75D.

002SM(B)-7 PAGE 1 OF 48

1 EH (electro-hydraulic) system operation principle

1.1 Preface
With the application of digital electro-hydraulic (DEH) control system to the unit,
the HP fire-resistant fluid based on the phosphate ester with 14 MPa pressure is
used as the control fluid in the control system, while the LP turbine oil with 0.7
MPa pressure as the mechanical protection oil. Each inlet steam valve has an
actuator to control its open/close, among which RSV (reheat stop valve) actuators
are of “ON-OFF Control” type and others are of “Proportional Control” type. All
the actuators can force their corresponding valve open by a hydraulic force and
close by a spring force. The valve close speed could be controlled by an adjustable
needle valve at the end of actuator cylinder.
1.2 Basic composition of EH control system
As per the function, EH control system could be constituted of three parts, which
are EH fluid supply system, actuators and emergency trip part.
EH fluid supply system can be further devided into EH fluid supply device, self-
circulation cooling system, fluid regeneration system as well as EH fluid piping &
accessory.
Actuator part shall be constituted of two MSV (main stop valve) actuators, two
RSV actuators, four GV (governor valve) actuators and four ICV (reheat
interceptor valve) actuators.
Emergency trip protection system shall be constituted of OPC/AST solenoid valve
unit, diaphragm valve, emergency governor, pilot valve of emergency governor,
safety operation device and manual injection stop valve.
1.3 EH fluid supply system
The main function of EH fluid supply system shall be to supply necessary
hydraulic power to actuators, and maintain the normal physical chemistry
characteristics of hydraulic fluid.
Electric power requirement for EH fluid supply system:
Two main oil pumps shall be of 45KW, 415VAC, 50HZ, three-phase,
One circulating pump shall be of 1.5KW, 415VAC, 50HZ, three-phase,
One regenerating pump shall be of 0.75KW, 415VAC,50HZ, three-phase,
One group of heater shall be of 32.4KW, 415VAC, 50HZ, three-phase
Warning: for high requirement of EH fluid cleanness and viscosity for
variable displacement piston pump, the pump shall not be started until fluid
temperature higher than 20℃ has been confirmed.
EH fluid supply system has two independent groups of pump, between which one
is for working and the other one is for standby during normal operation. When
more flow is needed for EH control system or system pressure is too low for some
reason, the other oil pump could be started through interlock start to meet system
flow and pressure requirement.
All sealing parts of the device shall be of fluorin rubber, while the accumulator
bladder shall be of butyl rubber and the paint shall be the special polyurethane
paint.
 75D.002SM(B)-7 PAGE 2 OF 48

Warning: sealing parts shall be the lifeline of hydraulic system, so nitrile

rubber sealing parts shall be kept away from the system.
For ensuring fluid performance, the self-circulation cooling and heating system
and fluid regenerating system shall be prepared for the system. Fluid regenerating
system shall be of two stages filter arrangement, one of which is resin filter and
the other is cellulose filter.
1.4 Actuators
1.4.1 RSV actuator
Two RSV actuators equipped with valve activity testing solenoid valve shall be
installed on RSV at unit side. RSV actuator shall be of “ON-OFF Control” type.
RSV actuator will receive the control signal from DEH system, and a plug-in type
dump valve is installed on the actuator. Should emergency condition occur during
steam turbine operation, auto stop emergency trip (AST) fluid is discharged so that
dump valve will open immediately to discharge the pressure fluid at working
chamber of actuator cylinder and RSV will close quickly by spring force.
There is an activity testing solenoid valve (2 position, 2 way) on actuator, which is
connected with cylinder working chamber and return fluid. When valve activity
test is performed, DEH control device will send out a signal to make the solenoid
valve open for discharging part of pressure fluid in cylinder working chamber,
then RSV is closed by spring force to perform valve activity test.
1.4.2 MSV actuator
MSV actuator is “Proportional Control” type actuator, which can control MSV at
any position and control steam admission to meet steam turbine operation
requirement according to control requirement.
DEH control signal drives servo valve to move main valve core and control servo
valve pass to make HP fire resistant fluid go into actuator working chamber to
move actuator piston, and finally to open MSV or to discharge pressure fluid from
working chamber to close MSV through piston converse movement by spring
force. When actuator piston moves, it will drive two linear displacement
transducers (LVDT) to transform actuator piston displacement into electrical
signal (as feedback signal) plus the aforesaid signal after computer treatment;
however, it’s actually minus each other because of the opposite polarity. Only in
the condition of original input signal plus feedback signal to make input
servoamplifier signal zero and main pilot valve of servo valve be back to center
position without high-pressure fluid coming into working chamber, MSV will stop
moving and remain at a new working position.
A plug-in type dump valve is installed on MSV actuator. Should emergency stop
condition occur during steam turbine operation, emergency trip system will act to
discharge AST header fluid so that dump valve will open immediately to discharge
the pressure fluid at working chamber of actuator cylinder and MSV will all close
quickly by spring force.
1.4.3 GV actuator
GV actuator is “Proportional Control” type actuator, which can control GV at any
position and control steam admission to meet steam turbine operation requirement
 75D.002SM(B)-7 PAGE 3 OF 48

according to control requirement.

The control principle of servo valve shall be the same as that of MSV actuator.
The GV actuator is equipped with one plug-in type dump valve. When steam
turbine running speed exceeds 103% of rated speed or emergency stop caused by
failure happens, after emergency trip system acts overspeed protection control
(OPC) header fluid will be discharged, dump valve will open immediately to
discharge pressure fluid inside actuator working chamber and each GV will be
closed quickly by spring force.
1.4.4 ICV actuator
Refer to GV actuator.
1.5 Emergency trip protection system
For avoiding serious damage accident of unit caused by failure of some equipment
during steam turbine operation, emergency trip protection system shall be
prepared for the unit.
1.5.1 Emergency trip testing device
Emergency trip testing device shall be constituted of one EH oil pressure test
block, one bearing oil pressure test block, two condenser vacuum test block and
two BOP & EOP start test block, which could be on-line tested and maintained.
1.5.2 OPC/AST solenoid valve unit
OPC/AST solenoid valve unit consists of two OPC solenoid valves (20/OPC-1、2),
two check valves, four AST solenoid valves (20/AST-1、2、3、4) and one control
block. Two OPC solenoid valves are in the parallel arrangement, and four AST
solenoid valves are in the series-parallel arrangement. When turbine speed exceeds
103% of rated speed, OPC acting signal will be sent out. OPC solenoid valves
open when they are energized so that OPC header fluid drains to EH fluid
reservoir through no pressure return (DV) fluid line. In that case, discharge valve
of the corresponding control valve actuator will open fast so that each HP control
valve will be closed immediately.
When emergency happens to unit, AST signal will be sent out. Four AST solenoid
valves will open for losing power so that AST header fluid drains to EH fluid
reservoir through DV fluid line. In that case, dump valves of main steam valve
actuator and control valve actuator will open fast to close each steam valve
immediately.
1.5.3 Diaphragm valve
Diaphragm valve provides an interface between the HP fire-resistant hydraulic
fluid and LP turbine oil, thus the LP overspeed tripping can be accomplished by
the diaphragm valve to shutdown the steam turbine.
1.5.4 Mechanical overspeed and manual trip device
Mechanical overspeed and manual trip device consists of emergency governor,
pilot valve of emergency governor and safety operation device.
1.5.4.1 Emergency governor, pilot valve of emergency governor
Emergency governor shall be equipped with one set of centrifugal stop bolt, which
controls pilot valve of emergency governor. When steam turbine operation speed
reaches to 110%-112% of rated speed, centrifugal force of centrifugal stop bolt
 75D.002SM(B)-7 PAGE 4 OF 48

overcomes the restriction force of spring and throws the centrifugal stop bolt
outward striking pilot valve trigger which make pilot valve move towards right
and then protection oil is connected with drain to open diaphragm valve rapidly.
Pilot valve of emergency governor that is installed inside front bearing housing is
the control and test device in emergency trip system, and it includes one trip pilot
valve, one test isolation pilot valve, one manual trip lever and one test lever.
Test isolation pilot valve could be used to isolate pilot valve of emergency
governor from LP protection oil header. During oil injection test, test stop valve
could be opened by manual to allow pressure oil coming into the chamber beneath
centrifugal stop bolt through nozzle, and centrifugal stop bolt overcomes the
restriction force of spring flying off.
1.5.4.2 Safety operation device
Safety operation device provides remote reset solenoid valve and reset air cylinder
for unit. When it receives DEH reset signal and air cylinder moves upwards
pushing connecting rod of emergency governor pilot valve, pilot valve of
emergency governor resets.
2 EH system set value
No. Description Set value Remarks
1 EH system pressure 14 MPa
2 EH fluid power unit overflow valve 16.8 MPa
opening pressure
3 HP accumulator nitrogen charging 9.4-9.8MPa
pressure
4 Fire resistant fluid in EH fluid
37-60C
reservoir allowable temperature
5 EH fluid reservoir level switch set Level switch
value acts when
Low EH fluid level alarm 450mm fluid level of
Low low EH fluid level pre-trip 370mm EH fluid
(stop heater) reservoir
Low low EH fluid level trip (stop 230mm reaches to
main oil pump) set value
Low low EH fluid level trip (stop 230mm
main oil pump)
6 Pressure transducer XD/EHP Output current is 4-20mA at
0-21MPa fluid pressure
7 63/HP (high EH fluid pressure 16.2Mpa
alarm)
8 63/MP (start standby oil pump) 11.2Mpa
9 63/LP (low EH fluid pressure alarm) 11.2MPa
10 63-1/LP (low EH fluid pressure trip) 9.8MPa
11 63-2/LP (low EH fluid pressure trip) 9.8Mpa
12 63-3/LP (low EH fluid pressure trip) 9.8Mpa
 75D.002SM(B)-7 PAGE 5 OF 48

13 63-4/LP (low EH fluid pressure trip) 9.8Mpa

23-1/EHR Start cooling water solenoid
valve, interlock start
circulating pump and stop
14
heater at 55C
23-2/EHR Stop cooling water solenoid
23/EHR valve, and stop circulating
pump at 40 C
23-3/EHR Prohibit starting MOP while
fluid temperature lower than
20C
23-4/EHR Alarm while fluid temperature
higher than 60C
15 63-1 /ASP Alarm while No.1
fluid pressure channel act
higher than 9.3 indicated
MPa
16 63-2 /ASP Alarm while No.2
fluid pressure channel act
lower than 4.2 indicated
MPa
17 63/OPC Fluid pressure Steam
lower than 7.0 turbine
MPa overspeed
indicated
18 63-1/MPF Differential High
pressure more differential
than 0.24 MPa pressure of
alarm No.1 pump
outlet filter
indicated
19 63-2/MPF Differential High
pressure more differential
than 0.24 MPa pressure of
alarm No.2 pump
outlet filter
indicated
 75D.002SM(B)-7 PAGE 6 OF 48

20 63-1、2、3/AST Closed while Steam

fluid pressure turbine
lower than 7.0 emergency
MPa, trip and stop
diaphragm indicated
valve acted
21 MSV actuator
Servo valve input current 40mA
22 GV actuator
Servo valve input current 40mA
23 ICV actuator
Servo valve input current 40mA
24 Cooling water pressure 0.2—0.5Mpa
25 Cooling water temperature
Less than 38
26 Rated pressure of turbine oil 0.7 MPa
3 EH system installation specification
3.1 Preface
HP EH system installation shall be an important work, which shall be paid much
attention to. In case that asbestos, weld residue, burr at the end of pipe, dust etc.
come into oil piping, orifice of EH system oil piping will be jammed and hydraulic
elements will be out of work. Good cleanness of oil piping during installation
could save fluid circulating time, which may make fluid quality meet specified
grade NAS5 or MOOG2 requirement as soon as possible. Otherwise, EH system
could not normally start for the reason of unqualified fluid, which will further
delay unit overhaul or installation schedule.
3.2 First installation procedure and each subassembly installation location
3.2.1 First installation procedure
3.2.1.1 EH fluid power unit shall be horizontally positioned and ground of
installation area shall be pre-leveled off.
3.2.1.2 EH oil piping shall be pre-cleaned clearly and crater shall be avoided as
much as possible during welding.
3.2.1.3 All welds of EH oil piping shall be X-ray inspected after welding.
3.2.1.4 Tee and connection shall be pre-cleaned clearly and packed in clean plastic
bag for standby.
3.2.1.5Pay attention to tube connecting direction of oil ports, during each actuator
installation.
3.2.1.6 Servo valves and filters shall be put in clean plastic bag for standby when
they are out of use.
3.2.2 Subassembly needed to be installed:
3.2.2.1 MSV actuator two sets
3.2.2.2 RSV actuator two sets
3.2.2.3 GV actuator four sets
 75D.002SM(B)-7 PAGE 7 OF 48

3.2.2.4 ICV actuator four sets

3.2.2.5 EH fluid reservoir(including regenerating device one set
3.2.2.6 HP accumulator two sets
3.2.2.7 OPC/AST solenoid valve unit one set
3.2.2.8 Diaphragm valve one set
3.2.2.9 Pneumatic valve one set
3.2.2.10 Trip pilot valve for RSV two sets
3.2.2.11 Installation of junction box A, B pipings one set
3.2.2.12 Emergency trip testing device one set
3.3 Installation and connection
3.3.1 EH system subassembly installation
Before installation relevant drawings and documents shall be learnt, e.g. electro-
hydraulic control system drawing, EH fluid piping & accessory, specification for
electro-hydraulic control system and relevant drawings as well as documents.
Refer to EH fluid piping & accessory. The subassemblies to be installed on
operating floor shall be two MSV actuators, two RSV actuators), four GV
actuators, four ICV actuators, two sets of HP accumulator assembly, one set of
OPC/AST solenoid valve unit, diaphragm valve , emergency trip testing
device 、 2# test block of BOP & EOP startand various instruments, switches as
well as transducer etc used for monitoring system. Before installation the
functions of all subassemblies shall be fully learnt and related
specification/documents shall be referred, so that the installation could be
performed well.
The subassemblies to be installed on zero-meter flat shall be EH fluid power unit
and oil piping.
3.3.1.1 Installation of actuator and spring housing
The actuator shall be installed on steam valve together with its spring housing.
During installation, piston rod and elements on actuator shall not be damaged and
the plug at union connection shall not be removed to avoid dust entrance. Ensure
6.5mm spare stroke between pistion rod and the bottom of cylinder at valve full
close position during actuator installation.
After mounting spring housing and actuator to valve, mount LVDT and adjust
limit switch. Ensure all moving parts can move smoothly without jamming.
3.3.1.2 EH fluid power unit location
EH fluid power unit shall be located on zero-meter flat.
It is recommended that oil outlet of EH fluid power unit shall be towards steam
turbine direction, and the installation dimension has been identified on drawing.
Because there is much dust during installation of piping and its accessories at
power plant, EH fluid power unit after package opening shall be covered by
canvas. After installation of EH fluid power unit, a temporary iron cover shall be
established above it to prevent asbestos, welding spark, dust etc, or a small room
built of aluminium alloy and glass with good ventilation could be optional. In
additional, there shall be tap water for washing hands by adjusting and operating
persons inside the room. Cooling water shall be close circulation water, and inlet
 75D.002SM(B)-7 PAGE 8 OF 48

water pressure shall be between 0.2MPa and 0.5MPa. Water quality shall be
qualified so that scaliness will not happen inside cooler. Cooling water tubing
shall be of F33´4(DN25), the material of which shall be stainless steel.
3.3.1.3 Accumulator assembly installation
Two sets of accumulator assemblies shall be respectively installed on steam
turbine sides on operating floor and their location shall be determined according to
EH oil piping and accessories as well as site situation. HP accumulator location
shall be close to combined main stop/governing valve as much as possible.
3.3.1.4 Diaphragm valve installation
Diaphragm valve shall be fastened by a support and chuck ring and installed at
front bearing housing side. Oil inlet of diaphragm valve upper chamber connects
to mechanic overspeed-manual trip header. Oil inlet and outlet on valve body shall
be respectively connected to AST header and DV header, and the orientation of
inlet/outlet shall be identical with the arrow marked on valve body. AST fluid shall
be connected to inlet of diaphragm valve, while DV fluid shall be connected to
outlet of diaphragm valve.
3.3.1.5 OPC/AST solenoid valve unit installation
OPC/AST solenoid valve unit shall be located nearby front bearing housing. Its
tubing connection refers to 75D.002Q(B)-7 and 75D.328Z(B)-7 and shall be
checked carefully.
3.4 Connection of subassemblies
3.4.1 Cleaning of tubing, tee, elbow and union connection
All stainless steel tubing shall be flushed by steam that is of high temperature
(300°C) and low pressure (1.0Mpa). Steam may come from small boiler. Put outlet
of steam piping into the tubing to be flushed and turn open steam valve to flush
the tubing for one minute. After cooling tubing, tubing inner wall shall be cleaned
by using iron thread packed white cloth until there is no dirty spot on white cloth.
After that, two ends of tubing shall be blocked to prevent dust. Finally, the inner
surface of parts shall be wiped by using white cloth until there is no dirty spot on
the white cloth, and then the parts shall be put into clean plastic bag for standby.
3.4.2 EH oil piping installation
3.4.2.1 Notice of EH oil piping installation
a) Cleanness shall be regarded in EH oil piping installation, which means the
outlet of piping shall be blocked by using sleeve or plastic bag and white cloth
to prevent dust.
b) All connections of EH oil piping shall adopt argon arc welding, and welded
connection quality shall be ensured.
c) Piping wall shall not be damaged during piping bending to avoid crack of
piping wall weak section caused by stress concentration during operation.
d) Cut piping shall be chamfered and deburred to prevent scrap iron and burr
entering piping.
e) The screw cap of union connection must be screwed tightly; otherwise,
 75D.002SM(B)-7 PAGE 9 OF 48

installation of union connection will be difficult after finishing piping welding

and leakage will happen.
f) The welder shall not knock EH oil piping with welding rod to check whether
the welding is normal or not, because that will burn out piping or damage
piping wall.
g) When reinstallation, O-ring shall be put at union connection, and the screw cap
shall not be screwed tightly until the boss and groove of union connection are
matched with each other completely.
h) Harbin Turbine Control engineering Co. Ltd proposes that it will dispatch
welders of full experience to complete EH oil piping and accessories’ welding.
i) Before installation related documents of EH system shall be learnt and piping
connection shall be executed according to relevant document e.g. EH oil
piping & accessory. Piping machining and installation shall be executed at site,
and piping shall be arranged across the area above 2M or be arranged
vertically along foundation. The piping arranged along building shall be as
straight as possible.
j) All lines shall pitch continuously downward a minimum of 3mm per 300mm
(1%) to the EH fluid reservoir.
k) After EH oil piping welded, the crater shall be X ray inspected.
l) Piping bent radius shall not be less than the minimum value specified by
manufacturer. See table 1.
Piping
diameter 33´4 40´4 28´4 22´3.5 16´3 11´2.5

F(mm)
Min. bent 80 90 60 50 30 20
radius
R(mm)
Table 1 Min. bent radius of stainless steel seamless pipe
3.4.2.2 Piping installation on zero-meter flat
Refer to 75D.002SM(B)-7 and 75D.328Z(B)-7. The piping connected with EH
fluid reservoir includes return fluid (DP1, DP2), no pressure return fluid (DV1,
DV2), high-pressure fluid (HP), which shall be marked on nameplates at EH fluid
reservoir outlets.
3.4.2.3 Cleaning the tubing on zero-meter flat
The tubing shall be marked and then disassembled and to be flushed with 1.0MPa
pressure, 300°C temperature steam for one minute on zero-meter flat. Steam may
come from small boiler. After being flushed, tubing inlet/outlet shall be blocked or
covered by special plug or plastic bag and iron thread packed white cloth to
prevent dust entrance.
3.4.2.4 Reinstallation of the tubing on zero-meter flat
All tubing shall be reinstalled according to the drawing and the mark after
 75D.002SM(B)-7 PAGE 10 OF 48

cleaning. The sealing parts like O-ring, gasket shall be located at position, the
connectors for cleaning but not welded shall be welded and expansion support
shall be fastened.
3.4.2.5 Installation of the tubing on operation floor
Installation of the tubing and expansion support on operation floor shall start from
two RSV actuators and four GV actuators.
Because the actuator will move for the heat expansion of steam section, the
displacement will happen between tubing terminal and tubing support or between
tubing terminals.
All stainless steel tubes adopt argon arc welding. After being cut, the tube ends
shall be cleaned without burr. Tubes could be connected with each other; however,
tube ends shall be chamfered. As indicated in following figure:

Distance between two tubes shall not be more than 0.5mm.

Final check:
Whether: installation has been complete after O ring installation; tubing has been
clamped by expansion support; all union connection screw caps have been
screwed tightly; all welds have been welded well and there is crack and air hole (if
necessary, X ray inspect shall be performed); all stop valves’ positions are correct;
installed tubing clamps and supports are firm. After all preparation works above
mentioned have been done, the next step could be started.
4. EH system fluid flushing
4.1 Prepararion before EH fluid reservoir filling
a) All servo valves, solenoid valves shall be disassembled and separately shipped
before equipments leaving factory, and flushing plates shall be installed at
relevant positions. Field check whether the screws of flushing plates have been
screwed tightly.
b) The orifices in relevant subassemblies shall be disassembled in the field, put
into clean plastic bag and marked.
See following table for installation position and disassembly method of orifices:
No. Subassembly Orifice Qty. Orifice position Disassembly
method
1 MSV 1×2 sets In the plug-in valve Remove the screw
actuator cover plug over the
orifice
2 GV actuator 1×4 sets In the plug-in valve Remove the screw
 75D.002SM(B)-7 PAGE 11 OF 48

cover plug over the

orifice
3 RSV 1×2 sets + 1. In the plug-in 1.Remove the
actuator 1×2 sets valve cover screw plug over
2. In the combined the orifice
block 2.Remove the
screw plug over
the orifice
4 ICV actuator 1×4 sets In the plug-in valve Remove the screw
cover plug over the
orifice
5 OPC/AST 6×1 1.Six in the plug-in 1.Remove the
solenoid set+2×1 set valve cover screw plug over
valve unit 2. Two in the orifice the orifice
seat 2.Remove orifice
seat
6 Test block 2×1 set In the fluid block Remove the screw
for EH oil plug over the
pressure orifice
c) Check each actuator whether 3 microns flushing filter has been installed at HP
inlet.
d) Pressure compensator adjusting rod of two MOPs shall be adjusted to full
loose condition.
e) Check whether 10 microns flushing filters on MOP outlets have been installed.
f) Check whether 3 microns flushing filter has been already installed on DP line.
g) Check whether stop valve at inlet of regenerating device has been closed.
h) Inlet valves of all accumulators shall be closed.
i) Check whether silica gel has been installed in the air cleaner.
j) Check whether the electric circuit of MOP control cabinet and HPU control
box is correct.
k) Carefully check whether valves have been at the position described in
following table:
No. Valve position Correct
position
1 1#，2# main oil pumps inlet Open
2 1#、2# main oil pumps outlet pressure gauge Open
3 1#、2# main oil pumps outlet Open
4 Circulating pump filling port Close
5 Circulating pump suction port Open
6 1#、2# cooling water inlet Open
7 Regenerating pump suction port Close
8 Vent valve on the top of regenerating device resin Close
filter, cellulose filter
 75D.002SM(B)-7 PAGE 12 OF 48

9 Pressure gauge of regenerating device resin filter, Open

cellulose filter
10 Isolation valves of 1#, 2# HP accumulator at pump Close
outlet
11 Discharge valves of 1# 、 2# HP accumulator at Open
pump outlet
12 Pressure gauges of 1#, 2# HP accumulator at Open
pump outlet
13 Isolation valves of HP accumulator at right and Close
left side
14 Discharge valves of HP accumulator at right and Open
left side
15 Pressure gauges of HP accumulator at right and Open
left side
16 HP fluid outlet of EH fluid reservoir Open
17 Stop valve of EH pressure fluid straight back EH Close
fluid reservoir
18 Isolation valves of pressure switch and pressure Close
transmitter on EH fluid reservoir HP header
19 EH fluid reservoir sampling port Close
20 Waste discharge port at the bottom of EH fluid Close
reservoir
21 Stop valve at inlet of each actuator Open
22 Pressure gauge on OPC header Open
23 Pressure gauge on AST header Open
24 ASP pressure gauge Open
25 OPC header pressure switch (two) Close
26 AST header pressure switch (three) Close
27 AST pressure switch (two) Close
28 Stop valve at inlet of low EH oil pressure test Open
block
29 Pressure gauge of low EH oil pressure test block Open
(two)
30 Manual test stop valve of low EH oil pressure test Open
block (two)
31 Stop valve at pressure switch inlet of low EH oil Close
pressure test block (four)

Attention: ball valve will be at open position when ball valve handle and valve
body centerline is at superposition; however, ball valve will be at closed position
when ball valve handle is perpendicular to valve body centerline.
l) Please confirm the pumps condition according to the following table:
No. Description Correct condition
 75D.002SM(B)-7 PAGE 13 OF 48

1 EH fluid reservoir MOP Close

2 EH fluid reservoir standby pump Close
3 Circulating pump Close
4 Regenerating pump Close
5 Heater Close

The control switch in control room shall also be at closed position.

2) In case that turbine oil piping has not been ready for oil passing through,
turbine oil piping in upper part of diaphragm valve could be removed and then
blocked to avoid turbine oil leakage. The upper part of diaphragm valve shall be
filled with compressed air to make diaphragm valve be at closed position.
4.2 Check the rotating direction of oil pump motor
4.2.1Open the following terminal circuits to eliminate low level and low oil
temperature interlock
4.2.1.1 MOP low-low level interlock
4.2.1.2 MOP low oil temperature interlock
4.2.1.3 Heater-circulating pump interlock
4.2.2 Set remote control and local control buttons on MOP control cabinet to local
position
4.2.3 Supply 415VAC power to MOP control cabinet
4.2.4 Confirm indicator lights of green and red control switches are all lighted
4.2.5 Push operation and stop buttons of pumps and heater, confirm control loop
and rotating direction of 1# MOP, 2# MOP, circulating pump and regenerating
pump, which means to check whether rotating direction of motor fan is identical to
arrow direction marked on motor (face to the fan, rotating direction is clockwise)
and whether control loop of heater is correct
4.2.6 Switch off 415VAC power
4.2.7 Eliminate open circuits specified in clause 1
4.3 EH fluid reservoir filling and level switch set value
4.3.1 EH fluid reservoir filling
Two methods are applied to EH fluid reservoir filling: use standby oil purifier or
circulating pump to fill fluid.
a) Clean the top of fire-resistant fluid jerrican, open vent and suction hole, insert
one end of hose into jerrican suction hole (big hole) and connect the other end
to filling port of EH fluid reservoir self-circulation system, and then start
circulating pump to fill fluid to EH fluid reservoir.
b) Circulating pump shall be stopped and filling stop valve shall be closed when
a jerrican is going to be taken empty.
 75D.002SM(B)-7 PAGE 14 OF 48

c) Change for another jerrican and repeat the mentioned clauses above until EH
fluid reservoir level reaching to high fluid level mark.
d) Pay attention to oil level during filling, and request thermal technology
personnel to set oil level alarm switch at site (the set point shall be in
accordance to EH fluid reservoir bottom). Level switch has four alarm points,
which shall be firstly tested by using ohm scale of multimeter.
e) Refer to control cabinet ER wiring diagram for contact points’ condition (NO
or NC) of two level switchs before oil filling.
Low EH oil level alarm 450mm (drop)
Low-low EH oil level trip alarm 370mm (drop)
Low-low EH oil level trip (stop MOP) 230mm (drop)
Low-low EH oil level trip (stop MOP) 230mm (drop)
f) When oil level is rised, each pair of contact points open/close condition shall
be recorded according to the above specification. Two pairs of contact points’
activity sequence shall be regarded and monitored together. Stop filling,
measure oil level and record oil level height once the contact point acts.
g) When finishing setting lower oil level, the circulating pump could be started
until oil level of EH fluid reservoir reaches to high oil level. During oil filling,
oil level alarm device acting oil level shall be continuously checked and
recorded.
h) For ensuring higher oil level after start, EH fluid reservoir shall be filled to the
highest oil level mark that is 100mm between oil surface and reservoir top (oil
level will be dropped a little bit when system pressure has been established
and accumulator has been filled with oil. When oil level is higher than low oil
level alarm level, EH fluid reservoir shall not be filled with oil).

i) When the temperature is lower than 20°C, heater and circulating pump shall be

started. After around 10 minutes, it shall be checked whether outer wall of EH

fluid reservoir is hot by hand and meanwhile thermometer of EH fluid
reservoir shall be monitored. Because of good viscosity and bad heat
conductivity of fire-resistant fluid when its temperature is low, circulating
 75D.002SM(B)-7 PAGE 15 OF 48

pump shall be started also to make whole fluid reservoir being uniformly
heated and to avoid part carbonization. It’s better to start MOP when fluid
reservoir temperature is around 40-50℃, so that the temperature will not be
too low during system oil circulation.
4.4 EH system oil circulation
EH main oil pump could be either local controlled or remote controlled in main
control room, which shall be communicated with each other well.
4.4.1After start button of one MOP being pushed, the oil pump will make scream
and metal bumping noise within seconds (when oil temperature is lower than
20°C), and then oil pump could operate smoothly. The pressure gauge at pump
outlet shall be monitored. The oil pressure may be very low (lower than 0.5MPa)
because of system large return flow, when it shall be checked whether oil leakage
of whole system happens. If leakage happens, the pump shall be stopped
immediately to solve the problem.
4.4.2 If the system is normal, pressure compensator of EH main oil pump shall be
tightened to make pressure rise until it will not rise any more. At this moment, unit
pressure value will not exceed 1.5MPa. It shall be checked again whether system
oil leakage happens; if it happens, the pump shall be stopped to solve the problem,
otherwise the unit shall operate continuously.
4.4.3 If the system is normal, the other EH main oil pump shall also be started and
then system pressure will rise a little bit. The pressure compensators of EH main
oil pump shall be tightened to make pressure rise until it will not rise any more;
however, outlet pressure shall not higher than 3.5Mpa. It shall be paid attention to
that spin length of screw rods of two main oil pumps’ pressure compensators shall
be the same, so that the outlet pressure of two EH main oil pumps could be the
same.
4.4.4 For system piping being flushed, both oil temperature and oil level will drop.
If the pump operates normally, it’s unnecessary to stop the pump; if the oil
temperature is over 20°C, the pump could operate continuously.
4.4.5 Oil thermometer on EH fluid reservoir shall be monitored to check whether
oil temperature rise and heater works normally. Once oil temperature exceeds
50°C, the heater shall be stopped to avoid oil becoming bad.
4.4.6 Meanwhile, it shall be monitored that whether strainer differential pressure
is normal. For big flow flush, large differential pressure alarm may happen, which
is normal phenomenon. However, the differential pressure shall be stable. If the
differential pressure continuously rises, the stainer shall be changed to go on
operating.
4.4.7 Self-circulation system shall also take part in fluid reservoir purifying, and it
shall be monitored whether the filter differential pressure at circulating pump
 75D.002SM(B)-7 PAGE 16 OF 48

outlet is stable. The self-circulation loop shall be put into operation until the oil
quality is qualified.
4.4.8 If power plant has purchased standby oil purifier, it should also be put into
operation to shorten the time of oil circulation flush.
4.4.9 Differential pressure stability of filters shall be checked frequently during
system being flushed. System leakage and vibration of oil piping and piping clamp
shall be checked, which shall be adjusted when it’s necessary. It shall be checked
whether partial obstruction happens to the piping; if so, the spring and valve core
of check valve or dump valve of actuator shall be disassembled.
4.4.10 Flushing system until differential pressure of all filters is stable, and inlet
isolation valve of all HP accumulators shall be opened slowly. After system being
flushed for over one hour or few days, isolation valve of HP accumulator shall be
closed (attention: for preventing bladder rupture caused by being draped, before
being flushed the accumulator must be pre-charged with nitrogen, the pressure of
which is normally between 1.0～4.5Mpa).
4.4.11The compressed air in upper chamber of diaphragm valve shall be shut off,
and the air tube shall be separated from diaphragm valve. The tubing under
diaphragm valve shall be flushed for over 10 hours or few days.
4.4.12First samping could be executed after continuous flushing for 7 days with
stable differential pressure, and the cleanness of samping port and sample
container shall be regarded during sampling.
4.4.13 Generally, it takes 15-30 days to flush oil piping to be clean. If the
cleanness of piping is very bad, it may take longer time that shall not be less than
10 days.
4.4.14 Oil flushing shall go on before test result comes out.
4.4.15After the test result is qualified, two main oil pumps shall be stopped and
the reinstallation work could be started.
4.5 Oil sample test
4.5.1 Sampling method: during oil flushing with single pump operation, the
sampling shall be performed at sampling port. Before sampling, sampling port
shall be cleaned and the stop valve shall be opened to release around 500ml oil
(reusable), and then sampling bottle shall be put at sampling port to accept around
100ml oil and finally the stop valve shall be closed.
4.5.2 Sampling shall be executed before starting work in the morning, when the
impurity in the air is quite few.
4.5.3 Sampling bottle that could not be replaced by common bottle must be
specially supplied by oil sample testing department.
4.5.4 Qualification standard of oil sample test: the granularity and acid value of
0.1L oil taken from sampling bottle shall be tested. Two cleanness standards of oil
sample test: higher than grade 5 for NAS standard, higher than grade 2 for SAE
standard.
Granularity index: 5-10 micron grain/100ml 9700
10-25 micron grain/100ml 2680
25-50 micron grain/100ml 380
 75D.002SM(B)-7 PAGE 17 OF 48

50-100 micron grain/100ml 56

>100 micron grain/100ml 5
Acid value: not exceed 0.25mgKOH/g
Oil sample shall be submitted to the qualified department for testing and the test
report shall be submitted, in which the detailed granularity data and cleanness
grade shall be included.
Oil flushing could be finished only after the oil quality is qualified. After all filters
being changed and system being flushed for another hours, the reinstallation could
be started.
5. EH system commissioning procedure
5.1 EH system hydraulic elements check and reinstallation
5.1.1Check the conditions before reinstallation
a) The actuator shall be located at related valve and correctly connected.
b) EH system oil piping shall be flushed to be qualified and the cleanness of oil
quality shall be tested to be qualified (as per the test report).
5.1.2 system hydraulic elements check and reinstallation
a) Orifice, servo valve, solenoid valve, OPC solenoid valve, AST solenoid valve
shall be reinstalled. Ten bottles of alcohol with the concentration over 99%
must be prepared during reinstallation to flush the mentioned valves above, the
purpose of which is to avoid second pollution of the system. Acetone must not
be used to flush valves, because it may erode O-ring of fluorin rubber.
b) The pressure of accumulator shall be checked by using air charging tool and be
charged to make the nitrogen pressure inside accumulator reach 9.4-9.8MPa.
The pressure of supplied nitrogen container shall be over 12MPa and the
nitrogen purity shall be 99.9%.
5.1.3 Accumulator nitrogen charging steps:
5.1.3.1 HP accumulator nitrogen charging
1) Prepare 8 nitrogen containers with 12MPa pressure and charging tool.
2) Close oil inlet stop valve of accumulator and open return stop valve (this step
could be omitted if the system pressure is zero).
3) Remove the air inlet cover of accumulator and install charging tool.
4) Measure the accumulator pressure by using charging tool.
5) Connect air inlet connector to nitrogen container with regard of the reliability
of connecting points. If the screw thread of nitrogen container is worned out,
the nitrogen container shall be changed for another one.
6) The stop valve shall be slowly opened, which shall be closed immediately and
checked once air leakage noise is sounded.
7) When the pressure inside nitrogen container is identical with the pressure
inside accumulator that is lower than set value 9.8MPa, it shall be changed to
the nitrogen container with pressure over 12.0±0.2MPa to charge
acuumulator.
 75D.002SM(B)-7 PAGE 18 OF 48

8) The stop valve shall be closed when the pressure inside HP accumulator
reaches to 9.4-9.8 MPa. The pressure inside accumulator shall be maintained
stable for one minute and then measured, which shall be charged again until
the pressure is stabilized at set value if the pressure is lower than set value.
9) Check whether outlet stop valve of nitrogen container is shut tightly and open
discharge valve of charging tool.
10) The connectors shall be disassembled separately from nitrogen container and
accumulator, and the accumulator shall be covered with air inlet cover.
11) When the next accumulator is being charged, it shall be first charged by using
nitrogen container of lower pressure to save gas.
12) The nitrogen pressure inside accumulator shall be measured each week or
according to actual situation. The set value of 6 HP accumulators’ pressure
shall be 9.6±0.2MPa.
5.1.3.2 LP accumulator nitrogen charging
1) LP accumulators shall be charged using LP nitrogen containers, which have
been used to charge HP accumulators.
2) Oil inlet stop valve of the actuator that is needed to be nitrogen charged shall be
closed.
3) Other steps shall be the same with that of HP accumulator, and the nitrogen
charging pressure shall be 0.35-0.4 MPa.
4) The nitrogen pressure inside accumulator shall be measured each week or
according to actual situation.
5.2 EH system commissioning items and its requirement
5.2.1System proof pressure test
a) Preparation work before proof pressure test
It shall be checked whether system valves have already been located at the
positions described in following table:
No. Valve position Correct
position
1 1#，2# main oil pumps inlet Open
2 1#、2# main oil pumps outlet pressure gauge Open
3 1#、2# main oil pumps outlet Open
4 Circulating pump filling port Close
5 Circulating pump suction port Open
6 1#、2# cooling water inlet Open
7 Regenerating pump suction port Close
8 Vent valve on the top of regenerating device resin Close
filter, cellulose filter
9 Pressure gauge of regenerating device resin filter, Open
cellulose filter
10 Isolation valves of 1#, 2# HP accumulator at pump Close
outlet
 75D.002SM(B)-7 PAGE 19 OF 48

11 Discharge valves of 1# 、 2# HP accumulator at Open

pump outlet
12 Pressure gauges of 1#, 2# HP accumulator at Open
pump outlet
13 Isolation valves of HP accumulator at right and Close
left side
14 Discharge valves of HP accumulator at right and Open
left side
15 Pressure gauges of HP accumulator at right and Open
left side
16 HP fluid outlet of EH fluid reservoir Open
17 Stop valve of EH pressure fluid straight back EH Close
fluid reservoir
18 Isolation valves of pressure switch and pressure Close
transmitter on EH fluid reservoir HP header
19 EH fluid reservoir sampling port Close
20 Waste discharge port at the bottom of EH fluid Close
reservoir
21 Stop valve at inlet of each actuator Open
22 Pressure gauge on OPC header Open
23 Pressure gauge on AST header Open
24 ASP pressure gauge Open
25 OPC header pressure switch (two) Close
26 AST header pressure switch (three) Close
27 ASP pressure switch (two) Close
28 Stop valve at inlet of low EH oil pressure test block Open
29 Pressure gauge of low EH oil pressure test block Open
(two)
30 Manual test stop valve of low EH oil pressure test Open
block (two)
31 Stop valve at pressure switch inlet of low EH oil Close
pressure test block (four)
b) In case that turbine oil piping has not been ready for oil passing through,
turbine oil piping in upper part of diaphragm valve could be removed and then
blocked to avoid turbine oil leakage. The upper part of diaphragm valve shall
be filled with compressed air to make diaphragm valve be at closed position; if
LP turbine oil system is ready for oil passing through, the unit shall be reset
and establishes protection oil pressure to make diaphragm valve at close
position.
c) AST solenoid valve shall be excitated to shut off emergency trip loop.
d) The pressure adjustment handle of overflow valve at two main oil pumps
outlet shall be closed fully, and pressure compensator pressure adjustment
screw of two main oil pumps shall be adjusted to fully loose condition.
 75D.002SM(B)-7 PAGE 20 OF 48

5.2.3 Proof pressure test

1# pump shall be started and pressure compensator pressure adjustment screw
shall be slowly screwed tight to force pump outlet pressure rise little by little. It
shall be paid attention to that whether leakage at any subassembly connections,
crater etc.happens; if it happens, the pump shall be stopped immediately and
checked. The pressure will rise to 21MPa to maintain for 3 minutes, after which
proof pressure test is completed. During proof pressure test, it shall be monitored
whether oil leakage of the subassembly happens. If oil leakage or oil penetration
happens, the pump shall be stopped immediately and relevant settlement measures
shall be taken.
5.2.4 Overflow valve setting: the pressure compensator pressure adjustment screw
shall be screwed loose to adjust system pressure from 21Mpa to 16.8Mpa. During
overflow valve pressure adjustment handle at 1# MOP outlet being adjusted loose
slowly, the pressure gauge at pump outlet shall be monitored; if the pressure drops,
it shall be stopped to adjust overflow valve handle and the locknut shall be
screwed tight, which means the overflow valve has been set to 16.8Mpa.
5.2.5 Rated pressure setting: after setting overflow valve, pressure compensator
pressure adjustment screw shall continue to be screwed loose to reduce pressure to
14.0±0.5Mpa and the locknut shall be screwed tight, after which rated oil pressure
of 1# pump is set completely.
5.2.6 2# overflow valve and rated pressure setting: 2# pump shall be started and
pressure compensator pressure adjustment screw shall be screwed tight slowly to
make pump outlet pressure rise. Pressure adjustment handle of overflow valve
shall be adjusted to make pump outlet pressure rise to 17.0±0.2Mpa. The

overflow valve shall be set to 17.0±0.2Mpa according to 5.2.4 and 5.2.5, and

rated oil pressure shall be set to 14.0±0.5Mpa.

After rated oil pressure being set, inlet isolation valve of HP accumulators shall be
opened slowly to make accumulators be put into operation.
5.2.7 Prepare relationship curve between turbine oil pressure (automatically trip
header) and AST pressure:
Requirement:
1) When turbine oil pressure (automaticallt trip main) is higher than 0.35 Mpa,
AST pressure shall be 13.0±0.5Mpa (0.5 ～ 1.0Mpa lower than EH main oil
pressure).
2) When steam turbin trips, AST pressure shall be lower than 0.5Mpa.
5.2.8 Valve stroke measuring: positive/negative signals transmitted by servo valve
signal generator shall be sent to servo valve, which may make cylinder bring valve
stem moving up and down to the maximum positions to measure its actual
maximum stroke. The measure datas shall be submitted to the personnel, who join
 75D.002SM(B)-7 PAGE 21 OF 48

DEH control device commissioning.

5.2.9 Interlock test:

The function test shall be performed according to interlock requirements specified
by client.
Recommended interlock methods:
a) Standby pump for low oil pressure start:
The solenoid valve 20/MPT inside EH fluid power unit terminal box shall be
closed during normal operation, and standby pump shall be started when the valve
is opened. The solenoid valve shall be excitated in control room.
b) Oil temperature interlock:

When the control point of digital temperature controller at 20°C is adjusted to

current temperature, the MOP could not be started and then be recovered.
When the control point of digital temperature controller at 55°C is adjusted to
current temperature, which means the temperature is adjusted to maximum value.
The solenoid valve shall be opened to make cooling water flow out and cooling oil
pump shall be interlocked to start, which shall be then recovered.
When the control point of digital temperature controller at 40°C is adjusted to
current temperature, which means the temperature is adjusted to minimum value.
The solenoid valve shall be closed and cooling oil pump shall be stopped, which
shall be then recovered.
c) Oil level interlock:
Oil level interlock test has been completed during EH fluid reservoir filling, which
will not be repeated. In case that the test is not performed during oil filling, short
circuit could be used to simulate low oil level to make level switch act to complete
the test.
d) The commissioning shall be performed associated with DEH control device,
during which the oil pinping shall not vibrate. The heater shall work to
increase oil temperature when oil temperature of EH fluid reservoir is too low.
e) LVDT setting: LVDT mechanical zero of actuators shall be set associated with
DEH and DCS system.
f) Limit switch adjustment: the limit switch of actuators shall be adjusted until it
could transmit signal at relevant position.
g) All oil piping vibration shall be monitored when the unit first starts, and piping
 75D.002SM(B)-7 PAGE 22 OF 48

clamps and supports shall be installed when necessary to avoid oil piping
cracked for big vibration.
6. EH system operation and maintenance
6.1 EH system operation and maintenance
When oil circulation and commissioning of HP fire-resistant fluid system and
turbine oil system are completed, EH control and protection system could be put
into normal operation.
6.1.1 EH pump start condition
If EH fluid supply system operates in low temperature condition (not lower than
20°C), the heater shall be started.
6.1.2 Mutual standby test and operation
When the operator starts one EH pump (pump A) on pump start operation platform
in the control room, he may press mutual standby test switch to start pump B after
pump A operates normally and then press pump B stop button to stop pump B.
After completion of mutual standby test, the standby pump shall be stopped. Then,
EH system has already been in normal working condition.
6.1.3 Perambulatory inspection
The operator shall record the following parameters every one hour.
Parameter Allowable limit scope Record
EH EH system pressure
14.0±0.5Mpa
system
Working oil pump
14.0±0.5Mpa
Pump outlet pressure
14.0±0.5Mpa
Level of EH fluid reservoir 500-730mm
EH fluid temperature of EH
37-60°C
fluid reservoir
System oil leakage none
Filter differential pressure
<0.24Mpa
P3
Filter differential pressure
<0.24Mpa
P4
Turbine System pressure
0.7±0.02Mpa
oil
system Level of oil reservoir
oil reservoir temperature
45-55°C
Pump outlet pressure
System oil leakage none
Diaphragm valve upper
0.7±0.02Mpa
chamber pressure
 75D.002SM(B)-7 PAGE 23 OF 48

6.1.5 Reset
Two reset methods: manual and remote control
Remote control: the lights indicated DEH reset and RSV actuator open shall be
lighted by pushing the reset button in control room. If unit fails to be reset, it shall
be checked whether 0.7MPa protection oil pressure has been established in
diaphragm valve upper chamber and whether 20/ASR solenoid valve has been
energized by using iron wire or saw blade. If there is no excitation, the solenoid
valve has not been energized by DEH.
Local control: the reset handle shall be wheeled counterclockwise by hand and
then loosened slowly which make handle back to normal position. If 0.7MPa
protection oil pressure has been established in diaphragm valve upper chamber,
unit successfully resets.
6.1.6 EH alarm and monitor signal
6.1.6.1 Alarm
a) High EH fluid pressure
The signal comes from 63/HP pressure switch inside EH fluid power unit terminal
box ER, which shall be acted when fluid pressure exceeds 16.2MPa. The cause
shall be found out.
b) High EH fluid temperature
The signal comes from WP digital temperature controller. EH fluid temperature
will exceed 50°C once it alarms, and it shall be checked.
c) Low EH fluid temperature
The signal comes from WP digital temperature controller. EH fluid temperature
will be lower than 20°C once it alarms, and the heater shall be put into operation.
d) Low EH fluid level
The signal comes from level switch 71/FL on EH fluid reservoir. When fluid level
is lower than 230mm, EH system could not work. It shall be monitored whether
EH oil piping is cracked and oil sprays when the alarm happens.
e) Low EH fluid level alarm
The signal comes from level switch 71/FL on EH fluid reservoir. When EH fluid
reservoir level is lower than 450mm, the alarm signal will be sent out.
f) Low EH fluid level pre-alarm
The signal comes from level switch 71/FL on EH fluid reservoir. When EH fluid
reservoir level is lower than 370mm, the alarm signal will be sent out.
g) Low EH fluid pressure
The signal comes from 63/LP pressure switch. When it alarms, the possibility of
low EH fluid pressure trip shall be considered.
h) Low EH fluid pressure trip
The signal comes from 63-1,2,3,4/LP pressure switches on EH header. The steam
turbine will trip once it alarms.
i) Large differential pressure of 1# oil pump outlet filter
 75D.002SM(B)-7 PAGE 24 OF 48

The signal comes from differential pressure switch 63/MPF-1. It’s normal that it
alarms when fluid temperature is lower than 45°C, while pump A outlet filter shall

be changed if it alarms when fluid temperature is higher than 45°C.

j) Large differential pressure of 2# oil pump outlet filter
The signal comes from differential pressure switch 63/MPF-2. It’s normal that it
alarms when fluid temperature is lower than 45°C, while pump B outlet filter shall

be changed if it alarms when fluid temperature is higher than 45°C.

k) Steam turbine over speed
The signal comes from 63/OPC pressure switch. OPC solenoid valve of OPC/AST
solenoid valve unit has acted and 103% overspeed has happened to the unit once it
alarms.
l) Steam turbine trip
The signal comes from 63-1/AST, 63-2/AST, 63-3/AST pressure switches. The
diaphragm valve has already been opened or AST solenloid valve has been de-
enegized and unit has been tripped once it alarms.
m) 1# or 2# channel trip
The signal comes from 63-1/ASP or 63-2/ASP pressure switch. 1# or 2# channel
solenoid valve of AST solenoid valve assembly has acted and the unit has tripped
once it alarms.
6.1.6.2 Power plant use computer monitoring signal
Plant use computer monitoring signal includes 230mm low level interlock, 370mm
low level and 450mm low level of level switch 71/FL, system pressure transmitter
XD/EHP and fluid temperature thermocouple for EH fluid reservoir. In case that
the above signals make a high level alarm, EH cooler may be cracked and cooling
water may enter fluid reservoir.
6.1.6.3 Operation platform monitoring signal and operation switch
MSV & RSV actuator open/close signal lights and steam turbine reset signal light
shall be set on DEH indicating panel. EH oil pump mutual standby switch and test
switch, pump start/stop buttons and indicating lights, heater start/stop switches
shall be in control room. The actuators of MSV, RSV, GV and ICV could be
monitored through DEH or DCS operation screen.
6.2 System fault analysis
6.2.1 Actuator fault (except steam valve stem getting stuck)
6.2.1.1 Failure to open
The connector plug on servo valve shall be disassembled and two solenoids
resistance of the servo valve shall be respectively 80W through measurement by
multimeter. 1.5V battery shall be connected to the two ends of single solenoid
without wrong connection, and the positive/negative ends shall be exchanged to
check whether the actuator could be opened. If the actuator could not be opened
 75D.002SM(B)-7 PAGE 25 OF 48

and fluid flow sound inside fluid inlet tube could not be heard, servo valve fault
happens; if fluid flow sound inside fluid inlet tube could be heard, dump valve
fault happens. In case that steam valve could be opened, the cable between DEH
cabinet and actuator or valve location control panel fault happens.
6.2.1.2 Failure to close
The connector plug on servo valve shall be disassembled. If actuator could not be
closed, servo valve has been getting stuck that shall be changed; if actuator could
be closed, valve location control panel cable or LVDT fault happens and LVDT
output shall be checked with full travel. Once steam valve stem gets stuck, inlet
stop valve of the actuator shall be closed and dump valve shall be opened.
6.2.1.3 Actuator delay
The filter or servo valve on actuator shall be changed.

6.2.1.4 Servo valve fault

When actuator is not at bottom stop position, the input value of servo valve on
DEH valve location control panel shall be monitored. If the value is not normal,
the servo valve shall be changed or repaired.
6.3 Routine maintenance
6.3.1 Filter
EH oil pump outlet filter shall be changed every 3 months (accumulated operation
time), and actuator inlet filter shall be changed every year.
Resin filter of regenerating device shall be changed when the fluid temperature of
the device is higher than 45°C and differential pressure inside resin filter canister
exceeds 0.35MPa as well as differential pressure inside cellulose filter canister
exceeds 0.24MPa. If the acid value of fire-resistant fluid (over 0.25) does not
decrease after regenerating device being put into operation for 48 hours, resin
filter shall also be changed. Generally, resin filter shall be changed every year.
Return filter of EH fluid power unit shall be changed when pressure gauge type
signal transmitter alarms at 45°C fluid temperature or the index moves to red area
of the panel, and the filter shall be changed every one year.
6.3.2 HP/LP accumulator
There shall be six HP accumulators, among which four are beside GV on
operating floor and two are on EH fluid reservoir. There shall be eight LP
accumulators, which are arranged in MSV, RSV and GV actuators. In the first one
month, the nitrogen pressure shall be checked every week. After that, it shall be
checked every month.
6.3.3 EH oil cooler
Oil cooler shall be changed when its cooling function does not work.
6.3.4 EH oil pump inlet filter
EH oil pump inlet filter shall be changed every year.
6.3.5Fire-resistant fluid (see the chapter fire-resistant settlement and use)
6.3.6 Rubber parts (O ring, Diaphragm valve diaphragm)
 75D.002SM(B)-7 PAGE 26 OF 48

They shall be changed every four years or according to the real situation. No
matter O-ring is good or not, it shall be changed for a new one when the sealing
part is damaged.
6.3.7Overflow valve, check valve of EH fluid power unit
It shall be changed every four years or according to real situation.
6.3.8 Actuator
One GV actuator, one ICV actuator, one MSV actuator and one RSV actuator shall
be checked every two years and other valve actuators shall also be checked if
necessary.
6.3.9 EH fluid reservoir
The magnetic filter shall be cleaned every one year and the reservoir shall be
cleaned every four years.
6.3.10 Remarks
The above mentioned time interval is the maintainance interval when the system
and subassemblies operate normally; however, the maitainance interval shall be
modified to satisfy the condition when abnormal operation fault or abnormal
condition happens and the affected subassemblies shall be repaired or replaced if
necessary. We suggest that the customer shall store whole set of replacements to
satisfy maintainance without tripping.
7.Settlement, use and notes of fire-resistant fluid
It includes system first fluid filling and complementary filling, flushing and fluid
refilling after system maintainance and anti-deteropration of fire-resistant fluid
etc.
7.1 Fire-resistant fluid supplier
The fire-resistant fluid applied to EH control system must be fire-resistant pure
phosphate ester hydraulic fluid and satisfy typical characteristic parameters listed
in the attached table.
When purchasing fire-resistant fluid, the customer shall ask the supplier for the
fluid physics characteristics, fire-resistant characteristics, safety use measures,
compatible material, inspection and test method etc. specification and suggestion
and shall obey complete personnel health protection and prevention measures.
For keeping fire-resistant fluid quality invariable at any time to ensure the
performance of EH control system, we suggest that some key parameters of fire-
resistant fluid shall be regularily tested. If the test result exceeds the specified
limitation, the related remedy measures shall be immediately taken. The
inspection shall include (but not limited to the followings):

Test item Application limitation

Chlorine content Max. 150ppm
Water content Max. 0.10% (percentage indicated)
Neutralization index (acid value) Max. 0.25 (mg KOH/g)
Impurity content MOOG class 2 or NAS class 5
If one or some characteristics shall be tested with sufficient excuse, the sample
 75D.002SM(B)-7 PAGE 27 OF 48

could be sent to the supplier or competent research institute at any time.

We suggest that the fire-resistant fluid shall be tested according to the following
intervals.
Start Sampling interval
First month Once each week
First year Once each month
Second year Once each two months
Third year and after Once each four months
The following items shall be indicated on the sample:
a）Company
b）Hydraulic fluid trademark
c）Factory location and unit number
d）Operating time
The fire-resistant fluid shall be commonly stored in bucket at dry location to
prevent damp and pollution. The bucket shall be covered by canvas or similarity to
keep cleanness of its outer surface.
New liquid may not clean, so it must be pumped from the bucket to fluid reservoir
through special pump, filter and hose. When the pump and hose are out of use,
they shall be put into clean and protected storage box.
If EH fluid reservoir level drops too much caused by system accident leakage or
other reasons during usage, the reservoir shall be filled. The temporary fluid filling
shall be performed as follows:
a) A bucket full of fluid shall be chosen. Bucket top shall be cleaned and filling
hole cover shall be removed.
b) The hose shall be washed clean, one end of which shall be put into bucket
filling hole and the other end shall be connected with the filling port of self-
circulation cooling system of EH fluid power unit.
c) Self-circulation cooling pump shall be started and the fluid in bucket shall be
filled into reservoir. When fluid complement has been completed, the pump
shall be stopped and the hose shall be removed. In case that the ambient
temperature is lower than 10°C and pump is unable to pump fluid, the fluid in
bucket shall be heated or bucket shall be put at high location so that fluid
could be easily pumped.
d) The self-circulation cooling pump shall be restarted to perform fluid
circulation inside reservoir.
The EH fluid reservoir shall be checked during overhaul or fire-resistant fluid
replacement and shall be cleaned by opening the upper cover if necessary.
For use of regenerating device, the recommendation is that no matter how good
the system fluid quality is, the regenerating device shall be duly started (e.g.
actuator repair, component replacement and reservoir fluid filling etc.)
 75D.002SM(B)-7 PAGE 28 OF 48

APPENDIX CLEANNESS STANDARD OF HYDRAULIC FLUID

1) NAS1638

NUMBERING METHOD
Particle number in each 100 ml fluid
Particle
dia. 5-15 15-25 25-50 50-100
>100
(mm)
class
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2850 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2025 360 64
9 128000 22800 4050 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2880 512
12 1024000 182400 32400 5760 1024
13 2048000 364800 64800 11520 2050
14 4096000 729600 129600 23050 4100
15 8192000 1459200 259200 46100 8200
16 16384000 2918400 518400 92200 16400

2) Hydraulic fluid pollution standard applied by American Mobile Engineer

Association, American Material Test Association, American Aircraft Industry
Association
Impurity granularity in each 100ml fluid for system of different pollution grade
Impurity Pollution grade
particle 0 1 2 3 4 5 6 7-10
size(micron)
 75D.002SM(B)-7 PAGE 29 OF 48

2.5-5 To be determined
5-10 2700 4600 9700 24000 320 8700 12800
00 0 0 To be
10-25 670 1340 2680 5360 107 2140 42000 determined
00 0
25-50 93 210 380 780 151 3130 6500
0
50-100 16 28 56 110 225 430 1000
1 3 5 11 21 41 92
>100

General use condition for polluted fluid of various grades

Grade 0----hard to achieve
Grade 1---- MIL—H—5606B
Grade 2----missile system of high requirement
Grade 3 & 4----system of commonly high requirement
Grade 5---- missile system of low requirement
Grade 6----untreated hydraulic fluid
Grade 7----industrial use

REVISION PAGE
Mark Qty. Page Revised doc. Signature Date Remarks
number number
75D.002SM(B)-7 PAGE 30 OF 48