W(Z)T

W(Z) T Series Hydraulic Turbine Microcomputer-based Governor

INSTRUCTION

Wuhan Strong Automatic Control Technology Co., Ltd.

Dear Customer, Thank you for your trust and your selection of Wuhan Strong Automatic Control Technology Co. Ltd. Please read this manual carefully, especially items on safety and attention before your installation, circuit connection, operation and maintenance to ensure your correct operation and usage .Items needing attention in this manual have been divided into two grades warning and be careful.

Safety Guidance
According to related regulations, be careful and warning items shall be read carefully before the installation and operation. Thus please read this manual and instruction as well as documents on controllers. Whats more, the installation and operation only can be started until you are familiar with related knowledge. Human death or injury and property loss may be caused if any violation of this manual.

Warning
The equipment is with dangerous voltage and also controls the dynamic components which have dangerous voltage. Human death or injury and property loss may be caused if any violation of this manual. The equipment is with dangerous voltage and also controls the hydraulic components which have dangerous voltage. Human death or injury and property loss may be caused if any violation of this manual. Only technicians who have been familiar with guidelines on safety, installation, operation and maintenance can operate this equipment.
1

The component which is connected with dynamic equipment directly operates under the dynamic voltage. Only constant input is allowed to connect and this equipment shall be earthing reliably. Be careful of the externally exposed component and no touch if you open the cabinet. Under normal condition, power terminal is also with dangerous voltage even if it does not work. , , Please do not draw any component during its work in order to not influence its normal work. Only qualified people can connect, start up this system and eliminate malfunction and those people must completely understand all warning and operation regulations in this manual. If any parameter setting operation, please do not modify the original setup randomly and shall contact with the supplier first. External power shall cut and warning plate also shall be hung before check and repair. The control power shall be cut and warning plate also shall be hung before operating electric or mechanical part of any equipment or machine.

Be careful
This mark will appear when installation error happens and it may bring mid or slight injury, or equipment damage. Please prevent the close of non-professional people to the equipment. The equipment shall be operated in the light of the suppliers
2

regulation. Any mismatch or non-performance of random change or usage of parts which are recommended not by the supplier may cause fire, electric attack, burn or property damage. , . Please screw down the screw of the terminal and any loose may cause break or fault. ,, Please keep it clean. Keys of governor cabinet and oil pump control cabinet shall be kept by related person. Please pay much attention to all mentioned above, which must be obeyed. Please take care of this manual for your future convenience. ISO90012000 ISO90012000 ISO90012000 The quality management system of this equipment complies with the requirements of ISO90012000.

....................................................................................................... 12

CHAPTER I GENERAL DESCRIPTION ............................................................... 12 ........................................................................................ 16 CHAPTER II SYSTEM STRUCTURE OF GOVERNOR ....................................... 16 2.1 BLOCK DIAGRAM OF THE SYSTEM STRUCTURE ........................... 16 2.2 BLOCK DIAGRAM SPECIFICATIONS .................................................... 17 2.3 SYSTEM WORKING PRINCIPLES .................................................. 18 ........................................................................................ 23 CHAPTER III GOVERNOR SYSTEM CONFIGURATION .................................... 23 3.1 CONFIGURATION OF THE ELECTRICAL SYSTEM............................ 23 3.1.1 Hardware Configuration ......................................................... 23 3.1.2 Software Basic Configuration.......................................... 25 3.1.3 Functional strengthen Software Configuration ......... 25 3.1.4 Equipments and Software for Debugging (not belong to Governor equipments) ........................................... 26 3.1.5 Equipments for Test (not included in Governor equipments) .................................................................................... 26 3.2 MECHANICAL SYSTEM CONFIGURATION ..................................... 26 .............................................................................. 27 CHAPTER IV MAIN FUNCTIONS AND FEATURES OF GOVERNOR ................ 27 4.1 MAIN FUNCTIONS ............................................................................ 27 4.1.1 Regulation and Control Functions ............................... 27 4.1.2 Diagnostics and Tolerance Functions.......................... 30 4.1.3 Developing and Debugging Functions ............................ 32 4.2 MAIN FEATURES.............................................................................. 33 ............................................................... 35 CHAPTER V MAIN TECHNICAL DATA AND PERFORMANCE INDEX OF GOVERNOR ......................................................................................................... 35
4

5.1 MAIN TECHNICAL DATA ............................................................. 35 5.2 MAIN PERFORMANCE INDEX ...................................................... 39 ........................................................................................ 41 CHAPTER VI HARDWARE CONFIGURATION ................................................... 41 6.1 PLC PLC HARDWARE CONFIGURATION ............................................. 41 6.1.1 Q PLC Japanese Mitsubishi Q series PLC..................... 41 6.1.2.S7-300 PLC S7-300 Series PLC .................................................... 42 6.1.3 Modicon TSX Premium PLC / Modicon TSX Premium Series PLC43 6.2
OPERATING TERMINAL

..................................................................... 44

6.3 ELECTRO-HYDRAULIC TRANDUCER PART ................................. 45 6.3.1 Step-by-step motor and Step-by-step motor driver module ............................................................................................................ 45 6.3.2 servo motor and driver module............................. 51 6.3.3 servo proportional valve and the amplifier ....... 56 6.4 FREQUENCY MEASUREMENT MODULE .............................................. 60 6.5 POWER SUPPLY SYSTEM .................................................................. 64 ................................................................................. 67 CHAPTER VII SOFTWARE PROGRAM SPECIFICATIONS................................ 67 7.1 FLOW BLOCK DIAGRAM OF MAIN PROGRAM............................. 67 7.2 REGULATING MODE ......................................................................... 69 7.3 STARUP AND SHUTDOWN RULES ............................................ 71 7.4 DIGITAL COORDINATION.................................................................... 72 7.4.1 coordination features of wicket and runner blade for Kaplan turbine.................................................................................. 72 7.4.2 Coordination interpretation arithmetic ............................ 73 7.5 MECHANICAL ,AUTO,ELECTRICAL /MANUAL
OPERATION AND BUMPLESS TRANSFER ....................................................

74

..................................................................................... 75 CHAPTER VIII PANEL DESCRIPTION ................................................................ 75 8.1 PANEL DESCRIPTION OF THE SEPERAT CUBICLE OF
5

ELECTRO-MECHANICS

........................................................................................... 75

8.2 PANEL DESCRIPTION OF THE UNIT CABINET OF

ELECTRO-MECHANICS

........................................................................................... 75

............................................................................................ 77 CHAPTER IX MECHANICAL HYDRAULIC SYSTEM.......................................... 77 9.1 GENERAL DESCRIPTION .......................................................................... 77 9.2 INTRODUCTION OF
MAIN COMPONENTS ....................................

81

9.2.1 ZL 00 2 24552.3 Oil-free Electro Hydraulic Transducer (patent NO. ZL 00 2 24552.3) .................................................. 81 9.2.2 Servo Proportional valve .................................................... 83 9.2.3. Main Distributing Valve ........................................................... 83 9.2.4 Emergency Stop solenoid valve .................................. 86 9.2.5 Displacement Sensor ........................................................ 87 9.2.6 Oil Filter ..................................................................................... 88 9.2.7 () Closing Device with serval rates(optional)............. 88 9.2.8 () Emergency distributing valve(optional)................... 90

9.2.9 mechanic-hydraulic cabinet ................................................ 92 9.2.10 Assemble and adjustment ................................................ 92 HYZ YZ ................................................................ 95 CHARPTER10 USAGE OF HYZ AND YZ OIL PRESSURE DEVICE................... 95 10.1 GENERAL DESCRIPTION ....................................................................... 95 10.2 MAIN PARAMETERS ....................................................................... 99 10.2.1 HYZ Basic parameters for HYZ oil pressure device ........................................................................................................................ 99 10.2.2 YZ Basic parameters for YZ oil pressure device . 99 10.3 WORK PRINCIPLE .......................................................................... 99 10.4 DESCRIPTION OF OIL DEVICES MAIN COMPONENTS .106 10.4.1 Pressire tank cnfiguration ................................................106 10.4.2 Oil return tank configuration............................................107 10.4.3 /Oil pump group .....................................................................110
6

10.4.3.1 Screw oil pump ............................................................. 111 10.4.3.2 Internal & straight tooth gear pump ...... 111 10.4.4 combined valve.......................................................................112 10.4.4.1 General description ..............................................................112 10.4.4.2 main parameters ...........................................................113 10.4.4.3 structure features ..........................................................113 10.4.4.4 Working principle ...........................................................114 10.4.4.5 The Adjustment and Checkup of the Combination Valve ...........................................................................................................117 10.4.5 Brief introduction of main automatic, test and ontrol components ..........................................................119 10.4.5.1 Oil level meter of pressure tank ( It is not included in the bladder accumulators)..........................................119 10.4.5.2 () Automatica air replenish device(optional).....120 10.4.5.3 oil level singal indicator of oil return tank(Optional) .............................................................................................121 10.4.5.4 oil mixing water signal device(optional) ....................................................................................................................122 10.4.5.5 Pessure meter, pressure controller and pressure transmitter(Optional)..............................................122 10.5 INSTALLATION OF OIL PRESSURE UNITS...............................123 10.5.1 Installation of oil return tank .........................................124 10.5.2 Installation of pressure oil tank.....................................125 10.5.3 Installation of motor......................................................126 10.5.4 Installation of valves and accessories of the pressure oil tank.............................................................................................127 10.5.4.1 Installation of the filling valve .................................127 10.5.4.2 Installation of release valve....................................127 10.5.4.3 Installation of main pressure oil valve .........128 10.5.4.4 Installation of assistant port valve ...............128
7

10.5.4.5 Installation of oil level shut-off valve............128 10.5.4.6 Installation of air safety valve ......................128 10.5.4.7 Installation of air filler valve.............................129 10.5.4.8 Installation of shelf.....................................................129 10.5.5 Installation of valves and accessories of oil return tank .................................................................................................129 10.5.5.1 Installation of oil discharging valve of the oil return tank...................................................................................................129 10.5.5.2 Installation of double oil-filter screens ..............130 10.5.6 Installation of Automatic components .....130 10.5.6.1 Installation of by-pass level indication and thermometer of the pressure tank ....................................................130 10.5.6.2 Installation of by-pass level indication and thermometer of the oil return tank ....................................................130 10.5.6.3 Installation of automatic air filler device ....130 10.5.6.4 Installation of manometer, electro connecting pressure gauge, and pressure transducer .................131 10.5.7 Installation of oil and air ducts ...........................131 10.5.7.1 Installation of the oil duct from the oil pump to the pressure tank.................................................................................132 10.5.7.2 Installation of the air duct from the automatic air filler device to the air filler hole of the pressure tank. ........................................................................................................132 ................................................................................133 CHAPTER XI USAGE OF OIL LEAKAGE DEVICE(OPTIONAL) .......................133 11.1 Note to installation...............................................................133 11.2 Technology parameters .......................................................134 11.3 The main accessories......................................................135 ......................................................................140 CHAPTER XII DESCRIPTION OF INSTALLING, DEBUGGING AND
8

MAINTAINING .....................................................................................................140 12.1 MECHANIC INSTALLATION AND DEBUGGING ..............................140 12.1.1 Assembling.................................................................................140 12.1.2 Zero setting .........................................................................140 12.2 ELECTRIC INSTALLATION AND DEBUGGING ...............................140 12.2.1 Installation ..................................................................................141 12.2.2 Debugging..................................................................................142 12.3 GOVERNOR INPSECTION AND MAINTENANCE.................150 12.3.1 Pay attention to following items while daily checking .....................................................................................................150 12.3.2 Pay attention to following items while daily maintaining .......................................................................................................................152 12.3.3 Breakdown Diagnosis ......................................................153 12.3.4 easily-abrasive spare parts .....................................................158 .............................................................................159 CHAPTER XIII OPERATING INSTRUCTION ......................................................159 13.1 GOVERNOR POWER UP OR RESET...................................159 13.2 CHANGING MODE .........................................................................160 13.3 INCREASING AND DECREASING OPERATION .........................161 13.4 MECHANIC OPERATION ..........................................................162 13.5 GOVERNOR OPERATION .....................................................162 13.5.1 necessary conditions before governor startup ............................................................................................................162 13.5.2 Automatic Starting and Synchronize ............................163 13.5.3 Load Increasing/Decreasing ...............................................164 13.5.4 phase modulation.......................................................................165 13.5.5 releasing phase modulation ................................................165 13.5.6 Automatic Stop....................................................................165 123.5.7 Start and Synchronize by Mechanical Manual ....166 13.5.8 Switching from Mechanical Manual to Auto ..............167
9

13.5.9 Mechanically manual stop ...............................................167 13.5.10 Electrically manual startup and synchronization .168 13.5.11 Electrically manual stop .................................................169 13.5.12 // Switch of mechanically manual/automatic/electrically manual ............................................................169 13.5.12.1 Mechanically manual operation conversed into automatic one: ............................................................................................169 13.5.12.2 automatic operation switching into mechanically manual operation ........................................................................................170 13.5.12.3 automatic operation switching into electrically manual operation ........................................................................................170 13.5.12.4 electrically manual switching into automatic ........171 13.5.13 The operation of the Runner blades is same as the guide vane .................................................................................171 13.5.14 Emergent stop...................................................................171 13.5.15 Power Operation ...............................................................172 13.5.16 Lubricate Oil-free Electro-hydraulic Transducer .......................................................................................................................172 .......................................................................................173 CHAPTER XIV OIL PUMP SYSTEM ...................................................................173 14.1 GENERAL DESCRIPTION .......................................................................173 14.2 INSTALLATION AND HARDWARE CONFIGURATION OF
OIL PUMP SYSTEM ................................................................................................175

14.2.1 Mechanical installation .........................................................175 14.2.2 Conditions ............................................................................177 14.2.3 Electric installation ...............................................................178 14.2.3.1 Main control circuit ........................................................178 14.2.3.3 Power supply ........................................................................178 14.2.3.4 Panel arrangement ........................................................178 14.2.3.5 There are several relays
10

and several peripheral wiring terminals. ..................................................179 14.3 CONTROL PRINCIPLE DIAGRAM OF OIL PUMP SYSTEM ..........................................................................................................................179 14.4 OPERATION DESCRIPTION OF OIL PUMP SYSTEM.........180 14.4.1 Oil pump automatic way..............................................180 14.4.2 OiI pump manual way................................................181

14.4.3 Oil pump Switchover way.............................................181 14.4.4 supplys air control ...............................................................182 14.4.5 Emergency stop ..................................................................183 14.4.6 Display .......................................................................................183 14.5 COMMISSIONING AND MAINTENANCE OF OIL PUMP
SYSTEM ..............................................................................................................184

14.5.1 System commissioning .......................................................184 14.5.2 System maintenance ...........................................................186 14.6 MAINTENANCE OF OIL PUMP SYSTEM .........................187

11

Chapter I General Description

The microcomputer-based hudraulic turbine Governor is indispensable part of hydro power station. This manual focuses on microcomputer-based hudraulic turbine Governor, oil pressure device ,oil leakage tank ,oil pump control system , Tachometric Relay and so on to state. The microcomputer-based hudraulic turbine Governor is a new product developed on the basis of electro-hydraulic Governor in the 1970s'. With the development of computer technology and control theory, the technology of hudraulic turbine Governor has been developed and improved constantly; the reliability and regulating performance have already met the requirements of unmanned operation completely in power plants. WZT GB/T9652-2007.2 Our company has been devoting to the development of microcomputer-based Governor technology of hudraulic turbines for many years. By cooperating with famous universities and colleges, research institutions, and learning from each other, our company has manufactured Governors with optimum reliability and excellent regulating performance constantly. W(Z)T Series Hydraulic Turbine

12

microcomputer-based Governor overcomes the breakdown that the Governor exists at present, and is really power cut-off keeping, completely digit and maintenance-free, its reliability and regulation performance have completely come up to the national standard GB/T9652-2007.2. The governor developed by STRONG Company has gained many national patents.

With many years efforts, our Hydraulic Turbine microcomputer-based Governors have been applied successfully to operating on over hundreds units in thousands of hydraulic power plants all over China, including Baishan, Xijin, Fuchunjiang, Fengman ,Lushui ,gutianxi, bapanxia etc.We are highly appraised by a great number of power plants for high-quality product and first-class service. Basing on

this , the products have been successfully put into use in many countries such as NORWAY. Afghanistan, Macedonian ,Ethiopia and so on W(Z)T (PLC) W(Z)T Series Hydraulic Turbine microcomputer-based governor is a new type of Hydraulic Turbine governor, with imported programmable logical controller (PLC) as the control core, oil-free electro-hydraulic transducer or Proportion servo valves as electro-hydraulic transducer link, and mechanical hydraulic system as actuator. W(Z)T-AA-BB-SC CD -D2- P The model of the W(Z)T-AA-BB-SC CD-D2-P Hydraulic Turbine

microcomputer-based governor is defined as follows: WT WTGovernor for Francis turbine; WZT WZTGovernor for Kaplan turbine;
13

AA WT mm WZT mm/ mm AA : number of size, as For WT governor for Francis turbine, it represents the diameter (mm) of wicket gate main distributing valve of wicket gates . For WZT governor for Kaplan turbine, it represents the diameter (mm) of main distributing valve of wicket gates/ the diameter (mm) of main distributing valve of runner blades.If the diameter of the two main distributing valves are the same, It is not necessary to show the diameter of main distributing valve for runner blade. BB 2.5Mpa4.0Mpa6.3Mpa

BB rated oil pressure code.There are main following codes: 2.5Mpa 4.0Mpa6.3Mpa SC SC: code of the manufacturer, that means Technology Co., Ltd C 0 1 2 3 4 5 6 7 8 + C: product characteristic code (electric conversion code), o means step-by-step motor type; 1 means servo motor type; 2 means servo proportional valve type; 3 means digital valve type; 4 means step-by-step double oil free electric conversion type; 5 means servo double electro-hydralic type; 6 means guide vane adopting oil free oil free Wuhan Strong Automatic Control

electro-hydralic and

runner blades using digital type; 7 means double

proportional servo valve type; 8 means proportional servo valve plus oil free electro-hydralic type D: PLC 0 FX2N 1 Q 3 PREMIUM 4 OMRON 5 S7-200
14

6 S7-3007 D: product characteristic code (PLC code),0 for Mitsubishi FX2N series; 1 for Mitsubishi Q series; 3 for Schneider PREMIUM series; 4 for OMRON series; 5 for Siemens S7-200, 6 for Siemens S7-300; 7 for Taida Series. D2 D2 PLC, PLC D2: product characteristic code (redundancy); D2 means double PLC , single PLC can be omitted, P P

P: product characteristic code (unit type); p means pump storage governor , if not ,it can not be omitted. WZT-80-4.0-SC 00 80 4.0Mpa FX2N PLC Taking WZT-80-4.0-SC 00 for example: it is blade type governor, diameters of both guide vane and the blade are 80, oil pressure is 4.0Mpa, manufactured by Wuhan Strong Automatic Control Technology Co., Ltd; step-by-step double oil free electric conversion type; the controller is FX2N, single PLC; W(Z)T The advantages of W(Z)T Series Hydraulic Turbine microcomputer-based

governor are: simple but reliable structure, with a low oil consumption, few starting times of oil pump, low requirement for oil quality, no occlusion, current opening holding of servomotor on power cut-off , easy accessibility, and convenient for human-machine to dialogue. W(Z)T Series , With LCD touch panel as human-machine interface, W(Z)T

microcomputer-based Governor displays various data, status, and performs various kinds of operation, test, record, alarm, print and communication functions.
15

 Chapter II System Structure of governor

2.1 Block Diagram of the System Structure (Here taking step-by-step governor as example to state.)
PC (P)
F

WT series

fg fn

Kf

Fg Fn

Ef

Kp YP
(D)

Kf

KDS YD + 1T + IVS + + +
(I)

+ -

fc

+ + Kf Fc

I Y 1

KI YI S

Ey Y bp

Yc

Ky Kpg Kpg

yc

Yc

+ + P
p e

A/D

Pc

pc pg

Ep

Kp

Pg

++
P

Ep

+
p

KI F

pc

16

Upper computer

Operation terminal touch industry PC

fg

Unit measure frequency

Frequency

Kf Kf

Fg Fn

fn

Net frequency

KDS YD + ++ + 1 + T IVS
(I)

fc

Frequency reference

+ + Kf Fc
Ey

I Y 1

KI YI S

Digital amplifier

Steppping motor feedback Servomotor

Y bp
Opening reference

Wicket gate

Yc

Ky Kpg
Power measure

yc
Open loop increment

+
Yc
Frequency

A/D module

Pc

Power reference

pc pg

+ -

P dead band p Ep e
p

Kp

Pg

Unit power

++
P
Unit power Water level signal Stepping Wicket gate motor feedback feedback

Kpg

Ep

+
p

KI F

pc

Block diagram of the system structure

2.2 Block Diagram Specifications 1 f Frequency Differencef 1) When the oil switch is shut, or when the oil switch is open with an abnormal net frequency, or when the oil switch is open with tracking frequency setter. f=fG-fJ 2) When the oil switch is open with normal net frequency, and net frequency is traced. f=fW-fJ 3) E Frequency dead band E (its value can be set)
17

Servomotor

(D)

Oil-free electro-hydraulic transducer

Frequency measure

Mechanical hydraulic system

Frequency measurement (P)

F

Ef

Kp

YP
Electric limiter

Computer communication module Stepping motor

Frequency regulation Opening/Power regulation 2

E=0

E=0.2Hz

Difference value between Setter and Actual Value 1) Frequency /Opening regulating mode 2) Power regulating mode 3) Ep Power dead band Ep Frequency/Opening regulating mode Power regulating mode 4) Permanent speed droop 1 Frequency regulating mode 2 Opening regulating mode 3 Power regulating mode bp=010 bp=010 bp=0% bp Ep=0~5%PN Adjustable Ep=0 =PG-P =YG-YPIG

2.3 system working principles CPU The whole regulator employs types of CPU modules, each of which has different
18

functions, and block module is adopted for the structure. The way that divides complex missions into different parts makes the system reparable and reliable; it is not only useful for single soft upgrade but also for the upgrade of the whole regulator system with good compability. (1) CPU PLC Frequency module is made of high-quality CPU to measure the frequency and send unit and net frequency to PLC by communication bus for the software upgrade. (2), A/D A/D Guide vane feedback device send the sampled guide vane opening signals and

active power signals to A/D module,and A/D module transfer these simulation into digital signals. (3) The switchgear input module collects secondary startup, shutdown, increase and decrease commands. (4) CPU CPU All above input signals will be sent to CPU module, which then will analyze and calculate corresponding guide vane control signal and status signal (including failure) according to regulating rule, which then will be sent to switching value output module or analog output module to complete the control output and status output. (5) The switchgear output moduel is to output the digital mechanical hydraulic
19

systems oil free clockwise and anti-clockwise movemet on the basis of the corresponding width pulsing open or close signal by calculated control valueIf the electro hydraulic convertor adopts oil free electro-hydraulic tansducer,then

simulation quantity output moduel is used to control the servo valve on calculated value to make the guide vane acts in the light of regualtion rules and sends signals when fault happens. (6) Communication unit is responsible for the communication with upper computer, and send or receive commands to or from the upper computer. (7) Touchable panel is human-computer interaction interface in Chinese to finish field operation orders of Governor and status data display, and also to remotely communicate through connection. PID PID , PID The hudraulic turbine regulating system whose control index and stability has attracted more attention of the public is a non-linear, changable and non-min phase system. The controlling rules of turbine speed regulating system has been perfecting with the development of controlling technology. Although in recently years, the study of controlling modes and methods based on modern controlling system (e.g. Automatic controlling, parameters self- perfection when changing

the structure, multi-quantity and best-controlling of modular reference) has begun, PID controlling principles have also wildely used presently since the turbine regulating system is a system with variation and compared quick-speed. However,
20

the common PID controlling system needed precise mathematical modes is only suitable for linearity system whose dynamic quality can not be secured with common PID. PID , , 9 , , ,, , , ,, , Herein, we adopt a new PID controller ---basic and logical controller (also called nine-point controller) which can be abstracted into nine operating points (strong plus, weak plus, plus, little plus, remaining, weak minus, miuns and heavly minus) to control aoocrding to the tolerance and its changing rate. Its fundamental principle is to continually change or adjust controlling methods in order to make the controlling rules of controller itself satisfy the system requests for good capacity according to the features of controlling system operating modes. As the controller works only influenced by the operating conditions of controlled objects, it is largely used by controlled objects. However, different operating points with different contolling methods, the new controller can change parameter, structure and control with non-linearity. Simple calculating in controlling makes its engine application come true. The stable controlled objects can simultaneaously obtain good static and dynamic qualities, even though it has effects on unstable ones, thus basic and logical controller can apply to water turbine speed regulating system to improve performance.
21

 PI AGC PI PID Governor has frequency regulation, opening regulation and power regulation three kinds of control modes, which can be chosen according to the practical needs. The change of them can be done through the touch key on terminal or secondary circuit contact, or through the digital communication interface. Frequency regulating mode has tracing frequency and network frequency. The mode of frequency regulating insures that unit frequency conforms to net frequency for synchronous operation. Power regulating mode utilizes PI link to regulate units according to the power difference for the constant output power. It is quite easy to realize the whole plant AGC (Automatic Generation Control) when units operating in this mode. Power setter is utilized to regulate units by PI link and, meanwhile, directly output by open-loop control to improve the increasing and decreasing speed. The power setter could be digital signal, which is set by upper computers . Electric limiter link limits the output of PID to make sure output not exceeding Electric limiter . PLC Digital amplifier compares the PLC output with the data sampled by servomotor feedback, amplifies and output. Dual closed loop structure is adopted for the control of servomotor, besides servomotor feedback, there is a motor feedback or Proportion servo valve feedback for the control of oil-free electro-hydraulic transduceror or Proportion cylinders accurate loacting, the compensation of various kinds of mechanical errors and abrasion etc.
22

 Chapter III Governor system configuration

The electric and mechanical parts compose of Governor system. Separate or united cubicle structure for electric and mechanical parts may be selected according to the customers request. 3.1 Configuration of the Electrical System PLC PLC ,/ The computer adopts PLC, and dual PLCs also can be selected. The electro-hydraulic converter is proportional valve Step-by-step motor and
servomotor motor.

As

for

frequency

measurement,

it

adopts

residual

voltage

frequency

measurement. Anyhow, double frequency measurements consisting of residual voltage and tooth-gear also can be selected and they are backup for each other. The electric feedback can select absolute encoder, linear replacement transducer and potentiometer etc. The human-machine interface is LED touchable screener.

3.1.1 Hardware Configuration 1 Cubicle Body (1) The separate cubicle of electro-mechanics 8006002260mm Dimensions8006002260mm
23

Colorselectable (2) The united cubicle of electro-mechanics 8006001860mm DimensionsSingle8006001860mm 12008001860mm Double12008001860mm Colorselectable

2 Power Supply System 1 1+24V Switch1 power supply +24V which is specialized for relay, operation terminal. 2 2+24V Switch power supply 2 +24V which is specialized for motor drive.

3+12V/+15V +12V/+15V power for feedback

3 Panel Operation terminal (Touchable panel )

4 Control part W(Z)T PLC, Q S7-300 PREMIUM / As for the control part of W(Z)T Series Hydraulic Turbine microcomputer-based governor, imported PLC such as Mitsubishi Q series, Siemens S7-300 series, Schneider PREMIUM series can be chosen if required by the client. The hardware is consisted of the following parts which can be increased or decreased according
24

to the real condition. 1 Power module 2CPU CPU module 3 Input simplifying module 4 Output simplifying module 5AD AD module 6 Communication module 7 Motor driver or proportional valve amplifier 8 Motor or proportional servo valve

3.1.2 Software Basic Configuration (1) PID Paralled connecting PID program adopts basic logical controller (2) Real-time graphic display, note and monitoring software (3) Real-time breakdown diagnosis program (4) Sub-program of double digital cooperation (5) Operation subroutine such as unit start, stop etc.

3.1.3 Functional strengthen Software Configuration (1) Communication software with upper computer (2) Power regulation Software with a closed control loop

25

3.1.4 Equipments and Software for Debugging (not belong to Governor equipments) (1) PC (2) The software programming Mitsubishi, Siemens or Schneider (3) HG-II HG-II Simulation and Testing Instrument of the Hydraulic Turbine Governor (4)89C51 89C51 Single-Chip assembler

3.1.5 Equipments for Test (not included in Governor equipments) (1) HG-II HG-II Simulation and Testing Instrument of the Hydraulic Turbine Governor (2) PC

3.2 Mechanical System Configuration (1) Step-by-step oil-free electro-hydraulic transducer (with automatic center-return mechanism) or Proportion servo valves

(2) Piston and body of main distributing valve (3) Mechanical manual operation (4) Emergency stop solenoid valve, double oil filter

26

 Chapter IV Main Functions and Features of governor

Notes +40-524h +35 Temperature the temperature around shall be not higher than +40 and lower than -5, and the average temperature during 24 hours shall be not more than +35. 2000m Height for inside use purpose, the elevation of place shall not be high than 2000m. +40 50% (+20 90%) Humid the relative humid around shall be not more than 50% when the highest temperature is +40 and higher humid is allowed if the temperature is lower, for example, the humid can be 90% when the temperature is +20 under which condition, the influence of condensing dew formation due to the temperature variation shall be take in to consideration. Bump the cabinet shall be protected from any bump. Vibration the equipment shall be equipped at the place without violated vibration and impaction. Pollution the equipment shall not be equipped at area with conductidust and corrosive gas. 4.1 Main Functions 4.1.1 Regulation and Control Functions 1 Unit frequency and net frequency is measured by integrating hardware

27

and software, it is diagnostics and breakdown tolerant. The unit frequency is measured by Two-circuit frequency measurement which can be measured by residual voltage and tooth-plate. 2 At no Load, there are two types of control modes trace frequency setting and trace net frequency. For latter mode, unit frequency automatically conforms to system frequency. 3 PID , 9 PID adopts basic logical controller which abstract actual operating conditions into 9 operating points (strong plus, weak plus, plus, little plus, remaining, weak minus, miuns and heavly minus) according to the tolerance and its variable rate so that efficient control can be done in the light of corresponding manners. 4 AGC Assure units work stably in every operation conditions No-load, isolated operation, parallel operation, AGC operation. 5 With open loop control in power setting regulating, unit output power is increased and decreased rapidly and accurately. 6 Touchable panel is adopted for real-time human-machine interface, which makes operators convenient to get Governor operating condition. 7 Real-time diagnose, display and alarm, and all breakdowns recorded 8 Recording operation for consultant 9 Analog signals sampling
28

function for water head, unit power, etc. 10 It addopts closed-loop stratup rules to supervise the unit speed all the time during startup to make sure water turbine reach rated speed fast and smoothly. With serial communication interface, this communicates with upper computer and realizes plant automatic operation 11 Double regulating unit can cooperate digits according to water head change and improve working efficency of motor units. 12 It is convenient to input cooperating data and store in the programmable controller by terminals in Chinese after cooperating curves offline qualification. 13 Realize power closed loop control (provided by the ouside if there is power in units), and power setting signals could be digital for the sake of connection with monitoring system. 14 Three types of operation mode automation and manual and electric manual, and no perturb switch between them. With computer automatically traces manual or electric manual operation, it realizes no warranty and no disturbing switch. 15 Water head signal may be input automatically or manually. 16 Different process monitoring and tests
29

dynamic

process

monitoring,

static

characteristics

test,

no-load

frequency disturbing, no-load frequency swing, load rejection test. 17 Set parameters by operation terminal in Chinese. 18 / As input/output is completely digital, it is easy for debugging and setting. 19 Security function Different operators access to different interface operation by unique passwords. 20 Have help function with integral instruction 4.1.2 Diagnostics and Tolerance Functions W(Z)T PLC CPU A/D The W(Z)T Series Hydraulic Turbine Governor is of the function of powerful Diagnostics and Breakdown Tolerance, which not only includes the diagnostics function of PLC for CPU module, A/D module, communication module and application software, but also includes those of governing system for measured frequency signal, power and water head signal, feedback signal, and of mechanical system and communication system. All breakdowns are displayed on terminal and recorded; meanwhile, comprehensive contact signals are sent out. 1 Breakdown tolerance of unit frequency signal (1) In the event of unit frequency signal error with no Load, it would automatically cut off frequency tracing, and close opening to the safety no-load position, and be ready to receive stop command. (2)

30

 In the event of net frequency signal error in generating casenet frequency signal is used instead of the unit frequency signal, without load disturbing, if unit frequency returns to normal, it would join to help regulate, without load disturbing. (3) In the event of unit frequency and net frequency signal errors in generation case, Governor would maintain the current load, and regulate units output by power setter or increasing/decreasing operation. (4) 20HZ 20HZ Two-curcuit frequency measurement Residual voltage and gear frequency measurements are supplement with each other. Normally, residual volatage frequency measurement will be adopted automatically if units frequency is higher than 20HZ, otherwise, it will be gear frequency measurement. If residual voltage requency measurement has broken, the other one will be used automacally, vice versa. 2 Breakdown tolerance of net frequency signal In the case of net frequency signal error at No Load, it would automatically track frequency setter. In generation operation, net frequency would not join regulation. 3 In the case of guide vane feedback error, motor feedback error, or driver module error, make servomotor maintain the current opening. And switch to mechanical manual if needed. 4 In the case of power signal error, Governor would not perform power closed loop regulation, it would automatically switch to opening regulating mode, and control units output by upper computers or
31

regular control. 5If any error occurs at water head signal, it would maintain the current water head value, and wait to be switched to manual command. 6 PLC In the case of PLC system error, and made servo motor maintain the current opening. Switch to mechanical manual if needed. 7PLC Even if error occurs at operation terminal, PLC performs the control functions, for instance, start, stop, load increase/decrease, breakdown protection, etc 8 When A/C, D/C breaks simultaneaously, mechanical hydraulic system will become zero automatically and no change to servometer. 9 Twin filter is made of two sets of foldable and stainless meshes one for working and the other for spare, and both can be converted and cleaned in operation without disturbance. 4.1.3 Developing and Debugging Functions 1 PLC PLC is extremely specialized for developing and debugging. 2 software Programming provides various man-machine interfaces, with which it

is quite convenient for users to develop and debug. 3Ladder diagram makes it easy for user to master. 4It is convient to equip and record on the terminal

32

4.2 Main Features 1 Better regulating performance

PID GB9652-2007 ID regulator adopts basic-logical controller which makes Governor used in different units and different operating in the same unit with well controlling results. And its functions have met or excelled the national standard GB9652-2007. 2 High reliability

30 The body of Governor hareware is the programmable controller of Q Series from MITSUBISHI, and its zero breakdown in more than 300,000 hours (on average) makes operation reliable.Electro-hydraulic transducer has automatic reset position device , the servomotor can keep current opening when D/C and A/C break at the same time. 3 Digitalization

Governor is digitalization, which improves data processing, filtering, amplifying and anti-interference capacities. Closed-loop positioning control of

electro-hydraulic transducer absolute postion can be realized by the way of pingpang-digital and opaque controlling. 4 Strong anti-interference capacity

PLC The PLC depending on industrial standards and application software has the function of self-diagnosis and breakdown tolerance, thus Governor has the anti-interference ability to withstand extreme circumstances in power plant.
33

5 FlexibilityIt can be applied to control and regulate various types and capacities of hydraulic turbines. 6 PowerfulIt establishes normal control and upper computer control; including start, stop operation, etc. Furthermore, it establishes functions for debugging, test, and remote

communication, etc. 7 Convenient human-machine dialogue. Operator can know the real-time operation situation of the Governor by industrial-class Touched LCD. 8 Strong function for expanding Special function may be added if power plant needs. Only need to add corresponding hardware and software into the original system by not making large change to original system. 9 Its test, maintenance and use are better than traditional one with easier installation, adjustment and maintenanceis.

34

 Chapter V Main Technical Data and Performance Index of governor

5.1 Main Technical Data 1 Frequency Measurement (1)() (2)0.3V200V24V (3)1~20ms (4)5~100Hz (5)<0.0015Hz

(1)Mode residual voltage and tooth-plate frequency measurement (2)Input voltage signal (3)Pulse modulation time1~20mSec (4)Frequency Test range 5~100Hz 0.0015Hz remanent voltage 0.3V~200V, tooth-plate 24V pulse

(5)Frequency Test precision

2 Setting Range of Regulating Parameters bp=0~10% bt =0~200% Td=1~20 ( 1%) ( 1%) ( 1 ) ( 0.1 )

Tn=0~3

KPKIKD KP=0~20.00 KI=0.5~10.00 KD=0~5.00 Permanent speed droop

bp

=0~10%

(resolution 1%)

35

Temporary speed droop Damping time constant Derivative time constant

bt =1~200% Td =1~20sec Tn =0~3sec

(resolution 1%) (resolution 1s) (resolution 0.1s)

For the governor adopted KP, KI,KD , the setting range of regulating Parametres is as follwing : Proportion: KP=0~20.00 Integral: KI=0.5~10.00 Differential: KD=0~5.00 3 Control Parameter Range Opening setter Frequency setter PG=0~100% FG=45~55Hz E=0~0.5Hz Ep=0~5%PN L=0~100% P=0~120% PN PG =0~100% FG =45~55Hz (resolution 1%) (resolution 0.01Hz) (resolution 0.01Hz) ( 1%) ( 1%) ( 0.01Hz) ( 0.01Hz)

Artificial frequency dead band range E =0~0.5Hz Power dead band Opening limiter Power setter E p =0~5% PN L =0~100% P=0~120% PN

(resolution 1%)

4PLC PLC Operation Rate 0.034S/ Basic command 0.034S/command

5 Parameter of Motor and proportional servo valve 1

36

 103H8222 2A/ 4.9NM

Parameter of Step-by-step motor Step-by-step motor model and manufacturer Model No103H8222 Manufacturer Japan Sanyo Corporation

Two-phase step-by-step motor 2A/Phase Holding torque 4.9NM

2 34S42 Kinco 3.5NM motor

Parameter of servomotor

servomotor model and manufacturer Model No34S42 Manufacturer Germany Kinco Corporation Holding torque 3.5NM

3/Proportional servo valve parameters 0811 6 DC24V Pmax=315 bar

37

 Qnom=40L/min P=35bar 100bar 1.1L/min max. 2.7A (1) 2.5

(2) max. 25VA (3) <10% (4) <0.1% (5) <0.2% (6) (0~100%)<10ms (7) 40<1%

Type and manufacturer Type: 0811 Diameter: 6 Structuer: Plate structure Control voltage: DC24V Pmax=315 bar Norminal flow Qnom=40L/min(valve port pressure P=35ba) Leakage(100bar/H): 1.1L/min Magnetic current: max. 2.7A 1Wiring resistance: 2.5 2Power consumption: max. 25VA 3Max flow tolerance: <10% 4Repeat accurancy: <0.1% 5Dead band: <0.2% 6Responding time(0~100%)<10ms 7Temperature float: zero float <1% when temperature difference larger than 40 6 Power (1) 50Hz220V15%<550
38

Plant AC power supply

50Hz220V15%<550VA

(2) 220V 110V15%<520 Plant DC power supply 220Vor 110V15%<520W

5.2 Main Performance Index 1 1Dynamic and static indexes 0.15%

0.25%0.3% When the governor is automatically operating at no-load condition, the relative

values of speed swing of unit:0.15% for large governors; 0.25% for mid-small governors; 0.3% for mini-governors. 100% 3%

After 100% rated load rejection, the wave peaks surpassing 3% rates speed

shall be no more than 2 . 1% t E

t M 8 12 15 0.9 The specific value between the regulating time t E of the units from load counting from

rejection to speed relative deviation less than 1% and t M which

load rejection to speed raising to the top speed less than 8 for middle,low water head pressure turbine , for axial flow turbine whose closing time is long less than 12,for high water head pressure turbine and impulse water turbine less than 15, for the uints which supply power to power station after network splitting, the lowest relative speed no less than 0.9 after load rejection. ( tubular turbine whose surge control and blade closing time is long is not included)

39



0.2S The speed or command signals are changed by the stipulated forms, and the

servomotor dead time is 0.2S. ix0.02%

0.06%0.10%0.20% The static characteristic curve is close to a line; and the speed dead band, is 0.06% for middle governor, 0.10% for small

0.02% for large governor,

governor, 0.20% for mini-governor. 0.8%

1% For Kaplan turbine governor system, the inaccuracy of runner blade servo

system shall be no more than 0.8%; and the deviation between actual coordinating curve and theoretical coordinating curve shall be mo more than 1% of the total stroke of the runner blade servomotor.

1%0.5% Under steady state operation, for multi-needle Pelton turbine, the position

tolerance between needles shall be no more than 1% in the whole scope, and the tolerances between every needle opening and average value of all needles openings shall be 0.5%. 1%

0.5%. For the pumped storage units whose wicket gate is individually controlled, the

position tolerance bewteen any wicket gate servomotors shall be no more than 1%; and the tolerances between every wicket gate servomotor opening and average value of all wicket gate servomotors openings shall be 0.5%.

0.3% 0.6% The comprehensive drift of large and mid-small governors converted into

relative values of the speed shall be no more than 0.3% and 0.6% respectively.

40

 Chapter VI Hardware Configuration

6.1 PLC PLC Hardware configuration W(Z)T PLC, Q S7-300 PREMIUM / PLC As for the control part of W(Z)T Series Hydraulic Turbine microcomputer-based governor, PLC of famous manufacturer such as Mitsubishi Q series, Siemens S7-300 series, Schneider PREMIUM series can be chosen if required by the client. The hardware is consisted of the following parts which can be increased or decreased according to the real condition. Features of different types of PLC are:

6.1.1 Q PLC Japanese Mitsubishi Q series PLC Q PLC SYSTEMBUS CPU PID Japanese Mitsubishi high performance Q series PLC uses standardized module structuere and all modules can be installed on the standard SYSTEMBUS directly. What more, all modules equips with individual processor with specific fucntions, CPU module can finish its logic judgement and PID calculation, input, output, opening sampling ect can be done via their own module with high speed, easy extension and uppgrading features.

Q The control part of the regualtor is consisted of Mitusbishi Q series and main configuratios are as following:
41

 name CPU CPU module Input mpdule Output module A/D A/D module Communication module Power supply Main basic plate

size Q01CPU QX40-S1 QY40P Q68ADU QJT1C24-R2 Q63P Q35B

quantity 1 1 1 1 1 1 1

manufacturer Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi Mitsubishi

remark

6.1.2.S7-300 PLC S7-300 Series PLC S7-300 SIEMENS PLC PLC USB SIMATIC S7-300 , SIMATIC S7-300 Siemens S7-300 PLC is the latest, highest and speed integrated one. Its advatages are: integrated standard ones characters at the largest extent, quicker progess execution, fully complementary of communication functionm suitable for different power supply all over the world, a lot of modules with special functions, making the power plant automation with most flexibility and control capability. The standard programme cable is convenient and quick. SIMATIC S7-300 programme controller is with module structure design, modules can be combined extendingly for the extension for purpose. SIMATIC S7-300 functions can help and support users program, start up and maintenance.

42

 S7-300 The control part of the regualtor is consisted of Siemens S7-300 series and main configuratios are as following:

name CPU CPU module Input mpdule Output module A/D A/D module Communication module Guide rail

size 6ES7313-6CF03-0AB0 6ES7321-1BH02-0AA0 6ES7332-5HB01-0AB0 6ES7331-7HF01-0AB0 6ES7340-1CH02-0AE0 6ES7390-1AE80-0AA0

quantity 1 1 1 1 1 1

manufacturer Siemens Siemens Siemens Siemens Siemens Siemens

remark

6.1.3 Modicon TSX Premium PLC / Modicon TSX Premium Series PLC 32 Modicon TSX Premium PLC BUS X RAM 48K 0.31uS CPU PID PLC IEC1131 25% LCU I/O 100% FLASH ROM The selected PLC is Schneider high performance Modicon TSX Premium serial with 32 digits. All is standardzied structure and installed on the standard BUS X directly. It is multi-mission operations, draw with power on, internal RAM at 48k max, single order execution time 0.31uS. What more, all modules equips with
43

individual processor with specific fucntions, CPU module can finish its logic judgement and PID calculation, input, output, opening sampling ect. can be done via their own module with high speed, easy extension and upgrading features. The programing language compies with IEC1131 standard. More than 25% margin has been reserved for storage capacity, input and output interfaces. Two communication interfaces has been set and are backup each other, which are connected with unit LCU I/O interface. The processor equips with enough internal storage for different kinds of system and application softwares, more than 100% extenstion capacity has been reserved. The internal capacity use FLASH ROM and backup storage for repalcement also can be replaced. Modicon TSX Premium PLC The control part of the regualtor is consisted of Modicon TSX Premium series and main configuratios are as following:

name CPU CPU module Input mpdule Output module A/D High speed A/D module Communication module PLC PLC power supply Rear plate

size TSX57103M TSXDEY16D2 TSXDSY08T2 TSXAEY420 TSXSCP114 TSXPSY1610M TSXRKY6

manufacturer Schneider Schneider Schneider Schneider Schneider Schneider Schneider

remark

4 MODBUS RS485

6.2 operating terminal . Non-professionals shall not operate or modify the parameter at

44

random. Operating terminal adopts Touchable panel. For the details of functions (operating, displaying, parameter setting and testing of the man-machine interface), please see << operating terminal instruction >>. It can communicate with upstream computer by the terminal. Furthermore, our company can provide specified communication regulation.

6.3 Electro-hydraulic tranducer part W(Z)T The elctro-hydraulic convertor part of W(Z)T Hydraulic Turbine

microcomputer-based governor also can use step motor, servo motor or proportional servo motor. And their functions are as following: 6.3.1 Step-by-step motor and Step-by-step motor driver module () ROZE RD323MS 3A/ Step-by-step motor driver module is selected from stepping motor driver module RD-323MS produced by Japan RORZE Corporation, which has oscillator to realize microsteps drivefor protecting microsteps operationmay drive from slow speed to high speed3A/phase high outputhigh frequencyadopt enclosure of aluminum magnesium alloyanti-interferencehigh heat emission. Automatic current down circuit is adopted.The performance is shown as follows Performance

45

 Model Power supply voltage Power supply current Excitation current Driver method

RD323MS DC18V40V 40V DC18V~40V (absolute maximum rated current 40V) 1.2 Approx. 1.2 times rated coil current of motor (max.) 0.33.0A/ 0.3~3.0A/phase Unipolar, constant current chopper method 180 14 1 to 80 pulses output per basic step angle

microsteps

set selectable microsteps14 kinds 6432168421 806020105 5025 0.3 CURRENT STOP

Auto. current down

080% 0 to 80% of the run current after about 0.3 seconds of inactivity according to stop current setting 600KppsMAX(SPEED =5V ) 600 kpps max. (SPEED input=5V) Overheat, protection 63(M)105(W)56(D)mm 250g over current and low supply voltage

Oscillating frequency Protective circuitry Outside dimensions Weight

24V
46

The step-by-step motor driver is used for driving step motor. The power is DC 24v and cut or used by manual relay. Motor speed, starting time, running current, shutdown current, segmental number and driving current etc. can be adjusted by the button on driver panel. Please refer wiring figure, external dimension and circuit diagram.

SPEED SPEED 0~5V LOW SPEED HIGH SPEED There are two types -- high and low speed step-by -step motor drivers. When speed terminal shortly connect with the power of step-by step motor driver, the motor will run with low speed. Otherwise, high speed. High running speed depends on voltage input to SPEED terminal. If the voltage changes in 0-5v, rotational

47

frequency changes in the frequency set from LOW SPEED to HIGH SPEED. / STOP/START STOP/START Step-by step motor on/off is controlled by STOP/START controlling signals from the driver. Step-by step motor starts when STOP/START controlling signals is at low level; otherwise, it shuts down. / CW/CCW CW/CCW Step-by step motor clockwise/reverse is controlled by CW/CCW controlling signals from the driver. Step-by step motor starts when CW/CCW controlling signals are in counter clockwise rotation; otherwise, it reverses. GROW OUT HIGH SPEED GROW OUT GROW OUT output port During accerlerating from stop to HIGH SPEED setting of step-by step motor, the signal output with low level. Thus, decreasing time can be calculated by pulses from GROW OUT outputting low level. CLOCK OUT DIP GROW OUT output port clock impulsing output port. The driver itself can choose basic step elongation pulse by DIP switch. ALARM 70ALARM PLC ALARM output port when it is 70, over heat protection circuit in the driver will be started, ALARM output becomes low level; meanwhile, the motor stops, its auto-current resists current startup, and PLC cuts driver power. ALARM LED ALARM LED over heat protection circuit turns on when working and output alarm signal. 17V OFF
48

Protecting circuit againt low voltage exciting current is off when power voltage is lower than 17v. A,/A,B,/B,CA,CB A,/A,CA A B,/B,CB B 2A step-by step motor controlling line output by the driver are A,/A,B,/B,CA,CB, among which A, /A,CA are A phase lines of step-by step motor; B,/B,CB are B phase lines. Herein, step-by step motor is the 2 phase one, and the current of each phase is 2A. Step-by step motor driver has five adjusting potentiometer and a set of code dialing switch for driver adjusting. Five adjusting potentiometers are 1 LOW SPEED Low-speed adjusting potentiometer for speed adjusting when step-by step motor is at low speed 2 HIGH SPEED High-speed adjusting potentiometer for speed adjusting when step-by step motor is at high speed 3 GROW TIME Time acceleration adjusting potentiometer GROW TIME used for adjusting speed rising time 4 RUN CURRENT Running current adjusting potentiometer RUN CURRENT used for current adjusting of running step-by step motor 5 STOP CURRENT stopping current adjusting potentiometerSTOP CURRENT for current adjusting of stop step-by step motor Setting of code dialing swirch 1 DIVISIOND1,D2,D3,D4,D5
49

1,5,25,50,64,80 Segmental number output impulse convertingDIVISION switches D1, D2, D3, D4, and D5. Every segmental number of stop step-by step motor may set as 1,5,25,50,64,80. the setting table is Switch D1 D2 D3 D4 D5 5 0 1 1 0 1 Segmental Number 80 0 1 0 0 1 1 0 1 1 1 0 64 0 0 0 1 0 25 1 0 1 0 0 50 0 0 1 0 0

2 3A 1.5A0 3A1 1.5A Switch setting of exciting current every phase current of step-by step motor may be 3A and 1.5AWhen the switchgear is 0, please select 3 A, 1 for 1.5A. 103H8222 The Step-by -step motor is chosen from 103H8222 step-by-step motor produced by Japan Sanyo Corporation, the concrete characteristics are shown below. Item Dielectric strength Insulation resistance Insulation type Allowable radial load Allowable thrust load Basic step angle Voltage Current Specifications

1000VAC 100M500VDC B 220N 60N 1.8o 2.8V 2A/ 2A/phase B type

50

 Resistance Inductance

0.7/ 5.7mH/

0.7phase 5.7mH/phase

Holding torque Mass Rotor inertia

4.9NM50kgcm 2.9 10-4kgm2 2.5kg

6.3.2 servo motor and driver module Kinco ECOSTEP100 Kinco 23S41 The motor driven modules adopts high quality servo driver ECOSTEP100 by Gemany Kinco, and the motor is servo 23S41 also from Kinco. ECOSTEP100 Features of AC servo driver ECOSTEP100 are as following: 1 If running for a long term, the motor will not feel hot, suitble for governor used in frequency and summit regulation turbine units. 2 Static vibration function: making the motor startup promptly so that dynamic respond speed of servo motor has been improved. 3 CANopenprofibus DPRS485 Connected with several site bues: CANopenprofibus DPRS485 4 Digitalized control of current, speed and position 5 Programmable controlled digit input and output 6 Intelligent gate close control 7 Compact installation dimension

51

8 24V 24V DC at lowest Basic functions 1 Digitalized speed and postion control, and limit control of position, speed and torque. 2 I2t To monitor whether the motor breaks, voltage and temperatures are overhigh, encoder signal is wrong, position tracing tolerance and I2t over large or not etc. 3 RS232RS485PROFIBUS CAN To set up communication interface parameters via RS232RS485 PROFIBUS or CAN 4 To set the simulation quantity signal output function ar a certain range 5 To control the braking device intelligently. 6 To input over stroke linit switch or original point switchgear 7 To control the driver power output via digit input and remove the fault 8 To show the driver ready status via digit output 9 To control position via site bus: the movement order can be input via site bus and curve of movement speed can be set in the driver via
52

program made. 10 To contol main and subordinate position 11 256 8 To control position via digit input: can store movement program with max 256 digits including position, speed and acceleration control orders; can input max 8 digital signals to execute different movement control program, has two digital output feedback signals which can be set by program. 12 RS422 Pulsing and direction signal control: pulsing and direction control singal interface which can be set by program and complies with RS422 standard; programmable max acceleration and max speed. 13 10V 10 To control speed and position by simulation signal: operation bar table set via program is in line with different movement speed and position; simulation signal input which is with 10 digits resolution and 10V settable range to control the movement speed. /basic parameters /servo driver parameter 1 Max output power 2
53

560W 560W 24~70VDC

Voltage: /servo motor parameters 3 No. of poles 4 Encoder resolution 5 Max DC voltage 6 Work torque 7 Rated phase current 8 max speed 9 10 Work environment temperature 11 Highest surface temperature 12 rotator quantity 13 Damping torque: 14 Phase resistance 15 Phase inductance 16 Insulation resistance 17 Inslation grade
54

24~70VDC

50 50 8000 8000 150 VDC max 150 VDC 2.8Nm 2.8Nm 6.5Arms 6.5Arms 3000min-1 3000min-1 -20+40 -20+40 90 90 0.069kgm210-3 0.069kgm210-3 0.15Nm 0.15Nm 0.6 0.6 1.2mH 1.2mH 100M Min 100M B130 B130

18 Protection grade 19 Max hoirizontal load 20 Max vertical load 21 Weight 22 Length (25) Axial diameter:

IP44( IP65) IP44(IP65 optional) 80N 80N 100N 100N 1.8kg 1.8kg 144mm 144mm 10mm 10mm

55

6.3.3 servo proportional valve and the amplifier BOCH 0811 Made by BOCH with the size of 0811. Proportional servo valve principle diagram

56

10V / The use of servo proportonal valve is to change from 10V input signal into output flow control to finally control main distributing valve stroke, servomotor open/close speed. The servomotor can have position feedback, be used together with amplifier to make little dead band and repeat. When magentic valve breaks, the valve has malfunction insuranceposition. 0811 5 The most obvious feature of 0811 404 039 is large magnetic operation force which is 5 times of that of ring spray and double cone type electro hydrualic servo valve. So that it is not only has high accuracy, high respondness but also large output, dirty resistat and blocking resistant capabilities etc. BOCH 0811 405 060 Coresponding BOCH manufactured amplifier with size of 0811 405 060 is selected. The following is front plate diagram 1 Green shows enable signal 2 Reb show power suppy malfunction 3 ZERO Potentiometers ZERO for regulation zero
57

4 Yellow light means that wiring for proportional servo valve feedback breaks

Plain diagram of proportional servo valve amplifier The following is the amplifier principles and please see the following data for basic technical paramaters. 0~70 Surrounding temperature range: 0~70 -20~70 Storage temperture range: -20~70 24VDC, 21~28V

Power supply voltage: 24VDC allowable waving range: 21~28V /2.7A/40VA Wiring current/max consumption: 2.7A/40VA 1.7A

Input current: 1.7A Power: 37W 37W 10V

58

Control signal: 10V 100K

Input resistance: 100K 15V 15V

Feedback power supply: 10V

Feedback signal: 10V Functions of amplifier: 1 Feedback wiring breaking protection 2PID PID position control 3 Quick response capability 4 Break protection function 5 Zero regulation function 6 Status indication and alarm function

59

 Amplifier principle diagram 6.4 Frequency Measurement Module Frequency Measurement Module Principles

60

CHMOS

PLC

Schematic diagram of the frequency measurement PT PT As shown in above figure, frequency measured by advanced digital impulse. The unit frequency signals from motor exit PT and net frequency signals from grid PT change into square-iscillation signals after isolating and plastic making, then directly send to the pin single-chip which will record the number of benchimpulse between the two rising ends, finally the frequency is gained with the square-iscillation signals period. Following conclusion can be made above principles the accuracy of digital impulse frequency measurement depends on benchimpulse frequency; that is to say, the higher the benchimpulse frequency, the more accurate of the data in the same frequency measurement. Frequency measurement characters PLC PLC 500K >750K Unique digital method since PLC has been used in turbine Governor, the frequemcy measurement accuracy required by turbine microcomputer Governor can not be reach for the max counting frequencyof the PLC high speed counting
61

module is only 500k. PLC PLC PLC 16Bit 16 I/O PLC PLC 16 I/O 16Bit PLC PLC PLC PLC Manufacturers who own PLC the Governor have been confused with how to measure frequency signals by PLC for a long time. Few make frequency measurement by PLC high speed counter through ignoring measrement accuracy; while most manufacturers adopt one single-chip to measure unit and net frequency first, then take difference between them, which finally is sent to PLC bus by a 16 points I/O input module in the 16Bit with data. latter method Increasing system circles and decreasing reliablity Owing to different time sequence between of single-chip frequency measurement modules and PLC 16 points I/O input modules, when sending 16Bit different data, it is easy to wrongly match time sequence which will lead PLC to reading wrong values and interrupting signals. Due to what PLC reads are different signals of unit and net frequency instead of their individual values, under no-load condition, PLC can not measure accurately system frequency which thus can not de displayed by colorful touch screen.
62

However, problems appear with the

 STRONG adopts bus way , sending data to PLC by bus directly to resolve the key point that puzzled the programmable Governor long term completely . in the

6MHz 50Hz 1/120000 PLC High measurement accuracy benchimpluse caused by single-chip Crystal oscillator is 6MHz; the measurement accuracy of 50Hz frequency signals is 1/120000, which is far beyond the standard and no PLC by high speed counting meets with.

CHMOS WatchDog Flash Ram High integral and strong anti-jamming the single-chip is made by largescale CHMOS with internal integral WatchDog and strong anti-disturbance; whats more, its integrating Flash Ram furtherly decreases external hardwares and improves reliability and anti-jamming and soft upgrade ability.

Fast calculation the frequency measurement adopts new advanced single-chip which integrates clock frequency multiplication circuit and is the fastest one among singlechips with same type

63

6.5 Power supply system warning .,. . To always use the voltage stipulated in the operation manual; to be careful with the power supply stability and any incorrect voltage may bring wrong action or burn. ,.. To be careful of the and + of the power. Otherwise, component may be burnt.

WZT AC220V DC220V , 2 DC110V AC220V DC110V . 24VDC/5VDC/12VDC/15V The YWT series high oil pressure PLC governor simultaneously adopts AC220V and DC220V for power supply and standby for each other; two circuits of DC110V supplying or AC220V and DC110Vat the same time can be selected according to the requirement of users. And its internal working voltage is 24VDC/5VDC.

WZT PLC DC24VDC5V DC12V DC15V The YWT series high oil pressure PLC governor system has also designed DC24VDC5VDC12V or DC15V external power supply besides PLC working power supply. External power supply selects switching power supply by Taiwan Mingwei are input the two power suppliers at the same time. The internal working principle of each power supply is the same, excepts output voltage and the schematic is as follows

64

+ DC110V + DC110V

AC220V + DC110V -

AC220V + DC220V -

+ + DC110V Regulator circuit DC110V

Voltage output

Regulator circuit

AC220V Filtering Protect + DC110V -

Recti -fier

Voltage output

Regulator circuit

AC220V Filtering Protect + DC220V -

Recti -fier

Voltage output

24V / +24V used for the outside relay, solenoid valve, driver / amplifier

65

human-machine interface and indicators. 12V 15V 12V or 15V for servomotor feedback. 5V 5V for opening meter and speed meter. 70% Efficiency typical 70% (full load)

AUL478BVDE0871B Safety standard satisfyAUL478BVDE0871B

Over-current protection all output terminals have short circuit protection and over-current protection.

Insulation test between input terminal and ground, between input

terminal and output terminal 30M Insulation resistance 30M

0~50 Operating ambient temperature 0~50

DC220V15% DC110V15% DC input voltage DC220V15% or DC110V15%

AC220V15% AC input voltage AC/DC power supply used as standby for each other. AC220V15%

66

 Chapter VII Software Program Specifications

7.1 Flow block diagram of Main Program The whole of main controller program is composed of lots of modules, each of which is composed the program that carries out the specific corresponding function.
Y>7%,f>40Hz DL Y<7% f<40Hz Y>7%,f>40Hz DL

f>45Hz DL DL DL

67

1 Power up/Reset Program 1D M Set the sign cell (D and M) 2PLC Set the initialization of PLC module 3 Set the initialization of timer 4 Sampling the wicket gate feedbackas well as frequency difference 5PID Set the initialization of PID parameter

2 Shutdown Waiting 1A/D A/D Sampling 2 Communicate with upper computer 3 Breakdown diagnosis and display 4 Supervise operation 5 PID Amend Parameters and calculate PID coefficient 3 Startup Process 1 Starting up 2 Read frequency deviation and error detection 3A/D A/D sampling and impulse output
68

4 Breakdown diagnosis and treatment 5 Operation processing 4 No-load Operation 1 Read frequency deviation and error detection 2 Breakdown diagnosis and treatment 3 Operation processing 4 PID Amend parameters and calculate PID coefficient 5PID Calculate PID parameters 6A/D A/D sampling and impulse output 7 Control Display 8 Communicate with upper computer 5 Load OperationBesides all functions of no-load operation, it has 1Mode judgment (manual and automatic) 2 Power closed cycle control, opening closed cycle control and frequency control

7.2 Regulating Mode W(Z)T W Z T has set two regulating modes frequency regulating mode and power
69

regulating mode 1/ Frequency /opening Regulating Mode 1 conditions a The governor is at frequency regulating mode when the unit is under No-load operation b The governor is at opening regulating mode when the unit is under load operation. c Power signal faults or the frequency is overproof regulating 2 running aPID Regulating rulePID b Set parameters frequency setter, opening setter when in load power

c 00.5Hz Artificial frequency dead band no-load is 0, load can be set 0.5Hz d Deceasing /increasing opening setting

2 Power Regulating Mode 1 conditions Power regulation command assigned while load running 2
70

running aPI Regulating rulePI b Set Parameter power setter c0~5%PN Power dead band0~5%PN

3 power setting signals Upper computer gives the power setter in digit with communication if adjusting the power.

7.3 Starup and Shutdown Rules 1 Starting up Rules 1 Essential startup charatersclosed-loop Startup rules a The Governor constantly is controlled by closed-loop during starting b Setting module decides the frequency value that is an expected rising line of unit rotational speed and the actual one will rise increasingly c Compared with open-loop starting rule, it is quicker under over speed d There is no need to set starting summit, any efficient water head can shut it for generating

71

2 Shutdown Rule 1 On receiving the stopping signal, guide vane must be closed immediately at the first stop speed. 2 20% While the guide vane is closed to 20% of opening, it must be closed completely at the second stop speed. (See the figure)
Y

a b

20 %

c t

7.4 Digital coordination 7.4.1 coordination features of wicket and runner blade for Kaplan turbine 1 coordination data 100 Dispersing the unit cooperating curves (shall be dispersed into 100) provided by users with table format. The cooperating data after dispersing can be input by

72

LCD touch screen or PC online. Input cooperating data can be remained without power. 2. Water head Value Water water head value can be acquired by such means as follows 1 Acquire it from upper computer through communication interface 2 A/D Acquire signal by A/D module and water water head sample sensor 3 Input by hand through the terminal 7.4.2 Coordination interpretation arithmetic =f(a,H) a H Cooperating curve of double-adjusting hudraulic turbine is a function with two individual variable; herein, isrunner blade opeing, a is guide vane opening, and H is the water head. See figture below

a f(a) a0
Hi H

f(a+1)
H i+1

Hi

H i+1

Hi,Hi+1 a0 Hi,Hi+1 H Hi Hi+1 H

73

H = H i +

H i +1 H i
H i +1 H i

(H H i )

The figture above is cooperating curves of guide vane andrunner blade under two water head. When guide vane opening is a0, meters can be checked directly in the dispersing zone, and the corner value ofrunner blade isHi, Hi+1. if current water water head H is bwtween certain two water heads-- Hi and Hi+1, the corner value ofrunner blade can be gained with

H = H i +

H i +1 H i
H i +1 H i

(H H i )

7.5 Mechanical ,Auto,Electrical /Manual operation and bumpless transfer

//PLC When the auto/manual switching over valve is at the automatic position, PLC starts to perform the automatic control program. It also includes the programs of mechanical manual control, mechanical manual switch to automatic, automatic switch to mechanical manual,electrical manual , electrical manual switch to automatic ,automatic switch to electrical manual which are not displayed in the

main program flow chart. And these operation modes would be introduced in detail in the next chapter.

74

 Chapter VIII Panel Description

W(Z)T W(Z)T Governor may adopt separate and unit cubicles which are introducd sa follows 8.1 Panel Description of the seperat cubicle of electro-mechanics W(Z)T On the electro-cubicle of W (Z) T Governor, there is an operating terminal (LCD touch screen), including touch keys, types of conditon monitors and operating interface etc. which are reliable and beautiful. Meanwhile, optional switch and indicators cock are set (lock closed indicator, lock open indicator, optional switch of guide vanes, guide vanes opening increase/decrease optional switch , optional switch of runner blades, opening increase/decrease optional switch of runner

blades, emergency stop button,faults reset button, emergency stop indicator and so on). W(Z)T There are guide vane opening indicator, opening indicator for runner blade of Kaplan turbine ,speed indicator ,Guide vane optional switch and optinonal switch of runner balde for Kaplan on the mechanic-cabinet of W (Z) T Governor. 8.2 Panel Description of the unit cabinet of electro-mechanics the layout of the unit cubicle of electro-mechanics is ;

75

 instrument indicator operating ternimal operating button and indicator

1 instrument indicator Runner blade angel(double adjusting) guide vane opening unit rotational speed 2 Operating button and indicator Buttons with indicators (either for operation, or indicating conditions)are always chosen for operation. The operation buttone are Lock closed (indicator) Lock open(indicator) / guide vane manual/ automatic switch / Runner plade manual/ automatic switch(double adjusting) / Guide vane opening Increase/decrease / Runner blade opening Increase/decrease Emergency stop button Fault reset button Emergency stop(indicator)

76

 Chapter IX Mechanical Hydraulic System

warning .,. . To always use the voltage stipulated in the operation manual; to be careful with the power supply stability and any incorrect voltage may bring wrong action or burn. ,.. To be careful of the and + of the power. Otherwise, component may be burnt. The pipe shall keep clean; otherwise, the oil may be polluted, which will influence different valves. 9.1 General Description W(Z)T () The eletro-hydraulic part of W(Z)T series Hydraulic Turbine computer-based governor, it can be divided into 2 types: 1. oil free electro-hydraulic transducer(oil free electro-hydraulic transducer can be connected with step-by-step motor or servo motor), 2. proportional servo valve, different functions of mechanical hydraulic system is as follows 1 The governor that oil-free electro

hydraulic transducer odaopted as mechanical hydraulic system WT WZT PLC Q

77

 The WT and WZT mechanical hydraulic system controls motor driver with

high accuracy through PLC Governor system, driving ball-screw and self-righting pinpoint position device, making pilot valve and main distributing valve move and output a some flux hydraulic pressure oil according to the rate in order to drive performable component to control rotate speed and load of hudraulic turbine to the extent with great high adjustment precision. Hence, we can meet user reliable actual request and get to the demand of high quality product.

The theory diagram & system composition for mechanical hydraulic control system is as follows:

PLC PID

78

The control system of PLC Governor works on PID operation and magnifies it according to input electrical signal and feedback, then, outputs digital signal to oil-free electro hydraulic transducer, which also outputs proportion displacement and an immense operating force, which operates the opening of the guide vane, and angelof paddle blade to realize speed adjusting and load control of turbine motor units. The electro-hydraulic servomechanism has 2-stage system for hydraulic

pressure magnifying. The first stage is pilot valve and auxiliary servomotor, and of the second is main distributing valve and main servomotor. PLC After comparing and magnifying the feedback signal of the servomotor position and output signal, the PLC controlling system output signal to make motor run ball-screw and self-righting pinpoint position device in order to produce displacement in proportion with output signal, which can let the pilot valve move the same displacement because of direct connection with pilot valve. Accordingly, the main distributing valve form the completely uniform displacement through auxiliary servomotor, at the same time, providing oil to the main servomotor and make it displacement till the signal of main servomotor is equal to the output digital signal. The characteristics of the product unique self-righting pinpoint position device of oil-free electro hydraulic transducer, it can be ensured that pilot valve,
79

auxiliary servomotor, main distributing valve quickly revert mid position and make the main servomotor initialization. It costs less oil in static state than any conditions together with reliable performance. Its very convenient to adjust and maintain. There is no traditional theittling orifice of electro-hydraulic servo valve, it has high reliability and oil pollution problems dont exist in it, meanwhile, avoid the system uncertainty because of too much procedure. 2 Proportional servo valve Output voltage controls proportional servo valve or via different wide impusling

signal to control open/close ball valve to realize loop close regulation. proportional servo valve open/close ball valve makes upper reservair of proportional cylinder connect with pressure oil or discharged oil to form flow difference with proportional cylinder piston. When propotional servo valveopen ball valve injects pressure oil into the upper reservair of proportional cylinder, proportioanl cylinder piston connects discharging oil, but its flow is smaller thant that of proportional piston; When propotional servo valve (close ball

valve )connects with upper reservair of proportional cylinder, proportional cylinder piston connects with pressure oil, but its flow is smaller thant that of proportional piston; to make main distributing valve piston move up and down to realize open/close. The flow difference depends on the stroke of main distributing valve piston. Under any condition, the operator can change work conditions manually and
80

change valve into digital valve conditiona manually, and then operate manually for ball valve open/close to finally realize manual operation. 3W(Z)T The system, via electric signal or site operation to emergency stop magnetic valve by the operator, to make the upper reservair of auxiloary servomotor discharge oil directly to finally realize emergency stop. For reliability purpose, mechanic feedbanck members and feedbanck wirngs are cancelled which are useful for workshop layout. WZT WZT mode is a double-adjusting mechanical hydraulic system which

consisted of guide vane and runner blade , two parts hydraulic system. It adopts electric coordination with the same principle and structure, but only the guide vane mechanical hydraulic system is equiped with emergency stop device. The mechanical closing device and emergency disturbting valve and other auxiliary devices can be supplied according to clients demands. 9.2 Introduction of main Components 9.2.1 ZL 00 2 24552.3Oil-free Electro Hydraulic

Transducer (patent NO. ZL 00 2 24552.3) BZ BZ BZ BZ BZ

81

The BZ oil-free electro hydraulic transducer is the latest generation electric-hydraulic servo actuator developed by our company. The product, which is patent of intellectual property of us, is elaborately manufactured by researchers under the condition of overcoming difficulties and exerting their advantages after studying the relative merits of electro-hydraulic servomechanism home and abroad. When running automatically, drive step motor and the long-lead ball bearings crew-pair relying on, making the pilot valve moving up and down and connecting the oil pocket with pressure oil or reservoir sweep in order to get the purpose of dominating the assistant servo and main pilot valve. The displacement sensor for motor feedback is also installed with it, which could form closed-loop control in BZ, hence compensating the stepout of the motor, mechanical wear, machining tolerance and so on, improving BZ positioning accuracy. BZ 2 The characteristic of which is that it has one locating piece, a pair of auto-revert up-spring. The down-spring directly takes advantage of pilot valve spring, of which the up-springs pre-stressing is 2 times than that of the down-spring (in pilot valve), however, the force value existing in valve core of up-down operating guide valve is equal. 5 1mm The auto-revert up-spring presses the locating piece to the limited space. While the auto-revert down-spring let the valve core of pilot valve cover the locating piece through Governor rod, forming the big revert force upside and the little
82

downside (the upside force doesnt act up and down being limited by locating piece, meanwhile, the downside force cant move the top position sleeve.), so the pilot valve shifts upside following the spring force when bond sleeve moving upwards; the pilot valve shifts downwards in the action of rotary moment when bond sleeve moving downwards. As the long-lead ball screw-pair could rotate conversely, which confine the bond sleeve to a fixing place through revert force, now you can only adjust the nil-position of pilot valve and make the main servos displacement less than 1 mm within 5 minutes, namely, that is auto-nil position and manual nil position. When motor is stopped, running the hand-wheel manually could simulate the operating core valve of motor. As you let the hand-wheel alone the valve core swiftly goes back the nil position through reverting device. 9.2.2 Servo Proportional valve 6.3.3 Please see 6.3.3 Proportional Servo Valve and Its Amplifier for Detailed Functions 9.2.3. Main Distributing Valve 405080100150200250 4050 1800300035005000 The main distributing valve is engaged in direct contol and operating guide/plam vane servomoter. Our company manufactures main distributing valves with seven diameters---40 50 80 100 150 200 250, among which40 and 50are used for Governor whose adjustingspeed power is180030003500

83

or 5000 reconstruction and matching. If it is double-adjusting, the main distributing valve diameterof guide vane shall be less equal to that of guid vane. It can be choosed by users. Main distributing valve adopts excellent materials with good abrasion.It is consists of the piston attached to the main distributing valvevalve bodyauxiliary servomotorpilot valve and switching time adjusting bolt and so on. The auxiliary servomotor and main distributing valve piston are of the whole in the structure. The main distributing valve forms one-stage hydraulic pressure magnify through pilot valve and auxiliary servomotor, at the same time, the two-hydraulic pressure magnify comes into being from the main distributing valve and the main servomotor. 80 The movement principle of main distributing valve whose diameter is equal or lesser than 80 mm: The upper-oil cavity is always switching on pressure oil ,when guiding the pilot valve to move a distance upward. While the lower oil cavity of assist servo is connected with pressure, the useful area of which is greater than that of the upper cavity of assist servo, so the pressure oil makes the piston of assist servo transfer a distance upside till the oil inlet is closed off again by piston of pilot valve, now the assist servo is newly in a steady balance state; the piston of pilot valve moves
84

down a single distance, the under cavity of assist servo is put through with reservoir sweep, as upper cavity is always connected with pressure oil, the assist servo moves down a single distance till the piston of pilot valve is again closed off the oil outlet so the assist servo could be stabilized at another balance position. As a result, the piston of assist servo is always following the piston of pilot valve. Being manufactured as a whole of piston of assist servo and main gate valve, the piston of main gate valve is also following piston of pilot valve. The pressure oil on the open side of main servomotor is switched on, meanwhile on the close side of which reservoir sweep is working, the piston of main servomotor moves towards to the starting when piston of main gate valve shifts upwards from zero position, Whereas, which shifts towards to the tailoff. 80 The movement principle of main distributing valve whose diameter is more than 80 mm: The under-oil cavity is always switching on pressure oil ,when guiding the pilot valve to move a distance downward. While the upper oil cavity of assist servo is connected with pressure, the useful area of which is greater than that of the under cavity of assist servo, so the pressure oil makes the piston of assist servo transfer
85

a distance downward till the oil inlet is closed off again by piston of pilot valve, now the assist servo is newly in a steady balance state; the piston of pilot valve moves up a single distance, the upper cavity of assist servo is put through with reservoir sweep, as under cavity is always connected with pressure oil, the assist servo moves up a single distance till the piston of pilot valve is again closed off the oil outlet so the assist servo could be stabilized at another balance position. As a result, the piston of assist servo is always following the piston of pilot valve. Being manufactured as a whole of piston of assist servo and main gate valve, the piston of main gate valve is also following piston of pilot valve. The pressure oil on the open side of main servomotor is switched on, meanwhile on the close side of which reservoir sweep is working, the piston of main servomotor moves towards to the starting when piston of main gate valve shifts downwards from zero position, Whereas, which shifts towards to the tailoff. Regulate the switch-time adjusting mechanism on the top of the main gate valve, which could confine the course of the piston of main gate valve and get the purpose to carry out the time adjustment of switch on-off. 9.2.4 Emergency Stop solenoid valve When normally working, solenoid valve of emergency shutoff device is in a position where puts through pressure oil of pilot valve and cut off the oilway between the bottom cavity of assist servomotor and reservoir sweep. Therefore, the pilot valve and assist servomotor run in a course of nature. 80 Emergency stop principle of man distributing valve with diamater lesser than 80:

86

 When emergency stop acts, magnetic valve will push emergency stop valve to another position to make oil from lower reservair of the auxiliary servomotor flow, cut oil from upper reservair of pilot valve. Thus auxiliary servomotor under the action of upper reservair would operate the piston of main distributing valve downwards to realize emergency stop with reliable position indicator(thrown-in, reset). 80 Emergency stop principle of man distributing valve with diamater larger than 80: When emergency stop acts, magnetic valve will push emergency stop valve to another position to make oil from upper reservair of the auxiliary servomotor flow, cut oil from lower reservair of pilot valve. Thus auxiliary servomotor under the action of lower reservair would operate the piston of main distributing valve upwards to realize emergency stop with reliable position indicator(thrown-in, reset). It is necessary to get emergency shutdown at point by pushing the button attached to the solenoid salve of emergency. 9.2.5 Displacement Sensor 0~10V The displacement sensor takes the potentiometer of antifriction and precision as its interface element. The servomotor is linked with chain wheel that is contorted tightly by spring through steel cable, in the mean time the axis of chain wheel is joined with potentiometer, which outputs 0~10v voltage. Displacement sensor is

87

made up of linear and wheel displacement . Absolute optical-electric encoder or other kind displacement sensor can be chosen all the same. 9.2.6 Oil Filter There are two swift-throwback dross filters in the fuel strainer when normally working. The oil pressure meter is set behind the dross filter and the oil pressure value can be observed through that meter. /Warning When perambulating, you should look into the pressure vaule ,If it is below the oil tank pressure ,to check out the filter if occlude, ortherwise the servomotor can not move.

9.2.7 () Closing Device with serval rates(optional) The step closure device can be devided into mechanical and solenoid valve type.Taking machanical step-closure for example: /Warning 1. If it is solenoid valve type step closure, and controlled by governor body, the governor shall keep power. 2. 2-5S Solenoid valve shall not work with power for a long time, 2-5S impulse is ok!
88

 The sectionalizing shutoff device is made up of section valveinverted valve cam and so on. The cam is fixed on the return-axis of swivel that is attached to the drive gear of servomotor. Before sectionalized the contact roller on the bottom of section valve doesnt touch with the cam. When servomotor is in a close point where the contact roller is propped up by the cam of reverting axis, making the pilot valve ascending. Here the bottom cavity subjected to the rolling piston of subsection valve instantaneously is put through with pressure oil. Throttle piston swiftly moves upwards to the position of adjust screw, which have the servomotor shutoff step by step during the course of the tailoff. The adjust screw on the top of adjust subsection valve could change throttle areas between throttle piston and valve body, thus slow and stepped shutdown speed can be changed The step closure turning position can be changed by rotating cam and changing its postion with returned shaft. One-way valve secures the guide vane servomoter starting to step-by -step turning point from full-closed position without throttling inflence from step-by-step vlave. This device adopts rigid connection with accurate adjustment. There is no speed change and reliable in step-by step turnings, once adjusted well. Due to the
89

device is closed to servometer, it also can make final subsection at eleco-hydraulic stations with accidental voltage valves (no need to intall step-by step closure device again). Solenoid valve is as the guide control of this device .when the servomotor close to the inflection point ,electrical control signal control the solenoid to move to realize fragments. We can also operate solenoid directly by manual. 9.2.8 () Emergency distributing valve(optional)

SGP SGP As a six-way directional valve, SGP integrated emergency distributing valve is used in hydro turbine over-speed protection. When the unit speed is over high and governor closing pilot organization operation is out of service, SGP integrated emergency distributing valve acts after receiving the over-speed signal. Valve core will change its direction with the function of pressure difference, cut of the governor, presssure oil from its device will operate guide vane servomotor directly to realize emergency stop of pilot organization and protect unit from over speed and protect turbine units working under normal and reliable conditions, The product has been optimized and integrated magnetic distributing valve, oil valve, emergency distributing valve on the over-speed limiter into one, which is with smal volume and more reliable actions. The hydraulic cushion device has

90

overcome the roar sound from the old limiter. It acts stably, is long lifetime, easy to be isntalled with little place. Integrated magnetic distributing valve, oil valve, emergency distributing valve on the over-speed limiter into one, which which is with smal volume light, and easy to be isntalled with little place.. The hydraulic cushion device is non vibration sound and long lifetime. When the governor malfunctional makes unit speed over high, the guide vane can not be closed via servomotor by the governor; the piston reservair at the right of emergency distributing valve is to connect pressure oil, since the area at right is larger than that of the left, when the piston moves left, the piston will cut off the oil supply of both close and open reservair of the main distributing valve, and connect close and open reservair of the guide vane with return oil and pressure oil. Namely, the system pressure oil is to connect with the close reservair of servomotor and open reservair of servomotor with oil return tank. This is the way of emergency stop,which avoid unit runaway. By the screw bar at the right of emergency distributing valve, opening between piston and valve body can be adjusted to limit its flow to achieve required action time of the emergency distributing valve.

91

9.2.9 mechanic-hydraulic cabinet W(Z)T ( )/ / 800kg Mechanic-hydraulic cabinet shall be 8006001860mm or made according to users demands. The front and above parts of cubicle have real opening, rotational speed, and banlance table, as well as manual /automatic contol buttons, emergency stop indicator, servometer lock-in/lock-out position indicators. In front and reverse cubicle, there are methacrylate plastics through which overall view of mechanic-hydraulic system in the cubicle shows. Main distributing vavle suspends under the bottom panel. The total weight of mechanic-hydraulic part is about 800kg (including foundation racks). 9.2.10 Assemble and adjustment Assemble

1 The technical requirements of correlative drawings must be achieved for all details assemble. 2 Before assemble, all details should be cleanout. Especially the valve cap of hydraulic-pressure integration pad and main guide valve together with details of other interior pipes are all should be blown off impurity by compressed air and be cleaned out with kerosene again and again. 3 O It is cautious that all the O seals are not impacted with each other and forgotten assembling. Especially, it is bond to be mounted vertically and fixed

92

position accurately through wedge pin or set screw for the up-down asbestos rubber blanket of the main guide valve, which stands up with high pressure and abrasion. 4 Connect the valve cap with its body and fix it on the bottom board. The assemble procedure make the coupling bolt between valve cap and bottom board tight. Then, reinforce the valve body and bottom board by screw bolt from the inverse bottom board through joining-up bar. After that, join the flange and pipes on the profile of the valve body 5 The piston of main distributing valve and pilot valve should glide automatically along the respective valve body or bush under the gravity of themselves and be careful of not bruising the closed angle of the piston 6 The motor or proportion servo valves of function mechanism must be

flexible and of no block after assemble. All the gliding surfaces must be painted with butter 7 It is not allowable for all the sealing surfaces to leak oil under the rated oil pressure Adjustment for Null Position

93

 5 1 The adjusting bolt of starting on-off should be set to the maximal course of main distributing valve, open the chief suction valve of Governor and let it full of oil everywhere. Since there is no need of adjustment for ball spiral auto-reversion device the null adjustment is actually to regulate the mesoposition of pilot valve. Firstly, loosen screw nut and regulate the joiningup lower screw stem so that the piston of pilot valve moves up and down relative to the gland. The adjustment working lasts till the main servomotor could stabilize in any place (rotate the handwheel of ball spiral auto-reversion device slowly, which makes the servomotor open and close). It is impossible to have the servomotor in a completely stable place because of open loop. It is generally allowable for servomotor to have deviation less than 1 mm within 5 minutes. Then merge the nut tightly.

94

 HYZ YZ Charpter10 Usage of HYZ AND YZ Oil Pressure Device

Warning All parts shall be cleaned before installation. All sealings shall be done if necessary during installation All firmware shall be fixed on average. No leakage is allowed in the oil absorption pump. Otherwise, the pump will be damaged by air There are two vertical loading hole Upside of the oil pressure device tank . They are used to equip and move the device .Dont hang up other parts of the epuipment.

Be careful The Oil Pressure Device shall be installed horizontally

and fixed with bolt without any slope.

10.1 General Description

95

 Oil pressure device is used to manufacture, storage and provide pressure oil for differenct kinds hyraulic pressure system. Currently, it is widely used in the hydro power station turbine units governor system and control system for oil supply purpose. It is also can be used in large water pump station, inlet valve, release valve and ball valve etc. HYZ YZ JB7836.3-1995< 1> 2.5MPa4.0MPa 6.3MPa There are two types of national-mae oil pressure device:combine HYZ oil pressure device and separate YZ oil presure device. All of them has been

standardized(JB7836.3-1995)(Please refer to Table 1). As for different types devices, the rated oil pressure can be divided into three grades: 2.5MPa 4.0Mpa & 6.3Mpa. The pressure tank can be normal pressure tank(work media is compressor air) and accumulator ,With accumulating type pressure tank, high pressure air compressor is no need. Thus the cost is saved.

96

 Warning ; The accumulator shall be installed vertically with air injection inlet above and oil inlet and outlet below. The accumulator as well as its up and low connecting interfaces shall not be impacted or pressed in order to avoid any explosion. The accumulator shall be stored or used under stipulated temperature and humid to avoid corrosion or explosion. The accumulator shall be nitrogen; if any other gas such as air or oxygen in it, explosion may cause.

HYZ Combined HYZ HYZ-0.3 HYZ-0.6 HYZ-1.0 HYZ-1.6 HYZ-2.5 HYZ-4.0 HYZ-6.0 HYZ-8.0

YZ SeparateYZ YZ-1.0 YZ-1.6 YZ-2.5 YZ-4.0 YZ-6.0 YZ-8.0 YZ-10 YZ-12.5 YZ-16or 16/2 YZ-20or 20/2 YZ-25or 25/2 YZ-32/2 YZ-40/2

1 /Table 1
97

The product type is consited of three parts which is separated by : 1 HYZ YZ First part : HYZ means combined oil pressure device; YZ means separate oil pressure device. 2 m3 Sencond part(numbers): numerator means total volumem3of pressure tank and letter behind means changed type, no letter mean standard type; denominator shows No. of pressure tanks, and it is nothing if each device equiped with one pressure tank. 3 2.5MPa Third part: the numbers shows the rated pressure, nothing will be showed if the rated pressure is 2.5Mpa. GB11120 46 The midea of oil pressure device is compressed air compressor and No.46 turbine oil or simliar meeting GB11120 requirements. 4000m 5t 5590% The oil pressure device shal be used at a place whose elevation is no more than 4000m and surrounding temperature is 5t55 and max relative moisture 90%.

98

10.2 Main parameters 10.2.1 HYZ Basic parameters for HYZ oil pressure device HYZ (please refer to the general drawing for HYZ oil pressure device ) 10.2.2 YZ Basic parameters for YZ oil pressure device YZ (please refer to the general drawing for YZ oil pressure device ) 10.3 Work principle HYZ YZ (please refer to hydraulic system diagram of HYZ, YZ oil pressure device) <15> <17><10> <18> The oil presure device forms a close loop of oil circulation together with oil comsumption. Oil from oil return tank(15), through the absorption tube of oil pump(17), will be absorbed by pump and increase pressure and then send to check valve in the combine valve(10). With the increasing of pressure gradually, pressure increases gradually and the check valve opens when the pressure exceeds that of upper reservair of check valve piston. Oil will enter the tank through the check valve and cut-off valve at the bottom of pressure tank. Oil pump is driven by motor(18) through coupling.

99

In order to keep reliablity, each oil pressure device equips with 2 oil pump: one for work and the other backup. Under special condition, when work pump is at work, the pressire will continue to drop unitil achieving presure for backup pump startup, and then backup pump starts. Two pumps can run at the same time shortly. Either screw pump or gear pump can be used.

Each front of oil pump has been equipped with combined valve which has integrated functions of check valve, load-off valve, safety valve, overflow valve etc. , protects oil pump, motor, pressure tank, keep tank presure stable. When the oil pump stops, check valve can prevent the pressure oil passing pump from discharging. Load-off load can drop pressure in the tube between the pump oulet and check valve, make motor at no-load condition if the pump restarts again; and if delaying, it can make motor at good atomosphere: not only saving engergy but also protecting the motor. Safety valve is to protect pressure tank.when failure happens on the second circuit of the oil pump, pressure in the tank exceeding the limit which makes pump stops, the pressure in the tank keeps increasing until safety valve acts, which makes the oil returns to oil return tank and prevents oil pressure from increasing to finaly realize the pressure tank safety. The oil pump is usually set by incontinuous work ssytem, if continous system needed, overflow
100

valve can keep pressure stable. 1/2~2/3 <1> ( ) Under normal condition, the upper part (1/2~2/3 of total volume) of pressure tank is filled with compressed air, and the lower part is media oil. The

complementary or discharging of the air can be realized either by automatic replenish device(1) or manual replenish/discharging valve at the bottom of tank air inlet.(Clients should read the user manual of the automatic air admission equipment manufacturer in details before putting to use.)

Bladder accumulator also can be chosen as pressure tank . high pressure nitrogen gas in the bladder accumulator has already fully inflated, so, generally speaking, no more inflation is needed. A special nitrogen inflating tool (please see the fig. below) can be used for air inflation at special situation.

1 2 3

101

 4 3 While inflating, firstly screwing off the bladder accumulator head cover and screwing on Lo 1 of the nitrogen inflating tool, then connecting nut 2 of the nitrogen inflating tool with the mouth of high pressure nitrogen gas flask. Clockwise rotating the rotary valve 3 of nitrogen inflating tool to open the accumulator valve inside, then beginning to inflate after opening the valve lead of nitrogen flask. Observe the pressure valve of manometer 4. Inflation finishes if the value reaches rated one after the close of valve lead of the nitrogen flask. Anticlockwise rotating the rotary valve 3 of nitrogen inflating tool to the end, removing the nitrogen inflating tool, then the inflation finishes. The accumulator inflating pressure: (MPa) Reference values of related setting values of oil pump and safety valve (MPa) P rated working pressure 2.5 3.0 2.5 2.3 2.1 2.0 1.5 2.6 2.9 4.0 4.8 4.0 3.6 3.4 3.2 2.4 4.2 4.6 6.3 7.5 6.3 5.8 5.6 5.0 3.8 6.5 7.3

over-high pressure pump stop pressure startup pressure of main pump startup pressure of backup pump emergency action pressure gas accumulation pressure overflow start pressure overflow full open pressure

<2> 4~20mA 0~10V To show the level of oil in the pressure tankno accumulator, different oil level

102

meters(2) can be selected in the light of clients requirement. The mostly selected one is the magnetic liquid level meter which can easy show the lelel straightly, and alarm when it is above or lower than corresponding upper or loawer limit. If a transducer equipped, it also can send continous signal of simulation with the range of 4~20mA or 0~10V for the sampling of computer monitoring.

<1><2> <3> According to clients requirement, different pressure transducer(1), pressure switchgear(2) and common pressure meter (3), which can be used for computer monitoring sampleing, startup & shutdown of work pumpand backup oil pump , emergency low presure signal sending, control of automatic air replenishing, and discharging and visual observation of site operators correspondingly, can be equipped on the pressure tank. Generally, they are installed on the frame connecting with pressure tank. Each frame has a valve to control oil tube breaking to ensure that all meters can be replaced or repaired

<19> On the pressure body, there are holes with different diameters, equipping with
103

corresponding valve. The functions are: two inlet valves which usually are angel type cut-off valve used on the tube between oil pump and pressure tankt; on oil discharging valve which which usually is angel type cut-off valve and same diameter as that of inlet valve(sometimes little smaller than that of inlet valve) used for pressure tank discharging and used during oil pump test, combine valve parameters setting and manual air replenishing; on check valve for main pressure oil supply, which is usually once through valve; one check valve for auxiliary pressure oil supply, which is usually once through valve or blind plate cover. The oil supply is educed through main or auxiliary pressure oil supply valve, through different control components and tube of hydraulic system, acts on execution components to make them work. Media oil after this energy exchange returns to dirty oil area of the oil return tank and comes into the clean area after filter (19). And then it is sent to pressure tank after increasing pressure and oil pump absorption. The pressure oil works in such circulation way. 2~4% As for the pressure device without automatic air replenish device, it is often euqipped with air safety valve installed at the top of the tank. Under out control of replenish status, it can protect pressure tank and its set value is 2~4% higher than that of safety valve. Warning ,

The check shall be done during stop with safety measures preparation. Otherwise, unit damage or human danger may cause. ,

Before the check, main oil supply valve shall be closed or the accumulator pressure shall be discharged. Otherwise, component damage or human danger may cause.
104

 Be careful Periodically check and clean (according to clients' large scale maintenance time) pump oil header, filter, and solenoid ball valve filter. , , 2MPa 6.3MPA , Periodically check (according to clients' large scale maintenance time) inflating pressure for bladder accumulators. When checking an accumulator, first close cut-off valve connecting another accumulator with the system, then oil pump is started. Observe the manometer finger whether it rapidly increases to original inflating pressure, then slowly and stably up to set value. After pump stop, the manometer finger shall slowly and stably reduce to the original inflating pressure, then quickly down to zero. This describes normal working. After pump stop, if the pressure finger slowly and stable declines to 2MPaTake 6.3MPA as example, then quick to zero, nitrogen gas shall be inflated in the light of abovementioned method.

105

Oil return tank is a storage of pressure oil and also the base of the whole equipment. Main components such as pressure tank, oil pump sets, valve group etc are arranged on the cover of oil return tank. In order to keep compact arrangement, mechanically hydraulic servo system,emergency distributing

valve ,closing device with serval rates and so on the oil return tank.

of the governor are installed on

10.4 Description of oil devices main components HYZ YZ Please read general installation diagram of HYZ & YZ oil pressure device. 10.4.1 Pressire tank cnfiguration 16MnR GB150 As made by steel, the presure tank is welded by cylinder and elliptic header. And raw material usual is 16MnR. Its design, manufacture, test and acceptance are in the light of national code named Safe Technology Monitoring Rules of Pressure Tank and internal code named GB150 Steel Pressure Tank. 2 , 3 The pressure tank is consisted of two oil inlets(sometimes 3 required by the client), oil discharging port, main oil supply port, auxiliary oil supply port, man hole(or check hole), safety valve, presssure meter, oil level meter, holes for oil in and out. Except holes for oil in and out valve, other holes on the pressure tank are lower than the low oil level position in order to prevent governor system from air when the oil level in the tank is at low level.
106

 combined oil pressure device At the lower part of pressure tank, a large flange paddle is welded for oil return installation purpose. Access hole or check hole, and cover at the bottom of pressure tank has been set for future check, repair and clean purposes. There are 2 lugs at the top of the tank for lifting purpose.

separate oil pressure device The botton of the pressure tank is a installed support in order to epuip Entrance

alone ,Lashing eye of holding down bolt is in the botton of the suprrot .

hole (checking hole )and cover is equipped on the side wall of the tank for clean and repair easily.

Installation of the accumulators Each of the bladder accumulators is installed on the support , on the botton of the bladder accumulators , valve and pipe put the bladder accumulators in series , There are Lashing eyes of holding down bolt is in the botton of the suprrot , you only need to fix the Lashing eyes when installing .

10.4.2 Oil return tank configuration

107

 The oil return tank is rectangle and welded by steel plate. Inside the tank, there are two parts: clean area & dirty area which are sperated by wall and double filtrating nets. The dirty oil area is used to collect return oil and leaked oil which flows to clean area after filtration and is to be absorbed by oil pump. The nets can be cleaned, repaired, maintained or replaced respectively when oil pressure device is at work. The bottom of oil return tank is slope along one side. At its lowest position, oil discharging valve is set, which can discharge oil if necessary.

On the top cover, oil return tank has equipped with man hole and its cover. Under the man hole, it is slide channel for double oil filtration nets which are easy to be taken or replaced by opening the hole. In the center of man hole cover, there is a oil tank respirator to prevent minus pressure in the closed oil tank during the oul pump operation. To keep air absorbed clean, the air filter on the respirator has been installed.

<1> 4~20mA 0~10V To monitoring the level of oil in the oil return tank, inserted oil level indicator (system drawing (1)) in the oil return tank. It is visual and also sends alram on hign or low level, if oil level transducer equipped, it also can send 4~20mA or 0~10V simulation quantity signals continously for the data collection of computer monitoring system.
108

 Sometimes due to air moisture or leakage from water system, part water has been mixed in the oil system in the hydro power station. This water has been distributed to different components of hydraulic system to make metal part rust and erode, which is harmful of technical performance. Oil mixing with water is easy to make oil emulsification and metamorphose. To test the water content in the oil return tanl, oil and water mixture signal device is always equiped in the oil return tank. When water suspass the alarm value, it will remind operator to check and find a solution.

109

10.4.3 /Oil pump group /Warning 10 Reuse after the first time or long-term stop(more than 3 month), work oil through the oil discharing port shall be injected into the oil pump and it shall work at least 10 minutes off-load before loading. When oil pump works, its axial rotating direction shall be in line with direction marked by the arrow, and no radial load is allowed by the rotating axial. 50 To guarantee the lifetime of rubber sealings, max oil temperature during continous work shall not exceed 50 During the connection of inlet & outlet flange of the oil pump, the bolt must be fixed in order to avoid air in or oil leakage. 150mm The level of oil inlet shall be higher than 150mm to protect agaist air absorption by the oil pump. Double oil filtration nets between the clean area and oil return area shall be often cleaned to keep oil supply smooth. 30S The time for oil pump running at highest pump shall not more than 30S.

110

The oil pump is heart of oil pressure device. The media oil only can be sent to different components of the hydraulic system through the oil pump that is driven by a motor connecting with coupling. Nowadays, oil pumps used in the oil presure devices are pump with three screws or straight tooth-gear conjugate internal pump.

10.4.3.1 Screw oil pump (one kind pump to each device): The screw pump, using three occulsive screws to discharging liquid, is consisted

of rotating pump, shell body, lining, up and low ends covers. The lining is consisted of three parallel and connected column holes, In the middle hole, there is a main and special screw, and 2 auxiliary screws at two sides. Screws, srcrew and lining are cooperated with each other , keep average and slight intervals to make the oil pump spilting into absorption and pressure resrvairs. The pump group is fixed on the oil return tank. The absorption is connected with the clean oil area through oil absorption tube. The pressure reservair is connected with pressure tank through one way valve or valve group. When the main screw driven by the motor, oil is in the reservair formed by screws, and bewten screw and lining, it moves along the axis and is pressed to the pressure reservair from oil absorption reservair. Due to its continuty and good sealing of joggle, the screw is stabl and high efficient.

10.4.3.2 Internal & straight tooth gear pump

111

NB NB series Internal & straight tooth gear pump is hysraulic dynamic component with a state-of-art design and internationally advance technology. Due to its simple structure, low noise, long lifetime, small dirty sensitivity etc. it has been widely used in the hydro power station.

The kind of pump is mainly consited of pump body, tooth gear, tooth ring, axis and cover etc. the tooth-gear outline is linear and tooth ring is linear and conjugate. Wheels drives ring rotating, oil absoption volume produces vaccum to absorb oil from small to big; and oil discharge reservair discharing oil liquid to diacharge media oil. Since there is almost no dead oil area, noise and pressure waving has been largely decreased.

10.4.4 combined valve 10.4.4.1 General description JSZF Due to the features of highly integration, small volume, compact structure, good sealing, over flow capability, long lifetime, it has been widely used in oil pressure device of hydro power station and becomes an important part of oil pressure device. combined valve configures different combined valve according to different fiow of

112

oil pump , the manual take JSZF mofular as example to state .(Operater should read the manual in detail before putting into use .)

10.4.4.2 main parameters 1.4L/S 3L/S 6L/S 10L/S Design flow: 1.4L/S 3L/S 6L/S 10L/S 2.5MPa 4.0MPa 6.3Mpa 4.0MPa 6.3Mpa

Work oil pressure : 2.5MPa

DN25DN32DN40DN50DN65

Diameter of oil inlet/outlet: DN25DN32DN40DN50DN65

10.4.4.3 structure features YV1 YV2 YV3 CV1 CV2 P P1 T P P1 T CV1- CV2- YV1- YV2- YV3- The valve is composed of two plug-in components and three pilot valves, which will perform as the backwards valve, shutoff valve, security valve and load-shed valve. In the control of pilot valves (YV1 YV2 YV3), the mainly valve (CV1) is responsible

113

for the start and close. The CV2 works as backwards valve. The combination valve system adopts the pilot control, so there is no noise or no oscillation when working. There are three holes of the combination valve, first is P for the entrance of pressured oilthe second is P1 for the exit of the compressed oil, and the last is T for the return of the oil. P is connected with the exit of the oil pump, and P1 has connection with the entrance of the pressure tank, while T is linked with the oil tank. In the figure of the liquid pressure system, the two plug-in componentsone is the mainly valve and the other is the backwards valve and three pilot valve is represented as CV1-mainly valve CV2-the backwards valve YV1-pilot control valve for shutoff YV2-pilot control valve for security YV3-pilot control valve for load-shedding

10.4.4.4 Working principle (please refer to the system diagram of combined valve) 10.4.4.4.1 Shut-off Valve YV1 CV1 P1 CV2 CV1 CV1 P CV1 CV1 P YV1 The inertia of the electric motor is very large for large power oil pumps, so it will
114

take a certain period from staring to working normally. It will do harm to the oil pump and liquid pressure system, if the load is taken before the screw pump reaches its nominal flux. If the shut-off valve is adopted, the oil pump will stay in the condition of load-shedding when initiating. Till the rotation speed of the electric motor reaches a special value, can the oil pump output the pressured oil in nominal pressure and flow. The shut-off valve consists of shut-off pilot valve YV1 and the mainly valve CV1. When the oil pump starts to work, the backwards valve CV2 is in the state of close, due to P1. The shut-off valve is in the state of open because of the spring. There is no pressured oil in the control cavity in the mainly valve CV1. The pressured oil in the oil pump return to the oil return tank through the mainly oil hole CV1.As the motor rotates faster and faster, the pressure in the P is increasing. When the control oil reaches the upper cavity of the shut-off valve, and overcome the power of the spring, the piston will move and close the shut-off valve. At this time, the pressured oil comes into the control cavity of CV1, and makes it close. As a result, the pressure in P reaches its nominal value, and the one-way valve is opened to offer oil to the pressure tank. When the pump stops, the shut-off valve restore to the initial state. The working pressure of the shut-off valve can be adjusted by the preset spring force of YV1. 10.4.4.4.2 Security Valve YV2 CV1 YV2 YV2 CV1 P CV1 CV2 The security valve is a kind of leaking equipment set for safety, to make sure

115

that the oil pressure in the pressure tank will not exceeds some allowable valve. The security valve consists of security pilot valve YV2 and mainly valve CV1. When fault happens, the oil pump works all the same, while the oil pressure increases. When the pushing force to the pilot control valve YV2 caused by the pressure exceeds the preset spring power, the YV2 works to expel the oil controlled by CV1. In the meantime, the mainly valve CV1 is pushed away by the pressure of P, and the backwards valve CV2 closes. The oil pump works in the status of self-circulation, and the pressure tank and oil pump works in the nominal pressure all the same. 10.4.4.4.3 Load-Shedding Valve YV3 CV1 CV1 CV1 YV3 CV1 YV2YV3 The load-shedding valve i.e. by-pass valve is composed of the load-shedding pilot valve YV3 and the mainly valve CV1, and is set for the continuous working of the oil pump. The oil pump works all day long, and the pressure of the pressure tank changes as the flow. When the input flow is larger than the output one, the pressure will increase. When the working pressure is larger than the upper limit, the pressure of the control cavity in the load-shedding pilot valve YV3 overcomes the spring force, and cut off the oil resource from the oil pump. The control cavity of CV1 gives the oil out, and the piston of the CV1 will be pushed away. The pressured oil in the mainly oil circuit leaves out, and the oil pump will work in the self-circulation status. As the consuming of the system, the oil pressure in the pressure tank decreases. Till the power falls below the lower limit of the working

116

oil pressure, load-shedding pilot valve YV3 will be closed by the spring force. The control cavity of CV1 closes the mainly valve, and the oil pump restarts to supply oil to the pressure tank. The operation pressure of the security valve and the load-shedding valve could be adjusted by the preset spring force of YV2 and YV3. (There is no such work condition, please cut off this valve) 10.4.4.4.4 The backwards valve CV2 P1 YV1 CV1 P There is a backwards valve CV2 in the way of the pressured oil to the system. It is closed because of the pressure of P1. When the oil pump starts with the help of the shut-off valve YV1the mainly valve CV1 closes. The pressure of P increases to a certain value, and overcome the of the backing pressure of the backwards valve so thatthe backwards valve is opened to supply oil to the pressure tank.

10.4.4.5 The Adjustment and Checkup of the Combination Valve 10.4.4.5.1 Adjust the security valve YV2 CV1 2 16 10 Adjusting the adjusting screw of the security pilot valve YV2, once the oil pressure of the main valve CV1 exceeds the upper limit of the working oil pressure by 2%, begin to expel the oil. And it should be totally opened, before the oil pressure exceeds the upper limit of the working oil pressure by 16%,(This valve could be totally opened, before the oil pressure exceeds the upper limit of the working oil pressure by 10%), so as to drain all the oil, and stop the increase of the oil pressure in the pressure tank. Before the pressure decreases till the lower limit of

117

the working oil pressure, it should be closed totally. Rotating the bolt clockwise when adjustment, the pressure will reach the setting value gradually. Do it time and time again, till the setting value does not change any more, and lock the adjusting screw with nut. 10.4.4.5.2 Adjust the relief valve YV3 CV1 Rotating the adjusting bolt of the relief pilot valve YV3, once the pressure in the pressure tank of the main valve CV1 exceeds the upper limit of the working oil pressure, it begins to drain oil, till empty. Make sure the oil pressure in the pressure tank will not increase, and close down till the pressure diminishes to the lower limit of the working oil pressure. The adjusting manner of the relief pilot valve is the same as that of security pilot valve. 10.4.4.5.3 Check the unloading valve 2-6 YV1 The duration time for oil pump electrical motor, from stationary state to nominal rotation speed, is about 2-6 seconds. If the duration time is too long, please clean the parts carefully, and make sure that the piston slides trippingly, without any baffle, or increase the orifice. Otherwise, if the duration time is too short, please diminish the orifice, prolonging the activity of YV1. 10.4.4.5.4 Check the backwards valve Once the oil pump stops working, make sure the backwards valve shut down immediately and tightly, so as to prevent the oil in the pressure tank flowing
118

backwards. If the valve is not flexible, please check the spool and the control hole. Please test again, when the abnormality is already get rid of. YV1 YV2 YV3 Make sure to chose the shutoff valve in the oil circuit from the combination valve to the pressure tank, before the removal of pilot valve (YV1 YV2 YV3) and cover. Because the control oil of the pilot valve comes from the latter of the one-way valve. Closing the shutoff valve will prevent the oil under pressure from rejecting through the control hole. 10.4.5 Brief introduction of main automatic, test and ontrol components 10.4.5.1 Oil level meter of pressure tank ( It is not included in the bladder accumulators) 4-20mA0-10V Whether equiping with message sending device, depending on the client. The meter without such device in traditional design is made of organic glass and used to show the oil level in the pressure tank. To avoid oil spray due to glass crack, generally the automatic safety device is equipped. With the improvement of power station automation, in order to meet the automatic control and computer monitoring requirements, float type magnetic level meter is used in modern oil pressure device.

119

This type of meter is not only show the level intuitionistic but also show the simulation signal of current 4-20mAor voltage0-10Vand switchgear quantity alarm signal of all set level switchgear quantity, adjust the alarm value online by equiping with related device under the clients requirements.

DN20 DC24V It is usually connected with presure tank by flange whose norminal diamater is selected DN20 by Strong to make the pressure same as rated one of the tank. Switchgear quantity message sending joint of the level and simulation message sending transducer,which is easy to be dismantled and adjusted, are installed on the meter body through the clip. The transducer work voltage is DC24V.

10.4.5.2 () Automatica air replenish device(optional) Generally speaking, the automatica air replenish device is consited of one safety valve, one air discharge valve, 4 manual valve and tubes. It has manual and automatic inject or discharge compresed air into the pressure tank in order to keep the ration between oil and air from the oil pressure device. The automatic work condition of the automatica air replenish device is realied by automatic control circuit. The device usually works from time to time but also can be continous work.

120

 If oil pressure device with the automatica air replenish device equipped, please read its instructions before using it.

10.4.5.3 oil level singal indicator of oil return tank(Optional) It is used to monitor the oil level in the tank and send different alarms in the light of levels. There are different kinds of this product with different structure but their basic functions as the same: 1. site monitoring; 2. sending alarm signals in the light of the level; 3. measure continous oil level change and send simulation quantity signals. Currently the following two types are widely used: A. A. orignally designed oil level signal meter of oil pressure device: consisted of indication tube, reed relay, magnetic ring, float pole, floater etc. and the floater moves up and down in line with the high to low oil level. Magnetic rings at different positions makes constant open joint close or release of reed relay to finally send the switchgear quantity signal. There are scares on the indication tube, which is convenient for the operator observes and monitors the oil level. There is no oil level transducer in the meter so that it can not provide simulation quantity signal outside.

121

B. B. oil level signal of oil return tank also can be equipped with float and magnetic oil level meter. It can be visual and send switchgear quantity signal and simulation quantity signal depending on the client.

10.4.5.4 oil mixing water signal device(optional) The oil mixing water signal device is used to measure the water content in the oil in the oil return tank of the oil pressure device. When the content value exceed the given value, alarm will remind watcher to find solution to ensure the oil quality in the system and keep unit safe. The device is consisted of capacitance transducers which are inserted into the midea oil. Oil quality has changed due to mixture of water, which produce signals in the transducer showing the ratio chane. After treatment, sending alarm signal. The device can be installed in 3 different ways: installing at top, side and bottom.

10.4.5.5 Pessure meter, pressure controller and pressure transmitter(Optional) Pessure meter, pressure controller and pressure transmitter are instruments showing pressure parameters changes in the pressure tank.

122

A. A. pressure meter is an istrument used for showing pressure value and visually test by operator, it also can be used for parameters adjustment of pressure controller, pressure transmitter, B. The pressure controller is also named pressure switchgear, which provides pressure meter switchgear quantity signal, specializes in control the startup and stundown of work pump and backup pump, sending over high or low pressure alarm and control of air replenish or release. There are many kinds of pressure controllers with different names such as pressure relay, electric contact pressure meter ect also pressure controller. The most used is electric contact pressure meter whose advantaegs are conveniet adjustment, visual test and easy maintenance.
C.

The pressure transmitter can provide pressure simulation quantity continously in order to meet automatic control and computer monitoring requirments. 10.5 Installation of Oil Pressure Units Since the volume of oil pressure device is usually large and difficult for transportation, the manufacturer will disasseble and reinstallation needs to be done again at site. To make it convenient, the sequence of installation is describes as following for your reference.

123

 1.6m 3 For the oil pressure device whose volume is below 1.6 m 3 ,STRONG may undisassembly departure to tansport easily , so there is no need to assemble and install in the scene , only need to install as a whole.

10.5.1 Installation of oil return tank Installation of Hanging mode oil tank A. Lift the oil return tank to the foundation; B. Select three supporting points for the six supports of the oil return tank, weld level- adjusting nuts to the supports, rotate the stud bolt into it till the stud bolt connects with the foundation, and put a small metal plate below each bolt; C. Adjust the levelness on the oil return tank through the nut that adjust level (measure the levelness with level instrument or level bar); D. Stabilize the lower parts of the six supports of the oil return tanks with drill key after the levelness of the oil return tanks is adjusted; E. Fix the oil return tank with concrete grout. Installation of console oil tank A. A. To hang the oil return tank to the aufgehoben installation site B B.adjusting the levelness of the horizon of the oil return tank (gradienter Or track level bar can be used to measure ) C C.Fixed the holding down bolt and the oil return tank.

124

10.5.2 Installation of pressure oil tank Please install the Pressure oil tank according to the following steps after the concrete that fixes the oil return tank is solidified

Installation of the combined oil pressure device A. Set the lifting point of the pressure oil tank on the upper part of mouth of the pressure tank of the oil return tank; B. Move the pressure oil tank to the vicinity of the oil return tank, and near its lower part to the mouth of the pressure tank of the oil return tank. Remove all its outside packages, and fix the wire cable to the tongue on the upper part if the pressure oil tank; C. Lift the pressure oil tank after the lifting work is well prepared and becomes reliable. In the process of lifting the tank, the upper part could be lifted gradually, and the lower past should be moved to the installation hole of the pressure tank of the oil return tank till the pressure oil tank is erected. The flange on the pressure oil tank should be connected with the flange on the oil return tank; D. Adjust the direction of mouth of pressure oil tank in line with the diagram, and align the connection hole of flange on the pressure oil tank with the connection mouth on the oil return tank; E.Fix the bolt that connects the pressure oil tank with the oil return tank; F.Loosen the rope that lifts the pressure oil tank

125

 Installation of separated oil pressure device A. A.Set the lifting point of the pressure oil tank on the upper part of the aufgehoben installation site of pressure tank .

B. B. Moving the oil pressure tank to place nearby the installation site , unloading all the package of outside , and fixing the wrie rope to the rings of the tank upside. C. C. After checking all preparing wrok and make sure it is reliable , and then to hang up the oil pressure tank. D D.Hanging up the installation support to the place nearby the installation site ,and corresponding the the aufgehoben holding down bolt and the foot margin hole of the support. E. E. Tightening the installation support and holding down bolt F. F.loosing the wrie rope of tank 10.5.3 Installation of motor Lift the motor to the motor support of oil pump with lifting instrument, and align the connecting tap. Please pay attention to the following few points when the motor is installed: A.Fix well the upper and lower connection shafts, and put well the elastic plate inside the connection shaft; B.The wire box of the

126

motor should near the wire pipe for the convenience of later wiring; C.Move the shaft coupling equally with hands after the motor is installed, and there should be free from block. After the above points are checked up, please fix the fastening stud bolt. 10.5.4 Installation of valves and accessories of the pressure oil tank 10.5.4.1 Installation of the filling valve 2 2 The filling valve of the pressure oil tank is two shut-off valves connecting with two filling on the pressure oil tanks, through crew stud only. When they are connected, the valve rod of the valve should be vertical to the pressure oil tank. The rubber asbestos mat should be put under the connection surfaces of the pressure oil tank and the valve so that the sealing surface could not leak oil when the oil pressure units work normally. 10.5.4.2 Installation of release valve 1 The release valve of the pressure oil tank is a shut-off valve. The outlet flange between the release valve and the release pipe should be connected with stud bolts prior to the installation of the between the release valve and the pressure oil tank. Then the release pipe is inserted into the release hole on the panel of the oil tank. After the installation, the release hole between the valve and the pressure oil tank should be connected. The rubber asbestos mat should be put on the sealing parts.

127

10.5.4.3 Installation of main pressure oil valve The main pressure oil valve is cut-off valve or ball valve. Please connect the side without external flange with the main oil port of pressure tank by bolt with two heads. It is noted that the rubber asbestos mat should be put on the sealing parts.

10.5.4.4 Installation of assistant port valve The auxiliary oil port is cut-off valve. Please connect it with the auxiliary oil port of pressure tank by bolt with two heads.It is noted that the rubber asbestos mat should be put on the sealing parts.

10.5.4.5 Installation of oil level shut-off valve 2 4 M16 The oil level shut-off valve is two ball valves, to be installed on the oil level meter mouth of the pressure oil tank through four M16 screw studs respectively. It is noted that the rubber asbestos mat should be put on the sealing parts.

10.5.4.6 Installation of air safety valve 4 M16 The air safety valve of oil pressure units is installed on the top of pressure oil tank, connecting with the safety valve mouth of top of the pressure oil tank through four M16 screw studs. It is noted that the rubber asbestos mat should be put on the sealing parts.

128

10.5.4.7 Installation of air filler valve 4 M12 The air filler valve is a cake-like valve with a hand wheel on the front and the back connecting with the charging hole of the pressure oil tank through four M12

socket head screws. It is noted that the rubber asbestos mat should be put on the sealing parts.

10.5.4.8 Installation of shelf 4 M14 The pressure oil tank is the installation mouth of two pressure instrument shelf and the shelf is assembled, connecting with the moveable flanges of the pressure tank for the convenience of adjusting the shelf while installing it. The shelf is connected with the pressure tank through four M14 screw studs. It is noted that the rubber asbestos mat should be put on the sealing parts.

10.5.5 Installation of valves and accessories of oil return tank 10.5.5.1 Installation of oil discharging valve of the oil return tank 4 M16 The oil discharging valve of the oil return tank is connected with the oil discharging hole on the bottom of the oil return tank through four M16 screw studs. It is noted that the rubber asbestos mat should be put on the sealing parts.

129

10.5.5.2 Installation of double oil-filter screens Open the over of the man hole, and insert the double oil-filter screens into the sideway below the man hole. Cover the man hole, and do not fix the bolt as the future check ups would be conducted through the man hole. 10.5.6 Installation of Automatic components 10.5.6.1 Installation of by-pass level indication and thermometer of the pressure tank 4 M16 The by-pass level indication and thermometer of the pressure tank, two moveable flanges on it connected to of the pressure tank respectively through four M16 bolts. It is noted that the rubber asbestos mat should be put on the sealing parts. The by-pass level indication and thermometer should not be reversed for installation. It should be subject to the characters on the nameplate.

10.5.6.2 Installation of by-pass level indication and thermometer of the oil return tank By-pass level indication and thermometer of the oil return tank. it could be directly connected to the flange of the oil return tank and fixed to the oil return tank through bolts.

10.5.6.3 Installation of automatic air filler device 400mm 2 M12 The installation plate of the automatic air filler device has been welded on the

130

pressure tank, 400mm below the air filler port of the pressure tank. The automatic air filler device could be connected to the installation plate directly through two M12 bolts.

10.5.6.4 Installation of manometer, electro connecting pressure gauge, and pressure transducer M201.5 The manometer, electro connecting pressure gauge, and pressure transducer should be installed on the shelf. The interface is M201.5 and they could be directly installed on the pressure switch of the shelf. The following two steps should be highlighted in the process of installation: A.O The O sealing ring below the interface should not be neglected (the meter has the ring and do not neglect it in the process of installation); B. Do not mover the meter itself when the above meters are installed. The right method is to use two wrenches, one for fixing the meter and the other for moving the moveable nut of the pressure switch.

10.5.7 Installation of oil and air ducts The installation of oil and air ducts of the oil pressure units mainly refers to the installation of the oil duct from the radial valves of the oil pump to the pressure oil tank and the installation of the air duct from the automatic air filler device to the air filler hole of the pressure tank.

131

10.5.7.1 Installation of the oil duct from the oil pump to the pressure tank O When the product is delivered, as the oil pump and the valves are not dismantled form the oil return tank, thus the installation of oil duct just requires to connect the oil ducts from the valves to the inlet valves of the pressure tank. One end of the oil duct is a bent pipe, welded to a flange and connected to the valves; the other end is a round flange, connected with oil filler valve of the pressure tank. Before the oil ducts are connected, the sealing parts should be set well, that is to say, to put O ring to the valves and rubber asbestos mat to the oil filler valve of the pressure tank. Each oil pressure unit has two oil pumps and two oil ducts. The installation of the other oil duct is the same as the that of the first one. Prior to installation, the steel characterized end should be the same, otherwise, it is quite difficult to conduct the installation.

10.5.7.2 Installation of the air duct from the automatic air filler device to the air filler hole of the pressure tank. The Copper duct used for the connected should be welded to the interface of the discharging hole of the automatic air filler device and to the interface of the charging hole of the air filler valve of the pressure tank through the mode of oxygen and copper brazing method.
132

 Chapter XI Usage of Oil Leakage Device(optional)

11.1 Note to installation Be careful The Oil Leakage Device shall be installed horizontally and fixed with bolt without any slope.

Warning On the top of the Oil Leakage Device , there are four corners with four rings which (not somewhere else) can be used for installation and replacement.

Please read the information carefully below

before the installation

1 2 3 1.6MPa 4 5 6 7 LYZ40-AZ 8 2.5Mpa30 9 10 11 150350L 12 ()

133

ball valve on the oil leakage device shall be set for inspection, otherwise fully open;

Paying attention to amount of turbine oil before the first start of the oil-pump.

The original overflow valve shall be 1.6Pa without the demand from users.

The oil leakage device shall be installed at the bottom of system oil-sump and oil-leakage tubes.

5 6

Once finish the installation of oil leakage device, fastening it with bolts. Dismantling the seals (except the asbestos and rubber seal gaskets) which are on the flanges of ball-valves and oil tanks.

7 8

Referring the installing diagram for oil leakage device to weld oil-tubes Testing welded oil-tubes and the standard pressure is 2.5Pa without leakage in 30m.

9 10 11 12

Cleaning tubes after the testing Keeping the cleaned tubes with seals Adding 150350L filtrated turbine oil. Adjust in the light of following instruction (if necessary).

11.2 Technology parameters 2.2KW 380VAC

1420r/min 40L/min 2.5MPa 1.6MPa 180L360L500L1000L1500L

3min9min
134

Capacity of the pump motor: 2.2KW Motor Voltage: 380VAC tri-phase A/C Rotating speed of pumps: 1420r/min Oil-pump output rate: 40L/min Max pressure: 2.5MPa Original pressure: 1.6MPa Oil tank capacity: 180L360L500L1000L1500L Oil-pump operating period: 3min9min

11.3 The main accessories 1 overflow valve Be careful

After rational adjustment of overflow value, it shall be tightened by screw cap to avoid change of overflow value to cause abnormality or danger.

1.6MPa Y-63B 63L/min 6.3Mpa Overflow valves here used as security valves. It will remains stop without overflow if the valve pressure is lower than limited set value (the original value is 1.9Pa), and it opens with overflow if higher. Thus this can avoid system overloading and protect oil-pump and hydraulic system. Twisting along the clockwise to adjust the pressure higher by handle. The type of overflow y-63B, delivery rate 63/min; max pressure capacity: 6.3Mpa

135

2 one-way valve I-63B 63L/min 6.3Mpa Since one-way valves only allow liquid oil to pass in one direction, it can protect the liquid oil in the hydraulic system from retuning to the oil leakage device when stopping oil-pump or opening the safe valve. Type of one-way valve: 1-63B; delivery rate: 63/min; max pressure capacity: 6.3MPa

3 oil-absorbed filter WU-100180-J100L/min 180m The oil-absorbed filter is installed in the oil-pump entrance to protect the pump and hydraulic valves from impurity The type of oil-absorbed filter: WU-100180-J (netting filter); delivery rate: 100L/min; filtrating precision 180m

4 gear oil-pump Be careful

If the unit is to be reused after a long time, it shall be operated without load more than 10 minutes before load operation.

CB-B40 40ml/2.5Mpa
136

CB-B40 gear oil pump owns the simple structure, easy operation and reliable work, and it is widely used in the low hydraulic system such as grinder and mechanism. Displacement: 40ml/extension max pressure capacity : 6.3MPa

5 air cleaner EF1-25 We choose EF1-25 air cleaner. Its combination of air and oil filtrating simplifies the oil tank structure, convenient for oil purifying and keep the pressure balance between oil tank and atmosphere. The air cleaner employs filtrating slices

sintered by copper powder, which can secure higher filtrating extension, intensity and plasticity, easy to be dismantled, whats more, can bear the thermal stress and work normally at higher temperature.

6 the hydraulic level control relay

The parameter,working principle of normal liquid level meter, liquid level control relay mode that STRONG configure on the oil leakage tank are as follows:

YKJD24-410-210-110 YKJD24-410-210-110( It can also configure according to the demand of the client)
1 The main functional reference

temperature requirement20100 operating time1.7 contact resistance0.1 contactor capacityDC24(V)0.2(A) lifetime(per)10 7 (2) Brief Introduction and principles

137

YKJD 1 YKJD24-410-210-110 YKJD hydraulic-level control relay, which is a new signal control device with liquid-level, well-designed, keenly controlled and simply installed, is mainly used for alarm or automatic control in the position of liquid of internal tanks and the motors. Figure 1 is sectional drawing and size for installation. The floater ascends or decreases following the level of liquid when it works. Contactor of the relay breaks to stop automatically and alarm when the floater comes to the signal send position. YKJD hydraulic-level control relay has three same floaters and three pairs of same contactors.

1 Fig.1

2 Fig. 2

YKJD24-410-210-110 420 2 L1

138

210 2 L2 110 2 L3 In YKJD24-410-210-110: In the Figure2 420 is the low oil-level (oil-pump shall stop now) In the Figure 210 is the high oil-level (oil-pump shall be started now)
In the Figure2 110 is the alarm oil-level (oil-pump may not stop but alarm). (3) Diagram for wirings and terminals

aviation plug

No.1 control point

No.2 control point

No.3 control point

YKJD24

wiring diagram for three-point liquid level control

139

 Chapter XII Description of Installing, Debugging and Maintaining

12.1 Mechanic Installation and Debugging 12.1.1 Assembling Referring Chapter IX 12.1.2 Zero setting Referring Chapter IX Electro-mechanic limit switch adjustment 6mm The Governor shall be manual to make balance mid-point, and manually rotate handwheel and remove limit up and down in 6mm, thus electro-mechanic limit switch begin to run, if failing to do so, electro-mechanic limit may be adjusted.when the limit switch is ruuning, please cut the power of the motor and driver to make step-by-step motor lose magnetism and oil-free electro-hydraulic automatic middle, and no change in the servomotor in order to protect the motor and units.

12.2 Electric Installation and Debugging Mechanic installation and debugging shall be done before that of electricity.

140

/Warning ,. Please always use the required voltage and be careful of its stability since incorrect voltage may cause by mistake or burn ,. Please be careful of the + & - polarity of DC; otherwise, component burn may cause Please follow the requriemets when installing other connection cables; otherwise, component burn may cause 12.2.1 Installation 1 Cubicle shall be well and reliably installed 2/ External wiring connect the external wiring in accordance with the Terminal Figure. Guide/runner plade feedback, motor feedback, unit active power, unit frequency, net frequency and communication cables shall be Shielded wires, and forbid to sharing the same trough with dynamic cables, so do A/C and D/C powers 3 Check the power to see whether power sources shortly breaking and earthing or not 4/ Guide/runner plade feedback, motor feedback, unit active power, unit frequency, net frequency and communication cables except Shielded wires forbid
141

to being shortly connected with the ground 5 To see whether terminal and plug are well connected and fittings are out of damage or not 12.2.2 Debugging 1. / Guide/runner plade feedback adjusting Notes: The adjusting of feedback of guide vane and the runner

blades must be operated under no-water conditions.

The steps are as follows 1 80mV~200mV Adjusting zero of guide vane feedback using Governor manually, closing servomotors,loosing the fastener of the fixed feedback transmitter and adjusting guide vane feedback to make feedback voltage between 80mV~200mV to lock fastener . Press zero determinationin the adjusting interface of zero of guide vane feedback. 2 9.5V~10V Adjusting full open value of guide vane feedback opening the servomotor manually and max adjusting feedback potentiometer (small one) to keep feedback voltage between 9.5V~10V.Pressfull-open determination in the adjusting interface of full-open of guide vane feedback. If the encoder is used in feedback, it only

142

needs to fully open the servomoter manually then pressfull-open determinationin the adjusting interface of full-open of guide vane feedback 3 Full open or close the servomotor for several times to see whether zero and full open value has changed or not, if so, readjust until satisfication 4 Set over-high and excessively low values of guide vane feedback according to the vane zero position and full open values. The over-high value shall be more than open values while the excessively low values shall be less than zero. The value range is the larger the better 5 With finishing of zero and full open adjustment, fully open the servometer, adjust the potentiometer behind guide vane opening which shows 100% Plam vane feedback adjusting is ditto 2. Electro-mechanic feedback adjusting Notes: The adjusting of the motor feedback must be operated under no-water conditions.

If taking oil free electro-hydralic as tanducer ,you need to adjust the motor feedback as follows 1 6mm

143

electro-mechanic feedback installation shall ensure that electro-mechanic feedback can move up and down beyond 6mm at the balance point 2 Manually use Governor and keep servomotor still, presently, the electro-mechanic feedback value is electro-mechanic feedback zero 3 If the electro-mechanic feedback is a sensor, there is no need to adusting potentiometer in the light of max adjusting electro-mechanic feedback, the unique necessity is to make voltage of electro-mechanic feedback zero half, then press zero determination and set current of electro-mechanic feedback value as electro-mechanic feedback zero 4 2 Notes: 406080 When the diameter of main distributing valve is 40 mm, 60mm,80mm ,the pilot valve moving downward direction . 100150200250 When the diameter of main distributing valve is is the tailoff

100mm,150mm,200mm,250mm , the pilot valve moving upward is the tailoff direction.

In the interface of full-close valve adjusting of electro-mechanic feedback, rotating electro-mechanism along closing button to make trip by electro-mechanic

144

feedback the max shutdown trip. Then press full-close determination and set current of electro-mechanic feedback value as electro-mechanic feedback full-close value 5 1.5 +- -+ Set over-high and excessively low values of guide vane feedback according to the vane zero and full- closed values. The over-high value shall be more than full-closed values and the excessively low values shall be less than zero2zero value- full-closed value. The value range is the larger the better Functional Tests of Governor With abovementioned adjustments and external wirings finished, the functional tests then can be done. 1 Startup trial command startup, the close loop startup rules of servomotor will make units the no-load opening and no-load opening to electric limit automatically.in the coursr of starup, if frequency breaks down, guide vane closes automatically to no-load limit, if tracing frequency indicator is on, the unit will follow given frequency for synchronization. If running normally, tracing net frequency turns on and the unit will follow, but if breakdown happens, the servomotor will trace given frequency automatically 2 45HZ~55HZ
145

Under no-load condition if the unit trace given frequency, this frequency can be got by pressing buttonincreasing given frequency, accordingly, the unit

rotational speed is rising; in the same way, this frequency can be decreased by pressing buttondecreasing given frequency, accordingly, the unit rotational

speed is down. With this function, the unit frequency can be adjusted among 45HZ~55HZ. The Governor now is adjuatable frequency 3 100% / BP Sycrinization working condition the oilswitch can be closed with premises met, the Governor becomes to opening adjusting mode after sycrinization and opening limit automatically increases to 100%. Then it is time to press the buttons (increasing/decreasing given power) on the panel, or adjust guide vane opening by remote given power increasing/decreasing to regulate the unit with active power Under sycrinization working condition, if the unit frequency is beyond dead zone, the Governor automatically changes into frequency regulating mode to adjust guide vane opening in the light of BP (permanent speed droop) to meet the viariation of grid frequency 4 Dropping load closure of oil switch will cause guide vane shut down by the Governor. When the rotational speed declines, please open guide vane to on-load opening which keep the unit rate rotational speed and Governor no-load working condition 5
146

The steps of shutdown are declining the unit active power to zero, closing oil switch, stopping command input, shutting the servometer by Governor, changing electric opening to zero, lighting chain indicators, Governor entering spare

conditions , then shutdown finishing. Meanwhile, the oil-free electro-hydraulic or propotional servo valve has shutted down stroke in tailoff direction, to make sure the close reservair of servomotor keep the oil pressure to prevent servomotor 6 static trial Notes: Static trial must be operated under the condition of on-water .

Purpose to inspecting unit rotational speed dead zone and non-linearity of servomotor. =50% =100% BP=6%,BT=5%,TD=1%,TN=0,E=0BP=6%,KP=2.00,KI=8.00,KD=0,E=0 2HZ Conditions sycronizing and given opening shall be 50% and electric opening is 100%, the parameter of large net load are BP=6%, BT=5%, TD=1%,TN=0,E=0 and small net artificial deadzone is 2HZ. Methods A 51HZ Send 51HZ by frequency generator, and record guide vane opening after stability. B 0.2HZ 12 Record guide vane opening after stability with every declining of 0.2HZ, and record 12 points in total. C B 0.2HZ 12

147

Record guide vane opening after stability with every increasing of 0.2HZ based on B least frequency, and record 12 points in total. D Get rid of the front and back points, drawing static curves, calculate rotational speed and non-linearity. 7 perturbation trial of no-load frequency Purpose to select best no-load parameter 50HZ, 100%BP=0% Conditions the unit is in on-load working conditon, traces given frequency which is 50HZ, electric opening is 100%, BP=0%. Methods A 48.00HZ, 48HZ Change the perturbated given frequency to 48 in the no-load frequency perturbation interface, and press beginning to perturbate unit frequency to 48HZ. B 52.00HZ, 52HZ When the frequency is stable, change the perturbated given frequency to 52.00 in the no-load frequency perturbation interface, and press beginning to perturbate unit frequency to 52HZ, and record the unit max frequency or upper perturbation waveform at the same time.Calculate over-varible values and adjusting time of the unit frequency. C 48.00HZ, 48HZ When the frequency is stable, change the perturbated given frequency to 48.00 in the no-load frequency perturbation interface, and press beginning to
148

perturbate unit frequency to 48HZ, and record the unit min-frequency or down-perturbation waveform at the same time.Calculate over-varible and adjusting time of the unit frequency. D BC Analyze outcomes from unit upper perturbation and down-perturbation. If they fail to requirements, choose another parameters, take step B and C again util appropriate parameters given. E 50HZ After parameters selection, finish trial with perurebation of unit frequency to 50HZ. 8 No-load frequency oscillating measure frequency oscillating after no-load parameter selection PID Purpose check no-load frequency oscillating and select best PID optimizing coefficient.

50HZ, 100%BP=0% Conditions the unit is in no-load working conditon, traces given frequency which is 50HZ, electric opening is 100%, BP=0%, and select best no-load parameter.

3 PID Method observing no-load frequency in 3mins. If it is beyond oscillating, verify PID optimizing parameter online

KPX Proportion optimizing coefficient KPX KIX

149

Integral optimizing coefficient KIX KDX Differentiation optimizing coefficient KDX

warning . Only after the right parameters chosen , automatic startup, shutdown , load rejection can be allowed. 0.3V The first startup after installation or repairing need manual startup to rated speed , if the redundent voltage is lower than 0.3v ,it needs to excitation to make sure the governor can measure the frequency of units ,andthen run Governor automaticly , after choosing the right parameter ,the units can automaticly startup and shutdown.

12.3 Governor Inpsection and Maintenance 12.3.1 Pay attention to following items while daily checking 1 check the temperature of motor proportion servo valves 2 the motor or proportion servo valves shall keep still with rate load. If electricmechanics is shaking, change it into manually running and examin 3 Exam the oil-filter pressure; then clean meshes if the pressure is too low

150

4 PLC Attend to breakdown and emergency measurement. Check the unit frequency, net frequency, guide vane opening meter, PLC output values and balance values etc if breakdown happens 5 emergency measurements for breakdowns PLC When breakdown happens in electric-mechanical feedback or proportion servo valves, electric-mechanical limit, drivers, guide vane feedback, drivers are power off, motor is out of magnetism, oil-free electri-hydraulic or proportion servo valves comes to the middle, and the servo motor remains current opening. In this case, run Governor manually, then notify to servicemen. If breakdown happens, the Governor with no-load working conditon shall stop; it is better to be electric manually running in load condition. It also can run without frequency shaking. However, Increasing /decreasing only is a non-frequency adjusting function. PLC PLC PLC PLC The Governor shall not be power off in order to protect PLC program when low- voltage indicator of PLC batteries is on. It is necessary to check batteries and its voltage (whether it is too low or not). If it is because of too low voltage, batteries shall be replaced (stati electric shall be avoided) in one week. However, the Governor still can run normally with too- low batteries voltage.
151

 If taking oil-free electro-hydralic transducer as transmitter ,it shall be maintained by lubrilating oil (turbine oil) every two months. In lubrication, do not go to deep of oil hole to avoid meeting ball screw. 12.3.2 Pay attention to following items while daily maintaining 1 PLC 0.2% (1) Checking if feedback sampling values have fluctuate via Touched LCD, if the fluctuate value exceed PLC sampling channel 0.2% of full range , it needs to check if the feedback and cable transmission loop are normal . The feedback can be governors simulation feedback or guide vane feedback , runner blade feedback,guide vane motor feedback ,runner blade motor feedback , guide vane servo propotional feedback , runner blade servo propotional servo feedback ,power feedback or water head feedback. (2) Check whether the mechanic zero position of the oli-free electro-hydraulic converter have been drifted. Run guide vane manually and keep servomotor still, otherwise, the mechanic zero position shall be regulated. After its regulation, reset the electric zero position, or it would not conform to that of mechanics

3 Check whether Governor terminals are suitable for earth connection 4 Check oil-filter to see whether the mesh is jammed and the pressure works well or not 5

152

Any other regular check and maintain etc 6 ,. If taking proportional servo valve as electro-hyraulic convertor, please check if the propotinal servo valve or its amplifier is normal , if has emit heat phenomenon . 12.3.3 Breakdown Diagnosis When the Governor breaks down, the results and possible reasons are below (only main breakdowns) Breaksdown Names For frequency measurement / Frequency indicator breakdown is breakdown on If 1. PT 1. Frequency shows zero with cut unit PT wires. 2. PT 2. Bad contact in the unit PT circuit exists. 3. PT 3. The unit PT is earthing. 4. 4. Breakdown exists in unit frequency isolating transformer. 5. 5. Bad shielding cables. 6. PT 6. Electromagnetic is interrupted by abrupt of dynamic cables if unit PT Charateristics Reasons

happens

during startup, the guide vane automatically closes to no-load opening set by Governor. If the opening is

153

suitable, remain

the rate

unit

will

shares

the

same

trough

with

rotational

dynamic cables. 7. PT PT 7. The PT system is the same with unit PT. 8.

speed; otherwise it would departure rated value . Shutdown command can be accepted. In sycronizing if no work condition, happens, breakdown frequency

8. Frequency measurement panel breakdowns 9. 9. Frequency measurement communication breakdowns.

exists in the Governor, but increasing/decreasing commands accepted, the regulating unit is active.

1. 1.Breakdowns in drver or motor If breakdown indicator in on, For electric-mechanic limit motor is out 2.

electric-mechanic limit is 2.The position of electric-mechanic of limit switch has changed or broken. magenism, the middle, oil-free and

electri-hydraulic comes to 3. 3.Wrong parameters, electric-mechanic 4. 4.electric-mechanic breakdowns 5. PLC 5.PLC breakdowns feedback electric-mechanic including feedback zero, servomotor remains still.

motor feedback whole shut value.

154

 no-action guide vane

1 of PLC 2 >2%, 3DA 4PLC

The switch handle of guide 5 vane is under automatic 6 status, the difference 1 drive or amplifier failure between PLC output value 2Electro-hydraulic convertor failure on Touched LCD and or its feedback failure guide vane opening value 3 DA module fault is more than 2%, and the 4PLC fault servomotor does not act. 5Servomotor oil mixing 6Servomotor feedback failure / 1. / 1.Cut or short break in guide/runner plade feedback. 2. / plade feedback If breakdown indicator in 2.Guide/runner guide/runner plade connects with the ground. / For guide/runner plade feedback feedback is on, motor is 3. Feedback power supply breakdown. out of magenism, oil-free electro-hydraulic to the middle, or 4. and 5. 5.Electromagnetic is interrupted by abruptance of dynamic cables if feedback cables share the same trough with dynamic cables 6. A/D propotional servo comes 4.Bad shielding cables servomotor remains still.

155

6.A/D breakdowns

module

sampleing

For feedback (taking oil-free Electro-hydralic transducer as transmitter) Ditto to guide vane feedback If breakdown indicator in electric-mechanic is on, oil-free and step-by-step motor is out of the magenism, middler, electri-hydraulic comes to servomotor remains still. If breakdown indicator in the driver is servo on, valve propotional Ditto to guide vane feedback

electric-mechanic feedback

Feedback fault (taking propotional servo valve as transmitter)

is out of voltage, and servomotor remains still. 1. 1.Breakdowns in driver itself

For the driver

2.

If breakdown indicator in 2. motor breakdowns the driver is on, motor is 3. out of magenism, oil-free 3.Oil-free electri-hydraulic is jamed electri-hydraulic comes to 4. the and 4.The stroke of motor is too long servomotor remains still. middler,

156

 1. For the driver 1.Breakdowns in driver itself 2. propotional valve

servo If breakdown indicator in 2. the driver is on, servo breakdowns propotional valve remains still. breakdown indicator in

is out 3.

of voltage, and servomotor 3. servo propotional valve is jamed 1. PLC CPU 1.The voltage of batteries in PLC CPU module is lower. 2. PLC CPU 2.Batteries in PLC, CPU module doesnt work well. PLC 1. PLC 1.PLC module breakdown I 2. CPU

For lower battery voltage

batteries is on

f breakdown indicator in 2.CPU stops ruunig PLC is on, motor is out of 3. magenism, PLC For PLC propotional voltage is servo 3.The program runs over-time out of 4. RAM

and servomotor 4.RAM breakdown remains still. 5. 5.clock breakdown 6. 6.logical resolving breakdown 7. 7.Wrong configuration

1.

157

 For Governor breakdown contactor output If the breakdown contactor is

1.Breakdowns abovementioned

velomotor 2.

output, the breakdown is 2.Breakdowns in A/C or monitoring remoted reported. relay 3. 3.Breakdowns in D/C or monitoring relay 4. 4.No D/C, A/C IN velomotor 5. 5.Breadown output relay of Governor breaks 1. emergency stop Electromagnetic valve. 2. 2.The connector at emergency stop breaks

For emergency shutdown

Emergency stop indicator 1.Operating is on.

12.3.4 easily-abrasive spare parts Name seal ring Filter net Pressure indicator fuse pipe Electrical relay Indicator Opening indicator Speeding indicator Commutate module size unit piece

4A 10*38

piece

158

 Chapter XIII Operating Instruction

13.1 Governor Power up or Reset /Warning ,. . Please always use the required voltage and be careful of its stability since incorrect voltage may cause by mistake or burn. ,.. Please be careful of the + & - polarity of DC; otherwise, component burn may cause. no random operation is allowed without permission by person in charge.

() CPU After closing the power supply switch (AC, DC) or resetting CPU key, different actions are taken according to different conditions. 1. / When wicket gate manual/auto switching over is at auto position, its according action process is as follows (1) Lock breakdown, and motor loses magnetic power (2) Sample guide vane feedback (3) Read frequency difference (4) 45Hz PLC If system frequency exceeds 40Hz PLC will trace gate opening, and reset breakdown lock. No-load operation if oil
159

switch is opened, and load operation if oil switch is closed (5) 45HzPLC If system frequency is less than 40Hz, PLC will not trace gate opening with zero output, reset breakdown lock, and be in stop and wait status; gate opening control motor turns to close direction a bit angle degree, so that gate has a little acting force towards close direction (6) Perform diagnose program with all error status lights off before performing. 2. / When wicket gate manual/auto switching over is at manual position (1)Manual status signal light is on (2) PLC Perform manual operation program, sample wicket gate opening with PLC trace

13.2 Changing Mode Regulating Mode Change Three types of regulating modes frequency regulating mode, gate opening regulating mode, power regulating mode. 1 When operating at No Load, Governor stays at frequency regulation mode 2 When operating at Load, Press power regulation key, Governor turns to frequency regulation mode, which forms a closed loop control with power feedback, and sets units to supply the fixed amount of power until power setting changes. Press gate opening regulation key, Governor turns to gate opening regulation mode, which forms a closed loop control with opening feedback, and sets gates to
160

the fixed opening until opening setting changes. 3 When operating in power regulation mode, if any error in power feedback or weak frequency, Governor will automatically cancel power to opening regulating mode. 4 The capacity is given by upstream computer communication in power adjusting mode Tracing Switch 1. Power up Governor and net frequency is traced automatically 2. When pressing frequency setting trace key, Governor traces frequency setting, with frequency setting trace signal light on 3. When pressing net frequency trace key, Governor traces net frequency, with net frequency trace signal light on

13.3 Increasing and Decreasing Operation 1/ Increasing/Decreasing Power Setting (1) When operating in opening regulation mode, press this key and thus opening setter changes. The power is changed by changing vane opening. (2) In power adjusting mode, manual power can change given power while automatic power is useless to switch increasing /decreasing. 2/ Increasing/Decreasing Frequency Setting / /
161

When operating at No Load and tracking set frequency, its value can be changed; otherwise, increasing /decreasing is invalid; 3/ Increasing/Decreasing Electric Limiter / Increase/Decrease electric limits by setting parameter to limit units supply power. 4 Changing Water Head When operating at head manual, change head by setting head value.

13.4 Mechanic operation Refer Chapter IX

13.5 Governor Operation 13.5.1 necessary conditions before governor startup

1 0% 2 0HZ

3 notices:
162

Confirm that oil supply valve has been opened and the manometer on the integrated module can normally show the pressure. Confirm that stop command and emergent stop command have been reset. Confirm that the machine is under automatic status. The governor has no fault signal output. The following content shall be correctly displayed on the touched display monitoring interface: (1)guide vane opening is 0% (2)unit frequency is 0HZ (3)display stop for standby and governor in normality states. lock quitting

Stop for Standby 1 00.00 Unit frequency shows 00.00 2Wicket gate opening is full closed 3 with negative value balance value. 4 WZT As for WZT series governor, it is original angel for the blade. 5 The status interface of LED shows: stop to be backup 13.5.2 Automatic Starting and Synchronize Warning: normal oil pressure of the equipment shall be guaranteed before startup 1With start requirements met, Governor stops at stop for standby condition 2
163

 Send start command and holding; show start condition on screen, vane opening starts to open at peak; and the thick liquid vane return from the starting position 3 45Hz Speed starts to rise and system frequency shows upwhen frequency is lower than 45Hz, guide vane will open with relative small slope which does not exceed off-load electric limit. 4 45Hz PID When system frequency exceeds 45 Hz, it automatically turns to PID regulation mode. If the governor is at network tracing, the unit frequency will trace network frequency automatically. Otherwise, it follows frequency given. 5 With synchronism requirements met, synchronize the units 6 100% After synchronizing,
synchronize signal shows on condition screen, with electric limit of 100%

13.5.3 Load Increasing/Decreasing ,. notices: .The operator shall be careful of current power, width and period of power increase/decrease impulse and no increase /decrease at discretion is allowed. In automatic operating mode 1 When power regulating, adjust load by power setting value sent from upper computer
164

2/ When frequency/opening regulating, adjust load by the increase/decrease key in central control room or on touch panel. 3 In power adjusting mode, if breakdown happens in digial power given or simulation power given, adjusting

load of touch keys can also be increased/ decreased by handle in mid-controlling chameber or touch screen 13.5.4 phase modulation Under unit sycronizing condition, input and keep phase modulation command, the interfance will displays phase modulation, and all guide vanes close automatically, the electric opening limit is zero 13.5.5 releasing phase modulation 100% Releasing phase modulation command, the interfance will displays phase modulation and the electric opening is 100%. The guide vane opens to no-load by Governor automatically, change unit capacity according to load adjusting program 13.5.6 Automatic Stop 10% Warning The stop order must be kept until the guide vane fully closed and

unit speed decreases to lower than 10% of that. 1 On sending stop command, shows stop signal on screen, and decrease load automatically 2Once load is decreased to zero, oil switch is closed 3Guide vane is shut down to zero position

165

4 15Hz 5S When the unit speed is lower than 15Hz, the governor will delay 5S and then becomes stop for backup status. As for Kaplan units, the blade shall be opened to original angel. 5 The unit stops stably, and then the stop finishes. 123.5.7 Start and Synchronize by Mechanical Manual Be careful When manually rotating the handwheel, the angle shall not be so large in order to open the servomotor slowly and control the guide vane opening easier.

Refer to the instructions in mechanical part for detail mechanical handwheel operations 1PLC 3% 25Hz Please choose mechanically manual button of the governor guide vane, and the status interface shows guide vane is at mechanically manual condition, PLC starts to trace guide vane openingas for kaplan units, if the guide vane is more than 3% and unit frequency is larger than 25 Hz, the blade comes into syncronization if it at automatic position, the blade will close along the original angel. 2

166

 Open the guide vane: If electro-hydraulic convertor is oil free convertor, rotating the hand wheel along opening direction to open the guide vane. If electro-hydraulic convertor is proportional valve, opening increase/decrease handle on the governor panel shall be put at increase postion to open the guide vane, 3PLC PLC automatically traces gate opening, reads frequency difference, and prepares for switching to auto 4Adjusting unit frequency into no-load and sycronize with conditions met

13.5.8 Switching from Mechanical Manual to Auto 1Inspect and assure that electrics work right 2 If normal, please select automatic switchgear of the governor guide vane and then the status interface will show guide vane automatic

13.5.9 Mechanically manual stop Note: if guide vane switch handle on the Governor panel is at mechanically manual mode position, the screener State form interface will display guide vane mechanically manual mode. 1 Close guide vane: If electro-hydraulic convertor is oil free convertor, rotating the hand wheel along closing direction to close the guide vane. If electro-hydraulic convertor is proportional valve, opening increase/decrease handle on the governor

167

panel shall be put at decrease postion to close the guide vane. Decreasing the unit load to zero and then cut the breaker, please continue to close the guide vane to full close position. 2 0% 0HZWith guide vane opening closing to 0%, the unit frequency will reduce to 0 HZ, then stop finishes.

13.5.10 Electrically manual startup and synchronization / With electrically manual function, electrically startup, synchronization and increase/decrease load can be realized. Note: Note: if guide vane switch handle on the Governor panel is at electrically manual mode position, the screener State form interface will display guide vane electrically manual mode. 1PLC Select guide vane switchgear at electrically automatic condition, PLC keeps current opening. 2 To open the guide vane via the guide vane opening increasing/decreasing handle on the governor panel or remote increasing/decreasing order. 3 3% 25Hz When the guide vane is more than 3% and unit frequency is larger than 25 Hz, the blade comes into syncronization if it at automatic position. 4 PLC PLC reads frequency error to make preparation for switching into automatic mode. 5 Unit to adjust the
168

frequency of no-load, in the same period to meet the conditions and after reaching the net.

13.5.11 Electrically manual stop Note: if guide vane switch handle on the Governor panel is at electrically manual mode position, the screener State form interface will display guide vane electrically manual mode. 1 To decrease the opening given via opening increase/decrease handle on the governor panel or remote increase/decrease order to decrease the guide vane. Decreasing the unit load to zero and then cut the breaker, please continue to close the guide vane to full close position. 2 0% 0HZWith guide vane opening closing to 0%, the unit frequency will reduce to 0 HZ, then stop finishes.

13.5.12

/ /

Switch

of

mechanically

manual/automatic/electrically manual 13.5.12.1 Mechanically manual operation conversed into automatic one: 1 To check whether electrical part works normally, and balance meter is balanced. 2 // If electrical part works normally and balance meter is balanced, guide vane switch handle ( mechanical manual/automatic/electrically manual) operation into automatic one, the touched

169

display State form interface will show guide vane automatic operation. And it shall be no disturbance in switchover. 13.5.12.2 automatic operation switching into mechanically manual operation 1// Guide vane switch handle (mechanical manual/automatic/electrically manual )operation into manual one, the touched display State form interface will show guide vane manual operation. And it shall be no disturbance in switchover. 2PLC PLC traces guide vane opening, balance meter is balanced. If the electro-hydraulic convertor is oil free, the motor losses magnetic, if the electro-hydraulic convertor is proportional valve, it losses power.

Warning: under mechanically manual condition, guide vane opening is controlled by open ring; if guide vane opening floats, kept guide vane only can be realized via manual adgjustment. 13.5.12.3 automatic operation switching into electrically manual operation 1// Guide vane switch handle (mechanical manual/automatic/electrically manual )operation into manual one, the touched display State form interface will show guide vane manual operation. And it shall be no disturbance in switchover. 2
170

Under automatically manual condition, to increase/decrease guide vane opening via opening increase/decrease handle on the governor panel or remote increase/decrease order to increase/decrease the guide vane opeing.

Warning: under electrically manual condition, it is move with constant opening and unit speed can not be adjusted automatically. 13.5.12.4 electrically manual switching into automatic 1To check whether electrical part works normally, and balance meter is balanced. 2// If electrical part works normally and balance meter is balanced, Guide vane switch handle (mechanical manual/automatic/electrically manual) operation into automatic one, the touched display State form interface will show guide vane automatic operation. And it shall be no disturbance in switchover. 13.5.13 The operation of the Runner blades is same as the guide vane 13.5.14 Emergent stop

,.

Dangerous: the unit is under operation and do not operate emergency stop button. (1) The emergent stop is only used when emergent event happens. (2) 0% By sending

171

emergent stop command, the emergent stop solenoid begins to move, rapidly close guide vane to 0%; can be realized. And emergent stop also can be realized by manually operating solenoid valve throw-in if electrical control failure. (3) After fault processing, the solenoid emergent stop can be reset via reset command or manual operation.

13.5.15 Power Operation

Be careful

PC
PC PC PC

If the governor operating terminal is industrial PC, when closing it, it

shall be closed first and only can be closed when it shows it is safe to close and then cut the AC & DC stwichgear.

If

the governor operating terminal is LED, cut directly.

AC & DC stwichgear can be

PC PC PCClose the power of Governor cubicle after closure of panel PC which can be shutted down with safe closing permission, then cut A/C and D/C.

13.5.16 Lubricate Oil-free Electro-hydraulic Transducer Lubricate (with steam-turbine oil) oil-free electr-hydraulic converter every two months. Be careful Do not come to the oil hole so deep when putting on oil in order to avoid any ball bearing bar damage.
172

 Chapter XIV oil pump system

14.1 General Description PLC ,, The oil pump system with programe controller from Siemens, electric product from Schneider, and various high quality components is automatic, simple and multi-functional. Those configured original programs, detailed principle diagrams, wiring diagrams are convenient for use and maintenance. The system functions and characters are as below: PLC PLC PLC oil pump control system adopts high reliable pressure transducer and high efficient dynamic control part as performance component to form a complete set of pressure control system via PLC automatic sampling control. The arrangement of the operating panel is as following emergency stop button fault rest button abnormality indicator of oil pressure and other status indication 1 2 selection switchgear(selection switchgear for unit No.1 & unit2 selection switchgear for air replenish) Manual, switchover and automatic methods The control panel is with proper arrangement and clear wiring of components, easy to be installed and maintained.

173

 Outlets for dynamic cable and control cable made at the end of the control panel. The dynamic power cables with different power supplies are to be connected with the inlet terminal of the oil pump cabinet.The dynamic power cable connected with motor is to be directly connected with the outlet terminal of oil pump cabinet. Each oil pump has individual breaker

Main functions 1 Automatically selecting operative/standby machine It can automatically set one machine as operating one and the other as standby. The two oil pumps can switch over by times of startup automatically. Once the working machine faults, the standby will work. 2) Automatic way Select automatic way and then the oil pump will be started up automatically in terms of the set oil pressure. 3 Manual startup The oil pump will directly stamp by choosing manual operation. 4 Switchover function: the oil pump will be switched off if this function is selected. 5 Fault alarm function
174

 When the system tests any fault, the indicator on the panel will be on and the fault signal, transmitted by empty node, will be sent to the upper computer. oil pump fault abnormal oil pressure in the tank dynamic and control power supplies faults PLC PLC fault 6 At site emergency case, the machine can stop manually or by pressing the emergency stop button. 7 Overcurrent and overheating protection functions of motor : when the motor is overcurrent or overheating , the breaker will automatically act to stop the pump , or via soft starter , thermorelay protect to shutdown the units. 8 Selective switchgear quantity control and simulation control. 9 Selective automatic air admission control .

14.2 Installation and hardware configuration of oil pump system 14.2.1 Mechanical installation warning

175

 The equipment shall be reliable earthing. Only qualified people who meet the manuals requirements can do the installation in order to guarantee safety of both operation and human. Common safety and regional regulations as well as rules of correct usage of tools and individual protections when using the equipment with voltage. The dynamic part may also be dangerous with voltage at non-work condition. Please check first before using and hang warning plate.

176

14.2.2 Conditions Notes: 5% +40-524h +35 2000m +40 50% (+20 90%) The gradient with the vertical section when installing shall not more than 5%. Temperature: the temperature around shall be not higher than +40 and lower than -5, and the average temperature during 24 hours shall be not more than +35. Height: for inside use purpose and the elevation of place shall not be higher than 2000m. Humidity: the relative humidity around shall be not more than 50% when the highest temperature is +40 and higher humid is allowed if the temperature is lower, for example, the humidity can be 90% when the temperature is +20 under which condition, the influence of condensing dew formation due to the temperature variation shall be take in to consideration. Bump: the cabinet shall be protected from any bump. Vibration: the equipment shall be equipped at the place without violated vibration and impaction. Pollution: the equipment shall not be equipped at area with conductive dust and corrosive gas. The customer can negotiate with the supplier if any special requirements.

177

14.2.3 Electric installation warning To make sure that the equipment is to be installed on the metal with fire protection function. To make sure that the power given motor is configured with power voltage and dynamic power and control power can be distinguished properly. To make sure that there is no power during installation and wire connection. Please do not change the wiring when it is power on. Otherwise an electric shock or human damage may happen. It shall not be equipped at the atmosphere with explosive gas otherwise an explosion may happen. 14.2.3.1 Main control circuit + The main control circuit adopts French Schneider air switchgear and soft starter or contactor plus thermorelay. 14.2.3.3 Power supply 380V 50Hz 24V Dynamic power supply adopts three phases AC 380V50Hz, while power for indicator and relay output is DC 24V. 14.2.3.4 Panel arrangement There are switchover switchgear emergency stop button oil pressure abnormality and status indicatorfault rest button.
178

14.2.3.5 There are several relays and several peripheral wiring terminals.

14.3 Control principle diagram of oil pump system S7-200 PLC PLC / / / PLC Using Siemens S7-200 series PLC as its core, this control equipment has three statuses: automatic, excise and manual. Under automatic condition, PLC will automatically control oil pump startup/ stop, switchover of main/backup oil pump, malfunction disposal and up-computer communication etc according to the oil pressure in the tank; under manual condition, corresponding oil pump will be started directly; under switchover condition, corresponding oil pump will stop directly; thus manual startup and stop can be realized. Other type of PLC can be selected if required by the customer. Oil pump control system diagram is as following:
LC U

R S 4 85 /R S2 32

1#

1# 2

179

C om p u te r m o nito rin g s ys te m u n it s ite LC U

R S 4 8 5 /R S 2 3 2 c o m m u n ic a tio n

P re s su re s ig na l

P LC o il pum p co n tro l un it

A ir re p o en ish d evice D yn a m i c power

D yn am ic power

b re ak e r

b re a k e r

N o .1 c o n ta c t N o .1 o il p um p

N o .2 c o n ta c t N o .2 oil p um p

O il p um p co n tro l sys te m dia g ram

14.4 Operation description of oil pump system

PLC It is every easy to operate the oil pump by automatic, excise or manual. At the same time, the system has perfect fault alarm, protection and status display functions.

14.4.1 Oil pump automatic way PLC 1 2 Under normal working condition, selecting automatic switch, the system will check its pressure to automatically control the shutdown and startup of the oil

180

pump. If the pressure is equal or less than that of normal startup, the unit will automatically start; if it reaches the rated value, it will automatically stop. ,/ / If the pressure is lower than that of backup pump startup, then main/backup pump will be put into operation and the pressure will increase to the normal pump stop pressure. Thus main/backup pump stops. If the system pressure is lower than that of the minimum low value, the working and standby units will start simultaneously and only stop until the pressure reaching the rated value. And it will alarm by signal simultaneously. PLC If the system pressure is higher than that of normal stop, no unit stop but continuous oil stamp, PLC will control air switch or breaker to act , and the pump will stop when the system pressure is over high. 1 2 No.1 and No.2 units can automatically switch over. Under automatic condition, given times startup of each unit will realize one switchover between main and standby units.

14.4.2

OiI pump manual way

The pump will be started promptly when the oil pump switch is at manual operation . 14.4.3 Oil pump Switchover way

181

 Manual stop of the pump will be realized once selecting switchover. And the exit function can be realized when it is changed from automatic to switchover position. 14.4.4 supplys air control Air admission control is selective functions. There are air admission way selective switch on the operating panel , automation , excise and manual operating can be choosen. PLC When on automatic operation , the PLC supplys air automaticly. When the system inspect the oil level reach the air supply level and the

pressure of the system do not reach the pressure pump stop , the air supply valves acts ,the pump start to supply air ,when the pressure of oil tank reach the normal pressure that pump stop,stop supplying. When suppling air , the pump dont need to start , until the oil level of tank reach the rated oil level ,the pump stop supplying air, to make the oil level and pressure restore normal . ( matching) :

Warning:manual operation , huaman inspection needed.

When air admission switch is on manual operation, air admission solenoid valve acts , the pump starts to supply air , it needs to inspect pressure ane oil level by human.(matching)
182

 When air admission selective switch is on excising operation ,air admission solenoid valve close , the pump stop supplying air . when the liquid level is abnormal , operating air admission valve and emputying valve by manual to adjust liquid level by human attempt.

14.4.5 Emergency stop If any emergency event happens, the system will stop immediately and send emergency stop signal via pushing emergency stop button. If emergency stop reverting needed, please reverting the emergency stop button and press the oil pump reverting button, thus the emergency stop release. 14.4.6 Display The status is displayed. //// // Status indication: No.1 pump running, No.2 pump running, No.1 pump automatic /switchgear/ manual, No.2 pump automatic /switchgear/ manual, No.1 pump main/backup status, No.2 pump main/backup status etc. Malfunction indication: No.1 pump malfunction, No.2 pump malfunction, oil pressure abnormal, oil level abnormal,power disappear, power disappear etc.

Button in the panel:

183

 emergency stop button oil pump rset

14.5 Commissioning and maintenance of oil pump system 14.5.1 System commissioning Appearance check

Before electricity connection, to check whether any abnormality of component, thread brushing off or abrasion; if any, replacement or other measures shall be taken. Power supply check 380V24V +24V Before electricity, to check three-phrase AC 380V24V. After confirmation, to break all air switches and check the dynamic power and control power by supplying the power; if both of them are normal, to check the +24V by combining the air switch. Setting value at site PLC To set oil pressure and level values according to requirements at site (backup

184

pump startup oil pressure, main pump startup oil pressure, pump stop pressure, high oil pump, low oil pump, emergency low oil pressure). If the simulation quantity control needs to set the following values on the screen (please see the Terminal Operation Instruction for details.): Pressure sampling over-high value, pressure sampling over-low value, pressure sampling max value, pressure sampling zero position value, pressure transforming trip, simulation quantity under-low oil pressure, simulation backup pump startup pressure, simulation quantity main pump startup pressure, simulation pump stop pressure, simulation Over-top pressure, times of oil pump transmigration. If the soft starter adopted , parameters of sofr starter need to be set.

System online commissioning After site wiring, to simulate various signals, check whether all indicators, signals sent to central control room or pump startup is normal. 1 Check hardware state : after electrifying ,checking if the hardware working state , position , panel indicator is normal . 2// Manual / automatic switchover operating startup/shutdown pump , inspecting if the revolve of oil pump is correct , the action of relay , panel indicator is normal . 3 , Checking if the oil pump automatic working way and active /standby pump

switchover is normal. 4 Manual Checking if Manual air admission is normal . 5 Checking if automaticly air admission is
185

normal .

6 simulation is normal.

Checking Other different kind faults test

14.5.2 System maintenance Oil pump fault There are following pump faults 1 overflow fault When the motor is blocked or overload, overflow fault alarms. Please check the motor and oil pump to whether they are normal or not. 2 Oil pump fault The oil pump fault alarm happens if oil pressure or level is not going to increase while the motor is rotating. Please stop the pump and check it and load-off valve. Abnormal oil pressure malfunction Both over-high pressure and over-low pressure are abnormal. Under this condition, all pumps shall stop ( started); if they do not stop (started), please check Controlling wirings of corresponding pumps. And checking if the inspecting components is normal . Control power supply fault 1PLC PLC malfunction PLC PLC malfunction may be caused by 1PLC PLC PLC PLC damage which makes PLC non-performance 2PLC PLC PLC internal test error pressure

186

3 PLC Bad contact or damage of the malfunction relay may also brings PLC fault alarm. 2Power supply fault The power supply faults are consisted of power supply fault and control supply fault. 1Dynamic power supply fault If any dynamic power supply circuit fault happens, the system will send dynamic power disappearance and the light of dynamic power monitoring relay is off. I II And reasons may be as following: wire breaking or phase lack of three-phase AC power supply; disappearance of one circuit of circuits I & II dynamic power supply, bad contact or damage of the malfunction relay. 2 Control power supply fault I II I II The control power supply selects until No.1 dynamic power supply phase 1,No.2 dynamic power supply phase 1 and DC. And they are backup for each other; if control power supply fails, please check whether No.1 and No.2 three phases dynamic power supply and DC , and center wire are normal.

14.6 Maintenance of oil pump system Periodic check

PLC 35
187

It shall be no consumable part which can shorten the lifetime in the PLC. However, the battery of the storage shall be replaced periodically every 3-5 years. Please purchase the quality reliable battery since it has natural discharge problem. Besides, considering the check of other related equipment, please pay attention to the following items: 1 To check whether the temperature in the unit is extremely high is due to other heater or direct solar irradiation. 2 To check whether any dust or conductive ash drops. 3 To check whether wiring or terminal is fixed or any other abnormality. The following periodic maintenance is suggested. 1 To check the hardware connection and fix statuses. 2 To make sure that the temperature around is under acceptable level. 3 To remove all ash and conductive dust on the radiator (if any).

Battery replacement

PLC When PLC battery voltage decrease ,the battery is in effective within one month accounting from the warning the battery that the voltage underlow when the power Is on . IF slow ,please change the battery to avoid parameter and programe lost when the power is off.
188

 The following items shall be noticed when replacing the battery: 1To close PLC power. 2To remove the cover while holding by fingers. 3To take out the old battery and draw the socket 4 20 To plug the socket of the new battery in 20s after the drawing of the old one. 5To close the cover after inserting the new battery on the battery frame.

189