4×350 MW Kamalanga Thermal Power Project

Rev.
Date Compiled by Review APPROVAL
Document No.: (WAK)B1620B-000301BSM Rev: A

Document Name:
Instruction for Governing and Protection System for 4×350MW KAMALANGA Thermal Power Project
PROJECT 4×350 MW Kamalanga Thermal Power Project
GMR 卡玛朗加能源有限公司
OWNER
GMR KAMALANGA ENERGY LIMITED
拉玛雅国际咨询有限公司
OWNER’s
ENGINEER LAHMEYER INTERNATIONAL (INDIA) PVT. LTD.
CONSULTING ENGINEERS,GURGAON
山东电力基本建设总公司
EPC
CONTRACTOR SEPCO ELECTRIC POWER CONSTRUCTION
CORPORATION
SUB- 东方汽轮机有限公司
CONTRACTOR Dongfang Turbine Co.,Ltd.
DOC NO. (WAK)B1620B-000301BSM
DESIGN 2010-11-09
CHECK 2010-11-15
VERIFICATION 2010-11-16
STD ENGINEER 2010-11-17
REVIEW 2010-11-16
APPROVE
Instruction for Governing and Protection System
Revision Record
版本号日期换版说明
Version Date Revision Explain
A Oct.2010 The First Issue

Contents
No Chapter- Description Pages Remarks
Paragraph
1 Preface 1
2 0-1 Overview 1
3 0-2 Actuator of control system 2
4 0-3
Hydraulic governor system 3
5 0-4 Low-pressure oil supply system and
2
Lubricating oil system
6 0-5 The aggregate value of the action for
1
pressure switches and limit switches
7 0-6
Flushing and Testing of System 1
(WAK)B1620B-000301BSM Page 1 of 1
Preface
Boiler feed pump turbine control system is digital electro-hydraulic control system; the
control system includes controller, peripherals, and hydraulic actuators. The controller
description was reflected on its instruction, the instruction only introduce hydraulic
actuators and hydraulic protection system. To make the user a comprehensive
understanding of the major components of the system function, this gives the set value of
the pressure switch, limit switch solenoid valves and other components in hydraulic oil and
lubricating oil system diagram.
0-1 Overview
The control & protection system is an actuating mechanism of HP fire-resistant oil
Digital Electro-Hydraulic Control System (MEH), which accepts orders from MEH and
accomplishes tasks such as latching-on turbine, actuating valves, and trip the unit, etc. The
control & protection system of this unit shall satisfy basic the system requirements as
below:
1 Able to set latching-on
2 Capable of rapidly and reliably intercepting turbine feed steam, when necessary
3 Adjustable for valve movement test
4 Provided with overspeed protection function
Electrical overspeed protection and TSI overspeed protection: When it is detected that the
unit speed is up to 110% of the rated speed, an electrical shutdown signal is sent out to
enable the solenoid valve and the mechanical shutdown electromagnet in the HP trip
module, to discharge the HP safety oil and to trip steam admission into the unit.
0-2 Actuator of control system

Actuator control system consists of three parts: LSV actuator, LCV actuator, accumulator
and actuator with outside switching valve.
The high-pressure oil of governing system was come from the host resistance to fuel oil
supply system; its role is provide high-pressure oil to LSV actuator, LCV actuator, piston
and the other hydraulic system components. Pump pressure of 14MPa, operating
temperature of 40 ± 5 ℃. The displacement sensor was equipped on LCV actuator and the
connecting rod of each hydraulic actuator with the valve fully open and fully closed
indication of the limit switch. In addition, there is a low-pressure main steam valve
opening 75% of the limit switch S26 (for the low-pressure main steam valve testing
activities).
LSV actuator is actuating mechanism of LSV, which is used to open or close the
low-pressure main steam valve. LSV actuator was consisted of a two four-way solenoid
valve, an unloading relief valve and a hydraulic cylinder component. Actuator was the
unilateral oil-in; high pressure oil can be used to open the main steam valve, main steam
valve with internal return spring, when the need to close the main steam valve, the
hydraulic actuator and the main steam valve in the spring under the effect of quickly
closed.
The high-pressure oil though a Ф1.6 throttle to hydraulic cylinder was controlled by two
four-way solenoid control valve, which consist of two coils, a valve core and valve body
parts, when one coil is energized, the slide valve hydraulic cylinder piston moves to the
lower chamber through the orifice Ф1.6 connected with the high pressure oil, the piston
upward, open the main steam valves, when the other coil is energized, the spool moves to
the lower part of the oil motivated the hydraulic cylinder piston back to the oil chamber
connected with the piston under the action of the spring force, so that the main steam valve
is closed.
In addition, under the chamber leading to the hydraulic cylinder is connected to a
pipeline on the road unloading relief valve, hydraulic control unloading of secondary
safety relief valve, oil pressure is established when the secondary security unloading relief
valve closed, the hydraulic cylinder under the action of the control signal on or off. When
the oil is being leaked out of the second safety when unloading relief valve to open, the
hydraulic cylinder oil spills off the next chamber, fast shutdown, storage assembly's
solenoid (Y12) received obstruction signal, can leak out secondary security oil.
Low-pressure main steam valve and its actuator have been in a fully open state when
the turbine is running, in order to prevent the resulting jam, so they should regularly call
the shots steam valve activity test, the activity test is the experiment to achieve the limit
switch S26 , and its steam turbine test principle see electrical diagram.
LCV actuator is a actuating mechanism which through the servo valve will be motivated
by electrical signals into hydraulic signals to control valve opening, were consisted of the
displacement sensor, servo valve, hydraulic cylinder and connecting other components.
The actuator is the bilateral oil into type, high pressure oil pressure regulating valve used to
open both, is also used to close the low-pressure regulating valve.
High-pressure oil through a filter first, then through piping into the servo valve of the
slide valve chamber room, the electro-hydraulic servo valve control signal from MEH,
when the two coil servo valve input signal, because the role of In the servo valve torque
motor torque on the imbalance caused by the servo valve and hydraulic cylinder moves to
change the oil out of the size of interlinked, so that low-pressure regulating valve action,
depending on the direction of motion control valve hydraulic servo valve piston movement
direction (ie input signal).
If the signal from MEH controller signal to open the low pressure regulating valve, the
servo valve piston movement direction is to the actuator the upper chamber of hydraulic
cylinder piston connected with the high pressure oil, resulting in the hydraulic cylinder
piston down, low-pressure valve opening increased. Conversely, the small signal control
valve signal is off, the servo valve piston movement direction is to lower the actuator
hydraulic cylinder piston chamber connected with the high pressure oil, and the piston
upper chamber and connected back to the oil, then the hydraulic cylinder piston upward,
low valve opening decreases.
In addition, LCV actuator has fully open, fully closed limit switches S30 and S15, when
low-pressure regulator valve is fully open or fully closed state send the signal to outside.
In order to maintain the control valve opening, use a displacement sensor to provide
valve position feedback signal. Sliding displacement sensor components and mechanical
connection of hydraulic cylinder piston rod, the sliding part of the valve position feedback
signal generated by the controller sent to MEH, MEH controller of the servo signal and the
input signal balance sheet, MEH controller output servo board zero, this time, the servo
valve and hydraulic cylinder similarities out of the oil window is closed. Then adjust the
valve opening to maintain the opening was unchanged until the servo valve control signal
received until the next input.
When actuator lost electrical control signal, servo valve with a mechanical bias force of
effect in that the hydraulic cylinder piston upward, close the valve to ensure crew safety.
In addition, exports and imports of high-pressure oil pipeline were set a bladder-type
accumulator; its use is when the control valve in the rapid closure of the actuator requires
large fuel consumption, the use of accumulator to provide an instant the huge oil and to
maintain system pressure in the normal operating range, to ensure rapid response of the
actuator. Meanwhile in the main steam valve and discharge valve closed to a larger amount
of oil, the use of accumulator oil absorption of the temporary increase in discharge, return
the oil back pressure to prevent excessive increases.
LP gas source and the standby steam source to switch between the uses of external
means. Specific ways of working turbine up and running product specifications and
instructions shall prevail.
This unit is equipped with external switching valve, switching valve outside purchased
equipment as a whole, which itself consists of a continuous external switching valve
hydraulic actuator control, the use of one side into the oil. External switching valve
hydraulic actuator with electro-hydraulic proportional valve, accepted 4 ~ 20mA control
signal proportional control valve position outside the switch; timely valve is converted to 4
~ 20mA signal output to the MEH, for the directions of the switching valve displacement.
In an emergency situation, Trip System must accept instruction, quick closing, and
interdiction unit admission.
0-3 Hydraulic governor system

1 Emergency trip device ((WAK) D3.6A.401Z)
The structure of emergency trip device was shown in Figure 0-3-1.
Emergency trip device is the most important turbine overspeed protection device.
Emergency trip device mainly consists of shell, impact device and spring components. It
is connected with the rigid main shaft.
When assembly, the center of gravity deviation from the rotation center line of sub-hit
5.5mm, when the turbine rotor speed below the speed of emergency governor's action, the
impact device does not operate. When the turbine rotor speed reaches the rated speed of
111% to 112% (ie, 6325 ~ 6384r/min), the impact to overcome the centrifugal force
generated by sub-spring preload and quickly fly out (stroke is 5.4mm). Doing speed test, if
the actual movement speed of a difference with the specified value can be changed to
adjust the thickness of washers, the adjusting spring preload, resulting in sub-action speed
impact requirements.
Emergency trip device housing and the positioning plate compose of chamber "C",
which was set to the following in the turbine speed is 5400r/min, the emergency trip device
hit a sub-pressure test. First let the isolation solenoid valve Y14 in charged state, after the
pressure switch PS50 act can do test for the Flyweight force off, then test the solenoid
valve Y15 electricity, to the "C" oil-filled room, into the "C" room of the oil produced
pressure P, the pressure P acting on the emergency governor hit sub-bottom, can not raise
the case of turbine speed to force off the impact device, stop oil-filled, the oil from the
bottom of the shell escape orifice Ф0.8, impact device sub reset.
2 Slide valve of emergency trip device ((WAK)D3.6A.411Z)
The structure of slide valve of emergency trip device was shown in Figure 0-3-1.
Slide valve of emergency trip device mainly consists of reset valve, valve body, hand
brake lever play, levers, springs, housing and other components.
Slide valve of emergency trip device is the hub connected to once security circuit, and
Trip reset circuit. Its stem at the top accept control of lever. By the sleeve, the reset valve,
valve stem, the shell chamber consisting of "D", the emergency trip device has no action,
by a safety circuit to the oil through the valve body orifice (Φ2× 2) to establish hydraulic
gate hanging. When the emergency trip device ((WAK)D3.6A.401Z) in sub-impact action
against leverage, leverage to promote stem the leakage of hydraulic gates hung out to the
body under the action of the spring, to the left, resulting in a security of oil leakage out, the
unit shut down.
The pressure oil from trip and reset port into chamber "E”, which composed of the
sleeve and reset valve, promote reset valve move to the right, thus promoting the lever to
reset the Slide valve of emergency trip device (ie, hanging gates.).
In addition, you can also press brake handle with hands, let lever move, the same can
drain off gate linked oil and once security oil, let the unit shut down.
3 Governor system
There are three oil circuits in governor system: a safety circuit, the pressure of the test
circuit, reset trip circuit.
The role of the governor system is this: When turbine speed rises more than emergency
governor setting value (6325 +100r/min), emergency governor centrifugal force to increase
due to the impact device to overcome the spring force flying against the emergency
governor slide valve lever, so that lever turn, pushed up the stem to the left, hanging out
brake oil leakage, the valve spring force to leave in the spring seat, the valve opens,
quickly drain the security oil out. In addition, if emergency governor refused to move,
through electrical circuit, let once security oil solenoid valve (Y11) move, also can quickly
drain the security oil out. As once security oil pressure decreased, the diaphragm open to
discharge of second safe oil. At this point, low-pressure main steam safety valve hydraulic
actuator as the secondary oil leaked out, and brings rapid closure of low-pressure main
steam valve. At the same time, the electrohydraulic servo valve of LCV actuator also
accept MEH output signal, close the low pressure regulating valve in order to achieve
downtime.
Trip down the turbine can also be manually implemented: pressing the lever turn handle
to play gate, open the valve stem, then it appears the same situation with speeding
interdiction.
In addition, at a safe oil way, also has a pressure switch (PS35), whose role is when the
diaphragm fails, through the pressure switch (PS35) connected to solenoid valve (Y12) as
the oil can drain off the second security to improve safety and reliability of the unit.
Normal operation of the unit, in order to prevent the emergency governor hit sub-jam,
the impact should put to press out test, and press out test must be 5400r/min out the
following operation.
In the prior to the press out test, first let isolated solenoid valve Y14 (NC) charged,
pressure switches (PS50) movement to determine once security circuit isolation to prevent
the carrying out of test pressure, causing oil leakage out of once security shutdown.
Carrying out the press out test, let solenoid valve of the press out test Y15 (normally
open) charged, the pressure oil into the emergency governor "C" chamber hit out impact
device.
After slide valve of emergency trip device each action, can rely on local operation reset
handle or remote reset solenoid valve (Y13) complete the unit reset. However, reset
operation can do after the unit rotational speed must be reduced to the impact device back.
There are two ways to realize slide valve of emergency trip device reset: pressing the
handle in place to achieve a manual reset or remote reset button operation, with the reset
solenoid valve (Y13), get the reset oil push the reset valve to achieve, regardless of the
manner in which the valve end rod and the valve is pressed in the guide block, making the
resumption of hanging brake oil pressure, oil chamber to be connected with the reset
pressure switch (PS38) movement only after the confirmation indicating successful
interdiction system reset.
Sealing ring Spring base

Axile bush Front box cover Sealing ring Sealing ring Valve rod Guide block Valve body Spring Lever
Barrel
Bumping block
Lock washer
Block ring
Reset hand hold
Adjustingwasher
Spring base
Rotor
Barrel Spring
Locating plate
Brake hand hold Shell of emergency trip device
Brake rod
Lock barrel Spring
Reset valve Axile bush
Bush
Reset oil-in
Shell
Once security oil-in
Lower half of front box
Fig 0-3-1
0-4 Low-pressure oil supply system and lubricating oil system

1 Oil supply system
Oil supply system is a low-pressure oil system. Oil is from the turbine fuel tank on the
chassis, is 22 turbine oil, and provides oil to lubrication, once security oil, press out the test
and reset oil.
The tank was equipped with two AC electric main oil pump, a pump current incidents,
two sets of side by side oil cooler, a double-filter, an oil level indicator and an exhaust fan.
Low-pressure system can be provided oil by either main oil pump, the other alternative.
Two main oil pump interlock with each other in the circuit, if the main oil pump 1st at run
time, through the pressure switch PS5 action, indicating the main oil pump 1st, in normal
operation. If the main pump outlet pressure reduced to the setting value 0.47Mpa (gauge)
below, the standby pump will pump the 2nd through the pressure switch PS6 action
implementation on the 2nd main oil pump from the start. Conversely, if the 2nd main oil
pump is running, the pressure switch can also be PS7 action, indicating its normal
operation, if the pressure is lower than setting value; the same action can be achieved
through the pressure switch PS4 1 main pump from the start.
Two main oil pump motor in the circuit interlock with each other, when either the pump
motor lose power, the other will automatically start.
Each pump discharge piping was connected with the return oil through an orifice Ф2, a
pressure switch and a pilot valve, which can be achieved test while one main pump run in
case of the accident the other pump can self-realize start or not.
Test procedure is as follows: when the normal operation of the 1st main oil pump, test
the 2nd main pump, then the solenoid valve (Y2) get power, analog the exports oil pressure
of 1st main oil pump reduces, through the pressure switch PS6 action to test whether the
main pump 2nd under accident conditions to achieve self-starting. Similarly, the 2nd main
oil pump is running, also available through the solenoid valve (Y3) and the pressure switch
PS4 to experiment 1, the main oil pump. The role of orifice Ф2 main pump during test, in
order not to export the normal operation of the main oil pump low oil pressure drop, which
affects the oil supply system to work properly set.
The check valve of discharge piping two pumps provides one pump running in the other
pump isolation for the convenience of maintenance.
The oil out of any one main pump was used to:
1) Through check valve, oil filter and oil cooler to provide oil to the lubrication system.
2) To provide oil to power reset the valve of manipulate the emergency governor slide
valve.
3) To provide press out test oil.
4) After cutting oil through the pore plate provide once security oil to the following
protect device in low pressure once secure oil security system.
Slide valve of emergency trip device
Solenoid valve (Y11)
Diaphragm Valve (control secondary security oil drain)
5) Low oil level, lower oil level test oil.
AC motor driven exhaust fan is a fan of arguments, used to the tank of flammable mist
out, while the formation of a small negative pressure to prevent the bearing housing oil seal
oil spill.
The dual filter system in the chamber room with two separate filter components, normal
operation, only one of them to work, switching valve can be separated from non-filter
components. When the filter is running in a two-part conversion, balancing valve should be
opened first, so that the two parts of pressure equal to the filter, and then switching valve
handle rotation 180 º, so that the filter is not operational components, while the original
work filter components stop working.
Oil flow into the inside of the filter, discharge from around the chamber. When the filter
before and after differential pressure greater than or equal 137.2KPa, the pressure switch
signal alarm.
2 Lubrication system
Oil source of lubrication system as described above was composed by the two mutual
the exchange stand by of the AC main oil pump and of a DC accident oil pump. Main oil
pump provide oil when the unit runs. The incidents oil pump provides oil to lubrication
system when the two main oil pumps are failure available.
In the system normal operation, the bearing into the oil pressure 0.137MPa (gauge
pressure), when the bearing oil pressure dropped to 0.1MPa, the pressure switch PS3 action,
an alarm signal, when the bearing oil pressure reduced to 0.07MPa, the pressure switch
PS40 action, issue stop signal, while the pressure switch PS8 action, so that the accident
pump start, and the pressure switch PS9 action, showing the normal operation of the
accident pump.
In addition, the main oil pump lubrication system normal operation, movement through
the solenoid valve Y1, hydraulic simulation reduced the pressure switch PS8 action, testing
whether the accident pump to achieve self-starting. The role of orifice Ф2 test does not
cause the lubricating oil system pressure is below the alarm value.
Lubricating oil system with two separate oil cooler, under normal circumstances, use one
of the only, the other as a backup.
Through the oil cooler cooling water should be adjusted to maintain the cold oil in the
outlet oil temperature below 55 ℃. When the turbine is started, oil cooler for cooling water
stopped, until the bearing back to the oil temperature is close to 60 ℃, and then for the
cooling water.
Between the two oil coolers were connected by a four-way switching valve, switching
valve for the oil cooler between the two options and switch.
In addition to external switching valve also has a manual valve to switch the oil cooler
before you should open the valve to the filling oil reserve oil cooler, so that equal pressure
on both oil cooler to prevent disruption when switching occurs and the elimination of oil
switching valve handle on the shaft due to pressure forces generated jam, and then turn the
switch be easy to complete oil cooler valve handle switching between the handle rotation
angle is 90 º.
Each oil cooler use 72.67t / h cooling water, the operation should be adjusted so that oil
cooler oil exports remained normal.
Oil level indicator is used to measure the level of oil level in the tank, oil level indicator
from the scale value directly read out.
There is also a low-pressure oil system storage component, which consists of three 60L
of bladder accumulators and accessories. Switch between the two main oil pump, it can
guarantee the normal two main oil pump can be switched to avoid switching the main
pump, hydraulic transient decline, which led to tripping accidents.
0-5 The aggregate value of the action for pressure switches and limit switches
1 Limit switch and pressure switch action value Summary:

Pressure switch (limit switch) setting value Role Notes
(Mpa)
The bearing oil PS3 0.103 Alarm normal pressure of
pressure PS40 0.07 Trip bearing 137Kpa (gauge)
Protection
PS8 0.07 Accidents pump
solenoid valve Y1 acts,
PS8 acts and starts
incident pump
PS9 0.32 Indicates the normal working platform
operation of the accident
pump
The protection PS２４ -0.0677 Alarm Normal back pressure
reduce vacuum PS３６ -0.04746 Trip 0.08133MPa
PS３９ -0.07746 low vacuum
PS３７ -0.08133 removal of low vacuum
trip
The protection PS２５ 9.6 Alarm signal Normal value of HP
of secondary resistant oil 12.4 ～
security lower 14.4MPa
oil pressure
The protection PS４、PS6 0.45 (the exit Start the main pump of S4, S5 corresponding to
of firstly of the main oil stand-by the main oil pump # 1,
security lower pump) S6, S7 corresponding to
oil pressure the main pump # 2.
Operating platform
PS５、PS７ 0.47(the exit Normal pressure of Operating platform
of pump) pump
PS38 0.4 Indicates hanging gate
oil pressure has been
built
PS50 0.45 Resection of isolated
loop
LSV actuator S１４ Fully opened position Indicates status
indication of actuator
S２６ stroke test of 75%
S１３ Fully closed position

indication
LCV actuator S１５ Fully opened position Indicates status
indication of actuator
S３０ Fully closed position
indication
Other signals not listed in the table can be found in other related instruction manual. Setting value to
start the operation manual shall prevail.
0-6 Flushing and Testing of System

Washing and static test procedure of oil system can refer to the instructions to complete the big
machine, when flushing system use flushing board replacement with solenoid valve and servo valves.
The following tests must be completed before the start up the turbine.
1 Static test
1.1 Fast closing test of valve;
1.2 Stroke brake test;
1.2.1 On site stroke brake test;
1.2.2 Stroke brake test in control room;
1.3 The test of valve activity;
2 The test after the constant speed;
When all the standing test and preparation work of the unit were completed, can surplus it(see MEH
instructions). Complete of the electrical test program, check whether the action set-conditioning system
is in normal or ministries and without leakage.

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Rev.

Date Compiled by Review APPROVAL

Document No.: (WAK)B1620B-000301BSM Rev: A

PROJECT 4×350 MW Kamalanga Thermal Power Project

STD ENGINEER 2010-11-17

A Oct.2010 The First Issue

0-2 Actuator of control system

0-3 Hydraulic governor system

Sealing ring Spring base

Once security oil-in

Lower half of front box

0-4 Low-pressure oil supply system and lubricating oil system

1 Limit switch and pressure switch action value Summary:

S１３ Fully closed position

0-6 Flushing and Testing of System

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