2300MW

2005


CHAPTER 1
SECTION 1
SECTION 2
SECTION3

MAINTENANCE DURING THE OPERATION OF TURBINE ...................................- 3 ROUTINE MAINTENANCE DURING OPERATION ........................................................................ - 3 SUPERVISION AND REGULATION OF THE SAFETY AND ECONOMY DURING OPERATION ........... - 6 INSPECTION PROJECTS FOR THE OVERHAUL AND MINI-OVERHAUL OF UNITS ........................... - 9 -

CHAPTER 2 ......................................................................................................................- 12 SECTION1

SECTION2
SECTION3
SECTION4

INSTRUCTION ON ELECTRIC MONITORING SYSTEM OF STEAM TURBINE ............................... - 12 MANUAL OF EMERGENCY TRIPPING DEVICE OF STEAM TURBINE ............................................ - 33 INSTRUCTION ON AUTOMATIC OPERATION DEVICE FOR TURNING GEAR .................................. - 42 DIGITAL ELECTRO-HYRAULIC (DEH) CONTROL SYSTEM SPECIFICATIONS .......................... - 53 -

CHAPTER 3 ................................................................................................................................ - 110 SECTION1

SPECIFICATION FOR MAIN BODY OF STEAM TURBINE AND LINE DRAINAGE
SYSTEM(N300-16.7/537/537-8) .................................................................................................................. - 110 SECTION2
N-17750 CONDENSER SPECIFICATIONS ................................................................................ - 117 SECTOION3
SPECIFICATION FOR PNEUMATIC CONTROL SYSTEM OF STEAM EXTRACTION CHECK VALVE OF

STEAM TURBINEN300-16.7/537/537-8 ............................................................................................... - 130 SECTION4

SELF-SEALING TURBINE STEAM SEAL SYSTEM SPECIFICATIONS ......................................... - 134 SECTION5
MAINTENANCE OF CONDENSATE PUMP ................................................................................. - 148 SECTION6
FEEDWATER PUMP................................................................................................................ - 151 SECTION7
LP HEATER SYSTEM SPECIFICATIONS .................................................................................. - 160 CHAPTER4 .................................................................................................................- 166 SECTION1
SPECIFICATION FOR LUBRICATING SYSTEM .......................................................................... - 166 SECTION2
DESCRIPTION OF INTEGRATED OIL TANK ............................................................................... - 174 SECTION3
MANUAL OF SHAFT-JACKING DEVICE .................................................................................... - 180 SECTION4
MANUAL OF OIL INJECTOR .................................................................................................... - 185 SECTION5 MAIN OIL PUMP DESCRIPTION................................................................................................... - 188 SECTION6
INSTRUCTION FOR SPILL VALVE ............................................................................................ - 190 SECTION7
INSTRUCTION FOR TWIN-TONGUE CHECK VALVE................................................................. - 194 SECTION8
OPERATING INSTRUCTION FOR OIL SMOKE SEPARATOR ....................................................... - 197 -

CHAPTER5
INSTRUCTION OF HYDROGENSEAL OILSTATOR COOLING WATER SYSTEM
FOR 300MW GENERATOR .......................................................................................................................- 199 SECTION1
GENERAL ........................................................................................................................... - 199 SECTION2
HYDROGEN CONTROL SYSTEM(SEE HYDROGEN CONTROL SYSTEM DIAGRAM)....................... - 199 SECTION3
SEAL OIL CONTROL SYSTEM(SEE THE SEAL OIL CONTROL SYSTEM DIAGRAM) ...................... - 204 SECTION4
STATOR WINDING COOLING WATER SYSTEM(SEE STATOR WINDING COOLING WATER CONTROL
SYSTEM DIAGRAM)....................................................................................................................................... - 208 -

CHAPTER6

DESCRIPTION OF CIRCULATING WATER SYSTEM.............................................- 212 -

SECTION1
SECTION2
SECTION3
SECTION4

GENERAL SITUATION ............................................................................................................ - 212 DESIGN DESCRIPTION OF CIRCULATING WATER SYSTEM ....................................................... - 213 THE CONSTRUCTION AND INSTALLATION DESCRIPTION OF THE CIRCULATING WATER SYSTEM - 217
OPERATING MANAGEMENT DESCRIPTION OF CIRCULATING WATER SYSTEM .......................... - 218 -

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Chapter 1

Maintenance during the Operation of Turbine

Section 1

Routine Maintenance during Operation

Operation of turbine with load is one of important section during the production of
electric power. It is the duty of operation persons of turbine to perform correctly rules and to
operate, check, supervise and regulate strictly during operation, and the precondition to ensure
the safe and economic operation of turbine devices.
Working contents of the routine maintenance during the operation of turbine are:
(1) To supervise the related devices and meters via supervising panel, transcribing readings
periodically, inspecting circularly, measuring vibration periodically, to do the meter
analysis, and to check the safe and economic condition of operation.
(2) To regulate the related operating parameters and patterns, to go through the economic
distribution principle of load, to enable the devices to operate under the best condition,
to reduce the ratio of heat consumption and auxiliary power, and to increase the
economic efficiency of operation.
(3) To enhance the supervision of failed devices, fault systems and devices under a special
operation pattern, to prevent the trouble occurrences and enlargement, to increase the
utilization factor and to ensure the safe operation of devices.
(4) To do various protective tests periodically and the normal tests and shift operation of
auxiliaries.
In short, the main roles of operation of power plants are: to supply the needed electric
energy to users or power network continuously & safely & economically.
I. The shift persons should do the following while the turbine normally operating:
(1) To supervise & operate & regulate strictly, notice at any time the variation of
indication of each meter and adopt the corresponding maintenance measures, and to
fill in the operation logs.
(2) To read meters every one hour and analyze the data. if the reading is different from the
normal value, the cause should be found out immediately and the necessary measures
should be taken.
(3) To inspect the unit periodically, especially notice the temperatures of babbit of each
trust bearing pad and each bearing, the oil return temperature, oil flow and vibration,
operation and tightness conditions of the cooling system of generator and prevention
of oil leakage and fire catching.
(4) To do the listening inspection for each part of turbine, especially while the operating
condition changes greatly.
(5) To inspect periodically or contact with maintenance persons to clean the screens
installed in the steam or water or oil system in terms of the exact condition during
operation.
(6) To regulate in time the steam pressure of shaft sealing, to prevent leaking steam caused
by too high pressure from entering the bearing box, resulting in the deterioration of oil
quality; and simultaneously prevent air leakage of low-pressure casing gland caused
by too low pressure resulting in the drop of the condenser vacuum.
(7) To keep the turbine operate under the economic condition, and the following
conditions should be met:
a) To retain the main steam temperature at the rating, steam pressure conform to the
prescribed value of variable pressure operation curve of the unit, and the variation
does not exceed the permissible range.
b) The regenerative system should run normally, the outlet water temperature of
heater should confirm to the designed value or in the range prescribed by the rules.

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c) To keep the condenser operating under the best condition, check the steam
extraction temperature of turbine periodically and regulate it in time if necessary.
d) The degree of supercooling of the condensate should not exceed the prescribed
value.
(8) To do the various periodic shifts and tests.
(9) To clean the devices of turbine generator periodically
II. Control parameters during the normal operation
In order to ensure the safe and economic operation of turbine devices, operation persons
should supervise and analyze the operating condition of devices via various meters and
regulate if necessary except for a visual method, to retain the various value in the permissive
range.
The values which should often be supervised are: the load of turbine, temperature and
pressure of the main steam, vacuum of the condenser, rotary speed of turbine (frequency) and
running condition of rotary devices. The parameters which should often be inspected are:
steam pressure of regulating chamber, steam pressure and temperature of each extraction port,
main steam flow, water temperature and level of inlet and outlet of each heater, oil level of oil
tank, anti-fire oil pressure, pressure and temperature of lubrication, vibration of each bearing,
thermal expansion and its difference of the unit, axial displacement of rotor, metal
temperature of trust bearing and main bearing, opening of steam regulating valve and wind
temperature of outlet of generator and so on.
Under the normal condition, the above parameters have a certain inherent connection,
such as: while the load of generator is increased, the steam flow into the turbine will increase
owing to the invariable main steam parameters, the opening of regulating valve is also
increased correspondingly, the steam pressure of regulating chamber and steam extraction
pressure of each section is increased proportionally (for the condensate unit), the steam
temperature before each section is also increased, and the thermal expansion of the unit is
increased; if the relationship between these parameters is out of rear during operation, there is
something wrong with the unit. if the steam pressure of regulating chamber and each
extraction port is higher than the pressure corresponding to the normal condition with this
power, the scaling or block exist in the flowing part.
Because the unit type is different, the value prescribed by operation rules of each unit
have to be carried out, these parameters can be kept in the permissive changing range via
check, analysis, regulation and maintenance, to ensure the safe and economic operation of the
unit.
III. Inspection during operation
Inspection is one of the important measures to understand devices, grasp the operation
condition, find the hidden trouble and ensure the safe operation of devices. Hence, the
following matters should be done carefully and strictly:
1. Inspection of the turbine proper
(1) The total expansion indication of turbine, oil return temperature and quantity, vibration,
servomotor travel and action of regulating valve and so on.
(2) Bearing: oil return temperatures of all the bearing pads, oil quantity, vibration, the
leakage of oil baffle.
(3) Cylinder: shaft sealing admission, running sound of the unit, relative expansion,
vibration of exhaust casing and exhaust temperature.
(4) Generator and exciter: wind temperature of outlet and inlet, cooling water pressure and
temperature of each cooler etc.

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(5) The devices of turning gear: the handle should be arranged at the OFF position, and the
operating power source should be right.
(6) The main automatic stop valve: the indication of position of the main stop valve, smooth
flowing of cooling water
(7) The main meter panel: the indication of pressure and vacuum of steam, water and oil
systems, relative expansion difference and indication of axial displacement.
2. Inspection of the pumps
(1) Motor: current, interlock "on" position, wind temperature of outlet, temperature and
vibration of bearing, running sound, good grounding wiring and firm foundational bolts.
(2) Pump: the outlet pressure should be right, gland packing should be of no heating or
watering, the running sound should be right, the cooling water of bearing pad should be
smooth, the water discharge hopper has no block, the oil level of bearing is normal and
quality of oil is good, the oil ring can carry oil normally and has no leakage, coupler
hood is fixed well.
(3) The insulation of tubes connecting with pump should be all right, its support rack is fast
and has no leakage, and opening of valve should be normal.
(4) The relative meters should be complete and perfect, and its indication should be correct.
3. Inspection of feed water pump
Except for the above items, the following items should be inspected because the feed
water pump has its own lubrication system:
(1) Indication of the pressure of balance disk should be normal.

(2) Position of the water inlet and outlet valve of cooling wind chamber of motor of
motor-driven feed water pump and the condition of wind temperature.
(3) Oil and water temperature condition and oil pressure of outlet and inlet of oil cooler
should be normal.
(4) The operating condition of hydraulic coupler.
4. Inspection of other auxiliaries
(1) The level of lubrication tank, anti-fire oil tank and auxiliary oil tank should be normal,
the operation of flue gas exhauster.
(2) Oil cooler: the temperature of outlet and inlet should be normal; waterside has no
accumulated gas or leakage of oil and water. The oil pressure should be more than the
water pressure.
(3) Each oil pump, oil filter and low-level oil tank, the oil level should be normal.
(4) The main air ejector and shaft seal air ejector: the pressure of working steam or water,
vacuum, water seal of vacuum break valve should be normal, the rotary devices using
vacuum pumps should have abnormality and each component should have no overheat.
(5) Condenser: the water level of condenser, the pressure and temperature of the condensate
outlet and inlet, the temperature of condensate and the position of switch of each valve.
(6) HP and LP heaters: the water level, the pressure of extraction steam, the position of the
switch of valve, the protective water source of hydraulic check valve should be put into
operation, the working condition of water level regulation, the piping and flanges should
have no leakage of water and steam.
(7) Shaft seal cooler: water level, the condition of siphon well, the position of watering
valve, the condition of steam extraction of exhaust outlet, the sufficient water flowing
quantity.
(8) Drain expander: the switch of valves should be right and have no leakage of steam.
(9) Deaerator: the pressure, temperature and water level should be normal, the condition of
steam extraction, and the position of switch of each valve, the working condition of
water level regulator. Also, the flange of tube should have no leakage of water and steam

-5-

and the safety valve should work normally. The abnormal condition should be analyzed
carefully and its causes should be found out and eliminated if it is found during
inspection. The measures should be taken if the abnormity cannot be eliminated
immediately, to prevent the enlargement of the trouble, and the trouble should be
recorded and reported.
IV.

Test during the normal operation and shifting of auxiliaries

In order to ensure the safety of the main devices, their protections and auxiliaries should
be safe and reliable, to avoid the damage to the main devices or shutdown caused by the fault
of protections or auxiliaries, so the following should be done:
(1) To operate the main stop valve periodically. The load should be changed in a large range
periodically for the turbine carrying a stationary load, to prevent the lever of regulating valve
from logging.

(2) Water (steam) pressure check valve on each regenerative extraction pipe, check valve
and safety valve on the regulating extraction pipe should be tested and verified
periodically according to the rules. If a fault occurs to one check valve or safety valve, it
should be eliminated immediately or the corresponding measures should be taken.
(3) The reserve emergency oil pump and its self-starting installation should be tested
periodically. In addition, this test should be done while the turbine starts or before the
turbine is shut down.
(4) The oil level should be done the movement test every day, and the accumulating water at
the bottom of oil tank should be discharged periodically.
(5) Various automatic protections, including annunciator and lighting signal, should be
tested periodically during operation if possible.
(6) The protection of HP heater should be tested periodically. If HP heater has no high-level
protection or the protection is abnormal, it is forbidden to put into operation.
(7) The sealing test should be done for the vacuum system periodically, in general, once
every month.
(8) The shifting test should be done for the auxiliaries periodically every day including the
main air ejector, vacuum pump, condensate pump, boosting pump, drain pump, service
water pump etc. The insulation condition of motor of the reserve pump (devices) should
be supervised to prevent damage to the motor from fault enlarging as emergency start.
In conclusion, the daily work is very complex during normal operation, so the operators
should be with responsibility that the quality of the bank can be kept and the network can get
the safe and economic supply.

Section 2

Supervision and Regulation of the Safety and Economy

during Operation

Some important parameters during normal operation of turbine, such as the main steam
parameters, vacuum of the condenser, axial displacement, expansion difference and the
pressure of supervised section and so on, act as the crucial function to the safe and economic
operation of turbine. Hence, these parameters should be supervised carefully during operation
and regulated in time to retain in a prescribed range.
I. The main steam parameters
During the normal operation of turbine, the steam parameters may be deflected from the
rating inevitably and temporarily. If the deflection is not more than the permissive range, it
cannot damage the strength of the components of turbine, otherwise, it will result in troubles
of reliability and safety of operation. While the initial and steam extraction pressure is

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invariable, the change of temperature of the main steam will result in the change of
temperature of the whole thermal cycling source and the change of thermal efficiency of the
circulation. If the temperature of the main steam rises, the ideal enthalpy drop in the turbine
increases and the ability of doing work enhances. Oppositely, while the temperature of the
main steam drops, the ability of doing working decreases and so the efficiency drops.
Under the condition of complete opening of regulating valve, the seam flow through the
turbine decreases along with the rise of initial temperature, and regulating blades may
overload. The strength of metal will rapidly drop along with the rise of temperature. In
addition, the creepage may occur to the metal with high temperature. So rapid overload and
super temperature are dangerous, at present the manufacturer prescribes the upper limit of
temperature, in general not more 58 than the rating.
While the opening of regulating valve is given, the initial temperature drops and results
in the increase of flow quantity; the enthalpy drop of regulating stage decrease, the enthalpy
drop of the final stage increases, and the final stage is easy to overload; also, the initial
temperature drops resulting in the humidity of extraction steam increases, the impulsion
damage to the final stage blades increases; and the initial temperature drop will increase the
axial thrust. So the initial temperature drop not only affects the economic efficiency of the
unit operation but also threaten the safety operation of the unit. In order to ensure the safety,
the load should be reduced while the initial temperature is less 1520 than the rating.
While the opening of regulating valve is invariable, initial temperature and backpressure
are invariable and the initial pressure increases, all the stages of turbine will overload,
thereinto, the final stage is most serious. Simultaneously, the rise of initial pressure will
threaten the piping of turbine and other bearing components. The initial pressure drop does
not affect the safety of the unit, but the output of the unit will drop. Hence, the main steam
pressure is required to operate under the prescribed pressure; especially the unit operation
should be retained according to the variable-pressure operating curve for the sliding-pressure
operation unit.
II. Vacuum of condenser
Vacuum of condenser is namely the pressure of steam extraction of turbine, owing to the
variation of steam load, the copper pipe is scaled, the tightness of vacuum system is
deteriorated and the cooling water temperature changes, their values can be changed in a large
range, directly affecting the safe and economic operation of the unit. While the vacuum drops,
the total enthalpy drop of turbine will decrease, and the decrease mainly happens to the final
stages. At this time, the stress of these stages will decrease and the reaction degree will
increase. While the vacuum drops rapidly, the variation of reaction degree will cause the
variation of axial thrust and the thrust bearing may have danger. In addition, if the vacuum is
deteriorated severely, the temperature of extraction steam will rise, resulting in the variation
of center of the unit, accordingly resulting in the nonpermissive vibration. So the vacuum of
the unit is permitted to drop in a certain range during operation, or the load must be reduced,
even the emergency shutdown should be done.
While the vacuum increase, the enthalpy drop of the final stage of turbine increases, and
the final stage may overload. Especially while the final stage reaches the critical flow
condition, the further increase of enthalpy drop will be borne only by the final stage.
The variation of condenser vacuum can greatly affect the economic efficiency of
operation of the turbine. it mainly shows that the variation of vacuum will cause that of ability
of doing work. So, the copper pipe should be kept clean during the practical operation, and the
tightness of vacuum system should be kept qualified, to improve the economic efficiency of
the unit operation.

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III. Monitoring of the pressure of supervised section

In the condensing turbine, the pressure of steam chamber of the regulating stage and the
pressure of extraction steam of each stage is directly proportional to the flow of the main
steam. According to this theory, the operation of convection part can be supervised via the
supervision of the pressure of steam chamber of the regulating stage and the pressure of
extraction steam during operation. Hence, this pressure is called that of supervised pressure.
In a common condition, the manufacturer gives the steam flow and pressure value of and
each supervised section under the rating load of each turbine and the permissive maximum
steam flow and the pressure value according to the calculating result of thermal and strength.
The pressure of each supervised section is not identical under the same load even the same
type of turbine because each unit has its own property. Hence, each unit should be measured
according to the given data by manufacturer after installation or overhauling while the
convection part is under the normal condition, to acquire the relationship among the load,
main steam flow and pressure of supervised section, which acts as criteria for regular
operation supervision.
If the pressure of supervised section rises under the same load (flow), it shows that the
convection area of the convection section decreases mostly because of the scaling, sometimes
because some metal components are cataclastic or mechanical foreign matter is blocked in the
convection part or the blade is damaged and deformed. So while a heater is out of service, the
pressure of corresponding extraction steam section will rise if admission quantity of turbine is
unchanged.
Not only the pressure up of supervised section but also the pressure difference between
each supervised section is noticed whether to exceed the prescribed value. If the pressure
difference of a section exceeds the prescribed value, the working stress of this section of
diaphragm and movable blade will increase, resulting in the damage to the devices.
The severe scaling should be eliminated (in general, the pressure of supervised section of
intermediate-pressure and LP unit raises relatively 15%, that of HP or above unit 10%); the
following four kinds of methods are commonly used:
(1) The turbine is shut down and the casing is opened, with a mechanical method.
(2) To rinse with heated water under the slowly turning condition.
(3) To rinse with wet heated steam under a low rotary speed.
(4) To rinse with wet steam with load.
IV. Supervision of axial displacement and the temperature of bearing pad
1. Axial displacement
The index of the axial displacement of turbine rotor is used to supervise the working
condition of the thrust bearing; the axial thrust functioning on the rotor is borne by the thrust
bearing, to ensure the reliable axial clearance between movable and stationary parts. Too
much axial thrust or abnormality of operation of bearing will result in the burning and damage
to the thrust pad, to produce the damage to devices caused by the wear of movable and
stationary part. Various turbines are equipped with axial displacement indicator, which is used
to supervise the working condition of the thrust pad; the turbine should be forced to shutdown
immediately if the displacement exceeds the permissive limit value, to prevent the convection
part from damage. Different types of units have different ZERO positions of indicators. The
number of positive value indicated by the axial displacement shows the axial displacement
quantity at the thrust disk during operation of turbine. So, the indicators are arranged near the
thrust pad. In general, the thrust clearance of an integrated thrust pad is in a range of 0.4 to
0.6mm or so.

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The main steam pressure of the turbine is high and its temperature is low, especially the
water enters cylinder, resulting in a great axial thrust. So, the axial thrust will change greatly
if the vacuum is low or the convection part is scaled.
If the displacement is found to increase during operation of the unit, the turbine should
be examined throughout, to listening to its inner sound and measure the vibration of bearing,
and simultaneously to supervise the variation of the thrust pad and oil return temperature, in
general, the babbitt temperature of the thrust pad is not more than 95 and the oil return
temperature is not more than 75, while the temperature exceeds the permissive value, the
load should be reduced to enable it to restore to the normal even if the displacement indication
is not too much, if the indication exceeds the permissive value to cause the protective action
to trip, the generator should be paralleled off and shut down. At this time if the protection
does not act, it should be checked carefully.
2. Temperature of bearing pad
The bearing of turbine rotates in the bearing pad, causing the temperature up of
lubricating oil and bearing pad. Too high temperature of bearing pad will threaten the safety
of bearing. The temperature of bearing pad can be supervised via supervision of the
temperature up of lubrication during operation, in general, the temperature up of lubrication
should not exceed 10 to 15, but it acts only as auxiliary supervision because the oil
temperature lags behind that of metal and cannot show immediately the variation of bearing
pad temperature.
In order to make the bearing pad operating normally, the temperature of oil supplying to
bearing pad is prescribed definitely, in general the specified temperature is within 35 45
.

Section3

Inspection projects for the overhaul and mini-overhaul of

units

In order to keep the unit can operate safely and economically for long time. Perform the
mini-overhaul once each time when the unit has been in operation for 4 to 8 months
accumulatively. Eliminate the defects occurred during operation in time and replace the
damaged components.
1

Imperative inspection items for mini-overhaul

1.1
Check each support bearing and thrust bearing, and check whether there are the
phenomenon of serious wearing, picking, crack, decrustation, etc. with the babbit alloy
surface so as to treat in time.
1.2
Check main oil pump and tooth coupling of main oil pump to ensure the safe
operation.
1.3
Take the static test of control system, oil spray test of emergency stopper and
over speed test again after the mini-overhaul so as to confirm the reliable operation of
control and security system.

Imperative inspection items for overhaul

2.1

Overall inspection
2.1.1

Check whether there are the phenomenon of leakage and erosion at the

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steam casing split;

2.1.2 Check and record the raise degree of rotor and each journal; Check and
record the longitudinal and transverse level of bearing box and steam casing split;
2.1.3

Check and record the flow clearance and gland clearance;

2.1.4 Remove the connection bolts of coupling, check and record the change of
alignment of coupling.
2.2

Rotor inspection
2.2.1

Clean the impeller and impeller blade and remove the scale.

2.2.2 Check the axial run-out of each part and run-out of end face. Check the
cylindricity of journal and the run-out of end face of thrust disk.
2.2.3 Check whether there are the defects of cracks, erosion and damage, etc. at
each part of impeller, blade and rotating part. Perform the static frequency test to the
long blades.
2.3

Bearing
2.3.1

Check the clearance and tightening force of bearing.

2.3.2 Check whether there are the defects of wearing, decrustation and cracks etc,
with babbit alloy.
2.3.3 Check the platinum resistance thermometer, and replace the damaged
elements.
2.4
2.5

Steam casing, holding ring and diaphragm

2.5.1 Check whether there are cracks with the HP inner casing and outer casing;
2.5.2 Check whether there are changes with the center of steam casing.
2.5.3 Check the split clearance of upper half and lower half.
2.5.4 Check whether there are cracks with the holding ring and diaphragm, and
whether there are deformation with the diaphragm.
2.5.5 Check the bolts, gland gaskets and the thermocouple, and replace the damaged
elements.

2.6

Valve
2.6.1 Disassemble and check whether the components of main steam valve and
control valve have become loosen or damaged;
2.6.2 Check whether there are any change with the stem and the clearance of sleeve.
Check whether there are crack and bend with the stems;
2.6.3 Check whether the touch between the valve disk and valve seat is tight;
2.6.4 Check whether there are any plastic deformation with the tooth gasket.

2.7

Control system
2.7.1 Check whether there are any erosion, crack with the control and safe part sets.
Check whether there are any changes occurring with the fitting clearance.
2.7.2 Check whether the geometrical size and rigidity of spring of emergency

- 10 -

stopper meet the requirement of drawing. Check whether there are cracks with the
spring surface.
2.7.3 Perform the static test, tightness test of valve, oil spray test of emergency
stopper and over speed test to the control system,
2.8

Oil system
2.8.1 Check the installation clearance of bearing of main oil pump, impeller and
tooth coupling;
2.8.2 Clean the oil cooler and check whether there area damages with the copper
pipe.
2.8.3 Check the filter and clean the oil box and oil filter..
2.8.4 Check and clean the fan and smoke exhaust system.
2.8.5 Check and clean the oil pipe line.

2.9

Vacuum system
2.9.1 Check the ejector
2.9.2 Check the tightness of vacuum system.

2.10

Exhaust system

2.10.1 Check each check valve of exhaust and the control system;
2.10.2 Check the check valve of high exhaust and keep the tight closing;
2.11

Drain system:

Check each drain pipe line and keep them expedite and have no block.
2.12

Centering support system:

Check each part of centering support system to see whether they meet the
designing requirements; Check whether the anchor bolts have become loose;
Check whether there are gapped phenomenon between the pedestal and filling
iron.

2.13 Monitor system:

Check the axial displacement, expansion differentia, vibration, and each element of monitor system.
Indicate and adjust over again.
2.1.4 Monitor the main steam pipe and reheat steam pipe line about the change of creepage in long
term.

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Chapter 2
Section1

Instruction on Electric Monitoring System of Steam Turbine

0-1 Overview of system

The electric monitoring protection system of steam turbine (see D300N-003005U) consists of
five parts, namely: shafting (D300N-003006C), oil pressure / vacuum (D300N-003008D),
temperature (D300N-003009D), auxiliaries (D300N-003010U) and ETS (D300N-003011E).
The instruction describes the arrangement of measuring points for shafting, the various
signals in oil pressure / vacuum and temperature parts related to normal safe operation of
turbine, the control logic of various electric equipment and motors, as well as the emergency
tripping system (ETS) of turbine.
All setting values for various signals concerned in this instruction are based on the setting
values in the Instruction on start-up and operation of steam turbine. This instruction can be
used as basis of corresponding design by the Design Institute.
0-2 Shafting
1

General
The parameters of shafting for the steam turbine-generator unit to be continuous
monitored are speed, zero speed, overspeed, differential expansion of HP/IP and LP
turbines, axial displacement, thermal expansion of HP/IP casing, eccentricity, shaft
vibration and vibration at cover of bearing pedestal. Unless specified otherwise, the
following parameters shall be monitored by the MMS6000 Serial from EPRO Company.
The description will be made for speed, displacement and vibration respectively hereafter.

Speed monitoring

2.1 Speed and zero speed

The monitoring function here is realized by two transducers, one of which is for speed and
the other for zero speed. Corresponding the speed measuring range of 05000 rpm there
are 420mA DC signal outputs from the monitoring module here to the DCS system for
display.
The zero speed relay contact signal is output as one of the starting-up signals for the
automatic turning gear of turbine while the speed falls down to 2 rpm.
2.2

2 out of 3 electric overspeed protection

There are 3 transducers used for electric overspeed protection. When the speed n of

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turbine is equal to or greater than 3300r/min and the 2 out of 3 logic requirement is met,
the overspeed protection signal is sent out to the relay to trip the turbine after logic
processing by the ETS.
2.3

Tachometer at head of unit

A domestic made CS-1 type magnetic resistance speed transducer and a domestic made
WZ-3 type intelligent transient tachometer with digital indication are adopted for the unit.
The tachometer possesses such functions as two level overspeed alarm, zero speed alarm,
fast speed indication, max. speed storing and reproduction, self check and calibration etc.
Two level overspeed alarm and the zero speed alarm are output through relay contact. The
tachometer is mounted on the cover of front bearing pedestal at head of unit.

Displacement monitoring

3.1 Differential expansion of HP/IP and LP turbines

These two monitoring channels here are provided with a transducer for each, which output
the corresponding 420mA DC signals to the DCS system for display. The alarm relay is
actuated and the alarm signal is sent out while the differential expansion value of HP/IP
turbine +6mm or -3mm and the differential expansion value of LP turbine
+14mm. The emergency relay is actuated and the differential expansion over limiting
signal is sent out while the differential expansion value of HP/IP turbine +7mm or
-5mm,and the differential expansion value of LP turbine +15mm.
3.2

Axial displacement
There are two transducers used for axial displacement monitoring. Corresponding to the
axial displacement measuring range of -2mm+2mm , the 420mA DC signals are
output from monitor to the DCS system for display. The alarm relay is actuated and the
alarm signal is sent out while the axial displacement value 0.6mm or-1.05mm . The
emergency relay is actuated and the axial displacement over limiting signal is sent out to
ETS for tripping the turbine while axial displacement value of both transducers
+1.2mm or -1.65mm.

3.3

Eccentricity and phase-shifting

The eccentricity and phase-shifting measuring is conducted by a transducer for each.
Corresponding to the eccentricity measuring range of 0100m , these monitors output
the 420mA DC signals to the DCS system for display. The alarm relay of monitor is

- 13 -

actuated to send out the alarm signal while the eccentricity of

shaft exceeds its original

value by 30m.
3.4

Thermal expansion of HP/IP casing

There are two monitoring channels for thermal expansion of casing located at both sides of
HP/IP casing of turbine respectively to monitor the casing expansion related to the
foundation of unit.
Two domestic made 50mm absolute expansion transducers and a completed absolute
expansion monitor are used for HP/IP casing expansion. Corresponding to the HP/IP
casing expansion measuring range of 0~50mm, the respective channel of monitor outputs
the 420mA DC signal to the DCS system for display. The alarm and emergency relays
of monitor are actuated to send out the corresponding alarm signal while the casing
expansion exceeds the setting value I and II respectively.

4
4.1

Vibration
Shaft vibration
In order to monitor the radial vibration of rotor related to the bearings, the 1#6# journal
bearings of unit are provided with two monitoring channels for shaft vibration respectively,
one of which is in horizontal (X) direction and the other in vertical (Y) direction. That
means there are total 12 channels. Corresponding to the shaft vibration measuring range of
0400m, each channel of monitor will output the respective 420mA DC signal to the
DCS system for display. The alarm relay in respective channel of the monitor is actuated
to output the alarm signal while the shaft vibration in any channel 0.127mm. The
emergency relay in respective channel of the monitor is actuated to output the emergency
alarm signal while the shaft vibration in any channel 0.25mm.

4.2 Vibration at cover of bearing pedestal

In order to monitor the absolute vibration of bearing pad related to the free space, the 1#
6# journal bearings of unit are provided with a monitoring channel for vertical vibration at
cover of bearing pedestal respectively. That means there are total 6 channels with total 6
speed transducers. Corresponding to the bearing pad vibration measuring range of 0100
m, each channel of the monitor will output the respective 420mA DC signal to the
DCS system for display. The alarm relay in respective channel of the monitor is actuated
to output the alarm signal while the vibration at cover of bearing pedestal in any channel

- 14 -

 50m. The emergency relay in respective channel of the monitor is actuated to output
the emergency alarm signal while the vibration at cover of bearing pedestal in any channel
80m
0-3
1

Oil Pressure /Vacuum

General
The oil pressure/vacuum part of electric monitoring protection system of the steam turbine
contains the destination of various signals related to the oil pressure and vacuum, as well
as the various control logic of valves, oil pump and turning gear related to the oil pressure
signal.

Tripping device for condenser low vacuum and lube oil low pressure
There are 4 vacuum switches mounted in the tripping device for condenser low vacuum
and 7 pressure switches in the tripping device for lube oil low pressure.

2.1

Signal output from tripping device for condenser low vacuum

The vacuum switch PSB1 is actuated to output the alarm signal while the condenser
vacuum becomes lower (i.e. the pressure in condenser P14.7kPa). Three vacuum
switches PSB2PSB4 are actuated to output the signal to the ETS for simultaneous alarm
while the condenser vacuum becomes too low ( i.e. the pressure in condenser P
19.7kPa).

2.2

Signal output from tripping device for lube oil low pressure
The pressure switch PSA1 is reset to output the alarm signal while the oil pressure in lube
line P 0.049MPa. Meantime the pressure switch PSA2 is also reset to output the signal
for automatic starting the AC lube oil pump.
The Pressure switch PSA3 is reset to output the signal for automatic staring the DC
emergency oil pump while the oil pressure in lube line P0.0392MPa. Meantime three
pressure switches PSA4PSA6 are also reset to output the signal to the ETS for
simultaneous alarm.
Its unavoidable for the turbine to come into the turning status after idling during
shut-down. So if the oil pressure in lube line continuously falls down to P
0.0294MPa,the pressure switch PSA7 will be reset to output the signal for turning stop and
for alarm at same time.

- 15 -

Logic control of two oil pumps for main oil reservoir

The turbine oil in protection system necessary for operation of steam turbine is supplied
directly by the main oil pump mounted on the same shaft with turbine. The lube oil is
supplied by the main oil pump through the oil injector. There are two oil pumps on the
main oil reservoir. The AC lube oil pump is used to supply the oil for latching-on of the
emergency tripping device during start-up of unit, as well as to supply the lube oil to the
bearings, turning gear and oil jacking device during start-up and shut-down of unit instead
of the oil injector at outlet of main oil pump, or to supply the lube oil to the above
mentioned areas with the oil injector at outlet of main oil pump in parallel while the oil
pressure in lube line P 0.049MPa during operation of unit. The DC lube oil pump is
used to supply lube oil to all bearings of unit with the AC lube oil pump together while the
oil pressure in lube line P 0.0392MPa (at this moment the unit has received the
shut-down signal) or supply lube oil to all bearings of unit independently while the AC
lube oil pump is out of work due to trouble, thus to make the unit coming into turning
status after idling.

3.1

Logic control of AC lube oil pump

3.1.1 Automatic mode
There is a Auto/Manual selection pushbutton for AC lube oil pump in the DCS system
and mounted on the block control panel in central control room. In case the pushbutton is
selected in Auto mode, the AC lube oil pump will be put into operation automatically
while the oil pressure at outlet of the main oil pump falls from the normal value down to P
1.8MPa, or the oil pressure in lube line falls down to P 0.049MPa, or the speed of
turbine falls down to n 2850 r/min during operation of unit. Unless the electric failure
happens with its motor, the AV lube oil pump will keep operation after automatic starting
until change- over to the Manual mode. And only in this case the pump can be stopped
with the stop pushbutton on UCP.
There are an oil draining solenoid valve 25YV and a pressure switch PSA2 for
simultaneous test of AC lube oil pump mounted after the orifice in sampling pipe for lube
oil pressure of the lube oil low pressure tripping device. After pressing down this
simultaneous test pushbutton, the solenoid valve 25YV is energized to drain the oil , then
the pressure switch PSA2 is reset to start the AC lube oil pump automatically through the
contact while the oil pressure falls down to P 0.049MPa.

- 16 -

3.1.2 Manual mode

In case the pushbutton in DCS is selected in Manual mode its possible to start or stop
the AC lube oil pump any time by means of the start/stop pushbutton in DCS. The
requirement for regular test of this pump can be also met by this mode.
3.1.3 Signal
The DCS is provided with the signal lights for Auto mode, start and stop of this pump.
Also the alarm signal will be sent out while any electric trouble happens with the motor
301M of this pump.
3.2

Control logic of DC emergency oil pump

The DC emergency oil pump is put into operation only while the failure happens with the
turbine. The DCS is provided with only the pushbuttons for start, stop and simultaneous
test for this pump instead of the Auto/Manual mode selection pushbutton. In addition,
the signal light for start and stop of this pump must be provided. The emergency oil
pump will start automatically while one of the following situations occurs during
operation of unit:
a)The AC lube oil pump fails to automatic start due to under- voltage of control power
source for its motor or electric failure occurring with its motor while the oil pressure in
lube line falls down to P 0.049MPa;
b) There are an oil draining solenoid valve 26YV and a pressure switch PSA3 for
simultaneous test of DC emergency oil pump mounted after the orifice in sampling pipe
for lube oil pressure of the lube oil low pressure tripping device. After pressing down this
simultaneous test pushbutton, the solenoid valve 26YV is energized to drain the oil , then
the pressure switch PSA3 is reset to start the DC emergency oil pump automatically
through the contact while the oil pressure falls down to P 0.0392MPa.
The DC emergency oil pump is un-necessary to be provided with any protection measures,
because its the last supplier of lube oil to the unit and to prevent the bearing pad of unit
from burning out will be much valuable comparing with protecting the relative cheaper
DC motor. For this reason only an alarm signal will be sent out while electric failure
happens with the motor 302M of pump.

Control logic of oil jacking pump

There are two oil pumps for the oil jacking device, one of which is for stand-by while the other one is
being in work. The oil jacking pump is used to establish high pressure to force the shaft journal

- 17 -

lifting-up during start-up and shut-down on unit, thus to create the necessary condition for turning the
unit.

4.1

Automatic mode
The DCS is provided with a selection pushbutton Auto/Manual for 1#2# oil jacking
pumps. In case this pushbutton is selected in Auto mode, both pumps are under
automatic control. The Auto mode is used during shut-down of unit. As soon as the
turbine suffers tripping, its speed falls from 3000r/min down to 1200r/min and the 1# oil
jacking pump receives the start signal first and time counting begins at same moment. If
the oil pressure at inlet of 1# oil jacking pump is normal(P0.1MPa), the pump will start
automatically. If 1# oil jacking pump fails to start within 5 sec. due to electric trouble, 2#
oil jacking pump will start automatically on the premise of the oil pressure at its inlet
normal (P 0.1MPa). In addition, if 1# oil jacking pump becomes out-of work due to
electric trouble during operation or due to oil pressure at its outlet lower than setting
value(P0.1MPa)during operation, 2# oil jacking pump will also start automatically on
the premise of the oil pressure at its inlet normal and vice versa. This kind of logic can
meet the requirement for both pumps serve for stand-by each other.
After automatic starting, the oil jacking pumps will keep operation. They will stop
automatically only when the speed of turbine becomes higher than 1200r/min, or oil
pressure at outlet of pump is lower than setting value, or electric trouble happens with its
motor. Alternately, they will stop by means of the Stop pushbutton after change-over to
the Manual mode.

4.2

Manual mode
In case the pushbutton for oil jacking pump is selected in Manual mode, its possible to
start or stop the oil jacking pump ant time as required by means of the start/stop
pushbuttons in DCS. One of these two oil jacking pumps is able to start while the oil
pressure at its inlet is normal and the other pump is not in working status. Any of these
two pumps is able to start by means of pushbutton only when the other pump being in
operation is out of work. Its not allowed to put two oil jacking pumps into operation at
same time.

4.3

Signal
The DCS is provided with the signal lights for Auto mode, start and stop of these two oil
jacking pumps. The alarm signal will be sent out while electric trouble happens with the

- 18 -

motors 303M, 304M of pumps. The alarm signal will be also sent out while the core of
twin-shell oil filter or plate-type oil filter becomes plugging.
5

Logic control of turning gear

Before normal turning the lube oil line must work normally(P 0.08MPa). The transmission of
turning gear is realized in following way: the motor transmits the movement to the swinging
pinion after speed reducing, then the pinion is engaged with the gear rim on the rotor (engagement
completed) to rotate the rotor. The procedures of tuning during start-up of the unit are as follows:

a)

Energize the solenoid valve to lead the pressurized oil in for relieving the interlock
of swinging oil cylinder first, and moving the swinging cylinder with pinion in
direction of the gear rim on rotor then.

b) Start the motor and keep it running while the swinging pinion is engaged with the
gear rim on rotor (engagement completed).
5.1 Automatic mode
The automatic turning mode is used during shut-down of unit. In case the selection
pushbutton Auto/Manual for turning gear on the local control panel is selected in
Auto mode, the above-mentioned two procedures a) and b) will be conducted
automatically while the oil pressure in lube line and oil jacking line is normal and the
speed of turbine falls from the rated value down to zero (n 2r/min,contact signal sent by
ESI). Namely energize the solenoid valve first, start the motor for tuning after 30 sec. then.
The purpose of time delay is to ensure sufficient time for swinging pinion to complete the
engagement with the gear rim on rotor. The motor for turning will keep running while the
turning gear completes engagement in place (the solenoid valve is de-energized at this
moment).
The motor for turning will stop automatically while the oil pressure in lube line is too low
(P 0.0294MPa) or electric trouble happens with the motor.
5.2 Manual mode
In case the selection pushbutton Auto/Manual for turning gear on the local control panel
is selected in Manual mode, its possible to control start and stop of the turning gear by
means of the start and stop pushbuttons on the local control.
There are two kinds of manual mode, one of which is realized by the signal of pushbutton
TG start on the local control panel instead of the zero speed signal

and the other is realized by the

- 19 -

pushbuttons for TG in and Motor start respectively. In case the latter manual mode is used, the
solenoid valve is energized after pressing down the TG in pushbutton, then is de-energized until
reaching the engagement completed or the stop pushbutton is pressed. The motor is able to re-start
through pressing the motor start pushbutton only after 30 sec. while the oil pressure in oil jacking
line is normal.

A motor emergency start pushbutton is provided specially for the possibility to make the
unit coming into turning in the emergency status such as the oil pressure in oil jacking line
abnormal.
In addition, for convenience the local operation can be realized for such pushbuttons and
lights as TG start, TG in, TG stop, motor start, motor emergency start and
disengagement etc.
The TG stop pushbutton on the local control panel is able to be effective after pressing,
no matter the turning gear is being in Auto or Manual mode.
Its necessary to press the TG stop pushbutton first while the turning cut is required.
Then press the disengagement pushbutton after falling down the speed of motor of
turning gear to have the motor rotating backward for swinging pinion disengagement.
Nothing will happen through directly pressing the disengagement pushbutton during
turning process.
The rolling-up of turbine is realized in turning status. When the speed of turbine reaches a
certain value, the swinging pinion will be disengaged automatically by the action of
increased centrifugal force of gear rim on rotor. The motor of turning gear will stop
automatically while the swinging pinion is in the disengagement status.
The local control panel is provided the corresponding interface for remote operation of the
turning gear (from DCS).
5.3

Signal
The local control panel is provided with such signal lights as Auto mode, Turning
completed, disengagement completed and turning on etc. An alarm signal will be
sent out while electric trouble happens with the motor 307M of turning gear.

Various pressure signals for steam turbine

Various signals for steam pressure and oil pressure at turbine side are shown in the Fig. All
measurement instruments for these pressures shall be supplied by the project owner itself.

- 20 -

0-4 Temperature
1

General
The temperature part of the electric monitoring protection system of steam turbine contains
the various temperature related measures taken to ensure the normal start-up and operation
of turbine proper and its corresponding auxiliaries, as sell as the various temperature
measuring points supplied by the turbine manufacturer.

Logic control of motor-driven valve for LP exhaust water spray device

There is a motor driven valve 401MV provided for LP exhaust water spray device. As
required the water comes from the outlet of condensate pump and sprays out of the nozzles
in the both LP exhausts at GOV. and GEN. Ends through the motor-driven valve, the duplex
screen and the duplex manual throttling valve successively. The duplex screen is provided
with the differential pressure transducer for plugging, one of screen is for working and the
other for stand-by.
Logic control of motor-driven valve of water spray device
a) The DCS is provided with a opening pushbutton and a closing pushbutton for
the valve. Both these buttons will become effective only when the Auto/Manual
selection button for the valve is in the Manual position.
b) In case the Auto/Manual button for the valve is selected to the Auto mode, the
motor driven valve will fully open automatically while the temperature at any of two
measuring points for exhaust steam in LP hood
t 80. And the valve will be fully closed while the temperature at both
measuring points is t 65.
c) There is an interlock between opening and closing of the valve, namely an interlock
between rotating forward and backward of the valve driven motor.
d) The stop signal for valve opening will be sent out only when the full opening limit
switch of the valve is not actuated, or the full closing limit switch is not actuated
but the torque limit switch at opening side is actuated, or electric trouble happens
with the valve driven motor.
e) The stop signal for valve closing will be sent out only when the torque limit switch at
closing side is actuated, or electric trouble happens with the valve driven motor.
f)

The signal will be sent out by the corresponding limit switch to the DCS system for

- 21 -

display while the full opening and closing of the valve is completed.
g) There is an alarm signal appearing on DCS for display while electric trouble happens
with the valve driven motor.
3

Control logic of turbine proper and its auxiliary systems

3.1 Control logic of motor driven valve 402MV before heating steam inlet header for
inter-space between two shells of casing
a) During cold start, speeding up and loading of steam turbine, the said valve shall be
open according to the temperature difference of casing metal and the differential
expansion between HP/IP casing and rotor and closed while the above mentioned
temperature difference and differential expansion become stable after warming. So
the UCP is provided with only an opening button, a closing button and an
opening/closing stop button for the valve. The valve will be open only under such
condition that the drain valve of heating steam inlet header for inter-space between
two shells of casing has been open already.
b) The stop signal for valve closing will be sent out only when the torque limit switch at
closing side is actuated, or electric trouble happens with the valve driven motor, or
the stop button is pressed.
c) The signal will be sent out by the corresponding limit switch to the DCS system for
display while the full opening and closing of the valve is completed. A resistance
signal will be sent out by a potentiometer to reflect the valve position status while the
valve is at the middle position.
d) There is an alarm signal appearing on DCS for display while electric trouble happens
with the valve driven motor.
3.2 Control logic of pre-warming of casing
The pre-warming steam enters into the casing through two motor driven valves in series,
the valve 403MV close to the casing is used as block valve and the other one 404MV as
throttling valve.
When the pre-warming is required, the block valve is fully open automatically by the
signal from the DEH and the throttling valve is slowly open by the operator with remote
button according to the HP casing metal temperature. In order to stop the pre-warming,
the DEH will send out the closing signal to close the block valve and throttling valve at
same time. So the UCP is provided with a Auto/Manual selection button an

- 22 -

opening button, a closing button and an opening/closing stop button for two motor driven
valves respectively. The requirement for temperature raising rate during pre-warming can
be met by means of adjusting the reverse warming valve and drain valves at various
sections to ensure the temperature difference of casing wall and the differential expansion
within the allowable range.
There are two control modes for the casing pre-warming: stop and manual in. See
points b), c) and d) in above item 3.1 for the corresponding signals of opening, closing
and stop for these two valves. The motor driven throttling valve can be open only after the
motor driven block valve is open.
3.2.1

Automatic mode

In case the Auto/Manual selection button for motor driven block valve and motor
driven throttling valve on the UCP is in Auto mode, the opening and closing of the
former valve and the closing of the latter valve will be controlled by the signal from the
DEH. The opening of the latter valve can not be controlled automatically.
3.2.2 Manual mode
In case the Auto/Manual selection button for motor driven block valve and motor
driven throttling valve on the UCP is in Manual mode, the opening of both valve can be
controlled to meet the requirement for temperature raising rate and differential expansion
during casing pre-warming by means of the opening button, closing button and stop
button on the UCP.
3.3 The emergency relieve valve BDV is of the pneumatic closing type and controlled by
the air control solenoid valve TBSV. When the pre-inlet valve of 1or 2 IV is fully
open, the corresponding servomotor leaves from full closing position and the valve TBSV
is energized to close the valve BDV by the pneumatic force. In case the pre-inlet valve is
not in full opening position, the valve TBSV is de-energized to open the valve BDV due to
the compressed air source cut.
The valve BDV is provided with position switches for opening and closing to send out the
signal to DCS for display.
3.4 Control logic of vent valve
There is a vent valve VV mounted in the HP exhaust steam pipe to keep vacuum of HP
casing with condenser together for preventing the HP casing from overtemperature caused
by windage effect during start with IP turbine or operation with lower load.

- 23 -

The pneumatic solenoid valve VSV to operate the opening/closing of the vent valve VV is
controlled by the contact signal of open VV valve from the DEH. The VV valve is open
while the signal contact is closing and is closed while the contact is open. The following
procedures have been realized by the logic of DEH:
a) The VV valve is closed during pre-warming and holding period of HP casing.
b) The VV valve is open during start with IP turbine and is closed until change-over
between HP and IP casings.
It should be emphasized that the VV valve for this unit is located downstream the exhaust
of HP casing, and shall not be open with closing the GV to prevent the unit from
overspeed.
4

Control logic of demisting fan of main oil reservoir

There are two demisting fans mounted on the main oil reservoir, one of which is for
normal working and the other one for stand-by. The DCS is provided with start and stop
buttons for the demisting fans. The 1# fan shall start and keep operation before the oil
system of turbine putting into operation. The other fan is able to start manually while the
fan being in operation is out of work due to trouble.
The demisting fans are provided with local start and stop lamps. Also an alarm signal will
be sent out to UCP and DAS while electric trouble happens with the fan driven motor.
5

Control logic of heater for main oil reservoir

The main oil reservoir is provided with 6 electric heaters which is divided into two groups
composed of three heaters for each in three-phase 380V star-connected circuit. The UCP
is provided with a start button, a stop button, a power-on button and a power-off button
for each group of heaters. In addition, an alarm signal will be sent out to DCS while
trouble happened with the heater.
The power-on lamp turns on while any of three heaters in same group is energized. But
the power-off lamp turns on only when all three heaters in same group are
de-energized.
The condition for putting heater into operation is: the oil level in main oil reservoir
normal (not in lower level), the AC lube oil pump or the DC emergency oil pump being in
work and the oil temperature in oil reservoir low.
In order to avoid degradation of turbine oil quality due to overtemperature on surface of
heater, the thermal resistance is provided for the surface of heater. The heating process

- 24 -

will be intercepted while the temperature on surface of heater is 140. In addition, the
heating process will be also intercepted while the oil temperature in oil reservoir is 35
, or electric trouble happens with heater (e.g. actuation of protection switch due to
overload or short circuit).
6

Various temperature signals of steam turbine

Fig.1317 show various temperature signals for bearing metal and drain oil from bearings of
turbine in detail and illustrate the type and application of thermal element. It should be noted that
the Dongfang Steam Turbine Works is responsible only to provide the primary thermal element in
its supply scope. The project owner shall be responsible for the primary thermal element
including the following transducer in its scope.

0-5 Auxiliaries
1

General
The auxiliaries part of electric monitoring protection system for steam turbine contains the
control logics for various motor-driven valves, solenoid valves and other motors in draining
system, pneumatic system for extraction check valves and HP exhaust check valves and self
sealing system of turbine proper.

Control logic of pneumatic valves in draining system for turbine proper

During start-up, shut-down and operation with lower load, or under abnormal operation
condition of turbine, any condensate in turbine proper and piping shall be drained through
motor-driven drain valves to avoid rotor bending or components damage caused by the
water entering into the casing. There are total 13 motor-driven drain pumps in draining
system of turbine, 7 from which are at HP section (501PV507PV in logic diagram),4 at IP
section (508PV511PV) and 2 at LP section (512PV, 513PV). All these drain valves are
controlled by their own air control solenoid valves(501SV 513SV)respectively for
opening and closing.
The pneumatic actuating system of these drain valves is composed of air control solenoid
valve, diaphragm-type actuator, and limit switches for full opening and full closing of valve.
The DCS is provided with a Auto/Manual selection button, a opening button and a
closing button.

2.1 Automatic control mode for pneumatic valves

In case the Auto/Manual selection button for any drain valve on the DCS is in the Auto

- 25 -

mode, the said drain valve is under automatic control for its opening and closing.
In automatic mode, the drain valve will be open while the oil switch of generator changes
from closing to opening, because the tripping of oil switch leads to de-energizing of the air
control solenoid valve, thus to cut the air source for pneumatic drain valves.
In automatic mode, as soon as the load of generator rises to 10%, 20%, 30% of rated value,
the DEH will send out signals to energize the air control solenoid valves for HP, IP and LP
sections successively for closing the drain valves at these sections by the action of
compressed air force. And when the load of generator falls down to 30%, 20%, 10% of
rated value, the DEH will send out signals to de-energize the air control solenoid valves for
HP, IP and LP sections successively for opening the drain valves at these sections due to air
source cutting.
2.2 Manual control mode for pneumatic valves
In case the Auto/Manual selection button for any drain valve on the DCS is in the
Manual mode, the said valve is under manual control. In this case the said drain valve can
be open or closed by means of the local opening button or closing button for this valve.
3

Control logic of check valves in pneumatic system of extraction and HP exhaust check
valves
The steam turbine is provided with check valves at all extraction ports with the purpose to
avoid overspeed caused by the steam in feedwater heaters returning back into the casing
through extraction piping due to pressure reducing during load rejection. And the check
valves mounted at HP exhaust are used to avoid the low temperature steam in reheater of
boiler returning back to HP casing during hot start and load rejection.
There are total 10 check valves (514PV521PV in logic diagram) at extraction ports and 2
check valves 522PV, 523PV in logic diagram) at HP exhaust. The free state of extraction
check valve is defined as it can be open while the working medium flows forward and be
closed while the working medium flows backward.
The DCS is provided with an Auto/Manual selection button, a manual opening button and
a manual closing button for each check valve. Also the DCS is provided with the
corresponding lamps to indicate the check valves being in Auto mode. In addition, the
DCS is also provided with signal lamps to indicate the extraction check valves being in
closing status and two check valves at HP exhaust being in opening status as well as the
corresponding alarm signals.

- 26 -

3.1 Automatic control mode of extraction check valves

In case the Auto/Manual selection button for extraction check valves on the DCS is in the
Auto mode, the said check valves are under automatic control for its opening and closing.
3.1.1 Automatic control mode of extraction check valves leading to feedwater heaters
There are total 8 extraction check valves leading to feedwater heaters, namely:
a)

#1 extraction check valve 514PV leading to #3 HP heater JG3.

b) #2 extraction check valve 515PV leading to #3 HP heater JG2.

c)

#3 extraction check valve 516PV leading to #1 HP heater JG1.

d) #4 extraction check valve 517PV, 518PV leading to deaerator (CY and house
service steam).
e)

#4 extraction check valve 519PV leading to the BFPT.

f)

#5 extraction check valve 520PV leading to #4 LP heater JD4.

g) #6 extraction check valve 521PV leading to #3 LP heater JD3.

3.1.1.1

Any of above mentioned extraction check valves will be open automatically

while the following conditions are met at same time:

a)

The corresponding heater (deaerator) has be put into working.

b)

The water level in corresponding heater (deaerator) is normal.

c)

The oil switch of generator didnt change from closing to opening.

d)

The main stop valve is full open.

3.1.1.2 Any of above mentioned extraction check valves will be closed automatically
while one of following conditions is met:
a)

The oil switch of generator trips (from closing to opening).

b)

All electric tripping signals are cut or the main stop valve is fully closed.

c)

The water level in corresponding heater (deaerator) is too high.

d)

The corresponding heater (deaerator) in cut manually.

3.1.2 Automatic control mode of extraction check valve for house service and BFPT
This is the #4 extraction check valve 519PV for BFPT.
3.1.2.1

The above mentioned extraction check valve will be open automatically

while the following conditions are met at same time:

a)

The oil switch of generator didnt change from closing to opening.

b) The main stop valve is open.

- 27 -

3.1.2.2

The above mentioned extraction check valve will be closed automatically

while one of following conditions is met

a)

The oil switch of generator trips (from closing to opening).

b) All electric tripping signals are cut.

c)

The main stop valve in fully closed.

The #4 extraction check valve 519PV for BFPT will be also closed automatically while
the tripping signal is sent out by the BFPT.
3.2 Automatic control mode of two HP exhaust check valves
In case the Auto/Manual selection button on DCS for two HP exhaust check valves is in
the Auto mode, these two check valves will be under automatic control for opening ( in
free state) and closing (forced closing).
When the main stop valve is open, two HP exhaust check valves will be open
automatically and come into free state. These two check valves will be closed while the
mode of start with IP turbine is selected and the change-over of valves is not performed at
same time, or all electric tripping signals are cut or the main stop valve is fully closed.
3.3

Manual control mode of check valves

In case the Auto/Manual selection button on DCS for any check valve is in the
Manual mode, the said check valve will be under the manual control for its opening and
closing. In this case the said check valve can be open or closed by means of the local
opening button or closing button respectively.
4

Control logic of motor-driven block valves in self-sealing system of turbine

There are total 10 motor-driven block valves in self-sealing system of turbine, namely the
block valve 502MV, regulating valve 504MV and bypass block valve 503MV of auxiliary
steam supply in control station for auxiliary gland steam; the block valve 505MV,
regulating valve 507MV and bypass block valve 506MV of main steam supply in control
station for main gland steam; the overflow regulating valve 508MV and bypass block
valve 509MV in control station for gland overflow; as well as the block valve 510MV,
regulating valve 511MV of cooling water supply for LP gland steam desuperheater.
4.1 Automatic control mode of motor- driven block valve
The DCS is provided with the Auto/Manual selection button only for the auxiliary steam
supply valve in control station for auxiliary gland steam. In case the selection button is in

- 28 -

the Auto mode, the said valve will be under automatic control.
Under various starting conditions of turbine, the auxiliary gland steam supply valve will
be open automatically while the steam temperature before the said valve is normal (210
t260), or the oil switch of generator changes from closing to opening and the steam
temperature before auxiliary gland steam supply valve
t260 at same time. The said valve will be closed automatically while the oil switch of
generator changes from closing to opening and the steam temperature before auxiliary
gland steam supply valve t<210 at same time.
4.2 Manual control mode of motor-driven block valves
In case the Auto/Manual selection button on DCS for auxiliary gland steam supply
valve is in the Manual mode, the said valve will be under manual control. The rest 9
motor-driven valves in self-sealing system of turbine can be controlled only manually.
The auxiliary gland steam supply valve can be controlled for full opening or full closing
by means of the corresponding opening button or closing button on the DCS respectively.
The rest 9 motor-driven valves in self-sealing system are provided with not only the
opening button and the closing button, but also the stop button, so the opening of these
valves can be controlled.
The control logic for 10 motor-driven valves in self-sealing system are as follows:
a) There is the interlock between opening and closing provided to these valves,
i e. between forward and backward rotating of the valve driven motor.
b) In case the stop button is not pressed, the signal for opening stop of the valve will be
sent out while the full opening limit switch of the valve is actuated, or the full
closing limit switch of the valve is not actuated but the torque limit switch at
opening side is actuated, or electric trouble happens with the valve driven motor.
c)

In case the stop button is not pressed, the signal for closing stop of the valve will
be sent out while the torque limit switch at closing side is actuated, or electric
trouble happens with the valve driven motor.

d) The DCS is provided with signal lamps corresponding to the opening/closing

completed and Auto mode of the valve. The indication lamps for opening and
closing of the valve are controlled by the position switch on corresponding
motor-driven valve.
e) There will be alarm signal output on DCS while electric trouble happens with the

- 29 -

valve driven motor.

4.3 Control logic of valve driven motors
See the drawing and information supplied by the supplier with equipment together for
concrete requirement of control for motor-driven regulating valves.
5

Control logic of motors in gland system

Each steam turbine is provided with two gland fans, one of which is for stand-by while the
other one is being working. The control logic for both fans is same as follows:
a)

The DCS is provided with the corresponding Auto/Manual selection button, a start
button and a stop button.

b)

In Auto mode the stop signal of one fan just is the start signal of the other fan.

c)

Both fans will start at same time while the pressure in inlet manifold of fans P
5kPa.

d)

In Auto mode the stop signal will be sent out only while electric trouble happens
with the fan driven motor but in Manual mode the stop signal will be sent out also
by means of the stop button.

e)

The DCS is provided with the signal lamps corresponding to the start, stop and
Auto mode of fans.

f)

There will be alarm signal output on DCS while electric trouble happens with the
fan driven motors.
0-6

ETS

General
The Emergency Trip System (ETS) of steam turbine is able to start automatically the
closing loop while trouble occurring with turbine, tripping occurring with generator and
tripping occurring with main fuel of boiler, thus to fast close the steam inlet valves( main
stop valves and control valves). The ETS is composed of mechanical-hydraulic and
electric-hydraulic parts. That means the trouble can be detected in mechanical mode and
electric mode. But the closing of steam inlet valves is controlled by the hydraulic control
and protection system finally.

Mechanical-hydraulic emergency tripping

The emergency governor is a mechanical detector for overspeed trouble. In case the speed
of turbine reaches n3300r/min, a stop ring will be flies out by the action of centrifugal
force to actuate the emergency tripping device. The emergency tripping device changes

- 30 -

the moving direction of the trip valve in tripping isolation valve group to drain the HP
control oil. After the HP control oil is drained, the overspeed limiting control oil is also
drained through the check valve. As a result the control oil pressure in dump valves for
servomotors of steam inlet valves disappears and the dump valves are open. Then the
pressure oil in both upper and lower chambers of servomotors is connected to the drain
port through the opened dump valves to fast close the steam inlet valves. After full closing
of the main stop valves the limiting switch signal will be sent out to the check valves
through electric control loop.
3

Electric-hydraulic emergency tripping

This is an electric mode to detect the trouble occurring with turbine, the tripping occurring
with generator and the tripping occurring with main fuel of boiler and also to send out the
electric tripping signal to the mechanical tripping electric magnet 3YV at same time.
As soon as the electric tripping signal is sent to the mechanical tripping electric magnet
3YV, the latte will be energized to actuate the emergency tripping device through linkage
mechanism. The following process will be performed as same as described in above point
2.
Although the extraction check valves can be closed by the signal after full closing of the
main stop valve, various electric tripping signals will be sent to the above solenoid valves
and the check valves at same time to fast close the latter valves.

Electric tripping signals

The electric tripping signals of ETS for the steam turbine are as follows:
a) Manual stop button in center control room.
b) Overspeed: In case the speed of turbine rises to 3300r/min and above, the overspeed
relays in overspeed monitoring channels of ETS are actuated and the tripping signal
is sent out after processing by the ETS in 2 out of 3 logic through the output contact.
c) Lube oil low pressure: In case the oil pressure in lube line P0.0392MPa (which is
the setting value for pressure switch as mentioned above), three pressure switches
PSA4PSA6 in

lube oil low pressure tripping device will be reset and three

normal-closed contacts will send out the tripping signal after processing by the ETS
in 2 out of 3 logic.
d) Fire-resistant oil low pressure: In case the oil pressure in fire-resistant oil line is too
lower, three pressure switches in resistant oil manifold supplied by the DEH

- 31 -

manufacturer will be reset and three normal-closed contacts will send out the
tripping signal after processing by the ETS in 2 out of 3 logic.
e) Condenser low vacuum: In case the pressure in condenser P19.7kPa, three
vacuum switches P19.7kPa in condenser low vacuum tripping device are actuated
and

three normal-open contacts will send out the tripping signal after processing

by the ETS in 2 out of 3 logic.

f) Axial displacement too big: In case the shaft displacement related to thrust bearing
increases (1.2mm or -1.65mm. It should be noted that the working pads of
thrust bearing in this turbine are mounted at generator end, so the axial displacement
will be positive while the shaft moves in the direction of generator and be negative
while the shaft moves in the direction of head of unit), the axial displacement
emergency relay in dual- channel axial displacement monitor will be closed after
processing in TSI in AND logic and the normal-open contacts will be used as
tripping signal.
g) The steam turbine will suffer tripping by trouble with main fuel of boiler and trouble
with generator, the former signal will be supplied by the boiler manufacturer and the
latter signal by the generator manufacturer.
h) Shaft vibration too high: The TSI will send out the shaft vibration too high signal
while the shaft vibration in X axis at any of 1#6 bearings is too high(
0.25mm) or the shaft vibration in Y axis at any of 1#6 bearings is too high(
0.25mm). Above mentioned combination logic has conducted in the TSI and a
contact signal is sent out by the TSI to the ETS for turbine tripping.
i)

DEH tripping: This is the turbine tripping signal supplied by the DEH manufacturer
and contains the turbine overspeed monitored by DEH, DEH speed signal trouble
and etc.. Its used to output the shut-down contact signal for turbine tripping.

j)

Other signals for shut-down of unit

- 32 -

Section2

Manual of emergency tripping device of steam turbine

General Introduction
The emergency tripping system receives the alarm signal or tripping signal from TSI system
or other system of steam turboset to conduct logical process and send alarm signal of
indicating lamp or tripping signal of steam turbine. Duplex PLCs (programmable controller)
are selected by us to conduct logical process so as to facilitate the usage and reliable operation.
The duplex PLCs work at the same time, any action can send alarm signal. In case the trouble
happens with any PlC, it can send alarm signal of itself and switch-off its tripping logical
output, another is still at normal work. This device can communicate with other system so as
to meet the automation requirement of power plant.
0-1 Device description
1. ETS device includes one control cabinet. The series programmable controller (PLC) made
by Siemens Company S7-300, German is substituted for traditional relay logic to realize
the inner logic. In order to improve the reliability and safety of ETS device, we adopt the
duplex PLC. The hardware distribution is as follows:
PLC Processor
PLC input module
PLC input module
PLC output module
PLC power supply
2. Environment conditions

TSX P57 102M

TSX DEY 08D2
TSX DEY 16D2
TSX DSY 16T2
TSX PSY 2600M

Operating environment:555
Relative humidity:35%85%RH (without dewing)
Vibration:2.0G (1055Hz)
Without caustic gas and conductive dust.
3. Stand-by batteries
One groove used for putting the battery is equipped on battery module to supply power for
inner RAM of processor and protect the data after the PLC power-off. Such battery is
supplied with CPU module.
While putting through the power source, CPU module monitors the status of battery. In case
the red alarm signal on BAT indicating lamp flashes during occurring failure, it shall be
replaced at once. The battery is replaced during power-on or within a short time of

- 33 -

power-off. Otherwise the data in RAM will be lost after removing the battery for 10min.
Caution: In order to protect the device, the battery shall be replaced every year.
4. Brief description of control cabinet
The control cabinet diagram refers to the first sheet of M913-042000A please.
0-2 Working principle
1. The duplex PLCs of ETS device works at the same time. The signal from site input to A

PLC and B PLC of the device, and the corresponding output signal are sent out after auto
processing by inner logic. Give an example of steam turbine over-speed, the electric
tripping signal inputs to PLC A and PLC B of device to process, and the tripping signal
outputs at the same time.
2. In case the trouble happens with any of PLC A/B, the alarm signal of the said PLC can be
sent to cut the tripping output contact automatically, and the other PLC will keep normal
working. The logic scheme of duplex PLC working/tripping is shown in Fig. 0-2-1.
tripping A
PLC A Normal

tripping A
Tripping
tripping B

tripping B
PLC B Normal
Figure 0-2-1 Duplex PLC working principle diagram

3. Two ways power source switching-over loop are equipped for ETS device. In case the
trouble happens with one power source, it can continue working by means of switching
over to another power source loop automatically. In case the trouble happens with the both
master/slave power source, one AC power source power-off alarm signal is sent. +24V
power source is provided for whole device after two QUINT-PS power source with
redundance. Such power sources together with TSX PLP 01 failure all inputs one +24V
power source power-off alarm signal.
4. This device shall be deigned according to the logic required by customer.
5. All input/output and wiring diagram of this device see from drawing0-2-2 to drawing 0-2-5.
The control logical scheme of device sees drawing from 0-2-6 to drawing 0-2-7.

- 34 -

Tripping 1 for electrical over-speed

D1 terminal row
Tripping 2 for electrical over-speed

field input signal

Tripping for generator failure

Tripping 3 for electrical over-speed

Tripping for boiler failure

Tripping for shaft vibration big

Tripping by DEH

Manual tripping

Tripping

Tripping stand-by 1

for axial displacement big

Tripping stand-by 2

Tripping for condenser vacuum low.

Tripping stand-by 3

Tripping 2 for condenser vacuum low

Standby
terminal

Tripping 3 for condenser vacuum low

Test for HP tripping solenoid valve 1

Tripping 1 for lube oil pressure low

Test for HP tripping solenoid valve 2

Tripping 2 for lube oil pressure low

Test for HP tripping solenoid valve 3

Tripping 3 for lube oil pressure low

Test for HP tripping solenoid valve 3

Tripping 2 for EH oil pressure

Reset signal

Tripping 3 for EH oil pressure

Figure 0-2-2

Terminal wiring diagram (1)

Standby terminal

Tripping 1 for EH oil pressure

D1 Terminal row
D1 Terminal row
master power source
master power source
slave power source
slave power source
output power source for
master breaker
output power source for
master breaker
output power source for
slave breaker
output power source for
slave breaker
Terminal for protection
Lighting power source
Input power source for
interference suppressor
Lighting power source
Input power source for
interference suppressor
PLC working power source
(terminal for protection)
PLC working power source
(terminal for protection)
PLC working power source
(terminal for protection)
PLC working power source
(terminal for protection)
PLC working power source
(terminal for protection)
PLC working power source
(terminal for protection)

24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)
24V
power
source
(terminal for protection)

(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)
(+)

PLC working power source

PLC working power source
PLC working power source
PLC working power source
PLC working power source
PLC working power source

Figure 0-2-3 Terminal wiring diagram (2)

Tripping output 1
electrical over-speed

D2 Terminal row
Tripping signal output

Tripping output 2
electrical over-speed

for

for

Tripping output 1 for generator

failure
Tripping 1 for shaft vibration
Tripping output 2 for generator
failure
Tripping output 1 for boiler failure

Tripping 2 for shaft vibration

Tripping output 2 for boiler failure

Tripping output 1 for DEH

Tripping output 2 for DEH

Manual tripping output 1

Manual tripping output 2

Tripping output
displacement big

for

axial

Tripping output
displacement big

for

axial
Tripping stand-by 1, output 1

Tripping output 1 for condenser

vacuum low
Tripping stand-by 1, output 1
Tripping output 2 for condenser
vacuum low
Tripping stand-by 2, output 1
Tripping output 1 for lube oil
pressure low
Tripping output 2 for lube oil
pressure low
Tripping output 1 for EH oil
pressure low
Tripping output 2 for EH oil
pressure low

Tripping stand-by 2, output 1

Tripping stand-by 3, output 1

Tripping stand-by 3, output 1

stand-by
terminal

Figure 0-2-4 Terminal wiring diagram (3)

Tripping output

Test for HP tripping

Slave
power
source
power-off alarm output

Test for HP tripping solenoid

valve 2

Master/slave power source

power-off alarm output 1
24VDC power-off alarm

Test for HP tripping solenoid

valve 3
Test for HP tripping solenoid
valve 4
Test for HP tripping solenoid
valve 4

stand-by terminal

Tripping signal to DEH

Tripping output 1

Tripping output 2

Tripping output 3

Alarm Output
Tripping output 4
PLC A failure alarm output

PLC B failure alarm output

stand-by terminal

Master power supply power-off alarm

output

Figure 0-2-5 Terminal wiring diagram (4)

Signal for generator failure

Reset signal output
The first way tripping output
of generator failure
The second way tripping output
of generator failure

reset button
reset signal

reset signal output

Tripping signal of boiler failure

Reset signal output
The first way tripping output of
boiler failure
The second way tripping output
of boiler failure

DEH tripping signal

Reset signal output
The first way tripping output of
DEH
The second way tripping output
of

tripping stand-by signal 1

reset signal output

Manual tripping signal

Reset signal output

The first way of manual

tripping output
The second way of manual
tripping output

2 out of 3

Tripping signal for axial

displacement big
Reset signal output

1Tripping signal 1 for condenser vacuum low

2Tripping signal 2 for condenser vacuum low
3Tripping signal 2 for condenser vacuum low

The first way tripping output of

axial displacement big
The second way tripping output of
axial displacement big

2 out of 3

2Tripping signal 2 for lube oil pressure low

3Tripping signal 3 for lube oil pressure low

tripping stand-by
signal 1
reset signal output

The first way tripping of shaft

vibration big
The second way tripping of
shaft vibration big

tripping stand-by 1, the first

way of tripping output
tripping stand-by 1, the second
way of tripping output

Tripping signal to DEH

tripping stand-by 2, the first

way of tripping output
tripping stand-by 2, the second
way of tripping output

tripping stand-by
signal 1
reset signal output

3Tripping signal 3 for EH oil pressure low

2 out of 3

1Tripping signal 1 for EH oil pressure low

Reset signal
output

Note: The logic of PLC A is same as that of PLC B.

Reset signal
output

The first way tripping output for

EH oil pressure low
The second way tripping output for
EH oil pressure low

Indicates the indicator light of this machine

Indicates the output contact
Indicates the output contact

3Tripping signal 3 for electrical over-speed

2 out of 3

1Tripping signal 1 for electrical over-speed

2Tripping signal 2 for electrical over-speed

Tripping signal to DEH

Tripping output 1

Tripping output 3
tripping stand-by 3, the first
way of tripping output
tripping stand-by 3, the second
way of tripping output

The first way tripping output of

lube oil pressure low
The second way tripping output of
lube oil pressure low

2Tripping signal 2 for EH oil pressure low

tripping A

Tripping output 2
Reset signal
output

The first way tripping output of

condenser vacuum low
The second way tripping output of
condenser vacuum low
1Tripping signal 1 for lube oil pressure low

Tripping signal for shaft

vibration big
Reset signal output

Reset signal
output

The first way tripping output of

electrical over-speed
The second way tripping output of
electrical over-speed

Figure 0-2-6 Logic diagram (1)

Tripping output 4

Test output (often close) for HP

tripping solenoid valve 1
Test output (often close) for HP
tripping solenoid valve 2
Test output (often close) for HP
tripping solenoid valve 3
Test output (often close) for HP
tripping solenoid valve 4

Test signal for HP tripping

solenoid valve1
Test signal for HP tripping
solenoid 2
Test signal for HP tripping
solenoid 3
Test signal for HP tripping
solenoid valve 4

Note: The logic of PLC A is same as that of PLC B.

Figure 0-2-7 Logical diagram

0-3
1

Function

Power-on
Switch-on the master, slave power source breaker, the indicating lamp is
on and the voltage indicating is normal.
Tripping: The tripping signal shall be sent by PLC while the following
items occur. The steam turbine will trip for shut-down.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)

m)

Steam turbine over-speed (2 out of 3)

Axial displacement
EH oil pressure too low (2 out of 3)
Condenser vacuum too low (2 out of 3)
Lube oil pressure too low (2 out of 3)
Steam turbine vibration too high;
Tripping by DEH;
Generator tripping;
Main fuel of boiler;
Manual tripping;
Stand-by 1 for tripping

Stand-by 3 for tripping

0-4 Power-on self-checking

Connect two lines of 220VAC power source to the input of master, slave breaker for
ETS device, and then switch-on breaker, the indicating of voltage meter on device
panel is correct, and the indicating lamp of master, slave power source is on, the
+24V power source indicating of device is normal. At this time, the PLC starts
self-checking. The RUN indicating lamp of CPU is on after finishing self-checking.
The ETS device can be put into operation in site.
0-5 Maintenance
This device is full controlled by computer. The complete check and test shall be
performed before putting into operation. It can be put into operation after free of
troubles. The check and test include the following:
a)

Check whether the master, slave power source work normally.

b)

The anti-interference suppresser is equipped to prevent the strong interference

signal input into control cabinet. Care for whether the indicating of voltage
meter on device cabinet is correct. The power source distribution of control
cabinet sees 0-5-1 scheme;

c)

Remove the dust in control cabinet;

d)

Replace the failed components.

Master
power
source
of
Breaker

Slave
power
source
of
Breaker

To Rack Light and Fan

Anti-interference
suppresser K

Figure 0-5-1 Wiring scheme of power source

- 41 -

section3

Instruction on automatic operation device for turning

gear
0-1

Overview

The automatic operation device of turning gear is used to provide an operation loop for
realizing the manual or automatic turning of unit. In automatic turning mode the device
receives the zero speed signal from TSI system. The programmable logic controller (PLC)
is adopted for the device to realize the logic control. In order to improve the start-up
feature during putting into operation of the turning gear the device is also provided with a
soft start-stop block, which is able to stop turning automatically while the oil-jacking
pump is out-of- work, lube oil pressure is lower than certain value, or the turning current
is too higher.

0-2 Device Description

The automatic operation device of turning gear contains a control cabinet, where the internal logic is realized by the PLC of TSX
serial from Schneider Atomization Company instead of the traditional relay logic.

PLC input/output
Input power supply: AC100AC240V ca.50VA
Input signal voltage: DC24V
Input:

16(with common contact supplied by TSX DEY 16D2 block)

16 (with common contact supplied by TSX DEY 16D2 block)

Output: 16 (with common contact supplied by TSX DSY 16R5 block)

16 (with common contact supplied by TSX DSY 16T2 block)
2 Working environment
Ambient temperature:
Relative humidity:

555

3095%RHwithout dewing

Anti-vibration capability: In accordance to IEC 68-2-6, Fc test.

3 Hardware feature
Control power supply: AV 220V single-phase 50Hz
4 Feature of Softstart:
4.1 The soft start-stop block Softstart is able to control the start-stop of AC
three-phase motor and provide the start-stop parameters.
4.2 Regulation-display option
There are terminal marks on the panel for 12 control loops
Terminal

Application

1, 2, 3

Power supply L, N, PE

4, 5, 6

Start-stop loop

7, 8

Fault signal loop

- 42 -

9, 10

Start-up completion indication relay loop (bypass)

11, 12

Connection to external current transformer

Status indication

Application

ON

Green

Ready

TOP OF RAMP

Green

Normal operation

EXTERNAL FAULT

Red

Motor and software missing

GENERAL FAULT

Red

Power supply side missing

The Softstart is provided with 3 rotary setting switches and a two-position toggle
switch.
Start-up curve: Set the raising time of voltage during start-up with 16 adjustable steps
in range of 1-30 sec.
Shut-down curve: Set the falling speed of voltage during start-up with 16 adjustable
steps in range of 0-30 sec. The immediate stop can be realized while choosing the 0
sec.
Initial voltage/limiting voltage: Set the initial voltage level for start-up curve and the
final voltage level for shut-down curve. In case the current transformer T2 is connected
to the terminals 11 and 12, set the limiting voltage with the same rotary switch as that
for initial voltage setting.
5 Description of control cabinet
The control cabinet is shown in Fig. 0-2-1.

- 43 -

Fig.0-2-1
1-Voltmeter;

Control cabinet scheme

2-Amperemeter;

3-Turning indication;

4-Disengagement

completed indication;
5-engagement completed indication;
6-Oil jacking pressure normal indication;
7-lube oil pressure normal/lower indication;
8-Turning admission indication;
9-Motor stop indication;
10-Power lamp;
11-Turning admission selection switch;
12-Local control selection switch;
13-Manual/Auto selection switch;
14-Lamp test pushbutton;
16-Inching / in pushbutton;
18-Test/bypass pushbutton;

15-SV action pushbutton;

17-TG stop pushbutton;
19- Turning-off pushbutto

0-3

Working Principle

1. The control scheme of turning gear is shown in Fig.0-3-1, the circuit scheme of control
loop and main loop are shown in Fig.0-3-2, and Fig.0-3-3 respectively and the control
logic scheme is shown in Fig.0-3-4.

control
system(PL
C)

Softstart

AC
motor

reducer

turbine
turning
gear

AC
motor
Fig. 0-3-1 control scheme of automatic turning gear

The three-phase power supply of turning gear is connected to the Softstart of motor
through the AC contactor in control loop. Then the output of Softstart of motor is sent
to the motor to drive the turning gear. According to the control requirement, the PLC
controls the solenoid valve for oil entering/draining in hydraulic mechanism and the
forward/backward rotation of the motor driving the turning gear.
2. Features of device
The device is able to realize such functions as automatic turning at zero speed, Manual
auto-turning, emergency turning, low oil pressure protection and remote control etc.
Since the imported PLC is adopted as the logic control component in the device and all
control logics are established by PLC software (ladder logic diagram), the control is
very flexible and the function is powerful. Also the imported ABB Softstart is used for
the drive motor, so as to reduce the attack to the motor and turning gear of turbine, as
well as to put the turning gear into operation smoothly and accurately.
The wiring of the device is quite clear and easy and convenient for maintenance. See
the corresponding system logic diagram and the PLC ladder logic diagram for concrete
control logic in detail.
3. Working principle
According to the requirement of system logic for turning gear, the control cabinet of
automatic operation device for turning gear shall receive the effective signal from the
contact for oil jacking pressure normal and lube oil pressure normal to meet the
external turning admission conditions, otherwise the control cabinet should reject to
start the drive motor of turning gear.
In order to proper put the turning gear into operation, the brief explanation is given for
related operation and logic relationship of three turning modes during start-up
hereafter.
a) Automatic turning at zero speed
As soon as the TSI sends out the zero speed signal to the control cabinet for turning
after meeting the external turning admission conditions and selecting the
automatic turning mode, the PLC in the control cabinet will energize the solenoid
valve automatically after confirming the receiving of zero speed signal (usually the
stable zero speed signal will be confirmed automatically with delay of about 30 sec.

by the system after receiving), so as to make the turning gear of turbine engaged
through hydraulic actuation mechanism. After 30 sec. while the solenoid valve is
energized, the PLC in control cabinet for turning begins to check whether the
engagement completed signal has been received. In case the engagement
completed signal has not been received, the motor for turning will periodically turn
forward in short time and in small steps through the Softstart to facilitate
engagement between gears. In case the engagement completed signal has been
received, the motor will start automatically and keep operation for turning. In case
the engagement completed signal still has not been received after small moving the
motor twice with above mentioned method, the motor for turning will be forced to
start, then the solenoid valve will automatically de-energized after motor running for
10 sec. to complete the automatic putting into operation of the turning gear.
As soon as pressing down the TG STOP pushbutton at any time, the motor for
turning will stop. The TG STOP pushbutton is an alternative one while the
engagement completed signal is effective to prevent the motor for turning from
automatic start due to not disengagement or the engagement completed signal still
existing while relieving the TG STOP pushbutton.
b) Manual auto-turning mode
The working principle in manual auto-turning mode is similar as that mentioned
above with the exception of a serial operation to be done manually. First of all the
external turning admission conditions shall be met. Then select the manual turning
mode and press down the SV ACTION pushbutton to complete the engagement of
turning gear through hydraulic actuation mechanism. In case the control device for
turning has received the engagement completed signal, it will start the motor for
turning automatically and de-energize the solenoid valve after 10 sec. In case the
control device for turning has not received the engagement completed signal, it
will force the motor for turning to start.
As soon as pressing down the TG STOP pushbutton at any time, the motor for
turning will stop. The TG STOP pushbutton is an alternative one while the
engagement completed signal is effective to prevent the motor for turning from
automatic start due to not disengagement or the engagement completed signal still
existing while relieving the TG STOP pushbutton.
c) Emergency turning mode
The emergency turning mode has to be used to ensure the rotor of turbine rotating
while the external condition for turning admission is not met yet, e.g. lube oil
pressure low, oil jacking pressure abnormal, or other electric fault existing. But this
mode shall be used very attentively, because the additional wear of damage will
occur with bearing pad in this case.
As soon as pressing down the TEST AND BYPASS pushbutton any time in manual
turning mode, all safety protection functions for the motor will be lost. In case of
pressing down the INCHING AND IN pushbutton, the motor for turning will
directly start. Naturally, its also possible to try to complete the engagement of
turning gear by means of pressing down the SV ACTION pushbutton first. The
TEST AND BYPASS pushbutton is an alternative one and this function can be
removed as necessary by pressing this pushbutton to have the lamp off in normal
case.
As soon as pressing down the TG STOP pushbutton at any time, the motor for
turning will stop. Meantime the TEST AND BYPASS
Function will lost automatically and the lamp will be off.

Fig.0-3-2

Control loop circuit scheme

Fig.0-3-3 Main loop circuit scheme

4. Its possible to realize remote control for the turning operation device. All wiring for
remote control has been connected to the terminal bar. The various outputs have been also
connected to the corresponding terminals and can be led out from the terminal bar by the
customer according to the concrete situation. There is an interlock between local control
cabinet and remote operation, only one of them could come into action any time. The
selection switch 12 is used for control priority selection. The local control becomes
effective and the remote control becomes non-effective while the switch is in LOCAL
CONTROL position. The remote control becomes effective and the local control
becomes non-effective while the switch is in REMOTE CONTROL position (See Fig.
0-3-4 for logic control ladder diagram).

0-4 TEST
1. Power-on test
Connect the power supply of AC380V to the terminal bar and close the breaker QF 1 and
MS450. The putting into operation and on-line test can be conducted on site while the power
indication lamp on the panel turns on and the indication of voltmeter on the panel of
equipment is proper to show the automatic turning gear has come into normal operation.
2 Check for Softstart
The various parameters of Softstart can be properly changed according to the concrete
situation of power plant.
3

Local control test

Set the selection switch 12 to the LOCAL CONTROL position to make the local control
effective and the remote control non-effective.
3.1 Lamp test
Press down the Lamp test pushbutton on the panel to make sure that all lamps shall turn
on. And all lamps shall return to their original status while relieving the pushbutton.
3.2 Adjustment and test of turning gear
3.2.1 Manual operation test
Set the selection pushbutton Auto/Manual to the Manual position and turn the key
switch to the TG admission position. If make sure through check that the TG
ADMISSION lamp 8, POWER SUPPLY lamp 10 and TG MOTOR STOP lamp 9 turn
on and 380V AC is indicated on the voltmeter, the condition for turning has been met.
3.2.1.1 Solenoid valve action test
Bridge the lube oil pressure switches JD9, JD10 and the oil jacking pressure switches JD7,
JD8, then press the SV ACTION pushbutton 15 to have the SV ACTION lamp on. If
make sure through check that the voltage 220V AC has been established at the output
terminals JD34, JD35 of solenoid valve, 30sec. later the turning contactor KM2 is actuated
every 2 sec. to indicate small movement of motor, the contactor KM2 is forced to close after
small movement two times, and the motor turns forward, the turning of unit begins.
3.2.1.2

Turning test

Bridge the engagement completed limit switches JD3, JD4 before the third forced closing.
If the turning contactor KM2 is closed, the TG RUNNING lamp 3 turns on and the motor
runs forward, the turning begins.
3.2.1.3

Test and bypass test

Cut any line from oil jacking pressure switches JD7, JD8 and lube oil pressure switches
JD9, JD10 , press the TEST AND BYPASS pushbutton 18 first to have the lamp on and
press the INCHING AND IN pushbutton 16 then. If the turning contactor KM2 is also
closed at this time, the TG RUNNING lamp turns on and the motor runs forward, the
turning begins.
3.2.1.4

Stop test

Press the TG STOP pushbutton 17. If the TG STOP lamp turns on and the turning
contactor KM2 powers off, the shut-down of unit is performed normally.
3.2.1.5

Disengagement test

Press the TG TRANSFER pushbutton 19. If the disengagement contactor KM3 is closed
and the motor runs backward, the disengagement is performed normally. If bridge the
disengagement completed switches JD1, JD2 at this moment, the contactor KM3 shall be
power-off, the motor stops running backward and the TG MOTOR STOP lamp HL9 turns
on.
3.2.2 Automatic operation test
Set the Auto/Manual selection pushbutton on the panel to the Auto position and turn the
key switch to the TG ADMISSION position. If make sure through check that the TG
ADMISSION lamp 8, POWER SUPPLY lamp 10 and TG MOTOR STOP lamp 9 turn
on, as well as 380V AC is indicated on the voltmeter, the condition for turning has been met.
3.2.2.1 Solenoid valve action test
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10, also bridge the zero speed signals JD5, JD6. If make sure through check that the
voltage 220V AC has been established at the output terminals JD34, JD35 of solenoid valve,
30sec. later the turning contactor KM2 is actuated every 2 sec. to indicate small movement
of motor, the contactor KM2 is forced to close after small movement two times, and the
motor turns forward, the turning of unit begins.
3.2.2.2 Turning test
Bridge the engagement completed switches JD3, JD4 before the third forced closing. If
the turning contactor KM2 is closed, the TG RUNNING lamp 3 turns on and the motor
runs forward, the turning begins.
3.2.2.3 Stop test
Press the TG STOP pushbutton 17. If the TG STOP lamp turns on and the turning
contactor KM2 powers off, the shut-down of unit is performed normally.
3.2.2.4 Disengagement test
Press the TG TRANSFER pushbutton 18 to have the TG TRANSFER lamp on. If the
disengagement contactor KM3 is closed and the motor runs backward, the disengagement is
performed normally. If bridge the disengagement completed switches JD1, JD2 at this
moment, the contactor KM3 shall be power-off, the motor stops running backward and the
TG MOTOR STOP lamp HL9 turns on.
3.2.3 Inching operation test
Set the selection switch 13 to the middle position, i.e. to the INCHING position.
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10, then press the INCHING AND IN pushbutton 16. At this moment the turning
contactor KM2 is closed, the TG RUNNING lamp 3 turns on, and the motor turns forward.
Thus the inching function can be realized by relieving the pushbutton to have the turning
contactor KM2 power-off.
4

Remote control test

Set the selection switch 12 to the REMOTE CONTROL position. In this case the remote
control will become effective and the local control un-effective.
4.1 Lamp test
Bridge the remote control LAMP TEST switches JD16, JD22 and all lamps on the panel

shall turn on. And all lamps shall return to their original status while removing the bridge
wire.
4.2 Adjustment and test of turning gear
4.2.1 Manual operation test
Set the remote selection pushbutton to the Manual position and bridge the switches
JD13andJD22. Then press the TG remote admission pushbutton to bridge the switches
JD15andJD22. If make sure through check that the TG ADMISSION lamp 8, POWER
SUPPLY lamp 10 and TG MOTOR STOP lamp 9 turn on and 380V AC is indicated on
the voltmeter, the condition for turning has been met.
4.2.1.1 Solenoid valve action test
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10, also bridge the solenoid valve remote action switches JD17andJD22. The SV
ACTION lamp will turn on at this moment. If make sure through check that the voltage
220V AC has been established at the output terminals JD34, JD35 of solenoid valve, 30sec.
later the turning contactor KM2 is actuated every 2 sec. to indicate small movement of
motor, the contactor KM2 is forced to close after small movement two times, and the motor
turns forward, the turning of unit begins.
4.2.1.2 Turning test
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10. Then bridge the engagement completed switches JD3, JD4 before the third forced
closing. If the turning contactor KM2 is closed, the TG RUNNING lamp 3 turns on and
the motor runs forward, the turning begins.
4.2.1.3 Test and bypass test
Cut any line from oil jacking pressure switches JD7, JD8 and lube oil pressure switches JD9,
JD10 and bridge the remote test and bypass switches JD18andJD22 to have the lamps on.
Then bridge the Remote inching and in switches JD20andJD46. If the turning contactor
KM2 is closed at this time, the TG RUNNING lamp turns on and the motor runs forward,
the turning begins.
4.2.1.4 Stop test
Bridge the TG STOP switches JD19andJD22. If the TG STOP lamp turns on and the
turning contactor KM2 is power-off, the shut-down of unit is performed normally.
4.2.1.5 Disengagement test
Bridge the remote disengagement switches JD21andJD22. If the disengagement contactor
KM3 is closed and the motor runs backward, the disengagement is performed normally. If
bridge the disengagement completed switches JD1, JD2 at this moment, the contactor
KM3 shall be power-off, the motor stops running backward and the TG MOTOR STOP
lamp HL9 turns on.
4.2.2 Automatic operation test
Remove all bridge wires and set the remote selection pushbutton on the panel to the Auto
position to bridge the switches JD14, JD22. Then press the REMOTE TG ADMISSION
pushbutton to bridge the switches JD15, JD22. If make sure through check that the TG
ADMISSION lamp 8, POWER SUPPLY lamp 10 and TG MOTOR STOP lamp 9 turn

on, as well as 380V AC is indicated on the voltmeter, the condition for turning has been
met.
4.2.2.1 Solenoid valve action test
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10, also bridge the zero speed signals JD5, JD6. If make sure through check after 30 sec.
that the voltage 220V AC has been established at the output terminals JD34, JD35 of
solenoid valve, another 30sec. later the turning contactor KM2 is actuated every 2 sec. to
indicate small movement of motor, the contactor KM2 is forced to close after small
movement two times, and the motor turns forward, the turning of unit

begins.

4.2.2.2 Turning test

Bridge the engagement completed switches JD3, JD4 before the third forced closing. If 30
sec latter the turning contactor KM2 is closed, the TG RUNNING lamp 3 turns on and the
motor runs forward, the turning begins.
4.2.2.3 Stop test
Bridge the TG STOP switches JD19andJD22. If the TG STOP lamp turns on and the
turning contactor KM2 is power-off, the shut-down of unit is performed normally.
4.2.2.4 Disengagement test
Bridge the remote disengagement switches JD21andJD22. The TG TRANSFER lamp
turns on. If the disengagement contactor KM3 is closed at this moment and the motor runs
backward, the disengagement is performed normally. If bridge the disengagement
completed switches JD1, JD2 at this moment, the contactor KM3 shall be power-off, the
motor stops running backward and the TG MOTOR STOP lamp HL9 turns on.
4.2.3 Inching operation test
Set the remote selection switch to the middle position, i.e. to the INCHING position.
Bridge the oil jacking pressure switches JD7, JD8 and the lube oil pressure switches JD9,
JD10, then press the INCHING AND IN pushbutton 16. At this moment the turning
contactor KM2 is closed, the TG RUNNING lamp 3 turns on, and the motor turns forward.
Thus the inching function can be realized by relieving the pushbutton to have the turning
contactor KM2 power-off.

0-5

Maintenance

The whole device is controlled by the computer with advanced PLC and Softstart, which shall be
subjected to full check and test as follows before putting into operation to confirm their proper
function:

a)
b)
c)
d)

Check for proper function of the power supplyAC380V, AC220V.

Check for proper indication of voltmeter on the panel.
Clean up the dust in control cabinet
Check for proper function of all indication lamps on the panel by means of the LAMP
TEST pushbutton.

e) Replace the defective element.

section4

Digital Electro-hyraulic (DEH) Control System

Specifications
1 Overview

In this chapter the control principle of steam turbine control system and the structural features
of 300MW steam turbine generator unit (hereafter referred to as the Unit) are presented.
1-1 Introduction
With the progress of computer technology, the Distributed Computer System (DSC) control
based on microprocessors is more and more widely used. The emergence of digital
electro-hyraulic (DEH) control systems has broken the fact that the adjustment of steam
turbine could only be finished by the special steam turbine maintainers who were heat
engineers more often than not. Meanwhile, for turbine operators, besides the technological
process of the control system, computer knowledge is also very important. Aiming at the new
generation 300MW DEH control system that is jointly developed by Dongfang Steam Turbine
Works (DFSTW) and FOXBORO, this instruction book presents the basic concepts of steam
turbine control system, the configuration of DEH, and the primary functions, operation
specifications, and installation and debugging methods of a control system.
The book is specially prepared to ensure that the system can be operated safely and reliably.
Control System Principle
For our D300N steam turbine generator unit, the high-pressure (hereafter referred to as HP)
steam admission is controlled by 2 HP stop valves (hereafter referred to as MSV) and 4 HP
control valves (hereafter referred to as CV), and the intermidiate-pressure (hereafter referred
to as IP) steam admission is controlled by 2 IP stop valves (hereafter referred to as RSV) and
2 IP control valves (hereafter referred to as ICV). All the above 6 admission control valves are
driven by hydraulic actuators to meet the requirements of short action time and high
positioning accuracy.
Normally the working rotation speed of the steam turbine is 3000r/min; however, when the
load in the grid varies, the actual rotation speed will change with it. The speed measurement
part of the steam turbine control system will measure the actual speed and compare it with the
rated speed 3000r/min, and then, through frequency difference amplification and regulator
servo control, control the opening extent of CVs and ICVs to form a negative feedback of
rotation speed, which will keep the rotation speed within a preset range.
All the above-mentioned 10 admission valves are driven by oil servo motors that adopt HP
fire-resistant oil as working medium. Except the six control valves (CVs and ICVs) that are
controlled continuously by using servo valves and microcomputer interface of DEH, the rest
two RSVs and two MSVs are controlled by solenoid valves and DEH interface in a two-digit
way.
In order to guarantee a safe operation, several redundant protection sleeves are available in the
hydraulic system:
Emergency tripping devices and testing solenoid valves;

HP and LP stop solenoid valves;

Overspeed restriction solenoid valve.
For the oil sources of HP fire-resistant oil, 2 redundant pressure oil pumps are also available
to guarantee a continuous oil supply. For detail, see the specifications for hydraulic system.
The primary mission of a steam turbine control system is to adjust the rotation speed of the
steam turbine via changing the opening extent of the control valve. When a steam turbine
generator unit operates within a grid, its rotation speed responds to the grid frequency. In a
grid system, when the whole generated output power is balanced by the power consumed by
all loads, the grid frequency will keep stable, i.e., the rotation speed of a grid-connected
generating set are adjusted by all the sets in the grid system.
For the rotation speed variation resulting from the fast but small load changes in the grid
system, the control system of steam turbine can balance it through using the energy
accumulation of the boiler, in which the set point of load needs not to be changed, when the
control system measures the variation of rotation speed, it automatically changes the opening
of the control valve, that is, it changes the power of the generator and makes it adapt to the
random fluctuation of the grid load. This is the so-called primary frequency regulation. In
order to ensure a rough balance of the primary frequency regulation amounts assumed by the
various generator sets in a grid system as well as to get a stable control system, it is required
that the static characteristic curves of the various generator sets are roughly the same.
The description of the relationship between the power and rotation speed of a steam turbine
generator unit under a steady working condition is called the static characteristics of control
system. Its slope in general is denoted as , the diversity factor of rotation speed.
=(n1 -n2 )/n0
(1--4)
Where, n1 --No-load rotation speed (fixed set point)
n2 --Full load rotation speed (fixed set point)
n0 --Rated rotation speed
In general varies between 3~ 6%, and factory-set value is 4.5%.
In general greatly varied non-linearity exists in the valves in the control system. Although
correction is conducted, non-linearity may still exist. So a concept of local diversity factor *
is introduced to represent the degree of the primary frequency regulation in the neighborhood
of the operating point.
* =-(dn/dN).N0 /n0 .100%
(1--5)
Where, N0--Generator power;
n0--Rated speed of rotation;
dn/dN--In the static state curve, the derivative of rotation speed to power.
Under the same deviation of rotation speed, the greater the (*) of generator set is, the
smaller the power change is; and vice versa.
Commonly the static characteristics can be obtained via calculational methods. Assuming that
steam parameters and other auxiliary systems are rated, through calculating the static

characteristics of velocity measurement, frequency difference amplification, servo drive, and

valves, the static characteristic of the control system can be worked out, and as a result the
diversity factors and * can be obtained. For the generator sets with base loads in a grid
system, in order to ensure that they can run at the most efficient operating condition points, a
dead zone for primary frequency regulation can be added to the control system artificially.
When the rotation speed of a generator set falls into the dead zone, the set will be free of
primary frequency regulation, that is, at this point the local diversity factor * is infinitely
great.
For the rotation speed variation resulting from large a load change (in general the change
occurs slowly) in a grid system, a method to change the load set point of the control system
can be used to change the power of generator and make it adapt to the random variation of the
grid load, as a result the rotation speed is controlled. This is the so-called secondary frequency
regulation. Changing the set point of the control system can make a translation of the static
characteristic line; as a result under the same rotation speed, the different line corresponds to
different power.
All modern steam turbine generator units belong to a reheat unit system, that is, one boiler
matches one steam turbine. Thus in order to sucessfully complete a secondary frequency
regulation task, not only the load set point of a steam turbine control system but also that of
the boiler control system shall be changed properly, so that adequate energy can be provided
and the boiler can run safely. This is the so-called coordination control.
In a grid system in general it is the specified generator sets that participate in secondary
frequency regulation. These generator sets receive the signals from the automatic frequency
controller to carry out the secondary frequency regulation.
For large changes in load, some special peakload units will be set up for peak regulation. On
receiving the load change instructions given by the control center, the peakload units will
change the loads they assume. In general the control center formulates its dispatching
schedule based on the statistic law of load change and sends load increasing or decreasing
instructions to the peakload units.
For the generator sets that participate in secondary frequency regulation and automatic peak
regulation, coordination control must be exercised. Commonly there are three ways for the
coordination control of unit and boiler:
Boiler following way: When the steam turbine control system receives the instruction of
secondary frequency regulation to increase the load set point, first of all it turns up the steam
turbine's control valves to increase the generator power. Then the increase of steam flow will
decrease the throttle pressure. At this point the boiler control system can detect such a
variation, and then it sends signals to the fuel control valve to increase the charge of fuel,
which will finally keep the throttle pressure invariable.
Steam turbine following (pressure regulated by steam turbine) way: When the boiler control
system receives the instructions of secondary frequency regulation to increase the load set
point, first of all it will turn up the fuel control valve. With the increase of fuel, the throttle
pressure and steam flow will increase, and as a result the generator power will increase. For
the purpose of keeping the throttle pressure as a constant, the steam turbine control system
adopts a steam pressure feedback system, which can change the control valve opening and
increase the steam flow and finally keep the pressure as a constant.

Steam turbine following (sliding pressure) way: When the boiler control system receives the
instruction of secondary frequency regulation to increase the load set point, it will turn up the
fuel control valve. With the enhancement of combustion intensity, the throttle pressure and
steam flow will increase and thus the generator power will also be increased. But the steam
turbine control system maintains the control valve in a fully open position all the while.
Unit-boiler coordination control mode: The method has the advantages of both the above
ways. The power instruction of secondary frequency regulation directly acts on both steam
turbine control system and boiler control system. First, it changes the opening of control valve.
Within the range of allowable variation of pressure, by using the boiler's accumulation of
energy, it improves the load response speed; meanwhile it changes the fuel control valve. With
the change of boiler output, the throttle pressure maintain constant.
The combined start by HP and IP cylinders is a traditional mode. With this method, the steam
simultaneously enters into HP cylinder (intermediate pressure cylinder) by way of CV (ICV)
from superheater (intermediate superheater) and finally brings the steam turbine to a rated
operating state. During the start, in order to reduce the throttling loss from ICV, the influence
resulting from intermediate superheater needs to be reduced. Under their respective working
pressures, the ratio of the flow capacity of CV to that of ICV is 1:3.
During the start, in general a full-admission method (throttle regulation) will be adopted for
the HP cylinder, so that the heat exposure will be uniform and thus the heat stress will be
reduced to the minimum. Under normal operation, because the temperature field in the
cylinder is roughly stable, a partial admission method (nozzle regulation) will be adopted for
the HP cylinder, so that the throttling loss can be reduced and the efficiency can be improved.
During the start, because the physical dimensions of rotor and cylinder are very large and the
temperature of the heating surface builds up quickly, staying at certain points during speed
raising and load up is required to reduce the heat stress of steam turbine. This is called
warm-up of turbine.
A rotor has its inherent natural frequency of vibration. During the rotating of a rotor, when the
exciting frequency resulting from the eccentric mass occurring prior to reaching equilibrium
is in agreement with the natural frequency of vibration, resonance will occur; at this point the
rotation speed is called critical speed of rotation. The resonance amplitude will increase with
time, and too large a amplitude will destroy the steam turbine generator unit; therefore, it is
required that the steam turbine shall rush through the zone in which critical speed of rotation
occurs.
In general a steam turbine generator unit is required to operate in a grid. Synchronous
grid-connection means a process in which a steam turbine generator unit is connected to an
electric grid after it reaches its running rotation speed. The conditions for synchronous
grid-connection are that the switch is closed and the potential difference of phase between
both sides (generator, electric grid) of oil switch is equal to zero, that is, both sides have the
same phase sequence, voltage, frequency, and phase.
The EHC adopts Foxboro's advanced open industrial control system, I/A Series, which
includes 2 cabinets, 1 printer, 1 application operating station AW51 (with the functions of
operator station (hereafter referred to as OIS) and engineering work station (hereafter referred
to as EWS)), and 1 OIS WP51.

OIS is a major device used to conduct a human-computer dialogue between power plant
operators and steam turbine control systems.
The printer is used to record all kinds of inportant data and keep them in the archives when
necessary.
EWSs facilitate the design, debugging, and revising of control logic.
The DEH adopts two-circuit AC 240VAC UPS for power supply and has redundancy design
in the interior. The internal power supply of I/A Series is realized by Industry Power Module
(hereafter referred to as IPM). One advantage is that the failure of one power supply module
will not affect the whole power supply; and the design is also featured by good heat
dispersion, simpleness, flexibility, safety, and high quality. Every card has a power supply
with both master and auxiliary IPMs.
Based on a design concept of decentralized control, the control system exercises its automatic
control by using a hydraulic servo system with I/A Series function module configurations.
The package unit consists of serialized standard hardware modules, each of which can
complete its respective functions independently and can communicate with each other.

Rate of
Rotation
speed two-out-of-three change
of
logic
load/pressure

CCS setting
Operator setting
Automatic setting

Target value

Rate of change of rotation speed

Rate limiter
Out of grid
connection

Primary frequency setting

Set point

Set point
selection

Automatic
setting
Rate
limiter

Adder

TPC action

Adder
Power

Throttle pressure
Power loop
governor

Speed loop governor

Throttle pressure loop governor

Power loop out

Throttle pressure loop in

Out of grid connection

Manual
setting

Manual
Lower selection

Overspeed

Manual minus

Valve limit
Runback setting

Runback action
Trip

Manual plus

OR gate

Gain 3
Function
generator

Input 1

Single valve Sequential valve

function
function generator
generator

Control signal

Valve test logic

Valve test logic

Output

Input 2

Single/Sequential
valve switch logic
Valve test

Valve test
To ICV servo card
To CV servo valve

Schematic diagram of
a control system

Output switch function (When the control

signal = 1, output = input 1; when the
control signal = 0, input = output 2)

2 Control system configuration

1 The DEH control system processor CP60 is divided into two pairs, of which the first pair is
defined as basic control station (BTC) to complete such functions as overspeed protection and
basic control of steam turbine, and the second pair is defined as automatic control station (ATC)
to complete such functions as steam turbine parameter monitoring and on-line testing. The
hardware configuration is mainly composed of the following parts:
FOXBORO standard cabinet;
DINFBM Template;
AW51 Application operating station;
WP51 Operating station.
2

Board Configuration for DEH system is as follows:

BTC (basic control station);
Three FBM206 velocity measurement boards;
Six FBM204 AI / AO boards;
Four FBM241 DI/ DO boards.
ATC station (automatic control station);
Three FBM201 large-signal AI boards;
Three FBM202 TC signal AI boards;
Four FBM203 RTD signal AI boards;
One FBM204 AI / AO board
One FBM207A DI board
Three FBM241C DI / DO boards.
The board configuration for DEH system is shown in Figure 2-1.

21

Control cabinet

The installation has two cabinets in total, in which the majority of the important
boards and related connecting pieces, wires, and cables of DEH are installed.

Fro
nt
boar
d

Printer

Cont
rol
proc
essor
(BT
C)

Fro
nt
boar
d

CV1
Servo
board
DFSC

CV2
Servo
board
DFSC

on site

LCD
color

CV4
Servo
board
DFSC

CV2
Servo
board
DFSC

Cont
rol
proc
essor
(AT
C)

Engineer keyboard

MSV2
Servo board
DFSC

On-site servo valve /LVDT

on site

Redundant on site busIEE1118

WP51 operating
station processor

Redundant node busIEEE802.3

Engineer keyboard

LCD
color

Figure 2-1 DEH system configuration diagram

On-site servo valve /LVDT

CV3
Servo
board
DFSC

CV1
Servo
board
DFSC

AW51
application
operation processor

Redundant on site bus (IEEI118)

Speed
measure
ment
signal

Fro
nt
boar
d

Overspeed 103% action / Overspeed 110% action

Overspeed 103% action / Overspeed 110% action

Overspeed 103% action / Overspeed 110% action

22 Boards of I/A Series

The control system of I/A Series consists of the following kinds of boards:
1 Control processor CP60;
2 Single-channel isolation voltage monitoring/contacting signal input interface module
FBM207;
3 Isolated DI / DO board FBM241;
4 Isolated AI board FBM201;
5 Isolated thermocouple /mV AI board FBM202;
6 Isolated hot resistance AI board FBM203;
7 Isolated AI / AO board FBM204;
8 Channel isolation, impulse input interface module FBM206;
The above boards are specified in the hardware manual provided by Foxboro.
23

AW51 application operating station

There is a suite of AW51 application operating station, which includes one Ultra
SPARC RISC 64 -bit processing machine, one colour 21LCD, one printer, and some
mouses amd keyboards.
AW51 is designed to help engineers to conduct design, configuration, debugging, and
monitoring.
Its major functions are as follows:
1 Application function
AW51 has the application functions related to display, production control, customer
application program, diagnosis, and configuration. AW51 also has the application
functions to developm and carry out data processing and filing service that need
expansion (FOXBORO and the third party). AW51 reduces the mass storage file
application required by the tasks of itself or from other stations.
Together with one or more file memory equipment, AW51 is used to conduct loading for
other stations; to perform production control tasks, such as data authentication,
electronic spreadsheet and performance calculation; to provide normal functions, such
as operator HELP and electronic files; to offer an application development environment,
such as compiler software, connection software, and text editing software.
2 Operating station functions
In a video frequency monitor, it can generate video signals to display both graphical and
literal information. Besides video frequency monitors, the devices connecting to AW51
can include touch screen, mouse, or ball cursor. These optional devices provide
command or data input as well as display selection and alarming management.
24

WP51 operating station

There is a suite of WP51 application operating station, which includes one Ultra SPARCRISC

64-bit processing machine, one colour 21CRT, and some mouses and operator combination
keyboards.
WP51 is the major device used to conduct a human-computer dialogue between power plant
operators and steam turbine control systems. Together with its peripheral equipment, WP51
provides an interface between users and all the system functions. Its major functions are to
provide command and data input, display selection, and alarming management. It receives both
graphical and literal information from the application processor or any other system station, and
displays the information on the video display.
3 Servo valve controller
DEA servo valve controllers are specially designed for DEH. The controller adopts 16-bit SCM
80C196 chips and high-performance programmable logic array CPLD to form its control core;
meanwhile it adopts 16-bit A/D and D/A chips to improve its conversion accuracy. The supply
unit adopts advanced DC-DC isolating converters to ensure that the operational power supply
and the electric power supply can be adequately isolated, and that the work of the power loop of
controller is effective and reliable. In terms of hot pluggable technology, the controller adopts
Philips I2C serial bus technology, with which the values of full-close and full-open of LVDT are
stored into E2PROM during the checking procedure, and as a result hot plug is realized. The
operational principle of servo card is, through the acquisition of LVDT's measured values and the
setting values sent out by the control system to form a comparing element and then through PI
calculation, to output regulating currents to control the movement of control valves, so that the
opening of valve can reach the setting expected position.
31 Servo valve controller hardware overview
The hardware of a servo valve controller primarily includes servo cards and cabinet modules:
1 Servo cards
Servo cards adopt a four-layer printed plate wiring technology, which is highly resistant to EMC.
Major parts of the plate are imported from overseas.
CPU adopts advanced 16-bit SCM 80C196 of Intel with a very high calculating and processing
speed. Built-in WATCH_DOG is available for the SCM, which shows a robust self recovery
capability.
16-bit A/D and D/A chips are adopted for the acquisition and output conversion of analog signals,
which has high conversion accuracy. One of the A/D chips picks up various simulating signals
through its front-mounting channel selector. In the two D/A chips, one is used for valve position
signal output, and the other for current output after PI calculation. Isolated amplifiers and
external interfaces are adopted for the separation of all analog signal channels of servo card.
By adopting the I2C serial bus technology of Philips, during the checking the full-close and
full-open values of LVDC resulting from checking are stored to E2PROM, which as a result will
not affect the service of the card for power loss reasons.
The LVDT acquisition channel employs two circuits, so when one of which fails it can switch to
the other. There is also a built-in oscillating circuit, which can be used for the excitation signals

of LVDT. The frequency and amplitude of excitation signal can be adjusted by setting up the
jumpers on the card.
2 Cabinet modules
19" electromagnetic shielding cabinet and modules are adopted. All the connecting terminals at
the rear of cabinet are welded to the power source motherboard for the convenience of wire
connection.
A push-and-pull mechanism is used for cards so that the pull and insert is very convenient.
32 Servo valve controller function overview
1 Control drive
Servo cards pick up the feedback values of LVDT, then compare the values with the specified
instructions from the control system (4-20mA signals), and then, through PI calculations, output
regulating currents (-40mA-40mA) to actuate the servo valve, and as a result control the travel of
the valve to a specified opening degree. While conducting auto regulation, servo cards can also
send a valve opening signal (4-20mA current signal or 1-5V voltage signal) to the control system
as the travel instruction. The scale factor and integrating factor used for PI calculation can be
adjusted through a thumb wheel dial. According to the indicator lights on panel the working state
of a card can be know in real time.
2
Two-circuit LVDT switch
Servo valve controllers provide two-circuit LVDT switch functions, that is, once the working
LVDT fails, the servo card can detect the corresponding trouble and switch to the standby LVDT
automatically.
3
Check
Servo valve controllers also provide check functions, that is, they can output close signals and
open sigals to control the movement of valves, make the valves fully open or fully closed, and as
a result proceed to the setting of servo static relation.
Bias
4
Servo valve controllers also provide bias functions, that is, they can output current or voltage signals to
force the valve closed under a bias input condition.

Manual function
Manual functions are also available for a servo valve controller, that is, manual increase and decrease
operations can be conducted for valves.

33 Operating instructions for servo valve controller

Prior to using a servo valve controller, first set up the jumpers. Meanwhile, before turning on the power,
be sure to connect the wires for the cabinet accurately.

Jumper setup

The jumper setup for master servo cards and digital-analog cards is as follows:
1.1

Jumper setup for master servo cards

J1 and J23 are used for the selections of CPU's working conditions. Of them, J1 is the jumper for
CPU's working clock, and J23 is used to select the operation mode of program memory. The
jumper connection mode set up at factory for J1 is of short-circuit (CPU is working), while that
for J23 is of (2, 3) short-circuit. Change is not allowed for both of them.
J3 and J8 are used to select the category of LVDT1 feedback (AC and DC selection). Of them,
the mode of J3 (1, 2) short-circuit and J8 disconnection is to select the LVDT1 AC feedback
system; while the mode of J3 (2, 3) short-circuit and J8 short-circuit is to select the LVDT1 DC
feedback system.
J4 and J9 are used to select the category of LVDT2 feedback (AC and DC selection). Of them,
the mode of J4 (1, 2) short-circuit and J9 disconnection is to select the LVDT2 AC feedback
system, while the mode of J4 (2, 3) short-circuit and J9 short-circuit is to select the LVDT2 DC
feedback system.
J10 is used to select the output mode for servo drive 1. The mode of J10 (1,2) short-circuit means
the servo drive 1 selects a current operation mode; the mode of simultaneous short-circuit of both
J10 (1, 2) and J10 (1,2,3) means that servo drive 1 selects a voltage operation mode. Under the
voltage operation mode, the mode of connection shall be changed; for details, see the following
wire connection illustrations.
J11 is used to select the output mode of servo drive 2. The mode of J11 (1,2) short-circuit means
the servo drive 2 selects a current operation mode; the mode of simultaneous short-circuit of both
J11 (1, 2) and J11 (1,2,3) means that servo drive 2 selects a voltage operation mode. Under the
voltage operation mode, the mode of connection shall be changed; for details, see the following
wire connection illustrations.
J12 (1,2) short-circuit does not include fluter component, while J12 (2, 3) short-circuit is the
superposition of servo drive signals and fluter component. The fluter frequency can be changed
through the setup of jumper combination (J13, J14). Under the condition of a factory setup of
(J13, J14) short-circuit, the frequency is in the order of 311HZ; in case of (J13, J14)
disconnection, the fluter frequency will become 208HZ or so.
The combination of (J15, J16, J17) is used to select the pumping frequency of LVDT. In this card
the (J15, J16, J17) is of short-circuit, and the frequency is in the order of 1.7KHZ. If the J17 is
short-circuited at factory, the frequency is about 1.1KHZ.
The combination of (J19, J20, J21, J22) is used to select the pumping amplitude of LVDT. The
maximum amplitude is available for a full short-circuit and the minimum is available for a full
disconnection. The descending sequence for sole short-circuit amplitude is J19>J20>J21>J22. In
case of the (J19, J20, J21) short-circuit set up at factory, the pumping amplitude is about 3.2V.
J18 (1, 2) short-circuit is to use cards for pumping frequency output; J18 (2,3) short-circuit is to
use a external pumping source. In service no full open is allowed, because in this way the
software will judge it as a pumping trouble of LVDT.
1.2

Jumper setup for digital-analog cards

Disconnection is set up for J1 at factory, and no change is allowed for it.

J3 is the setting adjustment. Disconnection is set up at factory, and no change is allowed for it.
J2 (1,2) short-circuit is to input setting current signal; J2 (2, 3) short-circuit is to input setting

voltage signal. J2 (3, 4) short-circuit is to input setting current differential signals; no

short-circuit of J2 is to input setting voltage differential signals.
J4 (1, 2) short-circuit valve position is outputting 1-5V voltage signals, and J4 (2, 3) short-circuit
valve positions is outputting 4-20mA current signals.
1.3 Servo cabinet
A servo cabinet consists of a electromagnetic shielding cabinet, backboard terminals, and bails.
The backboard is a printed circuit board on which all the sockets for servo cards are welded. All
external wires access the cabinet through the connecting terminals on the backboard.
1.3.1 Outside view of a servo card cabinet

To top cover and top guide rail

3-3-2

Figure 3-3-1: External view of servo card cabinet

In the above Figure, the above part is a front view of a cabinet with servo cards, in which (2) is the socket with
a card while (3) is a void socket with no card; the lower part is the top view of the cabinet.

1.3.2

Outside view of backboard of servo card

All external wires access the cabinet through the backboard of the servo card cabinet. TB23 is a

reserved design for communication, useless at present; TB25 is the incoming terminal for 24V
DC power supply; TB1-TB20 are the connecting terminals for all the interfaces on servo cards.
Each card occupies two connecting terminals, for example, the interface signals of the servo card
in the first left bail are accessed and outputted through (TB1, TB2). All the others are arranged in
the same way in sequence. The distribution of the connecting terminals of the whole backboard
is shown as the following Figure.

TB25

TB23

TB20 TB19 TB18 TB17 TB16 TB15 TB14 TB13 TB12 TB11 TB10 TB9

TB8

TB7

TB6

TB5

TB4

TB3

TB2

TB22 TB21

Figure 3-3-2 Terminals on the backboard of servo cabinet (back view)

1.3.3 Definition of TB25 power terminal on backboard of servo cabinet

+24V input +

+24V input +
+24V input -

+24V input -

Figure 3-3-3 Definition of power terminal

TB1

In the above Figure hte dotted portion denotes the internal wiring of backboard. From the Figure
it is observed that the four pairs of terminals (1, 2), (3, 4), (5,6), and (7, 8) have been
short-circuited internally, which can not be changed. (1, 2, 3, 4) terminals form a suite of input
power source, and (5, 6, 7, 8) terminals form another suite of input power source. The two
groups of power can be short-circuited through the jumpers within the backboard.
1.3.4 Definition of interface terminals on backboard of servo card
Two terminals serve one servo card. Here (TB1, TB2) is taken as an example to illustrate the
meanings of each connecting terminals, which are numbered as 1~16 from the top down.

Emergency manual input (DI)

Valve + input (DI)
Valve - input (DI)
Shutdown bias input (DI)
Rapid manual input (DI)
Check begin input (DI)
Check permit input (DI)
IN_COM (input common terminal)
Check status ouput (DO 24V/2A)
Emergency manual output (DO
24V/2A)

Valve + output (DO 24V/2A)

Valve - output (DO 24V/2A)
Failure output (DO 24V/2A)
OUT_COM
t

(input

common

i l)

Servo valve setting+ (4-20mA)

Servo valve setting -

TB2

TB1

10

10

11

11

12

12

13

13

14

14

15

15

16

16

SERV01+(servo 1drive +)
SERV01-(servo 1drive -)
SERV02+(servo 2 drive +)
SERV02-(servo 2 drive -)
Valve output +(1-5V or 4-20mA)
Valve output -(1-5Vor 4-20mA)
LVDT-AC(drive signal output)

LVDT1-1-1(LVDT1 order 1)
LVDT1-1-2(LVDT1 order 1)
LVDT1-2-1(LVDT1 order 2)
LVDT1-2-2(LVDT1 order 2)
LVDT2-1-1(LVDT2 order 1
LVDT2-1-2(LVDT2 order 1
LVDT2-2-1(LVDT2 order 2
LVDT2-2-2(LVDT2 order 2
GND(2)

Figure 3-3-4 Definition of connecting terminal

1.3.5 Access of setting signal

There is no differentiation between current and voltage in terms of access of setting signals, and
all the signals are accessd through the same terminal. The differentiation of setting current and
setting voltage depends on the jumper connection of J2. J2 (1,2) short-circuit is to input setting
current signals; J2 (2, 3) short-circuit is to input setting voltage signals. J2 (3, 4) short-circuit is
to input setting current differential signals; no short-circuit of J2 is to input setting voltage
differential signals.

TB2

15

16

Setting current of 4~20MA or setting

voltage 1~5V

Figure 3-3-5 Connection diagram with a setting current or voltage

1.3.6

Wiring for LVDT of servo card

Both DC LVDT and AC LVDT are taken into consideration from the point of view of design.
Modes of connectionare are shown in the following Figure.

TB1
7
8
9
10
11
12
13
14
15
16

LVDT-AC
LVDT1-1-1

LVDT1(AC)
LVDT1-1-2

Primary
coil of
LVDT1
LVDT1

LVDT1-2-1

LVDT1-2-2
LVDT2-1-1

TB1
LVDT2(AC)

LVDT2-1-2
LVDT2-2-1

LVDT2-2-2
GND(2)

Primary coil
LVDT2
of LVDT2

LVDT1-1-1

LVDT1-1-2

12

LVDT2-1-1

13

LVDT2-1-2 -

LVDT1(DC)

LVDT2(DC)

*LVDTs
input positive and negative 10V
* LVDT10V

Figure 3-3-6: LVDT connection diagram

1.4

Operation instructions

The operational process of servo card will be detailed in the following.

1.4.1

Power-up initialization

Dial the thumb switch from high-order positions to low-order positions. When the four-digit
switch SW1 is switched as ON_OFF_ON_OFF and the eight-digit switch as
OFF_ON_OFF_ON_OFF_ON_OFF_OFF, the servo card will begin its initialization process; at
this time, RUN light is green, D0-D7 serial lights turn on, the four (RXD, TXD) lights are also
on, and the program will conduct initialization presetting for the data stored in the E2PROM.
1.4.2

Regulating pqrameter setup

SW2 is used to adjust PI parameters, and at this time SW1 shall be switched to OFF or ON
position completely. See the following Table for detail about SW2.
Parameter
name
Thumb switch
position
ON position
OFFposition
ON=0 OFF=1

KP
1

No use

KI
2

0
0
1
1
KP=SW2(1-4)

0
1

0
1

0
0
1
1
KI=SW2(5-7)

0
1

From the above Table it can be learned that the first four digits (1~4) of SW2 are used for the
setup of scale factor; digits 5~7 are used for the setup of integrating factor; the eighth digit has
no use in the control parameter setup. When SW2 is switched downwards to the 0FF position,
the value is 1; when SW2 is switched upwards to the ON position, the value is 0. KP's dial-up
consists of 4 digits, which form 16 scale factors; the greater the dial-up value, the greater the
scale factor. KI's dial-up consists of 3 digits, which form 8 integrating factors; the greater the
dial-up value, the smaller the integrating factor, and the faster the integral calculation is.
1.4.3

Check function

After the DI signal "CHECK PERMITED INPUT is effective, CHK light on panel turn on.
After the signal "VIRIFICATION BEGIN" input is effective, CHK light flashes slowly, and the
servo card outputs forward current (or negative voltage) to drive the servo valve and make it
move towards the valve closing direction; after the valve reaches the full close position, it is time
to wait for current bias, and at this time (D4,D5) light turns on; with a minute of time delay,
CHK light flashes quickly, and the servo card outputs negative current (or positive voltage) to
drive the servo valve and make it move towards the valve openning direction; after the valve
reaches the full open position, it is time to wait for current bias, and at this time (D4,D5) light
turns on; with a minute of time delay, the servo card will record the full close and full open
values from check, and store them in the serial storage chip E2PROM. CHK light is normally on,
and the check is over.
1.4.4

Bias function

In any case, after the DI signal' SHUTDOWN BIAS INPUT is effective, the servo card will
output forward current (or negative voltage) to close the valve forcefully. The current output is in

the order of 50mA.

1.4.4

Manual function

After the DI signal "EMERGENCY MANNUAL INPUT is effective, the MAN light on
panel will turn on. At this time if the signal "VALVE +" input is effective, the UP light on panel
will turn on, and the current output of servo card will increase negatively (or increased output
voltage) to open the valve; if the signal "VALVE -" input is effective, the DOWN light on panel
will turn on, and the current output of servo card will increase positively (decreased output
voltage) to close the door.
1.4.5

DIT potentiometer hole:

Screwdrivers can be used to adjust the fluter amplitude potentiometer through the hole.
1.4.6

DIV test hole:

The amplitude of fluter can be tested through the hole.

1.5 Field use instructions
It is necessary to give a brief illustration for the use of servo card on site due to its intrinsic complexity.

1.5.1

Check prior to use

Prior to the use of card, jumpers must be well set up in advance according to corresponding
valve category, setting category, and valve position feedback category, and a thorough inspection
is required for the setup to ensure an absolute accuracy.
1.5.2

Installation of LVDT

During the in-situ installation of LVDT, in a general way first look for the zero point; then
according to the travel of oil servo motor, with the zero point as the symmetric midpoint, look
for the full open positions or full close positions for installation. The way to look for the zero
point is to look for the position of LVDT when two circuits of secondary voltage is equal, or to
look for the midpoint of LVDT within the effective travel by drawing out the LVDT rod. The
card has no high requirements for the accuracy of zero point.
1.5.3

Adjustment of LVDT secondary wire connection sequence

First be sure that the valve is in a full close state, and LVDT has been assembled and well wired.
Take TB1 as an example.Measure LVDT1 order 1(the voltage between terminals (TB1 (8,9)) and
LVDT1 order 2 (the voltage bewteen terminals TB1(10,11); if the measured AC feedback voltage
LVDT1 order 1 is lower than order 2, then the wire connection is right; otherwise, order 1 and
order 2 shall be exchanged.The redundant LVDT2 is the same as LVDT1. The measure points
are LVDT2 order 1 (voltage between terminals TB1 (12,13)) and LVDT2 order 2 (voltage
between terminals TB1 (14,15)). If the redundancy LVDT is not used, LVDT shall be conncected

to the corresponding TB1 terminal, that is, the feedback of LVDT is connected to the two
feedback input circuits of TB1 simultaneously.
1.5.4

Determination of servo outgoing feeder

After determining the secondary linear ordering of LVDT, increase or decrease the setting
quantity until the valve moves; then judge whether the movement direction of the valve is in
accordance with the setting direction; if it is, then the servo output connection is right; otherwise,
exchange the two output lines. Under the current operation mode, if only use one circuit of servo
output, short-circuit the other circuit or add a small load onto it.
1.5.6 Use of initialization
In general, unless in trouble, the cheking procedure can completely cover the stored LVDT check
values. If no success can be get again and again, an initialization process is available to check
whether the serial memory is damaged. If a reset operation is applied but success is still
unavailable, check the external interface signals. If resetting is unavailable, the card has
problems.
3-4 Fault indication for servo valve controller
The card uses the indicator light on the front panel for failure predication. The meaning of the indicator
light as well as their combination indicating troubles are described below:

Definition of lights on panel and functional specifications for test hole

RUN light :
When the card is in its initialization status, the light is orange (cold boot time is in the order of 2
seconds, and self-recovery reset time is dozens of milliseconds); when in normal operation, it is
green.
RXD light:
RXD is used to indicate which LVDT is working. If ARXD is on, it indicates that LVDT1 is the
current working LVDT; if BRXD is on, it indicates that LVDT2 is the current working LVDT.
TXD light:
TXD light serves as the indication of access LVDT. If ATXD is on, it is LVDT1 access; if BTXD
is on, it is LVDT2 access. If both ATXD and BTXD are on, both LVDT1 and LVDT2 are on.
Note: The criterion for the function is that when the valve is in the safe full close position
without servo drive, the feedback of LVDT is not zero. So in order to make the function valid,
when LVDT is installed it is necessary to avoid the full close state, and the LVDT rod cannot be
at mid point.
D0-D7:
The combination of D0 to D7 lights can be used to display various failure states. Under a normal

condition, the running light is on; however, if there is a failure state, the running light will turn
off and the corresponding failure combination code is displayed.
MAU:
Manual indication, meanwhile the DO signal "EMERGENCY MANUAL OUTPUT" of servo
card is effective.
ERR
Servo card fault indicating light. When the A/D chip and integral output D/A chip of a servo card
is abnormal, the light will be on; when the pumping frequency is abnormal, the light will flash
quickly. When a A/D chip is abnormal, the valve will be closed forcefully. When the light is on,
it also sets up the DO signal "SERVO TROUBLE OUTPUT" as effective.
CHK
Check light. After the DI signal "CHECK PERMITED INPUT" is effective, the light is on; when
the valve moving towards the full close direction is checked, the light flashes slowly; when the
valve moving towards the full open direction is checked, the light flashes quickly; when the
check is over, the light is on. After the DI signal "CHECK PERMITED INPUT" is canceled, the
light is off. When the light is on, it sets up the DO signal "CHECK OUTPUT" as effective.
UP:
Manual up indicator. When the light is on, it sets up the DO signal "VALVE POSITION UP
OUTPUT" as effective.
DW:
Manual down indicator. When the light is on, it sets up the DO signal "VALVE POSITION
DOOW OUTPUT" as effective.
1.10 Illustrations for D0~D7 composite codes
The composite codes of D0~D7 are used to denote various failures during operation, which are
detailed in the following Table.
Panel light status
D0 ON
D1 ON
D2 ON
D7 OFF

D3 ON
D4 ON
D5 ON

D7 ON

D6 ON
D0 ON
D1 ON
D2 ON
D3 ON
D4 ON
D5 ON
D6 ON

Failure meaning
A/D conversion chip failure
Valve
position
output
D/A
conversion chip failure
Adjustment output D/A conversion
chip failure
Undefined
Disconnection or bias of servo drive
1
Disconnection or bias of servo drive
2
E2PROM read/write failure
Illegal check value for LVDT1
Illegal check value for LVDT2
LVDT1 overrun
LVDT2 overrun
LVDT driving signal failure
Setting input signal failure
Undefined

ERR output
Yes

Yes

Flicker

1.11
Special illustrations for failure indication
1.11.1 In case of a failure of A/D conversion chip, RUN light is green, ERR light is red, and (D0,
D1, D2, D4, D5) lights are red. The servo drive will output a 39mA current to close the valve.
When an A/D conversion chip fails, all analog variable acquisition will fail, so except its own
failure is displayed, other failures will also be displayed.
1.11.2 In case of a failure of adjustment output D/A conversion chip, RUN light is orange, ERR
light is red, and (D2, D4, D5) lights are red. In this case the output and acquisition of current will
not be accurate and effective any more, so the failure of servo drive will also be displayed.

1.11.3 Other failure cases can be accurately judged according to the above Table.
4 Major functions of DEH control system
Major functions of the control system are as follows:
Automatic setting of static relation of servo system;
Remote latching-on prior to start;
Automatic thermal condition judgement;
HIP CV start mode
Full-range automatic closed-loop control of rotation speed from hand-turning speed to rated
speed;
Overspeed control and overspeed protection functions available;
Able to realize rapid synchronous grid-connection with the interface of automatic
synchronization installation;
Flexible selection between power control and valve position control and free switching;
Valve management functions available;
On-line HIP SV and HIP CV activity tests available;
Able to realize remote spray oil testing and automatic latching-on after testing;
On-line HP tripping solenoid valve testing available;
Mechanical and electric overspeed testing available;
Throttle Pressure Control (TPC), load control, and valve position control functions availale;
DEH-controlled SV and CV leak testing available
Cooperating with CCS to realize RUNBACK functions;
Cooperating with CCS to finish unit-boiler coordination control;
Sound parameter monitoring functions available;
ATC control available.
4-1 Automatic setting of static relation of servo system
Prior to the start of a unit, the static relation setting for servo valves, LVDTs, and servoboards
must be completed to guarantee the control accuracy and linearity of all servoactuators so that
the unit's requirement for the static relation of the servo system can be met. Such valves as CV,
ICV, and MSV can be checked simultaneously or respectively. The process goes on at the OIS
display.
1 The setting of static relation for a servo system prior to the start of a unit must fulfill the
following conditions:
Latching-on is available for the steam turbine.
All valves have been closed.
No steam is allowed in front of a SV; otherwise, when the valve is under check and the
rotation speed of the unit is greater than 100r/min, DEH will conduct tripping automatically.
In other words, the rotation speed of the steam turbine must be less than 100r/min.
2 Calibration procedure
a) Enter into OIS "STEAM TURBINE VALVE CALIBRATION" picture, and select "SINGLE

CALIBRATION PERMIT" or "DOUBLE CALIBRATION PERMIT" (Both can be selected

simultaneously for off-line calibration, but only one of them can be selected for on-line
calibration).
b) When "SINGLE CALIBRATION PERMIT" is lit, only the valves of odd number can be
selected for calibration; when "DOUBLE CALIBRATION PERMIT" is lit, only the valves of
even number can be selected for calibration. Select the valve to be checked, the corresponding
key is lit.
c) After selecting the valve for check, begin to check the corresponding servoboard, and at this
time the "CHK" light on the servoboard begin to flicker (down flicker frequency is slow but up
flicker frequency is fast), meanwhile the "VALVE CALIBRATION IN PROGRESS" light also
begin to flicker (the same flicker frequency with that of "CHK" light).
d) When "CHK" light and "VALVE CALIBRATION IN PROGRESS" light are normally on, the
check is over.
e) Again click the "single CALIBRATION" or "double CALIBRATION" buttons to quit from the
check mode, and at this time the "CHK" light is off and the "VALVE CALIBRATION IN
PROGRESS" light turns grey.
f) After finishing the check, inspect the static relation. Through the OIS station send out a valve
opening instruction, then check whether the opening instructions and the actual valve opening
meet the static relation's requirements; if not, conduct setting again according to the above steps.
4-2 Automatic thermal condition judgement
A steam turbine's start process is also a heating process for both the steam turbine and its rotor.
In order to reduce the heat stress resulting from start, for different initial temperature, different
start curve shall be adopted.
Every time when latching-on is conducted for DEH, the thermal state of the turbine is
automatically determined based on the temperature of the inner upper wall of the HP inner
casing at the control stage of the unit. If the temperature signal from the upper wall fails, it wall
be replaced by that of the lower wall automatically.
T150C
150C<T<300C
300CT<400C
400CT

Cold state;
Mild state;
Hot state;
Extremely hot state.
4-3 Automatic remote latching-on prior to start

Prior to start, first generate an latching-on instruction through OIS; then reset the testing valve
block to make the emergency tripping device engaged. After latching-on, a HP safe oil pressure
is established, and all SVs and CVs are in a close state.
Permissive conditions for latching-on:

Tripping of steam turbine;

All valves in a full close state.
Push the "RESET" button in the OIS "AUTOMATIC CONTROL" menu, then the HP tripping
solenoid valve acts, the oil pressure in the upper chamber of the slide valve on the emergency
governor gear is established, and HP security oil is established; at this time the OIS
"AUTOMATIC CONTROL" menu displays the "RESET" status of the steam turbine.
4-4 Startup and operating mode
1 Prewarming of HP cylinder
Prior to start, prewarming can be conducted through introducing HP by-pass steam to the HP
cylinder by way of RFV prewarming valve and HP cylinder's steam outlet. Drivers send out a
prewarming instruction to open the prewarming valve RFV, close the vacuum valve VV, and
close the HP exhaust check valve. When the temperature of the HP cylinder reaches the specified
value, keep warming for an hour, and close RFV, so the prewarming of HP cylinder is completed.
2 HP SV (HP stop valve) prewarming
Operators send out a prewarming instruction to open 10% of the HP SV in one side and
introduce main steam into the two SVs; when the temperature of the valve bodies reaches the
specified value, the prewarming is over and the HP SV shall be closed.
3 Startup mode
3.1 Intermediate pressure (IP) cylinder start
After the prewarming is completed and the start condition is available, open VV. Select the
"STARTUP MODE" button in OIS, and then select the "IP CYLINDER STARTUP" mode. The
IP control valve will be open gradually and the speed of the unit will be raised to 3000r/min.
After grid connection, the unit has an initial load. Set up the target load and load rate. Push the
"PROCEEDING/HOLD" button. At this time a "PROCEEDING" status displays on the menu
and the unit begin to raise its load. In order to keep the reheating pressure constant, the lower
by-pass system begins to close gradually; when the lower by-pass system is fully closed, HP and
IP cylinder switching can be conducted. Push the "CYLINDER SWITCHING" button, the
switching of HP and IP cylinder begins, that is, the IP control valve opens gradually. In order to
keep the throttle pressure constant, the higher by-pass system begins to close. When the steam
admission ratio of HP cylinder to IP cylinder reaches 1:3, it is thought that the switch is over. HP
and IP control valves participate in control simultaneously. When the cylinder switching is in
progress, the load control will be cancelled and the VV will be closed.
3.2 Combined start by HP and IP cylinders
When the by-pass system has performance problems or hot state and extremely hot state are used
for start, a combined start mode by adopting HP and IP cylinders can be adopted; at this point HP
and IP control valves are opened simultaneously.

4-5 Speed control

Prior to the grid-connection of steam turbine generator unit, DEH is a rotation-speed closed-loop
isochronous control system. Its set point is the setting rotation speed. Through the calculation of
PID regulator, the servo system uses the difference of setting speed and actual speed to control
the opening of the oil servo motor, making the actual speed vary with the setting speed. As per
different start modes, the oil servo motor is ICV or CV and ICV.
After a target speed is set, the setting speed automatically approaches the target speed with a
setting acceleration rate. When the speed reaches the critical speed zone, the acceleration rate
will be automatically changed into 400r/min/min. During speed raising, often the steam turbine
needs to be heated in medium or high speed to reduce heat stress.
1

Target rotation speed

Except the target rotation speed set up by operators through OIS, under the following conditions,
DEH automatically set up the target speed:
When the steam turbine is just engaged, the target is the current rotation speed;
When the oil switch is just disconnected, the target is 3000r/min;
In a manual state, the target is the current rotation speed;
When the turbine has tripped, the target is zero.
When the target exceeds the upper limit, it has been changed into 3060 or 3360r/min;
In a self-start mode, the target depends on ATC;
In synchronization, the target varies with the change of the synchronous fluctuation signals (rate
of change 60r/min/min).
When the target is set in the critical range by mistake, it has been changed to a specific critical
value.
2

Acceleration rate

Set by operator, within (0~400) r/min/min;

Under a self-stardup mode, 120, 180, 360r/min/min;
Within the critical speed range, 400r/min/min.
3

Critical speed of rotation

The calculated values of combined critical speed are:

First-order: 1399r/min electric machine rotor first order

Second-order: 1679r/min HIP rotor first order

Third-order: 1753r/min LP rotor first order
Fourth-order: 3465r/min electric machine rotor second order
In order to avoid the critical speed of rotation, DEH sets up two critical speed zones, the range of
which is about 50r/min different from the calculated values of the critical speed. If the
measured critical speed is greatly deviated from the calculated value, the critical speed zone
value and the critical speed plateau value must be revised.
Warm-up of turbine
The warm-up rotation speed depends on the specific unit, and each unit has its own warm-up
speed. When the target rotation speed is reached, the speed raising can be ceased for warm-up. If
intermitting is required during speed raising, the following operations can be conducted:
When not in an ATC mode, the operator sends out a "HOLD" instruction;
When in an ATC mode, the operator sends out a "HOLD" instruction after the system quits from
the ATC mode.
Within the critical speed zone, the hold instruction is invalid, and only the target rotation speed
can be modified.
Note: during the warm-up, the resonant frequency with rotor and blades must be avoided.
4

3000r/min constant speed

When the steam turbine's speed is stabilized above 30002r/min, all systems conduct an
inspection for grid connection. A pseudo grid connection test is conducted for the generator to
check the reliability of the automatic synchronous system and the accuracy of adjustment.
During the test period, the isolating switch on the side of generator power grid is disconnected
and a pseudo grid connection test signal is sent out. As the normal condition, the automatic
synchronous system changes the frequency and voltage of generator through DEH and generator
excited system. When the synchronization condition is met, the oil switch is closed. Because the
isolating switch is disconnected, actually the generator is not grid-connected.
As a result, during the pseudo synchronization testing, when DEH receives the pseudo grid
connection test signals and the oil switch is closed, it does not judge that the generator is
grid-connected. In this way, an initial load resulting from grid connection and the resultant speed
rising can be avoided.
During speed rising, warm-up is required. Push down the "HOLD" button in the "AUTOMATIC
CONTROL" menu of OIS. At this point, the OIS menu displays a "HOLD" status, and the
rotation speed keeps constant for warm-up. If the unit is stepping across the critical zone, the
operation of clicking "HOLD" button will be invalid.
Attention: in some works, for no DI signal of pseudo grid connection is sent to DEH, during the

test no grid connection signals can be sent to DEH; otherwise, DEH will think that the unit has
been grid-connected and thus turn up the control valve with an initial load, which will result in
considerable rise of rotation speed.
4-6

Synchronous grid-connection control

When the rotation speed of steam turbine is about 3000r/min, if DEH receives the synchronous
request signals from an automatic synchronization installation, automatic synchronization
functions can be input through OIS; at this point DEH can receive the rotation speed increase or
decrease instructions of the automatic synchronization installation, control the rotation speed,
make it in agreement with the grid frequency. The speed rate is 60r/min/min. At this point, the
generator voltage (including amplitude and phase) is controlled by the exciter control system.
When the grid connection condition is available, the generator will be grid-connected.
In case of one of the following instances, the synchronization mode will be cancelled.
Rotation speed: less than 2985 r/min or greater than 3015 r/min;
Manual status;
Rotation speed failure;
Have been grid-connected;
Tripping of turbine.
4-7

Control after grid connection (non CCS mode)

When a steam turbine generator unit is just grid-connected, DEH will immediately increase the
setting value, which will make the generator carry an initial load and thus avoid the occurrence
of reverse power. At the beginning of grid connection, DEH will use the throttle pressure to
correct the increased setting value, instead of inputting load feedback.
Setting value = original value +3+f (p0).
At the beginning of grid connection, the target is also equal to the setting value.
1 Load up
After the steam turbine generator unit is grid-connected, in order to realize the primary frequency
adjustment, rotation speed feedback is available for the control system. During testing or with a
base load, load control can also be input. During inputting load control, the target and setting
value find expression in the form of MW. After the power control is cancelled, the target and
setting value find expression in the percentage of the total flow under the rated pressure.
After the target is set, the setting value will approach the target value with a set change rate, and
along with it the generator power or throttle pressure will change gradually. During the load up,
often the steam turbine needs to be heated to reduce heat stress.

2 Target
Except the target set up by operators through OIS, under the following conditions, DEH
automatically set up the target:
When the power control is just input, the target is the current load (MW);
When the generator is just grid-connected, the target is the setting value for initial load (%);
In a manual state, the target is the reference quantity (%) (valve total flow instruction);
When the control is just cancelled, the target is the reference quantity (%);
When the turbine has tripped, the target is zero;
Under the mode of control of CCS, the target is CCS setting (%);
When the target is too large, it shall be replaced by the upper limit value.
3 Load rate
Set by operator, within (0~100) MW/min;
During Single / Sequential
Valve switching, 5.0MW/min.
4 Warm-up of turbine
During the load up of steam turbine, in view of such factors as heat stress and expansion
difference, in general warm-up is required. If the load up is required to pause, the following
operations can be conducted:
When not in a CCS mode, the operator sends out a "HOLD" instruction;
When in a CCS mode, the operator sends out a "HOLD" instruction after quitting it from the
CCS mode.
5 Power control
The power controller is a PI controller, used to compare the setting value and the actual power
and output CV and ICV instructions after calculation.
Power control input conditions:
With a grid-connected unit, the load varying between 6.0MW~310MW;
Normal power signal;

No CCS control input

No TPC action;
No quick release action;
No primary frequency adjustment action;
No high load restriction action;
No low load restriction;
The system in an automatic mode
When all the above conditions are met, click the IN button in the "AUTOMATIC
CONTROL" menu of the OIS to input power control.
Power control canceling conditions:
Operators clicking the "OUT" button in the "AUTOMATIC CONTROL" menu of OIS;
Load less than 6.0MW or greater than 310MW;
Abnormal power signal;
Tripping of steam turbine;
Change to a manual mode;
High load restriction action;
Low load restriction;
Quick release action;
When reaching the sliding pressure point;
TPC action;
Primary frequency adjustment action;
Tripping of oil switch;
CCS control input.
When there is power control input, the set point is denoted as MW. When PI isochronous control
is adopted, the steady-state load is equal to the set value.
6 Primary frequency adjustment

When a steam turbine generator unit is grid-connected, in order to ensure that the power supply
quality meets the requirement of the grid frequency, in general primary frequency adjustment
functions is required to input. When the rotation speed of the unit is within the dead zone, the
frequency adjustment setting is zero, and the primary frequency adjustment fails to actuate.
When the rotation speed is beyond the dead zone, the primary frequency adjustment acts and the
frequency adjustment setting changes with the speed variation as per the diversity factor.
The diversity factor of primary frequency adjustment is adjustable within a range of 3%~6%. Its
factory set value is 4.5%. The adjustment dead zone is adjustable within a range of 0~30r/min.
The factory set value for frequency dead zone is 10/min. When controlled by CCS, the
frequency adjustment dead zone changes itself into 30r/min. The diversity factor and frequency
adjustment dead zone of primary frequency adjustment can be displayed in the "AUTOMATIC
RESTRICTION" menu of OIS.
Primary frequency adjustment function input condition:
The system being in a automatic state;
After the load greater than 10% of the rated load for the first time.
4-8 CCS control
DEH can cooperate with CCS to complete the coordination control of unit and boiler.
Under the CCS control mode, DEH is one of actuator of CCS. DEH automatically cancels the
power control and, according to the instructions given by CCS, control the opening of all valves.
DEH can give a proper judgment or restriction to CCS instructions in terms of higher limit,
lower limit, and rate of change. The signal transmission between DEH and CCS is tabled as
below:
No.

Signal name

Signal
direction
CCSDEH
CCSDEH

1
2

CCS control request

CCS instruction

3
4

CCS control input

DEHCCS
Valve position of steam DEHCCS
turbine

Signal category
Digital signal
420mA Analog
signal
Digital signal
420mA Analog
signal

Here, it is required that during CCS input the "CCS CONTROL REQUEST" signal shall be
normally available; otherwise, DEH decides that CCS proper has canceled it and as a result DEH
changes from a CCS control mode to a valve position control mode.
When DEH receives the "CCS CONTROL REQUEST" signals, we can click the "CCS INPUT"
button in the "AUTOMATIC CONTROL" menu of OIS, and the menu will display "CCS
INPUT". Under the CCS control mode, the DEH target is equal to the CCS setting value. At this
point, the target follows the increase and decrease of CCS setting signals and the actual load also
changes accordingly. Under the following conditions, cancel CCS:
Operators clicking the "OUT" button in the "AUTOMATIC CONTROL" menu of OIS;

TPC action;;
Manual mode;
Tripping of oil switch;;
Without "CCS CONTROL REQUEST" signals;
Runback action.
All signals between DEH and CCS connected with hard wires.
4-9

Valve management

The philosophy for valve management is to require that within its whole range of operation a steam
turbine can select its mode of regulation as desired and realize a undisturbed switch between throttle
control (corresponding to single valve operating mode) and nozzle control (corresponding to sequence
valve operating mode). When a throttle steam distribution mode is adopted, the rapid start-stop and
varying duty of steam turbine will not go so far as to produce oversized heat stress, so that the unit life
loss can be reduced; however, within a normal load range when a nozzle governing variable-pressure
operation mode is adopted, the unit has the best economical efficiency and operational flexibility.

During the start, speed raising, grid connection, and with low load phases, in general the throttle
control mode, i.e., the "single valve" control mode, is adopted. With this mode, the steam flow
enters into the HP control stage in a full circle, which makes the cylinder and rotor be heated and
expanded uniformly, and as a result the heat stress resulting from start and the mechanical stress
resulting from rotor blade regulation can be effectively lowered.
Under a normal power, a nozzle control mode, i.e., the "sequence valve" control mode is
adopted to acquire relatively high thermal efficiency.
DEH has valve management functions, that is, it can realize the undisturbed switch between
throttle control and nozzle control. Operators are able to select the steam distribution mode of a
steam turbine's control valves, and the concrete steam distribution mode depends on the start
operation mode of the steam turbine.
When the unit's load rises to a certain degree, input power control, and click the "SEQUENCE
VALVE" button in the "AUTOMATIC CONTROL" menu of OIS to display "SINGLE /
SEQUENTIAL VALVE SWITCHING". About 10 minutes later, the switching is over. After the
switching, the load shall be stable. Then switch back to the single valve control mode. The load
shall be stable. If input pressure control, and repeat the above process, then after the switching
process is over the load shall be stable. If the start is conducted at a hot state or extremely hot
state, the sequential valve mode will be adopted forcefully. After the unit throw off the load, it
will automatically set the operation mode as sequential valve mode. If at this point you want to

switch back to the single valve mode, grid connection with an initial load is required before the
switching between single / sequential valves.
4-10 Overspeed
Overspeed control and overspeed protection are available for DEH.
1 Overspeed control
1.1 Load rejection
For the time constant of the rotor of a high-capacity steam turbine is commonly very small, the
time constant of the cylinder volume is often very large. When load rejection occurs, the rotation
speed rises very quickly. If the control only relies on the system itself, the maximum speed may
exceed the action speed of the protection system and as a result bring about steam turbine
intercepting. For this reason a set of load rejection overspeed limit logic must be set up.
If the oil switch is disconnected and load rejection occurs, both DEH hardware and software
circuits act simultaneously. The overspeed limit integrated package and the fast solenoid valves
of all oil servo motors will act quickly to close CVs and ICVs; meanwhile the target rotation
speed and setting rotation speed are changed into 3000r/min. 2 seconds later, all solenoid valves
are reset, and the control valves are restored to be under the control of servo valves, and the
control turns back to normal speed circuit control. Finally, the rotation speed of steam turbine is
stabilized at 3000r/min, so that a rapid grid connection is available after the emergency
disappears.
1.2 103% Overspeed
Overspeed has a large influence on the life of a steam turbine. Except in the overspeed test, at no
time the rotation speed is allowed to exceed 103% (for the max. grid frequency is 50.5Hz, that is,
101%)
Under the condition of no overspeed test, once the rotation speed exceeds 103%, the overspeed
limit integrated package and the fast solenoid valves of all oil servo motors will act quickly to
close CVs and ICVs. When the rotation speed is lower than 103%, all solenoid valves are reset,
the control valves are restored to be under the control of servo valves, and the control turns back
to the normal speed circuit control.
1.3 Acceleration limit
In DEH there also sets up a acceleration limit circuit. When the rotation speeds of two
consecutive cycles show a difference of 10r/min, the circuit will close both CV and ICV quickly;
when the rotation speed difference is <10r/min, all solenoid valves are reset.
2 Overspeed protection
If a steam turbine's rotation speed is too high, the steam turbine will be damaged due to the
action of centrifugal stress. Although overspeed limit functions are available for DEH to avoid
steam turbine overspeed, in the event of a failure of speed restriction, exceeding the preset speed

will result in tripping, and all the stop valves and control valves will be closed as quickly as
possible.
For the purpose of safe operation, there set up several layers of overspeed protection in the
system:
DEH electric overspeed protection 110%;
Mechanical overspeed protection
In addition, the following tripping functions are also available for DEH:
Mannual tripping by operator;
Sending out tripping signals by emergency stop cabinet ETS.
3 Overspeed test
Operators conduct test operation on the "OVERSPEED TEST" menu of OIS.
3.1 Mechanical overspeed test
First shift the overspeed test switch on the "OVERSPEED TEST" menu of OIS from
"NORMAL" to "MECHANICAL", then click the " MECHANICAL OVERSPEED TEST"
button, and a "TEST PROCEEDING" status will be displayed. Set the target rotation speed as
3360r/min and the speed rate as 100r/min/min for speed raising. When the speed rises so far as to
result in tripping, intercept the unit and display both the intercept speed and top speed. After the
test is over, reset the top speed, shift the overspeed test switch from the "MECHANICAL" to
"NORMAL" to quit the unit from the mechanical overspeed test.
3.2 Electric overspeed test
Shift the overspeed test switch on the "OVERSPEED TEST" menu of OIS from "NORMAL" to
"ELECTRIC", then click the "ELECTRIC OVERSPEED TEST" button, and a "TEST
PROCEEDING" status will be displayed. Set the target rotation speed as 3310r/min and the
speed rate as 100r/min/min for speed raising. When the rotation speed rises to exceed 110%, the
overspeed protection system acts, intercepting the unit and displaying the intercept rotation speed
and top speed. After the test is over, reset the top speed, shift the overspeed test switch from the
"ELECTRIC" to "NORMAL" to quit the unit from the Electric overspeed test.
4-11 Valve activity test
When a unit is in normal operation, activity tests to check MSVs, RSVs, CVs, and ICVs can be
conducted regularly to avoid jamming of these admission valves. Activity tests can be conducted
for CVs and SVs respectively.
Permissive conditions for valve activity test:
All SVs are full open;

Non CCS mode;

Automatic mode.
On the OIS menu, enter into the "VALVE TESTING" menu, shift the test switch from
"TESTING PERMIT" to "TESTING", click the button of the valve for activity test and begin the
valve activity test. At this point the valve begins to be closed with a certain speed rate. When the
closing reaches 85% opening extent, the valve reopens the position prior to testing. The test is
over.
After the activity test is over, shift the test switch from "TESTING PERMIT" to "NORMAL".
4-12 Spray oil testing
When the rotation speed is in the order of 3000r/min, DEH can complete the spray oil extruding
test for the centrifugal stop ring of emergency overspeed governor through resetting testing valve
combinations, so as to prevent the centrifugal stop ring from jamming due to long-term
motionlessness.
When an injection test is conducted, first the isolated solenoid valve in an intercepting isolation
valve block is powered up, which isolates the emergency tripping device from the system. Then
the spray oil solenoid valve of the emergency overspeed governor is powered up, which makes
the emergency tripping valve trip. Because the stop valve has been isolated from the system, the
unit will not trip. After the emergency tripping device trips successfully, DEH engage it through
resetting the solenoid valve. After the latching-on is available, the isolation solenoid valve loses
electricity, so the isolation is canceled, the system is restored to normal, and the spray oil test is
over.
Permissive conditions for spray oil testing: the rotation speed shall be within
2985r/min~3015r/min and all the indicators of the unit are within the testing allowed range.
First in the "SPRAY OIL TESTING" menu of OIS change the test switch from "TESTING
PERMIT" to "TESTING", and then click the "SPRAY OIL TESTING" button to input spray oil
testing. The screen displays that the spray oil testing is in progress: isolation solenoid valve 4YV
is electrified; after ZS4 enters into the testing position, it sends out messages; after DEH receives
the signals, spray oil solenoid valve 2YV is electrified, injects oil, and flies the centrifugal stop
ring; when DEH receives the intercepting signals of ZS2, it judges that the spray oil testing is
successful; then spray oil solenoid valve 2YV losses its electricity, the steam turbine generator
unit is reset, isolation solenoid valve 4YV losses its electricity, ZS5 returns to normal, and the
spray oil testing is over.
4-13 HP tripping solenoid valve testing
The HP tripping solenoid valves consist of four solenoid valves, of which two valves are connected in
series and the other two valves are connected in parallel. The design is based on a principle of stop for
electricity failure, that is, the sole electricity failure of any solenoid valve will not result in the intercept of
the unit; therefore, HP tripping solenoid valves can be tested on-line one by one. The test results can be
reflected by the action of two pressure switches PS4 or PS5. When a test for 6YV or 8YV is conducted,
the middle oil pressure will be lowered, at this point the pressure switch PS4 will send out a message to
show that the solenoid valve under testing has valid action; when a test for 7YV or 9YV is conducted, the

middle oil pressure will increase, at this point pressure switch PS5 will send out a message to show that
the solenoid valve under testing has valid action.

After the latching-on for the unit is conducted, a HP tripping solenoid valve test can be
conducted.
Enter into the "TRIPPING SOLENOID VALVE TESTING" menu in the OIS, and change the
test switch from "TESTING PERMIT" to "TESTING". Press the "HP INTERCEPT TESTING"
button, and then select solenoid valves 6YV, 7YV, 8YV, or 9YV for testing. The positions of the
corresponding solenoid valve in the menu will turn red. After the test is over, the red color will
disappear. If the testing succeeds, a "SUCCESS" message will display; if the testing fails, a
"FAILURE" message will display.
4-14 Valve leak test
When the steam turbine runs idle at the rated speed of rotation and the steam pressure of boiler
meet some specific conditions, DEH can control the unit for SV leak testing and CV leak testing.
When a SV leak test is conducted, all RSVs and MSVs shall be fully closed and the steam
turbine's rotation speed shall be lowered quickly. DEH works out an acceptable rotation speed
according to the current main stream pressure and confirms that the rotation speed of the unit can
be lowered below the above acceptable rotation speed, by means of which it decides whether the
SV is tightly closed.
When a CV leak test is conducted, all CVs and ICVs shall be fully closed and the steam turbine's
rotation speed shall be lowered quickly. DEH works out an acceptable rotation speed according
to the current main stream pressure and confirms that the rotation speed of the unit can be
lowered below the above acceptable rotation speed, by means of which it decides whether the
CV is tightly closed.
Permissive conditions for valve leak testing: automatic mode; latching-on available for the steam
turbine; rotation speed within 2985r/min~ 3015r/min; tripping of oil switch; in the "LEAK
TEST" menu in the OIS the test switch is in the "TESTING" position instead of "TESTING
PERMIT" position.
1 SV leak test
The turbine speed is stabilized at 3000r/min. In the "LEAK TEST" menu in the OIS, click the
"SV TESTING" button, and the button displays "TESTING PROCEEDING" and the color is red.
The control mode changes from "AUTOMATIC" to "MANUAL", all SVs are closed, and the
rpm drops. Display the steam turbine race time record.
2 CV leak test
The turbine speed is stabilized at 3000r/min.. In the "LEAK TEST" menu in the OIS, click the
"CV TESTING" button, and the button displays "TESTING PROCEEDING" and the color is red.
The control mode changes from "AUTOMATIC" to "MANUAL", all CVs are closed, and the
rpm drops. Display the steam turbine race time record.
3 When the rotation speed reaches the acceptable value, click the "OFF TEST" button to

terminate the leak test. After the test is over, the unit trips for shutdown and restart is required.
4-15 Automatic limit function
DEH is featured by automatic limit function, which is used to keep the power, throttle pressure
or valve position within certain limits.
DEH can set up the maximum and minimum load limits to limit the generator's developed power.
The value is given by the operator in the OIS.
When the difference between the measured power and given power exceeds the predeterined
value, DEH automatically cancels the power control loop and changes into a valve position
control mode to ensure the safety of the unit.
DEH also has low throttle pressure protection control function (TPC function). When the throttle
pressure drops to the set value (set by operator throught OIS), the throttle pressure limit loop is
brought into operation, outputting instructions to reduce steam valve opening so as to limit load
and help the boiler to restore its throttle pressure as quickly as possible. At this point, the power
control circuit is automatically cancelled.
DEH can also set up a maximum valve position limit to restrict the steam turbine's valve position
within a certain range. The value is set by the operator in the OIS.
1 High load limit
Operators can set up the high load limit in the "AUTOMATIC LIMIT" menu in the OIS (20~
330MW) to ensure that the DEH setting value is always smaller than the limit. After the system
is powered on, the high load limit is automatically set up as 330MW. If at this point the load is
higher than the limit, it will be automatically reduced to the limit.
2 Low load limit
Operators can set up the low load limit in the "AUTOMATIC LIMIT" menu in the OIS (0~
20MW) to ensure that the DEH load is always greater than the limit. After the system is powered
on, the low load limit is automatically set up as 3MW.
3 Valve position limit
Operators can set up the valve position limit in the "AUTOMATIC LIMIT" menu in the OIS
within (0~120)%, and after the system is powered on, the limit will be automatically set up as
120%.
4-16 Runback
When somec equipment failures of main and auxiliaries occur, DEH and DCS interface can
quickly release part of or the whole load.
According to the scale and importance of equipment failure (decided by DCS), DEH can receive
three grades of runback instructions (digital signals, conncected by hardwire), and each grade of

quick release instructions correspond to different target load value and quick release speed rate.
When a runback acts, DEH automatically cancels CCS control and power control and directly
reduces the valve positions of all valves to ensure the rapidity of action.
As per the size of failure, runback can be divided into three grades, which are triggered by the
three on-off input signals of runback 1#, 2#, and 3#'s respectively. The lower limits of runback
1#, 2#, and 3# are 75%, 50%, and 25% respectively, and the dropping load rates are 25%/min,
50%/min, and 75%/min respectively.
When the required conditions are are met, click the "RUNBACK" option in the "AUTOMATIC
CONTROL" menu in the OIS, and set it up as IN, as a result the quick release function is input.
With the quick release function being input, when there generates a quick release signal, the
"target" signal will be decreased with a scheduled speed until the signal disappears or the "target"
value is decreased to the lower limit value of the corresponding grade.
Operators can cancel the function in the OIS. That is, in the "AUTOMATIC CONTROL" menu
in the OIS, click the "RUNBACK" option, and set it as "cancel", and as a result the quick release
function will be out of service.
When the runback acts, the power control and CCS control will be automatically cancelled.
4-17 Manual control
When DEH is just powered on, it first enters into a manual mode. If possible, it can be switched
to an automatic mode through the instructions sent out by operators. Under the automatic mode,
if possible, it can be switched back to a manual mode through the instructions sent out by
operators. The switching from a low level to a high level cannot be achieved without operator
command, while the switching from a high level to a low level can be completed automatically
or by operating instructions.
If the automatic part fails, the manual mode shall be adopted.
If one of the following cases occurs, the system will exit from the automatic mode.
Control processor halting;
SV leak test;
CV leak test;
Software diagnosis abnormality.
If there are no the above cases, the valve position limit fails to act, and the difference between
the main valve position setting and its reference is within (-2, 2)%, then inputting an automatic
mode is allowed.
Under a manual mode, the valve positions of the six CVs and ICVs are increased or decreased
accordingly as per the instructions of the valve position fluctuation button.

4-18 Steam turbine tripping

The steam turbine tripping can be achieved either mannually or through the TRIP button on
the electric board. The action of the tripping solenoid valve makes the steam turbine trip. At this
point in the "AUTOMATIC CONTROL" menu in the OIS a steam turbine "SWITCH OPEN"
status is displayed; meanwhile, all valves are closed.
4-19 Parameter monitoring and recording
DEH can consecutively collect and process all the signals related to the control and protection of
steam turbine generator unit, and display the results in the CRT of the OIS in groups or in the
form of bar graph and tendency chart. All the process points can be tabled and recorded and
printed.
Each operation menu in the OIS tries to be illustrative and distinct, and operation instructions are
available for the important operations.
4-20 ATC control
ATC refers to automatic turbine control, which means that, with the least manual intervention,
DEH conducts an automatic control over the steam turbine by controlling its rotation speed from
hand-turning speed, through synchronous grid connection speed, and finally to the full load
speed.
ATC control is based on the thermal stress calculation of rotor and directed toward the
improvement of rotor life. With the base and aim, the acceleration rate, load raising rate,
warm-up point, and warm-up time are determined. When some non-key signals are lost, ATC
control can proceed over these signals. When an anomaly occurs, ATC control can either hold on
or exit, till the anomaly disappears.
5 Installation and debugging
The correct installation and careful debugging of DEH on site is an important step to ensure that
it can be smoothly put into service. The installation and debugging on site includes the following
steps:
Arrival unpacking;
Equipment installation;
System ground;
Power supply;
Onsite signal connection;
Onsite debugging.
5-1 Arrival unpacking

The on-site unpacking acceptance check for a DEH installation shall be conducted on an open
platform with enough carrying capacity. Excessive vibration shall be avoided for the cabinet and
the many devices in OIS and EWS, so they shall be handled with care. Lifting lugs shall be used
for the hoisting of cabinet. Special attention shall be given to the acceptance check for boards:
1 Use electrostatic prevention sacks. Prior to installation, it is preferred that the board be placed
in the electrostatic prevention sacks. Keep these electrostatic prevention sacks for future use.
2 Avoid contacting circuits by hand.
3 Ensure that all the devices connected with boards are correctly earthed.
4 Use non-electrostatic dust collectors to remove dust on boards.
During unpacking of board, immediately inspect the boards to make certain whether there are
problems during transportation. If there is damage, inform the manufacturer as quickly as
possible.
5-2 Installation
1 Installation environment
With special DEH operating room, without strong ElectroMagnetic Interference;
Proper ambient temperature and humidity;
Dust in the air meeting related national standards;
Fire Protection available.
2 Cabinet installation
Install the cabinet on a level ground. Fasten the cabinet to the ground with bolts or directly weld
it on the pre-buried strips.
Attention: if there is arc welding within a range 3.05m away from the cabinet, the power cord
must be cut off, and the boards shall be pulled out from the slots in the backboards, and close the
cabinet gate tightly. If this prompt is ignored, board damage will occur.
3 Installation of SUN workstation
According to the installation requirements, lay the communication cables, CRT cables, and
keyboard cables.
Put the side of the workstation with a floppy drive face oneself and the side with terminals
upwards, gently push it into the MMS slot, and confirm that the workstation has been in the slip
stop bayonet of the slot.
Connect all cable terminals with the workstation at one time, fix them by screwdrivers, and
finally plug a terminator in the SCSI equipment.

Installation of workstation modules

According to the system installation drawings, first make certain which cabinet and where in the
cabinet the workstation modules will be installed (in general, the cabinet slot for workstation
module installation is called MS slot).
According to the installation requirements, lay cables, and installed the sockets of cable terminal
in the corresponding MS slots. Push the modules into the corresponding slots and fix them with
bolts.
5-3 System ground
The DEH control system needs a complete and proper ground system, because a good ground
system can effectively inhibite the external interference, reduce the equipment idle hours, and
thus protect both equipment and personal safety.
The I/A Series system also needs a complete and proper ground system, because a good ground
system can effectively inhibite the external interference, reduce the equipment idle hours, and
thus protect both equipment and personal safety.
An independent earthing pile must be provided for the I/A system with earth resistance less than
1 ohm. The security protection ground, AC supply ground, and internal signals' logic ground of
I/A system shall be connected to the groud pile. Any non I/A equipment grounding cannot be
connected with the ground pile.
5-4 Power supply connection
Safety (both human and equipment) is the top priority of a power-supply distribution system.
After the safety is met, the reliability of the system shall also be met, which includes correctly
estimating power load, insulation, and line conditions, so that the interference can be eliminated,
the protection system can avoid the damage from poweroff, swing, and overload, and the
estimated system expansion can be conducted.
Power supply installation
According to the user guidance, calculate the loads of the complete appliance, including OIS and
EWS, and take into consideration the limited expansion in the future. According to standard
ANSI/NFPA70, select AC power conductors and linear diameters.
Main power supply must be exclusively used for I/A series installations and related installations.
In an industrial environment, the quality of power supply is relatively poor, so a discrete
actuating system such as insulating transformer or UPS shall be available to provide power
supply for the installation.
Main power supply requirements:

Voltage: 220AC10%
Frequency: 50Hz1Hz
5-5 External signal connection
Attention: Great attention must be paid to the installation of DEH and the connection of external
signals, for which a rational design and arrangement must be available. The installation of cable
has requirements on cable trench, route channel, and cable guide. When installation and wiring is
conducted, the atmospheric environment such as temperature, humidity, and erosion must be
taken into consideration. The electrical noise and signal level determine that space, quantity, and
shielding measures must be taken into consideration for cable trench and cable guide. When
cable wiring is conducted, attentions must be paid to the voltage range, signal characteristics, and
signal categories.
1 Analog signal cable
Twisted-pair-line shielded cables are adopted. The cable has a specially good effect in the
inhibition of electromagnetic coupling. All the shield layers must be insulated from other shield
layers electrically. In the DEH cabinet the shield layer is grounded, and the common bus in the
cabinet is suitable for the onsite signal shield layer and connected here for joint grounding.
For the metal cable guides and cable trenches sealed on site used for cable placing, if possible, a
special cable trough shall be designed to place analog signal cable.
2 Thermocouple input signal
It is required that the conductor metal in the dedicated cables or cables with continuation shall be
the same as or similar to the thermocouple, because in this way the electric potential difference
resulting from the connection of different metals can be reduced to the minimum. During the
transmission of thermocouple signal, there shall be no break points, switches, or connection
points in the conductors, all thermocouple signals must be shielded, and different shield layers
must be insulated with each other.
3

Hot resistance input signal

The resistance of all conductors connected with hot resistance must be equal, and the resistance
of the cable from the site to the cabinet must meet the limits of the input board.
4

Connection of digital signal

Do not install the onsite contact points of DC or AC into the same cable. If in a cable there are
only DC signals, either twisted-pair shielded cables or sole shielded cables can be adopted.
5-6 Testing and debugging
Before an installation is put into service on site, it is necessary to conduct full-scale testing and
debugging for all parts of the system, especially after a long haul, power plant installation and

external wire connection. As a result the items suggested by the chapter shall be strictly tested
and debugged one by one.
Primarily as follows:
Wire connection check;
Transmitter and external signal check;
Power ground testing;
System function check.
1

Wire connection check

Long haul and power plant assembly may result in some loosening of the wire and cable
connection in the Control cabinet of DEH; therefore, prior to signal detection and
debugging a connection check is necessary.
The connection for the installation can be divided into four parts:

1.1

For the connections between cabinets or within a cabinet, check them one by one according
to the interior connection drawings provided by the manufacturer, and fasten all the
loosened terminals.

1.2 Cable check: A cable shall be intact, both ends of a signal wire in the cable shall be well
conducted, and the insulation between conductors or between a conductor and its cable
shield layer shall be good; otherwise, the cable shall be replaced. Check whether the
redundant cores and shield layers of all cables are grounded in the control board according
to the grounding requirements and whether the grounding is good or not. The other ends of
the redundant cores and shield layers shall be insulated against ground.
1.3 Check whether all cables are correctly connected.
1.4 According to the cabinet terminal connection diagram, check whether the external signal
wires are correctly connected.
1.5 Check whether the original wire connection in the cabinet is loosened, and fasten the
loosened connecton based on terminal numbers. Check whether the welding points in the
cabinet are reliable, and whether there is break in soldering.
2

Transmitter and external signal testing

Before all the control and monitoring parameters of DEH are sent into the installation, they are
tested by the transmitter; therefore, whether the transmitter can work normally has a
direct influence on the reliability of the system. So prior to being put into service, the transmitter
shall be checked and calibrated in accordance with the measurement range in the signal list.
With regard to the external check, it primarily means to check whether the onsite digital signals
match the actual conditions. As per the actual on-site conditions, conduct some simulation to
verify the input/output digital signals.

Power supply and earth conductor check

Before power-on, be sure to check the installation connection of power supply and earth
conductors thoroughly.
Equipment required are as follows:
Universal instrument: for voltage and current measurement;
Earth resistance tester: for the measurement of the resistance to ground of grounding
electrode;
Connection tester: for checking whether the connection is right;
Power-supply monitor: for recording the voltage, current, temperature, humidity, radio wave
frequency, and nodal closing of AC/DC.

3.1 Grounding electrode check

The impedance of grounding electrode shall be tested prior to the power-up of the
installation or once a year. In order to test the electrode impedance, an earth resistance tester
is required, and the impedance of the earthing resistor shall be less than 5 ohm. Otherwise,
check the earth conductor connection and the connection between grounding electrode and
power grid.
3.2 Power supply measurement
Power supply measurement includes current testing, voltage testing, and impedance testing.
Current testing: Use an amperemeter to measure and record the related effective values of
current, including the currents of the wires under voltage, earth conductors, and zero
conductors in the power-supply distribution panels and cabinets.
Impedance testing: Measure the input impedance of the ground leads or zero conductors.
The smaller the input impedance is, the safer the equipment is.
3.3 Shield layer check
The check of shield layer can be conducted in cabinets. If the installation is not powered up,
first disconnect the DC earthed conductors, and then conduct the following three tests:
3.3.1 Measure the impedance between the cabinet and the insulated common ground conductor,
which shall be less than 1 ohm; if it is greater than 1 ohm, the related connections and
system connection shall be checked.
3.3.2 Measure the impedance between the cabinet frame and the DC ground strap, which shall be
greater than 1 mega ohm.
3.3.3 If the measurement of step 2 is less than 1 mega ohm, the common ground conductors

between the cabinet under measurement and the other cabinets shall be disconnected. Then
repeat the measurement until the error is detected.
The probable causes resulting in the above problems are as follows: short-circuit of the
onsite shield layer and the ground, or improper installation, or damaged wire connection, or
different ground for the I/O signals connected with DEH.
Tips: it is preferred to check a shield layer before the installation is powered up or during maintenance
downtime. When checking, be sure to turn off the power. Never conduct such checking when the
installation is controlling the unit.

5-7 System function check

Before the installation is put into service, a powered action test is required to check whether
there are hardware and software faulures and whether the system functions are normal, so that
the installation can be put into service normally.
1 Connecte the DEH installation to form a complete DEH system.
2 Conduct an electrified test for the DEH installation. Referring to Chapter 4, check it item by
item, and ensure that the DEH system can pass all the tests as follows:
2.1 Close the power switch, the indicator gage is normal, and the indicator lights of cabinet
boards are normal.
2.2 Close the main power switch of OIS, and close the switch on CRT. Several minutes later, the
menu displays normally, and all board indicator lights are normal.
2.3 Start the unit under the automatic, manual, and ATC modes respectively, operate it as per
operating standards, and the operation is normal.
When operating under an automatic mode, the following functions are normal:
Speed control;
Automatic synchronization;
Power control loop;
Frequency adjustment control;
CCS control loop;
Load limitation;
RUNBACK
Single / sequential valve mode switching;
TPC protection;
Valve position limit;
MSV and CV activity tests;
RSV and ICV activity tests;

Normal spray oil testing;

Normal overspeed test;
HPT intercept testing;
Valve calibration
A servoboard and its corresponding valve's LVDT shall have a certain linear relationship,
which makes the control system control CVs and ICVs through the servoboard. In case of the
following conditions, valve calibration is required:
Prior to unit start;
Replaced servoboards and LVDT;
After normal maintenance;
Valve LVDT has been disassembled;
Due to possible temperature drift of LVDT, regular valve calibration is required.
After re-download the configuration software.
6 Fault diagnosis and analyses
During the running of DEH, ,DEH conducts regular on-line self-diagnosis, through which the
failures are alarmed, displayed, and printed, so that the hot control personnel can conduct on-line
or off-line maintenance aiming at the problems.
Regular maintenance and overhaul is necessary for a long and steady operation of DEH system.
6-1 On-line self-diagnosis
During operation, DEH will conduct self testing and diagnosis for its important hardware units
and I/O signals. If any problem is found, alarm displaying and report printing will be conducted.
1

Rotation speed channel diagnosis and treatment

If the rotation speed signals in any of three rotation speed channels are lost, or if the speed
setpoint is greater than 200r/min, the rotation speed signal change quickly, then the rotation
speed channel has problems.
For any of the three rotation speed channels, if when the speed setpoint is greater than
200r/min, its difference from the medium value is greater than 50r/min, then the channel has
problems.
For the three speed measurement boards, if any one has problems in its microprocessor,
then the rotation speed board has problems.
For single-channel failure, ,OIS only displays the number of the failed channel.

When two channels fail or when the difference between the setting value of rotation speed
and the actual speed is greater than 500r/min, rotation speed system failure signals will be
generated, which will result in turbine trip signals.
2

System monitoring
Start the OIS, and then enter into the "SYSTEM MONITORING" menu, through which the
whole DEH system (including networks and boards) can be monitored and alarmed.
6-2 Failure analysis and maintenance

While the DEH installation exerts a control, the system also conducts an on-line diagnosis. For
the failed cells, alarming, displaying, and printing are available. According to the alarms in both
the OIS and the front panel of board, on-line or off-line maintenance can be conducted to make
DEH get right as quickly as possible.
Block diagrams of onsite diagnosis and maintenance are available for all the boards in the DEH
installation. If any board fails, observe the instructions in the user's manual.
Some cause analyses and handling methods for onsite signal failure are as follows:
1

Rotation speed channel failure: A short-time single-channel failure will not affect the
normal operation of the system. However, if there is a long-time failure or rotation speed
system failure, heat engineers shall be employed for maintenance and treatment. First, use
an oscilloscope to check whether the rotation speed of the failed channel is normal; if it is
abnormal, check whether the wire connection of the speed measurement message sending
head is correct and whether the installation meets the requirements. If the rotation speed
signals are normal but there are rotation speed channel failures, it is possible that the speed
measurement board proper fails.

If such parameters as power, throttle pressure, and control pressure do not agree with the
actual conditions, the following checks shall be made: First, check whether the signals of
the corresponding transmitter are normal and whether the output signal range is in
agreement with the designed value; if possible, recheck the transmitter; second, check
whether the wire connection of transmitter is correct and reliable; third, check the Analog
Input board.

As the interface of controller and onsite actuator, a servoboard has complex I/O signals, so
whether the servoboard can work correctly determines the reliability of the control.

3.1

The failure occurs during the checking, adjustment, and start of a servo board is called an
off-line failure. The causes may be incorrect or incomplete board installation and checking.
The following describes the signals of servo board and LVDT.
Servoamplifiers do not have servo drive signals: if the drive current signals of the
servoboard are correct, check the cable; if the cable has no problems, replace the servo
valve.
The primary of LVDT do not have drive signals: If the drive signals of the servoboard is

correct, check the cable outputting to LVDT; if the cable has no problems, replace LVDT.
The secondary of LVDT has no response output: Change the current output of the
servoboard, the voltage difference of the two secondaries of LVDTshall change; if there is
no variation, check the connecting cable; if the cable has no problems, replace LVDT.
3.2

The failure occurs during the operation of a servoboard is called an on-line failure.
The failure occurring during operation seldom results from connection (with regular
checking); in general, the reason is that there are faults in the cabinet interior or sub boards.
So the faults can be determined in accordance with the status of the indicator lights on the
boards. If there are actuator displacement alarm signals, check the primary or secondary of
LVDT. If the primary excitation voltage is less than 1.0VRMS, then the primary of LVDT
has failures; if it is greater than 1.0VRMS, check the secondary voltage of LVDT; if the
secondary has no sine wave output, then the secondary coil has problems; if both secondary
outputs are correct, check other parts.

7 Measuring point list of DEH

1 DI signals
No.

1
2
3

Signal name
HP

Signal source
oil Site proximity switch PS1

safety

Terminal number

Remarks

120014-1(cs,+)

Input

establishment 1
HP

different

safety

oil Site proximity switch PS2

120015-1(cs,+)

oil Site proximity switch PS3

120016-1(cs,+)

establishment 2
HP

safety

establishment 3

HP tripping test pass PS4

Site proximity switch PS4

220018-1(cs,+)

HP tripping test pass PS5

Site proximity switch PS5

220018-2(cs,+)

6
7
8
9
10

breaker Site travel switch ZS1

120014-5(cs,+)

Emergency breaker at a Site travel switch ZS2

120016-5(cs,+)

Emergency
latching-on reset
tripping position

Manual tripping position Site travel switch ZS3

120017-1(cs,+)

status
Isolation valve at a testing Site travel switch ZS4

220017-5(cs,+)

position
Isolation valve at a normal Site travel switch ZS5

220017-6(cs,+)

position

11

Synchronous input

Synchronism installation

120017-5(cs,+)

12

Synchronous increase

Synchronism installation

120017-6(cs,+)

13

Synchronous decrease

Synchronism installation

120017-7(cs,+)

Generator

Electric

TB2-(30/34)

Tripping of oil switch

Electric

TB2-(29/33)

Generator testing (pseudo

Electric

120015-5(cs,+)

14
15
16

grid

connection

grid connection)

17

Manual shut-down

Electric board

TB3-(65/66)

18

Switch openning of ETS

ETSDEH

120017-2(cs,+)

19

Hand-turning input

Turning gear

120016-6(cs,+)

20

Runback 1#

CCS

120014-2(cs,+)

21

Runback 2#

CCS

120015-2(cs,+)

22

Runback 3#

CCS

120016-2(cs,+)

23

CCS control request

CCS

120015-7(cs,+)

24

MSV1 full close

On site

120014-3(cs,+)

boards

from
DI

25

MSV2 full close

on site

120015-3(cs,+)

26

RSV1 full close

on site

120016-3(cs,+)

27

RSV2 full close

on site

120017-3(cs,+)

28

MSV1 full open

on site

120014-4(cs,+)

29

MSV2 full open

on site

120015-4(cs,+)

30

RSV1 full open

on site

120016-4(cs,+)

31

RSV2 full open

on site

120017-4(cs,+)

32

MSV1 85% travel

on site

220018-3(cs,+)

33

RSV1 85% travel

on site

220018-4(cs,+)

34

RSV2 85% travel

on site

220018-5(cs,+)

1# HP exhaust steam

on site

220021-5(cs,+)

on site

220021-6(cs,+)

35
36

valve full close

1# HP exhaust steam
valve full open

37

PWV full open

PWV

220017-1(cs,+)

38

PWV full close

PWV

220017-2(cs,+)

39

VV full open

VV

220017-3(cs,+)

40

VV full close

VV

220017-4(cs,+)

Lower by-pass system

by-pass system

224121-1(cs,+)

by-pass system

220021-2(cs,+)

by-pass system

220021-3(cs,+)

by-pass system

220021-4(cs,+)

servo valve controller

220016-1(cs,+)

internal signal

servo valve controller

220016-2(cs,+)

internal signal

CV1 servoboard failure

servo valve controller

220016-3(cs,+)

internal signal

CV1

servo valve controller

220016-4(cs,+)

internal signal

CV2 servoboard failure

servo valve controller

220016-5(cs,+)

internal signal

CV2

servo valve controller

220016-6(cs,+)

internal signal

CV3 servoboard failure

servo valve controller

220016-7(cs,+)

internal signal

CV3

servo valve controller

220016-8(cs,+)

internal signal

servo valve controller

220016-9(cs,+)

internal signal

41
42
43
44
45
46
47
48
49
50
51
52
53

full close
Lower by-pass system
Manual/Automatic
Higher by-pass system
full close
Higher by-pass system
Manual/Automatic
MSV2

servoboard

failure
MSV2

calibration

in

progress
calibration

in

progress
calibration

in

progress
calibration

in

progress
CV4 servoboard failure

54
55
56
57
58

CV4

calibration

in

servo valve controller

220016-10(cs,+)

internal signal

ICV1 servoboard failure

servo valve controller

220016-11(cs,+)

internal signal

ICV1

servo valve controller

220016-12(cs,+)

internal signal

ICV2 servoboard failure

servo valve controller

220016-13(cs,+)

internal signal

ICV2

servo valve controller

220016-14(cs,+)

internal signal

Signal destination

Terminal No.

Remarks

on site 1YV

TB4-(69/70)

R21 solenoid

injection solenoid valve

on site 2YV

TB4-(71/72)

R22 solenoid

mechanical

on site 3YV

TB4-(22/23)

R1 solenoid

isolated solenoid valve

on site 4YV

TB4-(73/74)

R23 solenoid

OSP overspeed solenoid

on site 5AYV

TB4-(56/57)

R16 solenoid

on site 5BYV

TB4-(58/59)

R17 solenoid

solenoid

on site 6YV

TB4-(25/26)

R2 solenoid

solenoid

on site 7YV

TB4-(29/30)

R4 solenoid

solenoid

on site 8YV

TB4-(27/28)

R3 solenoid

solenoid

on site 9YV

TB4-(31/32)

R5 solenoid

on site 10YV

TB4-(33/34)

R6 solenoid

on site 11YV

TB4-(35/36)

R7 solenoid

progress
calibration

in

progress
calibration

in

progress

2 DO signals
No

1
2
3
4
5
6
7
8
9
10
11
12

Signal name
Turbine

latching-on

solenoid valve
shutdown

solenoid valve

valve 1
OSP overspeed solenoid
valve 2
HP

tripping

valve 1
HP

tripping

valve 2
HP

tripping

valve 3
HP

tripping

valve 4
MSV2 tripping solenoid
valve
MSV1 tripping solenoid
valve

13

CV1 fast solenoid valve

on site 12YV

TB4-(41/42)

R10 solenoid

14

CV2 fast solenoid valve

on site 13YV

TB4-(43/44)

R11 solenoid

15

CV3 fast solenoid valve

on site 14YV

TB4-(45/46)

R12 solenoid

16

CV4 fast solenoid valve

on site 15YV

TB4-(47/48)

R13 solenoid

17

ICV2 fast solenoid valve

on site 16YV

TB4-(51/52)

R14 solenoid

18

ICV1 fast solenoid valve

on site 17YV

TB4-(53/54)

R15 solenoid

19
20

RSV2 tripping solenoid

on site 18YV

TB4-(37/38)

R8 solenoid

on site 19YV

TB4-(39/40)

R9 solenoid

valve
RSV1 tripping solenoid
valve

21

RSV2 test solenoid valve

on site 20YV

TB4-(61/62)

R18 solenoid

22

RSV1 test solenoid valve

on site 21YV

TB4-(63/64)

R19 solenoid

23

MSV1 test solenoid valve

on site 22YV

TB4-(65/66)

R20 solenoid

24

CCS control input

CCS

TB6-(9/10)

R42 solenoid

25

cold start

to by-pass controller

TB6-(23/24)

R47 solenoid

26

warm start

to by-pass controller

TB6-(25/26)

R48 solenoid

27

hot start

to by-pass controller

TB6-(27/28)

R49 solenoid

28

extremely hot start

to by-pass controller

TB6-(29/30)

R50 solenoid

29

IP cylinder start

by-pass controller

TB6-(31/32)

R51 solenoid

30

cylinder switching

by-pass controller

TB6-(33/34)

R52 solenoid

31

Open PWV

PWV

TB6-(15/16)

R43 solenoid

32

Close PWV

PWV

TB6-(17/18)

R44 solenoid

33

Open VV

VV

TB6-(19/20)

R45 solenoid

34

Close VV

VV

TB6-(20/21)

R46 solenoid

35

DEH tripping

ETS

TB6-(1/2)

R38 solenoid

36

HP tripping test 6YV

ETS

TB6-(35/36)

R53 solenoid

37

HP tripping test 7YV

ETS

TB6-(37/38)

R54 solenoid

38

HP tripping test 8YV

ETS

TB6-(39/40)

R55 solenoid

39

HP tripping test 9YV

ETS

TB6-(41/42)

R56 solenoid

40

OPC action

DEH relay cabinet

R40 solenoid

internal signal

41

overspeed test permit

DEH relay cabinet

R41 solenoid

internal signal

42

load greater than 15

DEH relay cabinet

R39 solenoid

internal signal

43

Single calibration permit

servo valve controller

220018-15(c, k)

internal signal

44

Double calibration permit

servo valve controller

220021-16(c, k)

internal signal

45

MSV2 check begin

servo valve controller

220021-9(c,k)

internal signal

46

CV1 check begin

servo valve controller

220021-10(c,k)

internal signal

47

CV2 check begin

servo valve controller

220021-11(c,k)

internal signal

48

CV3 check begin

servo valve controller

220021-12(c,k)

internal signal

49

CV4 check begin

servo valve controller

220021-13(c,k)

internal signal

50

ICV1 check begin

servo valve controller

220021-14(c,k)

internal signal

51

ICV2 check begin

servo valve controller

220021-15(c,k)

internal signal

3 AI signals
No

Signal name

Signal source

Terminal No.

Remarks

throttle pressure (left)

on site

120011-1(+iP,i+)

025MPa 420mA

throttle pressure (right)

on site

120012-1(+iP,i+)

025MPa 420mA

CV steam pressure

on site

120005-2(+iP,i+)

025MPa 420mA

Stem pressure before ICV (left)

on site

220001-1(+iP,i+)

06MPa 420mA

Stem pressure before ICV (right)

on site

220001-2(+iP,i+)

06MPa 420mA

Stem pressure after ICV (left)

on site

220001-3(+iP,i+)

06MPa 420mA

Stem pressure after ICV (right)

on site

220001-4(+iP,i+)

06MPa 420mA

8
9

Exhaust

pressure

of

HP

cylinder
Exhaust

pressure

of

intermediate pressure cylinnder

on site
on site

120006-2(+iP,i+)
120006-3(+iP,i+)

06MPa 420mA
06MPa 420mA

10

Steam condenser vacuum

on site

120004-3(+iP,i+)

-0.10MPa 420mA

11

Lubricating oil pressure

on site

120011-2(+iP,i+)

00.25MPa 0100

12

Fire-resistant oil pressure

on site

120012-2(+iP,i+)

00.25MPa 0100

13

Generator power 1

Electric

120004-1(i+,i-)

0300MW 420mA

14

Generator power 2

Electric

120005-1(i+,i-)

0300MW 420mA

15

Generator power 3

Electric

120006-1(i+,i-)

0300MW 420mA

16

CCS instructions

CCS

120004-2(i+,i-)

0100%420mA

17

Eccentricity

TSI

120013-1(i+,i-)

0100m 420mA

18

Axial displacement

TSI

220015-1(i+,i-)

-22mm 420mA

19
20
21
22
23
24
25
26
27
28
29

Expansion difference between

HP and IP cylinders
Expansion difference of LP
cylinder
Thermal expansion of HIP
cylinders (left)
Thermal expansion of HIP
cylinders (right)
1

bearing

vibration

(X-direction)
1

bearing

vibration

(Y-direction)
2

bearing

vibration

(X-direction)
2

bearing

vibration

(Y-direction)
3

bearing

vibration

(X-direction)
3

bearing

vibration

(Y-direction)
4

bearing

(X-direction)

vibration

TSI
TSI
TSI
TSI
TSI
TSI
TSI
TSI
TSI
TSI
TSI

220015-2(i+,i-)
220015-3(i+,i-)
220001-5(i+,i-)
220001-6(i+,i-)
220001-7(i+,i-)
220001-8(i+,i-)
220002-1(i+,i-)
220002-2(i+,i-)
220002-3(i+,i-)
220002-4(i+,i-)
220002-5(i+,i-)

-58mm 420mA
017mm 420mA
050mm 420mA
050mm 420mA
0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA

30
31
32
33
34

bearing

vibration

(Y-direction)
5

bearing

vibration

(X-direction)
5

bearing

vibration

(Y-direction)
6

bearing

vibration

(X-direction)
6

bearing

vibration

(Y-direction)

TSI
TSI
TSI
TSI
TSI

220002-6(i+,i-)
220002-7(i+,i-)
220002-8(i+,i-)
220003-1(i+,i-)
220003-2(i+,i-)

0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA
0400m 420mA

35

1 bearing cap vibration

TSI

220003-3(i+,i-)

0125m 420mA

36

2 bearing cap vibration

TSI

220003-4(i+,i-)

0125m 420mA

37

3 bearing cap vibration

TSI

220003-5(i+,i-)

0125m 420mA

38

4 bearing cap vibration

TSI

220003-6(i+,i-)

0125m 420mA

39

5 bearing cap vibration

TSI

220003-7(i+,i-)

0125m 420mA

40

6 bearing cap vibration

TSI

220003-8(i+,i-)

0125m 420mA

41

fire-resistant oil temperatuere

on site (RTD)

220011-7(i+,i-)

0100

42
43
44
45
46
47
48
49
50
51
52
53

1#

bearing

scavenge

oil

scavenge

oil

scavenge

oil

scavenge

oil

scavenge

oil

scavenge

oil

temperature
2#

bearing

temperature
3#

bearing

temperature
4#

bearing

temperature
5#

bearing

temperature
6#

bearing

temperature
1 positioning thrust washer
metal temperature
2 positioning thrust washer
metal temperature
3 positioning thrust washer
metal temperature
4 positioning thrust washer
metal temperature
5 positioning thrust washer
metal temperature
6 positioning thrust washer
metal temperature

on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)

220011-1(i+,i-)
220011-2(i+,i-)
220011-3(i+,i-)
220011-4(i+,i-)
220011-5(i+,i-)
220011-6(i+,i-)
220012-1(i+,i-)
220012-2(i+,i-)
220012-3(i+,i-)
220012-4(i+,i-)
220012-5(i+,i-)
220012-6(i+,i-)

065
080
080
080
080
080
0120
0120
0120
0120
0120
0120

54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69

7 positioning thrust washer

metal temperature
8 positioning thrust washer
metal temperature
9 positioning thrust washer
metal temperature
10 positioning thrust washer
metal temperature
11 positioning thrust washer
metal temperature
1 working thrust washer
metal temperature
2 working thrust washer
metal temperature
3 working thrust washer
metal temperature
4 working thrust washer
metal temperature
5 working thrust washer
metal temperature
6 working thrust washer
metal temperature
7 working thrust washer
metal temperature
8 working thrust washer
metal temperature
9 working thrust washer
metal temperature
10 working thrust washer
metal temperature
11 working thrust washer
metal temperature

on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)
on site (RTD)

220012-7(i+,i-)
220012-8(i+,i-)
220013-1(i+,i-)
220013-2(i+,i-)
220013-3(i+,i-)
220013-4(i+,i-)
220013-5(i+,i-)
220013-6(i+,i-)
220013-7(i+,i-)
220013-8(i+,i-)
220014-1(i+,i-)
220014-2(i+,i-)
220014-3(i+,i-)
220014-4(i+,i-)
220014-5(i+,i-)
220014-6(i+,i-)

0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120
0120

70

main steam temperature (left)

on site (TC)

220004-1(i+,i-)

0600

71

main steam temperature (right)

on site (TC)

220004-2(i+,i-)

0600

72

reheat steam temperature (left)

on site (TC)

220004-3(i+,i-)

0600

73
74
75

reheat

steam

temperature

(right)
MSV outer wall temperature
(left)
MSV outer wall temperature
(right)

on site (TC)
on site (TC)
on site (TC)

220004-4(i+,i-)
220004-5(i+,i-)
220004-6(i+,i-)

0600
0600
0600

76
77

MSV inwall temperature (left)

MSV

inwall

temperature

(right)

on site (TC)
on site (TC)

220004-7(i+,i-)
220004-8(i+,i-)

0600
0600

78

CV steam temperature

on site (TC)

220005-1(i+,i-)

0600

79

HP exhaust temperature

on site (TC)

220005-2(i+,i-)

0600

80

IP exhaust temperature

on site (TC)

220005-3(i+,i-)

0600

81
82
83
84
85
86
87
88
89
90
91
92

HP inside cylinder upper half

inwall temperature
HP inside cylinder lower half
inwall temperature
HP inside cylinder upper half
outwall temperature
HP inside cylinder lower half
outwall temperature
HIP outside cylinder IP admission upper
half inwall temperature
HIP outside cylinder IP admission lower
half inwall temperature
HIP outside cylinder IP admission upper
half outwall temperature
HIP outside cylinder IP admission lower
half outwall temperature
HP exhaust outlet upper half
inwall temperature
HP exhaust outlet lower half
inwall temperature
IP exhaust outlet upper half
inwall temperature
IP exhaust outlet lower half
inwall temperature

93

MSV2 valve location

94

CV1 valve location

95

CV2 valve location

96

CV3 valve location

97

CV4 valve location

on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
on site (TC)
servo

220005-4(i+,i-)
220005-5(i+,i-)
220005-6(i+,i-)
220005-7(i+,i-)
220006-1(i+,i-)
220006-2(i+,i-)
220006-3(i+,i-)
220006-4(i+,i-)
220006-5(i+,i-)
220006-6(i+,i-)
220006-7(i+,i-)
220006-8(i+,i-)

0600
0600
0600
0600
0600
0600
0600
0600
0510
0510
0515
0510

valve 220015-4(i+,i-)

internal signal

valve 120004-4(i+,i-)

internal signal

valve 120005-4(i+,i-)

internal signal

valve 120006-4(i+,i-)

internal signal

valve 120011-4(i+,i-)

internal signal

controller
servo
controller
servo
controller
servo
controller
servo
controller

98

ICV1 valve location

99

ICV2 valve location

servo

valve 120012-4(i+,i-)

internal signal

valve 120013-4(i+,i-)

internal signal

controller
servo
controller

4 AO Signals
No

Signal name

Signal source

Terminal No.

Remarks

Steam turbine valve location

CCS

120011-6(o+,o-)

MSV2 opening instruction

servo

valve 220015-5(o+,o-)

internal signal

CV1 opening instruction

valve 120004-5(o+,o-)

internal signal

CV2 opening instruction

valve 120005-5(o+,o-)

internal signal

CV3 opening instruction

valve 120006-5(o+,o-)

internal signal

CV4 opening instruction

valve 120011-5(o+,o-)

internal signal

ICV1 opening instruction

valve 120012-5(o+,o-)

internal signal

ICV2 opening instruction

valve 120013-5(o+,o-)

internal signal

controller
servo
controller
servo
controller
servo
controller
servo
controller
servo
controller
servo
controller

5 Other signals
No.

Name

Source

Terminal No.

Remarks

rotation speed 1

on site DEH

Bailing 1(15/19)

Reluctance type

rotation speed 2

on site DEH

Bailing 2(15/19)

Reluctance type

rotation speed 3

on site DEH

Bailing 3(15/19)

Reluctance type

MSV2 control signal 1

on site

TB7-(1/2)

+/-40mA

MSV2 control signal 2

on site

TB7-(3/4)

+/-40mA

LVDT1 first drive signal

on site

TB7-(6/15)

1.7kHz,2.23.5V

LVDT2 first drive signal

on site

TB7-(6/15)

1.7kHz,2.23.5V

LVDT1 secondary feedback 1

on site DEH

TB7-(7/8)

LVDT1 secondary feedback 2

on site DEH

TB7-(9/10)

10

LVDT2 secondary feedback 1

on site DEH

TB7-(11/12)

11

LVDT2 secondary feedback 2

on site DEH

TB7-(13/14)

12

CV1 control signal 1

on site

TB7-(18/19)

+/-40mA

13

CV1 control signal 2

on site

TB7-(20/21)

+/-40mA

14

LVDT3 first drive signal

on site

TB7-(23/32)

1.7kHz,2.23.5V

15

LVDT4 first drive signal

on site

TB7-(23/32)

1.7kHz,2.23.5V

16

LVDT3 secondary feedback 1

on site DEH

TB7-(24/25)

17

LVDT3 secondary feedback 2

on site DEH

TB7-(26/27)

18

LVDT4 secondary feedback 1

on site DEH

TB7-(28/29)

19

LVDT4 secondary feedback 2

on site DEH

TB7-(30/31)

20

CV2 control signal 1

on site

TB7-(35/36)

+/-40mA

21

CV2 control signal 2

on site

TB7-(37/38)

+/-40mA

22

LVDT5 first drive signal

on site

TB7-(40/49)

1.7kHz,2.23.5V

23

LVDT6 first drive signal

on site

TB7-(40/49)

1.7kHz,2.23.5V

24

LVDT5 secondary feedback 1

on site DEH

TB7-(41/42)

25

LVDT5 secondary feedback 2

on site DEH

TB7-(43/44)

26

LVDT6 secondary feedback 1

on site DEH

TB7-(45/46)

27

LVDT6 secondary feedback 2

on site DEH

TB7-(47/48)

28

CV3 control signal 1

on site

TB7-(51/52)

+/-40mA

29

CV3 control signal 2

on site

TB7-(53/54)

+/-40mA

30

LVDT7 first drive signal

on site

TB7-(56/65)

1.7kHz,2.23.5V

31

LVDT8 first drive signal

on site

TB7-(56/65)

1.7kHz,2.23.5V

32

LVDT7 secondary feedback 1

on site DEH

TB7-(57/58)

33

LVDT7 secondary feedback 2

on site DEH

TB7-(59/60)

34

LVDT8 secondary feedback 1

on site DEH

TB7-(61/62)

35

LVDT8 secondary feedback 2

on site DEH

TB7-(63/64)

36

CV4 control signal 1

on site

TB7-(68/69)

+/-40mA

37

CV4 control signal 2

on site

TB7-(70/71)

+/-40mA

38

LVDT9 first drive signal

on site

TB7-(73/82)

1.7kHz,2.23.5V

39

LVDT10 first drive signal

on site

TB7-(73/82)

1.7kHz,2.23.5V

40

LVDT9 secondary feedback 1

on site DEH

TB7-(74/75)

41

LVDT9 secondary feedback 2

on site DEH

TB7-(76/77)

42

LVDT10 secondary feedback 1

on site DEH

TB7-(78/79)

43

LVDT10 secondary feedback 2

on site DEH

TB7-(80/81)

44

ICV1 control signal 1

on site

TB7-(85/86)

+/-40mA

45

ICV1 control signal 2

on site

TB7-(87/88)

+/-40mA

46

LVDT11 first drive signal

on site

TB7-(90/99)

1.7kHz,2.23.5V

47

LVDT12 first drive signal

on site

TB7-(90/99)

1.7kHz,2.23.5V

48

LVDT11 secondary feedback 1

on site DEH

TB7-(91/92)

49

LVDT11 secondary feedback 2

on site DEH

TB7-(93/94)

50

LVDT12 secondary feedback 1

on site DEH

TB7-(95/96)

51

LVDT12 secondary feedback 2

on site DEH

TB7-(97/98)

52

ICV2 control signal 1

on site

TB7-(101/102)

+/-40mA

53

ICV2 control signal 2

on site

TB7-(103/104)

+/-40mA

54

LVDT13 first drive signal

on site

TB7-(106/115)

1.7kHz,2.23.5V

55

LVDT14 first drive signal

on site

TB7-(106/115)

1.7kHz,2.23.5V

56

LVDT13 secondary feedback 1

on site DEH

TB7-(107/108)

57

LVDT13 secondary feedback 2

on site DEH

TB7-(109/110)

58

LVDT14 secondary feedback 1

on site DEH

TB7-(111/112)

59

LVDT14 secondary feedback 2

on site DEH

TB7-(113/114)

68

ETS tripping

ETSDEH

TB3-(57/60)

DI (to relay loop)

69

ETS tripping

ETSDEH

TB3-(58/61)

DI (to relay loop)

70
71
72
73
74
75
76
77
78
79
80
81
82

Main 220VDC power supply ElectricDEH

(No. 1)

Circuit

breaker 240VDC, 20A

SW5-(1/3)

Auxiliary 220VDC power supply ElectricDEH

Circuit

(No. 2)

SW6-(1/3)

Main 220VDC malfunction alert DCS Guang TB6-(63/64)

brand

breaker 240VDC, 20A

switching value (normal
close)

Auxiliary 220VDC malfunction DCS Guang TB6-(66/67)

switching value (normal

alert

brand

close)

220VAC power supply (No. 1)

ElectricDEH

Circuit

breaker 220VAC15A

SW1-(1/3)
220VAC power supply (No. 2)

ElectricDEH

Circuit

breaker 220VAC15A

SW2-(1/3)
220VAC power supply (No. 3)

ElectricDEH

Circuit

breaker 220VAC15A

SW3-(1/3)
220VAC power supply (No. 4)

ElectricDEH

Circuit

breaker 220VAC15A

SW4-(1/3)
card

cabinet

main

220VAC DCS Guang TB6-(72/73)

malfunction alert

brand

switching value (normal

close)

Card cabinet auxiliary220VAC DCS Guang TB6-(75/76)

switching value (normal

malfunction alert

close)

Relay

cabinet

brand
main

malfunction alert

220VAC DCS Guang TB6-(78/79)

brand

switching value (normal

close)

Relay cabinet auxiliary 220VAC DCS Guang TB6-(81/82)

switching value (normal

malfunction alert

brand

close)

Relay cabinet 24VDC loss

DCS Guang TB6-(60/61)

switching value (normal

brand

close)

83

Manual shut down

SOE

TB6-(51/52)

84

DEH tripping

SOE

TB6-(53/54)

85

110% action

SOE

TB6-(55/56)

86

OPC action

SOE

TB6-(57/58)

87

110% action

Guang brand TB6-(69/70)

Chapter 3
section1

Specification for Main Body of Steam Turbine and Line

Drainage System(N300-16.7/537/537-8)

0-1 Specification for Main Body of Steam Turbine and Line Drainage System
1. System Function
The main function of drainage system is to discharge the condensed water in the main body of
steam turbine and its line when the assembling unit starts, stops or operates under low load or
under abnormal conditions so as to prevent the excess of water from bending the rotor of
steam turbine or damaging the internal parts and other serious accidents.
2. Brief Introduction about System
2.1 The drainage system is designed by following the relevant regulations in the Guidelines
for Preventing Excess of Water for Steam Turbines in Power Plants (ASME TDP-1-1980)
and absorbing the successful experiences of relevant drainage system improvements in China.
2.2 According to the responsibility of steam turbine works and the common practice of power
stations in China, the responsible range of drainage system includes the drainage of main
body of steam turbine and main body line, i.e. the drainage of main steam valve and line
between it and the steam turbine, the drainage of each steam extraction check valve and line
between it and the cylinder, the drainage of exhaust check valve for HP cylinder and line
between it and the HP steam drain, the drainage of HP steam source control station with self
sealing vapor lock system, auxiliary steam source control station, valves in the overflow
control station, line as well as the mother pipe and branch pieces of steam supply. The details
can be found in the drainage diagram of main body of steam turbine and its line (Fig.0-1-1).
Other drainages to be connected with the secondary steam separator of main body drainage
besides the main body are illustrated by the dotted lines. The drainage line specifications are
only for reference.
2.3 The system adopts two side-basket type drainage secondary steam separators that are
placed at the two sides of steam condenser casing. Seven drainage manifolds are connected to
the secondary steam separator at the steam turbine side for receiving the drainage of main
body of steam turbine and its line, the drainage of HP mean steam conduit, re-heat steam
conduit and small steam turbine for feed pump, the continuous drainage of LP heater, etc. Six
drainage manifolds are connected to the secondary steam separator at the motor side for
receiving the drainage of HP and LP heaters during accidents as well as the drainage of

deaerator overflow.
2.4 Pneumatic control cutoff valves, manual cutoff valves and throttle sets are installed on the
drainage branch pieces of main body of steam turbine and its line. The manual cutoff valve
shall normally be locked or be fully opened by other means.
2.5 The drainage lines in the system diagram adopt different materials depending on different
temperatures. When the steam temperature at the drainage point is more than 400, alloy
steel tube is used.
2.6 The supply range of system includes the main body of steam turbine, drainage throttle set
from the main body lines and pneumatic control cutoff valves. Other universal valves, pipes
and accessories are supplied by the project.
3. Installation Requirement
3.1 The drainage range of system is as shown in the diagram. Without the agreement of
manufacturer, other drainages can not be connected in at will. The drainage branch pieces
connected to the manifold shall be connected in the direction of 45with the center of
manifold and the inlet direction shall be the same as the flowing direction. The discharge
points of drainage branch pieces shall be oriented to the condenser to ensure smooth drainage.
Each drainage conduit shall be connected to the manifold in the sequence of pressure
step-down. The conduit with the highest pressure shall be the farthest from the secondary
steam separator of drainage to avoid it from being blocked or water from flowing backwards.
The welded joints for the straight tube for flowing water and the drainage mother pipe shall be
detected with ultrasonic according to JB4730. They shall meet Class 1 to ensure the welding
quality to prevent the welding line from cracking when the temperature changes dramatically,
which will affect the vacuum of condenser.
3.2 Each drainage conduit shall continuously descend along the drainage flow direction to avoid water
accumulation in the line.

3.3 Drainage points shall be located at the low position points of main steam conduit, reheat
steam conduit, steam extraction conduit, steam supply conduit with vapor lock, etc.
3.4 The throttle set shall be placed close to the drainage manifold, where shall be easy for
removal and cleaning. The inlet and outlet shall not be connected oppositely.
3.5 Drainage bags are recommended for the drainage points of self sealing steam supply
control station and steam extraction line. The drainage bag can be made of seamless tube with
the same material and its inside diameter shall be smaller than the main conduit one to two
levels, but no less than 150mm. The length of drainage bag, if calculating from the outside
wall of main conduit, shall be no less than 100mm.

4. Control Requirement
4.1 Start-up and Shutdown of Assembling Unit
Before the start-up of assembling unit, confirm the condenser working properly and make
sure certain vacuum formed. The control system of DEH automatically starts the pneumatic
control cutoff valve on each drainage branch piece. When the load is increased to 10%, the
pneumatic control drainage valve in the HP section is closed; when the load is increased to
20%, the pneumatic control drainage valve in the MP section is closed; when the load is
increased to 30%, the pneumatic control drainage valve in the LP is closed. The DEH
provides signals for all the above movements to automatically realize the close of pneumatic
control drainage cutoff valves through the interlocking device of auxiliary equipment. The
movements can also be displayed with the lights in the control compartment. During the
shutdown or the reduction of load, when the load is reduced to 30%, 20% and 10%, the DEH
provides signals through the interlocking device of auxiliary equipment to automatically open
the pneumatic cutoff check valves in the LP, MP and HP sections. The movements can also
be displayed with the lights in the control compartment. Refer to the drainage system part in
the diagram of electric monitoring protection system of steam turbine for details.
4.2 When the steam turbine trips to stop due to accidents, each pneumatic control cutoff valve
will automatically open.
4.3 When the HP and LP heaters stop working, the relevant drainage pneumatic control cutoff
check valves will automatically open.
4.4 When the auto opening fails, the operator can manually and remotely open the pneumatic
cut off valves in the control room.
4.5 Air source pressure for pneumatic control cutoff check valve: 0.4~0.7MPa(a).
5. Operation
5.1 The operator much master the handling measures for excess of water in the steam turbine
under various working states as well as take quick and specific actions on the preliminary
forecast of steam turbine flooding.
5.2 The load point for auto drainage mentioned in 4.1, the power plant can adjust it according
to actual operational experience. In particular, when the steam turbine restarts a while after
tripping and rejecting the load, the operator must decide according to the actual situation
whether the drainage pneumatic control cutoff valves of main steam conduit and HIP cylinder
shall be opened and the operation procedures shall be fixed to prevent the boiler heater and
main steam line from cooling down dramatically or cause excessive temperature difference
between the upper and lower cylinders due to the pressure reduction of main steam system,

etc.
5.3 Use thermometers, thermocouples or other methods regularly to check whether each
drainage conduit is obstructed.
5.4 During operation, if the steam turbine is flooded, the cause shall be identified immediately.
At the same time, the water source shall be isolated and the accumulated water shall be
drained. If the speed is lower than the rated one, the machine shall be stopped immediately; if
the speed is at the rated one and the load is carried, the problem shall be handled according to
the actual situation.
5.5 During the shut-down for repairing period, the inside of throttle set shall be cleaned to avoid it from
being blocked.

6. Test, Inspection and Maintenance

6.1 All the pneumatic control cutoff valves shall be operated for testing purpose each month.
Visually inspect the monitor of steam turbine to ensure that the meters for the differential
expansion, cylinder expansion, shaft bend, vibration, rotor axial displacement, metal
temperature and other are normal with correct readings.
6.2 Use contact thermometers or thermocouples every three months to inspect all the drainage
lines to see whether they are blocked. In the meanwhile, check whether the drainage valves
are agile and the throttle sets are unobstructed.
6.3 During the shutdown for repairing period, inspect all the pneumatic control cutoff valves,
interlocked devices and controllers. All the drainage valves controlled by water signal shall go
through the water movement mechanism test. All the throttle sets shall be cleaned. The inside
of obstructed lines shall be inspected to ensure smooth drainage.
6.4 Cleaning the throttle set: disassemble the nuts and bolts from the sealing flange, remove
the sealing flange and washer, remove the throttle cock with a hexagonal head wrench, flush
out the defilement in the throttle hole (Refer to Fig.0-1-2 for the structure of throttle set).
7. Recommendations for Line Drainage in Power Plant
7.1 Drainage cans with water level control valves shall be installed for the reheat cold line,
HP line, LP side line and HP inlet steam line for the steam turbine of feed pump. When the
water level of drainage can is high, the outlet valve of drainage can will open automatically.
The minimum diameter of drainage can shall be no less than 150mm.
7.2 A connection conduit of about 250mm long and min. diameter 100mm shall be installed
for the drainage of reheat hot section line, which is used for gravity drainage under the low
load.
7.3 Throttle plates shall be installed according to the requirement in the system diagram for
the line drainage in the power plant, which not only ensure smooth drainage for the maximum
discharge, but also prevent losing excessive steam.

Drainage Conduit of Main Steam

Conduit for No. III HP Regulating Valve

Drainage Conduit of Main Steam

Conduit for No. IV HP Regulating Valve

Section 1 Steam Extraction to JG2

Section 2 Steam Extraction to JG2

HP Cylinder

MP Cylinder

LP Cylinder

Cylinder interlayer heating to steam

combination box and drainage of inlet tube

Section 3 Steam Extraction to JG1

Condenser

Drainage Secondary
Steam Separator II

Drainage Secondary
Steam Separator I

Section 4 Steam Extraction to

Deaerator and Steam for Plant

Section 4 Steam Extraction to Small

Steam Turbine of Feed Pump

Section 5 Steam Extraction to JD4

Steam Supply for Main Steam

Section 6 Steam Extraction to JD3

Reheat Cold Section

old 6

LP Cylinder

View B

Auxiliary Steam Source

Drainage Manifold 1

rainage
anifold 7

Drainage
Conduit C
Drainage
Manifold 2

lectric Cutoff
Valve

Drainage
Manifold 5

Drainage
Conduit F

Drainage
Conduit E

Drainage
Conduit B

Drainage
Conduit A

To condenser (backup)

To Section 8 steam extraction heater

Drainage
Conduit D

Drainage
Conduit E

To steam supply for shaft seal of steam turbine of water pump

To HP and MP shaft seal

Legend
Check Valve

Manual Cutoff
Valve

Drainage Line of
Power Plant

Drainage Line of
Main Body

Steam Line

Drainage Interface

To LP shaft seal

Spray Type Desuperheater

Fig. 0-1-1 Diagram I of Drainage System

section2

N-17750 Condenser Specifications

0-1

N-17750 Condenser Specifications

1 Applications
As one of the major auxiliary equipment in a steam turbine, the condenser is primarily used to
condense the steam discharged from the steam turbine through recirculated cooling water,
establish and maintain the required vacuum state in the turbine discharge space, and recover
the clear condensate to feed the boiler.
2 Main characteristic parameters
Cooling area

17750m2

Cooling water temperature

26

Cooling water pressure

0.35MPag

Cooling water volume

41050 t/h

Steam pressure

6.7 kPa(absolute pressure)

Steam flow

610 t/h

Furthermore, a well installed condenser without water is about 360t weight (including
No.7/No.8 LP heaters, a temperature-decreased pressure reducer, and a drain flash tank).
During normal running, the water in a condenser is about 310t weight; when the steam
chamber is full of water, the water is about 820t weight.
3 Structure overview
The condenser is of an all-welded structure consisting of a throat, a shell (including hot well
and water chamber), and the sliding and fixed supports at the bottom (as shown in Figure
0-1-1). It is a single-shell dual-flow-path surface condenser.
3.1

Throat

The outside of the throat is welded by 20mm-thick steel plates and the inside is supported by
truss, both of which ensure a satisfactory rigidity. In the throat there are composite LP heater,
the steam exhaust connection of feed pump turbine, and the temperature-decreased pressure
reducer from the turbine by-pass system. The V, VI, VII, and VIII sections of extraction
steam pipe of steam turbine as well as the shaft seal backsteam and steam supply pipes go
into the condenser from the top the throat, the V and VI extraction steam pipes go out of the

condenser through the throat shell wall, and the VII and VIII sections of extraction steam pipe
are connected to the composite LP heater. The insulation design for the extraction steam pipe
is based on the heat insulation principle by adopting stainless steel insulation hood, which as
a result avoids the defect that when common heat insulating materials are used for insulation
the condensate quality is often contaminate by the flaking of heat insulating material.
3.2 Shell and water chamber
The shell consists of 20mm-thick steel plates welded together, and is strengthened by interior stand bars, so
satisfactory rigidity is available.
Cooling water pipes form four groups of pipe bundles in the shell (pipe bundles are arranged in the
form of triangle). Cooling water enters into the two groups of pipe bundles in the middle by way of
front intake chamber, and turns around through the back chamber, and flows across the front outlet
chambers on both sides through the two groups of pipe bundles on both sides, and finally flows out of
the condenser. Cooling water turns horizontally in pipe bundles (including back water chamber),
which ensures that the water velocity in cooling pipes are even and the heat load is distributed
uniformly. At the bottom of each group of pipe bundles, an air cooling zone is set up. Its air extraction
pipes find their outlets in the air side space. Surrounding the top of the main condensing zone, there
are two rows of cooling pipes, which are 25X0.7 titanium pipes, in total 856. In the air cooling zone
there are set up 1260 titanium pipes (25X0.7); In the rest of the main condensing zone, there are set
up 19336 titanium pipes (25X0.5). Both ends of a cooling pipe are fixed to an end pipe sheet by
expanded and welded tube joint, while the end pipe sheet and the shell are integrated into one body by
welding. The intermediate pipe sheet is welded to the side plate of the shell through stand bars, and
welded to the bottom plate of the shell through vertical stand bars. Within the shell there also set up
some collecting plates and steam baffles. Near the pipe sheets of both ends, there are set up sampling
tanks, which are used to test the leak proofness between cooling pipe and pipe sheet.

The lower part of the shell is a hot well. In the condenser the hot well and shell are integrated

together. The condensate outlet is arranged at the bottom of the hot well, where there is set up
a stilling device.
Both the front and back water chambers have an arc structure made of rolled steel plates, which is featured
by simplicity, good flowing property, small resistance, slight vibration, and being favorable for water
flowing into the cooling pipe. For the purpose of corrosion protection, the inner surface of the chamber
contacting sea water is lined with 5mm-thick rubber, which is vulcanized completely. The front water
chamber is divided into four independent small chambers, of which the two intake chambers are in the
middle, and the outlet chambers are in both sides. The back water chamber is divided into two independent
chambers. All pipe sheets are fixed to water chambers by flange connection, which is convenient for water
side corrosion protection and cooling pipe replacement.

For the purpose of overhaul and maintenance, manholes are set up in the throat, lower
shell, and water chambers. There are also set up air vents and extraction openings on
water chamber tops.
In the condenser there is set up a water gage, which can display and monitor the water levels
in the hot well and water chambers. During field installation, the actual position of hot well
water gage can be determined by customer, but the elevation indication must fulfill the design
requirements. The installation site of a water chamber water gage also must fulfill the
requirements of the drawing.
4

Connection and support pattern

Condenser and turbine discharge openings are connected by using stainless steel expansion
joints in the form of flexible connection. The lower part of condenser is supported by
non-yielding prop. During operation, the thermal expansion of the condenser is compensated
by the corrugated-type expansion joint in the throat. At the bottom there are set up one fixed
support and four slide supports. In respect that the self expansion of condenser resulting from
the load and working condition variation during operation, sliding supports are adopted for
the four corners, with PTFE boards as the sliding plane, and in the middle of condenser
bottom fixed supports are adopted to fix the condenser to the foundation, and the support
point is just the dead point of the LP cylinder of the steam turbine.
5

Installation

Because the condenser has a very large size, which makes integral transportation by railway
impossible, as a result it is made as manifolds or components in the plant and transported to

the site for assembly. When the condenser is assembled, the drawings and installation
technology provided by the manufacturer shall be followed.
In order to ensure good leak proofness for the unit, during assembly the welding quality must
be guaranteed and vacuum valves must be adopted in a vacuum system. When pipes of
different applications are installed, necessary buffer plates must be installed. If opening
piercing clashes on the reinforced accessory plates or stand bars, the original plates or bars
shall be reserved as much as possible.
The opening piercing for condenser shall follow the manufacturer's Condenser Piercing and
Accessory Drawings
When a cooling pipe is installed, it shall be confirmed that it is a qualified product. If a
cooling pipe is found with severe scoring or deformation, it shall be replaced with a new one.
In case that a cooling pipe is not long enough, it shall be replaced by a new one with an
adequate length. It is prohibited to prolong it by heating or any other forceful means. In order
to guarantee the quality and leak proofness of tube, no lubricants can be used for
expanded-connecting.
6

Working process

Under normal operations, cooling water is pumped by a water circulating pump to the two
front water chambers in the middle, and then, by way of the two groups of pipe bundles in the
middle, flows into the back water chambers, then turns around and goes through the two
groups of pipe bundles in both sides and flows back to the front water chambers in both sides,
and finally flows out of the condenser. Steam enters into the condenser from the turbine
exhaust outlet, then is scattered into the full length of the pipe uniformly, and then enters into
the main pipe bundle zone allsidedly through the pipe bundles in the middle and in both sides,
and finally is condensed through the heat exchange with cooling water pipe wall; part of the
steam, by way of the channels in the middle and in both sides, enters into the hot well to
reheat the condensate to reduce condenser depression. The rest steam-gaseous mixture suffers
heat exchange in the air cooling zone once again, and a little steam and gaseous mixture is
drawn out by vacuum pumping equipment finally. The condensate is collected in the hot well
and pumped out by condensate pump, and input into the full-flow condensate system after
boosting pressure.

Condenser testing

In order to ensure the unit's running performance, before a condenser is formally put into
service, a hydraulic pressure test must be conducted for the water side, a water filling test
must be conducted for the steam side, and a gas tight test must be conducted for the vacuum
system.
7.1Hydraulic pressure test for the water side
The hydraulic test pressure for condenser is 0.5MPa, and the water temperature shall be lower
than 15. The test procedure is as follows:
7.1.1 Close all the valves connected with water chambers.
7.1.2 Fill clean water and load a pressure to 0.5MPa (gauge pressure at the water chamber
bottom).
7.1.3 Keep the pressure for 30 minutes.
During testing, it has to be noted that there shall be no leakage and seepage in the chamber flanges,
manholes, and all attachment welds and the whole water chamber cannot be deformed. If any problem
is found, testing shall be stopped immediately and remedial actions shall be taken. If within the time
specified the check work cannot be finished completely, then the pressure hold time shall be
prolonged.
7.2 Water filling test for the steam side

For the purpose of checking the installation of shell and cooling pipe, a water filling test is
necessary prior to the operation of a condenser; however, it cannot be conducted with the
hydraulic pressure test in the water side simultaneously. The water temperature for a water
filling test shall not be lower than 15. When a water filling test is conducted, temporary
supports shall be available for the condenser. Prior to the restart of a steam turbine just after
an overhaul, a water filling test is also required.
The test procedure is as follows:
7.2.1 Close all the valves connected with the shell.
7.2.2 Fill clean water (The filling height shall be 300mm higher than the joint between
condenser and LP cylinder.
7.2.3 Maintain such a height for 24 hours.
During testing, if any leakage or seepage in the joints between cooling pipe and end pipe
sheet and in the various attachment welds of the shell or the whole external wall of the shell
is deformed, the test shall be halted immediately. The clean water shall be discharged

completely. The causes shall be found and some measures shall be taken.
7.3 Gas tight test for the vacuum system
In order to test the unit's installation level and learn about the tightness the whole vacuum
system, a gas tight test shall be conducted. The testing method is to close the motor-driven
door in the entry of the air extractor to measure the speed of breaking of vacuum. During
testing, the stipulations or requirements related to gas tight test stipulated by Steam Turbine
Start and Operation Illustration shall be followed.
The test procedure is as follows:
7.3.1 Close the motor-driven door in the air extractor entry. Note the condenser vacuum shall
drop slowly (during testing, the load shall be 80%~100% of the rated load).
7.3.2 Record the vacuum reading on time per minute.
7.3.3 Open the motor-driven door in the air extractor entry 5 minutes later.
7.3.4 Take the average from the third minute to the fifth minute as the speed of vacuum
breaking.
7.3.5 Record the load of the time and the average of vacuum breaking.
According to the testing results, the installation level of the whole vacuum system of the unit
can be determined. If the vacuum breaking rate is less than 0.13kPa/min (1mmHg/min), then
the installation is excellent; if less than 0.27kPa/min (2mmHg/min), it is good; if less than
0.4kPa/min (3mmHg/min), it is acceptable. If the vacuum breaking rate is greater than
0.67kpa/min (5mmHg/min), the unit shall be halted to find out causes and cannot be restarted
before the trouble is removed.
8

Condenser running

8.1 Definition of working pressure

The manufacturer defines the condenser pressure as the absolute pressure. Due to a
discrepancy between the local atmospheric pressure in the plant installation site and the
standard atmosphere pressure, the condenser pressure measured on site shall be converted
into the absolute pressure for pressure assessment:
PK=PO-PP
Where: POLocal atmospheric pressure, kPa;
PPMeasured condenser vacuum degree, kPa;

PKCondenser absolute pressure, kPa.

Or

PK=0.13332(h0-hp)
h0Local atmospheric pressure, mmHg;
hpMeasured condenser vacuum degree, mmHg;
PKCondenser absolute pressure, kPa.

8.2 Start
Be sure to put the condenser into service prior to the start of steam turbine. First put the air
extractor into service to form a vacuum to some extent within the condenser. Prior to
condenser start, check all valves associated with the condenser to make them in a correct state.
Meanwhile, open the air release valves on the tops of both front and back water chambers. In
order to start the condensate pump, fill the condensate from the water tank to the hot well in
advance (the filling level is determined according to the suction head of the condensate
pump). Then recycle the condensate.
When the following cases occur, stop the start:
8.2.1 Major meters such as temperature meter, vacuum gauge, and condenser water gage fail
to function.
8.2.2 The automatic low vacuum safety device fails to function.
8.2.3 Condensate throttle valves and circulating water valves fail to function.
8.3 Half side operation of condenser.
When cooling pipes become dirty and need half-side cleaning, or cooling pipes are damaged
and need plugging operation, the condenser allows half-side operation. During half-side
operation, the unit reduces its load to 75% of the rating.
8.4 Maintenance
Just like steam turbine, the on-load maintenance of condenser resides in the working
conditions of the supervising device as well as the safety and operating condition parameters
of the condenser.
The measurement items for operation monitoring are tabled as below:
Instrument
No.

Measurement items

Unit

Instrument installation site

name

Atmospheric pressure

MPa (mmHg)

Panel

Atmospheric

pressure
meter
Differential
2

Condenser pressure

MPa (mmHg)

Condenser throat
manometer
Against the cooling water

Cooling water inlet temperature

Thermometer

inlet

Cooling water inlet pressure

Against the cooling water

Pressure

inlet

gauge

MPa
Against the cooling water

Cooling water outlet temperature

Thermometer

outlet

Cooling water outlet pressure

Against the cooling water

Pressure

outlet

gauge

MPa
In front or back of

Condensate temperature

Thermometer

condensate pump

Condensate flow rate

t/h

In condensate pipe

Flow meter

TEMPERATURE OF
EXTRACTED STEAM-AIR
MIXTURE

At air extraction pipes

Thermometer

Besides, the water level of hot well and the quality of condensate shall also be monitored.
The water level of hot well is displayed by a water level indicator. During normal operation,
the normal water level in the hot well shall be 0.775m higher than the inner side of the
bottom plate. For the purpose of safe operation, too high or too low is not allowable. To check
the condensate quality, the oxygen content, salt content, hardness, and alkalinity shall be
monitored. Under normal operations, the oxygen content shall be no greater than 30ug/L.
8.4.1 In order to ensure the cleanliness of condenser titanium pipes, such cleaning measures
as rubber ball rinsing, half-side rinsing, circulating water dosing, or the combinations of them
shall be taken. A power plant can determine to adopt which cleaning combination based on
the quality of circulating water and the operating experience.
8.5 Load-dropping operation and condenser out-of-commission
Prior to the step-out of steam turbine, the load steps down, so does the steam discharged by

steam turbine. During a load-dropping operation, it has to be noted that whether the
condensing water level and vacuum are normal. If not normal, some measures must be taken
to bring it back to the normal water level; meanwhile, attention shall be given to whether the
exhaust temperature is normal.
If the idling time exceeds one week, the water in a condenser must be fully discharged and
dried against corrosion.
8.6 Operation troubles and treatment
Condenser running failures primarily result from the raising of condenser pressure (breaking
of vacuum). The raising of condenser pressure affects not only the economical efficiency of
the whole unit but also the life and reliability of the unit. If condenser pressure rising is found,
the causes shall be identified and then removed.
8.6.1 Check up the exhaust temperature and condensate temperature, and check whether the
load varies.
8.6.2 If there are operations at that time, they must be suspended. Restore it to the original
state immediately.
8.6.3 Check whether the circulating water inlet and outlet pressures and temperature vary.
8.6.4 Check whether the air extractor works normally.
8.6.5 Check the water level of hot well and whether the condenser booster pump works
normally.
8.6.6 Check other factors that have an influence on vacuum.
During checking, if the condenser pressure ascends to the unit's alarm limit or halt limit
specified by Steam Turbine Starting and Running Specifications, corresponding alarming and
halting shall be conducted.
For an emergency shutdown, the vacuum breaking valve shall be opened. For a normal
shutdown, it is not allowed to open the vacuum valve.

Pressure measurement unit

Row A

Row B

Stream turbine side

Motor side

Pressure measurement support

Condenser throat
Corrugated type expansion joint

LP heater
LP heater

Temperature-decreased
pressure reducer

Condenser shell

Front water chamber

Cooling water outlet

Back water chamber

Hot well

Water level well

Sliding support

Figure 0-1-1 Condenser figuration drawing

Fixed support

Cooling water inlet

0-2 Characteristic diagrams of condenser

Water resistance curve of condenser

Calculated water temperature: 26

Water resistance
loss

kPa

Water flow base: 41050 t/h

Water
amount

Figure
0-2-1
0-2-1

Condenser back pressure-water flow characteristic curve

17750 m2

Area:

Water flow base:

Heat load:

41050 t/h

381217.8 kJ/s

18

16

12

10
33
30

26
20

15

Inlet circulating water temperature

Condenser back pressure

kPa

14

10
5

2
40

60

80

100

Figure
0-2-2

0-2-2

120

Water volume %

Condenser back pressure-heat load characteristic curve

17750m2

Area:

Water flow base:

Heat load:

41050t/h
381217.8 kJ/s

33

11

30

26

20
5
15
10

Inlet circulating
water temperature

Condenser back pressure

kPa

1
0

20

40

60

80

0-2-3

100

120

sectoion3

Specification for Pneumatic Control System of Steam

Extraction Check Valve of Steam TurbineN300-16.7/537/537-8

0-1 Specification of Control System of Steam Extraction Check Valve
1. Purpose and Feature
The pneumatic control system of steam extraction check valve is the dynamic control center of
steam extraction check valve and exhaust check valve for HP cylinder for each section of steam
turbine. It introduces various set signals into the electromagnetic valve in the system according
to the requirements of assembling unit to control the working states of relevant check valves so
as to meet the needs of various working states of assembling unit, shown in Fig.0-1-1. The
system adopts the compressed air with 0.6MPa (absolute) pressure as the dynamic source. It
has the features of simple structure, easy setup of dynamic air source, free of contamination, etc.
When the dynamic source of compressed air acts on the operating devices of valves in the
system, it enables the steam extraction check valve and exhaust check valve for HP cylinder for
each section at the free state. When the medium flows in the positive direction, the valve opens;
when the medium flows in the reverse direction, the valve closes. When the controlling air
source is lost, the steam extraction check valve and exhaust check valve for HP cylinder rely on
the spring operating force and go to the closed state. Therefore, the system is safe and reliable.
Heat load

2. Composition of System
The air source part in the system adopts the mother pipe system. It consists of the air cylinder,
cut off valve, air filter, pressure gauge, etc as well as the air filter, relief valve, two-position

Figure 0-2-3

three-way electromagnetic valve, manual test valve, pneumatic control valve, etc. Among them,
the air cylinder, cut off valve, air filter and pressure gauge shall be prepared by the project. The
air filter on the mother pipe of air source is used to filter the sundries in the compressed air to
ensure the cleanness of compressed air. The cut off valves at the two ends are used to cut off
the air gateway when the air filter on the mother pipe needs to be repaired or replaced. At the
same time, a cut off valve is installed on the air supply branch piece of each check valve to
facilitate the replacement and maintenance when the electromagnetic valve, pneumatic control
valve and manual test valve are damaged. When one group of branch pieces is under repair, the
entire system can still work properly. This has been taken into the consideration during the
system design. It shall be noted that during the normal operation period of assembling unit,
only one group of branch pieces is permitted for repairing. Repairing more than two groups of
branch pieces at the same time will affect the system reliability and the safe operation of

assembling unit.
The control of check valve adopts the mode of one-to-one correspondence of branch pieces.
Based on the structural features of operating device of check valve and the operational
requirements of assembling unit for valve performance, the check valve adopts the two-position
three-way single normal power-on type of electromagnetic valve, manual test valve and
pneumatic control valve as the controlling and switching components. When the power is off,
the steam extraction check valve and exhaust check valve for HP cylinder are at the closed state
to ensure the safety and reliability of system.

3. Working Principle

Based on the requirements of various operating states of assembling unit, relevant open and
close signals are introduced into the corresponding electromagnetic valves in the system. The
valves are activated so as to enable each steam extraction check valve and exhaust check valve
for HP cylinder at the working states required by the operating state of assembling unit.
When receiving the open signal, the electromagnetic valve on each air passage is powered on
and connected to the air source. The compressed air enters into the operating device (cylinder
chamber) of corresponding check valve to enable the check valve at the free state. Under the
action of steam flow in the positive direction, the check valve opens.
If the steam turbine rejects the load or the main steam valve closes, for each steam extraction
check valve and exhaust check valve on each air passage, when receiving the close signal, the
electromagnetic valve loses the power and cuts off the gateway between the air source and the
operating device of check valve to enable the connection between the operating device and the
air exhaust orifice of pneumatic control valve. Under the action of spring force, the operating
device closes the check valve. When the internal water level of heater in the corresponding
section rises to the critical water level that needs to cut off the steam extraction, the
electromagnetic valve loses the power and disconnects the air source, and then the steam
extraction check valve closes.
The detailed operating principles of steam extraction check valve and exhaust check valve for
HP cylinder can be found in the manual of valves supplied with the machine.
4. Air Source and Signal Source in the System as well as the Requirements of Installation
and Maintenance.
4.1 Air source: clean compressed air with 0.6 MPa (absolute).
4.2 The air source shall dry, clean with adequate air quantity and constant pressure.
4.3 The air filter shall be periodically cleaned.

4.4 Working power for two-position three-way single electronic control electromagnetic valve:
AC220V/50Hz.
4.5 Ambient temperature for the electromagnetic valve: -5+40, medium temperature:
-10+60.
4.6 Before installation, all the lines in the system shall go through pickling and phosphorizing.
The system equipment shall be cleaned. The system cleanness shall meet the requirements of
J-1 in JB/T4058-1999 Cleanness of Steam Turbine.
4.7 The lowest point of system line shall have a drainage point. Depending on the water
accumulation situation in the system, regular drainage time shall be specified.
5. System Test and Method
5.1 After repairing or before the start-up of assembling unit, the system linkage test and
activation test of check valve shall be performed.
5.2 During the normal operation period of assembling unit, the activation test of steam
extraction check valve shall be performed monthly to check its flexibility.
5.3 Regular activation test shall be performed one by one. Only when one group is finished and
reset, the test of next group can be performed.
5.4 Procedures of Activation Test
5.4.1 Procedures of Activation Test of Check Valve

Press the test button on the manual test valve to connect the compressed air gateway that goes
into the part under the piston of operating device of valve with the atmosphere. Thus, the
compressed air in the chamber under the piston of operating device will leak to outside.
Because the chamber above the piston of operating device is connected with the atmosphere,
under the action of spring force, the piston will move downward. When the movement closes to
the half of stroke, release the manual button on the test valve to enable the check valve return to
the free state. The activation test is finished.
5.4.2 It shall be noted that the movement stroke shall not be excessive during the activation test,
otherwise the normal operation of assembling unit will be affected.
5.4.3 The activation test for the exhaust check valve for HP cylinder shall be performed once
per 2-3 months.

der

Cutoff Valve

Air Filter

Cutoff Valve

Pressure Gauge

Air Source 0.6

MPa (Absolute)

Cutoff Valve

Cutoff Valve

Free State

Free State

Cutoff Valve

Cutoff Valve

Free State

Cutoff Valve

Free State

Cutoff Valve

Free State

Cutoff Valv

Free State

ed by Each Air Passage

Purpose
for No.3 HP Heater
for No.2 HP Heater
for No.1 HP Heater
for Deaertor and Power Plant
for Deaertor and Power Plant
for Small Steam Turbine of Feed Pump
for No.5 HP Heater
for No.6 HP Heater
Steam (Cold Section)
Steam (Cold Section)

Remark
Inlet
Inlet
Inlet
Inlet
Inlet
Inlet
Inlet
Inlet
Inlet
Inlet

System Control Mode

Item
Control of Steam Extraction Check Valve
Movement Electromagnetic Air Valve (A-H)
signal

Check Valve

Control of Exhaust Check Valve for HP Cylinder

Electromagnetic Air Valve (I-J) Check Valve

set close
cut off air source
close
cut off air source
close
set open
connect to air source
free State
connect to air source
free State
set free
connect to air source
free State
connect to air source
free State
cut off heater cut off air source in corresponding section close in corresponding section
Note:
1 Refer to the start-up operation manual and the system specification for the details about the set signals.
2 Free State refers to the state that the check valve can be opened when the medium flows in the positive direction and closed when the
medium flows in the reverse direction.
3 Connect to Air Source means that the compressed air enters into the inlet of operating device of check valve through the electromagnetic air
valve; Cut off Air Source means that the electromagnetic air valve cuts off the compressed air to the operating device of check valve.

Fig. 0-1-1 Diagram of Pneumatic Control System of Steam Extraction Check Valve

1. Air source: compressed

2. During the installation
conduit shall be pickled a
of sundries. The cleanness
Cleanness of Steam Turb
3. Control air source inter
check valve for HP cylind
4. Working voltage of elec
5. The lowest place of sys
shall be performed.
6. Before the start-up of a
be performed per the syst
performed regularly. Refe
7. The valves and accesso
together with the exhaust
valve. Other valves and ac

section4

Self-sealing Turbine Steam Seal System Specifications

0-1 Self-sealing Turbine Steam Seal System Specifications

1 Overview
The turbine steam seal system is primarily used to prevent steam from leaking
outwards along the shaft ends of HP and IP cylinders and even flowing into the
bearing box and resulting in water polluting lubricating oil; it is also used to
prevent air from seeping into the steam cylinder and as a result destroying the
vacuum of the unit.
The self sealing turbine steam seal system refers to the system in which the steam
escaped from the shaft end steam seals of HP and IP cylinders is, after spray
desuperheating, used for the gland sealing steam supply for LP shaft ends during
the normal operation of a unit. The surplus leaked steam flows to the LP heater or
condenser through an overflow station. During the unit's start or low load phase,
the gland sealing steam supply comes from the outside. From the start to the
operation at full load, the turbine steam seal system can conduct automatic
switching in accordance with the unit's gland sealing steam supply requirements.
The system is featured by simplicity, safety, reliability, and good applicability.
2 System composition and major equipment
The system consists of the steam supply and leakage pipes of gland seal, the
valve-stem steam leakage pipes of stop valve and control valve, the valve-stem
steam leakage pipes of IP combined steam valve, and other related devices. (for
details, see Figure 0-1-2)
A three-valve system is adopted for gland steam supply, that is, under all
operation conditions, the steam supply pressure for a steam turbine is controlled
via three control valves, namely, HP steam supply control valve, subsidiary
source supply control valve, and overflow control valve, all of which ensure that
the set steam pressure in the steam supply main pipe can be maintained
automatically under any operation condition. The subsidiary source steam supply
station has two steam supply sources. Except the reheating section of the unit
itself, subsidiary steam supply from other than the unit is also available. During
start or operation at low load, the subsidiary steam enters into the self-sealing
system through the control valve of the subsidiary source station. The above three

control valves, their cut-off valves, and the necessary by-pass valves make up
three pressure control stations. Furthermore, in order to meet the LP cylinder
gland steam supply's temperature requirement, a direct-contact desuperheater is
set up in the main pipe of low-pressure shaft gland steam supply. Temperature
control is used to control the water spray, which as a result realizes that the
desuperheating steam meets the low-pressure shaft gland's steam supply
requirement.
The actuators for all control valves in the system runs in an electrically way and
are controlled by DCS. Import components are adopted for all the control valves
and actuators, which can perform stably and reliably.
In order to ensure that the main steam supply station is at a hot bank status all
along the normal operation, a bypass with throttling orifice plates is set up in
front of the control valve. During a normal operation, the steam goes from the
gland sealing steam supply main pipe to the pressure control station through the
bypass, which keep the station in a hot bank state.
In the system there are also set up a JQ-110-3 gland seal heater and two shaft
gland blower fan (one of them as a standby), which are used to extract the leaked
steam (or air) in the final section of shaft gland chamber and to keep the chamber
run at a minor negative pressure.
In order to prevent foreign substances from entering into the shaft gland, a Y-type
steam filter is set up at each branch pipe of steam supply. In the steam supply
main pipe there is set up a safety valve with a set-pressure of 0.3MPa(a), which
can prevent the occurrence the over high steam supply pressure.
3 System operation
3.1 Preparation for start
3.1.1 Shut down all pressure regulating stations, put through the steam supply
source, and adjust the temperature of the steam supply line to a superheating
temperature.
3.1.2 Confirm that the instruments and meters of the system are normal.
3.1.3 Confirm that the turning of steam turbine has been put into service.
3.1.4 Confirm that the recirculation of condensate has been established.
3.1.5 Open the manual and electric check valves of all the pressure control valves

and temperature control valves.

3.1.6 Put through the electric control valves and the corresponding EPSs.
3.1.7 Open the manual gate valve in the cooling water (condensate) line of the
gland seal heater, which puts the gland seal heater into service.
3.1.8 Open the shaft gland blower fan, and open the electric butterfly valve in the
fan's admission line. The fan is put into service normally (one for service, the
other for standby). The gland seal's steam return line maintains a negative
pressure, and the pressure is adjusted to about 95 99kPa (absolute).
3.2 Start
3.2.1 Cold start
3.2.1.1 In the cold start, the steam is supplied by the subsidiary source station.
3.2.1.2 After closing the control valves in both HP source station and overflow
station, open the electric check valves in the control valve line of the subsidiary
steam supply source station; confirm that the system is normal input and runs
automatically in accordance with the following steps:
A) Turning, rolling, and low load phase
The gland sealing steam supply comes from the subsidiary source, and the
pressure of the steam supply main pipe is maintained at 0.124MPa (absolute).
B) 25%-load to 60%-load phase
When the unit load ascends to 25% of the rated load, the cool head of reheat pipe
can fulfill all the requirements of gland sealing steam supply, the steam is
supplied by the cool head of reheat pipe, and the main pipe pressure is
automatically maintained at 0.127MPa (absolute).
C 60%+ load phase
When the load is increased to more than 60%, the quantity of steam leaked from
HIP cylinder shaft ends into the supply main pipe exceeds that required by the LP
cylinder gland seal. When the main pipe pressure ascends to 0.130MPa (absolute),
the control valves of all steam supply stations are closed automatically; the
control valves in the overflow station are opened automatically and discharge the
redundant steam to the condenser through the overflow control station. Up to this
point, the turbine steam seal system enters into a self sealing state and the

pressure of main pipe maintains at 0.13MPa. During a normal operation, the

electric check valve in the cool head of reheat pipe shall be shut down.
3.2.2 Hot start
3.2.2.1 If there is a qualified subsidiary steam supply source, the gland sealing
steam is supplied by the subsidiary source station.
The parameters of the subsidiary source fail to meet the requirements, the gland
sealing steam is supplied by the HP source station.
3.2.2.2 If adopting the HP steam source, confirm that after the control valves of
the subsidiary source station and the overflow station are closed and the electric
check valve in the control valve line of the main steam supply station is opened,
the steam supply system shall be put into service normally and run automatically
in accordance with the following steps:
A) Turning, rolling, and low load phase
The gland sealing steam supply comes from the main steam supply station, and
the pressure of the steam supply main pipe is maintained at 0.118MPa (absolute).
B) 25%-load to 60%-load phase
When the unit load ascends to 25% of the rated load, the cool head of reheat pipe
can fulfill all the requirements of gland sealing steam supply, the steam is
supplied by the cool head of reheat pipe, and the main pipe pressure is
automatically maintained at 0.127MPa (absolute).
C) 60%+ load phase
When the load is increased to more than 60%, the quantity of steam leaked from
HIP cylinder shaft ends into the supply main pipe exceeds that required by the LP
cylinder gland seal. By this time the main pipe pressure ascends to 0.130MPa
(absolute),

the

control

valves

of

all

steam

supply

stations

are

closed

automatically, and the control valves in the overflow station are opened
automatically and discharge the redundant steam to the condenser through the
overflow control station. Up to this point, the turbine steam seal system enters
into a self sealing state and the pressure of main pipe maintains at 0.13MPa.
During a normal operation, the electric check valve in the cool head of reheat
pipe shall be shut down.
3.2.3 Unit load rejection phase

When load rejection occurs, it shall be treated by the following two means:
a) If there is a standby subsidiary steam supply source conforming to the
temperature requirement, the pressure of the main pipe for gland sealing steam
supply can be down to 0.124MPa. Close the overflow governing valve and the
gland sealing steam is supplied by the subsidiary source station.
b) If the unit has no standby subsidiary steam sources or the parameters of the
subsidiary sources fail to meet the requirements, the subsidiary sources and cool
head of reheat pipe cannot be used. The electric check valve in front of the
control valve of the subsidiary source station must be closed. The pressure of the
main pipe for gland sealing steam supply is down to 0.118MPa. The overflow
governing valve has already been closed automatically, and the HP steam supply
control valve is opened automatically. The steam is supplied by the main steam
supply station, namely, the HP steam source adjustment station.
3.2.4 Putting into service of temperature adjustment station
Under all operation conditions, a temperature adjustment station can maintain
the temperature of the LP gland seal chamber at 121 177 .
3.2.5 Putting into service of by-pass valve
When the throttle pressure of a subsidiary steam supply control valve is 25%
lower than the rating, or when the steam turbine starts with a wearing gland seal,
in order to get adequate steam flow to seal the steam turbine, the by-pass valve of
the subsidiary steam station will be open for steam supplement. When the throttle
pressure is high enough to maintain the steam for gland seal, the by-pass valve
will be closed. If the by-pass valve is still open, the surplus steam will be
automatically discharged into LP heater or condenser by way of the overflow
valve. Such a case does not made any difference to the turbine operation, but it
will lower the efficiency of the power plant slightly.
3.2.6 Steam temperature requirements
3.2.6.1 Subsidiary steam parameters' requirements
No.

Application

Steam
MPa

pressure Temperature
()

Used for

Steam
source

Warming

About

Cold start

150~260
2

Steam

0.588~0.784MPa

About

turbine gland

208~375

sealing

About

Subsidiary
steam

Hot start

header

Cold start

150~260
3.2.6.2 Steam turbine gland sealing's temperature requirements
In order to avoid the inconsistency between the temperature of seal steam and
that of turbine rotor, the steam supply temperature must meet the required needs.
In general, in the main pipe of gland seal with a absolute pressure of 0.127MPa,
it is allowed that the temperature of seal steam is 167 higher or 167 lower
than that of the metal. Excessive temperature differences between seal steam and
rotor will result in a high heat stress on the rotor surface in the gland seal zone.
Each heat stress cycle will result in the alternate life loss of part of the metal,
while the recurrence of excessive temperature difference of rotor will give rise to
heat fatigue cracking on rotor surface; meanwhile, the excessive temperature
difference will also bring about excessive expansion difference between the rotor
and the stator.
3.2.6.3 Specific steam temperature requirements
In a cold state (when the first shell temperature of steam turbine is lower than
150 );
When the maximum steam temperature under the main pipe pressure is 260 and
when the minimum steam temperature under the main pipe pressure is 150 .
In a hot state (when the first shell temperature of steam turbine is higher than
150 );
When the maximum steam temperature under the pressure in the main pipe for
gland sealing is 375 and when the minimum steam temperature under the
pressure in the main pipe for gland sealing is 208 (the maximum temperature of
gland-packing leakage minus 167 ).
The above parameter requirements are shown in Figure 0-1-1.
3.3 Emergency adjustment
3.3.1 In order to prevent the occurrence of steam supply overpressure accident,

there are set up a full-open-type safety valve with radiator spring with a set
pressure of 0.3MPa in the main pipe for steam supply. In order to guarantee a safe
operation, there shall be set up sound and light alarm devices for overpressure
alarming with an alarm pressure of 0.25MPa in the main pipe for gland sealing
steam supply, so that the system operation can be monitored at any time.
3.3.2 Gland sealing back-steam pressure adjustment
If end steam leakage is found during operation, the throttle of gland sealing
blower fan can be adjusted to guarantee a certain negative pressure is maintained
in the gland sealing back-steam chamber, at about 95~99kPa (absolute).
3.3.3 When there are failures in the steam supply stations and overflow stations,
control valve hand wheels and by-pass valves can be used to adjust the system.
3.3.4 Under an abnormal working condition, if the bypass channel of the steam
supply control valve is opened or the control valve of the steam supply station is
open, excessive steam will enter into the main pipe for steam supply by way of
the steam supply station. No matter which case occurs, the overflow control valve
will be automatically opened. If the overflow control valve also goes wrong, the
motor operated gate valve in the bypass of overflow station can also be opened.
3.4 System shutdown
3.4.1 Confirm that the steam turbine is in the shutdown and turning phase.
3.4.2 Cut off the electric check valves of all steam supply pipes.
3.4.3 Cut off the motorized valve in the water inlet of the desuperheating station.
3.4.4 Cut off the power supply of the gland sealing control valve.
3.4.5 Confirm that all the drainage points are free from obstruction.
4 Precautions for installation and operation
4.1 In order to ensure that the system can run safely, the components such as
control valve bodies and actuators have been calibrated and aligned in the
manufacturer's plant, disassembly of them is not required during installation.
4.2 A drain pipe shall be set up the low level point after the valve of a steam
supply control station, and water in the drain pipe flows into the condenser by
way of a throttling device.
4.3 A drainage point shall also be set up after the direct-contact desuperheater,
with its position at least 2.5m after water spraying, and the drained water flows

into the condenser by way of a throttling device.

4.4 The minimum distance from the spraying part of the direct-contact
desuperheater from the LP gland seal shall be 15~17m. After water spraying, a
straight section at least 5m longer shall be available, and its diameter shall be the
same as that of the direct-contact desuperheater shell.
4.5 In a turbine steam seal system the pipes before the steam supply control
station shall have continuous incline towards the steam source (main steam,
subsidiary steam, and the steam in the cool head of reheat pipe) direction with a
gradient of slope of 1/50. If these pipes are connected to the source in a inclined
way, a drain pipe must be set up at the inlet side of each valve to prevent the water
from being accumulated. The drain pipe must be a continuous one with throttling
orifices.
4.6 All the pipes for gland sealing steam supply shall be inclined continuously
downwards to the gland sealing pressure control station direction with a slope of
1/50. If there is a low level point in the piping system, a continuous drain pipe
with throttling orifices shall be used to drain the water to the condenser.
4.7 All the pipes of steam-air mixture from gland seal and valve stem leakage
shall be inclined towards the direction of the gland seal heater, with a slope of
1/50. If there is a low level point in the piping system, a drainage point shall be
set up, and the drained water shall be discharged into the condenser.
4.8 The condensate from the gland seal heater is discharged into the condenser
through a water-sealed pipe.
4.9 Before the vertical climbing of the exhaust duct of a shaft gland blower fan, a
downward slope starting from the fan and ending in a low level drainage point
shall be available for the duct. During operation, it shall be guaranteed that the
drainage is clear. Two fans (one for standby) shall be connected in parallel.
4.10 The steam filter in a steam supply line shall be fitted on a horizontal
position.
4.11 The pressure control signals for all electric control valves come from the
main pipes for steam supply, and the temperature control signals from the gland
seal chambers. Due to such reasons as arrangement, the temperature measuring

point after a direct-contact desuperheater shall be set up on the main pipe, and the
distance from the measuring point to the desuperheating spraying part shall be no
less than 15m. It shall approach the gland seal chamber as near as possible.
4.12 The steam pipelines to the same place can be combined, but the pipe
diameter shall be big enough.
4.13 Purging is required for all pipes. The cleaning for all pipes and equipment in
the system shall be performed in accordance with clauses 3 and 2 in
JB/T4058-1999 Steam Turbine Cleanliness.
4.14 The inlet of the shaft gland blower fan for standby must be closed.
4.15 The steam filters shall be washed regularly.
4.16 When the pipe medium temperature is lower than 400 , No.20 steel pipes
shall be adopted; when it is higher than 400 , alloy -steel pipes shall be adopted.
5 The calibration and operating conditions of the control valves in all control
stations are as follows (see Table 0-1-1).
Table
Pressu re of gland
sealing main pip e
MPa

HP

steam

co ntrol

co ntrol

station

station

Close

0.127

Close

0.130

Close

0 .118

Subsidiary

source

0.124

0 .118

steam

Op en

Op en

adjust

source

Op en
adjust
Close
and

and

Overflow
co ntrol

Running statu s

station
and

adjust

adjust
Op en

0-1-1

and

Vacuu m

Close

(cold start)
25% load

Close
Op en
adjust

Close

Close

Close

Close

ph ase

and

Self sealing

Load rejection
Vacuu m
(hot start)

ph ase

Note: The valve set pressures in Table 0-1-1 are only for onsite adjustment
reference. Power plants can adjust the pressure setting value based on actual
operating conditions. If no smoking occurs in all HP, IP and LP gland seals and
the vacuum is not unaffected by the adjustment, it is appropriate.
6 Simple manipulation measures for common troubles (see Table 0-1-2)
Table 0-1-2
Failure
Too

high

pressure in
main pipes
fo r

gland

steam

Failure source

Simple manipulation measures

1 The steam su pply con trol

1 Check the control signals of the control

valve is not tightly closed.

valve and its tightn ess. If h aving co n firmed

2 External steam goes into

th at it is not tight, info rm the man u factu rer

th e system.

o r the suppo rt plants.

Th ere

leakage

supply

are

points

unclear
near

the

2 Identify the ex ternal sou rce and cu t o ff it.

3 Find out the leakage points near the gland

gland seal.

seal.

1 The outlet valve of the

1 Op en th e ou tlet valve o f g land seal blo wer

gland seal blower fan is

fan.

closed.

2 Adjust the cooling water volume in the

2 The v olu me o f cooling

gland seal heater to make the pressure in the

water in the gland seal

heater no greater than 95k Pa(a).

S mo ki ng in

heater is too small.

3 Let the steam-air mixture retu rn line be

th e

3 The steam-air mixture

in clined continuou sly to ward s the gland seal

return line is not rationally

heater d irection with a slope of 1/50,

arranged.

do not let the mixture enter into the inlet

4 The drainage for the low

pipe section of gland sealing heater from

level point of

lo wer p art.

gland

seal

steam-air

mixture is not clear.

and

4 Keep clear the passage for drainage in low

level point

High

temp eratur

fou ling

2 Clean the water filter.

2 Water filter fouling

3 Ch eck the po wer sou rce and co ntrol sig nals

pressure

control

of the control valve.

steam

valve fails
control

1.1 Check the power source and control

for

low

Desuperheater

The

spraying

nozzle

1 Clean the nozzle.

supply
Low

The

spraying

temp eratur
e

for

valve is no t tigh tly closed .

LP

sign als o f the co ntrol valve.

1 .2 Ch eck wh ether the con trol v alve has

steam

in tern al leakage. If it has, p lease co ntact the

supply

man u facturer o r support plants for treatment

measures.

Because whether the turbine steam seal system can run normally is related to not
only the equipment configuration but also the on-site arrangement, when the
system is abnormal, if the above simple manipulation measures do not take effect,
please contact DFSTW.
7 If the contents of the specification are not in agreement with the Unit Start and
Run Specifications, the latter will prevail.

Gland steam temperature

()

400

375
Allowable
temperature for hot

start of steam turbine

300
260
Gland steam

200

208

temperature requirements

Allowable

temperature

cold start of
turbine

for
steam

150
100
0

30% 50% 70% 100%

Load
%

Figure 0-1-1

Allowed band of gland steam temperature

IP Main Steam Governing Valve

ve Lever Leakage (Valve Cap)

Condenser throat

To Deaerator

IP Main Steam Valve Lever

Leakage (Valve Cap)

IP Main Steam Governing

Valve Lever Leakage

HP
Main
Steam Valve

ain Steam Governing

e Lever Leakage

Shaft seal fan

ed-water Pump Turbine Steam Seal Steam Supply

Steam Se

Overflow to Stage 8

To LP Heater

From condensate pum

Feed-water
Pump
Turbine Stem Seal

Steam Extraction Heater

Overflow to
Condenser

Main Steam Supply

Fro

Legend
Shaft seal

Steam Air-Smog
Condensate Control loop
pipeline
Mixture Pipeline Pipeline

Exhaustion to Reducer
Safety valve Check Valve Electric
butterfly valveAir

Figure 0-1-2

Electric
Temp check
valve
eratur
e
meas
Steam filter Dead end

Self-sealing Turbine Steam Seal System

Hand
valve

steamElectri
stop Main
contro
pressure
transmitter

overflow
Subsidiary
steam pressure pressure
transmitter
transmitter

Tempe
transm

section5

Maintenance of condensate pump

1OperationStartingShut down
11Preparation before starting and operation
(1)Check the water level of warm wellIts lowest level should not be smaller than the
lowest value specified in<<Technical Protocol of Condensate Pump>>
(2)Check if the installed instruments are working well
(3)Fill NO20 turbine lubricating oil in the thrust beating trunk to the position of oil
mark
(4)Separate the elastic couplingcheck if the rotating direction of the motor is right or
not (CW viewed from the motor side)then fix the elastic pin of the coupling
(5)Fill the water for the pumpcheck carefully the temporary and fixed filters in the
suction piping system smooth or notPlease pay attention to clean off in time
(6)Open the valve of outside supplied sealed cooling waterCheck if the pipeline of
sealed cooling water is smooththen adjust the pressure of outside supplied water through
adjusting valve and keep the pressure between 02504Mpa and water capacity between
0610 m3hOpen the valve of bearing cooling watercheck if the pipeline of bearing
water is smoothCapacity of beating cooling water is between 08 12 m3h and
pressure between 025
04Mpa

(7)Turn gear by handThe rotating circles of the pump rotor shouldnt be 1ess than 3
circles and check if there is something abnormal in rotating
(8)Close the discharge pipe gate valve of the pump and the screw plug of the pressure
meter
12Starting
(1)Starting the motor to the rated speedopen the screw plug of the pressure meter and
adjust the seal water and cooling water
(2)open the discharge pipe gate valve gradually to the required operation conditions
and check the readings of the different meters and the leakage of the
seal waterUnder the operation conditions of closed the gate valvethe rotatmg time
shouldnt be exceeded to 2 minutes
13Operation
(1)Check if the nonreturn valve at the discharge pipes of is open.
(2)Venfy if the discharge pressure meets the requirement
(3) Check if system operates smooth and vibration meets the requirement
(4) Observe control instruments of motor and thrust bearing of pump
Double metal thermometer for pump thrust bearing controls the temDeramre as
followsAlarming at 70Stop at 80Thermocouple tor stator winding of motor controls
temperature as followsAlarming at l30StoD at 140ThemlOcOuple for above and
below bearing Ot motor controls
temDerature as followsAlarming at 70Stop at 80
Attention (1)Installation position of pump depends on that pump alwavs has water
levelSo during the running of pumpunder any loadmg worng condition of motor unitthe

actual water level of condensate warm weII should be ensured not lower than the lowest
level
(2)Pump cant run under the minimum capacity!After start up pass this area quickly t0
avoid vibrationnoise and possible net positive suction-
(3)Stand-by unit should be put into running periodicallyWe recommend that 2 sets of
condensate pumps with the same motor should be alternately used every 30--40 days and
keep stand-by pump alwaYs m a normaI condition
14Shut down
l Shut down the motor and observe if pump rotors stop smoothly
(2)Water level of warm well is at the lowest level
3C10se the gate valve on the discharge pipeline and cock for manometer and keep pump
system in the condition ofTo Be Started
15Maintenance or delay the time of shut down
(1)Shut down the valve of suction
(2)Shut down the minflow valve
(3)Shut down system of cooling water
(4)Open a11 of vents and discharge the water in the pump
(5)Motor should be protected against the tide
2Maintenance of the Pump
21Mechanical sealing parts.
a Mechanical seal Axial interface of rotating and stationary rmg with
highDrecisionrubbing and the action of spring in sealing parts ensureS the thorough
axial sealThrottling function of little clearance between frictionsurface reduces leakage of
fluid to the least degree and ensure s_the transDortation efficiency of pumpLubrication and
cooling of friction-surface It is done by clean water resource(condensation water or
salt-removinLg water) flowing through position F in Fig7Pressure of suction nozzle
04-06Mpa Water Capacity08 12 m3hTemperature lower than 38CDischarge
nozzle
Fshould ensure that its pressure is between O102MpaIf resource pressure is lower
man 03Mpa or water capacity smaller than 05 m3hinspection should be done
immediatelyIf it cannot go back to normal value within12 hours, machine should be
stopped to repair
bstuffing seal before startingThe external sealing water system must be startupthe
pressure p=O25-040Mpacapacity Q===5l0 lhThe leakage of sealing water is
discharged by two holds in different place on the stuffing glandThe material of packing is
PTFEthe wearable capability of which is better than othersAdjust the tighmess of gland
according to the leakageWhen supply system of sealing water is normaljust adjust the nuts
on the gland
When replace the stuffingjust take the gland down and replace the stuffing
22Thrust bearing parts
Use No20 turbine lubricating oil for upper guiding bearing and thrust bearingbefore
filling the oilthe oil tank should be cleaned thoroughlyThe oil level should be kept to the
marked location of the oil gaugeThe temperature of the lubrication oil in the oil tank

shouldnt be higher than the environmental temperature of 25the alarm temperature is 70

and the shutdown temperature is 80Change the lubrication oilafter 300 hours of the
first operationafterwards check me oil level periodicallyIt shouldnt be lowest than the low
level marked on the oil gaugeThe cooling water of the inner oil cooler is industry pure
waterwith temperature t3 85pressure P=025~0.4MPa capacity Q=08
12m3hIt can be adjusted according to the environment temperature
23Guide bearing and journal bearing
These are the waterlubricated bearingsThey are sensible to the impurities and
particlesWhen the condensate pump(condensate booster pump)is involved in the pipe
flushing of the systemthe strainer must be installed on the upstream of the pump
suctionWhen the flushing is finishedthe temporary strainer on the suction side should be
disassembled to ensure the effective NPSHaIf the fixed strainer is installedthe screen hole
with 40 meshes is 0K
3.Common faults and solution of condensate pump:

Symptom

Cause
Solution
1. There is something wrong with
motor or electric system.
1. To check motor and electric system
It cant 2. Foreign matter enters rotary 2. To clean away the foreign matter
be started
part, resulting in block.
3. To repair the bearing
3. Bearing exists fault and is
blocks or too tight.
1. Air leaks from negative pressure

It is
under
capacity
or it
doesnt
discharge
water

It is
under
overload

1. To find out and eliminate the leaking

position
2. Impeller is spoilt.
2. To replace impeller.
3. Outlet valve is regulated
3. To regulate outlet valve again or overhaul
improperly or outlet/inlet valve
of fault.
core falls off.
4. To increase the water level of condenser.
4. Water level of condenser is too
5. To rearrange connection of motor and
low
correct its direction.
5. Rotary direction is reverse
1. Bearing is spoilt.
1. To overhaul of bearing.
2. Friction exists between
2. To overhaul and regulate rotary part.
impeller and shell.
3. To turn down recirculating valve or start
3. Flow is too large
standby pump.
4. Packing gland is too tight.
4. To loosen the packing gland.
5.Motor is in lacking phase
5. To check connection of motor and switch.
operation.
part.

1.Coupler is of disalignment.
2.Bearing is spoilt.
3.Shaft is bent, and rotor is

1. To make alignment again.

Pump or
unbalanced.
motor
4.Bolts of coupler are not in good
exists
connection
abnormal 5.Foundation bolts are loose or
vibration
foundation is weak.
6.Rotor part is loose.
7.Motor is out of service.

Section6

2. To replace bearing.
3. To straighten shaft and eliminate imbalance
4. To refasten or replace the bolts.
5. To fasten the bolts or reinforce foundation.
6. To overhaul loose part.
7. To repair motor.

Feedwater Pump

1 Function and 0perating Characteristic of Feedwater Pump

Feedwater pump is the most important water pump, it continuously provides boiler with
feed water possessing enough pressure & flow & temperature. Safe and reliable operation of
feedwater pump is directly related to safe operation of boiler devices.
With the increase of unit capacity of power plant, auxiliaries equipped are relatively
developed and position of feedwater pump providing boiler with feed water. Feedwater pump
of modern large-scaled boiler is large in capacity and high in rotary speed, and this kind of
boiler puts forward new request on drive pattern & structure & material of pump. At present
all the unit plants participate in power network cycling, resulting in increase of variable range
of flow in water pump and change of head & suction pressure & feedwater temperature along
with that, accordingly new problem occurs in operation of feedwater pump.
With the restrict of network frequency, the highest speed of motor cant exceed
3000r/min, this will result in much increase of not only series but also length and weight of
feedwater pump, severely affecting reliability and economy of feedwater pump.
Shell of previous high-pressure feedwater pump was generally of multistage sectional
type, but that of present is of double-shelled cylinder type, which makes slight difference of
temperature and pressure between each section of shell, heat stream and stress around axes of
water pump are uniformly symmetric, in addition inter-stage leakage can be reduced owing to
better sealing and safety and economy of operation are enhanced. Modern high-pressure
feedwater pump is high in pressure and flowing speed, this high flowing speed possesses
great scour for impeller & blade & guide blade, so utilized material should be of scour
resistance & erosion resistance & small heat-expansion coefficient & good mechanic property
& easy patch weld. On the operation pattern, previous feedwater pump generally ensured
continuous operation of main engine via parallel operation of standby pump and multiple
pumps and adapted change of load via the number of start-stop pumps and regulating opening
of feedwater regulating valve. Obviously it cant adapt the development of unit plant, modern
large capacity unit plant adopts variable speed feedwater pump. It can change rotary speed
and regulate load in a large range and meet requests of sliding parameter operation and
network cycling of unit plant, and economy of unit operation is increased.
2 Necessity of HydraulicVariable Speed Feedwater Pump

With increase of unit capacity of turbine, pressure of feed water is needed higher and
higher. Especially for go-through boiler, steam-water flowing resistance of boiler proper has
to be overcome with pressure of feedwater pump. Hence, motive power driving high-speed
pump should be quite large. If motor is adopted to drive high-speed pump, its highest rotary
speed can only reach3000r/min due to limit of network frequency, so speed should be raised
via raising speed gear at first.
For the sake of economic operation, the best measure is to adopt variable speed regulation
to suit change of condition. It is an ideal way to directly adopt hydraulic variable speed pump,
namely to adopt hydraulic coupler, changing rotary speed to suit starting condition.
More advantages to adopt hydraulic coupler are as follows:
(1) Hydraulic coupler transmits power with oil pressure. It is of stepless speed change,
convenient in regulation, fine in stability, small in noise and long in service life because
oil pressure is not limited by grades.
(2) Starting moment is large while motor-operated feedwater pump starts up from
motionless to speed rating, in order to suit this moment, schemed capacity of electric
machinery is often 30%50% more than power rating of water pump, so it is of
diseconomy. After using hydraulic coupler, feedwater pump can be started under lower
rotary speed (or large ratio of rotary differential. In this way, schemed capacity of motor
can be need not too abundant because of low rotary speed and smaller starting moment.
(3) If regulating speed via oil in and out combination (it will be introduced in the next
section), speed up and down will be rapid and meet special requirement of rapidly
starting of go-through boiler of unit plant.
(4) It can be regulated in a large range.
3 Hydraulic Coupler
I. Operating principle of hydraulic coupler
Hydraulic coupler mostly consists of pump
wheel, turbine and rotary inner bushing
(Fig.3-13). They form two chambers: circular
flowing circle is formed by working oil in
chamber between pump wheel and turbine;
Fig.3-13 Schematic drawing of
hydraulic
oil ring is formed by working oil discharged
coupler
from the clearance between pump wheel and
1-main shaft;2-pump wheel;3-turbine; 4-spoon-type
turbine (or orifices on the shell of turbine)
tube;5-rotary inner bushing; 6-reflux passage;7-driven
under the function of centrifugal force in
shaft;8-inlet of controlling oil
chamber of pump wheel and circular inner
bushing. Working oil gets energy in pump wheel and releases it in the turbine; transmission
power can be changed with quantity of working oil, resulting in speed change of turbine so as
to suit the need of load. Change of working oil quantity can be performed with regulating
valve of operating oil pump (or auxiliary oil pump) or entrance of turbine (or hollow shaft of
turbine), or via changing travel (radial) of spoon type tube in the rotary inner bushing
chamber, resulting in change of release of oil ring.
Rotary shaft of pump wheel is a kind of drive shaft that drives via speed up of
accelerating gear of motor, so drive shaft is a high-speed shaft with stationary rotary speed.

The shaft of turbine is a driven shaft, working oil from pump wheel impulses turbine to rotate
with a certain pressure, driving rotor of water pump jointed on the driven shaft. In addition,
speed can be changed via hydraulic coupler firstly and is raised then via accelerating gear,
driving rotor of feedwater pump
There are radial blades in the chamber formed by pump wheel and turbine, the number of
blades is generally 2040 pieces, the number of turbine is commonly l4 less than that of
pump wheel in order to avoid resonance, circular flowing passage is formed between blades.
Working oil is thrown along radial passage and its pressure is raised under the function of
centrifugal force in pump wheel, its radial relative speed is combined with circumferential
speed at outlet of pump wheel, crushing inlet radial passage of turbine, and working oil
impulses turbine to rotate via changing
momentum moment along radial
passage, its radial relative speed is
combined with circumferential speed
at outlet of turbine, crushing inlet
radial passage of pump wheel, then
energy can be attained in pump wheel.
So, natural reflux is formed between
pump wheel and turbine and power is
transmitted. But continuous reflux of
working oil can result in friction and
heat, working oil should be cooled in
order to avoid oil boiloff and
temperature up to impeller and affect
the safe operation of coupler: one is to
suck out oil cooled in heat exchanger
with spoon type tube, the other one is
to utilize nozzle, while outlet pressure
of pump wheel changes, pressure
Fig.3-14 Combination regulation with
differential ejected by nozzle will change
and
spoon-type
tube
and
oil
inlet
valve
oil quantity ejected by nozzle is changed,
then
oil is cooled in heat exchanger.
While hydraulic coupler is operating, working liquid in pump wheel will produce
centrifugal press with the function of centrifugal force caused by rotary pump wheel, and it is
the same while turbine rotates, the centrifugal force will prevent working liquid from pump
wheel from entering turbine, only when centrifugal force in pump wheel is more than that in
turbine, working liquid can go from chamber of pump wheel to turbine, liquid in working
chamber of hydraulic coupler can form reflux and torque can be transmitted, hence, rotary
speed of pump wheel must be more than that of turbine while hydraulic coupler is operating,
this is necessary condition under which hydraulic coupler can transmit torque.
II. Regulation manner of hydraulic coupler

Under the condition of stationary rotary speed of pump wheel, the more working oil is,
the larger kinetic torque transmitted is, and the higher rotary speed of turbine is; and rotary
speed of turbine can be regulated via changing working oil quantity to suit the requirement of
feedwater pump.
There are basically two manners to regulate working oil quantity: to regulate entering
quantity of working oil; to regulate discharge quantity of working oil. The former can be
performed with additional working oil pump and regulating valve while working oil, which is
ejected by nozzle on the rotary inner bushing, is cooled in heat exchanger. The more circular
oil is, the higher-pressure rise in pump wheel is, and the more oil quantity ejected by nozzle,
and oil temperature up is suppressed caused by increase of circular oil. Thus, ejected oil isnt
utilized and this means loss of energy, so oil ejecting orifice is shrunk as small as possible
(generally calculated according to 0.5% power rating), ensuring that temperature up of
working oil is not more than 30, under the maximum speed differential ratio (commonly
22 turbine oil exists no problem while it operates under 6570 or even up to 95).
The most disadvantage is: while ejected oil quantity is too small, it restricts the request for
rapid speed down of feedwater pump under the condition of failure load shedding in unit
plant. The latter is performed via changing radial displacement of spoon-type tube in rotary
inner bushing. Because oil ring increases in inner bushing (next to inner bushing) along with
radius (so centrifugal force increases), oil pressure will be increased, so change of radial
displacement will result in change of speed head of oil inlet spoon-type tube. Therefore, the
higher spoon-type tube is raised (the larger radial radius is), the more oil quantity is ejected,
and the oil goes into heat exchanger depending on kinetic pressure of thrown oil and is cooled
there. Under the condition of failure load shedding and request of rapid speed down of
turbine, speed can be reduced via swiftly discharging working oil to oil storing box if only
radial displacement of spoon-type tube is increased. This is the most disadvantage of
regulation manner in which discharge oil quantity of working oil is regulated. Thus, it cant
response rapid speed up of turbine while load of unit plant is swiftly increased, so oil inlet
pump is arranged. Therefore, modern coupler adopts combination of above two manners in
order to raise rapidly speed, shown as Fig. 3-14. In the figure, load signal of boiler feedwater
quantity controls servo motor which changes rotary angle of transfer bar via rotary cam
because displacement of spoon-type tube isnt of linear relationship with discharge oil
quantity, thereby, the radial displacement of spoon-type tube is changed to control discharged
oil quantity. At the same time, the other end of transfer bar changes opening of oil inlet valve
(regulating valve) via cam on the bar, controlling oil-in quantity to coupler. While boiler
feedwater quantity is needed increasing, servo motor rotates cam to + and drives transfer bar
to rotate counterclockwise, dropping spoon-type tube and reducing oil discharge quantity;
simultaneously because of counter rotation of transfer bar, cam on the bar opens oil inlet
valve larger and oil-in quantity to coupler will be increased, accordingly working oil quantity
will be increased in coupler and rotary speed of turbine will be raised, meeting the request for
increasing boiler feed water; while boiler feed water is needed reducing, servo motor rotates
cam to , increasing oil discharge quantity and reducing oil-in quantity, so working oil
quantity will be reduced in coupler and speed of turbine will be reduced, fitting the request
for decreasing boiler feed water. The oil discharged by spoon-type tube enters oil inlet valve

and then reverts to oil box under coupler foundation through oil return line after it is cooled in
heat exchanger. While boiler feed water quantity is increased, on one hand, opening of oil
inlet valve is increased, on the other hand, resistance of oil discharge of spoon-type tube is
increased with the function of small spring at the bottom of oil inlet valve, so oil discharge
quantity is reduced, namely, oil inlet valve simultaneously acts as controlling oil discharge
and enter quantity, so working oil quantity of coupler can be regulated swiftly.
4 Operation and Maintenance of Hydraulic Variable Speed Feedwater Pump
Feedwater pump providing boiler feed water possesses the outstanding position in power
plant, its start, stop and operation conditions are directly related to safe & economic operation
of boiler, it should be paid enough attention.
I. Start and stop of feedwater pump
Most feedwater pump has to be warmed up before starting. If warmth is not enough, the
upper and lower shell will exist temperature differential resulting in hogback and distortion
due to unequal heat expansion. It is known through testing a variable speed feed pump that
coupler of main pump sinks 0.40.6mm while temperature differential reaches 5060. If
water pump is started under this condition, friction will be produced between kinetic and
stationary parts to spoil devices.
Important condition for warming pump enough is to adopt correct warming pattern, to
ensure necessary time and to control metal temperature up & differential with reason.
Warming pump splits into two patterns: normal warming and reverse warming. Water
used for warming pump comes from deaerator, enters pump via suction tube and drains in
front of outlet check valve, and this is called normal warming. Water used for warming pump
from outlet check valve enters pump through high-pressure connecting tube (with throttle
plate), and then discharges by warm-pump drain valve at inlet of pump, this pattern is called
reverse warming; they can be adopted in line with operation pattern and practical condition of
system. Note: Mustnt turn the pump in the course of temperature up, preventing the rotor
from seizing. Warm-pump valve is closed after normal warming is over and opened while
having other conditions. While reverse, warm-pump drain valve and water valve of
high-pressure connecting tube should be closed after starting.
Before starting feedwater pump, every system should be checked, including oil system,
cooling water system, sealing water system and feed water system, each valve should be in
ON or OFF position prescribed by rules.
Water should prevent from leakage and air should be exhausted via exhaust valve in
system in the course of filling feedwater pump with water and loading systems. Oil system of
feedwater pump should be put into operation before starting, oil pressure and temperature
should comply with prescribe of manufacturer, oil system should have no leakage and each
pad returns oil normally. After above operation, protection of feedwater pump should be put
into operation and combination switch of feedwater and oil pump should be closed.
While starting feedwater pump, operation switch is to be on. Note the return time of
starting time and check vibration of bearing pad, oil temperature, axial displacement, sealing
of shaft end and outlet pressure. If normal, stop auxiliary oil pump and open outlet valve. For
variable speed feedwater pump, position of spoon-type tube should be at that of low rotary

speed before starting and at outlet valve after starting, and it should be regulated gradually
and speed is raised according to outlet pressure. While flow reaches the permissible minimum
value, recirculating valve should automatically close in order to prevent high-pressure water
from scouring valves, throttle installation and tubes.
After feedwater pump is put into service, outlet & inlet wind temperature and return oil
temperature of each bearing pad should be noticed and regulated according to prescribed
range by rules. High-pressure feedwater pump mustnt be operated at the minimum flow
under requirement, even if very short time from starting to fixed speed. If flow is insufficient,
water in pump will be heated and boiled off, resulting in vibration caused by friction of pump
and possible damage to devices. So before feedwater pump is started and stopped, reliability
of action of recirculating valve must be ensured. Manual valves before and after recirculating
valve should be in ON position.
While feedwater pump is needed stopping, auxiliary lubricating oil pump should be
started and spoon-type tube is regulated to reduce flow, outlet valve should be closed while
flow is reduced to zero. Pump can be stopped after outlet valve is entirely shut down. If outlet
valve isnt entirely closed while stopping pump, water pump will reverse once check valve is
seized. After stopping feedwater pump, inlet valve of oil cooler and air cooler of motor
should be shut down. If feedwater pump acts as standby, auxiliary oil pump should be kept
operating and dampproof heater of motor should be put into operation. Auxiliary oil pump
can be stopped after working for a period of time (generally about 10min) when it is needed
repairing.
II. Operation and maintenance of feedwater pump
During operation of feedwater pump, inlet pressure, inlet water temperature, current of
motor, pressure of balance chamber, pressure of lubricating oil, oil level of oil box,
temperature of bearing, leakage condition of mechanic sealing or padding sealing, wind
temperature and vibration of motor and so on should be checked mainly. Normal pressure of
balance chamber should be 0.050.2MPa more than that of inlet. If pressure of balance
chamber rises and exceeds 0.95Mpa, the cause should be found out. Pressure of lubricating
oil should be kept at 0.1 0.24Mpa, and pressure value can be regulated through
pressure-relief valve. The cause should be found out if pressure of oil is reduced, except for
leakage of oil system or abnormal operating of oil pump, it is usual that oil screen is blocked.
Outlet oil temperature of lubricating oil cooler should be 3546. Metal temperature of
bearing should not be more than 65, if it reaches 70, alarm single should be given, if up
to 75, pump should be shut down emergently.
After new water pump operates 200h for the first time, lubricating oil should be
discharged completely and be replaced with new oil, then replacing oil every 1000h. While
replacing oil, the whole lubrication zone (including bearing) should be cleaned out with
gasoline or benzene. Oil should be supplied in time according to oil level condition of oil
box.
While turbine sheds load emergently and is shut down, pressure of deaerator should be
kept. If pressure is dropped too swiftly and water temperature is dropped relatively, each

section of feedwater pump is rapidly shrunk, resulting in leakage of joint section. So inlet
water temperature drop of pump should not be more than 1/min.
Feedwater pump should be avoid frequent start and stop, especially when feedwater pump
adopts balance disc to balance axial trust, balance disc may touch and attrit while pump starts.
Rotor will swing to inlet if axial trust cant be balanced when pump is from start to stationary
speed; namely, outlet pressure is from zero to stationary pressure.
Permissible times of continuous start of feedwater pump should be executed according to
operation rules of motor. If continuous starting times are overmany or time interval is short,
motor will be ruined. Motor and its auxiliaries should be checked and motor insulation should
be measured if it trips, and it can be started again if everything is ok. If the second start is
unsuccessful, the cause should be found out and be eliminated, the third start should be done
after 1h. Rotary speed of variable-speed feed pump can be regulated, it consists of booster
pump, motor, hydraulic coupler and main pump. Booster pump is directly driven by one end
of motor shaft while the main pump is driven via hydraulic coupler driven with acceleration
gear by the other end of motor shaft. Drive wheel (pump wheel) and driven wheel (turbine)
composes a chamber, namely operating chamber of hydraulic coupler. Operating chamber is
full of working liquid, generally turbine oil. Rotary speed of main pump varies with working
oil quantity in hydraulic coupler. Oil quantity is regulated with spoon-type tube. Change of
position of spoon-type tube can result in rotary speed of main pump. Oil traveling to
hydraulic coupler is called operating oil while oil traveling to variable speed box and bearings
of pumps is called lubricating oil. Compared with feedwater pump with stationary speed,
feedwater pump with variable speed possesses the following properties on operation:
(1) Feedwater flow and pressure are regulated with change of rotary speed, not with throttle
of valves.
(2) Regulating test should be done with spoon-type tube before starting pump, spoon-type
tube is regulated manually to check its flexibility firstly and operated in the main
control room, indication of spoon-type tube position on meter panel should confirm to
local position.
(3) Booster pump and main pump should be warmed up simultaneously. For feedwater
pump with mechanic sealing, inner air should be exhausted adequately.
(4) Middle tap on the main pump acts as desuperheating water of boiler reheater, the
desuperheating water valve should be shut before starting, and it will be opened
according to the requirement of boiler after starting. It is reverse while stopping pump.
(5) During operation of variable speed pump, oil temperature of working oil cooler should
be monitored except for temperature of lubricating oil. Spoon-type tube position of
variable feedwater pump as linking standby should follow up automatically that of
operating feedwater pump. If automatic following cant be put into operation,
spoon-type tube can be put above 40%. So water level of boiler drum cant be too much
fluctuant while operating pump trips.
(6) While two variable speed pump operates in parallel, the differential between rotary
speeds should be the minimum, preventing too much deflection of flow.
(7) Temperature of discharged oil should not be 130, preventing fusible plug from
melting.

5 Automatic Regulation and Protection of Feedwater Pump

I. Automatic regulation of feedwater pump.
Automatic regulation of feedwater pump can usually be split into two main parts: the
minimum flow automatic regulation and feed water automatic regulation.
1. The minimum flow automatic regulation
Feedwater pump is generally prescribed a permissible minimum flow (about 25%30%
of rating) while designing, if operating flow is less than the minimum, feed water will be
boiled off due to rubbing heating, and water pressure in pump will be unstable, resulting in
swing of balance disc or rather friction with balance foundation, if severely, disc foundation
will be ruined or pump is blocked; Performance curve of centrifugal pump is flat in the range
of small flow, or of hump type, so pressure pulsation will occur and results in pant vibration
phenomenon because of which water pressure is suddenly high or low and flow is suddenly
heavy or low, in order to avoid this phenomenon, previously weighted automatic bypass valve
(generally combined with outlet check valve) and recirculating tube were adopted. While
flow is less than the minimum, standby valve overcomes the gravity of weighted hammer and
automatically opens with the help of growth of outlet pressure of water pump, a part of feed
water returns to deaerator or inlet of water pump via recirculating tubes. However, long dated
practice proved that this method is not ideal because the recirculating flow controls the switch
of standby valve only via the number of flow pressure drop and its setting value is difficult to
control. And then outlet pressure of water pump is very high and pressure drop is very large
with the condition of low flow, resulting in serious wear of standby valve which cant close
completely under the normal operation, leading no needed leakage and loss of power, and
efficiency of water pump is reduced. Hence, modern high-speed pump is equipped with
recirculating valve on the recirculating tube instead of weighted standby valve and multistage
pressure-relief orifices as throttle equipment before the valve. Recirculating valve is opened
via electromagnetic switching pneumatic switch by electric-contact signal of the minimum
permissible flow in outlet flow meter, ensuring the minimum flow through water pump as
well as avoiding wear of recirculating pump.
2. Feedwater pump of high pressure and capacity unit adopts variable speed regulation, its economy is
better than throttle regulation, but, variable speed regulation exists the difference between two
sections regulating scheme and one section, boiler feedwater regulator gives the signal in the
former, so opening of feed regulating valve is changed firstly for water to suit the need immediately,
then rotary speed of feedwater pump is changed via differential pressure regulator according to
changing value of differential pressure of regulating valve (it is caused by changing of opening of
regulating chamber), followed by outlet quantity of feedwater pump correspondingly until it is equal
to feed water quantity needed by boiler, simultaneously pressure differential of regulating valve is
restored as the constant value, the regulation is performed and operation will be resumed under the
new balance condition.

In above regulating scheme, feed water can rapidly adapt the need of boiler through
changing opening of regulating valve while load is changed, avoiding lack or fill of water
caused by delay of regulation. But, the rapid adaptability is gotten with stationary differential
pressure value of regulating valve, and it results in stationary loss in operation. Hence, the
modern developing tendency is to cancel stationary differential pressure value of regulating
valve, feedwater regulator (or three impulse pulse) gives off signal to directly change rotary

speed of regulating pump, only having one section regulation course, consequently
economy of regulation of feedwater system is enhanced.
Analyzing dynamic equation of hydraulic coupler drive variable speed feedwater pump, it
is known that dynamic time constant mainly rests with inertia of changing of oil quantity in
working chamber of hydraulic coupler, and this is relative with structure and regulating
manner of hydraulic coupler. Because device inertia is small while hydraulic coupler and
feedwater pump change torque, its impact on the whole dynamic time constant is less. It can
adapt the need to feed water of boiler in time from theoretical calculating value. In order to
reduce throttle loss of feedwater system and increase operation economy, the scheme one
section regulation is feasible.
II. Protection of feedwater pump
Feedwater pump is a kind of important auxiliary device with complex structure; its safety
and reliability should be ensured in operation. So high-capacity feedwater pump is equipped
with many protection equipments, mainly as follows:
(1) Feedwater pumps act as linking protection: once operating pump trips, standby pump
can automatically put into operation to ensure that boiler feed water isnt interrupted.
(2) Protection of low oil pressure: feedwater pump adopts sliding bearing and forces oil
circulation. So lubricating oil pressure should be kept as turbine. If oil pressure is too
low, oil film will be broken, resulting in burning of pad. Protection of low oil pressure
means that lubrication pressure links auxiliary oil pump in the prescribed value,
maintaining oil pressure normal, if oil pressure is too low to maintain, the protection
will link main pump to trip, ensuring that bearing pad isnt ruined.
In addition, for hydraulic coupler, while working oil pressure is low, auxiliary working
oil pump should automatically link and start, ensuring normal working oil pressure.
(3) Protection of high oil pressure: if oil pressure is too high, lubricating oil will leak from
oil baffle, that isnt safe either. Protection of high oil pressure can link to trip or lock
auxiliary lubricating oil pump while lubrication pressure is more than the prescribed
value. In addition, the protection can link to trip or lock auxiliary working oil pump
while working oil pressure is too high.
(4) Protection of high bearing temperature: some feedwater pumps, especially imported, are
equipped this kind of protection. While temperature of bearing pad reaches the
prescribed value, alarm signal will be sent out; if its temperature goes up continuously
to the value of stopping pump, the protection will link to trip feedwater pump, ensuring
the safety of bearing.
Except for above, high-capacity feedwater pump are equipped with: main pump starting is
locked if inlet valve isnt opened; low pressure of outlet manifold locks opening of outlet
valve, pump will trip if pressure differential of inlet screen of feedwater pump is large; an
alarm will be given and pump will trip if water level of deaerator is low; protection of low
flow of booster pump.

section7

LP Heater System Specifications

0-1 LP heater system specifications

1

Overview
1.1 The LP Heater System Specifications only applies to the Indonesia 2300MW
Coal-fired Unit Project.
1.2 In the Project there are set up two 300MW steam turbine units, which adopt
eight-grade steam extraction, of which grades 5, 6, 7, and 8 are used for the four LP
heaters respectively. In the water supply and heat recovery system, the LP heaters
are numbered as 5#, 6#, 7#, and 8# based on the sequence of extraction pressure
from high to low (see Figure 0-1-1 for the heat balance diagram), of which LP
heaters 7# and 8# share the same shell (called conjunction LP heater).
1.3 The system layout for LP heater is detailed in Figure D300N-005019Q, and the
system diagram is shown in Figure 0-1-2. In the system we only provide the
balance vessels and magnetic liquid level displays. The LP heater system diagram is
provided for information only, and the concrete arrangement and valve type
selection depend on the project.
1.4 The installation, commission, and overhaul of LP heater proper are detailed in
M706-021002BSM JD-1600-I LP Heater Installation and Operating Specifications,
M708-017002BSM JD-600-III LP Heater Installation and Operating
Specifications, and M709-017002CSM JD-600-IV LP Heater Installation and
Operating Specifications. In the system specifications, the installation, commission,
and overhaul for LP heater proper are not described.

System composition
The system consists of the LP heater proper, feed pipe, normal drain line, accident drain line,
extraction line, and water level display alarm and control equipment.

2.1 All LP heaters are of horizontal U-bend structure with a built-in drain cooling
section, of which the conjunction LP heaters of 7# and 8# is set up at the condenser
throat.
2.2 In the system the water supply bypasses consist of both big and small bypasses. LP
heaters 5# and 6# adopt small bypasses, and they can step out solely; LP heaters 7#
and 8# adopt big bypasses, but they can only step out simultaneously.
2.3The normal drainage for LP heater adopts a step-by-step gravity flow mode, that
is, the drained water from LP heater 5# flows to LP heater 6#, and then to LP heater
7# and then to LP heater 8#, and then to LP heater 8#, and finally to the condenser.
2.4 Accident drain lines are set up for every LP heater. Under accident conditions or
low-load working conditions, the drained water can directly enter into the drain

flash tank or condenser.

2.5 For every LP heater there are set up extraction pipes, which are used to extract the
incondensable gas in the LP heater shell side.
2.6 Each LP heater is equipped with three single-chamber balance vessels, which
output the water level changes in the LP heater. The changes are translated into
4~20mA electrical signals through a differential pressure transmitter and
transmitted into the DCS. Then the DCS controls the opening of the drainage
control valve of LP heater, which limits the water level of the LP heater within a
normal water-level fluctuation range. The differential pressure transmitter and
control valves shall be provided by the project as support devices, and the
connection is shown as in Figure 0-1-3.
2.7 Every LP heater is equipped with a magnetic flap liquid level meter, which can
display the variation of the water level in a LP heater and is equipped with a liquid
level switch. The meter can output 4~20mA electrical signals for long distance
transmission as alarm signals. The connection is shown in Figure 0-1-3.
3

System installation requirements

3.1 When the drainage control valve of a LP heater is fitted on a normal drain line, it
shall be set up by approaching the drainage entry of the next grade LP heater. A
bypass shall be set up for the drainage control valve for the convenience of
overhaul. We recommend adopting not steam-liquid two-phase flow equipment but
drainage control valves to control the water level of LP heater.
3.2 A accident drain control valve can be set up in a accident drain line. With regard to
the arrangement of a accident drain line, we recommend that sole pipes leading to
the condenser or drain flash tank shall be set up for the accident drain of each LP
heater, and we do not recommend to combine the accident drain pipes to the drain
flash tank or condenser. For the accident drain of LP heater 8#, when the drained
water goes to the drain flash tank, the pressure of the tank can not be greater than
that of LP heater 8#.
3.3For the continuous extraction pipe of each LP heater there shall be separate
pipes leading to the condenser, and connecting all pipes in series or using one main
pipe leading to the condenser is not allowed. It is best that the exhaust line is
straight, so that the blocking from condensate accumulation and the resulting
influence on the extraction of LP heater can be avoided. There shall be thermal
insulation devices in the continuous extraction pipes to make it the least possible to
block the extraction pipe by water.
3.4 There are stop valves set up in the continuous extraction pipes, and the users can
reduce the extraction heat loss through adjust the valves opening. Setting up
throttling orifice plate is also a good option, but when the plates are laid out, it shall
be avoided that water is accumulated in both sides of the plates and affects the

exhaust.
3.5 The start extraction pipe near the shell of a LP heater can not be connected to the
continuous extraction pipe of the LP heater.
3.6 In the feed water pipes there are set up safety valves with a set-pressure of 3.8MPa.
The safety valves shall be mounted near the LP heater proper as much as possible.
Beside LP heaters 5# and 6#, there are set up safety valves with a set-pressure of
0.6 MPa. In the discharge outlets of the safety valves there can not be no back
pressure.

To deaerator

Figure 0-1-1 Indonesia project T-MCR working condition heat balance diagram

opening of steam turbine, including the pipe loss.

Note 2: The steam admission pressure of LP heater in the figure is the pressure in the extraction

Note 1: Flow rate, enthalpy, temperature, pressure

To condenser

pump
pump

From condensate

The incondensable gas extracted from LP heater

5# entering into the condenser solely

Start or accident drain water of LP heater 5#

entering into the drain flash tank solely

The incondensable gas extracted from LP heater

6# entering into the condenser solely

Start or accident drain water of LP heater 6#

entering into the drain flash tank solely

The incondensable gas extracted from LP

heater 8# entering into the condenser solely

The incondensable gas extracted from LP

heater 7# entering into the condenser solely

Water supply
(from
condensate
pump)

Start or accident drain water

of LP heater entering into the
drain flash tank solely

Start or accident drain water

of LP heater entering into the
drain flash tank solely

direction

Drained water
7# drainage (to 8# drainage inlet)

Figure 0-1-2 LP heater system diagram

Magnetic liquid level

display connection sketch

Balance vessel connection sketch

Connected to the
LP heater

Connected to the
LP heater
High level cut off

High water level

Alarm for high water level

Single-chamber
balance vessel
High water level
Normal water level
Low water level

Connected to the
LP heater

Alarm for low water level

Connected to the
LP heater
Differential
pressure
transmitter

4~20mA electrical signal

Figure 0-1-3 Magnetic liquid level display and balance vessel connection sketch

Chapter4
section1

Specification for Lubricating system

0-1 Specification of Lubricating System

1 Overview
The lubricating system of steam turbine adopts the oil supply mode of main oil pump-oil jet. The main
oil pump is directly driven by the main shaft of steam turbine. Its outlet pressure oil drives the oil jet to
engage in operation. The lubricating system is mainly used for serving the following purposes: providing
lubricant to each bearing and jigger device of steam turbine generator set, some lubricant for the
regulating system and protection system, sealing oil source for the hydrogen seal system of generator,
adequate lubricant source for the shaft pushing up system of main shaft, cooling oil for the rotor coupling
of steam turbine generator set. The system also has the smog exhausting function for oil return. The
working medium of system is ISO-VG32 turbine oil.

2 System Composition
The system mainly consists of main oil pump, oil supply jet, lubricant supply jet, AC lubricant pump, DC
emergency oil pump, spill valve, concentrated oil box, oil smoke separator, oil level indicator, single flap
check valve, double-flap check valve, oil cooler, switch valve, shaft pushing up device, low lubricant
pressure shutoff device, set oil pipeline, electric heater, oil hydrogen separator (supplied by the motor
factory) as well as connecting lines, monitoring instruments, etc. Refer to the attached diagram for the
system diagram.

3 Brief Introduction about Main Devices in System

3.1 Main Oil Pump
The oil pump is of single-stage double suction centrifugal type, which is installed in the front bearing
box of steam turbine set. The pump shaft and main shaft of steam turbine adopt rigid connection that is
directly driven by the steam turbine rotor. It provides power oil for the oil supply jet and lubricant oil jet.
Major parameters are in the table below.
Oil Pressure at Suction Port
of Main Oil Pump

0.090.12 MPa

Oil Pressure at Outlet of Main

Oil Pump

1.75-1.85 MPa

Rated Speed of Main Oil

Pump

3000 r/min

Flow

>3000 L

Power Consumption

200 kw

Refer to Specification of Main Oil Pump for the detailed description (M109-511000ASM)

3.2 Oil Jet

The oil jet consists of oil supply jet (No.I) and lubricant supply jet (No.II). The jet nuzzle is porous.
There is a plate in the suction chamber of oil jet to stop the reverse flow of sucked oil flow. See the table
below for the characteristic parameters:
Name

Outlet Pressure

Outlet Flow

Oil Supply Jet (No. I)

0.21 MPa

3447 L/min

Lubricant Supply Jet (No.II)

0.31 MPa

3600 L/min

Refer to Users Manual for Oil Jet for the detailed description (D300N-505000ASM).
3.3 Concentrated Oil Box
The oil box adopts a concentrated mode. That is to locate various devices in the lubricating system in the
oil box, such as AC lubricant pump, DC emergency oil pump, single-flap check valve, double-flap check
valve, oil smoke separator, oil level indicator, oil jet, electric heater, spill valve, internal pipeline, etc. It
facilitates operation and monitoring, simplifies the arrangement of power station and is convenient for
fireproofing. During normal operation, the capacity of oil box is 30.6 m3
The details about the concentrated oil box can be found in the Operation Instruction of Concentrated Oil
Box (D300N-501000ASM).
3.4 AC Lubricant Pump
The pump is single-stage single-suction vertical electric centrifugal oil pump and the model is 125LY-35-4.
It supplies sufficient lubricant to each bearing, jigger and shaft pushing upof steam turbine set during the
start-up and shutdown as well as when the lubricant pressure is lower than 0.05MPa. The drive motor is
explosion proof motor. The characteristic data are as follows:
Delivery Lift

35 m

Speed

2950 r/min

Motor Power

45 kw

Flow
Power Supply

3000 L/min
AC 380V

The details can be found in the Installation and Operation Instruction of Model 125LY-35-4 Lubricant
Pump supplied with the machine.
3.5 DC Emergency Oil Pump
The pump is single-stage single-suction vertical electric centrifugal oil pump and the model is 125LY-23-4.
It is only used during the shutdown of steam turbine set. It supplies lubricant to each bearing when the
lubricant pressure is lower than 0.04MPa or the AC power is down to ensure the safe shutdown of steam
turbine set. The drive motor is DC motor. The characteristic data are as follows:

Delivery Lift

23 m

Speed

3000 r/min

Motor Power

22 kw

Flow
Power Supply

2600 L/min
DC 220V

The details can be found in the Installation and Operation Instruction of Model 125LY-23-4 Lubricant
Pump supplied with the machine.

3.6 Spill Valve

The spill valve is of spring-type, which is installed in the oil box and located on the mother pipe of
lubricant at the rear of oil cooler outlet. It is used to adjust the pressure of lubricant in the mother pipe to
ensure the inlet pressure of bearing and keep the flow stable so as to sufficiently and reliably supply
lubricant to the entire lubricating system. The characteristic data are as follows:
Normal
Oil
Spill Flow

100 L/min

Min. Oil Spill

Flow
Max. Oil Spill
Flow

Normal Oil Spill

Pressure

0.196 MPa

0 L/min

Min. Oil
Pressure

Spill

0.176 MPa

500 L/min

Max. Oil
Pressure

Spill

0.255 MPa

The details can be found in the Operation Instruction of Spill Valve (M536.X01SM).

3.7 Oil Cooler

There are two sets of oil coolers in the lubricating system, which are tubular type heat exchangers. The
model is YL-180-2. When one is running, the other is for backup. It uses circulating water as the cooling
medium, which takes away the heat resulted from the friction of bearing. The characteristic data are as
follows:
Cooling Area

180 m2

Inlet
Oil
Temperature

60

Cooling Water
Capacity

336 t/h

Outlet
Oil
Temperature

45

Cooling Water
Capacity

180 t/h

Cooling Water
Temperature

33

The details can be found in the Installation and Operation Instruction of Model YL-180-2 Oil Cooler
(M720.X07SM).
3.8 Oil Smoke Separator
There is a set of fume extractor in the system, which integrates the smoke discharge fan and the oil smoke
separator. It is vertically installed on the cover of concentrated oil box. It creates negative pressure in the oil
return tube, oil box and oil return chamber of each bearing box to ensure smooth oil return and separate the
mixture of oil smoke. It discharges the smoke and sends the oil drops back to the oil box to reduce
environmental pollution and ensure the safety and reliability of oil system. At the same time, in order to
prevent too high negative pressure in the chamber of each bearing box, the fume extractor is designed to
accommodate a set of air doors to control the smoke discharge and maintain the negative pressure in the
bearing box at 1Kpa. Otherwise, it will cause the leakage of shaft seal of steam turbine, thus the steam will
flee into the bearing box and the water will get into the oil.
The details can be found in the Operation Instruction of Oil Smoke Separator (M519.X02SM).
3.9 Switch Valve
The switch valve is of cylindrical plate type structure, which is installed between the two oil coolers. It
switches the two oil coolers and parallel them if necessary. The characteristic data are as follows:

Model

FQ-5-250-1

Nominal Diameter

250

Working
Pressure

0.4MPa

Max.
Working
Temperature

80

The details can be found in the Operation Instruction of Model FQ-5-250-1 Switch
Valve(M765.X02SM).
3.10 Electric Heater
There are 6 electric heaters installed in the concentrated oil box with total power of 60KW and voltage of
AC 220V. If the oil temperature is lower than 10 before the start-up, the heaters are switched on; when
the oil temperature rises to 35, the heaters are turned off.
3.11 Shaft Pushing up Device
This device is mainly used to supply high pressure oil to each bearing during the start-up, shutdown and
jigger, which forcibly pushes up each shaft neck and forms static pressure oil film between the neck and
bearing to eliminate the dry friction between the neck and bearing.
The details can be found in the Operation Instruction of Shaft Pushing up Device (D300N-601000ASM).

Operation of Lubricating System

4.1 Start-up State

Before the start-up of system, it is necessary to confirm whether the oiliness meets the cleanliness
requirement for the start-up. The oil level in the oil box shall be at the highest oil level. Switch off the
cooling water valve for the oil cooler. Heat the oil and start the AC lubricant pump when the oil
temperature meets the start-up requirements for the oil pump. Switch on the smoke discharge fan to
forcibly circulate the lubricant. When the oil temperature reaches 35, start the cooling water valve of
oil cooler to get the oil cooler engaged, then start the oil pump of shaft pushing up device and adjust the
pushed up height of each bearing neck to the designed valve. After these, it is ready to put the jigger into
operation. When the set speed reaches 1200 r/min, the shaft pushing up device can be removed (the
power plant can also regulate the speed of shaft pushing up device according to its operational
experience). During the period of raising speed, the AC lubricant pump shall work normally and provide
lubricant to the set. When the set reaches 3000 r/min and gets stable, the AC lubricant pump can be
stopped. Finally, adjust the spill valve to keep the oil pressure in the mother pipe within the set value.
4.2 Normal Operation State
During normal operation, all the high pressure oil in the system is supplied by the main oil pump located
in the front bearing box. The high pressure oil from the main oil pump serves as the dynamic oil source
of oil jet. The oil jet sucks the oil from the oil box. No. I oil jet provides the oil source for the main oil
pump while No. II oil jet supplies oil to each bearing, jigger and hydrogen seal system for the purposes
of lubricating, cooling and sealing. During normal operation, it is necessary to adjust the cooling water
flow of oil cooler according to the oil temperature of lubricant mother pipe so as to control the inlet oil
temperature of bearing within the set value.
4.3 Shutdown State
When shutting down the set under normal or emergent ( tripping ) condition, the AC lubricant pump
shall be started before the speed of steam turbine drops to 2850 r/min; when it drops to 1200 r/min, the
shaft pushing up device shall be started. If the AC lubricant pump fails to react, the DC emergency oil
pump shall be combined to ensure safe shutdown. During the jiggering, the shaft pushing up device and
AC lubricant pump can only be stopped after the jigger is stopped.

5 Introduction about Oil Return System

The system adopts a set pipeline with 2 mother pipes of return oil. The return oil of front bearing box
goes to the set pipe through two oil return tubes at the lower part of front bearing box and gets back to
the dirty oil compartment in the oil box. The return oil from the other bearing boxes goes to the set pipe
through respective branch tubes and gets back to the dirty oil compartment in the oil box. The oil drain
from the shaft pushing up device returns to the oil box.
The mother pipe of return oil shall be installed towards the direction of oil box with a gradually
descendant grade of slope that is 1%~3%. The return oil in the return oil tube shall be half full to
facilitate the oil smoke in each bearing box to flow to the oil box through the space over the oil surface.
Then the oil smoke is separated by the fume extractor and discharged into the atmosphere.
The return oil from the bearing of generator shall go through oil hydrogen separation before it is
connected to the mother pipe of return oil. Otherwise, it will endanger the set.
The return oil from each bearing box flows back to the dirty oil compartment in the oil box. After it is
filtered, it goes to the clean oil compartment in the oil box. There are oil level indicators separately
installed in the dirty and clean oil compartments. The unobstructed degree of sieve can be judged
through the difference of oil levels in the two oil level indicators. When the difference exceeds 100mm,
the sieve shall be cleaned.

6 Maintenance of Lubricating system

6.1 During normal operation, the normal outlet oil pressure of main oil pump is 1.80.05MPa. When it
drops to 1.65MPa, the AC lubricant pump shall be started. The root cause shall be investigated and the
machine shall be ready to shut down.
6.2 There shall be interlock protection among the pressure signals of AC lubricant pump, DC emergency
oil pump and lubricant mother pipe. When the steam turbine is in normal operation, the pressure of
lubricant flowing into the bearing shall be 0.08~0.12MPa. When the pressure drop at the midsplit surface
of bearing in the steam turbine reaches 0.049 MPa, the alarm will be turned on and the AC lubricant
pump will be started. After the start-up of AC lubricant pump, if the pressure drop of lubricant continues,
the brake shall be switched off. During the shutdown, when the pressure drop of lubricant at the midsplit
surface of bearing in the steam turbine reduces to 0.0392MPa. The DC emergency oil pump shall be
started and the cause of oil pressure reduction shall be checked immediately. Every half month, the test
of interlock protection with low oil pressure shall be performed.
6.3 Lubricant Temperature
The system adopts ISO-VG32 steam turbine oil. The set bearing requires the inlet lubricant temperature
to be 40~46. The normal temperature of return oil of bearing shall be less than 65. During normal
operation, the cooling water flow for the oil cooler shall be adjusted according to the lubricant mother
pipe to ensure the inlet oil temperature.
6.4 Oil Level in Concentrated Oil Box

Before shipping, the middle position between the highest and lowest oil levels shall be set as the zero
position according to the oil level requirement on the drawing of concentrated oil box. It will be the
normal oil level for the oil level indicator. During normal operation, the highest oil level is +250mm and
lowest 250mm. The first fill in the concentrated oil box shall be about 35m3.
Before the normal start-up, the oil level in the oil box is at the highest oil level. When the nested oil
pipeline with longer horizontal section is used, the operating oil level in the oil box will be lower than
the zero position. It is a normal phenomenon.

Requirements for Lubricating System

7.1 The installation requirements for the lubricating system shall meet Article 248-278 in SDJ53-83-- Technical Specifications for Power Construction and Acceptance (Steam Turbine Set Part) and
Technical Provisions for Lubricating System Installation set by the manufacturer.
7.2 The requirements for the oil circulating rinsing of lubricating system shall meet Article 533-547 in
SDJ53-83--- Technical Specifications for Power Construction and Acceptance (Steam Turbine Set
Part) and Technical Provisions for Lubricating System Rinsing set by the manufacturer.

D300N-000152ASM

Lubricant for Jigger

Main Oil Pump

Low Pressure Cylinder

HIP Cylinder

Generator

Technical Requirements

To Security Part

1.

Cooling Oil for Coupling 38X2.5

The details about the connection between

the lubricant supply pipe and the pipeline
of hydrogen seal system of generator part
(supplied by the motor factory) are in the

Cooling Oil for Coupling 38X2.5

diagram of hydrogen seal oil system of

generator of DFSTW.
2.

The return oil from the generator and

hydrogen seal system must go through
dehydrogenization before entering into the
system.

3.

Oil Hydrogen
Separator
( supplied by the

Set Oil Pipeline

When filling the oil box to the maximum

oil level, the external pipeline of oil box,
oil cooler and oil purifying device shall be
filled first.

4.

The filter cloth of movable sieve shall be

To Hydrogen Seal System

installed during the oil circulation and

Oil Level Indicator

removed after the oil quality becomes

good.

Shaft Pushing up Device

5.

The drawing number of each part in the

diagrams for each project is in relevant
project delivery list.

6.

The details about the pipe connection

between the system and the lubricant

Electric Heater

storage and disposal system can be found

Concentrated Oil Box

in the oil disposal system diagram. The

lubricant storage and disposal system shall
be purchased by customers.

Water Filter

Spill Valve

To Vacant Side of Generator

Circulating
Cooling Water

Oil Charge Valve of Oil Cooler

Oil Suction Interface of Seal Oil Pump

Summary of Air Pressure Measuring Points

Oil Jet
Oil Cooler

Oil Cooler

No.

Point Name

Qty

Switch Valve

DC Emergency Oil AC Lubricant Pump

Stop Valve

Oil
Pipeline

Oil
Suction
Pipeline of Main
Oil Pump

Drain Lubricant
Pipeline

Check Valve

Three
Valve

Way

Spill Valve

Explanatory Legend
Air Sm
Concentric
Reducer

Peep Tube

Centrifugal
Oil Pump

Radial
Oil Jet

Sieve

Throttle Plate

Thrust
Bearing

Exhaustion
Air

Slide One-way
Valve

to Drain

Oil Supply Pipeline Movable

for Shaft Pushing up Sieve

Smoke
Discharge Fan

Pressure
Gauge

Thermometer

Meter

Range

Lubricant
Storage
and Disposal System

Pressure
Oil Pipeline

Point

Outlet Pressure of DC Lubricant Pump

0-0.5MPa

Outlet Pressure of AC Lubricant Pump

0-0.5MPa

Outlet Oil Pressure of Main Oil Pump

0-0.5MPa

Outlet Oil Pressure of Oil Supply Jet

0-3.0MPa

Outlet Oil Pressure of Lubricating Jet

0-0.5MPa

Outlet Oil Temperature of Oil Cooler

0- 100

Inlet Oil Temperature of Oil Cooler

0- 100

Check Valve

Low Lubricant Pressure Switch Temperature

Pressure
Alarm or Switch

supplied with shaft

pushing up device

Outlet Oil Pressure of Oil Pump for

Shaft Pushing up

0-20.0MPa

supplied with shaft

pushing up device

0-1-10

section2
Description of integrated oil tank
0-1 Description integrated oil tank
1. Integrated oil tank general
The used oil capacity and oil tank volume in oil system increases as the unit capacity. In order to
make the equipment arrangement in oil system compact and convenient for installation, operation and
maintenance, this oil tank adopts integrated type to improve the safety and reliability of operation for
supply oil system of unit.

2.

Brief introduction of structure

The integrated oil tank is rectangle vessel welded by section bar, such as steel sheet, I beam. In order
to withstand the self-weight and oil weight of oil tank as well as the weight of equipment, supporting
plate is welded on the bottom of case, and reinforcing rib plate is welded on the external side and
external end face, I beam is welded on the cover board to strengthen the steel rigidity and ensure the
equipment on the cover board operating normally. The guardrail is provided at the top of oil tank.
Two cylindrical strainers are provided in the oil-return chamber inside oil tank to prevent the clean oil
zone of oil tank from foreign matter. This filter cartridge is cylindrical type with inner and external
layers to ensure the clean oil zone free of foreign matter during cleaning the inner filter cartridge. The
filter area of external filter cartridge shall not be cleaned during the unit overhaul. The bottom of
external filter cartridge connects with the glass liquid-level gauge outside the oil tank to monitor the
level and oil quality state and remove the impurities.
One AC lube oil pump, one DC emergency oil pump are provided on the cover board of oil tank (see
drawing 0-1-2). The oil level height in the oil tank shall be enough to ensure the suction inlet of two
oil pumps immerging sufficient depth under the oil surface so that the oil pump has sufficient suction
height to prevent the oil pump from cavitations erosion. The return oil shall return to oil tank through
pipe at normal oil level before strainer to minimize the disturbance caused by the return oil. The air
and impurities carried by return oil can be separated from oil through long return oil distance to
ensure the oil with well quality.
Demister is equipped at the top of oil tank and integrates the fan with separator. The fume discharge
outlet is upwards to extract the fume from oil tank and separate the oil and fume. The demister makes
the oil without deposit back to oil tank, and the oil drain piping drain the oil with deposit to slush tank.
In order to monitor the oil level in oil tank, one ultrasonic oil level detector is provided at the top of
the oil tank.
In addition, the interface of tube-in-tube oil pipe is mounted at the top cover of oil tank. This oil pipe
is divided into two ways, one is tube-in-tube oil pipe to front bearing housing and anther is
tube-in-tube oil pipe to rear bearing housing and motor bearing. This design will prevent the various
pipes in tube-in-tube pipe twist each other and make the oil flow smoothly as well as with small oil
resistance loss.
I# oil injector and II# lube injector, oil overflow valve, single/double tongue check valve on piping
and inner pipe are equipped inside the oil tank. 6 electrical heaters and 2 thermocouples are equipped
on the oil tank. Start the electrical heater in case the oil temperature is less than 20 and start AC

lube oil pump while heating the oil to 20.

Various interfaces and emergency blow-down port, oil overflow port of oil tank and interface for
flushing device connected with other oil system equipment are equipped at the side and end of oil
tank (see drawing 0-1-3).
The measuring pressure hole is equipped at the cover of oil tank to connect with the various interfaces
on the control instrument cabinet box. The instrument cabinet is installed in integrated oil tank on site.
Monitor and control the operation of oil system and various equipments.
The tube clip is equipped on the cover of oil tank to fix the monitoring tube of oil pressure and
prevent it from vibration.
The manhole cover plate on the cover of oil tank is push-draw type to make the maintenance
personnel entry the oil tank easily for check.

3. Operation of integrated oil tank

The max operating volume of this oil tank is 35m3, and the normal operating volume is 30.6m3, the
net weight of oil tank is of 20000kg. The oil level of the tank during shutdown shall be higher than
that during the unit normal operating. The increased value of oil level is based on the oil storage
capacity of oil supply pipe and return oil pipe at actual oil level above. The majority oil in the oil
supply pipe and oil return pipe return oil tank. The oil level variation can be observed through the use
of ultrasonic oil level detector located at the top of the clean oil zone of oil tank. The oil level in the
clean oil zone is kept at between low oil level and high oil level during the unit operating normally.
Certain negative pressure is formed in the return oil pipe and oil tank by the extraction function of fan
to facilitate the return oil return oil tank at once and prevent the oil or fume from overflowing, make
the whole lube system operate at safe state.
The negative pressure in oil tank shall be kept within the negative 1kPa. The oil temperature in tank
shall be below 65 during operating.

4. Maintenance of integrated oil tank

4.1 The oil pump, fan and other equipment of oil system shall be kept at well operating state.
4.2 The inner surface of oil tank shall be cleaned by cloth instead of cotton yarn or other floss.
4.3 Forbid impurities and solid matter into oil tank to avoid the great accident occurring.
4.4 The oil tank shall be sealed to prevent the air entry and form positive pressure.
4.5 Forbid the fire around the oil tank.
4.6 The strainer of oil tank shall be cleaned periodically.
4.7 The integrated oil tank shall be cleaned and checked completely during the unit overhaul.
4.8The operation, maintenance and inspection of equipment located on the oil tank refer to
various equipment instructions in detail.
5

Monitoring of oil quality

The GB11120-89 L-TSA32 turbine oil can be used for this oil tank.
The oil quality has a direct effect on normal working of system and safe operating of
various equipments in oil system. The following items must be performed seriously:
5.1The periodic test must be done for oil quality in oil tank to filter the impurities and water
from oil.
5.2 The oil purifier in system must be put into continuously or periodically.
5.3The oil level must be recorded every day. In case the oil level changes greatly, the reason
must be found; In case the water or fire-resistance hydraulic oil mixes into turbine oil tank,
it must be filtered to prevent oil contamination and cut off the contamination source.
5. 4 The stand-by oil storage equipment, piping, emergency oil storage tank must be cleaned
free of oil contamination.
5. 5 In case the ageing phenomenon is found in turbine oil, it must take measures to replace
the oil.
5. 6 In case the T501 anti-oxidant in oil is less than 50% of new oil, the oil must be added to
the standard of new oil.
5. 7In case the water in oil is greater than 0.05% or the destructive emulsifying time increases
fast, the purifier must be started.
5. 8 The T746 preservative and 902 antifoam agents must be added into turbine oil.

guardrail

Blow-down
mouth

Oil port for

hydrogen
sealing

ladder

Check mouth
of oil cooler

From
cooler

To oil cooler
Figure 0-1-1

oil

Suction oil mouth

for
flushing
device

Filter cartridge

anhole

Mark

Electrical heater

Ultrasonic oil level detector

Access

hole

Thermocouple

Tube clip

Tube

of

overflow oil valve

I access hole of oil

II access hole of oil

injector

injector

Fume discharge i

Pressure measuring port

Safety door

Fume
outlet

Figure 0-1-2

discharge

Demister

Oil

overflow
Return-oil port of oil
purifier

Oil suction of oil

purifier

stand-by valve for oil of hydrogen

sealing

Emergency oil discharge outlet

Figure 0-1-3

section3
1.

Manual of shaft-jacking device

Purpose
The shaft-jacking device is an important assembly in turbine. It functions as jacking rotor at turning
warm-up and even decreasing temperature during the unit start-up and showdown. HP shaft-jacking
oil pocket is provided for elliptical bearing of steam turboset. The HP oil provided by shaft-jacking
device forms static pressure oil film between rotor and oil pocket of bearing to jack the rotor forcedly
and prevent the dry rub between journal and bearing bush from as well as decrease the turning
moment during the steam turbine with low speed, it. It also plays an important role in protecting the
unit, especially for rotor and bearing. During operating, the pressure in shaft-jacking oil pocket
represents the oil film pressure of bearing and used as one of important measures to monitor the
elevation variation of shaft system and load division of bearing.
Working oil:ISO-VG32 Turbine oil

Structure
This device consists of some assemblies, such as motor, HP oil pump, auto reverse-flushing filter,
dual-cylindrical filter, plate filter, pressure relay, over-flow valve, one-way throttle valve etc. and
stainless steel tube, attachment (see drawing 0-1-1). The integrated type is used for this device to
facilitate installation and maintenance. In order to prevent the pump cavitations and protect system,
the LP oil supply (positive pressure oil0.4Mpa is adopted for inlet of system. The LP oil enters
the pump suction oil port through reverse-flushing oil filter and dual cylindrical oil filter. The HP oil
pumped enters various distributors and arrives at relative shaft-jacking oil port to jack the shaft.
Various outlet flow of distributor is regulated by single-way throttle valve. The overflow valve
regulates the safe pressure at pump outlet. The overflow valve limits the oil pressure of main to
prevent the oil pressure of oil supply system from exceeding the max allowable value.
The system adopts the oil filter with two-stage suction to ensure the cleanliness of system. The oil
pump is a imported plunger pumps with high efficiency, low heat output, low noise, reliable
continuous operation under high pressure, without leakage and the volume efficiency above 95%. The
coupling with compensation and high precise connecting transition frame are equipped between motor
and pump to decrease the vibration, noise of whole generator set of oil pump and ensure the system
with well and reliable integral performance.
The instrument panel located at the front of shaft-jacking device is used for monitoring the
shaft-jacking oil pressure of various bearings and oil film pressure at shaft-jacking pocket during the
unit at normal operation. In order to control the operation and switch-over of two shaft-jacking oil
pump, pressure relay is provided for two plat filter; The pressure relay is provided for inlet piping of
oil pump to ensure the required inlet oil pressure during the shaft-jacking device starting-up.
One pressure meter is equipped before and after the auto reserve-flushing filter to monitor the pressure
difference value. It shall be cleaned according to the case.
The tube-in-tube oil pipe is used for the pressure oil pipe and suction oil pipe of shaft-jacking device.

- 180 -

3. Technical parameters of main equipment

3.1 Imported plunger pump: Model A10VSO100
P>16MPa
Q=60 l/min

n=1480r/min

3.2 Motor: Model YB250M-4 anti-explosion motor

V=380V

N=55 kW

n=1480r/min

Installation mode B3

3.3 Dual cylindrical filter: Model 3PD110250A25C-1

PN=2.5MPa

Q=980 l/min

Filtering accurate :25m

Setting value of pressure difference :0.05MPa
3. 4 Plate oil filter: model 9PP80250A10C-1
PN=40MPa

Q=390 l/min

Filtering accurate:10m
Setting value of pressure difference: 0.35MPa
3.5 Auto reactive-flushing oil filter: model ZCL-I
Q=450 l/min

Filtering accurate:45m

3. 6 Oil overflow valve: Model DB30-2-30/315

PN=32MPa
4

Qmax=600 l/min

Installation

4.1 The connection between shaft-jacking device and unit refer to D300N-002004A Lube oil system
diagram. The pickling and phosphatizing treatment shall be performed for all piping connected with
shaft-jacking device. Any dirty and mechanical impurities in the piping shall be removed and its cleanliness
shall conform to the clean-2 requirement in JB/T4058-1999 Cleanliness standard for steam turbine.
4.2 The tightness of piping shall be checked and the oil cycle flushing shall be performed together with
lube oil system after installing the shaft-jacking device. It must be careful to protect the precise
elements in shaft-jacking device during oil cycle flushing.
4. 3 This system is an integral system. The lifting bolt on the base seat and the lifting hole on the side of
base seat are used during lifting. The lifting shall be stable, safe to avoid various elements, instrument,
piping from damage and deformed. In order to prevent impact, it shall be put on the ground slightly.
This device is mounted on the reinforced concrete and fixed with 8-M24 anchor bolt. The environment
around the device shall be dry, well venting quality.
5

Commissioning

- 181 -

5. 1 Check the strainer of filter to determine whether is required to replace strainer after finishing oil cycle.
The 10litre turbine oil is injected into pump casing through oil discharge outlet of oil pump.
5. 2 Open the valve on the inlet oil pipe and inlet oil pipe.
5. 3 Turn the coupling in manual to check its rotation whether is smooth and remove the air in the pump.
5. 4 Full loosen (counter-clockwise rotation) the constant pressure variable valve located on the pump.
5. 5 Inching the motor to check the rotating direction of motor whether is correct. The pump is at unloading
state and the motor starts with no-load. Inching the opening of the stop valve at the oil discharge outlet
of reverse flushing oil filter to ensure the pressure difference P = P3 - P2 = 0.12 0.18Mpa (i.e.
the difference between outlet oil pressure and oil discharge pressure of reactive-flushing oil filter), and
monitor the working frequency of blow-down mechanism with one click per second.
5. 6 Start-up the motor to check the rotating whether is normal and has any noise and leakage during the
device operation.
5. 7 Close the throttle valve located on the flow divider.
5. 8 Rotating clockwise the constant pressure variable valve and oil overflow valve to increase the outlet
pressure of pump to 16Mpa, and set the action pressure of oil overflow valve at 16Mpa.
5. 9 Rotate counter-clockwise the constant pressure variable valve to decrease its pressure to 14Mpa. Start
the motor after the valve operating normally.
5.10 The macrometer is used for measuring the position of the journal top before jacking, then open the
single-way throttle valve side by side to make each journal jacking height within 0.02mm0.05mm,
and record each jacking oil pressure and the jacking height of journal.
5.11 The turning gear can be put into operation after adjusting the jacking height of various journals at
acceptable value, and then observe the rotating of turning gear and steam turboset rotor whether is
normal.
5.12 The acceptance test shall be performed after finishing the above work and the shaft-jacking device is
allowed to put into operation.
6

Putting into of shaft-jacking device

6. 1 Start the shaft-jacking oil pump before starting the turning gear during starting the steam turbine, then
put into shaft-jacking device.
6. 2 Start the shaft-jacking device, and then put it into operation to prevent low speed burn-out while the
speed of steam turbine decreasing to 1200 r/min and steam turbine shutdown. The shaft-jacking oil
pump must be stopped while the speed of steam turbine rising to 1200 r/min.
6. 3 The shaft-jacking device can also be started, in case the rotor is required to rotate at static status and
the oil system with enough inlet oil pressure to jack the oil pump.
6. 4 If there is any difference between the putting into, stopping of shaft-jacking device and that of steam
turbine start-up operation instruction, the latter be regarded as the criterion.

- 182 -

Working process and parameter

7.1 The suction oil pressure is of 0.2Mpa after the suction oil of shaft-jacking device taking from oil cooler.
The suction oil is filtered roughly by one 45m auto reverse-flushing oil filter and enter jacking oil
pump through dual cylindrical oil filter. The outlet pressure of jacking oil pump shall be 16.0Mpa and
controlled by oil overflow valve. The pressure oil from oil pump shall pass through 10m plate filter
to ensure the cleanliness of jacking oil. The pressure oil enters the flow divider through plate filter;
finally enters various bearings through single-way throttle valve and single way valve. The said oil
capacity and oil pressure can be controlled by means of adjusting single-way throttle valve to ensure
the jacking height of journal within the reasonable range(theoretical calculating: The jacking height
shall be greater than 0.02mm, in case the jacking oil pressure of journal is of 814Mpa).
7.2 Control of shaft-jacking device
The pressure relay with power supply AC 220V is the key instrument used for start/shutdown of
shaft-jacking device.

PS1, PS2 monitor the inlet suction oil pressure of jacking oil pump. In case the

inlet oil pressure is less than 0.03Mpa, the pressure relay is off. PS3, PS4 monitor the outlet oil
pressure of jacking oil pump. In case the outlet oil pressure is less than 7Mpa, the pressure relay is off.
7.3

Switch-over of oil pump

Two HP oil pumps are equipped for this device, one for operating and the other for stand-by. In case
one pump or motor fails, the stand-by motor is started to complete the switch-over process.

8.

Maintenance

8.1 When the dual cylindrical filter sends the signal through setting value of pressure difference during
debugging and putting into operation, filter cartridge must be cleaned or replaced. During replace the
filter cartridge, the switch-over of dual-cylindrical filter can be finished by means of turning the filling
valve of filter to stand-by cylinder and opening the blow-off valve of stand-by cylinder, screwing the
blow-off valve tightly and turning the change-over valve to stand-by side. The blow-down port of
reverse-flushing oil filter shall be cleaned during the system stopping. In case the inlet/outlet pressure
difference is greater than or equal to 0.08MPa during using, the reverse-flushing oil filter shall be
cleaned and checked after stopping, opening the upper cover, exhausting the oil in the filter
completely.
8. 2 The tightness of piping shall be checked for shaft-jacking device constantly to keep the well sealing.
The oil pump and oil filter shall be filled constantly, and the press button and switch shall be dry and
with well contact to ensure putting into operation at any time.
8.3 The air in oil filter and oil pump shall be exhausted completely during the first starting after installing
or dismantling, maintaining to prevent the shaft-jacking device and oil pipe not pumping oil or the oil
with bubble and finally effecting the jacking.
8.4 The cleanliness of working oil shall conform to the operation requirement of unit (NAS8class).
8.5 Check periodically; calibrate pressure meter and pressure relay. Check periodically the performance of
various sealing parts whether is well. The troubles can be removed in time.

- 183 -

8.6 The jacking oil pressure shows the operation of shaft-jacking device whether is normal. After starting
various jacking oil pressure shall be in the range of 814Mpa. In case the oil pressure is too high, it
means that the rotor shall not be jacked fully and HP oil discharge is blocked. In case the oil pressure
is too low, it means that the oil leakage shall occur in HP oil piping system. While the shaft-jacking
device has been started but the shaft is not yet jacked, the oil jacking pressure will rise instantaneously.
When the shaft is jacked and after the oil discharge is smooth, the oil pressure shall decrease at a
stable value, the pressure at this time indicates the normal jacking pressure.
9

Requirement of shaft-jacking device

9.1 The shaft-jacking device shall be installed according to the Article 248278 in SDJ53-83 Specification
for electric power construction and acceptance (steam turbine unit volume).
9. 2 The oil cyclic flushing for shaft-jacking device shall be performed according to Article 535547 in
SDJ53-83 Specification for electric power construction and acceptance (steam turbine unit volume)
and Specification of flushing technology for oil system of manufactory.
10 Common trouble analysis
10. 1 Abnormal noise of pump
Check the oil flow of suction oil port for pump whether is enough and the check valve whether are
open and the oil filter whether is blocked.
10. 2 The reason for the pressure of system fails to rise
(1) Check the regulating pressure of overflow valve whether is proper and flexible.
(2) Check the max. setting value of pump whether is up to proper height (refer to the pump stylebook)
(3) Check various regulating valve of system whether full opens.
10. 3 Fluctuation of various outlet pressure of distributor
(1) The pressure fluctuating is related to the load size at various outlet..
(2) The pressure fluctuating is related to the opening of throttle valve. The throttle bar of
corresponding valve can be regulated.
11. This factory shall reserve the right to replace the original design by better element and material.

- 184 -

section4
1

Manual of oil injector

General
The oil injector is one of the important equipment in lube oil system for steam turboset.
The oil injector of lube oil system of steam turboset is divided into oil supply injector,
lube oil supply injector according to its working purpose. The working medium is of
L-TSA 32 turbine oil and the working oil temperature is of 4565. The unit shall
be put into operation in case the speed of unit reaches or approaches the rated speed.

1.1 Oil supply injector

During the unit at normal operating, the oil supply injector can supply sufficient oil for
main oil pump, and partial pressure oil at main oil pump outlet serve as its power oil
with pressure 1.96Mpa (gauge pressure) and nozzle flow 1266 l/min, outlet oil pressure
0.2Mpa (gauge pressure) and outlet oil capacity 3179 l/min.
1.2 Lube oil supply injector
During the unit at normal operation, the lube oil supply injector can supply the lube oil
for various bearing of steam turbo-set, and partial pressure oil at main oil pump outlet
serve as its power oil and partial oil of its power oil with pressure 1.96Mpa(gauge
pressure), nozzle flow 1913 l/min, outlet oil pressure 0.32Mpa (gauge pressure), outlet
oil capacity 3600 l/min.
2. Oil injector adjustment
The performance test and adjusting has been performed for oil injector to meet the
design requirement before ex-working. So the oil supply injector and lube oil supply
injector cant be adjusted in power plant.
It is difficult to distinguish from appearance due to the outline of oil supply injector
same as that of lube oil supply injector. Therefore, the both injector can be distinguished
by #I and #II symbol marked on the installation indicating board of diffusion tube in
appearance. #I shows oil supply injector and #II shows lube oil supply injector. The
both oil injector can be distinguished by inner dimension,i.e.5-9.6mm for nozzle hole
and 76mm for throat diameter of diffusion tube of oil supply inject; 5-11.8mm for
nozzle hole dimension and 70mm for throat diameter of diffusion tube of lube oil
supply injector,
3

Structure description
The oil supply injector consists of multi-hole nozzle, diffusion tube, sleeve and strainer
same as the lube oil supply injector in structure (see attached drawing 0-1-1). The
pressure oil jets out with high speed through nozzle and forms certain negative pressure
in suction chamber. The turbine oil in oil reservoir flow into oil injector under the action
of pressure difference, then enter into diffusion tube carried with high-speed power oil.
- 185 -

The power oil in diffusion tube mixes with the suction oil completely to meet the
required pressure value and flow value.
4.

Assembly and installation

The installing of oil injector has significant effect on performance. The nozzle support
and the flange of inlet oil tube must be tightened during installing the nozzle of oil
supply injector and lube oil supply injector to ensure the HP oil against leakage. The
flatness and fineness of all joint surfaces must be well.

5.

Maintenance
In case the oil injector isnt used immediately after arriving in site, it must be sealed
with grease. In case the oil injector isnt installed after arriving site within two months,
it must be dismantled to remove rust and dirty before installing.
During the unit overhaul, the oil injector is required to dismantle for checking,
especially for nozzle. The surface roughness of nozzle bore shall be
, . In case there
is any scripting or recess area, it must be replaced.
The possible failure and solve method is as follows :( see table 1)

Failure
Oil injector outlet without
flow and pressure
oil injector outlet with
small flow and low pressure

oil injector outlet with high

pressure
Oil injector with serious
vibration and increasing
noise level obviously

Table 1
Reason
Nozzle is blocked completely
or the pressure oil (power oil)
tube breaks up
Strainer is blocked or the
consumption oil in lube oil
tube leak-off system is too
high
System with small oil
capacity
Oil level is lower or the
strainer is loose and blocked

Solve method
Check the tightness of nozzle
and power oil pipe
Clean strainer and check the
lube oil pipe

Increasing the oil level and

check the strainer

7. Cleanliness re-checks
The oil injector shall be cleaned and rechecked before installing. The inner/external surface of
oil injector shall conform to the requirement of clean-2 in JB/T4058-1999. The rust must be
removed at once.

- 186 -

Suction inlet to main

oil pump

I# oil injector

To oil cooler

II# oil injector

From main oil pump

outlet

Attached drawing0-1-1

section5

Main oil pump description

1 General
The main oil pump is the most important element in the turbine oil supply system of steam
turbine. It supplies the whole turbine oil system with power oil source during the steam turbine
at rated speed and the unit at normal operation. The main oil pump is located in the front
bearing housing of steam turbine; it is rigid connection with the main shaft of steam turbine and
driven directly by main shaft. The main oil pump is horizontal centrifugal pump with single
stage and double suctions and the oil is supplied by pressure.
The design parameters of main oil pump are as follows:
speed

3000 r/min

flow

>3000 l/min

suction pressure

0.09~0.12 MPa

outlet pressure

1.85~2.05 MPa

wasted work

~200 kW

working medium

L-TSA32 turbine oil

medium temperature

45~65

2 .Structure description (see drawing 0-1-1)

2.1 Stationary section
The stationary section of main oil pump consists of pump casing, end cover, sealing ring and
floating bearing etc. The inlet and outlet interfaces of main oil pump are arranged in a line at
lower part and integrate with base seat of it. A screw plug with bore is equipped at the top of
various chamber of pump casing to exhaust the gas from each chambers during the unit start-up
to ensure the stable operation of main oil pump and oil system.
2.2 Rotating section
The rotating section of main oil pump consists of disc, pump shaft, sleeve and key etc. The dynamic
balance test has been performed for the rotor of main oil pump after assembling in factory to ensure
the stable operation of main oil pump. The pump shaft of main oil pump is connected with rigid
connection with the main shaft of steam turbine by rigid coupling with male-female spigot for
alignment The pump shaft is connected with main shaft by 12 M20 bolts. The tachometer gear
board located on pump shaft is used for measuring the speed and expansion difference of steam
turbine unit. The emergency tripping device is mounted at the front of pump shaft.
2.3 Sealing of main oil pump
The floating sealing ring is used for main oil pump. The sealing ring can float in the pump
casing freely. It is not only to allow the rotor of main oil pump moving axially but also to
compensate the displacement of rotor at the vertical direction. ZCuSn5Pb5Zn5 is used for
sealing ring.

2.4 Floating bearing and lubrication

The floating bearing located on main oil pump is a round bearing. It is used for compensating
the elevation variation caused by temperature difference between main shaft of steam turbine
and main oil pump during the unit operating. The floating bearing is mounted at the left end
cover. The sliding load used for fixing the bearing pedestal is adjusted by compression spring
mounted on the end cover. The turbine oil is used for forced lubricating the bearing. One lube
oil tube is lead out from lube oil main mounted in the front bearing housing to connect with the
contact at the lube oil inlet mounted on the pump casing of main oil pump.
3. Requirement for assembly and installation
3.1The cleanliness of various components and inner/external of main oil pump must conform to
the requirement clean-2 in JB/T4058-1999 Cleanliness standard of steam turbine before
assembling and installing the main oil pump
3.2 The clearance value at various sealing of main oil pump must conform to the requirement
on drawing.
3.3 The installing elevation of main oil pump must be adjusted according to the manual of main
turbine to ensure the well alignment between the rotor of main oil pump and main shaft of
steam turbine.
3.4 The installation type of pump shaft and steam turbine rotor shall be considered during
installing the main oil pump to ensure the rotating/static clearance between rotor disc and pump
casing of main oil pump conform to the requirement on drawing and prevent them from the rub
between rotating and static parts during the unit operation.
3.5 The relative lube oil pipe must be connected well according to the requirement of system.
4. Operation and maintenance
4.1The main oil pump is put into operation while the steam turbine with speed 3000r/min. It is
difficult to observe the operation state of main oil pump during operation. Therefore, we must
be careful for installing and maintaining of main oil pump.
4.2 In case the inlet parameter of main oil pump conforms to the design requirement, the reason
for the outlet oil pressure short of the design value must be analyzed. The main oil pump is
required to check after confirming the piping system without leakage and with normal
connection.
4.3 The main oil pump must be checked completely during the unit overhaul. The wear parts
must be replaced and the main oil pump must be cleaned completely.
4.4 The small bores of 3 screw plug with bore located on pump casing must be smooth and
without block, and various clearance requirement on drawing must be ensured during
re-assembling.

Joint for lube

il

rotor
bi

of

steam

Emergency

Expansion difference
check surface
speed metering gear

Figure 0-1-1
rotor right end cover sealing ring pump shellsealing ring
sealing ring left end cover floating bearing pipe connection

section6
1.

Instruction for Spill Valve

General Description

Spill valve is used to adjust the pressure of mother pipe for lube supply, to ensure a stable pressure and flow
of lube oil at bearings and to meet operational requirement of bearings, so that the entire lube system can supply
sufficient and reliable oil, to achieve a safe operation of the generating system. Under the variable working
conditions like startup and shutdown of unit, the spill valve has also the function for automatically adjusting the
lube pressure, to minimize the impact on the system due to change in oil pressure.
1.1 Performance Data
Maximum spill:

Qmax=500L/min

Maximum spill pressure:

Pmax=0.255MPa

Normal spill:

Qc=100L/min

Normal spill pressure:

Pc=0.196MPa

Minimum spill:

Qmin=0L/min

Minimum spill pressure:

Pmin=0.176MPa

1.2 Operating Principle

The valve is fitted on the mother lube pipe behind the outlet of oil cooler. The opening degree of the spill
valve (i.e. the spill quantity) depends on the balance position of such applied forces as pressure on the mother
lube pipe, reaction of spring, and weight of slide valve, etc. When pressure on the mother lube pipe is less than or
equal to 0.176MPa, the reaction forces of spring and so on will be larger than the opening force of slide valve
which will then be in the lower position and the outlet of spill valve will not overflow as fully blocked. When
pressure on the mother lube pipe is 0.196MPa, the slide valve will move upwards and spill outlet will appear
partially. Now the oil overflows from the outlet and moves back to oil tank through lower part of the spill valve,
to drain the oil and stabilize the pressure of mother pipe.
2.

Structure and Description

This device consists of valve shell, valve cap, sleeve of slide valve, slide valve, spring, and mandril, etc.
Refer to Figure 0-1-1.
To keep slide valve from getting stuck and to improve the valve sensitivity, buffer chamber is composed of
valve cap, sleeve of slide valve and slide valve to connect with lube oil in front of the spill valve through an
eyelet on the slide valve, and the pressure oil before the valve enters the chamber through this eyelet. When
any change in pressure before the valve takes place, the pressure in the chamber varies accordingly to
eliminate the insensitive zone of spring and to improve the sensitivity of spill valve. At the same time, the
lube oil into the chamber will play a lubricating and protective function for the slide valve, sleeve of slide
valve, spring and other parts. This part of lube l will be drained back to the oil tank through the eyelet on
valve cap.

3.

Installation, Assembly and Disassembly

The valve should be installed vertically and the interface before valve is connected with the mother lube pipe
at the outlet of oil cooler. Relieved oil should be directly drained into oil tank or oil return pipe free from pressure.
When valve is installed inside the oil tank, the interface behind the valve neednt be connected with the pipeline,
but oil drain tank directly instead. In the case when valve is fixed in other parts, a piece of pipeline is to be used to
connect the outlet of the chamber on valve cap into the oil return pipe of the spill valve outlet.
The disassembly sequence is:
Firstly loosen the cap nuts and write down H value in the drawing. Then unlock the mandril and dismantle
the valve cap to take out spring, and slide valve, etc. The valve sleeve and shell are assembled by tight fit and the
sleeve is not to be taken out generally.
The assembly sequence is contrary to that of disassembly.
4.

Maintenance

During installation and overhaul of the unit, the spill valve should be disassembled for inspection and
cleaning to ensure a safe, reliable and normal operation of the unit. During re-assembly after inspection and
cleaning, the slide valve can be manually pushed to check if it is free and flexible or not. In any jamming case, the
slide valve is to be re-cleaned. When re-assembling the mandril, its position should meet requirement of H value
which is to be further properly adjusted according to the pressure on the mother lube pipe when unit speed arrives
at 3000rpm and all auxiliary oil pumps are out of service. Rise in H value will lead to an increase in oil overflow
and decrease in pressure of mother lube pipe, and vice versa.
Adjustment of valve is to ensure that the lube pressure before entering all bearings is 0.08~0.12MPa. It is
worthwhile to emphasize that pressure of relieved oil in 1.1 is the design value before valve, with the
consideration about pressure change arising from elevation. In actual operation, when lube pressure exceeds
0.255MPa, oil overflow of spill valve will be more than 500L/min. Only the maximum value selected for design
is listed in 1.1.
The spill valve shall be thoroughly cleaned after the oil circulation of new unit and overhauled unit.

5.

Refer to Table 0-1-1 for possible failures and solutions.

Table 0-1-1
Failure

Fail to adjust pressure or no

spill

Cause

Solution

Slide valve jammed

Check and clean to eliminate dirt

Throttling before or
behind the buffer
chamber

Open up the throttling eyelets

Hole blocked

Open up the hole

Spring damaged

Replace the spring

Cap Nut

Mandril

Valve Cap
Oil Return Tank
Buffer Chamber

Spring
Oil Inlet

Slide Valve

Valve Shell

Oil Return Tank

Sleeve of Slide Valve

Figure 0-1-1 Spill Valve

Section7

Instruction for Twin-Tongue Check Valve

0-1 Instruction for Twin-Tongue Check Valve

6.

General description
In oil system pipeline of steam turbine, to ensure that all auxiliary pumps are normally put
into operation and cut off as well as a normal operation of the system, the pipeline is
equipped with several different check valves to meet requirement for safe operation of the
system. This twin-tongue check valve (Fig. 0-1) is used for oil supply pipe. Even when one
of the valve discs is not tight, it can still ensure a normal work of the lube system and proper
operation of the steam turbine.

7.

Structure and working principle

The check valve is composed of valve core, valve body, coupling flange and etc. The
twin-tongue check valve consists of 2 valve cores (See Fig. 0-1). The valve cores of the check
valve of the same diameter are interchangeable.
Resistance at opening of the check valve is shown in table 0-1
Drawing No.

M522.X01Z

Content
Pressure in front of the valve

Po

Valve disc sealing area ratio

0.877

Opening pressure

0.135Po

When pressure before valve is more than the sum of pressure behind valve and resistance at
opening check valve, the check valve is automatically opened under the function of hydraulic
pressure difference, and when pressure in front of the valve is less than pressure behind the valve,
the check valve will be automatically closed. In order to avoid the check valve from being
opened overwide and to ensure a tight close of the check valve, the measure for lengthening axis
of valve disc is adopted for limiting the opening degree of the valve and the valve sealing surface
is designed into a structure of 75 angle against the direction of fluid movement.
8.

Technical requirement for application

3.1 The structure description of the check valve is shown in table 0-2
Drawing No

M522.X01Z

Content
Nominal diameter

125

3.2 Maximum opening of the check valve: 650

3.3 Working temperature of the check valve should not be more than 350

3.4 Working pressure of the check valve cannot be more than 2.5 MPa
3.5 The medium used by check valve is oil or other liquid without corrosion.
9.

Installation Requirements

4.1 The check valve is installed on respective pipelines with melding method. When check valve
is arranged horizontally, the valve axis must be located on top.
4.2 Prior to installation, the check valve should be cleaned up, away from any deposit builder
such as dirt, rust and other contaminants. The valve shall be disassembled and cleaned when
necessary.
4.3 Pipelines connected with the check valve should be cleaned up before fitted in. If condition
permits, the pipes should be phosphorized with pickling (or passivated). When installed into the
oil system of steam turbine, the respective pipes shall comply with the Cleanliness-II
requirements of JB4058-85.
4.4 Connections between the check valve and pipes should be argon-arc welded to ensure the
quality of welds and piping cleanliness after welding.
4.5 After welding, welds between the check valve and pipes shall be cleaned up and coated with
HU-20 turbine oil for rust protection.
10. Overhaul and maintenance
5.1 The check valve shall be repaired and maintained periodically along with overhaul of the
unit.
5.2 It is only needed to twist off the bolts on the flange at both ends to dissemble the check valve.
If piping interference occurs, pipes can be properly pulled apart with chain hoist to easily
dismantle the check valve.
5.3 What is taken off the check valve is only a valve core, while another valve disc is still on the
pipeline. At this time, the valve core can be pulled out by grasping its sealing face.
5.4 Mainly the sealing face between valve core and disc is checked for overhauling the check
valve, and there should be no notch, nick and attachments. If the said exists, it is necessary to
polish and face up to meet the sealing requirements.
5.5 When check valve gets stuck, mainly the clearance between valve arm and disc is to be
adjusted and to ensure a smooth operation of the check valve by adding gasket into the said
clearance.
5.6 During repair of the check valve, pressure test shall be performed as per technical
requirements of related drawings. Refer to corresponding drawings for sealing requirements.
5.7 Pressure test of check valve can be conducted with corresponding valve body.
5.8 The sealing gasket between the flange faces shall be replaced when the check valve is
re-assembled.

Figure 0-1

section8

Operating Instruction for Oil Smoke Separator

1.

Structure
This device is composed of oil smoke separator, connecting tube, and smoke exhaust
fan.

2.

Application
This device is used to extract the oil smoke from the oil system, including bearing box, oil
pipe and oil tank, to prevent from fire and pollution arising from smoke emission. At the same
time, it can separate the oil drops from the smoke and let them flow back to the oil tank, to
reduce the loss of turbine oil.
Installation, Operation and Maintenance
This oil smoke separator is vertically installed on the oil tank cover, one in use and the
other standby. Inch the motor after closing the butterfly valve on the fan outlet to check if the
fan rotates properly. Start the fan motor if everything is normal. Then slowly open the
butterfly valve of the fan outlet, and adjust the negative pressure of the oil tank to 1 Kpa. This
equipment should be cleaned and maintained regularly.

3.

Refer to the operating instruction provided with the device for detailed structure as well
as operation of the fan and the oil smoke separator.

Smoke Exhaust Fan

Butterfly
Valve

Connecting
Tube

Oil Smoke Separator

Figure 0-1-1 Oil Smoke Separator

Chapter5
INSTRUCTION OF HYDROGENSEAL OIL
STATOR COOLING WATER SYSTEM FOR 300MW
GENERATOR
section1

GENERAL

The auxiliary device of the QFSN-300 type steam turbine generator

contains three parts: hydrogen control system, seal oil control system and
stator winding cooling water control system.
1.1 The functions of the gas control system include:
1.1.1 Displacement the gas in the generator.
1.1.2 Maintaining gas pressure in the generator.
1.1.3 Monitoring the operation condition of the generator for gas pressure and
purity and the presence of liquid in the generator at all times.
1.1.4
1.2

Drying the gas in the generator.

The functions of the seal oil control system is:

1.2.1 Providing seal oil to a sealing continuously.

1.2.2 Prevent the escape of hydrogen gas from the generator.
1.3 The functions of the water control system include:
1.3.1 Ensure supplying water to stator winding continually.
1.3.2 Monitoring the operation condition of the generator for water pressure
water flow and conductivity, containing and improving water quality.

section2

Hydrogen control system(See hydrogen control

system diagram)

2.1 Main technical parameters:

2.1.1 Rated hydrogen pressure in the generator:
Allowable maximum hydrogen pressure:

0.3MPa.g

0.35MPa.g

Hydrogen purity: 96% (a volume vat)

Hydrogen humidity: 4g/cu.m
(Under the condition of the rated hydrogen pressure 0.3MPa.g)
2.1.2 The filling hydrogen volume of the generator and the hydrogen piping
system is 83cu.m.
2.1.3 Hydrogen leakage amount of the generator and the hydrogen piping
system (except the hydrogen storage equipment on the supply hydrogen

station and the hydrogen bus duct): 5% of filling the hydrogen volume.
2.1.4 Volume and time for gas replacement is listed as follows
Required Gas

carbon dioxide

Changeover

volume

operation Gas

required Gas

Air

of Estimated
required time

180cu.m

5~6h

260cu.m

5~6h

(purity>85%)
Hydrogen

Carbon dioxide

(purity>96%)

Hydrogen pressure is 210cu.m

1~1.5h

increased to 0.3MPa
carbon dioxide

Hydrogen

150cu.m

4~5h

(purity>96%)

2.2

Operating principle of the hydrogen system:

Hydrogen is inputted to gas control station from the hydrogen supply

system through double bus duct and is delivered to the generator after
straining out solid impurities by a filter and removing moisture though a gas
dryer
Two sets of automatic hydrogen make up device will be provided on the
gas control station, one is solenoid valve, when the hydrogen pressure in the
generator is reduced to the lowest limit of a set value, the contact in the
pressure controller is turned on and the solenoid valve is opened, The
hydrogen enters the generator through the solenoid valve. When the hydrogen
pressure in the generator increases to the highest limit of a set value, the
contact in the pressure controller is turned off and the solenoid valve is closed
and filling hydrogen is stopped. Another is a pressure reducer, it's the output
pressure value is sets the rated hydrogen pressure value of the generator.
Therefore, as long as the hydrogen pressure in the generator is reduced,
hydrogen will occur at the output terminal of the pressure reducer until the
hydrogen pressure in the generator is resumed to the rated value.
A safety valve is installed on the gas control station. When the hydrogen
pressure in the generator is excessively high, hydrogen pressure can be
relieved.

Parts of hydrogen in the generator enter the hydrogen dryer along the
pipeline under the action of the fan. The dried hydrogen returns to the suction
zone of the fan in a continuous circulation so that the hydrogen moisture in the
generator is reduced. Similarly, the hydrogen flowed in the hydrogen purity
analyzer is also conducted by the action of the fan. The hydrogen purity in the
generator can be continuously analyzed by the analyzer, and 420mA signals
will be given out .
Four oil/water monitors are furnished in the hydrogen control system.
They separately are installed on the CO2 pipeline and the bottom of the
generator. When oil or water enters the generator and over setting valve, the
floats in proper will be rise and turned on electric enunciator circuit and alarm
signals will be given out.
When the generator and the gas pipe are required to be air tightness
tested with compressed air, the compressed air is inputted into the generator
through a valve on the gas control station after being dried by the gas dryer.
After the air tightness test is qualified, the compressed air is drained to the
outside of the power house.
It is prohibited to directly filling hydrogen (or air) into the generator when
the generator is filled with air (or hydrogen) so as to avoid the formation of
explosive air-hydrogen mixture. Therefore, gas replacement must be conducted
for the generator and hydrogen pipeline system. CO2 gas or N2 gas in a
standard gas bottle may be fed into the generator from the generator bottom
along piping after being reduced from the maximum pressure of 15MPa to
0.2~0.5MPa through the pressure reducer. Thus the replaced air (or hydrogen )
is drained to the outside of the power house along the hydrogen piping of the
generator.
2.3 About the gas displacement of the generator
2.3.1 After the pipeline installation ( or maintenance ) for the generator, and
the air-tightness test is qualified, gas replacement can be conducted, the way
is that inert gas, such as CO2 or N2 can be used to drive out air (or hydrogen )
in

the generator and then the inert gas is driven out from the machine with

hydrogen, so as to prevent hydrogen and air from contacting directly during

gas replacement, therefore, no explosive hydrogen-air mixture can be formed,

this process of gas replacement is called the intermediate medium
replacement way. Prior to hydrogen charging, CO2 gas ( or N2 gas ) is used to
drive out air from the generator, after CO2 gas content in the generator is over
85% ( N2 gas content over 95% ), and then CO2 gas ( or N2 gas ) shall be driven
out by hydrogen, finally, then the generator is charged with hydrogen.
During hydrogen discharging, CO2 gas ( or N2 gas ) is carried to the
generator to drive out hydrogen, after CO2 gas content is over 95% ( N2 gas
content

over

97% ), compressed

air

can be fed into the generator to

drive out CO2 gas ( or N2 gas ), after CO2 gas (or N2 gas ) content is lower than
15%, the compressed air introduced to the generator will be stop.
2.3.2.The following points shall be noticed during intermediate medium
replacement.
2.3.2.1

Hydrogen, compressed air and intermediate gas (CO2 gas is

preferable )must be introduced to the special inlet on the gas control station
and they cannot make a mistake.
2.3.2.2 Gas flow speed should be properly controlled to prevent producing a
heat source in variable diameter of pipe due to excessively high gas flow
speed.
2.3.2.3

A given gas pressure shall be stored during all process of gas

replacement in the generator (the pressure is between 0.01~0.03MPa ).

2.3.2.4 Fire is strictly prohibited near the site or the orifice of discharged pipes.
2.3.2.5

Correct and comprehensive sampling points are required, during the

process of gas replacement frequent discharging work shall be done for gas
displacing pipe and dead zones where gas can not be easily circulated such as
gas dryer, seal oil tank sample shall be taken from all these points, the test
results shall be in accordance with the requirement.
2.4
2.4.1

Main equipment of hydrogen control system :

Gas control unit and the carbon dioxide standard manifold bar are

designed on shape of closing to wall type.

2.4.2

Two refrigerating hydrogen dryer .

2.4.3

Hydrogen analyzer .

2.4.4
2.5

Gas dryer is adsorption type dryer .

Points of attention for installation :

2.5.1 All pipes are all seamless steel tube, the inner wall of tube must be
cleaned.
2.5.2 Sealed material of flanged coupling must use oil proof rubber plate
thicker than 3mm.
2.5.3 The hydrogen-side pipe of the gas control unit must be done gas -tight
test independently. Testing pressure is the same as that of hydrogen-storing
equipment, usually 1MPa. The other equipment and gas pipe better to be done
gas-tight test independently, testing pressure are about 0.6MPa, so shorten
time of looking for leakage.
2.5.4

Drying agent in dryer must be rightly placed before gas-tight test.

2.5.5 All the gauges and instrument of this unit must be recalibrate before
installation.
2.6

Regulating and test of hydrogen system.

After installing, the hydrogen system should be regulated and tested on

the working field as follows.

2.6.1 Setting of safety valve
There is a safety valve on the gas control unit. Its released pressure is
adjusted by spring. The released pressure of safety valve of this unit is set to
0.36MPa. Setting will be doing on the units pipe. Firstly, carrying into H2 gas or
compressed air from the pipe bus valve of carbon dioxide standard manifold.
when the gas pressure rises to 0.36MPa, by turn adjusting nut on the safety
valve, the safety can open automatically and released pressure in pipe. When
the pressure falls to 0.3MPa, close the safety valve. When pressure is
0.28MPa, you can check leakage by using soap water. The Safety valve must
avoid leakage condition.
2.6.2

Setting of the pressure controller

The pressure controller is a switch that opens on circuit's pressure

changing. You can open and close hydrogen makes up solenoid valve by it, at
the same time it can indicate low pressure in the generator.

When regulating

pressure controller, carrying into compressed air, the pressure gauge indicate

0.28MPa, then release lock of pressure controller, turn setting button, make
indicating needle point at pressure valve needed, that is point of 0.28MPa, at
this time, switch should be closed, if electric return circuit is energized, the
solenoid valve should be energized and open. Then raise pressure to 0.3MPa,
the switch should be turned off. Electric return is switch off, the solenoid valve
is closed. It should be calibrated twice at least. If there is no abnormal
condition, then lock out after one more recalibration, if there is no abnormal
condition, you can finish regulating work.
2.6.3 Installation and regulation of hydrogen analyzer and oil/water monitor
refer to manual provided by its factory.
2.7 The operation and maintenance of the hydrogen unit.
2.7.1 The drying agent in dryer should be changed at regular interval.
Especially for unit with high moisture lubricant, it should be changed frequently,
drying agent should be changed at first time three months after it is put into
operation. Therefore changing time depends on situation, but not more than
four and a half month.
2.7.2

Instrument and gauge should be calibrate at regular interval, the

pressure controller and the safety valve also should be set at regular interval. It
is recommend to set every 6 months.

Section3
3.1

Seal Oil control system(See the seal oil control

system diagram)

General
The turbine lubricating oil for generator seal ring is named seal oil

according its purpose. Seal oil system supplies oil to seal ring of the generator,
and the pressure of oil greater than the pressure of hydrogen to prevent
hydrogen in the generator leak out from the gap between seal ring and rotation
shaft, at the same time prevent oil pressure too high to a lots oil enters the
generator.
Seal oil system is decided according the type of the seal ring. The double
ring type seal oil system and the single ring type seal oil system are main
types.
This exposition is adequate for single ring type seal oil system designed
and made by DFEM.

3.2 Main technical parameters:

Seal oil: same as lubricating oil
Inlet oil temperature of the rings: 2550
Outlet oil temperature of the rings:70
Differential pressure between in the rings and hydrogen in generator:
0.0560.02Mpa
seal ring oil quantity:
turbine side:92l/min; excitation side:92l/min.
3.3 Operating principle:
Seal oil system includes the main circuits as following: regular operation
circuitemergency operation circuitemergency seal oil circuit (the third seal oil
source).
3.3.1 Regular operation circuit:
Bearing lubricating oil pipe vacuum tank main seal oil

pump (or

pump for stand-by )seal oil filterdifferential pressure regulating value

seal ring of the generatorhydrogen side drain (air side drain mixed with
bearing lubricating oil drain flow to air detraining section directly) oil drain
enlargement section float trapair detraining sectionbearing lubricating
drainturbine main oil tank
3.3.2 Emergency operation circuit:
Bearing lubricating oil pipe emergency seal oil pump (D.C pump)
differential pressure regulating valve seal oil filter seal ring of the
generatorhydrogen side drain

(air side drain mixed with bearing lubricating

oil drain flow to air detraining section directly)seal oil drain enlargement
section float trapair detraining sectionbearing lubricating drain
turbine oil tank .
3.3.3 emergency seal oil circuit: (third oil source)
This circuit is operated when both main seal oil pump and D.C pump were
stopped , the bearing lubricating oil can be used as seal oil for sealing the
hydrogen ,at this time the hydrogen pressure must be decreased to

0.05MPa~0.02MPa.
3.4

Main equipment of seal oil control system:

3.4.1 seal oil drain enlargement section

The hydrogen side drain pipe of the turbine side and the excitation side
connect to drain enlargement section, in which the drain oil can be
spread out and eliminated hydrogen.
3.4.2 float trap
The drain oil of hydrogen side pass by enlargement section then enters
float trap, which purpose is eliminate the hydrogen in oil any more.
3.4.3 Air detraining section
Air side drain mixed with bearing lubricating oil drain flow to air
detraining section, gas in oil is drained to outside of building through
pipe, lubricating oil flow back to turbine main oil tank

3.4.4 seal oil supply station

It consist of the following main equipments assembled on a base plate:
two main AC pumps, one emergency seal oil pump, vacuum device, one
differential pressure regulating valve, some instruments and valves.
3.4.4.1 Vacuum device
The vacuum tank, vacuum pump and recirculating pump are the main
equipments of vacuum device. they are oil purifying equipments of the seal oil
system for single-ring type.
3.4.4.1.1

Vacuum tank(refer to 3.4.5)

3.4.4.1.2

Vacuum pump works continually to keep high vacuum in the

vacuum tank, the air,and moisture in oil can be drained out at the same
time.
3.4.4.1.3

Recirculating pump works continually, so the oil in vacuum tank

come into a repeating local circulation through pipe, and it can be

clean much more.
3.4.4.2 Oil pump
There are two main seal oil pump ,one for regular and one for
stand-by .They are both driven by A.C motor ,so they are named A.C oil pump.
One emergency seal oil pump will start up when main oil pumps are

stopped in trouble .It is driven by D.C motor, so it is named D.C oil pump.
3.4.4.3 Differential pressure regulating valve
The regulating valve regulates oil pressure which enters seal ring
automatically, and it follows the change of the gas pressure in generator
automatically in order that the differential pressure between oil and hydrogen
should be maintained at needful range.
3.4.4.4 Seal oil filter
Seal oil filter is fitted the outlet pipes of the differential regulating valve, it
is used for filtering solid impurity in the seal oil.
3.4.5 Vacuum tank
When A.C seal oil pump is works normally, bearing lubricating oil enters vacuum
tank on and on, gas and moisture is separated from oil in vacuum tank, and
drained out through vacuum pump and pipe , therefore the oil which enter seal
ring can be cleaned and also air or moisture can be prevented to pollute hydrogen
in the generator.
There is a float valve in vacuum tank. its float ball rise or down following
oil level high or low to regulate the valves open-close angle, thus it can control
the speed for makeup oil

and

oil level.

Liquid level annunciator is a main adjunct too. oil level will be seen
through it and it will send alarm signal when oil level high or low.
3.5

Regulating and setting of seal oil system

3.5.1 The setting of the pressure controller

When the outlet oil pressure of oil pump is low to 0.54Mpa,the pressure
controller(PCL-201) delay 3~5 seconds to start standby oil pump. If PCL-201
turn off in low pressure condition and A.C standby pump cannot maintain normal
work pressure,then D.C pump control circuit be passed,D.C pump will start.
3.5.2 The setting of vacuum tanks vacuum degree:
PSH-202 is a pressure switch. For high purity of hydrogen, gas in
seal oil must be reduced to the lowest limit. The lowest limit setting value
of the vacuum degree is 88Kpa.g, when vacuum degree exceed the value,
it gives out alarm.
3.5.3 Reducer (S-18)
When running normally, the pressure of filter inlet pipeline maintain
0.65~0.7Mpa. S-18 should be set according the value.
3.5.4 the setting of vacuum tank liquid level annunciators position
The middle position of the liquid level annunciator is set as the normal oil level

position. Being up or down 100mm from the normal oil level position, it will give
out a signal.
3.5.5 The setting of low limit value of differential pressure regulating valve
The oil-gas differential pressure standard value is 0.056Mpa, which decrease to
0.036Mpa as the low limit alarm signal.
3.6

Daily monitor item

3.6.1 the value of oil-gas differential pressure in generator;

3.6.2 the oil level in vacuum tank and float trap;
3.6.3 whether there is oil in liquid level annunciator(LS-201 );
3.6.4 seal oil vacuum pump run condition
3.6.5 all instrumental display value
3.6.6

seal oil pump outlet pressure

section4
Stator winding cooling water system(see stator
winding cooling water control system diagram)
4.1 Main technical parameters:
4.1.1 Stator winding cooling Water:
Water pressure at the inlet:

0.1~0.2MPa

Water temperature at the inlet: 453

Return water temperature: 85
Total water flow: 45t/h
Water quality requirements:
Conductivity: 0.5~1.5s/cm(20)
PH value: 7-8
Hardness:

2 microgram equivalent litter

4.1.2 Whole volume of

the

system

4.1.3 Circulating water flow required:

3cu.m
~160t/h

Circulating water pressure required:

0.35MPa

4.2 Operating principle of cooling water system

Stator winding cooling water system is an independent closed circulating
circuit. Water from the tank is pumped and is introduced to exchanger to cool
after rising pressure, solid impurity is removed through filter and cooling water
flows into the stator winding of the generator. The return water flows back to

the tank by way of circulation.

Some auxiliary devices are installed in the system, such as demineralizer,
heat exchanger, some gauges are supplied to monitor water temperature,
water pressure, conductivity and flow. By-pass pipeline and valve is installed
on the stator winding inlet and outlet of the generator so as to wash stator
winding in an opposite direction.
4.3 Main equipment of stator cooling water control system, all of the following
equipment are assembled on a base plate :
4.3.1 Water tank, it is made from stainless steel. The tank volume is about 1.78
cubic meters. Max. filling water volume of the tank is about 1.6 cubic meters
(from horizontal plane to overflow pipe), filling water device and liquid level
annunciation is installed on the tank. When water level falls, the contacts

in

the annunciation turn on. Solenoid valve is opened by electric control circuit
and cooling water flows into the tank. When water level is high, cooling water
should be drained through overflow pipe.
4.3.2 Water pump. Two same type water pumps are furnished in the system,
one operating, other for standby. When pressure of pump outlet is less than
setting value, the contacts of the pressure control circuit turn on, standby pump
is started by electric control circuit.
4.3.3 Water exchanger. The shell of exchanger is made from stainless steel.
two heat exchangers are supplied in the system, one for operation, the other
for standby.
4.3.4 Water filter. The shell of filter is made from stainless steel. Strainer is
made from stainless steel screen. Two filters are installed in the system, one
for operating and the other for standby.
4.3.5 Demineralizer. After the system is operated for period of time, cooling
water quality will fall gradually, special demineralizer is supplied to improve
water quality, it is not allowed to improve hard water directly. Mixed bed type
demineralizer is adopted in the system. The cation and anion resin in
demineralizer is the ratio of two to one, cooling water flow through the
demineralizer is about 5t/h, and is 8% of total flow in the system. Regeneration
of resin should be made by the outside of the demineralizer. According to

source of goods, resin type is determined by user. General, filling is about 160
litre.
4.3.6 Conductivity meter. Two same type conductivity meters are supplied the
system, one is used to monitor conductivity of cooling water of the generator
stator winding inlet. Other to monitor counter conductivity of cooling water of
demineralizer outlet so as to determine if resin is need regenerated.
4.3.7 Temperature regulating valve.
It is installed on the inlet circulation water pipe of water cooler, it controls
circulating water flow so as to control outlet temperature of cooler.
4.4 Points of attention for installation.
4.4.1 Inner wall of pipe must be cleaned.
4.4.2 pipes and equipment of these units must be washed. It must be flanged
connected with water supplying control station without impurity.
4.4.3 After system is connected with generator, It should be rinsed

reversely

first, Then has the reverse and forward rinsed alternatively.

Water feeding pressures is no more than 0.25MPa.
4.4.4 Circulation water side of water cooler should have water pressure testing
of 0.8MPa30min. In testing, butterfly valve at inlet and outlet of temperature
regulator should be closed.
4.4.5 Water pump's overhaul and maintenance can refer to manual provided
manufacturer.
4.4.6 All instruments and gauges should be tested regulating in installation.
4.5 Regulating and setting.
4.5.1 Setting of protection value for cutting water.
Flow protection return circuit.
Stator winding water flow decrease to minimum value, and it cannot rise
again in 30 seconds, the protection equipment of generator will be operated.
Generator should unload and throw off load, normally the minimum setting
value is 37~35t/h.
4.5.2 Regulation and testing of temperature regulator under the load condition
according to manual, making feeding water temperature remain at 453.
4.6 Operation and maintenance of stator winding cooling water system.

4.6.1 According manual provide by manufacture under rated hydrogen

pressure. hydrogen pressure in generator should be about 0.1~0.2MPa higher
than feeding water pressure of stator winding cool water.
When feeding water's pressure is 0.2MPa but flow is stilling sufficient,
feeding water's pressure can be raised to 0.23MPa in order to increase flow,
but when hydrogen pressure decreased to 0.26MPa. Hydrogen must be
compensated. In a word, Hydrogen pressure in generator must be higher than
0.03MPa, darning water's temperature is not higher than 80.
4.6.2 When system is feed with water, pump cannot be started to open until
overflow pipe start to over flow water pressure should be raised to presetting
valve gradually. In this period, if water lever is too lower, operator should
compensate water manually. In the meantime, you should open W-52W-64
valve to drain gas till water flow, then close these valves.
4.6.3 When starting this unit in cold state, operator should heat cooling

water

to make its temperature higher 5 than hydrogen temperature by using

electric heating equipment. Before operation you must first open W-50W-51
valve, close W-57W-56W-58 valve, turn on electric heating so as to heater
and water control station forming circuit. Operator should monitor gauge when
water will be heating over H2 temperature 5 then cut off the heater power.
Heater may installation near W-52W-51 valve, so as to operation.
4.6.4 Sample gas from sampling valve on top of water tank is found its
hydrogen higher than standard content after analyzing gas, operator should
stop generator and check, putting stress on checking coil introduction water
pipe. Normal operation sample valve should be closed.
4.6.5 When water cooler is supplying water circulately. Gas should be drained
from water cooler's top.
4.6.6 Water feeding pressure of demineralizer should be limited under
0.35MPa. When water draining conductivity is higher than 0.5 s resin
regeneration should be considered.
4.6.7 All of instrument and meters should be calibrated regularity.

Chapter6

DESCRIPTION OF CIRCULATING WATER

SYSTEM
Section1

1.1

General situation

2300MW coal fired power plant is located in the north of Cilacap, Central

Java, Indonesia and adjacent on the INDIAN OCEAN.

1.2 meteorological condition
1.2.1 Atmospheric pressurembar
Average barometric pressure
1.2.2

1008.2

Temperature
Maximum monthly average ambient temperature32.7
Minimum monthly average ambient temperature20.9

1.2.3

Maximum extremely temperature

34.5

Minimum extremely temperature

17.4

Air relative humidity

Maximum monthly relative humidity

93

Minimum monthly relative humidity

1.2.4

Rainfallmm
Maximum recorded rainfall for 12 hrs
Maximum recorded rainfall for 24 hrs

73
77
230

Design rainfall intensity70mm per hour for a 60-minute

storm on a 15-year frequency
1.2.5

Wind speed
Maximum design wind speed at 10m120km/h
Direction of prevailing windfrom SE to NW for 80% of
year

1.2.6
1.3

Earthquake intensity

0.3g

Ocean hydrologic data

1.3.1 Tide level

99% tidal water level
97% tidal water level
10% tidal water level
1% tidal water level

0.37m
0.48m
1.99m
2.46m

0.1% tidal water level

2.67m

100 years return period highest tidal water level

33 years return period lowest tidal water level

2.973m
-0.077m

Wave
Deep-water wave for Cilacap Sea (50 years return period)
Extreme value

Cumulative frequency

Wave height (m)

Wave period (s)

H13%=Hs

4.86

10.58

H1%=1.51Hs

7.37

13.7

H4%=1.28Hs

6.20

12.03

H5%=1.22Hs

5.93

11.75

1.3.3Water temperature
design average seawater temperature: 26
design maximum seawater temperature: 34
4) suspend sediment
Year-to-year highest suspend sediment contentNo information
Year-to-year average suspend sediment contentNo information

Section2

Design description of circulating water system

The once through cooling water system is adopted in this project and 2 sets
circulating water pumps are installed for each 300MW unit. One circulating water
pump house is common for 2 units. Two main circulating water pipes for two units are
not connected with each other.
2.1

Main parameters of circulating water system

Cooling surface of condenser

17750 m2

Cooling water pipe of condenser

Ti, 250.5

C.W. Flow

41050 m3/h

C.W. inlet temp.

26

C.W. outlet temp.

34

Back pressure

0.0067MPa

 Water velocity

2.3m/s

When C.W. inlet temp. is 34 , Back pressure is 0.0118MPa

Hydraulic loss and calculation of C.W. system at 100% flow
1) From water Intake to inlet chamber

1.508 m

2) From C.W. pump to condenser inlet

3.492 m

3) Condenser

6.0 m

4) From condenser outlet to siphon well inlet

3.754 m

5) Total head loss

14.754 m

6) Static head from siphon well to mean water level:

7) Total head required:

2.879m
17.633 m

circulating water flow for 2 units

circulating water flow list (2X300MW)
Table 2-1
circulating water flow
NO.
1
2

Item of water demand

Cooling water for condeser
Cooling water for auxiliary heat
exchanger
Total

1300MW 2300MW
41050

82100

3300

6600

44350

88700

Remark

Circulating water pump is vertical style mixed-flow type, model number is

72LKXA17.9,the rated capacity is 6.26m3/s, total head is 0.179Mpa.The power
of the match motor for circulating water pump is 1600KW and voltage is 6000V.
2.2

The structures and buildings of circulating water system

The once through cooling water system is adopted in this project. The seawater

flow by gravity from water intake dock basin to C.W. pump inlet chamber through the
C.W. intake open channel and be pumped to condenser and auxiliary heat exchanger
through C.W. inlet FRP pipe by C.W. pump. After heat exchanged in condenser and
auxiliary heat exchanger, the outlet hot seawater flow to siphon well through C.W.
outlet FRP pipe and under drain, at last the hot seawater flow by gravity from siphon

well to sea through C.W. outlet open channel.

2.2.1

Structure of water intake

1) Water intake adopt bank side dock basin type according to the result of the
WATER INTAKE REPORTand water intake structure consist of breakwater,
dock basin, intake open channel and bar screen.
2) Bar screen is installed at the end of intake open channel, the distance between the
bars is 200mm.Water velocity across the bars is about 0.2m/s at design flow.
3) The detail design and arrangement of structure of water intake reference to the
drawings and description provided by PT.Zhenhua Indonesia.
2.2.2 Water inlet chamber
1) Water inlet chamber is outdoor rectangular type and union with C.W. pump house.
The dimension of inlet chamber is 24m21m12.3m.
2) The top platform elevation is +3.7m.
3) The water inlet chamber is divided into four independent parts for 4 sets
circulating water pump, in each part, 1 set cleaning trash device, 1 set travelling
band screen are installed. Distance between bars of cleaning trash device is 50mm
and the mesh size of traveling band screen is 6mmX6mm.
4) For the purpose to cut off the water flow when cleaning trash device, travelling
band screen and C.W. pump maintenance, 2 sets steel gate are installed upstream
of cleaning trash device common for four independent parts of inlet chamber. 1set
guiding groove for steel gate is installed in each part of inlet chamber. The start
and stop of the steel gate is static water type.
5) There is 1 set cleaning trash device in each part of inlet chamber, and 1 set mobile
trash rake is installed common for 4 sets cleaning trash devices.
6) 4 sets wash pumps, pipeworks and nozzles are provided for 4 sets travelling band
screen back washing. the back washing pump specification is as following:
EHG125-80-200 type Q=150m3/h H=0.46MPa N=37KW.
7) Two cooling water pumps for C.W.pump mating motor are installed at the
platform of inlet chamber. The pump is deep well pump and its specification is as
following:
12RJLC/4 type, Q=125~160~200m3/h H=0.39~0.345~0.285MPa N=30KW
2.2.3 Circulating water pump house

2sets C.W. pumps are installed for each 300MW unit in this project and one
C.W. pump house is common for 2 units. The C.W. pump house is located at opposite
side of the road which west of the turbine house.
4 sets 72LKXA-17.9 type C.W. Pump (Q=6.26m3/s, H=0.179MPan=425r/min,
mating motor is YKSL1600-14/1730-1 type, N=1600kW, V=6000V,IP54) and 2 sets
HFY65-12.5 type drainage sump pump (Q=25m3/h, H=0.125Mpa,N=3kW) are
installed in C.W. pump house. The start and stop of C.W. pump can control at central
control building and on site.
Hydraulic

control

butterfly

valve

(D741aX-6

type,

DN1800,

PN=0.60Mpa,N=4kW,V=380V) is installed at the outlet of C.W. pump and can be

closed automatically with quickly and slowly two closing stages. The closing time can
be determined by the shakedown test.
One electric double beam bridge crane (with cabinet) installed in C.W. pump
house for equipment maintenance. The operation platform of the C.W. pump house
has the control device room and maintenance area.
The operation platform elevation is +3.70m.
2.2.4 Circulating water pipe
The main circulating water inlet and outlet pipes nominal diameter is DN2200
and pipes are all fiberglass reinforced plastic pipe (FRP). The flow through circulating
water pipe is 12.51m3/s and flow velocity is about 3.294m/s. For the purpose to enter
into the pipe inside when pipe installation and maintenance, 2 manholes will be
arranged at each main DN2200 pipe (near the C.W. pump house and turbine house).
2.2.5 Circulating water outlet under drain
The circulating water flow out of the condenser and auxiliary heat exchanger of
2 units through the under drain enter into siphon well. The dimension of the R.C.
under drain is 2X2000mmX2500mm .the flow is 25.03m3/s and flow velocity is about
2.503m/s.
2.2.6 Siphon well
Siphon well is reinforced concrete construction and located at southwest of the
power plant. The dimension of siphon well is 12400mmX20000mmX8500mm.The
top platform elevation is +7.00m and the elevation of the top of weir in the siphon
well is +3.00m.
2.2.7 Circulating water outlet open channel
The circulating water flows out of the siphon well through the open channel
enter into the sea by gravity. The bottom width of the open channel is 4500mm and

bottom slope is 0.002.The flow is 25.03m3/s and flow velocity is about 3.01m/s.
2.2.8 Cooling water for auxiliary heat exchanger
There is 3300m3/h circulating cooling water flow from main circulating water
pipe to auxiliary heat exchanger for each unit. The inlet and outlet Cooling water
pipes for auxiliary heat exchanger nominal diameter is DN700 and are all FRP pipes.
The water discharge from the auxiliary heat exchanger enter into circulating water
outlet pipe and then flow to siphon well and enter into the sea through circulating
water outlet open channel at last.

Section3

The construction and installation description of the

circulating water system

3.1 The construction and installation dimensions in this project shall be according to
the data which written on the drawings and forbid using the data which is
measured in scale on the drawings.
3.2 The construction and installation shall be according to the requirements of the
drawings. Drawings and relative descriptions shall be understood before
construction and installation. If the drawings content isnt clear or has other
questions, please consult with site designer in time.
3.3 Embedded parts, embedded pipes and reserved holes in drawings shall be
constructed simultaneously with the construction of the structure. After checking
up the dimensions of arrival equipment and finding without mistake, the
embedded parts will be constructed. Allowable dimensions deviation of
embedded parts shall be not exceeded 10mm except for that noted specially in
drawings. Installation organization shall examine and cooperate at all hours in
the process of structure construction.
3.4 The installation management plan shall be done ,the construction order of
underground pipes shall be prepared at fist time, the lower pipes or foundations will
be constructed at first and upper pipes later.
3.5 For the requirement of installation for circulating water pipe, please see the
specification, which provided sub supplier by LIANYUNGANG LIANZHONG
FRP CO.LTD.
3.6 The heavy-duty equipments shall be transported through the reinforce area of
circulating water pipe after circulating water pipe backfilling, and the temporary
pillow shall be beded on the pipe reinforce area to protect the circulating water
pipe from crushing.
3.7 The shakedown test, installation and maintenance of all equipments in the
circulating water system shall be performed according to the requirements of
manufacturers.
3.8 Expansion joints for C.W. pump and hydraulic control butterfly valve are only use
for adjusting the clearance between pipes when valve or pump installation and
disassembly. After valve or pump installed, it must lock the lock bolt in joint to
make the pipe and joint as a rigid body.

section4

Operating management description of circulating

water system

4.1 C.W. pump

4.1.1 There are 4 sets C.W. pumps for 2 units in the C.W. pump house. And 2 sets
C.W. pumps provide cooling water for one 300MW unit jointly at normal
operation. When only one set C.W. pump provides cooling water for one unit at
certain case, the other C.W. pump for the same unit is standby and interlock with
the operation pump. And when the operation pump stop by accident, the
interlocked pump shall start up automatically.
4.1.2 The C.W. pump and its outlet hydraulic control butterfly valve can be started up
or stopped at central control room or at site by manual control. The operation
position of C.W. pumps and hydraulic control butterfly valves can be displayed
at C.W. pump house control device room and central control room.
4.1.3 The C.W. pump interlock with its outlet hydraulic control butterfly valve and
cooling water pump for C.W. pump mating motor. The interlocked operation
program is as following (for example with C.W. pump which code is
10PAC11APOO1,reference to drawing circulating water pump house system
flow diagram and drawing NO. is 50-F209S-S0203A-01):
4.1.3.1 Normal operation
The C.W. pump can be started up or stopped independently by manual control
and started up or stopped interlocked with outlet valve at central control room.
In addition, the C.W. pump and its outlet valve can be started up or stopped at
site by manual control.
1startup program of C.W. pump at normal operation:
After push the interlocked startup button of C.W. pump, the program
automatically confirm the C.W. pump outlet hydraulic control butterfly valve
(10PAB11AA001) is closed and simultaneously judge the cooling water pump
(00PAD11AP001 or 00PAD12AP002) for C.W. pump mating motor if startup.
If the cooling water pump is already startup then open the motorized valve
(10PAD11AA001), otherwise the program will start up the cooling water
pump and open the motorized valve. If above process complete, program will
open the C.W. pump outlet valve after 60 second (adjustable, 5 min for the fist
time to operate), when the open angle reach 15 degree the program will start
up the C.W. pump. Above process is interlocked at normal operation.
2stop program of C.W. pump at normal operation:
After push the interlocked stop button of C.W. pump, program will
close the C.W. pump outlet valve and stop the C.W. pump motor after the
valve closed angle reach 20 degree. 60 second (adjustable) later, the program
will close the motorized valve of cooling water pipe for C.W. pump mating
motor (only when 4 sets C.W. pump stop together, the cooling water pump
shall be stopped interlocked). The outlet valve can be closed automatically

with quickly and slowly two closing stages: the fist is quickly closing stage,
closing time is about 2.5~20 second (adjustable) and closing angle is about
708(adjustable); the second is slowly closing stage, closing time is about
6~60 second (adjustable) and closing angle is about 208(adjustable); Above
process is interlocked at normal operation.
3It shall be according to the order demanded at above description when above
devices independently operate . Adjusting the order is not allowed.
4.1.3.2 The processing when accident (for example with C.W. pump which code is
10PAC11APOO1)
1If operating personnel receive the alarm signal (such as motor bearing lube oil
temperature, electric current value, flow alarm switch signal of cooling water
inlet pipe for C.W. pump mating motor and so on) of C.W. pump and mating
motor(10PAC11APOO1)
or
hydraulic
control
butterfly
valve(10PAB11AA001),he shall make sure quickly what happened and stop the
C.W. pump by manual control after confirmed by the administration of power
plant. Its stop program is as same as stop program at normal operation.
2When C.W. pump (10PAC11APOO1)is stop by accident, it will send the alarm
signal to central control room and interlocked close the outlet hydraulic control
butterfly valve(10PAB11AA001) simultaneously. The outlet valve will close
automatically with quickly and slowly two closing stages according to the
adjusted closing angle and time. 60 second (adjustable) later after C.W. pump is
stopped, it will interlocked close the motorized valve (10PAD11AA001) of
cooling water pipe for C.W. pump mating motor.
3When hydraulic control butterfly valve(10PAB11AA001) automatically close by
accident, the alarm signal will be sent to central control room and interlocked
close the C.W. pump (10PAC11APOO1)60 second (adjustable) later after
C.W. pump is stopped , it will interlocked close the motorized valve
(10PAD11AA001) of cooling water pipe for C.W. pump mating motor.
4If hydraulic control butterfly valve(10PAB11AA001) can not open completely
by accident after C.W. pump start up 45 second, the alarm signal will be sent to
central

control

room

and

interlocked

close

the

C.W.

pump

(10PAC11APOO1)60 second (adjustable) later after C.W. pump is stopped ,

it will interlocked close the motorized valve (10PAD11AA001) of cooling
water pipe for C.W. pump mating motor.

4.1.3.3 For the purpose to reduce the pump stop water hammer pressure, the hydraulic
control butterfly valve (10PAB11AA001) closing time of two closing stages
shall be determined by the shakedown test. The requirement of the shakedown
test shall be reference to the relative specification, which provided by
manufacturers of C.W. pump and hydraulic control butterfly valve.
4.1.3.4 When the circulating water pipe is empty or the prime operation, the
suggestion opening extent of hydraulic control butterfly valve is about 1/3 of the
totally opening and it shall fill the water into the circulating water pipe slowly.
After confirmed that all pipes fully fill with the water, it can completely open
the valve.
4.1.3.5 There are pressure meters at the outlet of all C.W. pumps, the design operation
pressure is about 0.179MPa.
4.2 Cleaning trash device (with mobile trash rake)
The control of the cleaning trash device (with mobile trash rake) is according to
the water level difference between upstream and downstream of cleaning trash device.
For example with cleaning trash device which code is 10PAA21ATOO1,the operation
program of cleaning trash device is as following:
(1) Program will inspect the water levels of upstream and downstream of
cleaning trash device, when the water level difference reach to
0.3m(adjustable), the mobile trash rake will automatically start up, until the
water head reduce to 0.1m(adjustable) it will stop automatically. The
operation time shall be not less than 30min at each time.
(2) Mobile trash rake will start up automatically at intervals of 24 hours
(adjustable) for the purpose to prevent the revolving parts from being got
stuck. In this process the mobile trash rake shall clean cleaning trash device
one by one of each inlet chamber.

The operation time shall be not less

than 30min at each time.

(3) Cleaning trash device (with mobile trash rake) can be started up and stopped
by manual control at site.

4.2 Travelling band screen

The control of the travelling band screen is according to the water level
difference between upstream and downstream of travelling band screen. For example
with travelling band screen which code is 10PAA31ATOO1,the operation program of
travelling band screen is as following:

1 Program will inspect the water levels of upstream and downstream of

travelling band screen, when the water level difference reach to

0.3m(adjustable), the travelling band screen will start up automatically, until
the water head reduce to 0.1m(adjustable) it will stop automatically. The
operation time shall be not less than 30min at each time.

2 Travelling band screen will automatically start up at intervals of 24 hours

(adjustable) for the purpose to prevent the revolving parts from being got stuck.
The operation time shall be not less than 30min at each time.
3avelling band screen can be started up and stopped by manual control at site.

4.3 Travelling band screen back wash pump

The start up and stop of the travelling band screen back wash pump shall be
interlocked with the travelling band screen. When travelling band screen start up, the
program will start up the back wash pump too; when travelling band screen stop, the
program will stop the back wash pump too.
There are 4 sets back wash pump for 4 sets travelling band screen. One back
wash pump is working for one travelling band screen. When the operation back wash
pump is accident, the program will send the alarm signal to control room and display
the code of the accident pump.

4.4 Y type filter on the outlet of travelling band screen back wash pump
The differential pressure switch is installed between the inlet and outlet of the Y
type filter. When the pressure differential reach to 0.05MPa(adjustable), the switch
will send the alarm signal to C.W. pump house control device room and central
control room to remind the operating personnel to wash the filter at site.
The differential pressure can be displayed at control device room.

4.5 Cooling water pump for C.W. pump mating motor

4.6.1 there are 2 sets cooling water pumps for C.W. pump mating motor and
interlocked with each other. When the operation pump is stop by accident, the
interlocked pump shall start up automatically and at the same time the program
will send the alarm signal to control room and display the code of the accident
pump.
4.6.2 1 set cooling water pump provides cooling water for 4 sets C.W. pump mating

motors (the other stand by). The start up and stop of the cooling water pump is
interlocked with the C.W. pump (see section 4.1).
4.6.3 Cooling water pump can be started up and stopped by manual control at site or
at central control room. The operation position of cooling water pump can be
displayed at C.W. pump house control device room and central control room.
4.7 Drainage sump pump
2 sets drainage sump pumps are installed at drainage sump in the valve pit of
C.W. pump house. There are 2 sets drainage sump pumps interlocked with each
other.
2 sets pumps are controlled by the water level of drainage sump. When the water
level is 1.30m, a drainage sump pump will start up automatically and until the
water level reduce to 0.70m the pump will stop automatically. When a drainage
sump pump is already operating but the water level still rise to 1.80mthen the
other stand by pump will start up automatically and at the same time it will send
alarm signal to control room. When the operating personnel receive this signal
he shall inspect and treat the problem immediately at site.
When the operating pump is accident, the stand by pump will start up
automatically and at the same time it will send alarm signal to control room. The
operating personnel shall repair the accident pump soon.
The water level signal of drainage sump and operating position signal can be
displayed at site.
4.8 The water level of inlet chamber
The water level of inlet chamber at downstream of travelling band screen shall
be continuously displayed at site and central control room.
When the water level under 7.0m(from the chamber bottom), an alarm signal
will be sent to central control room for the purpose to remind the operating personnel
that the water level is under the design lowest water level. The operating personnel
shall take appropriate action after receive this low water level alarm signal.
4.9 The maintenance and checking of devices in circulating water system
There is maintenance area in C.W. pump house. The maintenance of C.W. pump
shall be performed in maintenance area. The hand oil pump is used for changing the
lubricating oil of C.W. pump mating motor. The hand oil pump can be put in the
maintenance area.
The steel gate shall be needed to cut off the flow when the inlet chamber
maintenance. The cut-off and start-up of steel gate is adopted static water type. When
cutting off the flow of the inlet chamber, it shall stop all the pumps which suck water

in this inlet chamber first and then put steel gate in the chamber to cut off the flow, at
last empty all water of inlet chamber by mobile discharge pump. After the chamber
maintenance complete, pump water fill with this chamber from near by chamber by
using mobile pump and still the water level upstream steel gate is as same as
downstream steel gate, the steel gate can be lifted. The steel gate shall put in the
maintenance area of inlet chamberthe robber water seal belt of steel gate shall be
not pressed when puttingand mobile discharge pump can be put in the maintenance
area of C.W. pump house. The mobile discharge pump shall be used to remove sand in
the inlet chamber too.
The devices of inlet chamber shall be lift to the maintenance area near by the
inlet chamber by truck crane

to check.

Before and after plant operating, it shall clean up the settling sand in intake dock
basin and intake open channel by dredger to prevent the large quantity sand from
entering into circulating water system; it shall clean up the marine life that adhere to
the surface of devices and inside surface of circulating water pipes in the period of the
unit maintenance
4.10 Notices
1 Operating personnel shall pay attention to the water level of inlet
chamber. It shall guarantee the submersed water depth of C.W. pump to prevent the
air from entering into inlet of C.W. pump.
2 To avoid air accumulation at the top of cooling water pipes of condenser
(or at top of condenser water chamber), it shall open the vent cock and vent valve
before the condenser operating, and then fill the cooling water pipes and water
chamber with water slowly. After doing this it can close the vent cock and vent valve.
3 It shall start up or stop C.W. pumps one by one with intervals more than
10min.
4

The appropriate closing stroke and closing time of C.W. pump outlet hydraulic

control butterfly valve are very important to reduce the pressure of water hammer and avoid the
C.W. pump rotating inverted. The closing time and closing stroke shall be determined by
shakedown test before the circulating water system operating.