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Beijing IWHR Technology Co., Ltd
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
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Catalogue
1 General
2 System Configuration
4 Working Principle
5 Operation
6 Installation of Equipment
8 Maintaining Suggestion
Notice: We will reserve the rigths of revising this document. The information in this
document is subject to change without notice and should not be construed as a
commitment by BITC. BITC assumes no responsibility for any errors that may appear
in this document. Please based on the actual product as the criterion, if there has any
discrepancies between the actual product and this document. Welcome to contact us
at any time.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
1 General
PLC +
This manual will describe the princilpe and operating about the CVT/ZT
XXdigital hydraulic turbine governor. The CVT/ZTXX governor is a new type
governor based on the modern hydraulic digital logic cartridge technology. Its model
number are defined as follows,
CVT/ZT-XX-XX
regulating governo
--
-/ +
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The Principle and User Manual for Digital Hydraulic Turbine Governor
This type governor is based on logic cartridge technology, that is combined with
high speed on-off valve and cartridge valve,via multi-level manifold block combination
and optimal design from components to subassembly to fluid loop, then proceed to
realize all the regulating and control functions of governor. It has successfully
breached the constraint of classic structure with electrical-mechanical/hydraulic
conveter or micro-motor plus main distributing valve, and it has also broken through
the constraint of manufacturing process and structural arrangement. It is without the
necessity for middle position and mechanical feedback to ensure the regulating and
control of system. That enable the design and manufacture of governor to be a
fundamental change. It make a compromise the motion reliability of mechanical
hydraulic section, applicability of micro-computer,and simplification of valve. It has
unique advantages of high reliability, quick response, smooth motion, and high
precision of positioning, high motion efficiency, save oil consumption,etc. It is unique
and place a position in the field of governor.
2 System Configulation
CVT/ZTXX
Its core part includes PLC, input/output signal disposing module, the
amplifier/driver circuit; it provides high reliabilitya friendly man-machine surface, and
direct measuring and debugging and maintaining method.
CPU
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The Principle and User Manual for Digital Hydraulic Turbine Governor
The PLC is composed of CPU unit, digital input/output (I/O) modules, analog
input modules, high speed counter modules, remote communication modules and
power supply modules.
/ DC24V
Adopting large scale digital display tube, light diode (light brand), dial ammeter,
switch and touch screen as the interface with the operator, it has the advantages of
clarity, visual display and easy to operate;
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Electric accessories element (switch power supply, relay, control switch, signal
light) are imported high quality implement, and have high reliability;
PID PI
Adaptable and parameter variable PID regulating rules were adopted for the
frequency regulating mode, and PI regulating rules were adopted for the opening and
active power regulating mode;
RS-422/RS485/RS232
The communication interface (RS-422 / RS485 / RS232) with LCU has been
provided.
The shut-up opening and the maximal active power limit of the turbine unit can
be changed according to different water head. As water head increased, the governor
can automatically decrease the shut-up opening and the maximal active power limit,
so as to ensure the hydraulic turbine generator switched on line quickly and
effectively and run with safety.
Accelerating characteristic of hydraulic turbine unit startup process can be set
through the touch screen(HMI).
CVT/ZT /
The list of main hardware/components of microcomputer regulator in CVZT
governor
Serial number designation
PLC
1.
High reliable PLC controller
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The Principle and User Manual for Digital Hydraulic Turbine Governor
2.
Flat touch screen HMI
3.
Peripheral circuit board or signal transform module
4.
Unit frequency transmitter
5.
Net frequency transmitter
6.
Displacement transducer
7.
Amplifier/driver module
8.
Dual AC/ DC power supply
9.
Accessories such as relay and plug and socket
10.
Electric control cabinet skid
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The Principle and User Manual for Digital Hydraulic Turbine Governor
The adjusting screw for open/close time and quick shutdown or emergency
shutdown time of servomotor
The oil filter with replaceable filter core and signal sending instrument for oil filter
clogged
Manual air releasing valve
The by-pass relief valve acting when the oil filter is clogged, invalid or being
cutting off
The startup/shutdown pulse control valve
The quick shutdown or emergency shutdown valve sets
()
Flow control valve (linear transformer between flux and pressure difference).
ISO
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The Principle and User Manual for Digital Hydraulic Turbine Governor
D/A
The hydraulic part of the governor has both the functions of D/A converter and
power amplification, thus the direct digital control can be realized.
The logical cartridge valve techniques: the main distributing valve is replaced by
the combined logical cartridge control valves. The logic cartridge control valve is
driven by hydraulic power which is more than hundreds of kilograms, therefore the
action reliability is greatly improved. And those disadvantages of traditional main
distributing valve are also avoided, such as the low standardization degree, the
difficult consistency of capability and bad interchangeability. Besides, the logical
cartridge control valve units contain abrasion resistance material of high rigidity, it can
be hardly disabled after long-term working.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
,
Even if the electrical part got to be absolutely failed, the main servomotor could
be kept the gate opening stable, and the system is automatically switched to run
manually, thus the fault extending and kickback of the fault could be avoided.
//
The mechanical-hydraulic part of the governor can realize not only all functions
of traditional mechanical-hydraulic equipment, but also fault tolerance running and
smooth switching between auto/manual/electrical- manual running.
The system structure is concise, the friction of internal liquid flow is small. From
the element to the system, the sealing is tight and with little leakage. The efficiency of
the system is extremely increased and the service life of oil pump and electromotor
are prolonged.
3 The main technique parameters
PID
Regulating rules: Adaptable and variable parameter PID
+
Frequency/speed measuring method: PT voltage frequency measuring or PT
voltage + toothed disc speed measuring;
The hydraulic turbine unit frequency/speed signal:
One way signal comes from PT voltage of generator;
0.6~100V
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The Principle and User Manual for Digital Hydraulic Turbine Governor
The other way signal comes from toothed disk proximity probe;
0~24V
The normal range of signal voltage: 0~24Vsquare wave
0~100Hz
The normal range of frequency measurement: 0~100Hz
0.002Hz
The resolution of frequency measurement: 0.002Hz
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The Principle and User Manual for Digital Hydraulic Turbine Governor
K d = 0 : 5( s )
gain ;
fG
=(4555)Hz
f
Frequency setting range G =(4555)Hz
P
G =(0120)%
P
Active power setting range G =0120%
H[] H (
0~10V 0~20mA)
Water head: Manually setting with [water head setting] button; or automatically
measuring the parameter H (Electrical level standard: 0~10V or 0~20mA).
Feedback signal of guide vane servomotor displacement:
+15V
Power supply voltage provided by microcomputer regulator: +15V
0~100%+0.35~+9.6V
Feedback voltage of guide vane servomotor displacement: the guide vane
opening range 0~100%, corresponding to the voltage+0.35~9.6V;
Contact between microcomputer regulator and secondary circuit
The isolated supplementary contact of the generator circuit breaker
Isolated supplementary contact of the line breaker at high voltage side
Isolated contact of the start-up relay
Isolated contact of the shut-down relay
/
Isolated contact of the increasing opening/speed/active power
/
Isolated contact of the decreasing opening/speed/active powe
Power supply
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The Principle and User Manual for Digital Hydraulic Turbine Governor
~220V10%50HZ1000VA
AC: ~220V10%50HZ1000VA
220V10%1000W
DC: 220V10%1000W
E
() f =(00.5)Hz
E
Frequency(speed) artificial dead band f =(00.5)Hz, adjustable.
/E(Y-P)=(05)%
Power/opening artificial dead bandE(Y-P)=(05)%, adjustable
Regulating mode
()EF=0,E(Y-P)=0,PID
Frequency/speed regulatingEF=0, E(Y-P)=0, PID regulating
/ EF=(00.5)Hz, E(Y-P)=(05)%, PI
Power/opening regulatingEF=(00.5)Hz,E(Y-P)=(05)%, PI regulating.
1.6MPa31.5MPa
Rated operating pressureadaptable to 1.6MPa31.5MPa
(37500)L/min(P0.2MPa)
Maximum designed flow of the main controlled valve sets 3
7500L/min(P0.2MPa), adjustable
/(170)s
The full stroke start-up/shut-down time of the main servomotor 1 70s,
adjustable
24V10%
Rated working voltage of high frequency on-off valveDC: 24V10%
35W()
Maximum power of high frequency on-off valve: 35W (single)
15
Action durability of high frequency on-off valvemore than 1.5109 times
200Hz
Working frequency of high frequency on-off valvemore than 200Hz
-40135
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The Principle and User Manual for Digital Hydraulic Turbine Governor
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The Principle and User Manual for Digital Hydraulic Turbine Governor
tM
setpoint remains below 1; is the time , from the beginning of load rejection to
the speed up to the maximum value. For the unit supplying power to the station
service network after seperating from the grid, the lowest relative speed after load
rejection wont be below 0.9.
Working Principle
4.
1.
CVT D/A
See also Fig.1, the regulating rules synthesizing and control variable calculating
is realized by electrical regulator, the CVT/ZT hydraulic servo system is just as power
amplifier, followed the electrical controlled variable, and realizing D/A conversion,
then drive guide vane servomotor and turbine operating ring.
4.1 The working principle of microcomputer regulator
CVT/ZT LCU /
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The Principle and User Manual for Digital Hydraulic Turbine Governor
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The Principle and User Manual for Digital Hydraulic Turbine Governor
1.1 CVT/ZT
Figure1.1 The CVT/ZT structure principle diagram---Micro computer regulator&
Hydraulic servo system
4.1.1 Software Components
1 ()
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The Principle and User Manual for Digital Hydraulic Turbine Governor
()
Hydraulic turbine generator unit is usually operating under complicated
conditions, the translation of operation conditions is realized by the turbine governor,
the figure below is the main operation condition of hydraulic turbine generator unit,
some of states, stop standby, no load, load, condensor, are steady cycle states(long
time keep-working states), others are transient states.
1
Stop standby
.
In this congition, the hydro turbine unit has been shut down and standing by, the
hydro turbine unit speed is zero, wicket gate is closed completely and compressed
tightly.
2
Automatic close-loop start-up
Choosing a proper start-up strategy of hydraulic turbine unitthe items below can
achieve to the best effect
a.The time length of unit reaching rated speed
shorter
b.Small Axial thrust
c.. Small fluctuations of hydraulic turbine torque
and axial thrust
d.Pressure changing of penstocks is small
CVT/ZT
PID PLC
During the start-up period of unit, the frequency signal of CVT/ZT governor can
be accessible; the governor is under close-loop control mode. According to the
difference between the setting frequency and current unit frequency, wicket gate
control value can be calculated by PID operations, then, by PLC high-speed output
and power amplifier module acting on the electro-hydraulic servo system, the wicket
gate displacement changes with the control variables changing, which leading the
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The Principle and User Manual for Digital Hydraulic Turbine Governor
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The Principle and User Manual for Digital Hydraulic Turbine Governor
3
No-load frequency tracking
50Hz
When the grid-frequency tracking mode exited, the default value of setting
frequency is 50Hz, the setting frequency value can be modified by using touch
screen(HMI), to make the unit frequency tracking setting frequency. When
grid-frequency tracking mode starting, the current grid frequency is taken as setting
frequency , the regulation object is tracking grid frequency, the unit frequency always
changes with the grid frequency, to make synchronization rapidly .
4
Load cycle
50Ef
After the hydro turbine unit connected to the grid, frequency of grid is within the
scale of 50Ef (Ef is artificial speed dead band setting for the governor), if the
governor don't accord with the power regulation condition, it will judge that the unit is
in large interconnected grid , the governor will translate the operation condition to
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The Principle and User Manual for Digital Hydraulic Turbine Governor
opening regulating mode. Actually, opening regulation mode is, when the grid
frequency fluctuates within the scale of 50Ef, the opening of servo motor do not
change with the changing of frequency, but keep a specific opening value.
50Ef
b
p
Under the opening regulating mode, if frequency of grid exceeds the scale of
50Ef, the governor will participate primary frequency regulating by itself, according
b
to the frequency variation and direction , and permanent speed droop p , change
the wicket gate opening of unit.
6
Active power regulating mode
AGC AGC
PI
This operating mode is applicable to the power station that has realized AGC
(Automatic Generation Control). After the hydraulic turbine unit of the power station
realized AGC is connected to the grid, the governor will receive the setting active
power as object value via computer network communication with LCU, and collect the
feedback value of active power automatically. Meanwhile the governor will compare
the active power setting value given by LCU with the feedback value of active power,
according to the compared result, regulate with PI rule, control the wicket gate
opening automatically, then ensure the active power of unit to the setting power
value.
50Ef
e
p
We call this regulating mode as power regulation mode which making active
power as closed-loop regulating. Under this regulating mode, if frequency of grid
exceed the scale of 50HzEf, the governor will participate primary frequency
regulating by itself, according to the variation value and direction of frequency , and
e
permanent droop p , change the active power of unit.
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7
Frequency regulation mode
50HzEf
b e
, p p /
50HZ(50Hz
0.033Hz) AGC AGC
It should be noted that the conception is strictly different between the frequency
regulation mode under generating condition and primary frequency regulating.
Primary frequency regulating applies in the opening regulating mode or power
regulating mode, for the frequency differential deviating from the rated frequency of
system (50HzEf), according to the static characteristic of permanent speed droop,
control the units opening/ power. Its characteristic is that the frequency regulating is
quick, but the regulating quantity differs from different units, and the regulating
quantity is limited , so the primary frequency control completed by the different unit
governor system cannot make up for the differential power value of grid, and the
regulating quantity is not enough for recovering the grid frequency to a allowable
range (50Hz0.033Hz) nearby the rated frequency (50 Hz). Moreover, its control
purpose is not in accordance with AGC, for example, AGC requires the unit operating
keeping a specific constant power value, but the primary frequency control need
change the power with the changing of frequency differential.
50Hz0.5Hz
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The Principle and User Manual for Digital Hydraulic Turbine Governor
mode. So, the frequency regulation mode of generator connected to the grid is
equivalent to the isolated grid operating mode.
8
Condensor operating mode
After the unit switched on line, the condensor command sent out from LCU, the
wicket gate servo motor will be closed by governor, the unit is operated by which
translate from generator to electric motor, absorbing the active power from grid line,
the unit is under condensor operation condition. If the command of condensor
released, the opening of wicket gate will be increased to the position of no-load. The
condensor operation mode on the unit of Tishrin hydro power plant is cancelled, so
as to avoid the unit lifting.
9
Shut-down mode
The shut-down command has the highest priority. Under any operation condition,
if the shut-down command received, the governor will close wicket gate quickly, and
the unit speed decreasing to zero. For reliability, when shut-down process completed,
the governor will translate to stand-by mode, the unit is under standby condition.
4.1.3 Hardware components
PLC PLC Microcomputer Platform
1 CPU
The PLC microcomputer platform mainly is composed of CPU module and
software storage unit.
2 Components of peripheral sub-system
CVT/ZT
Peripheral components of CVZT mainly include:
(DI)
Digital Input module (DI);
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The Principle and User Manual for Digital Hydraulic Turbine Governor
(DO)
Digital Output module (DO);
Hi-speed counter module, used for measuring frequency/speed in regulator
system;
(A/D)
Analog Input Module (A/D);
RS232RS422
RS485 CAN PROFIBUS
Communication Module (according to different communication objects,
communication modules use different ports: Serial port RS-232, RS-422 or RS-485,
CAN port, Ethernet communication processor, PROFIBUS communication processor,
etc.
/
Driver/Amplifier Module;
Power Supply Module;
Frequency signal reforming module;
Analog signal reforming module;
(HMI)
Human-Machine Interface (HMI), Here is touch screen;
Switch, button, meter circuit;
Relay circuit;
4.1.4 HMI Human-Machine Interface
HMI
About this part content, please refer to
Human-Machine Interface specifications.
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/
0.5ms3ms
D/A
()
()
()
High speed on-off valve (also called digital valve) is the key component that
convert from electric signal to hydraulic signal, its function is receiving the pulse serial
control signal that electrical regulator output, and cause direct-acting valve core
moving, then the control pressure will be changed, this pressure signal then regulate
the main control valve liquid flow to operate the servomotor.
High speed on-off valve in CVT/CVZT/YCVT/CJCVT series of governors, makes
the function of converting the electric pulse signal to hydro-pressure/flow signal, just
as electric hydraulic converter, compared to the competitors, traditional electric
hydraulic converting devices/components (electric hydraulic converter, servo valve,
proportional valve, step motor-pilot valve, servo motor-pilot valve), its a new valve
type and a upgrade product. Nowadays, high speed on-off valve has been widely
applied to automobile, fuel injection, engineering machinery, aerospace control,
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The Principle and User Manual for Digital Hydraulic Turbine Governor
metallurgy, medical devices, machine tool, robot fields. Its also of concern and has
some applications in the fields of hydraulic turbine governor. It is considered to have
the place of applications. It is classified pulse fluid control item, has only on-off status,
the response time is about 0.5ms~3ms. Its one of ideal project on the
computer-controlled hydraulic system, as the bridge between the computer and the
hydraulic system, it can access the interface of computer without D/A conversion,
then digitize the fluid control (obviously , high speed on-off valve used as digital
valve ). It has simple structure, high resistant oil contamination capability, good
repeatability, working stable and reliable, and energy-saving advantage. It should be
pointed out that, some people at our country think general electromagnetic valve as
high speed on-off valve (digital valve), its a misunderstanding. The performance of
general electromagnetic ball valve is far different from the high speed on-off valve.
Though it has some switch/digital features, but the response time constant is too
large, often between tens of milliseconds to hundreds of milliseconds, so it cannot
control the pressure/flow continuously and steady. If the general electromagnetic ball
valve used as digital valve, the regulating performance will be restricted greatly.
Additionally, the performance of materials and corrosion resistance is a problem. It
should be noticed that the conception of control of flow or pressure continuously
(that is the output flow or pressure is changing steady) is very important, it is the
most important characteristics that the high speed on-off valve distinguished from
general electromagnetic reverse valve, generally the output of common
electromagnetic valve is actually realizing the discontinuous control.
The high speed on-off valve with quality guaranteed should have the following
index:
11
Operation lifeMore than 1100 billion times
200Hz
Working frequency: More than 200Hz
0.5ms5ms
On-off regulating time: 0.5ms5ms
0.05ms
Repeatability precision 0.05ms
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The Principle and User Manual for Digital Hydraulic Turbine Governor
HSV
()
HSV
T
T
K
P
3
Figure3. High speed on-off valve unit schematic diagram
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Working principle
(
)
High speed on-off valve controls the oil circuit on-off by the axial movement of
the valve core in the valve body, which controlled by the electromagnet push pole. It
is a sectional ring groove cylinder, the spool has several working cones or steel-balls,
and the valve bush has several grooves, each groove connects outside through the
corresponding hole and channel.
2 HSV
3 P K T
K
High speed on-off pulse valve has only two working position, when
electromagnet HSV is power off, valve core moves upward by the force of bottom
spring, the valve position state see figure 3, at this time, the pressure oil P links to
the control port K, the link of return oil T and the control ports K is broken.
HSV 4
P K T K
When electromagnet HSV is electrified, valve core moves down by the force of
electromagnet push pole, the valve position state see figure 4, the pressure oil P
doest not link to the control port K, return oil T links to the control ports K.
CVZT
()
By pulse modulating to the on-off signals of high speed on-off valve, that is ,
controlling the pulse frequency and pulse width, we can realize the continuous
control of flow or pressure. As the output flow is small, in the CVZT series of
governors, it makes as pilot hydraulic pressure signal, and then drives the main
control valve (large scale cartridge valve). As far as its function, it makes electric
hydraulic converter actually.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
P
4. (HSV)
Figure4. Valve position when high speed on-off valve electromagnet (HSV)
electrified
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The Principle and User Manual for Digital Hydraulic Turbine Governor
13380cSt
Adaptable medium viscosity13380cSt
1.560L/min
The maximum working flow1.5~60L/min
/: 0.53ms
Rapid action response, regulating time of on-off is about 0.53ms
--- D/A
Similar to technique standard that D/A conversion circuit formative time.
Directly controlled by digital information, no signal distortion.
0.05ms
Repeated precision0.05ms
()
The material (cemented ceramics carbide) have enough rigidity, abrasion
resistance, anti-jamming
High capability of replacement, big electromagnetism driven force, good stability
and reliability of action
( 500
)
No else special demand for oil quality, and good anti-greasy
Simple structure, perfect manufaturability
Without disabled unit for abrasion in a long period
2
Main Control Valve
/
Main control valvelogical cartridge control valveis the key component that
realize governor main class control, its function is receiving the pressure signal that
high speed on-off valve provided, and cause main valve core to move, then control
working oil circuit changing, and control the displacement of main servomotor.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
5 ()
Figure5. Main Control Valve (logical cartridge control valve) Structure diagram
ABK A/B
K
K
Generally, working state of the cartridge assembly is determined by the resultant
force and its direction of valve core. If resultant force is greater than zero, valve
closed; if resultant force is less than zero, valve opened, when resultant force is
equal to zero, the valve core stayed in a balanced position. It should be pointed that,
the stress status and open/close process of valve core is much more complex than
the theoretical analysis in the relevant data. But the pressure relationship among the
ABK chambers is still to play a leading role, the pressure of chamber A/B is
determined by the working load condition, which cannot change at will, so ,we realize
the control of logical cartridge valve by changing the pressure of chamber K.
Obviously, we can change the opening of main valve by changing the control
pressure of chamber K.
()
Compared to the four-channels slide valve (as main distributing valve), it can
make pilot control by receiving different type of switch signals, analog and digital
signals, and integrate pressure, flow, direction and many functions in the same main
class, much more, is compatible to the switch valve, proportional valve, digital valve.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
See figure 6, Startup/Shutdown pulse valve mainly consists of valve body (1),
two electromagnets (2), control valve core (3), and the positioning devices in both
ends of valve core, etc.
P
TJL=OFF KJL=ON
T
T T
P
A P B
2. 1. 3. 2.
6.
Figure6. Structure diagram of Startup/Shutdown pulse valve
>> Working Principle
Startup/Shutdown pulse valve connects or disconnects the oil circuit by the axial
moving of valve core in the body, which controlled by the electromagnet push pole. It
is a sectional ring groove cylinder, the valve core has several shoulders, the valve
body has several grooves, each groove connects outside through the corresponding
hole and channel.
2 KJL TJL
(3) KJL
KJL
6 P A T
B
Startup/Shutdown pulse valve has only two working position, when right
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The Principle and User Manual for Digital Hydraulic Turbine Governor
electromagnet KJL is energized, and left (TJL) is not, valve core (3) moves left by the
force of right electromagnet KJL, at the same time, the positioning devices on the left
side of valve core keep it in the working position; even if the electromagnet KJL is
de-energized, the positing devices can keep the valve core not moving, the valve
position state just like figure 6, the pressure oil P links to the control port A, return oil
T links to the control port B.
TJL KJL (3) TJL
TJL 7
P B T A
When Left electromagnet TJL is energized, and right (KJL) is not, valve core (3)
will move right by the force of left electromagnet TJL, at the same time, the
positioning device on the right side of valve core keep it in the working position; even
if the electromagnet TJL is de-energized, the positing device can keep the valve core
not moving, the valve position state just like figure 7, the pressure oil P links to the
control port B, return oil T links to the control ports A.
TJL=ON KJL=OFF
T P T
A P B
7. (TJL)
Figure7. The Startup/Shutdown pulse valve position after left electromagnet (TJL)
energized
>> Main Technique Parameters
80L/min
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The Principle and User Manual for Digital Hydraulic Turbine Governor
See the system schematic diagram showed in attached drawing (CAD drawing)
wicket gate servo system consists of high speed on-off valve, flow control valve,
cartridge valve, startup/shutdown pulse valve, quick/emergency shut-down valve,
step closing valve, blade servo system is exactly similar to the wicket gate servo
system ,except for startup/shutdown pulse valve, quick/emergency shut-down valve,
step closing valve.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Then we will make some brief introductions for the different local circuits, if we
make a compression for the local circuits, we can handle the whole working principle
exactly. Blade servo motor system is similar to the wicket gate servo motor system,
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The Principle and User Manual for Digital Hydraulic Turbine Governor
so we take wicket gate servo motor system for example. The part of blade, please
refers to the attached drawing, and analyzes by yourself.
1
Opening Increasing Automatic Operation
8
WZ(7) K T T
(12) WZ(7)
(12)
(12) B
K K
From above, it is well known, when high speed valve WZ (7) power on, both of
the cartridge valves could be opened, then main pressure oil is linked to the left side
of servo motor through the left cartridge valve, the right side oil of servo motor will
discharge by the right side cartridge valve, the servo motor move to the side of
opening increasing.
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8
Figure 8 Opening Automatic Increasing Local Principle Diagram
WZ(7)
K T (12)
K, 2 /
When the displacement of servo motor accords with the needed control value,
high speed valve WZ (7) cut off, and the control port K and return oil port T close.
Then the pressure control oil flows through the flow control valve (12), directly effect
on the control chamber of cartridge valve (K), close both the cartridge valves, and
also close the oil route lead to the control chamber of servo motor open/close side.
The servo motor will then stop moving, and keep the position accords with control
value. So we can see that the motion control and steady regulation are not based on
the middle-position of control valve.
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(12)
It should be pointed that the title of flow control valve (12) may be less stringent.
Considering its function, it may be called discharge- pressure differential linear
conversion component exactly. From the point of view of hydrodynamic, the energy
conversion of Bernoulli equation shows, we can express the correspondence
between the discharge and differential pressure of throttle devices by any throttle
devices, a typical example as we well-known is Venturi tube and orifice meter. But
this type of throttle devices cannot acquire the linear conversion of discharge and
differential pressure. If we can make special design for the modeling of valve outlet of
throttle device, and make the valve core movable during the period of fluid flowing,
then we can get the linear conversion of discharge versus displacement and
discharge versus differential pressure. Swiss Berlingel, U.S Weeks, Germany
RWTH-Aachen have adopted the similar scheme. For the redundancy of the
theoretical derivation and equation formula, here is no more discussion.
2
Opening Decreasing Automatic Operating
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Refer to figure 9 and attached drawing. During the normal regulating process,
startup/shutdown pulse valve (8) is in ON (KJL=ON), it do not mean opening the
servo motor, at the moment, piloted control oil line is under normal oil supply state,
the servo motor can be operated normally.
(8)(TJL=ON) 9
When the on/off pulse valve (8) is in OFF (TJL=ON), the oil line as is shown in
the figure 9, wicket gate is compressed in this state. Generally, it occurs in the stop
standby condition. Here an analysis of the oil line is as follows:
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9
Figure9. The local principle diagram when startup/shutdown pulse valve in TJL
(8)(TJL=ON) A
Pr K (12) B A
(10) K Pc (8) A 2
When startup/shutdown pulse valve (8) is in OFF (TJL=ON), the oil returns from
the control port A, but it is closed by the pilot control pressure oil Pr, so, control
chamber of cartridge valve (K) is linked to the port B of flow control valve (12),then
port A, then port K of emergency stop valve (10), then outlet of Pc, port A of
startup/shutdown pulse valve (8), at last connect to the oil return tank, and will open
the left and right cartridge valves. So main pressure oil will connect to the right
chamber of servo motor through the left cartridge valve, the left chamber of servo
motor is linked to the return oil through the right cartridge valve, this can ensure the
servo motor is in the fully closed position, and a certain pressing force exists.
5 Quick/Emergency Shut Down Circuit
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10
Figure10. The Local working principle diagram of Emergency stop valve acting
10(10) K T
Pc K (12) B A
(10) K T 2
Refer to Figure 10, when emergency stop valve is energized, the control port K
will link to return oil T , but it is closed with control port Pc, then control chamber of
cartridge valve (K) is linked to the port B of flow control valve (12), then port A, then
port K of emergency stop valve (10), then port T, at last reaches the oil return tank,
and will open the left and right cartridge valves, then main pressure oil will connect to
the right chamber of servo motor through the left cartridge valve, the left chamber of
servo motor is linked to the return oil through the right cartridge valve, this can
ensure the servo motor is in the fully closed position
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1
Attached Figure 1: Principle Diagram of Wicket Gate Servo System
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2
Attached Figure 2: Principle Diagram of Blade Servo System
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The Principle and User Manual for Digital Hydraulic Turbine Governor
5 Operation
5.1 CVT/ZT-XX Operation conditions of CVT/ZT-XX
governor
46#
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The Principle and User Manual for Digital Hydraulic Turbine Governor
the criterion.)
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Each relational indicator of governor panel is normal.
The oil pressure is normal.
The oil filter blocked indicator light is off.
;
The generator potential transformer(PT) is normal, and high/low fuse of PT put
into use and not disconnected.
The indicator value of water head is corresponding to the current actual head.
Normal load operating condition
[]/[][]
The selecting switch [Gate Man./Aut.] & [Blade Man./Aut.] place in Aut.
Position.
[ 24V]
The indicator light [DC 24V] is lighten.
[]
The [Gate Openning] meter indicate to a relative value corresponding the current
position of wicket gate servomotor, the [Blade Openning] meter indicate to a relative
value corresponding the current angle of runner blade.
[]
The indicator light [Break ON] is lighten.
The oil pressure is normal.
The oil filter blocked indicator light is off.
The indicator value of water head is corresponding to the current actual head.
/
E
/ f
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The Principle and User Manual for Digital Hydraulic Turbine Governor
When governor receiving start-up command, the [Start-up] indicator lamp lighten,
wicket gate wiil be opened to no-load opening corresponding to the current actual
head, meanwhile the hydraulic turbine unit frequency track the grid frequency.
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[
]
After meeting the automatic synchronization condition, the synchronization
device will operate the breaker switched on line, the [Breaker on] indicator lamp
lighten.
Disconnected from line and shut-down
Decreasing the hydraulic turbine unit load to zero.
[]
The hydraulic turbine unit breaker will be switched off via LCU operating, the
[Breaker on] indicator lamp is off, the unit is at no-load operating mode.
[]
When governor receiving shut-down command, the [Shut-down] indicator lamp
lighten, wicket gate wiil be full closed, meanwhile the hydraulic turbine unit speed will
gradually decrease.
[]
When the air pressure of brake is released, the [Stop standby] indicator lamp in
HMI will be lightened, the governor translate the operation condition to standby
mode.
/ Load increasing/decreasing operating
/ LCU
LCU /
/
The load increasing/decreasing operation generally operated by LCU Inc./Dec.
pulse signal of active power setting. About the detail content, please see also the
LCU information. At special circumstances, if LCU chance fault, the operator can
switch over the governor to manual mode, then Inc./Dec. the unit load to the object
value via Inc./Dec. switch, finally switch to Aut. Mode.
Y+Y- LCU
/
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Y+/Y-
Y+/Y-
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The Principle and User Manual for Digital Hydraulic Turbine Governor
/()
LCU
The Man./Aut. switch over for CVT/ZT- governor is very simple, without any of
conditions to prepare before switch over. If you want switch over Aut. to Man. , just
whirl the Man./Aut. switch pointing Man. Position; if you want switch over Man. to
Aut. , just similarly whirl the Man./Aut. switch pointing Aut. Position;
Manual operation
.
Whirling the Man./Aut. switch to point Man. position, the governor will be
translated the operating mode to Manual mode. When Manual operating mode,
governor shall be minitored by operator.
. Increasing opening operation
/
Operating the Inc./Dec. switch allocating to Inc. side, the opening increase
operating can be executed.
(
)[] 2
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Before recover standby mode, you must confirm the following conditions are met,
the generator potential transformer(PT) is normal, and high/low fuse of PT put into
use and not disconnected, the main isolate valve of oil source is opened, the
indicator value of water head is corresponding to the current actual head.
Whirling the Man./Aut. switch to point Aut.
position.
/ 220V 24V AC/DC220V, DC24V power supply are normal
Making lock released
Filter replacement
11
See also the oil circuit Fig.11, generally, as long as the filter blocked indicator
lamp is not lightened, that neednt to execute this operation. If the filter blocked
indicator lamp lightened, and the filter red plunger push out, then indicating the filter
blocked, at this case, you need to replace the filter. Please refer to the recommended
following steps while replacing filter.
JZ1JZ2First, cut off the check valve
JZ1, JZ2, then unscrew the filter cartridge and disassemble the filter core.
Replace and assemble the new filter core, screw the filter
cartridge.
JZ1 JZ2 Open the check valve JZ1, but the check
valve JZ2 is still closed.
Rotate counterclockwise the air exhaust valve threaded
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The Principle and User Manual for Digital Hydraulic Turbine Governor
sleeve at the top of the filter cartridge, remove the isolation pads; then rotate
clockwise the threaded sleeve to the lower position, executing exhaust operating.
After exhaust operation fulfilled, recover filter
device to the original status.
6 Installation of equipment
Like other automatic equipment, CVT/ZT series governor has its special
installation demand. Therefor, before installation, the whole technical information
must be known well by customer, especially the content of this section. When you are
familiar with the technical documents, you must draft installation project according to
the site actual situation, then excute the installation work.
6.1 Preparations for installation
Installation preparations include technical preparation and materials preparation.
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The whole technical information about this equipment must be known well by
customer, especially the content of this section. The tagname definition of external
wiring of this equipment must be learned more.
The center, levels and elevation should be fully reviewed, then pouring the
foundation and bolt of the equipment.
You must do the comprehensive analysis and synthesis about unit automatic
operating loop and the demand of this governor equipment, determine the connection
project between the unit automatic operating loop and this governor equipment, and
plot the corresponding principle drawing. Then you need to cross-check the
process action from start-up, load, shut-down, etc. operation condition translation,
check whether the design is realistic.
According to the external wiring drawing, plot the the appropriate cable wiring
diagram.
The external wiring demand of this governor equipment
CVT/ZT-XX Refer
to the terminal drawing provided with the equipment, the external wiring of
CVT/ZT-XX governor cubicle can be devided into the following sections.
The power supply section
Digital input section
Digital output section
Frequency/speed measurement section
Opening signal input section
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The Principle and User Manual for Digital Hydraulic Turbine Governor
The breaker auxiliary contact is needed normal open dry contact. If condition
allowed, we recommend the generator breaker and main transformer high voltage
side breaker auxiliary contact are both provided.
LCU .
The Increase/Decrease pulse signal from LCU is needed normal open dry
contact.
CVT/ZT-XX
LCU DO
The Increase/Decrease speed pulse signal from synchronizer is needed normal
open dry contact, if this pair signal cancelled, it will not affect the normal regulation of
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governor. And this pair contact signal is permitted parallel connection with the
Inc./Dec. signal from LCU DO module.
/()
LCU
The position signal(lock engaged/lock released) of lock servomotor is needed
normal open dry contact, and it can also be provided from LCU translation relay
contact of DO module.
Quick shut-down/Emergency shut-down command dry contact is needed normal
open dry contact.
The digital output section
CVT/ZT-XX
PFR PFR
The digital output signal of governor includes: governor fault, power failure,
manual mode, PFR engaged, PFR acting, etc.
Frequency/speed measurement
AB CB AC PT
The turbine unit frequency signal source can use generator PT or toothed disk.
()
PT
The grid frequency signal source is PT voltage from low voltage side of main
transformer.
The generator and grid PT secondary coil used for frequency measurement must
be current isolated from all circuit, this secondary coil is only used for governor
controling and regulating.
: Opening signal input
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The Principle and User Manual for Digital Hydraulic Turbine Governor
The displacement sensor must be fixed on rigid support, the locking nut of
handspike must be locked, any radial or axial offset will cause the signal instability
and distortion; the power supply and wiring of conditioning circuit must be highly
reliable, otherwise it will cause the signal instability , distortion and disturbance,
implicate stability and reliability of the whole governor system.
The adjustment of feedback signal for gate opening and runner blade
Adjusting the gate opening feedback sensor and additional potentiometer, to
achieve:
Y=0% Gate full closed Y=0%
feedback voltage U YF =0.3~0.35V
Y=100% Gate full opened (Y=100%)
feedback voltage U YF =9.5~9.7V
Finally, fixing the displacement sensor reliably.
It is very similar between the runner blade angle sensor with gate
displacement sensor.
: Active power measurement
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CVT/ZT-XX 420mA
The active power measurement is realized by active power transducer, voltage
level standard: 420mA.
: Water head measurement
CVT/ZT-XX ()4
20mA
The net water head signal can be collected automatically(water head transducer
provided by customer), voltage level standard: 420mA.
Preparation of installation materials and tools
Cable and shielded wire
Standard fasteners
Rubber seal
Manifold flange
Seamless steel tube
Multimeter
Within six wrench, ordinary wrench, screwdriver, etc.
The box out checking program and main content
First, affirm if the box has any serious external damage after transport. If there
no serious external damage, please carefully open the box.
Check the variety and quantity of packing items, whether it is corresponding to
the packing list.
Check the exterior of the equipment, it shouldnt exist any serious injuries.
Open the door of the equipment, check and affirm if there have any abnormal
phenomenon, such as wire broken, components injury, loose fasteners, loose
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terminals ,etc.
The installation of equipment
6.
The installation of noumenon equipment, flange and steel pipe will be described
at this section content. The key factor is the standard installation of flange and pipe.
The quality of the installation will relate to oil medium pollution, reliability and safe
operation, so it must be given sufficient attention.
The installation of noumenon
The installation progress is as follows
Place: When placing the noumenon, you should pay attention to preventing the
panel and component damage, and giving solid and reliable connection to plant
foundation.
Wiring: The wiring must be accurate, solid and
reliable.
The installation of flange and steel pipe
CVT/ZT-XX O
O
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Taking into account that if pipeline cleaning is not strict, it will easily cause
secondary pollution to oil medium by solid pollutants. The solid pollutants has great
harm, it will accelerate wearing ,aging and performance degradation of hydraulic
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components, or plug the orifice leading to control failure and reducing the system
reliability. The requirements on oil cleanliness not only consider the security and
reliability of system, but also ensure the long life work of hydraulic components.
7. The fault type and processing
7.1 Fault type
The governor send out fault alarm signal
Unit frequency disappeared or broken
Grid frequency disappeared or broken
The active power signal is bad quality
()The runner blade angle feedback signal is bad quality
The wicket gate opening feedback signal is bad quality
Lithium cell with low voltage
Oil filter blocked
Fault type display: The specific
fault information will be shown at HMI screen.
7.2 Fault analyzing and processing
(1) Unit frequency fault
Reason: Signal wire broken, or frequency
measurement damaged.
,
Phenomenon: The indicator lamp Fj Disappear is lightened,
the fault alarm signal is sent to LCU. The servomotor is motionless and maintaining
the original position during load mode operation, or full closed during start-up process
or no-load mode operation.
Processing steps
(
)First,
it would be best to switch over the governor to manual operation mode.(During
start-up process, if unit frequency fault occurred, please shut-down the turbine at
once. During load operation mode , if unit frequency fault occurred, the governor
system can still remain automatic running; and also allowed to switch to manual
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mode, but you must find out the cause of the malfunction as quickly as possible.)
15V
Check whether the frequency
measurement module is normal: If the output voltage of frequency measurement
module is below 15V or external resistor is very hot, the frequency measurement
module may have been damaged, you must replace it to reserve module.
PT Signal
disappeared or wire broken: According to the principle drawing, find fault point by
point from frequency measurement module to PT .
After troubleshooting, the
governor is all normal, then it can be switched to automatic running.
(2)
Grid frequency fault
Reason: Signal wire broken, or frequency
measurement damaged.
Phenomenon: The indicator lamp Fw
Fault is lightened, the fault alarm signal is sent to LCU.
Processing steps
(
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The Principle and User Manual for Digital Hydraulic Turbine Governor
If the sensor damaged, after repaired or replaced, the zero and full-scale of
sensor should be proofreaded again. The proofreading method can see also section
6 contents.
If external terminal affected with water, you can drying it with hair dryer.
(5) The wicket gate opening feedback signal is bad quality
Reason: Displacement
sensor signal wire broken, or sensor damaged, or external terminal affected with
water.
Displacement sensor signal wire broken, or
sensor damaged.
Zero and full-scale of sensor is not proofreaded.
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Phenomenon: After the governor received start-up command from LCU, during
automatic start-up process, first the gate servomotor moving toward open direction, if
unit frequency or gate opening signal fault occurred at this time, the governor will
voluntarily close the servomotor, to ensure the equipment security.
LCU
Processing: The checking and processing for frequency or gate opening signal
fault is as reference to the above. If the failure has been discharged after processing,
then you want to execute the turbine unit start-up operation, you can switch the
governor to manual mode to operate start-up process. If you want to automatically
execute start-up process, in the first place, the normal shutdown command signal to
governor should be sent out by LCU, after the governor translate to stop standby
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The following maintaining suggestion is just for reference, please draw up detail
maintenance specification combined with the your actual power plant.
Regular maintenance
8.
()Clean once the dust in
control cubicle at every minor repairs period(In the case of power off).
()Fasten every wiring termals at
every heavy repairs period.
/
(0%100%)
Check gate
opening and runner blade angle feedback sensor at every minor/heavy repairs,
manual open/close the servomotor with the slowest velocity in the whole stroke
range(0%100%), observe whether the feedback voltage changing with
continuous and monotone, otherwise the sensor should be replaced. And proofread
the voltage at full close/open position.
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The Principle and User Manual for Digital Hydraulic Turbine Governor
Inspect relay,
active power transducer, water head transducer and frequency wave module at every
minor/heavy repairs period.
Inspect toothed disk speed detecting device at
every minor/heavy repairs period.
PLC ( 30
)We suggest that it is better to replace the Lithium
Battery/Cell at every heavy repairs period.(Dont power off the PLC controller power
supply source, when you replace the Lithium Battery/Cell , and execute the battery
replacing operation within 30s, otherwise may cause data loss.)
Replace the filter core at every heavy repairs
period.
O We suggest to replace the O ring of
hydraulic component at every heavy repairs period.
/()
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(0%100%)
After the servomotor displacement sensor position readjusted ,you must check
whether the sensor is normal? The suggestion method is: manual open/close the
servomotor with the slowest velocity in the whole stroke range(0%100%),
observe whether the feedback voltage changing with continuous and monotone.
Then proofread the voltage at full close/open position.
If active power display value is inaccurate, recalibrate the signal zero/ full-scale.
If water head display value is inaccurate, recalibrate the signal zero/ full-scale.
HMI
If HMI(touch screen) is abnormal, press HMI Reset button, then recover it.If it is still
abnormal, replace the screen.
PLC / PLC
/
If PLC controller or input/output module is abnormal, power off and then power
on, if still abnormal, replace PLC controller or input/output module.
AC220V
The active power transducer failure: Check whether the wiring correct or wire
broken or poor contact or AC power supply normal or output signal normal? Power off
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The water head transducer failure: Check whether the wiring correct or wire
broken or poor contact or DC power supply normal or output signal normal? Power
off and then power on, if still abnormal, replace the transducer.
Sending out alarm signal while running
8.3.
7 About the treatment
of the common possible fault phenomenon while running, that can see also the
content of section 7.
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