I&C Maintenance Manual PDF

Enterprise Standard of Indian RWPL 8×135MW Power Plant
RKSC—2009
Instrument and Control System

Maintenance Manual
（ Trial Edition）
Published on XX –XX 2009 Implemented on XX –XX 2009

Content
Preface 4
Volume I Maintenance Instruction of Instrument & Control ........................................................................... 5
Chapter I Maintenance Instruction of Temperature Measurement Element....................................................... 5
Section I Temperature Sensing Element ............................................................................................................. 5
Section II Bimetal Thermometer （Including Electrical Contact Bimetal Thermometer）......................... 5
Chapter II Maintenance Instruction of Flow, Pressure and Liquid Level Measuring System ........................ 8
Section I Maintenance Instruction of Corrugate Pipe Instrument
Section II Maintenance Instruction of EJA Transmitter ................................................................................. 18
Section III Maintenance Instruction of CWD Differential Pressure Gauge of the Double Corrugated Pipe
22
Section IV Maintenance Item and Quality Requirement of Electrical Contact Water Gauge................ 24
Chapter III Maintenance Instruction of SZC-O4 Operating Speed Measurement System............................... 26
Chapter IV Maintenance Instruction of DXZ Shaft Vibration Monitoring Instrument.................................... 30
Chapter V Maintenance Instruction of ZR202G Oxygen Analyser.................................................................... 32
Chapter VI Maintenance Instruction of ABB Quality Flow Meter .................................................................... 37
Volume I Implemented with heavy and minor repair of machine set............................................................. 39
Volume II Maintenance Instruction of Instrument & Control Protection System........................................ 40
Chapter I Maintenance Instruction of Pressure Switch ..................................................................................... 40
Chapter II Maintenance Instruction of ETS System .......................................................................................... 45
Section I General Description ....................................................................................................................... 45
Section II Function of ETS System.................................................................................................................... 45
Section III System Operating Principle ............................................................................................................ 46
Section IV ETS Maintenance ............................................................................................................................. 50
Chapter III TSI maintenance instruction ........................................................................................................... 51
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Chapter IV Automatic Alarm System ofDZXL Furnace Tube leakage .............................................................. 58
Chapter V DZHJ Maintenance Instruction.................................................................................................. 61
Section I System Introduction............................................................................................................................ 61
Section II Maintenance Items and Technical standards .................................................................................. 70
Section III Factor s of Influencing Fire Check Quality and Transaction ....................................................... 70
Section IV Flame Test System Maintenance ..................................................................................................... 71
Section V Fire Check Probe Cooling Air........................................................................................................... 72
Volume III Maintenance Instruction of Thermal control Automatic Adjusting Device ....................... 73
Chapter I Maintenance Instruction of DKZ\ DKJ Model Electric Drive Actuator......................................... 73
Volume IV DCS Maintenance Instruction ................................................................................................... 77
Chapter I Introduction to System Hardware................................................................................................. 77
ChapterⅡ Introduction to System Software ................................................................................................. 82
Chapter III Maintenance of DCS System ...................................................................................................... 86
Volume V DEH Maintenance Instruction ...................................................................................................... 89
Chapter I Configuration and Function of Steam Turbine Digital Electrohydraulic DEH Control System .. 89
Section I Configuration of Control System .................................................................................................... 89
Section II System Software............................................................................................................................ 95
Section III Main Functions of DEH Control System .................................................................................. 96
Chapter II Maintenance after DEH System out of Action............................................................................114
Section I Check before System out of Action ............................................................................................114
Section II Repair after System out of Action ...................................................................................................114
Chapter III Operation Description of Steam Turbine Digit Electrohydraulic Deh Control System ................116
Section I DEH Start up Control ........................................................................................................................116
Section II Raising Speed .................................................................................................................................118
Section III Incorporate in Power Network, Increase Load .........................................................................118
Section IV Single Valve / Sequence Valve Conversion .................................................................................119
Section V CCS Control .................................................................................................................................119
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Section VI Automatic Restriction of Steam Turbine ................................................................................... 120
Section VII Operation and Removal of Rapid Load（RUNBACK）................................................... 120
Section VIII Operation and Removal of Main Steam Pressure Control...................................................... 121
Section IX Overspeed , Oil Injection Test.................................................................................................... 121
Section X Valve Activity Test..................................................................................................................... 122
Section XI High Pressure Intercept Solenoid Valve Test .......................................................................... 122
Section XII Valve Leak Test ...................................................................................................................... 122
Section XIII Hand operate Control ................................................................................................................. 123
Chapter IV Failure diagnosis and analysis ....................................................................................................... 123
Section I Online Self diagnosis ......................................................................................................................... 123
Section II Fault Analysis and Maintenance ............................................................................................... 125
Chapter V Measuring Point List ................................................................................................................. 127
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Preface
This manual regulates maintaining specification for instrument & control equipments of
Indian RWPL power plant by which it can increase safety, reliability and economical
efficiency of all equipments to reach full life of operational life.
This manual is applicable to maintenance work of instrument & control equipments of
Indian RWPL power plant.
Main sources of standards:
● Preliminary design manual of Barmer circulating fluid bed power plant project
● Instruction of Instrument & control Equipment
This manual applies to:
● Maintenance personnel of steam turbine.
● Director, deputy director of Maintenance Department; engineer special responsible for
steam turbine of Maintenance Department; engineer special responsible for safety and
training.
● Director, deputy director of Maintenance Department; engineer special responsible for
steam turbine of Maintenance Department; engineer special responsible for safety and
training.
● Other persons who come to our plant to do related system work.
Editor
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Volume I Maintenance Instruction of Instrument & Control
Chapter I Maintenance Instruction of Temperature Measurement Element
Section I Temperature Sensing Element
Temperature measurement element mainly is thermocouple and hot resistance. Thermoelectric type
temperature element is to use temperature measurement element thermal electricity feature to change
temperature physical quantity into electric quantity, therefore to realize temperature measurement.
Measurement value is shown in the form of temperate value, to make the operating person observe and
understand the whole medium and service condition, to guide the operating person to implete right
operation.
1. Structure and Operating Principle
1.1. Thermocouple: it is usually composed of the following elements: hot electrode, protective casing,
junction box, insulating tube and so on.
The structure of thermocouple shall meet the following requirements:
a. electrical insulation between the two poles.
b. preventing hot electrode from being harmed by the harmful substance in the environment.
c. ensuring the good thermo contact between the measurement end and measured object.
d. ensuring thermocouple transducer to be installed on the measured object in a certain intensity and
rigidity.
Measurement principle of thermocouple is based on the phenomenon of thermoelectricity between
two kinds of metal. If the temperatures of the two metal junctions are different, it will come into being the
physical phenomenon of thermo current inside the closed loop. The greater the temperature difference of
the two metal junctions is, the more thermo electrical potentials are. Thermo electrical potentials produced
by thermocouple loop are mainly determined by the temperature difference of the thermo electrical
potentials produced by the different temperature of the two ends of metal. As the temperature of
thermocouple model and cold junction temperature reaches a certain point, thermocouple will be the
function relation of corresponding single value with working end temperature. Cold junction temperature
compensate: because of the influence of the change of cold junction temperature to the measurement value,
the cold junction compensation of the cold junction compensator to the thermocouple, to eliminate the
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measuring error brought by the change of the environment temperature.
1.2. Hot resistance: hot resistance is composing of the protective casing, resistance body, framework and
outgoing line and other parts.
The operating principle of hot resistance is based on the feature of resistance value of the conductor
or semiconductor change with temperature to measure temperature. When the temperature sensing element
of thermal resistance receipts the exist of the temperature gradient in the medium measured, then the
numerical value of resistance will change. The form of functional relation is as follows:
Ｒｔ＝Ｒｏ〔１＋α（ｔ－ｔ0）〕
of which:Ｒｏ－０℃ hot resistance value ;
Ｒｔ－ｔ℃ hot resistance value ;
ｔ－ is the medium temperature measured;
α－ resistance coefficient （the changing rate of the resistance value when temperature
change１℃）
2. Technical specification
Table I, Insulation resistance test of the temperature sensing element shall meet
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Insulation resistance
Insulation
Stabilization MΩ
Measured meter
time
Environment Relative instrument output
insulation Power Power
Measured object temperature humidity supply direct Signal c Signal
meter supply supply
% voltage current | |
℃ before | |
V voltage signal grounding
reading grounding signal
V
s
Thermocouple 500 ≮100 ≮100
Armor
500 ≮1000 ≮1000
Thermocouplea
Hot 15～35 ≯80 10
250/100 ≮100 ≮100
resistance/ Platinum
wall
temperature Copper 250/100 ≮50 ≮50
used specially
Table II. The table of the industrial thermocouple permissible error
Division
No.
First class Second class Third class
Thermocouple
name Temperatu Temperat Temperatur
re Permissible ure Permissible e Permissible
scope error scope error scope error
℃ ℃ ℃
Platinum LB-3 —— —— 600～1700 ±0.25%t 600～1700 ±4℃ or ±0.5%t

rhodium -
±1℃ or ±1+0.3%(t ±1.5℃ or
platinum R, S 0～1600 0～1600 —— ——
-1100） ±0.75%t
Nickel-chromiu ±1.5℃ or ±2.5℃ or

m - silicon K, N -40～1000 -40～1300 -200～167 ±2.5℃ or ±1.5%t
±0.4%t ±0.75%t
(aluminum）
Nickel-chromiu
±1.5℃ or ±2.5℃ or ±2.5℃ or
m— Ｅ -40～800 -40～900 -167～167
±0.4%t ±0.75%t ±1.5%t
cupronickel
Iron－ ±1.5℃ or ±2.5℃ or
Ｊ -40～750 -40～900 —— ——
cupronickel ±0.4%t ±0.75%t
Copper- ±0.5℃ or ±1℃ or ±1℃ or
T -40～350 -40～350 -200～40
constantan ±0.4%t ±0.75%t ±1.5%t
In the table, choose the larger value between the two permissible error values.
Note: t is the temperature of measurement end.
Table III. The table of the hot resistance permissible error
R0 nominal Measurement
Division Permissible error
Hot resistance resistance Resistance scope
No.
name value ratio R100/R0 ℃
℃
Ω
First Pt10 10.00 1.3851±0.05%
class -200～500 ±(0.15+0.2%|t|*）
Platinum Pt100 100.00 1.3851±0.05%
hot
resistanc Second Pt10 10.00 1.3851±0.05%
e class -200～500 ±(0.30+0.5%|t|）
Pt100 100.00 1.3851±0.05%
Cu50 50 1.428±0.2%
Copper hot
-50～150 ±(0.30+0.6%|t|）
resistance
Cu100 100 1.428±0.2%
Note 1: In the table, |t| is the absolute value of temperature, unit ℃
Note 2: Permissible error of class 1 is not fit for adopting platinum hot resistance of two wire
system.
3. Thermocouple maintenance
When checking thermocouple, firstly shall check insulation, and then check whether electrode has crack,
delamination, abrasion, oxygenation, dirt, small hole in working end, clearness on the surface and so on. If
find the electrode has the above condition, shall change it on time. Also shall have a check to the protective
sleeve which is important measuring object. Protective sleeve should not have bending, lamination, skew
motion, crack, air pocket, abrasion and obvious corrosion and other defects. The fixed screw on the bushing
shall be clearness, having no phenomenon of sliding tooth or rolling tooth, despite no problem of
appearance checking, it shall be checked by the metallographic room. For the damage of amour
thermocouple check element, have to change it wholly, also checking the reason for being burned broken
and making good record.
When install the thermocouple, it must meet installation requirement, avoid to install it at side of
boiler manhole valve, and observation hole, or placed too close to the object heated up and the field having
strong magnetic, the junction box of the thermocouple should not come up against the container wall of
measured medium. Its inserting depth, inserting direction and installation position and mode shall all meet
corresponding technical requirements of the measuring point, as the leak test of the 1.25 time working
pressure with the measured system, it shall have no leakage within 5 minutes; the temperature of
thermocouple referring ratio generally should not exceed 100 degree, and avoid the rained place. When
install the high temperature & high voltage thermocouple, it must be strict with guaranteeing the seal of the
sealing surface. The thermocouple with porcelain protecting tube, it must avoid to urgent cold and heat, to
avoid porcelain tube bursting.
Connection requirements: when connecting, it must be ensured that it is good contact, screw down
hole bolt, then fasten down junction box cover. As for the thermocouple has to be put outside, it is better to
take flashing measure, in case rain damages element or causes the short circuit. To protect the
compensating lead wire from the mechanical damage outside and influence to instrument because of
foreign field, compensating lead wire shall be shielded, shield layer shall be grounding beside DCS cabinet.
And do not allow the condition of winding and twisting.
Fault analysis:
The keys factors of influencing indicating value of the thermal electromotive force:
a. thermocouple internal current leakage ;
b. thermocouple internal wet ;
c. short circuit of the thermocouple junction box internal binding post, or bad contact between
compensating lead wire and ending post.
d. measurement ending damage;
e. the reverse polarity between compensating lead wire and hot electrode
f. the improper of installation position or heating length ;
g. temperature overtop in the referring ratio ending;
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h. no corresponding between the thermocouple category and instrument scale ;
i. fault use of the thermocouple category;
j. not according with each other between compensating lead wire and thermocouple category;
k. the improper of thermocouple installation method or inserting depth;
l. the instability of the measurement instrument indicating value;
m. thermocouple or compensating lead wire has the phenomenon of intermittent earth and short circuit;
n. the uncertain breaking- off of the hot electrode;
o. Infirmness of the installation, wavering of the thermocouple;
If the above conditions occurred, shall check and analyze carefully, remove the trouble and ensure
equipment safety operating.
4. Hot resistance maintenance
Appearance check: check whether the porcelain tube of the temperature sensing element is complete
and the resistance wire has phenomenon of damage, disorder, corrosion, and then check resistance value.
Installation and connection check same to thermocouple.
Fault analysis:
a. measurement indicating value is lower than the actual value or indicating value is not stable: there is
water inside the protecting tube or metal scraps, dust cohere in the junction box, short circuit of the
resistance;
b. measurement indicating value is infinitely great: hot resistance may be broken circuit;
c. indicating value is in the minimum: hot resistance happens short circuit, circuitry also short circuit or
indicating instrument connection is fault;
As for the above conditions, if checking the thermal sensing element to being damaged, shall restore or
change it.
5. Thermocouple verification
5.1. Check equipment: standard equipment
5.1.1. Measurement scope is a set of standard mercury thermometer of 300℃ ( verifying thermocouple
below 300℃);
5.1.2. Standard platinum rhodium - platinum thermocouple( verifying thermocouple above 300℃).
5.2 Matching equipment （all models are suspended.）
5.2.1. Checking system of the temperature verification;
5.2.2. More changing over switch, producing error electromotive force less than 1uV;
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5.2.3. Furnace of the thermocouple verification (bl-7);
5.2.4. Freezing point tank (heat preservation barrel);
5.2.5. Precise mercury thermometer;
5.2.6. Equipment of the temperature control (amphibious air-condition for cold and hot);
5.3. Method of calibration: put the thermocouple verified and standard thermocouple in the middle of assay
furnace, standard thermocouple is knotted by the porcelain bushing tube, and set in the freezing point tank
with the compensating lead wire.
The chart of connection is just like the following one:
5.4 Verification procedure:
5.4.1. Check and adjust the null point of the gage tester well.
5.4.2. Bundle the hot end of the measured thermocouple and the standard thermocouple together, insert into
the constant temperature zone of the temperature furnace.
5.4.3. Set the cold junction of the thermocouple into the freezing point tank to keep 0℃.
5.4.4. Connect the verification loop well according to the requirement.
5.4.5. Verification of furnace temperature from low to high gradually.
5.4.6. When furnace temperature deviates verification point, temperature should not exceed ±10℃, and
temperature change shall not exceeding 0.2℃ per minute, reading thermal electromotive force in the
temperature scope, check the degree division corresponding chart after averaging of the measurement value,
and then the error value of this measuring point can be gotten. After furnace temperature is constant, the
order of measurement is: standard →verified 1→……→verified n→ verified n→……→verified 1→
3
standard.
5.4.7. Continue warm-up after verifying a temperature point, continuously test several temperature points,
and make record in the test paper of the temperature instrument verification.
5.4.8. Through comparison, get the temperature error of the verified thermocouple in each temperature
point.
5.5. Compensating lead wire and compensating box
The big or small of thermocouple thermo electrical potentials is related to the temperature difference
of working end and cold junction, to avoid the influence of the cold junction temperature fluctuation, It
usually adopts the connection of the compensating lead wire and thermal couple, to make the
thermocouple free end extended into the area far away from the heat source. But this method is
comparatively careless, as to the refined measurement, must adopt compensating box. Its basic structure is
compensate electrical bridge, it is installed in the thermocouple free end.
6. Hot resistance verification
6.1. Standard equipment: two standard platinum hot resistance thermometers
6.2. Matching equipment.
6.2.1. Multipoint diverter switch;
6.2.2. 10Ω of 0.01 class or 100Ω standard resistance;
6.2.3. Temperature verification check system;
6.2.4. Direct current voltage regulation power supply;
6.2.5. Freezing point tank (heat preservation barrel);
6.2.6. Water-constant temperature tank;
6.2.7. Oil constant temperature bath (vertical temperature difference is not more than 0.02℃, horizontal
temperature difference is not more than 0.01℃).
6.3. Method of calibration:
6.3.1. Purity verification: measure R., put hot resistance into the freezing point tank, reading after 30
minutes. When t=100℃ and temperature deviates +/-2℃ from verification point, verify it. While reading,
temperature change shall not exceed 0.02℃ per minute, and every ten minutes, it shall not exceed 0.04℃.
6.3.2. When verify platinum resistance, class A should read three cycles, class B read two cycles. The order
of reading is as follows:
standard platinum thermometer → standard resistance → verified 1→ verified
2→……→verified 5→ verified 5→……→verified 2→ verified 1→ standard platinum thermometer →
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standard resistance.
Then calculate R100/R0, and compare with the permissible error, ensure the verified hot resistance
meets standard.
7. Equipment maintenance cycle
Implemented with heavy and minor repair of machine set..
8. Operating maintenance
8.1. During operating, it usually uses infrared thermometer to measure temperature on the spot and
compare with the indicating value in DCS, and find problems on time.
8.2. Regularly check whether the installation position has leakage.
8.3. Regularly check whether the cable has the problem of burning out.
Section II Bimetal Thermometer （Including Electrical Contact Bimetal Thermometer）
Bimetal thermometer is a kind of field monitoring instrument of measuring medium and low
temperature, and is directly used to measure gas, liquid and steam temperature. This thermometer has the
features of corrosion resistant, visual, easy reading, no harm of Hg, no auxiliary energy consumption etc.
both in design principle and structure. After it is installed on site, the temperature can be indicated on the
scale disk visually and correctly. It provide the direct help for the field scout and diagnosis.
1. Structure and operating principle
Bimetal thermometer uses the hot bimetal element circling the form of thread helix to be the
temperature sensing element, and put it in the protective sleeve, one end fixed (fixed end) and the other end
（free end）linked in a thin shaft, shaft end has pointer. When temperature changes, the free end of
temperature sensing element turns with it, therefore the thin shaft produces the angular displacement drived
with the pointer, indicates the temperature change on the scale disk; vertical type meter drives pointer
through steering gear. Because of temperature sensing element and temperature change are linear relation,
so the position of the printer indicated of the bimetal thermometer is that the measured temperature value.
The shell materials have steel plate, castaloy, stainless steel plate; measured element also has knockout core
type structure; the part of meter head of the adjustable angle type thermometer can turn arbitrary angle from
angle type to vertical type with the help of corrugated pipe, angle mechanism and other parts,.
Electrical contact bimetal thermometer adds the parts of electrical contact set, adjusting device and
outlet box and other parts in the structure. During the temperature changes, at the moment of contact or
cutoff with the preset temperature control point（ upper limit and lower limit ）, making relay or contactor
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in the control wiring act, from which, therefore the bimetal thermometer realizes automatic temperature
control or function of alarm.
Bimetal thermometer works by using the principle of two kinds of different metal with different
expanding degrees during the temperature change. The main element of the bimetal thermometer used in
the industry is a multilayer sheet metal compose of lapping two or several kinds of sheet metal. To increase
sensitivity of temperature measurement, it usually shapes the sheet metal into twist, when the temperature
of multilayer sheet metal changes, the expanding and shrinkage of each layer metal are not equal, made the
twist roll up or r loosen up. Owing to one end of twist fixed and the other end connected with the free
rotating pointer , therefore, when the bimetal element feels the temperature change, pointer can indicate the
temperature on the scale of a round graduated scale. Temperature measurement scope of this kind of
bimetal thermometer instrument is 200~650℃, the permissible error is about 1% of the scale. The usage of
this thermometer is similar to that of clubbed glass liquid thermometer, but it can be used under conditions
with higher demand of mechanical strength.
Product execution standard: JB/T8803-1998; GB3836-83
Nominal diameter of the scale disk: 60, 100, 150
Accuracy class: 1.0, 1.5
Thermal response time: ≤40s
Protection class: IP55
Angular adjustment error: angular adjustment error shall not exceed 1.0％ return difference of the
measurement range.
Thermometer return difference shall be not more than the absolute value of basic error limit.
repeatability : the limit range of thermometer repeatability shall be not more than 1／2 of the absolute
value of basic error limit.
3. Maintenance of the bimetal thermometer
3.1. Maintenance item and quality requirement
3.1.1. Before maintenance, shall perform checking calibration, and make good record.
3.1.2. Instrument should not have the defects of arousing larger measurement error and making the internal
parts easy to be damaged, otherwise, it shall be repaired
3.1.3. When repair moving element, be careful with disassembling. When assembling, hairspring should
level off, each circle is in concentricity; the shaft tine (or tensile spring up and down) shall be in the same
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vertical line, the distance everywhere between moving coil and iron-core should be equal, the turning of the
moving coil should be agility and stable.
3.1.4. The equipment of zero adjust shall make the pointer from the graduation line of starting point left
offset less than 2% of the whole distance.
3.1.5. Shell should be sealed well.
4. Verification of the bimetal thermometer
4.1. The calibrating point of the thermometer must be not less than 4 points, the thermometer calibrating
point having 0℃ scale shall include 0℃;
4.2. In the course of thermometer calibrating, pointer shall move steadily, shall not have the phenomenon of
jumping or stagnating.
4.3. The basic error of thermometer indicating value shall be not more than the permissible error of
instrument.
4.4. The return error of thermometer shall be not more than the absolute value of the permissible error limit.
4.5. The repeatability error of thermometer shall be not more than 1/2 of absolute value of the permissible
error.
5. The cycle of equipment maintenance
Implemented with heavy and minor repair of machine set.
6.1. During operating, usually use infrared thermometer to measure in situ temperature and comparing
with the indicating value of the bimetal thermometer, and find problems on time.
6.2. Regularly check whether installation position has leakage.
6.3. Clear thermometer once a day.
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Chapter II Maintenance Instruction of Flow, Pressure and Liquid Level Measuring System
Section I Maintenance Instruction of Corrugate Pipe Instrument
The pressure gauge of corrugate pipe, vacuum gauge, pressure vacuum gauge and electrical contact
pressure gauge are all called pressure gauges of corrugate pipe.
Under action of pressure, the free end of corrugate pipe produces displacement, this displacement
drives amplification mechanism via pulling bar, made the pointer deflecting, and indicating the measured
pressure value with the help of scale disk.
Composition: the pressure gauge of corrugate pipe is mainly composed of the supporter with screwed
joint, corrugate pipe, pull bar, adjusting screw, sector gear, pinion, hair wire, pointer, up and down clamp,
dial plate, casing shell and so on.
Table I. Category and accuracy of the pressure gauge

Model
Sort Accuracy class

Pressure Vacuum Pressure vacuum
1
1.6（1.5）
Common type Y Z YZ
2
2.5
0.1
Precision type YJ ZJ / 0.16
0.25
0.25
YB ZB / 0.4
Standard style
0.6
Electrical contact style YX ZX YZX 2.5
2.1. Conversion between common use pressure and international unit
1 mmHg=133.3224Pa
1mmH2O=9.80665Pa（acceleration of gravity is 980.665cm/s2, height is 1mm, density is pressure produced
8
by the 1g/cm3 water column）
1atm=101325Pa
1at=98066.5Pa
2.2. Technical index
Permissible error = measurement upper limit×accuracy class /100
The return error ≤ permissible error absolute value.
Tapping variation≤permissible error absolute value/2
2.3. Operating environment
Environment temperature of the instrument: 0.16 class, which is 20±2℃
0.25-0.5 class is 20±3℃
1.0—4.0 class is 20±5℃
3. Maintenance of the pressure gauge
3.1. Maintenance item:
3.1.1. Instrument disassemble
3.1.2. Verification and check before maintenance
3.1.3. Check, cleaning and overhaul of element
3.1.4. Maintenance of secondary valve or triple valve and check of sampling pipe.
3.1.5. Check and adjustment after the maintenance of pressure gauge
3.1.6. Pointer reassemble
3.2. Maintenance technology and quality standard
3.2.1. Disassembling of the pressure gauge
a. Disassemble the pressure gauge must close the primary valve and secondary valve of pressure gauge
firstly, confirm that pressure gauge has eliminated pressure, and then carry out disassembling.
b. After pressure gauge disassembling, must adopt measures, to protect and seal the pipe joint well, strictly
prohibit sundries enter into pipe joint during the course of maintenance.
c. After disassembling pressure gauge, mark well mark to avoid it confuses with other gauges, during the
course of carrying, strictly prohibit collision, and ensure it is cleaned up before check and verification of
pressure gauge.
3.2.2. Appearance check of pressure gauge
a. Do not have the corrosion, crack, perforation and other defects which influence metering performance,
pressure gauge under the condition of zero pressure or before check of boosting verification and after check
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of stepping down verification, its pointer should indicate zero value. The glass of pressure gauge shall be
clear, dial plate is neat, and the model, class, specs, measurement range, manufactory, leave factory number,
and leave factory date shall be complete.
b. The move of pointer of pressure gauge shall be balanced in the scope of whole degree division without
the phenomenon of jumping or being stuck.
c. After the pressure gauge is verified to be quality, it must be identified.
3.2.3. When verification, must consider the pressure correct from sampling point to the height difference of
instrument center point.
3.2.4. The corrugate pipe shall do the leak test, pressurize to 1.25 times of the full range, withstand pressure
5MIN, no distinct influence to the indicating value.
3.2.5. The clip of pressure pipeline and screw shall be complete and fix firmly.
3.2.6. The secondary valve or triple valve shall turn flexible and have no phenomenon of leakage, and shall
make withstand pressure test of 1.25 times of working pressure.
3.2.7. Check and verification before maintenance
Before instrument maintenance, pressurization check and verification must be implented. When
verifying, must according to verification item and procedure of pressure gauge strictly. Pressurization check
and verification can concurrently implemented, or can be check separately. After the completion of check
and verification, make record for data and the existed problems which can be the reference of maintenance.
a. Check whether the indicating value has change in the course of instrument boosting and step down. If not
chang, shall firstly check whether a piece of shim of the gauge end blocked. Otherwise, check whether
corrugate pipe blocked.
b. In the course of instrument boosting and step down, check whether has the phenomenon of jumping and
slack.
c. After boosting to the full range, then boosting to 1.25 times of the full range to do the withstand pressure
test , if the indicating value changed big, firstly shall check whether it has leakage between the valve and
the connecting piece related to verification platform. If the valve related to verification platform and the
connecting piece are perfect, then it is generally considered that corrugate pipe cracks or has leakage at
weld zone with frame.
d. After stepping down the pressure to zero, meter pointer does not return to zero. After adjusting,
indicating value is not being linearity and also does not return to zero, it is generally considered that
corrugate pipe distorts. In repairing, shall change corrugate pipe or out of use the instrument.
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3.2.8. Check and maintenance of the instrument main parts
a. Shell and scale disk
（1） The structure of the corrugate pipe pressure gauge has binding of screw thread, and close binding and
edge wheeling binding, the instrument disassemble should adopts different disassembling methods
according to the different structures.
（2） There are generally two kinds of scale disk: porcelain enamel surface and oil paint surface. Cleaning
methods are also different, scale disk of porcelain enamel generally adopts gasoline dipping in a certain
time, and rubbing it lightly using cotton cloth after brushing, while oil paint one only use the soft cloth
clean with water .
（3） Technical requirements of shell and scale disk:
Instrument shell shall be complete and have no damage, nameplate and every kind of mark shall be
complete and clarity; instrument scale disk shall be clean, and the screw, screw cap and gasket of fixing the
scale disk shall be complete and firm.
b. Gauge pointer
（1） Cannibalizing pointer generally adopts needle withdrawer. The operation method is to put included
angle of the needle withdrawer on the neck of the copper- shaft neck of pointer, turning the end of the
knob on the center of the sun gear shaft, and then turn the knob of the needle withdrawer in clockwise
direction, pull out the pointer slowly.
（2） The pointer of corrugate pipe pressure gauge shall meet:
A. instrument pointer should not have the phenomenon of deflection, stuck, and jumping, pinpoint shall
have the obvious color.
B. The length of needle clamp shall can cover 1/4 to 3/4 of the shortest graduation line.
C. The width of the pinpoint shall not exceed 1/5 of min. graduation distance.
D. When the scope of the plane distance between the pointer and dividing plate is 1~3mm and shell
external diameter is above 200mm, the scope of the plane distance between the pointer and dividing plate
should keep within the scope of 2~4mm.
c. Hair wire
(1) Unfixing the screw pin of clamp bolt and central axis, then the hair wire can be taken out, which
generally adopts gasoline cleaning.
（2） Hair wire requires the equality of the circle distance and concentricity level off, without fleck and
damnification, if hair wire has distortion, it can be corrected by using forceps, hair wire with big distortion
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and hardly being corrected should be changed, but please it shall be same specs.
d. Gear and clamp
（1）After disassembling clamp, then disassemble sun gear and sector gear. cleaning of the gear and clamp
generally dip into gasoline for about 10~20 minutes, then use hairbrush to clean oil stain between the
surface and gear and also use the willow stick to eliminate the remained contamination between each hole
and each gear. And then use gasoline clean and dry off.
（2）If the sun gear and sector gear have burrs, can use file or emery paper sanding, if the sun gear has
small abrasion, use it after turning an angle.
（3） Sun gear and sector gear shall be clear and neat. The part of up wheel, low axle clamp shall be
lubricity and straight. The wheel and the axle shall be upright.
（4） The clearance between sun gear and sector gear and clamp is based on standard of not exceeding
10% of the angel of the wheel and axle putting into the clamp, if exceeding 10%, so the fit clearance is too
large, shall shrinking hole of bushing by using ram head.
（5） After the completion of cassette mechanism part cleaning, shall check the intermeshing of each gear
seriously, and add a little watch oil in the connection of axle pore and moving interconnecting
position.(Notes: gear and hair wire shall not have oil.)
3.2.9. The maintenance of pressure gauge reerection
3.2.9.1. before reerection shall clean pipe joint, if having conditions, shall implement pipeline wash and
pollution discharge.
3.2.9.2. In the reerection of the pressure gauge, shall change to use different instrument shim according to
different measurement medium, pressure gauge in the necessary position, must twist raw material tape, to
prevent the leakage.
a. Use belt, rubber or nylon shim for low pressure , low temperature （below 80℃）
b. Use asbestos rubber or aluminum shim when medium pressure, and temperature is 350℃-420℃
c. Use anneal copper shim under operating condition of high temperature and high pressure.
d. When the measurement of pressure medium is oxygen, must use degrease aluminum shim or asbestos
pad, can not use the organic material.
e, When measure ethyne pressure, usually use asbestos pad.
3.2.9.3. After reerection, put the pressure gauge of premary and secondary valves into use. When use the
instrument, should slow turn on or turn off switch, to prevent the valve from being damaged under the
impact of high temperature & high pressure medium
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Fault analysis:
The usual fault phenomenon of the instrument in operating course: the big variation or obvious
indicate error, pressure gauge jumping turning, not flexible of turning of sun gear and sector gear, and the
hair wire distortion.
The reasons of big variation:
a. The organization has abrasion or dislocation of up and down clamp, which caused the deflection of the
axle.
b. The lock sways flexibly, the axle hole abraded largely, the connection is loose.
c. The uncleanness of the drive mechanism
d. The disorder and uncleanness of hair wire make the elasticity change.
e. Elastic of corrugate pipe lags largely.
Main reason of big indicating error:
a. Pointer and central axis get loose.
b. Pointer and copper knot get loose, pointer, dial plate and glass bump.
c. Scale and axle are misalignment.
Main reason of pressure gauge jumping move:
a. Connect too tightly between free end and connecting bar.
b. The connecting sliding piece of connecting bar and sector gear press too tight, which makes the
connecting bar get stuck.
c. The connecting side of sector gear, sun gear and clamp are disalignment or has damage, the gear
joggled too tight, which make it get stuck.
Sun gear and sector gear do not turn flexibly:
a. Gear interlocked too tight.
b. The contamination between gears are too much.
c. Sun gear is not misalignment.
d. The surface of sector gear and sun gear are not vertical each other.
e. Axial pore is too small.
3.2.10. Adjusting methods of instrument error
The pointer adjusting methods:
Instrument linearity is good, error direction and the big or small is basically coincidence, the
instrument having needle of nail remove linearity error by using reset pointer.
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The adjusting method of junction of sector gear and connecting bar:
Change the connecting relative position of sector gear and connecting bar is one of the main
methods of adjusting pressure gauge error of corrugate pipe. When the normal instrument indicates 1/2
value of the full range, the central line of the sector gear and the connecting bar shall be vertical, the
connecting screw shall be in the middle of slide way of the sector gear, when the indicating value of the
verified gauge is greater than the standard reading value, junction adjusting screw shall adjust outward;
When the indicating value is less than standard reading value, adjusting screw shall adjust inward.
The adjusting method of turning base plate:
The turning base plate is to change the initial included angle between the central line of sector gear
and the connecting bar, which is one of the effective methods of adjusting nonlinearity error, if the
indicating error is big in front and small rear, shall unbind and loose the fixed screw of the base plate,
turning the base plate to a certain degree anticlockwise, conversely, turning the base plate to a certain
degree clockwise.
The moment adjusting method of hair wire:
Hair wire is the element of countertorque in the instrument, the loose and tight of the hair wire has
influence to the null point of the instrument and upper limit and the error uniformity, especially has
influence to lower range pressure gauge. Generally for the small error of null position and upper limit, can
separate the gear intermeshing of the sun gear and sector gear, turning the sun gear shaft clockwise or
anticlockwise, to loose hair wire or fastening error adjust.
Length adjusting method of connecting bar:
For the instrument which can change the length of the connecting bar, can adjust junction
connecting bar to be longer or shorten, to change included angle between the central line of sector gear and
connecting bar, therefore to adjust the nonlinearity error of the instrument.
4. Verification of the pressure gauge
4.1. Verification equipment:
4.1.1. The select of standard equipment: the absolute value of standard equipment permissible error shall be
not more than 1/4 of the absolute value of the checked pressure gauge permissible error.
4.1.2. The auxiliary equipment has pressure verification platform（vacuum pump or multifunction check
meter）, or U pipe, the meter of insulation resistance（electrical contact meter use）, multimeter or
measurement signal device（electrical contact meter use）.
4.1.3. Requirement of verification environment:
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a. Environment temperature is（20±5℃）.
b. Relative humidity is not more than 85%.
c. Set above 2 hours in the verification environment silently, and avoid mechanical vibration of
influencing verification.
d. The pressure transmission medium of which the upper limit of measurement scope is not more than
0.25MPa is the clear gas.
e. The pressure transmission medium of which the upper limit of measurement scope is greater than
0.25-250MPa is the liquid of no corrosion.
4.2. Verification item
For the common pressure gauge, the verification has three items of indicating value error, return
error and tapping variation, for pressure gauge of electrical contact, shall increase item of insulation
resistance.
4.3. Verification method
When verifying, standard equipment and the pressure point of the verified gauge shall be in the same
plane, consider the error of the luid column difference if they are not in the same plane. The indicating
value of the pressure gauge should read according to 1/5 of graduation value of the division value.
Indicating value verification of the pressure gauge implement according to the graduation line
marked with numbers. When verifying, boost （or step down） pressure steadily. When the indicating
value reaches the upper limit, cut off the source of pressure（or source of vacuum）, withstand pressure 3
minutes. And then, step down（or boost）steadily according to the former point of verification, return
verification in the reverse sequence.
4.3.1. As for each point of verification, in boosting and stepping down verification, slightly tap at the shell
pointer, after it is stable, read it.
4.3.2. For the indicating value error, return error and tapping displacement shall meet requirement of 2.2.2.
4.3.3. For the gauge of pressure vacuum, the verification requirement of the vacuum part:
a. after the pressure vacuum gauge of which the upper limit of measurement is 0.3-2.4MPa, it shall point
the vacuum direction.
b. The part of vacuum of which the upper limit of the measurement is 0.15MPa, verify two points to
indicated value.
c. The part of vacuum of which the upper limit of the measurement is 0.06MPa, verify three points to
indicated value.
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4.3.4. Special verification requirement for pressure gauge of electrical contact:
a. Insulation resistance: the insulation resistance between electric part of the pressure gauge and shell
shall under condition of environment temperature of 15--35℃, if the relative humidity is not more
than 80%, it should be no more than 20MΩ.
b. The verification of the error of set point and change-over difference: make set pointer in the position
of set value, boost or step down steadily and slowly until turning on or cutting off of the signal, read
the pressure value in the standard equipment which is the upper change-over difference or below
change-over difference.
c. Error of set point shall meet the following table requirement:

Allowable value % of the set point deviation（calculate as the
Accuracy class percent of measurement range）
Direct acting type Magnetic acting type
1 ±1
1.6（1.5） ±1.6 ±0.5-±4
2.5 ±2.5
d. The requirement of change-over difference: direct acting type shall be not more than the absolute
value of the permissible error. Magnetic acting type shall be not more than 3.5% of measurement
range.
4.4. Result reduction
4.4.1 After verification, the qualified pressure gauge shall awarded with “verification certificate”, in the
certificate, describe the qualified accuracy class, those of forcing verification has lute mark.
4.4.2 After verification, those unqualified pressure gauge shall issue “Notice of unqualified verification”,
and give clear indication of unqualified items and content.
5. Verification cycle
Verification cycle of pressure gauge is generally not exceeding half a year.
6.1. Preparatory work before pressure gauge puts into operating;
6.1.1. Check if accessory of sample pipeline has leakage.
6.1.2. Close the secondary valve, check instrument null position;
6.1.3. Alarming pointer of pressure gauge of the electrical contact equipment shall adjust to the set value;
6.1.4. Check carefully that the connection line of pressure gauge of the electrical contact shall be right;
6.1.5. Wash pipeline
（1） After heavy & minor repair of the machine set, must implement pipe wash, pipe wash procedure is to
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close the secondary valve first, and then turn on primary valve and the valve of pollution discharge, carry
out pollution discharge and pipe wash;
（2）Pressure measurement system with isolator is not allowed to implement pipe wash in general, if it
must be washed, shall adopt the effective measure of antiisolation liquid washing up.
（3）The system with three-way valve, shall put the three-way valve in the position of pollution discharge,
and then discharge pollution;
（4） Washing pipe of the fuel pressure gauge, shall make preparation of depositary of oil discharge and
fire precaution measures.
（5） After finished the pipeline wash, closing the pollution discharge valve, wait for steam fluidity and
cooling. after liquid temperature of pipeline is below 80 centigrade, and then put the instrument into
operating.
6.2. Instrument is out of operation
6.2.1 Close secondary valve, if it is out of action for a long time, then shall contact the equipment operating
person and close primary valve;
6.2.2 Cut off instrument power supply;
6.2.3 The system having isolator, shall close the valve of pressure, disassemble the below joint of the
isolator, disassemble instrument after pressure relief.
6.3 Instrument routine maintenance
6.3.1 Clean one time once week, keep instrument and accessory clean.
6.3.2 Regularly check the seal condition of pressure pipe valve and joint seal, if find problems, shall
transact it on time, shall specially pay attention to the fireproofing and explosion protection of
measurement system of oil pressure.
6.3.3 Instrument field check shall be at least two points, that is, null point and normal use point, checking
methods:
(1) Close up secondary valve tightly, loose back valve joint, check instrument null point, if having no
system of fluid column correct, the null point indicates zero value; if having system of fluid column
correct, indicating value of the zero pressure shall be the fluid column pressure value from the below
interface of pressure hole to the height difference of the central line of the gauge.
(2) Connect the standard meter and the checked meter into the measurement system, check normal
operating point on site.
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Section II Maintenance Instruction of EJA Transmitter
Transmitter is divided into pressure transmitter, absolute pressure transmitter, elementary error
transmitter, transmitter of the low, medium, high differential pressure, high static pressure transmitter
according to different pressure of the measured medium, and also can implement the measurement of
pressurization, flow, and liquid.
Intelligent transmitter adopts the apacitance type sensor, when working, isolation diaphragm detects
and transfer the course pressure into the extender oil, then the liquid transfers the course pressure to the
central sensing membrane with a chamber. Difference of the differential pressure makes the sensing
membrane create excursion. The max. deviation is 0.004 inch (0.10mm) and is direct ratio to course
pressure. The electric capacitance plate beside the sensing membrane, check the position of membrane.
Convert the difference of capacitance between sensing piece and electric capacitance plate to a direct
current signal of two-wire 4-20mA and a number signal of a HART through the electronic part of the
transmitter.
2.1 Absolute pressure transmitter (differential pressure transmitter)
Zero adjusting: in the scope of upper and lower limit of the velamen box, null point can adjust arbitrarily.
external zero adjust: in the scope measurement range, null point continue to be adjustable, resolution is
0.01%, use the scope of gauge head to configure switch which can adjust measurement range.
Fault alarm: output state in CPU or hardware (only acceptable for output signal)
High output（110%≥21.6Ma DC）
Low output（-5%≤3.2 mA DC）
Output: two wire system 4~20Ma DC output, digital communication, programmer set linear or square root
output mode, the agreement of BRAIN or HART loads on the signal of 4~20Ma.
Damping period constant: constant of amplifier part and damping period of bellows, the constant of
amplifier part damping period can adjust within scope of 0.2~64 seconds.
Environment temperature: -40~85℃
Power supply and loading condition: supply voltage is 24V DC, max. Load is 570Ω.
Stability: ±0.1% measurement range upper limit /60 months.
3. Transmitter maintenance
3.1. Maintenance item
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3.1.1. Disassembling transmitter and returning to the laboratory, the transmitter should be cleaned and
checked
3.1.2. Insulation check and seal check
3.1.3. Verification before and after maintenance, and make good record.
3.1.4. Interchanging of the parts: as main models, features are the same, and then the parts can be
interchanged.
3.2. Maintenance technology and quality standard
3.2.1. Appearance shall be complete and have no damage, nameplate and every kind of mark （model,
specs, accuracy, scale and unit, instrument number , leave manufactory date and so on）shall be complete,
clear; internal shall be clean, the element and connecting line shall be in good order, the screw of the fix
element, screw cap and gasket shall be complete and firm, the solder point shall be velvet and have no fault
solder. The connecting plug-in unit contacts well and is firm and reliable.
3.2.2. Insulation check: don not use high voltage megohmmeter when checking insulation resistance, can
use the instrument of resistance test not more than 100V to check, and the insulation resistance is more than
10MΩ.
3.2.3. Verification of adjust and calibration
Calibrating the lower range transmitter, shall eliminate the influence of fluid column difference; if
having water column correct, shall add the correct value of the water column when calibrating; when the
pressure transmission medium is liquid, shall keep in the same horizontal surface between the geometric
center of transmitter pressure taking port and the piston of the pressure meter of the piston type.（or the
geometric center of standard pressure taking port）.
3.2.4. Check of transmitter tightness
After the close connection between transmitter and pressure verification equipment, boost（or air
channel off）evenly, after making the pressure of measurement room of the transmitter reach to the upper
limit of measurement value（or the 90% degree of air channel off of the local atmospheric pressure）, close
the isolating valve, seal for 15min, in the last 5min, the pressure value dropped down（ or raises） must not
exceed 2% of measurement upper limit;
When differential pressure transmitter implement test of leakage, the chamber of its high and low
pressure connects open, concurrently adding the rated working pressure to observe.
3.2.5. Static pressure error test of differential pressure transmitter（if implement this item determined by the
transmitter）.
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After the differential pressure transmitter changes elasticity element, reassembles the machine part and
changes measurement scope, shall implement the static pressure error test;
Using the pressure meter of the piston type as the pressure source, connect the isolation device of oil
and water before connecting transmitter;
After connecting the chamber of high and low pressure of the differential pressure transmitter with the
air, measure the output lower limit value., introduce the static pressure, change slowly to the rated working
pressure from the atmospheric pressure, after it is stable for 3 minutes, measure the output lower limit value;
and this value and the difference value of the output lower limit value under the atmospheric pressure.
Permissible error table of static pressure of the differential pressure transmitter
Item 1 accuracy class 0.2（0.25） 0.5 1.0 1.5 2.5

Lower limit value and the change
0.1 0.25 0.4 0.6 1.0
value % of the measurement range
If the practice working static pressure of the transmitter is less than its rated static pressure, the static
pressure error can get from the practice working static pressure test, if the static pressure error exceeds the
stipulation value, shall move the null point back to zero after releasing the pressure, adjust the static
pressure once again.
4. Verification of the transmitter
4.1. Calibrating of null position and full range
4.1.1. Input the lower limit pressure signal, the output current of adjusting the transmitter is physical null
position; boost to the pressure signal value of the upper limit, adjust the output current to be full range,
adjust them repeatedly to reach the requirement.
4.1.2. According to operating requirement, implement the positive and negative moving of the null point.
4.1.3. In the first calibrating of the intelligent transmitter, shall add measured physical value to implement,
practice and implement through the hand controlled equipment in the later calibrating. When verify, shall
implement calibrating of measured physical value.
4.2. Linear calibrating（generally not adjust on site）
4.2.1. Input the middle value of the needed measurement scope, record the difference value between the
theory value and actual value of the output signal;
4.2.2 Input the pressure value of the full range, adjust the potentiometer marking with “linear”, if the
deviation value is the negative value, then plus the calculate value to the output of the full range (equal to
the deviation value ×6×decreasing coefficient of measurement range), conversely, less the calculate value.
4.2.3. Readjust the full range and null point.
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Item 2 permissible error value table of the transmitter
Accuracy class 0.25 0.5 1.0 1.5 2.5
Basic error % ±0.25 ±0.5 ±1.0 ±1.5 ±2.5
Return error % 0.2 0.4 0.8 1.2 2.0

Output circuit break
0.1 0.25 0.4 0.6 1.0
measurement range change %
When the differential pressure signal is below 1% in the flow transmitter, do not count the basic
error value and return error value.
4.3. Verification method
4.3.1. Connect the circuitry according to the map of the verification connection and power on to warm up
for 30 minutes after checking that it is confirmed inerrability.
4.3.2. When the output signal of the pressure signal generator is zero, the transmitter output shall be 4mA,
otherwise, press the zero adjust key, making the output to be 4mA.
4.3.3. When the output signal of the pressure signal generator is the full range of transmitter, the output
current shall be 20mA, otherwise, press the measurement range adjust key, making the output to be 20Ma.
4.3.4. Repeat B, C procedure until the null point and measurement range are adjusted to meet standard
requirement.
4.3.5. Then boost to each verification point of the transmitter from the signal generator, implement the
verification. (including null point , common used point and the full range). It is not less than 5 points.
4.3.6. After verification completed, implement the performance test after maintenance.
5. Maintenance cycle
Maintenance time is determined by the big or small of the mainframe. It is generally maintenance once a
year.
6.1 Regularly comparing with the indicating value of the related instrument in operating, find the problems
on time.
6.2 Regularly check whether each part of the transmitter is perfect. .
6.3 Clean the transmitter once every day.
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Section III Maintenance Instruction of CWD Differential Pressure Gauge of the Double Corrugated
Pipe
CWD type differential pressure gauge of the double corrugated pipe is a differential pressure
instrument of fixed installation, and measure the flow of the liquid, gas, steam together with the throttle
device, concurrently it can be use for measuring liquid level of the differential pressure, gauge pressure and
open container or the pressured container. This instrument adopts weld corrugated pipe, its effective area is
consistent. It can eliminate the measurement error brought by the common differential pressure gauge
working in the high static pressure, have damping device, adjust the damping period, it can be used for the
measurement of the pulsant fluid.
The instrument mechanical record system is a simple four connecting bar organization, when the
differential pressure gauge set some differential pressure value, output shaft of the differential pressure
gauge turns an angle, driving the shift lever （driving lever）to act, then transfer to range minitrim
( passive lever ) fixed on the recording pen shaft through the connecting bar, to make the recording pen
turn a corresponding angle. The angle of the recording pen turned is in proportion to set differential
pressure value.
The function of differential pressure, pressure, flow transmitting system is to convert the varying
differential pressure of the measured fluid (saturation steam）and pressure value to the direct current
electrical signal which is proportional with the two ones on one hand, on the other hand, send the pressure
electrical signal and the differential pressure electrical signal to the arithmetic unit, implement a series
of simulative mathematical operation, to realize the conversion of differential pressure and flow and
compensate the pressure to flow and convert to the flow electrical signal.
Operating principle of the differential pressure and pressure transmitting part is the same, all adopting
differential coil to be the test sensing element.
Precision class: 0.5 class
Upper limit value of the differential pressure: CWD type -6, 10, 16, 25, 40, 60.
Output corner: 8 degree ±10%
Rated working pressure: dividing to 6.4, 16 and 32MPa.
Damping period: CWD type ≤7S , ≥60S(adjust arbitrarily) .
22
Indicating instrument:
Precision class 0.1 class.
Unit of the measurement flow: Kg/h, t/h, m3/h, l/h.
Measurement differential pressure or gauge pressure( positive pressure or negative pressure ):
CWD type -6, 10, 16, 25, 40, 60.
Centigrade nominal scale : “%”.
Measurement unit: KPa.
3. Maintenance of the double corrugated pipe of differential pressure gauge
3.1.1. Appearance check and clean.
3.1.2. Verification before maintenance.
3.1.3. Wash of the instrument measurement room and pulse washpipe.
3.1.4. Maintenance of the valve
3.1.5. Overhaul of the instrument connecting bar organization.
3.1.6. Cleaning and overhaul of the electric machine and the clock organization.
3.1.7. Check of the secondary line and the insulation resistance of the instrument internal
3.1.8. Disassembly maintenance of the measurement room.
3.1.9. The maintenance of throttle device and horizontal balance container.
3.2. Quality requirement:
a. The parts of instrument is perfect and leak, handwheel is complete, mark is right, operation is
flexible.
b. Instrument unit is complete, appearance is perfect and clean.
c. Do the static pressure test according to 1.25 times of the working pressure, keep for five minutes,
pressure decrease is not exceeding 2％.
d. The basic error of instrument, variation shall meet the accuracy class requirement.
e. The countering instrument with counter, its counter shall work reliablly, error meets the requirement
of the production producer.
3.3. Maintenance procedure:
a. Verify before maintenance and make record.
b. When maintenance, minor repair generally shall implement the common wash until no pollution
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water discharging. When heavy repair, shall disassembly the high and low pressure measurement room,
wash and check corrugated pipe.
c. Dissemble the indicating part, use clean gasoline to wash, after reassembling, each bearing hole and
the gear shall fill some watch oil.
d. After all the measurement unit disassembly or internal elementchanged, shall do static pressure test.
e. The undissembling instrument only verify the basic error and variation error.
Section IV Maintenance Item and Quality Requirement of
Electrical Contact Water Gauge
Electrical contact two-color water gauge is a control instrument which is used for showing water
level. It adopts two-color streamer and digital display liquid level, and is allowed to use with l5-17
electrical contact water level sensors and to self define show value of each water level. It has 4 alarm
control points which can be optional set and corresponding control relay output. Because electrical contact
water resistance intelligent test is adopted, it can adapt to water quality change automatically to detect
water level rightly. Field sensor connection can be connected at option. This instrument can automatically
identify and record. It also has 485 interfaces as accessory, which makes it convenient to link up the
networks for the chief computer to realize long-distance water level monitoring function.
Electrical contact water gauge is composed of measuring cylinder, electrode, electrode connecting
cable, electrode controller. It measures water level according to the difference of steam and water
conductivity. Water conductivity of high pressure boiler is usually ten of thousands to hundred of thousands
times higher than saturated steam conductivity. Electrical contact water gauge is composed of water level
measurement container, electrode, electrode core, and water level display lamp and power supply. Electrode
is installed on water level container to compose electrode water level transmitter. It is insulated between
electrode core and water level measurement container shell. Because water has higher conductivity and
lower resistance, when contact is submerged by water, short circuit happens between electrode core and
container shell, so corresponding water level display lamp lights and shows water level in steam drum. But
24
electrode in steam doesn’t be electrified because steam has lower conductivity and higher resistance, so
water level display lamp doesn’t light. So the number of light display lamp can show water level.
Input signal water level measuring point: 5-17 point
Output signal switch quantity: 4 relay output control with return difference, AC220V/3A
Communication: RS485, baud rate 1200/2400/4800/9600
Safety performance insulation strength: AC1500V 1min
Insulation impedance: above 20MΩ
Environment temperature: -10℃ ~ +55℃
Relative humidity: ≤85% without water spatter
Installation mode: instrument panel insertion
External dimension: 80*160*40
Power consumption: <3VA
Weight: 0.5Kg
Measurement scope: -1999mm ~ +1999mm
Water level display: 3 and half digit high-luminance LED numeric code and two-color streamer display
water level
Alarm and limit protection output position: optional set.
Alarm mode: acousto-optic alarm
Water resistance requirement: ≤250K
Voltage: AC220V±15%, 50Hz
Relay contact capacity : AC220V, 3A（load with resistance）
3. Maintenance of electrical contact water gauge
3.1. Quality requirement of measuring cylinder installation
3.1.1. Measuring cylinder shall be installed vertically, and vertical deviation mustn’t be more than 1°. Zero
point water level and steam drum normal water level of container shall be at the same horizontal.
3.1.2. Electrode screw thread and lamination surface shall be perfect and flawless; electrode surface shall
be clean, smooth, and have no crack or residual spot. Electrode core is insulation resistance to tunnel wall,
insulation impedance shall be more than 20MΩ with test of 500V insulation meter when
environment temperature is 5～35℃, relative humidity is not more than 85% .
3.1.3. During electrode installation, gasket shall be perfect, there is no radial colpa on its plane, daub
25
supramoly and ceruse oil on the screw thread.
3.1.4. Leading wire of electrical contact shall adopt fire-resistant fluoroplastics; check each connection
marking to be right.
3.2. Calibrating and technical standard of water level display
3.2.1. Connection between electrical contact leading wires and display shall be right.
3.2.2. After each heavy & minor repair, fill water at measuring cylinder by adopting waterfilled method to
carry out simulant check, display shall show rightly, and there is no wrong connection, no disordered
code or other abnormal phenomenon.
4.1. Check and preparation before operation
4.1.1. After heavy & minor repair of equipment, wash measuring cylinder and connecting pipe line before
operation.
4.1.2 There is no leakage at electrical contact.
4.1.3. Connection of water level display shall be right.
4.2. Put into operation.
4.2.1. Close pollution discharge valve, open measuring cylinder steam side and water side primary valve.
4.2.1. Turn on display power supply, water level shall appear.
4.3. Stop operation
4.3.1. Cut off instrument power supply to stop display.
4.3.2. Fully close steam side and water side primary valve, open pollution discharge valve during shutdown
maintenance or change of electrical contact.
4.4. Maintenance
4.4.1 Always keep instrument and equipment of whole set clean.
4.4.2 When water level of display is not clear, change relevant luminotron timely.
4.4.3 Regularly check electrical contact connection to be perfect, electrical contact has no leakage.
This system measuring cylinder belongs to category of repair based on condition of component, heavy
and minor repair of secondary display instrument is carried out along with unit.
Chapter III Maintenance Instruction of SZC-O4 Operating Speed Measurement System
SZC-04 intelligent operating speed instrument can carry out integrated measurement according to
26
operating speed of measured object by frequency measurement. User can set teeth number, coefficient, and
alarm value of instrument and so on with keyboard on site according to different conditions. It has power
on and power down protection functions, and can auto-save history peak value and history alarm state after
alarm, set parameter and measurement history parameter can be saved for long time after power failure.
Instrument can be installed on the actual measurement axes, and automatically calculate and display
operating speed of measured axes through speed ratio of actual measurement axes and measured axes.
Digital operating speed measurement system is mainly composed of digital operating speed
instrument, operating speed sensor, connecting cable.
Input signal: SZCB-01 model reluctance speed sensor signal;
Display mode: 5 digit 0.8 inch red LED digital display;
Measurement scope: 1~10000 turn/min; Measurement accuracy: ±1turn±1 character;
Speed measurement gear: set scope 1~200 gear, commend 60 gears
Operating coefficient: set scope 1~200;
Current output: measurement range linear output 4~20 mA;
Accuracy: ±1.0% of full range; maximum load : 500Ω;
Alarm set: upper limit 3 class, optional set in full range scope;
Alarm output: LED indicator light, relay normally open contact close up output, Capacity DC28V/2A,
AC250V/2A;
Use power supply: 220VAC±10％, 50Hz±5%; Power consumption ＜10W;
Operating environment: no corrosion, no strong magnetic field and so on;
Use temperature: 0~50℃;
Storing temperature: -40~60℃;
Relative humidity: 20~90%（non-condensing）;
External dimension: width 160 × height 80 × depth 85（mm3）;
Starter size: width 152 × height 76（mm2）;
Installation mode : panel mounting.
3. Maintenance of operating speed measurement system
3.1.1. Instrument appearance check
3.1.2. Reluctance transmitter maintenance, performance test
3.1.3. Secondary instrument maintenance, performance test
3.1.4. Verification after secondary instrument repair
3.1.5. Cable and instrument insulation resistance measurement
27
3.2. Quality standard
3.2.1. Instrument appearance shall meet relevant requirement.
3.2.2. Reluctance transmitter is fixed and reliable, and has no shaking, no abrasion. Outgoing line shall be
shielded well, ground insulation resistance is above 20MΩ, and loop direct current resistance of induction
coil is 130Ω-140Ω. Compare with measured value of last time, value discrepancy shall not be ±2%, and
clearance shall be less than 1mm after installation.
3.2.3. Cable interconnection and instrument insulation resistance shall meet relevant stipulation.
3.2.4. Turn instrument self-check switch to “self-check” position, instrument self-check shall be normal.
4. Verification of operating speed measurement device
4.1. Verification before adjustment and calibration
（1）Check toothed disc mill to be perfect, installation clearance shall meet requirement; turn on power
supply, power on to warm up 0.5h, turn switch to “ self-check ” position, its indicating value
shall meet factory stipulation;
（2）Select 8 calibrating points in sequence within measurement scope of measured instrument,
including normal use point and speed up point;
（3）Before start up operating speed calibrating device, turn speed regulation handle to the lowest
operating speed position, adjust clearance of measured instrument and standard device;
4.2. Start up operating speed calibrating device, raise speed smoothly, reach each verification point one by
one, read raising operating speed indicating value of each verification point of measured instrument; then
smoothly lower operating speed, reach each verification point one by one, read lowering operating speed
indicating value of each verification point of measured instrument; continuously read and record 10
indicating value of measured instrument at the same verification point.
4.3. Item and technical standard of adjustment and calibration
Quartz oscillator calibrating
（1） Calibrating output frequency accuracy A, calculate according to formula (18):
f i − fs
A= （18）
fs
10
∑f
i =1
i
fi =
10 （19）
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Of which:
fs— Frequency standard value, unit is Hz;
f i —Average value of 10 measured value of measured frequency f , unit is Hz;

i
fi —Reading of measured frequency meter, unit is Hz.
（2） Calculation formula of calibrating output frequency stability S:

f max − f min
S=
fS
Of which:
fmax—Within 4h, read max. value of 9 frequency measured value, unit is Hz;
fmin—Within 4h, read min. value of 9 frequency measured value, unit is Hz.
（3） Output frequency accuracy and stability of quartz oscillator shall meet requirement of table
20 .
4.4. Calibrate indicating value error and indicating value variability
（1）Implement calibrating according to verification procedure before calibration;
（2）Indicating value error and indicating value variability shall meet requirement of the following
table.
1 Accuracy class and error table of each item of digital operating speed instrument
Accuracy class ％ 0.05 0.1 0.2 0.5 1.0
Allowed indicating value ±0.05%n±1 ±0.1%n±1 ±0.2%n±1 ±0.5%n±1 ±1.0%n±1

error character character character character character
Allowed indicating value 0.05%n+2 0.1%n+2 0.2%n+2 0.5%n+2 1.0%n+2
variability character character character character character
-4
Counter time base 2.5×10
frequency accuracy exceed
Time base 4h frequency 2.5×10-4
stability exceed
Significant figure 5 4 4 4 4
Notice: n is indicating value of operating speed instrument.
5.1. Check whether primary sensor installation is firm, and whether clearance changes.
5.2. Clean instrument once every week, make instrument “self-check” once.
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Chapter IV Maintenance Instruction of DXZ Shaft Vibration Monitoring Instrument

Shaft vibration monitoring instrument and current vortex sensor are matching, which are mainly
used to measure axial radial vibration of rotor of rotating machinery device of sliding bearing. It has linear
finishing function, power on and power down protection function; It has indicate function for input signal
off-normal failure, and closes up alarm output; auto-save history peak value and history alarm state after
alarm; set parameter and measurement history parameter can be saved for long time after power off.
Vibration measurement makes use of vibration of rotary machine which can transfer to bearing shell
and movement speed of speed sensor measuring engine shell relative to free space, pallet part implements
detection and integral of speed signal from sensor, change to displacement value, and calculate
corresponding peak value position signal.
Digital vibration measurement device is mainly composed of digital display instrument, magnetic
electricity type speed sensor and connecting cable.
Input signal: DWQZ series φ8mm current vortex sensor voltage signal;
Measurement scope: within 0~500μm, Accuracy: ±1.0% of full range;
Display mode: 3 and half digit LED nixie tube display, Resolution: 1μm;
Current output: corresponding measurement range linear output4~20 mA; Accuracy: ± 1.0% of full range;
Maximum load: 500Ω;
Alarm set: limit 2 points for each channel, optional set within full range scope;
Alarm output: LED indicator light, relay normally open contact close up output, Capacity DC28V/2A,
AC250V/2A;
Power supply output: -24VDC, 100 mA power supply for external current vortex sensor;
Use power supply: 220VAC±10%, 50Hz±5%; Power consumption ＜10W; Operating environment: no
corrosion, no strong magnetic field and so on;
Use temperature: 0~50 ℃ ; Storing temperature: –40~60 ℃ ; Relative humidity : 20~90%
（non-condensing）;
External dimension: width 160 × height80 × depth 225（mm3）;
Starter size : width 152 × height76（mm2）;
Installation mode : panel mounting
3. Maintenance of vibration instrument
3.1 Check vibration sensor:
1) Installation base plane of sensor shall be smooth and flat, installation screw shall be perfect and
undamaged;
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2) Connection terminal in junction box shall be completed, weld of loop leading wire and
connection lug shall be firm and reliable;
3) Support spring leaf shall have no distortion or crack, loop movement in magnetic field clearance
shall be flexible and smooth, seal shall be good after assembly;
4) Regulating mechanism shall adjust freely, self-locking shall be good, indicating value of each
indicator shall be eye-striking and clear;
5) Resistance of loop and sensor insulation resistance shall meet stipulation value.
4. Verification of vibration instrument
4.1. Feature calibrating of vibration sensor
When excitation frequency is 55Hz, respectively adjust amplitude to（20, 40, 60, 80, 100）μm,
corresponding output voltage, amplitude and output voltage of sensor shall be in linear relation.
4.2. Linear calibrating of vibration meter amplitude indicating value
When vibration frequency is 55Hz, adjust vibration standard device to show more than 6 vibration
amplitude which are evenly distributed (including max. vibration amplitude), respectively
measure indicating value of measured vibration meter at different amplitude. Calculate relative
error of vibration meter amplitude nonlinearity according to the following formula:

Xi − Xs
δL = × 100%
XS
Of which :
δL——Vibration meter amplitude nonlinearity;
xi——Indicating value of vibration meter;
xs——Standard value given by vibration standard device
Max. relative error of indicating value shall be not more than ±5％if equipped with piezoelectric
acceleration sensor; it shall be not more than ±10％if equipped with other sensor.
4.3. Frequency response feature test
Keep amplitude to be 80μm, respectively read indicating value of measured instrument during
different frequency (20, 30, 40, 60, 80, 100)Hz. Calculate relative error of frequency response
according to the following formula:
Xi − Xr
δf = × 100%
Xr
Of which:
δf——Vibration meter amplitude nonlinearity;
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xi——Indicating value of vibration meter;
xr——Indicating value of vibration gauge at a referenced frequency point.
Max. relative error of frequency response: it shall be not more than ±5％ if equipped with
piezoelectric acceleration sensor; it shall be not more than ±10％if equipped with other sensor.
5. Operating and Maintenance
5.1. Put into operating
a) Check connection between each part to be right;
b) Turn change-over switch to “verification position”, turn power supply switch to “open” position on
amplifier, implement test and adjust;
c) Turn change-over switch to “measure” position, vibration instrument starts to put into operating.
5.2. Stopping
Turn power supply switch to “close” position on amplifier, cut off power supply, stop measurement.
Repair along with heavy and minor repair of unit.
Chapter V Maintenance Instruction of ZR202G Oxygen Analyser
1. Structure and operating principles
Oxygen analyser is mainly composed of zirconia probe, transmitter, furnace body flange, connecting
cable etc. It’s an electrochemical analyser that uses zirconia oxygen battery measurement to measure
oxygen content. Zirconia battery is installed on the top of the probe. It consists of a zirconia pipe and the
platinum electrode which is coated inside and outside the pipe wall. The zirconia pipe is made of yttrium
oxide or calcium oxide stable zirconia. In a certain high temperature, the Zirconia battery is a typical
oxygen concentration difference battery, because of the oxyanion cavity the zirconia pipe has in its cubic
crystal, and when there is different oxygen content between the two sides of the zirconia battery. The air is
the reference gas in a calcium cell. The air and the smoke flow into internal and external electrode
respectively. In a real probe, the air flows through the internal electrode and the smoke flows though the
external electrode. When the oxygen content P in the smoke less than the oxygen content P in the air, the
oxygen molecule capture 4 electrons from the external electrode and become 2 oxyanions, and electrode
reaction happens. The oxyanions moves to the smoke side swiftly in zirconia pipe, and the corresponding
electrode reaction happens in the internal electrode. The oxygen concentration difference leads oxyanions
to the smoke from the air, but the produced electrical potential sends the oxyanion to the air from the smoke
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again. When balance reached by this two kinds of movements, the probe signal E concerning the different
content of the oxygen was made between the electrodes. This signal meets the Nernst equation:
E=RT/4F*LnPo/P
of which: R, E stands for gas constant and faraday constant respectively, T stands for battery
temperature(K), Po and P stands for the oxygen content in the air and the oxygen content in the smoke
respectively. When the battery temperature is constant, oxygen content can be calculated if the probe signal
is measured.
Measurement object: the oxygen concentration in the diesel emission gas and mixed gas (inflammable gas
excluding)
The oxygen concentration: 0.01~100VOL%O2
Output signal: 4~20Ma DC (maximum load resistance 550Ω)
Measurement scope: between 0~5% to 0~100 VOL%O2（inside 1 VOL%O2 measurement range）, or
parts measurement range.
Digital communication (HART):250~550Ω, determined by the number of field devices in successive loops
(multipoint)
Repeatability: （exclude when the reference gas is natural convection mode）set scope max. value ±0.5%
（ no more than 0~25 VOL%O2 scope）; Set scope max. value ±1%（greater than 0~25 VOL%O2 to
0~100 VOL%O2 scope）
Linearity: （excluding standard air and reference gas is natural convection） using the known oxygen
concentration’s gas as null point, and measurement range cabilation gas, set the scope max. value ±1%;
No more than 0~25 VOL%O2 scope.（sample gas pressure: in ±4.9KPa）set scope max. value ±1%（greater
than 0~25 VOL%O2 to 0~50 VOL%O2 scope）
Drift: null point and measurement range scope set value ±2%/month.
Reaction time: 90% reaction in 5 seconds.
3. Maintenance of oxygen analyser
3.1. Maintenance items and quality required
3.1.1. Sample gas system check
Sampling flue should be without air leaking, good in heat preservation; if it is bypass flue, shall
implement purge to ensure smoothness of pipe;
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Air pump, air filter and flow meter should be perfect; disassemble and clean if possible, ensure its
cleanness, smoothness and leakproofness.
3.1.2. Zirconia probe check
Appearance check: silicon carbide dust filter permeability should be good, no jam, ash deposit, and
mechanical damage phenomenon; zirconia pipe should be clean, without crack, bending, serious abrasion
and corrosion; platinum electrode leading wire should be perfect, without drop binder; zirconia pipe and
alumina tube sealing should be closed, without leaking; flange joint face shouldn’t be corrupt, gasket
perfect, flange screw fasten; junction box without serious ash deposit and corrosion;
Probe internal resistance check: when probe temperature is 700℃, use ionic conduction mode to
measure the probe, its internal resistance should not more than 100Ω
Probe background electrical potential check: when probe temperature is 700℃, lead 300mL／h clean
air to working port and reference gas port respectively, measure probe background electrical potential. It
should not more than ±5mV;
After installing probe, reference gas hole and standard air hole towards the ground; the shield 0 line
from the probe to the converter should be perfect.
3.1.3. Insulation check
Under normal temperature, use 500V megohmmeter to measure the probe’s insulation resistance, the
resistance of thermocouple to shell insulation should be greater than 100MΩ, heater to shell insulation
resistance should be greater than 500MΩ, and internal electrode leading wire to shell insulation resistance
should be greater than 20MΩ;
Under normal temperature, use 500V megohmmeter to measure transmitter’s insulation resistance,
and it should be no less than 40MΩ.
4. Oxygen analyser verification
4.1. Temperature control accuracy calibrating: rise probe temperature to set point and stably last for 30
mins, measure thermocouple temperature, the difference between its value and setting value should be no
more than ±5℃.
4.2. Temperature stability calibrating: measure thermocouple temperature once every 5 mins, measure 10
times continuously. The max. value difference of the reading in 10 times should be no more than ±4℃.
4.3. Converter calibrating: use potentiometer in “oxygen potential”(different content electrical potential）to
input millivolt signal respectively of oxygen content of 0.5%, 2%, 4%, 6%, 8% and 10% (meter value add
probe background electrical potential value), measure and record converter output current value, the max.
34
value difference between its value and standard output value should be no more than converter’s basic error,
otherwise, adjustment should be implemented.
4.4. Constant current performance calibrating: when the output current is full range, every load resistance
in specified scope changing 1k Ω, output current’ s change should be no more than 0.1 mA.
4.5. Whole set instrument’s indicating value calibrating: after adjusting the display device’s starting point
and ending point’s indication, using standard gas within the date according to manufactory specified
flow(using 300mL/min flow if no manufactory specified flow）to pass over probe, implement all
instrument’s indicating value calibrating.
4.6. Measurement range calibrating: open probe standard air valve, cutting in 20.6% oxygen content
standard gas or 20.6% fresh air, observe secondary instrument（or display）reading, after it’s steady, if there
is deviation, adjust measurement range slightly to 20.6% on the display;
4.7. Null point calibrating: cutting in standard gas of about 1% oxygen content, observe secondary
instrument（or display）reading; after it is steady, if there is deviation, adjust null point slightly to display
the standard gas oxygen content value; repeat a） and b）till the measurement range and null position
reaches requirement（measurement range and null position slightly adjustment amplitude cannot be too
large, avoid influencing the basic voltage;
4.8. Accuracy check: after the measurement range and null position calibrating, cutting in the standard gas
close to the smoke’s oxygen content（if did not implement measurement range and null position calibrating,
use standard gases about 1% O2, 4% O2, 8% O2 respectively）to pass over the probe, check the display
device indicating value, record reading after its steady, and repeat 3 times; The max. value difference
between the indicating value and standard gas oxygen content shall be no more than measurement range’s
±5%.
4.9. All set instruments indicating value repeatability calibrating: when implementing all sets instrument’s
indicating value calibrating, the max. value difference between every two shall be notmore than ±0.2% of
measurement range.
4.10. Reaction time check: during implementing the whole set of instrument’s indicating value calibrating
course, when changing standard gas, the time display device’s indicating value from unsteady to steady
（reaches accuracy requirement）should be no more than 30s.
5.1. Preparations before put into operating
35
Check probe, connecting wire, air passage system, converter and display instrument, etc. They
should meet the requirements;
For new installed system, check sampling point furnace smoke temperature which shall meet the
requirements;
The probe’s installation should be prepared before boiler ignition, it’s temperature rises as boiler is
starting up; if install or change the probe in boiler’s operating, the probe should rises its temperature to
rated temperature, and then put in the flue.
5.2. Put into operating
5.2.1. Connected the power supply one or two days before ignition, to avoid the crack of the zirconium pile
caused by quenching or shockheating;
5.2.2. Adjust the reference gas flow to 250mL/min; as to boiler of positive pressure burning, increase
reference gas flow properly;
5.2.3. When the probe temperature rises to rated value for 30 min, working condition of the temperature
control equipment shall be normal.
5.3. The first week of the instrument put into use, heater voltage and probe temperature should be checked
once a day every day and check once every week;
5.4. Every quarter use calibration instrument to check indicating value once (including two kinds of oxygen
about 4% and 8%, flow is 300mL/min);
5.5. To prevent probe damage, take out probe from flue before boiler maintenance, clean up ash deposit and
keep it safe;
5.6. Make good record for system equipment installation, maintenance time and calibration.
5.7. Stopping
5.7.1 Cut off instrument and air pump power supply;
5.7.2 Instrument followed with boiler maintenance out of action, shall be taken out of the flue and kept
safely before maintenance probe.
Instrument’s verification and probe check should be implemented with heavy & minor repair of machine
set.
36
Chapter VI Maintenance Instruction of ABB Quality Flow Meter
Working of ABB automation product quality flow meter is based on Coriolis force principle.
FCM2000 structure adopts the classical parallel measurement pipe, in details saving space and bending
design are its features, provide wide massive flow meter dimension scope for users with overwhelming
price. When a certain quality fluid flows through the vibrate pipe, the Coriolis force will be produced to
make pipe bending and twisting. This minim pipe distortion is tested by sensor at optimum position;
implement electron evaluation. Because sensor detects the phase movement signal and quality flow is in
direct proportion, Coriolis force quality flow meter can directly measure quality flow. Measurement
principle has no relation with fluid density, temperature, viscosity, pressure and conductivity. Measurement
pipe always vibrates sympathetic in vibration mode. Under working condition, this sympathetic vibration
frequency is function for measuring pipe’s geometry form, flow meter material feature and the fluid quality
in the pipe（also vibrating）. Flow meter can precisely measure measured fluid’s density. One integrated
temperature sensor measures fluid temperature, to calibrate instrument parameter which is easily influenced
by temperature. After all, Coriolis force quality flow meter can concurrently measure quality flow, fluid
density and temperature. Other measurement values are calculated by these values, for example, volume
flow or thickness.
2. Instrument basic security information and using method
2.1. Basic security information
2.1.1 Instrument safety standard
This instrument meets pressure equipment rule and latest technology safety requirement. This
instrument has passed the plant test according to safety requirement, and delivers according to correct
purchase order. To make the instrument meet safety index at operation course, the listed requirements in the
operation manual must be obeyed.
For dimension reaches DN100（4”）Coriolis force quality flow meter has a waterproof shell option,
flow meter sensor max. working pressure is PS＝40bar（the shell’s blast pressure is PS>60bar）. In the
scope the pressure equipment indicates the protection design can not be failed. When power interruption
happened, the instrument parameter was stored in FRAM (including latest accumulated value). When
power supply recovers, instrument can work immediately.
2.2. The possible risk in the course of operation
37
2.2.1. Abradable medium and/or cavitation erosion may bring damage to press part.
2.2.2. When measuring high temperature medium, contacting flow meter surface may lead to scald.
2.2.3. Erosiveness medium may lead to corrosion and/or abrasion. Compress medium may leak from flow
meter.
2.3. The possible risk in checking and maintenance
2.3.1. Before checking the instrument confirm the instrument, the near pipes and the depositor has been
decompressed.
2.3.2. Confirm power supply has been cut off before open the shell cover.
2.3.3. Don’t loosen the installation bolt on the tube holder or the seal bolt on the flow meter sensor.
Medium with pressure may erupt and bring about serious harm. Before open flow meter, the pipe should be
decompressed.
3. Installation and maintenance of the flow meter sensor
3.1 Installation
3.1.1. Before installing the flow meter sensor, firstly check whether there is mechanical damage caused by
the improper operation in transport course, and it can work at any direction. The optimum installation
direction is vertical and flows upward. To implement system null point adjust, stopping valve should be
installed in the pipe.
3.1.2. No need to use fluid to adjust access to spool. Pay attention to ensure all valves, sluice, sight glass etc.
there should be no cavitation erosion, and shock will not be generated by flow meter sensor.
3.1.3. Air pocket in the fluid brings measure error, especially in density measurement. Therefore, flow
meter sensor should not be installed at the top of pipe.
3.1.4. Avoid exists lowering long pipe at flow meter sensor lower part to avoid measurement pipe being
evacuated.
3.1.5. Connecting pipe shall have proper length and avoid obvious axial direction deviation to ensure there
is no stress in flow meter sensor.
3.1.6. Flow meter sensor should not contact any other objects. Installing any appurtenance on the shell is
not allowed.
3.1.7. When interface of connecting pipe is greater than dimension of flow meter sensor, and suitable
dimension shrink part should be adopted.
3.2. Null point adjust
To adjust null point under working condition, must keep measurement pipe in full state to reduce
38
flow velocity to “zero”. When technology cannot stop, bypass pipe is most ideal. To ensure measurement
accuracy, ensure flow meter sensor have no air pocket during null point adjusting. Ensure temperature and
pressure in measurement pipe is same with that during working is very important.
3.3. Maintenance
3.3.1. Sensor should be installed at dry, and clean area after the environment temperature reaches about 20
℃.
3.3.2. Be careful to operate when remove screw and install pressure release valve.
3.3.3. Ensure pressure release valve is installed rightly and fastened completely, and seal ring is installed
correctly. Seal ring must be replaced after each removal.
3.3.4. Flow meter sensor basically needn’t maintaining. Annual check shall include environment condition
（air circulation, humidity）, leakproofness of course connection, cable access and close over screw, power
supply reliability, lightning protection and grounding check etc.
3.3.5. Parameter description (refer to parameter table in FCM2000 instruction manual)
39
Volume II Maintenance Instruction of Instrument & Control Protection System
Chapter I Maintenance Instruction of Pressure Switch
This chapter stipulated the instrument & control signal, protection and the maintenance, verification
technology and quality requirement of the interlock pressure switch.
General Description
Pressure control switch is the indispensable instrument equipment with which the modern power
plant realizes automotive control. It provides the switch signal for the control system, and it also can realize
the alarm of pressure high/low limit.
Pressure switch is mainly composed of adjust terminal of the set value, load binder, sensitive switch,
the adjust terminal of change-over difference and spring. When the sensing elements of the pressure
switch, such as membrane, piston or corrugated pipe, receive pressure, the displacement will happen.
When reaching a certain pressure, touch the sensitive switch to act, and send the contact signal to
control or alarm.
2.1Technical specification:
Item Sort Specs requirement
Pressure control scope pressure switch 15%-95%（ measurement range ）
vacuum switch 95%-15%（ measurement range ）
Set point nominal value 0.5 class ±0.5%（ measurement range ）
error 1 class ±1%（ measurement range ）
1.5 class ±1.5%（ measurement range ）
4 class ±4%（ measurement range ）
Repeatability error 0.5 class ±0.5%（ measurement range ）
Change-over difference Adjustable ≤10%（ measurement range ）
MAX≥30%（ measurement range ）
Unadjustable
MIN≤10%（ measurement range ）
Insulation resistance Terminal and shell ≥20MΩ
Among terminal
40
2.2 Main feature of pressure switch
Feature Index requirement
Use medium Steam, water, oil, mist and clouds, air
Work viscosity <1000 square millimeter per second
Environment temperature -5℃- +40℃
Medium temperature 0- +90℃
Switch element temperature max+80℃
Anti-seismic performance max×4g
3. Maintenance of pressure switch:
3.1. Appearance check:
Implement clean and routine maintenance of instrument. After maintenance, instrument shall meet the
following requirement:
3.1.1. The shell and surface parts of the checked switch shall be glabrous and perfect. The nameplate shall
be clear;
3.1.2. All parts shall be clean without dust and complete without damage, it must not be corrosive,
distorted;
3.1.3. Fastener shall be firm and reliable, it must have no phenomenon of being loose and fall-off and so on.
The moving element shall be operated flexibly and balance, and no block;
3.1.4. The connection sign of the connection terminal board shall be clear, and the seal of fairlead shall be
good;
3.1.5. The sensitive switch or mechanical contact inside the switch shall have no distinct oxidation and
burning loss.
Insulation check
Measure the middle between terminal and shell with 500V insulation ohmmeter, and insulation
resistance among terminal shall be ≥20MΩ.
3.2. In pressure switch maintenance, dismantling the connection must be putted after switch is off, and
dismounting connection shall take good protection measure.
3.3. Disassemble of the pressure switch must close pressure switch primary valve and secondary valve at
first. Confirming that pressure switch has already eliminated the pressure, then put disassembling into
practice.
3.4. After pressure switch is disassembled, the measure must be adopted to seal and protect the pipe joint
well, strictly prohibiting sundries entering into the pipe joint during maintenance.
41
3.5. After pressure switch disassembling, the sign must be made to prevent confusion from other switches.
Strictly prohibit collision during transport period. Pressure switch must be cleaned and placed in the
standard room for 4 hours before check verification.
3.6.For appearance check of the pressure switch, nameplate shall be complete and clear. Product name,
model, class, specs, pressure control scope, manufactory, leave factory number and leave factory date shall
be complete.
3.7. Pressure switch shall be complete. Fastener must be not loose, and the moving element shall be flexible
and reliable.
3.8. Maintenance of the pressure switch must be verify according to the state verification instruction.
3.9. After the verification of the pressure switch is up to standard, it must be marked.
3.10. Pipe joint shall be cleaned before pressure switch reerection, implementing pipeline wash and
pollution discharge if it is conditionally.
3.11. In pressure switch reerection, change different instrument shims to prevent seepage according to
different measurement medium.
3.12. After reerection, open the primary and secondary valve, put pressure switch into use.
4 Verification of pressure switch（checkout）
4.1. Verify equipment:
4.1.1. Selecting standard: the absolute value of standard permissible error shall be less than 1/3 of
absolute error indicating by pressure switch repeatability error.
4.1.2. Auxiliary equipment has pressure verification desk（or vacuum pump, or U-tube, insulation
ohmmeter, withstand pressure tester, multimeter（or measurement signal device）.
4.1.3. Verify environmental requirement:
4.1.3.1. Environment temperature is（20±5℃）
4.1.3.2. Relative humidity is 45%-75%
4.1.3.3. When verifying environment, to avoid influencing mechanical vibration of verification.
4.1.3.4. Pressure transmission medium which upper limit of the pressure control scope is not more than
0.25MPa is the clear gas.
4.1.3.5. Pressure transmission medium, which upper limit of pressure control scope is more than 0.25MPa
is uncorrosive liquid.
4.2. Verification item
4.2.1. Check of pressure control scope:
42
Connect verification system well; as for the adjustable pressure switch of change-over difference, firstly
adjust change-over difference to min, and set point to max. boost slowly until the sensitive switch outputs
the signal. At the moment, the reading value on the standard is the top switch value of max. value. Then
adjust set point to min., decompress slowly till the sensitive change-over act. At the moment, the reading
value on the standard is the bottom change-over value of min. value. The difference of the max. top
change-over value and min. bottom change-over value is the pressure control scope of the pressure switch.
4.2.2. Verification of set point error:
4.2.2.1. The verification of set point error of the pressure switch, which set point is adjustable and
change-over difference is unadjustable: firstly adjust set point to 10% scale of measurement range, boost
pressure slowly from null point until the sensitive switch act outputs the signal. At the moment, the reading
value on the standard is the top change-over value. Then decompress slowly from that point to the sensitive
switch act. At the moment, the reading value on the standard is the bottom change-over value. Verify 3
times according to this method repeatedly, the median of three-time top change-over difference average
value and three-time bottom change-over difference average value is the change-over median of set point.
Use the same method to adjust 1 set point to the scale of 50%, 90% in turn and implement the error
verification of this set point. The percentage of difference of change-over median and set point and
measurement range is set point error.
4.2.2.2. Verification of set point error of the pressure switch, which set point is adjustable and change-over
difference is adjustable: before verification, adjust the change-over difference to the middle position of
effective adjust scope, then follow the previous method to implement the verification. When pressure
switch set value controls the top change-over difference, the percentage of the actually measured top
change-over value difference and measurement range is the set point error. When the pressure switch set
value controls the bottom change-over difference, the percentage of the actually measured bottom
change-over value difference and measurement range is the set point error.
4.2.2.3. When the set point error checks that the set point is not needed to adjust, other items are same as
term a, b.
4.2.3. Verification of repeatability error
When verify the set point error, in the max. difference value that one verifying point’s three-time top
change-over and that of bottom change-over, the percentage abtained from the max. one of the above two
max. value and the measurement range is the repeatability error. Verification result accords with 2.2.2
specified in technical specification.
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4.2.4. Verification of rechange-over difference
4.2.4.1. The change-over difference verification of the unadjustable switch of change-over difference.
When verifying the set point error, change over the difference value between the top change-over difference
average value and the three-time bottom change-over difference average value at the same verification
point.
4.2.4.2. The change-over difference verification of the adjustable switch of the change-over difference.
When set point is the top change-over value, change-over difference verification shall verify two points of
50% and 90%. When set point is the bottom change-over value, change-over difference verification shall
verify two points of 10% and 50%.
（a） First adjust the change-over difference to min, boost slowly from null point until the sensitive switch
act outputs the signal. At that moment, the reading value on the standard is the top change-over value. Then
decompress slowly from that point to sensitive switch act. At that moment, the reading value on the
standard is the bottom change-over value. Verify 3 times according to this method, the difference value of
the three-time top change-over difference average value and three-time bottom change-over difference
average value is the min. change-over difference.
（b）First adjust the change-over difference to max, boost slowly from the null point until the sensitive
switch act outputs the signal. At that moment, the reading value on the standard is the top switching value.
Then decompress slowly from that point to the sensitive switch act. At that moment, the reading value on
the standard is the bottom switching value. Verify 3 times according to this method continuously, the
difference value of three-time top change-over difference average value and three-time bottom change-over
difference average value is the max. change-over difference.
4.2.5. Verification of the insulation resistance: use 500V insulation ohmmeter respectively to test the
insulation of terminal and shell, terminal and terminal, contact（when cutoff）, and read the value after 10
seconds.
4.3. Verification result reduction: qualified pressure switch will get the verification certificate, unqualified
pressure switch will get the verification result requisition, and note unqualified items.
5 Operating maintenance
5.1 Regularly check the accuracy of the switch set point value and the condition of the signal alarm, keep
alarm act reliable.
5.2 Regularly clean switch
6. Verification cycle
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The switch used for protection verifies once half a year and the pressure switch of the interlock and
alarm verifies once a year.
Chapter II Maintenance Instruction of ETS System
Section I General Description
ETS, steam turbine emergency trip system, accepts alarm or shutdown signal from TSI system or
other steam turbine generator unit system, implementing logical transaction and outputting the indicator
light alarm signal or steam turbine obstruction signal , and then having the function of protection.
In order to use it conveniently and run reliably, the plant adopts double-turbine PLC（programmable
controller）to implement logical transaction. Double-turbine PLC concurrently work, all act can output
alarm signal. When one of them fails, PLC sends machine failure alarm signal, and automatically cuts off
its shutdown logic output, but the other one can work normally. This device can communicate with other
system, meet automation demand of the power plant.
1.1. Steam turbine ETS is mainly formed by two sets programmable controller（PLC）, and all the trip
logic is completed by PLC. To increase reliability of ETS, two sets PLC coordinate operating mode are
adopted. ETS test and monitoring function are completed through man-machine interface of DEH and
DI/DO card. ETS monitors all trip signals; when trip signal inputs, i.e. output signal shuts down the steam
turbine, so as to protect machine set safety.
1.2. Some trip loop of ETS are the ones of two channels, these trip loops have 2 monitoring loops of
channel 1 and channel 2, only when channel 1 and channel 2 all happen trip, steam turbine shuts down.
So ETS system allows online test to implement these loop. Also some trip signals adopts 3 input signals,
after choosing 2 from 3, then make the condition of machine shutdown.
1.3. ETS system output respectively controls 4 AST solenoid valves, high pressure main throttle valve
and emergency trip valve of medium pressure main throttle valve in EH system. When one of solenoid
valves AST1, AST3 and AST2, AST4 loses electricity one each, steam turbine set trips. 4 AST solenoid
valves all can implement online test to check AST solenoid valve and its act loop rightness.
1.4 Besides some especially important protection signal such as hand operate shutdown, overspeed,
DEH deenergization, other trip signals set removal switch which can remove corresponding protection
item.
Section II Function of ETS System
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ETS system is an important method ensures machine set operating safely, monitors the important parameter
of steam turbine. When these parameters exceed operating limit, ETS system will close all inlet valves of
steam turbine, and emergently shut down to avoid accident happening.
2.1. Main functions of ETS system protection:
Operating desks 1, 2 use hand-operating to shut down turbine
Lubricating oil pressure is low（choose 2 from 3）
Vacuum is low（choose 2 from 3）
Control oil pressure is low（choose 2 from 3）
Dynamo main protection act
Boiler main fuel trips（choose 2 from 3）
Axial direction displaces greatly（choose 2 from 3）
Oil level of the oil tank is low（choose 2 from 3）
DEH failure
Cylinder differential expansion is large
#1～#5 tile bearing vibration is heavy
Main steam temperature is high（choose 2 from 3）
High ejection temperature is high（choose 2 from 3）
ETS 110％ is over speed （choose 2 from 3）
When system monitors the trip signal inputting, trip instruction is sent. Trip output lasts until the
operators press trip button and reset ETS. Besides the above monitoring signal of the shutdown condition,
ETS also has 5 alarm monitoring signals such as protection removal, power supply normal, steam turbine
trip, ETS protection channel power supply stop and main throttle valve close.
Section III System Operating Principle
1. Double-turbine PLC with ETS device work concurrently. Input signal from locale concurrently enters
into engine A and engine B after entering into this device. Through internal logic automatic process, then
send corresponding output signal. Take “steam turbine overspeed "for example, when electric is over speed
and the shutdown signal inputs this device, concurrently enter into engine A and engine B to implement
transact, then concurrently output the shutdown signal.
2. When one of A（B） is in failure, it can send out its alarm signal, automatically cut off the shutdown
output contact of this machine at the same time, while the other turbine works normally.
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The shutdown logic of double-engine work is as following chart:
3. This ETS device has two switch loops of power supply, when one of power supply broken down, it will
automatically switch over to another power supply loop to continue working, if main and secondary
power supply concurrently fails, then output one AC power supply deenergization alarm signal. When 2
QUINT-PS power supply redundancy, it provides ＋24V power supply for all device, this power supply
and 6ES73071EA000AA0 failure all output a ＋24V power supply deenergization alarm signal.
4. System logic chart and terminal chart:
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48
49
Section IV ETS Maintenance
This device is a complete computer control device, and it needs overall check and test before put into
operating. Put it into use after confirming that everything is right, including the following contents:
1. Power on self-check, connect two way 220VAC power supply to circuit breaker input terminal of ETS
device main & secondary power supply, turn on circuit breaker switch, voltmeter of device panel indicates
right, main & secondary power supply indicator lights are on, device ＋24V power supply indicates
normal. At this moment PLC begins to self-check, CPU “RUN“ indicator light will be on after self-check is
completed. ETS device begins to enter into normal work state, and then just put it into operating.
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2. Check whether main & secondary power supply works normally;
3. To prevent field high reject signal into control cabinet, anti interference suppressor is installed. Usually
pay attention to voltmeter of device cubicle to be normal or not. Control cabinet power supply configure is
shown in figure 0-5-1;
4. Clean dust in control cabinet;
5. Change failed parts.

Power supply connection figure
Chapter III TSI maintenance instruction
1. General description
TSI（steam turbine safety monitoring system）of this plant is produced by Bentley U.S., which
monitors and alarms to steam turbine axial direction displacement, bearing vibration, bearing cap vibration,
off center , operating speed and zero operating speed implement respectively.
TSI operating principles and realized functions are as following: probe sends displacement and other
signals, head amplifier changes it into voltage signal to monitor transact, monitor then sends it to panel,
output record signal and provide alarm.
2. TSI technical specification:

Name Parameter
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Unit
95～125Vac 50～60Hz max. current 10A
Power supply
or 190～250Vac 50～60Hz max. current 0.5A
26A（ peak value ） or every week 12A mean square
root
Power supply fluctuate
95～125Vac 1.5A slowly fusing
190～250Vac 0.5A slowly fusing
Output sensor power -24VDC 0%～-10.5%
V
supply or -18VDC 0%～-2%
Environment 0℃～+65℃ while using
℃
restriction -40℃～+85℃ while saving
3. TSI system maintenance
3.1. Please refer to TSI framework, loosen two screws of front panel to take out monitor, disassemble
monitor with powerand it has no impact on system.
Monitor models:
3500/01 system monitoring
3500/10 power supply
3500/16 axis vibration
3500/20 axial direction displacement
3500/40 off center, phase discrimination
3500/45 high and low cylinder differential expansion
3500/50 zero operating speed and operating speed
3500/55 cap vibration
Remove side cover plate after taking out monitor. Side cover plate has switch positions and
function-setting introduction which can be found in the following chapter. The scale can be changed, nip
out scale paper from front cover plate with forceps, and exchange to be the needed one.
3.2. 3500 system common failures are:
3.2.1. Extending cable and probe joint is easily broken.
3.2.2. In installation course, probe is easily touched.
3.2.3. Resistance caused by dirt at joints of cable will increase and is inaccurate
3.3. Transacting methods:
3.3.1. Change probe, be carefully when installing it.
3.3.2. Monitor it all the time when installing, handle it immediately when probe displacement is found.
3.3.3. Clear out oil stain and sand.
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4. System debugging
Maintenance tools needed: multimeter, TK-3 check meter and disassembly tools.
4.1. 3500/20 axial displacement
Adjusting and calibration consists probe and monitor which can be carried out respectively. This is
laboratory work , and they shall be prepared before they go out of factory, null position measurement
range of probe monitor will be adjusted as a whole in the field, which will be described respectively in the
following.
4.1.1. Probe function
a. Contact mechanical and open bearing cap.
b. Carefully dismount probe, reconnect joint with head amplifier, provide head amplifier 24V power supply
（available system power supply ）.
c. Fix probe on check meter, and fix suitable null position on micrometer.（The verified segment is about
0～5mm with requirement of 4mm linear）.
d. Turn micrometer outward at fixed interval, and record voltage value （ For example turning each 20
spaces of micrometer at 20 silk intervals）.
e. Analyze record, take 4mm of it if linear is good, set starting value （based on voltage or micrometer
reading, but don’t dismantle during the course of adjusting and calibration） and ending value, rechange
probe if liner is not good, and repeat the above procedures.
4.1.2. 3500/20 monitor
a. open front panel;
b. back switch ;
c. Introduction to indicator lights of all switches and front panel is as below:
ZA （Zero pon tion adjust） null position adjust （A channel ）
GA (Gain adjuv) gain adjust （A channel ）
ZB (Zero position adjust) (B channel)
GB (Gain adjust)（B channel ）
ST (Self test) self-check
BA (Bypass A) bypass A
BB (Bypass B) bypass B
DB monitor bypass
AA（Adjust A） adjust A
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AB（Adjust B） adjust B
U/O direction
Light OK lasting bright means input in input OK scope.
Light DAGGFD bright means danger value arriving.
Light ALERT bright means alarm value.
Light BYPASS bright means bypass.
4.1.3. Measurement range and null position adjustment
a. Turn A to ON position.
b. Set micrometer at starting value （as predescribed）, display （ null point ） shall be -2mm, monitor
output is 4mA, if it doesn’t show -2mm, adjust GA, then turn to ending value, it shall show 2mm and
monitor output shall be 20mA, adjust GA in the same way, repeat the above procedures until it is suitable,
then set micrometer in the middle of starting value and ending value, adjust ZA until it points to scale zero.
c. Pull probe once again（turn micrometer ）, record all indicating value data, and collect them.
e. Complete adjustment, turn AA switch to OFF position.
d. Screw front panel.
4.1.4. Adjust alarm setting point
a. Open front panel.
b. Turn A to ON position, press ALERT, and A alarm value will flicker.
c. Use （↑）
（↓） buttons of system plate to adjust its value.
e. Press DANGER button, repeat （3） procedure , and danger value will be set.
f. Turn U/D switch to the other side, repeat procedures from（2）to（4）, adjust alarm value and danger value
of another direction.
g. After setting, resume to all switch positions.
h. Close front panel closely.
4.1.5. If there is need to take a look at alarm or tripping value, respectively press ALERT or DANER.
4.1.6. Self-check
a. Self-check has three modes:
(a) Power on self-check
(b) Periodicity self-check
(c) Make front ST two point short circuit using screwdriver.
b. The following are self-check codes
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(a) ROM check and off-normal
（b）EPPROM No 1 off-normal
（c）EPPROM No 1 off-normal
（d）+7.5V/-VT test point exceeding error scope
（e）+VRH test point exceeding error scope
（f）+5V test point exceeding error scope
（g）MVREF test point exceeding error scope
（h）+7.5V test point exceeding error scope
（I）+VRL test point exceeding error scope
（j）+5V/-7.5V test point exceeding error scope
（k）SCIC clock off-normal
（l）RAM off-normal
（m）1CV4 output value
4.1.7. Refer to the following table if there is any item needed to change
Short films
Alarm time delay
Installation Remove
0.1S --- W15A,B
1S W15B W15A
3S W15A W15B
6S W15A,B
Instrument fast --- W21
responding time slow W21 ---
and W16c ---
Danger
or --- W16c
away from CHA W1
probe CHB W18
Probe direction
approaching CHA W1 ---
probe CHB W18 ---
put into W20 ---
Danger bypass
not put into --- W20
Record instrument
Short films installation
output
4～20mA W7 A, C, E, F;W8 B, C;W10 A, B;W11 B, CW12 A, C, E, F

+1～+5VDC W7 B, D;W8 A, E;W10 A, B ;W11 A, E;W12 B, D
0～-10VDC W7 B, D;W8 D, F;W9 A, B;W11 D, F;W 12 B, D
4.2. 3500/45 High and low cylinder differential expansion
4.2.1. Adjustment of null point and measurement range is basically same with adjustment of axial direction
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displacement.
4.2.2. Options of jumpering films are as below:

Jumpering films
Option Setting
Installation Remove
use W12A
Danger bypass switch
not use W12A
0.1S W14 A, B
Alarm delay 1S W14 A, B
3S W14A W14B
slow W21B
Display
fast W21B
and W14C
Danger logic
or W14C
Aproaching
W12C
probe
Channel A
Away from
W12C
probe
Approaching
W12B
probe
Channel B
Away from
W12B
probe
4.3 . 3500/16, 3500/55 alarm setting, self-check, display is the same as 3500/20, installation clearance （by
voltage） requires latching clearance voltage within 8～10V.
4.4 . 3500/16
a. Open front panel, turn AA to ON;
b. Press GAP while short circuiting ST;
c. Complete and put back AA to OFF.
d. Close front panel
4.5. Operating speed and zero operating speed
4.5.1. Self-check bypass is similar to 3500/20.
4.5.2. Full range adjusting
a. Optional scope of null speed full range [100, 200, 500, 1000, 9999];
Operating speed full range [100, 200, 500, 1000, 2000, 5000, 10000, 20000, 50000, 99999].
b. Adjusting procedures:
（a） Dismount monitor;
(b) Dismount side cover plate ;
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(c) Install adjusting plate W16A;
(d) Install monitor to framework;
(e) Turn switch ER to ON;
(f) Press ALERT, use（↑）

（↓） to adjust operating speed measurement range ;
(g) Press left ALERT and adjust null speed full range ;
(h) Put back ER to OFF;
(i) Take away monitor, remove W16A;
(j) Installation is finished when put monitor to framework and fasten it. .
c. Adjustment of events of each turning
According to machine operating speed, restriction of maximum events of each turning is shown in the
following table;
RPM full range Max. allowed event of each turning
100 255
200 255
500 255
1000 255
2000 255
5000 120
10000 60
20000 30
50000 6
99999 1
(a) Dismount monitor;
(b) Dismount side cover plate;
(c) Install W16C;
(d) Install monitor to framework, front panel shows numerator and denominator of;
(e) Turn 0E/R to ON;
(f) Press right ALERT button;
(g) Use （↑）

（↓） of system monitor to adjust numerator;
(h) Press left ALERT button, use （↑）

（↓）to adjust denominator;
(i) Adjustment is completed, resume to E/R switch, and take out W16C;
(j) Install monitor.
d. Monitor can latch all happened max. operating speeds , PH behind short-circuited panel can remove all
max. latching values.
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5.1. Every day, measure the working state of elements once at the field, check whether signal cable is
damaged.
5.2. Regularly clean equipment onsite.
6. Repair period
Implemented with heavy and minor repair of machine set, and. mainly verify once-measured element, and
change it if it is unqualified.
Chapter IV Automatic Alarm System of
DZXL Furnace Tube leakage
1. Function introduction
Boiler furnace tube leakage adopts DZXL- 135 model monitoring device of Shenzhen Eastern Boiler
Control Co., Ltd. used for testing boiler press heating pipe early stage water and steam leakage of boiler
superheater, reheater, economizer, and water wall.
2.1. Operating principle
By using boiler furnace water wall, superheater, reheater, horizontal flue, terminal vertical shaft and
sound wave sensor inside boiler wall and head amplifier to collect sound signals inside furnace,
change them into current signals, monitoring system through fast Fourier transform (FFT) technical
analysis to get sound signal frequency spectrum inside furnace and shown with form of bar graph;
through calculating analysis of noise strength, frequency spectrum character and duration, judge whether
furnace tube leaks. Power plant uses this system to prevent machine shut-down out of plan, prevent or
relieve damage by secondary leakage and prevent damage of heating surface pipe caused by fault of
sootblower. At the same time, it can shorten first-aid repair construction period of furnace leakage, relieve
labor intensity, relieve equipment loss by secondary leakage cause and increase in-commission rate of
machine set.
2.2. System composition and function features
1） System composition
“ DZXL model boiler furnace tube leakage automatic monitoring system ” is composed of three parts,
including signal collection system, signal transaction system and displaying alarm system.
● Signal collection system including: conduct tube, sound wave sensor and head amplifier.
● Signal transaction system is completed by industrial control computer, using fast Fourier transform
(FFT) to analyze collected electric signals and get signal frequency spectrum and display it in real time
curve or bar diagram. Through calculating analysis of frequency spectrum, test and judge whether boiler
has leakage and leakage degree.
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●Displaying alarm system is composed of three parts, including: simulating display screen,
microcomputer system and control compartment acousto-optic alarm word plate.
2） System function
a. Realize online test early stage of alarm furnace tube leakage.
b. Accurately judge furnace tube leaking area position
c. Follow up record of leaking development trend degree
d. Display leaking sound frequency spectrum
e. Real time monitor furnace inside noise
f. Effectively monitor steam sootblowing operating condition
g. Device system self-check test
h. Dust distinguishing and purging of waveguide
i. System abnormity alarm
3.1. System index
● System device sensitivity: test minim leakage <2mm
● System device resolution: isolation scope within hemisphere space of 4-8m radius;
● System device continuous operating time:>18000 hours .
3.2. Equipment performance index
● Enhancement mode sound wave sensor sensitivity: >25mV/Pa;
●Enhancement mode sound wave sensor testing scope: >12m hemisphere space ;
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●Enhancement mode sound wave sensor continuous operating time : >30000 hours;
●DZXL/model boiler furnace tube leak automatic monitoring system is designed by 32×2 line input
channel design and capable of dilatancy.
● Provide boiler furnace tube leak monitoring system 2 lines alarm contact output signal at
least( contact rating 220V AC, 1A, 220V DC, 1A).
4. System maintenance
4.1. Device operation
4.1.1. Operation of signal collection system
Sensor is an important element, pay attention to methods at field operation to prevent damage to sensor from
operating improperly. Operation skills:
4.1.1.1. At system normal work, close ball valve of waveguide.
4.1.1.2. At sensor field connection, connect sensor terminal line, then put it to sensor interface of sound wave
conduct tube, use special use king nut to screw it tightly.
4.1.1.3. When sensor is not used, pay attention to moisture proof and dustproof.
4.1.1.4. Don’t beat it with rigid objects.
4.1.1.5. Prevent long time contact with high temperature heat source.
4.1.2. Monitoring system operation
Connect power supply correctly, check power supply before operation, carry out standard debugging before
sensor goes out of factory.
4.2. Device maintenance
Device adopts terminal connection. Failure of any part can be completed through measurement terminal signal
with convenient work and little maintenance.
4.2.1. Device self -diagnosing function
System timely realize self-check, if failure is found, failure reason will be indicated.
4.2.2. Ash deposit alarm and cleaning of sound wave conduct tube
Positive pressure will be produced in boiler operating course sometimes, leading ash deposit inside furnace
blocking up sound wave conduct tube. At this moment, software interface will send dust alarm signal,
reminding operating personnel of ash removal transaction. Ash removal has two methods:
4.2.2.1. Manually ash removal: open terminal ball valve, use common metal bar of 1.5 meter of length and 8mm
of diameter to insert and dredge ash deposit.
4.2.2.2. Automatic ash removal: if conduct tube is installed with steam source purge device or electric ash
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removal device, operating personnel will start up automatic ash removal function when ash deposits.
5. System maintenance period
Chapter V DZHJ Maintenance Instruction
Flame Industrial television Monitoring System
Section I System Introduction
“DZHJ type full furnace flame industrial television monitoring system” is an endoscopic furnace FTV
which is self researched and developed by Shenzhen Eastern Boiler Control Co., Ltd. on basis of domestic
and overseas advanced technology. This system puts camera probe part into boiler furnace, and monitor
burning state wholly from the upper part of furnace wall, and get a whole the furnace flame state.
Operating personnel can observe real image of furnace flame from control compartment through
color TV monitor. When at boiler ignition, underload operating or failure of harming boiler’s normal
operating, this system helps to prevent boiler furnace fire-fighting, and is a safety, economy, reliable
operating indispensable equipment for boiler.
1. System main features:
● This system is acceptable for newly designed boiler and reconstructing reused boiler. This system is also
acceptable for flame monitoring of all kinds of industrial furnaces of directly burning fuel and blast furnace
of steel plant, and production monitoring under high temperature, high dust and other environmental
extremes conditions.
●This system, through putting camera probe part into furnace, can directly observe burner burning state
inside furnace, and it is especially designed air-breaking automatic protection function for fluctuation of
field cooling protection condition（cooling air source）.
●According to a lot of operating practice, flame information provided by this system is real and reliable,
and the system can long term stably operate with convenient installation debugging and little maintenance
workload.
2. System main technical parameters:
● System acceptable for boiler internal temperature under 2000℃;
● Viewing angle horizontal direction 60°, vertical direction 54°;
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● Horizontal resolution ≥480, vertical resolution ≥400;
● Line frequency 15625Hz, field frequency 50Hz, color system PAL mode;
● Electric servo device travel 600mm, travel time 40 seconds;
● Cooling air filtration accuracy 5μm;
● Electric control cabinet power supply AC240V, 200W;
● Monitor power supply 240VAC, 200W;
● Cooling air adopts instrument air, left and right sides shall meet : cooling air inlet pressure is 0.4～
0.7MPa, cooling air
flow is 5～10m3/h.
3. System composition and function
This system is mainly composed of TV system, cooling protection system and advance and retreat serve
system.
3.1. TV system
It is composed of high temperature pinhole shot, color video camera, video cable and color monitor.
3.1.1. High temperature pinhole shot
It is special lens of high temperature camera shot with fixed focal distance and electric aperture, and
material is YAG crystal. This lens, with protection of cooling protective sleeve, is inserted to furnace
through prepared sight hole on furnace wall, and send boiler internal flame image to CCD color video
camera.
Main technical index:
Focus 7.2 mm
Viewing angle horizontal direction60°, vertical direction54°
Optical axis deflection angle 70°
Target surface 1/3″
Roll adjustment scope 1m～∞
Aperture driver DC driver
Max. Diaphragm dimension φ8
Applying temperature not more than 2000 ℃
3.1.2. Color video camera
This machine is importing CCD color video camera with stable and reliable work, having
performance features of burn out proof, non-geometric distortion, antimagnetic influence, and strong
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resistibility of vibration and impact. In system, transfer flame image inversion observed by high
temperature pinhole shot to video signal, and send it to color monitor.
3.1.3. Color monitor and video cable
The monitor is color monitor with 22″ screen dimension. Its function is to handle video signal
transact delivered by color video camera, separate synchronized signal , RGB ristimulus signal and resume
to flame image signals through viewing tube.
Input impedance 75Ω
Horizontal resolution ≥550 line
Vertical resolution ≥400 line
Line frequency 15625±500 Hz
Field frequency 50±3 Hz
Color system PAL MODE
Power supply 240 VAC
21″ Monitor 180 W
Working environmental temperature 0～40 ℃
Cable is feature impedance 75Ω, which SYV75-5-1coaxial cable having little video signal transmitting
attenuation.
3.2. Protection system
Protection system is composed of control cabinet, cooling protective sleeve and outer pack steel
wires ebific duct. To ensure normal work of camera, camera lens in high temperature furnace, system
adopts cooling air mode, and adopts temperature and pressure sensing techniques for abnormal conditions
of system operating to design automatic protection function. In case that cooling system failure appears,
system can automatically exit camera probe part from furnace along with corresponding lighting alarm.
3.2.1. Control cabinet
Reduce gas from compressed air to rated pressure and filter off oil, water and other impurities and then
deliver them to camera part cooling protective sleeve; when pressure is below 0.4MPa, output cutting off
alarm signal will be on.
3.2.2. Cooling protective sleeve and camera protection shield
Cooling protective sleeve is used for ensuring camera lens lasting work under high temperature, high
dust and other environmental extremes conditions. This front part adopts anti high temperature oxidation
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corrosion heat resistant cast steel (8Cr26Ni4Mn3N), and its back part adopts stainless material
（1Cr18Ni9Ti）. Compressed air by cleansing process of control cabinet will enter pipe and cool it.
Compressed air comes in lens from the end and goes out from from lens of cooling protective sleeve. In
this way, it can cool lens, and on the other hand, it prevents lens soil pickup, sight hole blinding, sight hole
blocking off and smoke getting in while boiler at positive pressure. When camera video signal, camera
power supply and camera is over temperature （greater than 60℃） signal, join control cabinet through
socket.
3.2.3. Out pack steel wire tube
It is used for air supply pipeline, being connected between control cabinet and cooling protective sleeve.
Model: SL4210A1*(G1/2)-4
Inside nominal diameter: 10 mm
Length: 4m
Joint screw thread: G1/2
Working pressure: 1.5 MPa
3.2.4. Automatic protection control
When failure of cooling air supplier appears or camera parts are over heated, corresponding contact ST,
SP of sensing elements（air pressure relay, temperature switch）will close up , turn on corresponding line
coils of middle relay K5, K6, through relay contact turn on line coil of K2 in exit control loop, close normal
open contact of main control loop, electric machine exits furnace wall by driving cooling jacket reversely.
3.3. Advance and retreat serve system
It is composed of electric drive actuator, furnace valve organization, electric control cabinet, and remote
operation machine.
3.3.1. Electric drive actuator
It adopts electric machine driving synchronous belt drive, feed shaft insert with load and exit furnace
wall. Electric drive actuator goes up to available travel switch SQ1 and quits to available travel switch SQ2
and output cooling protective sleeve position signal to control cabinet, and connect by signal connection
terminal of control cable and electric control cabinet. Electric machine power supply of electric drive
actuator is connected by power supply connection terminal of power supply cable and electric control
cabinet.
Stroke: 600 mm (adjustable)
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Pushing force: 210 N
Travel time: 40 S
Electric machine power supply: 240 VAC50 Hz
Electric machine power: 15 W
3.3.2. Furnace valve organization
It adopts gravity type of selflocking furnace valve, with simple structure and reliable actions, which
will not occur mechanical failure caused by distortion of furnace valve heating. There are ringy sealing air
inside, which is good to prevent cooling protection jacket get in/out of channel to be coking and prevent
furnace smoke leakage. After cooling protection jacket quits furnace, it can automatically close peep hole to
seal furnace.
3.3.3. Control cabinet operation description
Operation button description:
QF General power supply switch (inside control cabinet)
SB1 Camera probe part insert furnace button (green)
SB2 Camera probe part exit furnace button (red)
SS Camera probe part crash stop button (yellow)
Panel indicator light description:
H1 In available indicator light (green)
H2 Out available indicator light (yellow)
H3 Temperature high failure indicator light (red)
H4 Cutting off or low pressure failure indicator light (red)
H5 Power supply turning on indicator light (red)
By pressing SB1, SB2 buttons of electric control cabinet panel, control cooling protective sleeve
can get in or exit furnace. When in available or out available, H1 or H2 signal indicator lights will be bright.
Press SS button of electric control cabinet panel, the operating cooling protective sleeve can stop at any
traveling position of electric drive actuator. Electric control cabinet receives cooling air pressure,
temperature signal from control cabinet air pressure switch and camera protection shield. When cutting off
or low pressure and camera over heated, output reverse signal to electric machine of electric drive actuator,
quit cooling protective sleeve from furnace to protect camera probe part, concurrently sent alarm signal to
display failure. Electric control cabinet also receives position signal from travel switch of electric drive
actuator to control electric drive actuator’s normal operating and display cooling protective sleeve current
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position.
3.3.4. Remote operation machine
Remote operation machine is installed on operating desk of control compartment.
Operation button description:
SB3A A side cooling protective sleeve inserting furnace button
SB4A A side cooling protective sleeve exiting furnace button
SBA A side video signal selecting button
SB5A A side light aperture +
SB6A A side light aperture -
SB3B B side cooling protective sleeve inserting furnace button
SB4B B side cooling protective sleeve exiting furnace button
SBB B side video signal selecting button
SB5B B side light aperture +
SB6B B side light aperture -
SBA/B Composite menu selecting button
Indicator light description:
VL2 A side in available indicator light
VL3 A side out available indicator light
VL4 A side over temperature indicator light
VL5 A side cutting off indicator light
VL10 A side video display indicator light
VL6 B side in available indicator light
VL7 B side out available indicator light
VL8 B side over temperature indicator light
VL9 B side cutting off indicator light
VL10 B side video display indicator light
VL11 Remote operation machine power supply turning on indicator light
By pressing SB3A(SB3B) or SB4A(SB4B) button, can control cooling protective sleeve to get in or exit
furnace ; When in available or out available, VL4(VL8) or VL5(VL9) signal indicator light will be bright.
Cutting off or over temperature failure will bring about corresponding alarm lightsVL4 (VL8), VL5 (VL9)
bright; At this moment system is under protection state, and check failure reason.
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4. System configure
Left and right sides of boiler are installed with camera probe part, which are composed of two sets of
independent system work.
Supplying list
No. Name Qty Remarks
1 Color video camera 2 set Panasonic WV-CP474
2 Color TV monitor 1 set 21"寸 LCD（interim）
3 High temperature pinhole shot 2 sets
4 Cooling protection device 2 sets including furnace valve organization
5 Electric drive actuator 2 sets
6 Control cabinet 2 sets
7 Remote operation machine 1 set
8 Video cable 2 sets
9 Control cable 2 sets
5. Debugging description
5.1. Debugging condition
5.1.1. Power supply: power supply is on, power supply indicator light of regulator cubicle panel is bright, if
air is not delivered, cutting-off alarm light is on, so power supply is normal.
5.1.2. Cooling air : inlet pressure shall be within 0.4～0.7MPa.
There can’t be air leakage in air supplier pipeline and joints, open pollution discharge valve before usage,
discharge dirt retention in the pipe, and open air inlet valve of control cabinet when air is clean.
5.2. Camera probe part and cooling protective sleeve, the distance between target surface of electric drive
actuator assembly debugging camera and lens has been adjusted before they go out factory, but the
optimum position may be damaged because of long transportation, disassembly and other reasons. So the
phenomenon of unclear image will appear. At this moment, readjust target surface position (adjustment of
focus and after-image focus) to make image clear. When adjusting focus and after-image focus, please
refer to outside drawing provided by camera instruction manual , use long nose pliers to loosen screw of
after-image focus, keep lens focusing on object one meter away, adjust camera after-image focus up and
down to make object image clear, fasten adjusting screw of after-image focus at last. Put cooling jacket in
anchor ear of holding device below electric drive actuator, through adjust bolt to adjust angle of inclination
of cooling jacket to keep cooling jacket and electric drive actuator cantilever paralleling with head aiming
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at furnace valve hole.
5.3. Monitor debugging
Turn on power supply, indicator light is on, grating or image appears, on the screen, and adjust
buttons of monitor contrast, brightness and color saturation to realize that image is clean, brightness is
moderate and color is real.
5.4. In the combining debugging power turn-off state of control cabinet, remote operation machine, electric
drive actuator, furnace valve organization, take out outer shield of actuator, check whether actuator and
cooling protective sleeve is aiming at furnace valve, turn the power on when the connection is right, press
“advance” button of control cabinet or remote operation machine, actuator acts, if actuator is operating
reversely, press “crash stop ” button to stop cooling protective sleeve. Then turn off power supply,
exchange two inlet lines L2 and L3 of electric machine power supply, power on again, press“advance”
button, actuator get in furnace with jacket, after it gets into the position, limit switch acts, in available
indicator light is bright. Press “ exit ” button , actuator exits furnace with cooling protective sleeve, after
it is in the right position, limit switch acts, out available indicator light is bright. Turn bolt of in available
travel pull bar to adjust depth of cooling protective sleeve insert furnace, if adjusted length is not enough,
add one shell ring. In the process of advancing and quitting, the operating should be stable with low noise
and head of cooling protective sleeve aiming at furnace valve. The opening and shutting of furnace valve
should be flexible with good tightness.
5.5. Automatic protection system debugging
5.5.1. Cutting off protection
Reduce air intake pressure (through pressure gauge monitoring). When pressure is below 0.4MPa, air
pressure switch is changed from normal open to normal close, turn on and exit control circuit, to make
actuator act, exit along with cooling protective sleeve, concurrently cutting- off alarm light is on along with
alarm signals.
5.5.2. Over heated protection
Heating temperature controller, when its temperature exceeds 60℃, its normal open contact act, and
make cooling protective sleeve to exit and alarm.
5.6. Debugging of length of lens extending inside furnace and its viewing angle
Four bulbs are inserted in fire eyes up furnace burner inside cold boiler. Normally, four bright spots
will be shown on monitor screen, loosen anchor ear and fasten bolt to adjust length of cooling jacket
extending to furnace , length is 60mm usually（or adjusting by in available travel switch）. Turn cooling
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protective sleeve, adjust height bolt to adjust viewing angle so as to distribute four bright spots at four
corner of screen evenly.
6. Operation description
When power supply and air supply is normal, open power supply, remote operation machine, and monitor.
Press “advance” button , and jacket extends to furnace , when it is in the right position the in available
light is on . Press “exit” button , and jacket will exit furnace, when it is in the right position, out
available light is on . If air pressure is below rated value, when pressing “advance” button, immediately
exit when it is in the right position, concurrently the corresponding alarm light is on . When some alarm
occurs in the operating, cooling protective sleeve automatically exit, operation personnel can remove faults
according to alarm lights, don’t put it into practice with force. If power failure appears in operating, pull out
cooling protective sleeve with force.
7. Routine maintenance
7.1. Lens: after working for a certain time, it may be polluted with unclear image, use absorbent cotton with
absolute ethyl alcohol to clean it.
7.2. Cooling protective sleeve : after φ12mm pinhole of its head working for a certain time, it may
appears coking with fixed coking in image frame, take out lens to decoking and recover φ12mm small hole.
7.3. Electric actuator: regularly remove ash of guide rail and travel switch pull bar, daub lubricating
grease , and check whether cooling protective sleeve head is aiming at furnace valve, for long term
vibration, it may reduce or left/right departed to cause not in the right positon, electric machine is
overloaded, refasten and reaim it. .
7.4. Control cabinet: regularly clean internal ash deposit, clean air filter internal ash, otherwise pipeline
flow will be affected, reduce cooling air flow to cause lens over heated.
7.5. Furnace valve: regularly check sealing situation of furnace valve.
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Section II Maintenance Items and Technical standards
1. General check
1.1. Measurement cabinet power supply, module power supply shall meet requirements of product
instruction manual;
1.2. When testing value fire check transact module in dark furnace, and changing setting values of strength
and frequency of all transact modules, respond flexibly, its scope shall meet real requirements of boiler
operating;
1.3. Testing fire check self-check function, confirm normal performance of flame signal transact module
and probe amplifier;
1.4. Grounding resistance of grounding copper bar inside fire check screen less than 5Ω,
signal earhing insulation not less than 20 MΩ, power supply earthing insulation not less than 50 MΩ.
2 Fire check probe maintenance
2.1. Clean probe, check lens, optical fiber, sensing element, amplifier and socket, change the aging and
burning parts;
2.2. Probe should be firm after re installation, seal with sampling bushing, connection of probe and cooling
wind pipe should be reliable; 3.2.3 When probe installation position changed or probe fixed pipe changed,
debug fire check again ;
2.4. Change damaged cable, fasten connection （pull slight connection without loosening）, perfect
waterproof, dustproof equipments of junction box.
3. Fire check transact instrument
Carry out self-check, change or maintain failure card.
Section III Factor s of Influencing Fire Check Quality and Transaction
For flame test system, probe installation position directly determines flame test effect, so decide the
position according to cooperating installation state of boiler burning gravitational field and jet burner and
boiler real, and it is usually confirmed by manufacturer. Its angle between installed axes and burner main
axes should be in the initial burning scope, detecting view is basically same with spraying direction of fuel,
slope slightly and cross it with flame root. Probe position must be carefully considered to ensure to reliably
detect flame of main burning arear of detected torch under different operating conditions. But because of
different boiler burning directions, flame burning areas will change accordingly, if installation position has
been taken into careful consideration, the following situations may happen to bring about ability reduction
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of probe flame detecting or even no fire signal :
a. Not enough flame within flame detector view to make flame detector respond correctly;
b. Flame detector does not aim at flame stable position, which makes flame flying out of view when
operating condition changes;
c. Flame detector that can’t be installed inside the secondary wind outlet, it doesn’t fully consider the
problem of coking and probe over heat for its position, viewing area can not avoid background flame.
To avoid the happening of the above situations, adjust probe viewing area to optimum by position
accurate arrangement or visual angle adjust organization, accurately aiming at initial burning areas. If
burner is swingtype and probe bushing is selected as soft, installation space can’t consider visual angle,
probe can just normally insert without blinding. If burner is not swingtype and probe bushing is selected as
rigid, moderately save some space for adjusting angle of fire check probe, space displacement can refer to
axes dimension of bellows along with max. scope of probe adjusting visual angle to carry out calculation of
radial displacement of furnace inside nozzle space, it also considers that flame probe outside bellows
should have contact with other equipments.
In MFT logic of machine set, it is “full furnace flame failure” that is related to fire check signal, if
load is low, coal quality is poor and burning disturbance is big, because of relatively dark flame inside
furnace, some flame detectors with defects at installation position will be affected, and they will easily send
wrong signal and cause accidental operation of MFT protection with normal disturbance of some discharge
jet flame, flame kindling point and movement.
According to principle of “simple and reliable”, simplify system and controlling logic as much as
possible on the basis of meeting equipment safety requirements. Coal pulverizer layer flame all adopts
logic of “Four- option two without flame”, and definition given by“ Explosion protection of Thermal Power
Plant Pulverized Coal Firing Boiler” is: “ Definition of full furnace flame failure is confirmed by design
function of furnace safety protection device . Usually take the monitored flame of the top burner as
the main one, when 3/4 of four flame detectors are out, it is judged as full furnace fire-fighting.”
Section IV Flame Test System Maintenance
The function of dust acting on element is likely to be an isolation plate and prevent heat emission,
which cause ability reduction of flame test probe detecting. Because of failures of fire check probe lens unit
ash deposit （ coking ）, breaking, light-guide fiber burning, flame test system can not make alarm, so it
will need to work operating or maintenance personnel to monitor and polling, according to experience of
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parameters changing scope under different operating conditions of polling records, to make judgments to
abnormal real time data , if real time data is relative low based on past experience or data fluctuate
scope is relatively big, the most likely reason is ash deposit of fire check probe lens unit or light
transmittance reduction of light-guide fiber, if without timely maintenance and defects removal , when
many probes have this situations and meet underload operating or coal change, they will easily send
wrong signal and cause accidental operation of protection system. If performance of probe or signal
transact unit is not stable, maybe because of amplifier null point drift or gain processor quality reason of
fire check template, lightness of fire check will be low, if without trimly transact in the operating, it will
easily make 3/4 flame signal of each layer below lower limit value condition, and send “full furnace
fire-fighting” signal, and lead to boiler MFT.
Section V Fire Check Probe Cooling Air
The influence of fire check probe cooling to fire check is also very important, if cooling air pressure is
not enough or cooling air is not clean, it will all cause probe coking or even damaged. So cooling fan
access should has air drying filtration device or at least ensure cooling fan not at air wet position, cooling
wind pipe can not be put on first pipe, quality requirements of cooling air are:
● Each probe cooling air flow no less than 1m3/mins.
●The difference between cooling air access air pressure and furnace inside pressure is greater than
2KPa.
● Dust in the air and rigid small grain no more than 2mg/m3.
Ensure cooling air continuing supplying. Start up boiler after starting up cooling fan, when furnace
shuts down, stop cooling fan when furnace temperature is reduced to 50

Comprehensively consider cooling air’s cooling effect and pollution to probe, usually cooling wind outlet
shall be opposite to lens. Cooling air pressure value shall be greater than normal value of furnace under
normal operating condition. Besides that, operating personnel regularly let two sets of fire check cooling
fans run parallelly for a certain time to reduce pollution of fire check lens or coking .
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Volume III Maintenance Instruction of Thermal control Automatic Adjusting Device
Chapter I Maintenance Instruction of DKZ\ DKJ Model Electric Drive Actuator
1. Basic operating principle

DKJ\DKZ model electric drive actuator is the position servo mechanism taking two phase alternating
current servomotor as prime mover driving; its system block diagram is as shown in diagram 1:
DFD
Input signal 0~20mA
ZPE SD Z
ＷＦ
0～20ｍＡ
Description: ZPE—— servo amplifier; ＷＦ—— position transmitter;
ＤＦＤ—— electric manipulator; ＳD—— single-phase alternating current servomotor; Z—— reducer;
ＺＪ—— actuator.
When there is a signal inputting in input end, compare the signal and position feedback signal. The
reality is that carrying out of algebraic addition of magnetic flux generated in flow of input signal current
through control winding and that of position feedback current with opposite polarity, amplifying compared
deviation signal makes enough power output of power level to drive two phase servomotor. Make output
shaft of reducer rotate facing reducing deviation signal until deviation signal is less than sensitive limit. At
this time, output shaft is stable at relative corner of input signal.
Because servo electric machine has actuator, so it can ensure the fast braking after electric machine
power turn-off to restrain inertia of output shaft and overcome influence of short load acting force and
improve stability of system.
DKJ model actuator is composed of servo electric machine, reducer position feedback device, etc..
2. Main technical performance

Model DKJ-210 DKJ-310 DKJ-410 DKJ-510 DKJ-610 DKJ-6110
(n.m) 100 250 600 1600 2500 4000
Output
moment
2.1. Output signal: 4-20mADC.
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2.2. Input channel: three.
2.3. Input resistance: 250Ω
2.4. Output moment: refer to table 1
2.5. Each rotating time of Output shaft: 100±20 seconds
2.6. Output shaft effective rotating angle: 90°
2.7. Damping feature output axis oscillation number not exceeding 1.5 cycles.
2.8. Nonlinearity error: ±2.5%
2.9. Supply voltage 200V+20V-30V 50HZ
2.10. Output current: 4-20mADC
2.11. Operating environment temperature: -10℃+55℃
2.12. Operating environment humidity: ≤95%
3. Maintenance and adjustment of signal
3. 1. Maintenance item and standard.
3.1.1. Maintenance of electric machine and device.
3.1.1.1. Appearance check and sanitation clear, its standards meet appearance check requirement in general
rules.
3.1.1.2. Check insulation resistance of electric machine coil to shell and between coils, its numerical value
of resistance shall be greater than 20MΩ.
3.1.1.3. Measure direct current resistance of electric machine coil, numerical value of resistance shall meet
its technical requirements.
3.1.1.4. Clean and check bearing, add high quality lubricating oil, bearing is clean without dirt and its
operation is flexible without locking and hard going phenomenon.
3.1.1.5. Check rotor, stator and coil: complete without breakage.
3.1.1.6. Clean and adjust arresting device: flexible with hand operating, and brake effect is good with
electromotion operating.
3.1.1.7. Electric machine is integral assembly, rotating is normal, without unpitched sound.
3.1.2 Maintenance of reducer
3.1.2.1 Appearance check and sanitation clear meet appearance check requirements in general rules.
3.1.2.2 Disassemble and clean all parts, and all parts should be clean without dirt and corrosion.
3.1.2.3 Check abrasion condition of all bearings, appearance is integral without distinct breakage.
3.1.2.4 Check abrasion condition of axle key, key seat, coupling pin and pin bush. There is integrity without
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distortion and breakage.
3.1.2.5 Check meshing condition of traction wheel and inner gear, it is close and flexible.
3.1.2.6 Assemble and adjust reducer, change lubricating oil. The operation is flexible and without unpitched
sound.
3.1.3 Maintenance of position transmitter
3.1.3.1 Appearance check and sanitation clear meet appearance requirement in general rules.
3.1.3.2 Insulation resistance value of power supply transformer coil to shell and coils shall be greater than
20MΩ.
3.1.3.3 Measure direct current resistance of power supply transformer coil which shall meet its technical
requirements.
3.1.3.4 Check abrasion condition of spring, cam and spacer pin. It is integral without distinct breakage
phenomenon.
3.1.3.5 Check position send potentiometer, fasten it to perfect.
3.1.4 Integral assembly of actuator: operating normally without unpitched sound.
3.2. Adjustment of actuator
3.2.1. Adjust used apparatus and instrument: one 4-20mA miliammeter, some leads, and some other tools.
3.2.2. All equipment of control system of actuator are prepared and connection is right.
3.2.3. Loosen fastening screw of mechanical stopper, screw down plug contact of electric machine, open
position transmitter mantle, take off current connection strap in two binding post in printed wiring plate to
joining a 4-20mA ammeter in series.
3.2.4. Turn on power supply of control system.
3.2.5. Turn handle at back of electric machine to manual position, vibrate handwheel in actuator, make
actuator output shaft to required mechanical zero position. Slightly loosen two screws fixing plastic
potentiometer, slowly rotate potentiometer with hand to make the milliamperemeter indicate to 4mA.
Screw down the two screw.
3.2.6. Put lower limit mechanical stopper closely laying to output regulating lever; fasten fastening screw,
concurrently loose fastening screw of closing cam, rotate closing cam to start sensitive switch act, fasten
closing cam fasten screw.
3.2.7. Rotate handwheel of actuator, make actuator rotate to required mechanical full range position at
clockwise, adjust potentiometer W1 in printed wiring board, make milliamperemeter indicate to 20mA.
3.2.8. Make upper limit mechanical stopper closely lying on output regulating lever, fasten fastening screw,
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concurrently loose fastening screw of cam, rotate cam to start sensitive switch act, fasten screw.
3.2.9. Recover electric machine connection, turn back handle of electric machine to electric drive position,
electric control actuator full switch, it shall indicate linear and correct.
3.2.10. Take off ammeter, recover connecting plate position of two binding posts on printed wiring board,
install position transmitter mantle, adjustment is completed.
4. Routine maintenance
4.1. Should carry out the following checks every day and if find the problem, handle it in time.
4.1.1. Whether the mechanical stopper is loose.
4.1.2. Whether reducer is leaking oil and whether oil level is above oil scale center line.
4.1.3. Whether handwheel is throw out.
4.1.4. Whether braking mechanism act condition is good.
4.1.5. Whether electric machine temperature is normal.
4.1.6. Whether actuator has oscillatory phenomenon.
4.1.7. Whether output shaft and connecting mechanism are flexible and reliable.
4.2. Every week implement once sanitation clean.
4.2.1. Each half year, add once lubricating oil.
Generally, with valve or system repair, implement equipment adjust and calibration and maintenance.
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Volume IV DCS Maintenance Instruction
DCS control system of India Barmer 8×135MW machine set adopts decentralized control system of Beijing
ABB company.
Chapter I Introduction to System Hardware
1. Hardware configuration
Hardware configuration including:
Unit plant:
Module cabinet 10
Terminal cabinet 18
Field cabinet 2
Power supply distribution cabinet 1
Isolation transformation cabinet 1
MFT cabinet 1
Engineering work station 1 set
Operator station (server) 2 set
Operator station (client machine) 2 set
Large screen operator station 1 set
History station 1 set
Interface computer 2 set
Performance monitoring / maintenance station 1 set
Public system :
Module cabinet 3
Terminal cabinet 5
Field module cabinet 4
Field terminal cabinet 1
Power supply distribution cabinet 1
Field UPS cabinet 2
Shift superintended station 2 set
2. Module general description
Controller BRC300
Main features of controller:
Support multi control languages, such as: function code, C, Batch90, Ladder
Support multi-type I/O sub module to transact all kinds of field data
In MMU module installation unit, occupy single groove
In module room, can realize one-to-one redundancy
Processor in C.W participates in Peer-to-Peer communication
Compatible with existing processor
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In redundancy configuration state, can realize online configuration
Operation mode of controller module:
1. Executive mode of module
a. Module collects I/O, executive control strategy
b. LED display module is in normal state
2. Configuration mode of module
a. Module is off line and can modify NVRAM data
b. LED display module is in configuration state
3. Mistake mode of module
a. According to procedure, stop operating and be off line
b. LED display module is wrong state
LED of BRC300 controller module

1. Module state LED
a. Module normal operation is stable green
b. Module abnormal is stable red
C. Module entering configuration is flicker green
2. LED of module CPU state
a. A group LED displays operation and error code
b. Using when B group LED is in site diagnosis
3. Redundancy chain interface of module
a. Paralleled redundancy chain interface under LED
b. Between modules, connect through PBA3000
Network interface sub module INNIS21
Main function of module
1. All system nodes, use NIS and Cnet to connect
2. And corresponding type data conveying module to composer different interface
3. Transmit another packet of node in network
4. Send the node packet and receive returned packet
5. Receive sent the node packet
LED of INNIS21 module
1 State LED（red/green）
Normal LED display: stable green
Error LED display: stable red
16 LEDs are divided into A and B groups
Normal LED display: event counting: packet number, retransmit number, loss number etc.
Error LED display: group A displays error code group B is closed
Network transact module INNPM12
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Main function of INNPM12 module
Compose HCU interface with NIS module
NPM module is main module of HCU network interface
Through C.W, collect exception report of the node
According to purpose address, packing information packet, and maintain database
Performance parameter of input/ output module
Input module of analog quantity:
Basic parameter of analog quantity input module:
4～20mA.DC signal（grounding or un-grounding, max. input impedance is 250Ω, system provides direct
current 24V power supply for 4～20mA.DC two wire system transmitter. As to 1～5VDC input, input
impedance is 500KΩ or larger.
Analog quantity input module has following features:
RTD/TC analog quantity
input module
Model IMASI23
Point /plate 16points
Analog input isolation mode Channel isolation
(whether point-to-point
isolation)
Common-mode rejection ratio -120dB
（dB）
Anti-common mode voltage 250VDC
（V）
Difference mode suppression -80dB
ratio（dB）
Anti-difference mode voltage 15VDC
（V）
When low level （%） 0.03%
A/D converter accuracy 24
Hot resistance input anti-break Circuit break test
protection mode
Thermocouple input Circuit break test
break-coupling protection
mode
Inner and outer power supply Dipshunt set
switch mode
Channel power supply Current limiting resistance
protection mode
Power consumption 2.5W
4~20mA analog quantity input

module
Model IMFEC12
Point /plate 15 points
Analog input isolation mode Channel isolation
(whether point-to-point
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isolation）
Common-mode rejection ratio 120dB
（dB）
Anti-common mode voltage 250V
（V）
Difference mode suppression 80dB
ratio（dB）
Anti-difference mode voltage 15V
（V）
When in low level （%） 0.25%
A/D converter accuracy 14 digit
Hot resistance input anti-break N/A
protection mode
Thermocouple input break N/A
protection mode
Inner and outer power supply Dipshunt set
switch mode
Channel power supply Current limiting resistance
protection mode
Analog quantity output:

Basic parameter of analog quantity output:
4～20mA.DC or 1～5VDC optional, load ability of driving loop impedance greater than 750Ω. Negative
terminal is connected into isolated signal ground. System provides 24VDC loop power supply.
Analog quantity output module has following features:
Analog quantity output module
Model IMASO11
Point /plate 14
Analog output load ability 750Ω
（Ω）
D/A analog output accuracy 10
（guaranteed value 1%）
Digital quantity input:

Basic parameter of digital quantity input module
Joint turn on is 1, open loop (resistance infinitely great) is 0. Negative terminal is connected to isolated
ground. System provides “inquiry” voltage of field input joint. “Inquiry” voltage is 24VDC.
Digital quantity input module has the following features:
Switching value input module
Model IMDSI13
Point /plate 16
Isolation mode opto-electronic isolation
Anti-shake measure Has (17ms)
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Inquiry voltage 24VDC
Digital quantity output:

Basic parameter of digital quantity output
Digital quantity output module shall adopt isolation output, isolation voltage≥400VAC, all use single relay
（with relay cabinet） output, and receive through middle relay to driver stage control loop to control
electric motor, motor-driven valve or solenoid valve.
Digital quantity output module has following features:
Switching value output module
(including relay output card )
Model IMDSO14
Point /plate 16
Whether totally set middle Yes
relay output
Output contact quantity and TRO02:16/dry contact ;
type TRO03:16X2/dry contact
Contact capacity
─ when in 240VAC （A） TRO02:5A;
TRO03:7.5A
─ when in 220VDC （A） 7.5A
Pulsed quantity input:

6600 pulses received per second.
Pulsed quantity input module
model IMDSM04
Each pulse in plate contact 8
number
Input pulse max. frequency 50KHz
Allowable max. pulse 27VDC
amplitude value （V）
Pulse width 　8.5ms
SOE module
SOE module
realize mode Distributivity SOE;
SOE max. allow points 1500 ponits/SOE server
SOE resolution guaranteed  millisecond
value （ms）
Whether soft and hardware is
no
single
Whether need to centralized Can cut up arrangement
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arrange SOE point
SOE synchronisation clock Hardware synchronisation, and GPS
chain type synchronisation interface IRIG-B
ChapterⅡ Introduction to System Software
System operating environment

Client ——unique design of server: several server PC, client machine PC;
Color display ;
Numeric keyboard ;
Mouse ;
Hard disk ,
External interface ;
Industrial IT Symphony system interface: SemAPI
Related auxiliary external equipment configure, for example:
Large screen etc;
High-speed printer.
Basic operation introduction
Operator station of Symphony decentralized control system can complete all operating operation through
mouse;
1. Can use keyboard to complete auxiliary operation functions (such as: system is equipped with keyboard,
can implement character input, task switch and other works）;
2. Operating personnel can understand current time, main monitoring parameter state and other contents
through fixed display on screen;
3. Operation order can reach all corresponding stations through row order mode;
4. System state diagram region shows communication state, unit state, trend state and order state etc of
current system;
Features of PGP operator station

By summarizing, PGP operator station has following features:
Adopt server / client machine structure;
Can realize automatic switchover of server multi redundancy;
Can receive data from all direction through several kinds of standard interfaces;
Support majority external equipment;
Can calculate online for adopted data according to need, new course data generated is used for displaying
and recording;
Have visual, flexible menu organization structure;
Standard gallery, can admit existing menu;
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Configuration menu supports several languages;
Dynamic menu renovates per second;
Configuration menu quantity is only depended on hard disk capacity;
Use user grouping, entitle different authority and realize overall safety management;
Unit or multi bounced out panel can be used for operating equipment on course menu;
Can set “Pegboard” using for concurrently operating several equipment of different systems;
Dendritic structure alarm level is clear;
Can select sequence display or course menu to display alarm;
Can classify displaying alarm according to priority, region etc different composition;
Divide 16 alarm classes, can use different colours to distinguish;
Any data can have real time and historical data trend;
Can use trend or list table to show historical data;
Can record accumulated operating time of double type equipment;
Report form uses standard software tool to realize, convenient for store and print;
Report form can display trend or column chart;
Through standard interface transmit information to real time database.
PGP alarm management system
PGP provides a complete alarm management system for users. It is not only for course, but also
provides guarantee for check, arrangement, display and confirmation of system alarm. When field and
system have any alarm, it can arrange alarm information according to requirements of alarm group, priority,
time etc . Alarm collection page provides rapid method for arranging and indexing alarm. In alarm tool
column pm PGP user interface window, 16（quantity can configure）rapid calling key alarm of main alarm
collection page are listed, and corresponding alarm group number are marked on key. Pressing or clicking
those keys can directly and rapidly get alarm information in corresponding alarming group. Latest and
unconfirmed alarm is at bottom of PGP user interface window, displayed as small alarm window. In order
to attract more attention of operator, sound effect for alarm can be also edited.
In order to ensure to response to happened alarm quickly, check of course alarm condition will be
implemented in control module. But, alarm condition will get report from course menu. Analog quantity
and switching value on course menu can change the colour with different alarm state to make operator
rapidly find failure point in monitoring course concurrently.
In order to manage alarm better, each label can be divided into one alarm group. In PGP, 16 main
alarm groups are defined, called “first class group”; while each alarm group also has 16 sub alarm groups,
called “second class group”. Each alarm group has a alarm group number, 1-16 respectively are 16 main
alarm group number, 17-32 respectively are 16 sub alarm groups number in first main alarm group; 33-48
respectively are 16 sub alarm groups number in second main alarm group; and the like , system totally
defines 272 alarm groups.
Different alarm for each label can appoint an alarm priority. In PGP, 16 alarm priorities （first class is
supreme） are defined, which realizes multiple management of alarm. Alarm for different alarm priorities
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and alarm identification in alarm collection display page is shown into different colours, concurrently show
priority so as to help operator to confirm class of happened alarm, and distinguish the importance of alarm.
All PGP alarm restriction and filtration functions make operator effectively omit abnormal phenomenon
without demand to alarm.
Each alarm page includes the following main area:
1）Alarm group tree in left of screen;
2）Alarm list arranged in time sequence in right of screen.
In alarm list area, according to time sequence, list all alarm information of certain alarm group. In
alarm list area, each row represents one item of alarm information and structure of alarm information
depends on type of information. Each alarm information is an alarm indicator at beginning （circle with
different colours marked by figure）. Colour of indicator is related to the priority of alarm, which can
implement configuration. If indicator flickers, it shows that this alarm is an unconfirmed alarm or normal
returned unconfirmed alarm; if indicator is shown as a stable colour, it shows that this alarm is a confirmed
alarm or normal returned confirmed alarm. Figure in indicator is corresponding priority of alarm. Structures
of alarm information can configure. Structure of simulative alarm information includes following contents:
1） Priority
2） Event time
3） Label name
4） Label description
5） Label value
6） Label quality postfix (such as off-scan and other information )
7） Nominal unit
8） Alarm limit value
Structure of digital quantity alarm information includes following content:
1） Priority
2） Event time
3） Label name
4） Label description
5） Label logic state description (such as OPEN and CLOSE etc)
6） Label quality postfix (such as off-scan and other information )
Returned normal information:
Its format is same with above mentioned alarm information format, but there is no eighth field in
analog quantity label (alarm limit information）.
Process control function
Control function provides ability to monitor single course return variate and equipment, and provides
ability to complete equipment control in manual and automatic mode. In a controller, information sent to
operating desk is collected as exception report form. Exception report establishes communication between
operating desk and controller. Types of exception report are different, types of its communication
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information are also different, such as: a ANALOG exception report may only includes a course value and
a alarm class used for displaying at operating desk, which need no control. On the other hand, when there is
need to control, possible communication of a STATION exception report is not only course value and alarm,
it also includes set point, control output mode etc. For operating desk needing same controller to
communicate, in operating desk label base, there must be a label to identify each exception report from
controller. If necessary, find label definition information of label base at operating desk. Information
provided by a label be referred in many ways, and panel is one of the ways. Panel can be fixed or bounced
out, and its display and control functions are the same. Control panel provides a method controlling
function block in controller. Through control panel, it can manually change course and monitor result of
automatic / manual control operation.
PGP trend menu
In PGP, through configuration tendency team, take the model of curve or list in tendency team page to
show simulative and numeral label data included in tendency team.
Tendency team can be divided into three categories, i.e. real time tendency team, history tendency team and
trip tendency team.
Real time tendency team: allow rapid obtainment and take the method of curve or list to show real
time data in tendency team. Playback is data source shown by real time tendency team. Real time tendency
team needs no file record.
History tendency team: periodically collect data from Playback, and implement corresponding
transaction for collected data, then, save to a group of circulation document（i.e. history base）. Once these
data is saved to history base, they can be shown with the method of curve or list in corresponding history
tendency team page according to request of operator. In Excel report form, these data can also be used to
generate report form and print.
Trip tendency team: in trip tendency tea, define a group of label, and define time before and after trip,
then appoint a certain numeral label as trigger of the trip tendency team. When the numeral label enters into
alarm state, trigger the trip tendency team, and collect and record data before and after trip of included label
from Playback to trip document（i.e. trip database）. In trip tendency team, data in certain trip record
document can be shown with the method of curve or list in corresponding trip tendency team page
according to request of operator.
Tendency team page includes the following contents:
Tendency team name
Tendency team description
Display mode
Display mode defines types shown by tendency team and data source of trend. There are following three
modes:
a) Live Mode Updating
Data is from real time database, and trend continuously renews. The mode is default display mode of real
time tendency team.
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b) Frozen Mode - Native Data
Data is from playback or trip file up data, and trend doesn’t continuously renew. The mode is default
display mode of trip tendency team and frozen mode of real time tendency team.
c) Frozen Mode - Sampled Data
Data is from history file up, and trend doesn’t continuously renew. The mode is default display mode
of history tendency team. Sampled data shows that some transaction have been taken to filed up data.
Trend curve
Tendency team window will show the trend curve in team. Colour of each curve is same with
corresponding icon colour in label list area. Default measuring scale scope of all curves in trend is 0% -
100%. When selecting certain label, it will show measuring scale of the label, for analog quantity label, it
also will show defined project unit. Label list at bottom of trend window lists all label information of
tendency team, including label name, description, current value （for real time trend） or history value,
project unit （for analog quantity label）, measuring scale scope etc. Tendency team has two showing modes,
one is trend mode, and the other is list mode. Trend mode is default mode.
PGP report form
PGP report form is EXCEL format. For report form configuration, shift & daily report and SOE report form
template document, different shift and daily reports only need to modify label name. In report form
configuration, mainly define report form name, index No., print, store cycle, the longest time of report form
stored in hard disk and max. quantity of report form document. Report form with different names is stored
in contents with the same report form name.
PGP historical data
In PGP, there is historical data function, i.e. Playback function. Stored data is exception report taking time
sequence as label, default stores time is 10 days. In System Setup, modify PlaybackMaxDays in Options to
modify data storage time. Besides Playback historical data, PGP also can implement sampling and calculate
based on Playback data to store into new history database, such as adopt up time value, calculate average
value, and adopt max. value and min. value etc, this configuration of historical data is finished at the same
time of configuration of trend menu.
Chapter III Maintenance of DCS System
1. According to check stipulation and check standard, implement check and fill in check record form
ontime.
1.1. Routine maintenance of hardware
1.1.1. Check environmental condition （temperature and humidity）, to make them meet normal operating
requirement of the system;
1.1.2. Check power supply and grounding system to make them meet standard;
1.1.3. There is the measure to prevent hurt of animal;
1.1.4. Ensure that cable joint, terminal, switching over plug-in doesn’t impact and contact is good;
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1.1.5. Observe system state menu and state of indicator light, confirm whether the system is normal;
1.1.6. Check operating state of the system;
1.1.7. Should regularly cleaning and change all kinds of filter screen;
1.1.8. Periodically, do well the clean work for equipment;
1.1.9. Battery of the system should be regularly changed;
1.1.10. Ensure correct storage of standby redundancy and condition, spare parts shall be stored in anti-static
plastic bag.
1.2. Daily management of software
1.2.1. Key of key lock switch should be kept by special person, password shall be kept secret;
1.2.2. Strictly operate according to operation authority;
1.2.3. System disk, database disk and user disk must have backup, there should be clear marker, they shall
be stored in metal cabinet to keep carefully. Backup should be two sets at least, and stored in another place.
If application software has great alteration, must backup ontime. Concurrently, shall establish system
software backup list.
1.2.4. Modification of system software and important user software should be implemented after approval
of authorities.
1.2.5. User software online modify must have strict safety protection measure, and there should be
monitoring person who makes good record. Modification of software should inform operating personnel
and maintenance personnel.
2. Failure handling
When system is operating, if there is abnormality or failure, maintenance personnel shall carry out
accident handling scheme ontime, inform operating on duty personnel in detail, when handling failure,
there may be some situations, the operating on duty personnel shall closely monitor and make good
countermeasure. When handling failure, there must have people to monitor and record failure phenomenon,
reason, handling method and result.
2.1. General procedure of failure handling
2.1.1. Observe and diagnose failure phenomenon
A. Listen to response of operating on duty personnel
B. Observe failure phenomenon, observe menu, check LED lamp state, listen, watch operating state of
equipment,
C. Call out equipment self diagnostics result, if necessary, can implement off line diagnosis for operation
station and external equipment.
2.1.2. Analysis failure reason
According to failure phenomenon, self diagnostics result, and LED lamp indicate and analysis
judgment failure reason, find out failure point.
2.1.3. Failure handling
According to judgment, adopt corresponding handling measures, check connection, cable, transit plug
of the system equipment, if necessary, change equipment, card or reinstall software. When handling failure,
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pay attention to personal and equipment safety, and pay attention to take measure for anti-static.
2.1.4. Handling result observe
After eliminating system failure, closely pay attention to operating state of the system, including
indicator light and display state. After confirming that the system works normally, inform operating on duty
personnel to recover normal operation.
3. System shutdown repair
3.1. Preparation before repair
3.1.1. According to system operating state and existing problem, constitute repair scheme in advance and
constitute practical repair time sheet.
3.1.2. Prepare used tool and instrument, test instrument, material and spare parts.
3.1.3. Implement software backup
3.2. Repair content
3.2.1. Clean the machine room carefully
3.2.2. Check card, terminal block, connection terminal, whether cable has damage or not. and whether the
marker is completed and clear; if lacking, shall supplement marking ontime.
3.2.3. Dismount connection of repair part to be cleaned, carefully take out cards according to sequence.
3.2.4. Suck off dust in operation station, in all cabinet and on all equipment with vacuum cleaner （frame,
card cabinet, CRT, connection terminal） and change air strainer.
3.2.5. Clean dust in card, unsucked dirt is cleaned by neutral cleaning agent, after cleaning, card should be
arranged on drying ventilation place in order.
3.3. After all cards and parts are cleaned and repaired, check sensitive switchn set. Check whether there are
wrong in span connection condition, after checking without error, should install the dismounted cards into
original position. Connection is good, cable connection is also good, and screw down fixed screw.
3.4. If the power supply on card is invalid before next repair, in this repair, change it.
3.5. Power on to implement debugging and diagnosis.
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Volume V DEH Maintenance Instruction
Chapter I Configuration and Function of Steam Turbine Digital Electrohydraulic DEH Control
System
Control system principle: main purpose of DEH control system is to control operating speed and
power of steam turbine generator unit so as to meet power supply requirement of power plant. When the
unit is starting up and in normal operation process, DEH receives CCS instruction or increasing or
decreasing instructions sent by operator through human- machine interface, collects rotating speed and
power of steam turbine generator unit and position feedback of control valve and other signals to treat,
comprehensively operate, output control signal to electro-hydraulic servo valve, and change opening of
control valve so as to control operation of the unit.
Section I Configuration of Control System

1. DEH control system hardware configuration is mainly composed of the following parts:
1.1. SYMPHONY control system standard cabinet;
1.2. Power supply system;
1.3. SYMPHONY control system template;
1.4. Terminal unit;
1.5. OIS operator interface station;
1.6. EWS engineer station;
2. DEH controller configuration capacity:
Digital quantity input 80 lines
Digital quantity output 64 lines
Analog quantity input 45 lines （4～20mA）
Analog quantity output 14 lines
Small signal input 64 lines
Note: the above mentioned capacity doesn’t include input / output configuration on specially used
template, such as servo template etc.
3. SYMPHONY control system template
All modules of control system are installed at 1＃cabinet.
Structure and type of module are the same, occupying one groove in installation unit MMU, and
connecting with external through three printed plug-in unit（P1, P2 and P3）. ＋5V and ±15V power supply
are introduced through P1; P2 connects module and extend general line used for carrying out
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communication with main module BRC－300; field signal is connected with P3 through terminal unit.
Each module has address identified by application software. This address is set by address switch on panel
and has no relation to insert plate position.
3.1. Figure output submodule IMDSO14
In system, there are 8 IMDSO14 panels in total used for relay output. Through configuration, it can
keep output during communication failure.
DSO14 technical index:
16 line isolation channel
Load voltage: 24VDC Load current : 250mA
Logic power supply: 5VDC±5％ Current: 150mA（normal）
Isolation voltage: 300VRMS
3.2. Digital input subtemplate IMDSI22
In device, there are 5 DSI22 panels in total. The template receives field signal and input signal of
button contact.
Technical index table.

Channel has 16 line independent channels with opto-electronic isolation
Logic power supply ±5VDC（±5％）
Typical input current 4.5mA24VDC, 5.0mA125VDC, 7.0mA120VRMS60Hz
DCI/O voltage24VDC（±10％）, 125VDC（±10％）
120VAC（±10％）
Logic current dissipation
55mA（typical value）, ＋5VDC 时 77mA max. value
Turn on voltage（min. value）
24VDC, turn on voltage: 21.4VDC
125VDC, turn on voltage: 95.0VDC
120VDC, turn on voltage: 85.0VAC
Turn off voltage（max. value） 24VDC, turn off voltage: 12VDC

125VDC, turn off voltage: 60VDC
120VAC, turn off voltage: 42VAC
When min. turn on voltage, 24VDC, current: 3mA（21.4VDC）
max. input current 125VDC, current is: 3mA（95.0VDC）
120VAC, current is: 5mA（85VAC, 60Hz）
Isolation Between input and logic circuit max. 300VRMS
Response time （Typical ） DC rapidly －1.5 millisecond DC slowly－18 millisecond
AC－0.5 second after first positive halfcycle
Antisurge Meet IEEE－472－1974 surge tolerance ability test
Table 2－2－1
3.3. Module TPS02 of steam turbine protection system
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Steam turbine protection system（TPS） is composed of three TPS02 modules and TPSTU02 terminal
unit connected with cable. All functions related with electric overspeed protection are monitored and
finished by module and terminal unit. These protection functions are independent on control system data
bus line and multi-function processor. The steam turbine protection system adopts three redundancy input
modes, two from three protection logic and online test ability to increase reliability. Overspeed protection
and high pressure intercept protection functions have four relay output. TPS module makes use of module
processor and memory on panel to handle input data, control output and communicate with SYMPHONY
open control system. The module provides the following overspeed protection function: overspeed
protection（OSP）, high pressure intercept protection （EHC）, power load unbalance protection（PLU）.
3.4. Hydraulic servo valve submodule IMHSS03
Main functions of HSS is carrying out position control, as a submodule of BRC－300, it compares
position feedback signal measured by LVDT and BRC－300 given value, through PI controller on panel to
adjust servo output current, control position of valve.
HSS card can reach 1inch‰ position accuracy, two ways paralleled servo drive output make it more
reliable. Technical index table:
This device totally adopts 6 HSS cards, respectively are used for four CV valve, two ICV valves.
Power supply requirement ＋5VDC@576mA typical
Operation ＋5VDC@15mA typical
－5VDC@12mA typical
＋24VDC@335mA typical
＋5VDC2.88W
Power consumption
+15VDC0.23W
－15VDC0.18W
＋24VDC8.04W
Operating operation 1000Hz, 4 to 12VP－P grading adjustable
LVDT power supply LVDT primary side min. impedance is 500Ω
Primary side excite 24VP－P, ±7VDC public mode
Output Impedance 10kΩ（differential pressure input）
LVDT side double
For two ±0.024A (each)output loop, min. impedance is 80Ω
Position input
Current limiting resistance make one circuit output short
Output to servo valve coil
circuit or open circuit, don’t influence another circuit.
Servo output isolation
Single isolation output, max. load 0.1A24VDC
Emergency hand operate output
Three signal lines provide 24VDC isolation contact input
Digital input
Meet IEEE － 472 － 1974 impact tolerance ability test
Surge protection
requirement
Table 2－2－2 Hydraulic servo valve submodule IMHSS03
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3.5. Field analog quantity output module IMASO11
ASO11 is mainly used for analog quantity output. Each plate has 14 lines channel. Each channel
decides output1～5DCV or 4～20mA analog quantity signal through software.
3.6. Field analog quantity input submodule IMASI23
ASI23 is mainly used for field small signal input transact, including thermocouple, hot resistance,
millivolt small signal etc. Each panel has 16 channels in total, signal of each channel can configure through
jumper. There is an isolation amplifier in each input channel used for isolation, filtering, amplifying input
signal. Microprocessor on the panel can set A/D conversion digit in 16～24.
3.7. BRC－300 controller
BRC－300 is high integration modularization microprocessor. BRC－300 scan I/O submodule
according to configuration through extending bus line; from submodule obtain information to complete
loop control and sequential control. In NVRAM of BRC－300, there is configuration meeting field control
requirement. Therefore data will not loss in deenergization.
Main technical index :
CPU: 68020
Clock : 32M
ROM: 1M
RAM: 2M
NVRAM: 512K
External interface: one RS232, one RS485
Load ability: 64 addresses
Function code: nearly 200
Function block: 10000
In the process, control PCU has 4 BRC－300
Module 2 and 3 are overspeed protection and basic control part
Module 4 and 5 are ATC and test control part
3.8. Communication template
In the system, two different communication interfaces are used; one for OIS and the other for EWS.
Interface used for OIS is a node. Communication template connected with process control unit PCU is NIS
（network interface slave）and NPM（Network Processor Module）. NPM completes communication
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between BRC－300 and NIS and saves PCU label database. NIS is used for ensuring reliability and
compatibility of INFI－NET communication. Communication interface of the system is redundancy
configuration, and respectively have two NIS and NPM.
Technical index table:

Model NIS NPM
Name NetworkInterfaceslave Network Processor Module
English NetworkInterfaceslave Network Processor Module
Communication 10M 1M
velocity ratio
Scan velocity ratio 8 times/ second
Load ability 32 addresses
CPU 68020 68020
ROM 64K 256K
RAM 128K 256K
Installation 1 groove 1 groove
3.9. Field simulative submodule FEC12
It is used for analog quantity signal input, can receive 15 lines 4～20mA analog quantity signal. The
system totally adopts 3 FEC12 cards.
4. Terminal unit
Submodule of device is complete PCU structure composed of template, terminal unit, cable and
terminal. Terminal unit prepares interface for field I/O, while some terminal boards can adjust signal.
Power supply of device is contributed to all places from here.
This device totally uses nine terminal boards TCL01, TAI05, TAI06, TPSTU02, TDI01, THS03,
NTMP01, NTRO02-AR and NTAO02-AR.
4.1. TCL01
TCL01 is special–used terminal board for communication for block, used for connecting PCU to INFI
－NET, three TCL can switch according to solid relay on board.
4.2. TPSTU02
This device uses 1 TPSTU02 in total, connect field signal to TPS02 submodule, through process of the
board, on the one hand directly output result to field, on the other hand, input into CPU to carry out logical
transaction.
4.3. TAI06
There are 4 TAI06 terminal boards corresponding to ASI23, and special used here.
When used for thermocouple input, on TAI06, there are two hot resistances on board, ASI23 will input
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the two -input as thermocouple cold junction temperature.
4.4、 TDI01
In this device, there are 5 TDI01 in total, the plate is used for DSI22, and for connecting field switching
value signal.
4.5. THS03
6 THS03 are corresponding to HSS03. They are used for connecting field servo valve and LVDT
signal.
4.6. TAI05
This device uses 3 TAI05 in total, and connects field I/O signal to FEC12 submodule, power of signal
connected with the board is supplied by system power, also by external power. Through short circuit block,
meet application requirement.
4.7. NTMP01
The board is used for connecting of ICT13 template, specially used for OIS communication.
4.8. NTRO02-AR
In this device, there are 4 NTRO02-AR in total, the board is used for DSO14 and for output of
redundancy switching value signal.
4.9. NTAO02-AR
In this device, there is 1 NTAO02-AR in total, the board is used for ASO11 and for output of
redundancy analog quantity signal.
5. Operator interface OIS
Operator interface station is an important man-machine interface. Through it, operating personnel can
participate in the whole control course, and modify corresponding control strategy, and can control course
and parameter to monitor.
6. Engineer work station EWS
EWS is tool specially used for engineer design, configuration, debugging and monitoring system.
EWS, based on personal computer, is equipped with system development standard software Composer and
some software which can be selected by users.
EWS is the tool for configuring SYMPHONY control system, also can monitor system online.
5.1. Module configuration application software Composer software can configure control logic of control
system online and off line.
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5.2. EWS and SYMPHONY control system communication, and has debugging and diagnosis function.
5.3. When carrying out EWS online operation, can obtain information from network, at the same time, can
adjust online. EWS has ability of monitoring and adjusting production course.
Section II System Software

SYMPHONY control software is software applicable to process control Use of software is convenient
and easy to debugging and make user further developing system. System software includes the following
parts:
a. Software used for process control BRC-300:
b. Application software in OIS;
c. Configuration tool software .
1. Software used for process control BRC-300
Because in SYMPHONY system PCU is the device to complete process control, BRC-300 playing an
important part is the core of application software. Its software is composed of loop control, sequential
control, data collection, optimizing control and other functions, it is modularization structure. These
modules are composed of function code （FC）, which is standard sub procedure and can adapt to process
control. Function code is saved in ROM of BRC-300. Marked numbers of these subprogram are actually
the address of ROM. In order to establish strong adaptability control strategy in BRC-300, user configures
function code according to demand and stores in NVRAM, execution ordering number of function code in
configuration is called block number. Having above mentioned mode, configuration designer can
according to logical relation provided by technology process requirement generates configuration logic.
At present, in BRC-300, 11 categories and 200 kinds function code are solidified, they are:
―――Functional operation function code;
―――Control algorithm function code;
―――Hardware interface function code;
―――Pulse and timer function code;
―――Communication function code;
―――Other function code;
―――Constant set function code;
―――Signal conversion and selection function code;
―――I/O function code;
―――Module control function code;
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―――BASIC function code;
Function code structure belongs to a kind of small block, middle block and large block reasonable
combination standard algorithm, provide good development environment for users.
For BRC-300 configuration, there are following tools:
―――OIS operator interface station;
―――EWS engineer work station;
If it is online configuration, so put new configuration in hot reserve BRC-300, through switch, can
put new configuration into operation, and can be copied to another BRC-300.
2. Application software in OIS
OIS has real time multi-task operation system to support operating of equipment. OIS database, figure
software etc are stored in hard disk.
PGP is the software for configuring OIS off line, the software is installed into OIS.It has edit menu,
label, trend record etc and other configuration functions.
3. Configuration tool software
EWS has SYMPHONY control system configuration tool software package Composer software
package, the software can be developed aiming at different systems.
Composer software package is interactive graphics procedure, mainly complete the following off line
configuration function:
3.1. For PCU, configure, draw module and terminal arrangement plan;
3.2. After completing generating and editing module configuration, draw configuration drawing, and file
and copy;
3.3. Edit and generate hard copy of several information list;
3.4. Generate conventional diagram and logic symbolic library;

3.5. Monitor process control logic.
Section III Main Functions of DEH Control System

This section shows the main functions of DEH control system. Its main functions are as follows:
a. Latch
b. Set servo system static relation automatically
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Valve online setting
c. Controlling before starting up.
Deciding hot state automatically
Selecting start up mode
d. Controlling operating speed
Raising speed: set target, set speed raising ratio, pass critical automatically
Constant speed 3000r/min
e. Load control
Combined grid with initial load
Generator simulating combined grid test
Rising load: set target, set load rate
Steady—slip—steady rising load
The feedback of main steam pressure
Load feedback control
Once frequency modulation
CCS control
Heavy load restriction
Low load restriction
Restriction of valve location
Restriction of main steam pressure
Rapid removal load
f. Single valve, sequence valve conversion
g. protection Overspeed and load unbalance
103% overspeed protection
Load off overspeed restriction
Power load unbalance
110％ overspeed protection
Online test
Oil injection test
Overspeed test: electric, mechanics
Valve activity test
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Solenoid valve test of high pressure intercept
h. ATC thermal stress control
i. Switching of control mode
Automatic and hand operate mode of steam turbine
1. Latch
Latch is the process of making protection system of steam turbine in alert state.
Reset solenoid valve (1YV) in reset test valve group of system setting and travel switch ZS1, ZS2 of
mechanic intercept organization are used for latch. The procedure of latch is as follows:
Press down the latch button (setted on DEH operation plate), the reset solenoid valve (1YV) of reset
test valve group acts with electronic power, and induces lubricating oil into the side chamber of emergency
governor gear device, the piston goes upward to top dead center, and makes stay hook of the emergent
governor gear device reset, and reset the mechanical intercept valve of intercept isolating valve group by
the use of mechanical intercept organization’s lever, seal the oil drain port of high pressure safety oil, and
form the high pressure safety oil. DEH test normally open contact of stoke switch ZS1 is closed, and
normal open contact of ZS2 is opened. After the two thirds pressure switch（PS1, PS2, PS3）in pressure
switch set detects the establishment of high pressure safety oil, send signal to DEH, and deenergizate the
reset solenoid valve (1YV). The emergent governor gear device piston returns to bottom dead center, DEH
detect normal open contact of the stroke switch ZS1, ZS2 are open. DEH detects that the procedure of
latch is completing. Concurrently high pressure intercept solenoid valve 5YV, 6YV, 7YV and 8YV
is powered.
The allowable conditions of latch:
1. Steam turbine has tripped;
2. All inlet steam valves shut down completely.
2. Static relation of setting servo system
2.1. Set servo system static relation automatically
The purpose of setting servo system static relation is to enable servo valve to control oil servo motor
in all strokes. The relation of valve setting signal and oil servo motor lift range is:
Given 0－100％――lift range 0－100％
To keep the good linearity of this relation, LVDT is required, which is used for feedback on the oil
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servo motor. Move in the middle linear part of the iron core when it is installed.
Before steam turbine starts up, set the six oil servo motors rapidly and concurrently to reduce
adjusting time. Circulation times and velocity ratio can be chosen when setting.
Circulation times 1 to 8 times
Velocity ratio（complete time）:
30 seconds, 60 seconds （before start up）
35 minutes, 70 minutes （after combining grids）
Oil servo motor setting can only be selected only on OIS.
Before starting up, the setting conditions are:
Steam turbine latch
All valves shut down completely
Notice: Should confitm that there is no steam in front of the main steam valve in order to avoid
steam turbine goes out of control when setting. During setting, machine set breaks automatically
when operating speed is greater than 100r/min.
After DEH receives oil servo motor setting instruction, open and shut down oil servo motor
completely, and record LVDT value in the two extremities position, correct null position and amplitude
automatically to make sure the given and lift range meet the above relation. To ensure the above relation
has good linear, implement LVDT null position calibration firstly. The given value is 50, move installation
position of LVDT, and make the stroke of the oil servo motor be 50％.
2.2. Valve online setting
Pure electronic setting DEH adopts SYMPHONY control system; one of its most important features is
that it not only can implement static relation setting conveniently before steam turbine start up
automatically, but also can implement convenient setting of a single valve respectively and automatically,
when steam turbine is operating with load normally.
Setting method is similar to that before start up. But because setting valve needs fully opening and
shut down completely, to reduce load change of setting course, it is suggested to carry out load feedback
and implement when machine set load is smaller. Online setting change rate can choose only in 3 and 4
gear, i.e, complete setting within 35, 70 minutes.
The allowable conditions of valve online setting:
Latch;
Oil switch closed;
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Single valve mode.
3. Control and start up mode before start up
3.1. Judge heat state automatically
The start up of the steam turbine is a heating process for steam turbine and rotor. To reduce the thermal
stress during the start up course, for different initial temperatures, different start up curves shall be adopted.
Every time when DEH latching, automatically divide the thermal condition of the unit according to
high pressure inner cylinder inside upper wall temperature T of steam turbine governing stage side; if the
temperature of upper wall is broke, it will be instead by temperature signal of lower wall automatically.
T＜150℃ cold state
150℃≤T＜300℃ warm state
300℃≤T＜400℃ thermal state
T≥400℃ extreme thermal state
Note: The specific temperature limited value of start-up state is based on the standard of the
main frame start up operating instruction manual.
3.2. Start-up mode
The start-up mode of this machine set is: high-medium pressure cylinder combined start-up.
4. Control of operating speed
Before steam turbine generator unit combining grids, DEH is in automatic operating mode,
and DEH is isochronous control system of operating speed closed loop. Its setting point is given
operating speed. The difference between given operating speed and real operating speed,
calculated by PID regulator, controls oil servo motor opening through servo system, and
changes the real operating speed by following the given operating speed.
After setting the target operating speed, the given operating speed approaches the target operating
speed by the setting speed raising ratio automatically. When it enters the critical operating speed area, it
automatically rushes into the area by speed raising ratio change to 400r/min/min rapidly. During raising
speed, steam turbine need be warmed up by medium speed and high speed usually to reduce thermal stress.
4.1. Target operating speed
Except for the operator sets target operating speed through OIS, DEH sets the target operating speed
automatically in the following condition:
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When steam turbine latches, the target is current operating speed;
When oil switch cuts off, the target is 3000r/min;
In hand operate state, the target is current operating speed;
Steam turbine has tripped, the target is zero;
When the target exceeding upper limit, change it to 3060 or 3360r/min;
In automatic start up mode, the target is decided by ATC;
In corresponding period, the target changes following the synchronized increase or decrease
signal (changing rate 60r/min/min);
If the target is set in the critical area, change it to special critical value.
4.2. Speed raising ratio
Operator sets, velocity ratio within（0~400）r/min/min,
In automatic start up mode, velocity ratio is 120, 180, 360r/min/min,
In critical operating speed, velocity ratio is 400r/min/min.
4.3. Warming up
The operating speed of the steam turbine warming up is confirmed according to different machine sets,
and each machine set has own warming up operating speed value. After it reaches the target operating
speed value, stop speed rising and implement warming up. During the rising speed course, if temperary
stop is needed, implement the following operations:
Not in ATR mode, the operator sends keeping “HOLD” instruction;
In ATR mode, send keeping instruction after exit ATR mode;
In critical operating speed area, keeping instruction is invalid, therefore only can modify target
operating speed.
Notice: When warmming up, avoid the rotor and sympathetic vibration frequency of blade.
4.4. Constant speed 3000r/min
When steam turbine operating speed stabilized at 3000±2r/min, check each system before incorporate
in power network. The generator carries out simulating combining grids test to check the reliability of
automatic synchronism system and the accuracy of the adjustment. During the test, the generator power
grid side isolation switch is open, and sends simulating combining grids signal. As in normal condition, the
automatic synchronism system changes the generator frequency and voltage through DEH and the
generator excitation system. When meets synchronism condition, the oil switch closes up. The generator
does not combine grid actually, because the isolation switch is opened.
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During the generator combining grids test, DEH receives the testing signal of generator combining
grids, and when the oil switch is closed, it is not the generator combining grids. This can prevent operating
speed increase caused by combining grids adding initial load.
5. Load control
5.1. Incorporate in power network, rising load and load normal adjustment
5.1.1. Incorporate in power network with initial load
Automatic synchronism
After unit at constant speed state, DEH has the interface links to synchronism device, it can receive
the increase and decrease signal from the synchronism device, control operating speed of unit to realize
rapid incorporate in power network.
When there is one of the following situations, exit the synchronism mode:
Operating speed is less than 2985, or greater than 3015r/min;
Hand operates state;
Operating speed failure;
Incorporate in power network;
Steam turbine has tripped.
Enter into synchronism mode according to operator’s instruction, and automatically enter into this
mode by ATR activate under the automatic start up (ATR) mode.
Incorporate in power network with initial load
When all incorporate in power network conditions are met, close oil switch, DEH increases the given
value immediately, to make the generator carry the initial load to avoid reverse power.
At the beginning of incorporate in power network, load feedback is not put in, so use main steam
pressure to correct the increased given value..
given value＝original value＋3＋f（P0）
At the beginning of incorporate in power network, the target value equals the given value.
5.1.2. Rising load
After incorporate in power network of steam turbine generator unit, DEH regulating system is
equipped with operating speed feedback to realize once frequency modulation. During test or carrying basic
load, it is allowed to put into load feedback or main steam pressure feedback. When the load feedback is
put into, target value and given value are represented in MW form. When load feedback is removed,
target value and given value are represented by the percentage of total flow under rated pressure.
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After setting the target, the given value automatically reaches the target value at the set load rate, then
generator load increases gradually. During rising load,,warm up of the steam turbine to reduce thermal
stress.
5.1.3. Target
Except that the operator can set the target through OIS, DEH sets target automatically under the
following condition:
At the beginning of putting into load feedback, the target is current load value（MW）;
At the beginning of incorporate in power network of generator, the target is given value of initial
load;（％）
In hand operate state, the target is reference quantity(％)（valve total flow instruction）;
At the beginning of feedback removal, the target is reference quantity（％）;
When tripping, the target is zero;
Under CCS control mode, target is given valve by CCS（％）;
When target valve is to high, change to upper limit value 105％ or 145MW.
5.1.4. Load rate
The operator sets load rate within（0~100）MW/min;
Under automatic start up mode, load rate is within（1.5~30）MW/min, step length is 0.5MW/min;
During single valve /sequence valve conversion or valve switch, load rate is 5.0MW/min;
In CCS control mode, load rate is 100MW/min.
When automatically starting up load rate set by ATR, correct once per minute according to stress
calculation. At the beginning of incorporate in power network, the initial load rate is one of 1.5, 3, 4, 5,
6MW/min.
5.1.5. Warming up
When steam turbine is in raising load course,, considering the thermal stress, and differential
expansion and other factors,. It is usually needed to warm up. If need to pause rising load, implement the
following operations:
Not in CCS mode, the operator sends out “keep” instruction;
In CCS mode, send out keep instruction after exiting CCS mode;
Under ATR mode, automatic start up procedure decides that conditions that need to be kept appear,
then send out load keeping instruction.
5.1.6. Set—slide—set rising load
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After high and low pressure bypass valves shut down completely, boiler increases burning, an high
pressure adjusting valve keep 90％opening. Load increases gradually with the increase of steam parameter.
During sliding pressure rising load, do not put into load feedback. If warming up is needed, keep
combustion level by combustion control system to keep load unchanged.
5.2. Load control mode
5.2.1 Load feedback
The load controller is a PID regulator, which is used to compare set value and actual power, after
calculation output instruction to control CV valve and ICV valve.
When the following conditions are met, the operator puts into this controller:
Machine set has incorporated in power network, load is between 0MW～145MW;
Power signal is normal;
Load restriction does not act;
TPC doesn’t act;
Fast unloading doesn’t act;
System is in automatic mode.
Removal conditions of load controller:
The operator removes the controller;
Load is less than 0MW or greater than 145MW;
Power signal failure;
Steam turbine trips;
Reach sliding pressure point;
Fast unloading acts;
TPC acts;
Once frequency modulation acts;
Hand operate mode;
High and low load restriction acts;
Oil switch is off.
When putting into the load control,, set point is represented by MW form. Adopt PID isochronous
control ,actual load equals the set value in steady state.
5.2.2. Control of main steam pressure
Main steam pressure controller is a PID controller, which is used to compare the set value and real
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main steam pressure, after calculation output control CV valve.
After the following conditions are met, the operator puts into this controller;
Machine set has incorporated in power network, main steam pressure is between 3MPa～13MPa;
Main steam pressure signal is normal;
Fast unloading doesn’t act;
TPC do not act;
Automatic mode;
Once frequency modulation does not act;
Load control loop doesn’t put into.
Removal condition of main steam pressure controller;
Operator hand operates removed;
Main steam pressure exceeds the high limits（13MPa）;
Load is less than underload restriction value or greater than high load restriction value;
Main steam pressure signal failure;
Steam turbine brake valve;
TPC acts;
Valve location restriction acts;
Hand operate mode;
Oil switch trips.
When putting into main steam pressure feedback, set point is represented by MPa form. Adopt PID
isochronous control, main steam pressure equals the set value in steady state.
5.2.3. Once frequency modulation
When the steam turbine generator unit is incorporate in power network operation, in order to ensure the
electric network stable and the quality of power supply, it is generally to put into the once frequency
modulation function. When the operating speed of the machine set is within the dead zone scope, the once
frequency modulation does not act. When the operating speed is out of the dead zone scope, once frequency
modulation acts, frequency adjustment given changes with operating speed according to the diversity
factor.
The condition of participating the once frequency modulation:
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Automatic state:
The diversity factor is adjustable within 4％～5％, set 4.5％in general. the dead zone is adjustable within
0～30/min, set 2r/min in general. The dead zone scope is 3000± dead zone value.
5.2.4. CCS control
When the following conditions are met, the operator put into CCS control:
Control system is in automatic mode;
Receive CCS enabling signal;
Rapid load removal doesn’t act;
TPC doesn’t act;
Deviation between CCS given and DEH master valve setting is less than 2％;
Load restriction doesn’t act;
Valve location restriction doesn’t act.
Remove CCS mode or condition;
Rapid load removal acts;
TPC acts;
Hand operate mode;
Oil switch is off.
No CCS request;
Load restriction acts;
Valve location restriction acts;
CCS given signal failure.
Under CCS mode, target value of steam turbine load is controlled by boiler control system; DEH
target equals CCS given, when putting into CCS function, remove load feedback automatically.
Coincidence relation between CCS given signal and target and master valve setting is: 4～20mA
corresponding 0～100%, and CCS given signal represents master valve setting.
5.2.4. Protection from low pressure of main steam（TPC function）
When boiler system can not maintain the main steam pressure because a kind of failure, decelerate the
decrease of the main steam pressure through turning down the adjusting valve opening to reduce steam
flow, to help the boiler combusting stability.
Removal condition of TPC mode:
Oil switch is off;
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Main steam pressure signal failure;
Load restriction acts;
Once frequency modulation acts;
Hand operate mode.
Put into condition of TPC mode:
Automatic mode;
Main steam pressure is greater than 90％ rated value;
Main steam pressure signal is normal.
Power on default value of the main steam pressure restriction value is 10MPa, the operator can set
this restriction value within（3～15）MPa when TPC mode is removed.
During putting into TPC mode, if the main steam pressure is lower than the restriction value, main
steam pressure restriction acts. When it is acting, set point reduces at rate of change of 1％/second on the
basis of just acting. Concurrently, the target and set point equal the total valve location reference quantity,
and also reduce. If main steam pressure rises back above the restriction value, stop the reduce of the set
point. If the main steam pressure does not rise back at all times, and the set point reduces to less than 20％
of the total valve location reference quantity, stop reducing.
When the main steam pressure restriction is acting, remove load feedback automatically, and exit
CCS mode.
5.2.5. Rapid load removal
When the steam turbine generator unit appears a kind of failure, reduce valve opening rapidly, remove
part load, to prevent failure expanding. During putting into the rapid load removal function, when DEH
receives rapid load removal entering signal, the total valve location reference quantity reduces according to
rate of change of corresponding shift on the basis of the original value, till the entering signal disappears or
remove the rapid load removal function or this reference quantity reduces to lower limit value of
corresponding shift. Concurrently, the target and set point equal the total valve location reference quantity,
and also reduce.
Removal condition of rapid load removal:
Load is less than 25％;
Steam turbine has tripped;
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Oil switch is off.
According to difference of failure, the rapid load removal is divided into three shifts, and is activated
respectively by input signal of three -switching value of rapid load removal 1＃, 2＃, 3＃
When rapid load removal acts, automatic removed load feedback, and exit CCS mode.
5.3. Load restriction
Load restriction can be divided into high load restriction and underload restriction; both
restriction value can be set by operation personnel on OIS station menu. Power ondefault value
of high load restriction is 145MW; power on default value of underload restriction is 0MW.
5.3.1. High load restriction
Because of some reasons, steam turbine generator unit doesn’t want load to be too high in a period of
time, operator can set high load restriction value in a certain scope to make steam turbine load point always
less than this restriction value. High load restriction value set should not be less than underload restriction
value.
When real load is higher than load restriction value, high load restriction will act,
automatically remove load feedback, and exit CCS mode.
5.3.2. Underload restriction
Because of some reasons, steam turbine generator doesn’t want load to be too low in a period of time,
operator can set underload restriction value in a certain scope to make DEH set point always greater than
this restriction corresponding value. When underload restriction acts, it will operate automatically
removal load feedback, and exit CCS mode. Concurrently it sends keep instruction and stops
reducing set point.
5.4. Valve location restriction
Because of some reasons, steam turbine generator unit doesn’t want valve to open large in a period of
time, operator can set valve location restriction in a scope of （0～120）％, DEH total valve setting value is
the smaller one between load reference quantity and restriction value.
To prevent valve location change, change restriction is added to valve location restriction value, rate of
change is 1％/ second.
When valve location restriction acts, if target is greater than set point, send keep instruction, and stop
increasing set point.
6. Single valve / sequence valve conversion
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In start-up course, to lessen thermal stress of high pressure cylinder, single valve mode start-up
always be adopted. In normal operating course, to lessen throttle loss of high pressure adjusting valve,
sequence valve mode always be adopted.
when load is less than 30％, single valve mode is adopted compulsorily. But when it starts up in
thermal state and extreme thermal state, because thermal stress is a little smaller, and steam parameter is a
little higher, if single valve mode is adopted, valve opens too small, it can bring about control instability,
then sequence valve mode always be adopted.
CV opening given ＝ single valve coefficient × single valve given ＋（ 1 － single valve
coefficient ）×sequence valve given
In single valve mode, single valve coefficient is 1. When operator sends instruction that the mode
changes to sequence valve, it will take 10 minutes for single valve coefficient to change to 0 from 1, and
finally keep being 0, which is so-called sequence valve mode. During conversion period of valve control
mode, in order to keep load unchanging, load feedback shall always be put in.
7. Overspeed protection and load imbalance
7.1. Overspeed restriction
Overspeed restriction refers to the method which can avoid steam turbine operating speedy value
reach to steam turbine brake valve operating speed.
7.1.1. Steam turbine load off
When oil switch of machine set cuts off and load off happens, act instantly overspeed restriction
solenoid valve, close high and medium pressure adjusting valve, concurrently change target operating
speed and given operating speed to 3000r/min, when operating speed reduces to less than 3090 r/min,
overspeed restriction solenoid valve deenergizes, high and medium pressure adjusting valve is controlled
by operating speed closed loop, finally keep steam turbine operating speed stable at 3000r/min to
incorporate in power network after accident.
7.1.2. 103％ overspeed
If overspeed happens, it will seriously influence life-span of steam turbine. During the time of
implementing overspeed test for steam turbine, operating speed can exceed 103％, at any other time it is
not allowed to exceed 103％, the rated operating speed（for the maximal frequency is 50.5Hz viz.101％）.
When there is no overspeed test, in case operating speed exceeds 103％, overspeed restriction
solenoid valve should be quickly acted, close high and medium pressure adjusting valve. When it runs at
normal speed, overspeed restriction solenoid valve deenergizes, high and medium pressure adjusting valve
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is controlled by operating speed closed loop, and finally keep steam turbine operating speed at 3000r/min.
Notice: when operating overspeed test, 103％ overspeed restriction function fails .
7.1.3. Acceleration restriction
When machine set load off, rotor will accelerate. When acceleration is greater than stipulation value,
overspeed control outputs control signal, close high and medium pressure adjusting valve through solenoid
valve, so as to prevent machine set overspeed.
7.2. Power load imbalance
When transmission line of electric power meets instant short circuit failure, total reactance of
equivalence system increases to make electric machine power decrease, in order to maintain system
operating, steam turbine power must be decreased at the time of failure. In other words, it requires DEH has
fast valving function.
Removal condition of power load imbalance function:
Load signal is broken;
Steam-discharge pressure signal of medium pressure cylinder is broken;
Load is less than 15MW;
Oil switch is off.
At the term of putting into power load imbalance function, when the load difference of medium
pressure and generator is greater than 30％, load imbalance acts, let solenoid valve act, close instantly
medium pressure adjusting valve, after 2 seconds, solenoid valve deenergizes, medium pressure adjusting
valve recovers servo valve control .
7.3. Overspeed protection
If operating speed of steam turbine is too high, steam turbine will be damaged because of centrifugal
stress. To prevent steam turbine overspeed, overspeed restriction function is equipped in DEH system, but
in case operating speed restriction doesn’t work and exceeds scheduled operating speed, then brake valve
immediately and close all main steam valve and adjusting valve rapidly. Several overspeed protections are
set in system for the safety and reliability:
DEH electric overspeed protection 110％,
Mechanical overspeed protection 110％～112％.
If DEH operating speed signal meets failure or overspeed part controller（BRC）failure, DEH electric
overspeed protection function will disappear. To ensure machine set safety, automatically intercept steam
turbine if accident happens.
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8. Online test
8.1. Oil injection test
To ensure emergency governor gear ring can fly out rapidly and intercept steam turbine in case
overspeed happens in machine set, activity test should regularly be implemented for the ring.
In activity test, oil is sprayed in the ring to increase centrifugal force and make it fly out, but ring flies
out in oil injection test, valve should not be braked. To increase reliability, test-used isolating valve is
added.
Allowed condition for oil injection test:
Test soft button is in allowed position;
Operating speed is within（2985～3015）r/min;
High pressure differential expansion is less than 3mm.
In oil injection test, isolation solenoid valve 4YV is powered. When testing isolation solenoid valve is
in isolation position, 2YV is powered, oil is sprayed in emergency governor gear, and ring flies out, ZS2
sends the instructions, then 2YV deenergizes. After a little time, 1YV automatically puts on valve. After
valve putting on, deenergize the isolation solenoid valve again, and then the whole test course is finished.
8.2. Overspeed test
After initial installation or heavy repair of steam turbine, accuracy of overspeed protection act must be
verified. Verification test shall be implemented to all overspeed protection.
In overspeed protection test, set DEH’s target operating speed at 3360r/min and raise slowly to steam
turbine operating speed. When act operating speed of tested overspeed protection is reached, this overspeed
protection act will intercept steam turbine. So overspeed test can also be called operating speed test. DEH
can automatically record steam turbine intercept operating speed and maximal operating speed.
8.2.1 DEH electric overspeed test
On OIS, set target at 3360r/min and velocity ratio at 180r/min/min, machine set operating speed starts
to increase slowly from 3000r/min. When operating speed reaches 3300r/min, DEH will send brake valve
instruction to intercept steam turbine and close all main throttle valves and adjust gate.
8.2.2 Mechanical overspeed test
On OIS, set target operating speed at 3360r/min, machine set operating speed starts to increase slowly
to ring act operating speed from 3000r/min, intercept steam turbine. Ring act operating speed will meet
requirement within 110%～111%.
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8.3. Valve activity test
To ensure valve act flexibly, activity test of valve needs to be implemented regularly in order to
prevent block.
Allowed condition for valve activity test:
All main steam valves fully open;
Load is within（65~135）MW;
Automatic state;
Non-CCS mode;
Incorporate in power network.
8.4. Valve leak test
To ensure valve close tightlyand can’t leak steam, closeness of main throttle valve and
adjust gate shall be verified through valve leak test.
Allowed condition for valve leak test:
Steam turbine latch;
Operating speed is greater than 2990r/min;
Oil switch trips;
Control system is in automatic mode.
8.5. Solenoid valve test
All high pressure intercept solenoid valve can implement test on OIS.
Under normal situation, 5YV, 6YV, 7YV, 8YV solenoid valves are powered, pressure switches PS4,
PS5are in normal position. In the test, 5YV deenergizes, 6YV, 7YV, 8YV are powered, PS4 sends the
instruction, which show 5YV test is success. Test for 7YV is same to 5YV. 6YV deenergizes, 5YV, 7YV,
8YV are powered, PS5 sends the instruction, which show 6YV test is successful. Test for 8YV is same to
6YV.
If travel switch signal is not right within 15 seconds after solenoid valve acts, test is considered failure.
9. Control mode switch
When DEH is just power on, enter into steam turbine hand operate mode, many automatic functions
can’t be put into in hand operate mode. If condition is allowed, operator can switch to automatic mode after
sending instruction, many functions can only be put into in automatic mode. If condition is allowed,
operator can respectively switch to CCS mode or ATR mode after sending instruction.
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Switch from low class to high class must have operator’s instruction. But switch from high class to
low class can be completed automatically or through operation instruction.
Exit automatic mode under the following situation:
Operator switches to hand operate;
BRC is just power on;
Chief valve setting is broken;
HSS watch dog is overtime;
At the beginning of incorporating in power network, operating speed is less than 2980r/min.
If there is no the above situation, valve location restriction does not act and the difference of chief
valve setting and reference quantity is within ±2％, automatic mode is allowed to put into.
Under steam turbine hand operate mode, BRC works normally, hand operate valve setting can set
through OIS, restriction of rate of change is 33.6％/min.
10. ATC thermal stress control
Condition of ATR mode cutoff:
CCS mode;
Hand operate state;
Oil switch is just cutoff;
Operating speed failure;
Steam turbine trip;
ATR brake valve;
Adjust class metal temperature is broken;
Medium pressure primary class metal temperature is broken;
Medium pressure steam drain metal temperature is broken;
Generator signal is broken;
Axial direction position signal is broken;
Differential expansion signal is broken;
Rotor stress is inefficacy.
Under ATR mode, control parameter of DEH is:
When oil switch is cutoff, target operating speed is 0 r/min, 500 r/min, 1200 r/min, 2000 r/min and
3000r/min, speed raising ratio is 120 r/min/min, 180 r/min/min and 360r/min/min.
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After machine set incorporates in power network, load rate is within 1.5MW/min～30MW/min,
change with step length of 0.5MW/min. During warming up, send load keep instruction.
Chapter II Maintenance after DEH System out of Action
Section I Check before System out of Action
1. Observe all menu vision and alarm state of DEH.
2. Print failure diagnosis record, check abnormal condition in print record.
3. Check work indicator light of DEH cabinet, module, power supply, controller, operating station,
engineer station, and record.
4. Backup the DEH’s configuration software, and record all set parameters.
Section II Repair after System out of Action

1. Backup the DEH control system software, including database and all configuration, database creates disc
and save;
2. Field equipment appearance check shall meet following requirement:
2.1. Appearance shall be perfect and undamaged, switch direction sign shall be clear; nameplate and sign
board be perfect and right, writing shall be clear;
2.2. In control device travel scope act shall be flexible, even and have no block,
2.3. Position transmitter installation shall be right and fixed firmly; fastener has no looseness, moving
element shall be flexible and reliable;
2.4. Connection shall be right, firm and have no looseness, plug and socket connect shall be reliable.
3. Performance check of power supply part: after power on, test output voltage in turn, all test data shall
meet manufactory manual requirement, all power supply switch, and indicator light of all units work
normally.
4. Ash removal, check for the system.
4.1. Clean dust thoroughly for computer mainframe by clean hairbrush;
4.2. Clean surface dust thoroughly for field LVDT sensor and oil servo motor servo valve by hairbrush;
4.3. Clean dust thoroughly for DEH control input and output cabinet by cleaner.
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5. Insulation check: all signal cable’s insulation resistance to the ground are greater than 20MΩ,
insulation resistance among them are greater than 50MΩ; （ Note: In insulation measurement, protection
measure shall be taken to prevent DEH card breakdown）
6. Check and test of interface between DEH system and outside system: communicating interface between
DEH system and outside system shall be right and effective; real time quality of transmission data shall
meet design requirement, content of check and test include:
7. Check on all connection terminal of control cabinet: connection shall be firm; terminal screw has no
corrosion and looseness. If necessary, change connection terminal, connecting cable has no breakage;
8. Check on communication cable: network: connection shall be reliable, plug and fastener shall be
integrated, cable arrangement specs meets design installation technology requirement;
9. Check on exhaust fan in control cabinet: fan runs well, has no abnormal sound during operating, has
uniform operating speed, and fills lubricant to fan axle;
10. LVDT sensor shifting axle acts flexibly and has no friction phenomenon, leading wires of differential
transformer has no breakage and aging phenomena, iron core of differential transformer works in linearity
range to ensure accurate measurement;
11. Servo valve &oil servo motor: servo valve connection is firm and has no oil and oil stain outside, max.
travel of oil servo motor shall meet full opening and complete shut down demand of main throttle valve;
12. Cable shield layer of control cabinet
12.1 Connection between shield layer wire core and special-used grounding terminal is reliable and has no
possibility of loosening and slipping, do grounding again if necessary;
12.2 Do not take power supply grounding as shield grounding, system grounding device is divided into
grounding electrode and connecting cable, grounding resistance of grounding electrode is less than 5 ohm;
12.3 Numerical value of resistance between measurement cabinet and insulation public grounding shall be
less than 1 ohm, if it is greater than 1ohm, check related connections and system connection;
12.4 Check impedance between frame of measurement cabinet and DC grounding busbar. The resistance
value shall be greater than 1 megohm, if the value is less than 1 megohm, cut off the public grounding lines
between other cabinets and measurement cabinet, measure it again until finding out failure reasons.
12.5 The reasons for grounding resistance change may be that there is short circuit between shield layer at
field and ground, or bad installation, or damaged connection, and that input and output signal connected to
SYMPHONY control system have different reference.
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12.6 Notice: before device power on or in shutdown repair is the best time for verification of shield layer.
When verifying, device power supply must be shut down, these test must not be implemented when device
is controlling machine set.
13. Check that control card and power supply loop indicator light of all cabinet work normally, voltage is
within stipulated use scope;
14. Pressure controller fixed value calibrating
High pressure safety oil oil pressure set-up use: PS1 PS2 PS3
High pressure intercept solenoid valve test use: PS4 oil pressure reduce to MPa is successful
PS5 oil pressure increases to MPa test is successful
Low lubricating oil pressure PSA1 oil pressure reduces to 0.049MPa, alarm
PSA2 oil pressure reduces to 0.049MPa , start up AC lubricating oil pump
PSA3 oil pressure reduces to 0.0392MPa, start up direct current lubricating oil pump
and alarm
PSA4, PSA5, PSA6 oil pressure reduce to 0.0392MPa, choose 2 from 3 logic shutdown
and alarm
PSA7 oil pressure reduces to 0.0294MPa , stop hand turning and alarm
Low condensation vacuum PSB1 vacuum reduces to 0.0147MPa, alarm
PSB2, PSB3, PSB4 vacuum reduces to 0.0197MPa, choose 2 from 3 logic shutdown
and alarm.
Fire-resistant oil pressure 6PS, 7PS, 8PS pressure drops 7.8±0.2MPa (drop), choose 2 from 3 logic
realize intercept shutdown
9PS pressure drops 11.2±0.2MPa (drop), alarm
10PS, 11PS pressure drops 11.2±0.2MPa (drop), realize main pump interlock.
Chapter III Operation Description of Steam Turbine Digit Electrohydraulic Deh Control
System
This DEH configure has operator interface(OIS), control of steam turbine can be realized through OIS
station. This chapter introduce system power on check, OIS station start up and the realization of each
function.
Section I DEH Start up Control

1 System power on
1.1. In measurement cabinet,＋24V power supply is normal, ±15V power supply is normal, ＋48V power
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supply is normal, ＋5V power supply is normal.
1.2. Check state indicator light of＃1 cabinet SYMPHONY control system submodule.
1.2.1. Two INNIS21 cards show the following state:
“A” group: lights of 1～5 are always on, lights of 6～8 flicker (out of step),
“B” group: lights of 1～8 flicker (at different velocity ratio).
1.2.2. For two INNPM12 cards, state indicator light is green, for main INNPM12 card, 7＃, 8＃red lights
are on, for accessory INNPM12 card, only 8＃red light is on.
1.2.3. For all BRC－300 cards, state indicator lights are green. For all BRC－300 cards working on the
main state, 7＃, 8＃red lights are on. For all BRC-300 cards working on the backup state, only 8＃red light
is on.
1.2.4. State indicator lights of three TPS02 cards are green.
1.2.5. State indicator lights of all IMHSS03 cards are green.
1.2.6. When external of all IMDSI22 cards have input signal, red lights of corresponding channel are on.
1.2.7. State indicator lights of all IMDSO14 cards are green.
1.2.8. State indicator lights of all IMASI23 cards are green.
1.2.9. State indicator light of IMCPM02 card is green.
1.2.10. State indicator light of IMASO11 card is green.
1.2.11. State indicator light of INICT13 card is green.
2. OIS station start up
2.1. On OIS operating desk, open power supply switch of each part.
2.2. Start up PGP, start up completes when display shows online menu.
3. Steam turbine operating
3.1. Latch
Enter into “automatic control” menu, press “steam turbine latch” key, change “steam turbine latch” to
“yes”, now steam turbine enters latch state.
3.2. Valve verification
Valve verification includes all valve verification and single valve verification. All valve verification
must be off line, single valve verification can be off line and online.
Pay attention to: ensure no steam enters into steam turbine, so that off line valve verification can be
implemented.
Enter into OIS “steam turbine valve verification” menu, press “verification all valve”, select all valve
verification.
3.2.1. Push “verification null position” key to implement null position test.
3.2.2. Push “valve select” key, select valve of verification during single valve verification, to confirm high
pressure adjusting valve or medium pressure adjusting valve.
3.2.3. Push “verification cycle” key, select cycle 1 or cycle 2.
3.2.4. Push “verification times” key, input number 1～8, set proper verification cycle times. Valve will run
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back and forth, times are the set number.
3.2.5. Push “implement/keep” key, select “implement”, verification starts. During verification, on OIS
“steam turbine valve verification” menu “verification” state flickers, concurrently selected oil servo motor
opening has streamer display. To stop verification, push “implement / keep”key and select“keep”.
4. Start up
4.1. On “automatic control” menu, push “automatic / hand operate” key, select “automatic” to be in
operator automatic mode.
4.2. On OIS enter into “automatic control” menu, push “operating” key, status display is “yes”, DEH starts
operating.
Notice: after implement of “operating” order, high pressure main steam valve (MSV),
medium pressure main steam valve (RSV) fully opens.
Section II Raising Speed
1. Set velocity ratio
On “automatic control” menu push “velocity ratio” key, then input proper velocity ratio within
(0r/min/min ~400r/min/min) scope. On OIS menu velocity ratio value will change to input value.
2. Set target
On “automatic control” menu push “target / given”, input scheduled operating speed.
3. Impulse starting
Pushes “implement / keep” key of “automatic control” menu put it into “implement” state.
“Implement” displays in “implement / keep” column of OIS menu, concurrently in “target / given”
column of OIS menu, given operating speed increases gradually, speed adjustment steam valve opens
gradually, real operating speed increases gradually. Machine set starts impulse starting. Approach to
target gradually.
Pay attention to: Machine set automatically raise speed, automatically pass critical, when target
operating speed value is set within critical operating speed region, target operating speed will automatically
change to designated value less than critical operating speed region. When given operating speed is in
critical region machine set raise speed at velocity ratio, and ensure not to stop.
If target is set to 3000r/min, machine set will automatically raise speed to 3000r/min.
4. Synchronism
When external given synchronism signal is received, on OIS “automatic control” menu, push
“automatic synchronism” key, put into synchronism function.
Section III Incorporate in Power Network, Increase Load

Machine set automatically carry original load after incorporate in power network.
1. Set load rate
On “automatic control” menu push “load rate” key, then input proper load rate within（0MW/min/min
~100MW/min/min）scope. On OIS menu load rate value will change to input value.
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2. Set target
On “automatic control” menu push “target” key, input scheduled load. Note: key in value must be
within stipulation scope; otherwise it is of no effect.
Pay attention to: show load feedback put into in the form of“MW”, show load feedback removal in
the form of per cent.
After modify is over, on OIS “automatic control” menu, push “implement / keep” key, to put it into
“implement” state.
3. Load feedback
3.1. Put load feedback into operation
Push “load feedback” key to enter “put into” when “load feedback” column shows “cuttoff” on OIS
“automatic control” menu.
3.2. Load feedback removal
After load feedback is put into operation, on OIS “automatic control” menu, push “load feedback”
key to enter “cuttoff”, so OIS “load feedback” column shows “cuttoff”, which shows that load feedback has
been removed.
4. Main steam pressure control
4.1. Put main steam pressure control into operation
On OIS “automatic control” menu, when “main steam pressure control” column shows “cuttoff”, if
there is allowable condition, click “main steam pressure control” key of menu to put main steam pressure
control into operation. Then “main steam pressure control” status bar shows “put into”.
4.2. Main steam pressure control removal
When main steam pressure control is put into operation, on OIS “automatic control” menu, click
again “main steam pressure control” key of menu, then status bar of “main steam pressure control” shows
“cuttoff”, which shows this main steam pressure control has been removed.
5. Once frequency modulation
Once frequency modulation automatically puts into operation after incorporate in power network,
movement of once frequency modulation depends on dead zone scope of operating speed.
Section IV Single Valve / Sequence Valve Conversion

During single valve / sequence valve conversion, put into load feedback.
1. During the conversion from single valve mode to sequence valve mode, on OIS “automatic control”
menu push “single /sequence valve” key to send out instruction (single /sequence), so switch to sequence
valve mode, the time to switch time lasts about 10 minutes, menu shows “sequence valve” after conversion.
2. During the conversion from sequence valve mode to single valve mode, the operation is same to the
above, the time to switch to single valve mode lasts about 10 minutes, menu shows “single valve” after
conversion.
Section V CCS Control
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When DEH meets all condition of CCS operation, operate “CCS” key of “automatic control” menu to
switch to CCS control, then “CCS” column of OIS menu shows “put into”.
During CCS control, operate “CCS” again to enter “CCS cutoff” state, so CCS control is removed,
“CCS” column of OIS shows “cuttoff”.
Section VI Automatic Restriction of Steam Turbine

1. High load restriction
After incorporate in power network, on OIS enter into “automatic restriction” menu, and set restriction
value of high load, which will limit target set point to be not more than the restriction value.
2. Underload restriction
After incorporate in power network, on OIS enter into “automatic restriction” menu, and set new
underload restriction value, which will limit load to be not less than the restriction value.
3. Valve position restriction
On OIS enter into “automatic restriction” menu; push “valve position restriction” key, input new value,
which is new valve position restriction value. This value will limit flow of valve to be not more than it.
4. Main steam pressure restriction（TPC）
When condition is met, on “automatic control” menu of OIS, push “TPC” key, select “put into”,
TPC” column of OIS menu changes to “put into” from “cuttoff”, which shows that TPC has been put into
operation. During TPC operation, operate “TPC” key on “automatic control” menu of OIS, select “cuttoff”
to change “TPC” column to “cuttoff”, which shows that TPC has been removed.
Main steam pressure restriction value: during TPC operation, prohibit modifying main steam
pressure restriction value, during TPC removal, entering into OIS “automatic restriction”menu, and
push“main steam pressure restriction key, input new restriction value.
Section VII Operation and Removal of Rapid Load（RUNBACK）
1. Put rapid load into operation

After condition is met, when it is in rapid load removal state (“rapid load removal” column of OIS
“automatic control” menu shows “cuttoff”), push “rapid load removal” key on OIS menu to enter “put into”,
when it is in “put into” state, RUNBACK has been put into operation.
2. Rapid load removal
To remove rapid load removal operation, push “rapid load removal” enter “cuttoff”, which shows that
RUNBACK has been removed.
Section VIII Operation and Removal of
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Main Steam Pressure Control
1. Put main steam pressure control into operation
When “main steam pressure control” status bar shows “cuttoff” on OIS “automatic control” menu,
which shows that it is in main steam pressure loop removal state, if condition is met, click “main steam
pressure control” button on OIS “automatic control” menu and select “put into”, below “main steam
pressure control” appears “put into”, which shows that main steam pressure control function has been put
into operation.
2. Main steam pressure control cutoff
To cutoff “main steam pressure control” operation function, on “automatic control” menu click
again “main steam pressure control” button and select “cuttoff”, below “main steam pressure control”
appears “cuttoff”, which shows that main steam pressure control function has been removed.
Section IX Overspeed , Oil Injection Test
1. Oil injection test

On OIS enter into “overspeed test” menu, push “test allow” key to enter “test” position.
During test, on “overspeed test” menu select “oil injection test”. After test, “success” or “failure”
appearing on this OIS menu can show whether the test is successful or not.
2. Overspeed test
2.1. DEH electric overspeed test
Implement the test after instrument & control personnel take off TSI protective wire. On OIS enter
into “overspeed test” menu, and then set “electric overspeed” to “test” position. The following are test
procedure:
Modify proper velocity ratio;
Modify target operating speed to 3360r/min;
Send out “implement” through OIS;
Machine set raise speed at given raising speed ratio from 3000r/min, when it reaches 3300r/min,
brake valve. DEH makes a record of trip operating speed value and shows it on OIS menu.
After test, set “electric overspeed” to “normal” position.
2.2. Machine overspeed test
After OIS enters into “overspeed test” menu, set “machine overspeed” to “test” position.
Modify proper velocity ratio;
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Modify target operating speed to 3360r/min.
Push this OIS menu to send out “implement” instruction, raising speed starts.
Machine set raise speed at given raising speed ratio from 3000r/min until ring flies off to make steam
turbine brake valve. DEH makes a record of trip operating speed value and shows it on OIS menu.When
operating speed of machine set reaches 3360r/min, ring doesn’t fly off, machine brake valve fails, electric
brake valve will operate.
After test, set “machine overspeed” to “normal” position.
Section X Valve Activity Test

On OIS enter into “valve activity test” menu, push “test switch” button, put it to “test” position, select
valve test button which is tested, and select “put into”. Test process has been described in control function.
To stop test, set valve test button which is tested to “cuttoff”, valve will turn to the position before test.
Note: During valve test, other valve cannot be tested concurrently.
Section XI High Pressure Intercept Solenoid Valve Test

On OIS enter into “intercept solenoid valve test” menu, push “solenoid valve test” button, put it to
“test” position, then push “5YV” button, and put it to “test”. During test, on “solenoid valve test” menu
corresponding position will change into red, test state shows “success” or “failure” to show
whether test is successful or not. After test, red disappears.
After test, put “solenoid valve test” button to “normal” position.
Test of 6YV, 7YV, 8YV is the same to 5YV test.
Note: 5YV, 6YV, 7YV, 8YV intercept solenoid valve cannot be tested concurrently.
Section XII Valve Leak Test
1. When the following conditions are met, implement valve leak test.
DEH is in “automatic” mode;
Operating speed of steam turbine is 3000r/min;
Oil switch is not off;
No test is implemented.
2. Enter into “valve leak test” menu, set DEH “leak test ”to “test” position, on OIS “valve leak test” menu
push “main throttle valve test” button, then high and medium pressure main throttle valve shall be closed,
DEH switches to hand operate, leak test starts to time, DEH calculates out acceptable operating speed
according to relevant parameter (there is operating speed trend chart on this menu), records operating speed
race time, decides valve closeness according to whether operating speed reaches acceptable operating
speed.
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After test, steam turbine brake valve hand operated.
3. On OIS “valve leak test” menu push “adjust gate test” button, then high and medium pressure adjust gate
shall be closed, DEH switches to hand operate, leak test starts to time, DEH calculates out acceptable
operating speed according to relevant parameter (there is operating speed trend chart on this menu), records
operating speed race time, decides valve closeness according to whether operating speed reaches acceptable
operating speed.
After test, hand operate brake valve to starts up again.
4. After test, return “leak test” to “normal” position.
Section XIII Hand operate Control

1. After DEH is power on, firstly enter into “operator hand operate” mode, OIS control menu shows“hand
operate”. When some conditions are met, operating personnel can switch from “operator hand operate”
mode to “automatic” mode. Press “ automatic / hand operate” button of OIS“ automatic control” menu or
“ hand operate control” menu, select “automatic”, after control mode is showing “automatic”, DEH has
been switched to automatic mode.
2. Under “hand operate” mode operating, operating personnel can change valve setting value by “hand
operate valve setting” button of OIS“hand operate control” menu, and directly control valve setting signal.
3., Switch “ hand operate ”to “ automatic ” when the following conditions are met:
Deviation between valve setting signal and reference quantity signal is less than 2%.
4. When the following conditions occur, “automatic” mode will switch to “hand operate” mode:
“valve setting” signal is broken;
Deviation between “valve setting” signal and “reference quantity ” signal is greater than 2%;
Operating personnel cut off “automatic” mode.
Chapter IV Failure diagnosis and analysis
In the operating course of DEH, system has online self diagnosing ability, alarming the failed parts
and printing failure content to guide heat control personnel specifically to carry out online or off line
maintenance and resume DEH system to normal as soon as possible Regular maintenance and repair must
be implemented to ensure system operation is long and stable.
Section I Online Self diagnosis

In operating course, DEH tests and diagnoses important hardware equipment and important input /
output signal by itself, and there will be alarm showing if failure is found. To ensure reliability of
controlling steam turbine process, SYMPHONY control system carries out system self diagnosis in
different layers, diagnosed failed system parts will be removed from real time control, which ensures to
control the process by a system without failure.
1. Diagnosis and transact of operating speed channel
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When one operating speed signal of the three operating speed channel losses , or operating speed set point
is greater than 200r/min, operating speed signal will rapidly change. This operating speed channel
has failure.
If operating speed set point is greater than 200r/min and difference between it and middle value is
greater than 10r/min, this operating speed channel has failure.
If any one of the three TPS02 templates failure in microprocessor, this template has failure.
When single channel has the above failures, OIS only shows failure channel signal.
When two channels have failure or and difference between operating speed set value and operating
speed is greater than 500r/min, operating speed system failure signal will appear, this signal will remove
overspeed protection function （OSP）, and it will show steam turbine trip signal if there is no integration.
2. BRC self diagnosis

BRC has self diagnostics system which can carry out hardware and configuration diagnosis and
produce failure indications. When BRC has hardware failures, this BRC stops operating, and shows failure
indications on front panel of BRC.
When NVRAM has errors, state indicator light of BRC front panel will flicker, but BRC will not stop
operating.
Please refer to hardware instruction manual for BRC failure display and transact method
When main control BRC has failure, it will stop clock of bus line of driven element submodule.
“warm back-up” BRC will detect loss of clock within 10ms,，it will immediately produce clock signal of
bus line of element submodule and replace mainboard to carry out process control. The original mainboard
can be removed because original standby module has replaced mainboard and produces clock of bus line of
element submodule, standby submodule has saved the processing data delivered by original mainboard.
Therefore, when mainboard BRC fails at one order, standby BRC will take over control directly by
last written order, which ensures the correctness of control process data.
3. Servo system self diagnosis

Hydraulic pressure servo system is mainly composed of HSS card and LVDT.
3.3.1. “VAVLE CONTINGENCY” signal will be produced if difference between HSS card valve setting
value and valve location feedback value is 5％greater than normal value, this signal prohibits valve test,
when one CV valve produces this signal, CV valve will be converted to single valve mode.
3.3.2. A/D, D/A converter of HSS card verification plate. When they have failures, “A/D, D/A TROUBLE”
signal will be produced, and this state prohibits valve test.
3.3.3. When “VALVE CONTINGENCY” signal appears and feedback voltage of two LVDT feedback
loops of this valve is zero, “OSCILLATOR TROUBLE” signal will appear. If only one feedback voltage is
zero, “SECONDARY TROUBLE” signal will appear, and valve test will be prohibited.
3.3.4. When HSS card fails at plate microprocessor, “SLV XX MOD MAN STATUS” signals will appear,
valve verification and valve test will be prohibited.
3.3.5. When communication between HSS card and BRC is broken, enter emergency hand operate state and
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produce “WATCHDOG TIME OUT”, this failure prohibits valve test and verification.
4. S21/NPM12 communication module self diagnosis
Communication interface of NIS21/NPM12 as PCU entering into INFI － NET is redundant
configuration.
4.1. When power supply has failure, communication template stops start up and turns off.
4.2. When NIS communication appears failure, NIS communication status bit of main module is wrong and
showe in NIS front panel.
4.3. Event counter and failure counter of NIS communication template always save record of happened
failures, receiving failures, loop information miscount and information loss, error code will displayed on
LED panel.
Section II Fault Analysis and Maintenance
When DEH device implements control, the system internal concurrently implements online diagnosis,
alarm for failure unit. According to OIS station and the alarm content of front panel of template implement
pertinence online or off line maintenance, to make DEH recovery to be normal as soon as possible.
Hardware manual have been provided, for all templates inside DEH device, if the template has failure,
please follow the instruction of hardware manual.
The following provides the reason analysis and transaction method for some field signal failure:
1. Operating speed channel failure: short signal channel failure will not influence normal operating of
the system, but if it is long time failure or operating speed system failure, it shall be maintained by
instrument & control personnel, firstly use oscilloscope to check whether operating speed of failure channel
is normal, if it is off-normal, check whether speed measurement connection is right, and whether
installation meets requirement. If the operating speed signal is normal, while operating speed channel
failure happens, the overspeed protection module TPS02 may has failure.
2. Parameters of power, main steam pressure, and governing regulating stage pressure etc.are not conform
with real stituation, so the following three aspects shall be checked: firstly check whether corresponding
transmitter signal is normal, and whether output signal scope is conform with design value, if condition is
allowed, transmitter can be rechecked; secondly check whether the transmitter connection is right, reliable;
Thirdly check analog input.
3. HSS card is the interface of controller and field actuator, the intercourse signal is complex, the
correctness of HSS work decides the reliability of control, HSS card arisen off line failure and online
failure.
3.1 Failure happening during verification, adjustment and start up of HSS template is called off line failure.
The reason mainly is template installation verification is not right or incomplet. The following talks about
the signal of HSS and LVDT.
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Servo amplifier has no servo drive signal: if the drive current signal of HSS card is right, check the
cable output to servo valve, if the cable hs no problem, please replace servo valve .
LVDT primary has no drive signal: if the drive signal of HSS card is right, please check the cable
output to LVDT, if cable has no problem, please replace LVDT.
LVDT secondary has no response output: change the output current of HSS card, the voltage difference
between the two secondary of LVDT shall be changed, if it has no change, please check connecting cable,
if the cable has no problem, please replace LVDT.
3.2 Failure happening during the operating of HSS is called online failure.
Failure caused by connection line during the operating shall be few（under regularly
check condition）; Generally failure happens in cabinet internal or subtemplate, the failure
detailed content can be confired through the state of indicator light on template, if alarm
signal of actuator displacement happens, please check primary or secondary of LVDT. If
primary energizing voltage is less than 1.0VRMS, it is LVDT primary failure, if this value is
greater than 1.0VRMS, please check the secondary voltage of LVDT, if secondary has no sine
wave output, so it is secondary loop failure, if the two secondary output are right, please
check other parts.
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Chapter V Measuring Point List
Operating speed measurement

No. Signal Name Terminal No. Signal Source Remark
1 Operating speed 1 2-8A,TB11-1, 2 In situ
Reluctance
type
Reluctance
type
Reluctance
type
DI signal
No. Signal name Internal terminal No. Signal source Remark
High pressure safety oil In situ pressure switch
1 establishment 1 2-8A,TB10-1, 2 PS1
4 Emergency governor gear has reset 2-2A,TB1-7, 8 In situ travel switch ZS1
Emergency governor gear at trip
5 position 2-3A,TB2-3, 4 In situ travel switch ZS2
6 Oil switch switch on 1 2-8A,TB10-3, 4 Electric
9 Synchronizes decrease 2-2A,TB3-3, 4 Electric
10 Synchronized increase 2-2A,TB2-1, 2 Electric
11 Synchronism request 2-3A,TB3-3, 4 Electric
12 MSV1 complete shut down 2-2A,TB4-3, 4 In situ
13 MSV1 full opening 2-2A,TB4-5, 6 In situ
14 MSV1 test available 2-2A,TB4-7, 8 In situ
15 RSV1 complete shut down 2-2A,TB1-1, 2 In situ
16 RSV1 full opening 2-2A,TB1-3, 4 In situ
17 RSV1 test available 2-2A,TB1-5, 6 In situ
18 MSV2 complete shut down 2-3A,TB4-3, 4 In situ
19 MSV2 full opening 2-3A,TB4-5, 6 In situ
20 MSV2 test available 2-3A,TB4-7, 8 In situ
21 RSV2 complete shut down 2-3A,TB1-1, 2 In situ
22 RSV2 full opening 2-3A,TB1-3, 4 In situ
23 RSV2 test available 2-3A,TB1-5, 6 In situ
24 Rapid load removal 1 2-4A,TB3-3, 4 CCS→DEH
27 CCS request 2-4A,TB3-1, 2 MCS→DEH
28 Hand operate intercept 2-3A,TB1-7, 8 Console →DEH 6R1 extend
29 Send electric machine incorporate in 2-2A,TB2-3, 4 Electric →DEH
power network test
30 Isolating valve at normal position 2-4A,TB1-3, 4 In situ travel switch ZS5
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31 Isolating valve at test position 2-3A,TB4-1, 2 In situ travel switch ZS4
32 Hand turning put into 2-4A,TB1-5, 6 in situ
33 High pressure bypass complete shut 2-4A,TB4-5, 6 In situ
down
34 Low pressure bypass complete shut 2-4A,TB4-7, 8 In situ
down
35 High pressure bypass automatic 2-4A,TB4-1, 2 Bypass controller
36 Low pressure bypass automatic 2-4A,TB4-3, 4 Bypass controller
DO signal
No. Signal Name Relay Internal Terminal External Terminal No. Signal direction to
No.
1 High pressure 5R5 2-1D,TB3-4 2-CS,TB4-13, 14 In situ 5YV
intercept 1
2 High pressure 5R2 2-1C,TB4-2 2-CS,TB4-7, 8 In situ 6YV
intercept 2
3 High pressure 5R3 2-1C,TB3-4 2-CS,TB4-9, 10 In situ 7YV
intercept 3
4 High pressure 5R4 2-1D,TB4-2 2-CS,TB4-11, 12 In situ 8YV
intercept 4
5 Shut down MSV1 3R8 2-1C,TB1-2 2-CS,TB4-17, 18 In situ 9YV
6 Shut down MSV2 3R7 2-1D,TB3-2 2-CS,TB4-15, 16 In situ 10YV
7 Shut down RSV1 4R6 2-1D,TB1-2 2-CS,TB4-21, 22 In situ 15YV
8 Shut down RSV2 4R5 2-1C,TB3-6 2-CS,TB4-19, 20 In situ 16YV
9 Overspeed 3R5 2-1C,TB1-4 2-CS,TB4-3, 4 In situ 27YV
restriction 1
10 Overspeed 3R6 2-1D,TB1-4 2-CS,TB4-5, 6 In situ 28YV
restriction 2
11 CV1 overspeed 3R9 2-1C,TB4-4 2-CS,TB4-23, 24 In situ 11YV
restriction
12 CV2 overspeed 3R10 2-1D,TB4-4 2-CS,TB4-25, 26 In situ 12YV
restriction
13 CV3 overspeed 4R1 2-1C,TB2-6 2-CS,TB4-27, 28 In situ 13YV
restriction
14 CV4 overspeed 4R2 2-1D,TB2-2 2-CS,TB4-29, 30 In situ 14YV
restriction
15 ICV1 overspeed 4R4 2-1C,TB4-6 2-CS,TB4-33, 34 In situ 17YV
restriction
16 ICV2 overspeed 4R3 2-1D,TB4-6 2-CS,TB4-31, 32 In situ 18YV
restriction
17 Steam turbine latch 3R1 2-1C,TB2-2 2-CS,TB4-43, 44 In situ 1YV
18 MSV1 activity test 4R9 2-1D,TB2-6 2-CS,TB4-35, 36 In situ 19YV
19 RSV1 activity test 4R8 2-1D,TB3-6 2-CS,TB4-39, 40 In situ 21YV
20 RSV2 activity test 4R7 2-1C,TB1-8 2-CS,TB4-37, 38 In situ 22YV
21 Oil injection 3R2 2-1C,TB3-2 2-CS,TB4-45, 46 In situ 2YV
22 Isolating valve 3R4 2-1C,TB4-8 2-CS,TB4-47, 48 In situ 4YV
23 ETS5YV 7R4 2-1D,TB1-6 2-DS,TB3-41, 42 DEH→ETS
24 ETS6YV 6R8 2-1C,TB2-4 2-DS,TB3-35, 36 DEH→ETS
25 ETS7YV 6R9 2-1C,TB1-6 2-DS,TB3-37, 38 DEH→ETS
26 ETS8YV 6R10 2-1D,TB2-4 2-DS,TB3-39, 40 DEH→ETS
27 103% 5R8 2-1D,TB1-8 2-DS,TB3-57, 58 DEH→ETS
128
28 DEH trip 5R10 2-1D,TB4-8 2-DS,TB3-7, 8 DEH→ETS
Servo control I/O signal

No. Name Signal Connection Remark
Source Terminal No.
1 LVDT1 primary excitation DEH→in situ 2-2B,TB1-19, 20 1kHz, 13.5V
3 CV1 control signal 1 DEH→in situ 2-2B,TB2-1, 2 +/-40mA
5 1*LVDT from secondary 1* In situ →DEH 2-2B,TB1-13, 14
input
input
input
8 2*LVDT from secondary 2* in situ →DEH 2-2B,TB2-16, 17
input
input
input
input
input
input
input
23 6*LVDT from econdary 1* In situ →DEH 2-4B,TB2-13, 14
input
input
input
input
31 8*LVDT from secondary 1* in situ →DEH 2-5B,TB2-13, 14
129
input
input
35 ICV1 control signal 1 DEH→in situ 2-6B,TB2-1, 2 +/-40mA
input
input
input
input
input
input
input
input
DI
No. Signal Name Terminal No. Signal Source Remark
1 High pressure intercept solenoid 2-5A,TB4-1, 2 In situ pressure
valve test 1 through switch PS5
2 High pressure intercept solenoid 2-5A,TB4-3, 4 In situ pressure
valve test 2 through switch PS4
3 1#high pressure exhaust valve 2-5A,TB4-5, 6 DCS
complete shut down
4 1#high pressure exhaust valve full 2-5A,TB4-7, 8 DCS
opening
5 2＃high pressure exhaust valve 2-6A,TB4-5, 6 DCS
complete shut down
6 2＃high pressure exhaust valve 2-6A,TB4-7, 8 DCS
full opening
DO
No. Signal Name Relay No. Internal Terminal External Connection Signal Source
No. Terminal No.
1 Cold stat start up 7R9 2-2D,TB1-4 2-DS,TB3-17, 18 Bypass
controller
2 Warm state start up 7R10 2-2D,TB1-6 2-DS,TB3-19, 20 Bypass
controller
3 Thermal state start up 8R1 2-2D,TB2-4 2-DS,TB3-21, 22 Bypass
controller
130
4 Extreme thermal state 8R2 2-2D,TB2-6 2-DS,TB3-23, 24 Bypass
start up controller
5 MSV2 activity test 4R10 2-2C,TB1-2 2-CS,TB4-41, 42 In situ 20YV
6 Synchronism put into 8R3 2-2D,TB4-2 2-DS,TB3-15, 16 DCS
allow
7 Operating speed 7R7 2-2C,TB1-6 2-DS,TB3-29, 30
<1200r/min
8 Operating speed 7R8 2-2C,TB3-6 2-DS,TB3-31, 32
<2850r/min
9 CCS control 7R6 2-2D,TB1-8 2-DS,TB3-13, 14 CCS
10 Steam turbine hand 6R3 2-2C,TB3-4 2-DS,TB3-27, 28 DEH→DCS
operate
11 DEH altready trip 5R1 2-2C,TB2-2 2-DS,TB3-11, 12 DEH→ETS
12 Steam turbine reset 6R2 2-2C,TB1-8 2-DS,TB3-25, 26 DEH→DCS
13 Load ＞10% 8R4 2-2C,TB4-2 2-DS,TB3-51, 52 DEH→DCS
Analog input
No. Signal Name Terminal No. Signal Remark
Source
1 Power1 2-8A,TB10-15, 16 Electric 0∼150MW⇔4∼20mA
PT
PT
PT
4 CCS instruction 1 1-8B,TB1-5, 6 CCS 0∼100%⇔4∼20mA
5 CCS instruction 2 1-9B,TB2-5, 6 CCS 0∼100%⇔4∼20mA
6 Main steam pressure (left) 1-8B,TB3-1, 2 In situ 0∼15MPa⇔4∼20mA
7 Main steam pressure (right) 1-9B,TB3-1, 2 In situ 0∼15MPa⇔4∼20mA
8 High pressure adjust class 1-8B,TB2-1, 2 In situ 0∼12MPa⇔4∼20mA
pressure
9 Reheat steam pressure (left) 1-8B,TB4-5, 6 In situ 0∼4MPa⇔4∼20mA
10 Reheat steam pressure 1-9B,TB4-5, 6 In situ 0∼4MPa⇔4∼20mA
(right)
11 Medium pressure 1 2-8A,TB10-17, 18 In situ 0∼4MPa⇔4∼20mA
14 Turbine oil working pressure 1-8B,TB1-1, 2 In situ 0～3MPa⇔4∼20mA
15 Lubricating oil pressure 1-9B,TB2-7, 8 In situ 0～0.5MPa⇔4∼20mA
16 Fire-resistant oil pressure 1-9B,TB4-1, 2 In situ 0～25MPa⇔4∼20mA
17 Condenser vacuum 1-8B,TB4-1, 2 In situ -0.1～+0.1MPa⇔4∼20mA
18 Off center 1-8B TB2-5, 6 0∼100μm⇔4∼20mA
19 Axial direction 1-9B TB3-3, 4 -2∼＋2mm⇔4∼20mA
displacement 1
displacement 2
131
displacement 3
22 High pressure cylinder 1-8B TB1-3, 4 -4∼＋8mm⇔4∼20mA
Differential expansion
23 Low pressure cylinder 1-8B TB1-7, 8 0∼＋15mm ⇔4∼20mA
differential expansion
24 High-medium pressure 1-8B TB2-3, 4 0∼＋35mm⇔4∼20mA
cylinder thermal expansion
left
25 High-medium pressure 1-8B TB3-3, 4 0∼＋35mm⇔4∼20mA
cylinder thermal expansion
left
26 1＃ axis vibration （X 1-10B TB1-1, 2 0∼400μm⇔4∼20mA
direction）
27 1＃ axis vibration （Y 1-9B TB1-1, 2 0∼400μm⇔4∼20mA
direction）
direction）
direction）
direction）
31 3＃ axis vibration （Y
1-9B TB1-5, 6 0∼400μm⇔4∼20mA
direction）
32 4＃ axis vibration （X
1-10B TB1-7, 8 0∼400μm⇔4∼20mA
direction）
33 4＃ axis vibration （Y
1-9B TB1-7, 8 0∼400μm⇔4∼20mA
direction）
34 5＃ axis vibration （X
1-10B TB2-1, 2 0∼400μm⇔4∼20mA
direction）
direction）
36 1＃ bearing cap vibration （X 1-10B TB2-3, 4 0∼100μm⇔4∼20mA
direction）
direction）
direction）
direction）
direction）
41 1＃ bearing cap vibration （Y 1-10B TB3-5, 6 0∼100μm⇔4∼20mA
direction）
direction）
direction）
direction）
132
direction）
AO (analog output)
No. Signal Name Terminal no. Signal Source Remark
1 Valve setting 1-7B,TB-5, 6 DEH→CCS 0∼100%⇔4∼20mA
2
Hot resistance signal （PT100）

No. Signal Name Terminal No. Remark
1 1# work thrust block metal temperature 1-9A TB1-1(+), 2(-), 3(c) 0∼150°C
12 1# bearing metal temperature 1-9A TB2-24(+), 23(-), 22(c) -50∼150°C
16 1# positioning thrust block metal temperature 1-10A TB1-1(+), 2(-), 3(c) 0∼150°C
133
Thermocouple signal ( thermocouple is K graduation )
No. Signal Name Terminal No. Remark
1 Main steam temperature (right) 1-7ATB1-1(+), 2(-) 0∼600°C
2 Main steam temperature (left) 1-8A TB1-1(+), 2-) 0∼600°C
3 Reheat steam temperature (right) 1-7ATB1-3(+), 4(-) 0∼600°C
4 Reheat steam temperature (left) 1-8A TB1-3(+), 4-) 0∼600°C
5 High pressure main steam valve inner wall metal 1-7A TB1-7(+), 8(-) 0∼600°C
temperature (right)
6 High pressure main steam valve inner wall metal 1-8A TB1-7(+), 8(-) 0∼600°C
temperature (left)
7 High pressure main steam valve outer wall metal 1-7A TB1-10(+), 11(-) 0∼600°C
temperature (right)
8 High pressure main steam valve outer wall metal 1-8A TB1-10(+), 11(-) 0∼600°C
temperature (left)
9 High pressure inner cylinder up half inner wall 1-7A TB1-13(+), 14(-) 0∼600°C
metal temperature
10 High pressure inner cylinder up half outer wall 1-7A TB1-16(+), 17(-) 0∼600°C
metal temperature
11 High pressure inner cylinder low half inner wall 1-8A TB1-13(+), 14(-) 0∼600°C
metal temperature
12 High pressure inner cylinder low half outer wall 1-8A TB1-16(+), 17(-) 0∼600°C
metal temperature
13 High-medium pressure outer cylinder up 1-7A TB2-12(+), 11(-) 0∼600°C
halfmedium pressure feed steam inner
walltemperature
14 High-medium pressure outer cylinder up 1-7A TB2-9(+), 8(-) 0∼600°C
halfmedium pressure feed steam outer wall
temperature
15 High-medium pressure outer cylinder up half 1-8A TB2-12(+), 11(-) 0∼600°C
medium pressure feed steam inner
walltemperature
16 High-medium pressure outer cylinder up half 1-8A TB2-9(+), 8(-) 0∼600°C
medium pressure feed steam outer wall
temperature
Other
No. Name Terminal No. Signal Remark
Source
1 Main trip power supply input 2-DS,TB6-JK1 In situ →DEH 220V DC
2(+), 1(-)
2 Auxiliary trip power supply 2-DS,TB6-JK2 In situ →DEH 220V DC
input 2(+), 1(-)
3 Main trip power supply 2-DS,TB5-11, 12 DEH→ control Bright words
deenergization ( normal close ) room alarm
4 Auxiliary trip power supply 2-DS,TB5-13, 14 DEH→ control Bright words
deenergization ( normal close ) room alarm
5 Main power supply input 1-2A INPUT-L1, N1, earth In situ →DEH 220VAC,50Hz
6 Auxiliary power supply input 1-2A INPUT-L2, N2, earth In situ →DEH 220VAC,50Hz
7 Main power supply 2-DS,TB5-15, 16 DEH→ control Bright words
deenergization（normal close） room alarm
134
8 Auxiliary power supply 2-DS,TB5-17, 18 DEH→ control Bright words
deenergization （normal close） room alarm
9 24VDC power supply 2-DS,TB5-19, 20 DEH→ control Bright words
10 48VDC power supply 2-DS,TB5-21, 22 DEH→ control Bright words
11 Hand operate intercept 2-DS TB3-5, 6 control
12 ETS shutdown 1 2-DS,TB3-1, 2 ETS→DEH
13 ETS shutdown 2 2-DS,TB3-3, 4 ETS→DEH
14 ETS 5YV TEST 2-DS,TB3-49, 50 ETS→DEH
18 Act mechanical intercept valve 2-CS,TB4-1, 2 JR14 In situ 3YV
135

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Enterprise Standard of Indian RWPL 8×135MW Power Plant

Instrument and Control System

Published on XX –XX 2009 Implemented on XX –XX 2009

Volume I Maintenance Instruction of Instrument & Control ........................................................................... 5

Chapter I Maintenance Instruction of Temperature Measurement Element....................................................... 5

Section I Temperature Sensing Element ............................................................................................................. 5

Section II Bimetal Thermometer （Including Electrical Contact Bimetal Thermometer）......................... 5

Section I Maintenance Instruction of Corrugate Pipe Instrument

Section II Maintenance Instruction of EJA Transmitter ................................................................................. 18

Chapter III Maintenance Instruction of SZC-O4 Operating Speed Measurement System............................... 26

Chapter IV Maintenance Instruction of DXZ Shaft Vibration Monitoring Instrument.................................... 30

Chapter V Maintenance Instruction of ZR202G Oxygen Analyser.................................................................... 32

Chapter VI Maintenance Instruction of ABB Quality Flow Meter .................................................................... 37

Volume I Implemented with heavy and minor repair of machine set............................................................. 39

Volume II Maintenance Instruction of Instrument & Control Protection System........................................ 40

Chapter I Maintenance Instruction of Pressure Switch ..................................................................................... 40

Chapter II Maintenance Instruction of ETS System .......................................................................................... 45

Section I General Description ....................................................................................................................... 45

Section II Function of ETS System.................................................................................................................... 45

Section III System Operating Principle ............................................................................................................ 46

Section IV ETS Maintenance ............................................................................................................................. 50

Chapter III TSI maintenance instruction ........................................................................................................... 51

Chapter V DZHJ Maintenance Instruction.................................................................................................. 61

Section I System Introduction............................................................................................................................ 61

Section II Maintenance Items and Technical standards .................................................................................. 70

Section IV Flame Test System Maintenance ..................................................................................................... 71

Section V Fire Check Probe Cooling Air........................................................................................................... 72

Chapter I Maintenance Instruction of DKZ\ DKJ Model Electric Drive Actuator......................................... 73

Volume IV DCS Maintenance Instruction ................................................................................................... 77

Chapter I Introduction to System Hardware................................................................................................. 77

ChapterⅡ Introduction to System Software ................................................................................................. 82

Chapter III Maintenance of DCS System ...................................................................................................... 86

Volume V DEH Maintenance Instruction ...................................................................................................... 89

Section I Configuration of Control System .................................................................................................... 89

Section II System Software............................................................................................................................ 95

Section III Main Functions of DEH Control System .................................................................................. 96

Chapter II Maintenance after DEH System out of Action............................................................................114

Section I Check before System out of Action ............................................................................................114

Section II Repair after System out of Action ...................................................................................................114

Section I DEH Start up Control ........................................................................................................................116

Section II Raising Speed .................................................................................................................................118

Section III Incorporate in Power Network, Increase Load .........................................................................118

Section IV Single Valve / Sequence Valve Conversion .................................................................................119

Section V CCS Control .................................................................................................................................119

Section VII Operation and Removal of Rapid Load（RUNBACK）................................................... 120

Section IX Overspeed , Oil Injection Test.................................................................................................... 121

Section X Valve Activity Test..................................................................................................................... 122

Section XI High Pressure Intercept Solenoid Valve Test .......................................................................... 122

Section XII Valve Leak Test ...................................................................................................................... 122

Section XIII Hand operate Control ................................................................................................................. 123

Chapter IV Failure diagnosis and analysis ....................................................................................................... 123

Section I Online Self diagnosis ......................................................................................................................... 123

Section II Fault Analysis and Maintenance ............................................................................................... 125

Chapter V Measuring Point List ................................................................................................................. 127

efficiency of all equipments to reach full life of operational life.

This manual is applicable to maintenance work of instrument & control equipments of

Indian RWPL power plant.

Main sources of standards:

● Instruction of Instrument & control Equipment

This manual applies to:

● Maintenance personnel of steam turbine.

● Director, deputy director of Maintenance Department; engineer special responsible for