CZ844.

08/01

Instruction of Control System of N9-4.9

9MW Condensing Turbine

Nanjing Turbine & Electric Machinery (Group) Co., Ltd

Nanjing Turbine & Electric Machinery (Group) Co., Ltd Code CZ844.08/01
Substitute
N9-4.9 Instruction of Control System of 9MW Condensing Page 23 no.1
Turbine

Prepared by: Mao Wenxuan 2012.11

Checked by: Lu Bo 2012.11

Verified by: Tang Jixing 2012.11

Countersigned by:

Standard reviewed by: Hao Sijun 2012.11

Examined by: Zhang Jing 2012.11

Approved by:

Label Quantity Page No. Document No. Brief Description Signature

Disk (Tape No.) Based Drawing No. Old based Drawing Filing
No.
 CZ844.08/01

1. Introduction

2. Main technical specifications of the regulating and protecting system

3. Operating principle and system introduction of the control system

3.1 Basic principle

3.2 DEH system composition

3.3 DEH system functions

4. Oil supply system

5. Protection system

6. Turbine supervisory instrument system

7. Adjustment and test of the regulating and protecting system

7.1 Test in static turbine state

7.2 Test in turbine operating state

8. Main installation data of the regulation and protection parts

9. Matters needing attention for control system

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1. Introduction

This instruction manual provides necessary basis for the installation, commissioning
and subsequent operation, maintenance and repair of N9-4.9 condensing turbine regulating
and protecting system and lists the main technical specifications of the regulating (control),
protecting, oil supply and thermal systems respectively. It describes their operation
principle, functions, regulation and test and the main installation data of al system parts
and briefly introduces the turbine thermal control system. When using this manual, it is
necessary to refer to the other unit-related documents and drawings at any time and
particularly the general system drawing and parts drawings related to the control system.

2. Main technical specifications of the regulating and protecting system

No. Item Unit Specification Remarks

1 Rated turbine speed r/min 3000
2 Oil pump inlet oil pressure MPa 0.1
3 Main oil pump outlet oil pressure MPa ～0.1
4 Speed diversity factor % 3-6
5 Delay rate % ≤0.2
6 Maximum oil servo motor travel mm 120
7 Emergency governor action speed r/min 3270～3330
8 Emergency governor resetting speed r/min 2885
9 Tachometer overspeed alarm value r/min 3150
10 Tachometer overspeed protection r/min 3270
value (shutdown)
11 mm +1.0 or -0.6 Negative is
Rotor axial displacement alarm value
reverse
(auxiliary thrust position)
direction
12 Rotor axial displacement protection mm +1.3 or -0.7 Shutdown
value value
13 Lube oil pressure drop alarm value MPa 0.05～0.055
14 Lube oil pressure drop alarm value MPa 0.04
15 Lube oil pressure drop protection MPa 0.02～0.03
value (shutdown)
16 Lube oil pressure drop protection MPa 0.015
value (stop turning gear)
17 Lube oil pressure rise alarm value MPa 0.16
(stop electric pump)
18 Main oil pump outlet oil pressure low MPa 0.7
alarm value
19 Bearing return oil temperature alarm ℃ 65
value
21 Bearing bush temperature alarm value ℃ 100
22 Bearing return oil temperature stop ℃ 75
value
23 Bearing bush temperature stop value ℃ 110
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24 Condenser vacuum drop alarm value MPa -0.087

25 Condenser vacuum drop protection MPa -0.061
value (shutdown value)
26 Bearing pedestal vibration alarm value mm 0.06
27 DEH controller overspeed shutdown r/min 3270
value

3. Operating principle and system introduction of the control system

The turbine control system uses digital electrohydraulic control system (DEH for short)
and DEH system has higher control accuracy than normal hydraulic system and automation
level is greatly improved. It can realize speed up (manual or auto), cooperation with electric
synchronization, load control (valve position control and power frequency control) and other
auxiliary controls, communication with DCS, control parameter on-line adjustment and
overspeed protection function etc and can enable the turbine to adapt to various conditions
and to safely operate for long time.

3.1 Basic principle

During speed up before synchronization, speed closed loop is isochronous control and
the 505 controller uses the deviation signal of the measured actual unit speed and set speed,
after analyzed and processed by software and operated by PID, as the given input to the
valve position controller and after compared with the oil servo motor feed back signal,
amplifies its deviation to current signal to control the opening of electrohydrolic valve and
regulating valve so as to reduce speed deviation and reach isochronous speed control.
When speed reaches 3000/min, the unit can operate at constant speed depending on needs
and at this time the DEH can receive the command sent by the automatic quasi-
synchronizer or the operators’ manual operation command to regulate the unit to realize
synchronization.

After unit synchronization, if closed loop power control is used, it can be decided
depending on needs that the DEH immediately makes the unit operate with initial load.
The unit power and unit speed measured by DEH are used as feed back signal and speed
deviation used as primary frequency modulation signal to correct the set power. After
comparison of the set power with power feed back and after PID operation and power
amplification, the solenoid servo valve and oil servo motor are used to control the
regulating valve opening to eliminate deviation signal and to realize isochronous control
for unit power. If the power is not fed back, the unit operates in valve position control
mode, i.e. increase speed setting and open wider the regulating valve to increase steam
admission to achieve the goal of load increase. At load rejection, the DEH automatically
switches the load control over to speed control mode. If the unit capacity is relatively low,
it is recommended that closed loop power control should not be used.

3.2 EH system composition

3.2.1 Mechanical overspeed protection system (Refer to 5.1 for details)

3.2.2 Main stop valve automatic closer and start trip device

The functional structure diagram of the main stop valve automatic closer and start
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gate hanging device is as follows. The start gate hanging device controls the up and down
movement of the main stop valve actuator (main stop valve automatic closer) and further
controls the opening of the main stop valve and at the same time the start gate hanging
device can perform mechanical unit overspeed reset. After receiving power, the DEH
system gate hanging electromagnet establishes reset oil and pressure oil goes through
throttling orifice to establish safety oil. Safety oil presses down the gate hanging device
transfer valve to connect through oil passage to open the main stop valve. At shutdown,
safety oil is released and the transfer valve cuts off start oil and releases the oil from the
automatic closer oil cylinder chamber so that the main stop valve closes quickly. The main
stop valve switch (movable) solenoid valve is not energized in normal condition and after
receiving power, it cuts off pressure oil and releases start oil to close the main stop valve,
thus main stop valve leak test can be performed by controlling this solenoid valve
energized duration through DEH system.

【上图文字译文如下：】

启动挂闸装置=start gate hanging device；压力油=pressure oil；主汽门自动关闭器

=main stop valve automatic closer；挂闸电磁铁=gate hanging electromagnet；主汽门开

关电磁铁=main stop valve switch electromagnet；复位油=reset oil；安全油=safety

oil；启动油=start oil；

3.2.3 Servo actuator, mainly including solenoid servo valve and oil servo motor

The electrohydraulic servo valve is the solenoid proportional valve from MOOG
Co. and DDV solenoid servo system is shown in the following figure: pressure oil is
applied to the upper and lower parts respectively of the oil servo motor pilot valve slide
valve and the upper application area is a half of the lower. The upper oil pressure is the
same as the main oil pump outlet oil pressure and lower oil pressure enters a dynamic
oil inlet of the pilot valve sleeve and exits an adjustable external fixed throttling orifice
to form a balance flow balance to establish control oil. At the same time, its oil pressure
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is a half of pressure oil and this oil is called pulse control oil. The valve position
command signal sent from the DEH is amplified by the servo amplifier and the DDV
servo valve changes the electric signal to pulse control oil pressure signal to control
dynamic oil feeding and directly control the oil servo motor to drive the regulating
valve so change the unit speed or power. When the oil servo motor moves, it drives
LVDT displacement sensor to add as negative feed back to valve position command
signal. When the two electric signals are balanced, the servo amplifier output remains
unchanged. At this time DDV valve returns to the original balance position and
maintains the pulse control oil constant and the oil servo motor is stabilized in a new
operation position. The OPC solenoid valve set in the DEH system is used for 103%
overspeed protection or electrical splitting , and AST solenoid valve is used for shut
down and adjustable throttling orifice is used to adjust oil servo motor pilot valve offset.

3.
2.4 DEH System

This system has one cabinets.

3.2.4.1 DEH Control Cabinet

Cabinet structure complies with NEMA standard (NEMA12<IP52>), dimension:

2200×800×600, single door at front, double door at rear, and cable entry from bottom.
Terminal block adopts the product made by Phoenix Company in German, the terminal
unit can adapt to connection of 1.5mm2 core wire; the cable glands, line slot are made of
flame-retardant material, installation position of the terminal block is convenient for wiring.
Electrical elements in the cabinet, such as, relay, circuit breaker, ON/OFF switch,
button and DC power supply all use import products. Exhaust fan and lighting are provided
in the cabinet.
Exchange of important control information between DEH system and ETS system is
realized through hard wiring between cabinets through respective I/O point, DEH system

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can provide corresponding output points for SOE, DCS or I&C signal alarm system to

use. 。

Grounding busbar of protection ground and shielding ground is provided in the

cabinet, the grounding system strictly requires single point grounding, is connected to
electrical main grounding through cable with diameter no less than 35mm2, grounding
resistance less than 2ohm.

3.2.4.2 Power Distribution System

Power supply of DEH cabinet is two-circuit 230VAC±10%/10A/50Hz±1Hz single

phase power supply (one of the circuits comes from UPS, the other circuit comes from
house emergency power supply) and one circuit 220VDC/2A power supply supplied by the
user. The two AC power supplies are mutual backup, failure of any one of the circuits will
not lead to power failure of any part of the system. Failure of any one of the circuits will
change over to the other healthy circuit to operate.

Power supply part in the cabinet is configured with a group of redundant 24VDC
power supply to supply power to 505 digital controller, SPC valve position controller,
DDV electro-hydraulic servo valve, DO isolating relay and DI isolating relay respectively.
The power supply has sufficient capacity and proper voltage, able to meet the equipment
load requirement.

220VDC power supply is used to supply power to OPC solenoid valve set.

3.2.4.3 DEH control system

DEH system core parts adopt American Woodward products, the model is Woodward
505.
Execution part valve position controller of DEH system adopts SPC type servo
position controller of Woodward Company, which receives command signal outputted
from 505 Controller and the servo motor feedback signal, the signal outputted by SPC
valve position controller controls DDV electro-hydraulic valve to control opening of the
servo motor.
WOODWARD 505 is a 32bit microprocessor-based digital controller suitable for
turbine control. It is integrated with field configuration control and operating panel.
Operating panel contains a two-line (24-character) display and a panel with 30
operating keys and is used to configure 505 controller on-line parameter adjustment and
operate turbine start, stop and operation. Through the two-line display on the operating
panel, it is possible to observe the actual value and set value of control parameters.
505 Controller has two internal mutually independent controller channels:
speed/load control PID loop, auxiliary control PID loop. The former two are output
through low selection. It has three types of communication ports. The controller has
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three operation modes: program mode, operation mode and service mode. Program
mode is used to configure controller functions to adapt to the specific control
requirements and once the program mode is configured, it will not change any more
until control functions are changed. Operation mode is mainly used to operate turbine
for the whole process from start, normal operation to stop. Service mode can modify the
set parameters in operation condition and can be used for the corresponding system
through programming configuration depending on needs.
For this system, only part of its functions is used. See the following block diagram:

【下图文字译文如下：】

数字控制器=digital controller；阀位控制器=valve position controller；进汽

=steam admission 汽轮机=steam turbine；发电机=generator；压力变送器=pressure

transducer；发电机断路开关=generator disconnecting switch；电网断路开关=power

grid disconnecting switch

Speed (SPEED) in the figure is used for speed/load control, and auxiliary control
(AUX) is used for main steam pressure restriction.

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3.2.4.4 DEH system input, output and measuring elements

Mainly including input, output, speed, valve position travel, power and pressure
measuring element of 505 Controller and SPC valve position controller
3.2.4.4.1 DEH cabinet input and output
DEH system receives DCS remote operation gate hanging and main steam valve
switch (movable) dry contact signals;
DEH system outputs two circuits of 230VAC signals to be used for controlling gate
hanging electromagnet and main stop valve switch (movable) electromagnet respectively;
DEH system outputs two circuits of 220VDC signals for controlling OPC solenoid
valve set;
DEH system also provides dry contact output signals of OPC operating, main steam
valve closing, etc.
3.2.4.4.2 505 Controller input and output
505 Controller has two control loops whose output is 4-20mA, load capacity is
360ohm (20-160mA and 60ohm can be selected through software configuration) and at the
same time 0-10mA AC fluttering current can be added.
505 Controller has two speed sensor input channels and its signal input is high
selection.
Analog input is 4-20mA and 6 channels can be used for configuration to meet the
specific use and input impedance is 200ohm. It can be used for power and main steam
pressure input and since only the 6th channel is isolated, when the other channel inputs are
used, it is necessary to consider signal isolation.
Analog output is 4-20mA and 6 channels can be used for configuration to meet the
specific use and load capacity is 600ohm. It can be used to output a variable, e.g. actual
speed value, etc.
Contact input is dry contact and there are totally 16, 4 of which are designated: for
shutdown (main stop valve automatic closer travel switch and enters through DEH system
internal relay extension output loop, normal close for unit in normal condition), external
reset (make short pulse signal), speed rise (make short pulse signal), speed fall (make short
pulse signal). Other contacts can be configured for use and the control system for turbine
synchronization and operation must have two configured contacts for generator and power
grid short circuiter status input. After turbine trip, if auxiliary power is not operated,
connect in parallel the generator circuit breaker status signals to these two contacts (normal
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close for unit synchronization) or it is allowed to configure external shutdown (make short
pulse signal), external operation (make short pulse signal), admission pressure rise (make
pulse signal) and admission pressure fall (make short pulse signal).
Contact output has totally 8 relays, two of which are designated for shutdown and
alarm. The shutdown relay is NC type, which live in normal condition and is not live at
shutdown, and other relays are NO type, which can be configured for the functions needed
and also for shutdown. The capacity is 28VDC/5A. The system has 3 circuits contact
output to extent output for the relay loop passing through DEH system, they are shutdown,
alarm and spare respectively.
505 Controller power supply is 24VDC/150W.
3.2.4.4.3 SPC valve position controller input and output
SPC valve position controller receives output of one 4-20mA control loop of 505
Controller.
SPC valve position controller selects to receive one circuit or two circuits (redundant)
displacement sensor signal (LVDT) to monitor position feedback of servo motor.
Contact input is dry contact, two in total, they are external shutdown (normal close for
unit in normal condition), external reset (make short pulse signal) respectively.
Servo output signal is ±10mA, used for controlling electro-hydraulic servo valve
(DDV solenoid proportional valve); in addition, proper amount of AC fluttering current
can be added.
Analog output is 4-20mA, used for displaying opening value of the servo motor, load
capacity is 200ohm.
Power supply of SPC valve position controller is 24VDC/50W.
3.2.4.4.4 Speed measuring elements
Speed measuring elements can use magneto-electric or eddy current type speed
measuring head and this system uses magneto-electric sensor which is internally installed
with permanent magnet steel and magnetic field is formed at its end face magnetic head.
Once magnetic resistance changes at this point, the internal coil of the sensor can
induction-output responsive AC voltage signal. Install magnetizer signaling gear or orifice
on the rotator and gear module is greater than 2 and sensor can be installed in radial.
Sensor end face is 1mm from the gear top shorter distance induces greater output signal.
Sensor output is a two-core shielded wire and its shielded net wire is parallel connected to
either of the two cores and then connected to the 505 Controller speed measuring channel
“-“ end.
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When automatic speed rise is used, the 505 Controller will control the turbine to
speed up from zero. In this case, the output signal detectable by the controller should be
available when the speed sensor is at relatively low speed, and the distance from sensor to
gear top can be reduced.
3.2.4.4.5 Valve position travel measuring elements
The displacement sensor used for valve position travel utilizes the differential
induction principle (LVDT) to change the mechanical displacement of linear movement
into corresponding electric quantity output so as to conduct valve displacement feedback
measurement. Valve position controller supplies exciting voltage to the primary coil of the
sensor and its secondary coil induced voltage is supplied to the valve position controller for
processing and for valve position feedback control.
Its linearity generally can reach 0.1% and output sensitivity is generally 0.1-1V/mn;
resolution 0.1μm; and sensor should have wide measuring range; time constant is small,
dynamic response is quick.
3.2.4.4.6 Pressure measuring elements
Pressure measuring elements (not supply for DEH system) use conventional
capacitance type two-wire system pressure transmitter which can be supplied by external
power supply or by the 505 Controller itself. Since the analog input channel of 505
Controller only has the 6th channel isolated, when pressure input uses the non-isolated
channels, it is necessary to consider the input isolation problem; otherwise power supply of
505 Controller is used (realized through 505 internal jumper).
3.3 DEH system functions
For turbine set, pure electric regulation and control method realized by the digital
electrohydraulic control system (DEH system) performs speed control for the turbine
before synchronization and performs load control for the turbine after synchronization.
And it can operate safely and economically in any of the following unit operation modes:
—load control operation condition;
—slide pressure control operation condition;
The basic automatic control functions of the DEH system are turbine speed control and
load control functions, and it also has other auxiliary functions.
3.3.1 Start speed rise and speed control and protection
One of the three start modes of auto, manual and semi-auto can be selected and the
switchover of these three modes can be realized only by change of the controller
program configuration after shutdown. This system generally uses the former two
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modes.
Electric overspeed protection test and mechanical overspeed protection test can be
carried out under DEH control.
DEH system itself has overspeed protection (103% OPC operating and 109%
shutdown) function.
3.3.2 Synchronization and automatic initial load control
After unit speed becomes constant, the operator can adjust unit speed for
synchronization through the speed increase or decrease signals sent manually or by the
“automatic quasi-synchronization” device. After unit synchronization, DEH
immediately automatically makes the unit operate with a certain initial load to prevent
reverse power operation of the unit. When power frequency control is not used, the
controller will not set initial load.
3.3.3 Load control and load rejection
For DEH system, after turbine generator is synchronized into the power grid, the
operators can control the turbine generator from operating with initial load to operating
with full target load by operating the controller speed setting according to operation
situation and power plant operation regulations and can participate in the primary
frequency modulation according to power grid requirement.
Load control can be realized by increasing or decreasing speed setting after
synchronization.
When unit rejects load, the controller immediately switches over to the speed control
mode and switches off admission pressure control and maintain turbine operating with no
load at synchronous speed (2,950rpm) so that the turbine can quickly re-synchronize.
3.3.4 Operation and communication
All control commands can witch ON/OFF of the switch, button, 505 Controller
keyboard or remote control contact and communication mode through operating DEH
cabinet. The 505 Controller is equipped with RS-232, RS-422 and RS-485 communication
ports for the user to choose to communicate with DCS. The communication protocol
adopts MODBUS protocol. For example, speed increase or decrease setting can be
adjusted by ADJ key on the 505 Controller panel or can be controlled by external speed
increase or decrease contact of the 505 Controller.
Hard wiring switch value uses dry contact and analog value is 4-20mA.
All control commands can switch ON/OFF the switch, button, 505 Controller
keyboard, remote control or communication mode input through operating DEH cabinet.
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DEH cabinet and 505 Controller operating panel are introduced below:
3.3.4.1 DEH cabinet buttons and indications
DEH cabinet panel has two-circuit 230VAC power supply and one circuit 220VDC
power supply indicator-lamps to indicate respectively the power supply status.
DEH cabinet has one circuit main stop valve closed status indicator-lamp.
There are 7 buttons arranged on the DEH cabinet to be used for operating respectively
the gate hanging main steam valve (self-reset button), movable main steam valve
(automatic reset button), main steam valve close protection force (self-locking button), 505
Controller external reset (self-reset button), external operation (self-reset button), external
shutdown (self-reset button) and SPC valve position controller (self-reset button).
There are two knobs arranged on the DEH cabinet to be used for controlling ON/OFF
of the speed 103% OPC operation, ON/OFF of stepout OPC operation respectively.
3.3.4.2 Functional keys on 505 Controller panel
505 Controller operating panel is composed of 30 operating keys and 24-character
LED display, LED display can display all information during control of turbine by 505
Controller and operating key can implement all operations for control of turbine.

Description of functional keys:

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SCROLL Diamond-shaped key in the middle of the panel. It can move left and right in the
same level of menus at operation or configuration mode, or moves up and down in the
same level of menus.
SELECT Used to select the variables in the two lines in the 505 Controller display screen
and only the parameters with @ can be adjusted by ADJ key. Only when the two
lines in the screen are adjustable parameters (dynamic or calibration mode),
SELECT key or @ is used to determine which line of parameters are adjusted.
When there is only one variable in the screen, this key is unrelated to the position
of @ mark.
ADJ Used to adjust parameter size in operation condition.
PRGM Used to select entry into configuration mode after shutdown, this key can be
used to search configuration mode parameters in operation mode. (Parameters are not
modifiable).
RUN Send operation command.
STOP Send the command to control shutdown. This key function can be cancelled in
service mode.
RESET Cancel alarm and shutdown in operation mode. After shutdown, pressing this
key can return to the initial position in control mode.
0/NO Enter O/NO or cancel a function.

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1/YES Enter 1/YES or switch on a function.

2/ACTR Enter 2 or display output of controller in operation mode (driver position).
3/CONT Enter 3 or display all control parameters in operation mode. SCROLL key is
used to scroll display the final trip cause and reach maximum speed and local and remote
control status (if this function is used).
4/CAS Enter 4 or display cascade control information in operation mode.
5/RMT Enter 5 or display remote control speed set point information in operation mode.
6/LMTR Enter 6 or display valve position limiter information in operation mode.
7/SPEED Enter 7 or display speed control information in operation mode.
8/AUX Enter 8 or display auxiliary control information in operation mode.
9/KW Enter 9 or display power control information in operation mode.
./EXTR Enter decimal point.
CLEAR Clear configuration or exit current status in operation mode.
ENTER Enter new value in configuration mode; it is allowed to directly enter the set
value in operation mode.
DYNAMICS Adjust currently controlled dynamic parameters in operation mode.
DECIMAL Enter decimal point.
ALARM(F1) Display alarm cause. SCROLL can be used to scroll screen.
OVERSPEED TEST ENABLE(F2) is used for overspeed test.
F3 Can configure functional key.
F4 Can configure functional key.
EMERGENCY SHUTDOWN BUTTON is used for emergency shutdown.
In operation mode, the 30 keys on the front panel are not always in the activated state
and only when the keys that can be activated are pressed, can functional menu be displayed
on LED screen and display status operated. When a hot key (AUX, CASC, KW etc.)
functional is not configured but is pressed, 505 Controller LED will display message
“FUNCTION NOT PROGRAMMED”. The following introduces the use of the functional
keys.
When the set point step is not in remote control or follow up, when a set point is
displayed, ADJ key is always in the activated state.
When the set point step is not in remote control or follow up, when a set point is
displayed, ENTER key is always in the activated state whether ADJ key is in activated
state or not.
YES/NO is always in the activated state when a state display is displayed and
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effective.

AUX, CASC，KW, RMT, F3, F4 functional keys are always activated only after

configured.
SPEED, ACTR, LMTR, CONT, DYN keys are always in activated state.
PRGM, RUN, STOP, RESET, ALARM keys are always in activated state.
OVERSPEED TESTENBL keys are activated only when OSPD is enabled.
3.3.5 Self-diagnosis and system protection
Before each start, DEH controller can self diagnose if the controller configuration,
wiring and internal hardware are normal. It can perform on-line fault diagnosis and give
alarm indication for the control parameters in the operation.
When it is needed to keep the items in protected state at unit overspeed or program
configuration, DEH controller executes shutdown.
3.3.6 System adjustment and monitoring
DEH controller can on-line adjust control parameters and monitor set parameters,
actual parameters and control parameters.
3.3.7 Valve position controller (servo position controller)
Valve position controller (SPC) is a valve position controller, which receives the 4-
20mA position command signal of 505 controller output and one circuit or two circuits
(redundant) servo motor position (LVDT) feedback signal; its output signals control the
electro-hydraulic servo valve (electro-hydraulic servo valve controls servo motor switch).
Control logic of the servo position controller (SPC) is realized through software. PC
software program interface connected to the SPC enables the user to configure, automatic
calibrate, dynamically adjust and manually control the servo system; therefore, when
calibrating the servo motor (valve) through SPC in the field, parameter configuration,
adjustment and monitoring operation must be carried out by PC through Windows
platform-based SPC software program. For facilitating the operation, SPC configuration
can be carried out under on-line status or off-line status. Once the configuration is
completed, the program can be uploaded or downloaded to other SPC.
3.3.8 Functions of remote gate hanging, remote main stop valve control
Remote gate hanging and open main stop valve can be carried out through
corresponding buttons on DEH cabinet; in addition, movable main stop valve can be
remotely controlled or the main stop valve closed for tightness test.

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4. Oil supply system

This turbine oil supply system consists of two parts. One is to have the main oil pump
supply lube oil to all bearings of the turbine generator set and supply pressure oil to the
regulating and protecting system; and another part is to have he main oil pump supply oil
to the electrohydraulic drive in the DEH. It is recommended that this unit use the L-TSA46
turbine oil specified in GB11120-89 and if cooling water temperature is often lower than
15℃, it is allowed to replace this oil with the L-TSA32 turbine oil specified in GB11120-
89.

It mainly includes main oil pump, oil filler I, oil filler II, high pressure AC oil pump,
AC and DC lube oil pump, oil tank, oil cooler, oil filter, lube oil pressure controller and
overpressure valve etc.

The centrifugal main oil pump is directly driven by the turbine shaft and in normal
operation, the outlet oil pressure of the main oil pump is 0.883MPa and oil discharge is
1.0m3/min . Most of this pressure oil is supplied to the two oil filler besides to the
regulating system and protection system. The two oil fillers are connected in parallel. The
outlet oil pressure of oil filler I is 0.10-0.15MPa and it supplies oil to the inlet of the main
oil pump. The outlet oil pressure of oil filler II is 0.22MPa and the oil is supplied via oil
cooler and oil filter to the lube oil system.

At unit start, it is necessary to first open the low pressure AC lube oil pump so as to
drive out air from oil pipe and all parts in low pressure. Then open the high pressure AC
oil pump to perform test regulation of the regulating and protecting system and unit start.
In turbine start process, the high pressure AC electric oil pump supplies oil to the
regulating and protecting system and via oil filler to all bearings. In order to prevent
pressure oil from leaking out of the main oil pump, a check valve is installed at the outlet
of the main oil pump. At the same time, the main oil pump start oil discharge valve is
installed so that the main oil pump has smooth oil flow during start. When turbine speed
rises to the rating (main oil pump outlet oil pressure is higher than electric oil pump outlet
oil pressure), oil supply amount can be reduced through the valve on the outlet pipe and
then this pump is stopped and the main oil pump supplies oil to the regulating and
protecting and lubricating system of the whole unit. At shut down, the high pressure
electric oil pump can be start first and then it can be changed over to the AC lube oil pump
during turning after shutdown.

To prevent shutdown accident of the control system due to pressure oil drop, when
the main oil pump outlet oil pressure drops to 0.683MPa , the pressure switch
automatically starts the high pressure AC oil pump and put it into operation.

When trouble occurs in operation and lube oil pressure drops, the lube oil pressure
controller automatically starts the AC lube oil pump. The system is provided with a DC
lube oil pump and when lube oil pressure drops and the AC lube oil pump can not be
normally put into operation, the lube oil pressure controller makes the DC lube oil pump
automatically start to supply oil to the lubrication system.

Normal lube oil pressure is: 0.08~0.15MPa

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Requirement when oil pressure drops:

<0.055MPa, AC lube oil pump automatically goes into operation IF CAN'T RUN, DC
AUTO RUN
<0.04MPa, DC lube oil pump automatically goes into operation

<0.02MPa, automatically stops 3 PRESS. SWITCH TO ETS

<0.015MPa, turning gear stops

Note: during normal unit operation, all electric auxiliary oil pumps should stop
operation and are only allowed to start operation in special cases.

A low pressure oil overpressure value is provided in the lube oil passage and when
lube oil pressure is higher than 0.15MPa, it can open automatically to discharge excessive
oil amount back to oil tank to ensure that lube oil pressure is maintained at 0.08～
0.15MPa .

Oil discharged from the oil servo motor directly goes into the oil pump set inlet and
so when load rejection or emergency stop causes the oil servo motor to quickly act, it will
not affect oil pump inlet oil pressure so as to improve the unit load rejection characteristics.

The electrohydraulic servo valve and AST solenoid valve and OPC solenoid valve
have oil supplied from the manifold pressure oil line after filtered by a double-filter to
ensure relatively high oil filtering accuracy.

5 Protection system

This system includes two parts of mechanical hydraulic protection device and electric
protection device. The unit is provided with three trip devices: the emergency trip device
emergently released by the operator; emergency governor tripped at high speed; and
electrically tripped electromagnetic protection device. Its main protection items include
overspeed, axial displacement, lube oil pressure drop, bearing return oil temperature high,
condenser vacuum low and oil switch trip, DEH protection shutdown etc. When protection
(shutdown) signal occurs, AST solenoid valve is actuated to immediately close the main
stop valve and regulating steam valve. And send alarm. The oil switch trip can close the
regulating valve depending on actual situation or closes the main stop valve at the same
time. The close of the main stop valve is realized by the release of protection oil and the
close of the regulating steam valve is realized by release of control oil.

5.1 Mechanical overspeed protection device

The emergency governor is the fly ball type and when unit speed rises to
3270~3330r/min, the fly ring overcomes the spring force due to increase of centrifugal
force and flies out to strike the hook of the emergency trip oil valve to make it tripped and
protection oil released to close the main stop valve and steam control valve.

5.2 Emergency trip oil valve

When the unit has special situations, you can hand beat the emergency trip oil valve
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for emergency shutdown and hand-push the large spring cap of the emergency trip oil
valve to close the main stop valve and steam control valve. At re-start, press the small
spring cap to reset it so that the oil passage becomes normal.

5.3 Electromagnetic protection device

The electromagnetic protection device actually consists of two AST solenoid valves
in parallel and two OPC solenoid valve in parallel. In normal unit operation, AST solenoid
valve is not energized and OPC solenoid valve is not energized. AST solenoid valve
receives stop signal (i.e. ETS system stop signal) from difference sources and the solenoid
valve receives power and actuates. Safety oil and control oil are released to close the main
stop valve and steam control valve and cut off turbine steam admission to make it stop.
Signal sources can be protection signals such as speed overlimit, axial displacement
overlimit,, lube oil pressure drop, bearing return oil temperature rise or bush temperature
high, condenser vacuum drop or manual control switch shutdown signal etc. OPC solenoid
valve receives OPC signal and closes steam control valve.

5.4 Unit emergency shutdown

When the unit speed exceeds 110-112% rated speed, the emergency governor acts so
that the unit stops emergently.

When the DEH signal controller sends out emergency signal, the unit stops
emergently.

When any of the following monitoring parameters of the turbine exceeds the
specified value, the solenoid valve acts to make the unit stop emergently.

a. Speed rises to 110% rating(3300r/min)

b. Axial displacement exceeds +1.3mm or -0.7mm

c. Lube oil pressure is lower than 0.02MPa

d.Bearing pedestal vibration exceeds 80μ m

e.Condenser vacuum is more than -0.061MPa

f. DEH sends shutdown

If the unit has other troubles and the operator think it necessary to shut down the unit,
or shutdown is needed in normal cases, hand beat the emergency trip deice installed at the
front bearing pedestal end face or pressure the manual electromagnetic protection device
button in the central control room to release safety oil and establish emergency oil so that
the unit is shut down. Do not cut off the power supply of protection system before turbine
stops. Hand beating the emergency trip deice after electromagnetic protection device works
can make the turbine safer.

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6 Turbine supervisory instrument system

The turbine supervision instrument system can continuously display and record the
mechanical state parameters of the turbine rotor, valve displacement and casing during
turbine turning, start, operation, overspeed test and shutdown, and sends out alarm when
the preset operation limit is exceeded, and sends out stop signal to make the unit stop
automatically when the preset danger value is exceeded. The system consists of cards and
relevant preamplifier and sensor with conductor.

The sensor (eddy current probe) installed in the turbine bearing pedestal is connected
via extension cable to the corresponding preamplifier which is installed in the junction box
near the bearing pedestal and then connected via shielded cable to the corresponding
module plate in the instrument frame in the central control room.

The eddy current type probe and proximitor are used to detect various variables of the
turbine so that it produces a signal in proportion to the distance between probe and
monitoring instrument and this signal is input to monitor module.

Magneto-electric transducer is used to measure the speed, displacement transducer is

used to measure the unit Case expansion and speed transducer is used to measure the
bearing vibration.

This system consists of axial displacement, speed, vibration, Case expansion, items.

Axial displacement and expansion difference are positioned by rotor against negative
thrust face.

7 Adjustment and test of the regulation and protection system

All main parts of the turbine regulation and protection system undergo necessary tests
in the manufacturer before delivery. In order to ensure reliable unit operation, necessary
tests are performed after they are installed in the power plant (station).
General tests are carried out according to the following items.
7.1 Test at turbine stationary state
a. Hydraulic projection system test;
b. I&C protection system test;
7.2 Test at turbine operation state
a. Start
b. Evaluation and setting of some parameters
c. Hydraulic protection system test
d. Electric protection system test
7.3 Commissioning at turbine stationary state
After all the unit installation works is completed and site is cleaned up ,

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commissioning work can be started.

First operate DEH cabinet system gate hanging button to supply power to the gate
hanging, electromagnet. The main stop valve switch electromagnet is not live. Start the
main stop valve.
7.3.1 Emergency trip oil valve test and reset test

Hand beat emergency trip oil valve for emergency stop and hand push the small
spring cap of the emergency trip oil valve to close the main stop valve and steam control
valve. At re-start, it is necessary to press the large spring cap to reset it so that oil path is
normal.

7.3.2 Start trip device test

The trip electromagnet receives power and the main stop valve switch electromagnet
is not energized. Build up safety oil and connect through the start oil path and the main
stop valve starts. The trip electromagnet receives power and the main stop valve switch
solenoid valve receives power and the main stop valve can close slowly.

7.3.3 Calibration of the regulation system DEH valve position

DEH system electric parts must be correctly wired and it shall be specially noted that
high and low voltage circuits, dry contact circuit and relay circuit can never be wrongly
connected; otherwise power-on may damage electric parts. Unit start oil pump starts and
adjusts the throttling orifice on DDV integrated control block to control servo motor full
open or full close (at this time servo valve is not supplied with power) and calibrate the
servo motor through SPC valve position controller software program.
7.3.4 Simulation test of regulation system DEH
After DEH calibration, conduct simulation test for the DEH: by using the signal
generator to simulate speed signal, it is possible to simulate unit start and synchronization
and increase, for example increase speed setting, the servo motor opening by operating 505
Controller operating panel keys.
7.3.5 I&C protection system test
This test means that when the current turbine proper electric protection signal is sent,
electro-magnetic protection device actuates, main stop valve, steam control valve and
extraction valve close and 505 Controller is interlocked and stops, in addition, the unit
stops through 505 Controller stop interlock I&C protection system.

7.4 Commissioning in turbine operation condition

When commissioning work in turbine stationary state is all completed, start the unit
according to startup procedure. When the unit speed becomes stable, start commissioning
in operation condition.

7.4.1 Startup
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After pipe heating and machine heating according to procedure, supply oil by using
high and low pressure oil system. Start the unit to constant speed using the method in 3.3.1.
During speed up, when the main oil pump outlet oil pressure is slightly higher than the HP
motor driven oil pump outlet oil pressure, gradually close the HP motor driven pump outlet
valve until almost close and then stop the HP motor driven oil pump.

When a new unit is started for the first time, it shall be manually started on site. When
it reaches the minimum control speed, use the 505 Controller keyboard to control the unit
to the constant speed. Automatic start can be used after main stop valve and steam control
valve leak test is accepted. In addition, manual and auto start changeover can only be
changed at shutdown but may be manually intervened externally in auto mode. The
following figure is a speed menu diagram. Manual start or auto start is recommended for
site start.

7.4.1.1 Site manual start

When manual start mode is selected, its procedure is: first reset the controller (press
RESET key) and clear all alarm stop signals; if start enable is set, press the external start
enable button. At this time the controller will fully close the HP servo motor and then
operate the controller to send operation command (press RUN key). Speed set point
automatically rises to the minimum control speed and then the steam control valve is fully
opened. Electric main stop valve closes and main stop valve fully opens. Raise the speed
using motor driven valve bypass valve. When manual speed rise to the set value (setting at
controller program configuration, e.g. 2800rpm), put the controller into operation. Then
raise the speed to the rated value using the controller and after the controller controls the
speed, fully open the electric main stop valve.

7.4.1.2 Automatic start

When automatic start mode is used, its procedure is: first reset the controller (press
SPEED
RESET key) and clear all alarm stop signals. If start enable is set, press the external start
enable button. At this time the controller will fully close the HP servo motor and open
Speed
main stop valve and electric main stop valve and then operate the RPM
controller to send
Status messages
operation command. The controller can make corresponding speed rise rate and
messages
machine heating time according to shutdown duration (self diagnose that the turbine is
Speed RPM
in cold state, hot state or between the two) and control the unit Hold
to 3000rpm constantTime
MIN low speed
speed. In automatic speed rise process, it automatically completes roll-off,
Speed RPM
machine heating, automatic passing critical point, medium speed machine heating,
messages
Setpt
RPM
3000rpm constant speed, automatic synchronization, and wait for unit synchronization
with grid. The heating time during speed rise can be operated bymessages
the operator
On-line Prop Gn on
* the
.
On-line Int Gn * .
operating panel for stop or continuation depending on site situation.
messages
Off-line Prop Gn * .
Off-line Int Gn * .
messages
Speed RPM
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Spd PID Output %

messages
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After unit operation, pressing “SPEED” key can display speed menu. By
“SCROOL”, the first and second screens in the figure only appear in auto start and
display speed rise state and heating time; the third screen adjusts speed before
synchronization and adjusts load after synchronization through “ADJ”. The last three
screens are unrelated to site operation.

7.4.2 Evaluation and setting of main parameters in operation

During operation at constant speed, it is necessary to observe some parameters to see
if they reach the design value.
7.4.3 Hydraulic protection system test
7.4.3.1 Emergency trip oil valve test

Hand push the small spring cap of the emergency trip oil valve to close the main stop
valve and steam control valve. At re-start, it is necessary to press the large spring cap to
reset it so that oil path is normal.

7.4.3.2 Mechanical overspeed test

Controller is used to raise unit speed. When the speed rises to a value between
3270~3330r/min, the fly ball of the emergency governor should fly out and the main stop
valve and steam control valve should quickly close. The test is performed three times
according to the “Turbine Operation Instructions”. If action speed does not conform to the
requirements, adjust the adjusting nut of the emergency governor to change the spring
pretightening force.

Emergency governor reset speed may not be strictly evaluated but should not be too
low.

7.4.4 I&C protection system test

Test purpose is to verify the work reliability of hydraulic loop when protection signal
occurs in the I&C protection loop, i.e. electro-magnetic protection device is actuated and
main stop, steam control valve and 505 Controller stop.
7.4.5 Synchronization and load on
After no-load test is completed, synchronization and load on can be started according
to operation regulations. Load increase and decrease operation can be realized by operating
the “ADJ” on the 505 Controller panel to increase or decrease speed setting. Speed setting
can also be controlled by contact, i.e. realized through 505 Controller speed rise and fall
terminal (this terminal can be connected to electric or DCS).
8 Main installation data of the regulation and protection parts

All parts of the regulating and protecting system are allowed to be disassembled and
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emergency trip oil valve
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cleaned when installed in the power station.

During installation, it is necessary to ensure the
installation clearance marked in the drawings
and the installation of speed measuring sensor
and displacement signal sender shall attain the
requirements of protection descriptions. Several
main installation data are listed below:

8.1 Installation clearance of emergency governor

(Z546.31.01) and emergency trip oil valve

rotor

(Z51703.31.02)

A=1.0±0.2

8.2 Installation of turbine supervision and protection device

The turbine supervision and protection device includes speed, axial displacement,
vibration, Case expansion. The axial displacement, speed probes are installed with speed
measuring mounting rack in the front bearing pedestal, the expansion difference probe is
installed with mounting rack at the rear casing coupling and the vibration speed sensor is
installed on the bearing cover. For details of installation gap between the probe and the
measured objects and the instrument commissioning, refer to the instrument user’s manual.

9 Matters needing attention for control system

Pay attention to the servo and servo oil system when DEH system is working.Clean or
replace the fliter screen at the right time.

All the oil pressure should reach the rated.While the turbine is working,the reset oil
pressure must be less than 0.05MPa(it can be changed by adjusting the throttle orifice for
rest oil.The safty oil should be less than 0.05MPa when the turbine trips.

Check the position of oil servo motor before starting the turbine: control command
is zero，the control valve must be closed,otherwise, calibrate DEH valve position and test
the regulation & protection system again.

9.1 Matters when the turbine starts

Encounter one of the following situations,DO NOT start-up or synchronization,load
on:

a. Speed signal is aberrant

b. Important valve (such as main stop valve and governing valve)can not close quickly or
close tightly
c. Overspeed test of the protection system failed
d. Oil motor pump(such as HP motor pump and lube oil motor pump) or the catenation is
conked
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e. Oil is unqualified
f. Speed is instable
g. Anyone of the tests for protection system failed

9.2 Matters when the turbine is working

Each oil pressure must be in normal range,Check the signal that is not connected to
DCS or DEH regularly.Test the activities of the main stop valve regularly.Speed signal
must be normal,otherwise decrease the load or shut down the turbine.Do not remove
important conservations of ETS while the turbine is working.

9.3 Matters when shut down the turbine

Eliminate the jam of regulation system in time when decrease load,do not split the
generator.Manual trip,close the main stop valve or electrical stop valve if it is necessary,
split the generator when load is zero.

Observe the speed after splitting the generator,manual trip when the speed raise
abnormally.

When the regenerative extraction valve or supplementary steam valve can not be
closed tightly,close the other valve on the pipe in case the turbine overspeed.

Do not cut off the power supply of protection system before turbine stops. Hand
beating the emergency trip deice after electromagnetic protection device works can make
the turbine safer.

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