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BHARAT HEAVY ELECTRICALS LIMITED
BHOPAL (INDIA) -462022





M/S ALAKNANDA HYDRO POWER COMPANY LIMITED


SHRINAGAR HYDRO POWER PLANT PROJECT
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DESCRIPTION, OPERATION, MAINTENANCE
&
COMMISSIONING INSTRUCTIONS


FOR


ELECTRO HYDRAULIC GOVERNOR (HMC)





Prepared by YATENDRA SINGH Rev DATE
Checked by SHIV PRABHAT SINGH 00 Dt.30.01.13
Approved by P K BHATANE


2



GOVERNOR HYDRO MECHANICAL CABINET

CONTENTS:

1.0: Principle of operation

2.0: Governor Parameters & Their Setting

2.1: Temporary Speed Droop

2.2: Permanent Speed Droop

2.3: Dead Band, Sensitivity & Damping Limits

2.4: Governing of Hydro Set

3.0: Electro-Hydraulic Governor Controller

4.0: Hydro Mechanical Cabinet

4.1: Hydro Mechanical Cabinet Data

4.2: Electro Hydraulic Transducer

4.2.1: Description

4.2.2: Sensitivity Adjustment

4.2.3: Transducer Characteristics

4.2.4: Assembly Instructions

4.2.5: Dismantling Procedure

4.2.6: Assembly Procedure

4.2.7: Auto/Manual Change Over Solenoid Valve

4.2.8: Pressure Switch for Electro Hydraulic Transducer




3




4.2.9: Test Procedure for EHT

4.3: Main Slide Valve ( 100)

4.3.1: Description

4.3.2: Operation

4.3.3: Checks for Main Slide Valve

4.3.4: Governor Opening & closing time Adjustment

4.4: Emergency Solenoid Valve

4.5: Rotary Cam Limit Switch Assembly (Master Controller)

4.5.1 Setting Instruction for Rotary Cam Switch Assembly

4.6: Pressure Reducer (Throttle)

4.6.1: Description

4.6.2: Maintenance

4.7: Feed back mechanism

4.7.1: Description

4.7.2: Settings

4.7.3: Maintenance

4.8: Gate Position, Limiter indicator & transmitter

4.9: Gate Limiter Contact device

4.10: Reduction Gear for Gate Limiter

4.11: Over Speed Protection device & Coincidence Limit Switch

4.12: Duplex Oil Filter

4





4.13: Shuttle Valve

4.13.1: Description

4.13.2: Application

4.13.3: Operation

4.13.4: Installation

5.0: Flow of Oil through Governor

6.0: Function of Governor

6.1: Load Variation

6.2 Load Rejection

7.0: Erection

8.0: Setting of Governor HMC

9.0: Trouble Shooting

10.0: Oil Specifications for Governing System

11.0: Maintenance

11.1: Maintenance of HMC

11.2: Oil Maintenance

11.3: Oil Change Frequency

12.0: Storage

13.0: List of spares

14.0: List of References drawings


5





ELECTRO-HYDRAULIC GOVERNOR (HMC)

1.0 PRINCIPLE OF OPERATION:

BHEL make Electro-Hydraulic Governor Type G-40 is capable of accepting, in
addition to speed, a variety of signals and combine these to achieve the desired
operation.

The governor is basically designed for speed control, however devices are provided to
satisfy operation of hydro-set under the following conditions:-

Steady state

Small transients

Large transients

Blocked gate

The governor type G-40 is of PID control type. The speed measuring unit and other
electronic circuits together with the transducer and main slide valve control the
movement of the main servomotor. The feedback mechanism makes it possible to
obtain steady-state operation of the servomotor.

Temporary droop circuit, receiving an electrical input from the feedback
potentiometer (which is operated by the main servomotor), sends a signal for
controlling the movement of the system without any oscillations. The two governor
parameters temporary speed droop percent (bt) and its decay time constant (Td) are
set to allow stable operation of the hydro-set. The stability of the governed hydro-set
is influenced by the water pipeline (penstock), generator inertia, turbine characteristics
and the grid.

Introduction of the feedback system in the form of temporary speed droop, influences
the response of the hydro-set to frequency or command signal. The response can be
improved by the addition of phase advance circuit adds a rate of change of speed error
in addition to the speed-error in addition to the speed-error.

This anticipatory signal greatly improves the performance of the hydro-set. The
governor parameter-Derivative time constant (Tn) can be set to achieve the desired
response.
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Permanent speed droop circuit derives its inputs from the feedback potentiometer.
Frequency versus gate servomotor relationship can be altered by changing the
permanent speed droop for the desired regulation.

Speed Setting Devices is provided to allow synchronizing, manual load control and
frequency control of the hydro-set. These Circuits are suitably designed to accept
signals from auto synchronizer also.

2.0 GOVERNOR PARAMETER AND THEIR SETTING:

2.1 TEMPORARY SPEED DROOP:

Temporary speed droop circuits have been provided in the governor to allow stable
operation of the hydro-set under all conditions.

The magnitude of temporary speed droop percent (bt) and its decay time constant (Td)
are dependent on the stability index (ratio of water time constant (Tw) to machine
time constant (Ta).

However the optimum setting of bt and Td can be visualized from the enclosed
drawing no. 32083949055. The setting is generally desired to be in the shaded zone.
It is obvious that higher the stability index, the higher are the setting required for bt
and Td. Increase in the setting of bt and Td results in sluggish response as basically
the circuit is based on adding negative signals which decays.

A Grid, which is predominantly resistive, has unstable influence on the governed
hydro-set therefore higher values of bt and Td are required. On the contrary a grid,
which is predominantly inductive, helps the hydro-set to stabilize and may require
even lower setting of bt and Td.

The advantage of a predominantly inductive grid together with a grid whose stiffness
(MW/HZ relationship) is high, is analogous to increase in the value of Ta.

2.2 PERMANENT SPEED DROOP:

Permanent speed droop (bp) is set to the desired value for regulation of a hydro-set in
a given system (Grid). Generally the setting is between 3 to 5%.


7





A higher permanent droop is provided for base load operation as compared to the
other generating sets in the grid. This helps, at times, to carry out optimum utilization
of river flows and short duration storage. On the other hand a lower droop is selected
in case the hydro-set has to carry out frequency control of the system.



2.3 DEAD BAND, SENSITIVITY & DAMPING LIMITS:

Temporary speed droop and permanent speed droop have been explained above.
Devices in the circuit like damping limit, dead band and sensitivity have been
provided in the governor for specific operation and response as explained below:

DEAD BAND:

A potentiometer has been provided for frequency dead band setting at around 50 Hz
operations. Utilization of this feature ensures that the governor will not make any gate
change for frequencies within the dead band. Dead band can be set to zero to allow the
governor to regulate the hydro-set- even for small frequency changes. The operation
depends also on the dead bands of the main slide valve & control valve. Frequency
dead band can be set between 0 and 0.5 Hz.

SENSITIVITY:

Sensitivity setting from 5 mA/Hz to 20 mA/Hz can vary the electrical signal fed to the
transducer. This setting is dependent upon the closing and opening times, mechanical
amplification of the hydraulic amplifier output and the desired response. This should
be set along with sensitivity of electro-hydraulic transducer to obtain stable operation
of hydro-set.

DAMPING LIMITS:

The influence of temporary speed droop is to stabilize the governed hydro-set by
utilizing a negative signal in relation to the command signal (system frequency and
speed setting). However temporary speed droop is a hindrance for large changes of
load therefore damping limit circuits have been added to limit the temporary droop
signal being fed to the summing point of control amplifier. Opening and closing
damping limits (both adjustable) can be set to suit the requirements. These setting
must be checked in relation to the opening and closing times and the temporary droop
setting otherwise damping limit may not be of much help.

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2.4 GOVERNING OF HYDRO-SET:(Refer drawing no. 32083949055)

A simplified graphical representation of stability of a governed hydro-set is shown in
the drawing mentioned above. This drawing shows the limits of stability. The
influence of permanent speed droop, grid and turbine characteristics have been
neglected. Generally point A defines the thumb rule method of calculating the values
of bt and Td. However the shaded zone has been shown and the temporary droop may
be set within this zone.


The limit of stability curve L shifts towards M or N depending upon the turbine
characteristics and grid. Oscillations (magnitude v/s time) have been shown at various
points of operation. Point X outside the limit of stability is unstable and is of
divergent nature. Point Y out side the stability curve is oscillating sinusoidally
(mathematically just stable). Point Z within the stable zone shows quick stabilizing
of any oscillation. Point C is critically damped i.e. although the oscillation dies down;
it still takes long time to achieve steady state operation. Thus optimum setting is
necessary to achieve the desired response.


3.0 ELECTRO HYDRAULIC GOVERNOR CONTROLLER (EHGC) :

For operation and maintenance of Electro-Hydraulic Governor Control refer to
instruction manual supplied separately.


4.0 HYDRO-MECHANICAL CABINET:

NOTE:

1. For all the item nos. mentioned within the brackets in the text, refer hydro
mechanical schematic drawing 02000016803 REV. 01 & for all the item numbers
marked # ( ) thus refer to relevant sub-assembly drawings.

2. All other enclosed drawings are for additional information/reference

3. To protect against possible damage when starting the turbine, be prepared to
make an emergency shutdown to protect against run away or over speed due to
any of the controls fail.


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CAUTION:

i) Read the complete instruction carefully before charging and operating the
system. Initial charging & operation may result in fast & uncontrolled
movements of system including gate servomotor & connected equipments,
which may cause deadly injuries.

ii). During initial charging of the system and dry stroking ensure that there is no
person:

* In the turbine pit.

iii) While working on or dismantling any sub assembly of the governor equipment
ensures that oil supply is cut off from governor cabinet. During dismantling
process the trapped oil in pipes etc. will also come out.

iv) During initial charging of the system, the pressure should be built-up in steps of
3 to 5 Kg/cm2. All leakages in the system must be attended before increasing
the pressure further.

v) Initial dry stroking & setting of governor should be carried out at a pressure of
10 Kg/cm2. Servomotor lock should be kept open.

DESCRIPTION:

The hydro-mechanical cabinet of the Electro-Hydraulic governor type G-40
houses the following mechanisms.

a) Electro-magnetic transducer with hydraulic amplifier.

b) Main slide valve.

c) Gate limiter with ECIL double shaft potentiometer.

d) Feedback mechanism with LVDT (mounted on Guide vane servomotor)

e) Duplex oil filter.

f) Control and measuring instruments.

g) Auto/Manual change over solenoid valve for EHT.
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h) Emergency solenoid valve.

i) Rotary cam limit switch assembly (master controller).

The above listed mechanism and devices are mounted on the bed covered with light
metal casing. The following instruments/devices are provided on the front panel of
hydro mechanical cabinet.

a) Electro tachometer.

b) Gate opening and limiter position indicator.

c) Balance indicator.

d) Oil pressure gauge.

e) Speed setting indicator.

f) Output setting indicator.

g) Emergency push button.

h) Hand wheel for manual control of gate limiter.


4.1 HYDRO-MECHANICAL CABINET DATA:

4.1.1 Cabinet size 916mm wide x 565mm deep x 1757mm height
excluding MDV dimensions.

4.1.2 Cabinet weight - 1160 kgs. without pedestal.

4.1.3 Cabinet handling Through two no. eye bolts provided inside
the cabinet after removing cover at top.

4.1.4 Normal Working Pressure - 100 Kg/cm2

4.1.5 Transducer Operating Pressure - 18-20Kg/cm2 irrespective of
working pressure.

4.1.7 Guide Vane servomotor size 1 X 320 X 566 stroke in mm.
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Guide Vane servomotor closing time - 8 Secs.

Guide Vane servomotor opening time - 12 Secs.

Speed rise allowed - 55 %

Pressure rise allowed - 25 %

4.1.8 Main Slide Valve size - 100 mm.

Port size used - Drg. no. 32083649049 REV. 03 Variant 4

No of ports used - 3 Nos.

4.1.9 Shuttle Valve with hydraulic over speed.

4.1.10 Auto/Manual changeover by Solenoid operated D.C. valve

4.1.11 Feedback
For manual operation: - Feedback from servomotor is through steel wire rope

For auto operation: - Feedback from servomotor is through LVDT than
transferred to regulating circuit of EHG cubicle.


4.2 ELECTRO-HYDRAULIC TRANSDUCER:
(Refer drawing no. 12083949022 & 12083949023)

4.2.1 DESCRIPTION:

The electro-hydraulic transducer consists of electro magnetic transducer
(EMT) (Drg.12083949023) and hydraulic amplifier (HA) (Drg.12083949022).
These assemblies are the linking devices between the electronic system and
mechanical-hydraulic system of the Governor. EMT converts electrical signals
of 50 mA in to a mechanical movement of 2 mm. A flapper, which is a part
of the moving coil assembly of the EMT, is located between the two nozzles.
Pressure oil continuously impinges on the flapper in the form of a jet. The total
gap between the nozzle and the flapper is approx. 0.35 mm (The exact gap
between the nozzle is 1.8 mm with flapper thickness of 1.45 mm approx).


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The purpose of the hydraulic amplifier is to add force to the mechanical
movement of the system of EMT so that control of Rod (28) and control valve
is possible this amplifier is therefore necessary as the force developed by the
coil and flapper, is not enough.

Throttle washers # (38) control the pressure in the two chambers formed
between Pistons # (20) and needle # (19). These chambers are under the
control of the nozzle. Variation of pressure in one chamber will create
unbalance thereby forcing, the needle to displace itself. Needle in turn controls
the movement of the piston # (20) by controlling the pressure in upper chamber
formed between the body # (40) and the piston. Thus the combination of
needle and piston together with the nozzle makes the moving devices of the
hydraulic amplifier operate quickly under any condition of flapper movement,
be it slow, fast or oscillatory. Thus sensitive and fast response is achieved by
ensuring the correct sizing of the throttle plates, nozzle sizing, gap between
nozzles and flapper and optimum running clearances.


Hydraulic amplifier operates at oil pressure of 18 kg/cm2. to 20 kg/cm2. This
Pressure is controlled by the pressure reducer (Throttle) located between the
Duplex filter and Hydraulic amplifier.


In case of manual control of the unit, the piston # (20) is raised to its top most
position under the action of oil pressure in the bottom chamber, thus giving an
opening signal to the pilot control valve and the opening of the main
servomotor is controlled by the gate limit mechanism.

A lever # (58) is attached to the thrust rod # (16) using a pin # (11). The thrust
rod # (16) is rigidly attached to the piston. The output of the lever # (58) is at a
distance of 65 mm from the centerline of the HA.

4.2.2 SENSITIVITY ADJUSTMENT:

Sensitivity of Electro-Hydraulic transducer can be varied by moving fulcrum
(56) of lever (stroke amplification) (57) with the help of hand screw (55),
which should be locked after commissioning. Sensitivity of the transducer
should be adjusted to get the stable operation of hydro-set. The stroke
amplification of rod (28) is approximately 2 to 5 times.


13





4.2.3 TRANSDUCER CHARACTERSTICS:

50 mA current is equivalent to 2 mm stroke of hydraulic amplifier.

Thrust rod: thrust rod stroke = 2 times hydraulic amplifier stroke at minimum
amplification.

Main Slide Valve: main slide valve stroke = 4.625 times thrust rod stroke

Main Slide Valve stroke is limited by timing nuts to achieve the desired
opening & closing times.

4.2.4 ASSEMBLY INSTRUCTIONS:

All devices of the hydraulic amplifier are carefully assembled for smooth
operation. The following devices help in its satisfactory operation.

i. Pins (Dowel) # (8) locate the cover # (37) on the piston # (20).

ii. Taper Dowel # (57) locate the body with the base # (18) in correct position.



iii. Pins # (47) locate the bracket # (10) on the base.

iv. Head peace # (33), which carries the two nozzles # (32), is guided by two
bearings located in fork # (9).

v. The lever # (58) along with the pin # (11) is guided within the bracket # (10).


vi. Membrane # (15) of rubber is firmly placed in position. This membrane
prevents spilling of oil.

vii. A paper gasket is provided between the body and base.

Thus, it is essential, that the moving parts consisting of needle, piston and lever
must operate if lifted by hand with the hydraulic amplifier not connected with
oil pressure system.


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4.2.5 DISMANTLING PROCEDURE:

a) Remove electro magnetic transducer (EMT) from the Assembly.

Follow the instruction as given in the drawing no. 42083949017.

b) Precautions: Do not disturb any setting of EMT.

c) Dismantle hydraulic amplifier in following steps (Refer Drawing no.
12083949022).

i) Dismantle four Bolts # (51), remove nut # (13) at grid G-5 & conical setting pin
# (57) also remove 4 nos. nut # (53). remove body # (40).

ii) Remove plug # (39) and throttle washer # (38) 2nos. one at a time.

iii) Clean throttle gently by steel wire. Then clean these (two throttle washer) by
petrol. The hole provided here are 0.7 mm nominal (nozzles have bigger
diameter hole).

iv) Remove nut # (13) at grid B-11 and bracket # (10),Then remove cylindrical pin
# (11) & lever # (58). now remove complete hydraulic amplifier and nut # (48).

v) Remove complete assembly of # (20) along with # (19) & head peace # (33).

vi) Clean the complete assembly.

vii) Apply the air pressure at the one port of throttle assembly without item 38, 39
for cleaning both nozzles # (32).

PRECAUTIONS:

1. Remove throttle washer one by one. Dont inter change.

2. Dismantle the piston # (20) along with # (19) and head piece # (33) by
removing bolt # (36) from piston # (20).

3. Internal surface should be gently cleaned by steel wire brush. Clean the control
edge & ports of needle # (19) & piston # (20).

4. Ensure the throttle and nozzles are properly cleaned.
15





5. EHT should be properly handled.

6. Scratches/dents should not occur.

7. Do not disturb the gap between nozzles of head peace # (32). it should be
maintained as it is.

8. Ensure free movement during assy. between head peace # (33) and bearing fork
# (9).


4.2.6 ASSEMBLY PROCEDURE:

1. Flush the internal parts of casting & components with clean turbine oil.

2. Assembly # (20) along with # (19) and # (33) Carefully.

3. Tighten all the nuts, washer etc. properly.

PRECAUTION:

i) The whole assembly should be inserted by own weight.

ii) Dont apply the pressure.

iii) Assemble the throttle washer # (38) and plug # (39) one by one. They should
not be interchanged.

iv) Replace # (41) packing with new packing to avoid leakage through hydraulic
amplifier.

4. Assemble body # (40) carefully with proper positioning.

5. Put dowels # (57), # (56) at proper place and tight nuts # (13) and other nuts #
(53) and bolts # (51) to be tighten carefully.

6. Check the movement of piston # (20) & # (19) needle. The piston should fall by
its own weight.

7. Apply the pressure and check the oil film. It must be horizontal, no deviation is
allowed.
16





8. Assemble the E.M.T.


CAUTION:

After re-assembly and cleaning of throttle and filter, stroking of the hydraulic
amplifier should be carried out a number of times to remove air from the
system, otherwise erratic operation can result due to the compressibility of air.

The EHT must be in automatic mode under conditions of governor operation.
The unit can be operated under manual mode but under constant observation of
the operating staff. In case, manual mode is necessary, the unit will not come to
no load spin (G.V. servomotor will not close) in the event of circuit breaker
tripping. Closing has to be initiated by emergency push button. The manual
mode of operation is a facility for pre-commissioning and checking of governor
under shutdown condition only. Note that automatic emergency closing due to
over speed is also possible under manual mode.

4.2.7 AUTO/MANUAL CHANGE OVER SOLENOID VALVE FOR ELECTRO-
HYDRAULIC TRANSDUCER:
(Refer drawing no. 42083949065)

The transducer (71) is provided with an auto/manual change over solenoid
valve (136) to facilitate changing the governor mode from auto to manual or
vice versa by selector switch from remote place like control room or unit
control board as the case may be. Energizing the respective solenoid does this.


The solenoid voltage rating is selected depending upon power station
requirement. However before changing the governor mode it should be ensured
that both and red pointers in gate and limit indicator of HM cabinet coincide.
The solenoid valve is of detent type and the solenoid need not be kept energized
for long. Suitable timers have been provided in the control circuit to cut off
supply after a certain time lag. The auto/manual change over function can also
be achieved manually by pushing the valve spool from either end of the
solenoid valve.





17





In case of manual control of the unit the piston (58) of hydraulic amplifier is
raised to its top most position due to action of oil pressure in the bottom
chamber; thus giving an opening signal to the pilot control valve and the
opening of the main servomotor is controlled by operating gate limit
mechanism hand wheel (10).

4.2.8 ELECTRONIC PRESSURE SWITCH FOR ELECTRO- HYDRAULIC
TRANSDUCER:

A pressure switch (069) has been provided between auto/manual change over
solenoid valve and hydraulic amplifier of E.H.T. The pressure switch is
mounted on the sub-plate of auto/manual solenoid valve by suitable piping.

This pressure switch is used for getting signal for auto to manual and manual to
auto-change over of transducer and this signal is further used in control circuits
of Turbine Generator set.

The pressure switch is having adjustable setting,

During commissioning, the air trapped in the pipeline connecting the pressure
switch with transducer should be properly bleed. The setting of pressure switch
should be regularly checked. All the transducer are supplied factory set and
tested and do not normally need any testing/rectification at site. However if it is
necessary to rectify and test the EHT the following procedure is to be followed.


4.2.9 TEST PROCEDURE FOR ELECTRO-HYDRAULIC TRANSDUCER:

1. Connect the electro-hydraulic transducer with oil pressure system and EHG
cubicle.

2. Adjust the pressure in the range of 18-20 kg/cm 2 by throttle device (54).

3. Install the dial indicator touching the out put rod of piston (58) of the hydraulic
amplifier.

4. Put the hydraulic amplifier in auto-mode and ensure good oil film formation
between the nozzle.



18





5. By changing the mode from manual to auto ensure output rod movement of 2
mm. If this is not 2 mm adjust height of flapper of electro-magnetic
transducer to get output rod displacement of 2 mm.

6. Very the supply via DC current in the steps of 1mA in the Range of 10 mA
and 5 mA in the range of 50 mA.

7. Note the displacement of hydraulic amplifier on the dial Indicator.

8. Plot the graph between displacement of hydraulic amplifier and current. The
graph should be linear.

9. Measure the oil leakage from EHT at zero current in both manual & auto mode
& record the same. In manual mode oil leakage is negligible. In auto mode it
should be less than 6LPM.

4.3 MAIN SLIDE VALVE
(Refer drawing no. 02083949056)

4.3.1 DESCRIPTION:

Main slide valve has been provided to regulated oil flow to the main servomotor
and allow steady state operation. All the devices are located in the main slide
valve body casting # (3). Oil pressure is connected through pipes to this body
and flanged connections are available for the opening and closing chambers of
the servomotor and drain (connected in-turn back to the sump tank of the oil
pressure system). Oil pressure is also connected to the pilot (control) valve.

The mechanical signal from the hydraulic transducer moves the floating lever
which in turn operates the pilot valve needle # (29). For opening sequence this
pilot valve needle moves up and drain the oil pressure from the auxiliary
servomotor there by the main slide valve spool # (21) moves upwards due to
differential area (the net force acting upwards). For closing sequence the needle
valve is forced down by the floating lever allowing oil pressure to the auxiliary
servomotor. The slide valve spool is forced down.





19





Movement of slide valve spool # (21) uncovers the ports in the sleeve # (22)
there by allowing oil pressure in the opening or closing chambers of the
servomotor, as the case may be. The magnitude of slide valve movement is
controlled by the floating lever which acts as feedback for re-setting of pilot
valve. For steady operation, the floating lever is in horizontal position with no
signal from the hydraulic amplifier. The sizing of the ports in slide valve sleeve,
over laps etc. are designed to suit individual requirements.
The pilot valve needle, its sleeve are designed for upward force due to oil
pressure, as such it is not rigidly connected to the lever.


4.3.2 OPERATION:

Over laps on the pilot valve and main slide valve ensure steady state operation.
Small signals within this over lap (dead band) do not result in any movement of
servomotors.

An A.C. ripple (Dither) is super-imposed on the D.C. signal to electro-
magnetic transducer, which results in constant small oscillations of hydraulic
amplifier and pilot slide valve. This is essential to prevent hydraulic lock of the
sliding needle. These oscillations may be around 0.05 mm to 0.10 mm
(approximately) and should be limited within the over laps.

Time adjusting nuts (37 & 38) have been provided for controlling the opening
and closing times of the servomotors and are locked in position after they have
been correctly set.

4.3.3 CHECKS FOR MAIN SLIDE VALVE:

With oil pressure disconnected ensure that both the pilot slide valve needle and
main slide valve can be stroked up and down by hand. Once lifted they should
fall down by their own weight. They should not have any rust and scratch
marks. The pilot slide valve sleeve # (31) should not be over tightened
otherwise the needle # (29) may not operate with full freedom. This needle #
(29) should not touch cover # (30).

The piston rod of the auxiliary servomotor # (54) should be well lubricated;
cleaning of all parts is essential to prevent entry of dust, foreign matter in to the
rubbing surfaces.

The above checks should be carried out at least once in 6 months.
20





4.3.4 GOVERNOR OPENING & CLOSING TIME ADJUSTMENT:
(Refer drawing no. 42083949082)

The opening & closing time of governor can be easily adjusted by using the
nuts (38 & 37) respectively.

Measure the opening & closing time by opening & closing the Guide Vane
servomotor by hand wheel (10) from governor HM cabinet, using a stopwatch.

If required, adjust nuts (38 & 37) to achieve the desired timings. Once the
desired timings are achieved, lock the nuts by tightening the grub screws
provided on the nuts.

NOTE:
1. The Guide Vane servomotor closing time is set from 100% opening to
cushioning point of servomotor.

2. For measuring the opening & closing timings, the hand wheel (10) of governor
HM cabinet should be operated at a faster rate so that red pointer moves faster
than the black pointer in Guide vane limit & position indicator (11). Otherwise
incorrect timings would be recorded.

4.4 EMERGENCY CLOSING VALVE:
(Refer drawing no. 22300449023)

A solenoid-operated valve (66) has been provided between the pilot valve (76)
and auxiliary servomotor (39) of main slide valve. During normal operation of
governor the oil flow is established between pilot valve and auxiliary
servomotor thro port A and B of valve. When solenoid coil(20ES-3C)of the
emergency valve (236) is energized or by manual pressing the solenoid coil the
system pressure P gets connected to auxiliary servomotor there by initialing
closing of governor (also refer drawing no. 22300449010). The oil supply from
pilot valve gets blocked under emergency operation.
The valve is of detent type and the solenoid need not be kept energized for long.
The re-setting of valve is done manually by pressing the button or by energizing
the rest solenoid provided at the bottom of the valve. For effective operation
and re-setting of detent device, the height of block housing to this device may
need slight adjustment, which should be done during carrying pre-
commissioning checks.


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4.5 ROTARY CAM LIMIT SWITCH & PULLEY ASSEMBLY:
(Refer drawing no. 32083649006)

A rotary cam limit switch assembly (63) has been provided to work as master
controller. It consists of six nos. limit switches (signal pole, single throw)
operated by six numbers independently adjustable cams (in two halves)
mounted on a shaft. This shaft gets movement through various pulleys and wire
rope from feedback shaft (32) of the Governor cabinet. The angular movement
of the cam shaft is nearly 300.The cams after tightening the grub screw
provided, should lock adjustment. All the limit switches are wired up to
terminal board of the cabinet.

4.5.1 SETTING INSTRUCTION FOR ROTARY CAM LIMIT SWITCH ASSEMBLY
(MASTER CONTROLLER)

1. Remove top cover of the assembly.

2. Put the governor to zero opening of Guide vane servomotor by using hand
wheel.

3. Loosen the grub screw in the setting dial and set the zero to the setting mark
then lock the grub screw.

4. Loosen the grub screws in both halves of the cam to be set.

5. Set the governor to required position where the switch should first close.

6. If the period is for less than 180 then use the normally closed A contact and
set the white cam to the position where the switch just releases.

7. If the period is for more than 180 uses the normally open B contacts & set
the RED cam to the position where the switch just operated.

8. Move the governor hand wheel to the position where the switch should open
and set the other half of the cam.

9. Switching differential: The difference in the switching position by rotating cam
shaft clock wise and then anti clock wise is 1-1/2. If required this can be
improved by hand setting of roller lever arm on each switch.


22





4.6 PRESSURE REDUCER (THROTTLE):
(Refer drawing no. 42083949053)

4.6.1 DESCRIPTION:

The pressure reducer (throttle) of the static type has been provided to supply
pressure oil to hydraulic amplifier at 20 kg/cm2. A number of throttle washers
are mounted on a rod which also carries a filter. A nut holds the throttle washers
& filter securely on the rod. Each throttle washer has a cut on its outer
periphery, thus the throttle washers should be adjusted to give the desired
pressure.

4.6.2 MAINTENANCE:

The filter should be cleaned whenever the pressure in the hydraulic amplifier is
low by more than 2 kg/cm2 compared to its initial setting. However, the main
oil filter should be checked & cleaned first before attending the filter located in
the pressure reducer (throttle).

CAUTION:

In case the pressure is more than that set originally, then the nozzle of the
hydraulic amplifier should be checked and choking, if any, eliminated.


4.7 FEEDBACK MECHANISM:

4.7.1 DESCRIPTION:

The feedback mechanism has been provided for governing of the hydro-set. The
mechanism essentially helps in restoring the main slide valve of governor to the
steady state condition. The feedback mechanism as such gives signal through
the LVDT (LVDT mounted on the G.V. servomotor) to the permanent droop
and temporary droop circuits in the electronic cabinet. The feedback mechanism
also gives mechanical feedback signal to the Gate limit mechanism.

For Manual operation: - The feedback mechanism consists of steel rope drive,
which transmits the movement of G.V. servomotor piston rod, through a system
of pulleys to the feedback shaft (located in governor HMC). The full stroke of
the G.V. servomotor is converted to 200 mm feedback stroke for governor by
utilizing pulley of different diameters.
23





Versatile rollers are located in the desired position (outside- governor HMC) for
changing the direction of the wire. The wire ropes are pre-cut and the ends are
unbraided and sealed with tin or lead.

4.7.2 SETTINGS:

The wire ropes are pre-cut at the time of commissioning. Adjustment is possible
at the driving end by adjusting the tie rod and the pulley block located in
governor HMC. Refer drawing no. 02085016801 REV. 02 (installation of
governor HMC). The following checks must be carried out after every
adjustment:-

i. Stroke the servomotor from 0% to 100% and 100% to 0%.

ii. Check that the indicator (black needle) on the governor HMC reads 0% to
100% corresponding to the servomotor openings. Adjust the indication if
required, through sector (1) located on the weight in HMC.

iii. Set the gate limit at minimum. Ensure that the servomotor closes at 0%
otherwise re-set the feedback mechanism or adjust the gate limit mechanism.

CAUTION:

i. Ensure that the wire rope NEVER winds itself over the combinatory pulley
more than 360 degree during full stroke movement of the servomotor.

ii. The counter weight in feedback mechanism moves freely in the pipe assembly
and tube.

iii. The rollers in the versatile roller assembly of feedback mechanism operate
freely. Ensuring also that the wire rope does not touch any part of the housing
tubes etc. otherwise there will be loss of return motion resulting in
unsatisfactory operation of the governor.

4.7.3 MAINTENECE:

i. Lubricate all ball bearings regularly.

ii. Grease wire rope, gears & versatile rollers regularly.


24





4.8 GATE POSITION LIMITER INDICATOR AND TRANSMITTERS:
(Refer drawing no. 12083949020)

The indication of gate opening & limit is purely mechanical while electrical
transmitters have been provided for remote indication in control room. The
pulley located in this assembly is operated by wire rope. One connected to the
feedback shaft and the other to the gate limiter. Suitable gears have been
provided for operation of the needle indicator & transmitters. Springs have been
located within the pulleys to create enough tension in the wire rope. These
springs must be wound in the correct direction for satisfactory operation. The
spring in the pulley for gate limit indication should be wound clockwise while
the spring located in the pulley for gate direction should be wound
anticlockwise. 1 to 2 turns should be left in the springs to allow free rotation of
the pulleys.

4.9 GATE LIMITER CONTACT DEVICE
(Refer drawing no. 22083949011)

Three limit switches have been mounted in the gate limit mechanism. The
setting of these limit switches is adjustable by fixing the cam # (6, 8 and 15) to
suit the requirements. Cam #6 & 8 are mounted on holder # (7) and cam # (15)
on holder # (14). They can be locked in the desired position by nuts # (5)
independently.

Care should be taken to mount the limit switches firmly using nuts for locking
purposes.

Limit switches MS 701, MS 702 and MS 703 are provided with cams on the
contact devices for starting opening, limiter full closed and limiter fully opened
position respectively to stop D.C. Limit motor.



All the three cams of limit switches are set to fulfill the following conditions.
Unscrewing the lock nuts of cams by using two spanners should do setting.

a) MS 701 to break at approx. 25% of G.V. opening i.e. starting, opening, in
opening direction.
b) MS 702 to break at 100% G.V. opening, in opening direction.
c) MS 703 to break at 0% of G.V. opening, (i.e. full closing) in closing direction.

25





4.10 REDUCTION GEAR FOR GATE LIMITER
(Refer drawing no. 12083949043)

Gate limiter allows Guide vane to open under normal control until this opening
is reached and then exercises an over riding command and prevents the gates
opening further. The limiter can be operated either by hand wheel (10) in case
of manual control or by electric motor in case of remote control. For operation
of mechanism by motor the tension of external spring is adjusted to optimum
values so that the motor engages properly. After this is achieved the setting is to
be locked by tightening the lock nut provided for this purpose.

Operating the motor (8) or turning hand wheel (10) raises or lowers rod (31),
which in turn actuates needle (47) for opening or closing of gate servomotor via
lever (42). Movement of gate servomotor rotates feedback shaft (32) through a
cable feedback thereby moving lever (42) till needle (47) again comes to its
mid-position and gate servomotor stops.

Total stroke of gate limiter is 60 mm with 5 mm over travel. Variable resistance
R 702 is mounted above the terminal board in hydro mechanical cabinet. The
time to raise the limit from 0 to 100% or lower the limit from 100% to 0 can be
adjusted by varying the resistance R-702.

The time to raise limit or lower the limit should be checked by holding the
raise/lower switch in either position. This check should be carried out during
dry stroking only.

LIMIT MOTOR TROUBLE SHOOTING:

The following checks should be carried out on DC limit motor of governor
cabinet to ensure healthy operation.

(1) Check the insulation resistance of the two windings, dry the windings for at
least 48 hours even if IR is OK.

(2) Check the Commutators and carbon brushes for cleanliness and ensure that
there is no moisture or carbon dust present.

(3) Check and ensure free rotation of motor shaft.

(4) Apply the rated DC voltage to the raise & lower circuits intermittently to check
the initial operation. Repeat for longer times.
26





(5) The limit switches on contract device of governor cabinet must be set properly
to ensure that limit motor does not remain in operation for ever. Check and
ensure healthiness of limit switches regularly.

(6) Check that the terminal blocks in the governor cabinet are dust and oil free.
This will eliminate the possibility of any leakage of DC supply.

(7) Check and ensure that all the terminal contacts are tightly screwed both in the
governor HM cabinet and on the governor electronic cabinet.

(8) Check voltage across the field winding after the limit motor moves to the limit
setting (zero and 100%) on indicator. The voltage should be zero. This check
should be regularly carried out during the first few weeks of operation and
every month afterwards.

(9) Check the operating time of the limit for raise and lower. A noticeable change
in operating times indicates development of fault and the above mentioned
checks should be carried out to find out the faults & corrective measures be
taken immediately.

4.11 OVER SPEED PROTECTION & COINCIDENCE LIMIT SWITCH
(Refer drawing no. 22083980001)

This device consists of limit switch mounted on main slide valve, which is
connected to the emergency protection circuit in series with contacts of the
speed relay. When the speed of the unit reaches 115-120% of the rated value
and the main slide valve is still in the opening direction, emergency closing of
the gate servomotor is performed through the emergency closing valve.

Coincidence limit switches: The height of this limit switch is to be adjusted so
that it is operated when the limiter lever touches screw (43) of floating lever.
This adjustment is to be done after completing mechanical setting of governor
cabinet. This limit switch is connected in the control circuit of auto/manual
change over mode of EHT. The change over from auto to manual mode should
not take place until & unless the limit switch contact is made. This will ensure
limit & position are coinciding before change over takes place.





27





4.12 DUPLEX OIL FILTER:

For the electro-hydraulic transducer to give trouble free operation, the hydro
mechanical cabinet is provided with a duplex oil filter. Degree of filtration is 50
micron with visual and electrical clogging indicator. Selection of element can
be done by turning handle (53).



4.13 SHUTTLE VALVE:

4.14.1. DESCRIPTION

This valve is a direct acting spool type shuttle valve.

4.14.2 APPLICATIONS

The shuttle valve provides a means of sensing the higher pressure out of two
lines in a hydraulic circuit and allowing the higher pressure to perform a
secondary function such as releasing a mechanical / hydraulic brake or
operating a pressure gauge / switch, auxiliary servomotor etc. Nitrile seals are
fitted as standard which are suitable for mineral oil or water / glycol hydraulic
systems over a wide temperature range.

4.14.2 OPERATION

When pressure is applied to the nose of the valve, the force realized by this
pressure acting on the end of the spool forces it along its bore. The pressure /
flow is now allowed out of the center port.
When pressure is applied to the port nearest the screw thread the spool is forced
over in the opposite direction allowing that pressure / flow to be sent out of the
center port


4.14.3 INSTALLTION

The shuttle valve is of cartridge design so that it can be installed or replaced
quickly and simply in either line mounted bodies, Polyhydrons or customers
manifolds. The valve fits into standard cavity. A line body is available.


28





5.0 FLOW OF OIL THROUGH GOVERNOR:

The control valve (pilot valve & main slide valve) operates at normal working
pressure. The oil pressure for the hydraulic amplifier is fed through isolating
valve (75), duplex filter (51) and pressure reducer (54). The pressure of
hydraulic amplifier is monitored from the pressure gauge (50) mounted on
HMC.

The pressure reducer (54) is of static type. The pressure reduction is achieved
by a number of orifice (throttle) plates. They are adjusted in such a way that
pressure of 18 to 20 kg/cm2 is achieved. This flow thro the nozzles is
controlled by throttle washers provided in the hydraulic amplifier.


Any chocking in the nozzles and throttle washers will result in the pressure
going-up. Some times, the pressure may momentarily increase due to sudden
variation may not be considerable, If the problem of the pressure variation in
transducer current. However, this variation may not be considered if the
problem of pressure variation continues during normal running then it is
advisable to flush the hydraulic amplifier by repeated stroking under shut-down
conditions, otherwise the hydraulic amplifier need over haul. All that one has to
do is to clean the hydraulic amplifier components including the auto/manual
change over valve as per details given earlier.


6.0 FUNCTION OF GOVERNOR:

6.1 Load variation:

Let us consider the case of partial drop of the load due to lesser demand, when
the unit is operating in an isolating grid and the governor is adjusted according
to static characteristics.

When the load is reduced, driving torque of turbine exceeds the resisting torque
of the generator, leading to an increase in frequency. The electronics cubicle of
the governor alters the current flowing in coil (68) causing downward
displacement of baffle (65).

The downward movement of coil (68) results in an equal amount of
displacement of the piston (58), which is then transmitted via levers and pilot
valve to the main slide valve as described in earlier section.
29





The servomotor thus moves for closing which is accompanied by a decrease in
motive force of turbine.

Movement of G.V. is transferred to the feedback shaft (32) and through wire
rope to potentiometers of feedback gear. The voltage collected from the
potentiometers is fed to the governor electronic cubicle regenerating the out put
signal of the magnitude, which complies with steady-state operating conditions
of the hydro unit. Coil (68) returns to its mid position due to which main slide
valve spool (40) also returns to its mid-position.

6.2 Load Rejection:

In case of load rejection the resistance torque moment of generator is sharply
decreased thus causing a fast increase in rotational speed. Sharp increase of
frequency generates a signal in governor which is sufficient in making the main
slide valve (40) move to its full closed position and close the Guide vane at
maximum speed allowed by governing guarantees.


After the unit speed is restored to the rated value the governor action for turbine
closing stops and the turbine generator operates at no load.

If due to some reason the main slide valve (40) is prevented from moving
towards closing after load rejection then the over speed protection device will
come in to action as soon the turbine reaches 115% of rated speed.



7.0 ERECTION:
(Refer drawing no. 02085016801 REV. 02)

a) For handling the hydro-mechanical cabinet after unpacking, use eyebolts
located inside the cabinet on the bed (it is necessary to remove the upper cover
of the casing).

CAUTION: Never sling the governor by its casing.

b) Before mounting the governor cabinet, inspect it visually to detect possible
damages caused by transportation or storage.


30





c) The governor should be assembled indoor. The assembly premises are to be
protected against dust and atmospheric precipitations.

d) The hydro-mechanical cabinet should be positioned by spirit level.

e) Parts removed when unpacking should be placed in proper position. Weights
and other parts fastened for transport purposes to be released.

f) It is absolutely forbidden to hammer the base plate and foundation frame when
mounting the governor cabinet.

g) For all external electronic connections use oil resistant insulated cable. Use
screened cables for connecting transducer, balance indicator and feedback
potentiometer in HMC with electronic cabinet.

h) Fill reduction gear of gate limiter (9) with clean oil from the governing system
up to the level specified on the dipstick. All hinged and movable joints should
be oil lubricated.

i) Using 500 V mega, check resistance of wiring insulation in relation to the base
plate. The resistance value should not be less than 10 mega ohms.

j) Check mounting of the mechanisms and assemblies in the governor, axes of all
rods and rope drives should lie in the plane of movement of the respective
levers, sectors and rollers.

k) Check seating of pins and tightening of stops in all assemblies of the governor
cabinet.

l) Check for jamming, friction and play in all the levers.

m) Connect feedback wire rope from servomotor to hydro mechanical cabinet. As
the counter weight (2) is in its lowest position the servomotor should be in its
fully open position for connecting feedback wire rope.

n) In case the hydro mechanical cabinet is required to be mounted on a pedestal to
allow for gravity drain of oil to pressure pumping set, then mounting is to be
done as per details given in enclosed drawing no. 02085016801 Rev. 02,
installation of governor Hydro mechanical cabinet.


31





8.0 SETTING OF GOVERNOR HMC:

The procedure given below is applicable for carrying out governor setting for
the first time or in case the main feedback rope breaks or is disconnected to
attend to the servomotor etc.

CAUTION:

All operation listed under this paragraph are performed with dry spiral casing,
reduced system pressure and slow rate of travel of servomotors.

a) Connect HMC & Electronic cabinet as per wiring diagrams. Put the EHT in to
manual mode. Open valve (75).

b) Shift over speed protection device (35) & coincidence limit switch to a position
on holders such that the auxiliary servomotor (39) cannot depress the limit
switch.

c) Ensure that the feedback rope runs properly on all the roller pulleys between
governor HM cabinets & Guide vane servomotor. Check for proper tension in
the rope.

d) Charge the governing system with oil from the oil pressure system at 3-5
kg/cm2 pressures. Remove air from the system by stroking servomotor a
number of times. Then apply full effective pressure, Check all oil pipes for
tightness of their joints. Oil leakage is not allowed.


e) Wash both cavities of oil filter, (51) several times. Check reading of pressure.
Gauge (60) against pressure, gauge of oil pressure unit. Discrepancy between
the readings should not exceed 1 kg/cm2.

f) Travel of main slide valve (40) to be limited by the respective nuts (37 and 38)
to the amounts so as to achieve desired opening and closing times at normal
working pressure. After governor setting is over, the adjustment nuts (37 and
38) should be locked by grub screws, in the slot provided for the purpose in
auxiliary servo piston rod.

g) Using hand wheel (10) of governor HM cabinet set stem (21) of limiter in mid-
position. Total stroke of stem (21) is 60 mm with 5 mm projection. For mid-
position, the stem (21) should project out (30+5mm) from the sleeve.
32





h) By means of bolt (43) set limiter lever (42) in horizontal position, Check
horizontality by using spirit level.

i) Check sector with weight (2) also for horizontality, the distance between red
line on weight (2) and foundation frame should be 310 mm approximately.

j) By adjusting the height of pulley block (3) set gate servomotor in its mid-
position.

k) At this stage, both the pointers of indicator (11) should be at reading 5. If both
the pointers are not are reading 5, open cover of the indicator (11) and bring
both the pointers to reading 5.

l) Now open & close the G.V. servomotor by using hand wheel (10) and check for
full opening & closing of G.V. servomotors.

m) Open & close the G.V. servomotor in steps of 10% and record corresponding
movement of black pointer on indicator (11). The discrepancy should not be
more than 3%.

n) If required, the sector (1) can be moved by using eccentric pin provided, to
adjust the travel of the black pointer on the scale.

o) Check travel of the feedback rope from the governor which should be 200 mm
approximately.

p) By hand wheel (10), shift the servomotor to full opening and adjust the stopper
of weight (2), check and ensure a gap of 2-3 mm between weight stopper. Lock
the stopper.



q) By adjusting position of cam (30) set micro switch (12) so that it comes in to
action when gate limiter is in position corresponding to gate full opening.

r) Carry out similar operations with the second micro switch (12) in full closing.
When doing so, provide shift of main slide valve (40) by 2-3 mm, in closing
direction.

s) By adjusting position of cam (29), set starting opening micro switch (14) so that
it comes in to action at 25% gate opening approximately.
33






NOTE: Cams (29) & (30) should be secured by grips using two spanners. Check for
proper working of limit switches. Malfunctioning of limit switches will damage
the limiter motor.

t) By means of hand wheel (10) shift gate limiter to position of full opening.

u) Using hand wheel (16) adjusts the position of limiter according to head in
accordance with the ideal line of power restrictions.

v) By means of screw (25) set gate servomotor opening equal to speed no load
opening.

w) By means of hand wheel (10) set gate servomotor to intermediate position. In
this case, the gate main slide valve (40) should be in its mid position.

x) By means of nut (33) set the switch of over speed protection device (35) so that
when the main slide valve (40) moves in closing direction the roller of the
switch gets released and opens the contacts of the switch, when the main slide
valve is about 1 mm from its mid position. For setting of this device refer
drawing no. 22083980001. Also set coincidence limit switch as per instruction
given in this drawing.

y) Check tripping of over speed protection circuit switch (35) at CLOSING
travel of gate main slide valve (40).

z) By means of hand wheel (10) shift gate limiter (9) to position of full closing.

a1) Select Automat position of transducer by using solenoid valve. In this case
pressure of the oil supplied to hydraulic amplifier (62) (if the filter is clean),
should be within the limit 18-20 kg/cm2 which is indicated by pressure gauge
(60). The pressure is adjusted by means of washers of throttle (54).

b1) Through adjustment of thrust rod (28) length, obtain such position at which the
gate servomotor is motionless (the limiter being backed away). Lock the thrust


rod in this position by using two spanners. In this condition the black pointer
should not follow the red pointer in opening direction and also the servomotor
should not move to closing. Slight creeping towards closing is allowed.

34





c1) Switch over EHT to manual mode.


NOTE: The speed of limiter motor can be adjusted by resistance (R701, R702).

d1) Connect electrical cubicle and perform common adjustment of governor cabinet
and electronic cubicle as described in O & M manual of electronic cubicle
issued separately.

e1) The feedback voltage to be adjusted as per requirement by adjusting/setting
potentiometer provided in governor HM cabinet.






























35






9.0 TROUBLE SHOOTING:

Problem check

1. At the time of auto start, the check the operation of various
inlet valve opens but Guide vane control relays.
limit does not open.

2. Gate limit raise/lower not a. Check limit motor operation.
possible. Replace if necessary.

b. Check the clutch mechanism
of limit motor.
Set it correctly.

c. Replace the whole limit
motor mechanism in case
there is problem with gears.

3. Gate opens beyond the a. Check the feed back system.
gate limit setting.

b. Check the limit mechanism.


4. At the time of auto start Check opening current
the gate limit opens to start through start relay 4, 4Z etc.
value but gate does not open.

5. Speed setting does not a. Check motor operation.
respond to raise/lower
commands.

b. Check clutch arrangement in
reduction gear.

c. Check raise/lower control
switch.


36





6. Speed setting increase or Check raise/lower switch.
decreases without operators ensuring clean contact and
actions. proper spring tension.




7. Machine speed is not 50Hz Check feed back signal and
with speed setting set at 50Hz control amplifier output. If all
for no-load operation. Inputs are O.K. then set 50 Hz
accurately by adjusting speed
trim.

8. Governor transducer pressure a. Clean the filters.
is not 20 kg/cm2 in auto mode.

b. Clean the filter of throttle.

c. Variation of 2 kg/cm2 is
allowed.


9. Hunting phenomena.

a. Oscillations of speed and a. Check feed back signal at
gate at no-load. droop unit card. If absent,
check feed back
potentiometer in HMC.

b. Oscillations when connected b. Operated the m/c on gate
to grid. Limit and check whether
the grid is unstable.

c. Check that temporary droop
percentage & decay time
constant are set correctly.





37






10.0 OIL SPECIFICATION FOR GOVERNING SYSTEM:

This oil is to be procured from reputed oil suppliers against their trade name
equivalent to ISO-VG-46. This contains antioxidant, anti rust and defoament
additives and broad characteristics are as under.

CHARACTERISTICS:

IOC Servo Prime 46 equivalent to ISO-VG 46

Kinetic viscosity cst at 40 degrees C 43.5 -47.5

Viscosity index min. 98

Flash point (coc) degrees C min. 210

Pour point degrees C max. (-) 6

Neutralization no, mg KOH/gm 0.2

Rust test (D-665A & B24 hrs.) Pass

Emulsion characteristics (D-140 minutes to
Complete separation) max. 25


11.0 MAINTENANCE:

11.1 Maintenance for HMC:

a) The governing system should be filled with turbine oil ISO-VG-46 or
equivalent. The oil quality should be regularly checked.

b) The oil should be regularly purified and quality checked. The oil filtration to be
better than 25 microns.

c) If the pressure of the oil supplied to the hydraulic amplifier (62) decreases by
more than 2 kg/cm2, the oil filter should be switched over, cleaned and washed.
When doing so, the filter should not be dismantled.

38





Depending upon condition of oil, the filter should be regularly switched over.
Make red and black pointers to coincide before switching the filter element.

The pan under the filter should be regularly cleaned of slime & dirt.

For switching and cleaning of filter refer filter drawing enclosed with this anual.

d) Throttle (54) is also provided with a small filter in the throttle housing itself
which should be regularly cleaned during shut downs (refer to drawing no.
42083949053).

e) After the first period of operation (20-30 days) and replacement of oil in the
governing system, filtering elements should be cleaned. Scrapers should be
dismantled and adjusted if they inadequately scrape the filtering elements.
Afterwards dismantling and cleaning of the filtering elements should be
performed once in two months. This should be done during shut- down.

f) All hinged and threaded movable joints should be lubricated once in two
months with oil.

g) Regularly check the availability of oil in the reduction gear of gate limiter (9).


h) Regularly check the governor cabinet indicators and the reading of the
duplicating instruments in the control room. Eliminate mismatching, if any.

i) Periodically check the governor for any surface leakages. Eliminate leakage, if
any, at once.

j) When changing over from automatic to manual control, turn hand wheel (10) to
closing direction till the red and the black pointers in indicator (11) come in to
coincidence, following which select solenoid to manual position.

k) When changing over from manual to automatic control give small signal
towards opening on balance-indicator by means of speed changer switch,
following which switch over automatic position.

l) Clean throttle (44) during shut down. Also check working of all limit switches
in HMC during shut down.


39






11.2 OIL MAINTENANCE:

Regular oil maintenance will prolong the life and the reliability of governor.
The oil should be regularly purified and quality checked. The oil filtration to be
better than 25 microns.

Only clean containers should be used for filling the governing system with oil.
Dirt, water or chemicals introduced in to the oil will contaminate the oil. Water,
even in small amounts, can contribute to early bearing failure or it can form
oxides, which cause failure of internal moving parts.

Formation of varnish on internal parts is an indication that operating
temperatures are too much on higher side. Varnish is an oil contaminant. It can
prevent free motion of small pistons and valves, which are machined to very
close tolerances.

Sludge formation in a governor is a complex mixture of water, carbon and
oxidized oil. It is a contaminant and not soluble in oil. Sludge is controlled by
changing oil more often or by changing the grade of oil.


CAUTION:

Once oil has been selected, do not use a different type or class oil. When
adding oil to the governing system, continue using the sane type or class of oil.
Mixing of two different grades of oil can form sludge, varnish etc, which will
affect the performance of governor. If the type or grade of oil needs to be
changed. Shut down the turbine, drain the complete oil from the governor
system, flush with the new oil selected & refills the system with new type of oil.

11.3 OIL CHANGE FREQUENCY:

Condition such as operating temperature, hostile environment (dirt, moisture, or
chemical contaminant) or anything that may change the composition of the oil
or shorten its useful life, must be taken in to account when determining the
frequency of oil changes.




40





The oil should be purified from time to time & sample should be sent to oil
supplier for checking the oil viscosity & any other changes in oil properties.
Decision to change oil should be taken in consultation with oil supplier after
checking the oil properties.

In general oil sample should be sent positively for checking if:

a) The oil looks different than when it was new.

b) The oil feels gritty when rubbed between fingers.

c) The oil smells different than when it was new.

d) The oil has been contaminated by water, sludge, varnish or any other
contaminates.

e) Excessive wear and tear of parts occurs.

f) Governor operating temperatures have change & affect oil viscosity.


Caution:

Reconditioned oil must not be used. Use new oil only supplied by reputed
companies.

12.0 STORAGE:

a) The hydro-mechanical cabinet and spare parts to be stored in their packing in
dry roofed premises, at air temperature not exceeding +50C. There should be
no harmful material in enclosure causing corrosion.

b) The term of storage in the manufactures packing is one year. When this time
expires, the governor and spare parts should be thoroughly inspected. The
surfaces with damaged corrosion proofing should be cleaned and a new
corrosion proofing should be applied (use fresh preserving grease).

Caution:

Do not store governor cabinet or spares in open yards.

41





13.0 LIST OF SPARES FOR PELTON GOV. HMC:

Following spares are recommended and supplied for governor hydro-
mechanical cabinet, per Power House, for trouble free operation of governor
cabinets. However the final list may slightly vary depending upon agreement
reached with project authorities.

S. No. Description Quantity
( Nos)

1. Pilot Valve sleeve & Needle sleeve assy. 2 set

2. Filter Elements (Duplex filter) 2 nos.

3. Membrane for EHT 2 No

4. 'O' Seal ring (6 nos. each type) 2 set

5. Internal circlips (six of each type) 2 set

6. Pressure Gauge 2 No.

7. Springs for G.V. Position /Limit Indicator 2 Nos.

8. Steel Wire ropes 2 set
(0.6 mm dia X 7 wires X 25 mtr long)

9. External circlips (Six of each type) 2 Set

10. Main slide valve sleeve & spool assy. 2 Set

11. Filter for throttle 2 No.

12. Sealing ring for Hydraulic Amplifier 2 No.

13. Electro hydraulic transducer assy. 2 No.

14. Limit switch for contact device 3 Nos.

15. Limit switch for over speed protection 3 Nos.

42





14.0 LIST OF REFERENCE DRAWINGS (FRANCIS)

1. Limits of stability for Governed Hydro set 32083949055

2. Hydro mechanical scheme of HMC for G.V. 02000016803 Rev.01

3. Installation of governor HMC for G.V. 02085016801 Rev02.

4. Hydraulic amplifier 12083949022

5. Electro Magnetic transducer 12083949023

6. Procedure for removal of transducer from 42083949017
Hydraulic amplifier

7. Auto manual changeover solenoid valve 42083949065

8. Main slide valve & pilot valve assy. (100) 02083949056

9. Governor opening closing time adjustment 42083949082

10. Emergency closing valve 22300449023

11. Hydraulic over speed valve 22300449010

12. Rotary Cam switch and pulley assembly 32083649006

13. Pressure reducer (Throttle) 42083949053

14. Gate position & limiter indicator (Transmitter) 12083949020

15. Contact device 22083949011

16. Reduction gear for gate limiter 12083949043

17. Installation of over speed protection device 22083980001
& Coincidence limit switch

18. Wiring scheme of hydro-mechanical cabinet 32083916801

19. Isolating valve 22083649051