)
1. insufficient driving force
9 other
2. The air in the system is not fully discharged
5.2.5.4 Fault "D": the motor does not rotate or rotate too slow
Table 6
Fault source Fault Cause
2 pump See B2 and B9-2
5 pressure valve See B5
6 flow control valve See B6
Start conditions are not met. Electrical control circuit wiring
12 other loose, control signal (such as pressure switch failure or
configuration issue) is not sent.
5.2.5.5 Fault "E": the motor does not turn or cannot be stopped
Table 7
Fault source Fault Cause
1. The check valve is not closed or shut down slow because of
7 check valve
backpressure
2. The seat dirty or malfunction
9 other 1. air in the system is not fully discharged
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Prepared:Man Can 2020.04
Eh System
Checked:Wei Yuan 2020.04
Specification
Countersign:Li Gang 2020.04
IC.Z10.62201.01-E00 Countersign:
CONTENTS
EH SYSTEM SPECIFICATION........................................................................1
1. Overview ...........................................................................................................1
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disclose or use otherwise without written consent.
EH SYSTEM SPECIFICATION
1. Overview
Electronic hydraulic servo system is applied to steam turbine valve control. The
high pressure fire resistant oil is used. Servo valve is the core component of
electro-hydraulic system. Servo valve receives the deviation of the electrical signal
and the feedback signal, further to control the spool movement, thereby controlling
the position of the actuator piston. The actuator piston drives the corresponding
turbine valve to quickly regulate the steam inlet as required.
The system consists two parts: the EH oil supply system and the EH actuator. The
oil supply system and the actuator are connected by a set of stainless steel. Pressure
and return pipes deliver hydraulic oil between the actuator and oil tank.
2. Hydraulic Supply Unit
Hydraulic supply unit is an integrated tank with about 1000L capacity. The other
devices are all arranged on the tank, and the compact structure, which is conducive to
power plant construction and layout. Fire resistant oil is a kind of synthetic fat
phosphate with high ignition point. However, the oil working condition is rigid. The
operating requirement for oil temperature is 35-55℃.
EH oil supply system is mainly composed of three parts: oil tank, pressure oil
system and online circulation system.
2.1 Oil Tank
The oil tank is the carrier of the oil supply system, made of stainless steel with a
capacity of about 1000L. The tank contains the fire resistant oil which required by
control system. In order to prevent system leakage, the oil pan is arranged under oil
tank to accommodate the whole capacity. For ease of system maintenance, the pump
adapt horizontal design and placed outside of the tank. In order to monitor the system
operation, the corresponding measure instruments are set, such as level switches, level
transmitters, resistance thermometer, pressure transmitters, pressure switches. There is
also an electrical junction box on the side of the tank, all the electrical signals are
connected to the junction box.
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Fire resistant oil is required to be trial phosphate type synthetic oil. Oil quality
should meet the DL / T571-2007 "New-phosphate fire resistant oil quality standards"
and "operation phosphate fire resistant oil standards." Please use FYRQUEL EHC
PLUS, FYRQUEL EHC or similar fire-resistant hydraulic oil.
2.2 Pressure Oil System
Pressure oil system consists EH main oil pump, filter, relief valve, accumulator,
controller and pressure measuring gauge, etc.
EH main oil pump is a variable-flow plunge pump under constant pressure, the
system has two main pumps with same capacity running multiply and standby for
each other. Normal working pressure of the pump is set to 160bar, pump outlet
pressure is adjusted by the pressure controller on the pump. Pump outlet pressure
adjustment uses remote control mode, adjusts through the relief valve installed on the
control block. Pump outlet fluid go through an overpressure valve and then enter into
the main filter. When the pump outlet pressure exceeds a certain value of normal
working pressure, overpressure valve opens to prevent system overpressure. The filter
has a 3μ filter cartridge, which filters impurities in the fluid in order to ensure the
cleanness of fluid in the system. Filter has differential pressure indication, when the
filter cartridge get dirty and clogged, it will send an alarm signal to remind
maintenance personnel to change the filter cartridge. Before and after the filter is
equipped with isolation valves so that people can change the filter cartridge easily.
Pressure transmitters are installed at the outlet of each main fluid pump and also the
manifold, pressure signals are sent to the control system to monitor the working
conditions of the system, and interlock control and protect.
Relief valve is installed on the control block, two in all. Relief valve
MAX01AA051 adjust the outlet pressure of MAX01AP001. Relief valve
MAX01AA052 adjust the outlet pressure of MAX01AP002.
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To maintain fluid pressure stable when the system changes working condition, six
50L capacity accumulators are configured, and installed on the side of the fluid
reservoir, connected to the pressure fluid manifold. Bladder accumulator consists of a
balloon filled with high pressure gas and steel cylinder. Bladder is filled with 93bar
nitrogen when working, the steel cylinder outside the bladder is connected to
high-pressure fluid system. When the system works, 160bar high-pressure fluid acts
on the bladder, compresses the nitrogen. When the system fluid pressure fluctuating
such as pressure decline, the compressed nitrogen expands and provides pressure to
the system. Accumulator inflation: each accumulator is equipped with a safety valve,
when the system overpressures it can decompress, it can also isolate the accumulator
from the system for maintenance. Specific inflation method see operating instructions.
Pressure fluid is divided into five branch through the manifold, and sent to main
stop valve actuators and governor valve actuators after passing through the isolating
valve (MAX01AA291-295). The five lines of fluid are: the left main stop valve,
governor valve actuator; the right main stop valve, governor valve actuator; the left
reheat stop valve, governor valve actuator; the right reheat stop valve, governor valve
actuator; overload valve actuator.
2.3 Online Circulation System
The key of the EH system is electro-hydraulic servo system; the core element is
servo valve. Servo valve decides the performance of the whole system (stability,
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Circulating system adopts two sets of redundant system. Each contains a circulation
pump. Part of the fire resistant oil goes into the fluid cooler for cooling, cooled fire
resistant oil return to the reservoir through drain fluid filter assembly.
Because the fluid viscosity is very sensitive to temperature, if the temperature is too
high, oil ageing will be very fast. Therefore, a good performance of oil cooler is very
important. The system uses tubular cooler, compact structure, using closed water, and
generally requires desalted water. Detailed parameters see the technical specifications
in following chapter. Cooling pump sends fluid from the reservoir to the shell side of
the tube cooler, cooling water on the pipe side cools the fluid, and fluid is sent to the
reservoir after going through the filter. There are two sets of filters, redundantly.
2.4 Regeneration Device
One connection coupling under the accumulator sends fluid into regeneration
device from the manifold. Regeneration system consists of diatomite and cellulose,
can improve fluid quality and filter impurities in the fluid, so as to change fire
resistant fluid quality.
Diatomite can adsorb acid radical ion and moisture. Using diatomite can
successfully process phosphate ester fluid continuously. It is found that continuous
processing (not intermittently) helps extend the life of fluid. Adsorbing moisture
through diatomite can keep the fluid dry, and continuous processing cost the least
consumption of diatomite. The proper use of diatomite is recommended to be 15Kg
per 100 liters per hour.
Cellulose filter is on the downstream of the diatomite filter, it is used to prevent the
diatomite powdery particles entering the EH fluid. Diatomite acts effectively in the
process of oil maintenance. In fact, when achieving a low moisture, hydrolysis has
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These advantages mean that this technology can be widely used, improving the use
and economic benefits of phosphate ester synthetic fluid, extending service life means
minimizing waste fluid treatment.
2.5 Measuring Equipment
In order to ensure the normal operation of the system, the system is also equipped
with corresponding measuring equipment. Mainly contains fluid level switches, fluid
reservoir temperature thermal resistances, fluid filter pressure difference switches,
fluid pressure transmitters, etc. These signals are sent to the control system to control
system to monitor the whole system.
3 Technical Specifications
3.1 Fluid Reservoir Nominal Volume: About 1000L
Material: 0Cr18Ni9
Main pump type: Axial constant pressure variable flow piston pump (Redundant)
Cooling area 8 m2
Dimensions:
Total weight 91 kg
3.7 Accumulator:
Bladder accumulator:
Nominal capacity 50 L
System sets two level switches and each level switch has 2 contacts. low, low-low,
low-low-low signals are used for turbine protection by 3 out of 3. High contact is for
alarm. The specific setting is subject to the setting list.
3.11 Gross Equipment Weight
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IC.Z10.62203.01-E00 Countersign:
Reviewed:Chi Dingnan 2020.04
CONTENTS
OIL FLUSHING INSTRUCTIONS........................................................................................ 1
1. Introduction .......................................................................................................................... 1
2. Safety Precautions ................................................................................................................ 2
3. Cleanliness Acceptance Criteria, Measurement, And Approval ...................................... 4
3.1 Acceptance Criteria .................................................................................................... 4
3.2 Measurement of Cleanliness ...................................................................................... 4
3.3 Approved ..................................................................................................................... 4
4. General Requirements ......................................................................................................... 4
5. The Reference ....................................................................................................................... 5
6. Attachments .......................................................................................................................... 6
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Thewritten
without Whole consent.
Book : Page 130 of 152
IC.Z10.62203.01-E00 Page 1 of 23
1. Introduction
The intent of this document is to define minimum requirements for flushing and
cleaning procedures used for piping of control fluid systems connected to
electro-hydraulic actuators supplied by SHANGHAI TURBINE (Steam Turbine
Division).
Remark:
This procedure must be read carefully and must be fully understood before
starting any flushing and cleaning activity. All work must be carried out by
qualified personnel who are familiar with this procedure and all other documents
referenced within this procedure. Failure to observe this procedure can cause
damage to equipment or hazard to personnel.
Control fluid systems (MAX) are complex systems, mainly consisting of a
minimum one or more centralized hydraulic supply units, electro-hydraulic valve
actuators and interconnecting piping.
Size and complexity of control fluid systems require extensive field fabrication and
assembly. Thus, contamination with sand, welding scale, dust, rust, etc., might occur,
although cleanliness at erection has high priority. Contaminants, if not removed, may
lead to failure of the hydraulic actuators or components of the hydraulic supply units,
or even pollute the control fluid so that the specified properties become lost.
Therefore, all contaminants must be removed prior to initial start-up. If any
contaminants are expected after major inspections or repairs, they must also be
removed.
The purpose of the cleaning and flushing operation is to provide a control fluid
system piping that is free of particle contaminants which could damage
electro-hydraulic actuators or hydraulic supply units, or influence their operation in a
negative way.
This can be accomplished by using a fluid to remove particle contaminants from the
pipe wall and finally flush them out of the system.
Distribution system flushing practices and procedures vary greatly. It is the Clients’
obligation to use an adequate method which finally ensures the specified cleanliness
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NO Flaming No Smoking
Usable ambulance Box, Fire Fighting Equipment and fire alarm is required
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HSU HSU
T P T P
Figure 1: Typical arrangement for single valve arrangement and combined valve
图1:一个阀门及一个组合阀门的典型布置
arrangement
Pre-fabrication, erection, and mechanical completion must be done for the control
fluid system(Including its hydraulic supply units) before starting any flushing and
cleaning operation.
The piping of the control fluid system shall be free of any contaminants as far as
possible (e.g.by air blasting in accordance with proven procedures) to shorten the
duration of flushing activity.
It is not permitted to let any fluid pass through the actuators before flushing has
been carried out successful. Therefore, all actuators must be disconnected from the
pipe work before flushing.
The HSUs are not allowed to be used for any flushing and cleaning activity except
for the procedure as described in attachment 1.
Control fluid and flushing fluid must be the same, flushing fluid can be re-used as
control fluid.
All temporary equipment used must be suitable for the design conditions of the
system (e.g. design pressure, temperature range, flow, density, medium resistance,
etc.). Special care has to be taken to ensure proper and tight installation of temporary
equipment.
Only clean equipment is allowed to be used.
5. The Reference
The following documents must be read and fully understood before starting any
activity described in this procedure:
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G11/2"connect
to T port
CVPRV
connection
T CVRF connection
P G11/4"pump connection
G11/4"accumulator Pressure Adjusting sample connection
line connection 180bar
FDAs are modules which must be connected to the lines instead of the EHAs to
bypass the EHAs avoiding particles entering them.
All EHAs must be disconnected from the EHA lines and replaced by FDAs before
starting any flushing operation.
An FDA consists of pressure line counter flange, connecting pipe, ball valve
(shut-off slide valve), and return line counter flange (see figure 2).
Figure 2 FDA
Notes:
The design depends on the actual working condition (for example the arrangement
of EH servo motor), adhesive elbow is allowable
The nominal pipe size of FDAs must be the same or larger than the nominal pipe
size of the piping to be cleaned, as shown in P&IDs.
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Pressure pipe counter flange and blank flange (if necessary) are required to be the
same size and pressure rating as the pressure pipe flange.
Oil return flange adapt SAE 3/4-3 standard flange (3000psi), oil return counter
flange must be the same size and pressure rating as the oil return flange.
Notes:
The connection between the flanges (between pressure line counter flange and
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The shut-off slide valve (part no. 3) can be located at any position in the piping
Notes:
Globe valves are also used for the drain of pipe pressure test.
Screws, bolts, nuts, washers, and gaskets may be required to connect the FDAs to
the MAX piping.
Collecting Vessel for Returning Fluid from Pressure Relieve Valve (CVPRV):
The CVPRV is used to collect fluid in case of safety valve actuation of the FDH
(pump side).
- Size must be of suitable volume to switch-off the pump in case of safety valve
actuation
It is recommended to use one of the barrels (if supplied) for the first filling of the
HSU.
It is not permitted to use the EHA tank for collection of the flushing fluid returning
from the piping system. Therefore, a separate vessel must be used.
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disclose or use otherwise without written consent.
It is recommended to use one of the barrels (if supplied) for the first filling of the
HSU.
Remark:
Vessel volume: smaller containers may be used if the vessel volume is higher
than the total volume of all accumulators.
The CVRF is full with flushing fluid, the fluid must be transferred back to the HSU
tank for use in further flushing cycles.
Pumping back to the HSU tank and filtering can be done by a barrel pump unit
consisting of a barrel pump, a filter with fine mesh (≤ 3 μm) and a hose which
connects the unit to the tank of the HSU.
The barrel pump unit must be suitable to be connected and fix tightly to the CVRF.
It must also be suitable to handle contaminants removed from the MAX piping
system.
All parts must be suitable for the pressure rating of the pump.
Particle Counter:
A calibrated particle counter must be used for analyzing the fluid. It must fulfill the
following requirements:
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System Preparation:
Remark:
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
Choose main pump to carry out the pressure test (AP002 is recommended)
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Set the overflow valve (on the pump) to maximum pressure (loosen
the screw, clockwise rotating)
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Adjust the overflow valve, set the pressure to 190bar, adjust AA052 active value to
190bar, and then hold on
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X1 X2 X3
SAE11/4" SAE11/4" SAE11/4"
50L 50L
35X4
35X4
35X4
S M1 M2 M2
G114" G112" G112" S M1
G2" G14" G14" G2" G14" G14"
P
I 38X5 P
P P
30X4
38X5
T T
G1" G12" G1" G12"
P T P
X1 M3 G14" G14" T
G114"
M1 M2 I
I P
P
G14"
G14"
B B
2
A A
坼开此接头
P T
P T T P
抗燃油油桶
(非供货范围)
1
坼开此接头
M G3/4" M G3/4" I
T
P T P T
30X4
30X4
SAE11/4 SAE11/4
3000psi
3000psi
B 6000psi B 6000psi
SAE2
SAE2
8X1.5
8X1.5
8X1.5
8X1.5
S S
L PP G1/4 L PP G1/4
L1 L1
60X4
60X4
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T6 T5 T4 T3 T2 T1
DN40 DN40 DN40 DN25 DN25 DN25
50L 50L
G11/2"
T
I P P
P
T T
M3 T
50L
I 50L
I P
P
S M1
G2" G14" P
P
T
A A
G1" G12"
T P T
G1" G21"
B B P
R T
B B T
A A
50L
50L
P T T P
G34" P
T
T
G1"
T P T
G1" G21"
P T
G11/4"
M
57X3 SAE1
M
P T
57X3
SAE1
M
hose
CVRF sample
CVRF
(not in the scope
of Shanghai Turbine
supply)
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
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Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
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preparation
FDA FDA
flushing
FDA FDA
Flowchart 9: sampling
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