Preface

This I & C Maintenance Manual is based on I & C equipment instruction and related drawings. It
is only for the maintenance of I & C equipment in Pacitan 2315MW coal-fired power plant,
Indonesia.
The manuals will be revised and improved with the project progress development.

Page 2 of 112

Content
1.1

MAINTENANCE OF I/A SERIES CONTROL SYSTEM.........................................................5

1.1.1

SYSTEM HARDWARE INSTALLATION AND ENERGIZATION.............................................................................5

1.1.2

SYSTEM MONITOR SOFTWARE.......................................................................................................................7

1.1.3

DAILY MAINTENANCE....................................................................................................................................11

1.1.4

OPERATION AND MAINTENANCE OF I/AS SYSTEM.....................................................................................14

1.1.5

COMMON FAULTS AND SOLUTIONS FOR I/A SYSTEM.................................................................................19

1.1.6

THE MAINTENANCE MANAGEMENT OF THE I/A SYSTEM EQUIPMENT.......................................................21

1.2

DIGITAL ELECTRO-HYDRAULIC SYSTEM (DEH)............................................................44

1.2.1

DEH SYSTEM GENERAL DESCRIPTION.......................................................................................................44

1.2.2

COMPOSITION OF DEH CONTROL SYSTEM HARDWARE............................................................................44

1.2.3

MAIN FUNCTIONS OF DEH CONTROL SYSTEM..........................................................................................61

1.2.4

BASIC MAINTENANCE ITEMS AND TECHNICAL REQUIREMENTS................................................................62

1.2.5

DEH SYSTEM FUNCTION TEST....................................................................................................................66

1.2.6

FAULT DIAGNOSES AND COMMON TROUBLE SHOOTING...........................................................................70

1.3

TSI SYSTEM MAINTENANCE............................................................................................72

1.3.1

TSI SYSTEM OVERVIEW................................................................................................................................72

1.3.2

TSI SYSTEM FUNCTIONS AND COMPONENTS.............................................................................................72

1.3.3

TSI SYSTEM OPERATION MONITORING.......................................................................................................79

1.3.4

TSI SYSTEM STARTUP..................................................................................................................................79

1.3.5

TSI TEST.......................................................................................................................................................81

1.3.6

LOCAL MAINTENANCE AND TECHNICAL REQUIREMENTS...........................................................................81

1.3.7

TYPICAL FAULT ANALYSIS & TROUBLE-SHOOTING OF TSI SYSTEM........................................................82

1.3.8

CAUSES OF AXIAL DISPLACEMENT AND PROTECTIVE METHODS..............................................................83

1.3.9

CAUSES OF EXCESSIVE EXPANSION DIFFERENCE AND MONITORING MEASURES...................................84

1.3.10

CAUSES OF TURBINE OVER-SPEED AND PROTECTIVE MEASURES...........................................................85

1.4

ETS SYSTEM MAINTENANCE...........................................................................................86

1.4.1

SYSTEM DESCRIPTION..................................................................................................................................86

1.4.2

WORKING PRINCIPLE....................................................................................................................................86

1.4.3

MAINTENANCE ITEMS AND TECHNICAL REQUIREMENTS OF ETS..............................................................87

1.4.4

TEST PRIOR TO UNIT STARTUP...................................................................................................................89

1.4.5

OPERATION AND MAINTENANCE OF ETS....................................................................................................89

1.4.6

COMMON FAULTS AND TROUBLE-SHOOTING OF ETS................................................................................90

1.5

ELEMENT AND INSTRUMENT FOR I&C MEASUREMENT...............................................91

1.5.1

INSTRUMENT FOR TEMPERATURE MEASUREMENT.....................................................................................91

1.5.2

PRESSURE MEASURING ELEMENT AND INSTRUMENT................................................................................96

1.5.3

ELECTRIC CONTACT WATER LEVEL GAUGE.............................................................................................100

1.5.4

ROTATION SPEED MEASURING EQUIPMENT..............................................................................................101

1.5.5

ZIRCONIA ANALYZER..................................................................................................................................102

1.5.6

FURNACE FLAME MONITORING SYSTEM...................................................................................................104

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1.5.7

DRUM WATER LEVEL TV MONITORING SYSTEM......................................................................................105

1.5.8

BOILER SOOT BLOWING PROGRAM CONTROL SYSTEM..........................................................................107

1.5.9

MAINTENANCE OF UNIVERSAL SMALL SIZE RELAY.................................................................................109

1.5.10

MAINTENANCE OF TRAVEL SWITCH...........................................................................................................109

1.5.11

ELECTRIC ACTUATOR.................................................................................................................................109

1.5.12

AI-MI SERIES ELECTRIC ACTUATOR.........................................................................................................110

1.5.13

PNEUMATIC ACTUATOR...............................................................................................................................110

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1.1

Maintenance of I/A Series Control System

1.1.1

System Hardware Installation and Energization

Before installation, power supply, grounding, etc. should be checked firstly. Install
equipment if everything is right. Usually, the control room should lay static
electricity-proof floor; I/A equipment cabinet and operation room should be isolated
by transparent glass, therefore, operator could inspect the front parts of cabinets to
know operation conditions of I/A modules; cabinet and operation console should be
installed on the base plate tightly; when installing cables, cable troughs should be
used to keep strong power apart from weak power.

1.1.1.1

Before installation, check whether following tools are well prepared:

(Hex Driver)
(Letterbug Tool)
System Installation Drawing
System Installation Manual
These goods will be delivered as accessories in I/A system. The Hex driver and the
Letterbug Tool are special tools for installing I/A equipment. Besides, the
customers should prepare one set of straight screwdrivers or cross screwdrivers.
The system installation drawing explains location, inter-connection, power
distribution and grounding of I/A system equipment. Equipment showed in
installation drawing has the Part Number which consists of numbers and letters.
Equipment has attached labels for checking.
Insert socket into MS slot. Drawing 11 is the Installation Drawing for FCP270.

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Push module into slot. Fasten fix screws with the Hex Driver.
Press terminal cable socket of external equipment with one hand slightly. On the
top of module, there is an external equipment loading/unloading screw. Use the
Hex Driver to drive this screw for 1/2 circle till contact pin contacting with socket.
1.1.1.2

Installation of AW390
Host computer for 390 is Pentium PC, No special installation and wire connections.
Installation of FBM
Before installation, please read System Installation Drawing to check FBM
positions in cabinets. Generally, slots for FBM is called FBM slot. Push FBM into
slots. Fasten fix screws at upper and lower corners with the Hex Driver. Fit FBM
terminal cable connection joints with opposite FBM. Fasten central screw with the
Hex Driver.

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Notice:

1.1.1.3

1.

Please install I/A series modules according to System Installation Drawing

carefully.

2.

Connect wires carefully. Arrange wires in order.

3.

During installation, please do not hurt equipment contacts pins.

Power on procedures
After installation, it can be energized. Before Energization, please check and make
sure urban power and UPS are normal. Each power wire is connected correctly.
After check, offer power to CRT, printer, etc. for self-inspection, and then, energize
equipment with modules. Activate AW work station. Check the green and red
lamps of DNBI or DNBX module of AW. At the beginning, red lamp is on, green
lamp blinks regularly. After module self-inspection, work station will load work
software. At this moment, only green lamp is on. Next, activate other work stations
and FBM cabinets. After self-inspections and startup, all the green lamps of
module are on while all the CRT displays. That is to say, system starts to work
normally. Please set clock after system startup. Detailed information about clock
set please refers to Notice: when energizing cabinet, turn on main power source
firstly and then secondary power source

1.1.1.4

Shutdown procedures
Operation system for I/A is a multi-customer multi-task system. Therefore, do not
cut off power randomly even there is nobody using computer. Shut down it
according to following procedures. Otherwise, file system or hardware may be
damaged.
AW/WP shutdown: enter into process control engineer station, select [SftMnt], and
Shutdown_AW. Wait and then cut off power if handing it.
Click Start button at left corner of Windows XP display and get a menu. Do not use
its last item Shut Down to turn off computer. Since that menu only closes XP in C:
but not close I/A in D and it may cause computer crash.

1.1.2

System Monitor Software

I/A system provide one set of software package to monitor working condition of the
system. We call it System Monitor. After activation of I/A, the software will put into
service automatically. By using the software and its MMI, we can know and
respond system equipment operation and system communication conditions.

1.1.2.1

Start MMI
Move the cursor to the SYS on menu, and click mouse left key. The pull-down
menu will appear.
Find Sys_MNt and select it; after several seconds, one display pops up. (See 1-3).
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This is MMI, which connects operator and system monitor software.

1-3
Fig. 1-3
Click CLOSE key on menu for quitting MMI.
Note:Sys_Mgmt location may change since the environment setting is changed for
the customers requirement. Please ask the designer for exact location.
CLR MSG Clear testing information on the top of screen
ACK CBL - Acknowledge cable alarm
ACK ALL - Acknowledge all alarms
SAL- System Alarm List, displaying alarm equipment name list
NETWORK - Display I/A network structure
TIME - Set the clock
PERF - Communication Performance display, display communication conditions
CONFIG - Display selected working station
OFFLINE- Offline diagnosis
INH DISP Equipment name list (its alarm is inhibited)
ACK ALL above is used for acknowledging all alarm. If need to confirm alarming
equipment, operate according to following steps:
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Select station Config select module. At this time, the bottom will appear
EQUIP INFO button; press it and then ACK button to confirm module alarm.
1.1.2.2

Time setting
Choose TIME key which is at the bottom of human-computer display. The display,
showing in 8-6, will display. Click the big or small arrows to adjust time.
Choose RETURN-SET, confirm time you set and get back to previous display.
Choose RETURN-CANCEL; get back to previous display without changing system
original time.

14
Fig 1-4
Notice: Use time setting function to confirm time after I/A system startup to keep
time of entire stations are the same. Otherwise, even if the times are correct, some
software still can not be activated, like CIO configuration device etc
1.1.2.3

Fault response
Any equipment in system fails to work, like printer cable comes free, the intelligent
transmitter can not communicate with I/A system, may activate system monitor
software alarm. SYS key zone on the I/A menu will turn to red and flash. At the
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same time, the preset printer will send out alarm signal. SYS zone exists in any
cases. It has four kinds of color to indicate present condition of different system
hardware.
Stable green

Normal

Blinking green
acknowledgement)
Blinking red
Stable red
1.1.2.4

System had fault but get back to normal now (without

System had fault (without acknowledgement)

Existing fault have not been solve yet (already acknowledged)

Fault location
The system monitor software indicates equipment present condition and system
communication condition according to Letterbug color changing and frame color
changing situations in each monitor display.
White frame

Normal condition; system communication is normal

Red frame

System has communication fault

Grey Letterbug
White Letterbug

this module should not be in the system

Module works normally

Yellow Letterbug
Sub-equipment of the modules or one part of redundant
modules may work abnormally
Red Letterbug

The module has fault.

The shining letters and asterisk() means that there is un-acknowledged faults in
system. If < appears at the back of equipment name, it means the alarm for
equipment is forbidden artificially. This Alarm can be restored in EQUIP CHG.
After system alarming, enter MMI of the equipment monitor software. Use the
NEXT LEVEL and double-direction arrow interchangeably, find out failed
equipment according to the above color definition. Diagnose the problem and find
out fault causes. As for the possible causes and solutions, see B0193AD, System
Maintenance
1.1.2.5

Fault acknowledgement
After finding out faulty equipment, we can use following methods to inform system
that we have already known system alarming reason. As for system
communication alarm, use the ACK CBL on the menu to confirm.
There are two methods for confirming equipment alarming:
Acknowledge all: in original display, choose the ACK ALL and acknowledge all the
equipment alarming.

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Acknowledge individual equipment alarm: in every equipment EQUIP INFO

display, choose the ACK to confirm the alarming. After that, the alarming color will
not blink.
1.1.3

Daily Maintenance

1.1.3.1

I/A Series system working environment requirements

I/A system working environment must meet some requirements that related to
power supply, temperature, humidity, grounding and the air particle.

1.1.3.1.1

Power supply
I/A system requires that the power supply should be continuous and stable and
have ability to supply power with battery to deal with the accident happens to the
municipal electricity line. It is suggested that the UPS which is constant power
supply with isolation should be used. UPS capacity should be decided by I/A
system size. Usually, 1.5KVA is enough for one cabinet plus one operating plat.
The battery is required to supply the power for 15-30 min.

1.1.3.1.2

Grounding
I/A system must be supplied with one isolated grounding stake. The grounding
resistance is smaller than 5 (in power plant it is 1). I/A system safety protection
area, AC power supply area and the inner signal logic area should be connected
with stake. Any equipment belongs to I/A can not be connected with the stake
during the grounding.

1.1.3.1.3

Temperature
The temperature in control room should be controlled in the range of 1530. In
order to calculate the ability of air conditioner, the radiating amount of the
equipment in I/A system has the detailed number in manual. Please refer to the
Site Planning in BO193AA manual.

1.1.3.1.4

Humidity
The humidity of control room should be controlled within 20-28%.

1.1.3.1.5

Air particle
The fine dust in air should be controlled in the controlling room to prevent the
entering of the dust. Please create the daily rules of controlling room and make
sure the normal operation of I/A system.
Besides, the regulations should be created in the computer room, which clearly
defines the equipment in the computer room should be maintained by special
personnel.

1.1.3.2

Maintenance of hardware
After the system operates normally, FOXBORO suggests that the customer should
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build up a I/A spare parts store. The customer will prepare some spare parts for
some components according to the system condition and some spare part for the
components that are easily broken (like mouse, ribbon), and purchase some tapes
and disks. All these are necessary. And the customers should store the FOXBORO
company material, drawing and disk which are attached with the computer. They
will play important roles in future.
If the fault equipment is found, and there is spare part, change it soon. During the
installation of spare part, please use Letterbug Tool change the Letterbug. Till the
new component green light shines, the component name can be seen in the
system managing software in white that means the spare part has already worked
normally. When the component is disassembled, release the external equipment
assembling screw first (see 7-3), and then screw off the assembling bolt. The
installation step is just opposite.
1.1.3.3

Maintenance of software
As for the maintenance of software, the main work is to make the backup of the
software and resume the damage/lost software and to monitor the condition of
system hard disk. If possible, it is better to make a tape backup of hard disk. When
the system is in normal operation, please do not change, delete or add the system
content. Please keep the secret of the code and memorize the code. If the system
is change for necessity, the changing part must have the backup. Please give clear
indication on the disk with the date and method and keep it well.

1.1.3.3.1

Software backup
Backup work has two types: make the backup to small amount of files and make
backup to the entire hard disk.

1.1.3.3.1.1

Files backup
The save path of this system backup file is D:\opt\nw\tools. Ciosave command can
be used to save backup file (ciosave command only can be used in commissioning
period. It should be deleted when unit is normal).
d:\opt\nw\tools
cd/opt/nw/tools
ls
ciosave

1.1.3.3.1.2

Hardware backup
70 system operation system uses XP system and its backup method is the same
with Windows. Only using COPY and STICK is ok.

1.1.3.3.2

Data backup of control processor FCP

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Save-all command can be used to save the data of control processor FCP to disk.
start
run
cmd
d
sh
cd opt/fox/ciocfg/api
save-all cp2001 /opt
1.1.3.3.3

Use backup to download the data of control processor FCP.

Load_all command can be used to download the backup file in disk to control
processor FCP.
start
run
cmd
d
sh
cd opt/fox/ciocfg/api
lood-all cp2001 /opt

1.1.3.3.4

System software reloading (DAYO reloading)

To ensure the completeness of these teaching materials, the installation of bare
computer [computer without software] should be introduced. But if it is not
necessary, DAY installation should not be used. We suggest that backup tape is
used to restore the hard disk.
AW390 series software installation can be invided into two parts: Windows XP
installation I/A's software installation. AW390 series software installation is
divided into two parts: Windows XP installation and I/A's software installation.

1.1.3.3.4.1

Windows XP installation
Firstly install the Airows NT 4.0 Workstation correctly. During installation, divide the
hard disk into C and D two partition. C disk size should be bigger than 600M and
the rest belongs to D disk. Name the computer in the Letterbug name that is
needed. During the installation, a password is required to be set, set it as
PASSWORD. Based on your XP edition, it may need to be upgrade.
By checking the display set of NT, examine whether the color is 256 color or not,
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but if it is not, please install the show-card drive software; otherwise, the I/A can
not be installed. The display resolution is required as 1024768.
Check to make sure the network card is installed well.
1.1.3.3.4.2

I/A's software installation

Put I/A's software CD into CD-ROM, and enter into the CD through Airows Explore
and then execute the Setup file in CD.
Then the installation display and the corresponding dialog box appear. When the
first Question dialog box appears, choose Yes to build the Fox customer. Then the
next dialog box Restart Now appears and choose Yes, I want..., press OK button.
After the computer restart, repeat the operation of a).
When the dialog box Committed Install Files Disk ID # 101 appears, put the
prepared Commit disk into FD and press Load button and then the installation will
continue.
And then the dialog box on the main network card selection will appear, AW70
should choose network card of PCI bus wire; WP70 should choose network card of
ISA bus wire. When the network card is selected, press Next button to continue the
installation.
When the dialog box Release Level Diskette Disk ID # 11001 appears, put the
matched disk into FD and press Load button and then the installation will continue.
Repeat the process till the #11005 disk finishes the installation.
If it is not PC-FB, there is no this step. The dialog box PCFB Card Settings
appears, set the IRQ as 11, Port as 340 and Shared Memory as D8000, and then
press OK button.
At this time the dialog box Setup Complete appears and press View Logs button;
the details of the software installation will appear and check whether there is
warning (yellow text) or fault (red text) appears during the installation. Press the X
button on the right corner of screen to close the box.
Take all of the magnetic disk and the CD out of the drive and choose OK. I want to
restart my computer now appears and then press Finish button.
Now the I/As software installation finishes.
Notice: do not close eXceed, FoxPanels, RSLinx or any other I/As icons.

1.1.4

Operation and Maintenance of I/As System

1.1.4.1

Check before activation

1.1.4.1.1

The environment temperature, humidity and cleanness of computer equipment

should meet the operation requirements.

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1.1.4.1.2

The air condition ventilation hole above the electrical equipment cabinet should
take measurements to prevent the water leaking.

1.1.4.1.3

The power supply fuse should meet the regulations.

1.1.4.1.4

The controlling cabinet and the intermediate terminal number and name should
strike the eye; terminal block wiring diagram should be put into the cabinet and
lightening is good; the wiring of common power supply wiring, earthing wire, light
wire and measurement loop wire should be correct and fastened.

1.1.4.1.5

The signal wiring and signal shielding grounding wire which get into the
intermediate terminal cabinet and the controlling station cabinet from the site
should be connected correctly, stably and good-looking. The cable number and the
wiring number should be complete and clear.

1.1.4.1.6

Check the following items one by one which should meet the requirements:

Control station:
1.

The power supply module, main controller and the functional module and
other equipment in cabinet should be reset and installed correctly and stably.

2.

The signal wiring, power supply wiring, grounding wire and the connecting
cable in cabinet should be connected correctly, stably and perfectly.

3.

The redundancy communication cable connect with several stations should be

connected correctly, stably and perfectly.

4.

The data communication wiring in the controlling station and the

communication wiring between several controlling stations should be
connected correctly, stably and perfectly.

5.

Connecting cable between functional module and the corresponding terminal

plate in intermediate terminal cabinet should be connected correctly, stably
and perfectly.

Operator station, engineer station and service station

1.

The power supply of the computer, display and printer of every station should
be connected well.

2.

The connection between keyboard, mouse, display signal wiring and the
printer wiring and the computer should be correct and perfect.

3.

The data communication wiring between stations should be connected

correctly, stably and perfectly.

1.1.4.2

DCS system operation patrol

1.1.4.2.1

During system operation, do not use the radio in the 3m area around computer
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controlling system.
1.1.4.2.2

The equipment on site which has the interference should be checked to make sure
the circuit wiring is complete and also it should be equipped with shielding cover.

1.1.4.2.3

There should be the record on the hardware and software faults and the software
modifying to record the details of the faults of system (includes fault information
and words), processing process and the modifying record of software each time.

1.1.4.2.4

It is forbidden to take the computer virus into computer. There should be no third
party software on the engineer station. The floppy should be specially used.

1.1.4.2.5

Make record on the defects during daily patrol check; arrange the defects
elimination according to the related regulations; the engineer on I&C should check
the patrol checking record periodically and examine the treatment. The content
and requirement of patrol checking includes:
1.

Check the operation log and extract the problems of the controlling system.

2.

Check SOE and the real time printer condition; input Ep content and time f.q
should be same with the reality; check the backup amount of the printing
paper, and if there is paper block or lacking, treat the problem as soon as
possible.

3.

The clocks of the computer controlling system and other system should have
the same time with the main clock.

4.

Check the display alarm, alarm printing record, sound-light alarming device
and the sequence order record (SOE). During normal operation, there should
be no alarm displaying.

5.

Check the indicating lights of the power supply system and every module
which should be in normal operation. If there is any problem, treat it in time.

6.

Check the environment temperature and humidity of the computer controlling

system, which should meet the requirements of manufacturer.

7.

As for the controlling cabinet with heat dispersion air fan, the air fan should
work normally. The failed air fan should be changed or take some necessary
measurements.

8.

Check the network fault record and make sure the network working condition
is normal and has no frequent shift.

9.

Check the system blank diagnose function display, it should have no abnormal
alarm. The redundant equipment should be in the hot standby state.

10.
10. The operator station, engineer station, service station and each controlling
stations should work normally.
Page 16 of 112

1.1.4.2.6

The environment index of equipment room, engineer station room and control
station room should meet the requirements of the manufacturer.

1.1.4.3

Periodic maintenance during operation of DCS

Periodically check and test the following items during the operation:
1.

The operating condition of operator station, communication interfaces, main

controller, communication network, system switchover, and main backup
power supply;

2.

Historical data storage devices should be active or in default status. CD, hard
disk and cassette tapes should be replaced if it has insufficient spare space. A
cleaning tape should be frequently used to clean the magnetic heads during
the using of cassette player;

3.

Use a special cleaning disk to clean the CD driver about once a month;

4.

Check whether the cooling fans works properly i.e., rotates normally, no
abnormal sounds, etc. If it does not work properly, find out the reasons and
handle the faults immediately.

1.1.4.4

Maintenance during normal shutdown and long term shutdown of DCS system

1.1.4.4.1

Shutdown computer control system

1.1.4.4.1.1

Normal shutdown of the computer control system:

1.1.4.4.1.2

1.

The computer control system should be continuously powered. The power

supply to equipment being repaired should be cut off;

2.

Before the computer control system is shut down, confirm the relevant
production processes have been taken out of service or relevant isolation
measures have been conducted. If not, do not shut down the computer control
system;

3.

All of the required checks, processing and information storage have been
finished;

4.

All of the subsystems related to the equipment to be power off should be

confirmed to be out of service and that power to this system is allowed to be
turned off;

5.

Confirm no personnel are working within the system and all power off
procedures are complete.

Long term shutdown of computer control system:

1.

Thorough backup of all software and data should be conducted before long
term shutdown;

2.

The ambient temperature, humidity and cleanliness should meet the

Page 17 of 112

requirements during long term shutdown;

3.

Regularly turn the system on and conduct relevant checks and tests to make
sure that the computer control system is in good condition.

1.1.4.4.1.3

Maintenance and testing cycle of the computer control system:

1.1.4.4.1.3.1

The maintenance and testing of the computer control system should be conducted
in conjunction with the unit major overhaul. The relevant maintenance should be
conducted on the basis of system status when the unit is undergoing minor
overhaul.

1.1.4.4.1.3.2

In the following situations, basic performance and functions of the computer control
system should be tested.

1.1.4.4.1.4

1.

New computer control system is being put into operation;

2.

The computer control system has updated hardware and software;

3.

The computer control system has important modified hardware and software.

Power off sequence

Power must not be randomly switched off. It must follow the following procedures:
1.

Turn off the main power supply of every operator station;

2.

Turn off the power supply of peripheral equipment, such as display monitor
and printer;

3.

Turn off the local power supply of control station;

4.

Turn off the system power supply of control station;

5.

Turn off the power switch of control station.

1.1.4.4.1.5

Checks and quality requirements relating to system energization

1.1.4.4.1.5.1

Directly energizing the computer control system after it has been repaired or
shutdown is not allowed. The following procedures should be obeyed:

1.1.4.4.1.5.1.1 Preparation:
1.

Confirm there are no personnel working within the power circuits of the
subsystems related to the computer control system;

2.

Conform all the subsystems related to the computer control system are
allowed to be turned on;

3.

The procedures for the operation of the system are complete.

1.1.4.4.1.5.1.2 Requirements of Poweron Process

1

During the Power-on process, every circuit output voltage of power module
and power equipment or system power voltage should be inspected one by
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one. When faults are found, it should be eliminated in time within the
specialized range.
2

Next stage Power-on operations of equipment and system may undergo after
confirming power voltage of Power-on equipment and system whether it is
normal or not

Power-on of Control Station

1 Close main supply switch of control station.

2 Close power supply switch in control station and Close field power supply
switch.
3 Start up control station to run automatic operation system. The indicator shows
a normal state, then run self- diagnostic program to observe.
4

Power-on of operator station, engineer station and service station

1 Close mian supply, main power of engineer station and all service stations.
When there is a display on the screen, entry the operation system and start
application program (or system stars automatically).
2)

Close all the switches for peripheral equipment, including printer, hardcopy
unit and monitor.

3)

Close the main power station switch of operator station. Application program
automatically starts after startups of all operator stations.

Startup all computers one by one following stages above until the whole
control system have started.

Check the indicators of communication link, display and all running equipment
of the whole system. Running should respond to the actual statement. If not,
problems need to be eliminated. When needed, dedicated inspect tools and
soft wares can be used for a further inspection.

1.1.5

Common Faults and Solutions for I/A system

1.1.5.1

Power System Failure Inspections and Solutions

Indicators of power components should be inspected at required time everyday.
When equipment operates abnormally and the light turns red, components should
be removed immediately (components use matrix power supply mode, and any
functional modules will not be affected). And then a new one should be changed.
At the same time, check the normal value of UPS, and confirm power supply within
stipulated range.

1.1.5.2

Faults and Solutions in Work station Processor

1.

Activate with Reboot in the menu on the top. If not, use b.

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2.

Press CTRL_ALT_F1 at the same time, and restart it.

3.

Start it from other stations, and then entry SYS-Mgmt. Select fail WP and
choose Reboot Station in Equipment Change display.

4.

If all above do not work, turn off main power of WP cabinet.Then power on,
and start it.

1.1.5.3

Faults of CP (Control Processor)

1.1.5.3.1

Symptom of failure: When one of the redundant CPs operates in a normal

statement, ones red and green lights are all on or offOne CP runs normally, so it
does not effect normal control. So use the following stage to lock CP.
Solutions:
Entry SYS-Mgmt, and choose CP with faults. Then entry Equipment Change, and
choose Reboot Station to start this CP.
If a does not work, this CP could be inserted and removed, then Power-on starts
(the other CP should not be removed). If not, this CP should be replaced.
New version of hardware needs to be considered if a new CP does not work. If
version marches, confirm that two redundant CPs are removed synchronously, and
inserted again in accordance with production. If two CPs running at the same time
is permitted, onsite monitoring should undergo closely with technologist. If not,
maintenance personnel should observe closely when a CP is running.

1.1.5.3.2

Faults: red light and green light of two sets of redundancy CP are both on (or red
light is on while green one is off)
Analysis: at this time, the producing device may out of control, so redundancy CP
should be started again. At same time, inform technical personnel to monitor field
device operation strictly.
Solutions:
In order to restore CP control function as soon as possible, unplug CP with fault
immediately, if the CP still cannot work normally, replace these two sets of CP.

1.1.5.3.3

Faults: one module in some loop or one control loop cannot operate normally.
(Especially PID, PIDE)
Solutions:
Switch this loop to manual mode immediately, and then withdraw the AOUT
module of this loop, which is used for technical personnel to control field operation
manually
Enter into CIOS configuration, select module loop and edit all parameters if there
are any faults, quit if the parameters are correct.

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Choose DELETE in the menu, delete this module, and then choose UNDELETE to
restore this module. In this way, module fault can be eliminated.
1.1.5.4

Input/output module, FBM trouble-shooting

There are two state indicating lights on FBM board. Maintenance personnel should
pay attention to light state during daily inspection, and take immediate measure if
there is fault.

1.1.5.4.1

Faults: one FBM state indicating light is abnormal: red light is on (green light is on
or off).
Solutions:

1.1.5.4.2

Inform technical personnel to monitor the field in FBM area carefully.

Replace FBM

Faults: channel alarm of AIN appears frequently, or the signal which is detected by
technical personnel is not correct.
Solutions:

1.1.5.4.3

Check the meter once, and put it into operation if there is no fault.

If the loop is control loop, change to manual operation firstly, and disconnect
FBM channel terminal which connects with this detecting signal, use this
signal to check FBM channel conversion accuracy. If this channel has fault,
connect FBM channel terminal to the reserved channel terminal. At the same
time, revise CIO parameters or replace FBM.

Faults:
Seen from operation interface, the loop can work normally, which means the output
parameters are consistent with that of original design. However, the parameter
which needs to be adjusted does not change correspondingly. or there is I/O
channel alarm on operating interface.
Solutions:
Firstly check whether adjusting valve is blocked, at the same time, check accuracy
of positioner. If there is no fault, use MA ammeter to check whether the
corresponding FBM output channel can complete D/A signal conversion correctly.
In this way, we can judge whether the output channel has fault or not. If there is
fault, ask technical personnel to operate at local immediately, and exchange with
reserved FBM channel, meanwhile revise CIO or replace the FBM.

1.1.5.5

System crash
Phenomenon: DCS display cannot be refreshed; the panel cannot be operated and
data indication shows no changing.

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Solutions: close the host computer power of crashed system, after waiting for three
minutes, supply host computer power; after PASSWORD interface shows, input
gnomes to restore the system.
1.1.6

The Maintenance Management of the I/A System Equipment

1.1.6.1

Basic maintenance items and quality requirements

1.1.6.1.1

Check up before shutdown

1

Check the condition of the computer control system, take a record of the
abnormal conditions for further maintenance.

Check the operating condition of the hot air fans

3)

Check the power supply voltage of the uninterrupted power supply (UPS) and
the power supply voltage of each cabinet, check the voltage of DC power
supply and the operating condition of each power module.

4)

Check the working condition of each module in the cabinets, check the
conditions of each channel and the operating condition of each operator
station, control station, service station and the communication network, etc.

5)

Check alarm system, take a detailed record of the crucial abnormal

information (such as redundance loss, abnormal switch, loss of important
signal, data spill, frequent bus switch, etc.).

6)

Check varied printing records and hard copy records.

7)

Measure the temperature and humidity of control room, engineer station and
electronic equipment room.

8)

Check the operation log and the data base alarming log of the computer
control system.

9)

Check the computer self-diagnosis system and collect the abnormal records of
self-diagnosis.

10) Check the equipment and daily maintenance record of computer system,
collect the items which need to be solved after shutdown.
11) Check and record the surrounding conditions, such as temperature, of the field
bus and the long-distance input/output local cabinets.
12) Make backup computer control system software and data, for the data and
documents which stored in the memorizer (RAM, for example) should be
uploaded and backed up in time.
1.1.6.1.2

Maintenance after shutdown

1.1.6.1.2.1

General regulation
1

Before maintenance stop equipment according to normal stop process of

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computer control system. Cut off the power supply pull out the plug of the
equipment which needs to be repaired.
2.

The air conditioner system inside electronic room, engineer room and control
room should have enough capacity. adjusting performance of temperature and
humidity are good. the ambient temperature humidity and cleanness should
comply with GB2887 or the regulation of the manufactory.

3.

The fuse of all the power circuit and channel fuse of module should comply
with the requirements of equipment operation. If any damage is found, take a
record of it, and after verifying the causes of the damagemake replacement
with the same capacity and mode of the fuse.

4.

The computer equipment should be complete, without rust corrosion,

deformation or distinct damage.

Confirm the computer equipment are in order and the marks are complete and
clear.

Clean the equipment after electricity of system or equipment is cut off.

For the equipment with antistatic requirements, anti-static measures must be

made before maintenance. Maintenance personnel must wear antistatic
grounding bracelet and keep away from circuit. The disassembled equipment
should be laid on anti-static plate, and the compressed air gun used for purge
should be grounded.

The compressed air for purge should be dry and without oil dirt, and the
pressure should be controlled around 0.05Mpa. the power of cleaner should
be big enough to absorb the dust, and special detergent must be used for
cleaning equipment.

The parts inside and outside cabinet should be installed firmly, all screws are
in place. The bolts of connection terminal board and grounding bus are tight.

10 The connection cable and lead in the computer equipment room should be
complete and and in good order, and the marks should be complete and clear.
1.1.6.1.2.2

The hardware maintenance of operator station, engineer station and service

station.
1.

Confirm the power of the equipment which needs to be repaired has been cut
off, and then open the cover of the cabinet.

There is no clear mark of damage or burning in circuit board, the elements of

circuitry plate has no weld loose. There is no line break of the connections or
connection cable, and the fixing of the inner equipment, cards and the
connection parts are tight, the fixing bolts are complete.

3.

Clean the inside and outside parts of the cover and radiator fan, after the
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clearing, the radiator fan should run flexibly

1.1.6.1.2.3

1.1.6.1.2.4

4.

Install the cover of the cabinet, and confirm that the power supply voltage
grade is set correctly.

After the power is supplied, equipment can be started normally and enter the
operation system, the equipment has no abnormal sound or smell. There is no
incorrect information in the process and the status indicator lights and
interface displays of the are normal. Check the radiator fan runs normally and
the rotate direction is correct. For the service station that has no display or
operating equipment (such as keyboard or mouse) in normal working
condition, display and operation equipment can be connected for inspection.

The maintenance of the control station:

1

Corresponding equipment of unit and computer control system are stopped,

the control system is stopped as well. Stop the sub-system and power supply
of the equipment that is to be repaired.

Take an detailed record of the module cabinet , slot number and the jumper
wire setting that need cleaning.

Clean the module and heat radiator fan, and confirm ther are no dust, dirt,
damage and burn. The module has no corrosion and contact pin or the finger
has no bend and crack. the assemblies in the module are firmly fixed, the
setting of jumper wire and the pin are correct, the connection is reliable. The
type and capacity of module are correct. all the marks of the module are clear.

Check the power-fail protection switch of the module of control station and the
jumping wire setting are correct. For the module with standby batteries, the
batteries should be examined and replaced in accordance with the relevant
regulation and requirements of the manufactory. When replacing the batteries,
make sure that the electricity loss time is within the permitted range.

After clean and inspection, restore cabinet, frame and slot of module
accroding to the number, and the position should be correct.

When the module is in place, check and make sure that the connection cable
of the module (such as the flat connection cable) are inserted at the proper
position and the installation is firm, and tighten the fix screw and bolts if
necessary.

Before energization of the module, check the fuse and capacity of module.
after energization, the indication of indicator light should be correct and the
heat radiator fan runs normally.

For the control station with display or keyboard or mouse interface, connect
display and operation equipment (keyboard, mouse) for checkup if necessary.

Maintenance of computer external equipment.

Page 24 of 112

1.1.6.1.2.4.1

1.1.6.1.2.4.2

1.1.6.1.2.4.3

The maintenance items of indicator:

1

Cut off the power supply of indicator.

Clean the inside and outside of the display, and clean the display screen with
specialized lotion. After maintenance, the appearance should be clean. Check
the elements inside circuit plate to make sure that the connection lines and
plugs are correct and without breake and loose, tighten the elements if
necessary. Check the signal cable inside indicator to confirm there is no short
circuit, breake or crack. The insulation of equipment should be measured
qualified.

Energize the display for checkup after the maintenance, the display menu
should be clear, without twinkle, twitter and abnormal color. The button
function of brightness, contrast, color temperature, focus and positioning are
normal. Adjust big screen display carefully to make sure the brightness and
color are even.

The running of heat radiator fan of the big screen display should be normal.

The maintenance items for printer:

1

Turn off the power of printer, and disconnect the power plug.

Clear out the wastepaper inside the printer, and clean the paper conveyer and
paper conveying channel. Confirm the printer has no dust and dirt, and the
elements of inner inner circuit plate has nothing abnormal. the connection
parts or connection wires are correct and without loose and breaks, tighten the
elements if necessary. The insulation should be measured qualified. add oil to
the mechanical rotating part of the printer accordingly.

Recover the printer, and check the switches, jumper wire and the setting of
relevant parameters are correct.

For the stylus printer, the paper thickness adjusting bar should be readjusted
according to the thickness of the printing papers. after energization of printer,
the automatic test program will be carried out to ensure that the characters are
correct and clear. If there is break, replace typing head or ribbon.

For the ink-jet printer, after energization, the self-test program will be carried
out to ensure that the characters are correct and clear, and there are no
deformed character, line loss or ink drop. when replacing the ink box, its type
must match the printer.

For the laser printer, after energization, the automatic test program will be
carried out to ensure that the characters are correct and clear, and there is no
character deformation, black lines or loose ink powder.

Maintenance items for the track ball and mouse:

Page 25 of 112

1.1.6.1.2.4.4

After deenergization, pull out the connection between the track ball and the
computer or between mouse and the computer.

Clean the track ball and mouse carefully, including the ball, the pulley and the
light mouse glistening board.

Confirm the elements of the circuit plate are normal, the connnection wire is
correct and there is no wire break and wire loose. fasten the fixing screws if
necessary.

Resume the connection with system, after energization, the operation for the
track ball and mouse should be flexible.

Maintenance items for the keyboard:

1

Operate each key under safety condition, if there is any key that moves not
flexibly or has no respond or wrong input, record its position.

Turn off the computer, pull out the connection between the keyboard and the
computer to clean the keyboard and shoot the trouble of keyboard, especially
the keyboard which record with defects previously. The elements of circuit
plate should be under good condition after maintenance, and there is no
connection loose or cable break.The contact point of keyboard and the
connection of the computer should be good and without dust or dirt.

Resume the connection with the system, and test each of the keys again after
energization to confirm that responses of the keys are quick and correct.

1.1.6.1.2.5

Maintenance of the network and interface:

1.1.6.1.2.5.1

The maintenance items for communication network:

1

Withdraw system

Replace the cable and fiber optic cable with fault, the communication cable
has no damage and break after the maintenance, and the cable or fiber optic
cable are well fixed and without bend.

Check the grounding condition of metal protective bushing of communication

cable (the metal protective bushing applied for local installation)

Measure the insulation resistance, and the impedance of the terminal matcher
to make sure they can meet the requirement.

Tighten all the connectors (or connector firm screws), all the insert connectors
(such as RJ45, AUI, BNC, etc.) and the terminal connection. After
maintenance, test each of the connector, plug-in connector and terminal
connection by pulling slightly to confirm there is no loose.

After energization, check the module indication lamps or via system diagnosis
function to confirm that the state of the module and the communication bus
Page 26 of 112

system can work normally. The redundant bus should be at working condition,
and the indication of the indicator lamp of the exchanger, the collecting tray,
the coupling, the transponder and the bus module are normal after
energization .
7
1.1.6.1.2.5.2

Check the control subsystem, I/O channels and the communication indications
via the system diagnosis or other methods provided by manufactory.

The checkup items of network interface equipment:

1

Before inspection, cut off the power supply of all equipment and mark the
connection cable and fiber optic cable, then disconnect the connection cable
and fiber optic cable, and wrap the connector of the fiber optic cable which has
been disconnected to prevent it from contamination.

Clean and repair the inside and outside of the network equipment, such as the
exchanger, the collecting tray, the coupler, transmitter and the fiber optic
converter. tighten wire connection if necessary. The equipment should be
clean and without dust or dirt after maintenance. the elements inside circuit
plate has no abnormal condition, and the wire connection or the cable
connection should be correct and without loose or break. all plugs should be
under working condition, and the insulaton test for fans and other equipment
should be qualified.

Carefully check the optical cable connection, Rj 45 interface or BNC interface

to confirm that there is no break, crack or deformation.

Restore the cover and supply power to confirm that the rotating direction of the
fan is correct, and there is no abnormal sound and smell. The automatic test
has no fault, and the indication of the light is normal.

1.1.6.1.2.6

Maintenance of power supply equipment:

1.1.6.1.2.6.1

Maintenance items of module power, system power and cabinet power supply

1.1.6.1.2.6.1.1 Cleaning and common test

1)

Stop relevant system, mark the power plugs or wire connection before pulling
out.

Clean power supply equipment and fans, pull out the inner pieces of the power
supply carefully, confirm that there is no burning mark in inner printed circuit
plate. The elements are normal, the connection wire, connection cable, signal
cable, power line and grouding cable have no break or loose, tighten again if
necessary. The big capacitance inside the power supply should have no
expansion, deformation or leakage, otherwise, replace the capacitance with a
new one with the same type and mode. Check the fuse, if there is any
damage, replace with the same type and mode.

3 Measure the insulation resistance between the primary side and the secondary
Page 27 of 112

side of the transformer, and between the terminal in primary side and the
ground, make sure that the insulation resistance can meet the requirement.
4

Resume the elements of power supply, the equipment should be clean and
without dust or dirt after maintenance. Insert the plugs according to the marks
that have been made, and supply power after confirmation.

1.1.6.1.2.6.1.2 The energization test:

1)

Before the energization , confirm that the voltage stage set of the power
supply is correct. After energization , there is no abnormal sound or smell from
the power device, and the temperature rising is normal. the fans rotate
normally, and the rotating direction is correct.

2)

Measure the output voltage according to the regulation to confirm the voltage
meets the requirement.

3)

Start the sub-system and make sure it works normally and without any alarm
fault, the indicating lights of the power supply indicate correctly.

4 For the redundant power supply, cut off any circuit of it to check whether the
relevant controller of it can work normally, or replace it.
1.1.6.1.2.7

The master clock and the GPS standard clock:

1.1.6.1.2.7.1

Cut off the power supply of the master clock system, clean the master clock or the
GPS standard clock.

1.1.6.1.2.7.2

The connection of the communication interface of the master clock should be right,
the communication cable has no damage. Startup the master clock, conduct
synchronized calibration for the master clock and the standard clock.

1.1.6.1.2.7.3

The GPS antenna should be installed upright, there is no surrounding building or

sundries. The antenna plugs should be inserted firmly, and there is no damage or
break in the feeder line.

1.1.6.1.2.7.4

The connection of the communication interface of the GPS standard clock should
be right, and the communication cable has no damage . Switch on the power to do
the initialization test and self-test to make sure there is no fault; after the
initialization test and the self-test, the indication of the GPS clock synchronization
system is normal. If the GPS is out-of-step, the punctual clock inside the device
should work normally.

1.1.6.1.2.7.5

Start the clock calibration function of each station, and calibrate the time indication
in each station to fulfill the synchronization of its master clock and the GPS
standard clock.

1.1.6.1.2.8

Software check

1.1.6.1.2.8.1

Check of operation system:

Page 28 of 112

1.1.6.1.2.8.2

1.

Energize each computer, start the display menu and the self-test, if there is
wrong information hint, take corresponding measure.

2.

Generally, there is no wrong information hint during energization and self-start

process of the operation system, and if there is erro, the error will be repaired
automatically. Restart operation system to check there is no error indication,
otherwise, consider back up resume or reinstallation.

3.

After startup of the operation system, the entire application document should
be closed. Start the disk testing and repairing program to test and repair the
disk error.

4.

Check and calibrate the system date and time.

5.

Search and delete the temporary document in the system, clear up the recycle
bin; for the computer station without the function of the automatic deleting of
the data document, clear up the useless data document manually.

6.

Check each user authority, the account command, the auditing and clientage
relation and the setting of the area and group are correct, and meet the
requirement of system. Check the authority set for the equipment or the
document, the document share and the access of document should be right
and meet the requirement.

7.

Check the residual space of the disks and make sure there is some spare
space. The disk chip tidying program should be started to optimize the disk.

The application software and the integrality test:

1.

After modifying of the computer control system logical configuration, back up

the software again.

2.

Check the integrality of application software according to software list supplied

by manufacturer.

3 Check and confirm system integrality according to system startup conditions

4. There are no abnormal and error indicates during startup of application system
software (as for energization auto start system, it will start after startup of
operation system
5. Start other software of operation station, engineer station and service station
separately, and there are no faults.
6.

Scan and check the integrality of the software system by employing the utility
program device that is provided,

7.

Start the self-monitor, fault searching, and self-diagnosis software of computer

control system to check whether the function can meet the regulation of the
manufactory,

Page 29 of 112

1.1.6.1.2.8.3

1.1.6.1.2.8.4

Check the authority setting:

1.

Check the setting of users authority in each operator station, engineer station
and service station to make sure the settingcan meet the requirement of
management and safety regulation.

2.

Check the users authority setting of the interface station network or the
gateway to make sure they can meet the requirement of management and
safety regulation.

Check the net work interface station or end VI service setting of gateway, and
stop the end VI service that is not used.

Data base checkup

1.

The setting of data base visitation authority should be correct and meet the
requirement of management and safety regulation.

2.

Explore the data base, and the relevant information of data base and sheets
should be correct.

3.

If the record of the data base diary is full, back up immediately and then delete
it.

1.1.6.2

The test after small repair and overhaul of DCS

1.1.6.2.1

For the computer control system after maintainance or upgrad, the performance
and functions of its system should be tested according to relevant requirements.

1.1.6.2.2

For the computer control system after maintainance or upgrad, if the test of the
performance and function of the equipment is normal, do the off-line operation for
72 hours to test the stability of the system, only when the stability of the system
meet the requirements can the system be put into on-line operation.

1.1.6.2.3

The DCS system redundant switch test

1.1.6.2.3.1

The redundant switch test of the module, system and cabinet power supply

1.1.6.2.3.1.1

For the self power supply or redundant power supply system of the module, control
system and computer cabinet, do the following redundant switch test
1 Disconnect the working power circuit to check that the stand-by power supply
is automatically put into service;
2)

For redundant power supply, cut off any circuit of the power supply.

3)

Do the reverse switch test for the above 1) and 2) in the same way.

1.1.6.2.3.1.2

Recover the system into normal status.

1.1.6.2.3.1.3

During the above test, the control system should work normally, no loss of the
middle data and the accumulated data, and the fault diagnosis indication should be
correct. There should be no fault, or other abnormal condition except I&C
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equipment fault alarms.

1.1.6.2.3.2

The redundant switch test of the operator station and the service station:

1.1.6.2.3.2.1

For the equipments that are in parallel operation, the operator station, for example,
shut down one of the equipment or one part of the equipment, and this should not
influence the normal operation of the whole computer control system.

1.1.6.2.3.2.2

For the equipment with redundant switch, when the main operation equipment is
shut down by cutting off the electricity or by shutting down the application software,
the subordinate operation equipment should be automatically started or switched
into main operation status.

1.1.6.2.3.2.3

Do the reverse switch test in the same way.

1.1.6.2.3.2.4

Recover the system into normal state.

1.1.6.2.3.2.5

During the above test, the fault diagnosis indication should be correct, there should
be no fault, or other abnormal condition except there is fault alarms from the I&C
equipment relevant to this test.

1.1.6.2.3.3

The main controller and module redundant switch test in the control station:

1.1.6.2.3.3.1

Before energization of the main controller and the module, check the fuse to
ensure that it is fine and complete, and the capacity is correct.

1.1.6.2.3.3.2

After energization of the main controller and the module, make sure that the
indication of the indicating light matches the normal practical condition.

1.1.6.2.3.3.3

Select the following methods to do the redundant switch test of the main controller
and the module.
1.

Take out the fuse of module and main controller under operation

2.

Reset the main controller and the module in main operation.

3.

Pull out the main controller and the module in main operation (the module can
be pulled out or inserted when it is live)

1.1.6.2.3.3.4

Do the reverse switch test in the same way.

1.1.6.2.3.3.5

Recover the system into normal state.

1.1.6.2.3.3.6

During the above test, the system should be able to be switched into the operation
of the main controller and module in the subordinate operation, or is able to
change the main controller and module from the subordinate operation into the
state of main operation. the fault diagnosing indication should be correct. There is
nothing abnormal in the system except the alarm for module fault and the
redundant loss occurs.

1.1.6.2.3.4

The redundant switch test of the communication bus

1.1.6.2.3.4.1

Check the following items before the test:

Page 31 of 112

1.

There is no damage or break in the bus cable;

2.

The connect and insert devices should be firm, the contact should be good,
and the end connection should be correct and firm.

3.

Check the resistance value in the bus terminal is normal, the connection is
firm and the indication of the exchanger, the collecting tray and the bus
module indicating lampare correct.

4.

Check that system works normally through system diagnosis and bus module
work indication. Redundant bus should be in redundant work condition.

1.1.6.2.3.4.2

Activate or deactivate the equipment on any node of the communication network,

the communication of the bus should be normal.

1.1.6.2.3.4.3

Cut off the communication connection between the node equipment and the bus
communication network in turn, there should be no fault, crash or other abnormal
condition in the system.

1.1.6.2.3.4.4

Take the following methods to do the redundant switch test of the communication
bus:
1

Cut off the power supply for the main operating bus module;

Pull out the plugs of the main operating bus;

Disconnect the main operating bus cable or the terminal matcher;

Simulate other conditions.

1.1.6.2.3.4.5

Do the reverse switch test of c) and d) in the same way.

1.1.6.2.3.4.6

Recover the system into normal condition.

1.1.6.2.3.4.7

During the test, the communication bus should be switched into redundant bus
operation automatically.The indication of the indicating light and the system should
be normal, and there is no system data loss, at the same time, confirm the
communication is not interrupted, the fault alarm of I&C instrument is correct and
the diagnosis menu display matches the practical condition.

1.1.6.2.3.5

Control loop redundancy switch test:

1.1.6.2.3.5.1

Put the computer control system as well as the main controller and modules
related to the control loop into service normally.

1.1.6.2.3.5.2

Select one of the following methods to conduct the control loop redundancy switch
test:
1)

Use a manual operating device or other equipment to manually make the

control loop to output a static value or status. Then reset or turn off the
corresponding main controller or output module that run in the main operation
state;
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2 Directly reset or turn off the corresponding main controller or output module
that run in the main operating mode.
1.1.6.2.3.5.3

The same method is used to conduct control loop reverse redundancy selecting
test.

1.1.6.2.3.5.4

Restore the system.

1.1.6.2.3.5.5

Observe the control loop output during the test. There should be no changes or
disturbances. Check whether the operating mode of standby main controller or
output module is right.

1.1.6.2.3.6

Fault tolerance performance test of the system:

1.1.6.2.3.6.1

When any undefined keys are operated on the keyboard of the operator station or
a series of illegal orders are inputted on the operator station, faults, crashes or
other abnormal situations of the operator station and control system should not be
occurred.

1.1.6.2.3.6.2

Conduct the reset test on the part of system and peripheral equipment:
1)

Shut off the system power supply of control station, and shut off all of the
power supply when the configuration is redundant. Turn it on after 30 seconds;

2)

Shut off the running display monitor, and then turn it on again;

3)

Shut off the running main computer of the operator station, and then turn it
back on;

4)

Shut off the running main computer of the communication station, and then
turn it on;

5)

Shut off the printers respectively then turn them on. This operation should be
conducted both when the printer is working and when it is not working;

6)

The control system should work normally and there not produce abnormal
situations during the test. The displaying of fault diagnosis should conform to
the actual situations.

1.1.6.2.4

UPS power auto activation and switch test

1.1.6.2.4.1

UPS test

1.1.6.2.4.1.1

UPS performance test:

1.1.6.2.4.1.2

Connect the UPS current input terminal to the output terminal of 0-250W AC
regulator. Connect the regulator input terminal to the 220V AC power supply, then
turn it on. According to the UPS manual, the current of voltage regulator should be
adjusted to AC 190V, AC 220V and AC250V. Then respectively measure the output
voltage of UPS power supply, which should be kept in the AC range of (15 )
220V

Page 33 of 112

1.1.6.2.4.1.3

1.1.6.2.4.1.4

Connect the UPS power supply to AC 220V. Start the computer system powered
by UPS power supply. Conduct the power switchover test and standby time test:
1)

Connect the testing circuit to oscilloscope.

2)

Confirm the charging indicator of UPS power supply is off. When the switched
voltage is equivalent with the output voltage adjusted by the voltage regulator,
UPS power supply should be switched to battery supply. Measure the output
voltage of UPS. It should in the AC range of (15)220V.

3)

Shut off the external power supply of the UPS and switch the UPS to battery
power until the computer system is automatically shut down, then correctly
shut down the computer.

4)

Check the standby time of the UPS. It should not be less than the required
time stated in the manufacturers manual. Generally, 30 minutes of continuous
supply should be guaranteed;

5)

Restore the UPS external power supply. Switch the power supply from battery
power to external power supply;

6)

Record the switchover time of the UPS power supply. It should be less than 5
mins;

7)

Observe the switchover process to check the corresponding sound and light
alarms, fault diagnosis displays and printing information. There should be no
abnormal situations occuring in the operation of computer control system and
other equipment. If there is, the UPS power supply should be repaired or
replaced.

Inspection of communication between UPS and computer

1.1.6.2.4.1.4.1 Check the communication between UPS and computer is in a normal state. Start
self-check of the UPS, and inspect the self-check report. It should be normal and
with no fail information.
1.1.6.2.4.1.4.2 Start up UPS power test program from the computer, and check the
communication with UPS is normal.
1.1.6.2.4.1.4.3 Cut off the UPS external power supply and transfer to battery supply, or cut off the
power before the computer shutdown and there should be relevant alarm
information.
1.1.6.2.5

Inspection and test of I/O module

1.1.6.2.5.1

Hot insertion and removal test of modules

1)

Confirm the modules which will be tested have hot insertion and removal
functions.

2)

Remove one module, and there is an error state on the display. Then the
Page 34 of 112

control system or equipment should automatically carry out relevant handling

(such as transferring to manual operation, actuator holding its position, etc).
During insertion and removal, other functions of the control system should not
be affected.
3)

When current signal is inputted into one I/O module channel and remains
constant, insert and remove this electrified I/O module twice. It should not
affect the system operation, process control and other inputs. Then the display
should show corresponding state when the module is inserted and removed.
The displays corresponding physical quantity value should remain constant
both before and after the test.

1.1.6.2.5.2

Real-time Test of System

1.1.6.2.5.2.1

Display response time: continuously switch display of the operator station 10

times, and test the time from the last operation to all contents of every display
through program or stop watch. Then calculate and the average response time
should be less than 1.5s. For normal displays, the time should be less than 1
second, 2 seconds for complex displays. The time should also not be lower than
the manufacturers standards.

1.1.6.2.5.2.2

Date refresh time in the display: observe process variable real-time data and
operation state change in the display. Then test 20 times via program or stop
watch. Display real-time date and operation state refresh period should be 1s.
Titles and display colors should change as the process changes.

1.1.6.2.5.2.3

Realtime function of on-off variables acquisition: select several on-off variables

channels, connect several test signals and alternately change state in accordance
with design on-off variables acquisition cycle. Check the real-time function of on-off
variables acquisition via on-off variables print function. The printing should be in
accordance with design acquisition cycle.

1.1.6.2.5.2.4

Processing cycle of controller module: test analog quantity and on-off variables
processing cycle via program to confirm analog quantity control system is no more
than 250ms and on-off variables control system no more than 100ms. In rapid
process loop, analog quantity control system should be no more than 125ms and
on-off variables control system no more than 50ms.

1.1.6.2.5.3

Test of System Response Time

1.1.6.2.5.3.1

Direct the switch value operation output signal to feedback signal input of
operation object. Then record the response signal time which the operation station
panel gives the command to display. Do it 10 times and take an average. The
average response time should be not more than 2.0s.

1.1.6.2.5.3.2

Put analog quantity value operation output signal to response signal input of
operation object directly. Then record the response signal time which the operation
station board gives the commander to display (or select one analog quantity value
Page 35 of 112

of engineer station as the detection point. Observe and record date change time of
the signal which is inputted through the keyboard is sent to another display). And it
should be done 10 times and take an average value of the time. The average
response time should be not more than 2.5s.
1.1.6.2.5.4

Test of system memory space and loading rate:

1.1.6.2.5.4.1

Use the system tool or the method provided by manufacturer. Check the memory
and external memory capacity and usage of historical data station or the station
with function of historical data storage of every control station. It should meet the
following requirements:

1.1.6.2.5.4.2

1)

The memory space should not less than 40%.

2)

The external memory space should not less than 40%.

Use the system tool or the method provided by manufacturer. Test the loading rate
of computer control system and data commnication bus. The loading rate should
be tested 5 times under the different working conditions and each test time is 10
seconds. The average value should meet the following requirements:
1)

The loading rate for all the CPU of control stations should not more than 60%
under the severe working conditions.

2)

The loading rate for the CPU of operator station and service station should not
more than 40% under the severe working conditions.

3)

In the loading rate of data communication bus, ethernet should not more than
20% and other networks should not more than 40%.

1.1.6.2.5.5

Test of anti-jamming capacity:

1.1.6.2.5.5.1

The test of anti-jamming capacity should be conducted when the operating

environment of the computer control system has been changed.

1.1.6.2.5.5.2

Test that bring interference voltage into onsite:

1)

Use the transformer as interference source. Bring the common-mode

disturbance voltage and differential-mode disturbance voltage from the singal
loop of onsite current, thermocouple and thermal resistance. Measure the
actual common-mode disturbance voltage and differential-mode disturbance
voltage on the input terminal of I/O of control station (see the method in
Appendix C).

2)

If the test condition that bring the interference voltage from the onsite is not
meet the requirement, Measure the actual common-mode disturbance voltage
and differential-mode disturbance voltage brought from the onsite on the input
terminal of I/O of control station when the accuracy of analog signals being
tested.

3)

Actually measured maximum common-mode disturbance voltage value should

Page 36 of 112

less than 60% of common-mode disturbance voltage restraining ability.

UN %/(10NMR / 20 ) 0.05

4 Actually measured channel error caused by the differential-mode singal should

meet the requirement of formula (1):
UN %/(10NMR / 20 ) 0.05

(1)

In the formula:
U % - The ratio of AC component peak value and full range of this point that
measured on the input terminal.
N NMR - Differential mode rejection ratio
1.1.6.2.5.5.3

The test of radio frequency immunity: Use the walkie-talkie with frequency of
400MHz-500MHz and power of 5W as the interference source. Transmit the
singals to conduct the test that 1.5 meters from the open machine cabinet, and the
computer system should work normally. The reading variation range of recorded
testing singnals should not more 2 times than integrated tolerance of measurement
system.

1.1.6.2.6

Accuracy test of module singal processing:

1.1.6.2.6.1

During the accuracy test of module singal processing, the matching of impedance
between standard source calibrator and module should be guaranteed and the
internal and external power supply should correspond with each other.

1.1.6.2.6.2

Check the transfer coefficient of every channel. It should meet value converting
requirement of the measurement system.

1.1.6.2.6.3

Accuracy test of analog input singal:

1.1.6.2.6.4

1)

For newly-built or overhauled unit, pointwise accuracy test should be

conducted on every I/O channel of module. For medium and minor overhaul,
1-4 channels could be selected randomly from every module (see table 1).

2)

The corresponding standard source is used to respectively input

0% 25% 50%75%100% of singal to the terminals that corresponding with
the measuring point. Read the displayed value from the operator station or
energineer station manual operator and compare it with the inputted
standard value.

Pulse input (PI) signal precision test

1.

Use relevant standard signal source to input signals 0%25%50%75% of

measuring range to the terminal of relevant measurement point, compare the
indication of the measurement point in the operator station or engineer station
(manual operating device) with standard value that has been put in;
Page 37 of 112

2.

1.1.6.2.6.5

Record the test data of each measurement point, calculate measurement

errors, and check the trigger level; they should meet the requirements in the
table 1. (Or meet the precision requirements of the manufacturer).

Analog output precision test

1.

Set the output value of each point according to 0% 25% 50% 75% of
measuring range through operator station (or engineer station, or manual
operation device), employ standard instrument to measure the indication value
of the output signal in the relevant output terminal of I/O station, and compare
this value with output standard calculation value;

2.

Record the test data and calculate measurement errors of each measurement
point; they should meet the precision requirement in table 2.

Table 1 the precision standard of output module channel

AO signal type

Basic error

Return error

Current (mA)

0.25%

0.125%

Voltage (V)

0.25%

0.125%

Pulse (Hz)

0.25%

0.125%

1.1.6.2.6.6

1.1.6.2.6.7

Pulse output (PO) signal precision test

1.

Set the output value of each point according to 0% 25% 50% 75% of
measuring range through operator station (engineer station, or manual
operation device), employ standard kilometer to measure the indication value
of output signal in the relevant output terminal of I/O station, and compare this
value with the output standard calculation value;

2.

Record the test data and measurement the errors of each measurement point,
they should meet the precision requirement of the manufacturer.

On-off (Digital) input (DI) correctness test

1. Change the status of each input point separately by disconnecting source-free
contact point or by short circuit, or by adding or removing level signal, check
the status change of each input point at operator station or engineer station
(manual operating device).
2.

Record the status change of each measured point and they should be correct.

Page 38 of 112

1.1.6.2.6.8

The correctness test for interruption type SOEdata input channel.

Send out 3~5 On-off signals by digital signal generator with time interval of
1ms~5ms to input terminal of SOE signal. Change the time interval of the signal
generator until the event sequence record is undistinguishable. The resolution of
the event sequence record should be equal or less than 1ms; the alarm display,
the sequence of printing signal and the time sequence should be consistent with
input signal; when printing again, the time sequence should not change;
If there is no On-off signal generator, input signals simultaneously to SOE signal
input terminal of different stations (for example, to connect SOE signal terminal of
different station to the same switch, then open or close the switch). The display
and printing record in SOE alarm list of operator station should be consistent with
input signal. It is not suggested to print again during the interval between signal
generating and disappearing; the time difference of signal activation should be
equal or less than 1ms.

1.1.6.2.6.9

1.1.6.2.6.10

Digital output DOcorrectness test

1.

Set the output given value of 1 and 0 through operator station (engineer
station or manual operating device), measure the pass and break condition of
the terminal relevant to I/O station. At the same time observe the status of
indicating lamp for digital output

2.

Record the status change of each measuring point, and make sure the status
change is correct.

Test of channel output self-keep function

1.

Set an output value for measured module channel at operator station,

measure and record the output value of relevant module output terminal at I/O
station.

2.

Cut off the system power supply of I/O station firstly, and then switch on,
measure and record the output once again of relevant output terminal;

3.

The indications of the module output value before and after switch off should
be within the precision range.

4.

The maximum error calculated from half value of the indications difference
before and after the above operation should not exceed the permissive error
of the module.

1.1.6.2.7

Basic functions test for control system

1.1.6.2.7.1

System configuration and on-line download function

1.

Confirm the authority setting for engineer station is correct and make sure only
engineer can enter the engineer station.

2.

Open the system configuration software at engineer station, build a

Page 39 of 112

configuration off-line according to configuration manual, carry out compiling if

the condition permits, and check that the functions of the configuration
software are normal.
3.

1.1.6.2.7.2

1.1.6.2.7.3

When the computer control system is energized, read the configuration of any
main controller or any functional module in control station back into the
engineer station; then download this configuration ( or modifying the
configuration and the conforming of it) into the original main controller or
functional module. When the new configuration has been downloaded, system
original configuration will be refreshed automatically; ensure that there is no
fault in the system or other abnormal conditions during operation process.

Test for man-machine interface (MMI) function at operator station.

1.

Confirm the authority setting for the operator station is correct, and operator
can enter the operator station.

2.

Confirm there is nothing abnormal on each process menu and parameter

monitoring menu.

3.

Operates device with different functions and menus at operation station one by
one through functional keyboard and mouse. Check that each display menu is
normal, each functional key or button, all connections of the functional menu,
the corresponding results of the operation should be correct. When operate
the key that has never been defined, ensure there are no faults or system
crash.

4.

Confirm that the main menus (such as the process menu, parameter
monitoring menu, real-time trend curve display menu, alarm displaying menu,
etc.) indicate normally; check that each of the dynamic parameters and the
real-time trend curve are refreshed automatically, and the refresh time can
meet the requirements.

5.

Confirm each alarm display; alarm window and the alarm confirming function
are normal, the connection of alarm clue and relating menu are correct.

6.

Confirm historical data searching menu indicates normally, when input data
(such as measurement point name, measurement point number) and time
period that need searching, the system should respond correctly and display
correct record (such as historical data report forms or the historical data curve,
historical event report forms and the operation record, etc.). When applying for
printing, the print result is the same as displayed result.

Check
system
operating
status
menu
(system
self-diagnosis
information)and the display should be consistent with practical status.

8.

Check that the help and/or the operation guide menu are normal.

Test of report form printing function and screen copy function.

Page 40 of 112

1.1.6.2.7.4

1.1.6.2.7.5

1.1.6.2.7.6

1.

Confirm that the display of report forms management function menu is normal;
start periodic printing function of report forms, confirm the format, content and
time, and make sure they can meet the requirements.

2.

Select the report forms at operator station that need printing by functional
keyboard and mouse, trigger the random printing function, the system should
print the selected forms immediately, and the format, content and time should
meet the requirements.

3.

Select one flow chart display and activate the screen copy function, check the
hard copy content and menu display are consistent.

4.

Activate any data signal in the SOE report forms, check that the SOE report
forms are printed normally. The data and activated data signal before or after
activation should be correct.

Function test for historical data storage and search:

1.

Select a group of record point from historical data base, the content include
analog, On-off variable, operation record and system event, etc.

2.

Make configuration separately for the report forms and curve of the current
historical data, display and print the forms and curve. Confirm the data and
time of the forms and curves are correct and there is no fault alarm during the
process.

3.

Separately configuration historical data report forms and curves that has been
stored into tapes or disks (long-term), and system should remind the necessity
of historical data tape or disks; insert relevant tape and disks, make activation,
and then display and print them. Check that the data and time of the forms
and curves are correct and there is no alarm during operation process.

Check the function of performance calculation:

1.

Check that all the measurement points relevant to the performance calculation
are correct, the calculation of the report forms, the display and the print of the
menu should be normal.

2.

Start the application program of the performance calculation and there is no

alarm.

3.

Cooperate with relevant department to check the calculation precision of the

performance calculation, if it fails to meet designed requirements, make
adjustment or modify the configuration.

Test on connection of communication interface:

1.

Energize the system and the indications of indicating lamps in the

communication interface module are normal.

2.

Start communication driving software, system should have no incorrect

Page 41 of 112

information
3.

Use network software devices or special communication test software device

to ensure that the physical connection of the communication is correct and
effective. Test data sending and receiving condition by using application
software or modulation method, the real time should meet the designed
requirements.

4.

Confirm the connections of interface and communication between computer

control system and other special devices are normal and the communication
data is correct.

1.1.6.3

Test and acceptance of maintenance:

1.1.6.3.1

Control system is in good condition

1.1.6.3.2

The inspection and maintenance items in the control system can meet the quality
requirements.

1.1.6.3.3

The standby channels of measuring module have been carried out with initial setup
according to the requirements for online operation channel.

1.1.6.3.4

The performance and function tests of control system have been tested according
to test program, and the technical target can meet the requirements.

1.1.6.3.5

Test at local and confirm the operation of control sub system is normal.

1.1.6.3.6

The maintenance record and report.

The following maintenance record should be complete and in good order, the data
should be correct meet the quality requirements, make a list for the items that fail
to meet the requirements
1.

Check the abnormal item record before shutdown and the conditions after
maintenance, confirm all problems have been solved.

2.

Measure insulation resistance, it should meet the requirements

3.

The precision calibration record of analog I/O module is also attached with a
classification statistic table for calibration qualification rate of different type of
modules.

4.

Performance test and test record for computer equipment and system are
complete, and can meet the requirements.

5.

The record for performance and function test of computer control system
should be complete and meet the regulated requirements.

6.

The record for repaired parts or replaced parts of computer control system is
complete and detailed. (Attached with reasons for maintenance and
replacements)

Page 42 of 112

7.

The record for inspection and modification of software should be complete and
detailed. (Attached with detailed instruction and modification approval permit)

8.

The quality and quantity of software backup for computer control system can
meet the requirement.

9.

Keep a detailed record for software or hardware modification of the computer

control system.

1.1.6.3.7

After computer control system is started, confirm the fault alarm record and selfdiagnosis record have nothing abnormal.

1.1.6.3.8

The printer runs normally after energize, and the printing paper is well fabricated.

Page 43 of 112

1.2

Digital Electro-hydraulic System (DEH)

1.2.1

DEH System General Description

1.2.1.1

The turbine DEH control system is made up of control part, EH hydraulic pressure
system and safeguard system. It is mainly used to control the rotation speed and
power of turbine generator. It adopts the advanced I/A Series open industry control
system of Foxboro.

1.2.1.2

Under the automatic condition, the operator carries out the control operations and
image operations mainly through the mouse of the operator station. The operators
command is transmitted to the control FCS through the operator station, and the
I/O card will carry out the output control. The unit state and result will be displayed
on CRT.

1.2.1.3

Four governing steam valves are equipped at the inlet of turbine HP casing. In
command to ensure the safety operation of the turbine, corresponding main stop
valves should be equipped. All of the ten steam inlet valves of turbine abovementioned adopt oil actuator driven with the HP fire-resistant oil as working
medium. The six governing valves, CVICV and the HP main stop valve MSV2 on
the right side is continuously controlled by the servo valve and the interface of the
DEH micro computer. The two-position control of HP main stop valve MSV1 on the
left side and two IP main stop valve RSV is carried out by the solenoid valve and
DEH interface.
In command to ensure the safety operation of turbine, there are redundant
protecting sleeves in the hydraulic pressure system.
Fly ring and test solenoid valve
HP and LP trip solenoid valve
Overspeed limiting solenoid valve

1.2.1.4

EH hydraulic pressure system includes oil feeding system, oil pipes, and oil motor.
EH oil feeding system also includes the emergency trip system which controls the
oil motor emergency shutdown and the diaphragm valve. HP fire-resistant oil
source is equipped with two redundant sets of pressure oil pumps to ensure the
continuous oil feeding.

1.2.1.5

The emergency trip system includes OPC solenoid valve, AST solenoid valve and
diaphragm valve. The structure of OPC solenoid valves is two vales parallel
connection. When the OPC solenoid valve is energized, release OPC safety oil,
and quickly close the governing steam valve. The structure of AST solenoid valves
is four valves series/parallel connection. When AST solenoid valve is de-energized,
release AST safety oil and OPC safety oil, close all of the valves and shut down.
Connect the diaphragm valve with LP safety oil interface. When there is no LP
safety oil, releases AST safety oil by the diaphragm valve. Quickly close the valve
and shut down.

1.2.2

Composition of DEH Control System Hardware

1.2.2.1

The turbine DEH control system adopts the advanced I/A Series open industry
control system of Foxboro. It includes two cabinets, one operation station WP70,
one application operation station AW70. (The operation state has the functions of
operator station and engineer station).

1.2.2.2

The processors FCP270 of DEH control system are two pairs. One couple is
defined as BTC, which finishes the over speed protection and turbine basic control.
The other couple is defined as ATC, which finishes the turbine parameters
monitoring and on-line test.
Page 44 of 112

1.2.2.3

DEH System Template Configuration:

BTC station (basic control station):

Items

Description

Model

Quantity

Speed measuring
boards

FBM206

AI/AO boards

FBM204

DI/DO boards

FBM241C

Preset speed
measurement boards

ATC station:

Items

Description

Model

Quantity

AI board

FBM201

TC signal AI board

FBM202

RTD signal AI board

FBM203

AI/AO board

FBM204

DI board

FBM207

DI/DO board

FBM241C

DEH DI signal

Item

Signal description

Signal source

Terminal No.

HP emergency oil
pressure build-up 1

PS1

1AD1141(cs,+)

Local
pressure
switch PS1

HP emergency oil
pressure build-up 2

Local
pressure
switch PS2

1AD1151(cs,+)

HP emergency oil
pressure build-up 3

Local
pressure
switch PS3

1AD1161(cs,+)

RB 1

DCS

1AD1142(cs,+)

RB 2

DCS

1AD115-

Page 45 of 112

Notes

2(cs,+)
6

RB 3

DCS

1AD1162(cs,+)

MSV1 full close

Local

1AD1143(cs,+)

MSV 1 full open

Local

1AD1144(cs,+)

MSV2 full close

Local

1AD1153(cs,+)

10

MSV2 full open

Local

1AD1154(cs,+)

11

RSV 1 full close

Local

1AD1163(cs,+)

12

RSV 1 full open

Local

1AD1164(cs,+)

13

RSV 2 full close

Local

1AD1173(cs,+)

14

RSV 2 full open

Local

1AD1174(cs,+)

15

Manual shutdown

Control
console

TB3-(65/66)

16

Generator
synchronization 1

Electric

TB2-(28/32)

17

Generator
synchronization 2

Electric

TB2-(29/33)

18

Generator
synchronization 3

Electric

TB2-(30/34)

19

Generator pseudo
synchronization test

Electric

1AD1155(cs,+)

20

CCS request

CCS

1AD1157(cs,+)

21

Emergency tripped latch

reset ZS1

Local travel
switch ZS1

1AD1145(cs,+)

Local travel
switch ZS2

1AD1165(cs,+)

22
Emergency tripped latch
reset ZS2
23

Manual trip position state

ZS3

Local travel
switch ZS3

1AD1171(cs,+)

24

Isolation valve in test

position ZS4

Local travel
switch ZS4

1BD1225(cs,+)

25

Isolation valve in normal

Local travel

1BD122-

Page 46 of 112

position ZS5

switch ZS5

6(cs,+)

26

HP trip solenoid valve test

succeeds PS4

Local
pressure
switch PS4

1BD1181(cs,+)

27

HP trip solenoid valve test

succeeds PS5

Local
pressure
switch PS5

1BD1182(cs,+)

28

ETS trip

ETS

1AD1172(cs,+)

29

Turning gear in service

Turning gear
device

1AD1166(cs,+)

30

Synchronization in
service

Electric

1AD1175(cs,+)

31

Synchronization increase

Electric

1AD1176(cs,+)

32

Synchronization decrease

Electric

1AD1177(cs,+)

33

Vacuum valve full open

Local

1BD1223(cs,+)

34

Vacuum valve full close

Local

1BD1224(cs,+)

35

RFV stop valve full open

Local

1BD1221(cs,+)

36

RFV stop valve full close

Local

1BD1222(cs,+)

37

MSV1 85% travel

Local

1BD1183(cs,+)

38

RSV1 85% travel

Local

1BD1184(cs,+)

39

RSV2 85% travel

Local

1BD1185(cs,+)

40

LP bypass full close

Bypass
controller

1BD1211(cs,+)

41

LP bypass auto

Bypass
controller

1BD1212(cs,+)

42

HP bypass full close

Bypass
controller

1BD1213(cs,+)

43

HP bypass auto

Bypass
controller

1BD1214(cs,+)

44

#1 HP exhaust check
valve full close

Local

1BD1215(cs,+)

45

#1 HP exhaust check

Local

1BD121-

Page 47 of 112

Interior signal

valve full open

6(cs,+)

46

#2 HP exhaust check
valve full close

Local

1BD1231(cs,+)

47

#2 HP exhaust check
valve full open

Local

1BD1232(cs,+)

48

MSV2 servo output failure

Servo
controller

1BD1251(cs,+)

Interior signal

49

MSV2 calibration
processing

1BD1252(cs,+)

Interior signal

Servo
controller

50

CV1 servo output failure

Servo
controller

1BD1253(cs,+)

Interior signal

51

CV1 calibration
processing

Servo
controller

1BD1254(cs,+)

Interior signal

52

CV2 servo output failure

Servo
controller

1BD1255(cs,+)

Interior signal

53

CV2 calibration
processing

Servo
controller

1BD1256(cs,+)

Interior signal

54

CV3 servo output failure

Servo
controller

1BD1257(cs,+)

Interior signal

55

CV3 calibration
processing

Servo
controller

1BD1258(cs,+)

Interior signal

56

CV4 servo output failure

Servo
controller

1BD1259(cs,+)

Interior signal

57

CV4 calibration
processing

Servo
controller

1BD12510(cs,+)

Interior signal

58

ICV1 servo output failure

Servo
controller

1BD12511(cs,+)

Interior signal

59

ICV1 calibration
processing

Servo
controller

1BD12512(cs,+)

Interior signal

60

ICV2 servo output failure

Servo
controller

1BD12513(cs,+)

Interior signal

61

ICV2 calibration
processing

Servo
controller

1BD12514(cs,+)

Interior signal

2.

DEH DO signal

Ite
m

Signal description

Signal source

Terminal No.

MSV1 tripping solenoid

valve acts

Local 11YV

TB9-(52/53)

MSV2 tripping solenoid

Local 10YV

TB9-(47/48)

Page 48 of 112

Notes

valve acts
3

RSV1 tripping solenoid

valve acts

Local 19YV

TB9-(92/93)

RSV2 tripping solenoid

valve acts

Local 18YV

TB9-(87/88)

CV1 fast close solenoid

valve acts

Local 12YV

TB9-(57/58)

CV2 fast close solenoid

valve acts

Local 13YV

TB9-(62/63)

CV3 fast close solenoid

valve acts

Local 14YV

TB9-(67/68)

CV4 fast close solenoid

valve acts

Local 15YV

TB9-(72/73)

ICV1 fast close solenoid

valve acts

Local 17YV

TB9-(82/83)

10

ICV2 fast close solenoid

valve acts

Local 16YV

TB9-(77/78)

11

OSP1 overspeed limit

solenoid valve acts

Local 5BYV

TB9-(17/18)

12

OSP2 overspeed limit

solenoid valve acts

Local 5BYV

TB9-(22/23)

13

HP trip solenoid valve 1 acts

Local 6YV

TB9-(27/28)

14

HP trip solenoid valve 2 acts

Local 7YV

TB9-(32/33)

15

HP trip solenoid valve 3 acts

Local 8YV

TB9-(37/38)

16

HP trip solenoid valve 4 acts

Local 9YV

TB9-(42/43)

17

MSV1 test solenoid valve

acts

Local 22YV

TB9-(107/108)

18

RSV1 test solenoid valve

acts

Local 21YV

TB9-(102/103)

19

RSV2 act test solenoid valve

acts

Local 20YV

TB9-(97/98)

20

Steam turbine latch

TB9-(2/3)
Local 1YV

21

Oil spray test solenoid valve

acts

Local 2YV

TB9-(7/8)

22

Mechanical shutdown
electric magnetic acts

Local 3YV

TB4-(22/23)

23

Isolation solenoid valve acts

Local 4YV

TB9-(12/13)

Page 49 of 112

24

Cool state startup

Bypass controller

TB6-(23/24)

25

Warm state startup

Bypass controller

TB6-(25/26)

26

Hot state startup

Bypass controller

TB6-(27/28)

27

Super hot state startup

Bypass controller

TB6-(29/30)

28

Open pre-warm valve

Local

TB6-(15/16)

29

Close pre-warm valve

Local

TB6-(17/18)

30

Open vacuuming valve

Local

TB6-(19/20)

31

Turbine tripped

ETS

TB6-(43/44)

32

Overspeed test permits

Relay cabinet

R41-(1,7)

33

Put CCS in service

CCS

TB6-(9/10)

34

OPC acts

Display alarm

TB6-(11/12)

35

Casing switch

Bypass controller

TB6-(33/34)

36

IP casing startup

Bypass controller

TB6-(31/32)

37

Load >15%

Relay cabinet

R39-(4,7)

Interior
signal

38

MSV2 calibration begins

Servo controller

1BD121-9(c,k)

Interior
signal

39

CV1 calibration begins

Servo controller

1BD121-10(c,k)

Interior
signal

40

CV2 calibration begins

Servo controller

1BD121-11(c,k)

Interior
signal

41

CV3 calibration begins

Servo controller

1BD121-12(c,k)

Interior
signal

42

CV4 calibration begins

Servo controller

1BD121-13(c,k)

Interior
signal

43

ICV1 calibration begins

Servo controller

1BD121-14(c,k)

Interior
signal

44

ICV2 calibration begins

Servo controller

1BD121-15(c,k)

Interior
signal

45

Calibration permits

Servo controller

1BD121-16(c,k)

Interior
signal

46

Synchronization permits

Electric

TB6-(92/93)

47

DEH trip

ETS

TB6-(1/2)

48

HP trip solenoid valve 1 test

6YV

ETS

TB6-(13/14)

49

HP trip solenoid valve 2 test

ETS

TB6-(5/6)

Page 50 of 112

Interior
signal

7YV
50

HP trip solenoid valve 3 test

8YV

ETS

TB6-(21/22)

51

HP trip solenoid valve 4 test

9YV

ETS

TB6-(7/8)

52

Rotation speed <2850r/min

DCS

TB6-(90/91)

53

HP casing pre-warm

DCS

TB6-(94/95)

54

Rotation speed <1200r/min

DCS

TB6-(3/4)

55

Turbine resets

ETS

TB6-(45/46)

56

110% act alarm

Display alarm

TB6-(69/70)

3 DEH AI signal

Ite
m

Signal description

Signal source

Terminal No.

Notes

Generator power 1

Local

1AD106-1(i+,i-)

0400MW

Generator power 2

Local

1AD107-1(i+,i-)

0400MW

Generator power 3

Local

1AD108-1(i+,i-)

0400MW

CCS command 1

CCS

1AD106-2(i+,i-)

0100%

CCS command 2

CCS

1AD107-3(i+,i-)

0100%

Condenser
vacuum

Local

1AD106-3(+iP,i+)

-0.11MPa

MSV2 valve
position feedback

Servo controller

1BD124-4(i+,i-)

0100%

CV1 valve position

feedback

Servo controller

1AD106-4(i+,i-)

0100%

CV2 valve position

feedback

Servo controller

1AD107-4(i+,i-)

0100%

CV3 valve position

feedback

Servo controller

1AD108-4(i+,i-)

0100%

10

CV4 valve position

feedback

Servo controller

1AD111-4(i+,i-)

0100%

11

ICV1 valve
position feedback

Servo controller

1AD112-4(i+,i-)

0100%

12

ICV2 valve
position feedback

Servo controller

1AD113-4(i+,i-)

0100%

13

Pressure behind
HP governing

Local

1AD107-2(+iP,i+)

016MPa

Page 51 of 112

state
14

HP casing exhaust
pressure

Local

1AD108-2(+iP,i+)

04MPa

15

IP casing exhaust
pressure

Local

1AD108-3(+iP,i+)

01MPa

16

Main steam
pressure (left)

Local

1AD111-1(+iP,i+)

025MPa

17

Main steam
pressure (right)

Local

1AD112-1(+iP,i+)

025MPa

18

Reheating steam
pressure (left)

Local

1BD103-1(+iP,i+)

06MPa

19

Reheating steam
pressure (right)

Local

1BD103-2(+iP,i+)

06MPa

20

Lube oil pressure

Local

1AD111-2(+iP,i+)

00.25MPa

21

EH oil pressure

Local

1AD112-2(+iP,i+)

025MPa

22

Axial displacement
1

TSI

1BD124-1(i+,i-)

-22um

23

Axial displacement
2

TSI

1BD124-2(i+,i-)

-22um

24

Eccentricity

TSI

1AD113-1(i+,i-)

0100um

25

HIP casing
thermal expansion
(left)

TSI

1BD103-5(i+,i-)

050mm

26

HIP casing
thermal expansion
(right)

TSI

1BD103-6(i+,i-)

050mm

27

HIP casing DE

TSI

1AD111-3(i+,i-)

-48um

28

LP casing DE

TSI

1BD124-3(i+,i-)

020um

29

#1 shaft vibration
(X)

TSI

1BD103-7(i+,i-)

0400m

30

#1 shaft
vibration(Y)

TSI

1BD103-8(i+,i-)

0400m

31

#2 shaft vibration
(X)

TSI

1BD104-1(i+,i-)

0400m

32

#2 shaft
vibration(Y)

TSI

1BD104-2(i+,i-)

0400m

33

#3 shaft
vibration(X)

TSI

1BD104-3(i+,i-)

0400m

34

#3 shaft
vibration(Y)

TSI

1BD104-4(i+,i-)

0400m

Page 52 of 112

35

#4 shaft
vibration(X)

TSI

1BD104-5(i+,i-)

0400m

36

#4 shaft
vibration(Y)

TSI

1BD104-6(i+,i-)

0400m

37

#5 shaft
vibration(X)

TSI

1BD104-7(i+,i-)

0400m

38

#5 shaft
vibration(Y)

TSI

1BD104-8(i+,i-)

0400m

39

#6 shaft
vibration(X)

TSI

1BD105-1(i+,i-)

0400m

40

#6 shaft
vibration(Y)

TSI

1BD105-2(i+,i-)

0400m

41

#1 casing vibration

TSI

1BD105-3(i+,i-)

0125m

42

#2 casing vibration

TSI

1BD105-4(i+,i-)

0125m

43

#3 casing vibration

TSI

1BD105-5(i+,i-)

0125m

44

#4 casing vibration

TSI

1BD105-6(i+,i-)

0125m

45

#5 casing vibration

TSI

1BD105-7(i+,i-)

0125m

46

#6 casing vibration

TSI

1BD105-8(i+,i-)

0125m

4 DEH AO signal
Item

Signal
description

Signal source

Terminal No.

Notes

MSV2 valve
position set

Servo controller

1BD124-5(o+,o-)

0100%

CV1 valve
position set

Servo controller

1AD106-5(o+,o-)

0100%

CV2 valve
position set

Servo controller

1AD107-5(o+,o-)

0100%

CV3 valve
position set

Servo controller

1AD108-5(o+,o-)

0100%

CV4 valve
position set

Servo controller

1AD111-5(o+,o-)

0100%

ICV1 valve
position set

Servo controller

1AD112-5(o+,o-)

0100%

ICV2 valve
position set

Servo controller

1AD113-5(o+,o-)

0100%

Turbine valve
position (valve
position
setting point)

CCS

1AD111-6(o+,o-)

0100%

Page 53 of 112

Actual load
(send to DCS)

DCS

1AD112-6(o+,o-)

0400MW

5 DEH RTD signal

item

Signal description

Signal source

Terminal No.

Notes

Lube oil temperature

Local

1BD116-1(ic,i+,i-)

0
60

EH oil temperature

Local

1BD115-7(ic,i+,i-)

0
80

#1 locating thrust
bearing metal
temperature

Local

1BD112-1(ic,i+,i-)

0
120

#2 locating thrust
bearing metal
temperature

Local

1BD112-2(ic,i+,i-)

0
120

#3 locating thrust
bearing metal
temperature

Local

1BD112-3(ic,i+,i-)

0
120

#4 locating thrust
bearing metal
temperature

Local

1BD112-4(ic,i+,i-)

0
120

#5 locating thrust
bearing metal
temperature

Local

1BD112-5(ic,i+,i-)

0
120

#6 locating thrust
bearing metal
temperature

Local

1BD112-6(ic,i+,i-)

0
120

#7 locating thrust
bearing metal
temperature

Local

1BD112-7(ic,i+,i-)

0
120

10

#8 locating thrust
bearing metal
temperature

Local

1BD112-8(ic,i+,i-)

0
120

11

#9 locating thrust
bearing metal
temperature

Local

1BD113-1(ic,i+,i-)

0
120

12

#10 locating thrust

bearing metal
temperature

Local

1BD113-2(ic,i+,i-)

0
120

13

#11 locating thrust

bearing metal
temperature

Local

1BD113-3(ic,i+,i-)

0
120

Page 54 of 112

14

#1 working thrust
bearing metal
temperature

1BD113-4(ic,i+,i-)

0
120

Local

15

#2 working thrust
bearing metal
temperature

Local

1BD113-5(ic,i+,i-)

0
120

16

#3 working thrust
bearing metal
temperature

Local

1BD113-6(ic,i+,i-)

0
120

17

#4 working thrust
bearing metal
temperature

Local

1BD113-7(ic,i+,i-)

0
120

18

#5 working thrust
bearing metal
temperature

Local

1BD113-8(ic,i+,i-)

0
120

19

#6 working thrust
bearing metal
temperature

Local

1BD114-1(ic,i+,i-)

0
120

20

#7 working thrust
bearing metal
temperature

Local

1BD114-2(ic,i+,i-)

0
120

21

#8 working thrust
bearing metal
temperature

Local

1BD114-3(ic,i+,i-)

0
120

22

#9 working thrust
bearing metal
temperature

Local

1BD114-4(ic,i+,i-)

0
120

6 DEH THC signal

Item

Signal description

Signal source

Terminal No.

Notes

Main steam
temperature (left)

Local

1BD106-1(i+,i-)

0
600

Main steam
temperature (right)

Local

1BD106-2(i+,i-)

0
600

Reheating steam
temperature (left)

Local

1BD106-3(i+,i-)

0
600

Reheating steam
temperature (right)

Local

1BD106-4(i+,i-)

0
600

HP main steam valve

exterior wall
temperature (left)

Local

1BD106-5(i+,i-)

0
600

HP main steam valve

exterior wall
temperature (right)

Local

1BD106-6(i+,i-)

0
600

Page 55 of 112

HP main steam valve

interior wall
temperature (left)

Local

1BD106-7(i+,i-)

0
600

Other signal

Item

Signal description

Signal source

Terminal No.

Notes

Rotation speed 1

Pre-processing
device

Local-DEH

Magneto
resistive
type

Rotation speed 2

Pre-processing
device

Local-DEH

Magneto
resistive
type

Rotation speed 3

Pre-processing
device

Local-DEH

Magneto
resistive
type

MSV2 control
signal 1

TB7-(1/2)

Local

+/-40mA

MSV2 control
signal 2

TB7-(3/4)

Local

+/-40mA

LVDT13 primary
excitation signal

TB7-(6/15)

Local

1.7kHz,2.2
3.5V

LVDT14 primary
excitation signal

TB7-(6/15)

Local

1.7kHz,2.2
3.5V

LVDT13 secondary
feedback1

TB7-(7/8)

Local-DEH

LVDT13 secondary
feedback2

TB7-(9/10)

Local-DEH

10

LVDT14 secondary
feedback1

TB7-(11/12)

Local-DEH

11

LVDT14 secondary
feedback1

TB7-(13/14)

Local-DEH

12

CV1 control signal

1

TB7-(18/19)

Local

+/-40mA

13

CV1 control signal

2

TB7-(20/21)

Local

+/-40mA

14

LVDT1 primary
excitation signal

TB7-(23/32)

Local

1.7kHz,2.2
3.5V

15

LVDT2 primary
excitation signal

TB7-(23/32)

Local

1.7kHz,2.2
3.5V

16

LVDT1 secondary
feedback1

TB7-(24/25)

Local-DEH

17

LVDT1 secondary

TB7-(26/27)

Local-DEH

Page 56 of 112

feedback2
18

LVDT2 secondary
feedback1

TB7-(28/29)

Local-DEH

19

LVDT2 secondary
feedback2

TB7-(30/31)

Local-DEH

20

CV2 control signal

1

TB7-(35/36)

Local

+/-40mA

21

CV2 control signal

2

TB7-(37/38)

Local

+/-40mA

22

LVDT3 primary
excitation signal

TB7-(40/49)

Local

1.7kHz,2.2
3.5V

23

LVDT4 primary
excitation signal

TB7-(40/49)

Local

1.7kHz,2.2
3.5V

24

LVDT3 secondary
feedback1

TB7-(41/42)

Local-DEH

25

LVDT3 secondary
feedback2

TB7-(43/44)

Local-DEH

26

LVDT4 secondary
feedback1

TB7-(45/46)

Local-DEH

27

LVDT4 secondary
feedback2

TB7-(47/48)

Local-DEH

28

CV3 control signal

1

TB7-(51/52)

Local

+/-40mA

29

CV3 control signal

2

TB7-(53/54)

Local

+/-40mA

30

LVDT5 primary
excitation signal

TB7-(56/65)

Local

1.7kHz,2.2
3.5V

31

LVDT6 primary
excitation signal

TB7-(56/65)

Local

1.7kHz,2.2
3.5V

32

LVDT5 secondary
feedback1

TB7-(57/58)

Local-DEH

33

LVDT5 secondary
feedback2

TB7-(59/60)

Local-DEH

34

LVDT6 secondary
feedback1

TB7-(61/62)

Local-DEH

35

LVDT6 secondary
feedback2

TB7-(63/64)

Local-DEH

36

CV4 control signal

1

TB7-(68/69)

Local

+/-40mA

37

CV4 control signal

2

TB7-(70/71)

Local

+/-40mA

Page 57 of 112

38

LVDT7 primary
excitation signal

TB7-(73/82)

Local

1.7kHz,2.2
3.5V

39

LVDT8 primary
excitation signal

TB7-(73/82)

Local

1.7kHz,2.2
3.5V

40

LVDT7 secondary
feedback1

TB7-(74/75)

Local-DEH

41

LVDT7 secondary
feedback2

TB7-(76/77)

Local-DEH

42

LVDT8 secondary
feedback1

TB7-(78/79)

Local-DEH

43

LVDT8 secondary
feedback2

TB7-(80/81)

Local-DEH

44

ICV1 control signal

1

TB7-(85/86)

Local

+/-40mA

45

ICV1 control signal

2

TB7-(87/88)

Local

+/-40mA

46

LVDT9 primary
excitation signal

TB7-(90/99)

Local

1.7kHz,2.2
3.5V

47

LVDT10 primary
excitation signal

TB7-(90/99)

Local

1.7kHz,2.2
3.5V

48

LVDT9 secondary
feedback1

TB7-(91/92)

Local-DEH

49

LVDT9 secondary
feedback2

TB7-(93/94)

Local-DEH

50

LVDT10 secondary
feedback1

TB7-(95/96)

Local-DEH

51

LVDT10 secondary
feedback2

TB7-(97/98)

Local-DEH

52

ICV2 control signal

1

TB7-(101/102)

Local

+/-40mA

53

ICV2 control signal

2

TB7-(103/104)

Local

+/-40mA

54

LVDT11 primary
excitation signal

TB7-(106/115)

Local

1.7kHz,2.2
3.5V

55

LVDT12 primary
excitation signal

TB7-(106/115)

Local

1.7kHz,2.2
3.5V

56

LVDT11 secondary
feedback1

TB7-(107/108)

Local-DEH

57

LVDT11 secondary
feedback2

TB7-(109/110)

Local-DEH

58

LVDT12 secondary
feedback1

TB7-(111/112)

Local-DEH

Page 58 of 112

59

LVDT12 secondary
feedback2

TB7-(113/114)

Local-DEH

60

Main 220VAC input

of card cabinet

230VAC50Hz

Main power
supply switch
(L,N,G)

61

Assistant 220VAC
input of card
cabinet

230VAC50Hz

power supply
switch (L,N,G)

62

Main 220VAC input

of relay

230VAC50Hz

Main power
supply switch
(L,N,G)

63

Assistant 220VAC
input of relay

230VAC50Hz

Assistant power
supply switch
(L,N,G)

64

Servo tower main

230VAC input

230VAC50Hz

TB4-808182

65

Servo tower
assistant 230VAC
input

230VAC50Hz

TB4-858687

66

Main 220VDC input

SW5(31)

67

Assistant 220VDC
input

SW6(31)

68

Card cabinet main

230VAC fault alarm

Alarm

TB6-(7273)

69

Card cabinet
assistant 230VAC
fault alarm

Alarm

TB6-(7576)

70

Relay main
230VAC fault alarm

Alarm

TB6-(7879)

71

Relay assistant
230VAC fault alarm

Alarm

TB6-(8182)

72

DEH main 220VDC

input loses

Alarm

TB6-(6364)

73

DEH assistant
220VDC input
loses

Alarm

TB6-(6667)

74

Relay cabinet
24VDC loses

TB6-(6061)
Alarm

75

Servo tower power

supply fault

Alarm

TB6-(9697)

76

6YV ETS test

ETSDEH

TB4-(9091)

77

7YV ETS test

ETSDEH

TB4-(9495)

Page 59 of 112

78

8YV ETS test

ETSDEH

TB4-(9293)

79

9YV ETS test

ETSDEH

TB4-(9697)

80

ETS shutdown 1

ETSDEH

TB3-(5760)

81

ETS shutdown 2

ETSDEH

TB3-(5861)

82

DEH trip

DEHSOE

TB6-(5354)

83

110% act

DEHSOE

TB6-(5556)

84

OPC act

DEHSOE

TB6-(5758)

85

Manual shutdown

DEHSOE

TB6-(5152)

Note:
1 TB7-(53/54) represents the No.53 and No.54 terminal of TB7 terminal strip.
The rest follow in the same pattern.
2)

1AD114-6(cs+) represents the cs end and + end of card 1D0114. The rest
follow in the same pattern.

3)

TB2TB3TB4TB6TB8 and TB9 terminal strips are laid in relay cabinet.

TB1TB5 and TB7 terminal strips are in card cabinet. Pre-processing speed
measurement card is in relay cabinet.

4)

One set of AW70 application operation station includes AW70 application

operation station, one colorful 21"LCD, mouse, keyboard and etc. AW70 is
used for design, configuration, commissioning and monitoring.

5)

One set of WP70 application operation station includes WP70 application

operation station, one colorful 21"LCD, mouse, keyboard and etc.

WP70 is the main equipment for the operators having communications with turbine
control system. WP70, together with its connected outside equipment, supplies the
interface between the users and all of the system functions. Its main functions are:
supplying the methods for commands and data input, display selections and
alarming management. It receives figure and literal information from application
processor and other system stations, then it displays these information on the
video display.
Control System Configuration Diagram:
1.2.3

Main Functions of DEH Control System

1.2.3.1

Latch on

1.2.3.2

Set the static relationship of servo system

1.2.3.3

Control and start up before the startup

1.2.3.4

Automatically inspect the thermal state

1.2.3.5

Rotating speed control

1.2.3.6

Speed up: Set target, set speed-up rate, automatic passing the critical point,
automatic turbine warming up, and constant speed with 3000r/min.

1.2.3.7

Load control

1.2.3.8

Synchronization with initial load.

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1.2.3.9

Pseudo - synchronization test of generator.

1.2.3.10

Automatic synchronization.

1.2.3.11

Run up: Set target, set loading rate, automatic turbine warming up.

1.2.3.12

Constant sliding - constant run up.

1.2.3.13

Load feedback control.

1.2.3.14

Primary frequency regulation.

1.2.3.15

CCS control.

1.2.3.16

High load limit.

1.2.3.17

Low load limit.

1.2.3.18

Valve position limit.

1.2.3.19

Main steam pressure control.

1.2.3.20

Main steam pressure limit.

1.2.3.21

Run back.

1.2.3.22

Switchover of single valve and sequence valve

1.2.3.23

Over speed protection control

1.2.3.24

Load rejection over speed limit

1.2.3.25

103% over speed control

1.2.3.26

Acceleration protection

1.2.3.27

Over speed protection

1.2.3.28

On-line test

1.2.3.29

Oil spray test

1.2.3.30

Over speed test: electrical over speed test, mechanical over speed test

1.2.3.31

Valve opening and closing tests

1.2.3.32

HP trip solenoid valve test

1.2.3.33

Valve leakage test

1.2.3.34

Control mode switchover

1.2.3.35

Turbine auto/manual mode

1.2.3.36

Shutdown

1.2.4

Basic Maintenance Items and Technical Requirements

1.2.4.1

Inspections before system shutdown

1.2.4.1.1

Observe each display menu and alarming of DEH.

1.2.4.1.2

Print the fault diagnosis records. Check the abnormal conditions in the printed
records.

1.2.4.1.3

Check the indicator of DEH cabinet, module, power, controller, operating station
and engineer station. Take notes.
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1.2.4.1.4

Back up the DEH configuration software. Record all of the set parameters.

1.2.4.2

Maintenance after system has been shut down

1.2.4.2.1

Visual inspections should meet the following requirements:

1)

The appearance should be complete and in good condition. The directions of

switches should be clearly marked. Name plate and signboard should be
complete and correct, and the figures are clear.

2)

The operation in the journey scope of control devices should be free, even and
no blockage.

3)

The position transmitter should be installed correctly and fixed firmly.

Fastenings should have no looseness. Movable parts should be free and
reliable.

4)

The wire connection should be correct, firm and no looseness. The connection
between plug and plug socket should be reliable.

1.2.4.2.2

The maintenance, tests and management for the hardware and software of DEH
control system should be carried out according to Chapter 4 and Chapter 5

1.2.4.2.3

Maintenance and calibration of measuring and process control instruments should

be carried out according to Chapter 5 and Chapter 5.

1.2.4.2.4

The maintenance and quality requirements of control circuit and measuring pipe
should be carried out according to Chapter 5

1.2.4.2.5

The performance inspections for power parts: step by step test the output voltage
after energized. Each testing data should meet the requirements of the
manufacturer manual. The power switches, indicators of all the modules should
work normally.

1.2.4.2.6

Inspection and tests for the interfaces of DEH system and outside system. The
communicating interfaces between DEH system and outside system should be
correct and valid. They can share the information. The real-time characteristic of
data transmission should meet the design requirements. Inspections and tests
include:
1)

Inspections of DEH system and bypass interface: step by step inspect the
locking logic deactivated and activated by the bypass. It should meet the
design requirements.

2)

Inspections of DEH system and coordination control system interface: by the

method of forced signal, check hard connection exchange signal and
communication exchange signal between DEH and coordination system
should be correct.

3)

Inspections of DEH system and MIS system interface: check to ensure that
the data transmitted from DEH to MIS should be correct. The real-time
characteristic should meet the requirements.

1.2.4.2.7

Inspections of DEH system monitoring, operation, alarming, print and emergency

SOE functions: check these functions to ensure they meet the requirements
according to Chapter 4.

1.2.4.3

Requirements for Outside Signal Connection

I/A Series system installation and outside signals connections should be treated
meticulously. They should be rationally designed and arranged. Requirements for
cable installation: if there is cable chute, cabling slot and pipes, when install and
Page 62 of 112

layout wires, the atmosphere conditions and electrical noise conditions should be
considered. There are specific requirements for cables when considering the
atmosphere conditions, such as temperature, moisture and corrosion during
installation.
1.2.4.3.1

Modulating Signal Cable

The cable should adopt double twisted wire screen cable. All of the screen layer
should electrically insulate with other screen layer. Make the screen layer
grounding in the cabinet. The public bus bar in the cabinet is suitable for the onsite
signal screen layer grounding after this connection.

1.2.4.3.2

Digital Signal Connection

Don not install the DC or AC onsite contact points in one cable. If the cable only
has DC signals, the cable can choose not only twist pair total shielded wire cable,
but also the cable only with total screen wire.

1.2.4.3.3

Input Signals of Thermocouple

The thermocouple input signal cable requires the special cable or the conducting
line metal in the extending cable should be the same or similar with the
thermocouple. This can reduce the potential difference produced during the
connection of different metals. During the thermocouple signal is being transmitted,
there can not be breakpoints, switches and connection points on the conducting
line. All of the thermocouple signals should be shielded. Screen layers should be
insulated.

1.2.4.3.4

Input Signals of Thermal resistance

The resistance of each conducting line connected with thermal resistance should
be the same. The cable resistance values from the site to the cabinet should meet
the limit of input template.

1.2.4.4

Inspection and commissioning

Before the device on-site activation, inspection on the following parts needs to be
conducted:

1.2.4.4.1

Inspection of wiring
The wiring of this device has four modes:

1.2.4.4.1.1

The wirings between cabinets or internal wirings of the cabinets should be checked
one by one according to manufacturer internal wiring diagram and tighten the
loose terminals.

1.2.4.4.1.2

Inspection of cables: all the cables should be complete without damage, the two
ends of signal wires inside the cable should be conducted, the insulations between
the wires and between the wire and the cable screen layer should be adequate. If
not, replace the cable. Check if all the empty residual cores and the screen layers
of all the cables are grounded in the control panel according to the requirements
and if the grounding is adequate. The empty residual core and the other end of the
screen layer should be insulated with the ground.

1.2.4.4.1.3

Check if the wiring of each cable is correct.

1.2.4.4.1.4

Check if the wirings of all the external signals are correct according to the cabinet
wiring terminal diagram.

1.2.4.4.1.5

Check if all the welding points of welded wiring inside the cabinet are reliable and
check if there is any loose welding.
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1.2.4.4.2

Inspection of the transmitter and the external signals

The control and monitoring parameters of the I/A Series control system are sent to
the device after being detected by the transmitter, and the operation of the
transmitter can directly influence the reliability of the system operation. Therefore,
it is required to inspect the calibrated transmitter strictly according to the
measurement range on the signal lists before activation.
All the external inspections described here mainly means the inspection if the
onsite binary signal state consistent with the actual phenomenon. Click the button
which represent the actual onsite condition and simulate certain state to verify the
I/O binary.

1.2.4.4.3

Inspection of power supply and grounding wire

Before energization of I/A Series device, thoroughly inspect the installation and
wiring of power supply and the grounding wire.
Following are the required equipment:
Multimeter: it is used to measuring the voltage and current;
Grounding resistance measurement tester: it is used to measuring the grounding
pole resistance to ground;
Connection tester: it is used to indicating is the connection is correct;
Power supply monitor: it is used to recording the AC/DC voltage, current,
temperature, humidity, radio wave frequency and the close/open state of the node.

1.2.4.4.3.1

Inspection of the grounding pole

The impedance of the grounding pole should be tested before the device has been
energized or once a year. There are lots of testing methods to test the impedance
of grounding pole. The grounding resistance tester is used to test the impedance,
and the impedance of the grounding resistance should be less than 5. If not,
check the grounding wiring and the connection between the grounding pole and
the power grid.

1.2.4.4.3.2

Measurement of electric grade

Power supply measurement includes: current, voltage and impedance testing;
Current test: use ammeter to measure and record the related current valid value;
Voltage test: use the multimeter to measure the AC magnitude of voltage from the
power input end LNLGNG part.
Impedance test: measure the input impedance of equipment connected with
grounding wire or the zero line, and the smaller the impedance, the safer would be
to the equipment and personnel.

1.2.4.4.3.3

Screen layer verification

The screen layer verification can be carried out in the cabinet. If the device is not
energized, disassemble the DC grounding lead to carry out the following three
tests:
Measure the resistance value between the cabinet and the insulation common
grounding connection and the value should be less than 1. If it is more than 1,
check the related connection and the system connection.
Measure the impedance between the cabinet support and the DC grounding
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busbar and the value should be more than 1 megaohm;

If the measurement of the second step is less than 1 megohm, disconnect the
common grounding wires of the other cabinets and the measuring cabinet. Then
measure it again until find out the errors.
The possible reasons for the above problems may due to the short-circuit
connection between the screen layer and the grounding, or the installation is
inadequate or the connection is damaged. It also may be due to the different
reference position of the input and output signals which are connected with the I/A
Series system.
It is better to carry out the screen layer verification before the device has been
energizated or during shutdown maintenance. During calibration, cut off the power
supply of the device and it is not allowed to carry out these inspections when the
devices controls the unit.
1.2.4.5

System function inspection

Before the activation of the I/A Series device, carry out the energization test via
DEH simulation program to check if the I/A Series device hardware and software
have any fault and if the system function can be normally operated, and this is one
of the most effective measures to ensure the normal activation of the device.
Servo plate and the corresponding valve LVDT should meet certain linear relation
so that the control system can normally control the CV and ICV valves. Calibrate
the valves under the following conditions:
Before unit startup;
After the replacement of servo plate and the LVDT;
After normal maintenance;
Valve LVDT has been disassembled.

1.2.5

DEH System Function Test

1.2.5.1

Valve test
DEH has two modes for testing: the valve test (full travel closing test) and the valve
looseness (movement) test. For the former one, close the full travel during the test
and for the latter close the valve for 10 -20 only on the current position. In
order to avoid the influence on the load, the fill travel test is required to be carried
out when unit load is 60 -80 of the rated load, and the power loop should be
put into service. The valve looseness test can be carried out under full load
condition.

1.2.5.1.1

Conditions for valve looseness test:

All the main stop valves are open;
Synchronization;
Load is within 50MW-310MW;
Test on the OTS display is in permission position.

1.2.5.1.2

Main stop valve movement test

Let OIS enter the VALVE TEST display and set the TEST ON/OFF to the TEST
position, and then press the TEST IN button of the valves which need to be carried
out with the movement test.
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Choose the corresponding HP and IP main stop valve test;

Close the chosen main stop valve and after it is in the correct position, reopen it
and then the test is finished.
1.2.5.1.3

Control valve movement test

Let OIS enter the VALVE TEST display and set the TEST ON/OFF to the TEST
position, and then press the TEST IN button of the valves which need to be carried
out with the movement test.
Choose the corresponding control valve test;
Close the chosen control valve and after it is in the correct position, reopen it and
the test is finished.
After the completion of the movement test, set the TEST ON/OFF button to
NORMAL position on the display.

1.2.5.2

Over speed protection test

During first installation or the overhaul of turbine, verify if the over-speed protection
works accurately. Carry out the test calibration to each over-speed protection.
During the over-speed test, set the DEH target rotating speed at 3360r/min, and
slowly increase the turbine rotating speed, and when the rotating speed reaches a
certain value at which a tested over-speed protection, this over-speed protection
would be put into operation and the turbine would trip. Therefore, the over-speed
test is called the rotating speed increase test. DEH can automatically record the
turbine trip rotating speed and the highest rotating speed.

1.2.5.2.1

DEH electrical over-speed test

Set the OVERSPEED TEST button to ELE OSP position on OIS display and set
the target rotating speed at 3360r/min and set the velocity at 180r/min/min, and
then carry out the test. Send out the GO command via OIS by clicking HOLD to
increase the speed temporarily; after the test is finished, set OSPTEST ON/OFF
button to NORMAL position.

1.2.5.2.2

Mechanical overspend test

Before the test, set the DEH electrical over-speed value a little higher. During the
mechanical over-speed test, the electrical over-speed trip value can be
automatically increased to 112 . Set the target rotating speed at 3360r/min, and
set the velocity at 180r/min/minand then increase the speed until the flying ring
is kicked out.
After the over-speed test is finished, the operators set the OSPTEST ON/OFF
button to NORMAL position on the OIS display.

1.2.5.3

Valve leak test

Verify the leakage of the main stop valves and the control valves through valve
leak test.
Permissible conditions for the valve leak test:
Turbine is latched;
Rotating speed is more than 2990r/min
Disconnect generator;
Test on the OTS display is in permission position.
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Enter the VALVE LEAK TESTS display on OIS and set the TEST ON/OFF to TEST
position and then carry out the corresponding tests.
1.2.5.3.1

Control valve leakage test

After the permissible requirements for the valve leakage test are met, operators
click the CV/ICV TEST button on the VALVE LEAK TESTS on the OIS, and then
the HP and IP control valves are closed. Operators should judge the valve leakage
by checking if the rotating speed reaches the acceptable rotating speed.

1.2.5.3.2

Main stop valve leakage test

After the requirements are met, operators click MSV/RSV display on the VALVE
LEAK TESTS on the OIS and then the HP and IP main stop valves are closed.
Operators should judge the main stop valve leakage by checking if the rotating
speed reaches the acceptable rotating speed. After the test, the HP and IP main
stop valves are closed and then the operators should push the emergency button.
The operators re-latch and increase the speed to restore the rotating speed to
around 3000r/min.

1.2.5.3.3

After the test is finished, set the TEST ON/OFF button to the NORMAL position on
the display.

1.2.5.3.4

After the completion of the valve leakage test, operator should manually latch off to
cut off the test.

1.2.5.4

Oil spray test

To ensure the emergency governor flying ring can fly out quickly to trip steam
turbine when the unit is over-speed, the movement test of the flying ring should be
regularly conducted. During this movement test, inject the oil to the flying ring to
increase the centrifugal force to make the flying ring fly out. However, the latch off
should not occur even if the flying ring fly out due to the oil spray test, add the
testing isolation valve to increase the reliability.
Conditions for oil spray test permission:
Oil spray test permission button should be at the permission position;
Rotating speed should be within 2985r/min-3015r/min;
HP differential expansion should be less than 3mm.
During the test, 4YV is energized, and after detecting the isolation solenoid valve is
after the isolation position, the 2YV would be energized and then oil is injected into
the emergency governor, so the flying ring is kicked out. At this time, ZS2 would
send out signal and then the 2YV is deenergized. After a period of time, 1YV
latches automatically and after latching the isolation solenoid valve would be
deenergized and the emergency governor would restore to NORMAL position, and
this means the test is successful.
After the completion of the oil spray test, operators should turn OIL SPRAY TEST
PERMISSION button to the NORMAL position.
Enter the SPRAY OIL TEST display on the OIS, set the TEST ON/OFF to TEST
position, and then click the SPRAY OIL TEST button to enter the oil spray test and
the display of the state would be IN.
After the completion of the test, PASS or FAILED would be displayed on this
display to represent pass or failure.
After the completion of the test, screw the TEST ON/OFF button to NORMAL
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position.
1.2.5.5

AST Solenoid Valve Test

For increasing the reliability, the HP trip solenoid valve use double redundant
structure which is two in parallel and two in serial. It ensures that the on-line test
can be carried out for the HP trip solenoid valve. The operator can do the HP trip
solenoid valve test on the display of OSI station, after switch the test key-switch to
the permitted position. During the test, the operator only can select one solenoid
valve to do the test each time.
Under the normal condition, if the electromagnets of the 6YV, 7YV, 8YV and 9YV
HP trip solenoid valve carry the power, the 4PS and 5PS of pressure switch
doesnt work. During the normal test, the electromagnet of 7YV or 9YV loss the
power and operate, the pressure switch 5PS operate. If the power lose time of
electromagnet is more than 15 seconds, and the signal of 5PS pressure switch
doesnt correct, the test can be considered in fault. After the test for electromagnet
of 7YV and 9YV is finished, make the 7YV and 9YV carry the power again. And
then, the test for 6YV and 8YV can be performed, the electromagnet of 6YV or
8YV lose the power and operate, the pressure 4PS operate. If the power lose time
of electromagnet is more than 15 seconds, and the signal of 4PS doesnt correct,
the test can be considered in fault. After the test for 6YV and 8YV is finished, make
the 6YV and 8YV carry the power again.
After the test for HP trip solenoid valve is finished, the operator should switch the
test key-switch to the Normal position on the OIS display.

1.2.5.6

Set Static Relation of Servo System

Before start up the unit, the static relation setting of servo valve, LVDT and servo
plate should be finished to ensure each of servo-motor from full closing to opening
and meet the requirement of valve position command from 0%-100% and the
linearity. The CV and ICV can be simultaneously or separately calibrated. The
process can be carried out in the OIS station.

1.2.5.6.1

Before start up the unit, the static relation setting for servo system should meet the
following conditions:
The steam turbine has been latched on.
All valves have been closed.
Precautions: confirm there is no steam in front of the main steam valve to avoid the
steam turbine is out of control during the setting. During the setting, when the
rotating speed of unit is more than 100r/min, the DEH will be automatically latched
off. Therefore, the rotating speed of steam turbine should be less than 100r/min.

1.2.5.6.2

Installation of linear variable differential transducer (LVDT)

Before calibrate the valve, the LVDT should be correctly installed to make the
LVDT in its linearity area during the valve from full closing to opening.

1.2.5.6.3

Calibration Procedures
1). Select CALIBRATION PERMIT
2). When the light of CALIBRATION PERMIT is on, select the valve need to be
calibrated, and the corresponding button can be lighted.
3). After selecting the calibrated valve, the corresponding servo plate will carry
out the calibration. The CHK indicator on the servo plate will blink (the blinking
frequency of lower line is slow, and the blinking frequency of the upper line is
Page 68 of 112

quick), the VALVE CALIBRATION on the display will blink too (the blinking
frequency is as same as the CHK).
4). When the indicator of CHK and VALVE CALIBRATION is constant lighting, the
calibration is finished.
5). Push the CALIBRATION PERMIT button again, and exit the calibration mode.
At that time the CHK indicator is off, and the indicator of VALVE
CALIBRATION turns to grey.
6). The calibration is finished.
1.2.5.7

Other Tests

1.2.5.7.1

EH Oil Pump Interlock Test

When the EH oil pump is controlled by DEH, there are startup, shutdown, interlock
and test button on the CRT of DEH. When the interlock does not be carried out,
the A and B oil pump of EH can be started up independently. When put the
interlock of A and B pump into operation, and if any pump operates, push the Oil
Pump Interlock Test button to test the operation of solenoid valve. When the DEH
receives the low pressure signal of EH main pipe, another pump will be
automatically interlock started up. It shows that the interlock loop is normal.

1.2.5.7.2

EH Heater Test
When the EH heater is controlled by DEH, there are startup, shutdown and
interlock button on the CRT of DEH. When the interlock does not be carried out,
the heater can be started up or shut down independently. When the interlock of
heater is put into operation, the DEH can automatically start up or shut down the
heater according to the temperature of EH oil tank. When the temperature of EH oil
tank is more than 35, shut down the heater, when it is less than 20, start up
the heater.

1.2.6

Fault Diagnoses and Common Trouble Shooting

During the operation of DEH, the system will carry out the on-line self-diagnoses,
display alarming and print fault content for the faulty part. It is used for guiding I&C
operator to carry out the on-line or off-line maintenance to recover the DEH
system.

1.2.6.1

On-line Self-Diagnosis
During the DEH operation, its important hardware equipment, important input or
output signals will perform the self-inspection and self-diagnosis. The system will
display alarming and print reports once finding out the problem. The I/A Series
system will carry out the self-diagnosis via layer by layer in order to ensure the
reliability of steam turbine controlling process. Withdraw the faulty system parts
from the concurrent control, which ensure the system controls the process in a
good condition.

1.2.6.1.1

Rotary Speed Channel Diagnosis and Trouble Shooting

If any one of three rotary speed channels loses rotary speed signal or the rotary
speed setting point is more than 200r/min, the rotary speed signal change quickly.
It shows that this rotary speed channel is faulty.
When the rotary speed setting point is more than 200rpm, and if the difference
between any one in three rotary speed channels and middle value is more than
10r/min, this rotary speed channel is faulty.
If any one of three FBM 206 modules microprocessor fails, this rotary speed panel
Page 69 of 112

is faulty.
When above faults occur in the signal channel, it only displays the fault channel
signal.
When two channels are faulty or the difference between rotary speed setting value
and rotary speed is more than 500r/min, the system fault signal will appear. This
signal will cut off the over-speed protection and send out the steam turbine trip
signal.
1.2.6.1.2

FCP270 Self-diagnosis
The FCP270 will perform the self-diagnosis when energized the power. It will carry
out the operation inspection and clock monitoring during the working period. In the
redundant control processor, if detecting a fault, both two control processors will
perform the inner self-diagnosis in order to define which processor is faulty. This
method ensures the I/A Series system in normal operation.

1.2.6.2

Fault Diagnosis & Maintenance

When the DEH device is controlling the system, the system inner will begin the online diagnosis. The system alarms, indicates and prints the faulty unit. Perform the
relevant on-line or off-line maintenance to recover DEH as soon as possible based
on the alarm description in WP70 station and the alarm on the panel before the
module.
Listed below are some faulty causes and corrective actions for local signals:
1)

Rotary speed channel fault: short-term faults in single channel would not affect
normal operation of the system. Whereas for the long-term or rotary speed
system faults, inform I&C maintenance personnel to solve. Firstly check if the
rotary speed of faulty channel is normal or not via oscillograph. If not, check
whether the wiring of speed measuring transmitter port correct and the
installation meets the requirements. If the speed signal is normal but the fault
is in the speed channel, speed measuring board FBM206 possibly is faulty.

2)

If the parameters such as power and main steam pressure are different from
the real value, check the following:

Check the corresponding transmitter signal is normal, and the output signal
scope accords with the designed value. Recalibrate the transmitter if possible.

Check the transmitter wiring is correct and reliable.

Check the input processing board.

3)

The servo board is the interface between the controller and the actuator with
complicated signal. Therefore, its reliability depends on its accuracy. When
servo output alarm appears on the VALVE TEST display, check the cable
connecting to servo board if the current signal on servo board is correct. If the
cable is normal, replace the servo valve.

4)

If DEH fails to latch on, check the following:

(1) Check the EH oil pump and the HP startup oil pump are started up; check the
oil pressure is normal.
(2) Check the DC power is normal.
(3) Check ETS is reset; check whether any of ATR tripping conditions is satisfied
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and ATR activates.

(4) Check no latch-on signal but latch-on actually.
(5) Check no oil pressure signal on emergency slide valve.
(6) Check no HP&LP emergency oil pressure signal.
(7) If above conditions meet the requirements, check whether the latch-on electric
circuit and the latch-on solenoid valve are normal

Page 71 of 112

1.3

TSI System Maintenance

1.3.1

TSI system Overview

Along with the continuous increasing of turbine generator unit capacity, more and
more items needed to be monitored. As the modernized huge type turbines usually
work under conditions which approach extreme limit, if there is thermal stress
which is close extreme limit generated during operation, it can easily damage the
turbine. At the same time, in order to improve economic operation, large power
units have smaller clearance between grades and gland seals. Under abnormal
workings conditions, it is easy to cause friction between motive and static
components, which causes serious accident such as shaft bending. For this
reason, in order to keep large power turbine safe, it is needed to monitor and
protect the operating conditions and operating parameters of turbine generator.
The application of TSI system could make effective and accurate monitoring to
operate turbine generator unit. Once the tested parameters exceed limit, the
protective device can activate accurately and reliably.
TSI are composed of rotary speed phase monitor, eccentricity monitor, axial
displacement monitor, expansion difference monitor, axial vibration monitor, casing
vibration monitor, thermal expansion monitor and over speed monitor. Except for
expansion monitor, the rest of components use MMS6000 monitoring system.
Therein, transient rotary speed meter uses DF9011. MMS6000 system is
composed of plug-in type modules which suit for standard 19 inch frame. It takes
matured vibration sensory technique, easy to install and could operate without
maintenance. Each card is equipped with micro processor, which not only provides
the standard solutions but also can solve special problems for client. MMS6000
system is suitable for monitoring different kinds of standard turbo machine.
Environment requirement:
Reference temperature

25

Main technical data:

Relative humidity

5%-95% without condensate

Normal working temperature range

0-65

Cards comply with standard DIN 41494(100160mm)

Front plate size 30mm (6TE) X 128.4 (3HE)
Net weight: 320g
One 19 inch frame, contain 14 modules/28 channels
Make serial port, read data and configuration by RS232,
Communicate through RS 485
1.3.2

TSI System Functions and Components

The external power supply is input via two circuits, one main and one assistant.
One circuit operates while the other one is standby. When any one or both circuits
have fault, alarm signals will be sent out. After being processed, the external power
supply will enter into two 24VDC QUINT power supply modules. When any power
supply module fails, there is alarm signal.
The power supply PS1 and PS2 receive external power supply and begin working
via terminal L1, L3 and PE. The 24VDC output by PS1 is connected to the two
power supply bus bars24VDC (1), as the first circuit of system; the 24VDC output
Page 72 of 112

by PS2 is separately connected to the two power supply bus bars24VDC (2), as
the second circuit of system. The 24VDC output from PS1 and PS2 are combined
into one via a diode and then lead to power terminals for system relays. All PS
plates have power supply fault output, and the contact is closed in normal
condition. The following diagram shows the connection of power supply modules.

Alarm connection point output

1.3.2.1

Electric Eddy Sensor

It is by using the gap changes between the coils at the bottom and the conductor
to measured that an eddy current sensor measures vibration and static
displacement. The coil at the bottom is applied an AC voltage of high frequency
(normally 1MHZ-2MHZ), as shown in Figure 1. When coil closes to the side of a
conductor, an eddy current ie will be induced as the magnetic flux link from the coil
passes through the conductor. On the other hand, the magnetic flux induced by ie
goes through the coil, thus a certain extent of coupling mutual induction between
the coil and the eddy current is produced. The coupling coefficient depends on the
distance between them and the material of the conductor. For a given material of
conductor, the coupling coefficient K depends on distance d, e.g., K=K (d). When
d increases, the coupling decrease and the value of k falls, which increase the
equivalent inductance. Therefore, measuring the corresponding equivalent
inductance changes means measuring variety of d.
As the output voltage from the probe is an AM (amplitude modification) signal, it is
need a wave pickup link to get the needed voltage wave, which represents the gap
changes with time. What is more, a high frequency oscillation source is needed.
Thus, a measuring circuit (pre- stage) is also be provided for an eddy current
sensor, shown in Figure 2. We can see that the output voltage V d from pre-stag
has the positive proportion to distance d, which could be divided into two parts:
e.g. DC voltage V de, corresponding to average distance (or initial distance) and
the AC voltage V ac, corresponding to vibration gap.

Page 73 of 112

Brief principle diagram of eddy sensor

Object measured

Clearance

Probe

Oscillator

Wave detector

Brief principle diagram of pre-stage device

1.3.2.2

Bearing Casing Vibration

There are six casing monitoring points for the whole turbine generator unit, and
two test points for each module. The device needs three MMS6120 monitors, and
when the casing vibration exceeds dangerous value, it sends the value to DCS in
order to alarm.

Board

Bearing
box

Upper bearing seat (#1~#4)

Shaft
Casing vibration measurement schematic diagram
Page 74 of 112

1.3.2.3

Rotary Speed
It is used to measure the rotary speed among turbine generator unit shafts. In
which, rotary speed and OS1 is arranged in one module, phase identification and
OS2 in another module and OS3 in the third module. In this device, 3 - MMS6312
modules are used to realize rotary speed monitoring and over speed control. All
the sensors are of PR9376 type.
Coil

Brief diagram of speed sensor

Speed measuring support
Rotary speed meter 1, 2 and 3

Pre-stage device
Sensor
Schematic Diagram for Measuring Over Speed
1.3.2.4

Differential Expansion
Since the expansion variation of turbine rotator and cylinder is different, it is
necessary to measure expansions between the turbine rotator in respect to turbine
casing. Measuring point selection should comply with the requirements provided
by the turbine manufacturer. For this generator unit, the monitoring of the
expansion difference include high voltage cylinder expansion difference and low
voltage cylinder expansion difference. The high and low pressure cylinder
expansion difference use one MMS6210, and the other sensors use PR6426.
Flange measured
Pre-stage device
Sensor

Shaft

Page 75 of 112

Board

Schematic Diagram for Expansion Difference Measuring

1.3.2.5

Axial Displacement
Measuring the axial displacement of turbine rotator in respect to casing. In order to
measure the displacement of this unit, one piece of MMS6210 module and the
sensor PR6426 together with pre-stage device CON02 are is used. There are 2
measuring points for single unit. The over-limit signals will be sent to ETS and
output to large axial displacement trip signal after Boolean calculation.
Flange measured

Pre-stage device

Board
Pre-stage device

Axial displacement support

Sensor
Schematic Diagram for Measuring Axial Displacement
1.3.2.6

Shaft Vibration
Measuring the vibration of main turbine axial with respect to bearing supporters
(relative vibration). For this purpose, MMS6110 modules are used, each module for
one measuring point, totally 6 measuring point for a whole steam-generator unit.
Each module provides 2 channels, which are responsible for the vibration on X and
Y direction for one point. PR6423/010 type sensor is used. When vibration value
exceeds allowable range, the output alarm signal will appear on the CRT in
operator station and cause I $ C signal blinking board alarm. The analogs output to
DEH, for it to display and when displacement value exceeds allowable range,
alarm and trip signal will be output.

Pre-stage device

Board
Pre-stage device

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Sensor

Bearing support

Upper bearing seat (#1-#4)

Shaft

Eccentricity
Measuring the instantaneous value and peak value of main shaft bend under low
speed condition (<120Rpm/min). For Eccentricity detecting, module MMS6220 and
PR6423/010 type eddy current sensor are used. This measuring module receives
two signals, one is for eccentricity measurement and the other is for phase
identification and connecting from peak-peak signal adjusting resistor. The phase
identification probe observes a key slot on the shaft, when the rotator rotates once,
there is an impulsive current which can be uses to calculate peak-peak value.
Certainly, phase demodulation signals can also be used to indicate the vibration
phase. Knowing the angle between vibration probe and phase demodulation
probe, we can determine the unbalanced location.
Vibration signal
Vibration detecting probe

Phase identification signal

Positive peak value

Phase identification probe

Schematic Diagram for Vibration Phase Detecting

Page 77 of 112

Pre-stage device
Phase identification probe
Board
Pre-stage device
Eccentricity probe

Eccentricity peak --peak value

Phase identification signal

Eccentricity Measuring Diagram

1.3.2.7

Thermal Expansion
Test the absolute expansion of turbine cylinder. On the two sides of the turbine
head, there are two test points. It takes DF9032 dual-channel thermal expansion
monitoring instrument.

LVDT (left)

Casing

Board

LVDT (right)
Thermal expansion test schematic diagram

1.3.2.8

Feedwater Pump Turbine TSI

The feedwater pump turbine needs to monitor the following parameters
continuously: rotary speed, axial displacement, eccentricity and shaft vibration. All
parameters mentioned are monitored via the instruments from EPRO Company.
Each auxiliary turbine needs to monitor the following items.

1.3.2.8.1

Rotary Speed Monitoring

1.3.2.8.1.1

A sensor is used to monitor the rotary speed. Corresponding to 0-10000r/min

rotary speed measurement range, it monitors the module to output 4-20mA DC
signal. During configuration, set a relay channel as the rotary speed alarm relay
channel.
Page 78 of 112

1.3.2.8.1.2

Electric Over-speed Protection of Taking Two out of Three

Three sensors are used for the electric over-speed protection, which correspond to
three over-speed protection monitors. When the unit rotary speed monitored by
any of the channels is 6327r/min, the over-speed protection relay channel
corresponding to this channel will outputs emergency alarm signal to ETS. After
ETS taking two out of three, the turbine will trip.

1.3.2.8.2

Axial Displacement
The axial displacement uses double-channel monitoring mode and uses two
sensors to output two ways of 4-20mA current signals. When #1 and #2 axial
displacements are 0.3mm or -0.55mm (the axial displacement is too big), they
will be respectively output signal to ETS via the too big axial displacement
emergency reply, taken as the electric shutdown signal.

1.3.2.8.3

Vibration
In order to monitor the radial vibration of the rotor corresponding to the bearing,
#1-#4 supporting bearings of the unit are equipped with horizontal (X direction) and
vertical (Y direction) two shaft vibration monitoring channels, totally 8. Four
monitoring modules are used.
Set the 8 signals as X direction and Y direction shaft vibration monitoring channels
of #1-#4 bearings in order. In any of the directions of any of #1-#4 bearings, if the
shaft vibration is 80m (the shaft vibration is big) or 125m (the shaft vibration is
too big), #1-#4 alarm relay channels in the monitoring module will output alarm
signal or #1-#4 shutdown relay channels will output emergency signal.
Corresponding to 0-300m shaft vibration measurement range, 4-20mA DC signal
is output from the corresponding monitoring channel.

1.3.2.8.4

Phase Identification
A special measurement module is used for phase identification. A sensor is used to
directly output a line of phase identification signal.

1.3.2.8.5

Eccentricity
A sensor is used to output a channel of 4-20mA current signal for eccentricity
monitoring. When the eccentricity is 0.08mm, a line of alarm signal will be output
via the alarm relay.

1.3.3

TSI System Operation Monitoring

1.3.3.1

The state of the TSI system, the sensor of the peripheral equipment and the prestage device accords with the unit operation condition.

1.3.3.2

The I&C personnel should not touch, adjust and modify the TSI system set at
random.

1.3.3.3

When the TSI has an abnormity during operation, the operator should inform the
I&C personnel to solve it and make a detailed record.

1.3.3.4

When working near the TSI device, supervise the workers to take good safety
prevention measures.

1.3.4

TSI System Startup

1.3.4.1

The TSI device only can be put into operation when it meets the following
conditions.

1.3.4.1.1

The TSI device and its peripheral equipment are all in a good condition.
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1.3.4.1.2

All sensors should be clean and tightly fixed; the thread has no damage; the
rotation of adjusting screw can make the sensor evenly move in a balanced way.
The installation clearance of the measured object should be set based on the
output characteristics and the installation requirements of the sensor.

1.3.4.1.3

The surface of the shaft corresponding to all sensors of TSI device should be
smooth, without hole, dent and scratch, etc.

1.3.4.1.4

The support installed for the sensor should be rigid enough; the self-vibration
frequency of the bracket should be 10 times more than that of the unit.

1.3.4.1.5

The detecting surface corresponding to the sensor should be two times more than
the sensor diameter and there should be no other metal material in this space. The
measured surface should not be magnetic.

1.3.4.1.6

Do not kink the special cable of the sensor excessively; do not assemble and
disassemble the cable contactor at random. After installing the special cable, its
position should be fixed to prevent leading line is broken because of displacement.
Its better to use metal hose to protect the cable.

1.3.4.1.7

Install the pre-stage device in a place with good ventilation and weak vibration.
Besides, install it in the floating mode. The environment temperature should meet
the specified requirements as follows: the rated working temperature: -55-70; the
limit temperature: -40-85.

1.3.4.1.8

Confirm the material of the measured surface accords with the material used for
the sensor demarcated by the manufacturer; otherwise, re-demarcate the sensor.

1.3.4.1.9

Keep all protection panels, protection cabinets and local junction boxes are tidy
and clean, and the signs are clear. Attach the correct and brief wiring diagrams of
the system to the internal side of the cabinet door, and the writing should be clear.
The protection earthing, power supply earthing, signal shielding earthing in the
equipment cabinet should accord with the relevant regulations or the
manufacturers requirements. Tightly seal the hole of the cables and the wallthrough pipe in the equipment cabinet and arrange the incoming and outgoing
lines tidy. The wiring should be firm and correct. The sign should be clear.

1.3.4.1.10

The power supply system is normal and meets the requirement of 220V22. The
specification of power supply automatic CB and the fuse capacity meet the design
requirements. The line and terminal should be complete and without damage. The
conducting wire and cable surface should be good and intact. Check and make
sure the insulation resistance to the earth of the power system is 20M (500V
megger). Various signs such as circuit breaker, terminal, fuse and cable of the
power system should be correct and clear.

1.3.4.1.11

The limit alarm and protection set value of all monitoring channels are correct.

1.3.4.1.12

The logic condition of TSI system, the limit alarm and protection set value are
correct. The system test meets the requirements.

1.3.4.2

System startup

1.3.4.2.1

Close the main and auxiliary power supply circuit breakers of the device, and the
power supply indicator on the cabinet door is normal. The TSI POWER SUPPLY
LOSS ALARM signal in I&C signals disappears. The LED indication on the power
supply board of the cabinet is normal. The voltage of the power supply busbar is
normal and meets the requirements.

1.3.4.2.2

Check whether all monitoring channels are put into service normally, check
whether the installation clearance between the sensors is normal. Check the
connection between the pre-stage device and the sensors, sensors and extending
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cables. Check the wiring of the signal loops.

1.3.4.2.3

In the whole process of the system is put into operation, the unit condition is not
influenced.

1.3.5

TSI Test
Before the test, I&C personnel must receive the permission from the operator. The
I&C personnel should know the test procedures and safety measures clearly and
work seriously. The operators should coordinate with the I&C personnel and take
the detailed record. Take the test until it meets the requirement.

1.3.5.1

Energizing Test

1.3.5.1.1

Close the main and auxiliary power supply circuit breakers of the device, and the
power supply indicator on the cabinet door is normal. The TSI POWER SUPPLY
LOSS ALARM signal in I&C signals disappears. At this time, TSI system enters
normal working status.

1.3.5.1.2

When respectively disconnecting the main or auxiliary power supply circuit breaker
of TSI system, the main or auxiliary power supply indicator will be off, and the main
or auxiliary power supply switching is normal. the TSI POWER SUPPLY LOSS
alarm signal in the I&C signals is not sent out. TSI system should be in normal
working status without influenced by the power supply switching.

1.3.5.1.3

After TSI system is energized, do not send wrong alarm and output activation
signal.

1.3.5.2

Local test after Maintenance

1.3.5.2.1

After the TSI and protection devices are reassembled, the acceptance should
strictly follow THREE-LEVEL ACCEPTANCE system. The TSI and protection
devices after maintenance should use cold-state acceptance. For the shutdown
protection, the plant production and planning department should organize the
maintenance personnel and operators to take part in the acceptance. If the
acceptance meets the requirements, the participants should sign their names on
the acceptance report.

1.3.5.2.2

Perform interlock test based on the protection items required by the turbine
maintenance and operation regulations. Confirm the protective set value is correct,
the logic is correct and the acousto-optic alarm is normal.

1.3.5.2.3

For the axial displacement protection, use the method of moving tow target to test
whether the monitoring and protection function are normal. For over-speed
protection, test it in the combining mode of the short-circuited connection point and
set value adjustment .

1.3.6

Local Maintenance and Technical Requirements

1.3.6.1

The I&C personnel must perform patrol inspection every day. Check the panel LED
indicator state of all detecting boards. Check the set value and the indication value
accord with the actual values. Check the CRT display value of DEH.

1.3.6.2

Check the system power supply is put into operation correctly, the power supply
system is normal and the voltage meets the normal operation requirements of the
boards.

1.3.6.3

Check the special cable is fixed& firm and without damaged. Check the cable
contactor and the pre-stage device are put in floating mode. Check the special
cable is sealed well without oil leakage when it goes out of the casing. Clean all
the devices and keep them clean and intact. Check the signs are complete and
correct.
Page 81 of 112

1.3.6.4

When the I&C personnel finds fault in TSI and protection device, inform the
operator in time and report it to the engineers of the production and planning
department. Record the fault on EQUIPMENT FAULT notebook in time.

1.3.6.5

When the device needs to be adjusted, professional personnel adjust it based on

the test data during installation. Others can not adjust it without permission. Before
adjustment, apply to withdraw the relevant protection.

1.3.6.6

The trouble shooting of the device should based on relevant systems. Take safety
measures during trouble shooting.

1.3.6.7

Measure the protection loop and cable insulation resistances periodically.

1.3.6.8

Regularly check the external wiring (before unit startup or during a repair period).
Clean the wiring terminal nameplate. Check and tighten screws.

1.3.6.9

Check and calibrate the alarms, protective set value and the logic relation of the
device boards every half a year. Check and calibrate the monitoring boards in all
channels every half a year. Fill the calibration record. Strictly follow the three-level
acceptance system.

1.3.6.10

Fill the technical logbook for periodic maintenance.

1.3.7

Typical Fault Analysis & Trouble-Shooting of TSI System

1.3.7.1

Installation fault of axial displacement & expansion difference sensors:

The axial displacement measurement system has protection and the requirement
for measurement system is high. The installation of axial displacement sensor may
directly influence the accuracy of system measurement. Therefore, a good point to
measure should be chosen and the mechanical zero point should be set accurately
for an accurate measurement.
The location selection principle for sensor is that it should be possibly near the
thrust bearing. The larger the distance between thrust disc and axial displacement
sensor, the more the possibility of distortion exists. Because, the distortion,
between thrust disc and measuring point, is influenced by factors such as thermal
expansion of shaft & casing and stress deformation, etc. The permissive moving
range of thrust disc is small, and the zero point is difficult to be accurately set.
The main reasons are: 1) it is difficult to make sure whether the thrust disc is lying
on the working surface of the bearing or not; 2) it is difficult to make sure how
much change that the clearance value caused by the thermal expansion & stress
deformation in cold calibration; 3) there is some elastic displacement on both sides
of the bearing. In determining the zero point, we should know the shaft & casing
temperature, the ambient temperature, the clearance between the thrust discs, and
the condition of the pad. And we have to push the shaft patiently to find the
reasonable zero point. Therefore, whether the axial displacement protection is
accurate or reliable is the key point to set the zero point accurately.

1.3.7.2

The installation and adjustment of the expansion difference sensor should be

carried on in cold state, and it is better to install with axial displacement transmitter
together. If unit has to be disassembled during maintenance, record the clearance
value before disassembly and then install the micrometer gauge. The reassembly
should be done based on the change of micrometer gauge, record before the
disassembly, as well as change of the axial displacement.
For the HP & IP casing expansion difference sensors which can not be installed
because originally designed installation position is changed due to actual
condition, they should be installed at the other side of measuring disc, which
makes clearance change between the sensor and measuring disc is totally
Page 82 of 112

opposite against the original one. Therefore, the installation clearance value is
changed. The connection inside the monitoring panel can be tripped to change the
output (original: 0 10VDCnow: 10 0VDC) in order to make the indication of
CRT is corresponding to the actual value.
1.3.7.3

Rotation speed sensor faults during Installation and operation

During installation, the round mark should be put in the section which is vertical to
the axis for getting pulse signal. The small turbine B of 2 turbine unit has
suffered such a problem. Its speed reaches about 1500r/min; however, there is no
signal output because the round mark has not been put in the section which is
vertical to the axis. (Refer to figure 3)

1.5mm

Round mark
position

Module number 1
Figure 3 Sensor Installation Positions
Figure 3

During installation, factors such as the influence caused by thermal expansion to

the measurement should be taken into consideration. The sensor is installed on
the support of cabinet while the measuring disc is connected with the shaft. The
expanding capacities of these two devices are different in the hot state. If the width
of measuring disc is too small, sensor could not detect any signal due to the
influence of axial displacement. Therefore, the installation clearance is very
significant to the signal picking. If clearance is too great, trigger pulse signal level
will become too small; therefore, the measuring value can not be accurately
shown. If the width of measuring disc tooth space is not suitable, the sensor could
not induct the normal pulse signal.
1.3.8

Causes of Axial Displacement and Protective Methods

1.3.8.1

Causes of axial displacement

1.3.8.1.1

Causes of reverse axial displacement

1.3.8.1.1.1

When the unit rejects load suddenly, the reverse axial thrust occurs.

1.3.8.1.1.2

When HP gland seal is seriously damaged, and the pressure of front part of
governing stage impeller decreases due to the extraction effect, the reverse thrust
occurs.
Page 83 of 112

1.3.8.1.2

Cause of axial displacement

1.3.8.1.2.1

The rotor axial thrust increases and makes oil film between the thrust disc and
thrust bearing broken.

1.3.8.1.2.2

Defects such as oil pressure of lubricating oil system are too low or oil temperature
is too high makes oil film broken.

1.3.8.2

Excessive turbine axial displacement hazard and protective measures

1.3.8.2.1

Great turbine axial displacement hazard

If turbine axial displacement increases, load for thrust bearing may beyond
limitation. Therefore, the oil film is broken, which makes black bronze of the thrust
pad melted, friction between moving part and static part of the turbine occurring
and causes damage to equipment.

1.3.8.2.2

Protective measures
Turbine axial displacement monitoring and protective devices should be installed.
During the operation, once the axial displacement increases, the monitoring
system may give out aural and visual alarms. If the displacement increases
continuously and exceeds limited value, the protection acts. At this time, the main
steam stop valve will be closed to ensure the safety of unit.

1.3.9

Causes of Excessive Expansion Difference and Monitoring Measures

1.3.9.1

Causes of excessive expansion difference

The relative expansion difference between rotor and casing is simply called
expansion difference. When the rotor expansion is larger than casing expansion,
the value is positive. When the rotor shrinkage is smaller than the casing
shrinkage, the value is negative.
The cause of excessive positive value of expansion difference: the time for
warming unit is not enough and the temperature rising speed is too quick or the
load increasing speed is too quick.
The cause of excessive negative value of the expansion difference becomes large:

1.3.9.2

1)

Load decreasing speed is too quick, or the unit dumps load from full-load to
no-load;

2)

Unit operates without load or with low-load for long period of time

3)

The water impacting;

4)

The speed of turbine cooling down (by gland seal steam) is too quick during
unit shutdown;

5)

Vacuum suddenly drops, therefore when the exhaust temperature increases

quickly, the negative expansion difference of the LP casing increases.

Hazards and preventive measures

The clearance between turbine gland seal and moving blade & static blade is very
small, if the change of expansion difference exceeds the normal axial clearance
between gland seal and static blade, the moving & static components would have
some friction, therefore, the violent vibration may occur and the equipment is
damaged.
Therefore, in command to ensure the safety of the unit during turbine startup,
warm, speed rising or shutdown, the turbine expansion difference monitoring
Page 84 of 112

device should be set, which can be used to alarm or shut down the unit.
1.3.10

Causes of Turbine Over-speed and Protective Measures

1.3.10.1

Causes of turbine over-speed

During turbine operation, the speed is automatically controlled and maintained to
be constant by speed governing device. When the load of turbine generator
changes, turbine speed may change, the speed governing device acts, the speed
governing steam valve may slightly close or open to change the admitted air
volume in command to maintain the constant speed. When following cases
happen, turbine speed may increases rapidly. If the speed governing system can
not normally work, the speed may lose control, therefore over-speed may occur.

1.3.10.2

1)

When generator disconnecting with grid due to generator fault or power

system fault, turbine rejects load to 0 suddenly

2)

The single unit operates with load, and the load decreases suddenly.

3)

During normal
disconnection).

4)

Turbine overspeed test.

5)

The speed governing system works abnormally.

shutdown,

the

generator

load

drops

to

0(generator

Hazards and preventive measures

When designing unit, the strength margin of the rotating component is limited. As
for the rotating component that is tightly fitted with the impeller, the loosen speed is
about 20% of the rated speed. Therefore, if turbine is over speed during operation,
the centrifugal force generated during the rotation of each component may cause
serious damage to equipment. Usually, manufacture regulates that speed of
turbine should not be exceed 110%-120% of rated speed.
Protective measures
In order to ensure unit safety, speed of turbine should be strictly monitored and
over-speed protection device should be installed. For the big unit, there should be
3 sets of protection devices. They are: emergency protector over-speed protecting
device, additional over-speed protecting device and electric over-speed protecting
device.

1.4

ETS System Maintenance

1.4.1

System Description
ETS (Emergency Trip System) which receives alarm signal or shut down signal
from TSI system or other systems in turbo-generator set, does logic process, and
outputs indicating lamp alarm signal or ETS signal. Redundant PLC are adopted to
do logic processing for convenience and reliable operation. Two PLCs work
Page 85 of 112

together. Any one of them can operate and output alarm signal. When one of the
PLC is in trouble, it will send out fault alarm signal, and cut off shutdown logic
output automatically. Another PLC works normally. The PLC can communicate with
other systems to satisfy automation requirements of power plant.
The system includes a control cabinet; its internal logic is realized by ROCKWELL
PLC (Dual PLC), which replaces the traditional relay, the logic hardware
configuration:
PLC processor
Input module

1747-L542
1746-IB32

Output module
PLC power supply

1746-OB32
1746-P2

1.4.2

Working Principle

1.4.2.1

Two ETS PLCs work at the same time. Signal from site is sent to ETS device, and
then delivered to PLC A and B at the same time. After automatic processing by
internal logic, it sends out corresponding signal. Take overspeed of turbine as an
example, when electric overspeed shutdown signal is sent to ETS, PLC A and B
process and send out shutdown signal at the same time.

1.4.2.2

Any one of PLC A (B) is in trouble, it will send out alarm and disconnect shutdown
output contacts automatically. Another PLC works normally. The work logic is
shown in the following parts.

1.4.2.3

The ETS device is equipped with dual power sources switching loop. When one of
the loops is in trouble, another will switch to work automatically. If two loops have
trouble at the same time, the AC power supply loss signal is sent out. Two QUINTPS power sources are redundant, and supply power (24V) to ETS device. 24V
power loss signal is sent if this power source and PLC power source are in trouble.

1.4.2.4

Protection items of ETS

When any one of following conditions is activated, ETS system will send out
TURBINE TRIP signal to DEH system to trip turbine.
1)

Overspeed of turbine: when speed of turbine increases to 3300r/min and

above, overspeed relay in overspeed monitoring channels of TSI activates.
Emergency trip signal is sent out by output interface after two out of three
processing carried out in ETS;

2)

Great axial displacement: when displacement between shaft of unit and thrust
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bearing increases 1.2mm or -1.65mm, TSI sends out an emergency trip

signal to ETS from a interface.
3)

EH oil pressure is excessively low: when pressure of fire-resistant oil pipe

7.8MP, three pressure switches on fire-resistant oil pipe are closed. Three
closed normally closed contacts send out emergency trip signal after two out
of three processing done in ETS;

4)

Lube oil pressure is low low: Set point of pressure switch is 0.1192MPa.
When pressure of lube oil pipe P0.0392MPa, three pressure switches (PSA4
PSA6) in low lube oil pressure ETS device are closed. Three closed
normally closed contacts send out emergency trip signal after two out of three
processing done in ETS;

5)

Vacuum of condenser is low: when pressure of condenser is 19.7KPa, three

vacuum switches (PSB2 PSB4) of low vacuum emergency trip device of
condenser activate. Three closed normally opened contacts send out
emergency trip signal after two out of three processing done in ETS;

6)

Emergency shutdown of DEH: turbine emergency trip signal provided by DEH

manufacturer.

7)

Boiler emergency shutdown: digital signal from boiler is sent to ETS to trip
turbine.

8)

Generator emergency shutdown: digital signal from generator is sent to ETS

to trip turbine.

9)

Shutdown caused by over temperature of exhaust casing: digital signal from

DCS is sent to ETS to trip turbine.

10) Shutdown caused by over temperature of metal of thrust bearing: digital signal
from DCS is sent to ETS to trip turbine.
11) Manual shutdown: press manual shutdown button in central control room to
shut down unit.
12) Excessive vibration of turbine: within 1# 6# bearings, if any shaft bearings
vibrates in X direction obviously 0.25mm or within 1# 6# bearings, if
any shaft vibrates in Y direction obviously 0.25mm , TSI outputs
excessive vibration signal of shaft. The above logics are completed in TSI. TSI
has an interface to connect with ETS to trip turbine.
1.4.3

Maintenance Items and Technical Requirements of ETS

1.4.3.1

Maintenance and calibration of primary elements

1.4.3.1.1

Lube oil pressure switch, condenser vacuum switch, and EH oil pressure switch
should be calibrated according to calibration cycle.

1.4.3.1.2

Limit switch of main steam stop valve and interlocking valve should operate well
and reliably. Lever should be fastened firmly. Polish contacts regularly.

1.4.3.1.3

Check secondary valves and blow-down valve carefully. The appearance of valve
does not have serious corrosion. Valve plug moves easily, no oil leakage.
Connection of pipeline is in good condition, without leakage and blocking. After
overhaul of pipeline, do blow-down till the pipeline is clean. Screws and handwheel should be complete.
Page 87 of 112

1.4.3.1.4

Symbol should be correct and clear.

1.4.3.2

Maintenance and checking of protection loop

1.4.3.2.1

Check loops according to drawing. Make sure that connection wires are in good
order and correct. Terminals are not loosening. Screws are tight and terminals are
complete.

1.4.3.2.2

Use the megger to check insulation of cables. Insulation resistance between lines
should be more than 20 M and cable to grounding resistance should be more
than 2M.

1.4.3.2.3

Check signal channel and short connect protection contacts signal at site. Then,
check and see whether PLC input signal lamp is on.
Notice: generally, the test is carried out before unit startup. If it is carried out during
operation, corresponding protection measures should be taken.

1.4.3.3

ETS power source

When inspection, check whether main and auxiliary power sources are normal;
interference suppressor is installed to prevent interference signal at site from
entering into control cabinet. Normally, inspect volt-meter of cabinet to see whether
it indicates correctly.

1.4.3.4

Standby battery of PLC

1.4.3.4.1

Battery inspection
Service life of auxiliary battery of PLC is 5 years. When voltage of battery
decreases to a certain degree, the alarm indication lamp on the panel will be on.
Replace the battery in time when battery alarm is found.

1.4.3.4.2

1.4.3.5

Procedures for replacing battery

1)

Cut off power supply of PLC.

2)

Remove cover. Take out old battery, and pull out the connector.

3)

Install new battery connector within 30s.

4)

Start PLC after putting the new battery.

Cabinet
Ensure that internal and external of cabinet are clean. All parts are complete and
reliable. Design of fuse meets the requirements. Foundation of fuse is complete
and clean, and leaf spring has a certain degree of elasticity. Clean connector by
alcohol.

1.4.3.6

Relay
Appearance of the relay should be clean and trim, the pins are complete, and
contacts are in good condition. Winding resistance should meet the requirements.
It can operate easily and reliable. Relay to grounding resistance should be more
than 10 M.

1.4.4

Test Prior to Unit Startup

Page 88 of 112

ETS static test should be done before unit startup to ensure that software,
hardware and protection of ETS system are correct and reliable. Except protection
items, other protections switches in ETS cabinet have to be put to OFF before test.
Take turbine low lube oil pressure protection as an example.
1.

Check if power supply of system is normal and if the test measures are
complete.

2.

Reset trip indication lamp on cabinet panel.

3.

Short connect contacts of low lube oil pressure protection at site. Signal of
indication lamps for alarm of low lube oil pressure and for shutdown are
displayed on panel.

4.

Corresponding indication lamp on PLC is on, and the corresponding relay

activates.

5.

Disconnect switch of low lube oil pressure protection. Reset alarm signal on
panel.

6.

Do next test.

1.4.5

Operation and Maintenance of ETS

1.4.5.1

Operation conditions of ETS

1.4.5.2

1)

ETS and auxiliary equipment are all in good conditions.

2)

Logical condition of ETS, alarm (beyond limitation) and protection activation

setting points are accurate. System test is satisfied.

Maintenance of ETS
1)

Check that if all protection items of ETS are put into service everyday.

2)

check that if power supply of ETS system is normal everyday.

3)

Check and make sure indication of indication lamp on ETS cabinet (panel) and
indication lamp of PLC are normal. Check and see whether there is alarm
(fault) everyday.

4)

Check operation of local pressure switch everyday. Make sure that there is no
leakage.

5)

Clean the equipment weekly. Keep equipment and nameplates complete and
clean.

6)

Check external connection half year or before unit startup. Clean the
connection terminals block, check that if terminals and screws are firm.

7)

Check logic of ETS system and set point of alarm value half a year. Record
the results.

1.4.6

Common Faults and Trouble-shooting of ETS

1.4.6.1

Operation wrongly caused by drift of set point of pressure switch

Solutions: 1. calibrate pressure switches regularly. 2. Check protection signal state
during inspection. Release protection when abnormal situation occurs and solve
the problems immediately.

1.4.6.2

During unit operation, closing feedback signals of main steam stop valve or
Page 89 of 112

interlocking valve are sent by mistake.

Solutions: during operation: if closing feedback signals of main steam valve or
interlocking valve are sent by mistake, inform operator to strength monitoring. Take
necessary protection measures and check travel switch at site.

Page 90 of 112

1.5
1.5.1

Element and Instrument for I&C Measurement

Instrument for Temperature Measurement
Temperature detecting element mainly means thermocouple and RTD.
Thermoelectric temperature detecting element uses thermoelectric characteristics
to transform physical quantity of temperature into electric quantity or resistance
and so on, then sends the electric quantity or resistance signals detected to
display instrument or DCS system. The measured value is displayed as
temperature value, which makes operator to observe and learn working condition
of medium and guides operator to operate correctly.

1.5.1.1

Thermocouple

1.5.1.1.1

Measurement principle and composition

The thermocouple measurement principle bases on the following: two conductors
(different compositions) are connected to a loop, if temperature at the two
connection points is different, thermocurrent will be produced in the loop. Two
conductors compose the two electrodes of the thermocouple. The more
temperature difference at the two points, the bigger the thermocurrent (thermo
emf) is. If one end is inserted into temperature measurement area (working end),
and the other end is connected to measured instrument (free end or cold end), the
instrument will display thermoelectric value. If instrument dial uses the relation of
temperature---electric potential, showing the temperature value, i.e., the
temperature value will be read out directly.
Thermo emf produced in thermocouple loop is composed by two parts: electric
potential for working end and electric potential for free end. The graduation dial of
thermocouple take free end temperature 0 as the standard. Thermoelectricity
produced by thermocouple is only related with materials and temperature
difference at two ends of thermocouple, not related with the length and diameter of
thermocouple.
Thermocouple consists of temperature-sensing element, protection sleeve, wiring
box, metal reinforce tube and so on. It should meet the following requirements:
1)

Electric insulation of the two poles.

2)

Prevent thermo electrode from damage of harmful substance.

3)

Ensure good thermocontact between measuring end and measured object.

4)

Ensure that thermocouple transmitter is installed on the measured object

intensitively and rigidly.

Pacitan power plant uses armored industrial thermocouple (mainly nickelchromiumnisiloy, nickel-chromium--nickel-alumin(i)um), category degree No. is K
and E.
1.5.1.1.2

Maintenance items and standard

1)

Maintenance items

(1) Clean wiring terminal board;

(2) Check insulation, electrode and wiring;
(3) Calibrate the thermocouple;
(4) Check the protection sleeve;
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(5) Check compensating conductor;

2)

Maintenance technological standard

(1) Materialsof temperature-sensing element plug and main pipeline should be

same. Provide the materials survey report to the plug on high pressure and
temperature pipeline.
(2) Thermocouple wiring box on insulation pipeline should not be in the insulation
layer;
(3) Correct and obvious nameplate should be on the temperature-sensing
element. Wiring box, cover board, screw should be complete, wiring should be
firm;
(4) Keep the good contact between the armored thermocouple which is used to
measure temperature of metal surface and the surface of measured object;
(5) There should be no foreign matter in protective sleeve. Ensure the proper
inserting length to measure the accurate temperature. For common sleeve,
the inserting length should reach the central line of main pipeline. As for the
protective sleeve which is used to measure temperature in pressure medium,
take the leakage test under 1.25 times of working pressure. There should be
no leakage within 1 minute;
(6) Electrode surface should be clean without cicatrices and cracks. Welding end
should be smooth and firm without embitterment and mechanical damage;
(7) Temperature at the joint of compensation conductor and thermocouple should
be less than 70. The polarity connection should be correct;
(8) When installing compensation conductor again, it should go through metal
tube or soft tube. It is not allowable to keep a joint between conductors. The
installation should not be in the high temperature area;
(9) Use the thermocouple after the calibration meets the requirements;
(10)
1.5.1.1.3

Clean the site after the thermocouple installation.

Common fault and corrective action of thermocouple

1)

Fault analysis:

(1) Thermo emf is less than the actual value;

a)

Electric leakage inside the thermocouple;

b)

Inconsistent thermocouple type and the instrument dial;

c)

Damp thermocouple inside;

d)

Short circuit of wiring terminal in thermocouple wiring box;

e)

Short circuit of compensation conductor;

f)

Damaged measurement end;

g)

Opposite polarities of compensation conductor and thermoelectrode;

h)

Improper installation position or heating length;

i)

Too high in temperature of reference end;

(2) Thermo emf is more than the actual value:

Page 92 of 112

a)

Improper thermocouple type;

b)

Inconsistent compensation conductor and thermocouple type;

c)

Improper thermocouple installation method or inserting depth;

d)

Loose wiring between compensation conductor and thermocouple.

(3) Unstable measuring instrument indication:

a)

Poor contact between wiring terminal and thermoelectrode;

b)

Intermittent grounding and short circuit of thermocouple;

c)

Nearly broken thermoelectrode;

d)

Infirm thermocouple installation causes the swinging;

e)

Intermittent grounding and short circuit of compensation conductor.

Carefully check and analyze the above condition. Eliminate fault to ensure the
equipment in safety operation.
1.5.1.2

RTD (Resistance Temperature Detector)

1.5.1.2.1

Measuring principles and components

RTD is generally composed by temperature-sensing elements (resistance
elements), insulated conduits, protective sleeve, leading wires and wiring boxes.
The heating part (temperature-sensing elements) is made by winding double fine
metal wires evenly around the framework of the insulated material. There are twowire, three-wire and four-wire systems of wiring modes and the three-wire mode is
more popular to be used.
The temperature-measuring principle of RTD: the resistance value of the conductor
or semi-conductor changes as the temperature varies. When the temperature
changes, the resistance value of the temperature-sensing element changes
correspondingly, and the changing resistance value is used as a signal and
inputted into the display instrument to measure or control the medium temperature.
Most of RTD used in Pacitan power plant are armored thermal resistors, and a few
others are assembly thermal resistors. The chosen category degree of the platinum
thermal resistors is Pt 100.

1.5.1.2.2

1.5.1.2.3

Maintenance items and routine maintenance

1)

Inspection of the protective sleeve: the method and requirement are same with
that of the thermocouple protective sleeve;

2)

Check the porcelain pipes of the temperature-sensing elements are in good

condition, and the resistance wire is not broken or corroded.

3)

Check circuit Insulation resistor;

4)

Calibrate thermal resistor;

5)

Check the historical trend of the important measuring points in every shift.
Timely remove the protective measures once finding out temperature
fluctuation;

6)

Tighten and clean the wiring terminals regularly.

Common faults and analysis

Page 93 of 112

1.5.1.3

1)

The indicating value is lower than the actual value or the indicating value is
unstable: there is water in the protective sleeve, there are sweepings, dust on
the wiring box or the thermal resistor is short circuit.

2)

The indicating value is infinitely high: the thermal resistor is short circuit.

3)

The indicating value is the minimum one: the thermal resistor is short circuit
and the display instrument wiring is wrong.

Bimetallic thermometer
The bimetallic thermometer is made up of two firmly combined metal pieces, and
the expansion coefficients of which are different. The temperature-sensing
elements of the bimetallic thermometer are wound into spiral shape; one end of the
bimetallic thermometer is fixed while the other end is connected to the shaft of the
indicator needle. When the temperature changes, due to the temperature influence
on the bimetallic pieces, the curvature of the temperature-sensing elements will be
changed and it will drive the indicator needles to rotate via the shaft and the
temperature value will be displayed on the graduated plate.
Maintenance and daily service

1.5.1.4

Clean up the bimetal thermometer;

Inspection for the protection sleeve;

Insulation resistance inspection for electric contact thermometer;

Insulation resistance inspection for electric contact connecting circuit;

Accuracy inspection for the indicating value

Temperature switch
The temperature controller is composed of shell, thermometer bulb, capillary
connecting line, thermometer protection sleeve, fixed end adjusting button of set
value and so on.
After the medium is filled into thermometer bulb, the temperature will increase, and
the liquid inside thermometer bulb will expand and flows to the moveable section
through the capillary tubes. Thus displacement will be caused to the moveable
section, after the temperature reaches to the set point, the switch will be activated,
and thus control and alarm signal will be sent out by external circuit.

1.5.1.4.1

Maintenance
Installation:
Before installation, protection measures should be made to prevent damage due to
corrosive air, strong variation ambient temperature, sun radiation and water
penetration.
Adjustment:
1)

For the fixed switch difference type controller, use the end button to adjust the
set value. The set value could be upper switch value or lower switch value.
The corresponding switch value after adjustment is controlled by the fixed
switch difference of this control switch.

2)

For the adjustable switch difference type controller, firstly adjust the lower
switch difference by the end button, and then use the switch difference
adjusting button to adjust switch value. The upper switch value after
Page 94 of 112

adjustment is the total value of lower switch value and switch difference value.
Move the set value adjusting button in a counter clockwise to make the upper
and lower switch value move upward. By moving switch difference end button
counter clockwise, only switch difference will increase.
3)

Example:

Adjust requirement;
The lower switch value after adjustment should be 20;
Upper switch value should be 30;
Switch difference value should be 20.

1.5.1.4.2

1.5.1.5

Method: adjust the value setting end button keep the lower switch value is
20, and then adjust switch difference adjusting button to keep the switch
difference value is 10.

Daily maintenance
1

Clean

Appearance inspections: there is no leakage on thermometer bulb and

capillary tube.

Check the historical trend of the signals which sent into DCS system
everyday. Make solutions if there are any faults.

Digital temperature indicator:

Digital temperature indicator: Digital temperature indicator transforms the nonlinear signal from the temperature measuring components into temperature linear
voltage signal after linearization. The voltage signal is converted through the A/D
converter. Finally the corresponding temperature value will be displayed by digital
code.

1.5.1.5.1

Maintenance and calibration for digital thermometer

Maintenance and quality requirements
1 After the power of instrument is cut off, disassemble the power thrum and it
should be bound with insulating tape. Mark the signal line, and clean the
instruments.
2 The outside of the instrument should be complete without any defects, and all
kinds of nameplates should be complete.
3 The components are complete and installed tightly.
4 The lead wire should have no crease, impairment and insulation damage, etc.
5 Make calibration before maintenance and take good record.
6 The digital tubes could keep changing continuously according to the set code
sequence of the instruments; the light is normal and there is no letterduplicating.
7 Indicating value variation at the zero point and full range position of the
instrument within one hour cannot exceed 1 letter.
8 When the voltage variation of the power is around 10%, variation of the
indicating value should not exceed the allowable error of the instrument.
Page 95 of 112

9 The alarming system of the instrument is normal.

1.5.2

Pressure Measuring Element and Instrument

1.5.2.1

Spring pressure gauge, vacuum gauge, pressure vacuum gauge and electric
contact pressure gauge.
Spring tube pressure gauge, vacuum meter, pressure vacuum meter and electric
contact pressure gauge are together named spring tube pressure gauge. It used
for measuring pressure and vacuum of liquid, air and steam. The working principle
is: the free end of spring will have displacement under action of pressure, which
will drive amplifying mechanism through pulling rod, thus the pointer will change
correspondingly, so the pressure value can be indicated on the meter. Spring
pressure gauge, with the advantages of simple structure, broad measuring range
and small volume, is widely used. The spring pressure gauge include common
spring pressure gauge and precise spring pressure gauge, the precise gauge is
generally used for calibration.

1.5.2.1.1

Maintenance items;
1,

Appearance inspection surface is clean;

2,

Make initial record before calibration;

3,

Clean the components before disassemble;

4,

Grind valve and increase or exchange packing;

5,

Purge pulse tube;

6,

Calibrate and adjust instrument;

7,

Clean the technical record.

1.5.2.1.2

Usage & maintenance and common failures

1.5.2.1.2.1

Usage & maintenance:

1,

Select instrument measuring range: under static load, the measuring range is
1/3 higher than working point of measured object; under move load, the
measuring range is 1/2 higher than working point of measured object;

2,

Select for pressure measuring point should not close to valve elbow so as to
avoid influence on indicate value. The distance between instrument and
measuring point should not over 50m;

3,

When choosing instrument, the type and specification should be taken into
consideration firstly, and consider precision and performance for 0.5-0.4 grade
instrument. If instrument precision decreases because the ambient
temperature exceeds 205, consider temperature influence on error;

4,

Take anti-freeze measures when ambient temperature of instrument and

pressure guide tube is close to 0 or below 0;

5,

Material selection for instrument gasket depends on measuring condition and

medium:

Under low pressure and low temperature (below 800), use rubber or nylon;

under mediate pressure and the temperature is within 350-420, use

asbestos rubber or aluminum mat;
Page 96 of 112

1.5.2.1.2.2

1.5.2.2

Under high pressure and temperature working condition, use anneal purple
copper mat;

If pressure measuring medium is oxygen, use oil grease removal aluminum

mat or asbestos mat, organic material can not be used;

Asbestos mat is always used for measuring acetylene pressure.

Startup and shutdown of instrument:

a.

Close primary and secondary valves before stop instrument, and open
blowdown valve to confirm there is no medium inside tubes, then disassemble
instrument for maintenance;

b.

Check the following items before instrument startup: primary valve, secondary
valve and blowdown valve are in good condition; the connection of pipelines
and joints are correct; packing is proper; operation hand wheel, screw and
gasket are complete; pressure gauge and fixed card are tight; electric contact
pressure gauge and signal adjusting device are checked well;

c,

when measuring steam and water, slowly open primary valve to fill the tubes
with medium. If the secondary valve is three-way valve, open discharge hand
wheel and use measured medium to flush guide tubes, then close hand wheel.
Slowly open secondary valve to start instrument. Carry out strictness test after
vacuum pressure gauge is put into operation. Under normal working condition,
when close primary valve, the indicating value drop should not more than 30%
within 5 minutes.

Equipment common failures

1,

big variation;

2,

Big indicating error:

3,

Pressure pointer keeps moving

1151 Capacitance pressure (pressure difference) transmitter

According to different pressure of measured medium, there are variable
transmitters, such as absolute pressure transmitter, micro difference transmitter,
low, medium & high pressure difference transmitter and high static pressure
transmitter. The transmitters are used for measuring pressure adding, flow and
liquid. The measured pressure signal is transferred to two sides of measuring
membrane and the measuring membranes and the electrodes at two sides of
insulator make up of two capacitors. When there is no pressure or the pressure at
two sides are equal, the measuring membrane is at middle position and the
capacitance values of the two capacitors are equal. When the pressure at two
sides is not same, there will be displacement of measuring membrane and the
displacement is proportional to pressure difference. The pressure which measured
by the two capacitor will become two linear system current signals after
amplification.

1.5.2.2.1

Maintenance items and technical standard

1,

Maintenance items:

Isolate transmitter (cut off power supply for disassemble after release auto
protection), appearance inspection and clean up;

Wire insulation resistance inspection;

Page 97 of 112

Pipe valve purge;

Transmitter calibration and adjustment;

e Technical record collating

1.5.2.2.2

2,

Maintenance technical standard:

After reinstallation of instrument, the construction site should be clean and

tidy;

Instrument installation is firm, wire connection is correct and thrum symbol is

correct and clear;

Pipelines have no leakage, valves are tight and without defects;

The symbols are complete and clear;

There is height difference between sampling point and instrument, and it

should be modified during calibration;

Maintenance and calibration report should be complete and clear.

Maintenance and common failures

1,

Operation

Pressure transmitter shutdown steps: cut off power supply; close primary and
secondary valves; open blowdown valve and confirm no medium inside
pipeline; disassemble transmitter for maintenance. When stop pressure
difference transmitter, first open balance valve.

Pressure transmitter startup: check the following items: check primary valve,
secondary valve and discharge valve; confirm the pipeline connection and
joint are correct and firm; confirm the packing is proper; confirm operation
hand wheel, fastening screw and gasket are in good condition; confirm
pressure transmitter is fixed stably;

when measuring steam and water, open primary valve slowly to fill medium
into instrument pipe. If secondary valve is three-way, open discharge
blowdown hand wheel slowly to flush guide pipe with the medium, and then
close hand wheel. Open secondary valve slowly and put pressure transmitter
into operation;

before put pressure transmitter into operation, check whether positive and
negative pressure valves are closed and whether the balance valve is opened
or not. Open discharge valve, and slowly open primary valve to flush guide
pipes at least twice. Close blowdown valve after flushing. After the
temperature of guide pipes decreases, put transmitter into operation. Open
positive pressure valve gradually, and if the medium is steam or water,
unscrew blowdown bolts of positive and negative measuring room after guide
pipes are filled with condensate water or other liquid. Screw the bolts after the
air inside guide pipes is discharged completely and check the leakage and
zero position of transmitter. Close balance valve and open negative pressure
valve gradually.

2,

Causes and solutions for equipment common failures

(1) Big output

a

check whether primary element is blocked and whether pipeline has water
leakage
Page 98 of 112

check if there is residual air or liquid

check whether the connection of sensitive parts is correct

check circuit board with fault by using standby board

check whether the output of power is normal

(2) Output is not stable:

a

check the transmitter voltage and confirm whether there is incontinuous short
circuit, open circuit and grounding.

adjust damper potential

check whether the pipeline has air leakage and residual liquid

check whether insert piece is connect well and contact pin 8 is fixed well.

check original circuit board by using standby board

(3) Output is low or no output:

1.5.2.3

check install position and state of primary element

check the change of tested medium

check transmitter voltage and short connection polarity.

check loop impedance (loop voltage should not less than 100V)

check whether pressure induce pipe is correct and whether it is blocked or

whether there is leakage.

Pressure (DP) switch

When the pressure produced at process pressure side acts on the sensing
element bellows, spring tube and piston of pressure switch, it will make the spindle
of sensing element move, and then act on switch elements. The pressure of
process pressure side can be balanced by adjustable spring force. This is the
working principle of pressure controller. Calibration is to set the action point via
adjusting spring force. When input pressure reaches set point, it can control or
alarm.

1.5.2.3.1

Maintenance items and process standards

Dismantle the switch after isolation (the protection should be released firstly
for the switches for protection) to clean and check the appearance;

Calibrate the switch;

Check the contact valve;

Test and check the loop;

File the technique record.

Maintenance process standards

After pressure switch is re-installed, the site should be tidy and clean;

Installation of pressure switch should be fixed and wring should be correct, tidy
and in order; thrum sign should be correct and clear;

Page 99 of 112

1.5.2.3.2

1.5.3

The pipe should be unobstructed and without leakage; valves should be tight
and without defects.

Various signs should be complete and clear;

Cable insulation should be tested well; loop check and test should be good;

Maintenance calibration report should be complete and clear.

Daily maintenance

Check if the instrument tube and switch have leakage;

Periodically purge the instrument tube;

Periodically calibrate the pressure switch

Periodically check the pressure signal history trend and treat it in time if it is
abnormal;

Release the protection firstly of pressure switch related to protection.

Electric Contact Water Level Gauge

Electric contact water level gauge makes use of the characteristic that the
resistances of steam and water are greatly different to identify the interface of
water and steam. If it is flooded by water, it is connected while steam electrodes
are not connected, which will reflect the water level. The measurement system of
electric contact water level gauge is composed of primary measurement elements
and secondary gauges. Primary measurement elements include measure cylinder,
contact and valves. Secondary gauges include pressure head and etc.

1.5.3.1

1.5.3.2

Put electric contact water level gauge into operation

Close electric contact water level gauge blowdown valve;

Slightly open water side PA valve of electric contact water level gauge;

Slightly open steam side PA valve of electric contact water level gauge;

Full open water & steam PA valves of electric contact water level gauge after
warming up is normal;

Connect the power supply of electric contact water level gauge.

Maintenance items and process standard

Replacement of electric contact;

Seal check of valve and electric contact;

Insulation check of electric contact and cable;

Check and calibration of alarm;

Calibration of display instrument;

Simulating test for measure cylinder via water filling method.

Maintenance process standards

Measure cylinder and display instrument should be clean and tidy;

Page 100 of 112

1.5.3.3

Electric contact and valves have no leakage;

Wiring should be correct and nameplates are complete and clear;

Display instrument alarm output contact should be good;

Simulating check display should be in good condition without wrong number

and mixed code;

Usage maintenance
Electric contact flushing
Close water & steam side PA valves;
Slowly open blowdown valve to discharge the accumulated water in measure
cylinder;
Slowly open steam side PA valve to make the steam preheat the electric contact
and gradually increase the opening until big flushing sound is heard. It is no need
to full open the steam valve;
Slowly open the water side PA valve to continue flushing;
Close water side PA valve and blowdown valve after flushing;
Open steam & water side PA valves.
Cut off the power supply of instrument; close steam & water side PA valve; open
blowdown valve; replace it after pressure is released and cooling;
Close blowdown valve after replacement; open steam & water side PA valve to
check if there is leakage.

1.5.4

Rotation Speed Measuring Equipment

1.5.4.1

Work principle of centrifugal type tachometer

When tachometer spindle rotating, weight dropper will leave spindle center with the
force of inertial centrifugal force and drive meter to run by driving devices. Rotation
speed is determined by balance indication position when pointer inertial force is
equal to spring elasticity.
Inertial force:
F=mr2
M: weight dropper quality
R: distance between weight dropper gravity center and rotation spindle
:turning rate

1.5.4.2

Work principle of SQSD-2 digital tachometer

SQSD-2 digital tachometer works along with magneto-electric tachometric
transducer. Its work principle is as following: 60 pulse signal produced by
tachometric transducer is amplified and re-shaped, then displayed by counter.
When selection button is put at Rotate Speed, the opening time for counter is 1s.
Since rotating pulse frequency is 60 times the rotating speed of object measured,
this rotating speed is equal to pulse frequency. That is work principle for
tachometer to indicate rotating speed directly. When selection button is put at
Cycle, the opening time for counter is 10/6. Therefore, counter gets 10/6 rotating
Page 101 of 112

pulse and its indication is 10/6 times the rotating speed, which is 100 times the
rotation frequency. Contract this value by a factor of 100, the indication is
frequency or grid net (turbo-generator is connected with grid).
The opening time of counter gate is oscillation frequency of quartz crystal,
controlled by frequency division circuit. Rotating sampling time of overspeed alarm
is 0.1s.
1.5.4.3

SZC-02(03) intelligent tachometer work principle

SZC-02(03) intelligent tachometer works with magnetic-electric transducer. Its
work principle is shown as following: irregular sine wave signal from transducer is
shaped into regular sine wave by amplifier. This regular sine wave is counted,
calculated by single leaf computer. The final result is displayed by display.
Magnetic-electric tachometric transducer is made up of magnetoelectricity probe
and rotating disc with teeth. Generally, the rotating disc has 60 teeth, made of
magnetic steel. The inside part of magnetic-electric probe is permanent magnet
while external part is winding. When shaft rotates, it drives gear to run. According
to electromagnetic induction theory, the ends of internal winding of transducer will
generate a voltage pulse signal. The shaft rotates for one cycle, it will generate
voltage pulse signal.

n
z
60

, (F: frequency N: rotating speed of shaft measured, rps Z:

number of gear teeth)

According to above formula, when gear teeth number is 60, n is changed into
voltage pulse signal and then induce output pulse potential, which is amplified and
sent into counter).
1.5.5

Zirconia Analyzer

1.5.5.1

Requirement for selecting measurement points when using in-line zirconia

oxymeter to test flue gas
1)

Measurement points should be put at main circulating part of duct. Do not

select dead angle.

2)

The temperature of measurement points should satisfy requirement for

zirconia probe. The higher the temperature, the smaller the resistance of
zirconia, and the more accurate the measurement is, vice versa. Additionally,
high temperature will influence probe service life.

3)

Keep probe away from flammable gas since it may be burnt by flame.
Generally, measurement point is set at super heater outlet part or duct
between high temperature super heater and low temperature super heater
where temperature is around 600 to 700 and can satisfy temperature
requirement.

As for tangentially fired boilers, oxygen content of flue gas is uniform along boiler
width. With different work conditions, maximum oxygen content difference between
oxymeter A and B is about 1%. In this way, there is no requirement for
measurement points along boiler width. As for boiler whose burners are installed
on side wall, the duct blocking situation is different due to unevenly coal supply, the
oxygen content difference between oxymeter A and B may be obvious, bypass
duct type is used.
In order to make oxymeter indication value more stabile and credible, install
Page 102 of 112

zirconia probe at rear wall of outlet duct of high temperature economizer. Flue gas
is led into square chest by sampling pipe and then into bypass duct. The head of
zirconia probe gets uniform flue gas from sampling pipe length part. The mixing
gas samples are even and their indication values are more stabile.
The measurement points of bypass duct sampling mode are set at superheater or
high temperature economizer outlet. Get sampling gas from two points since
mixing gas indication value are more stabile.
1.5.5.2

Work principle of zirconia oxymeter

Zirconia is solid electrolyte. When temperature becomes more than 700, cavity
zirconia will become good oxygen ionophore. Metal platinum electrodes with holes
are put in two sides of zirconia solid electrolyte. With high temperature( at least
700700), if oxygen content at two side are different, two electrodes has potential,
called oxygen content differential potential. With certain temperature
(unchangeable), this potential is determined by oxygen content of two sides. The
zirconia oxymeter compares flue gas with air and then get oxygen content.

1.5.5.3

Maintenance items of zirconia analyzer

1)

During repair and overhaul, cut off power source and disconnect wires
connections. Use black friction tape to wrap wires and mark signal wires.

2)

Disconnect wires connection of zirconia probe and put probe at a safe place.

3)

Remove dust on analyzer and probe and then get them back.

4)

Check zirconia probe. Filter should be clean, without blocking and free of
mechanical damage. Zirconia pipe should be clean, without cracks, bending
parts and corrosion parts. The leading wires of platinum electrode should be
complete. Adhesive should be complete, no flake off. The seal is good, no air
leakage. The flange composition face is good, no corrosion. The sealing pad is
complete.

5)

Check probe internal resistance. If temperature is more than 700, resistance

100.

6)

Check probe insulation resistance. With normal temperature, use a 500V

insulation ohmmeter to test insulation resistance. The thermometer to casing
insulation resistance: 100M. Heating wires to casing insulation resistance:
500M. Internal electrode leading wire to casing insulation resistance:
20M.

1.5.5.4

Faults and solutions

1)

Thermocouple faults
When Thermocouple indication is on, i.e., thermocouple circuit has problem.
Check wire connection of thermocouple to see whether it is become loose,
whether the polarity is right. Use ohmmeter to test thermocouple circuit
resistance to see whether resistance is too large or whether circuit is open. If
the wire is connected well, maybe thermocouple is break. Repair or replace
the thermocouple.

2)

Heating stove circuit fault

When Temperature indication lamp is on, i.e., heating stove circuit has
problem. Use ohmmeter to test heating stove circuit. If resistance is more than
or is less than 60, check wire connection to see whether it is good. If not, the
internal part of heating stove is break or short-circuited.
Page 103 of 112

3)

When Zirconia pipe indication lamp is on, i.e., concentration cell circuit is open
or oxygen content of air tested is too low(less than 0.1%). Check wire
connection of concentration cell circuit to see whether it is complete, whether
polarity is good. Low oxygen content may have relationship with boiler
operation.

4)

Zirconia pipe fault

When Zirconia pipe, Thermocouple, Temperature indication lamps are on at the

same time, i.e., zirconia pipe is expired or adjustable potentiometer is adjusted at
its end. Exchange adjustable potentiometer rolling position or replace zirconia
pipe.
When any fault indication lamp is on, heating stove will stop heating automatically.
Oxygen content is indicated as 10.0 automatically. Air excessive factor will turn to
black. At this moment, please find out the faults and solve them. When converter is
put at Wait state, press Reset button or re-energize to quit Wait state.
1.5.6

Furnace Flame Monitoring System

1.5.6.1

General description
DZH furnace flame industrial television monitoring system is inner-furnace FTV
developed by Shengzhen Eastern Boiler Control Com., Ltd, who consulted the
advanced technology at home and abroad and developed it by themselves. The
camera probe parts are put in furnace and monitor combustion in furnace at the
top of furnace wall. The viewing field covers whole furnace combustion. Operators
could observe furnace flame combustion by color television monitoring system in
central control room. When boiler firing, operating with low load or when faults
damaging boiler normal operation occurring, this system is used for preventing
furnace flame from dying. It brings safety, economy and credibility to boiler
operation.

1.5.6.2

System composition
This system is made up of three parts, television system, cooling protection system
and extending/withdrawing servo system. The television system consists of high
temperature pinhole lens, color camera, video cables and color monitor. Cooling
protection system includes control cabinet, cooling protection sleeve, and external
steel wire hose. In order to ensure camera, lens work normally in high temperature
furnace, system uses air cooling mode and is designed with automatic protection
function for preventing faulty during system operation. Once cooling system has
problem, system withdraw camera probe parts from furnace automatically and
alarm. Extending/ withdrawing servo system is made up of electric actuator,
furnace gate mechanism, electric control cabinet, remoter, etc.

1.5.6.3

Daily maintenance
1

Lens: after a period of operation, the lens may be stained

Description: image become unclearly.
Solution: dip absorbent cotton in dehydrated alcohol to clean them.

Cooling protective sleeve: its pinhole at front part may have coking after long
period of operation.
Description: image frame has fixed coking.
Solution: get lens out and remove coking parts. Keep pinhole as 12mm.
Page 104 of 112

Electric actuator: remove dust on guiding rail and tie bar of travel switch
regularly. Apply lubrication grease on them. Check and make sure cooling
protective sleeve is opposite to boiler door since its position maybe fall or
move due to vibration. If not, it will not reach set position and motor will be
overloaded.

Control cabinet: remove dust in cabinet regularly. Clean air filter. Otherwise,
these dust and contamination may obstruct pipe, reduce cooling air flow and
cause lens become overheated.

Boiler door: check the boil door tightness regularly.

Before unit startup or before/ after maintenance, carry out actuator extending
and withdraw tests and protection test. During daily inspection, check
indication of lamps of cooling air and control cabinet to make sure they are
normal.

1.5.7

Drum Water Level TV Monitoring System

1.5.7.1

General descriptions
DZSW-III type drum water level TV monitoring system is used by operators in
Central Control room of Power Plant to motor drum water level changing situation
remotely. They can know water level changing clearly and directly by color monitor
in control room.

1.5.7.2

Composition
This system is made up of three parts, video camera, monitoring part and control
part. As for video camera, it has a set of enclosed constant temperature devices of
automatic temperature controlled circuit to ensure camera work safely and
continuously in high temperature and serious dusty condition around boiler. The
monitoring part has two cameras and one monitor. These two cameras share the
monitor. The displays can be switched and combined to monitor water level meter
at each side. The control part includes one remote controller, which can adjust
focus, aperture, select displays, control supporting plate and alarm when
temperature is high.

1.5.7.3

1.5.7.4

Daily maintenance
1

During inspection, operator should go to site and check equipment operation

conditions. Remove the dust on dust-proof cover to keep fans ventilation well.

The lens of camera is put in dust-proof cover. Generally, it will not be

contaminated by dust. During operation, if sharpness falls off, it mainly
because dust accumulates on the front glass of constant temperature cover.
Use a piece of soft cloth to wipe it.

During boiler maintenance, cut off local power, monitor, split, remote controller.
It is helpful to increase camera and monitor service life.

Faults and trouble shooting

During system operating, power supply, constant temperature protective system or
monitoring system, etc may fail to work.
1

Power supply fault: if monitor image disappears suddenly, check whether its
power supply is good. Check DC power supply and power adaptor for split at
site.

Page 105 of 112

Constant temperature system fault: during operation, if image of one side

become bad or disappears suddenly and Over Temperature alarms, that
means internal temperature of camera protective cover is too high. Switch
display to another side, check over-temperature faults.Firstly, check constant
temperature protective cover locally to see whether temperature is high. If not,
the internal protection temperature control circuit may have faults. Replace
temperature control circuit elements.If temperature of constant temperature
protective cover is high, check whether axial fans and power source are
normal, whether circuit of axial fans and temperature control are normal.Check
local DC power source. It should be normal. Input power current and voltage
should be equal to output current voltage.

Three motored zoom lens adjustment fault: during operation, if relevant image
are not changed after adjusting aperture, focal length and zoom, check button
connections of +6V -6V V1 V2 V3 of terminal to see whether they
become loose. If all adjustment is disconnected, that is to say, remote
controller connection connectors are loose or common terminal connection of
three motored zoom lens are broken. If one of aperture/ focal length/ zoom
adjustment (+ and - adjustment) is unavailable, that means the motor which
control that adjustment are disconnected or damaged. If it is single adjustment
failure, normally, that is motor connection wires are broken. Solve this problem
according to faults conditions and drawing.

CCTV system faults: if monitor power supply is normal, however, monitor

image disappears suddenly and Over Temperature does not alarm, that
means CCTV system fails to work.

Firstly, check whether video cable in central control room has signal, whether
video cable joint is welded normally. Use a multi-meter to check it. The DC
voltage should be about 20mV. If the signal is normal, check monitor. If
monitor TV signal is normal, generally speaking, the welding of AV video input
plug may be detached. If TV does not have signal when HV applied, repair or
replace the monitor.

If video cable in central control room does not have signal, check DC power
source at site in accordance with drawing. If DC12V which is the power source
of camera does not have output, check DC power source at site.

If DC12V signal is normal, check whether camera outputs signal locally. Use a
multi-meter to check DC and make sure DC voltage is about 20Mv. If signal is
all right, video cable may be faulty. The welding of video cable joints may be
detached or cable may be break, find out reason and solve problems.

d If local camera does not output, check DC12V power source of camera. Check
and see whether cable is broken or whether welding is detached.

1.5.8

If equipment inspected above does not have fault, which means camera is
damaged. Repair or replace it.

If remote controller can not control display splitting selection, check control
cable and split input plug.

If remote controller can not control supporting plate, check connection cables
and plugs between feeder box and supporting plate.

Other faults: since working condition of different Power plant is various, this
document can not cover all the faults. The maintenance personnel should
check faults carefully and the solve them.

Boiler Soot Blowing Program Control System

Page 106 of 112

1.5.8.1

General description
DZCK-300 boiler soot blowing program control system uses PLC (ControlLogix
series) as control host computer and industrial personal computer (with touch
screen), made in Yanhua company as upper computer. Additionally, it has Ethernet
interface for communicating with DCS system. Operators can control and monitor
all soot blowers and soot blowing steam pipelines installed at boiler body in central
control room.

1.5.8.2

Composition
Boiler soot blowing system has a group of short soot blowers(66), a group of long
soot blowers(42), a group of rotary soot blowers(12) and a group of air preheater
soot blowers(2) and main steam inlet valve, auxiliary air valve and motor-driven
drain valve.
The
system
includes
cabinets(+1,+2,+3,+4,+5).

program

control

cabinet(+0),

power

The program control cabinet is equipped with PLC modules and interfaces for
connecting DCS and power cabinet. Additionally, it is also equipped with control
circuit for system pipeline valves.
+1 power cabinet is equipped with power circuit for system pipeline valves, control
circuits and interfaces. Additionally, it gets power distributed by main power and
sent it to program cabinet and other power cabinets.
+2 power Cabinet is equipped with control circuits for short soot blower of left front
wall and left air preheater soot blower, power circuit and interfaces.
+3 power Cabinet is equipped with control circuits for short soot blower of right
rear wall and right air preheater soot blower, power circuit and interfaces.
+4 power Cabinet is equipped with control circuits for left long retractable soot
blower and left rotary soot blower, power circuit and interfaces.
+5 power cabinet is equipped with right long retractable soot blower and right
rotary soot blower, power circuit and interface.
1.5.8.3

Daily maintenance and technical requirement

1.5.8.3.1

Module state indication lamp is normal.

1.5.8.3.2

Check I/O module and make sure there is no fault alarm. The system
communication should be good. Data should be refreshed normally.

1.5.8.3.3

Check Soot-blowing Log. Eliminate equipment faults if needed.

1.5.8.3.4

Keep elements in PLC control cabinets clean. Clean the PLC cabinet regularly.

1.5.8.3.5

Keep PLC program provided by manufactory and documents sent with equipment
well.

1.5.8.4

Common faults and trouble shooting

1.5.8.4.1

When MFT occurs, related indication lamp on operation display will turn to red. If
the system is in automatic operation mode, the program will complete soot blowing
automatically. The function of MFT signal is the same as end button.

Page 107 of 112

1.5.8.4.2

Steam pressure is high

If back pressure switch (with high setting valve) of pressure reducing valve of the
pipeline activates, system will alarm and stop operating program. Pressure
reduction station fault or abnormal steam source may cause such problems.

1.5.8.4.3

Steam pressure is low

If back pressure switch (with low setting valve) of pressure reducing valve of the
pipeline activates, system will alarm and stop operating program. Pressure
reduction station fault or abnormal steam source may cause such problems.

1.5.8.4.4

Valve fault
If switch opening/closing moment or non-full opening / non-closing time exceed
required valve, that means, valves has faults.

1.5.8.4.5

Soot blower over time

If time for soot blower staying at initial position exceeds system set time, which
means, soot blower operates abnormally and system recognizes it as Soot Blow
over Time. Faults like soot blower is blocked, motor stop working or system loses
power source may cause it.

1.5.8.4.6

Soot blower startup failure

After PLC sending out command for starting soot blower, if soot blower does not
leave its initial position (out of boiler) within required time, that means, soot blower
fails to start. Many kinds of faults, like motor is burnt, circuit is broken, power
source loss, soot blower is blocked, signal is fed back wrongly, can causes startup
failure.

1.5.8.4.7

Soot blower group lose power

PLC monitors three phase power source of drive motor of soot blower, if power
source disappears, PLC will alarm. If system is in automatic operation mode at that
moment, operators should find out reason and restore power source as soon as
possible and then start program again.

1.5.8.4.8

Program control interrupts

When system is operating in Automatic mode, if faults that interrupt system work
occur, like steam pressure is high, Program Control Interrupt will be activated. If
Interrupt button is pressed manually, this signal is also activated. No matter it is
activated by faults or manually, system will consider is as faults and alarm.

1.5.9

Maintenance of Universal Small Size Relay

1.5.9.1

Check important relays involved with protection and make sure they are fixed
firmly.

1.5.9.2

Remove dust inside of relays with compressed air.

1.5.9.3

The contacts should be complete. They should contact well, without burnt parts.

1.5.9.4

Winding to earth insulation, contact to contact insulation, contact to earth insulation

and winding to iron core should not be less 10M

1.5.9.5

Check and make sure its elements are complete, without deformation. The wires
Page 108 of 112

are fixed and welded well.

1.5.9.6

The wires inside of relay should be arranged in order and correct.

1.5.10

Maintenance of Travel Switch

1.5.10.1

Check and make sure internal parts of travel switch are clean, without dust and oil
stain.

1.5.10.2

Switch internal contacts are good, without burnt blacking parts.

1.5.10.3

Switch spring should be good, without rust or loosing parts.

1.5.10.4

Switch is sealed good. Insulating paper or sealing tape should be complete.

1.5.10.5

Cam or iron core work freely, without rust. Use indication lamp to check switch
on/off conditions. The contacts should contact well. The indication lamp does not
flash. The contacts have certain distance.

1.5.10.6

Each fastener to casing insulation should be more than 10M.

1.5.11

Electric Actuator
Electric actuator adopts electricity as power, which is widely used one in power
plant. It is convenient, no necessary of special air source and air cleaning unit, the
electric actuator can keep its position when power supply lose; signal can be
transmitted for long distance, installation of cable is easier than air tube, and
inspection is more convenient; the electric actuator can communicate with
computer in an easy way or to be the intelligent one; it has the advantages like
small volume, bigger thrust, high accuracy on positioning, fast reaction and short
lag time.

1.5.11.1

The maintenance standard of electric actuator

1)

The nameplate should be tidy and clear;

2)

The fixed parts of the actuator should be tight and the parts connected to the
valves should be firm;

3)

The insulation resistance of power supply and signal circuit should be

qualified;

4)

The actuator should rotate without blocking and run stably. And there should
be no abnormal sound and vibration;

5)

The command signal of actuator should be in accordance with feedback

signal, opening degree of damper and valve;

6)

The real operation of actuator should meet the requirements of production

process.

1.5.11.2

Operation and maintenance of electric actuator

1.5.11.2.1

Check the rotary parts periodically every week, they should be flexible and reliable,
there is no swing phenomenon at the mechanical connection parts.

1.5.11.2.2

Check the fixing screws of the mechanical stop blocks periodically every week,
they should be tight, and the brake gear should be sensitive and reliable.
Page 109 of 112

1.5.11.2.3

Check oil level of gear box periodically every week, and it should be no less than
center line of oil leveler hole. And the actuator should be no leakage.

1.5.11.2.4

Check manual operation panel periodically every week, switch button between
manual and auto.

1.5.12

AI-MI Series Electric Actuator

AI & MI series intelligent actuator is the product of Shang Hai Automatic Instrument
Company which is based on the technology introduced from A & M series of
ROTORK, UK; it is the intelligent, digital and multi-function actuator consists of
very-large scale integrated circuit.

1.5.12.1

Maintenance standards and routine maintenance items of AI-MI electric actuator:

1)

The nameplate should be tidy and clear;

2)

The fixed parts of the actuator should be tight and the parts connected to the
valves should be firm;

3)

The insulation resistance of power supply and signal circuit should be

qualified;

4)

The actuator should rotate without blocking and run stably. And there should
be no abnormal sound and vibration;

5)

The command signal of actuator should be in accordance with feedback

signal, opening degree of damper and valve;

6)

The real operation of actuator should meet the requirements of production

process.

7)

Actual operation state of actuator meets requirements of production.

8)

Electric actuator should be tested after shutdown of unit, trouble shooting is

carried out in time when any fault is founded.

1.5.13

Pneumatic Actuator

1.5.13.1

Inspection items and quality requirements

1.5.13.1.1

Common inspection

1.5.13.1.2

Actuator and the accessories are complete;

Fixing component should not be loosened or damaged;

Full stroke direction symbol of valves and actuator are clear, actuator action
direction are: opening degree of valve increases as long as increasing of input
signal, positive; opening degree of valve decreases as long as increasing of
input signal, negative; if it cannot meet the requirements, adjust according to
instruction.

Maintenance
1.

The movable parts should be flexible, no looseness of mechanical joint;

2.

No looseness of mechanical position limiting component, break is flexible and

reliable;

3.

No oil leakage phenomenon of actuator; and oil level of gear box should not
Page 110 of 112

be less than center line of oil scale;

1.5.13.1.3

4.

Add lube oil to bearing of outputting shaft, screw rod of manual operation
mechanism, switching shaft, and sliding component and so on for every three
months;

5.

Switch between auto and manual should be done before manual operation;

6.

Patrol inspection should be carried out periodically, fault should be treated in

time, and the trouble shooting record should be done;

7.

Cleaning is executed once a month, make sure that instrument and

accessories are clean and complete, the symbols are correct, clear and
complete.

8.

Air source of actuator should be treated for oil removal, water removal and so
on;

Shutdown
1.

Disconnect switch of instrument and power supply control panel;

2.

During maintenance, front and rear isolating valves should be closed;

3.

If connection wires need to be dismantled during maintenance, the wires

should be marked and bonded.

4.

For long time shutdown, air source should be cut off.

1.5.13.1.1

Solenoid valve of pneumatic actuator

1.5.13.1.1.1

Inspection and maintenance

1.5.13.1.1.2

6.5.13.2

1.

Ensure that solenoid valves for maintenance have been deenergized, and all
working conditions are satisfied;

2.

Clean dust and oil stain of equipments, and make sure that symbols are
complete;

3.

Fix solenoid valve and the limit switch (replace if it is damaged);

4.

Check if there is no leakage of air supply pipeline.

Inspection of insulation and winding resistance

1.

Dismantle connection wire, measure insulation resistance between winding of

solenoid valve and shell by 500V megger, it should be less than 20M;

2.

Measure resistance of winding by multimeter, it should meet the indexes from

manufacturer.

Calibration items and technical standards

1.

Recover connection wire, make sure that connection is correct and firm;

2.

Energize solenoid valve and it is controlled by remote mode, action of solenoid

valve is correct and reliable, no blocking and abnormal sound;

3.

Make sure that action of limit switch is reliable, which can reflect open or close
direction of the valve.

Page 111 of 112