hydraulic mechanical systems in power stations
TRANSCRIPT
Power Distribution Control Systems
Power Station Control Systems
Control Room Technology
Automation Equipment
Hydraulic Mechanical Systemsin Power Stations
2
3
Contents Page
Hydraulic and Mechanical Equipment Services 4
Turbine Protection 8
Turbine Operation Monitoring 10
Installation and Commissioning 11
4
Hydraulic Mechanical Systems
Mauell GmbH offers complete hydraulic and mechanical equipment services for the modernization of turbine hydraulic systems and HP, IP, LP bypass stations.
The scope of our services comprises:
• Planning and layout of hydraulic components and systems
• Design and delivery of hydraulic mechanical components
• Optimization tests of all hydraulic components in our own test bench before shipment
• Modernization of hydraulic systems (aggregates, pipelines, control modules) and adaptation on existing machines
• Commissioning of hydraulic systems and plants
• Delivery and installation of all measurement systems required for turbine expansion, vibration, speed, etc.
• Maintenance services after project completion
• Training of customer personnel for maintenance / monitoring
Our project engineers prepare hydraulic diagrams, define the component specifications and develop concepts for the constructing engineers. The project planning and design documentation is created with 3D (Solid Works Software (SW) and 2D (Auto CAD Software) systems.
8 bar
p0
trip valve
trip valve
measurement 4-20 mAredundant position
trip valve
E/H converter 4-20 mA
redundant position measurement 4-20 mA
E/H converter 4-20 mA
3/2 solenoid valve
pi
EMERGENCY STOP
G
G
CONTROL VALVE
G
VALVE ESV
G
CV
PROTECTION BLOCK 1oo2
CONTROL VALVECV
I
IP
PSystem pressure p0 8 bar
Impulse pressure pi
Drain
3/2 solenoid valve
Combination of two control valves and one emergency stop valve
5
p0
8 bar
p0
E/H converter 4-20 mA
trip valve
trip valve
trip valve
redundant position measurement 4-20 mA
pressuretransmitter
Emergency stop P. B.
ip
Emergency stop P. B.
STOP VALVE
SIL 3
Hydraulic safety block 2oo3
DESK
Servo motor
PI
GG
CONTROL VALVE
BP-ESVSTOP VALVEEMERGENCY EMERGENCY
ESVCVCVESV
CV full open < 12 sec.
HP-ESV
TCSOverspeedprotectionSIL 3 ON SITE
System pressure p0
8 bar
Impulse pressure pi
Drain
Combination of one control valve and two emergency stop valves
3D-model of hydraulic aggregate with three controllable radial piston pumps
6
Status checks of the hydraulic lines and components to modernization concepts, isometric diagrams, welding documentation and non-destructive testing will be carried out by qualified engineers according to time schedule.
Isometric diagram of the lines and components of a large-scale turbine
Isometric diagram of a hydraulic 2oo3 protection block, vacuum breaker control unit, and associated hydraulic accumulators
Isometric diagram of HP control valve and emergency stop valves
7
We are specialists in the design and manufacture of servomotors and special cylinders, if required with integrated control blocks, for steam turbine systems up to a capacity of 1100 MW.
Our scope of delivery and services fulfil the high quality standards for applications in nuclear power stations. Delivery and installation of our high-performance servomotors includes electro-hydraulic converters, position measuring devices, couplings or ball joints, and the provision of all specifications, material certificates, function test reports and performance records.
HP servomotor with integrated control block and coupling to steam valve spindle
BP servomotor with integrated control block and ball joint to the butterfly control valve
8
Turbine Protection
Core of every Mauell turbine protection concept is our own electronic overspeed protection system certified according to SIL 3 standard by the German Technical Control Board (TÜV). Three over-speed modules, each equipped with three integrated speed monitoring modules, operate on a subordinate protection level.
Two alternative concepts are implemented on this protection level:
• Central hydraulic turbine protection block 2oo3 (SIL 3 standard), which triggers the pressure release in the protec-tion pulse fluid circuit via three solenoid valves / cartridges and activates all emergency trip units.
Hydraulic protection block 2oo3 in operating mode
Hydraulic protection block 2oo3 in test mode
9
For new plants or modernization projects that include the hydraulic system and the servomotors, turbine protec-tion with decentralized hydraulic tripping will be the better solution for costs and efficiency.
• Electronic protection block 2oo3 with decentralized electronic activation of the subordinate solenoid valves and thus of the downstream cartridge valves for each regulating unit (steam shut-off valve and steam control valve)
Instead of the central 2oo3 hydraulic protection block, speed monitoring modules control the electronic 2oo3 protection modules (EAM 15A) and execute the protection commands via electronic ANS-MV control modules. The entire electronic protection system is certified according to SIL 3 standard.
Both protection concepts are fully integrated in our ME 4012 power station control system and can be tested automatically during plant operation.
Electronic 2oo3 protection block with decentralized tripping
Electronic / hydraulic tripping, 1oo2 for each regulating unit
# # #
Failsafeclosed-circuit
protectionDW module 1
Quartzcomp.
Quartzcomp.
Quartzcomp.DWDW DW DW DW DW DW DW DW
RS
AS
RS
AS
RS
AS RS
AS
RS
AS
RS
AS
RS
AS
RS
AS
RS
AS
& & &2oo3
&t 0 2oo3
&t 0
& & &2oo3
&t 0
& & &
Failsafeclosed-circuitprotection
DW module 2
Failsafeclosed-circuit
protectionDW module 3
OC protection (closed-circuit transmission)
Turbineshaft
Turbine controller(slave)
Turbine controller(master)
+L1 +L2
+L3
Activate turbine>3 revolutions min -1
24V +L124V +L224V +L3
from FG Turbine control
Emergency stop switch(turbine trip)
ElectronicdisconnectionSolenoid valves(2oo3)
Test programElectricaltripping devices
#
#
#
#
Mon
itorin
g
#
#
Mon
itorin
g
Mon
itorin
g
EAM 15A EAM 15A EAM 15A
Test programShut-off valves
Solenoid valveactivation(current controller)
G SV servomotor
2oo3-type electronic turbine protection with distributed hydraulic trip devices in 1oo2 logic
G SV servomotor
# Criterion-specific 2oo3 signal operations through permutation
MV
MV
MV
MV
Hyd
raul
ics
E
lect
roni
cs
=>1
=>1
=>1
C=>1
=>1
=>1
C=>1
=>1
=>1
C
Generatorprotection
SUB-NET
OCprotect. 1
OCprotect. 2
OCprotect. 3
Protection criteria and operation monitoring
# #
OC protection system
2 v 32oo32oo3
ANS-MV ANS-MV ANS-MV ANS-MV
Shut-off valve 1Channel 1
Shut-off valve 1Channel 2
Shut-off valve nChannel 1
Shut-off v. nChannel 2
Test Test Test Test
Power busbar 24V -
Test programOverspeed governor
Turbine protectionManual trip
2oo3LSN24
and control valves
# # #
Failsafeclosed-circuit
protectionDW module 1
Quartzcomp.
Quartzcomp.
Quartzcomp.DWDW DW DW DW DW DW DW DW
RS
AS
RS
AS
RS
AS RS
AS
RS
AS
RS
AS
RS
AS
RS
AS
RS
AS
& & &2oo3
&t 0 2oo3
&t 0
& & &2oo3
&t 0
& & &
Failsafeclosed-circuitprotection
DW module 2
Failsafeclosed-circuit
protectionDW module 3
OC protection (closed-circuit transmission)
Turbineshaft
Turbine controller(slave)
Turbine controller(master)
+L1 +L2
+L3
Activate turbine>3 revolutions min -1
24V +L124V +L224V +L3
from FG Turbine control
Emergency stop switch(turbine trip)
ElectronicdisconnectionSolenoid valves(2oo3)
Test programElectricaltripping devices
#
#
#
#
Mon
itorin
g
#
#
Mon
itorin
g
Mon
itorin
g
EAM 15A EAM 15A EAM 15A
Test programshut off valveand control valves
Solenoid valveactivation(current controller)
G SV servomotor
2oo3-type electronic turbine protection with distributed hydraulic trip devices in 1oo2 logic
G SV servomotor
# Criterion-specific 2oo3 signal operations through permutation
MV
MV
MV
MV
Hyd
raul
ics
E
lect
roni
cs
=>1
=>1
=>1
C=>1
=>1
=>1
C=>1
=>1
=>1
C
Generatorprotection
SUB-NET
OCprotect. 1
OCprotect. 2
OCprotect. 3
Protection criteria and operation monitoring
# #
OC protection system
2 v 32oo32oo3
ANS-MV ANS-MV ANS-MV ANS-MV
Shut-off valve 1Channel 1 Channel 2
Shut-off valve nChannel 1
Shut-off v. nChannel 2
Test Test Test Test
Power busbar 24V -
Test programOverspeed governor
Turbine protectionManual trip
2oo3LSN24
Shut-off valve1CP 1SOVCompact drives 1 SOV
CP 1 CV
CP 12 SOVCP 12 CV
CP 1CV
10
Turbine Condition Monitoring During Operation
Constant monitoring of the operation characteristics of the turbine is an essential contribution to the turbine‘s durability. Expansion, vibration and bearing temperature measurements are very important turbine protection measures. Trouble-free, non-stop turbine operation and preventive maintenance can only be achieved with an appropriate turbine monitoring system.
spee
d
HP G
Intermediate bearing 1 Intermediate bearing 2 Generatorbearing
TScenterbearing
Oil pump
ES
LP F
Fieldbearing
WS
RD
WP
WS
Key
Pha
ser
P
P
FD
IP
P
HZÜ
P
P
P
P
WS
RD
P
P
P
RD
WS
WS
WS
RD :WP :
Relativ expansionShaft position thrust bearing P
: Metall temperature / Steam temperature: Pressure measurement
ABS:Absolut expansionSpeed: Turbine speed 3-channelWS: Shaft vibration
Bearing HP front
VS: Valve positionLS: Bearing vibrations
M
Turn drive
Measuring point arrangement for turbine operation monitoring
Speed measurement with standstill moni-toring
Bearing vibration measurement Shaft position monitoring
Shaft vibration measurement Absolute expansion measurement Relative expansion measurement
Measuring Transducer Examples
11
Installation and Commissioning
We provide you with an experienced team of construction supervisors, hydraulic technicians, fitters and welders, for all tasks, from system analysis to delivery, installation, piping and system flushing, over pressure test and commissioning. We also offer a wide range of maintenance services.
Vacuum breaker and control unit for extraction check valve Servomotors for HP control valves
Emergency stop valve with new trip valve to enhance plant reliability
Hydraulic aggregate with radial piston pumps in redundant arrangement
Servomotor for BP control valve Hydraulic 2oo3 protection block
www.mauell.com
Head officeGermanyHelmut Mauell GmbHAm Rosenhügel 1-742553 VelbertGermany
BrazilHelmut Mauell do Brasil Ltda.Estr. Est. Salvador de Leone 299806850-000 ITAPECERICA DA SERRA SAO PAULOBrazil
NetherlandsHelmut Mauell B.V.Lorentzstraat 313846 AV HARDERWIJKNetherlands
SwitzerlandMauell AGFurtbachstraße 178107 BUCHSSwitzerland
USAMauell Corporation31 Old Cabin Hollow RoadDILLSBURG PA 17019USA
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01_4012_39E12 Subject to change without notice.