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OWNER: CONSULTANT
VIETNAM ELECTRICITY
VINH TAN THERMAL POWER MANAGEMENT
: POWER ENGINEERING
CONSULTING J.S.C 2 (PECC2)
BOARD
EPC
CONTRACTOR: SHANGHAI ELECTRIC GROUP CO.,LTD.
COMPILE:
CHD POWER PLANT OPERATION CO.,LTD.
PROJECT: DESIGN STAGE:
VINH TAN 2 2×622MW THERMAL POWER Detail Design
CONTENTS
1.7.1 The major repair period of thermal control equipment is synchronous with major repair period of main
engine and the standard items of major repairs are as follows besides the standards of minor repairs:
1.7.1.1 Verification of all thermocouple and thermal resistance;
1.7.1.2 Verification of all special instruments and devices;
1.7.1.3 Verification of all pressure meters and differential pressure transmitters;
1.7.1.4 Verification of all pressure meters and thermometers;
1.7.1.5 Insulation inspection of all cables and compensating lines;
1.7.1.6 Leakproofness inspection of all pressure-containing members;
1.7.1.7 Inspection and verification of all sensors and pre-amplifiers of large and small crank shafts and system
transmission;
1.7.1.8 Verification of all the dial gauges;
1.7.1.9 Verification of all tachometers;
1.7.1.10 Program check of all programmed control system;
1.7.1.11 Static test of all regulator system; parameter setting and checking;
1.7.1.12 Linkage test of all equipment;
1.7.1.13 Site renovation of all equipment;
1.7.1.14 Verification of DCS system;
1.7.1.15 Verification of DEH, MEH system;
1.7.1.16 Verification of PLC system;
1.7.1.17 Hygiene sweeping of all equipments
2. Maintenance of primary equipment and control device (thermo technical measurement and
conventional instrument)
2.1 Maintenance rules on pressure switch
2.1.1 Overview
This section is to introduce the two-digit pressure switch produced by American SOR Company.
2.1.1.1 Technical specification
1) The model parameters of SOR are expressed as follows:
6---- NN---- K5---- M4---- CIA——— YY
Piston Enclosure Switch Diaphragm and pressure tap Annex
Element Spring specification O-ring
2) Switching error fixation: switching error is reached by basic error multiplying by a correction factor.
3) Switch element K-model
a. Single-pole switch element;
b. AC voltage class: 250VAC,15A;
c. DC voltage class: 30VDC,5A;
d. Working principle: sensing element of pressure switch: piston and spring pipe or corrugated pipe will
generate displacement when they bear pressure. When certain pressure value is reached, it will touch the
micro-switch to send contact signal for control or alarm.
2.1.2 Maintenance items and quality requirements
2.1.2.1 Appearance inspection: wiring shall be complete, marking shall be correct and complete and enclosure
shall be in good condition.
2.1.2.2 Switch disassembly: first disassemble the end cover, remove the wiring, mark it and bind with
insulating tape. Sample connection shall be blocked and sealed firmly.
2.1.2.3 Hygiene sweeping: external and internal switch shall be free of dust and sampling pipeline shall be
clean.
2.1.2.4 Switch calibration
1) Select suitable standard meter and calibration console.
2) Calibration steps:
a. Check the original value, which shall be true and accurate.
b. Check of pressure control range: adjust the set value to the maximum and booster slowly till the contact
acts; at this time, the pressure value on standard shall be the upper switching value of maximum value. Then
adjust the set value to the minimum, decompress slowly until the contact acts; at this time, the pressure value on
standard shall be the lower switching value of minimum value. The difference between upper switching value of
maximum value and lower switching value of minimum value shall be the pressure control range of switch and
the result shall conform to:
Pressure switch is (15~95) %× range
Vacuum switch: (95~15) %× range
c. Certification of set point error: adjust the set point to certain scale, booster slowly until contact acts and
the pressure value on standard shall be the upper switching value; then decompress slowly until the contact acts
and the pressure on standard shall be the lower switching value. Measure it by this method for three times and
the mid-value between average value of three-time upper switching value and lower switching value shall be the
switching mid-value. The percentage of the difference between switching mid-value and set point with range is
the set point error and the absolute value of the result shall not exceed the accuracy grade of switch.
d. Verification of switching error: when verifying the set value error, the difference value between average
value of upper switching value and average value of lower switching value at the same set point shall be the
switching error of switch and the value shall not be larger than 10% of range, unless it is specially specified by
manufacturer on switching error.
e. Verification of repeatability error: when verifying the set value error of controller, the percentage of the
larger one from the maximum difference value of upper switching value and lower switching value measured by
three times at the same verification point with range is the repeatability error of controller and the absolute
Regulations of Thermal Control and Maintenance
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
adopt PROFIBUS PA,FOUNDATION field bus and Modbus to protocol to send digital signal; it can be used for
far-end configuration and monitoring through software configuration.
2.4.1.2 Model of ABB 266 series transmitter
Pressure transmitter: 266GSH/266HSH
Differential pressure transmitter: 266DSH/266MSH(high hydrostatic pressure)
Liquid level transmitter: 266DDH(differential pressure) /266GDH&266HDH(pressure)
Far east tone transmitter: 266DRH(differential pressure) /266GRH&266HRH(pressure)
2.4.1.3 Technical performance and index
1) Object to be used: liquid, gas and steam.
2) Output: 4~20mA.
3) Power: 10.5VDC Maximum: 42VDC.
4) Load limit:
Total loop resistance under 4-20mA and HART conditions:
R(KΩ) =voltage-minimum working voltage (VDC)
22MA
At least 250Ωresistance is required for HART communication.
5) Output current limit
Overload condition: lower limit: 3.8mA (can be set within 3.8-4mA range)
Upper limit: 20.5mA (can be set within 20-21mA range)
Alarm current: lower limit: 3.6mA (can be set within 3.6-4mA range)
Upper limit: 21mA (can be set within 20-22mA range)
6) Temperature range: amplifier works within-20℃~/120℃.
7) Common-mode interference: it has no influence under the condition of 100Vrms@50HZ or 50V DC.
8) Precision: ±0.25% of adjustment range, including linear, variation and repeatability.
9) Stability: ±0.25% of URL during the ten-year trail period.
10) Power influence: the total effect shall be less than 0.005% of URL within specified voltage and load
limit range.
11) Opening time: Operate with the minimum damping within the longest 10s.
12) Migration of zero and range: zero and range can be adjusted as any value within limit range in the table,
but the premise is that calibration range shall be ≥minimum range.
2.4.1.4 Working principle
1) Working principle of measurement
ABB 266 series transmitter and pressure (differential pressure) transmitter voltage take voltage dependent
resistor as sensitive element. The measured pressure will be transferred to the measurement membrane of the
other side through isolation diaphragm so as to cause the voltage variation at both ends of resistor through the
change in position.
2) Transformational component
The function of transformational component is to transfer the change of capacity ratio to 4~20mADC
standard signal so as to realize zero, range, positive and negative migration and damping adjustment and other
functions. Switching circuit is composed of demodulator, zero setting circuit, range circuit, current control
amplifier, current limit circuit, reference voltage and so on.
Test
Current limiter
Oscillator +
Current
-
amplifier
Oscillation
amplifier Voltage rectifier
Current controller
hand-held adjuster and it will display “ENABLE”, press “ENTER” key twice to confirm that import transmitter
has been set as “Allow” before delivery. Use “一 ”character screwdriver to rotate the zero adjustment bolt on
enclosure of transmitter. For clockwise adjustment, output will be increased, or it will be decreased. The
precision of zero adjustment value can be 0.01% of range.
The display of zero adjustment can also be selected A10: OUTPUT% 0.0% display from hand-held adjuster
parameter and millammeter at this time will be 4mA.
Note: Do not disconnect power within 30s after zero adjustment, or zero will restore the original value.
2) Zero adjustment by hand-held adjuster:
When the lower limit pressure of transmitter is 0:
a. Search “J10:ZERO ADJ” parameter item and press “ENTER” key for twice, the zero at this time will
be adjusted to 0% automatically and signal output is 4MADC.
b. Press F4 key after zero adjustment is finished.
c. Select the parameter item A10: OUT PUT (%) and the display value is 0.0%.
When the lower limit pressure of transmitter is not 0, calculate the corresponding reference value with
actual measurement range, i.e. percentage of actual measurement value. Calculate by following formula:
Percentage of actual value= [(Actual value-lower limit) ÷ (upper limit-lower limit)]%
a. Input the zero pressure value of transmitter and the output of transmitter is X% of some value:
A10.OUTPUT (%) displays X%
b. Parameter option selects J10:ZERO A D J 0.0% and input the actual value percentage below. Pay
attention to input the plus-minus sign of percentage and confirm by pressing “ENTER” key for twice and the
output A10: OUTPUT (%) will be Y% of actual value output.
Due to the deviation between output and input parameter when adding pressure value, error correction
shall be taken.
Output error of this time=Y%-X%.
Select parameter optionJ11: ZERO and DEV will display Z%, which is the corrected value of previous
time.
Corrected value of this time= corrected value of previous time + output error (Y%-X%).
Input the corrected value of this time under J11: ZERO DEV option, press “ENTER” key for twice to finish
zero setting.
2.4.2.6 Verification
When verifying pressure (differential pressure) transmitter, the verification point shall not be less than 5 points:
including zero point and range and common points. After verification, check whether calculation results
conform to requirements. Fill in verification report if it is qualified and re-adjust it till it is qualified if it is
disqualified.
2.4.2.7 Start/stop steps of transmitter
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
of general bimetal thermometer, which can adjust the angle of deflection of header within 90 degrees according
to user’s requirements to simplify type selection conditions. It adopts stainless steel housing protection, which
has strong resistance to corrosion. It is suitable for all kinds of environment and it is one of the general forms in
domestic and international today.
2.5.1.2 Technical index
Temperature measurement range : -80℃ ~ 500℃
Accuracy grade: 1.0grade, 1.5grade
Thermal response time :≤ 40S
Nominal pressure: ≤ 3MPa
Diameter of protective tube : ∮6、∮8、∮10
Diameter of header :∮120mm ( 100mm )
Placement depth:( 75 ~ 500 ) mm
Adjustable angle of header : 90°
Operating environmental condition of header:-20℃ ~ 60℃
2.5.1.3 Working principle
Bimetal thermometer temperature-sensing element adopts multi-turn straight spiral bimetallic strips with
one end fixed and another end connecting central spindle freely. Axial direction type thermometer indicator is
directly installed in central spindle (radial direction structure indicator is connected with central spindle through
corner spring) ; when temperature changes, temperature-sensing element free end will rotate and rotate indicator
of radial and central spindle will indicate the change value of measured medium temperature on scale.
The temperature measurement principle of WSS angle adjustable bimetal thermometer is the same as
general bimetal thermometer. It adopts flexible connection way in structure to connect protective tube and
header so that header may rotate along axial direction to adjust the angle of deflection of header. Meanwhile,
dial plate adopts adjustable structure, which can rotate 360°along with axis to adjust the temperature indicator
deviation.
2.5.2 Maintenance items and quality requirements
2.5.2.1 Appearance inspection
1) All parts of thermometer shall be free of corrosion and protective layer shall be firm, uniform and smooth.
2) Glass and other transparent materials used for the surface of thermometer shall be transparent without
defects or damage hindering correct reading.
3) Scale, figure or other marks on thermometer surface shall be complete, clear and correct.
4) The distance between indicator and dial face shall not be larger than 5mm, but it shall not contact dial face.
2.5.2.2 Adjustment items and technical standards
1) Equipment to be verified:
Standard: second-class mercurial thermometer
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
Corollary equipment: freezing point groove, oil groove and reading glass (5-10) times
2) Verification methods:
Thermal bulb of thermometer must be immersed completely and the immersion length of protective tube
shall not be less than 75mm, nor shall it be larger than 500mm.
a. Verification sequence: the verification of thermometer shall be conducted on positive and negative
travels to upper limit or lower limit direction respectively point by point; measurement of upper limit and lower
limit is only verified on one-stroke.
b. Reading method: when reading measured thermometer indicating value, the sight shall be vertical to dial
plate; when using reading glass, the sight shall pass through the center of glass and the reading shall be
estimated to 1/10 of division value.
c. Zero verification: insert the temperature detection element of thermometer into freezing point groove of
ice and water mixture and take reading after indicating value is stable.
d. Verification of other points: insert the thermometer into thermostatic bath and take reading after
indicating value is stable. When reading, groove temperature deviation verification point temperature shall not
exceed +2℃(standard thermometer shall prevail) , record the indicating value of positive and negative travel of
standard thermometer and measured thermometer. During reading process, groove temperature change shall not
be larger than 0.1℃ (when groove temperature exceeds 300℃ and above, the groove temperature change shall
not be larger than 0.5℃).
e. Error calculation of measured thermometer:
Actual temperature of thermostatic bath=indicating value of standard thermometer + corrected value of this
thermometer
Measured thermometer error=indicating value of measured thermometer – actual temperature of
thermostatic bath
The error shall conform to the requirements in table below:
1.0 +1.0
1.5 +1.5
2.5 +2.5
Hysterisis error of thermometer shall not be larger than the absolute value of allowable error.
The repeatability of thermometer shall not be larger than 1/2 of absolute value of allowable error.
f. Fill in verification record.
2.5.2.3 Content of operating maintenance
Hygiene sweeping: disc inspection, gauge reading inspection and instrument appearance inspection.
2.6 Maintenance rules on thermocouple
2.6.1 Overview
Thermocouple is one of the common temperature-sensing elements in industry. It converts the temperature
signal into thermal electromotive force and equipped with display instrument and transmitter to realize the
measurement and signal conversion of temperature.
Thermocouple model can be classified into K graduation (nickel-chromium---nisiloy) and E graduation
(nickel-chromium---constantan) .
2.6.1.1 Technical requirements: See Table (I)
Range of
Name of thermocouple Grade Allowable error
application( ℃)
0~400 ±1.6℃
Ⅰ
400~1100 ±0.4%t
Nickel-chromium---nisiloy
0~400 ±3℃
Ⅱ
400~1300 ±0.75%t
Ⅰ -40~800 ±1.5℃ or ±0.4%t
Nickel-chromium---constantan Ⅱ -40~900 ±2.5℃ or ±0.75%t
Ⅲ -200~40 ±2.5℃ or ±1.5%t
Ⅰ -40~350 ±0.5℃ or ±0.4%t
Copper- constantan Ⅱ -40~350 ±1℃ or ±0.75%t
Ⅲ -200~40 ±1℃ or ±1.5%t
(Table I)
The allowable error of thermoelectromotive force of thermocouple (within specified temperature range,
when reference end temperature is 0 ℃ ) shall conform to the provisions in Table I when it is indicating by
temperature value.
2.6.1.2 Working principle
Temperature measurement principle of thermocouple is the physical phenomenon based on the condition
that two conductors with different components connect into loop and it will generate thermal electromotive
force in loop if the temperature of two connection points is different. Conductor of different component will
constitute the two electrodes of thermocouple. The bigger the temperature difference of two joints is, the bigger
the thermal electromotive force is. The three basic principles of thermocouple are: conductor homogeneous law,
middle conductor law and medium temperature law.
A电极
Electrode A
t0 t1
t0 I
B电极
Electrode B
every test point of every tested thermocouple as well as the temperature error.
i. The time for temperature rise, constant temperature and verification of every test point shall be about
30min.
j. Temperature test of furnace for verification can be taken.
Working process: connect system wiring according to the tested object requirements, then determine the
calibration method (select the integer hundred degree or fixed point of thermometric scale with calibration key)
according to type selection key (corresponding to thermocouple type) , then input necessary parameters through
keyboard, press RUN key and device will start automatic verification of work condition. Calibrating apparatus
will firstly print the input parameters for calibrator for verification, then the temperature will automatically rise
to the first preset calibration point. After the temperature field is stable, take tour sampling by the sequence of
from the first point to the fifth point and the fifth point to the first point, calculate and print the verification
result of this point, then temperature will rise automatically to the second verification point for calibration and
print until the last verification point is printed. At this time, the display of calibrating apparatus will display:
“END” and send out audio alarm and the calibrating furnace power will be disconnected automatically after a
period of time.
2.6.2.3 Instrument for verifying thermocouple
1) Standard:
a. A first-class and second-class standard Pt-Rh 10-Pt thermocouple respectively.
b. A set of standard mercury thermometer with measurement range of —30 ~ 300 ℃ ; or second-class
standard platinum resistance thermometer can be selected.
2) Instrument and equipment:
a. Reference thermostat: the interior temperature of thermostate shall be (±0.1℃) .
b. Oil thermostatic bath: the temperature difference within effective working area shall be less than 0.2℃.
c. The maximum temperature of tube furnace shall be 1200 ℃ ; the deviation between the maximum
uniform thermal field center and furnace geometric center along axis shall not be larger than 10mm; the
temperature difference between any two points within the scope of uniform thermal field length not less than
60mm and radius of 14mm shall not be larger than 1℃.
d. Reading telescope or 3-5 times magnifier.
2.6.2.4 Verify the wiring diagram
Constant
恒温炉
temperature
furnace
Calibrating
检定仪
apparatus
冰 点 point
Freezing 槽 groove
Calibrated
被 检 11 被检2 2
Calibrated
2.6.5.3 Inspection and test of compensating lead wire and measurement circuit.
2.6.5.4 Element verification.
2.7 Maintenance rules on thermal resistance
2.7.1 Overview
2.7.1.1 Temperature measurement principle
Thermal resistance is the common temperature measurer used in power plant. The frequently used are
platinum thermistor and copper thermal resistance such as Pt100, Cu50 and Cu100, with usage range of -200~
+850 ℃ . Industrial platinum and copper thermal resistance is to measure the temperature by utilizing the
temperature variation of metallic resistance value.
2.7.1.2 Composition of thermal resistance
Thermal resistance is classified into common industrial thermal resistance and sheathed thermoresistor by
outline structure. The majority in our plant is sheathed thermoresistor. It is composed of temperature-sensing
element, metallic sheath, metallic lead, insulating materials and junction box.
2.7.1.3 Technical requirements f thermal
1) The appearance of assembly quality of thermal resistance shall conform to the following requirements:
a. All part assembly shall be correct, reliable without defect parts.
b. It shall be free of open circuit or short circuit.
c. Skeleton of thermal resistance shall be free of crackle and significant bend.
d. Protective tube shall be complete without damage and shall be free of dent, scratch and obvious
corrosion.
e. Surface coating shall be firm.
f. Thermal resistance shall have nameplate with the following marks: manufacturer name or emblem mark,
thermal resistance model, graduation number, allowable deviation grade, applicable temperature range,
ex-factory date and ex-factory number.
2) When environmental temperature is (15 ~ 35) ℃ and relative humidity is not larger than 80%, the
insulation resistance between temperature-sensing element of platinum thermistor and protective tube and
several temperature-sensing elements shall not be less than 100MΩ; copper thermal resistance shall not be less
than 20MΩ.
3) See Table 1 for the allowable deviation Et of actual resistance value of thermal resistance and graduation
nominal resistance represented by temperature:
Table 1:
Graduation
Name of thermal resistance Nominal resistance at 0℃ Et(℃)
number
Pt10 10
Platinum A-class ±(0.15+0.002|t|)
Pt100 100
thermistor
B-class Pt10 10 ±(0.30+0.005|t|)
Regulations of Thermal Control and Maintenance
26
Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
Pt100 100
Cu50 50
Copper thermal resistance ±(0.30+0.006|t|)
Cu100 100
Note: (1) |t| in Table 1 refers to the absolute value of temperature by degree centigrade.
(2) A-class allowable deviation is not applicable to the platinum thermistor adopting two-wire system.
(3) For platinum thermistor with R。=100.00R, the A-class allowable deviation is not applicable to t>
650℃ temperature range.
(4) Verification of two-wire system thermal resistance tolerance, including the resistance of internal lead,
if only temperature-sensing elements need to be taken deviation verification, manufacturer shall provide the
internal lead resistance.
4) The resistance ratio of thermal resistance between 100℃ and 0℃ is called resistance purity W100 and
see Table 2 for the allowable deviationΔWˊ100of nominal resistance ratio of W100.
5) New platinum thermistor shall be sufficiently stable. After upper and lower temperature endure 250h, the
conversion of resistance variation at 0℃ into temperature value shall not exceed the provisions in Table 3.
6) New platinum thermal resistance shall conform to the technical requirements of this regulation; thermal
resistance after repair and in service shall conform to the requirements of a, b, c, f clauses in Article I and
Article IV of this regulation.
Table 2:
Name of thermal resistance ΔWˊ100 ΔW100
Grade A ±0.0006
Platinum thermistor 1.3850
Grade B ±0.0012
Copper thermal resistance 1.428 ±0.002
Table 3:
Allowable deviation class Allowable variation
A 0.15
B 0.30
another conductor of binding post of megger shall be connected on protective sleeve of thermal resistance.
b. Requirements of insulation resistance of thermal resistance:
The insulation resistance between platinum resistance temperature-sensing element and protective sleeve
shall not be less than 100MΩ;
The insulation resistance between copper resistance temperature-sensing element and protective sleeve
shall not be less than 20MΩ;
The insulation resistance of thermal resistance input end to ground shall not be less than 40 MΩ;
The insulation resistance of thermal resistance input end to power supply shall not be less than 20 MΩ;
The insulation resistance of power supply end to ground shall not be less than 20 MΩ
2.7.2.2 Standard and equipment for verifying thermal resistance
1) Second-class platinum resistance thermometer. For verifying copper thermal resistance, second-class
standard mercurial thermometer can also be taken.
2) The following auxiliary equipment can be selected according to different electric measurement
equipment: one 0.01 class 10Ωand 100Ωstandard resistance respectively.
3) Freezing point groove.
4) Water thermostatic bath or oil thermostatic bath, which shall conform to following technical
requirements:
The maximum temperature difference between water thermostatic bath jack shall not be larger than 0.01℃;
the vertical temperature difference in working area of oil thermostatic bath shall not be larger than 0.02℃ and
horizontal temperature difference shall not be larger than 0.01℃.
5) 100V megger.
6) Automatic calibrating apparatus of thermal resistance.
For verification, insert the thermal resistance with glass test tube into medium and the insertion depth of
test tube shall not be less than 300mm. When measuring the resistance of thermal resistance at 100 ℃ , the
temperature deviation of oil thermostatic bath at 100℃ shall not be larger than 2℃; temperature variation shall
not exceed 0.04℃ every 10 min.
2.7.2.3 Verification of thermal resistance
1) Automatic verification block diagram:
Verified
被校
Furnace for
检定炉
verification Subtracte
减法器 Recorder
记录仪 Regulator
调节器
use
Standard
标准
Function
函数
generator
发生器
Program
程序控制器
controller
2) Principle
During verification process, the function of program controller is to make the whole inspection process
conduct automatically by the preset program. It includes temperature rise indicator, constant temperature time
controller and record controller three parts. Indicator is to control the temperature rise process and gives out
signal when it reaches verification point temperature—constant temperature indicator will give out signal when
it reaches provisions—record controller will give out signal when it reaches provisions—circulation till the
program is over and record controller will give out signal to cut off power automatically.
3) Technical requirements of automatic calibrating apparatus
a. After oil groove reaches verification point, the temperature fluctuation shall be less than 0.2 ℃ /min
during measurement and record process.
b. The accuracy of instruments for automatic measurement and automatic record shall be the same with the
accuracy of 0.05 level (level 0.02) DC low potential potentiometer.
c. It shall have automatic protective device, such as automatic alarm, automatic cut-off power device.
d. The time for verification point temperature rise, constant temperature and verification is about 30min.
4) Working process
Connect the system wiring according to the requirements (two-wire system and three-wire system) of
tested object (thermal resistance) , then determine the calibration way according to the type option key
(corresponding to resistance type) , then input necessary parameters through keyboard and press the RUN key,
the device will start automatic inspection to work conditions.
Calibrating apparatus will firstly print the input parameter for verifiers for verification. For the verification
of resistance at 0 ℃ , use freezing point groove (ice flowers shall conform to requirements) . After the
temperature field is stable, take tour sampling by the sequence of from the first point to the N point and the N
point to the first point, then temperature will rise automatically to the 100℃ verification point for calibration
and print. At this time, the display of calibrating apparatus will display: “END” and send out audio alarm and
the calibrating furnace power will be disconnected automatically after a period of time.
2.7.2.4 Analysis and handling of common fault causes of temperature-sensing elements of thermal resistance
Structural style
Case diameter
Case diameter specification: 40, 60, 100, 150, 160, 200 and 250mm.
Structural style: null-radial direction without boundary; ZT-axial direction without boundary; T-radial
direction with boundary; Z-axial direction without boundary
2.8.1.2 Principle
Bourdon tube is also called bourdon tube, which is a hollow thin walled tube with cross section as ellipse
or oblate. The open end of bourdon tube is fixed on instrument joint socket, which is called fixed end. Pressure
signal is led in bourdon tube by joint socket and another end blocked, which is called free end. After measured
pressure is led in burden tube, free end will generate corresponding displacement, which will transmit to
amplifying structure of instrument through connecting rod. Bourdon tube will generate elastic deformation
according to Hooke's law, i.e. tubular elastic component and the size of deformation will form proportional
relation with the size of pressure within certain elastic range and thus forms bourdon tub pressure gauge.
Single coil bourdon gauge is classified into pressure gauge vacuum meter and pressure vacuum meter
III-class according to pressure measurement range, mainly including bourdon tube, transmission amplifying
structure, indicating mechanism and enclosure.
Regulations of Thermal Control and Maintenance
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
When pressure is led to bourdon tube, the free end 5 of bourdon tube will generate displacement and this
displacement will drive sector gear 7 to rotate by connecting rod 6 so that pinion 8 meshed with 7 will rotate
and indicator 9 fixed on pinion shaft will rotate also to take pressure value indication. One end of balance spring
is fixed with pinion shaft and another end fixed on support. By virtue of the elastic force of balance spring,
pinion only has one side occlusal surface with sector gear for occlusion, thus the measurement error between
sector gear and pinion due to occlusion interval face will be eliminated.
Sector gear has open slot at the end where is connected with pull rod to change the connection position
between pull rod and sector gear, which can change the transmission ratio of transmission mechanism. If R is to
show the radius of sector gear,, r is the distance between sector gear and pull rod connection point, under the
condition that bourdon tube free end displacement is the same, the larger than R/r ratio, the bigger the pointer
travel is. Therefore the change of R/r ratio can change the transmission amplification coefficient of instrument
so as to realize the adjustment of range full scale.
2.8.1.3 Technical index
Grade: precision pressure gauge: 0.2, 0.25, 0.35, and 0.5.
General pressure gauge: 1.0, 1.5, 2.5.
Instrument environmental temperature: 0.16 level: 20±2℃
0.25~0.5 level: 20±3℃
0~4.0 level: 20±5℃.
2.8.2 Maintenance items and quality requirements
2.8.2.1 General inspection
1) Appearance inspection: check whether bourdon gauge enclosure is complete without dust.
2) Hardware and mechanical part inspection
a. Instrument interior shall be clean and component and wire shall be aligned orderly; screw, nut and gasket
for fixing all components shall be complete and firm.
b. Instrument indicator shall be free of skew, blocking and bounce and the needle point shall have obvious
color.
c. The length of needle point shall cover 1/4 to 1/3 of the shortest reference line and the width shall not
exceed 1/5 of the minimum scale spacing.
d. Balance spring shall be uniform in circle distance, concentric and flat, spotless and damage-free. If
balance spring is slightly deformed, rectify it by tweezers. If it is significantly deformed, replace it.
e. If there is burr in pressure gauge sun gear or sector gear, polish it by needle file or emery cloth. If sun
gear is slightly worn, rotate to another angle for polishing.
f. Sun gear and sector gear shall be bright, flat and axle upper and lower part shall be smooth and straight.
Wheel shall be vertical to shaft.
g. The interval between sun gear and sector shaft as well as splint mating hole shall subject to not
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exceeding 10 degrees of the angle of inclination in splint. If it exceeds 10 degrees, the mating interval is too big,
which shall be shrunk the cavity by punch or inserted bushing.
h. Bourdon tube shall be free of loophole or rent, or repair it or abandon it.
2.8.2.2 Adjustment items and verification standards
1) Verification of bourdon gauge
a. Bourdon gauge shall be taken leakage test. Pressurize to 1.25 times of full scale and withstand voltage
for 5 min, it shall have no significant influence to indicating value.
b. Zero indicating value shall conform to requirements. Pressure gauge with zero limit, and the pointer
shall adjoin on limit nail. “Indentation” shall not exceed the absolute value of maximum allowable intrinsic
error. Zero reference line shall not exceed twice of the absolute value of maximum allowable intrinsic error.
c. Verification of pressure indicating value shall be taken by reference line marked with figure and boost
(or vacuum) gradually for verification. When indicating value reaches the upper limit of measurement,
withstand the pressure for 3min. The difference of indicating value before and after tapping case and standard
shall not exceed 1/2 of the absolute value of maximum allowable intrinsic error.
d. During the lifting process of instrument, check whether indicating value is changed and whether pointer
has bouncing and dull phenomenon.
e. In case of error during verification, pointer adjustment method, sector gear and connecting rod
adjustment method, rotating bottom plate adjustment method, balance spring moment adjustment method,
connecting rod length adjustment method can be adopted to adjust error.
2) Verification results or verification period
a. Pre-seal or issue qualification certificate to pressure gauge after qualification and issue qualification
certificate also for sealing when necessary.
b. Pressure gauge that is disqualified is allowed to be used by degradation, but the accuracy grade mark
must be changed.
c. The verification period of pressure gauge can be determined according to specific condition, which
generally shall not exceed half a year.
2.8.2.3 Commissioning and operating maintenance of bourdon gauge
1) When commissioning bourdon gauge, the sequence is to open the primary gate first and then open the
secondary gate.
2) Operating maintenance
a. Primary and secondary gate shall rotate flexibly without leakage.
b. Instrument case shall be complete without damage and pointer shall be free of jam.
c. Sampling tube shall be free of cracks and deformation.
d. The hand wheels of all primary and secondary gates shall be complete without damage.
2.8.2.4 Major repair and minor repair items of bourdon gauge
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1) Hygiene sweeping in inside of pressure gauge: internal and external hygiene shall be clean without oil
and dust.
2) Disconnect the case and check whether sector gear, center shaft and all parts are complete.
3) Determine the volume of migration according to installation position and take migration.
4) Check the rear pipeline of primary gate and eliminate the defects.
5) Check the secondary gate and eliminate the defects.
2.9 Maintenance rules on UHZ
2.9.1 Overview
2.9.1.1 Working principle
Take side mount UHZ as example, it is composed of liquid meter cavity, columnar floater, magnetism
platform trap door and transmitter and alarm switch selected by user.
Liquid meter cavity can be taken as part of pressure vessel, which is connected with pressure vessel
through up and lower side flange. Thus the liquid level change in liquid meter cavity will be consistent with the
change of actual liquid level in pressure vessel. Liquid level signal is transmitted through the magnetic field
generated by magnet of columnar floater liquid meter cavity.
Magnetism platform trap door displays the liquid level, in which the red and white beads are arranged
uniformly in aluminium slot. When liquid level rises, the magnet in red and white bead is influenced by the
magnet in floater and drive bead to turn to red from white gradually from down to up. Similarly, when liquid
level drops, beads will turn to white from red gradually from up to down so that no power is needed to display
the change of liquid level in pressure vessel.
Transmitter or alarm switch is converted to standard 4~20mA current output signal or relay output signal
through the magnetic field generated by floater magnet and the change of actual liquid level of sampling.
Transmitter is mainly composed of resistance, reed switch and transmission module. When liquid level
drives floater to change from up to down, the magnetic field generated by floater magnet will cause the
actuation of reed switch uniformly arranged so as to decide the size of loop resistance of series resistor. It also
output 4~20mA current signal through the conversion of transmission module.
Alarm switch is mainly composed of reed switch and magnet. When liquid level drives floater to change
from up to down, the magnetic field generated by floater magnet will cause the actuation or release of reed
switch at corresponding position so as to output relay signal. The magnet of alarm switch makes the relay signal
output by magnet of alarm switch keep function.
2.9.1.2 Characteristics of instrument
1) The structure if simple, which can display the liquid level intuitively.
2) Reliable and durable, needing no special maintenance.
3) No power is needed for the operation of display unit and alarm switch.
4) It is not influenced by the high temperature, easy flow, combustible and toxicity and other factors of
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tested liquid.
5) It can be used in high temperature and high voltage environment.
6) Corrosion resistance is strong, applicable to most of corrosive liquid.
7) It is applicable to the most of low-density liquid.
2.9.1.3 Technical parameters
Measuring distance: 0.3~10m
Accuracy: ±10mm
Pillar diameter: 10mm
Working pressure: 1.6MPa High pressure type≤4.0MPa
UPVC≤1.0MPa
Working temperature:-20℃~150℃ High temperature type:≤350℃
UPVC:-20℃~60℃
Medium density:≥0.45g/cm3
2.9.1.4 Output calibration of transmitter
1) Connect wire according to the wiring diagram of transmitter and pay attention to the positive and
negative of 24V power.
2) Flow in water slowly to make beads turn to zero of scale plate precisely (or low position preset by user)
and adjust the zero potentiometer to make the current output value as 4mA.
3) Flow in water slowly to make beads turn to full scale of scale plate precisely (or full scale preset by user)
and adjust the full scale potentiometer to make the current output value as 4mA.
4) Repeat the (2) and (3) step till the current output is accurate.
Note: Before delivery, transmitter has been strictly calibrated according to the zero and full scale of scale
plate. If user wants to calibrate extra, calibrate it for 2-3 times.
2.9.2 Maintenance items and quality standards
2.9.2.1 General inspection
1) Instrument appearance inspection: enclosure shall be complete without damage and dust.
2) Instrument signboard shall be clear in character, correct and complete.
3) Instrument terminal block inspection: screw and gasket shall be free of defect and dust.
2.9.2.2 Interior inspection of instrument
1) Disassemble the case and the interior shall be free of dust.
2) Interior elements of instrument shall be free of cold solder joint and desoldering.
3) Components shall be arranged in alignment without bend or deformation.
2.10 Maintenance rules on intelligent flow meter
2.10.1 Overview
Programmable flow totalizer is used to measure the parameters of starting boiler feed water and steam flow.
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By adopting single chip microprocessor, it has high reliability, excellent stability and multiple application
functions, which can satisfy the measurement display of common industrial parameters.
2.10.1.1 Characteristics
1) It can display integer four-digit flow measurement value (0~9999 digit) ; can display integer ten-digit
flow accumulative measurement value (0~9999999999) ; can correct to three digits after decimal point (0.001)
for accumulation.
2) It adopts look-up table for calculation and take integrating control to superheated steam and saturated
steam.
3) High brightness LED display or large screen Chinese with backlight LCD liquid crystal display can be
selected to display the current measurement value.
Optoelectronic isolation
Transmis
sion
Optoelectronic output
isolation
Microprocessor Optoelectronic
isolation Switch
output
A / D converter
Channel switch
Analog input
Optoelectronic
isolation Commu
nication
Panel interface
settings
The principle block diagram of this instrument is as shown above. This integrating instrument is based on
single chip processor and converts all analog signals to digital signals by A/D converter through input signal.
Microprocessor displays the measured parameter value after comparison with sampling result and preset content
of digit.
Input signal:4~20mA
Accuracy: 0.2%FS± 1 digit or 0.5%FS±1 digit.
Display mode:0~9999 instantaneous flow rate measured value display;
0~999999999 aggregate-value.
Type of alarm: upper limit and lower limit alarm output of relay can be selected and LED alarm indication.
Type of setting: panel of touch key figure setting. Set value outage permanent retention. Parameter set
value is locked by password.
Protection mode: under voltage program reset automatically and working abnormal program reset
automatically; outage flow accumulated value keeping time is longer than two years; set parameter permanent
retention.
Operating environment:
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Environment temperature:0~50℃
Relative humidity: ≤85RH
Supply voltage:AC220V+10~15%,50HZ±2HZ
Power consumption: ≤ 5W(220VAC power supply).
2.10.2 Maintenance items and quality standards
2.10.2.1 General inspection
1) Instrument appearance inspection: enclosure shall be complete without damage and dust.
2) Instrument signboard shall be clear in character, correct and complete.
3) Instrument terminal block inspection: screw and gasket shall be free of defect and dust.
2.10.1.2 Interior inspection of instrument
1) Disassemble the case and the interior shall be free of dust.
2) Interior elements of instrument shall be free of cold solder joint and desoldering.
3) Components shall be arranged in alignment without bend or deformation.
2.10.1.3 Nuclear test of instrument
1) Connect wire according to the figure below:
+
+ 220VAC
24VDC
Transmitter
generator
Pressure
1.220 V AC
22
+
mA
Input
2) Take POST (power on self test) for instrument and preheat for 10min.
3) After self-test is correct, it will turn to working condition automatically.
4) Add the differential pressure of another point and adjust the transmitter of another point; mA meter
indicator lamp shall display 4mA, instrument indication shall be 0, or adjust the instrument to another position.
5) Add range value and adjust the transmitter range screw; mA meter indicator lamp shall display 20mA
and instrument indication shall display full scale, or adjust the instrument range.
6) Respectively add signal and verify the middle contact indicating value. All contact indicating values
shall be within allowable error scope (calculate the allowable error according to the range and accuracy of
meter) .
7) Fill in verification report
2.10.3 Common faults and maintenance of instrument
2.10.3.1 Instrument indication is not correct.
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Probe sends ultrasonic pulse signal to material surface direction and material surface will reflect echo and
this part of echo will be received by probe.
Transmitter will calculate the time difference between probe sending and receiving ultrasonic pulse signal.
The distance between probe working surface and material surface can be calculated by running time and sound
velocity:
D=c t/2
The values of the following measurements under ideal condition can be calculated through calculating the
given value:
Material level: L
Volume: V
Quantity of material through measurement weir or open channel: Q
2.11.2 Technical parameter
Type:UWB-AAKA1
Supply voltage:115/230VAC 50/60HZ
Power consumption:30W
Working temperature:-49℃-149℃
Figure 2
Field control
Clockwise rotate the red option rotary knob to site position and respectively rotate the back rotary knobs to
ON and OFF position. Anticlockwise rotate the red rotary knob to stop operation.
Remote control
Anticlockwise rotate the red selector rotary knob to remote position and the signal control value of remote
control determines the position of valve. Then clockwise rotate the red option rotary knob to stop the actuator
from operating.
3.1.5.1 Display of actuator
1) Valve position indication
Figure 4.1
Full open is indicated by red indicator light and open signal.
Figure 4.2
Travel middle is indicated by yellow indicator light and percentage open value.
Figure 4.3
All-off is indicated by green indicator light and close symbol.
After main power supply is closed, LCD is supplier power by battery to continue displaying the valve
position of actuator. No matter what condition it is, battery will not supply power to background light and valve
indicator light.
2) Running status indication
Running status indication is classified into normal running status indication and alarm status indication.
a. Normal running status indication
Normal running status indication: upper screen will display the working condition of actuator and the
lower screen will display the input control signal.
Normal running status indication is as shown in figure below:
Valve-opening is running
Valve-opening is running
Over-moment alarm
Valve blocking alarm
Over-moment alarm indication is as shown in figure below:
Figure 6.1
Figure 6.2
Figure 6.3
During operating process of actuator, if the detected moment value has exceeded the maximum moment set
value on this operating direction, take moment jumping protection and the electric operation on this direction
will be static. Close direction over moment is as shown in Figure 6.1; open direction over moment is as shown
in Figure 6.2; full direction over moment is as shown in Figure 6.3. If actuator operates along the opposite
direction, alarm indication can be eliminated. If moment set needs to be changed, disassemble the moment
control hood and reset.
Valve blocking alarm is as shown in figure below:
Control alarm
Emergency
Control alarm
Interrupt signal
Actuator alarm
Motor trips due to over temperature
Figure 10
When motor temperature exceeds the limiting temperature, alarm will display to prohibit electric operation.
When motor temperature reduces to limiting temperature, alarm display will disappear.
Low battery alarm
Actuator alarm
Low battery
Figure 11
When actuator detects low battery during self-inspection, alarm will display. After battery is replaced,
alarm display will disappear.
Internal power failure alarm
Actuator alarm
Internal power failure
Figure 12
When actuator detects internal power failure during AC self-inspection, alarm will display.
Power default phase alarm
Actuator alarm
Power default phase
Figure 13
When actuator system detects power default phase during connecting power, or during operation of
actuator, it will send the order to cut off the power of motor and alarm will display. Alarm will not disappear
until actuator detects the normal power.
Internal system fault alarm of actuator
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Actuator alarm
Internal system fault
Figure 14
When actuator detects the fault existed by system itself during self-inspection process, alarm will display
and electric operation will be prohibited.
Valve position signal loss alarm
Actuator alarm
Valve position signal loss
Figure 15
When valve position in control system is disconnected or not connected which has caused valve position
signal loss, alarm will display and electric operation will be prohibited. When actuator control system
re-receives effective valve position signal, alarm will be relieved.
Local wiring fault alarm
Actuator alarm
Local wiring fault
Figure 16
When system panel wiring is fallen, alarm will display.
This actuator used non-intrusive setting, that is, it’s not necessary to open electric end cap for debugging
after wiring is finished. The setting of moment, travel and other functions can be realized by using infrared
remote controller. Controller can be debugged with power within dangerous area after authentication of intrinsic
safety type.
All setting functions can be stored in memory of actuator. All functional parameters of actuator can be set
and modified through remote controller and all function and parameter set values can be found on display
screen. When necessary, it can be changed through remote controller. All parameters and functions have default
settings for ex-factory inspection.
Pneumatic actuator is applied in deaerator water level control, shaft seal pressure control, high and low
pressure heater drain control, soot blowing and steam pressure control.
3.2.2 Maintenance items and quality requirements
3.2.2.1 General inspection
1) Appearance inspection:
Check whether appearance of actuator is free of obvious damage; whether air supply pipeline is free of
leakage; whether air supply pipeline direction is straight and free of flattening; whether pressure gauge is
damaged; whether pneumatic convertor and reducing valve is in good sealing; whether air supply pipe is flowed
and all accessories are firm.
Insulation test:
a. Solenoid valve ground insulation shall be ≥20MΩ.
b. Insulation between cable phases shall be ≥20MΩ and ground insulation shall be 50MΩ.
3) Take solenoid valve winding DC resistance test and resistance shall conform to the requirements of all
equipment specifications.
4) Hygiene sweeping:
a. Reducing valve shall be removed the sewage, which shall be thorough and clean.
b. Clear pneumatic convertor, valve positioned and the dirt in reducing valve.
3.2.2.2 Adjustment item and technical standard
1) Adjustment of pneumatic converter (take direct action as example) :
a. Input 4mADC signal and observe whether output is 0.02Mpa. If it is not, adjust ZERO rotary knob to
make output pressure as 0.02Mpa.
b. Input 20mADC signal and observe whether output is 0.1Mpa. If it is not, adjust SPAN rotary knob to
make output pressure as 0.1Mpa.
c. Repeat the above steps till when inputting 4mA and 20mA, output is 0.02Mpa and 0.1Mpa.
2) Adjustment of positioned (take fisher direct action, input signal 0.02~0.1 Mpa as example) :
a. Input 0.02Mpa signal and observe whether actuator is in all-off position, or loosen the nozzle and lock
the nut. Adjust the distance between nozzle and baffle to make actuator reach all-off position and lock nut.
b. Input 0.1Mpa signal and observe whether actuator is in full open position, or adjust the baffle’s position
on push plate till actuator is in full open position.
c. Repeat above steps till the output position corresponding to input 0.02 Mpa~0.1 Mpa is correct and
lock the nut.
3) Adjustment of position transmitter (Take pneumatic valve as example):
a. Adjust the actuator to all-off position and measure whether position change output current is 4mA; if
the deviation is large, adjust ZERO potentiometer to make output current 4mADC.
b. Adjust the actuator to full open position and measure whether position change output current is 20mA;
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if the deviation is large, adjust SPAN potentiometer to make output current 20mADC.
c. Repeat above steps till the corresponding output 20mA and 4mA of full open and all-off position is
correct.
3.2.2.3 Adjustment of travel switch (only for actuator with travel switch)
1) After position transmitter is adjusted, fix the pinion relevant to position transmitter signal; press the cam
connected with travel switch and rotate cam position to make corresponding travel switch act when actuator is
in full open and all-off position.
2) After adjustment, tighten all screws.
3.2.2.4 Adjustment of positioned (take cam with linear as example)
1) Make actuator at 50% opening and adjust the cam fulcrum to make it just at 50% scale of cam.
2) Input 50% signal and adjust zero to make actuator just at 50% opening.
3) Input 100% signal and adjust range to make actuator just at full open position.
4) Repeat 2.5.1 and 2.5.3 till it conforms to requirements.
5) Actuator exists nonlinearity at ±3% opening, which can be compensated by the length of contact
connecting with feedback rod and the length of feedback rod on output link.
3.2.2.5 Adjustment of lock up valve
Slowly reduce air supply pressure to make the air supply pressure value as set value of lock up valve when
actuator does not act. The difference between lock up valve and reducing valve shall be at least 0.1Mpa, or it
will easily take place vibration.
3.2.2.6 Adjustment of system
Input 4-20mADC signal on pneumatic converter and actuator shall be from all-off to full open position.
Position transmitter shall send out 4-20mADC signal and then take out at least 5 points (including zero and full
scale) for verification. When losing air supply pressure, power supply and control signal, actuator shall remain
unchanged (to lock up valve).
3.2.3 Operating maintenance
3.2.3.1 Routine maintenance
1) Check whether air supply pipeline is free of leakage and whether the direction is straight without
flattening phenomenon.
2) Check whether pneumatic converter and reducing valve is in good seal and whether air supply pipe is
flooded with water.
3) Check whether pressure gauge is damaged.
4) Check whether all accessories are fixed firmly and actuator is free of obvious damage.
3.2.3.2 Start and stop step
1) Start step: open the air supply valve of all parts and supply power to pneumatic convertor.
2) Stop step: disconnect the power of pneumatic converter and then close the air supply valve.
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2.5-100,000 circles. The minimum angular resolution of output center sleeve of actuator is 15 degrees.
b. Setting of moment switch:
40% to 100% of rated moment
Remote control power of actuator: rated power is 15VA; rated voltage is 120VAC.
c. Remote control has 6 control input terminals:
Open valve, close valve, stop/keeping
Emergency protection (ESD)
An effective ESD signal will surpass any site or remote control signal. Power common port operated by
ESD is independent to remote control signal of open valve, close valve and stop.
ESD option configurations are as follows:
ESD signal: high level on (closing of contact) ; low level on (breaking of contact) .
ESD action: close valve, open valve and keeping position.
ESD precedence: surpass motor temperature protection * * , local stop, interlocking operation, interrupt
timer.
2) Open valve interlocking and close valve interlocking
Control function
Corresponding position of low input signal: close limit, middle position and open limit.
Corresponding position of high input signal: close limit, middle position and open limit.
Dead zone: the travel between full open and all-off limit is 0~9.9%.
Forbidden running time: 2~99s
3.3.1.3 Remote valve position and monitoring display
Four passives and unipolar lockable contact S1, S2, S3 and S4 have been provided. Every contact may use
IQ to set one of the following signals:
1) Valve position
Full open, all-off (accurate) or any middle position (0~99%) .
2) Status
Valve is being opened, being closed, being operating (continuous or pulse signal) , select local stop, select
local, select remote, open valve or close valve, interlocking start, ESD start.
3) Valve alarm
Moment jumps when motor is in operation, moment jumps when motor is in open valve, moment jumps
when motor is in close valve, valve gets stuck, actuator is operated by hand wheel.
4) Actuator alarm
Power supply phase losing, lost of internal 24V DC (120V AC) , too low battery voltage, internal
inspection fault, temperature protection trips.
Every contact may set “normally open” or “normally closed) . Contact capacity is 5mA-5A,120V AC or
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30V DC.
S1- Close for all-off.
S2- Close for full open.
S3-Disconnect for all-off.
S4-Disconnect for full open.
3.3.2 Maintenance items and quality standards
3.3.2.1 Maintenance items
1) Maintenance of actuator components
a. Drive sleeve;
b. Manual/automatic handle;
c. Hand wheel;
d. Mechanical stop;
e. Motor or reduction gearbox.
f. Main control panel and feedback circuit board.
2) Maintenance of actuator installation:
a. Installation of actuator output shaft.
b. Install the actuator on valve.
3) Maintenance items of actuator debugging:
a. Determination of baffle switch position;
b. Determination of actuator’s direction of motion;
c. Determination of ON and OFF position of actuator;
d. Determination of actuator torque;
e. Adjustment of working range of dead zone of actuator;
f. Determination of category and size of control signal of actuator;
g. Adjustment of feedback signal of actuator.
4) Maintenance process:
a. Maintenance of drive sleeve: drive sleeve can be processed according to different valves.
b. Manual/automatic handle: used to realize the conversion of manual and automatic.
c. Mechanical stop: used to fix the switch position of valve, which is composed of two stop bolts to mainly
check whether it is tightened.
d. Motor and reduction box: check the performance and rotation condition of motor; reduction box is
mainly used to check the mesh condition and abrasion condition.
e. Control circuit boards: check the connection of all connecting plugs; check the working condition of all
electronic components.
5) Installation process of actuator:
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9) Feedback signal shall be accurate without error, that is 20mA for full open and 4mA for all-off.
Feedback signal in the middle position must have favorable linear relation.
3.3.2.3 Common faults and handling methods
1) There is control signal but actuator does not act:
The reason behind this is usually that main control panel is damaged and the phenomenon is the frequent
flicker of open and closure torque light on actuator but actuator does not act.
Handling method: replace the main control panel.
2) Poor linearity of actuator feedback signal:
There are several reasons behind this condition: the first is that the angle deviation between the position of
baffle and actuator is too big; the second is that control signal is not regulated properly and the error is big; the
third is that position return is not regulated properly and the error is big; the fourth is the poor quality of
potentiometer. Handling method: adjust carefully for several times to make sure that error is within the range.
3) Error appears in position return
There are several reasons behind this condition: the first is that position return line is damaged; the second
is that trimming potentiometer is damaged; the third is that position transmitter is loosened. Handling method:
the first is to check the position return line and the second is to replace position transmitter or trimming
potentiometer.
3.4 Maintenance rules on SMC series pneumatic actuator
3.4.1 Overview
3.4.1.1 Overview
This maintenance rule is applicable to the maintenance and major and minor repair items of SMC series
pneumatic actuator of Tianjin Bailu Ertong Machinery Co., Ltd.
SMC series valve switch pneumatic device is the execution unit of SCS control system, which is applicable
to the operation of brake valve, stop valve and other valves. The function is to receive the switch order of
control system, drive valve action and realize remote control. It has integrated motor, reducer, part electric
secondary control loop and status feedback on electric device. The level of protection is IP55 and output torque
range is 50-10000Nm; output speed range: 12-36rpm. It is widely used in our plant.
3.4.1.2 Basic technical parameter (Take TYPE as example)
1) Significance of parameter on SMC series actuator nameplate:
Actuator nameplate:TYPE: DZW20-DS1
Nominal torque:N.m
Output speed: r/min
Maximum controlling torque:N.m
Minimum controlling torque:< N.m
2) Power:380VAC 50HZ。
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4) Full open and all-off test under remote control and local mode.
5) System linkage test.
6) Inspection of internal wiring and verification.
7) Debugging of valve electric fitting.
8) Insulation between cable phases, ground insulation test and motor ground insulation test.
9) Inspection of D.E wheel and LED.
3.5 Maintenance rules on FISHER positioner
3.5.1 Overview
The equipped DVC2000 series digital valve controller on Fisher pneumatic regulating valve can be
communicative. The electricity-air convertor based on microprocessor can easily access the crucial information
for process operation through 275 type HART communicator, besides the standard function of converting
current signal into pneumatic output pressure.
3.5.2 Technical specification
Technical parameter
Input signal: 3-20mA DC
Minimum voltage: the minimum available voltage used for instrument terminal of analog control is 8.5V
and it is 9.0V for HART communication.
Maximum voltage: 30V DC voltage
Output signal: to execute the pneumatic signal required by actuator, it can at maximum reach 95% of air supply
pressure.
Minimum range: 0.5bar(7 psig)
Maximum range: 7 bar (101 psig)
Air supply pressure: minimum value is recommended: 0.5bar (7 psig) higher than the maximum value
required by actuator.
Maximum:7 bar(101 psig)
Temperature limit: working temperature range is -40~85℃; when temperature is lower than -20℃, LCD
may not read message.
3.5.3 Debugging steps and methods of positioner
To run QUICK SETUP program on main screen, press arrow key first and then press right arrow key. At
this time, a warning will pop up to hint that this step will cause the valve action. Press the right arrow key for 3s
to access checking routine. Press the left arrow key to back to main menu. This program will automatically
verify the instrument and is applicable to the setting parameter of this actuator. To suspend this program at any
time, please press the right arrow key and left arrow key simultaneously for 3s. When this program is finished,
press right arrow key to back to status display screen. If right arrow key is not pressed within 30s, the
equipment will return to status display screen automatically.
Check whether the pressure is too low or too high (generally select 05~0.7MPa) ;
Valve switch does not act
whether mechanical valve is stuck.
Check whether +11,-12 terminals have 4~20MA signal; switch to manual mode to
Remote control does not act
check whether local manual mode acts.
outputs 4 Ma) .
3.6.4 Debugging and maintenance
3.6.4.1 General rules
1) The newly installed and improved pneumatic actuators shall cooperate with the maintenance for
debugging before being put into operation, which can be delivered for use after meeting various technical
requirements.
2) The faults occurred during operation, cannot be put into operation after the maintenance with debugging.
Before the debugging, handle the work tickets, and conduct the debugging after contacting the operation
personnel for system disconnection.
3) After the temporary repair and minor repair, according to the maintenance requirements before the
start-up, conduct the operation test on the pneumatic actuator having taken maintenance or without, see whether
its switch meets the requirements, if found abnormal, eliminate it timely.
4) At debugging, get familiar with relevant provisions, understand the equipment performance, usage
method and debugging steps, and carry out the adjustment according to relevant instructions.
5) At maintenance and adjustment, get familiar with the corresponding thermodynamic system of
pneumatic actuator, in order to avoid the mistakes.
3.6.4.2 Debugging
1) Appearance inspection: Check whether all parts have any abnormal circumstances.
2) Check whether the air supply is available, and whether the gas path is smooth and there is leakage.
3) Whether locator air inlet pressure meets the requirements within the prescribed range.
4) Deliver power source and control power.
5) Positioning according to the methods of 3.6.3
3.6.4.3 Maintenance
1) Terminal row cleaning and wiring inspection.
2) Cable insulation resistance test.
3) Conduct inspection on control cable and signal cable wiring, and check whether the short circuit
connection is correct.
4) Locator and position feedback device inspection.
3.6.5 Common fault treatment:
3.6.5.1 The valve switch does not act:
1) Check whether the pressure is too low or too high (generally select 0.5~0.7MPa)
2) Check whether the mechanical valve is jammed
3) Whether the power source is DC24V
3.6.5.2 No feedback:
Check whether +31 and -32 terminals have 4~20MA signal
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~ 6 years.
3.6.7.4 Overhaul standard items
1) Appearance inspection;
2) Locator inspection;
3) Actuator internal wiring inspection;
4) Actuator debugging.
3.6.8 Security measures
3.6.8.1 Risk analysis
1) Use qualified electrical tools in the work, to prevent personnel from electric shock.
2) Fasten the safety belt at high-altitude operation, to prevent high altitude falling.
3) At the pneumatic valve disassembly and removal process, be careful especially, to prevent personal
injury.
4) Before system maintenance, the monitor shall explain the key safety parts and safety notes in the
maintenance.
5) System maintenance needs to stop sending instrument gas, which must be carried out in strict
accordance with the steps of system stop sending instrument gas, the stop sending instrument gas is handled by
operating personnel, and the staff shall stop sending gas to the equipment before equipment maintenance.
3.6.8.2 Work ticket security measures
1) Release the regulation system “automatism”.
2) Close the front stop valve of the pneumatic regulating valve.
3) Close the back stop valve of the pneumatic regulating valve.
4) Stop pneumatic regulating valve instrument air supply.
4. Primary equipment and control device maintenance (furnace side thermal control device)
4.1 ZHJZ series flame detection system maintenance rules
4.1.1 Overview
4.1.1.1 Flame detection system
The flame detector is the indispensable key auxiliary equipment to realize the boiler combustion control
automation for modern thermal power plants, the most important part of FSSS system, which is important
guarantee for preventing the occurrence of the furnace implosion and explosion accidents, reducing energy
consumption, improving the combustion efficiency, reducing dust emissions, and ensuring the unit under safe,
highly efficient, and environmental protection operation, and the company has 36 coal detectors and 36 oil
detectors in total.
4.1.1.2 Technical parameters:
Working voltage: ±15V DC power source for each circuit
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Operation
操作面板
+5V panel
DGND
数字地
Self-checki Output Head
有头继电器relay Fire switch output
有火开关量输出
自检回路 输出回路
ng circuit circuit
Fault relay
Fault switch output
故障开关量输出
故障继电器
+15V
模拟地
AGND A/D
-15V A/D转换
conversion
Logarithmic
对数放大
amplification Current Photoelectric
光电隔离
signal
电流信号 Current, Self-adapti
isolation
电流、电 自适应
火焰
Flame 光电管
Phototube voltage ve滤波
filtering
压转换
conversio
D/A
D/A转换
conversion
模拟量输出
Analog output 485 interface
485接口
Figure 1
4.1.2 Fault phenomenon, fault judgment method and treatment
See flame detection processing cards in Table 1.
Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
●Probe S line meets broken
circuit.
●Probe connector contact is
●Check the wiring
bad.
●Insert the probe connector again,
Fault light is ●Terminal row wiring is not Immediate
F01 OK with reference to the flame
lit (red) firm. treatment
detection probe in Chapter 8.
●Probe S line is connected by
●Replace the probe amplifier.
fault, with S and G in reverse
order.
●Probe amplifier is damaged.
Fault light is Immediate Replace the probe amplifier
F02 OK Probe amplifier zero drift
lit (red) treatment Refer to Chapter 8
●Check the wiring
●Use the multi-meter to measure
Fault light is ●+15V power failure Immediate whether there is +15V power
F03 OK
lit (red) ●Short circuit treatment output
●Insert the probe connector again
●The power card meets fault
The main role of the converter is to transfer the oxygen potential return signal (MV) measured by the detector to
the digital quantity. Transfer the oxygen content value obtained through the CPU logarithm value calculation to
the display, and output the current value corresponding to the oxygen content, at the same time, the converter
shall control the temperature of the working electric furnace in the detector, to make the zirconia tube
temperature stabilized at 700 ℃ . Transformer’s role is to supply power for working electric furnace in the
detector.
4.2.1.4 Maintenance and calibration of zirconia oxygen analyzer
1) Maintenance items and quality requirements
a. Check sampling gas path system
(1) Check the bypass flue, which shall be tight with no air leakage and have good insulation; purge bypass
flue, to ensure the smoothness of the pipeline.
(2) Check the air filter and flow meter, take disassembly and cleaning when necessary, and ensure its
cleanness, smoothness and tightness without leakage.
b. Check the zirconia probe
(1) Appearance inspection: Silicon carbide dust filter shall be clean and smooth, with no mechanical
damage; the zirconia tube shall be clean, with no cracks, bending, and no serious wear and corrosion; the
platinum electrode lead shall be intact, and the binder shall have no shedding; zirconia tube and alumina tube
sealing shall be tight, with no leakage; the flange joint surface shall have no corrosion, and the gasket shall be
intact and tight.
(2) Probe internal resistance inspection: When the probe temperature is 700℃, the internal resistance of the
measuring probe on the basis of the ionic conduction mode shall be no more than 100Ω.
(3) Probe bottom electric potential inspection: When the probe temperature is 700℃, inlet 15L/h clean air
through the working air port and the reference port, and bottom electric potential of the measuring probe shall
be no more than ±5mV.
(4) Inspection of probe insulation resistance: Use 500V insulation meter to measure the probe insulation
resistance under normal temperature, of which the thermocouple outer casing insulation resistance shall be
greater than 100MΩ, the heating wire outer casing insulation resistance shall be greater than 500ΜΩ, and the
inner electrode lead wire outer casing insulation resistance shall be greater than 20ΜΩ.
The shielding line from the probe to the converter shall be intact.
2) Calibration items and technical standards
a. Temperature control accuracy calibration: The probe temperature shall be risen to a given point, keep it
stable for 30min, and measure the thermocouple temperature, with the difference of its value and the given
value of no more than±5℃.
b. Temperature stability calibration: Measure the thermocouple temperature for once every 5min,
continuously for 10 times. The maximum difference value in 10 times shall not exceed ±4℃.
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c. Calibration of the converter: Input the MV signals (look-up table value and the probe bottom potential
value) with the oxygen content equal to 0.5%, 2%, 4%, 6%, 8% and 10% to the “oxygen potential”
(concentration potential) input end with the potential difference meter, and the measuring converter outputs the
current value, with the difference of the value and the standard output value of no more than ± (2%+0.2 of the
current reading) mA.
d. Constant current performance calibration: When the output current is 10mA, the output current changes
shall not exceed 0.01mA as the load resistance changes for 1kΩ every time within the prescribed scope.
e. Calibration of the whole set of instrument value: Adjust the instrument indications of the starting point
and end point, inlet the standard gas with the oxygen content of 1%, 4%, and 8% respectively and the flow rate
of 120L/h and the reference gas with the flow rate of 15L/h into the probe, and record the readings after the
indication is stable, with the difference of the indication value and the actual oxygen content of no more than ±
(5%+0.2% of the oxygen standard value) O2.
f. Calibration of the whole set of instrument indication value stability: Inlet the standard gas and reference
gas, after keeping it stable for 30min, read the first number, and then read the second number every 2h, with the
difference of the two readings of no more than 0.2% O2.
3) Operation and maintenance
a. Preparations before operation
(1) Check whether the probe, connecting wires, gas path system, transducer and display instrument meet
the requirements.
(2) As for the newly installed instruments, check whether the flue gas temperature of the sampling point
meet the requirements.
(3) The probe shall be installed well generally before the boiler ignition, and the temperature rises with the
boiler start-up. If the probe is installed or replaced in the boiler operation, rise the probe temperature to the rated
temperature and then insert it in the flue.
b. Input
(1) Input the power source, and adjust the reference gas flow to 15L/h.
(2) When the probe temperature is risen to the rated value, keep it stable for 30min, and check the working
conditions of the temperature control equipment.
(3) As for the boilers under positive pressure combustion, appropriately increase the reference gas flow.
c. Outage
(1) Cut off the instrument and air pump power.
(2) As for the instruments under outage with boiler maintenance, pull out the probe from the flue and keep
it well before the maintenance.
d. Maintenance
(1) As for the instrument put into operation for the first time, check the heating wire voltage and probe
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temperature once every day in the first week, and it can be extended to check for once a week later.
(2) The converter shall be proofread once with the millivolt signal monthly.
(3) The instrument indication value shall be proofread for once every three months with the standard gas
(oxygen content is divided into two types of 2.02% and 20.9%, with the flow rate 120L/h) .
4.2.2 Maintenance items and quality requirements
4.2.2.1 General inspection
1) Zirconium head part:
a. The equipment shall be clean, and its true color can be seen.
b. Mechanical system (internal and external pipes, installation flange, and junction box) ; measurement
system (protective sleeve, sensitive reaction chamber, the internal wiring, controller, sealing parts, and
ventilation pipe) ; temperature system (heater and thermocouple) shall be inspected wholly, to ensure their
availability.
c. Zirconium head insulation test:
In order to ensure the accuracy of the component measurement and the safety of the transmitter, conduct
the insulation test on the zirconium head, including: the sensing part with the outer shell; the sensing part with
the electric furnace, electric furnace with the outer shell and so on. The signal line and power line insulation
shall comply with the requirements, and use 500V shaking meter to measure the insulation resistance, which
shall be greater than 20MΩ.
d. Zirconium head resistance test:
On condition that the electric furnace is started up, rise the temperature of zirconium head to 00 ℃ , and
measure that the zirconium head battery internal resistance shall be about 100Ω or so.
Note: It shall be 1000 ohms at the cold state.
2) Transmitter section:
Thermocouple temperature signals shall adopt K type shield compensation cable.
Wiring shall go through the insulation test, and use the 500V shaking meter to measure its resistance value,
which shall be greater than 50MΩ.
4.2.2.2 AZ20 oxygen analyzer fault judgment and treatment
1) Fault phenomenon: No heating:
Reasons: a. probe heater burning.
b. Oxygen probe heating wire and the transmitter wiring connection is not correct.
c. The loop heating is normal, or without heating.
Treatment methods: a. Measure whether the heater is damaged, if so, replace it for a new heater.
b. Comply with the correct wiring of the wiring diagram.
c. If the controller is normal, the normal power output direction shall be wrong, and reverse A and N lines
of the output power source shall be all right.
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insulation resistance between the insulation test (with neutral points apart) lines shall be > 50MΩ, and the coil
ground insulation resistance shall be 50MΩ (use 500V megohmmeter) .
3) Travel switch inspection: The travel switch contact resistance value shall be no more than 0.5Ω, and the
break contact resistance value shall be less than 20MΩ.
4) Mechanical transmission part inspection: no jamming, flexible transmission.
5) Air cooling system:
The air cooling system includes the main pipeline and protective chamber, clean air filter, and ensure that
the gas path pressure is constant.
6) On-site equipment maintenance
a. Power outage and inspection
b. Conduct controller cleaning (clean, true colors can be seen on surface) inspection (no defect parts, no
corrosion traces, no element loosening) , motor travel switch with advance and retreat lens shall act accurately
and flexibly, conduct ash cleaning, on-site control box key contact shall be in good conditions, no jamming, AC
contactor action is accurate, and the contact is in good conditions.
7) Image transmission system:
Image transmission system is composed of CRT driver, camera and the indirect video cable, check the
aviation plugs, which shall have no cable loosening phenomenon, so as not to affect the image quality, while
CRT adjustment shall focus on the brightness and color adjustment mainly, consistent with the true color of the
furnace as far as possible, and clean the screen.
8) Control room alarm test:
Apply the gas supply stop method to do under voltage and alarm function tests.
4.3.2.4 Common faults and treatment
1) The image jump is instable, and the cable connection part is badly contacted, well connect it again.
2) The image suddenly disappears, the grating appears on the screen, and the cable is open, find them out
and well connect them.
3) The image display lens is sticky with dirt, exit from the lens and thrust it as well after the soot blowing.
4.3.2.5 Major and minor maintenance items
1) Each connector inspection and cable inspection
2) Lens cleaning, and glass replacement of the lens tube.
3) Lens telescopic mechanical device inspection.
4) Monitoring system inspection and regulation
a. Monitor inspection and regulation
b. Monitor grating integrity inspection
c. Brightness adjustable range inspection
d. Video distortion degree inspection
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regularly, and discharge the effusion in the filter at least half a month. After the filter is filled with dirt, timely
clean it, making the camera in the outage state at cleaning, then turn off the valve to cut off the gas, and remove
the filter for cleaning. Conduct the cleaning at least once every minor repair cycle.
4.4.2.4 Maintenance
Table 1 Common fault and maintenance methods
Fault
Fault reasons and maintenance parts Maintenance and treatment methods
phenomenon
Check whether the monitor power supply is Put through the monitor power supply and adjust it to the
opened and in the VIDEO state VIDEO state
Check whether the monitor video is connected. Connect the video connectors
Use the multi-meter 200Ω ohm measurement monitor to
Check whether monitor VIDEO output end
measure the monitor VIDEO input end, with 75 ~ 80
outputs signal
resistances existing normally, and repair the monitor if not.
Check whether the camera power supply is
No images Put through the power supply
available
Check whether the camera video plug is
Insert the video plug, weld the broken circuit or change lines
inserted and the video cable line has no broken
otherwise
circuit
Use the multi-meter AC 2V voltage to measure the camera
Check whether the camera VIDEO output end
VIDEO output end, with 0.8 ~ 1.2V voltage existing
outputs signal
normally, if not, repair or change the camera
Check whether the monitor brightness, color
Regulate various settings
and other settings are correct
Check whether oil, water, dust and other
Clean up the dust inside the protective cover, scrub or replace
impurities enter into the protective cover, and
the lens
whether there is dirt in the camera and lens
Check whether the lens aperture, zoom, and Regulate the lens aperture, zoom, and focus through the
focus are appropriate controller
Check whether the position of PTZ, PTZ
Regulate the position of PTZ, PTZ support, protective cover,
Unclear support, protective cover, and camera is
and the camera
images appropriate
Check whether the camera rear ring position is
Regulate the camera rear ring position
appropriate
Check whether the input and output video
connectors are under good connection, and Insert or replace the connectors, and weld them again at the
whether there is pseudo soldering at the pseudo soldering places
welding places
Check the water level meter display effect or Adjust the water level meter display effect, cancel or remove
whether there is interference source the interference source
Check whether the connectors of the lens are
Lens out of Insert or replace the connectors again, and weld them again at
inserted in good conditions, and whether the
control the pseudo soldering places
welding part has pseudo soldering
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Fault
Fault reasons and maintenance parts Maintenance and treatment methods
phenomenon
Check whether the lens shall supply power, and Put through the power supply, weld the broken circuit or
whether the cable line has broken circuit change lines otherwise
Use the multi-meter DC 20V to measure the voltage between
Check the voltage of the controller lens output the lens public output ends according to the controller end
end wiring diagram, with ±7.5V voltage existing normally, if not,
repair or replace the controller and the lens
Check whether the valves and the pressure
Open the valves and regulate the pressure regulating valve
Air filtration regulating valves are closed
system can Check whether the air filter has seeper inside, Dredge pipelines, drain away the water inside the air filter,
not work and whether the pipeline is blocked clean or replace it
normally Check whether the primary gas supply can
Restore the gas supply to make it work normally
work normally
6) Conduct pressure switch back loading and the panel manual operation test. Indicating lamp indicates
correctly. PCV valve does not take the popping seat and the amber lamp is lit up, after the popping seat, the red
light is lit up.
4.5.2.2 PCV valve control system maintenance quality standards
1) Control box sealing is good, and its cable outlet and inlet sealing is good, which can be waterproof and
dustproof.
2) The control box surface light display is normal, and the light test is normal.
3) Control box internal terminal connection is firm, the wiring is neither loose nor tight, and the relay is
normal.
4) Pressure switch wiring terminal crimping is firm, its cable and connection sealing is good, and the cable
insulation meets the requirements.
5) Solenoid valve wiring terminal is firm, the cable and control box connection sealing is good, the cable
insulation meets the requirements, and the solenoid valve heating is good during the work.
4.5.2.3 Common problems of safety valve control system in the operation
1) Pressure switch setting drift makes the safety valve malfunction.
2) The cables between the pressure switch and the control box meet short circuit or broken circuit, which
makes the solenoid valve power failure, leading to malfunction.
3) The cables between the solenoid valve and the control box meet short circuit or broken circuit, which
makes the solenoid valve power failure, leading to malfunction.
4) Terminal unit K540 - fault cause disk light display error.
4.5.2.4 PCV valve major repair item:
1) General inspection.
2) Pressure sensor calibration.
3) PCV valve system test.
4.5.2.5 PCV valve minor repair item:
1) General inspection and cleaning.
2) PCV valve system test.
4.6 STOCK coal feeder control device maintenance rules
4.6.1 Overview
The project adopts 12 EG2490 type electronic weighing belt coal feeders, produced by America
technology and introduced by Shenyang STOCK Company, and each boiler has 6 sets (double-inlet and
double-outlet coal mill for Yongxin project) . The control system has the following functions:
The local, remote start and stop coal feeders realize the belt positive inversion under the local no-load
mode.
Configure a set of precise weighing system, to calculate the coal feed rate through measuring the coal
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feeder speed and the pulverized coal weight per unit length, and enable to adjust the coal feeder rate the rated
value automatically according to DCS order.
Monitor the broken coal, coal blockage and various abnormal working conditions, and send out the
alarm signal or take automatic tripping.
Display the coal feeder rate, total coal volume, speed and coal feeder operation, fault, alarm and other
working conditions.
Self-check some information related to the system and find out the causes of the fault alarm.
Set the coal feeder parameters and regularly calibrate the weighing system. Control the coal feeder
lower gate damper.
The working principle of coal feeder: The coal feeder measures the weight of the objects in the weighing
span through its weighing device, after the micro processing calculation, the belt unit length weight is obtained,
and the coal feed rate can be obtained from the product of the numerical and the belt speed. After the
comparison of the coal feed rate and the set value through processing and transformation to control the
frequency of variable frequency controller, so as to control the driving motor speed, achieving that the actual
coal feed rate is consistent with the set value finally.
4.6.2 Maintenance items and quality requirements
4.6.2.1 Coal feeder weighing calibration
Calibrate the coal feeder after the start-up and initial operation and every six months later, weighing roller
adjustment or replacing the belt, CPU board, weighing element module and microprocessor programmed chip
shall be used for coal feeder calibration.
1) Calibration tool:
Calibrating the coal feeder shall adopt the calibration tool box provided by STOCK Equipment Company,
which includes: two calibration weights, two verification probes and the connecting wires, reflective paper (at
least 4 pieces) , and two inspection bars. In addition, the ruler, measuring tape, a set of British inner six-angle,
wrench, feeler, multi-meter, 4 - 20mA signal generator and a brush shall be needed.
2) Calibration principle:
STOCK coal feeder calibration is divided into two steps: The first step is to eliminate the system self
weight, including weighing roller, weighing element support parts and coal feeder belt weight; at the same time,
measure the relationship of the belt speed and the motor speed. The second step is to calibrate the output
amount of the known weight from the weighing elements. When the belt takes idle rotation and the measuring
belt rotates for two times, the average output of the weighing system is calculated, and then subtract this value
from the total weight, to eliminate the system self weight. In normal operation, subtract the average self weight
automatically from the belt gross weight, therefore, the weight reflected at this time is the weight of the
substances on the belt.
In the empty belt calibration process, except eliminating the self weight, precisely measure the belt speed.
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This step is completed through measuring the time of the reflective paper action between two fixed points on
the belt. Through the measurement for many times, this parameter is used for compensating the changes of the
belt thickness.
3) Coal feeder verification:
a. Preparation before calibration:
(1) Before calibrating the coal feeder, put the coal feeder into operation for 15 - 30 minutes to make the
belt soft.
(2) Close to coal feeder inlet gate valve and drain the belt empty.
(3) Close the sealing air valve.
(4) Open the coal feeder two side doors, the front and rear manholes and the microprocessor control
cabinet door.
(5) Switch off the main circuit breaker, and clean the control cabinet cards and coal feeder weighing
device.
b. Coal feeder belt adjustment:
The belt adjustment is completed by maintenance. When the belt is adjusted to the appropriate tightness,
put the coal feeder into operation in the LOCAL state. The maintenance shall check whether there is deviation
phenomenon on the belt.
c. Weighing roller adjustment
The weighing roller adjustment falls into the adjustment of the weighing roller alignment and weighing
roller spacing.
(1) The adjustment of the weighing roller alignment: The purpose is to place the weighing roller in the
alignment of the weighing span. Both two sides shall be limited between - 0.05- + 0.05mm, so as to ensure the
accuracy of weighing readings, which shall be no more than -0.178- +0.178mm.
Loosen the two locking screws on the weighing roller side, rotate the adjuster to adjust the weighing roller
position, and fasten the locking screws after placing it in the right center of the weighing span.
(2) The adjustment of weighing roller spacing: The purpose is to reflect the belt weight in the span actually.
Add the weight calibration weights on two load elements; place the check levers on both sides of the span roller;
loosen two locking screw adjustment adjusters, to keep the weighing roller check lever working surface under
0.127mm space, generally with feeler 13-wire for inspection; as shown above, adjust the other side of the coal
feeder, and put the locking screws at the lockout state.
d. Coal feeder verification process
(1) Paste four pieces of reflective paper to the right side edge of the belt. The position of the reflective
paper position is at the outside of the driving wheel and the tension pulley (front and rear inlets) placed with a
piece of reflective paper; the other two is put on the upper and lower belts near the side door of the weighing
roller;
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(2) Unscrew the plug beside the span roller lubrication fittings, and clean it. Screw the calibration probe
into the verification socket, and pay attention to that the probe pin and the concave point beside the coal feeder
socket shall be in alignment;
(3) Stop the coal feeder power (open main circuit short circuiting device) , and connect the probe cable
with A and B sockets on the circuit board in the control cabinet. Note: The connection shall be taken under the
condition that the power is cut off;
(4) Compare whether the calibration weight is consistent with the microprocessor and the microprocessor
memory values. Press SETUP13 to display the values in memory. If the memory display value is not correct,
input the correct calibration weight. As follows: Press **. ***ENTER;
(5) Compare the ideal calibration speed and the value in the memory, and press SETUP01 to display the
numerical value in the memory, so as to display set addressing and numerical value. If the calibration speed is
not correct, input the ideal numerical value, Press: ***ENTER, and the new numerical value shall be displayed.
Note: If the input value is incorrect, press CLEAR key, and then input the correct value. Not to input any set
order again;
(6) Confirm that the weighing elements have no hanging calibration weight:
(7) Start the first step of calibration, to measure the system weight and belt travel. Press CAL1 and the coal
feeder shall be put into operation under the control of the microprocessor, and confirm it for calibration
according to the following mode:
● Screen is cleared to zero, and the line at the top shall initially display <CAL1> state for 2 seconds.
● In the process that the belt driven motor reaches the calibration speed and is stabilized, it is changed
to display as follows after the display delay for 25 seconds:
● When the delay is terminated, the first reflective paper leads to the display as follows through probe
A:
When the reflective paper goes through probe B, the display shall be changed as:
<CAL1> TareandBeltSpeed
Factor
HH:MM:SS Pass#1Done
When the reflective paper goes through probe B at the eighth time, the display shall be changed as:
<CAL1> FinishingBelt
Revolution
HH:MM:SS Pass#8Done
When the reflective paper goes through probe A at the ninth time, the belt has just rotated for 2 cycles.
Driving motor meets power failure, and the screen displays the speed measurement accuracy percentage for 8
times within 45 seconds:
<CAL1> Dev:0.20%
GoodValues=8
<CAL1> TarefactorNNNNNN
Speedfactor0.xxx<ENTER>saves
Therein, NNNNNN is the system weight and XXX is speed factor stored under control. Press ENTER key
to save the new measurement values and carry out the step in 1.2.4.7.
If this error is greater than the program limit range, the display is as follows:
(9) Press CAL2, start the second step of calibration and the display shall be as follows:
Therein, xxxx represents the calibration speed of inputting 01 address, and the calibration process is the
same as CAL1.
<CAL2> Dev:0.20%
Good Values=8
Therein, NNNNNN is the span number stored in the controller, pressing ENTER to save the new data.
Calibration inspection
Compare the current calibration with the previous data, the operator can judge the repeatability of
calibration and the change conditions. When conducting the following operation, the microprocessor will
calculate the change percentage of the calibration values of two times:
Display the ratio of system weight change: Press SELFTEST01
Display the ratio of belt running change: Press SELFTEST02
Display the ratio of span change: Press SELFTEST03
The three inspection results above shall be no greater than ± 0.25%. If they exceed, check the suspension
conditions of the calibration weights or other abnormal mechanical conditions.
e. Input / output card verification
Input card responds to the (4-20) mA signal sent by DCS, set as A1 card.
Output card is used for (4 - 20) mA feedback signal and the control signal sent to frequency conversion
motor, respectively set as A2, A2 card.
The preferred signal of verification comes from the combustion control system (4 - 20) mA corresponding
to (0 - 100) per hour.
Note: Conduct the verification under OFF state.
(1) Press TRIM to enter the adjustment of I/O card, the numerical value and instructions of which can be
browsed, and the display is shown as follows:
<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure
Therein, xxxx is the frequency existing in the storage in the last measurement, send the input signal to the
input channel, add 4mA and press SETUP to enter the measurement mode, and the display is:
<TRIM>A1Card:0% storde=xxxxHz
EXIT=Cancel ENTER=Store
(2) Pressing EXIT can return to the adjustment state without the storage of measurement value, to press
ENTER to store the results, and the display is as follows:
<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure
xxxx is a new value. Press ↑ to switch to 100% of A1 card, and the display is:
<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure
Add 20mA to the input channel and press SETUP to enter measurement mode, and the display is:
<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—AdjustFreq
Select SETUP to enter the adjustment state and the display is:
<TRIM>A2Card:0% storde=xxxxHz
Up/Down-AdjustFreq ENTER=Store
Press ↑↓ for adjustment, until the output is 4mA, and press ENTER to input the correct value. Adjust the
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At any time, check the fault information of the eight times through pressing ERRORRECALL, and the
display is:
Therein, xx represents the fault code, YY means the newest fault catalogue of eight times from 00 – 07,
press ↑↓ for inspection and replacement. The false code list is as follows:
Error
Illustration Alarm/tripping Fault causes
code
The motor is out of operation or the electrical sensor does not work;
03 Speed feedback is lost Tripping Motor only works under JOG state;
Sensor connection has faults;
CPU is unable to write data to EEPROM, and also cannot read the
data;
05 EFPROM is written wrong Alarm
U15 line or socket has problems (Note: If it needs to be replaced,
refer to the operation manual) ;
U14 line has faults, the sensing circuit voltage is reduced or without
The battery is short for alarm the support of power; The data inspection received from RAM
06 Alarm
Alarm battery is not correct, indicating that the data stored in BatRAM have
problems;
The coal blockage sensor is found blocked up, the time of which is
longer than that in setting address 16;
Coal feeder is blocked with
07 Tripping Coal feeder discharge valve is closed or to coal feeder outlet
coal
warehouse or the drop tube is blocked up;
The coal blockage sensor of the coal feeder is out of order;
There is coal found on the coal conveyor belt for more than 2
There is coal on the belt
seconds, meanwhile, it is under the LOCAL or CALJBRATE state;
08 under the “local machine” or Tripping
Close the inlet valve, and clean the belt with previous operation
“calibration” state
under LOCAL or CALIBRATE state;
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Error
Illustration Alarm/tripping Fault causes
code
At event process The frequency output towards the feedback card or the speed control
14 configuration, EPA watchdog Alarm circuit may have faults, immediately contacting with STOCK
relay gives an alarm company;
A/D converter electronic self-test results are inconsistent, and A/D
converter is damaged;
A/D converter 14 and 15 lead reference voltage is instable;
15 A/D calibration is wrong Alarm
DC voltage may be lowered by 10V, with reference to
SELFTEST10, the alarm can be relieved automatically when the
electronic calibration results are stable;
16 Useless
The above error codes only represent the faults of the coal feeder itself, and the tripping, due to external
causes, can not be reflected in the coal feeder, such as DCS tripping signal, low voltage, and so forth.
4.6.2.3 PC control board: 196NTCPU and power supply board
1) Input voltage inspection
Measure the voltage between 102 and 103 in the control cabinet with the input voltage range of 100 -
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through the conversion. Conduct communication diagnosis on SPU through SCU and SmartBUS software
installed on the notebook computer. Complete the gain adjustment on the sensor probe signal through the
trimmer potentiometer of SPU.
3) Station control unit (SCU)
SCU provides 48V DC power supply for the analyzer on local data bus. The power supply of SCU is 86 ~
264VAC. The power supply unit is encapsulated on one side of SCU, and the inner part of 48V DC rail mounted
power supply is connected to SCU processor. SCU is connected with the field analyzer through 4-wire data bus
(local data bus) . The bus consists of 2-core 48V DC power supply and 2-core MOSI (main output/ entry
followed) and MISO (main entry/output followed) communication bus, in the data bus, SCU is taken as the
communication station, and field analyzer is taken as the communication with the data communication from the
station. Note: SCU may be integrated in the gas control unit (GCU) of G-CEM4000 gas analyzer.
4.7.2.3 Equipment installation positioning
At positioning the equipment, the following factors shall be considered:
1) The positions on both sides of the flue must be easily accessible, so as to be convenient for the
maintenance of the transmit-receiver. Positions shall avoid extreme temperature and vibration as far as possible.
2) The permitted ambient temperature range of the transmit-receiver is -20℃- 80℃, with SPU temperature
range of -20 ℃ - 70℃ . (At lower temperature, condensation may appear on the instrument lens, resulting in
inaccurate (too high) reading of the blackness value)
3) There must be a continuous visible light path between each transceiver.
4) SPU and sensor shall be fixed on the site, and the standard cable of 10 meters is attached between SPU
and the probe.
4.7.2.4 Daily maintenance
Keeping the optical window between the transmit-receiver clean is very important, and the installed short
pipes must be removable at the dust accumulation place and spray place. In order to complete the cleaning work
on the transmit-receiver, use the soft and dry cloth to wipe the lens. Only when the lens is kept clean, the
equipment verification can be carried out.
4.7.3 Gas flow rate and flow measuring instrument
4.7.3.1 Principle
V-CEM5000 measures the flue gas velocity by using the principle of infrared measurement technology,
and the analyzer does not need to directly contact with the flue gas at measurement. The velocity measurement
method is similar to the chemical method or the method of ray tracing, velocity is calculated by passing the time
through the signals and the fixed distance between the two sensors. However, the difference from the artificial
measurement trajectory is that the infrared measurement technology takes the Infrared energy change waveform
as the trajectory tracking. In the use process, the sensor purge can be completed without the need of moving the
sensor devices, so V-CEM5000 is the best option for monitoring pollution hot gas flow rate. Each sensor unit
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comprises a broad band infrared detector, an infrared detector absorbing radiation through the lens, and a
preamplifier circuit board, while all devices are completely encapsulated by using alumina. Gas blowing unit of
the sensor is used to keep the lens of the sensor clean.
4.7.3.2 V-CEM5000 (gas flow rate, flow measuring instrument) composition
1) Signal processing unit (SPU)
V-CEM5000 SPU provides 48V DC power supply by SCU through four-wire SmartBUS serial data line.
The signals of two transmitter transmit-receiver units are output in the form of transmittance and blackness after
the conversion. Conduct communication diagnosis on SPU through SCU and the SmartBUS software installed
on the notebook computer.
2) Station control unit (SCU)
SCU provides 48V DC power for analyzer on the local data bus. The power supply of SCU is 86 ~
264VAC. The power supply unit is encapsulated on one side of SCU, and 48V DC rail mounted power is
internally connected to SCU processor. SCU is connected with the field analyzer through 4-wire data bus (local
data bus) . Bus consists of 2-core 48V DC power supply and 2-core MOSI (main output/ entry followed) and
MISO (main entry/output followed) communication bus, in the data bus, SCU is taken as the communication
master station, and field analyzer is taken as communication followed station to carry out the data
communication.
3) V-CEM5000 (gas flow rate, flow measurement instrument) technical parameters:
Measuring range: 0-50m/s can be selected.
Response time: Rolling values from 10 seconds to 30 days can be selected.
Accuracy: < ± 2% measurement value
Serial data interface: serial communication
Structure: epoxy coated aluminum, with protection level of IP65
Ambient temperature: -20℃ to +70℃
Input power: SCU 86-264V AC
VECM 48V DC,(from SCU)
Counter blowing gas consumption: 1 l/s @ 0.15MPa
Drying (-20 ° C)
Cleaning (less than 10µm)
4.7.3.3 Equipment installation positioning
Equipment installation shall consider the following factors: Determination of position shall avoid flue
elbow and the parts with rapid section changes, arranged with the 4 times of the diameter from the downstream
direction of the elbow head, and with no less than 3 ~ 5 times of the diameter form the upstream direction of the
above mentioned parts. As for the rectangular flue, its equivalent diameter is D=2AB/ (A+B) , in which A and B
are side lengths. When the installation position can not meet the requirements, please contact CODEL technical
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staff to carry out technical advice. The positions on both sides of the flue must be easily accessible, so as to
facilitate the maintenance of the transmit-receiver.
4.7.3.4 Daily maintenance
All the CODEL equipments have considered the site sustainable use and reliable operation at design, to
reduce the frequency of maintenance to the minimum. Electronic devices require no maintenance cycle; they are
solid through rigorous factory firing process. Keeping the optical window between the transmit-receiver clean is
very important, and the installed pipes at the dust accumulation places and the spray places must be removable.
In order to complete the cleaning work of the transmit-receiver, use the soft and dry cloth to wipe the lens.
Clean the probe lens about once every 6 months. It wholly depends on the operating conditions, if the dust is too
high, it may require regular cleaning.
4.7.4 Multi-component gas analyzer
4.7.4.1 Basic principle
G-CEM4080 analysis instrument uses the locally inserted probe installed on the flue to measure the
concentration of NO, SO2, CO2 and H2O in the flue gas. The probe includes a measurement chamber with the
length of the one meter, which allows the flue gas to diffuse into through the sintered stainless steel filter, and
allows zero blowback and gas range verification as well.
When the gas diffuses and enters into the measuring chamber, the analysis instrument uses the infrared gas
laboratory relevant techniques to determine the concentration of flue gas. The diffusion chamber can conduct
the high precision measurement under the condition that the dust concentration measurement is as high as a few
grams per cubic meter.
The measurement integrated in the temperature, pressure, CO2 and H2O of the analyzer can make the
output data carry out the standardized display in the form of mg/Nm3 completely.
Use the compressed air to carry out the fully automatic zero verification, to ensure the long-term stability,
making the maintenance amount reduced to the minimum.
4.7.4.2 Technical parameters
Measuring components: The temperature and pressure measurement of NO, SO2, CO2 and H2O gas
Measuring range: Selected (NO & SO2) , 0-25% (CO2 and H2O) (other ranges can be selected according to
the requirements) within the range of 0-1000ppm.
Temperature of the gas: The gas dew point reaches 300ºC
Response time: 1-60 minutes is optional
Precision: ±/-10ppm(0.5% CO2 and H2O)
Resolution: ±/-5ppm(0.2% CO2 and H2O)
Ambient temperature: -20℃~ +50℃ or 0℃~ +70℃
Probe length: 1.0m or 1.8m (refracted beam)
Probe material: 316L stainless steel
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Standard: 89/336/EEC
Low voltage: 73/23/EEC
Analog output: 2 4-20mA isolation outputs, 500 Ω load, and complete configuration from the keyboard
Digital output: 2 SPCO dry contact outputs, 50V/1A configuration output in alarm; 1 SPCO dry contact
output, 50V/1A used for data validity output.
Input: 3 4-20mA standard data inputs; temperature, pressure and oxygen.
Serial communication: RS232/RS485
Display: 32 alphanumeric digits, and black bottom and bright characters of LCD.
Keyboard: Input of 4 soft touch keys
Ambient temperature: -20℃ ~ +50℃
Power supply: 24VDC@15A
Verification gas: 20 L / min @4 kg dry oil-free compressed air.
4.7.4.3 Components
The components of the whole system include:
1) Probe and sensor: They are installed on the chimney or flue
2) Data display unit (DDU) : The 4-core cable connected to the sensor is used for the data to display the
unit power supply and communication transmission, which can be installed in the place 1km away from the
sensor. The second optionally installed data display unit can go beyond the first data display unit, to make the
display screen installed on a detachable installation point of the analyzer.
3) Compressed air filtration/drying unit: When the fully standardized data output provides the form of
mg/Nm3, supply the unit.
4) SmartCom software: One set of software can make all the analysis data output and the diagnostic data
outputs enter and be stored in the computer.
4.7.4.4 Equipment installation positioning
At positioning equipment, the following factors shall be considered:
1) Avoid the position that the flue gas may form the layer.
2) The flue gas pressure is required to be considered, better to select the negative pressure for measurement
with the aspect of reliability taken into consideration.
3) Keep the chimney concussion to the minimum at the mounting points as far as possible.
4) Enough time shall be ensured, to insert the probe and the sensor, and ensure the maintenance work in the
future.
5) Short pipe and the probe shall be fixed in at the position with downward inclination of about 5°, so that
the flue gas in the probe shall flow upward and evaporated with the heating gas.
4.7.4.5 Equipment debugging
1) Preparations before debugging:
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a. Detect that all the wiring and lines shall be consistent with the wiring diagram.
b. Check and confirm that the minimum compressed air pressure for the probe shall be 4bar.
2) Start-up:
Remove the protective cover of the control unit on one side of the sensor, and start 24VDC power supply.
If each LED shall be correctly displayed, the control unit protective cover can be replaced and DDU shall be
noticed. DDU backlight LCD display shall be lightened and the display shall show the normal Mode 0 data
output. The temperature control loop will start the operation when the power supply is started.
4.7.4.6 DDU operation
1) Display mode:
MODE1: Normal operation mode: It displays gas concentration
MODE2: Parameter mode: It displays the operating parameters
MODE3: Standard pattern: It displays standard data
MODE4: Diagnostic mode: It displays the analyzer diagnostic data
MODE5: Set mode: Set the operating parameters, this model can only be entered with the password.
In all modes, the analyzer output data are not affected by the keyboard operation, in addition to MODE5.
2) Keyboard operation:
The keyboard comprises 4 keys, respectively as:
Mode key: Pressing MODE key will move the instrument to the next operation mode, if the key is pressed
again in another mode, it shall return to the previous mode selection.
Arrow ↑↓: According to the program conditions, pressing ARROW key will lead to the selection between
the two options. Pressing ARROW key in one pattern or its sub patterns can gradually enter into all the
available options, or under mode 5, ↑ means the increase of the displayed value, and ↓ means the reduction of
the displayed value.
Input: According to the program conditions, pressing ENTER key will lead to the selection between the
two options. Pressing this key in one pattern or its sub modes will select the displayed modes or options, or
under mode 5, which can be used to input the selected parameter values.
4.7.4.7 Common fault conditions
1) D→C communication fault: It is the communication fault happening between DDU and analyzer control
processor.
2) C→M communication fault: It is the communication fault happening between the analyzer control
processor and the sensor internal main processor.
3) Temp>Range<: It is the fault of the probe installed in the flue gas temperature sensor.
4) Press>Range<: It is the fault of the probe installed in the flue gas pressure sensor.
5) Tx IR Failure: It fails to provide the infrared light source.
6) RxTOC→HIGH: The receiver temperature is too high.
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Condenser Condenser
Trench Trench
Circulating Circulating Circulating Circulating
water outlet water inlet water inlet water outlet
5.2.1 Overview
The control system is the special electrical machine control device equipped for rotary filter screen sewage
disposal machine. The whole set of system consists of a water level control cabinet and two sets of field power
boxes (only main circuit and control circuit of the rotary screen) . Water level control cabinet controls the
operation of the two rotary filter screens respectively through the control of two field power boxes, and control
the signals of the flushing pump and flushing valve at the same time.
The control system adopts Schneider quantum series PLC, and the monochrome LCD touch screen is the
display, with stable performance and wide application range, which can facilitate the realization of the control
on rotary filter screen sewage disposal machine.
Instrument control and electrical requirements:
Power supply of each secondary filter screen control cabinet: 380VAC/220VAC. Power: 4.5kW.
Power supply of each industrial cooling water filter control cabinet: 380VAC/220VAC. Power: 1.5kW.
The raw water enters into the filter cylinder through the inlet pipe with the nominal diameter of 2200mm,
and the fresh water flows out from the outlet pipe through the stainless steel filter screen, completing the raw
water filtration process. Various particles and impurities with the size greater than 6mm accumulate in the filter
cylinder or attached to the inner wall of the filter screen. When the accumulated dirt gradually increases to block
up part of the filter screen holes, the inlet and outlet water pressure shall be changed, generating pressure
difference. When the water pressure difference reaches 0.002~0.005MPa, differential pressure controller switch
shall trip, generating system cleaning and filtering signals, to control the motor operation in the secondary filter
screen and the sewage recovery device, When the motor rotates through the reducer driving the two rows of
brush rods in the filter screen, the brushes shall wipe out the dirt on the inner wall of the filter screen, mixed
with water, and enter into the sewage recovery device timely after sucking groove hollow shaft; at the same
time, the system control electric butterfly valve is opened, under the filter pressure shock, the dirt mixed with
water is discharged from sewage discharge valve, and the filter screen hole is smooth after the flushing, with the
inlet and outlet water pressure difference reduced to zero; pressure difference control switch takes action, at the
same time, the cleaning timing time is up (time of 15~60S is adjustable) , the motor stops, the brushes stop
working, the sewage butterfly valve is closed, and the sewage disposal process is ended.
5.2.2 Maintenance items and quality standards
1) The circuit connection must be consistent with the circuit diagram.
2) Check whether the overload protection settings are correct.
3) Open the inlet valve, close the outlet valve, open the electric butterfly valve through the handle, and
close the electric butterfly valve tightly after the exhaust is ended.
4) Press the control button, start the motor, and observe whether the axial direction moves along clockwise
direction. If not, turn off the power, to change the rotation direction of the motor.
5) Open the outlet valve, and the system can take normal operation.
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6) Set programmable timing controller working procedure (see setting methods in Appendix instructions) ,
the cleaning work is suggested being taken for 4 times every day generally, with 30min each time, and increase
or decrease the working times according to the field water quality.
7) Regularly check whether the sealing parts have leakage and sealing ring aging phenomena.
8) Regularly check whether the gear box has lubricating oil.
9) Regularly check the filter, unscrew the lower plug to release sewage, and tighten it again.
10) Regularly open the manual drain valve, to discharge the deposition at the bottom of the cylinder body.
11) Regularly check whether the contact of electrical components in the control box is good, as well as the
insulation performance.
5.3 Circulating water butterfly valve control device maintenance rules
5.3.1 Overview
5.3.1.1 Driving device of butterfly valves has the following properties:
Valve overload protection;
Valve travel protection;
Valve opening position indicating device;
The valves and the travel switches are fully opened, the middle travel (open for 15 degrees) contact points
are led out, in order to interlock with the pump motor, and the above-mentioned contact wire leading out shall
meet the local and remote control room requirements.
5.3.1.2 Local control cabinet shall meet the following requirements:
There are local/remote operation switching devices;
Local control cabinet is equipped with open and close buttons;
The indicating lamp indicating the valve state and opening;
Control cabinet alarm indication;
5.3.1.3 Signals transmitted from the local control cabinet to the central control room DCS:
The valve open and closed states; (normally open the contacts, and the contacts are closed at action) ;
The main switch of the local control cabinet is switched to “automatic” and “manual” position;
Local control cabinet or butterfly valve has faults, and a fault signal can be sent out for alarm at any case.
5.3.1.4 Control signal transmitted from the central control room DCS to local control cabinet:
Open the valves (normally open contacts, and the contacts shall be closed when the instruction is issued);
Close the valves (normally open contacts, and the contacts shall be closed when the instruction is issued).
Each electric device shall be equipped with 2 pairs of full open travel switches, 2 pairs of full travel
switches, 2 pairs of open torque switches, 2 pairs of closed torque switches.
5.3.1.5 Working principle
This butterfly valve control system mainly consists of two parts, namely, hydraulic system and electrical
system.
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The power supply of electrical system is provided by dual AC 220V control power, there are two ways of
automatic interlock and local control, the valve is opened firstly when the interlock mode starts circulating
water pump and the travel reaches 15 degrees, the circulating water pump starts, the valve is fully opened 90
degrees continuously, while the valve shall be closed firstly when stopping the circulating water pump, the
circulating water pump shall be stopped when the travel reaches 15 degrees, with the valve closed at the same
time. The local mode is the hard operation on the local control box, at which the switches shall be placed at the
local mode position. At interlock or local operation on opening the valve, the solenoid valves 1YV, 2YV and
3YV are charged, the pressure oil enters into the upper part of the oil cylinder, and the lower oil is discharged, to
push the piston movement and realize quick valve opening before reaching 15 degrees. After 15 degrees, 3YV
shall lose power, the slow opening valve reaches 90 degrees, and the solenoid valves of 1YV and 2YV shall lose
power when there is closing valve signals, the pressure oil enters into the lower part of the cylinder (when the
3YV loses power) , the upper part is discharged, and the valve is closed.
5.3.2 Maintenance items and quality standards
5.3.2.1 Maintenance of power supply system
Conduct the maintenance on whether the control box butterfly valve power switch capacity is appropriate,
and whether the action is flexible and reliable, and use 500 MΩ meter to check whether the power insulation
resistance shall be greater than 10 MΩ.
Power insurance capacity of the local control box is checked with no errors, the cable insulation meets the
requirements, electric box wiring is standard, the number is clear without defects, the wiring is solid, and there
is no grease and dust in the box.
At button and indicating lamp maintenance, the action of all buttons shall be flexible, the contact resistance
shall be less than 0.2Ω, the alcohol can be used to cleanse the contacts of the connectors out of standards, which
shall be replaced if the requirements can not be reached, the indicating lamp shall be intact without defects, the
defected ones shall be replaced, the button wiring shall be correct and solid, and the appearance shall be clean,
with no grease.
5.3.2.2 Travel switch maintenance
The wiring shall be firm, and the number shall be clear and complete, the switch is flexible, with no jam
phenomenon, and the contact resistance shall be less than 0.2Ω. The appearance inspection shall be complete,
with no defect, and the surface shall be clean and free of grease.
5.3.2.3 Electric contact pressure gauge maintenance
The appearance of electric contact pressure gauge shall be complete, with no defects, the contact resistance
shall be less than 0.2Ω, electric contact pressure gauge can be used after the qualified verification, the upper and
lower limit values shall be accurate, firmly installed, with no leakage, and the boundary is correct and reliable.
5.3.2.4 Solenoid valve maintenance
Solenoid valve coil resistance and insulation resistance measurement shall has no open circuit and short
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circuit phenomena, with firm installation and flexible action, without blocking phenomenon, and the appearance
shall be neat.
5.3.2.5 Relay maintenance
Relay appearance shall be complete and clean. Use the multi-meter to measure that the coil resistance has
no short circuit and open circuit phenomena. Relay socket shall be firm, with reliable boundaries, and the
contact resistance shall be less than or equal to 0.2Ω.
Common faults and treatment methods
Fault Reason Treatment methods
1. Manual stop valve mouth is not closed
tightly 1. Close the stop valve mouth
The motor operating system has no
2. Oil pump operating direction is not 2. Adjust the motor phase
pressure
correct, 3. Clean or replace the oil filter
3. Oil filter is blocked
1. Identify the electric contact pressure
Pump keeps working for a long time 1. Pressure controller fails to work
gauge again
without stop 2. Overflow valve does not work
2. Adjust or clean the overflow valve
with 2 network interfaces, truly making interface redundancy and the medium redundancy.
4) All the interface modules are equal on the functions.
5) Based on the power plant application specific multi loop structure, it is easy to form a plurality of
mutually independent and mutually combined sub systems.
6) Taking PCU as the unit, each PCU has many controllers, and each PCU cabinet can complete an
independent control system, but each system can be distributed to different controllers, more in line with the
centralized and decentralized principles.
6.1.1.2 Symphony Plus system composition
Symphony Plus system is composed by the operator station, engineer station, history data station,
redundant control processor, communication processor, redundant via bus and field bus and I/O card, the relay
cabinet, printer and other equipments, to complete the data acquisition, display, record, alarm processing and
real-time functions of the unit thermodynamic parameters.
1) Uninterruptible power supply (UPS)
a. DCS shall use the dual UPS redundant mode for power supply, and the inlet wire of each path shall be
connected to the bus bar section of different power supply;
b. UPS secondary side shall not be connected with new load without being permitted. Under the maximum
load, UPS capacity shall have 20% - 30% of margin;
c. Main technical indicators of PS power supply:
Voltage fluctuation is less than 10% of the rated voltage
The frequency range is 50HZ ± 0.5HZ
Waveform distortion is less than 5%
The standby power supply switch time is less than 5ms
Voltage stability: It shall not exceed ±5% of the rated voltage at the stable state, with no more than ±10% at
dynamic state.
Frequency stability: The stable leaf is greater than ±1%, and the dynamic process is no greater than ± 10%.
UPS shall have the over current, overvoltage, and input surge protection functions, and has fault switching
alarm display.
2) Power supply isolation and power distribution
The unit under operation shall check the following contents:
Distributed control system power supply must be provided by UPS, rather than provided by the power
plant service power directly.
UPS output side is not allowed for grounding, use the isolation transformer for isolation, and make the
secondary side of the isolation transformer grounded.
At overhaul for each time, check the power supply switch or the insurance of UPS output side power
distribution panel.
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Power supply wire diameter depends on the DCS system loading, and the grounding wire diameter shall be
identical to the power supply wire diameter.
6.1.1.3 DCS grounding
1) The cabinet shell of DCS system is not allowed to be connected directly with the building reinforcing
bars, and the cabinets shall be connected through the grounding wire, connected with electrical ground; the
phase cabinet shell, power ground, shielding ground shall be connected directly to the machine cabinet
grounding wire; ensure that DCS system shall meet the requirements of “one point grounding”, the whole
grounding system finally only has one point connected to the electrical grounding wire, and meets the
requirements of electrical grounding resistance.
2) DCS system input and output signal shielded wire grounding.
DCS system input and output signal shielded wire, usually is connected directly with the grounding cabinet
AC grounding wire. Signal shielding requires single end grounding. Signal end is non-grounded, and the
shielded wire is directly connected to the cabinet grounding wire; the signal end is grounded, and the shielded
wire shall be grounded at the signal end.
6.1.1.4 DCS system grounding system inspection and test
The inspection on DCS system grounding system shall be carried out at the unit major repair, which shall
at least include the following contents:
1) The cabinet shell of DCS system is not allowed to be connected directly with the building reinforcing
bars, and the cabinets shall be connected through the grounding wire, connected with DC grounding pole or AC
ground at one point.
2) The grounding wire and the earth pole connection point shall use the welding mode, with the welding
points of no fracture, rosin joint, and corrosion; the grounding wire between the cabinets can use the fixed mode
of bolts, which requires the gaskets, fastened bolts, with no rust.
3) The grounding pole shall not be loosened, and the grounding resistance shall comply with the
requirements.
4) The grounding resistance of the whole grounding system from the cabinet to the electrical ground shall
comply with the requirements of DCS system.
5) The input and output signal shielded wires shall comply with the single end grounding requirements.
6.1.2 System maintenance
6.1.2.1 Maintenance during DCS operation
1) DCS control cabinet
Inspection cycle shall be taken at least once a week, the inspection contents are as follows:
a. DCS control cabinet ambient temperature and humidity;
b. Fan filter cleaning and degree of soundness;
c. Cabinet temperature shall comply with the requirements of manufacturers. Fan shall work normally;
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immediately replace the fans that are abnormal during the operation, or take necessary measures;
d. The controller state and the working state of all the power supply and modules.
2) Control room, engineer station and its equipment
Inspection cycle shall be taken at least once a week, the inspection contents are as follows:
a. Get familiar with the thermal equipment operation conditions from the operating personnel;
b. The printer works properly, and the printing paper is sufficient;
c. The operation button, indicating bulb, the main parameters display card of LED liquid crystal, and the
display instruments work normally;
d. The operator station, engineer station, man-machine interface equipment, module, power supply, and the
fan work properly, with clean filters;
e. Use the operator station or the engineer station, to check the module working state, whether the
communication has alarm and the important thermal signal state.
f. The inspection shall keep records, and the monitor or team technician shall conduct acceptance on the
results of the inspection records.
g. As for the defects found at inspection, timely register and deal with them in accordance with the relevant
provisions.
6.1.2.2 Regular maintenance of equipment under operation
1) Keep backups of the whole project tree regularly. At making backups, a backup directory is better to be
established, under which a sub directory shall be established in the form of date, and then copy the whole
project tree to the sub directory, so as to facilitate the management.
2) Put all the configurations in the controller, that is, the CFG files, into EWS regularly. At making the
backup, a directory for CFG file shall be better to be established, under which a sub directory shall be
established in the form of date, and then put all the configurations in the controller into this sub directory.
3) Regularly check whether EWS works normally, including the existence of the security dogs and
LICENSE, and the communication established with ICI. They can be checked with the following methods:
Firstly, open a logic diagram randomly, and then click MONITOR order, if the data can be monitored, it means
that EWS works normally, otherwise, conduct corresponding inspection according to the error information on
the screen. Generally speaking, if any logic diagram can be opened, it means that there are no problems in
security dogs and LICENSE. In this case, most of the problems exist in ICI hardware. If the ICI hardware has
no problem, the computer communication interface setting may be wrong, or the computer communication baud
rate settings or the hardware configuration of ICI does not match, or the communication lines have problems,
and so forth.
4) Regular file the Event Log, and select Clear to eliminate the original event records in the project tree at
filing.
6.1.3 Hardware maintenance
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drawings. Right click on Print while pressing on Ctrl key, and print dialogue box will pop up. Then you can
bulk print the drawings.
6.1.4.8 Increasing I/O analog quantity
In logic diagram, find out an empty channel; define some information, such as point name. Click data base
→ Tag data base, copy a similar point and a window will pop up. In “general” column, fill in some information,
such as INDEX, NAME, Description and plant tag name. In “harmony” column, fill in some information, such
as ICI index pcu number and module block. Click the OK key.
6.1.4.9 Newly establishing or revising the logical configuration
For example, in the configuration software Control Engineering, open List/L1/P1/M3 of project tree one by
one, right click M3, click new → logic Document, and the window Add control logic will pop up. Fill in the
name of logic diagram and the newly-built logic diagram is created. Open it and logical configuration can be
conducted.
6.1.4.10 Revising graphics
Click the “DATA BASE” in graphics, then click the “Display”, and open the graphics authoring software
Display builder. Click OPEN, under the category of C:/Program data/ABB Symphony plus/operations/
SV1.0/display/work/UNIT GRAPHICS 14 DEC 13, open the graphics that need to be revised. If you want
displaying analog quantity points to be added, after unfolding the graphics, copy the points of the same type that
you want to add (points with the same temperature, pressure or percent) and paste in the graphics. Then change
the name of displaying points. In the end, click the “save” key and add it in the system.
6.1.4.11 Steps to download the controller
Firstly, pitch on the controller you want to download, right click, and choose “compile” for compiling.
After that, right click on the controller, click the “Run time → online configuration”, and it is finished.
6.1.4.12 Download of HMI station
Unfold the desktop folder named OSI-DISPLAY.BIN. If you have modified a graphics, five files would be
created. Copy these five files, unfold the folder named SEND TO ALL HMI, and right click for pasting. In the
end, click the batch file named S2BAT on the desktop and the task is completed. All the operator stations could
check the revised graphics.
6.1.5 System standby parts management and maintenance
6.1.5.1 Storage requirements
Requirements of storing modules are as follows:
1) All the modules shall be stored with antistatic bags wrapped or stored according to the requirements of
the manufacturer;
2) Temperature and humidity of module storage room shall meet the requirements of the manufacturer;
3) During storage, antistatic precautions shall be taken and actions of touching circuit board with hands are
forbidden;
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4) Time of storing modules shall be registered and it shall go through the in-warehouse and ex-warehouse
procedures.
6.1.5.2 Regular inspection
1) There shall be testing control cabinet for inspection and test of all kinds of modules in thermal specialty.
The control cabinet shall have the function of testing the reliability, functionality and stability of modules,
cables, terminal blocks and power supply.
2) Thermal staff shall inspect a few common spare parts saved in this major semiannually. The inspection
contents are as follows:
a. Surface is clean. There is no oil stain on printing plate plug-ins, and everything is normal after slight
click;
b. Everything is normal in software loading and unloading tests;
c. It is in proper working order in communication port and hand operating station;
d. It is in proper working order in analog quantity and on-off input and output channels;
e. Install the testing software and it shall work normally for no fewer than 48 hours;
f. Switchover test of redundant modules;
g. After the inspection, fill in the inspection record and stick the mark of conformity.
6.1.5.3 Inspection before using
Modules shall be inspected before being used:
a. Function inspection: all kinds of communication ports, I/O function and control algorithm;
b. Status inspection: inspecting the status of modules at the operator station;
c. Configuration inspection: configuration shall be loaded in modules and examine whether it is correct;
When putting it into use, set the module location and other switches. After the confirmation of guardian,
insert into right trench and fill in the record card.
6.1.6 Distributed control system maintenance
6.1.6.1 Thermal preparations before unit maintenance
1) Before unit maintenance, inspect, analyze and verdict the following devices through DCS operator
station and engineer station, so as to formulate and supplement the maintenance items:
a. DCS system modules, power supply, fans, I/O channel, communication network, operator station and
engineer station;
b. Measuring element, transmitter, actuator and various plate cabinets;
c. Major trend record and PID parameters of analog quantity control;
d. Steam engine vibration, differential expansion, eccentricity, boiler metal wall temperature, steam engine
wall temperature, generator coil and iron core temperature;
e. Verifying the exited guard and its definite value.
2) Before unit inspection, taking advantage of machine halt, test the system or equipment with defects
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specifically.
6.1.6.2 Maintenance items and cycle
Major repair goes along with major unit equipment maintenance. Major repair items include:
1) Major repair items
a. Comprehensively inspect the control equipments and make a good record;
b. Copy the configuration of all the modules;
c. Verify the configuration of the module marks;
d. Clean the control cabinet power supply and modules;
e. Clean dustproof strainer of the plate cabinet;
f. Examine and fasten the control cabinet wiring and set screws;
g. Examine the grounding system;
h. Take some dustproof and sealing actions over control cabinet;
i. Replace the cooling fan;
j. Power supply performance test;
k. Line insulation test;
l. Maintenance of recorder, printer, alarm window and man-machine interface device;
m. Eliminate the defects that cannot be handled in operation;
n. Recover and improve all kinds of marks;
o. Functional test of hardware equipments;
p. Loading and checking of configuration software;
q. Verification of measuring modules;
r. Site device maintenance;
s. Guard interlock test;
t. Examine and replace the cable, pipeline and its affixes.
2) Minor repair items
a. Minor repair goes along with unit minor repair. Minor items include:
b. Clean the dustproof strainer of the plate cabinet;
c. Inspect various cooking fans;
d. Inspecting the working condition of power supply and modules;
e. Functional test of hardware device;
f. Defects that cannot be handled during firefighting;
g. Maintenance of some in-place device;
h. Unit main protection and interlock tests;
i. Verification of some I/O modules;
6.1.6.3 Distributed control system equipment maintenance
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1) Regularly inspect the penetration point and leakage point of transmitter and seal of joint.
2) Verification of transmitter accuracy
6.3.3.2 Operating maintenance of FSSS system pressure, differential pressure and flow switch.
1) Regularly inspect the penetration point, leakage point and seal of joint
2) Inspect whether the sampling pipe of air and smoke system is blocked
6.3.3.3 Operating maintenance of thermocouple element
6.3.3.4 Operating maintenance of thermal resistance element
6.3.3.5 Operating maintenance of oil gun
Conduct once action test of oil gun every week to ensure that the oil gun is always in good hot stand-by
status.
6.3.3.6 Operating maintenance of high-energy ignition device
Conduct once action test every week to ensure that the ignition device is always in good hot stand-by
status.
7.3.3.7 Operating maintenance of oil valve and blow-down valve control system
Conduct once action test every week to ensure that the oil valve and blow-down valve control system are
always in good hot stand-by status.
6.3.3.8 Operating maintenance of oil trip valve and recycle valve control system
Conduct once action test every week to ensure that the oil trip valve and recycle valve control system are
always in good hot stand-by status.
6.3.3.9 Operating maintenance of flame detecting system
1) Regularly inspect the flame detection probe, cooling air house. No falling-off or leakage.
2) Regularly inspect the flame detection cabinet. No flame detection fault alarm.
6.3.4 FSSS system simulation test
6.3.4.1 MFT logic and the first condition of MFT
1) Manual MFT: purge and reset the MFT signal, manually press the MFT hard trip button on emergency
halt desk, and inspect the action of MFT relay in DCS power distribution cabinet. The CRT screen displays the
MFT signal, and the first condition of MFT is “manual MFT”.
2) The two forced air fan full halt: purge and reset the MFT signal, simulate the halt of two forced air fan.
The CRT screen displays the MFT signal, and the first condition of MFT is “the two forced air fan full halt”.
3) The two induced air fan full halt: purge and reset the MFT signal, simulate the halt of two induced air
fan. The CST screen displays the MFT signal, and the first condition of MFT is “the two induced air fan full
halt”
4) Furnace pressure third high-value: purge and reset the MFT signal, connect the two furnace pressure
third high-value signal from the terminal board. The CRT screen displays the MFT signal, and the first
condition of MFT is “furnace pressure third high-value”.
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5) Furnace pressure third low-value: purge and rest the MFT signal, connect the two furnace pressure third
low-value signal from the terminal board. The CRT screen displays the MFT signal, and the first condition of
MFT is “furnace pressure third low-value”.
6) Boiler water level third low-value: purge and rest the MFT signal, connect the two boiler water level
third low-value signal from the terminal board. The CRT screen displays the MFT signal, and the first condition
of MFT is “boiler water level third low-value”.
7) Primary air loss MFT: purge and reset the MFT signal, stimulate the primary air loss logic with software.
The CRT screen displays the MFT signal, and the first condition of MFT is “primary sir loss”.
8) Total air volume is less than 30%: purge and reset the MFT signal, stimulate the logic of that total air
volume is less than 30% with software. The CRT screen displays the MFT signal, and the first condition of MFT
is “total air volume is less than 30%”.
9) Fuel interruption MFT: purge and reset the MFT signal, stimulate the logic of fuel interruption. The CRT
screen displays the MFT signal, and the first condition of MFT is “fuel interruption MFT”.
10) Ignition failure MFT: purge and reset the MFT signal, imitate the logic of ignition failure. The CRT
screen displays the MFT signal, and the first condition of MFT is “ignition failure MFT”.
11) All furnace flameout MFT: purge and reset the MFT signal, imitate the logic of “all furnace flameout
MFT”. The CRT screen displays the MFT signal, and the first condition is “all furnace flameout MFT”.
12) Steam turbine trip MFT: purge and reset the MFT signal, imitate the logic of “steam turbine trip MFT”.
The CRT screen displays the MFT signal, and the first condition is “steam turbine trip MFT”.
13) Flame detection cooling air loss MFT: purge and reset the MFT signal, connect any two switch from
three pressure switch of A, B, C of “flame detection cooling air low pressure”. The CRT screen displays the
MFT signal, and the first condition is “flame detection cooling air loss MFT”.
6.3.4.2 FSSS system purging test:
1) Adjust any side of motor switch of forced air fan and induced air fan to the test position, start the forced
air fan and induced air fan. The CRT displays “any forced air fan or induced air fan operates”. The condition is
satisfied.
2) Adjust the motor switch of air preheater on both sides of A, B to the test position, start the air preheater.
The CRT displays “two air preheater operates”. The condition is satisfied.
3) Conduct oil leakage test. The CRT displays “oil leakage test is finished”. The condition is satisfied.
Close the oil.
4) Close all oil angle valve. The CRT displays “all oil valves are closed”. The condition is satisfied.
5) Trip valve. The CRT displays “oil trip valve is closed”. The condition is satisfied.
6) Close the separator outlet door of mill. The CRT displays “all outlet doors of separator are closed”. The
condition is satisfied.
7) Confirm that the condition of CRT’s displaying “coal mill is all halt” is satisfied.
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8) Confirm that the condition of CRT’s displaying “coal feeder is all halt” is satisfied.
9) Confirm that the condition of CRT’s displaying “primary air fan is all halt” is satisfied.
10) Confirm that the condition of CRT’s displaying “air volume is less than 30%” is satisfied.
11) Confirm that the condition of CRT’s displaying “pressure of furnace is normal” is satisfied.
12) Simulate the normal signal of boiler water level. Confirm that the condition of CRT’s displaying
“boiler water level is normal” is satisfied.
13) Confirm that the condition of CRT’s displaying “no MFT trip condition” is satisfied.
14) Confirm that the condition of CRT’s displaying “no flame in the whole furnace” is satisfied.
15) Start the flame detection cooling air fan. The CRT displays “differential pressure of flame detection
cooling air furnace is proper”. The condition is satisfied.
16) Set the automatic auxiliary air baffle. The CRT displays “auxiliary air baffle is automatic and not all
closed”. The condition is satisfied.
After the purging condition is satisfied, the CRT displays “purging request”. Start the purging procedure.
The CRT displays “in purging”, at the same time, count down the purging time for five minutes. If one
condition is not satisfied in the process of purging, the CRT displays “purging interruption”. If the procedure is
finished, the CRT displays “purging finish”. At the same time, reset the MFT signal.
6.3.4.3 Powder system logic
1) MTR logic:
a. Conditions of MTR are:
Manual MTR
MFT existence
Loss of primary air (two primary air fans all halt or the value of primary air/low differential pressure of
furnace is less than 5Kpa with a delay of 10 seconds of choosing two from three.
When the main motor of coal mill operates, all outlet doors of separator are closed.
When the main motor of coal mill operates, there is something wrong with the lubricating oil (two low
pressure pump all halt or the delay of low pressure of lubricating oil is 10 seconds)
High temperature of bearing before or after the operation of coal miller main motor is over 53℃ with a
delay of 1 minute.
When the main motor of coal mill is operating, time of any outlet door of separator’s being in middle
position is over 3 minutes.
The primary air door is closed without operators’ giving out the order to close the door.
The main motor of coal mill trips when the primary air shutoff door is not closed.
RB trips C coal mill
b. Reset the MTR signal: after the MFT is reset and no MTR condition, operators give the instruction of
“reset MTR” ON CRT. Then the “MTR existence” logical signal reset. Specially inspect this operation when
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control. The former mainly chooses the external ADS order, boiler order or maximum order permitted of unit.
After processed, these order converts to load order accepted by the unit as load set value. The latter mainly
chooses proper control method in accordance with unit operating conditions and requirements. According to
actual load order output power and pressure set value, the engine-boiler load control compares them with the
measured value, then output unit load order signal to control unit load.
a. Unit load order: when the unit ADS is automatic, accept ADS order signal, after line frequency deviation
correction, compare it with maximum load permitted, and choose the smaller one as unit load order.
When the manual DAS and ADS have fault or it appears working condition of RB, the smaller value of
boiler order and maximum load permitted is the load unit load order.
b. Unit load control: the engine-boiler load control has four methods: boiler/manual steam engine, boiler
follow, steam engine follow and coordinated control.
⑴ Boiler/manual steam engine: in the process of unit startup and halt or when the boiler and steam engine
equipment have flaw and cannot control automatically, switch the boiler/steam engine to manual to control and
regulate the fuel volume, maintain pressure; manually regulate the air volume to meet the volume needed of
boiler combustion, guarantee the optimum coefficient of excess air; manually control and regulate the power of
steam engine, maintain unit load.
⑵ Boiler follow method: the steam engine regulates and outputs electric power . Boiler regulates the
steam pressure automatically. When the load changes, the steam engine gives out control action, after the PT
changes, then the boil follow gives out control action.
⑶ Steam engine follow method: the boiler regulating unit outputs power. The main control of steam
engine regulates the steam pressure automatically. When the load changes, first, the boiler gives out control
order, after the PT changes, the steam engine gives out control order in accordance with steam pressure
deviation to regulate the steam pressure.
⑷ Coordinated control method: our plant adopts the coordinated control method based on boiler follow.
In this method, main control of steam engine regulates the electric power automatically, and main control of
boiler regulates steam pressure automatically. Because the difference between dynamic behaviors of
engine-boiler, control of boiler to steam pressure cannot keep pace with the disturbance from steam pressure
due to power change on steam engine side. Therefore, when the main control of steam engine controls the
power, at the same time, it controls the steam pressure. When the steam pressure decreases to a certain value,
the steam engine limits to open the main door of steam engine. The main control of boiler adopts some measure
to quicken the regulating of steam pressure as far as possible, in this way, it forms the coordinated control
method based on boiler follow.
RUNBACK
If the minimum capacity load is over actual unit load, then it is not permitted to give out RUNBACK
signal; if the minimum capacity load is less than actual unit load, then it is permitted to give out RUNBACK
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signal.
Block increase
When any one of the following condition satisfies, give out block increase signal:
Boiler water level is low
Total air volume<fuel quantity
Main control of steam engine block increase (PT>SETPOINT or GV AT HI LIMIT)
Primary air order is in maximum
Forced air fan order is in maximum
Induced air fan order is in maximum
Block decrease
When any one of the following condition satisfies, give out block decrease signal:
Boiler water level is high
Total air volume>fuel quantity
Main control of steam engine block decrease (PT<SETPOINT or GV AT LOW LIMIT)
2) MCS control subsystem mainly includes: combustion control, feed water control, steam temperature and
other parts.
a. Combustion control system:
The combustion system adopts air powder cross control. Fuel and air volume control system accept the
boiler order simultaneously, guarantee a certain coal-air ratio (air volume: coal volume = 1: 0.8) ; when
decrease the load, first, decrease the coal, and then decrease the air. When increase the load, firs, increase the air,
and then increase the coal; when control the air volume, increase the oxygen correction.
b. Fuel volume control:
The fuel volume control of our plant adopts the method that the volume of coal which enters into the
furnace is controlled by the volume of primary air. The system accepts the boiler load order, after limited by air
volume signal cross as total fuel order, output the order to coal order through fuel-control unit, add bias to the
coal order, then calculate the deviation Xd with the opening of primary air baffle, and Xd is the control
deviation of primary air baffle, regulate the primary air baffle opening, control the volume of powder which
enters into furnace, regulate the fuel volume.
c. Coal mill primary air control:
According to the coal volume, deviation of outlet temperature of separator and the primary air volume,
control the opening of bypass air baffle, and control the total volume of primary air which enters into the
furnace.
d. Coal feeder rotating speed control:
The system controls the volume of coal which enters into the coal mill and the coal level of coal mill
through controlling the rotating speed of coal feeder. When the boiler load changes, the system treats the change
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of primary air as leading signal, and it increases the rotating speed of coal feeder in advance and increases the
coal quantity and maintains the coal level of coal mill.
e. Coal mill outlet temperature control:
Control the coal mill outlet temperature through regulating the opening of cool and hot primary air baffles,
control the outlet temperature of coal mill separator in certain temperature. When start the mill, control the
outlet temperature of coal mill, heat the mill slowly.
f. Seal air fan baffle control:
According to the deviation of inlet pressure of coal mill and the set value, regulate the opening of seal air
fan baffle, control the outlet pressure of seal air fan in certain set value.
g. Fuel oil pressure control:
According to the average value (two pressure measure points) of pressure of main fuel oil pipe (behind the
tone) and the deviation of fuel oil pressure set value, the system regulates the opening of valve and maintains
the set value of fuel oil pressure.
h. Primary air fan static blade control:
According to the pressure set value (the pressure set value is calculated in accordance with main steam
flow by function) and air pressure of hot air pipe, the system regulates the opening of primary air fan static
blade and maintains hot air pipe air pressure as pressure set value.
i. Secondary air fan baffle control:
According to the deviation of air bellow/furnace differential pressure and set value (the set value is
calculated in accordance with main steam flow by function) , the system regulates the opening of secondary air
fan baffle and maintains the air bellow/furnace differential pressure as a set value.
j. Fuel air baffle control:
According to the value within 0 to 100% calculated in accordance with the air volume in each adjusting
valve of coal mill by function and comparison between the value and order output of regulator, the system
regulates the opening of secondary air fan baffle and maintains a certain secondary air volume.
k. Overfire air baffle control
According to comparison between the baffle opening of main steam flow calculated by function (the
opening which is not over 70% is 0, and the opening over 70% increases as the linear) and output order of
regulator, the system regulates the opening of overfire air baffle in accordance with the deviation to make the
overfire air volume match with the load.
l. Air supply control system
According to comparison between the output total air volume order (Can be put into the oxygen correction)
of main control of boiler and actual air volume, the system regulates the opening of forced air fan static blade in
accordance with the deviation and controls the total volume of air which enters into the furnace.
m. Furnace pressure control
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According to the deviation of furnace pressure and set value, the system regulates the opening of forced air
fan inlet dynamic blade and maintains the furnace pressure as set value. At the same time, the system add
differential of forced air fan even order signal as leading signal to guarantee that when the air supply volume
changes, the inlet dynamic blade act in advance to decrease the pressure surge in furnace.
n. Feed water control system
Under normal working condition, the system controls the rotation speed of steam pump and feed water
flow. Under startup or halt and abnormal condition, regulate the scoop of electric pump and the opening of
bypass feed water valve in outlet pipe to change the feed water volume.
o. Boiler water level control
Feed water control system of our plant adopts grading control of single-element and three-element. When
the unit starts or halts or bears low load (load <30%) , the system adopts single-element control. The system
regulates the rotating speed of feed water pump and feed water volume with deviation of boiler water level and
set value as the input signal of regulator. Under normal working condition (load >30%) , the system adopts
cascade three-element control (boiler water level is the regulated variable, and feed water flow is the feedback
signal of water level control, and steam flow is the feed forward signal) .
p. Feed water pump minimum flow recycling control
In order to prevent the feed water pump from cavitation, each pump is equipped with recycle. According to
comparison between the rotating speed of each feed water pump and the flow of pump, the system controls the
opening of recycle valve to make the cycle flow be over the flow limiting value.
q. Steam temperature control system
r. Overheating steam temperature control
It adopts two-level water-spraying regulating. Outlet temperature of overheater is the regulated variable
and temperature behind desuperheater is the leading steam temperature signal. The overheating steam
temperature is calculated from main steam flow by function to control the opening of water-spray valve and
maintain the steam temperature as a set value.
s. Reheating steam temperature control
⑴ Reheating smoke baffle control
In normal operation, the regulated variable of system is the average value of steam temperature of right and
left sides of reheater outlet, and the set value is the value calculated from main steam flow by function (operator
can add bias to correct in accordance with conditions) . According to the deviation, the system regulates the
position of reheating smoke baffle and regulates the temperature of reheating steam.
⑵ Reheater water-spraying temperature-reducing control
According to the deviation of outlet temperature of right and left sides of reheater and set value (it is
calculated from main steam flow by function, and operators can add bias to correct in accordance with
conditions) , the system regulates the valve opening of right and left sides, controls the water-spray flow and
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The connection shall be firm and orderly. Each name board and nameplate shall be complete.
b. Inspect the mechanical part. Connection of actuator mechanical part shall be firm. Travel switch shall be
installed firmly.
5) General inspection of AP control cabinet and relay cabinet
a. Clean the cabinet and inspect the mark. Clean the inner and outside of AP cabinet and relay cabinet of
MCS system. The relay shall have no dirt. Mark shall be complete.
b. Connection shall be firm. Inspect the coil resistance of relay. The connection shall be orderly and firm
without damage. Coil resistance of relay shall be consistent basically.
6) General inspection of oxygen volume measurement system (see oxygen volume measurement system
maintenance rules)
a. Clean the system and inspect the mark. Clean the zirconia probe and oxygen volume transmitter cabinet.
The connection shall be firm and each name board and nameplate shall be complete. Zirconia probe shall be
installed firmly.
b. Inspect the connection. The oxygen volume measurement system shall be installed firmly.
6.4.2.2 Maintenance items and technical standards of MCS system
1) Debugging of transmitter of MCS system. Debugging items are same with transmitter maintenance
rules.
2) Debugging items and technical standards of thermocouple and thermal resistance of MCS system.
Debugging items of thermocouple and thermal resistance are same with thermocouple and thermal resistance
maintenance rules.
3) Debugging items and technical standards of pneumatic actuator of MCS system. Debugging items of
pneumatic actuator are same with pneumatic actuator maintenance rules.
4) Debugging items and technical standards of electric actuator of MCS system. Debugging items of
electric actuator are same with electric actuator maintenance rules.
5) Debugging items and technical standards of card, relay and separator of MCS system. Debugging items
of clamping pieces, relay and separator maintenance rules.
6) Debugging items and technical standards of oxygen volume measurement system of MCS system.
Debugging items of oxygen volume measurement system are same with oxygen volume measurement system
maintenance rules.
7) MCS control system test
a. Preparation before test
⑴ Handle work tickets
⑵ Contact the maintenance department to ensure that all maintenance work has been finished.
⑶ Deliver power for regulating valve and baffle actuator of related system.
b. Test content
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matches the theory. If not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed action test respectively with cold air baffle and hot
air baffle of coal mill A, cold air baffle and hot air baffle of coal mill B, cold air baffle and hot air baffle of coal
mill C, cold air baffle and hot air baffle of coal mill D, cold air baffle and hot air baffle of coal mill E and cold
air baffle and hot air baffle of coal mill F. Respectively observe whether the position of regulating valve
corresponds to the order output. If not, then adjust the zero position and measuring range until they correspond
to each other.
Linkage test: at operator station, respectively open cold air baffle and hot air baffle of coal mill A, cold
air baffle and hot air baffle of coal mill B, cold air baffle and hot air baffle of coal mill C, cold air baffle and hot
air baffle of coal mill D, cold air baffle and hot air baffle of coal mill E and cold air baffle and hot air baffle of
coal mill F to an opening, manually trigger the primary air gate of coal mill A, B, C, D, E, F closure feedback,
observe whether the cold air baffles of coal mill A, B, C, D, E, F are fully opened and whether hot air baffles of
coal mill A, B, C, D, E, F are fully closed.
⑸ Coal mill bypass air volume control system
Locally add 4~20mA respectively to A1 side bypass air baffle and A2 side bypass air baffle of coal mill
A, B1 side bypass air baffle and B2 side bypass air baffle of coal mill B, C1 side bypass air baffle and C2 side
bypass air baffle of coal mill C, D1 side bypass air baffle and D2 side bypass air baffle of coal mill D and E1
side bypass air baffle and E2 side bypass air baffle of coal mill E. 4mA corresponds to the opening of 0%, and
20mA corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If
not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test respectively with A1 side bypass air baffle
and A2 side bypass air baffle of coal mill A, B1 side bypass air baffle and B2 side bypass air baffle of coal mill
B, C1 side bypass air baffle and C2 side bypass air baffle of coal mill C, D1 side bypass air baffle and D2 side
bypass air baffle of coal mill D and E1 side bypass air baffle and E2 side bypass air baffle of coal mill E.
Respectively observe whether the position of regulating valve corresponds to the order output. If not, then
adjust the zero position and measuring range until they correspond to each other.
⑹ Forced air fan control system
Locally add 4~20mA signal respectively to dynamic blade of forced air fan A and B with signal
generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe
whether the actual action of actuator matches the theory. If not, then adjust the zero position and measuring
range.
At operator station, conduct full open and full closed test respectively with dynamic blade of forced air
fan A and B. Respectively observe whether the position of dynamic valve corresponds to order output. If not,
then adjust the zero position and measuring range.
Linkage test: at operator station, respectively open the dynamic blade of forced air fan A and B to an
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opening. Manually trigger the forced air fan stopping feedback, observe whether dynamic blade of forced air
fan A and B are fully closed. Manually trigger the full closed signal of two forced air fan to observe whether
dynamic blade of forced air fan are fully opened. (delay 5 minutes) .
⑺ Induced air fan control system
Locally add 4~20mA signal respectively to dynamic blade of forced air fan A and B with signal
generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe
whether the actual action of actuator matches the theory. If not, then adjust the zero position and measuring
range.
At operator station, conduct full open and full closed test respectively with dynamic blade of induced air
fan A and B. Respectively observe whether the position of dynamic valve corresponds to order output. If not,
then adjust the zero position and measuring range.
Linkage test: at operator station, respectively open the dynamic blade of induced air fan A and B to an
opening. Manually trigger the forced air fan stopping feedback (it must ≥operation of one forced air fan) ,
observe whether dynamic blade of induced air fan A and B are fully closed. Manually trigger the full closed
signal of two induced air fan to observe whether dynamic blade of induced air fan are fully opened. (delay 5
minutes) .
⑻ Deaerator pressure regulating system
Locally add 4~20mA signal respectively to deaerator pressure regulating valve with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with deaerator pressure regulating valve.
Respectively observe whether valve position of deaerator pressure regulating valve corresponds to order output.
If not, then adjust the zero position and measuring range.
Linkage test: at operator station, open the deaerator pressure regulating valve to an opening, manually
trigger (PG PRESSUR HH) to observe whether the deaerator pressure regulating valve is fully closed.
⑼ Deaerator water level regulating system
Locally add 4~20mA signal respectively to deaerator water level regulating valves (main valve and
auxiliary valve) with signal generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the
opening of 100%. Observe whether the actual action of actuator matches the theory. If not, then adjust the zero
position and measuring range.
At operator station, conduct full open and full closed test with deaerator water level regulating valves
(main valve and auxiliary valve) . Respectively observe whether valves position of deaerator water level
regulating valves (main valve and auxiliary valve) correspond to order output. If not, then adjust the zero
position and measuring range.
Linkage test: at operator station, open the deaerator water level regulating valves (main valve and
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auxiliary valve) to an opening, manually trigger high water level signal of deaerator to observe whether the
deaerator water level regulating valves (main valve and auxiliary valve) are fully closed.
⑽ Reheater water-spraying temperature-reducing regulating system
Locally add 4~20mA signal to reheater water-spraying temperature-reducing regulating valve (valve in
left side and valve in right side) with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with reheater water-spraying
temperature-reducing regulating valves (valve in left side and valve in right side) . Respectively observe
whether valves position of reheater water-spraying temperature-reducing regulating valves (valve in left side
and valve in right side) correspond to order output. If not, then adjust the zero position and measuring range.
Linkage test: at operator station, open the reheater water-spraying temperature-reducing regulating
valves (valve in left side and valve in right side) to an opening, manually trigger MFT signal to observe whether
the deaerator water level regulating valve (main valve and auxiliary valve) are fully closed.
⑾ Air bellow furnace differential pressure regulating system
Locally add 4~20mA signal respectively to secondary air baffles (6) , auxiliary air baffles (3) , fuel air
baffles (6) and overfire air baffles (2) . 4mA corresponds to the opening of 0%, and 20mA corresponds to the
opening of 100%. Observe whether the actual action of actuator matches the theory. If not, then adjust the zero
position and measuring range.
At operator station, conduct full open and full closed test with secondary air baffles (6) , auxiliary air
baffles (3) , fuel air baffles (6) and overfire air baffles (2) . Respectively observe whether valves position of
secondary baffles (6) , auxiliary air baffles (3) , fuel air baffles (6) and overfire air baffles (2) correspond to
order output. If not, then adjust the zero position and measuring range.
Linkage test: at operator station, open the secondary air baffles (6) , auxiliary air baffles (3) , fuel air
baffles (6) and overfire air baffles (2) to an opening, manually trigger MFT signal to observe whether the
secondary air baffles (6) are fully opened, manually trigger all secondary air baffles to open feedback to observe
whether auxiliary air baffles (3) are fully opened.
⑿ Air preheater cold end temperature regulating system
Locally add 4~20mA signal respectively to control valve of air preheater A and B with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with control valve of air preheater A and B.
Respectively observe whether valves positions of control valve of air preheater A and B correspond to order
output. If not, then adjust the zero position and measuring range.
⒀ Primary air pressure regulating system
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Locally add 4~20mA signal to static blade of primary air fan (A, B) with signal generator. 4mA
corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the actual
action of actuator matches the theory. If not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with static blade of primary air fan (A, B) .
Respectively observe whether valves positions of static blade of primary air fan (A, B) correspond to order
output. If not, then adjust the zero position and measuring range.
Linkage test: at operator station, open the static blade of primary air fan (A, B) to an opening, manually
trigger primary air fan A stopping feedback signal to observe whether static blade of primary air fan A is fully
closed; manually trigger primary air fan B to stop the feedback signal to observe whether static blade of primary
air fan B is fully closed.
⒁ Seal air pressure regulating system
Locally add 4~20mA signal respectively to outlet baffles of seal air fan (A, B) with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with outlet baffles of seal air fan (A, B) .
Respectively observe whether valves positions of outlet baffles of seal air fan (A, B) correspond to order output.
If not, then adjust the zero position and measuring range.
⒂ Minimum flow recycle valve control system
Locally add 4~20mA signal respectively to recycle valve of electric pump, recycle valve of steam pump
A and recycle valve of steam pump B with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
At operator station, conduct full open and full closed test with recycle valve of electric pump, recycle
valve of steam pump A and recycle valve of steam pump B. Respectively observe whether valves positions of
recycle valve of electric pump, recycle valve of steam pump A and recycle valve of steam pump B correspond
to order output. If not, then adjust the zero position and measuring range.
Linkage test: at operator station, open the electric pump, recycle valve of steam pump A and recycle
valve of steam pump B to an opening, manually trigger the inlet flow <50t/h signal of steam pump A or B to
observe whether the recycle valves of steam pump A or B are fully closed.
6.4.2.3 Operation and maintenance of MCS control system
1) Carefully inspect the on-site equipment and its control equipment before delivering power for MCS
control system. Guarantee that the equipment is in good condition, and then deliver power for it.
2) After delivering power for MCS control system, carefully inspect that all signal of system is right, and
then conduct relevant operation with the equipment.
3) When the equipment is in operation, carefully monitor the operation of equipment. When the equipment
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has abnormal conditions, carefully inspect the equipment and handle the corresponding conditions.
4) In the process of operation, regularly inspect and clean the on-site equipment and control equipment of
MCS system to guarantee the operation of equipment is in good condition.
5) Common fault causes and their settlement methods
a. Remote operation does not act.
⑴ First, judge that whether the present signal has forced signal.
⑵ Inspect whether the local actuator is jammed and whether connecting lever and connecting rod have
falling-off.
⑶ Inspect whether the servo power supply is normal, whether the fuse is burnt, whether the air switch
trips and whether MCC delivers power.
⑷ Inspect whether the 4~20mA signal has been given out and whether closure of limit switch is normal.
b. Feedback indication is abnormal
⑴ Inspect whether the feedback potentiometer is normal.
⑵ Inspect whether the servo is normal.
⑶ Inspect whether the cable has grounding.
⑷ Inspect whether the feedback gear is worn.
c. Maloperation of limit switch
⑴ Inspect whether the adjustment of limit switch is appropriate.
⑵ Inspect whether the limit switch is worn.
6.5 Attendance Instruction for the maintenance and operation of automation system
6.5.1 Overview
6.5.1.1 Scope
This standard regulates the standards for the contents, methods and technical management of the
maintenance and operation of thermal automation system.
This standard is applicable for the maintenance and daily operation of thermal automation system in units which
have been put into production in power plant.
6.5.1.2 Standard reference documents
Technical Supervision Provision of Thermal Meter and Control Device in Thermal Power Plant (State
Power Safety Operation (1998) No.483)
Attendance Instruction for the Maintenance and Operation of Thermal Automation System in Thermal
Power Plant (DL/T 774-2004)
On-line Acceptance Test Instruction for Modulating Control System in Thermal Power Plant
(DL/T657—1998)
6.5.1.3 Preface
To ensure that automatic regulatory system stably operates before units start working, according to the
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standards regulated in Technical Supervision Provision of Thermal Meter and Control Device in Thermal Power
Plant (State Power Safety Operation (1998) No.483) , automatic regulatory system of operating units shall go
through inspection and maintenance, and regular disturbing test, and the automatic regulatory system after
maintenance, after main equipments are put into operation, shall act in time. The quality of regulation shall
comply with the requirements of regulatory system operation quality index. According to the real situation of
Daihai Company, main automatic regulatory system of operating units is checked every day. For regulatory
quality not compliant with requirements, disturbing test shall be conducted, and modify parameters in time to
reach maximum regulatory quality. Under other circumstances, disturbing test shall be conducted once a season,
and once after major repair of maintenance units. At present, according to standards regulated in Attendance
Instruction for the Maintenance and Operation of Thermal Automation System in Thermal Power Plant (DL/T
774-2004) and On-line Acceptance Test Instruction for Modulating Control System in Thermal Power Plant
(DL/T657—1998) , attendance instruction for the maintenance and operation of each automatic regulatory
system is therefore specially formulated.
6.5.2 Maintenance items and quality standards
6.5.2.1 Basic maintenance items and requirements
1) Inspection and check items:
a. Inspection after modulating control system hardware blacks out:
⑴Inspection of control module setup;
⑵Inspection of I/O module setup;
⑶Inspection of binding and setup of backup M/A (manual/automatic) ;
⑷Inspection of terminal board setup;
⑸Inspection of ground system before charging
b. Inspection and test after charging modulating control system hardware:
⑴Inspection of power module main/backup switching;
⑵Inspection of communication module main/backup switching;
⑶ Inspection of control module main/backup switching;
⑷Inspection of backup M/A operation station switching.
c. Inspection and test of modulating control system software:
⑴Inspection of coefficients and compensating parameters of flow signals;
⑵Inspection of exception report range and alarm limiting values;
⑶Inspection and simulation test of control software logic, set value, and parameter setup of each system;
⑷Inspection of relevant pictures of each control system
d. Inspection of peripheral equipments:
⑴Verification and confirmation of transmitter range;
⑵Confirmation of the schedule and direction of executing agency
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⑴The maximum flow when adjusting valve of feed pump exit shall meet maximum load requirements of
single feed pump, and there shall be a 10% surplus capacity;
⑵ When adjusting valves are all closed, leakage flow shall be smaller than 10% of maximum flow of
adjusting valve.
⑶Linear working segment of adjusting valve’s characteristic curve shall be over 70% of the whole journey,
and the hysteresis error shall not be larger than 3% of maximum flow of adjusting valve.
⑷Adjusting valve’s dead schedule shall be less than 5% of the whole journey.
b. Basic methods of characteristic test of feed water adjusting valve flow:
⑴ Before test, check when adjusting valve is wide open, whether feed water pressure has reached rated
value. Otherwise, adjust to elevate water pressure.
⑵During test, adjust feed water regulation to manual control; when unit is under stable operation condition,
manually opens adjusting valve discontinuously in one direction, and each time shall be best with 10% of
amplitude till adjusting valve is wide open.
⑶And then close adjusting valve with the same manner till it is completely closed up.
⑷Each closing or opening operation must be conducted after flow is stable.
4) Characteristic test of electric liquid speed regulating feed pump: electric liquid speed regulating feed
pump newly put into operation shall undergo test of relation characteristic between feed water exit pressure and
feed water flow under different rotating speed (speed regulating pump scoop pipe’s position and opening) . The
quality requirements are:
a. Regulating range of hydraulic coupling shall reach 25%-100%;
b. The relationship between the position and opening of hydraulic speed regulating pump scoop pump and
feedback voltage shall be linear, and its hysteresis error shall not be larger than 2%;
c. Within speed regulating range, feed pressure of pump exit and feed water flow characteristic shall
comply with the technical requirements of manufacturer.
5) Characteristic test of steam-driven speed regulating feed pump: steam-driven speed regulating feed
pump newly put into operation shall undergo test of relation characteristic between feed water exit pressure and
feed water flow under different rotating speed. The quality requirements are:
a. Adjusting range, according to the range confirmed by small steam engine, shall be set as 1-100%;
b. The relationship between feed water flow and load command shall be linear, and its hysteresis error shall
not be larger than 2%;
c. Within speed regulating range, feed pressure of pump exit and feed water flow characteristic shall
comply with the technical requirements of manufacturer.
6) Characteristic test of feed pump minimum flow recirculation control door: feed pump minimum flow
recirculation control door newly put into operation shall undergo test the quality requirements are:
a. Recirculation control flow shall be higher than feed pump minimum design flow;
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c. Dynamic condition and stability quality compliance report of boiler water level control.
10) Operation maintenance:
a. According to boiler water level, steam flow, and feed water flow, record curve every day and analyze
working condition of control system. If problems occur, they shall be eliminated in time;
b. Regularly compare boiler water level, steam flow, and feed water flow, and the output value of triplex
level redundancy transmitter. For transmitter out of tolerance, failures shall be eliminated in time;
c. Regularly check sampling measuring point, and the validity of measuring signals;
d. Regularly check characteristics of executing institutes and adjusting institutes;
e. Regularly check control quality recording curve of system under various working conditions. In case of
abnormalities, they shall be dealt with in time, and system shall be ensured to be intact.
11) Tests during operation: when stability quality index in operation is out of tolerance, disturbing test of
boiler water level shall be conducted.
12) Removal of control system:
In case of the following conditions, system could be automatically removed:
a. Feed pressure is lower than allowable minimum pressure;
b. When boiler load is in stable working condition and boiler water level exceeds alarm value;
c. Feed water control system breaks down.
6.5.2.3 Steam temperature control system
Steam temperature control includes control system of overheating steam temperature and reheating steam
temperature.
1) Test items and quality requirements before putting into operation:
a. Dynamic characteristic test of overheating steam temperature (conduct if necessary) : test contents
mainly include main steam temperature class under the disturbing of class two de-superheating water, dynamic
characteristic of class two steam temperature before circulating, temperature of intermediate point under the
disturbing of class one de-superheating water, and dynamic characteristic of class one steam temperature before
circulating, etc.; tests shall best be done under two kinds of load of 70% and 100%, and tests under each test
shall not be less than two times.
Thermo-reduction shall be controlled by manual operation. When units are under stable operation,
manually turn down (step change) the opening of de-superheating water’s adjusting valve for one time. The best
reduction (increase) range is 10% of de-superheating water flow. Record main steam temperature changes, and
end tests when main steam temperature rises (drops) and stay at new values.
b. Dynamic characteristic test of reheating steam temperature (conduct if necessary) : test contents include
dynamic characteristic of reheating steam temperature of swinging combustor inclination angle, or under the
swinging of rear smoke channel control baffle, and dynamic characteristic of reheating steam temperature under
the disturbing of re-heater de-superheating water; tests shall best be done under two kinds of load of 70% and
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100%, and tests under each test shall not be less than two times.
c. Characteristic test of de-superheating water adjusting valve: adjusting valves newly put into operation
shall undergo this test, and the quality requirements are as follows:
⑴ Maximum flow of adjusting valve shall meet the requirements of maximum load with about 10%
surplus capacity;
⑵Leakage volume of adjusting valve shall be less than 10% of the maximum flow;
⑶Adjusting valve characteristic curve is linear, working section shall be over 70%, and its hysteresis error
shall be less than 3% of the maximum flow;
⑷Dead schedule of adjusting valve shall be less than 5% of the whole journey.
When unit is under stable operation condition, manually turn up de-superheating water adjusting valve
discontinuously in one direction, and each time shall be best with 10% of amplitude till adjusting valve is wide
open; and then turn down valve in the same way till it is completely closed; turning down or up each shall be
conducted after flow is stable.
During test, when steam temperature is lower than allowed range because of excessive flow of
de-superheating flow, to ensure the safety of unit, characteristic test shall be conducted in different sections and
under various operation conditions according to the above mentioned methods. To prevent steam temperature
exceeds allowed range, test procedure shall be strongly monitored. If steam temperature is severely out of limit
or out of control, test shall be stopped immediately, and quickly resume valve opening to the position before test
till parameters are stable.
d. Swing characteristic test of smoke channel control baffle: After smoke channel control baffle major
repair, conduct rear smoke channel control baffle test under thermal state. Mechanical parts are required to
move flexibly without jam.
2) Control system input conditions:
a. Temperatures at each level and reheating steam temperature of main steam shall be correctly indicated
and clearly recorded;
b. De-superheating water adjusting valve and rear smoke channel control baffle shall have enough
adjusting surplus;
c. M/A operation station shall normally operate. Tracking signal shall be correct, and there is no switching
signal for manual operation.
3) Quality index (load range 70%-100%) :
a. Stability quality index: overheating temperature is ±3℃; reheating steam temperature is ±4℃; Actuator
shall not frequently operate.
b. When set value of overheating steam temperature and reheating steam temperature undergo a change of
±5℃, transient procedure attenuation rate is 0.75~1, and stability time is less than 20mins.
c. Dynamic condition and stability quality index under boiler-turbine coordinated control mode are listed in
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Table 1.
4) Maintenance acceptance check; after boiler major repair, the following test reports shall be provided:
a. De-superheating adjusting valve newly put into operation shall be provided with characteristic test
compliance report;
b. Rear smoke channel control baffle after major repair shall be provided with characteristic test
compliance report;
c. Dynamic condition and stability quality index compliance report of over-heating steam temperature and
reheating temperature control;
d. Dynamic characteristic test report of overheating steam temperature/reheating steam temperature (if
necessary)
5) Operation maintenance:
a. Get to know overheating and reheating steam temperature recording curve from operator on duty every
day, and according to the curve, analyze the operation condition of control system. If problems are found,
eliminate in time;
b. Regularly check the validity of measuring signals;
c. Regularly check the characteristics of executing institute and adjusting institute;
d. Regularly check control quality recording curve of the system under various operation conditions. In
case of abnormalities, they shall be dealt with immediately to ensure that system is intact.
6) Tests during operation:
a. If necessary, conduct disturbing test of de-superheating water flow;
b. If necessary, conduct swinging test rear smoke channel control baffle;
c. If necessary, conduct disturbing test of overheating steam temperature and reheating steam temperature
set value.
7) Removal of control system; in case of the following conditions, automatic removal could be considered:
a. When boiler is stable operation, and overheating steam temperature and reheating steam temperature
exceeds alarm value;
b.De-superheating water adjusting valve is wide open, but steam temperature still keeps rising, or
de-superheating water adjusting valve is completely closed, and steam temperature still keeps dropping;
c. Control system operation is not stable, de-superheating water flow undergoes great fluctuation, and
steam temperature shows regular attenuation fluctuation;
d. Leakage flow of de-superheating water adjusting valve is larger than 15% of the maximum flow;
e. Boiler operation is abnormal, and overheating steam temperature and reheating steam temperature
parameters are lower than rated value.
6.5.2.4 Combustion control system
Combustion control system includes furnace pressure control, air volume and oxygen volume control
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(secondary air register and air volume control, secondary air pressure control, oxygen volume correction, and
after-combustion air control) , primary air pressure control, and coal mill control (primary air volume control,
exit temperature control, and coal feed control) etc.
1) Furnace pressure control system:
a. Test items and requirements before putting into operation:
Dynamic characteristic test of furnace pressure (conduct if necessary) : after boiler major repair, if
necessary, conduct dynamic characteristic test of furnace pressure, and tests shall include dynamic characteristic
of blowing-in air volume, and furnace pressure change under induced air volume change, which shall be
conducted under different load sections.
b. Conditions for control system input:
⑴Boiler operation is normal, combustion is table and furnace pressure signal is correct and reliable;
⑵Protection circuit input such as Furnace pressure is under directivity lock, furnace pressure is under low
override control, and MFT override control;
⑶ Induced air volume of induced draft fan baffle, under maximum opening, shall meet boiler maximum
load requirements with enough surpluses;
⑷ M/A operation station operates normally, tracing signal is correct, and there is no switching signal for
manual operation.
c. Quality index (Load range 70%~100%) :
⑴Stable quality index: ±100Pa.
⑵ Furnace pressure set value disturbing (±150Pa) : transient procedure attenuation rate is 0.75~0.9, and
stability time is less than 1min.
d. Maintenance acceptance check; after boiler major repair, the following test reports shall be provided:
⑴Furnace pressure dynamic characteristic rest report (if necessary) ;
⑵Compliance report of furnace pressure control system quality index.
e. Operation maintenance:
⑴Furnace pressure sampling tube shall be continuously blown to ensure smoothness.
⑵Compare output value of furnace pressure triple level redundancy transmitter every day. For transmitter
out of tolerance, failure shall be eliminated immediately.
⑶ Get to know furnace pressure recording curve from operator on duty every day, and according to the
curve, analyze the operation condition of control system. If problems are found, eliminate in time;
f. Tests in operation: during operation, when stability quality index is out of tolerance, disturbing test of
furnace pressure set value shall be conducted.
g. Removal of control system: in case of the following conditions, automatic removal could be considered:
⑴Boiler combustion is not stable;
⑵Control system operation is not stable, and furnace pressure undergoes great fluctuation;
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adjusting baffle is wide open; and then turn down valve in the same way till it is completely closed; turning
down or up each shall be conducted after flow is stable.
When coal miller is under operation, choose to conduct when coal miller is started and grounded, and
stopped and cleansed; under other circumstances, opening-flow check could be conducted in sections according
to the above-mentioned methods, but primary air volume characteristic test for a whole journey shall not be
conducted.
⑵Dynamic characteristic test of temperature at coal miller exit (conduct if necessary) : tests include under
coal volume and hot wind air volume change, dynamic characteristic of temperature change at coal miller exit.
b. Condition for control system input:
⑴Coal miller system operation is normal, and there is enough desiccation output;
⑵Adjusting baffle opening shall have enough adjusting range;
⑶Signals of primary air volume, coal miller exit temperature, and coal feed volume, etc. It shall be correct
and reliable, and clearly recorded;
⑷Protection interlock circuit input between control system, and FSSS, and SCS system.
⑸Air and coal crossed and limited circuit input;
⑹M/A operation station normally operates, tracking signal is correct, and there is no switching signal for
manual operation;
⑺Primary air pressure control system is put into operation.
c. Quality index (load range 70%~100%) :
⑴Stability quality index: coal miller entrance primary air volume is ±5%; coal miller exit temperature is
±3℃.
⑵When primary air volume set value change by 5%, transient procedure attenuation rate is 0.75~0.9, and
stability time is less than 20s.
⑶Coal miller exit temperature set value change by 3℃, transient procedure attenuation rate is 0.75~0.9,
and stability time is less than 5min.
⑷ When opening change of high temperature air (or low temperature air) baffle change by 10%, control
system shall be capable to removal disturbing within in 3min, and maximum deviation of coal miller exit
temperature shall not be larger than 5℃.
d. Maintenance and acceptance check: after boiler major repair, the following test reports shall be
provided:
⑴Compliance report of primary air register air volume characteristic test;
⑵Dynamic characteristic test report of coal miller exit temperature (if required) ;
⑶Compliance report of control system quality index of primary air volume, exit temperature and coal feed
volume.
e. Operation and maintenance:
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Dead schedule of adjusting valve shall be smaller than 5% of the whole journey.
b. Conditions for control system input:
⑴De-aerator water level, feed water flow, and main condensation water flow shall be correctly indicated
and clearly recorded;
⑵Adjusting valve of de-aerator water level shall have enough adjusting range;
⑶De-aerator water level protection shall be put into operation;
⑷Condensation water recirculation flow control system shall be put into operation;
⑸M/A operation station normally operates, tracking signal shall be correct, and there shall be no switching
signal of manual operation;
⑹ Single impulse and three impulse adjusting performance shall be complete to realize no disturbing
switching.
c. Quality index (load range 70%~100%) ;
⑴ Stability quality index: ±20mm.
⑵ When water level set value change by 100mm, transient procedure attenuation rate is 0.7 ~ 0.8, and
stability time shall be less than 20min.
d. Operation maintenance; according to recording curve of de-aerator water level, analyze operation
condition of de-aerator water level control system. If abnormalities are found, eliminate them in time.
e. Tests during operation; when stability quality index during operation is out of tolerance, disturbing test
of water level set valve shall be conducted.
f. Removal of control system; when operation condition is stable and de-aerator water level exceeds set
value by ±200mm, automatic removal could be conducted.
2) De-aerator pressure control system:
a. Conditions of control system input:
⑴De-aerator normally operates, and operation mode complies with requirements of automatic adjustment;
⑵Adjusting valve shall have enough adjusting range;
⑶De-aerator pressure shall be correctly indicated and clearly recorded;
⑷De-aerator pressure protective device shall be put into operation.
b. Quality index (load range 70%~100%) :
⑴Stability quality index: ±20kPa.
⑵When de-aerator pressure set value change by 50kPa, control system shall stabilize pressure at new set
value within 1min, and transient procedure attenuation rate is 0.75~1.
c. Operation maintenance: if necessary, conduct disturbing test of de-aerator pressure set value.
d. Removal of control system: in case the following conditions, automatic removal could be considered:
⑴When operation is stable, de-aerator pressure exceeds alarm valve;
⑵ When adjusting valve is completely open and pressure continuously decreases, or adjusting valve is
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⑴ For load dynamic response characteristic test (conduct if necessary) of stabilizing pressure operation
mode, test shall be conducted under two load sections of 60% and 90%;
⑵ Load dynamic response characteristic test of sliding pressure operation mode shall be conducted during
the load section of 70%~80%.
2) Conditions for control system input:
a. Boiler operation is normal, and furnace combustion is stable;
b. Main and key parameters of unit power, load command, main steam pressure, speed regulating pressure,
total air volume, total combustion volume, etc. are correct and reliable, and clearly recorded;
c. DEH system function is normal, and could switch into CCS control mode;
d. Main control system of combustion, feed water, overheating steam temperature, reheating steam
temperature, and de-aerator, etc. have been put into operation;
e. Coordinated control system’s control modes and each parameter are correctly set and M/A operation
station of steam-turbine main control and boiler main control, etc. normally operates, tracking signal is correct,
and there is no switching signal for manual operation.
3) Quality index:
a. Load change test: under boiler-turbine coordinated control mode, within the load range of 70%~100%,
load command has a change rate of 2% Pe/min or 3%Pe/min, and load change volume is P=15% Pe. Load
unidirectional change test shall be separately conducted; trends and stability quality index of mainly adjusted
parameters of unit are shown in Table 1.
b. AGC load following test: under AGC control mode, and within the load range of 70 % ~ 100 % ,
bidirectional change test with continuous increase and decrease (or decrease and increase) shall be conducted
when load command is under declination mode with a change rate of 1.5% Pe/min and a load change rate of
P=10%Pe; Trends and stability quality index of mainly adjusted parameters of unit are shown in Table 1.
Table 1 Trends and stability quality index of mainly adjusted parameters of unit are shown in Table 1.
4) Maintenance and acceptance check. After unit major repair, the following test reports shall be provided:
a. After modifying control system software, coordinated control system functionality check and mode
switching test report shall be provided;
b. After modifying control system software, RB function simulating test report of coordinated control
system shall be provided;
c. Test report of load dynamic response characteristic (if required) ;
d. Under boiler-turbine coordinated control mode, qualification report of trends and stability quality index
of main adjusted parameters.
5) Operation maintenance; according to mainly adjusted parameters of unit power, load command, main
steam pressure, total air volume, total combustion volume, main steam temperature, reheating steam
temperature, boiler water level, furnace pressure, and smoke oxygen content, etc., analyze operation condition
of coordinated control system and each sub-systems. In case of abnormalities, eliminate them in time.
6) Test in operation; during operation, when stability quality index is out of tolerance, each sub-system
shall undergo set value disturbing test.
7) Removal of control system; in case of the following conditions, automatic removal could be considered:
a. Main measuring parameters, affecting coordinated control system decision, such as unit power, main
steam pressure, speed regulating pressure, total air volume, and total combustion volume, etc. have great signal
deviation or lose redundancy.
b. Mainly adjusted parameter severely exceeds limits, for example: main steam temperature deviation
exceeds ±15 ℃ ; reheating steam temperature deviation exceeds ±15 ℃ ; boiler water level deviation exceeds
±100mm; main steam pressure deviation exceeds ±1MPa.
c. Coordinated control system breaks down.
d. Computer control system has partial failure, and unit operation condition is deteriorated.
Main purpose of DEH control system is to control rotating speed and power of steam-turbine generator
unit to meet the requirements of power supply in power plant.
When unit is started and normally operates, DEH receives CCS command or operators, through human
machine interface, send out increasing and decreasing command. Collect signals of steam-turbine generator
unit’s rotating speed and power, and position feedback of adjusting valve, analyze and treat for comprehensive
calculation. Output control signals to hydraulic serving valve, and change the opening of adjusting valve to
control unit operation.
When unit is rising (namely units are not synchronized) , DEH, by means of acceleration control circuit
and speed control circuit, controls unit rising and rotating speed till actual rotating speed and target rotating
speed are equal. When DEH receives synchronous command, actual rotating speed undergoes periodic swinging
at around rated rotating speed and with certain amplitude and frequency till synchronization is completed.
After unit is synchronized, first by means of ring opening directly set flow command to control valve
opening with load. Input power at the side of DEH or pressure closed-loop for adjustment, or by means of CCS
input to control load.
DEH has valve management function, capable of realizing mutual switching from single valve to sequence
valve or from sequence valve to single valve.
DEH has valve action test function. When one high pressure adjusting steam valve action is under test,
main steam compensator produces load compensatory command and controls the opening of other high pressure
adjusting steam valve, which makes the actual load remains the same during high pressure adjusting steam
valve action. Besides, there are high pressure main steam valve and medium pressure steam valve action test
function.
When unit trips, set valve opening set signal as 0%, and close all valves.
DEH control system is set with valve limitation, quick release load, steam-turbine protection, and primary
frequency modulation, etc. Multi-DEH control system is set with operation modes of CCS coordinated control,
ATC self-starting, automatic control, and manual control, etc.
When DEH enters ATC control mode, according to thermal stress calculation result, automatically set
target, and choose appropriate speed rising rate or load rate to conduct automatic control of unit.
7.1.2 DEH engineer station
7.1.2.1 Overview
Engineer station adopts DELL Precision T3600: interface module adopts the latest IET800. IET800 could
be compatible with former Modbus communication through rear panel and through Ethernet communication on
front panel. It is widely applied with simple usage. Communication rate is improved and performance is stable.
Operation system is Windows7 64 bit in English professional version, and configuration software is
S+Engineering: Composer Harmony System 6.0.
Engineer station has the following functions:
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6) Call historical alarm and data, check the operation condition of magneto optical drive, and record test
conditions;
7) Open each test group, each configuration software function is normal, and make records;
8) After modifying some configurations, download database configuration or image configuration, and
record modifications;
9) Power cable insulation test: adopt 500V mage meter to measure insulation between lines and ground
insulation, and record test results;
10) Turn on two routes of power, and then turn off one power, and check whether another power has
automatically switched, and whether the operation state of engineer station has been affected. Otherwise, turn of
the other power, and check the operation state of system, and record switching results.
7.1.2.5 Quality standards of acceptance check
1) Main engine, CRT, keyboard, and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, cabinet door shall be complete and well sealed, and environment
temperature is required with load;
3) Check records and examine whether functions of operating image, trend chart, alarm log, etc. comply
with requirements;
4) Check test records, engineer station and interchanger shall be normally connected, system state diagram
displays that network communication is normal, and conduct real-time monitoring of network redundancy
switching, which shall not affect engineer station;
5) Check test records, and engineer station shall have no printing failure display;
6) Check test records, take it as historical station, the function to call historical alarm and data is normal,
and magneto optical drive operation is normal;
7) Check record condition, and each software configuration function of engineer station shall be normal;
8) Check configuration modification records with complete standards;
9) Power cable insulation test: adopt 500V mega meter to measure insulation between lines and ground
insulation, and insulation resistance shall be larger than 20 megger;
10) Check record results, and two routes of power are required to be completely redundant, and switching
time complies with requirements;
7.1.3 DEH operator station
7.1.3.1 Overview
Operator station adopts DELL POWEREDGE R420, client adopts DELL precision T3600, and interface
module also adopts the latest IET800. Operation system is Windows7 64 bit in English professional version, and
operation software is S+Operation 1.1.1.
Operator station has the following functions:
● Procedure chart monitoring and operation
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● Alarm management
● Trend display
● Measuring point information/measuring point check
● Operator event report
7.1.3.2 Common failure and treatments
1) Common failures
a. Printing service failure
b. Image point is connected by mistake.
c. Machine opening window failure
2) Treatments:
a. Check whether alarm printer is normally connected, printer power is normal, and confirms alarming.
b. Modify picture connection, and re-download pictures.
c. Log in as super user, and restart machine.
7.1.3.3 Maintenance items
1) Check main machine, CRT, keyboard, and mouse appearance, make use of each downtime opportunity
to cleanse inner dust in machine;
2) Check operating desk and cabinet appearance, and make use of each downtime opportunity to cleanse
interior and exterior of operating desk;
3) Function test of operation pictures, trend chart, and alarm log, etc;
4) Check connection cable between engineer station and interchanger, and network communication;
5) Check the connection between operator station and alarm printer, and test printing function;
6) Power cable insulation test;
7) Power switching test;
8) System data backup
7.1.3.4 Maintenance process standard
1) Main engine, CRT, keyboard and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, and cabinet door shall be complete and well sealed;
3) Check whether functions of operating pictures, trend chart, and alarm log are normal, and record check
results;
4) Check the communication connection between engineer station and interchanger, and conduct network
redundancy switching, and record test conditions;
5) Check the connection of printer, test printing functions, and record test conditions;
6) Power cable insulation test: adopt 500V mage meter to measure insulation between lines and ground
insulation, and record test results;
7) Turn on two routes of power, and then turn off one power, and check whether another power has
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automatically switched, and whether the operation state of engineer station has been affected. Otherwise, turn of
the other power, and check the operation state of system, and record switching results.
7.1.3.5 Quality standards of acceptance check
1) Main engine, CRT, keyboard, and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, cabinet door shall be complete and well sealed, and environment
temperature is required with load;
3) Check records and examine whether functions of operating image, trend chart, alarm log, etc. comply
with requirements;
4) Check test records, operator station and interchanger shall be normally connected, system state diagram
displays that network communication is normal, and conduct real-time monitoring of network 5.5 redundancy
switching, which shall not affect engineer station;
5) Check test records, and operator station shall have no printing failure display;
6) Power cable insulation test: adopt 500V mega meter to measure insulation between lines and ground
insulation, and insulation resistance shall be larger than 20 megger;
7) Check record results, and two routes of power are required to be completely redundant, and switching
time complies with requirements;
7.1.4 DEH power cabinet
7.1.4.1 Overview
DEH power cabinet accepts two routes of 220VAC power, from security section and UPS. Un-switched
power is directly sent to power switcher with a small power, and two routes of power are output to ensure
normal operation of two interchangers. Un-switched two routes of power are separately sent to control cabinet
and two power modulates to conduct redundancy power supply for controller. OPC magnetic valve accepts two
routes of 220VDC power from electric 220VDC direct current screen 1 and electric 220VDC direct current
screen 2.
7.1.4.1 Failure treatment
Common failure: cable insulation declines and power switch trips.
Treatment method: turn off relevant power switch, check the insulation condition of output lines, replace
backup line for recovery, and after insulation is tested to be qualified, turn on power to check whether power has
been restored.
7.1.4.3 Maintenance items
1) Power supply state and supply voltage check;
2) Contact operation, turn off upper-end power, and clean up;
3) Fasten terminal connection;
4) Insulation test of 220VAC power supply cable;
5) Turn off each output switch, charge for on-load test, and power is switched to another circuit;
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steam-turbine reaches 30%~ 40%, high pressure steam source and low pressure steam source jointly provide
steam. At this time, low profile governing valve LPGV follows feed water command and is completely opened,
and then adopt high profile governing valve HPGV to control.
Control system has three operation modes: boiler automation, rotating speed automation and manual
operation. Switching among three modes is realized by software.
7.2.1.2 Main functions of control system, also technical requirements after equipment maintenance.
1) Automatic control of boiler feed water volume.
2) Automatic control of feed pump steam-turbine rotating speed
3) Regulating valve position control
4) Normal operation and monitoring
5) Over speed protection and test
6) ETS tripping protection of small steam-turbine feed pump
7.2.1.3 System hardware configuration:
MEH is procedure control unit (PCU) . Its node number on control loop is 22, and unit plant has two
cabinets. Terminal cabinet number is 22A, and module cabinet number is 22B. The type and quantity of this
module adopted in this system are as follows:
No. Equipment name Specifications and models Quantity Unit
Redundant network interface module, terminal and
1 SPNIS21/SPNPM22 1 set
cable
2 Redundant bridge controller module and cable SPBRC410 2 set
3 Digital input sub-module, terminal and cable SPDSI14 4 set
4 Digital output sub-module, terminal and cable SPDS014 4 set
5 Frequency calculating sub-module, terminal and cable SPFCS01 6 set
6 Simulating input sub-module, terminal and cable SPFEC12 2 set
7 Simulating output sub-module, terminal and cable SPAS011 2 set
8 Hydraulic serving sub-module, terminal and cable SPHSS03 4 set
9 III type power MPSIII 1 set
2) For general check of MEH system local equipments, check MEH sensors, including each sensor and its
extension cord, front-end machine, transmitter, electro-hydraulic convertor, etc. Check site magnetic valve,
secondary valve, and whether each measuring point of oil system has leakage point. At the same time, check
whether there is evident damage and burning, etc at cabinet switches. Check each cable, relay and transformer
inside local control box has any damage and burning, etc. Record test results.
7.2.2.2 Maintenance procedure
1) MEH cabinet maintenance
a. Make maintenance work ticket. Stop plant UPS, and send plant security power to the two routes of
power controlled by MEH.
b. Stop each route of power and security inside each MEH cabinet.
c. Inner check of cabinet and clean up dust
d. Use hairbrush and vacuum cleaner to clean up fan.
e. Clean up dust in terminal strip, and check whether connection is fastened.
f. Check rotating speed passage and shielded line.
g. Appearance check of preset cable inside cabinet, check whether plugs are loosened, fasted, and set
screws are complete.
h. SG inside cabinet, and CG ground check is normal.
i. Clean printed board inside cabinet: use hairbrush and silk to clean each card. When cards are plugged in
and pulled out, adopt appropriate force. After maintenance, connection on printed board shall be firm.
2) Control cabinet power transmission
a. Provide MEH control cabinet with two routes of 24VDC power, check whether 24VDC power from
CUM01/CUM02 cabinets and voltage of power switching diode are balanced. If normal, check whether 24VDC
of electro-hydraulic convertor is normal.
b. After power is checked to be normal, close mini fuses on terminal strip under MEH cabinet. Send
module and turn on power switch of DPU control power module, confirm whether power indicator light on
DPU is normal and SPU indicator light is normal.
c. Observe whether indication of each MEH cabinet module is normal. By means of engineer station lower
computer, observe operation condition of DPU and I/O cards, and confirm that their operation is normal.
3) Local equipment maintenance
a. Make maintenance work ticket; turn off lubricating oil system of small engine, and turn off local panel
power of small engine.
b. Adopt multi-meter to test power, and confirm that there is no electricity in local panel.
c. Pressure switch maintenance
⑴ Appearance check; Switch connector has no leakage of oil. Switch contact normally actions, set value
calibration is correct, and switch is cleaned up.
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⑵ Insulation test; in local panel, disconnect each switch connection, and adopt 500V megger to measure
ground resistance value against each line, which shall be over 10MΩ.
⑶ Record switch connection, disconnect switch, wrap wires with insulating tape, and wrap up sampling
tubes.
⑷ Switch re-installation
d. Magnetic valve maintenance
⑴Check magnetic valve appearance
⑵Check magnetic valve plug, and whether connection is firm, and connection shall be fasted.
⑶Test direct current resistance of magnetic valve, and resistance value shall comply with values indicated
in nameplate and comply with its working requirements.
⑷ Conduct magnetic valve power-on test, and slide valve inside valve shall move flexibly without
jamming.
e. Relay maintenance
⑴Clean up relay, and connection shall be checked to be fastened.
⑵ Check relay output contacts. Adopt multi-meter to measure its closed resistance value. If resistance
value is larger than 0.1Ω, relay is taken as unqualified. Polish contact to make the resistance value less than
0.1Ω, or change relay.
f. Switch maintenance at valve position
⑴For switch maintenance at valve position , first conduct appearance check of switch at the position, and
check whether set screws are loose, and connection are firm.
⑵ Use hand to move each moving parts, which shall be flexible without jamming; At the same time,
adopt multi-meter to measure each contact, and closed resistance shall be below 0.1Ω.
g. Local panel charging, and rotating speed indication is normal.
h. Valve LVDT check; conduct appearance check of LVDT, and whether set screws are loose, connection
are firm, and whether snakeskin casing pipe has worn out. The position of LVDT shall be correct, iron core
connecting rod moves flexibly without jamming.
4) Static joint debugging and performance test of MEH control system
a. Installation debugging of speed measuring passage
⑴The installation of speed measuring probe requires that the space between gear and speed measurement
shall be δ=1.2±0.1mm, stand and speed measuring probe shall be fastened, and gear shall not have burr.
⑵Check speed measuring cable, and shielding layer shall be grounded with “single point” at MEH.
⑶Connection requirements
Connection between local terminal box and MEH cabinet shall adopt cable with shielding layer, and the
shielding layer has ground insulation. At MEH terminal strip, shielding layer is connected with terminal “I”.
Local terminal box is not connected, but shall be wrapped and fastened.
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Speed measuring probe introduces line to local terminal box, and shielding cable, signal line and
shielding layer could be installed at the terminal of connection box.
The three speed measuring probes of MEH shall adopt three cables to avoid mutual disturbance. Passage
test: adopt frequency generator signal to simulate speed measuring probe signal. Untie speed measuring probe
line at local terminal, connect simulating signal, change signal frequency and fill the following table:
F
50 100 500 1000 2000 3000 4000 4500 5000 5500 6000 6500 7000
(Frequency)
N
According to actual requirements, separately test electric over speed value f=5800 and backup electric over
speed value 5920, the value of n, and f is frequency generator frequency, and n is the rotating speed display of
engineer station or operator station. Required control precision: f=n±1%f.
b. Static joint debugging operation: signals of each pressure switch correctly transmit, the action of LVDT
whole journey is linear without jamming, and the display of zero and full point correspondently shown on upper
machine are 0~100%. Adopt laboratory table frequency signal to correspond with tachometer and display shall
be correct, and correspond with upper machine and rotating speed shall be correctly displayed.
c. When valve is actually latched, pressure of starting oil and quickly closing oil are normally established,
action time is correct, and the time of valve latching is within design range. When valve is locally latched, valve
is quickly closed, and valve closing time shall not exceed 2s.
d. Serve circuit adjustment
⑴Static test of serve system ring opening
Adjustment of LVDT amplifier zero point and gain adjustment; after confirming the mechanical zero
position of LVDT, adjust the zero position potentiometer of amplifier to make the valve indication of DCS
indicate at 0, and then confirm the full scale of LVDT. Adjust gain potentiometer, and make the valve indication
of DCS indicate at 0.
Repeat for several times till the value stays the same.
⑵Adjustment of electro-hydraulic converter
Switch position adjustment of electro-hydraulic converter:
The command of electro-hydraulic converter output from DCS is 0, the current of correspondent
electro-hydraulic converter is 4mA, and conduct professional maintenance, and adjust electro-hydraulic
converter’s oil circuit to change valve position till it is completely closed.
Adjust valve opening with the same methods.
Position record of adjusting valve:
After small machine is latched, DCS system controls the output command of valve, and at the same time,
record command of valve, position feedback and the actual position of local valve.
In the table, four special operation conditions are: tripping, latched, medium and wide open. Each valve:
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d. Stop MEH cabinet, and stop small engine local panel power.
3) Under live state, it is strictly forbidden to remove cards or disassemble components on cards.
4) Cabinet shall be kept clean and dry.
5) Regularly conduct light test on control panel.
6) Regularly check whether each light indication is normal, and whether state indication on passage board
is normal.
7) Note operation state and mode of MEH controller.
8) Regularly conduct quickly closing valve test.
9) If MEH breaks down, MEH could be maintained by professionals.
7.2.2.4 Item list of MEH major repair and minor repair
1) MEH system power and cabinet cleaning
2) MEH system card dust cleaning and maintain, and partial adjustment
3) MEH logic check
4) Small engine local equipment, and magnetic valve maintenance and cleaning
5) Maintenance of temperature measuring elements, pressure switch, valve journey switch, and LVDT in
small engine
6) MEH function test
7.3 Maintenance rules of big machine ETS system
7.3.1 Overview
7.3.1.1 Technical regulations
1) Vinh Tan power plant ETS adopts PLC system from Schneider and redundancy configuration. Through
communication, connect to DCS system factory main bus, and conduct resetting and test operations on image.
But signals of all protection function adopt hardwiring connection.
2) ETS system monitors some important signals of steam-turbine to ensure the safety of steam-turbine
equipment, in accordance with ASME standard TDP-1-1985 and other requirements.
3) By adopting proper redundancy technology and independent control system, ensure the high reliability
of ETS system. Any system failure shall not affect the operation of the whole system.
4) Adopt the method of “power loss tripping”.
5) Control system has complete self-diagnostic function, and the condition for action to send SOE to DCS
system.
6) ETS provides information at key point to DCS system to give alarm and display.
7) All functions of ETS meet the technical requirements put forward by steam-turbine manufacturer.
8) Control system has independent power, supplied by DCS system. DCS power is provided by two routes
of UPS and security section.
7.3.1.2 Fundamental working principle of ETS
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1) ETS system, under dangerous operation condition, could make emergency trip magnetic valve AST lose
power and steam-turbine trip. Its main function is to check the validity of the signal for tripping, and make sure
that tripping action immediately reacts to effective tripping command signal, so as to reduce equipment damage
to the great extent.
2) ETS shall meet the following requirements:
a. Each tripping function is designed with proper delay and limit condition to make sure that tripping
action is correct and to reduce tripping by mistake as much as possible.
b. Important signals and simulating tripping function could be tested on-line. During function test or
maintenance, if protection conditions are not compulsory, protection still works.
c. Tripping source of all electric signals comes from contacts without source.
d. Provide two outputs for each tripping input, and one for steam-turbine tripping, and one for SOE of DCS
system.
e. The first emitted tripping signal shall be used for identifying the main cause for tripping, and this signal
shall be sent to the initial image of DCS system.
7.3.1.3 Steam-turbine emergency tripping system ETS shall include the following tripping conditions:
1) EH oil pressure is lower than 9.30MPa (two points on one side or given again) ;
2) Lubricating oil pressure is lower than 0.048MPa (two points on one side or given again) ;
3) Condenser vacuum (high pressure side) is lower than -20.3KPa (two points on one side or given again) ;
4) Condenser vacuum (low pressure side) is lower than -20.3KPa (two points on one side or given again) ;
5) Axial displacement is larger than 1.0mm or smaller than -1.0mm (two points on one side or given
again) , and at every point of TSI, there is 1S delay;
6) 110% over speed (take 2 out of 3) ;
7) Mechanical backup 114% over speed (take 2 out of 3) ;
8) Bearing vibration is larger than 254μm, and bearing vibration alarm of upper nearby tile is larger than
127μm, and at every point of TSI, there is 3S delay.
9) DEH power loss (take 2 out of 3)
10) Bypass operation without synchronization (DEH signal) and high bypass tripping (bypass signal) has a
1min delay;
11) Boiler MFT protection;
12) Manual shut-down;
a. Press two buttons on operating desk at the same time, normally closed contacts of each button are in
parallel connection to form four groups of normally closed contacts and connect with four AST magnetic valve
power circuit, which is hardwiring tripping;
b. Press two buttons on operating desk at the same time, normally open contacts of each button are in
parallel connection to form four groups of normally open contacts, and send ETS with logic tripping of 2 in 3,
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three latching signals fail to come in 1 minute, namely steam-turbine is not latched, the four AST magnetic
valves’ electrification will lose power.
7.3.2 Maintenance items and quality standards
7.3.2.1 ETS system power cut
1) Cut ETS system power.
2) In ETS cabinet, measure power input, and start operation after confirming that there is no voltage.
7.3.2.2 Local equipment maintenance
1) Pressure switch verification
a. Close pressure switch secondary valve, dismantle pressure switch connection, wrap thread residues with
insulation tape, make marks, and get back to pressure switch.
b. Pressure switch appearance check: mark shall be clear, correct and tidy. Appearance shall be intact.
c. Clean up dust, and there is not dust inside and outside switches.
d. Pressure switch verification: verify according to pressure switch verification regulations.
2) Maintenance of axial displacement and vibration are introduced in TSI.
3) Magnetic valve maintenance
a. For appearance check, mark shall be clear, correct and tidy. Appearance shall be intact.
b. Resistance value test of magnetic valve coil and R is regulated value.
c. Insulation test of magnetic valve coil and shell, and insulation resistance is larger than 50MΩ.
d. While magnetic valve stops power supply, feel magnetic valve and the difference of sending or stopping
power supply.
4) Maintenance of ETS over speed measuring probe
a. Check connection in local junction box, and whether there is short-circuit and local, connection is in
good state, cable from junction box to speed measuring probe is intact, and whether there is heated cable
insulation damage;
b. Adopt multi-meter to measure whether the resistance of over speed measuring probe is normal around
160Ω;
c. Check whether speed measuring probe has serious abrasion, and if so, it shall be replaced.
d. When speed measuring probe is fit back, it shall pair with the tooth on axle, and the space between teeth
shall be between 1.2mm and 1.5mm.
7.3.2.3 ETS cabinet maintenance
1) Relay verification
a. The resistance of relay contact against shell is larger than 20MΩ. Resistance value test of contacts is
smaller than 0.1Ω.
b. The starting value of relay, and verify release value.
c. Adopt multi-meter to measure coil resistance value. Dc resistance is 100Ω.
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2) Check and verification of over speed card: circuit board is intact, elements are firmly welded, and both
are clean and tidy. Check whether the connection and state of pre-amplifier are normal.
3) Check 24VDC cabinet power, AST power, and test magnetic valve power:
a. Check whether 24VDC cabinet power fuse is intact, and whether each connection is grounded or in poor
contact;
b. Check that the insulation of AST power and test magnetic valve power shall be qualified, and each air
switch shall comply with requirements.
7.3.2.4 Local cable insulation test and space insulation test, and insulation resistance shall be larger than
20MΩ.
7.3.2.5 Terminal strip and label plate check, connection shall be firm and number shall be clear.
7.3.2.6 Local equipments installation shall be correct and connection shall be correct.
7.3.2.7 Button and connection check of manual latching operating desk
7.3.2.8 System circuit check, and if there is no error, power could be sent.
7.3.2.9 I/O module check
1) Check the module state in ETS system, and whether the state of ETS, communication module, and I/O
module indicator light are normal.
2) Test whether the precision and accuracy of I/O module passage are normal.
3) Check whether communication point display of all ETS in DCS image are normal.
7.3.2.10 Check the logic configuration of ETS system carefully, and if there is no error, conduct the following
test.
7.3.2.11 Steam-turbine latching test
1) Latching conditions:
EH oil pressure and lubricating oil pressure shall be normal, start seal oil pump, and relieve condenser
vacuum low signal. Press “Steam-turbine latching” button on DEH image, then steam-turbine shall be latched,
and “Latching” is displayed on DEH image.
2) If turbine couldn’t be latched during the period, check whether each magnetic valve in AST is electrified.
If so, it means that ETS system is normal .Otherwise, conduct overall check of ETS system.
3) After steam-turbine latching, press latching button again, then steam-turbine leaks oil and trips, and on
DEH image, “Trip” is displayed.
7.3.2.12 Test magnetic valve
In logic, force control relay to close, and magnetic valve shall be electrified. Otherwise, check circuit, relay
and power circuit.
7.3.2.13 Transmission check of protection circuit
1) Relieve current tripping conditions, and when steam-turbine latching conditions are met, steam-turbine
shall be latched.
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2) Check the display state of all points in ETS image, and if all are normal, start transmission.
3) Conduct passage test. Conduct test for four test blocks of EH oil pressure low, lubricating oil pressure
low, high, and low pressure condenser vacuum low and eight magnetic valves. During test, mainly check
whether EH oil pressure low, lubricating oil pressure low, high, and low pressure condenser vacuum low and
ASP1, and ASP2 switch action are normal. Check whether the actions of group 1 of AST1 and AST 3, and
group 2 of AST2 and AST4 are normal, and whether after resuming electrification, ASP oil pressure is normal.
Normal ASP oil pressure is around 7MPa and ASP1 is larger than 9.3MPa. ASP1 action shows that group 1 of
AST1 and AST3 (one or two) has power loss or is not closed; ASP2 is smaller than 4.14MPa, and ASP2 action
shows that group 2 of AST2 and AST4 (one or two) has power loss or is not closed.
4) Protection logic transmission from local simulating signal; On TSI cabinet or terminal, simulate signal;
in DEH logic, simulate enforcement, on bypass terminal, add signal, check each tripping condition, check
whether steam-turbine could normally trip, delay time is correct, and the first image is correct.
7.3.2.14 Operation and maintenance:
1) Daily maintenance:
a. Local pressure switch and magnetic check; Pressure tap is without leakage, and switch connection is
intact. Secondary valve mark is clear without leakage.
b. Cabinet relay check: relay mark is intact, and action is normal. Lines are firmly impressed.
2) General failure maintenance:
False switch off; steam-turbine switch off mainly because of the following accident causes
a. Power cabinet loses all power or is instantly switched off, which causes relay failure and efficacy loss.
b. At least each passage has one switch-off relay or switch-off relay breaks down and loses efficacy.
c. One pressure switch of each passage breaks down and loses efficacy, or one medium relay breaks down
and loses efficacy.
d. Local switch contact 24VDC is grounded, which causes module power fuse breaks. In this module, if
there is a single protection condition, tripping condition could be met.
e. Noise is added with sensor input.
f. Element breaks down.
g. SI module circuit breaks down.
h. Relay breaks down and loses efficacy.
3) Test valve won’t move:
a. Valve element is jammed.
b. Coil is not electrified, and there is something wrong with the control circuit.
4) Pressure gauge indication of test block is not right, and pressure meter breaks down.
5) Check PLC system state, and check and inspect the state of each point in image. In case of any problem,
treat it in time.
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Initial
image
Don’t touch connector or connector on elements board. Don’t touch circuit elements in processer. When
not used, all elements shall be stored in special anti-static packing bags. When plugging and pulling processer,
electrostatic discharge device shall be adopted to connect with grounding conductor to release potential static
electricity.
7.5.2.7 Installation of I/O module
Align module circuit board with guide grove on rack. Slightly slide module forward till the alignment pin
at the top and bottom are firmly stuck. Install wire stab to fasten connection or use wiring arm to keep
connection clean. Adopt groove cover plate to cover grooves that are not used to avoid fragments or dust from
falling into rack. Before dismantling module, first cut off power to avoid module from damaging or other
failures. While dismantling module, press the alignment pin at the top or bottom, and then pull the module out.
7.5.2.8 Maintenance of I/O module
Don’t touch circuit elements inside module. Keep I/O module clean.
7.5.2.9 Meaning of I/O module indicator lights:
Table 1
DI (95300S)
LED indication Display state Meaning Solutions
OK Green light on Input is under normal operation state
Green light Module passes internal diagnosis, but there
OK Configure module
flashing is not input from multi-point transmission
Module has undergone unrecoverable
OK Red light on Change module
mistake
Check whether
communication between
OK Red light flashing Initially established communication time out
controller and base plate is
normal
Passage state light (with
Yellow light on Input activation
number)
OFF-ON: enable
(COS) Change of state
ON-OFF: enable
Detailed description could refer to
OFF-ON:1ms
Software configurable filter time performance manual
ON-OFF:1ms
Communication format Input data
7.5.3.2 DO module
In control system, normally sued DI modules are two types of SDI95300S and DRA84000. Except input
points, other performance parameters basically are the same. Here take DRA84000 as an example to illustrate
performance parameter.
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Table 6 Failure treatment table of CPU device and I/O extension device
No. Abnormalities Possible causes Treatments
1Voltage switching terminal is not
(POWER) LED light is not Correctly set up switching device.
1 well set up.
on
2 Fuse is blown. Change fuse tube.
1Voltage switching terminal is not
Fuse tubes are blown for Correctly set up
2 well set up.
several times
2line short-circuit or burnt. Change power unit.
1 Program is wrong change program
2 Power circuit is not in good
Change CPU
condition
3 (RUN) LED light is not on
3I/O unit number is repeated Modify I/O unit number
4 Distant I/O power is off without
Connect power
terminal
(Output during
transmission) terminal is not
4 Power circuit is not in good condition Change CPU unit
switched off (POWER) and
light is on
Relay after a certain number
5 I/O main bus is not in good condition Change base plate unit
won’t work
(output) connection of
6 I/O main bus is not in good condition Change base plate unit
specific replay number
All relays in specific unit are
7 I/O main bus is not in good condition Change base plate unit
not connected