DEH control system overview 71.D195-01E调节保安系统说明-英文

A 2020.03.
30 TURBINE I&C SYSTEM MANUAL 魏远满灿迟鼎南

Document No.:71.D195-01E
PROLEGOMENON
1.This is an all-purpose manual, which can be applied to typical steam
turbines, if some of the contents and data may conflict with transmitted
drawings, the drawings shall be taken as authentic.
2.The transmitted drawings are not included in the manual due to their
print limitation, therefore, readers should refer to some transmitted
drawings if necessary.
3.The original manual is made of a leaflet book and bound up, each of
which is unattached, but the contents connected each other.
4.If readers find inconsistencies, please contact with Shanghai Turbine
in order to revise and clarify them.
This document contains proprietary information owned by Shanghai Electric Group Co., Ltd. and
its subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use
otherwise without written consent.
Table of Units Conversion
Factor of
Units Used Transformation Units Available
Length millimeter (mm) 25.4 inch(in)
1.00E-03 liter(L)
Volume cubic meter ( m 3 ) 4.55E-03 gallon(UKgal)

3.79E-03 gallon(USgal)
1.00E+03 tonne(t)
Weight kilogram(kg)
0.45359 pound(LB)
1.00E-01 bar(bar)
1.00E-03 kilopascal(kPa)
9.80E-06 millimeter of water ( mmH 2 O )
Pressure Mega Pascal(Mpa)

1.33E-04 millimeter of mercury (mmHg)
6.90E-03 pound per square inch (psi)
0.101325 standard atmosphere (atm)
0.0981 engineering atmosphere (at)
Energy joule (J) 4186.8 kilocalorie (kcal)
Power watt (W) 746 horsepower
Force Newton(N) 4.45 pound force(lbf)

Note: G (Acceleration of gravity) = 9.8 m / s 2
(Units Used) × (Factor of Transformation) ＝ (Units Available)
This document contains proprietary information owned by Shanghai Electric Group Co.,
Ltd. and its subsidiaries. Use this document solely for the purpose given. Do not reproduce,
disclose or use otherwise without written consent.
CONTENT
Chapter1. Control System Overview............................................................................. 1

Chapter2. DEH Graphic And Operation Specification.................................................... 8
Chapter3. Automatic Startup Control for Steam Turbine and Auxiliary 20
systems...........
Chapter4. Emergency trip system................................................................................. 77
Chapter5. Servomotor Specification............................................................................. 88
Chapter6. Fire-resistant Hydraulic Oil System Operation and Maintenance................. 94
Chapter7. EH system specification................................................................................ 121
Chapter8. Oil Flushing Instructions............................................................................... 130
This document contains proprietary information owned by Shanghai Electric Group Co., Ltd. and its
subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use
otherwise without written consent.
Prepared：Man Can 2020.04
Control System
2020.04
Overview Checked：Wei Yuan
Reviewed：Li Gang 2020.04
IC.Z10.60001.01-E00 Reviewed：
Approved：Chidingnan 2020.04
CONTENTS
CONTROL SYSTEM OVERVIEW ..................................................................1
1. DEH Control System Overview ......................................................................1
2. Task and Function: ..........................................................................................1
2.1 Load Controller ........................................................................................1
2.2 Speed Controller.......................................................................................2
2.3 Frequency Support...................................................................................3
2.4 Pressure Controller ..................................................................................3
2.5 Valve Position Controller.........................................................................3
2.6 Start-Up Device ........................................................................................4
2.7 Turbine Stress Evaluator(TSE) ...............................................................4
2.8 Turbine And Auxiliary System Auto Startup Control ..........................5
The Whole Book : Page 1 of 152

IC.Z10.60001.01-E00 Page 1 of 6
CONTROL SYSTEM OVERVIEW
1. DEH Control System Overview
Turbine speed and load are determined by adjusting the position of emergency stop
valve and control valve. DEH send the valve position signal to servo electro-hydraulic
actuator, then control the steam intake by servo electro-hydraulic actuator. DEH
receive the feedback signal (speed, load, main steam pressure and so on.) and operator
command, then derive the flow rate to servo electro-hydraulic actuator. DEH is
mainly consist of DEH cabinet, human machine interface, servo electro-hydraulic
actuator and so on.
2. Task and Function:
The digital Steam Turbine Controller (STC) regulates the steam flow that is passed
through the control valves to the turbine. Depending on the operational requirements,
the steam turbine can be operated under speed, load, or pressure control.
2.1 Load Controller
The load controller controls the turbine load with the allowable variable load
gradient. The maximum variable load factor depends not only on the boiler's capacity,
but also on the turbine thermal stress evaluator (TSE). Turbine control valves are
throttled by the pressure limit controller when boiler fault or the frequently load
change, thus main steam pressure surges.
The load can be set either manually by the operator using the manual setpoint, or
automatically by an external setpoint issued by a superordinate unit coordinator or a
load dispatch controller. In order to improve the dynamic stability, an adjustable
proportion of the load setpoint is directly carried to the output of the load controller.
The function of the load controller is:
Switch from pressure limit mode to initial pressure control mode
During intercepting over speed excursions upon load rejections.
During load operation, synchronize grid frequency by adjusting frequency/load


IC.Z10.60001.01-E00 Page 2 of 6
static.
In order to meet the grid requirement, Turbine will be Parallel-operate dynamically

and steadily on load Island (separate with grid).
2.2 Speed Controller
As long as the generator is isolated from the grid, the controller acts as a speed
controller. With the synchronization being performed, i.e. main breaker ON (MBO),
the parameters are switched over and the controller becomes a load controller.
If, during start-up, the acceleration of the turbine generator tends to become too low
in the critical speed ranges, the speed-gradient monitoring will respond, and
automatically return the turbine generator to a lower holding speed (warm-up speed).
An automatic synchronizer automatically matches the turbine speed with the grid
frequency(The synchronizer is not part of the turbine generator I&C scope of supply).
The speed controller acts as a P-controller
In load operation above a minimum level, the speed setpoint is automatically

returned to the nominal speed so as to be able to control the turbine to exactly this
speed when load is rejected.
During the shutdown of the turbine generator, the load setpoint is switched off
when the generator is separated from the grid, and the control returns automatically to
P-speed control.
While the unit is carrying load, it is possible to switch from load control operation
to speed control operation. The corresponding set points are tracked automatically
according to the actual values to ensure a bumpless transfer.
Speed Control is active on these following situations:
During start up of the turbine starting off from turning speed.
During synchronization.

IC.Z10.60001.01-E00 Page 3 of 6
During shutdown of the turbine with separation of the generator from the grid.
2.3 Frequency Support
The grid frequency affects the STC in two ways.
The limit frequency influence: The limit frequency influence ensures that the
turbine generator remains frequency-controlled within a predefined dead band when
operating in a grid with a varying frequency (e.g. island grid). The limit frequency
influence is always effective and cannot be deactivated.
The frequency influence is to support the grid frequency. If the grid frequency is
too low, the power generated is increased. If the grid frequency is too high, the power
generated is reduced. The frequency influence can be activated and deactivated by the
OM system.
2.4 Pressure Controller
The pressure controller can operate in two operational modes:
(1)Limit Pressure Mode
The limit pressure mode is actived in load operation. The limit pressure controller
itself acts as a limit controller; it supports the boiler pressure control during
fault-related HP pressure drops. If the HP pressure falls below an adjustable limit
value, e.g. 10 bar below the nominal operating pressure, the turbine control valves
will throttle to counteract any further HP pressure reduction. In this way, the pressure
will recover to nominal as quickly as possible.
(2)Initial Pressure Mode
When switching over from limit pressure mode to initial pressure mode, the speed /
load controller is replaced by the pressure controller. In initial pressure mode, the HP
pressure is maintained at a specified value by the turbine control valves. load changes
in the steam generator will result in corresponding changes of the valve position.
2.5 Valve Position Controller
A proportional acting controller is assigned to each turbine control valve. To

improve the control dynamics, these position controllers are subordinate to the master

IC.Z10.60001.01-E00 Page 4 of 6
controllers. A correction of the valve characteristic is provided for each control valve;
this correction converts the admission demand (steam flow) from the master
controllers to valve position signals (valve lift). The controlled variable is the valve
position that is measured in the EHA and serves as feedback for the valve position
controller. The controller modulates the valve position of the allocated control valve
within its control range in accordance with the position setpoint. If the actual valve
position measurement becomes defective, the corresponding control valve will be
caused to close slowly.
(1)Valve Position Limitation
A valve position setpoint limitation is provided for each valve position controller.
This permits the position of each control valve to be changed individually within the
range below its setpoint. This can be by manual intervention from the control room or
by intervention from the automatic turbine tester (ATT) in conjunction with the valve
testing.
2.6 Start-Up Device
The start-up device provides an analog signal to gate in a MIN selection function
with the outputs from the speed/load controller and main steam pressure controller.
before turbine start-up.
While the turbine is being started-up, the position of the start-up device is raised.
This in turn causes the speed controller to assume the control. When the turbine has
reached its nominal speed and the generator has been synchronized, the start-up
device will be placed in its 100% position, so that the master controller signals will no
longer be limited.
2.7 Turbine Stress Evaluator(TSE)
Turbine stress evaluation serves to prevent the thick-walled components of the

turbine (casing, valve bodies and shafts) from being subjected to excessive thermal
stresses as a result of steam temperature changes.
The turbine stress evaluator (TSE) functions are calculating and monitoring the
operational heat stresses of the turbine during every operational phase. The TSE

IC.Z10.60001.01-E00 Page 5 of 6
determines the thermic stresses of representative turbine components and uses the
temperature differences, which are a measure for the thermic stresses, and the
comparison with the permissible values to calculate the temperature margins. This so
achieves a continuous optimization between material stresses on the turbine and the
largest possible flexibility in being able to react to operational changes. All measured
temperatures and calculated temperature margins are indicated and recorded.
When the temperature margin of a component becomes a negative value, the

material is overstressed, the turbine startup or load change would not be allowed.
Following channels will be monitored: HP emergency stop valve casing, HP control

valve casing, HP casing, HP shaft, IP shaft.
2.8 Turbine And Auxiliary System Auto Startup Control
The steam turbine can be started up safely and within an optimum time with the aid
of an automatic startup system. This meets economic requirements which prescribe
the shortest possible startup time and high plant availability.
The task of the turbine master control program is to bring the turbine and all the
auxiliary systems required for startup into a state which allows safe and reliable
transition of the steam turbine from the shutdown state to power operation.
The turbine master control program comprises the following submodules:
1.The auxiliary system auto startup contains these following system
(1) Turbine lube oil system
(2) Turbine seal system
(3) Control fluid supply for turbine valves and brings the steam turbine and the
bypass system into a state which allows turning gear operation of the steam turbine
and bypass operation.
2.Automatic startup control for turbine-generator
After the auxiliary systems have been started up and brought into a steady state,
which can either be achieved using "Automatic startup control for auxiliary systems"
or by starting the auxiliary systems manually, the "Automatic startup control for

IC.Z10.60001.01-E00 Page 6 of 6
turbine-generator" transfers the steam turbine from turning gear operation to power
operation.
After Turbine changed over to load operation, the auto startup procedure is
completed.
The automatic SHUTDOWN program brings the turbine-generator from power

operation or initial pressure mode to a defined state in which the turbine valves are
completely closed. In the course of this, it also takes all the actions required to allow
the turbine to coast down to turning gear operation.
The automatic startup includes the sequence program from turbine warm up to load
on the grid. During shutdown process, the program gives the set up speed and
determines the rate of speed and load based on the calculated thermal stresses of the
valve, casing and shaft.
Meanwhile, during the process of startup and shutdown, the turbine master control
program controls the drain valve, HP exhaust none return valve, HP non-return valve,
LP water injection system and seal steam system by turbine operation status.

DEH Graphic And
2020.04.
Operation Specification Checked：Wei Yuan
Approved：Chi Dingnan 2020.04
CONTENTS
DEH GRAPHIC AND OPERATION SPECIFICATION ................................1
1. Turbine Controller ...........................................................................................1
1.1 Startup Automation..................................................................................2
1.2 SGC OPEN HP-TURB ............................................................................3
2. Turbine Auto Tester .........................................................................................4
2.1 ATT Test Considerations .........................................................................5
3. Warm Up Valves/TSE ......................................................................................5
4. Turbine Bearing VIB/TEMP...........................................................................7
5. Turbine Protection Signals ..............................................................................8
6. First Out ............................................................................................................9
7. Turbine Overview ......................................................................................... 10

IC.Z10.60104.01-E00 Page 1 of 11
DEH GRAPHIC AND OPERATION SPECIFICATION
1. Turbine Controller
Turbine controller graphic contains three primary modules: S / UP DEVICE, SPD / LOAD
CTRL and HP PRES CTRL. These modules are applied to generate the flow rate from three
calculation loops. The overall flow rate is derived by the low selector function. After modified by
both HP EXH TEMP CTRL and HP BLAD PRES CTRL functions, the POSN LIMIT function
separate the final overall flow rate to 5 independent branches. Each dominates the corresponding
valve position.
TAB acts on the turbine start-up phase only. The command output value (0~100%) is
calculated automatically. When TAB value reaches a certain limit, it stops changing and waits for
essential action. After receiving a valid feedback, TAB keeps working again. Under some special
conditions, TAB is able to switch to manual input to modify the overall flow rate value. TAB is
primly used for equipment reset, inspection and so on.
SPEED SETP configure is used to set turbine speed, the value can be generated by closed-loop
controller while turbine start-up. After warm-up phase the operator should confirm to ramp up
turbine speed to nominal synchronize speed. Operators are able to input the target speed value
only if the speed set point manual function is unlocked.
Notes:
Nominal turning gear speed: 50-60 rev/min
Nominal warm up speed: 360 rev/min
Nominal synchronize speed: 3009 rev/min
The turbine speed (ST SPEED) ramps up to the target speed at a rate limited which determined
by the TSE. TSE INFL function requires to be active manually before starting-up process. If this
function fails to work, the start-up procedure is forbidden while TSE fault shows up. When the
deviation of speed set point and the actual speed is too high, the set point function (STOP) is
locked, and the set value decrease automatically. If the acceleration is too low (ACCL <MIN),
the speed tracking mode is on. The target speed is going to decrease at the rate of 60r / min until
the manual reset (RELS SETP-CTRL).
LOAD SETP configuration is to set the turbine load, the initial value is automatically
generated as minimum set value after synchronization (the initial load is generally 15% of the
nominal load, which can also be modified in logic diagram). During load ramping up, the LOAD
GRAD SETP is affected by both TSE and manual input. When EXT LOAD SP mode is ON, the
subsidiaries. Use this document solely for the purpose given. Do not reproduce, disclose or use otherwise
Thewritten
without Whole consent.
Book : Page 9 of 152
IC.Z10.60104.01-E00 Page 2 of 11
target load value receive the CCS external load communication (EXTERN LOAD SETP). The
delayed load set value is also adjust by maximum load set point (MAX LOAD SETP).
The SPD/LOAD CTRL derive the overall flow rate by input the deviation of actual speed and
speed set point or the actual load and load set point. Once the primary frequency modulation
function (FREQU INFL) is active by the operator, the according value is displayed up on the
button.
DEH receives pressure set point (HP SETP) from DCS and controlls the main steam pressure.
The LIMIT PRES mode and the INITIAL PRES mode are selected by the operator. During the
start-up process, it should be in the limited pressure mode; after turbine on load, due to pressure
fluctuation at the moment of bypass shutting down, HP SETP should be switch to the INITIAL
PRES mode. Deviation of the actual pressure value and the pressure set point is sent to the
pressure controller for closed-loop operation. When the deviation is greater than 15 bar which is
regard as the critical value, the turbine switch to pressure control from load control.
1.1 Startup Automation

When it is ready to start up, the operator starts the SGC TURBINE function or accepts the
start-up command from CCS. The main start-up sequence has 35 steps which contain the
operation check before the start-up procedure, open/shutdown the valve, on load inspection and
so on. (For more details, see related logic instructions).
Attention during start-up process:
Thewritten
IC.Z10.60104.01-E00 Page 3 of 11
When the steam quality meet the requirement, the operator confirms and starts STM PURITY
function at SGC step 11. If the steam quality does not satisfy the requirement in step 11 and 50%
of HP CV temperature is lower than 350 Celsius degrees, the start-up sequence pauses till decent
steam quality, then skip back to step 11.
After turbine warm-up phase, the operator should set the nominal speed by active REL
NOMINAL SPEED function; the latch procedure (RESET O / S TRIP) is automatically
completed by TAB. The high-temperature controller and high-pressure blade controller is active
automatically.
The valve position limit is set manually, the range is from -5% to 105%, operators set the
value for all valves as 105% before start-up process;
As long as the high-exhaust temperature hits the limit value, the high-pressure cylinder stops
taking in more steam. When the load is more than 100MW and the high-pressure exhaust
temperature drops to nominal value, SGC OPEN HP-TURB is active. If the temperature
continues to rise to trip value, the unit shuts down.
1.2 SGC OPEN HP-TURB

When high-pressure cylinder blade temperature (MAA50CT115 / 116/117) is too high during
operation, the high-temperature controller is active to modulate the valve positions. Turn down
IP CVs and turn up HP CVs at the same time to increase high-pressure cylinder cooling steam
flow. If the high-exhaust temperature continues raising, these actions are taken, HP ESVs and HP
CVs are closed. The high-pressure exhaust valve opens to vacuumize the HP cylinder, stop the
HP cylinder steam inlet, IP cylinder is the only one to take in the steam.
When the high-pressure cylinder blade temperature rolls back to nominal operation value at
100MW or higher load, SGC OPEN HP-TURB automatically activates, HP ESVs and HP CVs
open again, the system is normal.
In addition, if the turbine is tripped after the high-pressure cylinder is cut off, this sequence
control is also activated to reset the system.
Indicator light units display on the graph, green represents “not activated”, red represents
“active”.
The list of abbreviations appeared in this graphic:
ON LOAD
TRIPPED
LAW_KU
Thewritten
IC.Z10.60104.01-E00 Page 4 of 11
LAW_GPLSPQU
CONTORLLER NOT OK
HATRIE
NTRIE
PRIE
FDPRIE
TABIE
STPSWF
SPSWF
HBDRIE
WTS
NTGRKL
NSNF
DNTGR
DCS REQ INET MODE
DCS REQ REMOTE LOAD CTRL
2. Turbine Auto Tester

There are seven groups of steam turbine valve test (ATT), including the left HP ESV and HP
CV MAA1, the right HP ESV and HP CV MAA2, the left IP ESV and IP CV MAB1, the right IP
ESV and IP CV MAB2, OLV, high-pressure exhaust check valve, high-pressure ventilation valve.
When a set of ATT tests need to be carry on, the corresponding ATT SLC should be active. After
the test finishes, the feedback signal “test ok” pops up. If any set of the ATT fails, the ATT SLC
is reset automatically.
Take the HP ESV and HP CV ATT test as an example. When the set of HP valves test is caring
on, the corresponding HP CV is closed, at the same time, the other side of the HP CV turns up.
When the tested HP CV is completely closed, HP ESV solenoid and valves activity test are able
to carry out. Two solenoid are respectively deenergize once to close the corresponding valve
twice. After receiving successful feedback of the test, the corresponding ATT test is completed.
The OLV, high pressure exhaust check valve and the ventilation valve should be tested by the
same method.
ESV LEAKAGE TEST and CV LEAKAGE TEST buttons on the screen are used to
active/inactive the corresponding SLC.
Thewritten
IC.Z10.60104.01-E00 Page 5 of 11
2.1 ATT Test Considerations

1. It is not recommended to use the high-pressure check valve SLC due to feedback
calibration.
2. It is recommended to carry on the test at below 80% of the rated load, whitch depends on
the circumstances.
3. Before the ATT test, please ensure that the valve is not fully opened. For initial pressure
mode unit, when the parameters are low enough and the valve is fully opened. In this case, our
company recommend to carry on ATT test on pressure limit mode to ensure the stability of the
load;
4. During ATT test, if any of CV cannot be opened, also the EH oil pressure drops at this
moment, please set valve position limit to 0% to avoid trip. Pay attention to the EH oil pressure
when ATT is carried on;
5. It is recommended to monitor EHC tank by operator during ATT test. If any fast closing
solenoid valve malfunction, DEH program automatically takes measures to close the
electro-hydraulic servo valve, and also closes the corresponding oil supply valve. Oil tube should
be partitioned, then the malfunction parts are able to take into repair. While malfunction occurred
the operator should set position limit to 0% manually to avoid the damage of the oil actuator.
6. ATT test can be finished individually.
3. Warm Up Valves/TSE
Thewritten
IC.Z10.60104.01-E00 Page 6 of 11
Stress calculation and X criterion graphic is used to monitor the temperature of cylinder, rotor,
valve and other components of the steam turbine during start-up process. The way is to record
the deviation of the corresponding components temperature then derive thermal stress by
physical equation. The thermal stress should be maintained in an allowable range. Compare the
measured temperature difference and the allowable temperature difference to gain the allowable
temperature rise rate. All measured temperature and calculated temperature margin are indicated
and recorded, the temperature margin determines the speed rate of change and the load rate of
change. In the lower right corner of the screen, "TSE-MARGINS" influences the minimum stress
margin of five parts of the thermal stress, they are ESV, CV, high pressure cylinder, high pressure
rotor and medium pressure rotor. If any part of the calculated stress margin is not satisfied during
the start-up process, a negative stress occurs, then the fault alarm is triggered.
X-Criterion (X-CRIT), a variable temperature standard, is used to ensure that the main steam
and reheat steam parameters meet the requirements during the start-up process. As a condition of
turbine start-up, the program decides whether the unit can endure the thermal stress. The
X-Criterion is used to determine if the turbine start-up process is able to carry on. When the X
criterion is satisfied, the rectangle on the top of the bar turns "red" and "Green" indicates X
criterion unsatisfied. X1, X2 are used before opening the main steam door; X4, X5, X6 are used
before the steam turbine turned; X7A, X7B are used before the nominal speed released; X8 is
used before the unit synchronized.
This is the list of abbreviations appeared in this graphic:
MIN UPPER TEMP MARGIN
MIN LOWER TEMP MARGIN
HP ESV
HP CV
HP CSG
HPS
IPS
OPT HP ST TEMP
OPT IP ST TEMP
Z-CRIT
Thewritten
IC.Z10.60104.01-E00 Page 7 of 11
4. Turbine Bearing VIB/TEMP

Turbine bearing VIB/TEMP graphic is mainly used to monitor the vibration and temperature
of turbine and generator bearing. The absolute vibration protection strategy is two out of two,
bearing temperature protection strategy is two out of three, axial displacement protection strategy
is two out of three. The monitor of relative vibration, low pressure cylinder expansion, rotor
eccentric is applied for visual alarm. The relative vibration value is vector synthesis, and X, Y
vibration are measured by TSI. Specific bad qualities in the protection points can also lead to trip,
for example, the bad qualities of Channel 1 & 2 of absolute vibration trip the turbine.
AXIAL DISPLACEMENT
LP CASING EXPANSION
ROTOR ECCENTRICITY
GEN H2 TEMP
EXCIT WIND TEMP
CHANNEL NOT OK
ST/GEN ABS VIB
ST/GEN REL VIB
Thewritten
IC.Z10.60104.01-E00 Page 8 of 11
5. Turbine Protection Signals

The turbine protection signal graphic monitors the measuring points which are important for
safety operation. If any of the tripping conditions achieved, the electric power of shut-off
solenoid valves rapidly cut off by ETS, then the valves is mechanically closed for shutdown
protection. Green Square on the graph indicates normal status on, red indicates the trip action on.
When a critical analog point reaches the trip value, the frame flashes and the number turns red.
When a critical analog point reaches the warning value, the frame flashes and the number turns
yellow. All protection items adopts redundant configuration. Values in graphic are just for
reference.
BRG TEMP PROT ( 2OO3)
BRG PED ABS VIB ( 2OO2)
BOILER PROTECTION ( 2OO3)
SGC MS STEP54
STATOR CLG WTR FLW ( 2OO3)
CF TANK LEVEL LOW ( 2OO3)
FAIL SAFE FAULT
O/S PROT SYS 1ACT ( 2OO3)
O/S PROT SYS 2 ACT ( 2OO3)
MANUAL TRIP PB
Thewritten
IC.Z10.60104.01-E00 Page 9 of 11
GENERATOR UNIT ( 2OO3)
LUBE OIL TANK LEVEL ( 2OO3)
LUBE OIL PRESSURE ( 2OO3)
AXIAL DISPLACEMENT ( 2OO3)
TURB CONDR PRES 1( 2OO3)
TURB CONDR PRES 2( 2OO3)
FM458 FAULT
TEMP HP BLADING ( 2OO3)
GEN H2 TEMP A ( 2OO3)
GEN H2 TEMP B ( 2OO3)
EXCIT WIND TEMP ( 2OO3)
LP1 EXHAUST TEMP ( 2OO3)
LP2 EXHAUST TEMP ( 2OO3)
COND LEVEL( 2OO3)
STATOR INLET WTR TEMP ( 2OO3)
GEN LEAKAGE LEVEL A ( 2OO3)
GEN LEAKAGE LEVEL B ( 2OO3)
6. First Out
When trip occurs, the turbine first out graphic is used for instantaneously recording the first
Thewritten
IC.Z10.60104.01-E00 Page 10 of 11
protection point so as to analyze the trip reason. Green Square on the graph indicates normal
status on, red indicates the trip action on.
7. Turbine Overview
Turbine overview graphic is primarily used for monitoring the steam turbine valves status,
solenoid valve status and critical parameters value of the intake and exhaust. Each fast closing
solenoid adopt double redundant, charged latch, loss of power protection design. The direction
control valve losses power during operation. When it is charged, the EH oil rapidly flows to the
drain back tank. The green sign of the valve represents valve off-mode and the red sign of the
valve represents valve on-mode; Hydraulic servo-motor lacquer tray monitor (LEAKAGE)
Green indicates normal mode, red indicates alarm status. In the process of starting the steam
turbine, the solenoid valves are automatically latched by the TAB without manual work. Low
Pressure Cylinder Spray Solenoid Valves (CNDS) operate at low temperatures as a cooler. High
exhaust ventilation valve automatically opens after trip.
Thewritten
IC.Z10.60104.01-E00 Page 11 of 11
Thewritten
Automatic Startup
2020.04
Control For Steam
Turbine And Auxiliary Checked：Wei Yuan
Systems
CONTENTS
AUTOMATIC STARTUP CONTROL FOR STEAM TURBINE AND
AUXILIARY SYSTEMS ........................................................................................ 1
1. Introduction ..................................................................................................... 1
2. Variable Temperature Criteria for Warmup of Steam Turbine ................. 1
2.1 Criteria Effective Prior to Opening of HP Steam Emergency Stop Valves2
2.2 Criteria Effective Prior to Opening of HP & IP Steam Control Valves ... 2
2.3 Criteria Effective Prior to Acceleration to Rated Speed and for Loading
Following Synchronization/Clutch Engagement .............................................. 3
3. Design ............................................................................................................... 3
3.1 Subgroup Control Turbine ........................................................................... 3
3.1.1 Control Coordination & Signal Formation ............................................. 3
3.1.2 Automatic Startup of Steam Turbine (STPP) - STARTUP Step Program
............................................................................................................................. 16
Thewritten
Page M160 .......................................................................................................... 29
3.1.3 Automatic Steam Turbine Shutdown Control (STPP) - SHUTDOWN
Step Program ..................................................................................................... 47
Thewritten
IC.Z10.62102.01-E00 Page 1 of 55
AUTOMATIC STARTUP CONTROL FOR STEAM TURBINE AND

AUXILIARY SYSTEMS
1. Introduction
The steam turbine can be started up safely and within an optimum time with the aid of an
automatic startup system. This meets economic requirements which prescribe the shortest
possible startup time and high plant availability.
The task of the turbine master control program is to bring the turbine and all the auxiliary
systems required for startup into a state which allows safe and reliable transition of the steam
turbine from the shutdown state to power operation.
The turbine master control program comprises the following submodules:
(1) Automatic startup control for auxiliary systems:
This automatically starts up the following systems: Steam turbine turbine lube supply, Seal
steam system and evacuation pumps, Control fluid supply for turbine valves and bypass valves
and brings the steam turbine and the bypass system into a state which allows turning gear
operation of the steam turbine and bypass operation.
(2) Automatic startup control for turbine-generator
After the auxiliary systems have been started up and brought into a steady state, which can
either be achieved using "Automatic startup control for auxiliary systems" or by starting the
auxiliary systems manually, the "Automatic startup control for turbine-generator" transfers the
steam turbine from turning gear operation to power operation. The startup program is complete
as soon as the turbine controller has been changed over to load control. The automatic
SHUTDOWN program brings the turbine-generator from power operation or initial pressure
mode to a defined state in which the turbine valves are completely closed. In the course of this, it
also takes all the actions required to allow the turbine to coast down to turning gear operation.
2. Variable Temperature Criteria for Warmup of Steam Turbine

Mode changes such as roll off under steam, acceleration to warmup speed or rated speed and
likewise the turbine loading process impose loads on the turbine in the form of sudden changes
in steam pressure and steam mass flow. This gives rise to an increase in heat transfer. Criteria are
required which provide information as to whether the desired mode changes are permitted under
the existing operating conditions. The variable temperature criteria (X criteria) describe the
steam conditions which are required to allow the turbine to be started up in an optimum time
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without violation of the set wall temperature limits.
2.1 Criteria Effective Prior to Opening of HP Steam Emergency Stop Valves

Temperature criterion X1： ϑHP > ϑCTRL-V 50%+ X1
Task：To avoid inadmissible cooling of the HP steam valve bodies.
Measuring point：ϑMS - main steam temperature upstream of HP bypass station(s)

ϑCTRL-V 50% - temperature in control valve
Temperature criterion X2 ：ϑSATN STM < ϑCTRL-V 50%+ X2
Task: To avoid inadmissible loadings on the HP steam control valve as a result of a step
temperature increase in saturated steam.
Measuring point：ϑCTRL-V 50% - temperature in control valve

ϑSATN STM  is calculated from the main steam pressure
Note: The heat transfer levels are very high in the condensation phase. An upper limit is
defined for the saturated main steam temperature and consequently main steam pressure to
ensure that the permitted WT limits (thermal stress limits) for the HP steam control valve body
are not violated.
2.2 Criteria Effective Prior to Opening of HP & IP Steam Control Valves

Temperature criterion X4：ϑMS > ϑ SATN STM + X4
Task：HP turbine  To avoid the presence of wet steam in the final stages.
Measuring point：
ϑMS - main steam temperature directly upstream of HP steam valves
ϑ SATN STM  is calculated from the main steam pressure
Note: This temperature criterion ensures an adequate degree of superheat for the main steam
such as to rule out the presence of wet steam in the final stages on loading of the turbine.
Warmup of the main steam line is continued until such time as an adequate degree of superheat is
effective upstream of the HP steam valves. The degree of superheat is defined relative to main
steam pressure (variable temperature criterion X4) and takes into consideration the
mode-dependent throttling characteristics of the control valves.
Temperature criterion X5：ϑMS > ϑm HPS/HPT CSG+ X5
Task：HP turbine  To avoid cooling of the HP turbine casing/turbine shaft.
Measuring point:
ϑMS - main steam temperature directly upstream of the HP steam valves
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ϑm HPS is calculated within the TSE/TSC
ϑm HPT CSG  is measured and gated with ϑm HPS in a MAX logic
Note: The throttling effects in the HP control valve are taken into consideration.
Temperature criterion X6 ：ϑRH > ϑm IPTS+ X6
Task: IP turbine  To avoid cooling of the turbine shaft.
Measuring point:
ϑRH - Reheat temperature directly upstream of IP steam valves
ϑm HPS  is calculated within the TSE/TSC
Note: The throttling effects in the IP steam control valve are taken into consideration.
2.3 Criteria Effective Prior to Acceleration to Rated Speed and for Loading
Following Synchronization/Clutch Engagement
Temperature criterion X7 ：ϑMS < ϑm HPS+ X7a
ϑMS < ϑm HPT CSG+ X7b
Task: Adequate degree of heat soak for HP turbine shaft/casing
Measuring point:
ϑMS - main steam temperature upstream of HP bypass station(s)
ϑm HPS  is the calculated integral mean shaft temperature
ϑm HPT CSG  is measured
Note: The criterion is interrogated at warmup speed. It ensures that the permitted thermal
stress limits are not exhausted on acceleration to rated speed.
Temperature criterion X8： ϑRH < ϑm IPS+ X8
Task: Adequate degree of heat soak for IP turbine shaft
Measuring point:
ϑRH - reheat temperature upstream of IP bypass station(s)
ϑm IPS  is the calculated integral mean shaft temperature
Note: The criterion is interrogated at rated speed. It ensures that the permitted thermal stress
limits are not exhausted on synchronization and during subsequent loading.
3. Design
3.1 Subgroup Control Turbine
3.1.1 Control Coordination & Signal Formation

3.1.1.1 Logic 1: Control coordinator module
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Description of sheet L010
The turbine master control program forms the link to the unit control level. The "STARTUP"
and "SHUTDOWN" step programs are started by the unit control level and process the steps
described in Sections 3.1.2 "STARTUP Step Program" and 3.1.3 "SHUTDOWN Step Program".
Provision is made for manual starting of the step programs.
STARTUP step program.
The STARTUP step program obtains its enable signal from logic L040.
SHUTDOWN step program.
The SHUTDOWN program can also be started up by the protection input (logic L070).
3.1.1.2 Logic 2: Group Signal for Emergency Stop Valve (ESV) and Extraction Check Valve
(EXTN CHK-V) Position
Signal formation: ESVs open
This signal detects whether the turbine emergency stop valves are open.
Interrogation: at least one HP STM ESV OPEN.
Interrogation: at least one IP STM ESV OPEN.
Signal formation: All ESVs closed
This signal detects whether all turbine emergency stop valves are closed.
Interrogation: All HP STM ESVs CLOSED
Interrogation: All IP STM ESVs CLOSED
Signal formation: All extraction check valves closed
This signal detects whether all extraction check valves are closed.
Interrogation: Position of all extraction check valves < 5%.
3.1.1.3 Logic 3: Checkback Signals following Execution of Step Programs
Signal formation: Abort valve test
Command: ATT Valves ABORT
If a valve test is being performed by the automatic turbine tester, it must be aborted before the
SHUTDOWN step program can be executed. The checkback signal from the SHUTDOWN step
program is used for this purpose.
Checkback: SHUTDOWN step program RUNNING
Signal formation: Execute "STARTUP" step program
The "STARTUP" step program has been executed when
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(1) The last step of the sequence has been reached
(2) The steam turbine is in power operation. For this purpose, all the emergency stop valves
(ESV) must be open, the generator must be synchronized and the turbine controller must be
changed over from limit pressure mode to power operation.
Interrogations
Interrogation: Last step of "STARTUP" executed.
Interrogation: All ESVs open (logic L020).
Interrogation: Generator SYNCHRONIZED.
Interrogation: Turbine-generator at rated speed > 95%.
Interrogation: Turbine controller power operation IS ON.
Signal formation: Execute "SHUTDOWN" step program
The "SHUTDOWN" step program has been executed when
(1) The last step of the sequence has been reached.
(2) All the emergency stop valves are closed and the turbine-generator speed has fallen below
the critical speed band.
Interrogations
Interrogation: Last step of "SHUTDOWN" executed.
Interrogation: All ESVs closed (logic L020).
Interrogation: Turbine-generator speed < 9 rev/s.
3.1.1.4 Logic 4: Enable for "STARTUP" Step Program
Before the "STARTUP" step program is enabled, a check is performed to ensure that turbine
shutdown was performed as specified. This is the case if the admission controller output has been
reduced to 0%.
Signal formation: Enable for "STARTUP" step program
Interrogation: Valve opening limited by speed/load controller
The speed/load controller in the turbine controller limits valve opening by setting the
speed/load setpoint to 0%. This setpoint is set to this value for the turbine controller during
shutdown or in turning gear operation. It prevents unwanted opening of the CV when increasing
the the turbine startup and lift limiter later on (see logic 9).
Interrogation: Turbine controller speed/load setpoint =0%
Bypass criterion: Emergency stop valves are open
If the turbine master control program is restarted during operation, the emergency stop valves
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are open and the limit setting for the turbine startup and lift limiter is above 62%.
Interrogation: All ESVs open (logic L020)
Interrogation: TAB > 62%
Interrogation: TAB in operation, trip solenoid valves reset and ESVs closed
The "STARTUP" step program is enabled as soon as the trip solenoid valves have been reset
with the emergency stop valves still closed.
Interrogation: TAB < 35%
Bypass criterion: Emergency stop valves are open
Interrogation: All emergency stop valves open (logic L020)
Interrogation: Turbine trip not initiated
If a turbine trip has been initiated, the SHUTDOWN program is called up after the emergency
stop valves are closed. This brings the turbine-generator into a defined state.
When a turbine trip is initiated, the turbine startup and lift limiter (TAB) is not ramped down
in the usual way. Its limit setting is abruptly set to 0%.
Interrogation: TAB = 0%
Bypass criterion: Turbine-generator speed has entered the critical speed band
Interrogation: Turbine trip NOT INITIATED
Interrogation: Automatic valve test not running (automatic turbine tester)
If the automatic turbine tester is performing a valve test, it is not possible to execute the
"STARTUP" step program.
Interrogation: ATT Valves NOT IN OPERATION
Interrogation: Electrical unit protection unfaulted (optional)
Redundant auxiliary voltage supply to electrical unit protection from batteries present. This is
a prerequisite for proper operation of the electrical unit protection system.
Interrogation: Electrical unit protection UNFAULTED.
Interrogation: Exciter not disabled (optional)
Interrogation: Exciter NOT DISABLED
Interrogation: Paralleling unit not in operation (optional)
Interrogation: Paralleling unit NOT IN OPERATION
Interrogation: Synchronizer not disabled (optional)
Interrogation: Synchronizer NOT DISABLED
Interrogation: Grid tie breaker not selected (optional)
Interrogation: Grid tie breaker NOT SELECTED
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Interrogation: Pointer set for load controller
After the generator has been synchronized, a changeover to the load controller is effected.
Interrogation: Load controller ACTIVE
Interrogation: TSE/TSC influence on STC active
Interrogation: TSE/TSC influence on STC NOT OFF
3.1.1.5 Logic 5: Faults in Steam Generator and WT Sensor
Faults in the SG can give rise to steam parameter conflicts with criterion X4, degree of
superheat for the hot reheat steam and to an insufficient temperature margin. If a fault occurs
while the "STARTUP" step program is being executed, an appropriate alarm is displayed
provided the sequence has already opened the control valves and the turbine has been rolled off
under steam. (logic L060).
Signal formation: Steam generator fault
(1) Turbine-generator rolled off
Interrogation: Speed/load controller > 0.5 %
Interrogation: Speed setpoint defined > 6.5 rev/s
A steam generator fault is assumed in the following cases:
(2) Degree of superheat for the main steam, measured upstream of the HP steam emergency
stop valves (variable temperature criteria X4 - 15K) is too low.
Interrogation: MS superheat < X4 15K
(3) Degree of superheat for hot reheat steam is too low.
Interrogation: Hot reheat superheat upstream of IP STM ESVs (Z4 criterion) < 15K
(4) The turbine is heated on startup. Only limited initial cooling takes place during proper
operation of the plant. In any case, this will not exhaust the permitted limits for the inlet. If the
lower margin is exhausted, a steam generator-related drop in steam temperature can thus be
assumed.
Interrogation: Lower temperature margin (HP steam valve) < 0K
Signal formation: Fault due to closed HP STM ESV
An 80 s switch-on delay is defined for this criterion, so as to prevent deactivation of the SGC
in response to closure of ESVs when the automatic turbine tester is performing a valve test.
Interrogation: HP STM ESV CLOSED
Interrogation: HP STM ESV NOT OPEN
Enable: "STARTUP" step program running
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Interrogation: "STARTUP" step program running (see logic L010)
3.1.1.6 Logic 6: Stop Setpoint Control of Speed/Load Controller
If faults occur during automatic startup, the "STARTUP" step program is stopped (automatic
control "OFF"/manual operation).
Signal formation: Fault ⇒ "STARTUP" step program: Automatic control OFF
Command: "Automatic control OFF" for "STARTUP" step program (logic L010)
Interrogation: Monitoring of speed transient
The acceleration rate (speed transient) is monitored by the turbine controller in order to ensure
as rapid as possible passage through critical speed bands. If the monitoring circuit responds, the
startup process is aborted and the step program is set to "Automatic control OFF".
Interrogation: Speed transient TOO LOW
Interrogation: Logic L070 (shutdown due to protection) NOT ON
Interrogation: Faults in Steam Generator
Interrogation: Logic L050
Interrogation: Faults in turbine controller and TSE
Fault-free operation of the turbine controller are prerequisites for automatic operation of the
turbine-generator. The sequence is therefore set to "Automatic control OFF" when
(1) The turbine controller is faulted
(2) TSE NOT O.K.
(3) The stress assessment of the steam turbine does not respond to the response of the set value
control of the steam turbine controller.
Interrogation: The turbine controller NOT OK
Interrogation: Response of steam turbine stress assessment to control of set value of steam
turbine controller TURN OFF
Interrogation: X criterion NOT OK
Interrogation: Z criterion NOT OK
Signal formation: Fault ⇒ Stop speed/load setpoint (turbine controller)
If the turbine is at rated speed, speed/load setpoint control is stopped in the turbine controller.
The duration of this signal is limited to 2s.
Command: Speed/load setpoint STOP
Interrogation: Turbine at rated speed
Interrogation: Speed > 95%
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Interrogation: Reset criteria for command "Speed/load setpoint STOP"
The load setpoint is re-enabled by the following OR-gated signals.
Interrogation: "SHUTDOWN" step program LAST STEP EXECUTED
Interrogation: Reset signal from turbine controller (pushbutton) ENABLED
3.1.1.7 Logic 7: Initiate "SHUTDOWN" program via Protection
Signal formation: Initiate "SHUTDOWN" program via protection input, turbine trip
during execution of "STARTUP" program
If a turbine trip occurs when the turbine is being started up by the "STARTUP" step program
or during steady-state turbine operation, the "SHUTDOWN" step program is initiated via the
protection input accompanied by Automatic control ON. The initiation of the "SHUTDOWN"
program is blocked by steps 9 and 10 so that testing the trip system does not result in turbine
shutdown. The initiation signal for protection OFF is limited to a duration of 15 seconds to rule
out the presence of a static signal when the turbine is at a standstill. In addition to the turbine trip
signal, the system waits until the emergency stop valves are closed before initiating the
"SHUTDOWN" program.
Command: "Automatic control ON" for "SHUTDOWN" step program (logic L010)
Interrogation: "STARTUP" step program started
Interrogation: "STARTUP" step program started (logic L010)
Interrogation: Turbine trip initiated
Interrogation: Turbine trip INITIATED
Interrogation: Emergency stop valves closed
Interrogation: All ESVs closed (logic L020)
Signal formation: Initiate "SHUTDOWN" program via protection input, control valves
not closed before opening of ESVs
All control valves must be closed before the emergency stop valves are opened.
Command: "Protection ON command" for "SHUTDOWN" step program (logic L010)
Interrogation: Control valves not closed before opening emergency stop valves
Interrogation: TAB NOT > 62%
Interrogation: HP STM CTRL-V N.CLSD
Interrogation: IP HP STM CTRL-V N.CLSD
Interrogation: Step 15: Admission controller not in operation. The control valves are kept
closed by the speed controller
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Interrogation: Generator NOT SYNCHRONIZED
Interrogation: Turbine-generator not at rated speed < 90%
3.1.1.8 Logic 8: Close emergency stop valves if Steam Purity is Inadequate, Enable emergency
stop valves if Steam Purity is Adequate
Steam purity - Cold start
In the case of a cold start, the emergency stop valves are opened in order to warm up the
control valves. The limit setting for the turbine startup and lift limiter is increased for this
purpose.
When the main steam pressure is under 20 bar, the difference between the saturated steam
temperature and the mean casing temperature at the control valve is so small that the emergency
stop valves remain open initially. This makes it possible to warm up the main steam line and the
valve chambers simultaneously.
The opened emergency stop valves are closed after a set delay when the main steam
pressure is over 20 bar. When the pressure is between 20 bar and 30 bar, the HP steam control
valves can then be warmed up for a period of 30 minutes. When the pressure is between 30 bar
and 40 bar, the HP steam control valves can then be warmed up for a period of 15 minutes. It
can be assumed that the steam turbine can only be contaminated slightly by unconditioned steam
in this pressure range even on postulated steam leakage through the control valves.
The emergency stop valves are closed immediately when the main steam pressure rises
above 40 bar.
Leakage through the control valves can accelerate the steam turbine to speeds within the
critical speed band. In this case, the emergency stop valves must be closed. The critical speed
band is order-specific.
Steam purity - Hot start
The emergency stop valves are closed again until such time as an adequate level of steam
purity is reached. This serves to rule out turbine cooling in the case of a hot start (high startup
pressure, possible leakage through the control valves).
The emergency stop valves are closed by decreasing the limit setting for the turbine startup
and lift limiter to 35% (see logic 090).
Signal formation: Adequate steam purity reached
Interrogation: Adequate steam purity reached (5-second switch-on delay)
The turbine speed must be under the critical speed band when specified steam purity is
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reached.
Interrogation: Steam purity ENABLE
Interrogation: Speed < 18%
Signal formation: Inadequate steam purity - close ESVs
Interrogation: Adequate steam purity on cold start (30-minute switch-on delay)
Interrogation: Steam purity NO ENABLE
Interrogation: Mean wall temperature of HP STM CTRL-V < 150°C
Interrogation: MS pressure (limit 1 after set delay) > 20 bar
Interrogation: Adequate steam purity for main steam pressure over 30 bar (15-minute
switch-on delay)
Interrogation: Mean wall temperature of HP STM CTRL-V < 150°C
Interrogation: MS pressure (limit 2) > 30 bar
Interrogation: Adequate steam purity for main steam pressure over 40 bar
Interrogation: MS pressure (limit 3) > 40 bar
Interrogation: Adequate steam purity on hot start
Interrogation: Mean wall temperature of HP STM CTRL-V > 150°C
Interrogation: Main steam pressure > 20 bar
Interrogation: Adequate steam purity
The steam purity is determined manually for the steam generator prior to opening the control
valves. This action serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam. The test for steam purity
a) Determines the chemical steam purity
b) Tests the electrical conductivity
Interrogation: Steam purity ENABLE
Interrogation: Duration of ESV opening limited to 60 min
If the steam purity is not adequate, the emergency stop valves must not remain open longer
than 60 min with the control valves closed. If the sequence has not executed Step 16 to Step 20
within 60 min, the emergency stop valves are closed as the result of reset of the turbine startup
and lift limiter.
Interrogation: Step 16: Interrogation for Emergency Stop Valves Open
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Interrogation: Step 17: < Idle Step >
Interrogation: Step 18: Interrogation for Adequate Steam Mass Flow prior to Opening of
Control Valves
Interrogation: Step 19: < Idle Step >
Interrogation: Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System
Conditions prior to Opening Control Valves
Bypass criterion: Turbine accelerates to speed within critical speed band
During the wait for adequate steam purity prior to opening control valves, the ESVs are open.
Under these conditions, postulated steam leakage through the control valves can accelerate the
turbine-generator to the lower region of the critical speed band. A speed monitoring function is
implemented to prevent this. If this type of acceleration occurs, the ESVs are automatically
closed. To allow the steam turbine to be decelerated only to warmup speed in the case of a
program restart following a trip during the startup process, this monitoring circuit is only enabled
under the following conditions: Speed not above warmup speed AND speed setpoint not set to
warmup speed.
Interrogation: Speed > 18%
Interrogation: Speed NOT > 16 Hz (project-specific)
Interrogation: Speed setpoint NOT > 16 Hz (project-specific)
Logic
3.1.1.9 Logic9: Open and Close Valves via Turbine Startup and Lift Limiter TAB, Acceleration
to Rated Speed
Signal formation: Raise startup and lift limiter
When an adequate level of steam purity is reached, the turbine startup and lift limiter opens
the emergency stop valves. The limit setting for the turbine startup and lift limiter is increased to
62% (this value would allow to accelerate to minimum load).
Interrogation: Open emergency stop valves
Interrogation: Step15：Open emergency stop valves.: Admission controller not active The
control valves are kept closed by the speed controller

Interrogation: TAB NOT > 62%
Signal formation: Close emergency stop valves
The emergency stop valves are closed again if steam purity is inadequate.
Interrogation: Close emergency stop and control valves
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The command for decreasing the limit setting for the turbine startup and lift limiter remains
active until 35% is reached. This results in the emergency stop valves being "CLOSED". This is
implemented into the logic using a memory block which is reset when the startup device reaches
a value below 35%.
Interrogation: Inadequate steam purity - close ESVs (logic L080)

Interrogation: Step 20: Wait for adequate steam purity
Provision is made for continued reduction of the limit setting for the turbine startup and lift
limiter until the control valves are no longer closed and the generator is no longer synchronized
(to give restart capability).
Interrogation: All HP STM CTRL-V CLOSED
Interrogation: All IP STN CTRL-V CLOSED
Interrogation: Overload valve CLOSED

Bypass criterion: Speed transient too small
The speed transient monitoring function closes the ESVs to ensure safe coastdown of the
steam turbine even in the event of postulated steam leakage through the control valves.
Interrogation: Limit setting for TAB reduced to 35%
3.1.1.10 Logic 10: Test Auxiliary Systems

The state of the auxiliary systems is interrogated in several steps before the emergency stop
valves and the control valves are opened. The following systems are interrogated:
Interrogation: Turbine Valve Control Fluid Supply Unit
Interrogation: SLC Control Fluid Recirc. Pumps/ Cooling Pumps operating and pressure
building up. READY
Interrogation: SLC Turbine Valve Control Fluid Pumps operating and pressure building up.
READY
Interrogation: SLC Steam Line Drains activated
Interrogation: SLC Main Steam Line Drain ON
Interrogation: SLC Hot Reheat Line Drain ON
Interrogation: SLC LP Induction Steam Line Drain ON
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Interrogation: SLC Cold Reheat Line Drain ON
Interrogation: Turbine drains
Interrogation is performed to determine whether all turbine drains were opened within a
defined period of time.
Interrogation: Turbine drains NOT FAULTED
Interrogation: Turbine oil supply system
Interrogation: Turbine oil supply system IN OPERATION
Interrogation: Turbine not at standstill
Interrogation: Speed > 0.5%
Interrogation: Turbine trip not active
Interrogation: Turbine trip NO TRIP CRITERIA
Interrogation: Control air supply system in operation
The air supply for pneumatic valves and fittings (valves in cold reheat line and extraction
line, injection water valves, LP bypass steam or seal steam system) must be operational. Proper
functioning of the control air supply is tested on the basis of the following process criteria:
Interrogation: Minimum air pressure > 4 bar
Interrogation: Closed cooling water system in operation
The oil cooler in the turbine oil system is cooled by a dedicated cooling water system. This
comprises clean but not deaerated water which is cooled by a heat exchanger in the condensate
cycle. The check is based on the pressure difference which has built up between the pump inlet
and outlet.
Interrogation: Closed cooling water system IN OPERATION
Interrogation: Seal steam system in operation
Condenser evacuation has already been initiated by starting the ELMO vacuum pumps.
Evacuation is facilitated by starting up the seal steam system and sealing the turbine. A pressure
of at least 4 bar must have built up upstream of the control valve in the seal steam header.
Interrogation: Seal steam system AUTO
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Interrogation: Main condensate system in operation
Only one group signal is supplied by the associated I&C for the water-steam cycle for the
operating state of the main condensate pump, regardless of the total number of main condensate
pumps.
Interrogation: Main condensate system IN OPERATION
3.1.1.11 Logic 11: Signal to OM display
Signal formation: Signal to OM display “Release for Steam Purity”
Interrogation:The input for confirming adequate steam purity is flashing on the OM display.
Interrogation: Wait for confirmation of adequate steam purity
Interrogation: Steam purity NO RELEASE
Signal formation: Signal to OM display “ Release for Rated speed”
Interrogation: The input for confirming release for rated speed is flashing on the OM
display.
Interrogation: Wait for Release for Rated Speed
Interrogation: Step25: Improve synchronous speed
Interrogation: Rated speed NO RELEASE
3.1.1.12 Logic 12: Warmup of main steam line
Signal formation: Main steam line warmed up
Prior to opening the control valves, it must be ensured that no moisture is present in the
main steam line.
Interrogation: Superheated steam conditions in force in main steam line
Interrogation: Degree of superheat in main steam line > 10K
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Bypass criterion: No moisture present in main steam line
If steam flow has been in force through this line for at least 5 minutes AND the drain
upstream of the associated ESV is open, it is likewise assumed that no moisture is present in the
main steam line.
Interrogation: Drain upstream of HP STM CTRL-V OPEN
Interrogation: MS pressure > 5 bar
3.1.1.13 Logic 13: Warmup of reheat steam line
Signal formation: Reheat steam line warmed up
Prior to opening the control valves, it must be ensured that no moisture is present in the
reheat steam line.
Interrogation: Superheated steam conditions in force in reheat steam line
Interrogation: Degree of superheat in reheat steam line > 10K
Bypass criterion: No moisture present in reheat steam line
If steam flow has been in force through this line for at least 5 minutes AND the drain
upstream of the associated ESV is open, it is likewise assumed that no moisture is present in the
reheat steam line.
Interrogation: Drain upstream of IP STM ESV OPEN
Interrogation: RH pressure > 5 bar
3.1.2 Automatic Startup of Steam Turbine (STPP) - STARTUP Step Program
3.1.2.1 Step 1: Initiate Startup
Page M010
Monitoring time -
Wait time -
Commands: -
Checkback signals
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3.1.2.2 Step 2: Interrogate Valve Position and Activate SLC Extraction Check Valves
Page M020
Monitoring time -
Wait time -
Commands: Activate SLC Extraction Check Valves
Command: SLC Extraction Check Valves "ON"
Command: SLC Extraction Check Valves ON
Checkback: (See below)
Command: Deactivate SGC open turbine control valves
Command: SGC open turbine control valves OFF
Checkback: (see below)
Before startup it must be ensured that SGC open turbine control valves, which is employed
for preservation of the turbine on outages (see module MAA01), is not active. This automatic
control is therefore switched off at this point in the sequence.
Checkback signals
Checkback signal to command: Deactivate SGC open turbine control valves
Checkback: SGC open turbine control valves OFF
Interrogation: SLC Extraction Check Valves activated
Interrogation: SLC Extraction Check Valves IS ON
Interrogation: Enable SLCs for emergency stop valve control
Interrogation: SLC HP STM ESV IS ON
Interrogation: SLC IP STM ESV IS ON
Interrogation: Enable SLCs for control valve control
Interrogation: SLC HP STM CTRL-V IS ON
Interrogation: SLC IP STM CTRL-V IS ON
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Interrogation: SLC overload valve IS ON
Interrogation: ESVs and cold reheat check valve closed
Interrogation: All emergency stop valves closed (logic L020)
Interrogation: Cold reheat check valve IS CLOSED
Bypass criteria: ESVs open
Interrogation: Control valves and cold reheat check valve closed
Interrogation: All control valves closed (logic L090)
Interrogation: Cold reheat check valve IS CLOSED
Bypass criteria: Turbine rolloff under steam
The control valves leave the "IS CLOSED" position if the turbine startup and lift limiter
permits them to be opened and if the turbine controller specifies a position setpoint > 0%.
Interrogation: Speed/load controller > 0.5%
Interrogation: All extraction check valves closed
Interrogation: Position of all extraction check valves < 5%
Bypass criteria: Turbine at rated speed
Interrogation: Turbine-generator at rated speed > 47.5 rev/s
3.1.2.3 Step 3: Activate Turbine Limit Controllers
Page M030
Monitoring time 5 s
Wait time -
Commands: Activate turbine limit controllers
Command: HP blading limit pressure controller "ON"

Thewritten
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The controller for gradually building up pressure in the HP cylinder is activated.
Command: HP blading limit pressure controller ON
Command: Activate HP exhaust steam temperature controller
Command: HP exhaust steam temperature controller ON
Command: Activate HP pressure ratio controller
Command: HP pressure ratio controller ON
Checkback signals
Checkback signals: MS limit pressure controller "IS ON"
Checkback: Main steam limit pressure controller IS ON
Bypass criterion: Turbine-generator at warmup speed
Interrogation: Turbine-generator at warmup speed > 16 rev/s
Checkback signals to command: HP blading limit pressure controller "ON"

Interrogation: HP blading limit pressure controller IS "ON"
Bypass criterion: Speed > 33 rev/s
Interrogation: Speed > 33 rev/s
The HP blading limit pressure controller is deactivated here when speed is above 33 rev/s.
This bypass criterion is necessary to allow immediate restart even when speed is already at this
level
Checkback signals to command: HP exhaust steam temperature controller "ON"
Checkback: HP exhaust steam temperature controller IS ON
3.1.2.4 Step 4: Activate SLC Turbine Drains
Page M040
Thewritten
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Monitoring time -
Wait time 5 s
Condensate can accumulate throughout the entire steam turbine system in the course of a
prolonged shutdown phase. This is removed at the beginning of the startup process.
Commands: Activate SLC Turbine Drains
Command: SLC Turbine Drains "ON"
The SLC Turbine Drains is activated. Warmup drains and lowest point drains are
implemented. They are only required during the startup process.
Command: SLC Turbine Drains ON
Checkback signals
Checkback signals & SLC Turbine Drains "ON"
Checkback: SLC Turbine Drains IS ON
3.1.2.5 Step 5: Open Warmup Drains
Page M050
Monitoring time 100 s
Wait time 90 s
Condensate can accumulate throughout the entire steam turbine system in the course of a
prolonged shutdown phase. This is removed at the beginning of the startup process (see above
for wait time).
Commands: Open Warmup Drains
Command: Warmup drain "OPEN"
In the course of the shutdown process for the steam turbine, the drain valves upstream of the
control valves are opened when the temperature falls below the defined limit. For safety reasons
the isolation valves are opened again at the start of the "STARTUP" program and a check is
performed to ensure that they are open.
Thewritten
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Command: Drain valve upstream of HP STM CTRL-V OPEN
Command: Drain valve upstream of IP STM CTRL-V OPEN
Command: Drain valve upstream of overload valve OPEN
Checkback signals
Checkback signals to command: Warmup drains "OPEN"
Checkback: Drain valve upstream of HP STM CTRL-V IS OPEN
Checkback: Drain valve upstream of IP STM CTRL-V IS OPEN
Checkback: Drain valve upstream of overload valve IS OPEN
Bypass criteria: All ESVs are open -control valve opening is limited
The emergency stop valves are open. The control valves leave the "IS CLOSED" position if
the turbine startup and lift limiter permits them to be opened and if the turbine controller
specifies a position setpoint > 0%.
3.1.2.6 Step 6: <Idle Step>
Page M060
Monitoring time -
Wait time
Commands: -
Checkback signals
3.1.2.7 Step 7: <Idle Step>
Page M070
Thewritten
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Monitoring time -
Wait time -
Checkback: Commands:
Checkback signals
3.1.2.8 Step 8: Oil Pump Test & Interrogate Auxiliary Systems
Page M080
Wait time -
Commands: Oil pump test
Command: SGC "Activate oil pump test"
Command: SGC Oil Pump Test ON
Checkback signals
Checkback signals to command: "Activate oil pump test"
Checkback: SGC oil pump test ON
Interrogation: TAB =0%
Interrogation: Auxiliary systems in operation (logic L100)
Interrogation: Auxiliary systems (logic L100) O.K.
Bypass criteria: Restart of turbine following a trip during startup process
Restart of the turbine following a trip during the startup process is possible without having
to wait for coastdown of the turbine-generator. For this, the oil pump test normally performed in
this step is bypassed. As this test entails deactivation of the main oil pump, it is only permissible
to perform this at turning gear speed.
Interrogation: Turbine-generator not at turning gear speed > 4%
Thewritten
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Interrogation: Turbine-generator not in critical speed band < 18%
3.1.2.9 Step 9: <Idle step>
Page M090
Monitoring time -
Wait time
Commands:
Checkback signals
Page M100
Monitoring time -
Wait time
Commands:
Checkback signals
3.1.2.11 Step 11: Wait for Adequate Steam Conditions prior to Opening ESV, Activate SLC
"Generator Shutdown Dryer"
Page M110
In loop between Step 11and Step 20
Monitoring time -
Wait time -
Wait loop until adequate steam purity is reached
Step 11and Step 20 are the start and end points of a loop which is passed through several
times when steam purity is inadequate. If an adequate level of steam purity is not reached, the
emergency stop valves which are open initially, are closed. The emergency stop valves remain
closed until an enable signal is issued for steam purity. The signal ESVOPND (logic L020) acts
as a bypass criterion.
Thewritten
IC.Z10.62102.01-E00 Page 24 of 55
Commands: Activate SLC "Generator Shutdown Dryer"
Command: Activate shutdown dryer on generator
Command: SLC "Generator Shutdown Dryer" ON
Command: Release OM button for steam purity
Command: OM button for steam purity NOT LOCKED
The steam purity is determined manually for the steam generator prior to opening the
control valves. This serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam. During warm and hot starts steam purity is to be released
already prior to opening the ESV (usually prior to opening the CV). That prevents the logic from
jumping back from Step 20 to Step 11.
Checkback signals
Interrogation: X1 criterion fulfilled
Temperature criterion X1 (see Section1.1) prevents inadmissible cooling of the HP steam

valve body.
Interrogation: X1 criterion FULFILLED
Interrogation: Hot start &superheated up steam conditions
A minimum degree of superheat of 30K is required in order to avoid the presence of

moisture in the valve bodies.
Interrogation: MS superheat upstream of B/PS > 30K
Interrogation: Hot reheat superheat upstream of B/PS > 30K
Bypass criterion: Cold start & with SG as controlling component
The main steam line and the main steam valve body are warmed up together with the steam
generator in the case of an absolute cold start when a temperature of less than 150°C is measured
at the reference measuring points in HP steam emergency stop valves and HP steam control
valves.
Thewritten
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Interrogation: Mean casing temp. at HP STM CTRL-V < 150 °C
Interrogation: SG must supply adequate steam mass flow
In the event of a hot start (mean temperature of HP shaft > 400°C), a minimum main steam
flow of 15% is required from the SG. If the mean temperature of the HP shaft is < 400°C, a
minimum main steam flow of 10% is adequate. The minimum main steam flow can be defined
order-specifically if required.
Interrogation: Mean temperature of HP shaft < 400 °C
Interrogation: MS mass flow if ϑHP shaft > 400°C > 15%
Interrogation: MS mass flow if ϑHP shaft < 400°C > 10%
Interrogation: X2 criterion fulfilled
To avoid inadmissible loadings on the HP steam control valves due to a step temperature
increase for saturated steam
Bypass criterion: All ESVs open
Checkback signal: Command - Activate shutdown dryer on generator
Checkback: SLC "Generator Shutdown Dryer" IS ON
Interrogation: No liquid underneath the generator
Interrogation: Liquid level exciter end < MAX
Interrogation: Liquid level turbine end < MAX
Interrogation: Oil pump test completed without faults
Interrogation: SGC Oil Pump Test IS OFF
Interrogation: SGC Oil Pump Test NOT FAULTED
Interrogation: Steam purity (manually by push button) ENABLE
Thewritten
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Bypass criterion: no warm or hot start
Interrogation: Mean casing temp. of HP STM CTRL-V < 350°C
Interrogation: Casing distortion not critical
Casing distortion is monitored by module MAY20, "Temperature and pressure monitoring".

A warning signal is implemented for casing distortion.
Interrogation: Distortion of outer HP casing NOT HIGH < 30°C
Interrogation: Distortion of outer HP casing NOT LOW >-30°C
Interrogation: Distortion of outer IP/LP casing NOT HIGH < 30°C
Interrogation: Distortion of outer IP/LP casing NOT LOW >-30°C
Interrogation: Auxiliary systems in operation (logic L100)
Interrogation: Auxiliary systems (logic L100) O.K.
Page M120
In loop between Step11 and Step 20
Monitoring time -
Wait time -
See Step 6 for description.
Commands:
Checkback signals
3.1.2.13 Step 13: Warmup of HP and Reheat Line upstream of Turbine Complete
Page M130
Monitoring time -
Wait time -
Thewritten
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See Step11 for description.
Commands:
Checkback signals
Interrogation: Main steam and hot reheat lines warmed up
The main steam and hot reheat lines are warmed up by the water-steam cycle. A check is
performed to ensure that warmup valve(s) upstream of ESV(s) are open and that steam flow is in
force for these OR that the steam turbine is at rated speed. OR steam flow is in force at all
temperature measuring points in the main steam and hot reheat lines up to the ESVs. A minimum
degree of superheat (>10K) is likewise in force at all temperature measuring points (i.e. at all
low points and upstream of the steam turbine ESVs) in the main steam and hot reheat lines,
meaning that no moisture is present at these locations. Signal formation is active under all
operating conditions.
Interrogation: Warm up of main steam line O.K.
Interrogation: Warm up of reheat line O.K.
Bypass criteria: Turbine at warmup speed
3.1.2.14 Step 14: Open drains upstream of ESVs
Page M140
Wait time 90 s
Commands: Open drains upstream of ESV
Thewritten
IC.Z10.62102.01-E00 Page 28 of 55
The drains upstream of ESV(s) are not opened until warmup of the main steam and hot
reheat lines has been performed. This serves to prevent possible cooling of the steam lines by
reverse flow via the drains in the event of startup with MS isolation valve open and early
activation of the automatic startup control (before the steam generator is in operation).
Command: Drain upstream of HP STM ESV and IP STM ESV "OPEN"
Command: Drain valve upstream of HP STM ESV OPEN
Comm Command: Drain valve upstream of IP STM ESV OPEN
Comm Command : (See below)
Checkback signals
Checkback signals to command: Drains upstream of HP STM ESV and IP STM ESV
"OPEN"
Checkback: Drain valve upstream of HP STM ESV IS OPEN
Checkback: Drain valve upstream of IP STM ESV IS OPEN
Bypass criteria: All ESVs are open - control valve opening is limited
The emergency stop valves are open. The control valves leave the "IS CLOSED" position if
the turbine startup and lift limiter permits them to be opened and if the turbine controller
specifies a position setpoint > 0%.
3.1.2.15 Step 15: Open Emergency Stop Valves
Page M150
Wait time -
Thewritten
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Commands: Open Emergency Stop Valves
Command: Set load controller to > 15%
In the event of a hot or warm start, the turbine can be accelerated to rated speed and loaded
immediately after startup. To rule out unnecessary no-load or low-load operation with the
associated risk of windage in the HP turbine and to ensure reliable synchronization, a check is
performed prior to startup to determine whether the enable signal for loading to an appropriate
level has been issued.
Command: Turbine controller load setpoint >15 %
Command: Enable "TAB (L090)" and "SHUTDOWN step program via protection
(L070)"
The emergency stop valves are opened initially when the turbine startup and lift limiter
(TAB) is started up. The TAB is ramped on up to 62%. This makes limited opening of the
control valves possible. This lift limit allows runup of the steam turbine to rated speed and
synchronization of the generator.
If a valve position setpoint > 1% is defined due to a malfunction, turbine rolloff under steam
is performed by the TAB which opens the emergency stop valves. This spurious startup initiates
the "SHUTDOWN" step program via the protection input.
Command: Enable logic L070 & L090
Checkback signals
Checkback signal to command: Emergency stop valves OPEN
Checkback: Turbine controller load setpoint > 15 %
Checkback: TAB > 62%
3.1.2.16 Step 16: Interrogation for Emergency Stop Valves Open

Page M160
Thewritten
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Wait time -
The emergency stop valves are closed again in the event that the steam purity is inadequate
or the speed is too high.
Commands: -
Checkback signals
Interrogation: HP evacuation valve closed
Interrogation: HP evacuation valve IS CLOSED
Interrogation: HP evacuation valve IS NOT OPEN
Bypass criterion: Coastdown of steam turbine
To allow the steam turbine to be decelerated only to warmup speed in the case of a program
restart following a trip during the startup process, a bypass must be provided at this point in the
sequence. This disables the interrogation criterion for HP evacuation valve closed under the
above conditions when turbine speed is above 33 Hz.
Interrogation: Speed > 33 Hz
Interrogation: All emergency stop valves open
Bypass criterion: Adequate steam purity not yet reached
Interrogation: Inadequate steam purity - close ESVs (logic L080)
3.1.2.17 Step 17: < Idle Step >
Page M170
In loop between Step 11 and Step 20
Thewritten
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Monitoring time -
Wait time
The emergency stop valves are closed in the event that the steam purity is inadequate or the
speed is too high.
Commands: -
Checkback signals
3.1.2.18 Step 18: Interrogation for Adequate Steam Mass Flow prior to Opening of Control
Valves
Page M180
In loop between Step 11and Step 20
Monitoring time -
Wait time -
Commands: -
Checkback signals
In the event of a hot start (mean temperature of HP shaft > 400°C), a minimum main steam
flow of 15% is required from the SG. If the mean temperature of the HP shaft is < 400°C, a
minimum main steam flow of 10% is adequate. The minimum main steam flow can be defined
order-specifically if required.
Interrogation: Mean temperature of HP shaft < 400 °C
Thewritten
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Interrogation: MS mass flow if ϑHP shaft > 400°C > 15%
Interrogation: MS mass flow if ϑHP shaft < 400°C > 10%
3.1.2.19 Step 19: < Idle Step >
Page M190
In loop between Step 11 and Step 20
Wait time -
Commands: -
Checkback signals
3.1.2.20 Step 20: Wait for Adequate Steam Purity, Interrogate Steam and System Conditions
prior to Opening Control Valves
Page M200 & M201
In loop between Fehler! Verweisquelle konnte nicht gefunden werden and Step 20
Monitoring time -
Wait time -
The sequence waits for adequate steam purity in Step 20. Adequate steam purity is
confirmed manually by operating a pushbutton. The emergency stop valves are not opened until
adequate steam purity is in force.
Commands: Release OM button for the subcontrol of steam purity
Thewritten
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Command: Release OM button for steam purity
Command: OM button for steam purity NOT LOCKED
Checkback signals
Interrogation: Main steam temperature
Interrogation: MS temperature > 360°C
The steam purity is determined manually for the steam generator prior to opening the
control valves. This serves to prevent the occurrence of impurities and deposits in the steam
turbine due to contaminated steam.
Interrogation: Steam purity (manually by pushbutton) ENABLE
Steam purity is assumed when restarting. Bypassing the release prevents delays.
Interrogation: Condenser pressure for turbine operation reached
Interrogating condenser pressure ensures that the condenser low vacuum trip does not
respond when the speed is increased.
Interrogation: Condenser vacuum < 0.2 bar abs
Interrogation: Casing distortion not critical
Casing distortion is monitored by module MAY20, "Temperature and pressure monitoring".

A warning signal is output from the casing distortion monitoring.
Interrogation: Distortion of outer HP casing NOT HIGH <30°C
Interrogation: Distortion of outer HP casing NOT LOW >-30°C
Interrogation: Distortion of outer IP casing NOT HIGH <30°C
Interrogation: Distortion of outer IP casing NOT LOW >-30°C
Thewritten
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Interrogation: Temperature margins
For opening of the control valves to be admissible, the lowest of the temperature margins
must amount to at least 30K for all components. The turbine controller is not expected to limit
the acceleration rate when accelerating to rated speed in this case.
Interrogation: Temperature margin > 30K
Interrogation: Check main steam and hot reheat steam conditions
The main steam and hot reheat steam conditions are checked on the basis of the following X
criteria:
* X4 - HP turbine: Avoid admission of wet steam
* X5 - HP turbine: Avoid cooling
* X6 - IP turbine: Avoid cooling
It must also be ensured that the degree of steam superheat is at least 30K.
Interrogation: MS temperature: Superheat (Z3 crit.) > 30K
Interrogation: Hot reheat temperature: Superheat (Z4 crit.) > 30K
A check is performed to ensure that the main steam and hot reheat temperatures are within a
permitted tolerance band. For this purpose, the system checks whether the warning limits for
main steam and hot reheat temperature have been exceeded.
Interrogation: MS temperature HIGH NOT ACTUATED
Interrogation: Hot reheat temperature HIGH NOT ACTUATED
Interrogation: Check main steam pressure
A check is performed to ensure that the discrepancy between the pressure setpoint of the
turbine controller and the actual pressure of the main steam is not too high. This is designed to
avoid a situation whereby the turbine controller has to compensate for an excessive control
deviation at the time when the control valves are opened.
Thewritten
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Interrogation: MS pressure: Setpoint - Actual value > ε NOT REACHED
Interrogation: Temperature protection for HP blading not actuated
Interrogation: Temperature protection for HP blading NOT ACTUATED
Interrogation: Turbine oil supply system ready
Interrogation: Turbine oil supply system IN OPERATION
Interrogation: Turbine oil temperature > 37°C
Interrogation: Turbine controller lift limitation by means of TAB
The limit setting for the turbine startup and lift limiter has been increased to 62%. The TAB
therefore acts as a lift limiter. The control valves are kept closed until the speed setpoint is
increased.
Interrogation: Turbine-generator speed not within critical speed band
This interrogation is necessary to allow the steam turbine to be decelerated only to warmup
speed in the case of a program restart following a trip during the startup process. This ensures
that reversal of the speed gradient in the subsequent step does not coincide with speed being
within the critical speed band.
Interrogation: Auxiliary systems ready
The auxiliary systems are tested again before the control valves are opened (see Section
1.3.1.1.10).
Interrogation: Auxiliary systems (logic L100) ready
Interrogation: ESVs open
Signal formation: Enable ESVs if steam purity is adequate
The system waits for adequate steam purity with the emergency stop valves closed (Step
Thewritten
IC.Z10.62102.01-E00 Page 36 of 55
20). Steam purity is determined by means of a chemical analysis. Adequate steam purity must be
confirmed manually (logic L110). The sequence makes a return jump to Step 11. In the steps
which follow, the emergency stop valves are then opened again and all the criteria are
interrogated in order to accelerate the turbine to warmup speed by opening the control valves.
Interrogation: Adequate steam purity reached
Interrogation: Adequate steam purity reached (logic L080) ENABLE
Interrogation: Turbine controller lift limitation by means of TAB
The limit setting for the turbine startup and lift limiter is reduced if steam purity is
inadequate. This closes the emergency stop valves.
Interrogation: All ESVs closed and wait for adequate steam purity complete
The sequence does not go into the wait loop until all the emergency stop valves are closed
and the startup program has reached Step 20.
3.1.2.21 Step 21: Open Control Valves Accelerate to Warmup Speed
Page M210
Monitoring time 5 s
Wait time -
Commands: Open control valves
Command: Open control valves by increasing the speed setpoint
The turbine is accelerated to warmup speed. The speed setpoint is increased. This causes the
control valves to be opened. All the turbine sections, but primarily the HP turbine, are warmed
up at warmup speed. The TSE/TSC monitors the warmup process.
Command: Speed setpoint INCREASE

Thewritten
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Command: Enable speed control
To allow the steam turbine to be decelerated only to warmup speed in the case of a program
restart following a trip during the startup process, the alarm for speed gradient too small stored in
the steam turbine controller must be reset. This takes place when turbine speed is within the
permissible operating window.
Command: Speed control ENABLE
Checkback signals
Checkback signal: Speed setpoint defined
Checkback: Speed setpoint defined > 16.5 rev/s * (*order-specific)
Checkback signal to command: Enable speed control
Checkback: Speed control ENABLE
Interrogation: Speed/admission setpoint > 0.5%
Bypass criterion: Turbine-generator at rated speed
3.1.2.22 Step 22: Deactivate SLC Steam Purity
Page M220
Monitoring time -
Wait time -
Commands: Deactivate SLC Steam Purity
Command: Deactivate SLC Steam Purity
Command: SLC Steam Purity OFF
Checkback: None
Thewritten
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The SLC Steam Purity is also deactivated due to turbine trip (signal with 2 s delay).
Checkback signals
Checkback signal: SLC Steam Purity deactivated
Checkback: Steam purity (pushbutton) NO ENABLE
Interrogation: Turbine-generator reaches warmup speed
Interrogation: Speed > 33 %
3.1.2.23 Step 23: Maintain at Warmup Speed: Increase Degree of Heat Soak for HP Turbine
Page M230
Monitoring time -
Wait time 200 s
Commands: -
Checkback signals
Interrogation: Enable for acceleration to rated speed
The enable for acceleration to rated speed is issued manually by means of an OM

pushbutton.
Interrogation: Enable for rated speed ISSUED
Interrogation: No limiting effect of position controller on control valve position
The system ensures that the position controller in the turbine controller does not have a
limiting effect when the turbine startup and lift limiter opens the control valves.
Interrogation: Position limiting of HP STM CTRL-V = 105%
Interrogation: Position limiting of IP STM CTRL-V = 105%
Interrogation: IP shaft temperature > 20°C
In the event of extremely low ambient temperatures, it must be ensured that IP shaft
centerline temperature is at least 20°C.
Interrogation: IP shaft centerline temperature (from TSE/TSC) > 20°C
Thewritten
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Interrogation: Temperature criterion X7, margins, superheat
(1) X7 fulfilled (see Section 1.2.3)
(2) In addition to testing for the X criteria, a check is performed to determine whether the
temperature margins exceed the minimum value of 30K.
A degree of superheat of at least 30K must be in force for the steam upstream of the HP and
IP turbines.
Interrogation: MS temp. upstream of HPT (Z3 crit.) Superheat to > +30K
Interrogation: Hot reheat temp. upstream of IPT (Z4 crit.) Superheat to > +30K
Interrogation: Minimum upper temperature margin > 30K
A minimum main steam flow of 15% is required from the SG prior to opening the control
valves. The minimum main steam flow can be defined order-specifically if required.
Interrogation: MS mass flow > 15%
Interrogation: Limit for condenser low vacuum trip reached
The evacuation pumps (ELMO vacuum pumps) give rise to a condenser vacuum. The
following limit applies for condenser vacuum:
√ p < 0.13 bar abs Limit for "Condenser pressure protection" reached
Interrogation: Condenser vacuum < 0.13 bar abs
Bypass criterion: Turbine-generator at rated speed
3.1.2.24 Step 24: < Idle Step >
Page M240
Monitoring time -
Wait time -
Thewritten
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Commands: -
Checkback signals
3.1.2.25 Step 25: Accelerate to Synchronizing Speed
Page M250
Monitoring time 5 s
Wait time -
Commands: Accelerate to synchronizing speed
Command: Increase speed setpoint to synchronizing speed
Increasing the speed setpoint causes the turbine to accelerate to above rated speed (rated
speed + 0.25 rev/s). The generator can be synchronized at this speed. The turbine startup and lift
limiter is set to limit setting 62% to limit valve opening.
Command: Increase speed setpoint
Checkback signals
Checkback signal to command: Increase speed setpoint to synchronizing speed
Checkback: Speed setpoint > 50.20 rev/s * (*order-specific)
Bypass criterion: Generator is synchronized
Interrogation: Generator SYNCHRONIZED
Interrogation: Turbine-generator at rated speed > 95%
3.1.2.26 Step 26: Close Drains upstream of HP & IP Turbines
Page M260
Wait time -
Commands: Close drain
Command: Close drain upstream of HP STM ESV & HP STM CTRL-V
Thewritten
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These drains are closed before the TAB reaches a limit setting > 99%.
Command: Drain valve upstream of HP STM ESV CLOSE
Command: Drain valve upstream of HP STM CTRL-V CLOSE
Command: Close drain upstream of IP STM ESV & IP STM CTRL-V
Command: Drain valve upstream of IP STM ESV CLOSED
Command: Drain valve upstream of IP STM CTRL-V CLOSED
Command: Close drain upstream of overload valve
Command: Drain valve upstream of overload valve CLOSED
Checkback signals
Checkback signals to command: Close drain upstream of HP STM ESV & HP STM
CTRL-V
Checkback: Drain valve upstream of HP STM ESV IS CLOSED
Checkback: Drain valve upstream of HP STM CTRL-V IS CLOSED
Checkback signals to command: Close drain upstream of IP STM ESV & IP STM
CTRL-V
Checkback: Drain valve upstream of IP STM ESV IS CLOSED
Checkback: Drain valve upstream of IP HP STM CTRL-V IS CLOSED
Checkback signals to command: Close drain upstream of overload valve
Checkback: Drain valve upstream of overload valve IS CLOSED
Thewritten
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3.1.2.27 Step 27: Deactivate SLC Speed Enable
Page M270
Monitoring time -
Wait time -
Commands: - Deactivate SLC Speed Enable
Command: Deactivate SLC Speed Enable
Command: SLC Speed Enable OFF
The SLC Speed Enable is also deactivated due to turbine trip (signal with 2 s delay).
Checkback signals
Checkback signal: Deactivate SLC Speed Enable
Checkback: Speed enable (pushbutton) NO ENABLE
3.1.2.28 Step 28: Voltage Regulator Activated
Page M280
Monitoring time -
Wait time -
Commands: Activate voltage regulator
Command: Activate voltage regulator
Command: Voltage regulator AUTO
Checkback signals
Thewritten
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Checkback signal to command: Activate voltage regulator
Checkback: Voltage regulator IS AUTO
3.1.2.29 Step 29: Maintain Rated Speed prior to Synchronizing Generator
Page M290
Monitoring time -
Wait time -
Commands: -
Checkback signals: -
Interrogation: Temperature criterion X8, margins, cooling, exciter unit
(1) X8 fulfilled (see Section 1.2.3)
(2) In addition to testing for the X criteria, a check is performed to determine whether the
temperature margins exceed the minimum value of 30K.
Comment: This value was used prior to implementation of the X criteria. It is still
implemented today in cases where thick-walled valves are used, in order to ensure an adequate
temperature margin.
Interrogation: Minimum upper temperature margin > 30K
Interrogation: Exciter unit
Interrogation: Exciter unit NOT FAULTED
Interrogation: Generator - cold gas temperature protection
Interrogation: Cold gas temperature protection NOT ACTIVATED
Interrogation: Generator & cooling temperatures
Interrogation: Cold gas temperature < 45°C
Thewritten
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3.1.2.30 Step 30: Prepare Synchronization
Page M300
Monitoring time 5s
Wait time -
Commands: Activate exciter system & preselect grid tie breaker (optional)
Command: Activate exciter system
Command: Exciter system ON
Command: Preselect grid tie breaker
It is possible to close the grid tie breaker in the next step having preselected it here.
Command: Grid tie breaker PRESELECTED
Checkback signals
Checkback signal to command: Activate exciter system
Checkback: Exciter system IS ON
Interrogation: Exciter unit circuit breaker not in test position
Interrogation: Exciter unit circuit breaker NOT IN TEST POSITION
Checkback signal to command: Grid tie breaker preselected
Checkback: Grid tie breaker IS PRESELECTED
Bypass criterion: Turbine-generator is synchronized
Interrogation: Turbine-generator SYNCHRONIZED
3.1.2.31 Step 31: Synchronize
Page M310
Thewritten
IC.Z10.62102.01-E00 Page 45 of 55
Wait time -
Commands: Synchronize
Command: Enable paralleling unit
Command: Paralleling unit ENABLE
Checkback signals
Checkback signal: Generator synchronized
Checkback: Generator SYNCHRONIZED
3.1.2.32 Step 32: Open Control Valves by Increasing Limit Setting for Turbine Startup and Lift
Limiter
Page M320
Wait time -
Commands: Deactivate effect of TAB in turbine controller
Command: Increase limit setting for TAB
After the generator has been synchronized, the position of the control valves is only limited
via the turbine controller by the limit pressure, and by the limit setting for the turbine startup and
lift limiter. The limiting effect of the turbine startup and lift limiter is cancelled during this
step.The speed controller does not act to limit valve opening following synchronization. The
control valves are opened by means of the load controller. The bypass controller closes the
bypass valves. The limit pressure controller can intervene where appropriate whenever the
pressure of the SG falls below the limit value. The control valves are throttled in this case.
Command: TAB INCREASE
Checkback signals
Checkback signal to command: Increase limit setting for TAB
Thewritten
IC.Z10.62102.01-E00 Page 46 of 55
Checkback: TAB > 99%
3.1.2.33 Step 33: Complete Steam Turbine-Generator Startup Process
Page M330
Monitoring time -
Wait time -
Commands: -
Interrogation: Startup process complete
The startup process is complete when the following conditions are met.
(1)Generator synchronized
(2) HP bypass stations closed
(3) Steam generator supplying sufficient steam mass flow
(4) Pressure upstream of HP blading > 25 bar .The steam turbine is supplying power.
Interrogation: HP bypass stations CLOSED
Interrogation: MS mass flow > 20%
Interrogation: Pressure upstream of HP blading > 25 bar
3.1.2.34 Step 34: Interrogate Turbine Controller
Page M340
Monitoring time 5 s
Wait time -
Commands:
Checkback signals
Interrogation: Load controller in operation
Thewritten
IC.Z10.62102.01-E00 Page 47 of 55
The load controller in the turbine controller is activated following synchronization. The
turbine controller remains in power operation after the bypass stations have been closed.
Interrogation: Load controller ACTIVE
3.1.2.35 Step 35: End of STARTUP Step Program
Page M350
Monitoring time -
Wait time -
Commands: -
Checkback signals: -
3.1.3 Automatic Steam Turbine Shutdown Control (STPP) - SHUTDOWN Step Program
The "SHUTDOWN" step program is started from the unit control level. The SHUTDOWN
program can also be activated by means of a protection input if a turbine trip occurs or if
problems occur during execution of the STARTUP program. This brings the turbine-generator
into a defined state.
3.1.3.1 Step 51: Release Cold Reheat Check Valves
Page N010
Monitoring time 5 s
Wait time 10 s
Commands: Release cold reheat check valves
Command: Release cold reheat check valves
The cold reheat check valves are released before the turbine power output is run down. This
ensures that the pressure in the HP turbine can be decreased as required.
Command: Cold reheat check valves RELEASE
Checkback signals
Checkback signal to command: Release cold reheat check valves
Thewritten
IC.Z10.62102.01-E00 Page 48 of 55
The cold reheat check valves must have moved from the OPEN position within 10 s.
Checkback: Cold reheat check valves NOT OPEN
Interrogation: Cold reheat check valves NOT > 85%
3.1.3.2 Step 52: Rundown of Turbine-Generator by Means of Load Setpoint
Page N020
Monitoring time -
Wait time -
Commands: Close control valves
Command: Decrease load setpoint
The power contribution of the steam turbine is reduced by closing the control valves.
Command: Load setpoint DECREASE
Command: Reactive power zero balance
Command: Reactive power zero balance
Checkback: (None)
Command: Disable the influence of lower temperature margins on the unloading rate
Experience shows that the standard limitation of load gradients imposed by the minimum
temperature margins is not necessary for rundown. This is due to the fact that the lower margins
normally remain above zero even at maximum loading gradient. As the lower WT limits are
often very restrictive for high mean shaft temperatures (e.g. 15K), these basically limit the
unloading gradient under these conditions. This command sets the minimum lower WT margin
in the turbine controller to a fixed value of 30K. As a result, the maximum load gradient is
effective under these conditions, without limitation by the TSE/TSC.
Checkback: Lower TSE margin in the controller 30K
Checkback signals
Thewritten
IC.Z10.62102.01-E00 Page 49 of 55
Checkback signal: Command "DECREASE" load setpoint
Checkback: Delayed load setpoint = 0%
The turbine-generator is run down by means of the speed controller in the event of load
rejection.
Interrogation: Speed controller IN OPERATION
Bypass criterion: Load rejection
The turbine-generator is run down by means of the speed controller in the event of load
rejection.
Bypass criterion: Grid tie breaker not closed
Interrogation: The turbine controller is changed over to limit pressure control
The turbine controller must be changed over to "LIMIT PRESSURE" right at the start of the
"SHUTDOWN" program in order to prevent spurious opening of the HP bypass stations.
Interrogation: Limit pressure controller IS ON
Bypass criterion: WT margin very low
Interrogation: Minimum lower temperature margin < 2K
Bypass criterion: HP exhaust steam temperature controller active
The temperature controller is in operation so as to prevent the maximum permitted HP

exhaust temperature from being exceeded.
Interrogation: HP exhaust steam temperature controller IN OPERATION
Bypass criterion: Turbine trip initiated
3.1.3.3 Step 53: Valve Leak Test / Wait for Grid Tie Breaker to Open
Page N030
Thewritten
IC.Z10.62102.01-E00 Page 50 of 55
Wait time 60 s
Commands: -
Checkback signals
The system waits for 60 s for the generator breaker to open before closing the valves as the
result of a turbine trip. Motoring of the generator is limited to this time period provided the HP
evacuation line is open with the HP steam valves closed.
Bypass criterion: Speed controller active
As soon as the speed controller is activated, the valve leak test is aborted.
Bypass criterion: Minimum lower WT margin not violated
The valve leak test is aborted if a minimum WT margin is violated.
Interrogation: Minimum lower temperature margin < 2K
Bypass criterion: HP exhaust steam temperature controller active
As soon as the HP exhaust steam temperature controller initiates valve position trimming,
the valve leak test is aborted.
Interrogation: HP exhaust steam temperature controller IN OPERATION
Bypass criterion: Turbine trip initiated
Bypass criterion: Generator breaker open
3.1.3.4 Step 54: Close Emergency Stop Valves
Page N040
Monitoring time 5 s
Wait time -
Thewritten
IC.Z10.62102.01-E00 Page 51 of 55
Commands: Close emergency stop valves
Command: Initiate turbine trip
Command: Turbine trip INITIATE
Command: Deactivate exciter system
Command: Exciter system OFF
Command: Reset grid tie breaker preselection
Command: Grid tie breaker preselection RESET
Checkback signals
Checkback signal to command: Turbine trip
Checkback: Turbine trip INITIATED
Interrogation: TAB =0%
Checkback signal to command: Deactivate exciter system
Interrogation: Exciter system IS OFF
Interrogation: Generator breaker open
3.1.3.5 Step 55: SLC Turbine Drains ON
Page N050
Wait time -
Commands: Open drains
Thewritten
IC.Z10.62102.01-E00 Page 52 of 55
Command: SLC Turbine Drains "ON"
Command: SLC Turbine Drains ON
Checkback signals
Checkback signals to command: SLC Turbine Drains "ON"
Checkback: SLC Turbine Drains IS ON
3.1.3.6 Step 56: Jacking Oil Pumps Ready
Page N060
Monitoring time -
Wait time -
Commands:
Checkback signals
Interrogation: Jacking oil pumps ready
The jacking oil pumps must be ready for operation and the turbine-generator in turning gear
operation before the oil pump test program is started.
Interrogation: Control for jacking oil pumps IS ON
Interrogation: Turbine-generator speed < 2 rev/s
Interrogation: Turbine-generator speed < 0.16 rev/s
3.1.3.7 Step 57: Start Oil Pump Test
Page N070
Monitoring time -
Wait time -
Commands: Start oil pump test
Command: Start SGC Oil Pump Test
Command: SGC Oil Pump Test START

Thewritten
IC.Z10.62102.01-E00 Page 53 of 55
Checkback signals
Checkback signals to command: Start SGC Oil Pump Test
Checkback: SGC Oil Pump Test IS STARTED
SGC Oil Pump Test is only started on shutdown of the turbine if a 30-day interval has
expired since the last test was performed. If the lube oil pressure protection is actuated in the
course of testing, an appropriate alarm is then generated. If this occurs, the lube oil system must
then be checked and SGC Oil Pump Test activated again manually following this.
Bypass criterion: Oil pump testing restarted manually
Interrogation: Oil pump testing NOT AUTO
3.1.3.8 Step 58: Oil Pump Test Completed without Faults
Page N080
Monitoring time -
Wait time -
Commands: -
Checkback signals
Interrogation: Oil pump test completed without faults
Interrogation: SGC Oil Pump Test IS OFF
Interrogation: SGC Oil Pump Test FAULT-FREE
3.1.3.9 Step 59: Wait for Cold HP Steam Control Valves
Page N090
Monitoring time
Wait time
Commands: -
Checkback signals:
Thewritten
IC.Z10.62102.01-E00 Page 54 of 55
The warmup drains are not opened until the temperature of the HP steam control valves
falls below 200°C.
Interrogation: Mean temperature of HP STM CTRL-V
Interrogation: HP STM CTRL-V temperature (at 50% wall depth) < 200°C
3.1.3.10 Step 60: Open Warmup Drains
Page N100
Wait time -
Commands: Open warmup drains
Command: Open drains upstream of HP STM CTRL-V and IP STM CTRL-V
Command: Drain valve upstream of HP STM CTRL-V OPEN
Command: Drain valve upstream of IP STM CTRL-V OPEN
Command: Drain valve upstream of overload valve OPEN
Checkback signals:
Checkback signal to command: Open drains upstream of HP STM CTRL-V and IP

STM CTRL-V
Checkback: Drain valve upstream of HP STM CTRL-V IS OPEN
Checkback: Drain valve upstream of IP STM CTRL-V IS OPEN
Checkback: Drain valve upstream of overload valve IS OPEN
3.1.3.11 Step 61: End of SHUTDOWN Program
Page N110
Monitoring time -
Thewritten
IC.Z10.62102.01-E00 Page 55 of 55
Wait time -
Commands: -
Checkback signals:-
Thewritten
Emergency Trip
2020.04
System Checked：Wei Yuan
CONTENTS
1. Overview ..................................................................................................... 1
2. Overspeed protection device..................................................................... 1
3. Data acquisition system............................................................................. 2
4. EH Shutdown System ................................................................................ 4
5. Protection Specification ............................................................................ 5
5.1 Shutdown Manually ................................................................................ 5
5.2 Vibration Protection MAD11/12/13/14/15CY121，MKD11CY121，
MKD12CY121，MKD21CY121 .................................................................. 6
5.3 Axial Displacement MAD12CY111/112/113 .......................................... 6
5.4 Bearing Temperature .............................................................................. 6
5.5 Lube Oil System MAV42CP/116/117/118、MAV10CL121/122/123 ... 6
5.6 Condenser Vacuum MAG10CP103/104/105MAG20CP103/104/105.. 7
5.7 EH Low Pressure Protection MAX01CP101/102 ................................. 7
5.8 HP blading temperature protection MAA50CT115A/116A/117A ...... 7
Thewritten
5.10 Other Protection .................................................................................... 8
6. ETS Figure specification ........................................................................... 8
Thewritten
IC.Z10.60302.01-E00 Page 1 of 9
EMERGENCY TRIP SYSTEM
1. Overview
Turbine emergency trip system is used to monitor important turbine operation parameters,
when these value exceed the allowable limit, the trip signal will be occurred to close the steam
inlet rapidly, and these sequences of action avoid the further damage of the turbine.
ETS is mainly consist of Overspeed protection device, data acquisition process system and EH
trip system.
2. Overspeed protection device

Overspeed protection system cancel traditional fly ball instead by using two units of electrical
overspeed protection device. Each overspeed protection device include three speed tunnels
which are used to receive the measurement of the turbine speed individually. The monitor
module continuously monitor the value received of three tunnels. It is able to change the setting
of the system by the button on the front panel.
Two units of overspeed protection device provide the electric power of the rapid close valve.
When any of the unit acts, all rapid close solenoid valve will lose power immediately then the
valve will be closed rapidly by spring action, then the turbine will be tripped.
Speed module emits “trip” signal after logic deal. Two units of protection system is in series
and cut off the power supply of rapid close solenoid valves to trip the turbine.
The overspeed protection signal also send the action signal to ETS, after 2 oo 3 logic deal,
with other protection signal, the protection signal will send trip signal to rapid close solenoid
valve through the module.
Turbine speed signal comes from six speed measurement probes which installed at #2 bearing
pedestal to six speed module of two overspeed protection device units, DEH receive pulse signal
by overspeed protection device.
Figure 1. Speed measurement probes
Thewritten
IC.Z10.60302.01-E00 Page 2 of 9
To match up with E16 series overspeed protection device, A5S contactless series Hall speed
transmitter is picked to measure the turbine speed.
A5S series speed probe is active device, which power is supplied by DEH cabinet. The output
is nominal square wave. Installation gap is recommended as 2-2.5mm, further installation
information will be showed on probe specification.
3. Data acquisition system

Data acquisition includes input/output cards, DPU and other related logic process. Protection
signals from turbine and other systems will be send to card then to DPU, after related logic deals,
the trip signal will be formed to trip solenoid valve by output card to trip the turbine
immediately.
Due to not use of special trip solenoid valve, ETS send separated trip signal to each rapid
close solenoid valve. In addition, this unit does not adapt the design of OPC solenoid valve, DEH
send overspeed protection signal to governor rapid close solenoid valve to close the governor
valve immediately.
The system consists of DPU, input/out cards, overspeed protection device, and etc.
The processor adopts TRICON triple-module redundancy structure. These processors run in
parallel. The degradation mode of the system controller、IO module and the bus are 3-2-1-0. The
system achieves the safety integrity 1, 2, or 3 defined in the functional safety standard IEC
61508. Each digital module contains intelligent control circuits suitable for three identical sub
circuits (A, B, C). Although these sub circuits are mounted in the same module, they are
completely isolated from each other and work independently. A fault on one branch will not be
transmitted to another. Each branch contains a 8 bit microprocessor (IOP), which processes
communication with its corresponding main processors.
Each sub-circuits asynchronously measures the input signals on the analog input module. And
places the results in the numerical table. The three input tables are transmitted to the
corresponding master processor modules through the corresponding I/O bus. Input tables in each
main processor module are transmitted to adjacent main processors via TBIBUS, and select the
medium value. The input tables in each main processor are modified according to the medium
value. In TMR mode, the medium value is applied to the control programs, and average value is
Thewritten
IC.Z10.60302.01-E00 Page 3 of 9
used in dual modules.
Figure 2 Configuration diagram for TRICON system

超速保护#1
速度传感器1
速度传感器2
三取二
切断电磁阀供电电源速度传感器3
处理器 2
处理器 1
通道 1
汽轮机遮断按钮
通道 2
通道 1
通道 2 发电机保护信号
I/O通道 3
超速保护#2
I/O通道 2 I/O通道2
速度传感器4
故障安全卡件
I/O通道 1 I/O通道1
速度传感器5
三取二
速度传感器6
保护条件1
保护条件2
保护条件3 主汽门/调门油动机
再热主汽门/再热调门油动机
#1关闭电磁阀 #2关闭电磁阀补汽阀油动机
冷再热逆止阀
高排通风阀
Figure3 Schematic diagram of emergency trip system

Turbine protection system receive signals from transmitters, thermocouples and other devices.
Protection signal send to DPU through input cards. The redundant signals is distributed to
different cards, and deal two out of three logic by controller, finally trip signal is sent to rapid
close valve through redundant DO cards. When these signal values exceed the preset alarm value,
alarm occurs. When these value exceed the trip value, trip signal forms to trip the turbine.
Protection loop structure
Thewritten
IC.Z10.60302.01-E00 Page 4 of 9
Standard protection strategy is 2 out of 3 logic configuration (except bearing vibration signal
is 2 out of 2). The loop consists of data acquisition device, data processor, limiter, trip signal
producer and output device. Turbine protection adapts analog measurement and signals are
continuously monitored and compared. Signal processing is performed through a digital
automatic system. With this design, all turbine protection loop can be accuratly completed
without additional testing equipment. The protection conditions of steam turbine unit are
determined by the safe operation of steam turbine unit. If protection loop are not on ,the unit will
not be allowed to operate. After the signals are summed up, the turbine protection trip
signal is sent to the TTS system (Turbine Trip System) for processing.
TTS system receive digital signal, including Overspeed protection, generator protection, boiler
MFT, emergency trip button and turbine protection signals, through relative input modules to
DPU, then the data will be processed in DPU as trip signal, through the redundant output module
to rapid close solenoid valve on EH motor, the signal will be sent to close the valve immediately.
TTS logic should be in one independent DPU.
4. EH Shutdown System
For the shutdown system of this turbine unit, every EH motor is individually to act. Two
series-wound rapid close solenoid valve is installed on each EH motor. If one of the solenoid
valve act, the valve will close rapidly. Every solenoid valve receive ETS trip signal individually,
then close the valve. The solenoid valve is nominal charged, acts when power off. The power
supply is 24VDC, from ETS DO card.
单向阀快关电磁阀
电液伺服阀
过滤器
P 压力油 T 回油
Figure4 Oil motive principle diagram

Thewritten
IC.Z10.60302.01-E00 Page 5 of 9
5. Protection Specification
5.1 Shutdown Manually

Due to no fly ball, emergency governor pilot valve, and diaphragm valves for this turbine unit,
it is unable to stop the turbine at the front of turbine unit by mechanical device. Thus, there is an
electronic emergency stop button at the front of the turbine instead, for this loop there has 3 NC
and 1 NO contact, the turbine emergency trip button together with the emergency button in
control room are in 1 series loop. These buttons connect to ETS system to cut off the power
supply of the rapid close solenoid valve, then the turbine will be tripped. The button in control
room adapt toggle button design, each button has 4 NC and 1 NO contacts. 3 NC contacts with 1
contact of turbine front loop combined as a new loop, after two out of three logic deal, the signal
will be used for trip. One signal will connect to the solenoid valve power supply circuit to act the
valve directly.
Figure5 Electronic emergency stop button principle diagram

Three trip signal connect ETS cabinet separately, and refer the schematic diagram for
connection.
Thewritten
IC.Z10.60302.01-E00 Page 6 of 9
5.2 Vibration Protection MAD11/12/13/14/15CY121 ， MKD11CY121 ，
MKD12CY121，MKD21CY121
This turbine unit adapt bearing landing structure design, turbine adapt flexible design, thus,
bearing protection use bearing pedestal (absolute vibration) protection, and bearing vibration
( relative vibration) is only used for alarm. If the vibration value exceed the recommend trip
value, operators trip the turbine manually.
Two bearing pedestal vibration probe installs at 45 degree horizontally close to each other.
These two signals send to ETS protection system through TSI as 4-20 mA analog signal, after 2
out of 3 deal, turbine will be tripped if the measurement value exceed the trip value.
Also, TSI send channel alarm signals after vibration channel fault. Trip value signal and
channel fault signal combined together then trip the turbine.
Probe from X, Y direction will send the vibration signal to TSI, after composition the signal
will be sent to DEH for alarm.
5.3 Axial Displacement MAD12CY111/112/113

At #2 bearing pedestal there installs 3 axial displacement measuring probes, the signal will be
sent to ETS after TSI process, and deal with 2 out of 3 in DEH.
5.4 Bearing Temperature

Each bearing of the unit is equipped with two triple thermocouples to measure the metal
temperature of the bearing (of which #1, #2 bearings are equipped with two upper and lower).
The thrust bearing is equipped with two triple thermocouples on each positive and negative
thrust surfaces. Three signals of each thermocouple enter into the ETS system and deal with 2
out of 3 logic. When the temperature exceeds the limit action， the turbine will be triped.
5.5 Lube Oil System MAV42CP/116/117/118、MAV10CL121/122/123

Lube oil system has lube oil pressure and lube oil tank level protection. The signals are all
received by three transmitters, then convert to 4-20mA signal to ETS, with two out of three deal.
Pressure measure points and oil tank level transmitter are integrated at lube oil pipes. Lube oil
pressure-measure points locates at the main oil pump after oil filter. The trip value is according
to lube oil working pressure function(refer 00.92).
Thewritten
IC.Z10.60302.01-E00 Page 7 of 9
5.6 Condenser Vacuum MAG10CP103/104/105，MAG20CP103/104/105

To protect the last stage blade of turbine and condenser, it is necessary to restrict the pressure
of condenser, when the pressure exceed the trip value, the turbine will be tripped.
Condenser vacuum protection pick a fixed value and alterable set value in protection process.
When the pressure exceeds the set value, the trip signal will be formed. Alternative condenser
pressure is relative to set point and LP inlet pressure (flow tube pressure). After the value exceed
the trip value for 5 seconds, the trip signal formed. The diagram below is just for reference, the
actual value of the project shall prevail.
Each condenser vacuum measurement and LP inlet steam pressure measurement use three
transmitters. Two condensers are equipped separately.
5.7 EH Low Pressure Protection MAX01CP101/102

There is a pressure transmitter at every outer of the EH fluid pump. When two pressure value
are under the specific value, protection signal will be occurred after 5 seconds.
5.8 HP blading temperature protection MAA50CT115A/116A/117A

HP blading temperature protection is used for inlet steam temperature protection (after balding
stage 12), due to the special design of ultra-super critical unit model, this temperature measure is
used for HP exhaust protection. Three thermocouples will be installed here, when the
Thewritten
IC.Z10.60302.01-E00 Page 8 of 9
temperature exceed the alarm value, HP temp controller will be active to cut off the HP exhaust
temperature by increasing HP inlet flow; when the temperature exceed the protection value. The
turbine will be tripped.
5.9 LP Exhaust Temperature High Protection MAC10CT171A/172A/173A，
MAC20CT171A/172A/173A
To prevent the last stage blade not exceeding the nominal working temperature, add three
thermocouple at the end of the LP cylinder to monitor the temperature. When the temperature
reach a high value, DEH will open the LP water injection to cut down the temperature, if the
temperature keep raising, the turbine will be tripped.
5.10 Other Protection

Protection system receive the protection signals from other system including generator
protection signal, boiler MFT, generator water level protection and etc.
6. ETS Figure specification
Thewritten
IC.Z10.60302.01-E00 Page 9 of 9
Fifure6 ETS Monitor
Figure 7 ETS First out
Thewritten
Servomotor
2020.04
Specification Checked：Wei Yuan
CONTENTS
SERVOMOTOR SPECIFICATION ................................................................. 1
1. General ............................................................................................................. 1
2. Governor Valve Actuator ................................................................................ 1
3. Stop Valve ......................................................................................................... 3
4. Specification ..................................................................................................... 3
Thewritten
IC.Z10.61201.01-E00 Page 1 of 4
SERVOMOTOR SPECIFICATION
1. General
EH oil actuator is single side acting, that is, opens by the pressure of the EH supply system
and closes by the spring force.
The actuator is mounted directly on the valve. Closing spring chamber is between valves and
oil actuator, which also can play the role of insulation. When the actuator in the fully closed
position, the spring has a certain amount of pre-compression, this can provide pre-pressure. The
high pressure oil acts on the piston of the cylinder to overcome the force of the spring, so as to
open the oil actuator.
The actuators, depending on the control mode, divided into the main valve actuator and
control valve actuator. The main valve actuator is fully closed and fully open type, only the fully
open and fully closed two positions. The control valve actuator can keep under control
requirements in different valve position.
The number of actuator, depends on unit design. One unit contains 2 stop valve actuator(SV),
2 governor valve actuator(GV), 2 reheat stop valve actuator(RSV), 2 intercept valve actuator(IV)
and maybe1 overload valve actuator(OLV).
2. Governor Valve Actuator

Governor valve actuator, intercept valve actuator and overload actuator are regulated, can
maintain at different valve position base on the control requirements.
As shown in Figure 1, the governor valve actuator are consist of spring chamber (including
closing spring) ,cylinder, servo valve, quick closing solenoid valve, check valve, filter,
displacement sensor, spill tray, electrical junction box and other components.
Pressure oil from the oil supply system runs through the filter, and then divided into two ways,
one way to a fast-off solenoid valve, the other to the electro-hydraulic servo valve. Fast close
solenoid valve is redundant configurations, receives signal come from the turbine protection
system. During normal operation the solenoid valve is energized state, if it loss of power, lead to
the valve close quickly. When the fast off solenoid valve lost the power supply from the
protection system, the solenoid valve will control the one-way valve connected to the return oil,
the check valve opens. The check valve connects the upper with lower chambers of the cylinder
piston, so that the upper and lower chamber of the piston chamber was connected, balance the oil
pressure of piston on both sides. The actuator moves rapidly under the spring force, the oil in the
Thewritten
IC.Z10.61201.01-E00 Page 2 of 4
cylinder lower part return to the upper portion, and to accelerate the speed of the oil return, so
that the closing time of the entire oil actuator is controlled within 0.2 seconds.
The electro-hydraulic servo valve receives an electric signal from control system, according to
the needs sent pressure oil to the piston to open the valve, or release the pressure oil from the
cylinder so that the valve is closed .The control system accepts the position feedback signal of
the valve, compare with control signal, issued a directive deviation signal to the electro-hydraulic
servo valve, thus to precisely control the valve to the required position.
In order to prevent the impurities in the oil entering into the oil actuator, before pressure oil
into the solenoid valve and the electro-hydraulic converter, first pass the 25 μ and 10 μ filter.
Solenoid valve block is installed in the cylinder body. The quick closing solenoid valve, check
valve and an inserted type one-way valve are fixed on this block. Solenoid valve block
connected the internal oil loop with oil cylinder line. Quick closing solenoid valve is two
positions-three way electromagnetic valve, it is used to receive the protection system’s control
signa.When the coil energized, the pressure oil P port and control port A are connected, the
pressure oil effect on the check valve. When the coil power is lost, the electromagnetic valve
pressure oil P port closed, that will connect control the oil A port with return oil port T, the
pressure oil of the one-way valve will connect to return line, the one-way valve opens, and then
control the oil X1 connect to oil return T. In the pressure oil port P of solenoid valve is also
arranged an φ 0.8 orifice. The control oil for an electromagnetic valve X through the check valve
connect to control oil X1, to ensure after the electromagnetic valve is electrified, control oil X1
can establish directly pressure.
For accelerate close rate, add a bigger through-flow area check valve in the downstream
additionally.
Thewritten
IC.Z10.61201.01-E00 Page 3 of 4
Fig1 Schematic diagram of governor valve actuator
Fig 2 Schematic diagram of electro-hydraulic converter

Electric hydraulic converter is a kind of 2 stage servo direction valve, consist of the motor
with permanent magnet (2) of the first (1) and the design of nozzle flapper valve hydraulic
Thewritten
IC.Z10.61201.01-E00 Page 4 of 4
amplifier, used to control the mainstream volume second (4).Pilot control is nozzle baffle type
amplifier. When the torque motor (2) is not running, the tube keep straight (5) so that the baffle
(6) and the armature (7) in the middle position. Baffle (6) moves (9) in intermediate position of
the nozzle, that results pressure difference on the side of control valve core (10). Due to this
pressure difference, the feedback rod change the position. The feedback rod (11) fixed to the
armature (7) is inserted in the control valve core groove. Control valve (10) changes its position
until the feedback torque and torque electric motor phase equilibrium, the pressure is reduced to
zero. Thus, the control spool (10) trip is proportional to input signal. The actual flow rate from
the valve to the actuator of depends on the valve differential pressure. External electronic
amplifier (servo amplifier), is used to control the valve. The analog input signal (a given signal)
magnified, mading output signal from control electronic amplifier can be used to control servo
valve.
Displacement transducer uses the type of magnetostriction, built inside withnoncontact
structure. It is characterized by high precision, high reliability, and is not easy to damage. The
device is mainly composed of a rod, an electronic storehouse and sheathed on the rod of
non-contact magnetic ring, magnetic ring fixed in the actuator piston rod, moves with the piston
together. By measuring time differences between the magnetic pulse electronic cabin and the ring,
the displacement can be precisely measured. The output signal is 4-20mA, and the signal is sent
to the control system as feedback. When the transmitter is break down, the actuator will close
gradually.Principle of overload valve actuator is the same as governor valve actuator, the only
difference is the number of check valve, overload valve actuator just have one tier check valve.
3. Stop Valve
The main valve actuator is fully closed and fully open type, only the fully open and fully
closed two positions.
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IC.Z10.61201.01-E00 Page 5 of 4
Fig3 Schematic diagram of stop valve actuator
4. Specification
Electrical junction box on the cylinder block, all electrical signals ( valve, electro-hydraulic
converter, liquid level switch, and displacement sensor) connects to junction box, then to control
cabinet.
Return oil directly back to the tank through a return pipe.
The actuator assembled in factory must be clean, without any impurities. In the power plant
after installation, there is no need to flush again.
The main stop valve and control valve share one pressure pipe and a return pipe. Tank outlet
for the pressure oil is equipped with isolation valve, actuator failure needs no shutting down of
the unit for maintenance. Close the isolation valve, the corresponding main stop valve and
control valve can be isolated from system, and process the equipment.
Thewritten
Fire-Resistant
Hydraulic Oil
Checked：Wei Yuan 2020.04
System Operation
And Maintenance
Countersign：Li Gang 2020.04
IC.Z10.62202.01-E00 Countersign：
Reviewed：Chi Dingnan 2020.04
CONTENTS
FIRE-RESISTANT HYDRAULIC OIL SYSTEM OPERATION
AND MAINTENANCE .......................................................................................1
1. Use Safety Instruction .....................................................................................1
1.1 Introduction ............................................................................................1
1.2 Hydraulic System Safety Tips ...............................................................1
1.3 Transportation And Storage .................................................................3
2 Installation And Debugging Of Hydraulic Equipment .................................5
2.1 Hydraulic Oil ..........................................................................................5
2.2 Placement of EH Tank ...........................................................................6
2.3 Electrical Connection ............................................................................7
2.4 Startup Procedure ..................................................................................7
3. Maintenance .....................................................................................................9

3.1 Replace The Filter ................................................................................ 11
3.2 Check Hydraulic Oil ............................................................................ 11
3.3 Motor..................................................................................................... 11
3.4 Replace Air Filter ................................................................................. 11
3.5 Cooler .................................................................................................... 11
3.6 Accumulator Pressure Checking And Re-Inflates Description ....... 11
4. Correct Maintenance .................................................................................... 13
5. Maintenance .................................................................................................. 13
5.1 Preventive Maintenance And Inspection .......................................... 14
5.2 Maintenance ........................................................................................ 18

IC.Z10.62202.01-E00 page 1 of 25
FIRE-RESISTANT HYDRAULIC OIL SYSTEM OPERATION AND
MAINTENANCE
1. Use Safety Instruction
1.1 Introduction
In order to skillfully operate this hydraulic system, operator should follow these instructions
and familiar with its contents.
This specification provides the normal guidelines and maintenance of hydraulic system for
operators. Lacking of knowledge of the oil system, may lead to misuse of the facilities, which
will lead to dangerous to some extent. Or cannot develop the system function sufficiently.
After reading this specification does not mean that the operators can ensure the safe operation
of the hydraulic system. Instead, the operators should pay attention to the relevant part, and well
aware of security matters within its scope of work.
Pay attention to the following normal operation, maintenance and debugging security matters:
1. Before activating the system, pay attention to the surrounding environment, particularly
other people or sundries in the working area.
2. Before activating the motor, check and make sure all control elements (such as valves,
buttons etc.) are in work-off state.
3. During the operation of the system, be aware of other people not entering non-secure or
dangerous areas. Once find, stop the system immediately.
1.2 Hydraulic System Safety Tips
1.2.1 Potential Dangerous For Hydraulic System Under Normal Operation
Can Be Divided Into Two Categories:

1. "Potential dangerous of action components"
Levers, cylinders or other components in the system which can still move after system stop, or
the components may move while the seal was tear, it's gonna be dangerous if the operator
accidentally approach to their scope of work .
2. " Potential dangerous after hydraulic oil be pressed"
Hydraulic system includes the assemblies, such as check valves, accumulators and other
similar facilities, that can still retain system pressure in some pipes after hydraulic oil pump and
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IC.Z10.62202.01-E00 page 2 of 25
the motor stopped, the cause of the pipeline pressure, one of which may be the system has a
regular load (such as crane system), when these assemblies need repairing or changing, without
proper treatment or system pressure release, will probably pose a danger.
1.2.2 Warning:
Before removing the seal, components or pipes on the systems, must be aware of the following
four points:
1. The motor power must be switched off (an electrical engineer in charge of power-off work).
2. When the power is switched off, it should be in a secure location for operation, if necessary,
can use safety belts or other safety equipment.
3. Use mechanical bracket or support tools to support the load of all actions components (such
as cylinder, motor etc.), then start repair or adjustment work. In addition, we also need to cut off
the supply of the oil.
4. Release residual pressure of system, piping and components.
1.2.3 Notes：
Even if the reading of pressure gauges are zero, this cannot fully guarantee the hydraulic
system has released all the residual pressure in the pipes. Check all pressure relief points and
measurement points while reopen if necessary. Make sure that all residual pressure has been
released before work.
1.2.4 Re-Inject Pressure To System:

It must re-adjust the system after repair and maintenance. When pressure of system and
components increase gradually, pay attention to the pressure whether it rises smoothly or not.
1.2.5 Note Items When Re-Activate The System：

1. Notify each employee that the system is about to be re-activated.
2. Check all the pipes, fittings and pipe clamps, make sure they arefully tightened.
3. Check all security settings are ready or not, such as safety door has been shut, the protective
cover has been dropped etc. Electric box door must be closed.
4. Ensure that each staff clearly know that the system is about to be activated.
5. Make sure that no one are in the "danger zone."
1.2.6 Environmental Protection Consciousness:

Do not dispose of hydraulic oil to the drain water pipes, rivers and sea.
Fill waste oil in containers, clean the greasy dirt with water and abluent.
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IC.Z10.62202.01-E00 page 3 of 25
Dilute stored waste oil with pure water before disposal.
1.2.7 High-Pressure Hydraulic Jet:

High-pressure hydraulic jet is very dangerous. It may cause permanent damage to human eyes.
To avoid danger, do not let your hand or fingers on the holes or the cracks.when the system
pressure raise, high-pressure hydraulic jet tends to occur in these areas. In addition, fittings or
flange fails to tighten, will cause high pressure hydraulic jet or other hazards. Therefore, we
should raised the system pressure gradually during commissioning, and pay attention to the
system to make sure weather there is any leakage, do not rise the pressure from the lowest to the
highest value abruptly, or even exceed the system maximum working pressure setpoint.
Warning:
High-pressure hydraulic jet would cause serious eye injury, also can invade into the
bloodstream through the skin. Therefore, if the staff is injured by high-pressure hydraulic jet,
immediately seek medical treatment of the hospital.
The hydraulic oil has chemically toxic, once contacted, rinse with water, and once serious
need to seek medical treatment of the hospital immediately.
1.2.8 Lifting Equipment

The device weighs about 4 tons (without oil), lifting rope angle should less than 45 degrees.
1.3 Transportation And Storage
1.3.1 Transportation
Hydraulic oil tank can be transported with lifting equipment. Only suitable lifting attachments
can be used.
The general safety guidelines must be complied during transportation. Exhaust the oil in tank
before transporting.
Make sure Hydraulic oil tank is clean and no oil in it. But the hydraulic oil may still in the
tank after leave-factory check and acceptance (see 3.2.1 "Factory corrosion protection").
Transport with lifting equipment
Members (parts, pipes, etc.) on the tank must not be in contact with the lifting device.
- Install appropriate eyebolts on the box.
- lifting carefully, keeping the center of gravity stable.
Note: hanging loads
1.3.2 Storage
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IC.Z10.62202.01-E00 page 4 of 25
1.3.2.1 Anticorrosion in plant
The residual oil film after the test may provide short-term protection against internal
corrosion.
On the other hand, if the tank tends to be stored for a long time, we can choose
corrosion-resistant hydraulic fluid.
Further internal anticorrosion can be accomplished by oiling (internal chamber refilling
corrosion-resistant hydraulic fluid).
1.3.2.2 Internal protection
Provide protection to achieve internal storage time shown in Table 3 through the tank test or
refilling protective liquid to equipment and tank.
Refill protective liquid to tank, start briefly then let the liquid out. All pipe connections should
be sealed through plugs.
If the protection is taken by refilling oil as shown in Table 1, we can use appropriate protective
liquid to test the tank. Protective liquid will remain in the equipment and components.
The connecting tubes are sealed via plug screws or flanges. There is no need to full fill the
tank with oil. Injecting suitable anticorrosion oil through any device components, such as pumps,
control devices and filters, is enough.
Table 1
Storage conditions Package anticorrosion storage time (months)
oil 3 6 9 12 24
| | | | |
storage at a constant seaworthy A
temperature, dry site not seaworthy A
B
Outdoor storage (to seaworthy A
prevent damage and B
moisture from not seaworthy A
entering) B
Use preservative fluid test A= Mineral oil / phosphate oil
Full filled with preservative fluid B= preservative fluid
If storage time is longer than the time shown in table 1, some of the equipment, especially the
hydraulic pump must be disassembled, cleaned with suitable cleaning to remove the residual oil
inside the device and replace the seal.
1.3.2.3 External protection information
Suitable paint is used to provide external protection (anticorrosion).
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IC.Z10.62202.01-E00 page 5 of 25
If stored in dry, constant temperature environment, and storage time no more than six months,
then use basic paint protection.
If stored for longer than six months, it is necessary to use an appropriate topcoat.
1.3.2.4 packaged hydraulic equipment and information systems
If open the package for check, it is necessary to reseal the unit carefully. For shipping
packaging, it is necessary to add new desiccant.
2 Installation And Debugging Of Hydraulic Equipment
2.1 Hydraulic Oil

Please use the AKZO Company’s FYRQUEL EHC PLUS or similar fire resistant hydraulic oil.
Only the prescribed oil can be added to the tank. Pay attention to preventing the infiltration of
water during refueling.
Fluid cleanliness recommendations:
- Must be flushing before the system starts, for details, see “install and flush instructions of
fire resistant oil".
- When filling the hydraulic oil to the tank, use dedicated tools.
- Solid particles in the system should not exceed the NAS1638 level 5.
- According to the prescribed maintenance period, analysis the hydraulic fluid regularly,
especially vigilant that when removing components for repair or maintenance, make sure the
system are sealed perfectly in order to prevent the dirt entering the hydraulic system.
Requirements:
According to ISO 6743/4 resistant oil is anhydrous liquid and composed of phosphate. Marked
with the ISO-L-HFDR. Triaryl phosphates is the reaction product between phosphate hydroxide ,
phenol and phenol derivatives containing natural raw materials (natural fire resistant oil) or
artificial material (fire-resistant oil). The final product must be phosphorus cresol compound that
free of nerve hazardous.
In order to improve certain properties, such as corrosion protection, oxidation stability, it may
contain additives that have no side effects on material and performance. Resistant oil must not
cause deposition of the following materials: iron, copper, copper alloy, zinc, tin and aluminum.
Fire resistant oil used in the system must have the material erosion protection function. The oil
can be regenerated continuously by the regeneration device. It must not cause any erosion and
corrosion, especially to the edge of the control module.
Resistant oil viscosity level must comply with ISO VG46.
Under normal conditions and regeneration conditions mentioned above, the fire resistant oil
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IC.Z10.62202.01-E00 page 6 of 25
can operate at least 25,000 hours without any maintenance. FRF must have shear stability. It
should not contain any chemical amendment.
The oil leaking from the system cannot be ignited or burned when contact with hot surfaces
(550°C). And its physical and chemical properties should not change at 75 °C during long time
running.
Resistant oil must be able to mix with other types but the same "group"(natural or synthetic)
triaryl phosphate ester (volume ratio of 3%). And the nature of the oil should not change at this
mixing ratio.
Resistant oil system must be compatible with the following packaging material:
Fluorocarbon rubber, butyl rubber, triaryl phosphates, polyethylene, polyamide acid,
hydrochloric acid diisocyanate adhesives, polyurethane / polyester.
Resistant oil must not cause the safety and health damage to staff who observe the general
industrial use.
Limit values:
During the lifetime, cannot exceed the following limits:
a) Kinematic viscosity: maximum ±5% change compared with delivery conditions.
b) Neutral Number: at most increase 0.20mgKOH/g compared with delivery conditions.
c) Air release: maximum 12 minutes
d) Foaming: 50 °C
Trend: Max 220ml
Stability: Maximum 450s
2.2 Placement of EH Tank

A certain space should be reserved around the EH oil tank to ensure free ventilation and
sufficient maintenance space.
All the tubes (either water or hydraulic lines) must reserve sufficient space for maintenance
when installed, major maintenance (for example: a motor or pump replacement) will require
more space. Tank assembly cannot be installed in the vicinity of high temperature (such as heat,
spotlight, etc.). The media (fire resistant oil) flash point and burning point information see data
sheet.
Before installation, remove dirt on the pipe, attachments, burr, iron, etc., especially welded
pipe wall should smooth and clean.Waste cotton for cleaning is forbidden.
According to the manufacturer's operating instructions for assembly, packaging materials,
such as fibers and fillers, are not allowed in order to avoid contaminating the system.
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IC.Z10.62202.01-E00 page 7 of 25
Also attention the following points:
- Solid foundation (to avoid vibrations)
- Convenient for maintenance and repair
- Proper protection from weather, fog, heavy pollution and radiation
- Ensure adequate air flow, so that the motor can work very well.
- As short as possible of the pipe.
2.3 Electrical Connection

a. EH tank terminal box/junction box.
Connect the terminals according to the drawings of the terminal box wiring.
b. Main motor
Accomplish the voltage connection according to the value on the nameplate.
2.4 Startup Procedure
2.4.1Before Start
Cleanliness requirements:
- Hydraulic system must be thoroughly flushed to ensure that the internal system is
absolutely clean.
- check the cleanliness of the system before filling hydraulic oil.
Inspect the Pipeline system:
- Joints are tightened?
- Piping system is already clean?
- Are there any presence of stress in the the piping system after installation?
- Whether all the pipes are well arranged according to the installation plan or piping
arrangement diagram?
Check electronic control components:
- Check the voltage of the motor, control system and other electrical components?
- Check the function of electrical components and monitoring system manually. If the element
not working, check the wiring weather is correct or not, the possibility of manual operation.
When oiling the tank, check the fluid level switch and level gauge.
2.4.2 Fill Hydraulic Oil To The System

Before refueling
- Check the grade and quality of hydraulic oil, do not mix different brands of hydraulic oil to
use.
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IC.Z10.62202.01-E00 page 8 of 25
- Check the hydraulic oil container, tank and hose, make sure they are not contaminated by
water or other substances.
Use trolley equipped with oil filter to refueling the hydraulic system, filter filtering accuracy
3μ. New oil can bring the pollutants into the hydraulic system, so be sure refueling through the
oiler. Observe with the naked eye when refueling the first time, tank level gauge must reach
914mm. Use fuel filter device to ensure that the granularity meet the requirement. Pay close
attention to the tank highest/lowest level, considering the residual oil in the fuel pipeline and
consumption.
2.4.3 Initial Startup Program

Attention！
- Ensure that the drive system and the drive mechanism are in the standby state, warn all
relevant staff that the starting is about to begin.
- Do not use defective tools or control elements to operate the EH tank.
- Flammable items must be far away from the EH tank.
- During start-up, dirt particles embedded in the hydraulic system are washed out, so we
should observe filter indicator during the whole starting process. When the weatheris cold，oil
viscosity is relatively large, there may be a short blockage indication. If the system has reached
operating temperature and indicator cannot be eliminated, the filter must be replaced.
Step 1 before start
- Check the fluid level in the tank, the tank level must reach 914mm.
- Check whether some elements need to add clean hydraulic fluid.
- Check safety equipment.
- According to the control summary, check all the electrical signals whether meeting the motor
start conditions or not.
Step 2 the hydraulic pump short start of no-load
First check the pump rotation is correct or not, incorrect steering certainly cause damage to the
hydraulic pump. There are clear signs on the motor for rotation. We should start the motor of EH
tank in a completely no-load conditions.
Step 3 the hydraulic pump long operate with no-load
Pump run long time in no-load state, and exclude the air in the pipe through the piezometric
joint until the system is stable and operable.
- Check the fluid level of the tank, because hydraulic components in the system must be filled
with the oil, then it need to increase the hydraulic oil again, so that the oil level restored to its
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IC.Z10.62202.01-E00 page 9 of 25
original state.
- Check abnormal noise and vibration.
- According to the technical documentation that came with the hydraulic system of the values
indicated in the figure, inspect EH tank pressure value that has been previously set-normally at
the factory.
- Check the leakage.
Debugging Problem: The device installed in the system, under certain operating conditions
(weight, speed, control, different set points), the same tank will play different performance (may
also have a different error message). Overall, during the pre-debugging and debugging, it is
necessary to test and analysis the oil.
Refer to the "cause of the malfunction and impacts on the fuel tank" to diagnose system faults
and limitations.
Stop motor
- Correct all deficiencies found in the above.
- Check all connections, bolts, etc., if necessary, re-tighten.
- Restart when finished.
Step 4 load for hydraulic system
When the hydraulic system functions under no-load conditions has reached all the technical
parameters, the system can be loaded.
- Gradually increasing the load until a satisfactory operation.
- In this process, it is possible to adjust output flow of the pump.
- Make the system work cycle until the system has reached normal operating temperature.
Step 5 checks
- Check unusual noises or vibrations.
- Check functional of safety equipment.
- Check the cooler control is stable.
- Check the leak.
- Check the pump pressure set point.
3. Maintenance
Planned hydraulic system maintenance can prevent the failure of the hydraulic system, while
the system can operate effectively as required. This particular maintenance procedures depends
on the characteristics of the device, the environment and work cycle, as well as the importance of
the systems. In order to maintain the life cycle economically, lifetime cycle cost (LCC) analysis
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IC.Z10.62202.01-E00 page 10 of 25
is recommended.
Routine inspections after the first week of operation
- Oil Leakage
- Tank level
- Operating temperature
- System pressure
- System performance and overall state
- Unusual noise
- Contamination indication of the filter
Check before each starting
- Oil Leak
- Tank level
- Suction valves open or not
Always check
- Abnormal vibration
- Unusual noise
- Oil Leak
- Tank level
- EH tank clean? Airflow duct patency?
- The usual pressure value is stable?
- Operating temperature
Scheduled maintenance
There are plans to maintain within a specific period, include the following checks and actions:
- Always check all the points
- Check all pressure values
- Check a fixed temperature value around the system
- Release water and mud from EH tank vent valve
- Check the motor
- Check function of monitoring equipment / switches and other components
- Clean dirt area
- Check wiring
- Check drain line flows and oil condition
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IC.Z10.62202.01-E00 page 11 of 25
- Check the hoses, connections and pumps, pay attention to whether there are cracks, leaks
happened
- Check coupling through inspection hole
3.1 Replace The Filter

- Stop operating and stop the motor
- Unscrew the filter cartridge counterclockwise to replace the filter
Do not take out the new filter immediately to avoid infected with dirt during installation.
Check the filter canister O-ring is damaged?
- Install the filter cartridge, tighten the screw.
3.2 Check Hydraulic Oil

It is recommend that to test hydraulic oil every six month, such tests include viscosity,
oxidation, water content, impurities and dirt content. In most cases, oil supplier can engage the
laboratory work, provide the current status of the hydraulic oil, and recommend appropriate
action. If the tests indicate the quality of the hydraulic oil cannot meet the "hydraulic oil
cleanliness requirements" requirements, the oil cannot be in use and must be replaced or cleaned
immediately.
3.3 Motor
Check whether the motor vents are blocked by trash and whether the air is easy to enter the
motor.
3.4 Replace Air Filter

- Cleanthe surface of air filter
- Remove the cap and replace the filter
- Fit the cap, ensure that no foreign matter into the tank
3.5 Cooler
The temperature is below 0℃, and the cooler does not work, so the water must be exhausted
in order to avoid cracking.
3.6 Accumulator Pressure Checking And Re-Inflates Description

Normal operating pressure of Nitrogen pressure accumulator is 93bar, can be read from the
accumulator pressure gage, then the lower part of accumulator pressure should be zero. Inspect
accumulator weekly, if the pressure drops to 82.7bar, it should be re-inflated. When checking the
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IC.Z10.62202.01-E00 page 12 of 25
pressure, if you follow the outline described below, operation of the unit will not be affected.
The HP oil connected to the accumulator through the safety valve, safety valve contains an
isolation valve, a drain valve and a pressure relief valve. Accumulator can be isolated from the
system through isolation valve. Drain valve connect accumulator side oil with the drain oil.
When the system pressure exceeds setting of the safety relief valve, the relief valve opens, the
pressure oil return to the drain oil.
If necessary, it can be isolated an accumulator to refilling. It is not allowed once cut off more
than one pressure accumulator while the unit in run.
Re-aeration step:
3.6.1 Close The Isolation Valve（MAX01AA251）Of Safety Valve.
3.6.2 Open The Discharge Valve (MAX01AA261), And Let The Hydraulic
Pressure Of Bottom Accumulator Disappear.
3.6.3 Read Out Accumulator Barometer Readings And Record For Future
Reference.
Normal inflation pressure is 93bar. When the pressure gauge reading is less than 82.7bar,
indicating that the accumulator should be re-inflated with dry nitrogen.
3.6.4 Remove The Insurance The Lid Of Pneumatic Pressure Accumulator
Valve.
3.6.5 Connect The Nitrogen Hose And Pressure Accumulator Valve Hose.
Hexagonal nut located top of the pressure accumulator valve loose a circle, so that check valve
released and can be inflated. Open the valve on the nitrogen bottle, till the accumulator pressure
gauge indicates 93bar.
3.6.6 When Charge To The Desired Pressure, Close The Valve On The
Nitrogen Bottle, Tighten Hexagonal Nut On The Top Of The Pressure Control
Valve Accumulator, Closed Check Valve Tightly, Remove The Hose.
3.6.7 Close Accumulator Drain Valve (MAX01AA261).
3.6.8 Slowly Open Accumulator Isolation Valve (MAX01AA251) To The Fully
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IC.Z10.62202.01-E00 page 13 of 25
Open Position.
Repeat the above steps, one by one for other accumulators.
4. Correct Maintenance
Before removing hydraulic or electrical components, first disconnect the connection of EH
tank. Ensure that the system and the motor is safe at present.
Before disassembling
- do fault diagnosis and proper test for EH tank.
- Clean all assemblies and components, bearing in mind the warnings to avoid dirt into the
system.
- Demolition work can only be done by qualified personnel.
Disassembly
- Mark all components, and protect the finished surface or mechanical surface.
- Inspect all parts during disassembly for wear or damage.
- If the hydraulic oil discharged need to be put into use again, then oil containers must be clean,
and should be sealed when not use.
- Before reassembling, using suitable solvent to clean all the metal parts and then use clean
linen to absorb the oil.
Reassemble
- With hydraulic oil to lubricate.
- Replace all seals, gaskets and O-ring with new and the same size spare.
- Make sure the pipe connection completely sealed.
- Refill the hydraulic oil in accordance with the requirements of the refueling system.
5. Maintenance
Maintenance includes prevention and recovery.
Maintenance work is divided into three parts:
- Preventive maintenance: measures to maintain device-specific operating conditions.
- Check: take measures to establish and assess the actual condition of equipment.
- Repair: Measures to restore the specific conditions.
By these means, it can use the most economical way to ensure the reliability of fire resistant
tank.
Fire resistant tank design ensures the most excellent reliability (operation reliability, service
life). They only require little maintenance, but for the device stability was essential.
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IC.Z10.62202.01-E00 page 14 of 25
Experience has shown that 70% faults and damage of the fire resistant tank are indirectly
caused by fire resistant oil. So most of the inspection and preventive maintenance is concentrated
to checking and taking measures to ensure that fire resistant oil properties (physical and chemical
properties, cleanliness, etc.).
5.1 Preventive Maintenance And Inspection
5.1.1. General Information

5.1.1.1 Qualified service personnel
Preventive maintenance and inspection can be performed only by trained professionals.
5.1.1.2 Safety
See "Basic Safety Guide."
5.1.1.3 Preventive maintenance intervals and scope
Intervals and scope of recommended maintenance based on the following criteria: climate,
moderate load and operating conditions and environmental pollution of typical metal industry
(see 5.1.8 "Maintenance and service cycle").
5.1.1.4 Check record
Record the test results is recommended.
This can be considered reliable and economical to adjust and prevent maintenance interval
based on the actual operating conditions.
At the same time through cooperation, it is more easy to find fault.
The temperature gradually increased or filter replacement cycle is gradually shortened shows
that pumps, control components, seal wear and fuel aging, it is necessary to immediately inspect
all those parts.
If the temperature suddenly rises rapidly, it should check the system immediately.
5.1.2 Hydraulic Oil

5.1.2.1 Hydraulic oil temperature
It is recommended tank oil temperature should not exceed 50℃, because the higher the oil
temperature, the faster oil aging, the shorter the life of the seal.
5.1.2.2 Hydraulic oil quality
Hydraulic oil pollution, aging that deterioration of the quality depends on many operating
conditions: such as temperature, operating pressure, filter case, breathing filters, seals connector,
moist air and entering the impurities from the outside environment,etc.
Visual inspection only provide a rough assessment of the oil quality (turbidity situation, looks
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IC.Z10.62202.01-E00 page 15 of 25
darker than when the oil has just added to the fuel tank, and precipitate, etc.).
Hydraulic oil requires laboratory analysis. Take appropriate measures based on results of the
analysis:
-Replacement of aging or the formation sludge of fire resistant oil.
-For impurity fire resistant oil (cleanliness cannot be maintained), use independent filter
cartridge.
In order to remove sludge and water, we suggest remove capacity of about 90% fire resistant
oil, to clean the tank with an outside filter device. The residual oil containing dirt and water
should be discarded. (Important: All waste should be disposed in accordance with the relevant
provisions).
5.1.2.3 Change Oil
According to oil analysis results determine oil change.
Usually, oil analysis before debugging and during debugging process.
Thereafter, the same analysis required annually.
It is recommend every 3 months to conduct a qualitative analysis of the oil.
Take oil samples from the specialized sampling port.
By taking appropriate measures to deal with the oil and the test method, fire resistant oil
change cycle can be significantly extended. (See 5.1.5 “regeneration apparatus")
Warning: Check the fuel tank level is necessary, if necessary, then add the oil, because the oil
level is below the minimum level scale may cause malfunction.
Note: ensure that refueling with fire resistant oil products from the same company, and have
the same cleanliness.
5.1.3 Check Filter

5.1.3.1 Filter with clogged indication
Filter with clogged indication has monitor pollution levels continuously.
There is a cartridge replacement alarm, but filter clogging indicator shows that the filter needs
not to be replaced. If the filter clogging indicator operate normally, the filter must have a fault, or
if bypass valve is installed, it may be because there are impurities in the oil, the bypass valve is
not closed properly.
5.1.3.2 Replace filter (see Maintenance 5.2.4)
Important!
Safety requirements and qualifications of maintenance personnel must meet the requirements.
Air/drying filter allows filtered air into the tank at different tank level. Check the filter in
Thewritten
IC.Z10.62202.01-E00 page 16 of 25
accordance with environmental performance, replace if necessary.
5.1.4 Accumulator
Accumulator is pressure vessel that required to meet the valid local safety regulations (see
"Product-specific operation guidance").
Before the disintegration of the accumulator, the accumulator oil measure necessary relief.
Warning Important: Only use nitrogen (nitrogen volume purity of 99.99% ).
When the accumulator installation must be careful, because improper operation may lead to
serious consequences.
Do not allow welding or machining operations to the accumulator housing.
See also "product-specific operation guidance".
5.1.5 Regeneration Apparatus

Regeneration apparatus filter should be replaced annually (see " product-specific operation
guidance").
5.1.6 Setting
Pressure and flow control valve and pump controller also signal components such as: pressure
switch, filter blockage indicators, etc. are set during debugging. During operation needs to check
these settings do not change.
Setting of pressure valve (e.g. variable pump pressure controller) has a great influence, if the
setting is not accurate, such as: pressure relief valve and pressure valve set difference is small,
during the process of the operation, the safety valve will open, and cause increased power losses
and a sharp rise of the oil temperature.
5.1.7 Maintenance And Service Period

Periodic maintenance and repair parts listed separately maintenance tasks listed below:
All maintenance and repair work must be documented.
Table 2: Inspection and Maintenance Plan
period location item remark
Hydraulic components Visually inspect Oil spill required immediate
on the tank treatment.
Hydraulic pipes and Remove adjacent components, wipe
Every 3 fittings clean leaked oil immediately.
months Note the risk of slipping.
Electrical connection, Visually inspect If damaged need to be replaced
cable immediately, and check for correct
plug installation.
Thewritten
IC.Z10.62202.01-E00 page 17 of 25
inlet of electrical Remove all dirt
motor
accumulator Inspect nitrogen
pressure
Accumulator group, periodically check
safety valve of
accumulator
cooler periodically check
Level of tank Visually inspect
Recommended: Recommended: analysis Recommended: sampling
resistant oil
pressure of gauge Visually inspect
Regeneration Replace filter

Every 12
apparatus
months
Fire resistant oil analysis sampling
all parts Clean all dirty parts. It’s easy to inspect leak oil
Wipe leaked oil with a
cloth
Filter(air filter) Replace filter If filter is dirty, replace in time
Measuring element check the operation
Noise, vibration Inspect flexible parts
Accumulator group, periodically check Adjust
safety valve of
accumulator
cooler clean
Hydraulic pipes Check all hydraulic If any of the following happen,
pipes and threaded Replace pipes at once.
Every connections leaking, see —damage
24months（at the damage. —leak
lease every If damage, repair at —aging
3years） once.
Jetted anti- resistant oil
may cause damage.
Hydraulic components Visually inspect If leak, repair at once.
on the tank Remove adjacent parts, wipe leaking
oil.
Note slipping danger。
Electrical connection, particular inspect There is an aging, needs to be
cable replaced immediately
plug And check for correct installation.
All electrical
equipment
filter pollution Visually inspect
Thewritten
IC.Z10.62202.01-E00 page 18 of 25
indicator If necessary check the
operation
all seals Replace seals seal replacement only by trained and

qualified personnel
Every 5/6
In addition, the In addition, the In addition, the maintenance content
years, or if
maintenance content maintenance content same with "every 24-month check
necessary
same with "every same with "every item"
24-month check item" 24-month check item"
* If it is found abnormal phenomenon at test point, shorten the maintenance cycle.
All test results required an accurate recording. If the test point is not abnormal, the
maintenance cycle can be extended, especially for oil quality testing.
During the Fire resistant oil tank running and the long running, we need pay more attention to
the operation of equipment, reference to the past maintenance cases, to take an accurate
preventive maintenance.
Important!
Some abnormal test parameters, such as: Fire resistant oil temperature, filter replacement
cycle or noise, indicate that the system is changed. Use the troubleshooting tables to pinpoint the
problem.
Replace Parts
Replacing parts must meet the manufacturer's specifications. This can be achieved by using
spare parts.
Use only proven spare parts.
All maintenance and repair work should be implemented by the manufacturer or a qualified
(trained by the manufacturer) personnel. All work are documented.
5.2 Maintenance
5.2.1 General Information

5.2.1.1 Qualified personnel
Maintenance work can only be performed by trained personnel with hydraulic expertise.
5.2.1.2 Safety
Based on security reasons, the system under pressurized conditions, pipe joints, fittings and
components should be tight. It must let load down, relief the accumulator pressure, switch off the
pump and guarante not to be restarted. Must comply with appropriate safety guidelines.
5.2.1.3 Cleanliness
Ensure a high degree of cleaning of all operating regions, because contamination can lead the
Thewritten
IC.Z10.62202.01-E00 page 19 of 25
failure of equipment and may cause harmful influence to safety operation. Before unscrewing
parts and other components, make sure the surrounding area is clean. All opening portion should
be sealed with a protective cap to prevent debris entering the system. Waste cotton for cleaning is
forbidden.
5.2.2 Maintenance Tasks

5.2.2.1 Failure diagnosis
Identification of damage or preventive maintenance. Failure to identify potential causes of
signs.
It requires an accurate understanding of the structure and operation principle, especially
combine of hydraulic and electrical to diagnose Hydraulic System. But electronic systems make
troubleshooting complex, which requires electrical and hydraulic engineers collaborate.
Flowchart, bill of materials and all functional maps will need to be prepared in advance.
Refer to "fire resistant tank failure and cause analysis" to do system failure analysis (see
5.2.5).
5.2.2.2 Fault maintenance
Mainly replace the damaged parts at site.
Only those in the list of materials (spare parts list) can be replaced, only with the new,
identical parts.
Repair work is usually carried out by the manufacturer or qualify personnel. If operating
instructions described the repair work, it also allows operating personnel to repair, if provided
with the corresponding expertise and specialized equipment.
Once the repair is completed, the consequences of failure consequential should also be
eliminated. For example: because of wear causing pump failure, the system will need to wash
clean or replace the hydraulic oil.
5.2.2.3 Function testing and acceptance
According to the scope of work, it is need debugging after maintenance. If necessary, modify
the appropriate file or add guidance in the maintenance manual, through preventive maintenance
can avoid future occurrence of a failure or less possible again.
5.2.3 Assembled Disassembly/Assembly
Thewritten
IC.Z10.62202.01-E00 page 20 of 25
Operating instructions of special offer must comply.

In general
To prevent the control slide valve jamming, it cannot have stress when hydraulic components
installed, which requires the installation of smooth enough. Tighten the mounting screws by
required torque.
It must be careful when install the accumulator, because improper operation may lead to
serious consequences. Do not allow welding or machining operations to the accumulator housing.
It must comply with the relevant accumulator operating instructions.
5.2.4 Replace filter

Important!
5.2.4.1 The safety provisions and staff qualification requirements must be obeyed.
5.2.4.2 Replace filter
If the filter clogging indicator shows that the filter is dirty, replace the filter at the latest at the
time of the end of this class. It needs careful when replace.
5.2.4.3 Replace or clean filter
- Fiber filter must be replaced and cannot be cleaned.
- Used filters soaked in oil at first, and then droplets the oil carefully of filter, the waste should
comply with regulations (environmental protection).
5.2.5 Fire Resistant Tank Failure And Cause Analysis

Fault List:
A) Noise is too large
B) Driving part output torque inadequate
C) Motor rotation is not smooth (pressure or flow fluctuations)
D) Motor does not rotate or rotate too slow (no flow or insufficient flow)
E) Motor does not turn or stop
F) The pump switch speed is too high
G) The impact of switching valve
H) High oil temperature
I) Oil Pollution
Thewritten
IC.Z10.62202.01-E00 page 21 of 25
5.2.5.1 Fault "A": too noisy

Table 3
Fault source Fault Cause
1. Coupling: misalignment, looseness, damage ring
1 Mechanical drive section 2. The pump or motor mounting bolts loose

3. The pump or motor failure
4. turned upside down
1. Pump speed too high or turned upside down
2. The suction and pressure ports staggered
2pump 3. Pump Seal/oil pump failure
4. Vibration of Control System
5. see A1、A2
1. loosening
2. Incorrect installation (such as stress)
3 pressure pipes
the flow noise caused by the small cross-section
4. see A8
1. see A3
4 drain pipes
2. switch shock caused by long pipes or heavy traffic
1. flow noise and vibration due to the size of unworthiness,
non-optimal characteristic lines or due to overload
5 pressure valve
2. The valve vibration caused by other control equipment
vibration
6 flow control valve 1. see A5
1. see A5
2. noise caused by pilot type check valve controlled by pressure

7 check valve
changes generated
3. exceed the performance limit (over-flow)）
1. Hydraulic oil tank level is too low
2. The viscosity is too high (temperature is too low, the viscosity
8 hydraulic oil
does not match)
3. The hydraulic oil bubble (air content is too high)
Thewritten
IC.Z10.62202.01-E00 page 22 of 25
Above three combination can cause inhalation problems: pump

noise, flow noises, switching shocks
5.2.5.2 Fault "B": drive means output/torque is insufficient
Table 4
1. Pump Fault（see A2）
2. the pump displacement is too small or for variable pump, the
2pump
return pressure is set too low, see B 9-2
3. Control equipment failure

penstock pipe resistance is too high (length, cross section,
3 pressure pipes
bending)
4 drain pipes See B3
1.Run the pressure is set too low, see B9-2
2.The seat is dirty, damaged or worn
5 pressure valve
3.The safety valve pressure setting and operating pressure is too
close(d> 20bar), so that part of the oil flow back to the tank
6 flow control valve set improperly, see B9-2
7 check valve See B9-2
1. hydraulic oil viscosity is too low> high leakage
8 hydraulic oil 2. The viscosity is too high> flow resistance is too high
1. Check the exception indication
9 other 2. The flow resistance, load resistance, etc. / leakage is too high
5.2.5.3 Fault "C": the motor rotation is not smooth

Table 5
variable pump output fluctuations, due to
1. The pump regulator malfunction
3 pump 2. Pilot valve inappropriate
3. The system causes effects on the regulator

4. see B2-2
5 pressure valve See B5
Thewritten
IC.Z10.62202.01-E00 page 23 of 25
6 flow control valve 1. Pressure changes lead to changes flow rate of throttle valve
7 check valve See A7-2
8 hydraulic oil oil hydraulic oil has not decomposed air (see I)
1. insufficient driving force
9 other
2. The air in the system is not fully discharged
5.2.5.4 Fault "D": the motor does not rotate or rotate too slow
Table 6
2 pump See B2 and B9-2
5 pressure valve See B5
6 flow control valve See B6
Start conditions are not met. Electrical control circuit wiring
12 other loose, control signal (such as pressure switch failure or
configuration issue) is not sent.
5.2.5.5 Fault "E": the motor does not turn or cannot be stopped
Table 7
1. The check valve is not closed or shut down slow because of
7 check valve
backpressure
2. The seat dirty or malfunction
9 other 1. air in the system is not fully discharged
2. From the sensor to the actuator signal processing faulty or too

slow
3. The slide valve stuck (such as the oil is dirty)
5.2.5.6 Fault "F": pump switching speed is too high
Table 8
for having the accumulator system：

9 other
1. The oil or hydraulic oil leaks too much
Thewritten
IC.Z10.62202.01-E00 page 24 of 25
2．No oil or only a part of the hydraulic oil

- Accumulator inlet valve closed
- Bladder damage
- Pre-charge pressure, operating and set pressure
5.2.5.7 Fault "G": the impact of switching valve
Table 9
3 pressure pipes See A3
4 drain pipes See A4
pressure valve is opened too soon; extend the use of the orifice
5 pressure valve
switching time
check valve is opened too soon; extend the use of the orifice
7 check valve
switching time
8 hydraulic oil See malfunction "I" reasons; the oil has undecomposed air
9 other 1.Air in the system is not fully discharged
5.2.5.8 Fault "H": oil temperature is too high
Table 10
For fixed displacement pump, produce energy (pressure X
3 pump output) exceeds the required flow device (such as in the setting
mode)
Thewritten
IC.Z10.62202.01-E00 page 25 of 25
1．Due to changing conditions caused by loss of efficiency is

increased. Most of the reasons is same as "B- drive means
output/torque is insufficient "
2．Not sufficiently heat
- Too little oil in the tank
- Ambient temperature too high
12 other - Due to insufficient cooling ventilation reasons
- Oil cooler Poor circulation
- Check the control elements and cooler operation
mechanism, to ensure that they are set up and operating
correctly.
3． Operating pressure relief valve is set too low or shut-off

valve on the accumulator is not closed properly.
5.2.5.9 Fault "I": oil pollution
Table 11
large particles cause parts a sudden failure in the absence of

signs of physical
solid particles pollution Small particles of wear parts (resulting in leakage, control
accuracy drops), affecting valve operation, so that the fuel
produce anti-sludge
Moisture content is too high corrosion, increasing wear
Undissolved air increased resistance to fuel compressibility, can
lead to rapid action control device
Undissolved air
It increases the risk of the metal surface wear, local high
temperature damage seal
Various types of fire assistant oil pollution lead to oil aging and lead to a chain reaction.
Thewritten
Eh System
Specification
CONTENTS
EH SYSTEM SPECIFICATION........................................................................1
1. Overview ...........................................................................................................1
2. Hydraulic Supply Unit.....................................................................................1
2.1 Oil Tank ..................................................................................................1
2.2 Pressure Oil System ...............................................................................2
2.3 Online Circulation System ....................................................................3
2.4 Regeneration Device ..............................................................................4
2.5 Measuring Equipment ...........................................................................5
3 Technical Specifications ....................................................................................5
3.1 Fluid Reservoir Nominal Volume: About 1000L ................................5
3.2 Hydraulic System Working Medium: Phosphate Ester .....................5
3.3 System Fluid Cleanliness: NAS1638 level5 .........................................5
3.4 Main Motor Pump Group： .................................................................5
3.5 Auxiliary Motor Pump Group： ..........................................................5
3.6 Fire Resistant Fluid Cooler： ...............................................................6

3.7 Accumulator： .......................................................................................6
3.8 Filter： ....................................................................................................6
3.9 Temperature Control .............................................................................7
3.10 Level Switching Setting .......................................................................7
3.11 Gross Equipment Weight ....................................................................7

IC.Z10.62201.01-E00 Page 1 of 7
EH SYSTEM SPECIFICATION
1. Overview
Electronic hydraulic servo system is applied to steam turbine valve control. The
high pressure fire resistant oil is used. Servo valve is the core component of
electro-hydraulic system. Servo valve receives the deviation of the electrical signal
and the feedback signal, further to control the spool movement, thereby controlling
the position of the actuator piston. The actuator piston drives the corresponding
turbine valve to quickly regulate the steam inlet as required.
The system consists two parts: the EH oil supply system and the EH actuator. The
oil supply system and the actuator are connected by a set of stainless steel. Pressure
and return pipes deliver hydraulic oil between the actuator and oil tank.
2. Hydraulic Supply Unit
Hydraulic supply unit is an integrated tank with about 1000L capacity. The other
devices are all arranged on the tank, and the compact structure, which is conducive to
power plant construction and layout. Fire resistant oil is a kind of synthetic fat
phosphate with high ignition point. However, the oil working condition is rigid. The
operating requirement for oil temperature is 35-55℃.
EH oil supply system is mainly composed of three parts: oil tank, pressure oil
system and online circulation system.
2.1 Oil Tank
The oil tank is the carrier of the oil supply system, made of stainless steel with a
capacity of about 1000L. The tank contains the fire resistant oil which required by
control system. In order to prevent system leakage, the oil pan is arranged under oil
tank to accommodate the whole capacity. For ease of system maintenance, the pump
adapt horizontal design and placed outside of the tank. In order to monitor the system
operation, the corresponding measure instruments are set, such as level switches, level
transmitters, resistance thermometer, pressure transmitters, pressure switches. There is
also an electrical junction box on the side of the tank, all the electrical signals are
connected to the junction box.

IC.Z10.62201.01-E00 Page 2 of 7
Oil tank contains oil level indicator, drain valve and also a respirator on the top of
the tank.
Fire resistant oil is required to be trial phosphate type synthetic oil. Oil quality
should meet the DL / T571-2007 "New-phosphate fire resistant oil quality standards"
and "operation phosphate fire resistant oil standards." Please use FYRQUEL EHC
PLUS, FYRQUEL EHC or similar fire-resistant hydraulic oil.
2.2 Pressure Oil System
Pressure oil system consists EH main oil pump, filter, relief valve, accumulator,
controller and pressure measuring gauge, etc.
EH main oil pump is a variable-flow plunge pump under constant pressure, the
system has two main pumps with same capacity running multiply and standby for
each other. Normal working pressure of the pump is set to 160bar, pump outlet
pressure is adjusted by the pressure controller on the pump. Pump outlet pressure
adjustment uses remote control mode, adjusts through the relief valve installed on the
control block. Pump outlet fluid go through an overpressure valve and then enter into
the main filter. When the pump outlet pressure exceeds a certain value of normal
working pressure, overpressure valve opens to prevent system overpressure. The filter
has a 3μ filter cartridge, which filters impurities in the fluid in order to ensure the
cleanness of fluid in the system. Filter has differential pressure indication, when the
filter cartridge get dirty and clogged, it will send an alarm signal to remind
maintenance personnel to change the filter cartridge. Before and after the filter is
equipped with isolation valves so that people can change the filter cartridge easily.
Pressure transmitters are installed at the outlet of each main fluid pump and also the
manifold, pressure signals are sent to the control system to monitor the working
conditions of the system, and interlock control and protect.
Relief valve is installed on the control block, two in all. Relief valve
MAX01AA051 adjust the outlet pressure of MAX01AP001. Relief valve
MAX01AA052 adjust the outlet pressure of MAX01AP002.

IC.Z10.62201.01-E00 Page 3 of 7
Picture 1 Oil supply system PID diagram
To maintain fluid pressure stable when the system changes working condition, six
50L capacity accumulators are configured, and installed on the side of the fluid
reservoir, connected to the pressure fluid manifold. Bladder accumulator consists of a
balloon filled with high pressure gas and steel cylinder. Bladder is filled with 93bar
nitrogen when working, the steel cylinder outside the bladder is connected to
high-pressure fluid system. When the system works, 160bar high-pressure fluid acts
on the bladder, compresses the nitrogen. When the system fluid pressure fluctuating
such as pressure decline, the compressed nitrogen expands and provides pressure to
the system. Accumulator inflation: each accumulator is equipped with a safety valve,
when the system overpressures it can decompress, it can also isolate the accumulator
from the system for maintenance. Specific inflation method see operating instructions.
Pressure fluid is divided into five branch through the manifold, and sent to main
stop valve actuators and governor valve actuators after passing through the isolating
valve (MAX01AA291-295). The five lines of fluid are: the left main stop valve,
governor valve actuator; the right main stop valve, governor valve actuator; the left
reheat stop valve, governor valve actuator; the right reheat stop valve, governor valve
actuator; overload valve actuator.
2.3 Online Circulation System
The key of the EH system is electro-hydraulic servo system; the core element is
servo valve. Servo valve decides the performance of the whole system (stability,

IC.Z10.62201.01-E00 Page 4 of 7
speediness, accuracy). Servo valve is very sensitive to the oil pollution, 90% failure of
electro-hydraulic servo system dues to the oil pollution. For the request of oil is very
high, such as temperature and impurity and oil physical and chemical properties (such
as electrical conductivity, acid value, moisture content etc.), in order to guarantee the
long-term reliable operation, and maintain the oil characteristics stable, using high
efficiency filters is very important. The system equipped the online circulation system,
mainly including the cooling system and regeneration system.
Circulating system adopts two sets of redundant system. Each contains a circulation
pump. Part of the fire resistant oil goes into the fluid cooler for cooling, cooled fire
resistant oil return to the reservoir through drain fluid filter assembly.
Because the fluid viscosity is very sensitive to temperature, if the temperature is too
high, oil ageing will be very fast. Therefore, a good performance of oil cooler is very
important. The system uses tubular cooler, compact structure, using closed water, and
generally requires desalted water. Detailed parameters see the technical specifications
in following chapter. Cooling pump sends fluid from the reservoir to the shell side of
the tube cooler, cooling water on the pipe side cools the fluid, and fluid is sent to the
reservoir after going through the filter. There are two sets of filters, redundantly.
2.4 Regeneration Device
One connection coupling under the accumulator sends fluid into regeneration
device from the manifold. Regeneration system consists of diatomite and cellulose,
can improve fluid quality and filter impurities in the fluid, so as to change fire
resistant fluid quality.
Diatomite can adsorb acid radical ion and moisture. Using diatomite can
successfully process phosphate ester fluid continuously. It is found that continuous
processing (not intermittently) helps extend the life of fluid. Adsorbing moisture
through diatomite can keep the fluid dry, and continuous processing cost the least
consumption of diatomite. The proper use of diatomite is recommended to be 15Kg
per 100 liters per hour.
Cellulose filter is on the downstream of the diatomite filter, it is used to prevent the
diatomite powdery particles entering the EH fluid. Diatomite acts effectively in the
process of oil maintenance. In fact, when achieving a low moisture, hydrolysis has

IC.Z10.62201.01-E00 Page 5 of 7
been eliminated, and the accumulation of acid degradation products is stopped. It
avoids the formation of metal soap and problems caused by other types of internal
processing, extends the life of the oil.
These advantages mean that this technology can be widely used, improving the use
and economic benefits of phosphate ester synthetic fluid, extending service life means
minimizing waste fluid treatment.
2.5 Measuring Equipment
In order to ensure the normal operation of the system, the system is also equipped
with corresponding measuring equipment. Mainly contains fluid level switches, fluid
reservoir temperature thermal resistances, fluid filter pressure difference switches,
fluid pressure transmitters, etc. These signals are sent to the control system to control
system to monitor the whole system.
3 Technical Specifications
3.1 Fluid Reservoir Nominal Volume: About 1000L
Material: 0Cr18Ni9
3.2 Hydraulic System Working Medium: Phosphate Ester

3.3 System Fluid Cleanliness: NAS1638 level5
3.4 Main Motor Pump Group：
Main working pump：
Main pump type: Axial constant pressure variable flow piston pump (Redundant)
Control mechanism Remote pressure control
Maximum output flow 108 L/min
Normal working pressure 160bar
Main motor (clockwise rotation)： 30KW/380V/50HZ/1450RPM
3.5 Auxiliary Motor Pump Group：
Cooling circulation pump：
Pump type Quantitative vane pump (redundant)


IC.Z10.62201.01-E00 Page 6 of 7
Output flow: 43 L/min
Normal working pressure: 7 bar
Auxiliary motor (clockwise rotation):2.2KW/380V/50HZ/1450RPM

3.6 Fire Resistant Fluid Cooler：
Type (redundancy) water cooling (tube)
Cooling area 8 m2
Tube side (water) design pressure 1.6MPa.g=17 bar(a)
Shell side (oil) design pressure 0.2 MPa.g=3 bar(a)
Shell side (oil) design temperature 93.3℃
Tube side (water) design temperature 149℃
Material Stainless steel
Dimensions:
Shell diameter φ168 mm
Total length 1244 mm
Total weight 91 kg
3.7 Accumulator：
Bladder accumulator:
Nominal capacity 50 L
Effective capacity 4.1 L (160bar -120bar)
Accumulator inflation pressure 20 ℃ nitrogen 93 bar
Maximum working pressure 330 bar

3.8 Filter：
High Pressure Filter：
Filtering accuracy 10μm


IC.Z10.62201.01-E00 Page 7 of 7
Differential pressure alarm 6.9bar
Maximum working pressure 420bar
Cooling circulating filter：
Filtering accuracy 3μm
Differential pressure alarm 2bar
Maximum working pressure 16bar

3.9 Temperature Control
Minimum working temperature (circulation pumps on) 10℃
Initial cooling temperature 45℃
Maximum cooling temperature 55℃
3.10 Level Switching Setting
System sets two level switches and each level switch has 2 contacts. low, low-low,
low-low-low signals are used for turbine protection by 3 out of 3. High contact is for
alarm. The specific setting is subject to the setting list.
3.11 Gross Equipment Weight
About 4 tons (exclusive of EH oil

Oil Flushing
Instructions
CONTENTS
OIL FLUSHING INSTRUCTIONS........................................................................................ 1
1. Introduction .......................................................................................................................... 1
2. Safety Precautions ................................................................................................................ 2
3. Cleanliness Acceptance Criteria, Measurement, And Approval ...................................... 4
3.1 Acceptance Criteria .................................................................................................... 4
3.2 Measurement of Cleanliness ...................................................................................... 4
3.3 Approved ..................................................................................................................... 4
4. General Requirements ......................................................................................................... 4
5. The Reference ....................................................................................................................... 5
6. Attachments .......................................................................................................................... 6
Thewritten
IC.Z10.62203.01-E00 Page 1 of 23
OIL FLUSHING INSTRUCTIONS
1. Introduction
The intent of this document is to define minimum requirements for flushing and
cleaning procedures used for piping of control fluid systems connected to
electro-hydraulic actuators supplied by SHANGHAI TURBINE (Steam Turbine
Division).
Remark:
This procedure must be read carefully and must be fully understood before
starting any flushing and cleaning activity. All work must be carried out by
qualified personnel who are familiar with this procedure and all other documents
referenced within this procedure. Failure to observe this procedure can cause
damage to equipment or hazard to personnel.
Control fluid systems (MAX) are complex systems, mainly consisting of a
minimum one or more centralized hydraulic supply units, electro-hydraulic valve
actuators and interconnecting piping.
Size and complexity of control fluid systems require extensive field fabrication and
assembly. Thus, contamination with sand, welding scale, dust, rust, etc., might occur,
although cleanliness at erection has high priority. Contaminants, if not removed, may
lead to failure of the hydraulic actuators or components of the hydraulic supply units,
or even pollute the control fluid so that the specified properties become lost.
Therefore, all contaminants must be removed prior to initial start-up. If any
contaminants are expected after major inspections or repairs, they must also be
removed.
The purpose of the cleaning and flushing operation is to provide a control fluid
system piping that is free of particle contaminants which could damage
electro-hydraulic actuators or hydraulic supply units, or influence their operation in a
negative way.
This can be accomplished by using a fluid to remove particle contaminants from the
pipe wall and finally flush them out of the system.
Distribution system flushing practices and procedures vary greatly. It is the Clients’
obligation to use an adequate method which finally ensures the specified cleanliness

IC.Z10.62203.01-E00 Page 2 of 23
of the control fluid system piping. Recommend performing high velocity flushing.
Whichever method is used, the general aspects listed below must be followed.
2. Safety Precautions
All work must be carried out by qualified, well experienced, and
authorized personnel. Activities associated with flushing and cleaning
process of a power plant present numerous conditions that are potentially
hazardous, including, but not limited to the following:
-- high temperatures
-- high pressure
-- combustible or explosive material
-- toxic liquid, chemical and vapors
-- high voltage
--moving machinery
-- heavy components or unergonomic arrangement of them
-- high noise levels
Specialized procedures and instructions are required and must be
adhered to by personnel involved in the flushing and cleaning operations.
A safe and reliable procedure for all work covered by this document must
be in place.
Also, the personnel must be familiar with the operating manuals
(especially with the safety instructions) of the hydraulic supply unit and
the electro-hydraulic actuators.
Beside these procedures, all applicable safety procedures such as
OSHA requirements, regional and local safety requirements, safe working
practices, and good judgment must be used by personnel during the
flushing operation.
All work must be carried out by at least two qualified workers.

IC.Z10.62203.01-E00 Page 3 of 23
Professional Glasses Working Suits
NO Flaming No Smoking
Usable ambulance Box, Fire Fighting Equipment and fire alarm is required
Potential dangerous exit in control fluid please refer to safety data.

Oil-absorbing material should be ready.
Rotating machinery has potential dangerous, Electric facility has potential

dangerous, follow the supplier safety guidance follow the operating with electric
safety guidance.
Safety equipment is not allowed to be cancelled. Temporary equipment shall be
manufactured and installed in accordance with “good work practice standards”
considering special working conditions during start-up and commissioning of power

IC.Z10.62203.01-E00 Page 4 of 23
plants.
3. Cleanliness Acceptance Criteria, Measurement, And Approval
3.1 Acceptance Criteria
Cleanliness acceptance criteria are: ISO 4406, code 18/15/12 and NAS 1638, gr. 6
3.2 Measurement of Cleanliness
The measurement of cleanliness should be done with a particle count measuring
instrument. The sample point must be located at the return line, close to the hydraulic
supply unit.
For continuous flushing procedures (e.g. conventional flushing) at least two
successive samples (at least five minutes between measurements) must fulfill the
cleanliness requirements.
For discontinuous flushing procedures (e.g. high velocity flushing as described in
attachment 1), the cleanliness requirements must be fulfilled for at least after two
successive flushing cycles.
3.3 Approved
Record sheets of the chemical analysis and the cleanliness measurement result must
be given to relative department for approval. Additionally, the technical specification
of the flushing and cleaning fluid (e.g. safety data sheets or product data sheet) must
be handed-over for information purposes.
4. General Requirements
Flushing and cleaning must be carried out successfully for all control fluid lines
between each HSU and each EHA before the system can be taken into operation.
Figure 1 shows a single valve arrangement and a combined valve arrangement.
Wherever the hydraulic line branches into two lines (refer to the combined valve
arrangement) attention has to be paid to proper cleaning of every pipe branch must be
ensured.

IC.Z10.62203.01-E00 Page 5 of 23
HSU HSU
T P T P
Figure 1: Typical arrangement for single valve arrangement and combined valve
图1:一个阀门及一个组合阀门的典型布置
arrangement
Pre-fabrication, erection, and mechanical completion must be done for the control
fluid system(Including its hydraulic supply units) before starting any flushing and
cleaning operation.
The piping of the control fluid system shall be free of any contaminants as far as
possible (e.g.by air blasting in accordance with proven procedures) to shorten the
duration of flushing activity.
It is not permitted to let any fluid pass through the actuators before flushing has
been carried out successful. Therefore, all actuators must be disconnected from the
pipe work before flushing.
The HSUs are not allowed to be used for any flushing and cleaning activity except
for the procedure as described in attachment 1.
Control fluid and flushing fluid must be the same, flushing fluid can be re-used as
control fluid.
All temporary equipment used must be suitable for the design conditions of the
system (e.g. design pressure, temperature range, flow, density, medium resistance,
etc.). Special care has to be taken to ensure proper and tight installation of temporary
equipment.
Only clean equipment is allowed to be used.
5. The Reference
The following documents must be read and fully understood before starting any
activity described in this procedure:

IC.Z10.62203.01-E00 Page 6 of 23
All P&IDs of the control fluid system (e.g. “Control Oil System”, doc.“Hydraulic
Supply Unit”, doc.)
Remark:
Depending on the quantity of hydraulic supply units and actuators, more
P&IDs may also be valid.
Specification “Requirements on Control Fluid Piping”, doc.
Specification for “Control Fluid Piping Design”, doc.
Specification for “Hydraulic Fluid”, doc.
Safety Data Sheet of Control Fluid
Site Safety Instructions
Installation Manual for Steam Turbines
Vendor Documentation of Hydraulic Supply Unit
Vendor Documentation of Electro-Hydraulic Actuators
6. Attachments
Attachment 1: High speed Flushing and Cleaning Procedure
General:
This attachment describes the high velocity flushing procedure using the existing
hydraulic supply unit(s) and special temporary equipment.
Our experience shows that this is the most efficient and successful way to flush and
clean control fluid piping systems.
Chapters 1 to 5 of this procedure have to be followed.
Abbreviations:
MAX: control fluid system
EHA: electro-hydraulic actuator
HSU: hydraulic supply unit
FRF: fire resistant fluid
FDA: flushing device for actuator manifold block
FDH: flushing device for hydraulic supply unit
CVPRV: collecting vessel for returning fluid from pressure relieve valve
CVRF: collecting vessel for returning fluid
Definitions:
Line: any piping of MAX system
MAX line: piping between one HSU outlet connection and EHAs of one valve (incl.

IC.Z10.62203.01-E00 Page 7 of 23
return line)
EHA line: piping between a branch of a MAX line and one EHA (incl. return line)
Safety Precautions:
see chapter 2 of this procedure.
Requirements for Temporary Equipment:
For flushing operation, several temporary installations are necessary to protect the
HSU and the EHAs.
The following temporary equipment must be prepared and used for the flushing
sequence:
- Flushing device for hydraulic supply unit (tank and pump) (FDH)
- Flushing device for actuator manifold block (FDA)
- Collecting vessel for returning fluid from pressure relieve valve (CVPRV)
- Collecting vessel for returning fluid (CVRF)
- Barrel pump unit
- Particle counter
Remark:
All temporary equipment must be suitable for the hydraulic test of the system.
Flushing Device for Hydraulic Supply Unit (FDH):
The FDH is a module which is required to prepare the HSU for the flushing
procedure.
The module contains the following parts:
- one (1) FDH (pump side), mainly consisting of hose with safety valve (see figure
3)
- one (1) FDH (tank side), mainly consisting of hose with sample connection and
block valve (see figure 4)

IC.Z10.62203.01-E00 Page 8 of 23
G11/2"connect
to T port
CVPRV
connection
T CVRF connection
P G11/4"pump connection
G11/4"accumulator Pressure Adjusting sample connection
line connection 180bar
Figure 3 FDH (pump side) Figure 4 FDH (tank side)
Flushing Device for Actuator Manifold Block (FDA):
FDAs are modules which must be connected to the lines instead of the EHAs to
bypass the EHAs avoiding particles entering them.
All EHAs must be disconnected from the EHA lines and replaced by FDAs before
starting any flushing operation.
An FDA consists of pressure line counter flange, connecting pipe, ball valve
(shut-off slide valve), and return line counter flange (see figure 2).
Figure 2 FDA
Notes:
The design depends on the actual working condition (for example the arrangement
of EH servo motor), adhesive elbow is allowable
The nominal pipe size of FDAs must be the same or larger than the nominal pipe
size of the piping to be cleaned, as shown in P&IDs.

IC.Z10.62203.01-E00 Page 9 of 23
Pressure pipe flanges（1 1/4”/48.3mm）as figure 2a, small size（3/4”/33.4 or
33.7mm）ones are used by SAE standard (3000psi).
Pressure pipe counter flange and blank flange (if necessary) are required to be the
same size and pressure rating as the pressure pipe flange.
Oil return flange size shown in Figure 2b.
Oil return flange adapt SAE 3/4-3 standard flange (3000psi), oil return counter
flange must be the same size and pressure rating as the oil return flange.
Notes:
Counter flange and blank flange does not have O-rings.
The connection between the flanges (between pressure line counter flange and

IC.Z10.62203.01-E00 Page 10 of 23
shut-off slide valve) must be made by piping. The material must be stainless steel.
The shut-off slide valve (part no. 3) can be located at any position in the piping
Notes:
Globe valves are also used for the drain of pipe pressure test.
Screws, bolts, nuts, washers, and gaskets may be required to connect the FDAs to
the MAX piping.
Gaskets must be made of Viton®.
All parts must be connected tightly to each other.
Collecting Vessel for Returning Fluid from Pressure Relieve Valve (CVPRV):
The CVPRV is used to collect fluid in case of safety valve actuation of the FDH
(pump side).
Therefore the safety valve hose must be connected to a CVPRV.
The CVPRV must fulfill the following requirements:
- Drum type with fixed cover and hose connection
- Design temperature 50°C
- Size must be of suitable volume to switch-off the pump in case of safety valve
actuation
- Medium resistance against flushing fluid
It is recommended to use one of the barrels (if supplied) for the first filling of the
HSU.
Collecting Vessel for Returning Fluid (CVRF):
It is not permitted to use the EHA tank for collection of the flushing fluid returning
from the piping system. Therefore, a separate vessel must be used.
The CVRF must fulfill the following requirements:
- Barrel type (recommended)

IC.Z10.62203.01-E00 Page 11 of 23
- Volume: 200 L
- Design temperature 50°C
- Medium resistance against flushing fluid
- Fixed cover with hose connection / barrel pump connection
It is recommended to use one of the barrels (if supplied) for the first filling of the
HSU.
Remark:
Vessel volume: smaller containers may be used if the vessel volume is higher
than the total volume of all accumulators.
Barrel Pump Unit:
The CVRF is full with flushing fluid, the fluid must be transferred back to the HSU
tank for use in further flushing cycles.
Pumping back to the HSU tank and filtering can be done by a barrel pump unit
consisting of a barrel pump, a filter with fine mesh (≤ 3 μm) and a hose which
connects the unit to the tank of the HSU.
The barrel pump unit must be suitable to be connected and fix tightly to the CVRF.
It must also be suitable to handle contaminants removed from the MAX piping
system.
All parts must be suitable for the pressure rating of the pump.
Particle Counter:
A calibrated particle counter must be used for analyzing the fluid. It must fulfill the
following requirements:
- type: container particle counter (e.g. made PALL)
- medium resistance: suitable for flushing and cleaning fluid
- particle size and concentration detection:
see chapter 3.1

IC.Z10.62203.01-E00 Page 12 of 23
- recommended sample volume: ≥ 100 ml (depending on the type of particle
counter)
System Preparation:
The workflow for system preparation is shown in flowcharts 1 to 6 and figures 5 to

6.
Remark:
Standard KKS-numbering system is used in the following flowcharts and

figures.

IC.Z10.62203.01-E00 Page 13 of 23
Choose main pump to carry out the pressure test (AP002 is recommended)
Choose purifier pump as inner cleaning (AP011 is recommended)
You must manually start and stop of oil pump.
Install temporary switches to active the pumps

Install temporary switches to active the filter oil pumps
HSU is ready to start, add fluid till the tank is full
Open all discharge stop valves AA29X
Close all accumulator stop valves AA25X, open all accumulator

bypass stop valves AA26X

IC.Z10.62203.01-E00 Page 14 of 23
Close all stop valves for pressure transmeters
Set the overflow valve (on the pump) to maximum pressure (loosen
the screw, clockwise rotating)
Set the overflow valve (on the pump) to minimum

pressure (loosen the screw, anti-clockwise rotating)
Active the fluid pump 2(AP002)
Set the pump 2 supply pressure to 210bar
Monitor the pressure through pressure gauge
Inspect the HSU leakage, pressure should be sustain at least

20min
Adjust the pressure of overflow valve to 160bar
Adjust AA052, set the pressure limit value to 190bar

IC.Z10.62203.01-E00 Page 15 of 23
Adjust the overflow valve, set the pressure to 190bar, adjust AA052 active value to
190bar, and then hold on
Adjust AA062, sustain the pressure at 160bar then hold on
Stop main pump AP012
Stop the circulation pump AP012
Cut down all pressure of manifold
Flowchart 3: installing FDHs (pump side)

IC.Z10.62203.01-E00 Page 16 of 23
X1 X2 X3
SAE11/4" SAE11/4" SAE11/4"
50L 50L
35X4
35X4
35X4
S M1 M2 M2
G114" G112" G112" S M1
G2" G14" G14" G2" G14" G14"
P
I 38X5 P
P P
30X4
38X5
T T
G1" G12" G1" G12"
P T P
X1 M3 G14" G14" T
G114"
M1 M2 I
I P
P
G14"
G14"
B B
2
A A
坼开此接头
P T
P T T P
G1" G34" G1" CVPRV

P1 T P2
25X3
25X3
抗燃油油桶
（非供货范围）
1
坼开此接头
M G3/4" M G3/4" I
T
P T P T
30X4
30X4
SAE11/4 SAE11/4
3000psi
3000psi
B 6000psi B 6000psi
SAE2
SAE2
8X1.5
8X1.5
8X1.5
8X1.5
S S
L PP G1/4 L PP G1/4
L1 L1
60X4
60X4
Figure 5 Installation of FDH(pump side)

IC.Z10.62203.01-E00 Page 17 of 23
T6 T5 T4 T3 T2 T1
DN40 DN40 DN40 DN25 DN25 DN25
50L 50L
10MAX01 10MAX01 10MAX01 10MAX01 10MAX01 10MAX01

AA291 AA292 AA293 AA294 AA295 AA296
DN20 DN20 DN20 DN32 DN32 DN32
G11/2"
T
I P P
P
T T
M3 T
50L
I 50L
I P
P
S M1
G2" G14" P
P
T
A A
G1" G12"
T P T
G1" G21"
B B P
R T
B B T
A A
50L
50L
P T T P
G34" P
T
T
G1"
T P T
G1" G21"
P T
G11/4"
M
57X3 SAE1
M
P T
57X3
SAE1
M
Temporary manifolds schematic diagram (SH fluid station)
Disconnect HSU manifold from

return line(3)（see figure 6）
Sealed connection must be ensured

Connect HSU manifold toFDH
Arrange CVRF close to HSU tank
CVPRV must be fixed

Prevent falling down Adjust safety valve to180 bar g
Connect FDH to CVRF and fix the hose
hose can be move

CVPRV must be fixed
Adjust safety valve to 180 bar g
Prevent falling down
Close sample connection block

valve of FDH

IC.Z10.62203.01-E00 Page 18 of 23
Flowchart 4: FDH installation (tank side)
hose
CVRF sample
CVRF
（not in the scope
of Shanghai Turbine
supply）
Figure 6 Installation of FDH(tank side)

IC.Z10.62203.01-E00 Page 19 of 23
Flowchart 5: installing pump
Flowchart 6: HSU preparation

Note: in the system of oil flushing before the system pressure test.

IC.Z10.62203.01-E00 Page 20 of 23
Flowchart 7: oil flushing

IC.Z10.62203.01-E00 Page 21 of 23
Flowchart 8: oil pipeline flushing sequence

IC.Z10.62203.01-E00 Page 22 of 23
EHA pipe1 EHA pipe2
preparation
EHA 1 EHA 2 EHA 1 EHA 2
FDA FDA
HSU AA 29X HSU AA 29X
flushing
EHA 1 EHA 2 EHA 1 EHA 2
FDA FDA
HSU AA 29X HSU AA 29X
Figure 7：block valve arrangement
Flowchart 9: sampling

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A 2020.03.

30 TURBINE I&C SYSTEM MANUAL 魏远 满灿 迟鼎南

Table of Units Conversion

Length millimeter (mm) 25.4 inch(in)

Volume cubic meter ( m 3 ) 4.55E-03 gallon(UKgal)

9.80E-06 millimeter of water ( mmH 2 O )

Pressure Mega Pascal(Mpa)

Energy joule (J) 4186.8 kilocalorie (kcal)

Power watt (W) 746 horsepower

Force Newton(N) 4.45 pound force(lbf)

Chapter1. Control System Overview............................................................................. 1

Reviewed：Li Gang 2020.04

1. DEH Control System Overview ......................................................................1

2. Task and Function: ..........................................................................................1

2.1 Load Controller ........................................................................................1

2.2 Speed Controller.......................................................................................2

2.3 Frequency Support...................................................................................3

2.4 Pressure Controller ..................................................................................3

2.5 Valve Position Controller.........................................................................3

2.6 Start-Up Device ........................................................................................4

2.7 Turbine Stress Evaluator(TSE) ...............................................................4

2.8 Turbine And Auxiliary System Auto Startup Control ..........................5

The Whole Book : Page 1 of 152

CONTROL SYSTEM OVERVIEW

1. DEH Control System Overview

2. Task and Function:

2.1 Load Controller

The function of the load controller is:

Switch from pressure limit mode to initial pressure control mode

During intercepting over speed excursions upon load rejections.

During load operation, synchronize grid frequency by adjusting frequency/load

The Whole Book : Page 2 of 152

In order to meet the grid requirement, Turbine will be Parallel-operate dynamically

2.2 Speed Controller

In load operation above a minimum level, the speed setpoint is automatically

Speed Control is active on these following situations:

During start up of the turbine starting off from turning speed.

During intercepting over speed excursions upon load rejections.

During intercepting over speed excursions upon load rejections.

The Whole Book : Page 3 of 152

2.3 Frequency Support

The grid frequency affects the STC in two ways.

2.4 Pressure Controller

The pressure controller can operate in two operational modes:

(1)Limit Pressure Mode

(2)Initial Pressure Mode

2.5 Valve Position Controller

A proportional acting controller is assigned to each turbine control valve. To

The Whole Book : Page 4 of 152

(1)Valve Position Limitation

2.6 Start-Up Device

2.7 Turbine Stress Evaluator(TSE)

Turbine stress evaluation serves to prevent the thick-walled components of the

The Whole Book : Page 5 of 152

When the temperature margin of a component becomes a negative value, the

Following channels will be monitored: HP emergency stop valve casing, HP control

2.8 Turbine And Auxiliary System Auto Startup Control

The turbine master control program comprises the following submodules:

30 TURBINE I&C SYSTEM MANUAL 魏远满灿迟鼎南