Specifications for HYZ Series

Oil Pressure Supply Units

Beijing IWHR Technology Co. Ltd

(Department of Automation China Institute of Water
resource and Hydropower Research)

ADD: A-1 fuxing road Beijing China Post code 100038

TEL 010-68781925 FAX 010-68576176
010-68781923 E_mail gover@iwhr.com
Web http://aec.iwhr.com
1 General
The function of the oil pressure supply units is to supply pressure to all kinds of
hydraulic equipment. Now it was widely utilized in the hydraulic turbine governor
equipment system, the turbine unit control system, the large-scale pumping station,
inlet valve, emptying valve and globe valve etc, it can also be used in the place which
use the oil pressure as the power resource.
The oil pressure supply units is composed of pressure tank and sump tank, the
units is compacted, and is with smaller footprints, and easy to install. its connecting
pipe is short.
The operational medium of the oil pressure supply units is compressed air and
the No.46 turbine oil.

2 Working principle
The oil pressure supply units and other equipments, which use the pressure oil
as the power resources, compose a close oil loop. The clean oil in the sump tank are
pressured and piped into the pressure tank by the oil suction pipe of the screw oil
pump. The screw oil pump is driven by the motor through the coupling. The oil was
piped into the check valve. With the increase of the oil, the pressure in the inner of
the retaining valve is increase too. Until the pressure exceed the pressure of the
check valve upper limit, the oil was piped into the pressure tank through the check
valve.
The oil pressure supply units are equipped with two screw pumps to guarantee
the operational reliability of units, one is in service, the other is in standby. There
should be switched, and can operate simultaneous in short period at special
occasion.
In general, the upper of pressure tank is filled with 2/3 compressed air, the lower
is filled with 1/3 turbine oil. The supplement and discharge of compressed air was
completed by the air check valve.
In order to indicate the oil level in the pressure tank, a level indicator is applied.
From the indicator plate, the indicator can monitor the oil level in the pressure tank
from the plate directly, and give an alarm when the oil level exceed to the
upper/lower limit.

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 According to the capacitance, some different pressure electrical contact pressure
meter or pressure indicators are installed on the pressure tank. They are used to
control the main pump and the standby pump start or stop, and to emit the tripping
pressure signal etc.
The check valve is used to drainage the oil in the pressure tank. In general, it is
used when we adjust the meters and parts of oil pressure supply units, or supply the
air manually.
The pressure oil was piped to the destination through the check valve, and the
returned oil are send to the sump tank, then through the filter into the clean oil
section, at last was inhaled to pressure tank by the screw oil pump. The oil is
circulated through the loop.

3 Specification of main structure

3.1 Pressure tank assemble

The pressure tank is consisted of a columned canister and two elliptic end
socket the three parts are welded together, its material is 16MnR. Because it
should undertake very high pressure, it has good welding quality, and has pass the
pressure test and inspection check
Depending on a flange, the pressure tank is stood on the sump tank vertically,
there is a ring on the top of it. The bracket of pressure indicator is on the side of the
tank. When checking, we can turn the hand wheel on the bracket to cut off the oil
loop which is convenient for removing the electrical contact pressure meter. Because
the littler capacitance of the electrical contact pressure meter, we use a relay to void
hurting the units.
An air check valve is at the side of the pressure tank. Through it, the high
compressed airs are pumped into the pressure tank. When the compressed airs are
overabundance, there can be evacuate by the valve. In general, tighten the valve to
void leaking,
The oil level indicator, which is at the side of pressure tank, is use to indicate the
proportional of the pressure oil and the compressed air.
Two oil inlet flange of oil pump, the extension main oil resources flange and the
extension assistant oil resources little flange are welded on the tankthey are in

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standby for the other needs of the customs. There is a flange which is used to
support the check valve for release oil
At the bottom of the pressure tank, there is a checking hole or enter hole for
exam an repair

3.2 Sump tank assemble

The quadrate sump tank is the place where the oil of the hydraulic system influx
after operating, it is also the clean oil resources of the oil system. It is made up of
welded armor plate.
Under the upper cover of the sump tank, we welded the channel steel or the
angle steel into a rigidity frame, and mounted directly and fixed to the floor of the
workshop.
There is a drain hole at the side of sump tank, and connect it with the drain pipe
of the user. In order to keep the oil clean, the returned oil must be filtrated by the filter
before enter the inhaled section of pump(it was called clean sectionthe other side
of filter was call neat section).
The oil level indicator was used as the indicator of the oil level. When the oil
level is higher or lower, the indicator will give the alarm single.
The check valve is at the bottom of the sump tank, was used for pipe the oil
from or to the sump tank. It can be connect with the total oil supply system.
The enter hole of the sump tank (dont be indicated in the system) is on the top
of filter. When opened, we can enter into the sump tank, and clean or check the
sump tank, also can take out or place the filter at here.
The bottom of the sump tank is gradient, it can drain out all the oil when we
clean the sump.

3.3 Screw oil pump

The screw oil pump of oil pressure supply units is vertical, this structure is
simpler then horizontal structure. It is plane installation area is small, and easy to
install and overhaul, The leaking oil is in the inner of the pump. The screw oil pump
has some merit, such as good efficiency, even flux, running steady, long life, start
instantaneous with high pressure etc.
This pump has three screws, one initiative screw meshed with the other two
driven screw, and operated simultaneity in the bush. The initiative was driven by the

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motor. With the rotating of the screw, the oil of inner was pipe into the meshing space,
the raised tooth of initiative screw meshed closely with the concave tooth of driven
screw. Insuring the definite working length of the initiative screw, the meshing space
form the sealed cavum, the liquid which enter the sealed cavum can not rotate as the
liquid screw, and moved along the screw equabley, at last are evacuate from the
vent orifical.
Except the moment of the startup, the driven screw always driven by the
pressure oil, so the driven screw do not endured the main torque. it worked as the
pressurized set which prevent the oil circumfluence, for this reason, the contact
stress between the screws is smaller then the contact stress between the gear of
gear pump. At the same time, because the support area of the screw structure is very
big, the friction is very small.
This structure feature ensure the pump with longer life.

3.4 Oil level indicator

The function of the oil level indicator is to express the oil storage quantity of
sump tank as the level of oil. When the oil is at lower point, the lower switch point
was closed and a single was emitted, give the information to refill oil. When the oil is
enough, the upper switch point was closed, and a signal of cut off the oil loop was
emitted.
The oil indicator is composed of indicator, reed relay, magnetism loop, float pole
and float ball etc. the float ball fluctuated with the oil level,
There is a scale on the indicator, it is convenient for observation and watch.

3.5 Oil pump combined valve

The valve is composed of unload valve and safety valve, it include the function
of unloading valve, relief valve and no-return valveUnder the control of the pilot
valve YV1 YV2 YV3the main valve CV1 accomplished the action of unlock and
close. CV2 is the inverted valve. Because the combined valve adopt the precursor
control, when the valve is operating, there are no noise, no shake, and run smoothly.
The combined valve has three orificepressure oil inlet P, export orifice P1 and
the exhaust orificethe inlet P is connected with the outlet of pump, the export orifice
is connected with the inlet of pressure tank, the exhaust orific T is connected with oil
tank.

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 In the hydraulic system figure, the two main component(one main valve and one
check valve) and three pilot valve was figure as following symbol:
CV1- main valve
CV2- check valve
YV1- unloading pilot valve
YV2- relief pilot valve
YV3- unloading pilot valve
(1) Unloading valve
Because of the big motor inertia of the high power screw pump, it need some
time from startup to stable state. It is a great disadvantage for screw pump and
hydraulic pressure, if the loading was loaded before the screw pump arrived the rated
flux. Using the unloading valve, the screw pump was in the unloading state when it
was started, until the motor arrived the rotated speed, the screw pump output the
rated operated pressure and flux.
The unloading valve is composed of unloading pilot valve and main valve.
When oil pump is startup, because of the action of P, the check valve is at the
closed state. At the action of spring, the leakage valve is at the opening state. There
are no pressure oil in the control cavity of the main valve, the pressure oil was piped
to the sump tank through the main orificeWith the increase of the rotate speed of
the motor, the pressure of P is increase, the control oil are piped to the upper cavity
of leakage valveovercome the force of spring and move the piston, close the
leakage valveAt the moments, pressure oil enter into the control cavity and close
the cavity. For this reason, the pressure of P reach the rating value, the check valve
is opened and piped the oil to the pressure tank. After the pump was stopped, the
leakage valve go back to the initial state. The operational pressure of leakage valve
can be adjusted by the preset force of spring
Note there is no that valve when the motor power is very low.
(2) Relief valve
The relief vale is the discharge setting for the safety of the pressure tank. It
prevent the screw pump and the pressure tank to over loading.
The relief valve is composed of relief pilot valve and main valve.
When there are some failure, the screw pump is still running, the oil pressure is
higher. When the force is acted on the pilot valve, the push force is bigger then the
adjusting force of spring, YV2 acted, the oil, which was controlled by CV1, is

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drainaged. Under the action of pressure of P, the main valve was opened ,the check
valve was closed, the oil pump is running under the self-circulation state, the
pressure tank and screw are both operated under the rating pressure.
(3)Unloading valve
The unloading valve (by-pass valve) is composed of unloading pilot valve and
main valveIt is used for the continuously running of the screw pump.
when the screw pump running continuously, the pressure of the pressure tank is
variety with the flux, when input flux is bigger then output flux, the pressure is
increase. When the pressure arrived at the upper limit, the control cavity pressure of
unloading pilot valve overcome the spring force, and cut off the control oil resource
from the oil pump, because the CV1 control the antrum to release the oil, the piston
was pushed through, the pressure oil in the main oil path was released, and the
screw pump worked in the self-cycle state. With the deplete of the system, the
pressure in the pressure tank is reduce, when the pressure arrived at the lower limit,
the unloading pilot valve was closed by the spring. The control antrum was closed
with the main valve, the screw pump restart to supply the oil to pressure tank. The
action pressure of the relief valve and the unloading can be adjusted through the
spring force of YV2 YV3(the pressure deviation of unloading decided by the
construction of the combination valve)
(4) Check valve
There is check valve at the front of the system. Under the action of the pressure
P, the check valve is at closed state. After the oil pump is start up, the discharge
valve is running, until the main valve is closed, the pressure of P is increasing. When
the pressure is overcome the pressure of check valve, the check valve is open and
the oil are piped to pressure tank.

4 Installation and maintenance

4.1 Installation and adjust of oil pressure supply units

Before installed, all component of the oil pressure supply units should be
cleaned carefully, then all the pipe should be cleaned by compressed air, at last
assemble the all components according to the assemble figure.
All the connection must compactness
(1) Attention

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 a. After the screw oil pump was connected with the motor by coupling
manual rotating it softly, it require that the screw oil pump running neatly, and no
block instance appeared.
b. The screw oil pump was close connected with inlet pipe, assure the seal,
dont allow any cavity
c. Before the first installation or the first operation after the screw oil pump
was checked, the oil should be filled into the pump through the flange at the back of
pump.
(2) The first time startup after installation
a. all the valve from the screw pump to pressure tank should be opened.
b. Start up the screw pump by press, check the rotate direction of the motor,
the rotate direction should be consistent with the arrowhead direction on the screw oil
pump, then start up the screw oil pump, piped the oil to the pressure tank until the oil
level arrived at the normal value. In this period, check that whether the oil pump
operated smoothly, no quiver and unwonted noise, at last open the automation refill
setting, fill the pressure tank with compressed air manually or automatically(if there is
no automatically refill setting, we can use the air inverted valve to refill the
compressed air manually). When the pressure arrived at 0.5Mpa. check the seal of
the oil pipe and all components at the joint. Ensure no leaking air and oil.
c. Piped the air to pressure tank until the pressure arrived at 2 Mpa, lasting 30
minutes, the oil level should be in the normal level, check the seal at the joint, ensure
no leaking.
Note: the compressed air to pressure tank must be dry air that be
separated from water and air.
(3) Setting the electric-point pressure meter
for example the rating pressure is 6.3Mpa.
a. When the lower limit switch point pressure value arrive at 5.8Mpa, the
working oil pump was operated automatically; when the upper limit switch point
pressure value arrive at 6.3Mpa, the working oil pump stop running.
b. When the lower limit switch point pressure value arrive at 5.6Mpa, the
standby oil pump was operated automatically; when the upper limit switch point
pressure value arrive at 6.3Mpa, the standby oil pump stop running.
c. The tripping pressure value is decided by the engineer. (the engineer can
calculate the value according to the power station design.)

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 (4) Setting the pressure relay (for YL PCB )
When the oil pressure is high (for example the rating pressure is 16Mpa)
a. setting the pressure point of stop pump: adjust the oil pressure to stop
pressure( watching the pressure meter), adjust the adjusting nut beside the indicator
light of stop pump, until the indicator light is light form dead, and check whether the
corresponding out put point is closed.
b. the adjusting way of other three point is same as the pressure point of stop
pump.

4.2 Adjust and check of the combined valve

(1) Adjust the adjusting bolt of the relief pilot valve
When the oil pressure of main is higher then the upper limit 2%, start to
drainage the oil. When the oil pressure is higher then the upper limit 16%, in order to
drainage the oil fully, open the valve fully.( the valve can be open fully when the oil
pressure is higher then the upper limit 10%), the oil pressure of the pressure tank
dont increase. Before the oil pressure decrease to the lower limit, the valve should
be closed. clockwise rotating the bolt slowly until the pressure arrive the setting value,
repeat some times until the setting pressure dont variety, then lock the bolt with nut.
(2) Adjust the discharge pilot valve
Rotating the bolt of the discharge pilot valve of, when the oil pressure of main is
higher then the upper limit 2%, start to drainage the oil, then drainage the oil entirely
and keep the oil pressure of pressure tank steady. When the oil pressure decrease to
the lower limit, close all the valve entirely.
The adjusting way is the same as the relief pilot valve
(3) Checking the discharge pilot valve
When the oil pump motor is running from zero to rating speed, the time is 2 to 6
second. When the time is too long, we must check the part carefully, insuring the
piston is working neatly, and is blocked , or increase the damp of the throttle orifice;
when the time is too short, we must decrease the throttle orifice, delaying the time of
the YV1.
(4) Checking the check valve
After the oil pump stop running, checking it carefully, insure the check valve is
closed quickly and strictly against the counter flowing of the oil to pressure tank. If the valve

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dont work neatly, we must check whether the valve plug is blocked, and whether the
control orifice is jammed, after eliminating the abnormity, restart the test.

Note: Before dismantling the pilot valve and valve cover, we must cut off the

check valve of the combined valve which is on the line to the pressure tank, the

control oil of the pilot valve is come from the back of the one way valve. Cutting off

the stop valve can void the pressure oil ejected from the control orifice.

5 Installation in site
Installation of the equipment is a very important working procedure in the
process of equipment operation, because it connects with the security, reliability and
normal capability of the equipment. So before the installation, the whole technique
files must be acquainted. Based on spot situations, the installation can be carried on.

5.1 Preparations before the installation

Standard tighteners
Rubber airproof fittings
Oil route flange
Seamless steel piping
Cable and shielding wire
Installation tools

5.2 Installation of the equipment

(1) Open box and check
at first, check the packing box to see whether serious outside damage exists
after the transportation. When there is no serious damage, the packing box can be
opened carefully
check the variety and quantity in the packing box with packing bill
check the appearance of the equipment: whether all the fittings is complete and
tighteners is loose.
(2) Installation of the equipment
suspend the equipment to installation position, and check the center, level and
altitude of the equipment completely again, then construct the base and floor bolt.

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 according to outside oil pole, connect each piping respectively;
Demand:
Flange is seamed by O shape ring of fluorinated rubber material to reduce
the contamination of the working medium by any possibility and strengthen the effect
of seaming. Furthermore, in the seaming of flange, the O shape ring must be put
down to prevent it from high temperature cauterization damage during the seaming.
Steel piping
a. Steel piping must have adequate strength, and inside wall is lubricity without
sand and fault of rust erosion and ferric oxide husk, etc. If one of the following
situations is detected, it can not be used:
The outside and inside wall have been eroded or change color notably;
Cut crack exist;
Surface is concave;
Absciss layer or scar is on the surface.
b. During the process of piping bending, the following fault is not permitted:
there is wring damage and press damage in the inside of the bending part;
corrugation in the inside of the bending is scraggy.
c. To quakeproof, long piping must be fix supports; on the turn location of the
right angle corner, a fixed support must be install on each end. The piping must be
installed on fixed position, and underlay block such as wood block, ebonite installed
on the support to prevent base from contacting the piping.
d. The whole piping length is short and has few turn corner by any possibility
and be assured the telescopic distortion of the piping. Each section of the piping can
be disassembled freely without affecting other groupware.
e. The whole piping must be install twice. After the first installation, the piping
may be disassembled, cleaned up completely and installed again. If the conditions
are permitted, washing with acid may be better.

6 Operation
(1) After installation of the pressure oil supply unit, the piping must be checked
whether it is right, and can be supply the oil and air;
(2) According to blueprint, the whole connection controlling the loop must be
checked whether it is right;
(3) After all the check, turn on the power supply and pressure oil source. When
the testing based on national standard GB/T9652.1 Technical qualifications of

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governors and pressure oil supply units for hydro-turbines and GB/T9652.2
Testing check and accept guide of governors and pressure oil supply units for hydro-
turbines is eligible, the equipment can be launched into operation formally.

7 Examination and repair

According to the demand of the national standard GB/T9652.1 Technical
qualifications of governors and pressure oil supply units for hydro-turbines,
examination and repair can be carried on.

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