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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

A 2014.06.18 FIRST SUBMISSION Gao Junjie LiWenke ChenJing


REV. DATE DESCRIPTION PREPARED CHECKED hai
APPROVE
REVISION
OWNER IDENTIFICATION No.:
REV.:

OWNER: CONSULTANT
VIETNAM ELECTRICITY
VINH TAN THERMAL POWER MANAGEMENT
: POWER ENGINEERING
CONSULTING J.S.C 2 (PECC2)
BOARD

EPC
CONTRACTOR: SHANGHAI ELECTRIC GROUP CO.,LTD.
COMPILE:
CHD POWER PLANT OPERATION CO.,LTD.
PROJECT: DESIGN STAGE:
VINH TAN 2 2×622MW THERMAL POWER Detail Design

APPROVED ChenJinghai CHECKED LiWenke


热控维护手册
REVIEWED LiPing PREPARED GaoJunjie
Thermal Control Maintenance Manual

DATE 2014.06.18 SCALE N/A


DRAWING No. YXZL-WH-K-001 RE A
Regulations of Thermal Control and Maintenance V.
Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

CONTENTS

1. Overview of Thermal Control Equipment......................................................................................................3


1.1 Overview................................................................................................................................................... 3
1.2 Maintenance Content of Thermal Control Equipment............................................................................. 3
1.3 Test items and period of regular inspection.............................................................................................. 3
1.4 Periodic test items and period................................................................................................................... 6
1.5 Periodic verification period of standard instrument................................................................................. 7
1.6 Standard items of minor repair................................................................................................................. 8
1.7 Standard items of major repair..................................................................................................................9
2. Maintenance of primary equipment and control device (thermo technical measurement and
conventional instrument) ....................................................................................................................................9
2.1 Maintenance rules on pressure switch...................................................................................................... 9
2.2 Maintenance rules on differential pressure switch................................................................................. 12
2.3 Maintenance rules on liquid level switch............................................................................................... 13
2.4 Maintenance rules on ABB 266 series transmitter................................................................................. 14
2.5 Maintenance rules on bimetal thermometer............................................................................................19
2.6 Maintenance rules on thermocouple....................................................................................................... 21
2.7 Maintenance rules on thermal resistance................................................................................................ 26
2.8 aintenance rules on Bourdon gauge........................................................................................................ 30
2.9 Maintenance rules on UHZ..................................................................................................................... 33
2.10 Maintenance rules on intelligent flow meter........................................................................................ 35
2.11 KM series ultrasonic wave material level detector...............................................................................38
3. Maintenance of primary equipment and control device (actuator control device) ................................40
3.1 Maintenance rules on SIT intelligent electric actuating mechanism......................................................40
3.2 Maintenance rules on pneumatic actuator.............................................................................................. 51
3.3 Maintenance of ROTORK actuator........................................................................................................ 54
3.4 Maintenance rules on SMC series pneumatic actuator...........................................................................58
3.5 Maintenance rules on FISHER positioner.............................................................................................. 61
3.6 ABB pneumatic valve maintenance technical rules................................................................................64
4. Primary equipment and control device maintenance (furnace side thermal control device) ............... 68
4.1 ZHJZ series flame detection system maintenance rules.........................................................................68
4.2 ABB AZ20.0700 series zirconia oxygen analyzer maintenance rules....................................................73
4.3 HL-2308H/4 flame TV system maintenance rules................................................................................. 78
4.4 HLTV-200B/2 level TV system maintenance rules................................................................................ 81

Regulations of Thermal Control and Maintenance


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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

4.5 PCV valve control device maintenance rules......................................................................................... 85


4.6 STOCK coal feeder control device maintenance rules...........................................................................87
4.7 CEMS system maintenance rules............................................................................................................97
5. Primary equipment and control device maintenance (thermal control device on machine side) .......103
5.1 Condenser rubber ball cleaning device maintenance rules...................................................................103
5.2 Rotating filter control device maintenance rules.................................................................................. 105
5.3 Circulating water butterfly valve control device maintenance rules.................................................... 107
6. Thermal control system maintenance (DCS system maintenance rules) .............................................. 109
6.1 ABB Symphony Plus control system....................................................................................................109
6.2 SCS system............................................................................................................................................123
6.3 FSSS system..........................................................................................................................................125
6.4 MCS system.......................................................................................................................................... 132
6.5 Attendance Instruction for the maintenance and operation of automation system.............................. 145
7. Thermal control system maintenance (DEH/MEH/ETS system maintenance rules) .......................... 163
7.1 DEH system maintenance rules............................................................................................................ 163
7.2 MEH system maintenance rules............................................................................................................170
7.3 Maintenance rules of big machine ETS system....................................................................................176
7.4 Small engine ETS system maintenance rules....................................................................................... 182
7.5 Schneider series PLC maintenance rules.............................................................................................. 185

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1 Overview of Thermal Control Equipment


1.1 Overview
Two sets of unit plants of Vietnam Vinh Tan 2x622MW coal fired power plant adopts centralized control
way of furnace, machine, power and network. Two units share a single unit control room to realize monitoring
control to unit operation in control room. Thermal control adopts Symphony PLUS DCS (distributed control
system) of ABB company, and the temperature measure points need monitoring adopt remote I/O access DCS.
Circulating water pump room control, fuel oil pump room control, air compressor room control adopts remote
I/O or remote control station. Every unit shall set two screens; fuel coal, chemistry, waste water, hydrogen
generation station and auxiliary system shall adopt 67160quantum hot standby series product PLC system of
Schneider QUANTUM and access DCS through OPC foe monitoring and operation.
Auxiliary shop has: water network remote control system composed of steam water sampling water,
comprehensive sewage treatment, hydrogen generation station and other auxiliary system. Coal handling system
adopts centralized control system and has set up industrial television; pneumatic ash removal, deslagging, air
compressor, electrostatic precipitator control system and coal network control system.
1.2 Maintenance Content of Thermal Control Equipment
1.2.1 Routine inspection, defect eliminating, equipment renovation, hygiene sweeping
1.2.2 Equipment plan maintenance and temporary repair
1.2.3 Regular inspection, verification and test of equipment (system)
1.2.4 Minor repair, medium repair and major repair of equipment
1.2.5 Seasonal safety maintenance twice every year
1.3 Test items and period of regular inspection
1.3.1 Regular verification of instrument: the verification of standard instrument and apparatus shall execute
the provisions by periodic verification of superior measuring instrument period; the verification of
thermocouple, thermal resistance, pressure, differential pressure, temperature and liquid level switch shall
1.3.2 Verification of system transmission: the verification period of main and auxiliary protection,
inter-system signal, main parameter and other system transmission are specified as three months, six months,
one year, temporary repair, minor repair and major repair.
1.3.3 Regular inspection: The inspection period of cable motor, ground resistance, connecting bonding wire
terminal, plug and socket, switch, all fuses, relay, button, actuator, solenoid valve, position sensor (reverse
position of adjusting valve) are specified as temporary repair, minor repair and major repair.

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1.3.4 Specific regular inspection items and period list:


No. Item Period
Air feeder, induced draft fan, primary air fan bearing and motor bearing temperature Six months or temporary
1
signal transmission repair
Coal mill motor bearing temperature signal transmission, furnace primary and
2 One year or minor repair
secondary superheat temperature signal transmission
Main engine bearing temperature signal transmission, steam pump, electric pump Six months or temporary
3
bearing temperature signal, hot air temperature signal transmission repair
Boiler water level, pressure signal transmission, deaerator, high and low pressure
4 heater, condenser signal transmission, big and small oil tank oil level signal One year or minor repair
transmission
Feedwater flow, reheater flow, feed pressure, air preheater outlet primary air pressure,
main steam pressure, reheater pressure, overheating desuperheating water flow, high
and low pressure heater extraction pressure, condenser water tank water level, steam air
5 One year or minor repair
heater, fuel oil pressure, compressed air pressure, drum pressure, primary air volume,
sealing air differential pressure, high and low pressure heater water level, heat supply
network water level verification
Pump busbar pressure, pump discharge pressure, pump inlet flow, booster pump inlet
and outlet differential pressure, pump lubrication pressure, pump strainer differential
pressure, steam pump vacuum, primary oil pressure, steam pump booster pump strainer
6 differential pressure, steam pump inlet and outlet differential pressure, shaft seal Major repair
pressure, demineralized water pressure, industrial water pressure, pump outlet pressure,
steam pump outlet flow, inlet pressure, steam pump oil tank oil level, steam pump
recirculation flow, steam pump steam pressure verification
Condensate outlet flow, condensate inlet pressure, bypass flow, main engine control
(fire resistant oil) oil pressure, generator cooling water outlet pressure, high and low
7 Major repair
pressure shaft seal pressure, high and low bypass pressure, deaerator water level
pressure verification
Secondary air volume, primary air pressure before milling, primary fan outlet pressure,
auxiliary steam pressure, flow, continuous blowdown flow, reheater cooling end
pressure, heater pressure, steam pump extraction flow, temperature and pressure
reduction station pressure, air preheater pressure before blowing, air feeder volume,
8 pressure, air preheater gas pressure, hearth gas pressure and other examination; Minor repair
extraction pressure, machine jacking oil pressure, electric pump bypass flow, motor
cooling water pressure, industrial water pressure, electric pump sealing water strainer
differential pressure, condensate outlet pressure, drain pump outlet pressure, steam
pump five-section extraction steam pressure and other examinations
Primary air temperature before milling, front and back temperature of desuperheater,
front and back temperature of reheater, outlet temperature of reheater, steam turbine
9 cylinder temperature, bearing temperature, electric pump body temperature, generator Minor repair
side temperature, steam pump body temperature, high and low bypass temperature,
machine side, furnace side metal wall temperature signal and other examinations
10 Primary air volume for milling, primary air pressure for milling, sealing air pressure, Every month or temporary

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
No. Item Period
secondary air volume and gauge tube purging repair
Three months or temporary
11 Inter-cabinet bonding wire, plug and socket, fuse, relay and other examination
repair
12 Intersystem signal transmission Six months or minor repair
13 Cable, motor insulation check, ground resistance check One year or major repair
Verification of flue gas oxygen content measuring device, flying ash carbon content Three months or temporary
14
meter repair
Three months or minor
15 Check and verification of electronic scale, weighing coal feeder
repair
16 Switching value inspection Minor repair
17 Switching value verification Major repair
Check and debugging of electrically operated gate actuator and power distribution
18 Temporary repair
circuit
Control loop inspection of auxiliary machine oil station equipment and local control
19 Temporary repair
device
Check and debugging of high and low pressure heater drain water system, stator
Three months or temporary
cooling water pressure temperature adjusting valve, feedwater system, desuperheating
20 repair
water system, electric pump rotate speed, coal feeder rotate speed, mill cold and hot air
door, fan adjusting baffle and other important adjusting valve actuator
Verification of hearth pressure protection loop system transmission, gauge tube purging
21 Three months
and pressure switch
Six months or temporary
22 Other main protection loop system transmission
repair
Verification of pressure switch, transmitter (except hearth pressure) of main protection Six months or temporary
23
system repair
24 Monitoring probe verification of large and small steam turbine noumenon Major repair
Monitoring system plug-in, cable and booster device inspection of large and small
25 Temporary repair
steam turbine noumenon
26 Verification of drum water level industrial television Six months
27 Check of hearth flame camera system Temporary repair
Reverse adjustment of high and medium pressure adjusting valve, main steam valve
28 Temporary repair
and bypass adjusting valve position of large and small turbine
29 Check and debugging of shaft seal adjusting valve Temporary repair
Disposable parts verification and loop transmission relevant to small index and energy
30 6 months
saving index
31 Check of UPS discharge of DCS system Six months
32 Power source inspection of DCS system, ground system inspection, terminal fastening One year
33 Cable connector inspection of DCS system network One year
Sweeping of DCS system cabinet, operating desk; cleaning of strainer and oil charging
34 Six months
of fan
35 Cleaning of anti-static cleaner for DCS system module and passage verification Major repair
36 Inspection of DCS system software and configuration backups Six months
Regulations of Thermal Control and Maintenance
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
No. Item Period
37 Configuration inspection of DCS system (MCS, CCS, DAS, FSSS, SCS) Temporary repair
Power source inspection of DEH, MEH, TSI system; inspection of ground system and One year
38
terminal fastening
39 Cable connector inspection of DEH, MEH and TSI system network One year
Sweeping of DEH, MEH and TSI system cabinet, cleaning of strainer and oil charging
40 Six months
of fan
Cleaning of anti-static cleaner for DEH, MEH and TSI system module and passage
41 Major repair
verification
42 Inspection of DEH, MEH and TSI system software and configuration backups Six months
43 Configuration inspection of DEH, MEH and TSI system Temporary repair
Fan inspection of engineer station, operator station (Including: DCS, DEH, water, coal
44 Once every two days
and ash screen) CPU and power supply module
Internal hygiene sweeping of engineering station, operator station (Including: DCS,
45 Temporary repair
DEH, water, coal and ash screen) cabinet
Inspection of all card status of electronic room CBA control cabinet, BUK power
46 cabinet, DEH, MEH control cabinet, remote I/O station, water network, coal network, Every day
ash network PLC remote control system
47 Inspection of large screen splicer and main engine status, sweeping Every week

1.4 Periodic test items and period


No. Item Period
1 Oil gun test
2 Electric pump small oil pump test
Oil pump linkage test of air feeder, induced draft fan, primary air fan and coal mill oil
3
pump
4 Air preheater motor linkage test
Linkage test of vacuum pump, AC and DC seal oil pump, stator cold water pump,
5 auxiliary cooling water pump, air compressor cooling water pump, flame check
cooling fan linkage test Every time before unit starts
6 Air feeder, induced draft fan and primary fan baffle test
7 Combustion chamber draft and secondary air pressure test
8 Blowing down, stop button test
9 Machine, power and furnace interlocking test
10 All oil pumps linkage test of large and small steam turbine oil system
11 Large and small shaft sensor test
12 DEH, MEH system valve verification

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1.5 Periodic verification period of standard instrument

No. Item Period

1 High precision numeration table One year

2 Multi-purpose calibrator One year

3 Temperature calibrator One year

4 Loop calibrator One year

5 Digital megohm meter One year

6 AC stabilized voltage power One year

7 One-way DC stabilized voltage power One year

8 Self-coupler voltage regulator One year

9 Resistance box One year

10 Digital multi-meter One year

11 Second-class standard platinum resistor Two years

12 Second-class standard thermocouple Two years

13 Standard resistance Two years

14 Second-class mercurial thermometer Two years

15 Standard piston pressure gage Two years

16 Gas piston pressure vacuum gauge One year

17 Precision pressure gauge One year

18 Portable pressure calibrator One year

19 Hydraulic test One year

20 Pneumatic test pump One year

21 Low pressure test pump One year

22 Gage pressure module One year

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1.6 Standard items of minor repair


1.6.1 The minor repair period of thermal control equipment is synchronous with minor repair period of main
engine and the standard items of minor repairs are as follows:
1.6.1.1 Power supply inspection and sweeping of all thermal control devices;
1.6.1.2 Fastening of all wiring terminal and disposable parts sealing;
1.6.1.3 Air pressure and air volume pipeline purging;
1.6.1.4 Leakproofness inspection of connectors of all valves and transmitters;
1.6.1.5 Polishing of all markings;
1.6.1.6 Desk tray signal and button inspection;
1.6.1.7 Periodic verification of main instruments;
1.6.1.8 Linkage test of main equipment;
1.6.1.9 Opening calibration of all adjusting valves;
1.6.1.10 Sweeping and wiring settling of all thermostat and junction box;
1.6.1.11 Set value and transmission test of engine, furnace protection and signal;
1.6.1.12 Spot check of transmission of main auxiliary machine program and protection set value;
1.6.1.13 Cable insulation inspection of main equipment;
1.6.1.14 Signal loop inspection of adjusting system;
1.6.1.15 Inspection and test of oil gun control system;
1.6.1.16 Verification of program control and protection system;
1.6.1.17 Inspection of power supply and plug-in of DCS system;
1.6.1.18 DEH system test;
1.6.1.19 MEH system test;
1.6.1.20 TSI system inspection;
1.6.1.21 Clean and inspect flame camera and large screen;
1.6.1.22 Measurement circuit inspection of oxygen content meter, flaying ash carbon content instrument;
1.6.1.23 PDR and print-an-alarm of computer;
1.6.1.24 Inspection of safety valve control system and verification of pressure switch;
1.6.1.25 FSSS protection circuit inspection;
1.6.1.26 Inspection of circulating pump house control system;
1.6.1.27 Inspection of fuel oil pump’s house control system;
1.6.1.28 Equipment inspection of air compressor room;
1.6.1.29 Calibration of all standard instruments and meters;
1.6.1.30 Inspection and test of all hydraulic valves;
1.6.1.31 Sweep the instrument and desk tray.
1.7 Standard items of major repair
Regulations of Thermal Control and Maintenance
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1.7.1 The major repair period of thermal control equipment is synchronous with major repair period of main
engine and the standard items of major repairs are as follows besides the standards of minor repairs:
1.7.1.1 Verification of all thermocouple and thermal resistance;
1.7.1.2 Verification of all special instruments and devices;
1.7.1.3 Verification of all pressure meters and differential pressure transmitters;
1.7.1.4 Verification of all pressure meters and thermometers;
1.7.1.5 Insulation inspection of all cables and compensating lines;
1.7.1.6 Leakproofness inspection of all pressure-containing members;
1.7.1.7 Inspection and verification of all sensors and pre-amplifiers of large and small crank shafts and system
transmission;
1.7.1.8 Verification of all the dial gauges;
1.7.1.9 Verification of all tachometers;
1.7.1.10 Program check of all programmed control system;
1.7.1.11 Static test of all regulator system; parameter setting and checking;
1.7.1.12 Linkage test of all equipment;
1.7.1.13 Site renovation of all equipment;
1.7.1.14 Verification of DCS system;
1.7.1.15 Verification of DEH, MEH system;
1.7.1.16 Verification of PLC system;
1.7.1.17 Hygiene sweeping of all equipments
2. Maintenance of primary equipment and control device (thermo technical measurement and
conventional instrument)
2.1 Maintenance rules on pressure switch
2.1.1 Overview
This section is to introduce the two-digit pressure switch produced by American SOR Company.
2.1.1.1 Technical specification
1) The model parameters of SOR are expressed as follows:
6---- NN---- K5---- M4---- CIA——— YY
Piston Enclosure Switch Diaphragm and pressure tap Annex
Element Spring specification O-ring

2) Switching error fixation: switching error is reached by basic error multiplying by a correction factor.
3) Switch element K-model
a. Single-pole switch element;
b. AC voltage class: 250VAC,15A;
c. DC voltage class: 30VDC,5A;

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

d. Working principle: sensing element of pressure switch: piston and spring pipe or corrugated pipe will
generate displacement when they bear pressure. When certain pressure value is reached, it will touch the
micro-switch to send contact signal for control or alarm.
2.1.2 Maintenance items and quality requirements
2.1.2.1 Appearance inspection: wiring shall be complete, marking shall be correct and complete and enclosure
shall be in good condition.
2.1.2.2 Switch disassembly: first disassemble the end cover, remove the wiring, mark it and bind with
insulating tape. Sample connection shall be blocked and sealed firmly.
2.1.2.3 Hygiene sweeping: external and internal switch shall be free of dust and sampling pipeline shall be
clean.
2.1.2.4 Switch calibration
1) Select suitable standard meter and calibration console.
2) Calibration steps:
a. Check the original value, which shall be true and accurate.
b. Check of pressure control range: adjust the set value to the maximum and booster slowly till the contact
acts; at this time, the pressure value on standard shall be the upper switching value of maximum value. Then
adjust the set value to the minimum, decompress slowly until the contact acts; at this time, the pressure value on
standard shall be the lower switching value of minimum value. The difference between upper switching value of
maximum value and lower switching value of minimum value shall be the pressure control range of switch and
the result shall conform to:
Pressure switch is (15~95) %× range
Vacuum switch: (95~15) %× range
c. Certification of set point error: adjust the set point to certain scale, booster slowly until contact acts and
the pressure value on standard shall be the upper switching value; then decompress slowly until the contact acts
and the pressure on standard shall be the lower switching value. Measure it by this method for three times and
the mid-value between average value of three-time upper switching value and lower switching value shall be the
switching mid-value. The percentage of the difference between switching mid-value and set point with range is
the set point error and the absolute value of the result shall not exceed the accuracy grade of switch.
d. Verification of switching error: when verifying the set value error, the difference value between average
value of upper switching value and average value of lower switching value at the same set point shall be the
switching error of switch and the value shall not be larger than 10% of range, unless it is specially specified by
manufacturer on switching error.
e. Verification of repeatability error: when verifying the set value error of controller, the percentage of the
larger one from the maximum difference value of upper switching value and lower switching value measured by
three times at the same verification point with range is the repeatability error of controller and the absolute
Regulations of Thermal Control and Maintenance
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

value shall not exceed the accuracy grade of switch.


f. Verification of insulation resistance: disconnect the controller and measure the resistance between
terminal and enclosure by 500VDC insulation resistance meter and the insulation resistance between terminals
shall be ≥20MΩ.
g. Sealing of switch adjustment unit: after switch verification is finished, seal the switch constant value
regulating device to prevent from change of constant value.
h. Measurement of contact resistance shall be ≤0.1Ω.
2.1.2.5 Switch installation
1) Install switch: handle with care during transportation to prevent from the change of fixed value; it shall
be installed on the original position and connector shall be connected tightly.
2) Recover wiring and number shall be clear and correct; line shall be fastened.
2.1.2.6 Secondary door inspection: it shall be smooth without leakage.
2.1.2.7 Terminal and signboard shall be clear and accurate.
2.1.2.8 Switching point information check: shall be accurate without error.
2.1.2.9 Software archiving: verification report shall conform to measurement requirements.
2.1.2.10 Operating maintenance
1) When unit is in normal operation, check whether switch connector part is free of leakage or seepage and
whether wiring is free of water drop on the site to prevent from short circuit.
2) Sweep switch on the site periodically and do not touch the thread end when sweeping.
3) For major and minor repair, disassemble the switch to check the sweeping and then verify and take the
original record. If set value needs to be re-adjusted, record it.
4) If water is flowing to the switch and diaphragm is damaged or set value can not be adjusted, take out the
diaphragm and replace the new diaphragm before verification. If it is qualified, use it continuously, or replace a
new switch. When contact is rusting, polish it and clean with gasoline.
2.1.2.11 Major repair and minor repair items
1) Disassemble the switch after isolation; sweep and check the appearance;
2) Switch calibration;
3) Contact valve inspection;
4) Cable insulation test;
5) Re-installation of switch;
6) Loop check and test.
2.2 Maintenance rules on differential pressure switch
2.2.1 Overview
Two-digit switch is produced by SOR Company. SOR model has 203 series and 204 series.
2.2.1.1 Technical specification
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1) Parameter description of SOR model:


203—— C—— AIA—— C—— B4—— N4—— CRTT×321
Model Connection type
Material Material Switching mechanism Switch end cap Accessory
sequence Bore

2) Switching mechanism (B4) :


a. Model: DPDT.
b. Switch pole: single-pole.
c. Switch contact: high temperature dry contact.
d. Switch electric grade.
Voltage Impendence current Inductance current
110~130VAC 5A 5A
210~250VAC 5A 5A
20~30VDC 1.5A 1A
110~130VDC 0.5A 0.25A

2.2.1.2 Working principle


Fix the magnet to the shaft shifting switching mechanism with fulcrum. When floating ball rises with
liquidometer, magnetism shaft sleeve will rise to the magnetic field generated by magnetism and magnet will
absorb to the external side of magnetism insulation tube rapidly to make switching mechanism act and send out
switch signal. Insulation tube has provided the pressure isolation between switching mechanism and process
opening. When liquid level drops, spring will haul back the magnet and switching mechanism will reset.
2.2.2 Maintenance items and quality standards
2.2.2.1 Appearance inspection: marking shall be accurate and complete and appearance is in good condition.
2.2.2.2 Calibration of measurement barrel body installation geometric position shall be accurate.
2.2.2.3 The action value of measuring switch shall be accurate.
2.2.2.4 Hygiene sweeping: internal and external switch shall be free of dust and sample pipeline shall be
clean.
2.2.2.5 Contact resistance measurement: contact resistance shall be ≤0.1Ω.
2.2.2.6 Contact ground (enclosure) insulation measurement: insulation resistance shall be ≥100MΩ.
2.2.2.7 Cable insulation measurement: wiring at two ends of cable shall be removed and cable ground and
insulation between phases test shall be ≥100MΩ.
2.2.2.8 Recover wiring: number shall be clear and correct and line shall be fastened.
2.2.2.9 Inspection of secondary door pipe: it shall be smooth without leakage.
2.2.2.10 Terminals and signboard inspection: it shall be clear and accurate.
2.2.2.11 Switch point information inspection: it shall be accurate without error.
2.2.2.12 Software archiving

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

2.2.2.13 Operating maintenance


1) When unit is in normal operation, check whether switch connector part is free of leakage or seepage
2) Sweep switch on the site periodically.
3) If switch contact is damaged, replace the new micro-switch.
2.2.2.14 Major and minor repair items
1) Switch calibration on the site.
2) Contact valve inspection.
3) Cable insulation test.
4) Loop check and test.
2.3 Maintenance rules on liquid level switch
2.3.1 Overview
Two-digit switch is produced by SOR Company. SOR model has 203 series and 204 series.
2.3.1.1 Technical specification:
1) Parameter description of SOR model:
203—— C—— AIA—— C—— B4—— N4—— CRTT×321
Model Connection type
Material Material Switching mechanism Switch end cap Accessory
sequence Bore

2) Switching mechanism (B4) .


a. Model: DPDT.
b. Switch pole: single-pole.
c. Switch contact: high temperature dry contact.
d. Switch electric grade.
Voltage Impendance current Inductance current
110~130VAC 5A 5A
210~250VAC 5A 5A
20~30VDC 1.5A 1A
110~130VDC 0.5A 0.25A

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

2.3.1.2 Working principle


Fix the magnet to the shaft shifting switching mechanism with fulcrum. When floating ball rises with
liquidometer, magnetism shaft sleeve will rise to the magnetic field generated by magnetism and magnet will
absorb to the external side of magnetism insulation tube rapidly to make switching mechanism act and send out
switch signal. Insulation tube has provided the pressure isolation between switching mechanism and process
opening. When liquid level drops, spring will haul back the magnet and switching mechanism will reset.
2.3.2 Maintenance items and quality standards
2.3.2.1 Appearance inspection: marking shall be accurate and complete and appearance is in good condition.
2.3.2.2 Calibration of measurement barrel body installation geometric position shall be accurate.
2.3.2.3 The action value of measuring switch shall be accurate.
2.3.2.4 Hygiene sweeping: internal and external switch shall be free of dust and sample pipeline shall be
clean.
2.3.2.5 Contact resistance measurement: contact resistance shall be ≤0.1Ω.
2.3.2.6 Contact ground (enclosure) insulation measurement: insulation resistance shall be ≥100MΩ.
2.3.2.7 Cable insulation measurement: wiring at two ends of cable shall be removed and cable ground and
insulation between phases test shall be ≥100MΩ.
2.3.2.8 Recover wiring: number shall be clear and correct and line shall be fastened.
2.3.2.9 Inspection of secondary door pipe: it shall be smooth without leakage.
2.3.2.10 Terminals and signboard inspection: it shall be clear and accurate.
2.3.2.11 Switch point information inspection: it shall be accurate without error.
2.3.2.12 Software archiving
2.3.2.13 Operating maintenance
1) When unit is in normal operation, check whether switch connector part is free of leakage or seepage.
2) Sweep switch on the site periodically.
3) If switch contact is damaged, replace the new micro-switch.
2.3.2.14 Major and minor repair items
1) Switch calibration on the site.
2) Contact valve inspection.
3) Cable insulation test.
4) Loop check and test.
2.4 Maintenance rules on ABB 266 series transmitter
2.4.1 Overview
2.4.1.1 Overview
ABB 266 series intelligent two-wire system transmitter can accurately and reliably measure the meter
pressure, absolute pressure, differential pressure or liquid level and send a HART/4 to 20MA output signal, or
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adopt PROFIBUS PA,FOUNDATION field bus and Modbus to protocol to send digital signal; it can be used for
far-end configuration and monitoring through software configuration.
2.4.1.2 Model of ABB 266 series transmitter
Pressure transmitter: 266GSH/266HSH
Differential pressure transmitter: 266DSH/266MSH(high hydrostatic pressure)
Liquid level transmitter: 266DDH(differential pressure) /266GDH&266HDH(pressure)
Far east tone transmitter: 266DRH(differential pressure) /266GRH&266HRH(pressure)
2.4.1.3 Technical performance and index
1) Object to be used: liquid, gas and steam.
2) Output: 4~20mA.
3) Power: 10.5VDC Maximum: 42VDC.
4) Load limit:
Total loop resistance under 4-20mA and HART conditions:
R(KΩ) =voltage-minimum working voltage (VDC)
22MA
At least 250Ωresistance is required for HART communication.
5) Output current limit
Overload condition: lower limit: 3.8mA (can be set within 3.8-4mA range)
Upper limit: 20.5mA (can be set within 20-21mA range)
Alarm current: lower limit: 3.6mA (can be set within 3.6-4mA range)
Upper limit: 21mA (can be set within 20-22mA range)
6) Temperature range: amplifier works within-20℃~/120℃.
7) Common-mode interference: it has no influence under the condition of 100Vrms@50HZ or 50V DC.
8) Precision: ±0.25% of adjustment range, including linear, variation and repeatability.
9) Stability: ±0.25% of URL during the ten-year trail period.
10) Power influence: the total effect shall be less than 0.005% of URL within specified voltage and load
limit range.
11) Opening time: Operate with the minimum damping within the longest 10s.
12) Migration of zero and range: zero and range can be adjusted as any value within limit range in the table,
but the premise is that calibration range shall be ≥minimum range.
2.4.1.4 Working principle
1) Working principle of measurement
ABB 266 series transmitter and pressure (differential pressure) transmitter voltage take voltage dependent
resistor as sensitive element. The measured pressure will be transferred to the measurement membrane of the
other side through isolation diaphragm so as to cause the voltage variation at both ends of resistor through the

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change in position.
2) Transformational component
The function of transformational component is to transfer the change of capacity ratio to 4~20mADC
standard signal so as to realize zero, range, positive and negative migration and damping adjustment and other
functions. Switching circuit is composed of demodulator, zero setting circuit, range circuit, current control
amplifier, current limit circuit, reference voltage and so on.

Demodulator Current probe

Test
Current limiter

Oscillator +

Current
-
amplifier
Oscillation
amplifier Voltage rectifier
Current controller

2.4.2 Maintenance items and quality requirements


2.4.2.1 Appearance inspection
It shall be complete without damage; parts shall be free of looseness.
2.4.2.2 Cable insulation test: use 100VDC meter to measure the resistance, which shall be larger than 20MΩ.
2.4.2.3 Ash removal: secondary door and instrument pipeline inspection, which shall be free of leakage.
2.4.2.4 Insulation resistance test
1) Connect the “+”and“-”of power (SUPPLY) in junction box by wire.
2) Disconnect the 100VDC insulating-resistance meter and connect insulating-resistance meter between
shorting stub and ground wire. Shorting stub shall be positive and ground wire shall be negative.
3) Connect the insulating-resistance meter for insulating resistance test. Pressurization time shall not be too
long and insulation resistance shall be larger than 20MΩ.
4) After test, disconnect the resistance meter and connect 100Ω resistance for discharge.
2.4.2.5 Zero adjustment
There are two methods for zero adjustment of pressure (differential pressure) transmitter: one is by
hand-held adjuster and the other is to use zero adjustment bolt.
1) Zero adjustment by zero adjustment bolt:
Make the input of transmitter as the lower limit of measurement:
Select external zero adjustment bolt “Allow/forbid zero adjustment” (ZERO.ADJ) on parameter option of
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hand-held adjuster and it will display “ENABLE”, press “ENTER” key twice to confirm that import transmitter
has been set as “Allow” before delivery. Use “一 ”character screwdriver to rotate the zero adjustment bolt on
enclosure of transmitter. For clockwise adjustment, output will be increased, or it will be decreased. The
precision of zero adjustment value can be 0.01% of range.
The display of zero adjustment can also be selected A10: OUTPUT% 0.0% display from hand-held adjuster
parameter and millammeter at this time will be 4mA.
Note: Do not disconnect power within 30s after zero adjustment, or zero will restore the original value.
2) Zero adjustment by hand-held adjuster:
When the lower limit pressure of transmitter is 0:
a. Search “J10:ZERO ADJ” parameter item and press “ENTER” key for twice, the zero at this time will
be adjusted to 0% automatically and signal output is 4MADC.
b. Press F4 key after zero adjustment is finished.
c. Select the parameter item A10: OUT PUT (%) and the display value is 0.0%.
When the lower limit pressure of transmitter is not 0, calculate the corresponding reference value with
actual measurement range, i.e. percentage of actual measurement value. Calculate by following formula:
Percentage of actual value= [(Actual value-lower limit) ÷ (upper limit-lower limit)]%
a. Input the zero pressure value of transmitter and the output of transmitter is X% of some value:
A10.OUTPUT (%) displays X%
b. Parameter option selects J10:ZERO A D J 0.0% and input the actual value percentage below. Pay
attention to input the plus-minus sign of percentage and confirm by pressing “ENTER” key for twice and the
output A10: OUTPUT (%) will be Y% of actual value output.
Due to the deviation between output and input parameter when adding pressure value, error correction
shall be taken.
Output error of this time=Y%-X%.
Select parameter optionJ11: ZERO and DEV will display Z%, which is the corrected value of previous
time.
Corrected value of this time= corrected value of previous time + output error (Y%-X%).
Input the corrected value of this time under J11: ZERO DEV option, press “ENTER” key for twice to finish
zero setting.
2.4.2.6 Verification
When verifying pressure (differential pressure) transmitter, the verification point shall not be less than 5 points:
including zero point and range and common points. After verification, check whether calculation results
conform to requirements. Fill in verification report if it is qualified and re-adjust it till it is qualified if it is
disqualified.
2.4.2.7 Start/stop steps of transmitter
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1) Input of pressure transmitter:


a. Open the blow-down valve for air discharge and sewage disposal.
b. Close the blow-down valve.
c. Slowly open the secondary valve.
d. Check whether it is free of leakage.
2) Stop of pressure transmitter:
a. Cut off the power.
b. Close the secondary valve.
3) Input of differential pressure transmitter:
a. Open the balance gate.
b. Open the blow-down valve at high and low pressure side for air discharge and sewage disposal.
c. Close the blow-down valve at high and low pressure side.
d. Open the secondary valve at high pressure side.
e. Close the balance gate.
f. Open the secondary valve at low pressure side.
g. Check whether it is free of leakage.
4) Stop of differential pressure transmitter:
a. Cut off the power.
b. Close the secondary valve at low pressure side.
c. Open the balance gate.
d. Close the secondary valve at high pressure side.
2.4.2.8 List of major repair items
1) Verification of transmitter: it’s required to follow measuring regulation and error shall be within
allowable range.
2) Cable insulation test: it shall reach the provision of requirement≥20MΩ.
3) Inspection of instrument piping: it’s required to be free of blocking and leakage.
4) Inspection of secondary valve: it’s required to be tight without leakage.
5) Loop check and test: signal is required to be correct.
2.5 Maintenance rules on bimetal thermometer
2.5.1 Overview
2.5.1.1 Overview
Bimetal thermometer can be used to measure the temperature of gas, liquid and steam directly, which has
the advantages of easy reading, firm and shock-proof. It can replace industrial mercury-in-glass thermometer
and it has three types: axial direction type, radial direction type and 135 degree direction type. The WSS angle
adjustable (universal) industrial bimetal thermometer selected by our plant has the functions and characteristics
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of general bimetal thermometer, which can adjust the angle of deflection of header within 90 degrees according
to user’s requirements to simplify type selection conditions. It adopts stainless steel housing protection, which
has strong resistance to corrosion. It is suitable for all kinds of environment and it is one of the general forms in
domestic and international today.
2.5.1.2 Technical index
Temperature measurement range : -80℃ ~ 500℃
Accuracy grade: 1.0grade, 1.5grade
Thermal response time :≤ 40S
Nominal pressure: ≤ 3MPa
Diameter of protective tube : ∮6、∮8、∮10
Diameter of header :∮120mm ( 100mm )
Placement depth:( 75 ~ 500 ) mm
Adjustable angle of header : 90°
Operating environmental condition of header:-20℃ ~ 60℃
2.5.1.3 Working principle
Bimetal thermometer temperature-sensing element adopts multi-turn straight spiral bimetallic strips with
one end fixed and another end connecting central spindle freely. Axial direction type thermometer indicator is
directly installed in central spindle (radial direction structure indicator is connected with central spindle through
corner spring) ; when temperature changes, temperature-sensing element free end will rotate and rotate indicator
of radial and central spindle will indicate the change value of measured medium temperature on scale.
The temperature measurement principle of WSS angle adjustable bimetal thermometer is the same as
general bimetal thermometer. It adopts flexible connection way in structure to connect protective tube and
header so that header may rotate along axial direction to adjust the angle of deflection of header. Meanwhile,
dial plate adopts adjustable structure, which can rotate 360°along with axis to adjust the temperature indicator
deviation.
2.5.2 Maintenance items and quality requirements
2.5.2.1 Appearance inspection
1) All parts of thermometer shall be free of corrosion and protective layer shall be firm, uniform and smooth.
2) Glass and other transparent materials used for the surface of thermometer shall be transparent without
defects or damage hindering correct reading.
3) Scale, figure or other marks on thermometer surface shall be complete, clear and correct.
4) The distance between indicator and dial face shall not be larger than 5mm, but it shall not contact dial face.
2.5.2.2 Adjustment items and technical standards
1) Equipment to be verified:
Standard: second-class mercurial thermometer
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Corollary equipment: freezing point groove, oil groove and reading glass (5-10) times
2) Verification methods:
Thermal bulb of thermometer must be immersed completely and the immersion length of protective tube
shall not be less than 75mm, nor shall it be larger than 500mm.
a. Verification sequence: the verification of thermometer shall be conducted on positive and negative
travels to upper limit or lower limit direction respectively point by point; measurement of upper limit and lower
limit is only verified on one-stroke.
b. Reading method: when reading measured thermometer indicating value, the sight shall be vertical to dial
plate; when using reading glass, the sight shall pass through the center of glass and the reading shall be
estimated to 1/10 of division value.
c. Zero verification: insert the temperature detection element of thermometer into freezing point groove of
ice and water mixture and take reading after indicating value is stable.
d. Verification of other points: insert the thermometer into thermostatic bath and take reading after
indicating value is stable. When reading, groove temperature deviation verification point temperature shall not
exceed +2℃(standard thermometer shall prevail) , record the indicating value of positive and negative travel of
standard thermometer and measured thermometer. During reading process, groove temperature change shall not
be larger than 0.1℃ (when groove temperature exceeds 300℃ and above, the groove temperature change shall
not be larger than 0.5℃).
e. Error calculation of measured thermometer:
Actual temperature of thermostatic bath=indicating value of standard thermometer + corrected value of this
thermometer
Measured thermometer error=indicating value of measured thermometer – actual temperature of
thermostatic bath
The error shall conform to the requirements in table below:

Accuracy class Allowable error (% of range)

1.0 +1.0

1.5 +1.5

2.5 +2.5

Hysterisis error of thermometer shall not be larger than the absolute value of allowable error.
The repeatability of thermometer shall not be larger than 1/2 of absolute value of allowable error.
f. Fill in verification record.
2.5.2.3 Content of operating maintenance
Hygiene sweeping: disc inspection, gauge reading inspection and instrument appearance inspection.
2.6 Maintenance rules on thermocouple

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2.6.1 Overview
Thermocouple is one of the common temperature-sensing elements in industry. It converts the temperature
signal into thermal electromotive force and equipped with display instrument and transmitter to realize the
measurement and signal conversion of temperature.
Thermocouple model can be classified into K graduation (nickel-chromium---nisiloy) and E graduation
(nickel-chromium---constantan) .
2.6.1.1 Technical requirements: See Table (I)
Range of
Name of thermocouple Grade Allowable error
application( ℃)
0~400 ±1.6℃

400~1100 ±0.4%t
Nickel-chromium---nisiloy
0~400 ±3℃

400~1300 ±0.75%t
Ⅰ -40~800 ±1.5℃ or ±0.4%t
Nickel-chromium---constantan Ⅱ -40~900 ±2.5℃ or ±0.75%t
Ⅲ -200~40 ±2.5℃ or ±1.5%t
Ⅰ -40~350 ±0.5℃ or ±0.4%t
Copper- constantan Ⅱ -40~350 ±1℃ or ±0.75%t
Ⅲ -200~40 ±1℃ or ±1.5%t

(Table I)
The allowable error of thermoelectromotive force of thermocouple (within specified temperature range,
when reference end temperature is 0 ℃ ) shall conform to the provisions in Table I when it is indicating by
temperature value.
2.6.1.2 Working principle
Temperature measurement principle of thermocouple is the physical phenomenon based on the condition
that two conductors with different components connect into loop and it will generate thermal electromotive
force in loop if the temperature of two connection points is different. Conductor of different component will
constitute the two electrodes of thermocouple. The bigger the temperature difference of two joints is, the bigger
the thermal electromotive force is. The three basic principles of thermocouple are: conductor homogeneous law,
middle conductor law and medium temperature law.

A电极
Electrode A

t0 t1

t0 I

B电极
Electrode B

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Figure I Temperature measurement principle of thermocouple

2.6.2 Maintenance items and quality requirements


2.6.2.1 General inspection
1) Check the insulation of thermocouple: Input—ground≥40MΩ
Input—power≥20MΩ
Power—ground≥20MΩ
2) Check whether electrode is free of crackle, delamination and abrasion; whether work terminal is free of
aperture and whether surface is smooth.
3) Metallographic inspection of protective casing: except surface inspection, it shall be sent to test group
for flaw detection verification. Replace the disqualified ones.
2.6.2.2 Method of verification
1) Place the tested thermocouple and standard thermocouple into the center of furnace for verification use.
Standard thermocouple shall be sheathed by porcelain sleeve and shall be placed into freezing point groove with
compensation wire. The total number shall not be more than 6. Verification point includes common point and
upper limit point shall be 5℃ higher than the maximum temperature point.
2) To guarantee the verification quality, the automatic verification device of thermocouple shall satisfy the
following technical conditions:
a. Except shove charge and wiring of thermocouple, the temperature rise, the whole process of the
verification of constant temperature, measurement and record can be automatically conducted, or automatically
conducted partially. However, the whole verification process must be conducted by the preset program and shall
accurate and reliable without misoperation.
b. Compare the furnace temperature with verification point temperature and the deviation shall not exceed
±5℃.
c. After furnace for verification reaches constant temperature, water temperature fluctuation shall be less
than 0.2℃/min during measurement and record of thermocouple potential.
d. The accuracy of instrument for automatic measurement and automatic record shall be the same with 0.05
level (or 0.02 level) DC low potentiometer.
e. The resolution ratio of instrument for automatic measurement and automatic record shall be not larger
than 10μV when verifying metallic thermocouple.
f. Verify the parasitic potential of automatic change-over of several thermocouples, which shall be less than
1μV when verifying metallic thermocouple.
g. It shall be equipped with automatic protective device, such as automatic alarm, automatic power-off
device, etc.
h. Print function includes the print of standard potential and temperature, thermal electromotive force of
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every test point of every tested thermocouple as well as the temperature error.
i. The time for temperature rise, constant temperature and verification of every test point shall be about
30min.
j. Temperature test of furnace for verification can be taken.
Working process: connect system wiring according to the tested object requirements, then determine the
calibration method (select the integer hundred degree or fixed point of thermometric scale with calibration key)
according to type selection key (corresponding to thermocouple type) , then input necessary parameters through
keyboard, press RUN key and device will start automatic verification of work condition. Calibrating apparatus
will firstly print the input parameters for calibrator for verification, then the temperature will automatically rise
to the first preset calibration point. After the temperature field is stable, take tour sampling by the sequence of
from the first point to the fifth point and the fifth point to the first point, calculate and print the verification
result of this point, then temperature will rise automatically to the second verification point for calibration and
print until the last verification point is printed. At this time, the display of calibrating apparatus will display:
“END” and send out audio alarm and the calibrating furnace power will be disconnected automatically after a
period of time.
2.6.2.3 Instrument for verifying thermocouple
1) Standard:
a. A first-class and second-class standard Pt-Rh 10-Pt thermocouple respectively.
b. A set of standard mercury thermometer with measurement range of —30 ~ 300 ℃ ; or second-class
standard platinum resistance thermometer can be selected.
2) Instrument and equipment:
a. Reference thermostat: the interior temperature of thermostate shall be (±0.1℃) .
b. Oil thermostatic bath: the temperature difference within effective working area shall be less than 0.2℃.
c. The maximum temperature of tube furnace shall be 1200 ℃ ; the deviation between the maximum
uniform thermal field center and furnace geometric center along axis shall not be larger than 10mm; the
temperature difference between any two points within the scope of uniform thermal field length not less than
60mm and radius of 14mm shall not be larger than 1℃.
d. Reading telescope or 3-5 times magnifier.
2.6.2.4 Verify the wiring diagram

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Standard
标准

Constant
恒温炉
temperature
furnace
Calibrating
检定仪
apparatus

冰 点 point
Freezing 槽 groove
Calibrated
被 检 11 被检2 2
Calibrated

2.6.3 Common fault causes and handling methods of thermocouple:


Fault
Cause analysis Handling method
phenomenon
1. Electric leakage of electrode in interior
thermocouple (short circuit)
2. The interior of thermocouple is humid.
3. Short circuit between binding post in 1. If it is caused by humidity after checking, then dry the
junction box of thermocouple. thermocouple; if it is due to poor porcelain tube insulation, then
4. Short circuit of compensating lead update it.
wire due to burnout of insulation. 2. Dry the protective casing of thermocouple and thermocouple
Thermal 5. Electrode metamorphism of respectively; check whether protective casing is free of air
electromotive thermocouple or hot junction will be leakage and water leakage; update the protective casing that is
force is smaller broken by corrosion. disqualified.
than actual value 6. Wrong matching connection of 3. Open the junction box and brush the connecting plate.
(display compensating lead wire and 4. Find out the short dot for handling or replace new
instrument thermocouple on type. compensating lead wire.
indicating value 7. Reverse connection of compensating 5. Replace thermocouple.
is low) lead wire with polarity of thermocouple. 6. Replace the compensating lead wire of the same type.
8. Installation position and depth of 7. Re-connect correctly.
penetration of thermocouple do not 8. Change the installation position and the depth of penetration.
conform to requirement. 9. Remove the high temperature zone from cold end.
9. Cold end temperature of thermocouple 10. Change it with the same type.
is too high.
10. Thermocouple type and secondary
instrument type are inconsistent.
1. Thermocouple type and secondary 1. Change it with the same type.
Thermal instrument type are inconsistent. 2. Change it with the same type.
electromotive 2. Compensating lead wire type and 3. Replace thermocouple.
force is larger thermocouple type are inconsistent. 4. Re-install according to provisions.
than actual value 3. Metamorphism of thermode. 5. Repair or replace insulating materials.
(display 4. Installation method, position or 6. Handle compensating lead wire to make the temperature of
instrument penetration depth of thermocouple is two junctions the same.
indicating value improper. 7. Check and eliminate interference source.
is high) 5. External power access thermocouple 8. Adjust reference temperature or take correction.
loop caused by insulation damage.

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Fault
Cause analysis Handling method
phenomenon
6. The temperature of two points between
compensating lead wire and thermode
connection is different.
7. Access of interference signal.
8.Reference end temperature of
thermocouple is high (when minus
temperature is measured)
1. Poor contact of thermode on binding 1. Reconnect.
post. 2. Take out the thermode of thermocouple from protective
2. Interrupted short circuit or ground casing, find out the fault point and eliminate.
phenomenon of thermocouple. 3. Replace new electrode.
Indicating value
3. Electrode of thermocouple seems 4. Install firmly.
of measuring
broken. 5. Find out the fault point and eliminate.
meter is unstable
4. Insecure installation of thermocouple
and swing.
5. Interrupted short circuit of ground of
compensating lead wire.
1. Metamorphism of thermode. 1. Replace the thermode.
2. Installation position and method of 2. Change the installation position and method.
thermocouple are improper. 3. Clear it.
3. Scale depositing on protective casing 4. Re-take insulation treatment to short circuit.
Error of
of thermocouple is too much. 5. Find out the broken line and re-connect.
thermocouple
4. Short circuit of measuring circuit 6. Tighten the binding post.
potential is big
(thermocouple and compensating lead
wire) .
5. Broken line of thermocouple loop.
6. Binding post is loosened.

2.6.4 Installation of thermocouple


2.6.4.1 It shall not be installed beside furnace or near heating object or high magnetic field.
2.6.4.2 Junction box of thermocouple shall not touch the wall of container of measured medium.
2.6.4.3 The cold end temperature of thermocouple shall generally not be higher than 100 ℃ and avoid the
places that may be caught in the rain.
2.6.4.4 When installing high temperature high voltage thermocouple, the seal of sealing face must be
guaranteed.
2.6.4.5 Thermocouple with porcelain protective casing must be avoided shock cooling and hot to prevent from
burst of porcelain tube.
2.6.5 Major repair items of thermocouple
2.6.5.1 Appearance inspection.
2.6.5.2 Inspection and change of temperature casing at abrasion place.
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2.6.5.3 Inspection and test of compensating lead wire and measurement circuit.
2.6.5.4 Element verification.
2.7 Maintenance rules on thermal resistance
2.7.1 Overview
2.7.1.1 Temperature measurement principle
Thermal resistance is the common temperature measurer used in power plant. The frequently used are
platinum thermistor and copper thermal resistance such as Pt100, Cu50 and Cu100, with usage range of -200~
+850 ℃ . Industrial platinum and copper thermal resistance is to measure the temperature by utilizing the
temperature variation of metallic resistance value.
2.7.1.2 Composition of thermal resistance
Thermal resistance is classified into common industrial thermal resistance and sheathed thermoresistor by
outline structure. The majority in our plant is sheathed thermoresistor. It is composed of temperature-sensing
element, metallic sheath, metallic lead, insulating materials and junction box.
2.7.1.3 Technical requirements f thermal
1) The appearance of assembly quality of thermal resistance shall conform to the following requirements:
a. All part assembly shall be correct, reliable without defect parts.
b. It shall be free of open circuit or short circuit.
c. Skeleton of thermal resistance shall be free of crackle and significant bend.
d. Protective tube shall be complete without damage and shall be free of dent, scratch and obvious
corrosion.
e. Surface coating shall be firm.
f. Thermal resistance shall have nameplate with the following marks: manufacturer name or emblem mark,
thermal resistance model, graduation number, allowable deviation grade, applicable temperature range,
ex-factory date and ex-factory number.
2) When environmental temperature is (15 ~ 35) ℃ and relative humidity is not larger than 80%, the
insulation resistance between temperature-sensing element of platinum thermistor and protective tube and
several temperature-sensing elements shall not be less than 100MΩ; copper thermal resistance shall not be less
than 20MΩ.
3) See Table 1 for the allowable deviation Et of actual resistance value of thermal resistance and graduation
nominal resistance represented by temperature:
Table 1:
Graduation
Name of thermal resistance Nominal resistance at 0℃ Et(℃)
number
Pt10 10
Platinum A-class ±(0.15+0.002|t|)
Pt100 100
thermistor
B-class Pt10 10 ±(0.30+0.005|t|)
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit
Pt100 100
Cu50 50
Copper thermal resistance ±(0.30+0.006|t|)
Cu100 100

Note: (1) |t| in Table 1 refers to the absolute value of temperature by degree centigrade.
(2) A-class allowable deviation is not applicable to the platinum thermistor adopting two-wire system.
(3) For platinum thermistor with R。=100.00R, the A-class allowable deviation is not applicable to t>
650℃ temperature range.
(4) Verification of two-wire system thermal resistance tolerance, including the resistance of internal lead,
if only temperature-sensing elements need to be taken deviation verification, manufacturer shall provide the
internal lead resistance.
4) The resistance ratio of thermal resistance between 100℃ and 0℃ is called resistance purity W100 and
see Table 2 for the allowable deviationΔWˊ100of nominal resistance ratio of W100.
5) New platinum thermistor shall be sufficiently stable. After upper and lower temperature endure 250h, the
conversion of resistance variation at 0℃ into temperature value shall not exceed the provisions in Table 3.
6) New platinum thermal resistance shall conform to the technical requirements of this regulation; thermal
resistance after repair and in service shall conform to the requirements of a, b, c, f clauses in Article I and
Article IV of this regulation.
Table 2:
Name of thermal resistance ΔWˊ100 ΔW100
Grade A ±0.0006
Platinum thermistor 1.3850
Grade B ±0.0012
Copper thermal resistance 1.428 ±0.002

Table 3:
Allowable deviation class Allowable variation
A 0.15
B 0.30

2.7.2 Maintenance items and quality requirements


2.7.2.1 Adjustment items and technical requirements of thermal resistance
1) Assembly quality and appearance inspection
Check whether thermal resistance has open circuit or short circuit by multi-meter and check other
assembly quality and appearance inspection by visual. Check whether porcelain sleeve of temperature-sensing
element is complete, whether resistance wire is free of damage and corrosion phenomena and whether
protective sleeve is complete without damage.
2) Measurement and requirements of insulation resistance
a. Measure the insulation resistance of thermal resistance by 100V megger. For measurement, all terminal
blocks of thermal resistance shall be in short circuit mutually and spliced to a binding post of megger and
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

another conductor of binding post of megger shall be connected on protective sleeve of thermal resistance.
b. Requirements of insulation resistance of thermal resistance:
The insulation resistance between platinum resistance temperature-sensing element and protective sleeve
shall not be less than 100MΩ;
The insulation resistance between copper resistance temperature-sensing element and protective sleeve
shall not be less than 20MΩ;
The insulation resistance of thermal resistance input end to ground shall not be less than 40 MΩ;
The insulation resistance of thermal resistance input end to power supply shall not be less than 20 MΩ;
The insulation resistance of power supply end to ground shall not be less than 20 MΩ
2.7.2.2 Standard and equipment for verifying thermal resistance
1) Second-class platinum resistance thermometer. For verifying copper thermal resistance, second-class
standard mercurial thermometer can also be taken.
2) The following auxiliary equipment can be selected according to different electric measurement
equipment: one 0.01 class 10Ωand 100Ωstandard resistance respectively.
3) Freezing point groove.
4) Water thermostatic bath or oil thermostatic bath, which shall conform to following technical
requirements:
The maximum temperature difference between water thermostatic bath jack shall not be larger than 0.01℃;
the vertical temperature difference in working area of oil thermostatic bath shall not be larger than 0.02℃ and
horizontal temperature difference shall not be larger than 0.01℃.
5) 100V megger.
6) Automatic calibrating apparatus of thermal resistance.
For verification, insert the thermal resistance with glass test tube into medium and the insertion depth of
test tube shall not be less than 300mm. When measuring the resistance of thermal resistance at 100 ℃ , the
temperature deviation of oil thermostatic bath at 100℃ shall not be larger than 2℃; temperature variation shall
not exceed 0.04℃ every 10 min.
2.7.2.3 Verification of thermal resistance
1) Automatic verification block diagram:

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

Verified
被校
Furnace for
检定炉
verification Subtracte
减法器 Recorder
记录仪 Regulator
调节器
use
Standard
标准

Function
函数
generator
发生器
Program
程序控制器
controller

2) Principle
During verification process, the function of program controller is to make the whole inspection process
conduct automatically by the preset program. It includes temperature rise indicator, constant temperature time
controller and record controller three parts. Indicator is to control the temperature rise process and gives out
signal when it reaches verification point temperature—constant temperature indicator will give out signal when
it reaches provisions—record controller will give out signal when it reaches provisions—circulation till the
program is over and record controller will give out signal to cut off power automatically.
3) Technical requirements of automatic calibrating apparatus
a. After oil groove reaches verification point, the temperature fluctuation shall be less than 0.2 ℃ /min
during measurement and record process.
b. The accuracy of instruments for automatic measurement and automatic record shall be the same with the
accuracy of 0.05 level (level 0.02) DC low potential potentiometer.
c. It shall have automatic protective device, such as automatic alarm, automatic cut-off power device.
d. The time for verification point temperature rise, constant temperature and verification is about 30min.
4) Working process
Connect the system wiring according to the requirements (two-wire system and three-wire system) of
tested object (thermal resistance) , then determine the calibration way according to the type option key
(corresponding to resistance type) , then input necessary parameters through keyboard and press the RUN key,
the device will start automatic inspection to work conditions.
Calibrating apparatus will firstly print the input parameter for verifiers for verification. For the verification
of resistance at 0 ℃ , use freezing point groove (ice flowers shall conform to requirements) . After the
temperature field is stable, take tour sampling by the sequence of from the first point to the N point and the N
point to the first point, then temperature will rise automatically to the 100℃ verification point for calibration
and print. At this time, the display of calibrating apparatus will display: “END” and send out audio alarm and
the calibrating furnace power will be disconnected automatically after a period of time.
2.7.2.4 Analysis and handling of common fault causes of temperature-sensing elements of thermal resistance

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

Instrument indication is lower than the actual temperature or indication is unstable:


a. Analyze the cause: there is water in protective casing;
There is metal filing or dust in junction box;
There is short circuit or contact ground between thermal resistances
b. Handling: take corresponding handling according to above causes. If it is still disqualified after handling,
replace the element.
2.7.2.5 Major and minor repair items of thermal resistance element
1) Spot check of minor repair
2) Weekly check of major repair
3) Check of temperature measurement system and test of insulation resistance.
4) Take system inspection to the main temperature measurement system.
2.8 aintenance rules on Bourdon gauge
2.8.1 Overview
2.8.1.1 Common type and specification of general single coil bourdon gauge

Structural style

Case diameter

A Ammonia, B Standard meter, C Oil forbidden for


Ammonia use, O hydrogen use, X electric contact
Y- Single coil pressure gage, Z- Single coil vacuum
guage, YZ- Single coil vacuum pressure gauge

Case diameter specification: 40, 60, 100, 150, 160, 200 and 250mm.
Structural style: null-radial direction without boundary; ZT-axial direction without boundary; T-radial
direction with boundary; Z-axial direction without boundary
2.8.1.2 Principle
Bourdon tube is also called bourdon tube, which is a hollow thin walled tube with cross section as ellipse
or oblate. The open end of bourdon tube is fixed on instrument joint socket, which is called fixed end. Pressure
signal is led in bourdon tube by joint socket and another end blocked, which is called free end. After measured
pressure is led in burden tube, free end will generate corresponding displacement, which will transmit to
amplifying structure of instrument through connecting rod. Bourdon tube will generate elastic deformation
according to Hooke's law, i.e. tubular elastic component and the size of deformation will form proportional
relation with the size of pressure within certain elastic range and thus forms bourdon tub pressure gauge.
Single coil bourdon gauge is classified into pressure gauge vacuum meter and pressure vacuum meter
III-class according to pressure measurement range, mainly including bourdon tube, transmission amplifying
structure, indicating mechanism and enclosure.
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

When pressure is led to bourdon tube, the free end 5 of bourdon tube will generate displacement and this
displacement will drive sector gear 7 to rotate by connecting rod 6 so that pinion 8 meshed with 7 will rotate
and indicator 9 fixed on pinion shaft will rotate also to take pressure value indication. One end of balance spring
is fixed with pinion shaft and another end fixed on support. By virtue of the elastic force of balance spring,
pinion only has one side occlusal surface with sector gear for occlusion, thus the measurement error between
sector gear and pinion due to occlusion interval face will be eliminated.
Sector gear has open slot at the end where is connected with pull rod to change the connection position
between pull rod and sector gear, which can change the transmission ratio of transmission mechanism. If R is to
show the radius of sector gear,, r is the distance between sector gear and pull rod connection point, under the
condition that bourdon tube free end displacement is the same, the larger than R/r ratio, the bigger the pointer
travel is. Therefore the change of R/r ratio can change the transmission amplification coefficient of instrument
so as to realize the adjustment of range full scale.
2.8.1.3 Technical index
Grade: precision pressure gauge: 0.2, 0.25, 0.35, and 0.5.
General pressure gauge: 1.0, 1.5, 2.5.
Instrument environmental temperature: 0.16 level: 20±2℃
0.25~0.5 level: 20±3℃
0~4.0 level: 20±5℃.
2.8.2 Maintenance items and quality requirements
2.8.2.1 General inspection
1) Appearance inspection: check whether bourdon gauge enclosure is complete without dust.
2) Hardware and mechanical part inspection
a. Instrument interior shall be clean and component and wire shall be aligned orderly; screw, nut and gasket
for fixing all components shall be complete and firm.
b. Instrument indicator shall be free of skew, blocking and bounce and the needle point shall have obvious
color.
c. The length of needle point shall cover 1/4 to 1/3 of the shortest reference line and the width shall not
exceed 1/5 of the minimum scale spacing.
d. Balance spring shall be uniform in circle distance, concentric and flat, spotless and damage-free. If
balance spring is slightly deformed, rectify it by tweezers. If it is significantly deformed, replace it.
e. If there is burr in pressure gauge sun gear or sector gear, polish it by needle file or emery cloth. If sun
gear is slightly worn, rotate to another angle for polishing.
f. Sun gear and sector gear shall be bright, flat and axle upper and lower part shall be smooth and straight.
Wheel shall be vertical to shaft.
g. The interval between sun gear and sector shaft as well as splint mating hole shall subject to not
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

exceeding 10 degrees of the angle of inclination in splint. If it exceeds 10 degrees, the mating interval is too big,
which shall be shrunk the cavity by punch or inserted bushing.
h. Bourdon tube shall be free of loophole or rent, or repair it or abandon it.
2.8.2.2 Adjustment items and verification standards
1) Verification of bourdon gauge
a. Bourdon gauge shall be taken leakage test. Pressurize to 1.25 times of full scale and withstand voltage
for 5 min, it shall have no significant influence to indicating value.
b. Zero indicating value shall conform to requirements. Pressure gauge with zero limit, and the pointer
shall adjoin on limit nail. “Indentation” shall not exceed the absolute value of maximum allowable intrinsic
error. Zero reference line shall not exceed twice of the absolute value of maximum allowable intrinsic error.
c. Verification of pressure indicating value shall be taken by reference line marked with figure and boost
(or vacuum) gradually for verification. When indicating value reaches the upper limit of measurement,
withstand the pressure for 3min. The difference of indicating value before and after tapping case and standard
shall not exceed 1/2 of the absolute value of maximum allowable intrinsic error.
d. During the lifting process of instrument, check whether indicating value is changed and whether pointer
has bouncing and dull phenomenon.
e. In case of error during verification, pointer adjustment method, sector gear and connecting rod
adjustment method, rotating bottom plate adjustment method, balance spring moment adjustment method,
connecting rod length adjustment method can be adopted to adjust error.
2) Verification results or verification period
a. Pre-seal or issue qualification certificate to pressure gauge after qualification and issue qualification
certificate also for sealing when necessary.
b. Pressure gauge that is disqualified is allowed to be used by degradation, but the accuracy grade mark
must be changed.
c. The verification period of pressure gauge can be determined according to specific condition, which
generally shall not exceed half a year.
2.8.2.3 Commissioning and operating maintenance of bourdon gauge
1) When commissioning bourdon gauge, the sequence is to open the primary gate first and then open the
secondary gate.
2) Operating maintenance
a. Primary and secondary gate shall rotate flexibly without leakage.
b. Instrument case shall be complete without damage and pointer shall be free of jam.
c. Sampling tube shall be free of cracks and deformation.
d. The hand wheels of all primary and secondary gates shall be complete without damage.
2.8.2.4 Major repair and minor repair items of bourdon gauge
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1) Hygiene sweeping in inside of pressure gauge: internal and external hygiene shall be clean without oil
and dust.
2) Disconnect the case and check whether sector gear, center shaft and all parts are complete.
3) Determine the volume of migration according to installation position and take migration.
4) Check the rear pipeline of primary gate and eliminate the defects.
5) Check the secondary gate and eliminate the defects.
2.9 Maintenance rules on UHZ
2.9.1 Overview
2.9.1.1 Working principle
Take side mount UHZ as example, it is composed of liquid meter cavity, columnar floater, magnetism
platform trap door and transmitter and alarm switch selected by user.
Liquid meter cavity can be taken as part of pressure vessel, which is connected with pressure vessel
through up and lower side flange. Thus the liquid level change in liquid meter cavity will be consistent with the
change of actual liquid level in pressure vessel. Liquid level signal is transmitted through the magnetic field
generated by magnet of columnar floater liquid meter cavity.
Magnetism platform trap door displays the liquid level, in which the red and white beads are arranged
uniformly in aluminium slot. When liquid level rises, the magnet in red and white bead is influenced by the
magnet in floater and drive bead to turn to red from white gradually from down to up. Similarly, when liquid
level drops, beads will turn to white from red gradually from up to down so that no power is needed to display
the change of liquid level in pressure vessel.
Transmitter or alarm switch is converted to standard 4~20mA current output signal or relay output signal
through the magnetic field generated by floater magnet and the change of actual liquid level of sampling.
Transmitter is mainly composed of resistance, reed switch and transmission module. When liquid level
drives floater to change from up to down, the magnetic field generated by floater magnet will cause the
actuation of reed switch uniformly arranged so as to decide the size of loop resistance of series resistor. It also
output 4~20mA current signal through the conversion of transmission module.
Alarm switch is mainly composed of reed switch and magnet. When liquid level drives floater to change
from up to down, the magnetic field generated by floater magnet will cause the actuation or release of reed
switch at corresponding position so as to output relay signal. The magnet of alarm switch makes the relay signal
output by magnet of alarm switch keep function.
2.9.1.2 Characteristics of instrument
1) The structure if simple, which can display the liquid level intuitively.
2) Reliable and durable, needing no special maintenance.
3) No power is needed for the operation of display unit and alarm switch.
4) It is not influenced by the high temperature, easy flow, combustible and toxicity and other factors of
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

tested liquid.
5) It can be used in high temperature and high voltage environment.
6) Corrosion resistance is strong, applicable to most of corrosive liquid.
7) It is applicable to the most of low-density liquid.
2.9.1.3 Technical parameters
Measuring distance: 0.3~10m
Accuracy: ±10mm
Pillar diameter: 10mm
Working pressure: 1.6MPa High pressure type≤4.0MPa
UPVC≤1.0MPa
Working temperature:-20℃~150℃ High temperature type:≤350℃
UPVC:-20℃~60℃
Medium density:≥0.45g/cm3
2.9.1.4 Output calibration of transmitter
1) Connect wire according to the wiring diagram of transmitter and pay attention to the positive and
negative of 24V power.
2) Flow in water slowly to make beads turn to zero of scale plate precisely (or low position preset by user)
and adjust the zero potentiometer to make the current output value as 4mA.
3) Flow in water slowly to make beads turn to full scale of scale plate precisely (or full scale preset by user)
and adjust the full scale potentiometer to make the current output value as 4mA.
4) Repeat the (2) and (3) step till the current output is accurate.
Note: Before delivery, transmitter has been strictly calibrated according to the zero and full scale of scale
plate. If user wants to calibrate extra, calibrate it for 2-3 times.
2.9.2 Maintenance items and quality standards
2.9.2.1 General inspection
1) Instrument appearance inspection: enclosure shall be complete without damage and dust.
2) Instrument signboard shall be clear in character, correct and complete.
3) Instrument terminal block inspection: screw and gasket shall be free of defect and dust.
2.9.2.2 Interior inspection of instrument
1) Disassemble the case and the interior shall be free of dust.
2) Interior elements of instrument shall be free of cold solder joint and desoldering.
3) Components shall be arranged in alignment without bend or deformation.
2.10 Maintenance rules on intelligent flow meter
2.10.1 Overview
Programmable flow totalizer is used to measure the parameters of starting boiler feed water and steam flow.
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

By adopting single chip microprocessor, it has high reliability, excellent stability and multiple application
functions, which can satisfy the measurement display of common industrial parameters.
2.10.1.1 Characteristics
1) It can display integer four-digit flow measurement value (0~9999 digit) ; can display integer ten-digit
flow accumulative measurement value (0~9999999999) ; can correct to three digits after decimal point (0.001)
for accumulation.
2) It adopts look-up table for calculation and take integrating control to superheated steam and saturated
steam.
3) High brightness LED display or large screen Chinese with backlight LCD liquid crystal display can be
selected to display the current measurement value.

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

2.10.1.2 Working principle


Frequency/ On-off input

LED display or LCDdisplay

Optoelectronic isolation
Transmis
sion
Optoelectronic output
isolation

Microprocessor Optoelectronic
isolation Switch
output
A / D converter
Channel switch
Analog input

Optoelectronic
isolation Commu
nication
Panel interface
settings

The principle block diagram of this instrument is as shown above. This integrating instrument is based on
single chip processor and converts all analog signals to digital signals by A/D converter through input signal.
Microprocessor displays the measured parameter value after comparison with sampling result and preset content
of digit.
Input signal:4~20mA
Accuracy: 0.2%FS± 1 digit or 0.5%FS±1 digit.
Display mode:0~9999 instantaneous flow rate measured value display;
0~999999999 aggregate-value.
Type of alarm: upper limit and lower limit alarm output of relay can be selected and LED alarm indication.
Type of setting: panel of touch key figure setting. Set value outage permanent retention. Parameter set
value is locked by password.
Protection mode: under voltage program reset automatically and working abnormal program reset
automatically; outage flow accumulated value keeping time is longer than two years; set parameter permanent
retention.
Operating environment:
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

Environment temperature:0~50℃
Relative humidity: ≤85RH
Supply voltage:AC220V+10~15%,50HZ±2HZ
Power consumption: ≤ 5W(220VAC power supply).
2.10.2 Maintenance items and quality standards
2.10.2.1 General inspection
1) Instrument appearance inspection: enclosure shall be complete without damage and dust.
2) Instrument signboard shall be clear in character, correct and complete.
3) Instrument terminal block inspection: screw and gasket shall be free of defect and dust.
2.10.1.2 Interior inspection of instrument
1) Disassemble the case and the interior shall be free of dust.
2) Interior elements of instrument shall be free of cold solder joint and desoldering.
3) Components shall be arranged in alignment without bend or deformation.
2.10.1.3 Nuclear test of instrument
1) Connect wire according to the figure below:
+
+ 220VAC
24VDC
Transmitter
generator
Pressure

1.220 V AC
22
+
mA

Input

2) Take POST (power on self test) for instrument and preheat for 10min.
3) After self-test is correct, it will turn to working condition automatically.
4) Add the differential pressure of another point and adjust the transmitter of another point; mA meter
indicator lamp shall display 4mA, instrument indication shall be 0, or adjust the instrument to another position.
5) Add range value and adjust the transmitter range screw; mA meter indicator lamp shall display 20mA
and instrument indication shall display full scale, or adjust the instrument range.
6) Respectively add signal and verify the middle contact indicating value. All contact indicating values
shall be within allowable error scope (calculate the allowable error according to the range and accuracy of
meter) .
7) Fill in verification report
2.10.3 Common faults and maintenance of instrument
2.10.3.1 Instrument indication is not correct.
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

1) Disassemble the instrument and mark out.


2) Connect the power line, input wire and confirm it without error.
3) Take POST for instrument and preheat for 10min.
4) Check the interior instrument parameter setting condition; if it is wrong data, re-input and re-save the
data.
5) Instrument calibration.
6) If calibration is disqualified, check whether instrument components are free of cold solder joint and
desoldering; whether components are damage; if it is damaged, replace it.
2.10.3.2 No indication of instrument
1) Check whether power supply of instrument is normal.
2) Check whether internal and external wiring of instrument terminal is firm.
3) Check whether instrument power loop is normal.
4) Check whether Nixie tube for display is normal; replace it if it is damaged.
2.10.3.3 List of major and minor repair items
1) Remove the ash on meter, take appearance inspection and input resistance test.
2) Take meter verification and fill in verification report.
3) Take field cable insulation resistance test.
4) Check the auxiliary equipment; confirm that power switch on and off is in good condition and terminal
number is clear, complete with firm wiring.
5) Power on and take system test; check and confirm that instrument indication shall be correct.
2.11 KM series ultrasonic wave material level detector
2.11.1 Overview
Working principle of ultrasonic wave material level detector:

Probe sends ultrasonic pulse signal to material surface direction and material surface will reflect echo and
this part of echo will be received by probe.

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

Transmitter will calculate the time difference between probe sending and receiving ultrasonic pulse signal.
The distance between probe working surface and material surface can be calculated by running time and sound
velocity:
D=c t/2
The values of the following measurements under ideal condition can be calculated through calculating the
given value:
 Material level: L
 Volume: V
 Quantity of material through measurement weir or open channel: Q
2.11.2 Technical parameter
Type:UWB-AAKA1
Supply voltage:115/230VAC 50/60HZ
Power consumption:30W
Working temperature:-49℃-149℃

Slot 3 belt 2 group 4-20MA output


Slot 1 select 2 points Slot 2deselect card
Transducer scanning card
NEMA-4X glass fiber reinforced plastics shell

Multipoint level meter


Serial number

2.11.3 Maintenance items and quality standard


2.11.3.1. Appearance inspection: marking shall be accurate and complete with appearance in good condition.
2.11.3.2 Geometric position calibration of measurement of barrel installation: accurate.
2.11.3.3 Operating value of measuring switch: accurate.
2.11.3.4 Hygiene sweeping: internal and external switch shall be free of dust and sampling pipeline shall be
clean.
2.11.3.5 Contact resistance measurement: contact resistance shall be ≤0.1Ω.
2.11.3.6 Contact ground (shell) insulation measurement: insulation resistance shall be ≥100MΩ.
2.11.3.7 Cable insulation measurement: remove the two-end wiring of cable; cable-ground and insulation
between phases test shall be ≥100MΩ.
2.11.3.8 Recover wiring: number shall be clear and correct and line shall be fastened.
2.11.3.9 Inspection of secondary gate: smooth without leakage.
2.11.3.10 Inspection of terminal and signboard: clear and accurate.
2.11.3.11 Inspection of switch point information: accurate without error.

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

3. Maintenance of primary equipment and control device (actuator control device)


3.1 Maintenance rules on SIT intelligent electric actuating mechanism
3.1.1 Overview
This maintenance rule is applicable to maintenance and major and minor repair items of electric actuating
mechanism of SIT series of Vinh Tan Power Plant.
AI and MI series intelligent electric actuating mechanism is driven by three-phase asynchronous motor and
reduced speed by worm and gear and drive hollow output shaft to output torque. Reducer has manual/electric
switching mechanism: when switching handle is on manual position, hand wheel will drive hollow output shaft
to rotate through clutch; when I t is electric operation, switching mechanism will fall to electric position
automatically and clutch will mesh worm gear and three-phase motor will drive hollow output shaft to rotate.
The rotation of actuator shaft is to transmit Hall effect impulse type sensor through acceleration gear, while
the axial displacement generated by motor worm axial force will transmit to mechanical type torque control
mechanism (switching mechanism) to realize the control of valve position and torque. Intelligent controller of
actuator receives the standard analog current control signal or switching value control signal or bus bar signal to
locate the output shaft of actuator and input signal to corresponding location; what’s more, it can locate the
position preset by control system according to interlocking control, two-wire control or emergency ESD event
signal.
3.1.2 Main technical parameters
Power supply: 380VAC 50HZ
Input and output signal: 4--20mA DC
Operating environmental temperature: -25℃ ~ +70℃(Flame-proof type: -20℃ ~ +60℃) 。
Relative environmental humidity: 5%--95%
Atmospheric pressure:86--106KPa。
Prohibited running time:0--99s adjustable。
Dead zone:0.1-9.9% adjustable(Default setting is 0.5%) 。
3.1.3 Maintenance items and quality requirements
3.1.3.1 General inspection
1) Equipment shall be free of obvious bruise and damage; equipment nameplate shall be complete and
clear; standard shall be correct; equipment leakproofness shall be in good condition without leakage.
2) Inspection of mechanical part: it shall be free of obvious damage part; check whether gear and hollow
shaft is free of damage; after checking, coat lubricating oil and seal the joint face of mechanical part; after all
inspections, check whether seal ring of enclosure is in good condition; tighten the screw while installing
enclosure to guarantee the good leakproofness of engine body.
3) Micro control panel shall be free of extraneous odor and abnormal color; LCD shall display normally.
4) Inspection of electric control part:
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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

a. Power in electronic power supply cabinet shall be normal.


b. Output signal of AP terminal block shall be normal.
c. Wiring of actuator shall be firm.
d. Insulation test:
Motor phase wire to ground insulation shall be ≥20MΩ; insulation between phases shall be ≥20MΩ.
Insulation between cable phases shall be ≥50MΩ; ground insulation shall be ≥20MΩ.
3.1.4 Adjustment items and technical standards
3.1.4.1 Preparations before debugging
1) Actuator has been correctly installed.
2) All set screw, connecting pieces and electrical connection parts have been tightened.
3) Ground connection and equipotential connection have been correctly implemented.
4) Electrical connection is correct without error.
5) All measures have been taken to prevent finger from touching running or moving parts.
6) Electric actuating mechanism and valves are in good condition without damage.
7) Check the power voltage, which shall conform to the nominal on actuator nameplate and then open the
power. Phase position needs not be checked. If preliminary check is not taken, then electric operation shall not
be taken. Infrared remote controller shall be at least used to finish primary setting.
3.1.5 Select site/stop/remote operation
The red option rotary knob can select site, stop and remote operation and every state can be locked by a
padlock with 6.5mm iron hook.
When selector is locked on local or remote position, stop function is still valid. Selector may also be locked
on stop state to prevent site or remote electric operation.

Figure 2
Field control
Clockwise rotate the red option rotary knob to site position and respectively rotate the back rotary knobs to
ON and OFF position. Anticlockwise rotate the red rotary knob to stop operation.
Remote control
Anticlockwise rotate the red selector rotary knob to remote position and the signal control value of remote
control determines the position of valve. Then clockwise rotate the red option rotary knob to stop the actuator

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

from operating.
3.1.5.1 Display of actuator
1) Valve position indication

Figure 3 Display of actuator


Composition of display:
1. Red-valve position indicator light (Full open)
2. Yellow-valve position indicator light (Middle)
3. Green- valve position indicator light (All-off)
4. Liquid crystal display (LCD) -valve position indication
5. Liquid crystal display (LCD) -running status indication
6. Infrared ray reception indicator light and alarm indication (Red)
7. Infrared ray reception sensor
After power on, the yellow background lamp of actuator LCD and an indicator light of indicating valve
will also be lightened and valve display can display the percentage of opening of valve or the symbol of travel
tail end. (See Figure 4.1、4.2、4.3)
According to the standard, red light indicates that valve is opened; yellow light indicates that it is in the
middle; green light indicates that valve is closed. The color of open valve and closing valve indicator light can
be turned over according to requirements.

Keep the valve position

Figure 4.1
Full open is indicated by red indicator light and open signal.

Keep the valve position

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Vietnam Yunghsin Period Ⅱ 2×622MWcoal-fired Generating Unit

Figure 4.2
Travel middle is indicated by yellow indicator light and percentage open value.

Keep the valve position

Figure 4.3
All-off is indicated by green indicator light and close symbol.
After main power supply is closed, LCD is supplier power by battery to continue displaying the valve
position of actuator. No matter what condition it is, battery will not supply power to background light and valve
indicator light.
2) Running status indication
Running status indication is classified into normal running status indication and alarm status indication.
a. Normal running status indication
Normal running status indication: upper screen will display the working condition of actuator and the
lower screen will display the input control signal.
Normal running status indication is as shown in figure below:

Keep the valve position

Figure 5.1: Stop state

Valve-opening is running

Figure 5.2 Valve opening state

Valve-opening is running

Figure 5.3 Valve-closing state


b. Alarm status indication
⑴ Valve alarm indication:

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Over-moment alarm
Valve blocking alarm
Over-moment alarm indication is as shown in figure below:

Valve fault alarm


Close direction over moment

Figure 6.1

Valve fault alarm


Open direction blocking

Figure 6.2

Valve fault alarm


Full direction blocking

Figure 6.3
During operating process of actuator, if the detected moment value has exceeded the maximum moment set
value on this operating direction, take moment jumping protection and the electric operation on this direction
will be static. Close direction over moment is as shown in Figure 6.1; open direction over moment is as shown
in Figure 6.2; full direction over moment is as shown in Figure 6.3. If actuator operates along the opposite
direction, alarm indication can be eliminated. If moment set needs to be changed, disassemble the moment
control hood and reset.
Valve blocking alarm is as shown in figure below:

Valve fault alarm


Close direction blocking

Figure 7.1 Close direction blocking

Valve fault alarm


Open direction blocking

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Figure 7.2 Open direction blocking

Valve fault alarm


Full direction blocking

Figure 7.3 Full direction blocking


When actuator is in positive line and negative line running process, control circuit will detect valve
position real time. If the internal control system of actuator sends a positive line or negative line command and
real-time detection has not detected the change of valve position signal within 7s, then control system will send
out valve blocking alarm and trip contact signal. Moreover, the electric operation on this direction will be
prohibited and operate with reverse direction, then the alarm display can be eliminated.
Note: when accessing setting status, blocking protection will be relieved automatically.
(2) Control system alarm indication:
Emergency alarm
Interrupt signal alarm

Control alarm
Emergency

Figure 8 Emergency alarm


Emergency alarm: actuator will take position protection, full open and all-off positioning to control
operation according to presetting. When emergency signal is removed, control alarm will be eliminated.

Control alarm
Interrupt signal

Figure 9 Interrupt signal alarm


When input control signal is lost, control alarm will display interrupt signal and actuator will take position
protection, full open and all-off positioning to control operation according to presetting. Once signal is
recovered, control alarm will display elimination.
⑶Actuator alarm indication:
 Motor temperature alarm

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Actuator alarm
Motor trips due to over temperature

Figure 10
When motor temperature exceeds the limiting temperature, alarm will display to prohibit electric operation.
When motor temperature reduces to limiting temperature, alarm display will disappear.
 Low battery alarm

Actuator alarm
Low battery

Figure 11
When actuator detects low battery during self-inspection, alarm will display. After battery is replaced,
alarm display will disappear.
 Internal power failure alarm

Actuator alarm
Internal power failure

Figure 12
When actuator detects internal power failure during AC self-inspection, alarm will display.
 Power default phase alarm

Actuator alarm
Power default phase

Figure 13
When actuator system detects power default phase during connecting power, or during operation of
actuator, it will send the order to cut off the power of motor and alarm will display. Alarm will not disappear
until actuator detects the normal power.
 Internal system fault alarm of actuator
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Actuator alarm
Internal system fault

Figure 14
When actuator detects the fault existed by system itself during self-inspection process, alarm will display
and electric operation will be prohibited.
 Valve position signal loss alarm

Actuator alarm
Valve position signal loss

Figure 15

When valve position in control system is disconnected or not connected which has caused valve position
signal loss, alarm will display and electric operation will be prohibited. When actuator control system
re-receives effective valve position signal, alarm will be relieved.
 Local wiring fault alarm

Actuator alarm
Local wiring fault

Figure 16
When system panel wiring is fallen, alarm will display.
This actuator used non-intrusive setting, that is, it’s not necessary to open electric end cap for debugging
after wiring is finished. The setting of moment, travel and other functions can be realized by using infrared
remote controller. Controller can be debugged with power within dangerous area after authentication of intrinsic
safety type.
All setting functions can be stored in memory of actuator. All functional parameters of actuator can be set
and modified through remote controller and all function and parameter set values can be found on display
screen. When necessary, it can be changed through remote controller. All parameters and functions have default
settings for ex-factory inspection.

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This default setting can be taken as reference when debugging.


Setting procedure is classified into two levels:
Primary setting—set the primary level
Secondary setting-set control, indication and alternative functions.
3.1.6 Remote controller
Remote controller setter can set the control, indication and protective functions of actuator according to field
requirements. All actuators shall be checked the compatibility with process control system requirement before
debugging and putting into operation.
Performance:
Level of protection: IP67
Explosion proofing authentication ibIIBT4 (Intrinsic safety type)
Power: 9V battery (Has been provided and installed)
Usage distance: 0.75m (from display window of actuator)

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Name Description Figure 28 Remote controller


Down to display next function or
1.↓ Setting up area of function parameter
reduce a numerical magnitude
Operation of remote-controlling
Up to display previous function or add
2.↑
a numerical magnitude
3.OK Confirm new set value or option
4. Back to the previous level display state
Local operation of infrared remote controller
5.Stop Stop actuator
6. Open actuator
7. Close actuator
8. Infrared ray beaming window

Change of battery for remote controller:


Battery state can be checked by infrared beaming window. Press any key and the red indicator light in
window shall be brilliant.
Battery change must be taken in safety region. Disassemble the six bolts at the back of remote controller
and remove the rear cover to change battery.
If it is used in dangerous area, pay attention to the type of replaceable battery marked in rear cover of
remote controller.
When re-assembling rear cover, make sure that red indicator light has the consistent direction with infrared
beaming window direction of rear cover.
When pressing the key, remote controller will send relevant command to actuator through infrared ray.
Therefore remote controller must be aligned at actuator and shall be used within 0.75m range.
3.1.7 Function and parameter setting of actuator control system
After actuator is connected with valve reliably, connect the main power and turn the option rotary button of
actuator to stop position or local operation position, then setting can be taken.
The upper display screen above the whole display window is valve position indication display and the
lower display screen is running status indication display.
During setting process, valve position display screen only displays the change of valve position. Running
status indication display screen will vary with the difference of function and parameter. Up and down frame
indications all refer to the contents of running status indication screen.

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3.1.8 Routine maintenance during operation


3.1.8.1 Observe whether LCD has alarm message.
3.1.8.2 Observe whether lubricating oil is free of leakage and deficiency.
3.1.9 Minor repair items
3.1.9.1 Wiring terminal shall be firmly connected and dust in control unit shall be swept.
3.1.9.2 Control panel and connection panel shall be sealed.
3.1.9.3 Cable insulation shall be in good condition and cable sleeve joint shall be firmly connected.
3.1.9.4 DCS operation shall be flexible and feedback shall be correct.
3.1.10 Major repair items
3.1.10.1 Wiring terminal shall be firmly connected and dust in control unit shall be swept.
3.1.10.2 Check the external control loop wiring and test insulation.
3.1.10.3 Screw connecting actuator with mechanical part shall be tightened and rotating element shall be
refueled.
3.1.10.4 Valve positioning check shall be taken and re-position when necessary.
3.1.10.5 Interior lubricating oil in gear box shall be replaced.
3.1.10.6 DCS operation shall be flexible and feedback shall be correct.

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3.2 Maintenance rules on pneumatic actuator


3.2.1 Overview
3.2.1.1 Overview
Pneumatic actuator refers to actuator with compressed air as power source. Pneumatic actuator mainly
includes diaphragm type and piston type and diaphragm type actuator is of the widest application. In pneumatic
base regulating system, diaphragm type actuator is majorly adopted. Since piston actuator may obtain large
thrust, it is applicable to places where high hydrostatic pressure, high differential pressure and large thrust and
displacement are required (corner or linear displacement) .
Pneumatic actuator is mainly composed of pneumatic convertor, valve positioner, position transmitter, solenoid
valve, travel switch, air filtration reducing valve and valve noumenon.
3.2.1.2 Working principle
Pneumatic convertor receives 4 ~ 20mADC signal and convert it into 0.02 ~ 0.1Mpa pneumatic signal.
After amplification by valve positioned, it outputs air to the air chamber of actuator and diaphragm (or piston)
will drive output link to move. Displacement of valve rod will send to position transmitter through feedback
device and position transmitter will convert it into 4 ~ 20mADC output. When valve is in full open, all-off
position, travel switch will send the display of valve full open and all-off signal through ON-OFF. For
pneumatic actuator with lock up valve, it can guarantee that valve position will not change when air source,
power source and control signal disappear.
3.2.1.3 Technical requirements
1) Pneumatic convertor
Input signal:4~20mADC,Impedance(176±10) Ω.
Output signal: 3~15psi (0.02~0.1Mpa) and 6~30 psi(0.04~0.2 Mpa) two kinds.
Psi (0.35 Mpa) 。At least 5 psi (0.03 Mpa) larger than upper limit of output and the maximum is 50 psi
(0.35 Mpa).
2) Valve positioner:
Input signal: 3~15 psi and 6~30 psi two kinds.
Output signal: output is determined according to the requirement of actuator and the maximum is 95% of
air supply pressure.
Air supply pressure: at least larger than the maximum value 5 psi required by actuator and the maximum is
50 psi.
3) Position transmitter:
Output signal: normal range is 4 ~ 20mA; maximum is 30mADC; load capacity is 11 ~ 30VDC; power
supply is 0~900Ω(24VDC corresponds 650Ω).
Power supply: voltage is 11~30VDC, rated voltage is 24VDC and maximum current is 20mA.
3.2.1.4 Application
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Pneumatic actuator is applied in deaerator water level control, shaft seal pressure control, high and low
pressure heater drain control, soot blowing and steam pressure control.
3.2.2 Maintenance items and quality requirements
3.2.2.1 General inspection
1) Appearance inspection:
Check whether appearance of actuator is free of obvious damage; whether air supply pipeline is free of
leakage; whether air supply pipeline direction is straight and free of flattening; whether pressure gauge is
damaged; whether pneumatic convertor and reducing valve is in good sealing; whether air supply pipe is flowed
and all accessories are firm.
Insulation test:
a. Solenoid valve ground insulation shall be ≥20MΩ.
b. Insulation between cable phases shall be ≥20MΩ and ground insulation shall be 50MΩ.
3) Take solenoid valve winding DC resistance test and resistance shall conform to the requirements of all
equipment specifications.
4) Hygiene sweeping:
a. Reducing valve shall be removed the sewage, which shall be thorough and clean.
b. Clear pneumatic convertor, valve positioned and the dirt in reducing valve.
3.2.2.2 Adjustment item and technical standard
1) Adjustment of pneumatic converter (take direct action as example) :
a. Input 4mADC signal and observe whether output is 0.02Mpa. If it is not, adjust ZERO rotary knob to
make output pressure as 0.02Mpa.
b. Input 20mADC signal and observe whether output is 0.1Mpa. If it is not, adjust SPAN rotary knob to
make output pressure as 0.1Mpa.
c. Repeat the above steps till when inputting 4mA and 20mA, output is 0.02Mpa and 0.1Mpa.
2) Adjustment of positioned (take fisher direct action, input signal 0.02~0.1 Mpa as example) :
a. Input 0.02Mpa signal and observe whether actuator is in all-off position, or loosen the nozzle and lock
the nut. Adjust the distance between nozzle and baffle to make actuator reach all-off position and lock nut.
b. Input 0.1Mpa signal and observe whether actuator is in full open position, or adjust the baffle’s position
on push plate till actuator is in full open position.
c. Repeat above steps till the output position corresponding to input 0.02 Mpa~0.1 Mpa is correct and
lock the nut.
3) Adjustment of position transmitter (Take pneumatic valve as example):
a. Adjust the actuator to all-off position and measure whether position change output current is 4mA; if
the deviation is large, adjust ZERO potentiometer to make output current 4mADC.
b. Adjust the actuator to full open position and measure whether position change output current is 20mA;
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if the deviation is large, adjust SPAN potentiometer to make output current 20mADC.
c. Repeat above steps till the corresponding output 20mA and 4mA of full open and all-off position is
correct.
3.2.2.3 Adjustment of travel switch (only for actuator with travel switch)
1) After position transmitter is adjusted, fix the pinion relevant to position transmitter signal; press the cam
connected with travel switch and rotate cam position to make corresponding travel switch act when actuator is
in full open and all-off position.
2) After adjustment, tighten all screws.
3.2.2.4 Adjustment of positioned (take cam with linear as example)
1) Make actuator at 50% opening and adjust the cam fulcrum to make it just at 50% scale of cam.
2) Input 50% signal and adjust zero to make actuator just at 50% opening.
3) Input 100% signal and adjust range to make actuator just at full open position.
4) Repeat 2.5.1 and 2.5.3 till it conforms to requirements.
5) Actuator exists nonlinearity at ±3% opening, which can be compensated by the length of contact
connecting with feedback rod and the length of feedback rod on output link.
3.2.2.5 Adjustment of lock up valve
Slowly reduce air supply pressure to make the air supply pressure value as set value of lock up valve when
actuator does not act. The difference between lock up valve and reducing valve shall be at least 0.1Mpa, or it
will easily take place vibration.
3.2.2.6 Adjustment of system
Input 4-20mADC signal on pneumatic converter and actuator shall be from all-off to full open position.
Position transmitter shall send out 4-20mADC signal and then take out at least 5 points (including zero and full
scale) for verification. When losing air supply pressure, power supply and control signal, actuator shall remain
unchanged (to lock up valve).
3.2.3 Operating maintenance
3.2.3.1 Routine maintenance
1) Check whether air supply pipeline is free of leakage and whether the direction is straight without
flattening phenomenon.
2) Check whether pneumatic converter and reducing valve is in good seal and whether air supply pipe is
flooded with water.
3) Check whether pressure gauge is damaged.
4) Check whether all accessories are fixed firmly and actuator is free of obvious damage.
3.2.3.2 Start and stop step
1) Start step: open the air supply valve of all parts and supply power to pneumatic convertor.
2) Stop step: disconnect the power of pneumatic converter and then close the air supply valve.
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3) General fault handling:


a. Phenomenon: no input signal for pneumatic converter.
Causes: A. cable fault; B. card fault.
b. Phenomenon: valve does not move.
Causes: A. valve is jammed; B. no air supply; C. pneumatic converter fault.
c. Phenomenon: valve shakes.
Causes: inside screw of positioned is loosened.
d. Phenomenon: valve opening is inconsistent with input signal.
Causes: A. pneumatic converter is inaccurate; B. positioned is inaccurate; C. air supply pressure is
inappropriate.
3.2.4 Major repair items
3.2.4.1 Inspection of air leakage of all connecting components.
3.2.4.2 Maintenance of reducing valve and filter.
3.2.4.3 Checking and cleaning of solenoid valve and cable test.
3.2.4.4 Adjustment of position transmitter.
3.2.4.5 Determination of full travel action time.
3.3 Maintenance of ROTORK actuator
3.3.1 Overview
3.3.1.1 ROTORK actuator used for plant is produced by ROTORK, but with different technical specification.
The specific technical specifications are as follows:
ROTORK:
Actuator type:IQML10-F10-A
Speed:0.9mm/sec
Motor rating: 0.08KW
Motor supply: 380-3-50
Seating thrust max:15888N
Modulating thrust max:7944N
3.3.1.2 Electrical specification of IQ actuator
IQ actuator can work under the condition that voltage deviation is 10% and frequency deviation is 5%.
Adopt high-moment, low-inertia three-phase F-class squirrel cage motor that is specially designed. Under
standard voltage, operate it with 33% rated output moment, 25% cycle length coefficient for 15min and
temperature rise shall not exceed the allowable value of B-class insulation.
IQ single-phase squirrel cage, capacitor start/operation sensing is motor.
1) Moment switch and position control:
a. Position setting range
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2.5-100,000 circles. The minimum angular resolution of output center sleeve of actuator is 15 degrees.
b. Setting of moment switch:
40% to 100% of rated moment
Remote control power of actuator: rated power is 15VA; rated voltage is 120VAC.
c. Remote control has 6 control input terminals:
Open valve, close valve, stop/keeping
Emergency protection (ESD)
An effective ESD signal will surpass any site or remote control signal. Power common port operated by
ESD is independent to remote control signal of open valve, close valve and stop.
ESD option configurations are as follows:
ESD signal: high level on (closing of contact) ; low level on (breaking of contact) .
ESD action: close valve, open valve and keeping position.
ESD precedence: surpass motor temperature protection * * , local stop, interlocking operation, interrupt
timer.
2) Open valve interlocking and close valve interlocking
Control function
Corresponding position of low input signal: close limit, middle position and open limit.
Corresponding position of high input signal: close limit, middle position and open limit.
Dead zone: the travel between full open and all-off limit is 0~9.9%.
Forbidden running time: 2~99s
3.3.1.3 Remote valve position and monitoring display
Four passives and unipolar lockable contact S1, S2, S3 and S4 have been provided. Every contact may use
IQ to set one of the following signals:
1) Valve position
Full open, all-off (accurate) or any middle position (0~99%) .
2) Status
Valve is being opened, being closed, being operating (continuous or pulse signal) , select local stop, select
local, select remote, open valve or close valve, interlocking start, ESD start.
3) Valve alarm
Moment jumps when motor is in operation, moment jumps when motor is in open valve, moment jumps
when motor is in close valve, valve gets stuck, actuator is operated by hand wheel.
4) Actuator alarm
Power supply phase losing, lost of internal 24V DC (120V AC) , too low battery voltage, internal
inspection fault, temperature protection trips.
Every contact may set “normally open” or “normally closed) . Contact capacity is 5mA-5A,120V AC or
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30V DC.
S1- Close for all-off.
S2- Close for full open.
S3-Disconnect for all-off.
S4-Disconnect for full open.
3.3.2 Maintenance items and quality standards
3.3.2.1 Maintenance items
1) Maintenance of actuator components
a. Drive sleeve;
b. Manual/automatic handle;
c. Hand wheel;
d. Mechanical stop;
e. Motor or reduction gearbox.
f. Main control panel and feedback circuit board.
2) Maintenance of actuator installation:
a. Installation of actuator output shaft.
b. Install the actuator on valve.
3) Maintenance items of actuator debugging:
a. Determination of baffle switch position;
b. Determination of actuator’s direction of motion;
c. Determination of ON and OFF position of actuator;
d. Determination of actuator torque;
e. Adjustment of working range of dead zone of actuator;
f. Determination of category and size of control signal of actuator;
g. Adjustment of feedback signal of actuator.
4) Maintenance process:
a. Maintenance of drive sleeve: drive sleeve can be processed according to different valves.
b. Manual/automatic handle: used to realize the conversion of manual and automatic.
c. Mechanical stop: used to fix the switch position of valve, which is composed of two stop bolts to mainly
check whether it is tightened.
d. Motor and reduction box: check the performance and rotation condition of motor; reduction box is
mainly used to check the mesh condition and abrasion condition.
e. Control circuit boards: check the connection of all connecting plugs; check the working condition of all
electronic components.
5) Installation process of actuator:
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a. Select suitable base and weld the base on noumenon.


b. Fix the actuator on base by screw.
c. Install the actuating arm and fix the cardan joint on actuating arm.
d. Connect the actuating arm with connecting rod correctly through cardan joint.
6) Debugging process of actuator:
a. Determination of baffle switch position: firstly determine the switch position of connecting rod when
baffle is full open and all-off.
b. Limit of actuator: after the ON and OFF position of baffle is determined, stop bolt can be used to
correctly determine the ON and OFF position of actuator.
c. Determine the motor direction of motion: first, confirm whether motor is opened clockwise or
anticlockwise; second, confirm that corresponding motor shall be close direction of motion when control signal
is 4mA. After above two points are confirmed, the fixed switch can be utilized to set the motor direction of
motion.
d. Setting of motor torque: torque can be adjusted according to the degree of tightness of baffle actually
linked.
e. Adjustment of dead zone of motor: to extend the service life of actuator and reduce the vibration of
actuator action, it shall be paid special attention while adjusting dead zone to guarantee that the action is
flexible but not frequent.
f. Category selection of control signal and debugging of control signal: we select 4-20mA analog quantity
for the control signal of “IQ” actuator, which can be set by the switch on main board.
g. Make baffle output 4mA for all-off and 20mA for full open through adjusting “SPAN”“ZERO” rotary
knob on feedback board.
3.3.2.2 Maintenance process standard
1) Shaft sleeve must be fixed by a locking bolt.
2 Manual/ automatic handle must switch every working condition correctly.
3) Mechanical backstop shall be adjusted to the position suitable for valve opening and closing.
4) Reduction box must be flexible.
5) All connecting plugs on circuit board must be connected firmly; all electronic elements on circuit board
must be free of looseness and all relay contact must be free of burnout.
6) Actuator must be cushioned by spring cushion and fixed by screw; base must be welded firmly and
reliably.
7) Cardan joint on connecting rod must be flexible without jam; the plan formed by connecting rod and
actuating arm must be vertical with the output shaft of actuator; the hole to fix cardan joint must be consistent
with the shaft diameter of cardan joint without moving gap.
8) Torque limit of motor must guarantee that baffle can be opened and closed flexibly.
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9) Feedback signal shall be accurate without error, that is 20mA for full open and 4mA for all-off.
Feedback signal in the middle position must have favorable linear relation.
3.3.2.3 Common faults and handling methods
1) There is control signal but actuator does not act:
The reason behind this is usually that main control panel is damaged and the phenomenon is the frequent
flicker of open and closure torque light on actuator but actuator does not act.
Handling method: replace the main control panel.
2) Poor linearity of actuator feedback signal:
There are several reasons behind this condition: the first is that the angle deviation between the position of
baffle and actuator is too big; the second is that control signal is not regulated properly and the error is big; the
third is that position return is not regulated properly and the error is big; the fourth is the poor quality of
potentiometer. Handling method: adjust carefully for several times to make sure that error is within the range.
3) Error appears in position return
There are several reasons behind this condition: the first is that position return line is damaged; the second
is that trimming potentiometer is damaged; the third is that position transmitter is loosened. Handling method:
the first is to check the position return line and the second is to replace position transmitter or trimming
potentiometer.
3.4 Maintenance rules on SMC series pneumatic actuator
3.4.1 Overview
3.4.1.1 Overview
This maintenance rule is applicable to the maintenance and major and minor repair items of SMC series
pneumatic actuator of Tianjin Bailu Ertong Machinery Co., Ltd.
SMC series valve switch pneumatic device is the execution unit of SCS control system, which is applicable
to the operation of brake valve, stop valve and other valves. The function is to receive the switch order of
control system, drive valve action and realize remote control. It has integrated motor, reducer, part electric
secondary control loop and status feedback on electric device. The level of protection is IP55 and output torque
range is 50-10000Nm; output speed range: 12-36rpm. It is widely used in our plant.
3.4.1.2 Basic technical parameter (Take TYPE as example)
1) Significance of parameter on SMC series actuator nameplate:
Actuator nameplate:TYPE: DZW20-DS1
Nominal torque:N.m
Output speed: r/min
Maximum controlling torque:N.m
Minimum controlling torque:< N.m
2) Power:380VAC 50HZ。
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3) Operating environmental temperature:-25℃-+60℃。


3.4.1.3 Main structure
Electric actuator includes: motor, reduction gear, control circuit, junction box, remote/local shifter, local
operating knob, valve position indicating device and hand wheel.
3.4.2 Maintenance items and quality requirements
3.4.2.1 General inspection
1) Equipment shall be free of obvious bruise, damage and equipment nameplate shall be complete, clear;
standard shall be correct; seal of equipment shall be in good condition without leakage.
2) Inspection of mechanical part: it shall be free of obvious damage parts; check whether gear and shaft is
free of damage; coat lubricating oil after checking and seal the joint face of mechanical part; after all
inspections are finished, check whether the seal ring of enclosure is in good condition; tighten the screw while
installing enclosure to guarantee the sealing of engine body.
3) Motor in electric device shall be free from extraneous odor and exceptional discoloration; internal
wiring and terminal shall be free of burnout.
4) Inspection of electric control part:
a. Power in MCC power cabinet shall be normal.
b. Output signal of trimming position switch shall be normal.
c. Wiring of actuator shall be firm.
d. Insulation test:
Motor phase wire ground insulation shall be ≥20MΩ; insulation between phases shall be≥20MΩ.
Insulation between cable phases shall be≥50MΩ; ground insulation shall be ≥20MΩ.
3.4.2.2 Adjustment items and technical standard
1) Preparations before debugging
a. Actuator has been correctly installed.
b. All set screw, connecting pieces and electrical connection parts have been tightened.
c. Ground connection and equipotential connection have been correctly implemented.
d. Electrical connection is correct without error.
e. All measures have been taken to prevent finger from touching running or moving parts.
f. Electric actuating mechanism and valves are in good condition without damage.
g. Environmental temperature shall be within the allowable working range of pneumatic actuator (the
influence of heat transmitted from control object shall be considered) .
h. Some further inspections are necessary according to the specific environmental conditions of plant.
2) Debugging of electric device
a. Setting of travel switch
⑴Close the travel position setting and drag the hand wheel to keep manual mode of mesh. Carefully rotate
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the hand wheel until the valve is completely closed.


⑵Press the middle rotation axis of valve position counter and rotate 90 °to stick, then press the adjusting
spindle on closure feedback of counter. Rotate adjusting spindle according to the rotation direction of spindle
when valve is closed. When it is regulated to certain degree, closure feedback baffle will press the trimming
position switch of closure feedback. Meanwhile you will feel and hear a "crack" sound and thus trimming
switch acts and closure feedback is sent. At this time, press the middle rotation axis of position counter and
rotate 90° with opposite direction to release the open regulation position. Till now, adjustment of closure
feedback is finished.
⑶Setting of open travel position: drag the hand wheel and keep the manual mode of mesh. Carefully rotate
the hand wheel until the valve is completely open. Repeat the adjustment method mentioned in closure travel.
b. Setting of torque limit switch: torque limit can be adjusted through adjusting torque spring and this
adjustment shall be taken with the cooperation of manufacturer or maintenance personnel.
c. Power-on test of electric device:
⑴ Operate the electrically operated gate through the local button switch and observe whether it is free of
exceptions;
⑵ Operate electrically operated gate through DCS picture and observe whether it is free of exceptions.
3.4.2.3 Operating maintenance
1) Equipment shall be in good condition without leakage; cable wiring shall be correct, firm without
damage; signboard shall be complete; open and closure feedback shall be correct and indicator light shall be
correct.
2) Manual and electric switching shall be flexible; valve shall act normally without jam.
3) General fault handling:
a. Switch is not in place: check whether the wiring of position feedback switch is normal; check whether
the setting of travel switch is correct and adjust according to above methods.
b. Overheat of motor: phase dislocation and open phase of power; frequent operation; overload and check
one by one.
c. Over torque of actuator: check whether the setting of torque switch is correct; reset if it is incorrect; or
check whether valve and baffle are jammed.
d. Inaction of motor: check whether order has been sent; check whether the wiring of contactor and
thermorelay is normal.
3.4.2.4 Maintenance items
1) Appearance inspection and cleaning of valve electric fitting.
2) Checking and refueling of all circuit boards and internal components of disassembly (Do not
disassemble for minor repair) .
3) Motor coil DC resistance test.
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4) Full open and all-off test under remote control and local mode.
5) System linkage test.
6) Inspection of internal wiring and verification.
7) Debugging of valve electric fitting.
8) Insulation between cable phases, ground insulation test and motor ground insulation test.
9) Inspection of D.E wheel and LED.
3.5 Maintenance rules on FISHER positioner
3.5.1 Overview
The equipped DVC2000 series digital valve controller on Fisher pneumatic regulating valve can be
communicative. The electricity-air convertor based on microprocessor can easily access the crucial information
for process operation through 275 type HART communicator, besides the standard function of converting
current signal into pneumatic output pressure.
3.5.2 Technical specification
Technical parameter
Input signal: 3-20mA DC
Minimum voltage: the minimum available voltage used for instrument terminal of analog control is 8.5V
and it is 9.0V for HART communication.
Maximum voltage: 30V DC voltage
Output signal: to execute the pneumatic signal required by actuator, it can at maximum reach 95% of air supply
pressure.
Minimum range: 0.5bar(7 psig)
Maximum range: 7 bar (101 psig)
Air supply pressure: minimum value is recommended: 0.5bar (7 psig) higher than the maximum value
required by actuator.
Maximum:7 bar(101 psig)
Temperature limit: working temperature range is -40~85℃; when temperature is lower than -20℃, LCD
may not read message.
3.5.3 Debugging steps and methods of positioner
To run QUICK SETUP program on main screen, press arrow key first and then press right arrow key. At
this time, a warning will pop up to hint that this step will cause the valve action. Press the right arrow key for 3s
to access checking routine. Press the left arrow key to back to main menu. This program will automatically
verify the instrument and is applicable to the setting parameter of this actuator. To suspend this program at any
time, please press the right arrow key and left arrow key simultaneously for 3s. When this program is finished,
press right arrow key to back to status display screen. If right arrow key is not pressed within 30s, the
equipment will return to status display screen automatically.

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3.5.4 Debugging and maintenance


3.5.4.1 General rules
1) All newly installed and modified pneumatic actuators shall be taken debugging before putting into
operation, which can not be delivered for use only after they reach all technical requirements.
2) In case of fault during operation, do not put it into operation without debugging after maintenance.
Handle work ticket before debugging and contact operators to take system sectionalizing before taking
debugging.
3) Every time after temporary repair and minor repair and before starting up, take operation test to
pneumatic actuator that has been repaired or not repaired according to maintenance requirements to check
whether the switch conforms to requirements and eliminate the defects timely in case of any exceptions.
4) Before debugging, get familiar with relevant provisions, understand equipment performance, application
method and debugging steps and take debugging according to relevant specification.
5) Get familiar with the corresponding thermodynamic system of actuator during maintenance and
adjustment to prevent from mistakes.
3.5.4.2 Debugging
1) Appearance inspection: check whether all components are free of exceptions.
2) Check whether compressed air is supplied and whether gas circuit is smooth without leakage.
3) Check whether positioner inlet pressure conforms to requirements and within specified range.
4) Supply power and control power.
5) Position according to the method of 3.5.3.
3.5.4.3 Maintenance
Control part:
1) Open the outer cover of control cabinet;
2) Check whether control card terminal wiring is firm;
3) Check whether display panel is normal;
4) Check whether compressed air pressure is normal;
5) Check whether positioned is normal.
3.5.5 Common faults and handling methods
Fault Cause analysis and handling methods

Check whether the pressure is too low or too high (generally select 05~0.7MPa) ;
Valve switch does not act
whether mechanical valve is stuck.

No feedback Check whether +31,-32 terminals have 4~20MA signal;

Check whether +11,-12 terminals have 4~20MA signal; switch to manual mode to
Remote control does not act
check whether local manual mode acts.

3.5.6 Maintenance period and maintenance items


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3.5.6.1 Minor repair period


Pneumatic actuator shall be taken repair with minor repair of unit, which is generally 1-2 years.
3.5.6.2 Minor repair standard items
1)Check of appearance and air supply;
2)Check of control cable insulation;
3) Debugging of actuator.
3.5.6.3 Major repair period
Pneumatic actuator shall be taken repair with major repair of unit, which is generally 4-6 years.
3.5.6.4 Major repair standard items
1)Appearance inspection;
2)Positioner inspection;
3)Internal wiring check of actuator;
4) Debugging of actuator.
3.5.7 Safety precautions
3.5.7.1 Risk analysis
1) Use qualified electric tools during working to prevent people from electric shock.
2) Fasten the safety belt during working at heights to prevent high-altitute falling.
3) Pay special attention during disassembly and transportation process of pneumatic valve to prevent from
personal injury.
4) Monitor shall explain the key safety parts and safety precautions in maintenance before system
maintenance.
5) Stop and sending instrument gas is required for system maintenance, which shall be taken according to
the steps of system stop and sending instrument gas and operated by operators. Before equipment maintenance,
operator shall stop the supply of gas to equipment.
3.5.7.2 Safety precautions for work ticket
1) Relieve the “Automatic” of regulating system.
2) Close the front stop valve of pneumatic regulating valve.
3) Close the rear stop valve of pneumatic regulating valve.
4) Stop the supply of gas to pneumatic regulating valve instrument.
3.6 ABB pneumatic valve maintenance technical rules
3.6.1 Overview
ABB electrical locator takes the instrument compressed air as the power energy source, accepts the analog
input signal, which is converted to the pressure signal, and outputs direct / angular displacement, to promote the
regulated agencies through the compressed air under a certain pressure.
3.6.2 Technical specifications
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Input signal: 4-20mA.


Gas supply pressure: 1.4-6bar (20-90psi) .
Gas consumption: <0.03kg/h.
Environment temperature: -40℃ - 85℃.
The humidity of environment: 95%RH.
Input characteristics: linear.
Deviation of characteristics: ≤ 0.5%.
Dead zone: 0.1-10%, adjustable.
Feedback signal: 4-20mA.
3.6.3 Equipment calibration
3.6.3.1 Check whether the installation angle sum of position feedback rod is installed firmly.
3.6.3.2 Start automatic adjustment procedure (after the actuator or valve is installed in the system, it shall be
better to set it again through this procedure) :
Press MODE key
Click key once or more, until it displays “P1.1”
Loosen MODE key
Press ENTER key for 3 seconds until the counter counts down to 0
Loosen ENTER key, and the automatic adjustment procedure starts to run (the display shows the ongoing
program statement number) .
After automatic adjustment procedure is completed successfully, the display shows “COMPLETE”.
3.6.3.3 Storage setting results:
Press MODE key
Click key once or more, until it displays “P1.4”
Loosen MODE key
Use or key to select NV_SAVE (If ‘CANCEL’ is selected, the modifications made previously shall not be
stored.)
Press ENTER key for 3 seconds and loosen it until the counter countdown is completed.
3.6.3.4 Selection of self-adaptive control mode (remote control)
Press MODE key and click ⇧ key once or more, until it displays “1.0 CTRL_ADP”
Loosen MODE key
Note: Except P1.1, P2.3, P3.2 and P8.2, generally other parameters need no modification.
P1.1 is the automatic tuning procedure, P2.3 is the positive and negative action forms of the actuator (the
positive action is that the pressure increase valve stem runs downwards at output 1) and P3.2 is the positive and
negative adjustment forms (the positive action is the corresponding valve position 0% of 4 Ma) , P8.2 is the
valve position feedback positive and negative action forms (the positive action is that the valve position at 0%
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outputs 4 Ma) .
3.6.4 Debugging and maintenance
3.6.4.1 General rules
1) The newly installed and improved pneumatic actuators shall cooperate with the maintenance for
debugging before being put into operation, which can be delivered for use after meeting various technical
requirements.
2) The faults occurred during operation, cannot be put into operation after the maintenance with debugging.
Before the debugging, handle the work tickets, and conduct the debugging after contacting the operation
personnel for system disconnection.
3) After the temporary repair and minor repair, according to the maintenance requirements before the
start-up, conduct the operation test on the pneumatic actuator having taken maintenance or without, see whether
its switch meets the requirements, if found abnormal, eliminate it timely.
4) At debugging, get familiar with relevant provisions, understand the equipment performance, usage
method and debugging steps, and carry out the adjustment according to relevant instructions.
5) At maintenance and adjustment, get familiar with the corresponding thermodynamic system of
pneumatic actuator, in order to avoid the mistakes.
3.6.4.2 Debugging
1) Appearance inspection: Check whether all parts have any abnormal circumstances.
2) Check whether the air supply is available, and whether the gas path is smooth and there is leakage.
3) Whether locator air inlet pressure meets the requirements within the prescribed range.
4) Deliver power source and control power.
5) Positioning according to the methods of 3.6.3
3.6.4.3 Maintenance
1) Terminal row cleaning and wiring inspection.
2) Cable insulation resistance test.
3) Conduct inspection on control cable and signal cable wiring, and check whether the short circuit
connection is correct.
4) Locator and position feedback device inspection.
3.6.5 Common fault treatment:
3.6.5.1 The valve switch does not act:
1) Check whether the pressure is too low or too high (generally select 0.5~0.7MPa)
2) Check whether the mechanical valve is jammed
3) Whether the power source is DC24V
3.6.5.2 No feedback:
Check whether +31 and -32 terminals have 4~20MA signal
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3.6.5.3 Remote control does not act:


1) Check whether +11 and -12 terminals have 4~20MA signal
2) Switch it to 1.2 or 1.3 model and check whether the local manual mode acts
3.6.6 Common parameters setting table
P1.0 ACTUATOR Define the positioner mounting form
P1.1 AUTO_ADJ Start the automatic tuning procedure
P1.
P1.2 TOL_BAND Set the deviation band or dead zone
STANDARD
P1.3 TEST Test the modification results
Basic parameter groups
P1.4 EXIT Exit to operation level
P2.0 MIN_RGE Set the minimum value of the given signal (default is 4mA)
P2.1 MAX_PRG Set the maximum value of the given signal (default is 20mA)
P2.2 CHARACT Select the regulation characteristic curve
P2.3 ACTION Set the valve positive and negative action mode
P2
P2.4 SHUT-OFF Set the valve opening degree threshold
SETPOINT
P2.5 RAMP⋀ Reduce speed in the open direction
Given signal group
P2.6 RAMP⋁ Reduce speed in the closed direction
P2.7 EXIT Exit to the operating level
P3.0 MIN_RGE Adjustment curve starting opening (0% by default)
P3 P3.1 MAX_RGE Adjustment curve ending opening (100% by default)
ACTUATOR Set the starting point direction (default is the full closure,
P3.2 ZERO_POS
Actuator performance namely, the counterclockwise direction of feedback rod)
group P3.3 EXIT Exit to the operating level
P8.0 MIN_RGE Valve position starting point current value (default is 4mA)
P8.1 MAX_RGE 100% valve position current value (default is 20mA)
Valve positive and negative direction selection (4mA
P8 P8.2 ACTION
corresponding valve position is 0% by default)
ANLG_OUT
P8.3 ALARM
Analog signal output
P8.4 TEST
P8.5 EXIT Exit to the operating level

3.6.7 Maintenance cycle and maintenance items


3.6.7.1 Minor repair cycle
Pneumatic actuator is carried out with the unit minor repair, generally for 1 ~ 2 years.
3.6.7.2 Minor repair standards items
1) Appearance and air source inspection;
2) Control cable insulation inspection;
3) Actuator debugging.
3.6.7.3 Overhaul cycle
The pneumatic actuator maintenance is carried out with the unit overhaul, with the maintenance cycle of 4

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~ 6 years.
3.6.7.4 Overhaul standard items
1) Appearance inspection;
2) Locator inspection;
3) Actuator internal wiring inspection;
4) Actuator debugging.
3.6.8 Security measures
3.6.8.1 Risk analysis
1) Use qualified electrical tools in the work, to prevent personnel from electric shock.
2) Fasten the safety belt at high-altitude operation, to prevent high altitude falling.
3) At the pneumatic valve disassembly and removal process, be careful especially, to prevent personal
injury.
4) Before system maintenance, the monitor shall explain the key safety parts and safety notes in the
maintenance.
5) System maintenance needs to stop sending instrument gas, which must be carried out in strict
accordance with the steps of system stop sending instrument gas, the stop sending instrument gas is handled by
operating personnel, and the staff shall stop sending gas to the equipment before equipment maintenance.
3.6.8.2 Work ticket security measures
1) Release the regulation system “automatism”.
2) Close the front stop valve of the pneumatic regulating valve.
3) Close the back stop valve of the pneumatic regulating valve.
4) Stop pneumatic regulating valve instrument air supply.

4. Primary equipment and control device maintenance (furnace side thermal control device)
4.1 ZHJZ series flame detection system maintenance rules
4.1.1 Overview
4.1.1.1 Flame detection system
The flame detector is the indispensable key auxiliary equipment to realize the boiler combustion control
automation for modern thermal power plants, the most important part of FSSS system, which is important
guarantee for preventing the occurrence of the furnace implosion and explosion accidents, reducing energy
consumption, improving the combustion efficiency, reducing dust emissions, and ensuring the unit under safe,
highly efficient, and environmental protection operation, and the company has 36 coal detectors and 36 oil
detectors in total.
4.1.1.2 Technical parameters:
Working voltage: ±15V DC power source for each circuit
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Output signal: 0-2mA current signal.


Under rated working conditions, the maximum power of the device is: 0.3W.
Probe amplifier weight: 0.5Kg.
Weight of standard 2.3 meter probe: 16Kg.
The probe front end temperature: 800℃.
Cooling air flow required for each probe: 1 m3/ min.
Probe cooling air pressure: The pressure difference of air pressure at the cooling air inlet and the furnace
inner pressure shall be greater than 2Kpa.
Air source requirements: The dust and hard particles contained in the air shall be no more than 30mg/ m3.
Cooling air interface size: The external screw thread is M48X2 (it can be customized according to the
users’ requirements) .
External cable specifications: 5-cores (or 4-cores) 0.75mm square shielded cable and the outer insulating
sleeve.
Suitable for flame detection signal processing apparatus: It can match with the flame detection processing
board of any type.
Probe length: It is determined according to the length of boiler secondary air duct.
4.1.1.3 Working principle
The flame detector probe transmits the collected visible light signal to the probe amplifier through the
optical transmission system composed by convex lens, optical fiber and other components, the photosensitive
elements of the probe amplifier (phototube) transforms the light signal into the electrical signal, and then stable
to 4-20mA current signal through logarithmic amplifications, and uses the logarithmic amplification mode to
ensure the linear gain relationship between the flame brightness and the signal intensity, to prevent the
occurrence of current signal saturation, then transmits the flame signal in the current form to the flame detection
treatment instrument through the 4-core shielded flexible cable, while using current mode for transmission can
ensure the signal out of distortion, the flame detection treatment instrument is dual signal flame treatment
instrument, which transforms the flame current signal from the probe to the voltage signal for acceptance
through the sense resistor of 1000 ohms, and the voltage signal is divided into two channels of signals through
the intensity treatment circuit and frequency treatment circuit of the flame treatment instrument: namely, the
intensity signal and frequency signal. Intensity signal represents the flame luminance, and the frequency signal
represents the flame pulsation or flicker frequency. When both the intensity real-time value and the frequency
real-time value are higher than the intensity threshold and frequency threshold, the fire relay shall take action,
sending out a fire contact signal, and sends out the no fire signal if any of the conditions is out of being satisfied.
The process of signal acquisition, conversion, amplification, transmission, processing, judgment, and signal
output can be seen in Figure 1:

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Probe amplifier
探头放大器
Flame detection
火检处理卡件 processing card

Operation
操作面板
+5V panel

DGND
数字地
Self-checki Output Head
有头继电器relay Fire switch output
有火开关量输出
自检回路 输出回路
ng circuit circuit

Fault relay
Fault switch output
故障开关量输出
故障继电器
+15V
模拟地
AGND A/D
-15V A/D转换
conversion
Logarithmic
对数放大
amplification Current Photoelectric
光电隔离
signal
电流信号 Current, Self-adapti
isolation
电流、电 自适应
火焰
Flame 光电管
Phototube voltage ve滤波
filtering
压转换
conversio
D/A
D/A转换
conversion

模拟量输出
Analog output 485 interface
485接口

Figure 1
4.1.2 Fault phenomenon, fault judgment method and treatment
See flame detection processing cards in Table 1.
Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
●Probe S line meets broken
circuit.
●Probe connector contact is
●Check the wiring
bad.
●Insert the probe connector again,
Fault light is ●Terminal row wiring is not Immediate
F01 OK with reference to the flame
lit (red) firm. treatment
detection probe in Chapter 8.
●Probe S line is connected by
●Replace the probe amplifier.
fault, with S and G in reverse
order.
●Probe amplifier is damaged.
Fault light is Immediate Replace the probe amplifier
F02 OK Probe amplifier zero drift
lit (red) treatment Refer to Chapter 8
●Check the wiring
●Use the multi-meter to measure
Fault light is ●+15V power failure Immediate whether there is +15V power
F03 OK
lit (red) ●Short circuit treatment output
●Insert the probe connector again
●The power card meets fault

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Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
●Check the wiring
●Use the multi-meter to measure
Fault light is ●-15V power failure Immediate whether there is +15V power
F04 OK
lit (red) ●Short circuit treatment output
●Insert the probe connector again
●The power card meets fault
●Check the wiring.
●Use the multi-meter to measure
●+15V and -15V power
Fault light is Immediate whether there is ±15V power
F05 OK failure
lit (red) treatment output
●Short circuit
●Insert the probe connector again.
●The power card meets fault.
It can be used for slight fault,
Fault light is Replace it for the new flame
OK F01 but it shall be better to be Available
lit (red) detection processing card.
repaired or replaced.
Fault light is It can be used temporarily as Temporary Replace it for the new flame
OK F02
lit (red) for common faults use detection processing card.
Fault light is Immediately deal with the Immediate Replace it for the new flame
OK F03
lit (red) serious faults treatment detection processing card.
IMMEDIA
Display of Replace it for the new flame
Immediately deal with the TE
“processor detection processing card, and it
serious faults TREATME
fault” cannot be repaired.
NT
Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
●The data line of part ② in
Figure 21 is loose ●Pull out the card, then reconnect
Immediate
No display ●Flame detection and the data line
treatment
processing card display board ●Replace the card
meets fault
The OK Flame detection and Immediate ●Insert and pull out the card for

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Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
displayed processing card display board treatment once again
character is meets fault ●Replace the card
not complete
Flame detection and ●Insert and pull out the card for
Display the Immediate
OK processing card display board once again
mosaic treatment
meets fault ●Replace the card
The
●Spring meets failure ●Insert and pull out the card for
operation Immediate
●Flame detection processing once again
key meets treatment
card is halted. ●Replace the card
failure
The
displayed Display control potentiometer Immediate Adjust part ① potentiometer
OK
character is value is not correct. treatment according to Figure 21
unclear
Real-time Probe optical fiber is
Clean the lens, and replace the
value is damaged, with the lens under Immediate
OK optical fiber with reference to
abnormal dust stratification or probe treatment
Chapter 8
(low) angle under coking.
●Flame detection processing
Real-time ●Insert the card again
card is halted. Immediate
value has no ●Check the wiring
●Probe G line contact is bad treatment
changes ●Check the wire jumper
●Type 2 jumper is not correct
Dark furnace Under power frequency
Handle it according to the
frequency interference, the flame
OK grounding requirements in
value 100 detection cable shielding
Chapter 3
(50) treatment is unqualified
Dark furnace
intensity is ●Probe amplifier zero drift ●To confirm whether the fire or
greater than ●Actual furnace has naked lamp furnace.
Immediate
3 OK flame or lamp ●Replace the probe amplifier
treatment
The fault ●Flame detection processing ●Replace the flame detection
light does card meets faults processing card
not work
Intensity and ●S line and G line are under
Immediate
frequency is OK reverse connection Check the wiring
treatment
maintained ●G line meets broken circuit

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Performance of self
checking
Fault code
Fault
Flame Fault reasons Fault level Fault treatment
phenomenon Flame
detection
detection
processing
probe
card
at a constant
value

●Pull out the card, and insert it


●Flame detecting box dial
Channel again rapidly
switch is set incorrectly
address is Immediate ●Reset the dial switch
●Flame detection processing
incorrect or treatment ●Flame detection treatment
card address register is not
repeated instrument firstly lose the power
synchronized
and send it again.
No analog 24VDC detection power Immediate
OK Check the power source
output meets faults treatment
The display
Flame detection processing
has no Immediate Replace the flame detection
OK card background light sheet is
background treatment processing card
damaged
light
The
indicating
lamp is dark
or not bright
LED indicating lamp meets Immediate Replace the flame detection
But the OK
faults treatment processing card
implementati
on of
self-checking
is normal

PROMPT: THE FLAME DETECTION PROCESSING CARD HAS A SELF-RESET INSURANCE.

4.1.3 Maintenance items and quality requirements


4.1.3.1 Maintenance of flame detection system
1) General inspection
a. Handle the work tickets, and the flame inspection system meets power failure.
b. Conduct equipment cleaning
c. The flame detection probe, optical fiber, and control cable inspection: There are no damage and no high
temperature damage phenomena, with no dirt on both ends.
d. Conduct flame detection control cabinet insurance inspection, fan inspection and lighting inspection.
e. Conduct flame detection cooling air inspection, the air pipe valve is at the full open position, and the air
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pipe has no shedding, cracking and leakage phenomena.


2) Adjustment items and technical standards
a. The flame detection control cabinet sends power, and check whether the terminal row, flame detection
probe +50VDC, and +15VDC power supply are normal or not.
b. Illuminate the probe with auxiliary light source, the corresponding “FLAME” signal light is lit, and the
corresponding flame detection signal of the operator station CRT is lit up.
When the light source is removed, the related signal shall disappear.
4.1.3.2 Flame detection system operation and maintenance
1) Conduct a regular inspection on the flame detection probe, cooling air duct, without the phenomena of
shedding and leakage.
2) Conduct a regular inspection on the flame detection control cabinet, without flame detection fault alarm.
◆ The cable shielding layer shall be suspended, rather than the contact with the connector housing and
probe metal parts.
4.2 ABB AZ20.0700 series zirconia oxygen analyzer maintenance rules
4.2.1 Overview
4.2.1.1 Brief introduction
Zirconia oxygen analyzer, applied in the continuous monitoring of oxygen content in the industrial furnace
flue gas, as the basis for the operator to adjust the combustion ratio, realizes the hypoxia reasonable fuel, and
achieves the purpose of reducing the fuel consumption and reducing the environment pollution.
AZ20 series zirconia is an in-line type oxygen sensor, the internal zirconia elements is put directly in the flue
gas produced by combustion, and the probe design is not used in the flue gas with the temperature of no more
than 1472℉ (800℃) , with no need to measure the places full of combustible gas.
4.2.1.2 Working principle
The zirconia oxygen measuring principle adopts that it is a good oxygen ion conductor under the high
temperature, if the zirconia tube is heated to the stable temperature of 700℃, the gas to be measured and the
reference gas shall flow through the two sides of the zirconium tube respectively, and there is a fixed
relationship between the produced electric potential and the zirconia tube working temperature and the oxygen
concentration on both sides, if the reference gas concentration is known, the measured gas oxygen concentration
can be calculated according to the working temperature of the oxygen potential and zirconium tube on both
sides of the zirconium tube.
4.2.1.3 Composition of zirconia analyzer
Zirconia oxygen analyzer is composed of three parts: zirconia detector, zirconia converter and transformer.
The detector structure consists of zirconia tube (used to measure the oxygen potential in the flue gas) ,
thermocouple (used to measure the working temperature of zirconium tube) , standard gas path (can be used for
conducting on-line standard gas operation with the converter) and junction box, strainer and other accessories.
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The main role of the converter is to transfer the oxygen potential return signal (MV) measured by the detector to
the digital quantity. Transfer the oxygen content value obtained through the CPU logarithm value calculation to
the display, and output the current value corresponding to the oxygen content, at the same time, the converter
shall control the temperature of the working electric furnace in the detector, to make the zirconia tube
temperature stabilized at 700 ℃ . Transformer’s role is to supply power for working electric furnace in the
detector.
4.2.1.4 Maintenance and calibration of zirconia oxygen analyzer
1) Maintenance items and quality requirements
a. Check sampling gas path system
(1) Check the bypass flue, which shall be tight with no air leakage and have good insulation; purge bypass
flue, to ensure the smoothness of the pipeline.
(2) Check the air filter and flow meter, take disassembly and cleaning when necessary, and ensure its
cleanness, smoothness and tightness without leakage.
b. Check the zirconia probe
(1) Appearance inspection: Silicon carbide dust filter shall be clean and smooth, with no mechanical
damage; the zirconia tube shall be clean, with no cracks, bending, and no serious wear and corrosion; the
platinum electrode lead shall be intact, and the binder shall have no shedding; zirconia tube and alumina tube
sealing shall be tight, with no leakage; the flange joint surface shall have no corrosion, and the gasket shall be
intact and tight.
(2) Probe internal resistance inspection: When the probe temperature is 700℃, the internal resistance of the
measuring probe on the basis of the ionic conduction mode shall be no more than 100Ω.
(3) Probe bottom electric potential inspection: When the probe temperature is 700℃, inlet 15L/h clean air
through the working air port and the reference port, and bottom electric potential of the measuring probe shall
be no more than ±5mV.
(4) Inspection of probe insulation resistance: Use 500V insulation meter to measure the probe insulation
resistance under normal temperature, of which the thermocouple outer casing insulation resistance shall be
greater than 100MΩ, the heating wire outer casing insulation resistance shall be greater than 500ΜΩ, and the
inner electrode lead wire outer casing insulation resistance shall be greater than 20ΜΩ.
The shielding line from the probe to the converter shall be intact.
2) Calibration items and technical standards
a. Temperature control accuracy calibration: The probe temperature shall be risen to a given point, keep it
stable for 30min, and measure the thermocouple temperature, with the difference of its value and the given
value of no more than±5℃.
b. Temperature stability calibration: Measure the thermocouple temperature for once every 5min,
continuously for 10 times. The maximum difference value in 10 times shall not exceed ±4℃.
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c. Calibration of the converter: Input the MV signals (look-up table value and the probe bottom potential
value) with the oxygen content equal to 0.5%, 2%, 4%, 6%, 8% and 10% to the “oxygen potential”
(concentration potential) input end with the potential difference meter, and the measuring converter outputs the
current value, with the difference of the value and the standard output value of no more than ± (2%+0.2 of the
current reading) mA.
d. Constant current performance calibration: When the output current is 10mA, the output current changes
shall not exceed 0.01mA as the load resistance changes for 1kΩ every time within the prescribed scope.
e. Calibration of the whole set of instrument value: Adjust the instrument indications of the starting point
and end point, inlet the standard gas with the oxygen content of 1%, 4%, and 8% respectively and the flow rate
of 120L/h and the reference gas with the flow rate of 15L/h into the probe, and record the readings after the
indication is stable, with the difference of the indication value and the actual oxygen content of no more than ±
(5%+0.2% of the oxygen standard value) O2.
f. Calibration of the whole set of instrument indication value stability: Inlet the standard gas and reference
gas, after keeping it stable for 30min, read the first number, and then read the second number every 2h, with the
difference of the two readings of no more than 0.2% O2.
3) Operation and maintenance
a. Preparations before operation
(1) Check whether the probe, connecting wires, gas path system, transducer and display instrument meet
the requirements.
(2) As for the newly installed instruments, check whether the flue gas temperature of the sampling point
meet the requirements.
(3) The probe shall be installed well generally before the boiler ignition, and the temperature rises with the
boiler start-up. If the probe is installed or replaced in the boiler operation, rise the probe temperature to the rated
temperature and then insert it in the flue.
b. Input
(1) Input the power source, and adjust the reference gas flow to 15L/h.
(2) When the probe temperature is risen to the rated value, keep it stable for 30min, and check the working
conditions of the temperature control equipment.
(3) As for the boilers under positive pressure combustion, appropriately increase the reference gas flow.
c. Outage
(1) Cut off the instrument and air pump power.
(2) As for the instruments under outage with boiler maintenance, pull out the probe from the flue and keep
it well before the maintenance.
d. Maintenance
(1) As for the instrument put into operation for the first time, check the heating wire voltage and probe
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temperature once every day in the first week, and it can be extended to check for once a week later.
(2) The converter shall be proofread once with the millivolt signal monthly.
(3) The instrument indication value shall be proofread for once every three months with the standard gas
(oxygen content is divided into two types of 2.02% and 20.9%, with the flow rate 120L/h) .
4.2.2 Maintenance items and quality requirements
4.2.2.1 General inspection
1) Zirconium head part:
a. The equipment shall be clean, and its true color can be seen.
b. Mechanical system (internal and external pipes, installation flange, and junction box) ; measurement
system (protective sleeve, sensitive reaction chamber, the internal wiring, controller, sealing parts, and
ventilation pipe) ; temperature system (heater and thermocouple) shall be inspected wholly, to ensure their
availability.
c. Zirconium head insulation test:
In order to ensure the accuracy of the component measurement and the safety of the transmitter, conduct
the insulation test on the zirconium head, including: the sensing part with the outer shell; the sensing part with
the electric furnace, electric furnace with the outer shell and so on. The signal line and power line insulation
shall comply with the requirements, and use 500V shaking meter to measure the insulation resistance, which
shall be greater than 20MΩ.
d. Zirconium head resistance test:
On condition that the electric furnace is started up, rise the temperature of zirconium head to 00 ℃ , and
measure that the zirconium head battery internal resistance shall be about 100Ω or so.
Note: It shall be 1000 ohms at the cold state.
2) Transmitter section:
Thermocouple temperature signals shall adopt K type shield compensation cable.
Wiring shall go through the insulation test, and use the 500V shaking meter to measure its resistance value,
which shall be greater than 50MΩ.
4.2.2.2 AZ20 oxygen analyzer fault judgment and treatment
1) Fault phenomenon: No heating:
Reasons: a. probe heater burning.
b. Oxygen probe heating wire and the transmitter wiring connection is not correct.
c. The loop heating is normal, or without heating.
Treatment methods: a. Measure whether the heater is damaged, if so, replace it for a new heater.
b. Comply with the correct wiring of the wiring diagram.
c. If the controller is normal, the normal power output direction shall be wrong, and reverse A and N lines
of the output power source shall be all right.
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2) fault phenomenon: no output:


Reasons: a. The controller is damaged.
b. Current conversion module is damaged.
c. Power is not available.
Treatment methods: a. Cut off the power source, and replace the controller display circuit board.
b. Cut off the power source, replace the current conversion module, and pay attention to the directions at
installation.
c. Replace the switch power source.
3) Fault phenomenon: No display:
Reasons: a. 220V power line wiring meets error.
b. The switch power source has no output.
c. Controller display board power source is not added.
Treatment methods: a. Check 220V power line and connect it correctly.
b. Replace the switch power source.
c. Check whether the power line is connected in place.
4.2.2.3 Main start-up and stop steps
1) Start-up:
a. Check whether the wiring is correct and good.
b. Check whether the instrument power supply inspection is normal.
c. Initialize the transmitter processing.
d. Press RESET key for resetting.
e. Data input.
f. Verification process
g. Necessary adjustment of other items.
h. Commissioning.
2) Outage:
a. Handle the related outage formalities well.
b. Shut down the instrument.
c. Power failure.
4.2.2.4 Main items of major repair

No. Main items Quality requirements

Hygiene cleaning and wiring


1 No fouling, firm wiring, and no injury
inspection
Firstly remove the cabinet wiring, to prevent the high voltage from damaging the
2 Cable insulation test
analyzer and cards.

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Zirconia probe inspection and The zirconium head is not damaged, and calibrate the errors according to the
3
calibration steps in the instructions until it meets the requirements.
Analyzer output signal
4 0 ~ 21% corresponding output is 4 ~ 20mA
adjustment

4.3 HL-2308H/4 flame TV system maintenance rules


4.3.1 Overview
4.3.1.1 Overview
The whole furnace flame monitoring uses the optical, mechanical, electronic integrated products, which is
suitable for the whole furnace monitoring of various kiln boilers in the thermal power plant unit boiler,
petroleum chemical industry, smelting and other industries.
The system enters into the furnace directly through the endoscopic optical imaging system. Transfer the
working situation of burners at each layer and the boiler inner combustion state after normal combustion in the
ignition initial stage into the video signal, after going through the high-temperature peep mirror imaging,
transmit it to the central control room through the video cable, and restore the images to the screen through the
monitor, further to reflect the flame whole combustion conditions in the furnace.
4.3.1.2 Control system
1) Remote controller of central control room
a. When the excess temperature, under voltage and plant power source shall disappear, sending out an
alarm automatically, the system shall exit the furnace, so as to protect the system.
b. Endoscopic optical imaging system can timely be controlled of entering and getting out of the furnace,
automatically detecting and displaying the fault source.
c. Control the camera electronic shutter, which can adjust the image effect timely.
d. The controller can complete corresponding lens forward, backward, shutter settings and other functions
with DCS interface.
2) Site control box
At the work site, the camera system can be timely controlled from entering and getting out of the furnace,
convenient for maintenance and overhaul.
3) Transmission device
Transmission mode: rack transmission is suitable for different site working environment, and the
transmission device can ensure that the endoscopic optical imaging system can enter and exit from the furnace
flexibly.
4) Air source filtration system
Image transmission system blowing air adopts the site instrument level of compressed air, or the system
owned air source. Through the air source filtration system, filtered through the steam and water separator,
ensure that the image transmission system works under dry and clean blowing air, and it can change the air
pressure through the regulating valve, eliminating the coking matters at the front of the lens.
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4.3.1.3 Device composition


The furnace flame television monitor device is composed of the image transmission system, control system,
air source filtration system, monitor the transmission device, and the support.
4.3.1.4 System parameters
Viewing angle: Diagonal line 105o (endoscopic optical imaging system)
Resolution: more than 480 lines (color camera and monitor)
Lens heat-resistant temperature is ≤2000℃. Protective cover working environment temperature is ≤70℃
Air source pressure required by the device is ≥0.15MPa.
Air source flow required by the device is ≥0.4m3/min.
Air source temperature required by the device is ≤80℃.
Working power supply: on-site AC of 380V, 50HZ and 500W; 220V, control room AC of 220V, 50HZ, and
200W.
4.3.2 Maintenance items and quality requirements
4.3.2.1 General inspection
1) Appearance inspection
2) Hardware and mechanical parts inspection:
a. Check whether the indicating lamp display is normal.
b. Check whether the functions of the lens and operation keys are normal, and whether the connector
socket and the connection are broken.
c. Check whether the fixed parts are firm.
3) Cable insulation inspection: The insulation resistance shall be no less than 50MΩ.
4.3.2.2 Debugging
After completing the system installation and wiring, put through power for debugging after the system is
normal after inspection. Firstly, open the system gas source valve, to ensure that the blowing air works normally,
and control the advance and retreat of the endoscopic optical imaging system through the advance and retreat
keys in the on-site control box, after ensuring that the optical imaging system works freely, complete the control
and use of all the system parts through the lens advance and retreat keys, shutter high set keys (composed of
function key, left key, right key, and down key) on the controller panel, and the lens inlet door, retreat door, over
temperature indicator, under voltage indication and other indicating lamps.
4.3.2.3 Operation and maintenance
1) Lens maintenance
After operation for a long time, the dust and oil in the gas supply shall make the lens dirty, remove all the
parts by order at the maintenance to carry out thorough ash cleaning and maintenance, and conduct the
re-installation in the reverse order of the removal.
2) Motor inspection: DC resistance measurement (three-phase) three-phase resistance is symmetrical, the
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insulation resistance between the insulation test (with neutral points apart) lines shall be > 50MΩ, and the coil
ground insulation resistance shall be 50MΩ (use 500V megohmmeter) .
3) Travel switch inspection: The travel switch contact resistance value shall be no more than 0.5Ω, and the
break contact resistance value shall be less than 20MΩ.
4) Mechanical transmission part inspection: no jamming, flexible transmission.
5) Air cooling system:
The air cooling system includes the main pipeline and protective chamber, clean air filter, and ensure that
the gas path pressure is constant.
6) On-site equipment maintenance
a. Power outage and inspection
b. Conduct controller cleaning (clean, true colors can be seen on surface) inspection (no defect parts, no
corrosion traces, no element loosening) , motor travel switch with advance and retreat lens shall act accurately
and flexibly, conduct ash cleaning, on-site control box key contact shall be in good conditions, no jamming, AC
contactor action is accurate, and the contact is in good conditions.
7) Image transmission system:
Image transmission system is composed of CRT driver, camera and the indirect video cable, check the
aviation plugs, which shall have no cable loosening phenomenon, so as not to affect the image quality, while
CRT adjustment shall focus on the brightness and color adjustment mainly, consistent with the true color of the
furnace as far as possible, and clean the screen.
8) Control room alarm test:
Apply the gas supply stop method to do under voltage and alarm function tests.
4.3.2.4 Common faults and treatment
1) The image jump is instable, and the cable connection part is badly contacted, well connect it again.
2) The image suddenly disappears, the grating appears on the screen, and the cable is open, find them out
and well connect them.
3) The image display lens is sticky with dirt, exit from the lens and thrust it as well after the soot blowing.
4.3.2.5 Major and minor maintenance items
1) Each connector inspection and cable inspection
2) Lens cleaning, and glass replacement of the lens tube.
3) Lens telescopic mechanical device inspection.
4) Monitoring system inspection and regulation
a. Monitor inspection and regulation
b. Monitor grating integrity inspection
c. Brightness adjustable range inspection
d. Video distortion degree inspection
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4.4 HLTV-200B/2 level TV system maintenance rules


4.4.1 Overview
4.4.1.1 Usage
HLTV-200B/2 water TV monitoring system is mainly applied to the thermal power plant unit boiler drum
water level remote monitoring. This system conducts direct monitoring on the site goals, with high reliability
and safety.
4.4.1.2 Working principle
This system shall be transferred to the video signal by the monitored goals through CCD camera, to the
monitor in the central control room through the video cable, and it is restored to the images through the monitor,
to conduct the targeted monitoring. The operator can adjust the camera lens and adjust the semi-fixed PTZ on
site in the central control room through the controller or DCS operator station, so as to clearly monitor various
angles of the targeted scene.
4.4.1.3 Basic configuration
The system consists of the following four parts:
● Image transmission system: It is composed of the camera, lens and video cable;
● Monitoring system: It is composed of the monitor and the central control room remote controller;
● Protection system: It is composed of the protective cover, air source filter and its protective box;
● Support system: It is composed of the PTZ and PTZ support.
4.4.1.4 Technical indexes
1) Air source:
Instrument air pressure is ≥ 0.1MPa and ≤ 0.6MPa;
Instrument air supply flow rate is 10 ~ 20m3/h;
Air temperature ≤ 35℃;
Pressure regulating valve range: 0.05 ~ 0.6MPa.
Environment requirements: Temperature is at -10℃ ~ 80 ℃, and relative humidity is ≤80%
2) Power index:
Power plant power AC 240×(1±10%) V,50Hz,5A.
4.4.2 Maintenance items and quality requirements
4.4.2.1 General inspection
1) Appearance inspection
Check whether the water meter and the camera lens are clean, with dust or not, and check whether other
devices are intact.
2) Hardware and mechanical parts inspection
Check the water filter condenser water storage conditions, and discharge it timely if the cup is filled with
water.
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Check whether the keyboard indicating lamp is normal.


Check whether the lens and PTZ control key operation and control function are normal, and whether the
connector socket and the connection are firm.
Conduct the bulb inspection, and check whether the wiring is firm.
Cable insulation resistance inspection: The insulation resistance shall be no less than 50MΩ.
4.4.2.2 Calibration steps
Put through the controller AC220V power source, press the power key [power/switch] at the function area
on the controller keyboard, then the power indicating lamp is lit up, switch Ⅰindicating lamp is lit up, and the
system enters the automatic cycle switching state. Automatic cycle switching time can be set by the users, but
when the system is running under the automatic cycle switching state, various function keys cannot be available,
while the function keys can only respond under the manual control state. Under the automatic cycle state, click
automatic/manual keys, and the manual indicating lamp and the switch Ⅰ indicating lamp are lit up. At this
time, the manual switching and lens setting (timing) operation can be carried out. Press the switch Ⅱ key, it is
lit up, and the image is switched from Ⅰto Ⅱ, press the lens related keys [lens control] at the function area,
namely, the far zoom, near zoom, far focus, near focus, large aperture, and small aperture keys shall be used to
adjust the zoom, focus and aperture, so as to adjust the clarity of monitoring field goals, so that the picture can
achieve the best effect of observation.
If the controller is in the dead state at the operation or running process, please turn the controller power off
and on again for once, after the microprocessor is reset, the controller will be restored for normal use.
4.4.2.3 Operation and maintenance
1) The system is related with the expensive and sophisticated set of equipment. After the arrival of the
goods, firstly check the conditions of packaging, which shall be intact, after opening the case, check whether all
the parts are complete and intact according to the packing list. If there is no damage and no rush for installation,
store them in the dry and ventilated room based on the original packaging state, rather than the open place.
2) Conduct the operation in strict accordance with the usage requirements, and master the use methods,
operation essentials and the precautions.
3) In order to ensure the normal operation of the system, the system power supply shall be guaranteed and
gas supply shall be without interruption. Before the system maintenance, cut off the power supply firstly, then
take the camera out, and shut off the gas source.
4) When monitoring the double color water meter, in order to make the monitor picture clear, the double
color water meter shall be ensured of the normal operation, and the red and green signal display is clear and
intact; there shall be no other light source or strong reflection light on one side of the water meter, or it shall
affect the monitor display effects.
5) Ensure that the protective cover shall be clean without dust, and the camera lens shall be without dirt.
6) Under air cooling protection mode, the air supply shall be free of oil and water, if not, discharge it
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regularly, and discharge the effusion in the filter at least half a month. After the filter is filled with dirt, timely
clean it, making the camera in the outage state at cleaning, then turn off the valve to cut off the gas, and remove
the filter for cleaning. Conduct the cleaning at least once every minor repair cycle.
4.4.2.4 Maintenance
Table 1 Common fault and maintenance methods
Fault
Fault reasons and maintenance parts Maintenance and treatment methods
phenomenon
Check whether the monitor power supply is Put through the monitor power supply and adjust it to the
opened and in the VIDEO state VIDEO state
Check whether the monitor video is connected. Connect the video connectors
Use the multi-meter 200Ω ohm measurement monitor to
Check whether monitor VIDEO output end
measure the monitor VIDEO input end, with 75 ~ 80
outputs signal
resistances existing normally, and repair the monitor if not.
Check whether the camera power supply is
No images Put through the power supply
available
Check whether the camera video plug is
Insert the video plug, weld the broken circuit or change lines
inserted and the video cable line has no broken
otherwise
circuit
Use the multi-meter AC 2V voltage to measure the camera
Check whether the camera VIDEO output end
VIDEO output end, with 0.8 ~ 1.2V voltage existing
outputs signal
normally, if not, repair or change the camera
Check whether the monitor brightness, color
Regulate various settings
and other settings are correct
Check whether oil, water, dust and other
Clean up the dust inside the protective cover, scrub or replace
impurities enter into the protective cover, and
the lens
whether there is dirt in the camera and lens
Check whether the lens aperture, zoom, and Regulate the lens aperture, zoom, and focus through the
focus are appropriate controller
Check whether the position of PTZ, PTZ
Regulate the position of PTZ, PTZ support, protective cover,
Unclear support, protective cover, and camera is
and the camera
images appropriate
Check whether the camera rear ring position is
Regulate the camera rear ring position
appropriate
Check whether the input and output video
connectors are under good connection, and Insert or replace the connectors, and weld them again at the
whether there is pseudo soldering at the pseudo soldering places
welding places
Check the water level meter display effect or Adjust the water level meter display effect, cancel or remove
whether there is interference source the interference source
Check whether the connectors of the lens are
Lens out of Insert or replace the connectors again, and weld them again at
inserted in good conditions, and whether the
control the pseudo soldering places
welding part has pseudo soldering
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Fault
Fault reasons and maintenance parts Maintenance and treatment methods
phenomenon
Check whether the lens shall supply power, and Put through the power supply, weld the broken circuit or
whether the cable line has broken circuit change lines otherwise
Use the multi-meter DC 20V to measure the voltage between
Check the voltage of the controller lens output the lens public output ends according to the controller end
end wiring diagram, with ±7.5V voltage existing normally, if not,
repair or replace the controller and the lens
Check whether the valves and the pressure
Open the valves and regulate the pressure regulating valve
Air filtration regulating valves are closed
system can Check whether the air filter has seeper inside, Dredge pipelines, drain away the water inside the air filter,
not work and whether the pipeline is blocked clean or replace it
normally Check whether the primary gas supply can
Restore the gas supply to make it work normally
work normally

4.4.2.5 Major and minor maintenance items


1) Each connector inspection and cable insulation inspection
2) Reflecting plate cleaning, and glass replacement of the lens tube
3) Bulb inspection
4) Monitoring system inspection and regulation
a. Monitor grating integrity inspection
b. Brightness adjustable range inspection
c. Video distortion degree inspection
4.5 PCV valve control device maintenance rules
4.5.1 Overview
4.5.1.1 Working principle of PCV valve control system
Safety valve is to prevent the accident propagation when the superheater outlet pressure is overrun,
automatically start the safety valve and drain the overpressure steam away. The control system comprises a
spring tube contact switch for the measurement of the steam pressure, two corresponding solenoid valves, and
the corresponding relay control system. During normal operation of the boiler, when the steam pressure does not
exceed the rated limit value of the pressure switch, the charged electromagnet shall cut off the compressed air
toward the safety valve, with the safety valve at the judgment state, when the steam pressure exceeds the
pressure rated limited value or power failure and other fault states, the electromagnet shall be uncharged, and
put through the compressed air toward the safety valve, which shall be at the start-up state, when the steam
pressure is reduced below the switch rated value, the safety valve shall be back to the seat, in the off state. When
the valve is required to be opened to the manual position, press the console switch to the manual position only.
When closing the valve, just press the console switch to the closed position.
● Note: When the switch is placed at the automatic position, the valve will be opened at a predetermined
pressure.
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4.5.1.2 System design characteristics


The controller includes a pressure sensor, a relay, and the control box with the relay and sensor inside. The
console speed three-bit selector allows the manual, closing or the automatic selection. It includes a box, selector
switch and two indicating lamps. The gas actuator assembly includes a bidirectional gas transmitter, two
three-way solenoid valves (usually one is open, the other is closed) , a DPST rotary switch and the junction box
for transmitter installation.
Power supply system consists of a control circuit and an electromagnetic circuit. Confucius circuit voltage
is 120V AC voltage generally, with the current required of 5A.
The electromagnetic circuit is the required voltage provided for the electromagnetic coil. The standard
electromagnetic voltage shall be 120V AC voltage, which can conduct the AC-DC conversion under different
voltages. Power lines of the electromagnetic circuit must be arranged according to the size, so that the voltage
decline rate shall not exceed 5% under the action of electromagnetic surge current.
The site wires must be insulated, which shall be applied to at least 600V voltage. Electromagnetic
insulation level is F.
4.5.1.3 Environment conditions
1) Indoor or outdoor use.
2) Sea level is below 2000 meters.
3) The highest temperature of the operating environment is 140° F.
4) Pollution degree level is -2.
5) Overvoltage types belong to the third category.
6) The main voltage fluctuation range is -5% ~+10% of the rated voltage.
7) International standard protection classification is 1P65.
4.5.1.4 PCV valve control system technical specifications:
Compressed air pressure: 0.8MPa
Popping seat pressure: 18.4MPa
Back seat pressure: 17.75MPa
4.5.2 Maintenance items and quality standards
4.5.2.1 PCV valve control system maintenance items
1) Safety valve pressure switches disassembly and verification.
2) Safety valve control box power inspection, relay circuit inspection.
3) Control box internal wiring terminal shall be firm.
4) Conduct control cable insulation inspection. The cable lines and the ground insulation resistance shall be
greater than 50MΩ.
5) Conduct controller and console inspection. It includes the pressure sensor, and solenoid valve test and
calibration.
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6) Conduct pressure switch back loading and the panel manual operation test. Indicating lamp indicates
correctly. PCV valve does not take the popping seat and the amber lamp is lit up, after the popping seat, the red
light is lit up.
4.5.2.2 PCV valve control system maintenance quality standards
1) Control box sealing is good, and its cable outlet and inlet sealing is good, which can be waterproof and
dustproof.
2) The control box surface light display is normal, and the light test is normal.
3) Control box internal terminal connection is firm, the wiring is neither loose nor tight, and the relay is
normal.
4) Pressure switch wiring terminal crimping is firm, its cable and connection sealing is good, and the cable
insulation meets the requirements.
5) Solenoid valve wiring terminal is firm, the cable and control box connection sealing is good, the cable
insulation meets the requirements, and the solenoid valve heating is good during the work.
4.5.2.3 Common problems of safety valve control system in the operation
1) Pressure switch setting drift makes the safety valve malfunction.
2) The cables between the pressure switch and the control box meet short circuit or broken circuit, which
makes the solenoid valve power failure, leading to malfunction.
3) The cables between the solenoid valve and the control box meet short circuit or broken circuit, which
makes the solenoid valve power failure, leading to malfunction.
4) Terminal unit K540 - fault cause disk light display error.
4.5.2.4 PCV valve major repair item:
1) General inspection.
2) Pressure sensor calibration.
3) PCV valve system test.
4.5.2.5 PCV valve minor repair item:
1) General inspection and cleaning.
2) PCV valve system test.
4.6 STOCK coal feeder control device maintenance rules
4.6.1 Overview
The project adopts 12 EG2490 type electronic weighing belt coal feeders, produced by America
technology and introduced by Shenyang STOCK Company, and each boiler has 6 sets (double-inlet and
double-outlet coal mill for Yongxin project) . The control system has the following functions:
 The local, remote start and stop coal feeders realize the belt positive inversion under the local no-load
mode.
 Configure a set of precise weighing system, to calculate the coal feed rate through measuring the coal
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feeder speed and the pulverized coal weight per unit length, and enable to adjust the coal feeder rate the rated
value automatically according to DCS order.
 Monitor the broken coal, coal blockage and various abnormal working conditions, and send out the
alarm signal or take automatic tripping.
 Display the coal feeder rate, total coal volume, speed and coal feeder operation, fault, alarm and other
working conditions.
 Self-check some information related to the system and find out the causes of the fault alarm.
 Set the coal feeder parameters and regularly calibrate the weighing system. Control the coal feeder
lower gate damper.
The working principle of coal feeder: The coal feeder measures the weight of the objects in the weighing
span through its weighing device, after the micro processing calculation, the belt unit length weight is obtained,
and the coal feed rate can be obtained from the product of the numerical and the belt speed. After the
comparison of the coal feed rate and the set value through processing and transformation to control the
frequency of variable frequency controller, so as to control the driving motor speed, achieving that the actual
coal feed rate is consistent with the set value finally.
4.6.2 Maintenance items and quality requirements
4.6.2.1 Coal feeder weighing calibration
Calibrate the coal feeder after the start-up and initial operation and every six months later, weighing roller
adjustment or replacing the belt, CPU board, weighing element module and microprocessor programmed chip
shall be used for coal feeder calibration.
1) Calibration tool:
Calibrating the coal feeder shall adopt the calibration tool box provided by STOCK Equipment Company,
which includes: two calibration weights, two verification probes and the connecting wires, reflective paper (at
least 4 pieces) , and two inspection bars. In addition, the ruler, measuring tape, a set of British inner six-angle,
wrench, feeler, multi-meter, 4 - 20mA signal generator and a brush shall be needed.
2) Calibration principle:
STOCK coal feeder calibration is divided into two steps: The first step is to eliminate the system self
weight, including weighing roller, weighing element support parts and coal feeder belt weight; at the same time,
measure the relationship of the belt speed and the motor speed. The second step is to calibrate the output
amount of the known weight from the weighing elements. When the belt takes idle rotation and the measuring
belt rotates for two times, the average output of the weighing system is calculated, and then subtract this value
from the total weight, to eliminate the system self weight. In normal operation, subtract the average self weight
automatically from the belt gross weight, therefore, the weight reflected at this time is the weight of the
substances on the belt.
In the empty belt calibration process, except eliminating the self weight, precisely measure the belt speed.
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This step is completed through measuring the time of the reflective paper action between two fixed points on
the belt. Through the measurement for many times, this parameter is used for compensating the changes of the
belt thickness.
3) Coal feeder verification:
a. Preparation before calibration:
(1) Before calibrating the coal feeder, put the coal feeder into operation for 15 - 30 minutes to make the
belt soft.
(2) Close to coal feeder inlet gate valve and drain the belt empty.
(3) Close the sealing air valve.
(4) Open the coal feeder two side doors, the front and rear manholes and the microprocessor control
cabinet door.
(5) Switch off the main circuit breaker, and clean the control cabinet cards and coal feeder weighing
device.
b. Coal feeder belt adjustment:
The belt adjustment is completed by maintenance. When the belt is adjusted to the appropriate tightness,
put the coal feeder into operation in the LOCAL state. The maintenance shall check whether there is deviation
phenomenon on the belt.
c. Weighing roller adjustment
The weighing roller adjustment falls into the adjustment of the weighing roller alignment and weighing
roller spacing.
(1) The adjustment of the weighing roller alignment: The purpose is to place the weighing roller in the
alignment of the weighing span. Both two sides shall be limited between - 0.05- + 0.05mm, so as to ensure the
accuracy of weighing readings, which shall be no more than -0.178- +0.178mm.
Loosen the two locking screws on the weighing roller side, rotate the adjuster to adjust the weighing roller
position, and fasten the locking screws after placing it in the right center of the weighing span.
(2) The adjustment of weighing roller spacing: The purpose is to reflect the belt weight in the span actually.
Add the weight calibration weights on two load elements; place the check levers on both sides of the span roller;
loosen two locking screw adjustment adjusters, to keep the weighing roller check lever working surface under
0.127mm space, generally with feeler 13-wire for inspection; as shown above, adjust the other side of the coal
feeder, and put the locking screws at the lockout state.
d. Coal feeder verification process
(1) Paste four pieces of reflective paper to the right side edge of the belt. The position of the reflective
paper position is at the outside of the driving wheel and the tension pulley (front and rear inlets) placed with a
piece of reflective paper; the other two is put on the upper and lower belts near the side door of the weighing
roller;
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(2) Unscrew the plug beside the span roller lubrication fittings, and clean it. Screw the calibration probe
into the verification socket, and pay attention to that the probe pin and the concave point beside the coal feeder
socket shall be in alignment;
(3) Stop the coal feeder power (open main circuit short circuiting device) , and connect the probe cable
with A and B sockets on the circuit board in the control cabinet. Note: The connection shall be taken under the
condition that the power is cut off;
(4) Compare whether the calibration weight is consistent with the microprocessor and the microprocessor
memory values. Press SETUP13 to display the values in memory. If the memory display value is not correct,
input the correct calibration weight. As follows: Press **. ***ENTER;
(5) Compare the ideal calibration speed and the value in the memory, and press SETUP01 to display the
numerical value in the memory, so as to display set addressing and numerical value. If the calibration speed is
not correct, input the ideal numerical value, Press: ***ENTER, and the new numerical value shall be displayed.
Note: If the input value is incorrect, press CLEAR key, and then input the correct value. Not to input any set
order again;
(6) Confirm that the weighing elements have no hanging calibration weight:
(7) Start the first step of calibration, to measure the system weight and belt travel. Press CAL1 and the coal
feeder shall be put into operation under the control of the microprocessor, and confirm it for calibration
according to the following mode:
● Screen is cleared to zero, and the line at the top shall initially display <CAL1> state for 2 seconds.
● In the process that the belt driven motor reaches the calibration speed and is stabilized, it is changed
to display as follows after the display delay for 25 seconds:

<CAL1> Tare and Belt Speed


Factor
HH:MM:SS Stabizing @****RPM

● When the delay is terminated, the first reflective paper leads to the display as follows through probe
A:

<CAL1> Tare and Belt Speed


Factor
HH:MM:SS Pass#1Timing

When the reflective paper goes through probe B, the display shall be changed as:

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<CAL1> TareandBeltSpeed
Factor
HH:MM:SS Pass#1Done

When the reflective paper goes through probe B at the eighth time, the display shall be changed as:

<CAL1> FinishingBelt
Revolution
HH:MM:SS Pass#8Done

When the reflective paper goes through probe A at the ninth time, the belt has just rotated for 2 cycles.
Driving motor meets power failure, and the screen displays the speed measurement accuracy percentage for 8
times within 45 seconds:

<CAL1> Dev:0.20%
GoodValues=8

Display CAL1 calibration value:

<CAL1> TarefactorNNNNNN
Speedfactor0.xxx<ENTER>saves

Therein, NNNNNN is the system weight and XXX is speed factor stored under control. Press ENTER key
to save the new measurement values and carry out the step in 1.2.4.7.
If this error is greater than the program limit range, the display is as follows:

<CAL1> Dev:0.70% BAD!


<ENTER>toreCAL<EXIT>toQUIT

Press ENTER again to test.


If the calibration fails after many tests, press EXIT key to end the calibration and eliminate the motor speed
and belt operation. The following conditions will lead to the automatic exit from calibration and display the
diagnostic information:
 The coal feeder is stopped during CAL1 period;
 The calibration reflective paper is too close;
 During the CAL1 period, the weighing system volume measurement has faults.
(8) If CAL1 system weight and belt operation measurement can be completed correctly, carry on the step
in 1.2.4.9 and the step of (7) can be repeated for many times according to requirements;

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(9) Press CAL2, start the second step of calibration and the display shall be as follows:

Add Calibration Weight Of


xxx.xxxKg
<ENTER>tostart CAL2

Check whether the calibration weights are consistent;


(10) Hang the weighing weights on the weighing elements. Press ENTER key to start the CAL2
verification:
Screen is cleared to zero, the line at the top shall initially display <CAL2> state for 2 seconds, the motor
shall be stabilized with the calibration speed after the delay for 25 seconds, and it shall display as follows:

<CAL2> Span Factor:


HH:MM:SS Stabilizing @
Xxxx RPM

Therein, xxxx represents the calibration speed of inputting 01 address, and the calibration process is the
same as CAL1.

<CAL2> Dev:0.20%
Good Values=8

Then, the calibration value of CAL2 is shown:

<CAL2> Span factor NNNNNN


Speedfactor0.xxx<ENTER>saves

Therein, NNNNNN is the span number stored in the controller, pressing ENTER to save the new data.
Calibration inspection
Compare the current calibration with the previous data, the operator can judge the repeatability of
calibration and the change conditions. When conducting the following operation, the microprocessor will
calculate the change percentage of the calibration values of two times:
Display the ratio of system weight change: Press SELFTEST01
Display the ratio of belt running change: Press SELFTEST02
Display the ratio of span change: Press SELFTEST03
The three inspection results above shall be no greater than ± 0.25%. If they exceed, check the suspension
conditions of the calibration weights or other abnormal mechanical conditions.
e. Input / output card verification

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Input card responds to the (4-20) mA signal sent by DCS, set as A1 card.
Output card is used for (4 - 20) mA feedback signal and the control signal sent to frequency conversion
motor, respectively set as A2, A2 card.
The preferred signal of verification comes from the combustion control system (4 - 20) mA corresponding
to (0 - 100) per hour.
Note: Conduct the verification under OFF state.
(1) Press TRIM to enter the adjustment of I/O card, the numerical value and instructions of which can be
browsed, and the display is shown as follows:

<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure

Therein, xxxx is the frequency existing in the storage in the last measurement, send the input signal to the
input channel, add 4mA and press SETUP to enter the measurement mode, and the display is:

<TRIM>A1Card:0% storde=xxxxHz
EXIT=Cancel ENTER=Store

(2) Pressing EXIT can return to the adjustment state without the storage of measurement value, to press
ENTER to store the results, and the display is as follows:

<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure

xxxx is a new value. Press ↑ to switch to 100% of A1 card, and the display is:

<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—Measure

Add 20mA to the input channel and press SETUP to enter measurement mode, and the display is:

<TRIM>A1Card:0% storde=xxxxHz
Up/Down-Nest/Prov SETUP—AdjustFreq

Select SETUP to enter the adjustment state and the display is:

<TRIM>A2Card:0% storde=xxxxHz
Up/Down-AdjustFreq ENTER=Store

Press ↑↓ for adjustment, until the output is 4mA, and press ENTER to input the correct value. Adjust the
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full-scale output and store it in the same way.


(3) The above operation is to adjust the A3 feedback card.
Note: All the new values shall be recorded for future variation inspection.
(4) Press EXIT can eventually retreat to the original state.
4.6.2.2 Maintenance defect elimination.
1) Put the coal feeder into operation under LOCAL state:
a. Check whether the coal signal is correct: examination is coal signal is correct: The action bar and coal
signal are sent out, with the coal feeder at outage.
b. Check whether the coal blockage signal is correct: The action capacitive measurement signal and the
coal blockage signal are sent out, with the coal feeder at outage.
c. Start the coal feeder, place the cleaning motor at RUN position, and check the cleaning motor operation
conditions.
d. Check whether the indicating lamp status is correct, and check whether the display panel and remote
data are normal.
2) Elimination guide:
Alarm: It indicates that there are faults existing for special attention, but there is no need to stop the coal
feeder immediately. Press ERRORRECALL for inspection. When the faults are eliminated, press any white key
to release the alarm, and the alarm light is burnt out. If the coal feeder is being put into operation, press the
corresponding button to release the alarm. Note: Some alarm can be automatically removed after the faults are
eliminated.
Tripping: It indicates the faults existing are very serious, causing the coal feeder to stop work, mainly
leading to the occurrence of the following conditions: The coal feeder has no coal, the coal feeder outlet is
blocked by coal, the speed feedback signal is lost, the motor start has faults, the power supply voltage is too low,
the speed faults are very serious or there are impurities on the belt under LOCAL state. After the faults are
eliminated, press the white key to eliminate the tripping state.
3) Capacity mode operation: It indicates that the weighing system has completed the prevention of coal
feeder fault existing in the electronic equipment under operation in the weighing measurement state, and this
fault may be only a temporary state initially, such as A/D ultra amplitude or A/D reading errors; It may also be a
permanent error, such as the weighing circuit open or A/D broken circuit. Under the capacity mode operation,
firstly check whether there is alarm, with the error codes are 01, 02 and 15; At the same time, pay attention to
the other two conditions that may not cause the error code alarm: One is that the two weighing elements have
not been tracked, which occurs when the deviation of the two weighing elements is not too large (deviation is
greater than 1/8 of the sum) ; The second conditions is that the A/D converter output is zero or negative. In the
capacity measuring state, if there is no alarm, SELF TEST09 can be used to isolate the two states. When the
fault is eliminated, the microprocessor shall automatically return to the measured state.
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At any time, check the fault information of the eight times through pressing ERRORRECALL, and the
display is:

<ERRROR CODE xx> YY


Date:MM/DD/YY
Diagnostic Message
Time:HH:MM:SS

Therein, xx represents the fault code, YY means the newest fault catalogue of eight times from 00 – 07,
press ↑↓ for inspection and replacement. The false code list is as follows:

Error
Illustration Alarm/tripping Fault causes
code

Weighing elements or cables have faults;


Weighing span is overloaded;
A/D converter ultra
01 Alarm The A/D converter weighing sensor voltage on 14.15 lead is not
amplitude
correct;
A/D converter has faults;

CPU has detected that A/D converter is ready for signal;


02 A/D reading error Alarm +10VDC power supply is lost, refer to SELFTEST10;
A/D converter has faults;

The motor is out of operation or the electrical sensor does not work;
03 Speed feedback is lost Tripping Motor only works under JOG state;
Sensor connection has faults;

04 The factory doesn’t design it.

CPU is unable to write data to EEPROM, and also cannot read the
data;
05 EFPROM is written wrong Alarm
U15 line or socket has problems (Note: If it needs to be replaced,
refer to the operation manual) ;
U14 line has faults, the sensing circuit voltage is reduced or without
The battery is short for alarm the support of power; The data inspection received from RAM
06 Alarm
Alarm battery is not correct, indicating that the data stored in BatRAM have
problems;
The coal blockage sensor is found blocked up, the time of which is
longer than that in setting address 16;
Coal feeder is blocked with
07 Tripping Coal feeder discharge valve is closed or to coal feeder outlet
coal
warehouse or the drop tube is blocked up;
The coal blockage sensor of the coal feeder is out of order;
There is coal found on the coal conveyor belt for more than 2
There is coal on the belt
seconds, meanwhile, it is under the LOCAL or CALJBRATE state;
08 under the “local machine” or Tripping
Close the inlet valve, and clean the belt with previous operation
“calibration” state
under LOCAL or CALIBRATE state;
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Error
Illustration Alarm/tripping Fault causes
code

The total amount of coal accumulation pulse cannot follow the


Remote TCL increment is too
09 Alarm transfer rate, with some pulse at loss;
small
Reset 07 and 35 addresses according to the operation manual;
The required coal feed rate cannot be obtained, which is probably
due to the empty belt or blocked inlet. Within 20 seconds, the actual
coal feed rate has more than 5% difference from the required inlet
10 Coal feed rate is wrong Alarm
coal feed rate, and how much coal and where is coal blockage can be
checked on the belt, if the difference is less than 5%, the error shall
be relieved;
Motor starter cannot receive power or loss power within 2 seconds
11 Motor starter has faults Tripping after receiving the order, and the motor starter or the accessories may
have been damaged;
The belt driving motor or motor speed leads to a serious speed
deviation, at 10000rpm/s, when the motor speed deviation is greater
12 RPM has deviation Tripping than ±100RPM, it will cause the system tripping, which may be
caused by motor over speed or unstable speed or incorrect address
input;

In setting address 18, specific material volume shall be transported


Horizontal or high
13 Tripping and level detector shall continuously issue a amount of useless coal,
temperature sensor has faults
or the over temperature phenomenon is detected in the coal feeder;

At event process The frequency output towards the feedback card or the speed control
14 configuration, EPA watchdog Alarm circuit may have faults, immediately contacting with STOCK
relay gives an alarm company;
A/D converter electronic self-test results are inconsistent, and A/D
converter is damaged;
A/D converter 14 and 15 lead reference voltage is instable;
15 A/D calibration is wrong Alarm
DC voltage may be lowered by 10V, with reference to
SELFTEST10, the alarm can be relieved automatically when the
electronic calibration results are stable;

16 Useless

Coal belt load switch time than address setup time;


There is no coal on the belt;
17 No coal faults Tripping
Belt coal carrier switch has faults or the power supply board has
faults;

The above error codes only represent the faults of the coal feeder itself, and the tripping, due to external
causes, can not be reflected in the coal feeder, such as DCS tripping signal, low voltage, and so forth.
4.6.2.3 PC control board: 196NTCPU and power supply board
1) Input voltage inspection
Measure the voltage between 102 and 103 in the control cabinet with the input voltage range of 100 -
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130VAC and 50 - 60Hz.


There is 3A insurance on the power supply board, which can be used to check the insurance conditions.
2) DC voltage measurement
Instable voltage: Taking TP13 as the ground point, TP10 DC voltage shall be between +5.1V~+5.3VDC.
Regulator U1: Taking TP13 as the ground point, TP7 DC voltage shall be between +10V~+14VDC.
Regulator U2: Taking TP9 as the ground point, TP11 DC voltage shall be between +10.0V~+10.25VDC.
Regulator U3: Taking TP9 as the ground point, TP8 DC voltage shall be between +10.0V~-10.25VDC.
Regulator U4: Taking TP6 as the ground point, TP5 DC voltage shall be between +14.25V~+15.75DCV.
Regulator U5: Taking TP6 as the ground point, TP4 DC voltage shall be between -14.25V~-15.75VDC.
3) Signal switching card inspection
Input signal switching card (A1) : This card receives the user signals and connected to the user signals and
switch them into frequency signals accepted by the microprocessor. Taking TP13 as the ground point, use the
frequency meter to measure the TP3 when conducting A1 card adjustment, and the measured data shall be
consistent with the displayed numerical value. When 100% inputting to perform adjustment, if there is
difference between the display frequency and (9600 ± 200) Hz, send A1 back to STOCK company for
maintenance.
4.7 CEMS system maintenance rules
4.7.1 Overview
This system includes D-CEM2000 analyzer (dust analyzer) , V-CEM5000 (gas flow rate, flow measuring
instrument) , and G-CEM4080 (multi component gas analyzer) .
4.7.2 Dust analyzer
4.7.2.1 D-CEM2000 analyzer principle
D-CEM2000 is the dual light path transmission analysis instrument, used to measure the blackness and
dust concentration in flue gas. Its matchless design can continuously measure the visible light transmittance of
the flue gas in the opposite direction, which not only can accurately measure dust concentration in the flue, but
also can conduct the dynamic analysis on the light source deviation brought by the flue movement.
4.7.2.2 D-CEM2000 analyzer composition and functions of each part
1) Transmit-receiver unit
Two identical transmit-receiver units are installed along the chimney diameter direction. Transmit-receiver
unit is equipped with an inductive probe (including the light source, detector and related optical accessories) ;
verification lens, ball valves and related electronic devices for control and measurement. When the power
failure happens, the valves shall be closed automatically to protect the sensor probe.
2) Signal processing unit (SPU)
D-CEM2000 SPU provides 48V DC power supply by SCU through four-wire SmartBUS serial data line.
The signals of two transmitter transmit-receiver units are output in the forms of transmittance and blackness
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through the conversion. Conduct communication diagnosis on SPU through SCU and SmartBUS software
installed on the notebook computer. Complete the gain adjustment on the sensor probe signal through the
trimmer potentiometer of SPU.
3) Station control unit (SCU)
SCU provides 48V DC power supply for the analyzer on local data bus. The power supply of SCU is 86 ~
264VAC. The power supply unit is encapsulated on one side of SCU, and the inner part of 48V DC rail mounted
power supply is connected to SCU processor. SCU is connected with the field analyzer through 4-wire data bus
(local data bus) . The bus consists of 2-core 48V DC power supply and 2-core MOSI (main output/ entry
followed) and MISO (main entry/output followed) communication bus, in the data bus, SCU is taken as the
communication station, and field analyzer is taken as the communication with the data communication from the
station. Note: SCU may be integrated in the gas control unit (GCU) of G-CEM4000 gas analyzer.
4.7.2.3 Equipment installation positioning
At positioning the equipment, the following factors shall be considered:
1) The positions on both sides of the flue must be easily accessible, so as to be convenient for the
maintenance of the transmit-receiver. Positions shall avoid extreme temperature and vibration as far as possible.
2) The permitted ambient temperature range of the transmit-receiver is -20℃- 80℃, with SPU temperature
range of -20 ℃ - 70℃ . (At lower temperature, condensation may appear on the instrument lens, resulting in
inaccurate (too high) reading of the blackness value)
3) There must be a continuous visible light path between each transceiver.
4) SPU and sensor shall be fixed on the site, and the standard cable of 10 meters is attached between SPU
and the probe.
4.7.2.4 Daily maintenance
Keeping the optical window between the transmit-receiver clean is very important, and the installed short
pipes must be removable at the dust accumulation place and spray place. In order to complete the cleaning work
on the transmit-receiver, use the soft and dry cloth to wipe the lens. Only when the lens is kept clean, the
equipment verification can be carried out.
4.7.3 Gas flow rate and flow measuring instrument
4.7.3.1 Principle
V-CEM5000 measures the flue gas velocity by using the principle of infrared measurement technology,
and the analyzer does not need to directly contact with the flue gas at measurement. The velocity measurement
method is similar to the chemical method or the method of ray tracing, velocity is calculated by passing the time
through the signals and the fixed distance between the two sensors. However, the difference from the artificial
measurement trajectory is that the infrared measurement technology takes the Infrared energy change waveform
as the trajectory tracking. In the use process, the sensor purge can be completed without the need of moving the
sensor devices, so V-CEM5000 is the best option for monitoring pollution hot gas flow rate. Each sensor unit
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comprises a broad band infrared detector, an infrared detector absorbing radiation through the lens, and a
preamplifier circuit board, while all devices are completely encapsulated by using alumina. Gas blowing unit of
the sensor is used to keep the lens of the sensor clean.
4.7.3.2 V-CEM5000 (gas flow rate, flow measuring instrument) composition
1) Signal processing unit (SPU)
V-CEM5000 SPU provides 48V DC power supply by SCU through four-wire SmartBUS serial data line.
The signals of two transmitter transmit-receiver units are output in the form of transmittance and blackness after
the conversion. Conduct communication diagnosis on SPU through SCU and the SmartBUS software installed
on the notebook computer.
2) Station control unit (SCU)
SCU provides 48V DC power for analyzer on the local data bus. The power supply of SCU is 86 ~
264VAC. The power supply unit is encapsulated on one side of SCU, and 48V DC rail mounted power is
internally connected to SCU processor. SCU is connected with the field analyzer through 4-wire data bus (local
data bus) . Bus consists of 2-core 48V DC power supply and 2-core MOSI (main output/ entry followed) and
MISO (main entry/output followed) communication bus, in the data bus, SCU is taken as the communication
master station, and field analyzer is taken as communication followed station to carry out the data
communication.
3) V-CEM5000 (gas flow rate, flow measurement instrument) technical parameters:
Measuring range: 0-50m/s can be selected.
Response time: Rolling values from 10 seconds to 30 days can be selected.
Accuracy: < ± 2% measurement value
Serial data interface: serial communication
Structure: epoxy coated aluminum, with protection level of IP65
Ambient temperature: -20℃ to +70℃
Input power: SCU 86-264V AC
VECM 48V DC,(from SCU)
Counter blowing gas consumption: 1 l/s @ 0.15MPa
Drying (-20 ° C)
Cleaning (less than 10µm)
4.7.3.3 Equipment installation positioning
Equipment installation shall consider the following factors: Determination of position shall avoid flue
elbow and the parts with rapid section changes, arranged with the 4 times of the diameter from the downstream
direction of the elbow head, and with no less than 3 ~ 5 times of the diameter form the upstream direction of the
above mentioned parts. As for the rectangular flue, its equivalent diameter is D=2AB/ (A+B) , in which A and B
are side lengths. When the installation position can not meet the requirements, please contact CODEL technical
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staff to carry out technical advice. The positions on both sides of the flue must be easily accessible, so as to
facilitate the maintenance of the transmit-receiver.
4.7.3.4 Daily maintenance
All the CODEL equipments have considered the site sustainable use and reliable operation at design, to
reduce the frequency of maintenance to the minimum. Electronic devices require no maintenance cycle; they are
solid through rigorous factory firing process. Keeping the optical window between the transmit-receiver clean is
very important, and the installed pipes at the dust accumulation places and the spray places must be removable.
In order to complete the cleaning work of the transmit-receiver, use the soft and dry cloth to wipe the lens.
Clean the probe lens about once every 6 months. It wholly depends on the operating conditions, if the dust is too
high, it may require regular cleaning.
4.7.4 Multi-component gas analyzer
4.7.4.1 Basic principle
G-CEM4080 analysis instrument uses the locally inserted probe installed on the flue to measure the
concentration of NO, SO2, CO2 and H2O in the flue gas. The probe includes a measurement chamber with the
length of the one meter, which allows the flue gas to diffuse into through the sintered stainless steel filter, and
allows zero blowback and gas range verification as well.
When the gas diffuses and enters into the measuring chamber, the analysis instrument uses the infrared gas
laboratory relevant techniques to determine the concentration of flue gas. The diffusion chamber can conduct
the high precision measurement under the condition that the dust concentration measurement is as high as a few
grams per cubic meter.
The measurement integrated in the temperature, pressure, CO2 and H2O of the analyzer can make the
output data carry out the standardized display in the form of mg/Nm3 completely.
Use the compressed air to carry out the fully automatic zero verification, to ensure the long-term stability,
making the maintenance amount reduced to the minimum.
4.7.4.2 Technical parameters
Measuring components: The temperature and pressure measurement of NO, SO2, CO2 and H2O gas
Measuring range: Selected (NO & SO2) , 0-25% (CO2 and H2O) (other ranges can be selected according to
the requirements) within the range of 0-1000ppm.
Temperature of the gas: The gas dew point reaches 300ºC
Response time: 1-60 minutes is optional
Precision: ±/-10ppm(0.5% CO2 and H2O)
Resolution: ±/-5ppm(0.2% CO2 and H2O)
Ambient temperature: -20℃~ +50℃ or 0℃~ +70℃
Probe length: 1.0m or 1.8m (refracted beam)
Probe material: 316L stainless steel
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Standard: 89/336/EEC
Low voltage: 73/23/EEC
Analog output: 2 4-20mA isolation outputs, 500 Ω load, and complete configuration from the keyboard
Digital output: 2 SPCO dry contact outputs, 50V/1A configuration output in alarm; 1 SPCO dry contact
output, 50V/1A used for data validity output.
Input: 3 4-20mA standard data inputs; temperature, pressure and oxygen.
Serial communication: RS232/RS485
Display: 32 alphanumeric digits, and black bottom and bright characters of LCD.
Keyboard: Input of 4 soft touch keys
Ambient temperature: -20℃ ~ +50℃
Power supply: 24VDC@15A
Verification gas: 20 L / min @4 kg dry oil-free compressed air.
4.7.4.3 Components
The components of the whole system include:
1) Probe and sensor: They are installed on the chimney or flue
2) Data display unit (DDU) : The 4-core cable connected to the sensor is used for the data to display the
unit power supply and communication transmission, which can be installed in the place 1km away from the
sensor. The second optionally installed data display unit can go beyond the first data display unit, to make the
display screen installed on a detachable installation point of the analyzer.
3) Compressed air filtration/drying unit: When the fully standardized data output provides the form of
mg/Nm3, supply the unit.
4) SmartCom software: One set of software can make all the analysis data output and the diagnostic data
outputs enter and be stored in the computer.
4.7.4.4 Equipment installation positioning
At positioning equipment, the following factors shall be considered:
1) Avoid the position that the flue gas may form the layer.
2) The flue gas pressure is required to be considered, better to select the negative pressure for measurement
with the aspect of reliability taken into consideration.
3) Keep the chimney concussion to the minimum at the mounting points as far as possible.
4) Enough time shall be ensured, to insert the probe and the sensor, and ensure the maintenance work in the
future.
5) Short pipe and the probe shall be fixed in at the position with downward inclination of about 5°, so that
the flue gas in the probe shall flow upward and evaporated with the heating gas.
4.7.4.5 Equipment debugging
1) Preparations before debugging:
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a. Detect that all the wiring and lines shall be consistent with the wiring diagram.
b. Check and confirm that the minimum compressed air pressure for the probe shall be 4bar.
2) Start-up:
Remove the protective cover of the control unit on one side of the sensor, and start 24VDC power supply.
If each LED shall be correctly displayed, the control unit protective cover can be replaced and DDU shall be
noticed. DDU backlight LCD display shall be lightened and the display shall show the normal Mode 0 data
output. The temperature control loop will start the operation when the power supply is started.
4.7.4.6 DDU operation
1) Display mode:
MODE1: Normal operation mode: It displays gas concentration
MODE2: Parameter mode: It displays the operating parameters
MODE3: Standard pattern: It displays standard data
MODE4: Diagnostic mode: It displays the analyzer diagnostic data
MODE5: Set mode: Set the operating parameters, this model can only be entered with the password.
In all modes, the analyzer output data are not affected by the keyboard operation, in addition to MODE5.
2) Keyboard operation:
The keyboard comprises 4 keys, respectively as:
Mode key: Pressing MODE key will move the instrument to the next operation mode, if the key is pressed
again in another mode, it shall return to the previous mode selection.
Arrow ↑↓: According to the program conditions, pressing ARROW key will lead to the selection between
the two options. Pressing ARROW key in one pattern or its sub patterns can gradually enter into all the
available options, or under mode 5, ↑ means the increase of the displayed value, and ↓ means the reduction of
the displayed value.
Input: According to the program conditions, pressing ENTER key will lead to the selection between the
two options. Pressing this key in one pattern or its sub modes will select the displayed modes or options, or
under mode 5, which can be used to input the selected parameter values.
4.7.4.7 Common fault conditions
1) D→C communication fault: It is the communication fault happening between DDU and analyzer control
processor.
2) C→M communication fault: It is the communication fault happening between the analyzer control
processor and the sensor internal main processor.
3) Temp>Range<: It is the fault of the probe installed in the flue gas temperature sensor.
4) Press>Range<: It is the fault of the probe installed in the flue gas pressure sensor.
5) Tx IR Failure: It fails to provide the infrared light source.
6) RxTOC→HIGH: The receiver temperature is too high.
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7) Therm>Range<: The electric actuator control is out of range.


8) Detector>Range<: The detection values of one or more detectors are out of range.
5. Primary equipment and control device maintenance (thermal control device on machine side)
5.1 Condenser rubber ball cleaning device maintenance rules
5.1.1 Overview
The accumulation of the dirt on the power plant condenser water side heat surface, not only makes the
vacuum worsened, reduces the thermal efficiency of steam turbine, but also causes the titanium steel corrosion
and leakage, threatening the steam turbine safe operation when serious. Therefore, the condenser is provided
with the rubber ball cleaning device, and input the rubber ball flushing system when the condenser titanium pipe
is dirty, to clean the condenser titanium pipe. Condenser rubber ball cleaning device is composed by the ball
screen, secondary filter screen, ball loading room, rubber ball transfer pump, electrical control cabinet and other
components.
The working principle of the rubber ball cleaning: The power plant condenser rubber ball cleaning PLC
control system can carry out work in the unit operation process without changing the load, which has the
advantages of low energy consumption, good effect, simple equipment, convenient operation and so forth.
The power plant condenser rubber ball cleaning system is shown as in Figure 1. After the sponge rubber
ball with the similar density to water (made of natural rubber or synthetic resin) is put into the ball room,
starting the rubber ball pump can send the rubber ball to the condenser water chamber with the water flow
pressure higher than that of the circulating water. Though the rubber ball diameter is 1 ~ 2mm larger than the
copper pipe internal diameter, it is easily taken into the titanium pipe by the water flow and compressed into the
oval shape, because it is a porous and soft elastic body. The rubber ball wipes the dirt on the pipe wall in the
moving process, which depends on its own elastic force to flick off the dirt on the surface when flowing out of
the pipe wall, and flows into the ball receiving room with the circulating water, sent into the condenser by the
rubber ball pump again.
5.1.2 Maintenance items and quality standards
The cleaning device is controlled by the program controller, when the condenser titanium pipe needs
cleaning, the program controller opens or closes corresponding execution and rubber ball pump by sequence
through the manual cleaning command button (previously set by users) , to complete the cleaning process for
once automatically, with each execution action switch state instructions displaying on the touch screen.
The control system is provided with the operation, stop, fault and the large ball screen pressure difference
alarm signals, with hard line interface reserved between itself and DCS. The automatic cleaning time can be
changed through the modification of the program.

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Simulation diagram of rubber ball cleaning system

Condenser Condenser

Trench Trench
Circulating Circulating Circulating Circulating
water outlet water inlet water inlet water outlet

Fig. 1 Power plant condenser rubber ball cleaning system diagram


5.1.2.1 General inspection
1) Appearance inspection: The wiring is intact and solid, and the appearance is neat, with no oil stain.
2) Program control cabinet, control cabinet button, and switch tests: The buttons and switches are complete,
with correct action. The feedback of each actuator on the touch panel is normal, and CRT analog displays
correctly.
3) Cabinet internal wiring: The cable cards are complete, cable arrangement is neat, the terminal cable
heads are tidy, and the number and terminal cable are complete.
4) Electric valve inspection: The action is normal, the travel is in place, and there are no phenomena of jam
and motor overheating in the action process.
5) The hard wired signals towards DCS are normal.
6) Power supply part: The contactor action is reliable, the switch is flexible and easy for use, the wiring is
correct and firm, the heating of each part is normal, and the power supply switch action is normal.
7) Time counter: The time counter is set correctly, and timing and action are normal.
8) Module parts: The modules are well connected with the module frame, the wiring is correct, the module
indicating lamp is normal, and the heating of each part is normal.
5.1.2.2 PLC module state inspection
1) PLC power supply wiring: The wiring is correct and reliable, PLC touch panel communication interface
shall be intact, and the indicating lamp displays correctly.
2) CPU module status indicating lamp displays and the work is normal.
3) I/O module: Each input and output channel is normal, and the lightening of switch module indicating
lamps corresponding to each channel means that there is input or output in the channel.
5.2 Rotating filter control device maintenance rules
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5.2.1 Overview
The control system is the special electrical machine control device equipped for rotary filter screen sewage
disposal machine. The whole set of system consists of a water level control cabinet and two sets of field power
boxes (only main circuit and control circuit of the rotary screen) . Water level control cabinet controls the
operation of the two rotary filter screens respectively through the control of two field power boxes, and control
the signals of the flushing pump and flushing valve at the same time.
The control system adopts Schneider quantum series PLC, and the monochrome LCD touch screen is the
display, with stable performance and wide application range, which can facilitate the realization of the control
on rotary filter screen sewage disposal machine.
Instrument control and electrical requirements:
Power supply of each secondary filter screen control cabinet: 380VAC/220VAC. Power: 4.5kW.
Power supply of each industrial cooling water filter control cabinet: 380VAC/220VAC. Power: 1.5kW.
The raw water enters into the filter cylinder through the inlet pipe with the nominal diameter of 2200mm,
and the fresh water flows out from the outlet pipe through the stainless steel filter screen, completing the raw
water filtration process. Various particles and impurities with the size greater than 6mm accumulate in the filter
cylinder or attached to the inner wall of the filter screen. When the accumulated dirt gradually increases to block
up part of the filter screen holes, the inlet and outlet water pressure shall be changed, generating pressure
difference. When the water pressure difference reaches 0.002~0.005MPa, differential pressure controller switch
shall trip, generating system cleaning and filtering signals, to control the motor operation in the secondary filter
screen and the sewage recovery device, When the motor rotates through the reducer driving the two rows of
brush rods in the filter screen, the brushes shall wipe out the dirt on the inner wall of the filter screen, mixed
with water, and enter into the sewage recovery device timely after sucking groove hollow shaft; at the same
time, the system control electric butterfly valve is opened, under the filter pressure shock, the dirt mixed with
water is discharged from sewage discharge valve, and the filter screen hole is smooth after the flushing, with the
inlet and outlet water pressure difference reduced to zero; pressure difference control switch takes action, at the
same time, the cleaning timing time is up (time of 15~60S is adjustable) , the motor stops, the brushes stop
working, the sewage butterfly valve is closed, and the sewage disposal process is ended.
5.2.2 Maintenance items and quality standards
1) The circuit connection must be consistent with the circuit diagram.
2) Check whether the overload protection settings are correct.
3) Open the inlet valve, close the outlet valve, open the electric butterfly valve through the handle, and
close the electric butterfly valve tightly after the exhaust is ended.
4) Press the control button, start the motor, and observe whether the axial direction moves along clockwise
direction. If not, turn off the power, to change the rotation direction of the motor.
5) Open the outlet valve, and the system can take normal operation.
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6) Set programmable timing controller working procedure (see setting methods in Appendix instructions) ,
the cleaning work is suggested being taken for 4 times every day generally, with 30min each time, and increase
or decrease the working times according to the field water quality.
7) Regularly check whether the sealing parts have leakage and sealing ring aging phenomena.
8) Regularly check whether the gear box has lubricating oil.
9) Regularly check the filter, unscrew the lower plug to release sewage, and tighten it again.
10) Regularly open the manual drain valve, to discharge the deposition at the bottom of the cylinder body.
11) Regularly check whether the contact of electrical components in the control box is good, as well as the
insulation performance.
5.3 Circulating water butterfly valve control device maintenance rules
5.3.1 Overview
5.3.1.1 Driving device of butterfly valves has the following properties:
Valve overload protection;
Valve travel protection;
Valve opening position indicating device;
The valves and the travel switches are fully opened, the middle travel (open for 15 degrees) contact points
are led out, in order to interlock with the pump motor, and the above-mentioned contact wire leading out shall
meet the local and remote control room requirements.
5.3.1.2 Local control cabinet shall meet the following requirements:
There are local/remote operation switching devices;
Local control cabinet is equipped with open and close buttons;
The indicating lamp indicating the valve state and opening;
Control cabinet alarm indication;
5.3.1.3 Signals transmitted from the local control cabinet to the central control room DCS:
The valve open and closed states; (normally open the contacts, and the contacts are closed at action) ;
The main switch of the local control cabinet is switched to “automatic” and “manual” position;
Local control cabinet or butterfly valve has faults, and a fault signal can be sent out for alarm at any case.
5.3.1.4 Control signal transmitted from the central control room DCS to local control cabinet:
Open the valves (normally open contacts, and the contacts shall be closed when the instruction is issued);
Close the valves (normally open contacts, and the contacts shall be closed when the instruction is issued).
Each electric device shall be equipped with 2 pairs of full open travel switches, 2 pairs of full travel
switches, 2 pairs of open torque switches, 2 pairs of closed torque switches.
5.3.1.5 Working principle
This butterfly valve control system mainly consists of two parts, namely, hydraulic system and electrical
system.
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The power supply of electrical system is provided by dual AC 220V control power, there are two ways of
automatic interlock and local control, the valve is opened firstly when the interlock mode starts circulating
water pump and the travel reaches 15 degrees, the circulating water pump starts, the valve is fully opened 90
degrees continuously, while the valve shall be closed firstly when stopping the circulating water pump, the
circulating water pump shall be stopped when the travel reaches 15 degrees, with the valve closed at the same
time. The local mode is the hard operation on the local control box, at which the switches shall be placed at the
local mode position. At interlock or local operation on opening the valve, the solenoid valves 1YV, 2YV and
3YV are charged, the pressure oil enters into the upper part of the oil cylinder, and the lower oil is discharged, to
push the piston movement and realize quick valve opening before reaching 15 degrees. After 15 degrees, 3YV
shall lose power, the slow opening valve reaches 90 degrees, and the solenoid valves of 1YV and 2YV shall lose
power when there is closing valve signals, the pressure oil enters into the lower part of the cylinder (when the
3YV loses power) , the upper part is discharged, and the valve is closed.
5.3.2 Maintenance items and quality standards
5.3.2.1 Maintenance of power supply system
Conduct the maintenance on whether the control box butterfly valve power switch capacity is appropriate,
and whether the action is flexible and reliable, and use 500 MΩ meter to check whether the power insulation
resistance shall be greater than 10 MΩ.
Power insurance capacity of the local control box is checked with no errors, the cable insulation meets the
requirements, electric box wiring is standard, the number is clear without defects, the wiring is solid, and there
is no grease and dust in the box.
At button and indicating lamp maintenance, the action of all buttons shall be flexible, the contact resistance
shall be less than 0.2Ω, the alcohol can be used to cleanse the contacts of the connectors out of standards, which
shall be replaced if the requirements can not be reached, the indicating lamp shall be intact without defects, the
defected ones shall be replaced, the button wiring shall be correct and solid, and the appearance shall be clean,
with no grease.
5.3.2.2 Travel switch maintenance
The wiring shall be firm, and the number shall be clear and complete, the switch is flexible, with no jam
phenomenon, and the contact resistance shall be less than 0.2Ω. The appearance inspection shall be complete,
with no defect, and the surface shall be clean and free of grease.
5.3.2.3 Electric contact pressure gauge maintenance
The appearance of electric contact pressure gauge shall be complete, with no defects, the contact resistance
shall be less than 0.2Ω, electric contact pressure gauge can be used after the qualified verification, the upper and
lower limit values shall be accurate, firmly installed, with no leakage, and the boundary is correct and reliable.
5.3.2.4 Solenoid valve maintenance
Solenoid valve coil resistance and insulation resistance measurement shall has no open circuit and short
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circuit phenomena, with firm installation and flexible action, without blocking phenomenon, and the appearance
shall be neat.
5.3.2.5 Relay maintenance
Relay appearance shall be complete and clean. Use the multi-meter to measure that the coil resistance has
no short circuit and open circuit phenomena. Relay socket shall be firm, with reliable boundaries, and the
contact resistance shall be less than or equal to 0.2Ω.
Common faults and treatment methods
Fault Reason Treatment methods
1. Manual stop valve mouth is not closed
tightly 1. Close the stop valve mouth
The motor operating system has no
2. Oil pump operating direction is not 2. Adjust the motor phase
pressure
correct, 3. Clean or replace the oil filter
3. Oil filter is blocked
1. Identify the electric contact pressure
Pump keeps working for a long time 1. Pressure controller fails to work
gauge again
without stop 2. Overflow valve does not work
2. Adjust or clean the overflow valve

1. Check the intermediate relay, button


1. The wiring is loosen due to vibration and the travel switch terminals and other
Valve switch does not act 2. Electric element are burnt and junction places, which shall be tightened
damaged 2. Check the electrical elements, to
repair or replace them

Solenoid valve loses power Insurance is burnt Replace the insurance

6. Thermal control system maintenance (DCS system maintenance rules)


6.1 ABB Symphony Plus control system
6.1.1 System overview
Distributed control system (DCS) mainly completes the logic control, equipment start and stop, analog
adjustment, data acquisition, interlock protection, alarming monitoring, parameter monitoring and adjusting
functions of FSSS system, SCS system, DAS system, ECS system and MCS system. DCS control device of this
project uses Symphony distributed control system of ABB Company, the control software configuration of
which is flexible and convenient, easy for debugging and maintenance.
Node bus adopts double bus redundancy configuration, and the field bus also adopts the dual bus
redundancy configuration, to reduce the fault rate.
6.1.1.1 Symphony Plus system characteristics
1) With specialized protocol and special interface, it is not vulnerable to cyber attacks.
2) According to the characteristics of the industrial field, with strong anti-jamming performance, it can
withstand the sudden large amounts of data, with the low requirements of the outside environment.
3) It has the redundancy on complete meaning. Each specialized network interface module is equipped
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with 2 network interfaces, truly making interface redundancy and the medium redundancy.
4) All the interface modules are equal on the functions.
5) Based on the power plant application specific multi loop structure, it is easy to form a plurality of
mutually independent and mutually combined sub systems.
6) Taking PCU as the unit, each PCU has many controllers, and each PCU cabinet can complete an
independent control system, but each system can be distributed to different controllers, more in line with the
centralized and decentralized principles.
6.1.1.2 Symphony Plus system composition
Symphony Plus system is composed by the operator station, engineer station, history data station,
redundant control processor, communication processor, redundant via bus and field bus and I/O card, the relay
cabinet, printer and other equipments, to complete the data acquisition, display, record, alarm processing and
real-time functions of the unit thermodynamic parameters.
1) Uninterruptible power supply (UPS)
a. DCS shall use the dual UPS redundant mode for power supply, and the inlet wire of each path shall be
connected to the bus bar section of different power supply;
b. UPS secondary side shall not be connected with new load without being permitted. Under the maximum
load, UPS capacity shall have 20% - 30% of margin;
c. Main technical indicators of PS power supply:
Voltage fluctuation is less than 10% of the rated voltage
The frequency range is 50HZ ± 0.5HZ
Waveform distortion is less than 5%
The standby power supply switch time is less than 5ms
Voltage stability: It shall not exceed ±5% of the rated voltage at the stable state, with no more than ±10% at
dynamic state.
Frequency stability: The stable leaf is greater than ±1%, and the dynamic process is no greater than ± 10%.
UPS shall have the over current, overvoltage, and input surge protection functions, and has fault switching
alarm display.
2) Power supply isolation and power distribution
The unit under operation shall check the following contents:
Distributed control system power supply must be provided by UPS, rather than provided by the power
plant service power directly.
UPS output side is not allowed for grounding, use the isolation transformer for isolation, and make the
secondary side of the isolation transformer grounded.
At overhaul for each time, check the power supply switch or the insurance of UPS output side power
distribution panel.
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Power supply wire diameter depends on the DCS system loading, and the grounding wire diameter shall be
identical to the power supply wire diameter.
6.1.1.3 DCS grounding
1) The cabinet shell of DCS system is not allowed to be connected directly with the building reinforcing
bars, and the cabinets shall be connected through the grounding wire, connected with electrical ground; the
phase cabinet shell, power ground, shielding ground shall be connected directly to the machine cabinet
grounding wire; ensure that DCS system shall meet the requirements of “one point grounding”, the whole
grounding system finally only has one point connected to the electrical grounding wire, and meets the
requirements of electrical grounding resistance.
2) DCS system input and output signal shielded wire grounding.
DCS system input and output signal shielded wire, usually is connected directly with the grounding cabinet
AC grounding wire. Signal shielding requires single end grounding. Signal end is non-grounded, and the
shielded wire is directly connected to the cabinet grounding wire; the signal end is grounded, and the shielded
wire shall be grounded at the signal end.
6.1.1.4 DCS system grounding system inspection and test
The inspection on DCS system grounding system shall be carried out at the unit major repair, which shall
at least include the following contents:
1) The cabinet shell of DCS system is not allowed to be connected directly with the building reinforcing
bars, and the cabinets shall be connected through the grounding wire, connected with DC grounding pole or AC
ground at one point.
2) The grounding wire and the earth pole connection point shall use the welding mode, with the welding
points of no fracture, rosin joint, and corrosion; the grounding wire between the cabinets can use the fixed mode
of bolts, which requires the gaskets, fastened bolts, with no rust.
3) The grounding pole shall not be loosened, and the grounding resistance shall comply with the
requirements.
4) The grounding resistance of the whole grounding system from the cabinet to the electrical ground shall
comply with the requirements of DCS system.
5) The input and output signal shielded wires shall comply with the single end grounding requirements.
6.1.2 System maintenance
6.1.2.1 Maintenance during DCS operation
1) DCS control cabinet
Inspection cycle shall be taken at least once a week, the inspection contents are as follows:
a. DCS control cabinet ambient temperature and humidity;
b. Fan filter cleaning and degree of soundness;
c. Cabinet temperature shall comply with the requirements of manufacturers. Fan shall work normally;
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immediately replace the fans that are abnormal during the operation, or take necessary measures;
d. The controller state and the working state of all the power supply and modules.
2) Control room, engineer station and its equipment
Inspection cycle shall be taken at least once a week, the inspection contents are as follows:
a. Get familiar with the thermal equipment operation conditions from the operating personnel;
b. The printer works properly, and the printing paper is sufficient;
c. The operation button, indicating bulb, the main parameters display card of LED liquid crystal, and the
display instruments work normally;
d. The operator station, engineer station, man-machine interface equipment, module, power supply, and the
fan work properly, with clean filters;
e. Use the operator station or the engineer station, to check the module working state, whether the
communication has alarm and the important thermal signal state.
f. The inspection shall keep records, and the monitor or team technician shall conduct acceptance on the
results of the inspection records.
g. As for the defects found at inspection, timely register and deal with them in accordance with the relevant
provisions.
6.1.2.2 Regular maintenance of equipment under operation
1) Keep backups of the whole project tree regularly. At making backups, a backup directory is better to be
established, under which a sub directory shall be established in the form of date, and then copy the whole
project tree to the sub directory, so as to facilitate the management.
2) Put all the configurations in the controller, that is, the CFG files, into EWS regularly. At making the
backup, a directory for CFG file shall be better to be established, under which a sub directory shall be
established in the form of date, and then put all the configurations in the controller into this sub directory.
3) Regularly check whether EWS works normally, including the existence of the security dogs and
LICENSE, and the communication established with ICI. They can be checked with the following methods:
Firstly, open a logic diagram randomly, and then click MONITOR order, if the data can be monitored, it means
that EWS works normally, otherwise, conduct corresponding inspection according to the error information on
the screen. Generally speaking, if any logic diagram can be opened, it means that there are no problems in
security dogs and LICENSE. In this case, most of the problems exist in ICI hardware. If the ICI hardware has
no problem, the computer communication interface setting may be wrong, or the computer communication baud
rate settings or the hardware configuration of ICI does not match, or the communication lines have problems,
and so forth.
4) Regular file the Event Log, and select Clear to eliminate the original event records in the project tree at
filing.
6.1.3 Hardware maintenance
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6.1.3.1 Controller maintenance


During the unit maintenance period, seize the opportunity to carry out some maintenance work that cannot
be carried out at the unit operation due to the consideration the safety reasons, including the following contents:
1) Because the machine cabinet heat-dissipating method is the cabinet top fan ventilation method, which is
easy to accumulate dust after a long time, and it may have a bad influence on system operation, so the thermal
personnel shall carry out the dust removal with the dust cleaner (short-term power can be used for fan, in
addition: the dust cleaner can not be extended into the internal chassis) .
2) Dust is also the hidden danger of DCS system, because the computer system is easy to accumulate dust
after a long time. The thermal personnel shall use the soft brush to remove the dust (very carefully) . The printer
shall also pay attention to the dust prevention and removal. In this process, prevent the charged computer from
hot plugging, and pay attention to the correct connection of the computer after the dust removal.
3) Before the machine being started, conduct a general inspection on the air switches of all the cabinets, so
as to prevent the empty machine tripping due to the machine cabinet loop maintenance.
4) Confirm that the fan operation of each cabinet is normal. The cooling fan is the vulnerable part of the
system, which shall be inspected and replaced regularly, and it may cause the local high temperature affecting
the service life of part components if the inspection and replacement is not taken timely.
5) Detect the voltage at the test terminal and the output terminal of each power device, to ensure that the
voltage at the output terminal is out of the specified range in the following. If the detected voltage exceeds the
rated range, adjustment shall be carried out
5V power supply: 5V+0.1V
±15V power supply: ±15V±0.2V
24V power supply: 24V+0.2V
48V power supply: 48V+0.4V
6) Check whether each connector and cable has laxity and damage phenomena, insert it tightly if there is
laxity, and replace it for a new one if there is damage.
7) Module LED instructions:
a. Instructions of network interface module LED: The front panel of SPNIS21 module has 16 red LED,
which are divided into A and B two groups. In addition, they also include a state LED (red/green color) . At
normal operation, LED of group A and B will take beating display, and report the counting information of
communication loop. LED display counting mode is determined by SW4 switch. When the module appears
abnormally, LED of group A will display the error code, and LED of group B will be closed.
When the module is under normal operation, but loop appears abnormally, the display is as follows:
Abnormality of Loop1: LED of group A shall flash simultaneously (determined by SW3 switch setting) ;
Abnormality of Loop2: LED of group B shall flash simultaneously (determined by SW3 switch setting) .
b. LED display of network processing main modules: There are two kinds of LED on SPNPM22 module
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with 9 in total, in which:


The first LED is green / red dual color, used to indicate the module state.
The second to ninth are the red single color LED, to indicate the operation state of CPU.
c. LED display of BRC: The front panel of BRC410 has 17 LED indicating lamps, one of which is a stop /
reset switch. 1 LED is the module operating state indicating lamp; 2~17 are module LED operating indicating
lamp of CPU.
BRC410 LED of group A indicates the error code, and BRC410 LED of group B uses different colors, only
used in testing the modules.
d. Classification of I/O sub module:
Analog input includes: SPASI23 and SPFEC12;
Analog output includes: SPASO11;
Digital input includes: SPDSI22/13/14 and SPDSM04;
Digital output includes: SPDSO14;
Special Function of special application includes: SPFCS01, SPTPS02, SPHSS03, SPSET01, and SPSED01
8) Bridge controller:
The bridge controller is the core module of the series completing process control. It can complete the
process control and data acquisition of various types. There are configurations existing in NVRAM of the
controller, meeting the site control requirements. Because of the support of the corresponding back-up batteries,
the configuration can not be lost under the conditions of power failure. In order to improve the system reliability
and control integrity, the controller modules can constitute the redundant configuration. The redundancy method
does not occupy the communication bus, which is the one-to-one redundancy of the controller, hanging on the
control channel as an address. The redundant controllers together support the sub bus, and get the information
from the scene. When the controller is under practical work, one of the modules shall be set as the main module,
to complete the process control. Another module shall be set as the auxiliary module in hot standby state, which
can only track the main module information rather than conduct operation online. Because two module
configurations are the same, only need to read the important data into the auxiliary module to complete the
switching when there is a need for switching. In addition, the controller redundancy can also provide: The
ability to modify the configuration online, without any impact on process control. Through the engineer
operation, the newly modified configuration can be copied to another module to complete the modification
process of the configuration. BRC410 front panel adds an Ethernet interface, used for Modbus TCP protocol
communication with other equipments. In order to use the communication function, HGS (Harmony Gateway
Software) software needs to be installed and configured.
BRC410 controller module setting Controller Module (BRC) Setting
There are 3 configurable 8-bit switches and 4 jumpers on BRC circuit board. In which:
SW1: Stop/Reset switch (without configuration) ;
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SW2: Set the module options and special operation;


SW3: Not use (not to change the settings) ;
SW4: Set the options of installation unit and the memory;
SW5: Set the BRC module address;
J1: Set the machinery fault timer;
J2: Set the diagnosis interface communication mode;
J3: Set the module installation unit;
J4: Set by Bailey engineer;
6.1.4 Symphony Plus system software maintenance
Composer6.0 software requires to use the operating system of English version (Windows 764-bit version) ,
rather than the use of Chinese operating system.
6.1.4.1 Software backup
During the debugging period, pay attention to the backup of the configuration every day, and try not to
compress the configuration files at backup; After the debugging is completed, conduct the backup of the
configuration after 168, and the configuration backup is conducted before and after larger logical modification
every time.
6.1.4.2 Project tree compression
Because Composer uses Access database structure to save all kinds of information of the project tree, and
Access structure database shall gradually expanded with the increase of use, so there is a need to usually use the
built-in compression tools of Composer to compress the project tree under the normal use conditions.
6.1.4.3 Project tree restoration
When the situation happens that the project tree logical page cannot be opened, restore Composer project
tree.
Method 1: Use the built-in restoration tools of Composer to restore the project tree.
Method 2: Restore or compress the project tree through ODBC method:
Step 1:Open the control panel -> Administrative Tools-> Data Sources(ODBC) ,
Step 2: Select MS Access Database, click Configure on the right side, select Repair, and select the “.ebp”
file of the project tree for restoration in the pop-up dialog box.
Method 3: Use Access software to restore or compress the project tree, open the project file with Microsoft
ACCESS, and select tools->Database Utilities->compact and repair database, to restore the original database
If the project tree files cannot be compressed through the above methods, or the files opened by Access
through ODBC compression are found lack of tables or the query needs some manual modification, the specific
methods can refer to corresponding technical documents of ABB Company.
No matter which method is taken, before the restoration of the project tree, carry out the backup of the
project tree.
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6.1.4.4 Project tree copy


If the logical drawings are copied among the project trees, pay attention not to modify the drawing logic of
the targeted and the original project trees or open the drawings at this time, it is recommended that any
operation shall be not taken on the computer system at the copy, so as to avoid turning off the project trees or
the forced shutdown after the copy is completed.
6.1.4.5 Enabling log function
Enabling log function plays an important role in recording modification of Composer logical configuration
and the remembrance and query of accidents. Enabling method is as follows:
As to the new project, if you want to enable LOG function automatically when setting up a project tree,
you just need to modify the registry. The registry is as follows:
HKEY_LOCAL_MACHINE\SOFTWARE\ABB\Composer\InstalledComposerSettings\EventLogDefaultS
tatus registry value shall be changed to 1 (default value is 0) . In this way, when establishing a project tree, LOG
record will open automatically, but it doesn’t work on the well established project trees.
b. As to project trees that have existed but haven’t enabled this function, function can be enabled through
Log tab control under Tools->Options. But the computer name (capital) and the user name of “Log
administrator” in DISABLE state shall be modified, and then click the Enable key.
c. View the Log record: through View->Event Log, modification record of configuration can be checked.
d. Archive the Log data of Composer: first of all, make sure that Log function has been enabled and
computer name and user name are all current names. In the Log tab control under Tools->Options, click the
Archive Log Data key and Log data can be archived. The document that has been archived is in “*.mdb” format.
Use Access to open and check operation data that have been saved before archiving(here is a tip: when enabling
the Log function and making a large amount of copies of project trees, in order to finish copying as soon as
possible, disable the Log function and enable it again after finishing copying) .
e. In some cases, it can be found that Enable action and Disable action in the Log function cannot be
modified and Archive operation cannot be conducted. That is because that computer name when setting up
project trees and the current computer name are not the same one. The solution is: change the current name to
its recorded original name in the Log function and restart the computer. In this way, the original name in Log
function can be modified and change it to the current name. Then exit. Change it back to the current computer
name and Enable and Disable can be modified in the open project tree. Archive action can be enabled.
6.1.4.6 Viewing the compiling and download data of configuration
Right click and choose the current controller. Choose View Last Compile in drop-down list and you can
view the time and content of last configuration compile. In Output window, you can view the download
condition of the compiled configuration.
6.1.4.7 Printing drawings in bulk
When you need to bulk print the drawings, expand the project tree and choose module or several CLD
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drawings. Right click on Print while pressing on Ctrl key, and print dialogue box will pop up. Then you can
bulk print the drawings.
6.1.4.8 Increasing I/O analog quantity
In logic diagram, find out an empty channel; define some information, such as point name. Click data base
→ Tag data base, copy a similar point and a window will pop up. In “general” column, fill in some information,
such as INDEX, NAME, Description and plant tag name. In “harmony” column, fill in some information, such
as ICI index pcu number and module block. Click the OK key.
6.1.4.9 Newly establishing or revising the logical configuration
For example, in the configuration software Control Engineering, open List/L1/P1/M3 of project tree one by
one, right click M3, click new → logic Document, and the window Add control logic will pop up. Fill in the
name of logic diagram and the newly-built logic diagram is created. Open it and logical configuration can be
conducted.
6.1.4.10 Revising graphics
Click the “DATA BASE” in graphics, then click the “Display”, and open the graphics authoring software
Display builder. Click OPEN, under the category of C:/Program data/ABB Symphony plus/operations/
SV1.0/display/work/UNIT GRAPHICS 14 DEC 13, open the graphics that need to be revised. If you want
displaying analog quantity points to be added, after unfolding the graphics, copy the points of the same type that
you want to add (points with the same temperature, pressure or percent) and paste in the graphics. Then change
the name of displaying points. In the end, click the “save” key and add it in the system.
6.1.4.11 Steps to download the controller
Firstly, pitch on the controller you want to download, right click, and choose “compile” for compiling.
After that, right click on the controller, click the “Run time → online configuration”, and it is finished.
6.1.4.12 Download of HMI station
Unfold the desktop folder named OSI-DISPLAY.BIN. If you have modified a graphics, five files would be
created. Copy these five files, unfold the folder named SEND TO ALL HMI, and right click for pasting. In the
end, click the batch file named S2BAT on the desktop and the task is completed. All the operator stations could
check the revised graphics.
6.1.5 System standby parts management and maintenance
6.1.5.1 Storage requirements
Requirements of storing modules are as follows:
1) All the modules shall be stored with antistatic bags wrapped or stored according to the requirements of
the manufacturer;
2) Temperature and humidity of module storage room shall meet the requirements of the manufacturer;
3) During storage, antistatic precautions shall be taken and actions of touching circuit board with hands are
forbidden;
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4) Time of storing modules shall be registered and it shall go through the in-warehouse and ex-warehouse
procedures.
6.1.5.2 Regular inspection
1) There shall be testing control cabinet for inspection and test of all kinds of modules in thermal specialty.
The control cabinet shall have the function of testing the reliability, functionality and stability of modules,
cables, terminal blocks and power supply.
2) Thermal staff shall inspect a few common spare parts saved in this major semiannually. The inspection
contents are as follows:
a. Surface is clean. There is no oil stain on printing plate plug-ins, and everything is normal after slight
click;
b. Everything is normal in software loading and unloading tests;
c. It is in proper working order in communication port and hand operating station;
d. It is in proper working order in analog quantity and on-off input and output channels;
e. Install the testing software and it shall work normally for no fewer than 48 hours;
f. Switchover test of redundant modules;
g. After the inspection, fill in the inspection record and stick the mark of conformity.
6.1.5.3 Inspection before using
Modules shall be inspected before being used:
a. Function inspection: all kinds of communication ports, I/O function and control algorithm;
b. Status inspection: inspecting the status of modules at the operator station;
c. Configuration inspection: configuration shall be loaded in modules and examine whether it is correct;
When putting it into use, set the module location and other switches. After the confirmation of guardian,
insert into right trench and fill in the record card.
6.1.6 Distributed control system maintenance
6.1.6.1 Thermal preparations before unit maintenance
1) Before unit maintenance, inspect, analyze and verdict the following devices through DCS operator
station and engineer station, so as to formulate and supplement the maintenance items:
a. DCS system modules, power supply, fans, I/O channel, communication network, operator station and
engineer station;
b. Measuring element, transmitter, actuator and various plate cabinets;
c. Major trend record and PID parameters of analog quantity control;
d. Steam engine vibration, differential expansion, eccentricity, boiler metal wall temperature, steam engine
wall temperature, generator coil and iron core temperature;
e. Verifying the exited guard and its definite value.
2) Before unit inspection, taking advantage of machine halt, test the system or equipment with defects
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specifically.
6.1.6.2 Maintenance items and cycle
Major repair goes along with major unit equipment maintenance. Major repair items include:
1) Major repair items
a. Comprehensively inspect the control equipments and make a good record;
b. Copy the configuration of all the modules;
c. Verify the configuration of the module marks;
d. Clean the control cabinet power supply and modules;
e. Clean dustproof strainer of the plate cabinet;
f. Examine and fasten the control cabinet wiring and set screws;
g. Examine the grounding system;
h. Take some dustproof and sealing actions over control cabinet;
i. Replace the cooling fan;
j. Power supply performance test;
k. Line insulation test;
l. Maintenance of recorder, printer, alarm window and man-machine interface device;
m. Eliminate the defects that cannot be handled in operation;
n. Recover and improve all kinds of marks;
o. Functional test of hardware equipments;
p. Loading and checking of configuration software;
q. Verification of measuring modules;
r. Site device maintenance;
s. Guard interlock test;
t. Examine and replace the cable, pipeline and its affixes.
2) Minor repair items
a. Minor repair goes along with unit minor repair. Minor items include:
b. Clean the dustproof strainer of the plate cabinet;
c. Inspect various cooking fans;
d. Inspecting the working condition of power supply and modules;
e. Functional test of hardware device;
f. Defects that cannot be handled during firefighting;
g. Maintenance of some in-place device;
h. Unit main protection and interlock tests;
i. Verification of some I/O modules;
6.1.6.3 Distributed control system equipment maintenance
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1) Work before power failure


a. Software backup;
b. Compare the configuration files, find out the problems and make a good record for verification;
c. Check the state of power and modules;
d. Check the operation state of fans.
2) Power supply maintenance
a. Power supply maintenance shall be carried out after disconnecting the power.
b. Before power supply maintenance, make a record of the switching system and wiring of power supply;
c. Do the power-on test of the power supply and debug all kinds of parameters, so as to meet the
requirements of the manufacturer.
3) Cooling fan maintenance
a. Cooling fan is a damageable part of the distributed control system, and shall be regularly replaced;
b. Before replacement, bear in mind that voltage, power and revolving speed of the replacing fan are same
with that of the replaced one;
c. Power supply wiring of the fan shall be secure and reliable;
d. Make sure that the rotation direction of the fan is correct;
e. After replacement, make a record, so as to confirm its replacement period.
4) Sweeping and cleaning of modules
a. Module cleanup shall be conducted after disconnecting the power.
b. Mark the location of modules before module sweeping, and record the location of equipment switches
and jumpers, so as to do verification after sweeping.
c. When sweeping the modules, staff shall wear static electricity protection grounding ring, and try not to
touch the circuit section.
d. Tools for module sweeping are as follows:
A reducing valve with strainer;
A static-free air gun;
Several static electricity protection grounding rings;
A static-free resistance;
A high-power cleaner (no less than 3KW)
e. Sweeping method:
Connect the instrument air to inlet of pressure reducing valve;
Connect the static-free air gun to outlet of pressure reducing valve and set the output pressure of pressure
reducing valve to 0.5 Mpa;
Make ground connection of static-free plates;
Staff shall take static electricity protection grounding ring
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Start the cleaner;


Put modules on the static-free plates and blow the modules by air gun.
f. Module cleaning
After blowing the modules, clean the circuit board connectors of modules and parts with remaining dirt
after blowing;
When cleaning, staff shall wear static electricity protection grounding ring.
Specified cleaning agent must be used.
5) Control cabinet cleaning
a. Control cabinet cleaning must be conducted after disconnecting the power;
b. Before cleaning, pull out the modules;
c. Clean the dust-proof strainer and equipment cabinet;
d. Clean the module trench and socket;
e. When blowing, use cleaner for dust collection;
f. After blowing, check the wiring in the cabinet.
6) Module back fitting
a. When fitting back the modules, staff shall wear static electricity protection grounding ring.
b. Before fitting back, check the module number and switch settings carefully;
c. When inserting the modules, pay attention to the location of guide slots, so as to avoid damaging
modules;
d. After fitting back, make sure that the insert position is correct and the connection is reliable.
7) Maintenance of operator station
a. Make a backup of application software before disconnecting the power;
b. Clean modules and case after disconnecting the power;
c. Check the cooling fan and replace it if necessary;
d. Check the power voltage after power transmission, and make sure that it can meet the requirement of
manufacturer;
e. After fitting back of modules, check and examine the operator station;
f. Check the interface devices, such as keyboard, mouse.
8) Check the distributed control system after power transmission
a. Check the power voltage of modules and inquire voltage, make sure that they can meet the requirement
of manufacturer. Otherwise, make some adjustment or replacement.
b. After loading thrown on the power supply, check the temperature rising condition of the power supply;
c. Conduct switching test of redundant modules, redundant power source and redundant communication
network;
d. Check the status indicator lamp of modules;
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e. Check configuration of modules;


f. Verify the modules;
g. Conduct anti-interference test of equipment cabinet;
h. Check the control station and operator interface device.
9) Circuit inspection
Circuit inspection shall be done in the following way:
During repair, check important measurement signals and line insulation condition. Insulation inspection
shall be conducted by megger that meets the standards. Before measuring the inspection, separate the measured
cable with control equipment, so as to avoid the damage of control equipment;
Fasten the wiring;
As to position with disorder in wiring, make some adjustment during repair. After that, check the wiring
and do a test if necessary.
6.1.6.4 System inspection and test before start-up
1) Measurement signal inspection
Check the measured parameters in operator station and engineer station. Check if there is deviation alarm
in redundant measured parameters.
2) Operation test of actuator
Conduct switch test of valves, along with actuator that has gone through repair. Test shall be conducted in
operator station;
In the test, there is no jam in valves and valve feedback signal shall conform to mechanical position of
valve;
Before conducting pneumatic actuator test, check the air supply pressure;
Make a record of total-travel switching time and operation response time of valves.
6.2 SCS system
6.2.1 Overview
Sequence control system is divided into group level sequence control and subgroup sequence control. The
subgroup level sequence control consists of primary equipment and some auxiliary items.
6.2.1.1 Theory
The logic adopts step type AP subgroup functional block control and output the control instruction through
the combination of all kinds of conditions, and the priority level of instruction is that the automatic control is
prior to manual control.
6.2.1.2 Subgroup level control and its equipment
1) Air preheater A (B) : main motor of air preheater, auxiliary motor of air preheater, oil pump of air
preheater, air admission side baffle and air outlet baffle, smoke admission side baffle and smoke outlet baffle.
2) Force draft fan A (B) : electric motor of force draft fan, oil pump of force draft fan, inlet and outlet
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baffle of force draft fan, dynamic blade of force draft fan.


3) Induced draft fan A (B) : electric motor of induced draft fan, oil pump of induced draft fan, cooling fan,
inlet and outlet baffles of induced draft fan, static blade of induced draft fan, baffle of dirt catcher.
4) Primary air fan A (B) : electric motor A (B) : electric motor of primary air fan, outlet baffle of primary
air fan, inlet baffle of primary air fan.
5) Coal powder system: startup and halt of coal feeder, startup and halt of coal mill.
6) Pollution discharge, water delivery and steam escape of steam pocket: steam escape valve and
continuous blow down of steam pocket.
7) Electric feed water pump: motor of electric pump, oil pump of electric pump, inlet valve of booster
pump, outlet valve of electric pump, recycle valve of electric pump.
8) Steam feed water pump A (B) : motor of booster pump of steam pump, lube oil pump of steam pump,
inlet valve of booster pump of steam pump, outlet valve of steam pump, recycle valve of steam pump, inlet
valve of steam turbine of steam pump.
9) Trap and steam escape valve of steam pipe line: trap and steam escape valve of main steam pipe line,
trap and steam escape valve of reheater, trap of steam admission pipe line of steam turbine.
10) Water-inflowing precaution system of steam turbine: check valve of steam extraction pipe line.
11) Low pressure heating system: outlet valve of low pressure heater, bypass valve of low pressure heater,
steam extraction isolation valve, steam extraction check valve, steam extraction trap, trap of low pressure
heater.
12) Deaerator system: steam extraction isolation valve, steam extraction check valve, steam extraction trap,
trap of deaerator, steam escape valve of deaerator.
13) Condensate system: motor of condensate pump, inlet and outlet valve of condensate pump, other valve
of condensate pipe line.
14) Condenser system: recycled water inlet and outlet valve of condenser.
15) Vacuum-pumping system of steam turbine: vacuum pump, valve of vacuum pump.
16) Oil system of steam turbine: bearing oil pump, jacking oil pump, emergency oil pump, smoke extractor
exhaust fan of oil tank, heater of oil tank.
6.2.2 Maintenance items and quality standards
1) Inspect the equipment connection, and it is required to be trim, beautiful and right. The connection
number shall be clear.
2) Test the power cable of equipment. Measure the insulation of line-to-earth with tramegger of 500V. The
insulation resistance shall be over 20MΩ. Insulation resistance between lines shall be over 50 MΩ.
3) Maintain the switch of equipment. Action of switch shall be right and reliable.
4) Maintain and check the voltage switch, transmitter and magnetic valve of equipment.
5) Maintain the AP cabinet, relay cabinet and terminals cabinet. See the AS620 system regulation for the
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verification of clamping pieces.


6) Constant value check:Consult the original record to inspect.
7) Static test: The startup and halt procedure of sequence control block of OM650 system can start and halt
the equipment in accordance with scheduled sequence. If the system is failure to start and halt the equipment
within regulated time, then there is something wrong with the system. If some conditions, such as oil pressure
signal, cannot satisfy the condition in test, then imitate the signal from engineer station (and record them well to
prepare elimination) to finish the test. Record them well.
6.2.3 Overhaul items
1) Clean the equipment cabinet and inspect the connection of terminals board.
2) Inspect the power supply. Test cable insulation.
3) Test the clamping pieces. Inspect and test the switch, magnetic valve and relay.
4) Inspect and check the constant value and parameters
5) Test the action of system and record its travel time.
6.3 FSSS system
6.3.1 Overview
6.3.1.1 Overview
FSSS system is a necessary furnace safety supervisory system of modern large thermal power generating
unit boiler. The system can collect and calculate all kinds of parameters of combustion system logically when
the boiler operates normally and under the working conditions of startup and halt to make the relevant
equipment of combustion system finish necessary operation or handle uncompleted emergency in strictly
accordance with established procedure to protect the safety of boiler combustion system.
FSSS system can be divided into two parts from its function: combustor control system and boiler safety
system. The combustor control system monitors and controls the combustion system continuously and provides
distant operation. At the same time, the system also provide status signal for MCS system and alarm system of
the whole plant. The function of boiler safety system is to prevent explosion due to detonation of hearth and
other equipment caused by combustible. Those are MFT logic and MTR logic.
6.3.1.3 Composition of FSSS
1) Site equipment: Oil angle equipment, powder system equipment, flame detection system and furnace
water recycling system.
2) Electron equipment: Control cabinet and corresponding terminals cabinet, relay cabinet; MFT relay;
corresponding MCC cabinet and flame detecting control cabinet.
3) Central control equipment: Operator station, manual MFT and MTR buttons.
4) Logic composition: Public logic, oil angle logic and powder system logic.
6.3.2 Maintenance items and quality standards
6.3.2.1 Primary measurement element maintenance of FSSS system.
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1) Maintenance of FSSS system transmitter


a. General inspection
⑴ Handle work tickets. Isolate the transmitter which is going to be repaired.
⑵ Cut the power of transmitter, dismantle the transmitter. Mark the dismantling line.
b. Adjusting items and technical standards: see maintenance and verification regulation of transmitter.
c. Reassemble the transmitter and clean the pipeline of instrument.
2) Pressure, differential pressure and flow switch maintenance of FSSS system.
a. General inspection
⑴ Handle the work tickets. Isolate the switch which is going to be repaired.
⑵ Cut the power of switch, dismantle the switch, and mark the dismantling line.
⑶ Clean the switch. Standard: no dust, oil footprint, and the natural color of equipment can be seen.
⑷ Inspect the connection of switch. The connection shall be firm.
⑸ Test the cable insulation. The insulation resistance shall be over 50 MΩ.
b. Adjusting items and technical standards: see the maintenance and verification regulation of switch.
3) The maintenance of thermocouple element, see maintenance and verification regulation of thermocouple
element for details
4) The maintenance of thermal resistance element, see maintenance and verification regulation of thermal
resistance element for details.
6.3.2.2 Maintenance of oil gun equipment
Maintenance of oil gun:
1) General inspection
a. Handle work tickets
b. Clean the equipment
c. Test the local action of oil gun. The action shall be normal and smooth without jam.
2) Adjusting items and technical standards
a. Oil gun action test: when the gun stretches into, the into-position switch shall be closed, and when he
gun quits, the back in position switch shall be closed. Otherwise, readjust the switch to make the action of travel
switch be right. After the contact is closed, the resistance measured of contact shall be less than 0.1 MΩ. After
the contact is opened, the resistance measured of contact shall be infinity.
b. Measure the DC resistance of oil gun magnetic valve coil. The resistance shall meet the requirement of
specification.
c. Inspect the air impermeability of oil gun cylinder. No air leakage in inner and outside.
d. Test the power-driven oil gun. The local and remote control operation shall be normal.
6.3.2.3 Ignition device maintenance
1) General inspection
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a. Handle work tickets


b. Clean the equipment
c. Test the local action. The action shall be normal and smooth without jam.
d. Inspect the ignition transformer insurance, and it shall be in good condition.
e. Air plug contact of ignition device shall be in good condition without looseness.
2) Adjusting items and technical standards
a. Manual test of ignition device: when the gun stretches into, the into-position switch shall be closed, and
when the gun quits, the back in position switch shall be closed. Otherwise, readjust the switch to make the
action of travel switch be right. After the contact is closed, the resistance measured of contact shall be less than
0.1 MΩ. After the contact is opened, the resistance measured of contact shall be infinity.
b. Measure the DC resistance of magnetic valve coil. The resistance shall meet the requirement of
specification.
c. Inspect the cylinder air impermeability of ignition pusher. No air leakage in inner and outside.
d. Inspect the ignition rod, ignition mouth. No curve and coking.
e. Test the on-site sparking: the sparking is even, no power leakage.
f. Ignition rod locates in the position of 10cm from the front end of ignition rod, generally.
g Test the power-driven ignition device: local and remote control action and ignition shall be normal.
6.3.2.4 Maintenance of oil valve and blow-down valve control system.
1) General inspection
a. Handle work tickets
b. Clean the equipment
2) Adjusting items and technical standards
a. The oil valve and blow-down valve shall have no air leakage.
b. Manual test of oil valve and blow-down valve: when the valve is in full open, open the switch, and when
the valve is closed, close the switch. Otherwise, readjust the switch to make the action of travel switch be right.
After the contact is closed, the resistance measured of contact shall be less than 0.1 MΩ. After the contact is
opened, the resistance measured of contact shall be infinity.
c. Measure the DC resistance of magnetic valve coil. The resistance shall meet the requirement of
specification, and direction-change of magnetic valve is normal. No air leakage.
d. Test the cable insulation. Insulation between phase and to-earth shall be over 50 MΩ.
e. Test the power-driven oil valve and blow-down valve: the local and remote control action shall be
normal.
6.3.2.5 Test of oil trip valve and recycle valve control system
1) General inspection
a. Handle work tickets
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b. Clean the equipment


c. Inspect the air impermeability of oil trip valve and recycle valve. No air leakage.
2) Adjusting items and technical standards
a. Action test of oil trip valve and recycle valve: when the valve is in full open, open the switch, and when
the valve is closed, close the switch. Otherwise, readjust the switch to make the action of travel switch be right.
After the contact is closed, the resistance measured of contact shall be less than 0.1 MΩ. After the contact is
opened, the resistance measured of contact shall be infinity.
b. Measure the DC resistance of magnetic valve coil. The resistance shall meet the requirement of
specification, and direction-change of magnetic valve is normal. No air leakage.
c. Test the cable insulation. Insulation between phase and to-earth shall be over 50 MΩ.
d. Power-driven test: the local and remote control action shall be normal.
6.3.2.6 Maintenance of flame detection
1) General inspection
a. Handle work tickets, cut the power of flame detection system.
b. Clean the equipment
c. Inspect the flame detection probe, optical fiber and control cable: no damage and high temperature
damage, and the fiber have no fracture, and its both ends have no dirt.
d. Inspect the flame detection control cabinet insurance, fan and lighting.
e. Inspect the flame detection cooling air. The air-duct shall be in full open position and has no falling-off,
fracture or leakage.
2) Adjusting items and technical standards
a. Inspect whether the flame detection control cabinet power transmission, each terminal board and flame
detection probe +50VDC, +15VDC power supply are normal.
b. Light the probe with secondary light source, then the corresponding signal light of “FLAME” lights, at
the same time, the corresponding flame detection signal light of CRT of operator station lights. When remove
the light source, the relevant signal disappears.
6.3.2.7 Maintenance of powder system equipment
1) Maintenance of coal mill oil station
2) Maintenance of powder pipe blow-down door
3) Maintenance of coal powder shutoff door
4) Maintenance of primary air shutoff door
5) Maintenance of coal mill seal air system
6) Maintenance of coal mill fire fighting system
6.3.3 Operating maintenance
6.3.3.1 Operating maintenance of FSSS system transmitter
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1) Regularly inspect the penetration point and leakage point of transmitter and seal of joint.
2) Verification of transmitter accuracy
6.3.3.2 Operating maintenance of FSSS system pressure, differential pressure and flow switch.
1) Regularly inspect the penetration point, leakage point and seal of joint
2) Inspect whether the sampling pipe of air and smoke system is blocked
6.3.3.3 Operating maintenance of thermocouple element
6.3.3.4 Operating maintenance of thermal resistance element
6.3.3.5 Operating maintenance of oil gun
Conduct once action test of oil gun every week to ensure that the oil gun is always in good hot stand-by
status.
6.3.3.6 Operating maintenance of high-energy ignition device
Conduct once action test every week to ensure that the ignition device is always in good hot stand-by
status.
7.3.3.7 Operating maintenance of oil valve and blow-down valve control system
Conduct once action test every week to ensure that the oil valve and blow-down valve control system are
always in good hot stand-by status.
6.3.3.8 Operating maintenance of oil trip valve and recycle valve control system
Conduct once action test every week to ensure that the oil trip valve and recycle valve control system are
always in good hot stand-by status.
6.3.3.9 Operating maintenance of flame detecting system
1) Regularly inspect the flame detection probe, cooling air house. No falling-off or leakage.
2) Regularly inspect the flame detection cabinet. No flame detection fault alarm.
6.3.4 FSSS system simulation test
6.3.4.1 MFT logic and the first condition of MFT
1) Manual MFT: purge and reset the MFT signal, manually press the MFT hard trip button on emergency
halt desk, and inspect the action of MFT relay in DCS power distribution cabinet. The CRT screen displays the
MFT signal, and the first condition of MFT is “manual MFT”.
2) The two forced air fan full halt: purge and reset the MFT signal, simulate the halt of two forced air fan.
The CRT screen displays the MFT signal, and the first condition of MFT is “the two forced air fan full halt”.
3) The two induced air fan full halt: purge and reset the MFT signal, simulate the halt of two induced air
fan. The CST screen displays the MFT signal, and the first condition of MFT is “the two induced air fan full
halt”
4) Furnace pressure third high-value: purge and reset the MFT signal, connect the two furnace pressure
third high-value signal from the terminal board. The CRT screen displays the MFT signal, and the first
condition of MFT is “furnace pressure third high-value”.
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5) Furnace pressure third low-value: purge and rest the MFT signal, connect the two furnace pressure third
low-value signal from the terminal board. The CRT screen displays the MFT signal, and the first condition of
MFT is “furnace pressure third low-value”.
6) Boiler water level third low-value: purge and rest the MFT signal, connect the two boiler water level
third low-value signal from the terminal board. The CRT screen displays the MFT signal, and the first condition
of MFT is “boiler water level third low-value”.
7) Primary air loss MFT: purge and reset the MFT signal, stimulate the primary air loss logic with software.
The CRT screen displays the MFT signal, and the first condition of MFT is “primary sir loss”.
8) Total air volume is less than 30%: purge and reset the MFT signal, stimulate the logic of that total air
volume is less than 30% with software. The CRT screen displays the MFT signal, and the first condition of MFT
is “total air volume is less than 30%”.
9) Fuel interruption MFT: purge and reset the MFT signal, stimulate the logic of fuel interruption. The CRT
screen displays the MFT signal, and the first condition of MFT is “fuel interruption MFT”.
10) Ignition failure MFT: purge and reset the MFT signal, imitate the logic of ignition failure. The CRT
screen displays the MFT signal, and the first condition of MFT is “ignition failure MFT”.
11) All furnace flameout MFT: purge and reset the MFT signal, imitate the logic of “all furnace flameout
MFT”. The CRT screen displays the MFT signal, and the first condition is “all furnace flameout MFT”.
12) Steam turbine trip MFT: purge and reset the MFT signal, imitate the logic of “steam turbine trip MFT”.
The CRT screen displays the MFT signal, and the first condition is “steam turbine trip MFT”.
13) Flame detection cooling air loss MFT: purge and reset the MFT signal, connect any two switch from
three pressure switch of A, B, C of “flame detection cooling air low pressure”. The CRT screen displays the
MFT signal, and the first condition is “flame detection cooling air loss MFT”.
6.3.4.2 FSSS system purging test:
1) Adjust any side of motor switch of forced air fan and induced air fan to the test position, start the forced
air fan and induced air fan. The CRT displays “any forced air fan or induced air fan operates”. The condition is
satisfied.
2) Adjust the motor switch of air preheater on both sides of A, B to the test position, start the air preheater.
The CRT displays “two air preheater operates”. The condition is satisfied.
3) Conduct oil leakage test. The CRT displays “oil leakage test is finished”. The condition is satisfied.
Close the oil.
4) Close all oil angle valve. The CRT displays “all oil valves are closed”. The condition is satisfied.
5) Trip valve. The CRT displays “oil trip valve is closed”. The condition is satisfied.
6) Close the separator outlet door of mill. The CRT displays “all outlet doors of separator are closed”. The
condition is satisfied.
7) Confirm that the condition of CRT’s displaying “coal mill is all halt” is satisfied.
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8) Confirm that the condition of CRT’s displaying “coal feeder is all halt” is satisfied.
9) Confirm that the condition of CRT’s displaying “primary air fan is all halt” is satisfied.
10) Confirm that the condition of CRT’s displaying “air volume is less than 30%” is satisfied.
11) Confirm that the condition of CRT’s displaying “pressure of furnace is normal” is satisfied.
12) Simulate the normal signal of boiler water level. Confirm that the condition of CRT’s displaying
“boiler water level is normal” is satisfied.
13) Confirm that the condition of CRT’s displaying “no MFT trip condition” is satisfied.
14) Confirm that the condition of CRT’s displaying “no flame in the whole furnace” is satisfied.
15) Start the flame detection cooling air fan. The CRT displays “differential pressure of flame detection
cooling air furnace is proper”. The condition is satisfied.
16) Set the automatic auxiliary air baffle. The CRT displays “auxiliary air baffle is automatic and not all
closed”. The condition is satisfied.
After the purging condition is satisfied, the CRT displays “purging request”. Start the purging procedure.
The CRT displays “in purging”, at the same time, count down the purging time for five minutes. If one
condition is not satisfied in the process of purging, the CRT displays “purging interruption”. If the procedure is
finished, the CRT displays “purging finish”. At the same time, reset the MFT signal.
6.3.4.3 Powder system logic
1) MTR logic:
a. Conditions of MTR are:
Manual MTR
MFT existence
Loss of primary air (two primary air fans all halt or the value of primary air/low differential pressure of
furnace is less than 5Kpa with a delay of 10 seconds of choosing two from three.
When the main motor of coal mill operates, all outlet doors of separator are closed.
When the main motor of coal mill operates, there is something wrong with the lubricating oil (two low
pressure pump all halt or the delay of low pressure of lubricating oil is 10 seconds)
High temperature of bearing before or after the operation of coal miller main motor is over 53℃ with a
delay of 1 minute.
When the main motor of coal mill is operating, time of any outlet door of separator’s being in middle
position is over 3 minutes.
The primary air door is closed without operators’ giving out the order to close the door.
The main motor of coal mill trips when the primary air shutoff door is not closed.
RB trips C coal mill
b. Reset the MTR signal: after the MFT is reset and no MTR condition, operators give the instruction of
“reset MTR” ON CRT. Then the “MTR existence” logical signal reset. Specially inspect this operation when
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start the mill.


2) Coal seam flame detection judgment
a. Judge that the single burner of coal nozzle has flame: the separator outlet door of this burner is open and
not closed and the flame detection has flame; otherwise, judge that it has no flame.
b. Judge that the coal seam has flame: choose three single burner’s having flame judgment signal from four
and operate any coal feeder of this mill for 5 seconds, then judge that this coal seam has flame.
c. Judge that the coal seam has no flame: when any coal feeder operates for 5 seconds or main motor of
mill operates and the shutoff door of primary is not closed, choose two single burner’s having no flame
judgment signal from four to judge that this coal seam has flame. This logical signal will be judged in the logic
of “whole furnace has no flame MFT”.
6.4 MCS system
6.4.1 Overview
6.4.1.1 Overview
MCS control system mainly consists of the following subsystems:
1) Unit coordinated control system
2) Main steam temperature control system: Ⅰlevel temperature-decrease; Ⅱ level temperature-decrease
3) Whole course feed-water control system
4) Fuel pressure control system
5) Coal mill outlet temperature control system
6) Coal mill bypass air volume control system
7) Forced air fan dynamic blade control system
8) Induced air fan static blade control system
9) Coal mill air volume control system
10) Deaerator pressure regulating system
11) Deaerator water level regulating system
12) Reheater emergency water-spraying regulating system
13) Bellows furnace air volume regulating system
14) Smoke reheater baffle control system
15) Air preheater cold side temperature regulating system
16) Primary air pressure regulating system
17) Seal air pressure regulating system
18) Maximum flow recycling valve control system
6.4.1.2 Brief introduction of each function
1) Unit coordinated control system:
The unit coordinated control system consists of two parts: unit load order signal and engine-boiler load
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control. The former mainly chooses the external ADS order, boiler order or maximum order permitted of unit.
After processed, these order converts to load order accepted by the unit as load set value. The latter mainly
chooses proper control method in accordance with unit operating conditions and requirements. According to
actual load order output power and pressure set value, the engine-boiler load control compares them with the
measured value, then output unit load order signal to control unit load.
a. Unit load order: when the unit ADS is automatic, accept ADS order signal, after line frequency deviation
correction, compare it with maximum load permitted, and choose the smaller one as unit load order.
When the manual DAS and ADS have fault or it appears working condition of RB, the smaller value of
boiler order and maximum load permitted is the load unit load order.
b. Unit load control: the engine-boiler load control has four methods: boiler/manual steam engine, boiler
follow, steam engine follow and coordinated control.
⑴ Boiler/manual steam engine: in the process of unit startup and halt or when the boiler and steam engine
equipment have flaw and cannot control automatically, switch the boiler/steam engine to manual to control and
regulate the fuel volume, maintain pressure; manually regulate the air volume to meet the volume needed of
boiler combustion, guarantee the optimum coefficient of excess air; manually control and regulate the power of
steam engine, maintain unit load.
⑵ Boiler follow method: the steam engine regulates and outputs electric power . Boiler regulates the
steam pressure automatically. When the load changes, the steam engine gives out control action, after the PT
changes, then the boil follow gives out control action.
⑶ Steam engine follow method: the boiler regulating unit outputs power. The main control of steam
engine regulates the steam pressure automatically. When the load changes, first, the boiler gives out control
order, after the PT changes, the steam engine gives out control order in accordance with steam pressure
deviation to regulate the steam pressure.
⑷ Coordinated control method: our plant adopts the coordinated control method based on boiler follow.
In this method, main control of steam engine regulates the electric power automatically, and main control of
boiler regulates steam pressure automatically. Because the difference between dynamic behaviors of
engine-boiler, control of boiler to steam pressure cannot keep pace with the disturbance from steam pressure
due to power change on steam engine side. Therefore, when the main control of steam engine controls the
power, at the same time, it controls the steam pressure. When the steam pressure decreases to a certain value,
the steam engine limits to open the main door of steam engine. The main control of boiler adopts some measure
to quicken the regulating of steam pressure as far as possible, in this way, it forms the coordinated control
method based on boiler follow.
 RUNBACK
If the minimum capacity load is over actual unit load, then it is not permitted to give out RUNBACK
signal; if the minimum capacity load is less than actual unit load, then it is permitted to give out RUNBACK
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signal.
Block increase
When any one of the following condition satisfies, give out block increase signal:
Boiler water level is low
Total air volume<fuel quantity
Main control of steam engine block increase (PT>SETPOINT or GV AT HI LIMIT)
Primary air order is in maximum
Forced air fan order is in maximum
Induced air fan order is in maximum
Block decrease
When any one of the following condition satisfies, give out block decrease signal:
Boiler water level is high
Total air volume>fuel quantity
Main control of steam engine block decrease (PT<SETPOINT or GV AT LOW LIMIT)
2) MCS control subsystem mainly includes: combustion control, feed water control, steam temperature and
other parts.
a. Combustion control system:
The combustion system adopts air powder cross control. Fuel and air volume control system accept the
boiler order simultaneously, guarantee a certain coal-air ratio (air volume: coal volume = 1: 0.8) ; when
decrease the load, first, decrease the coal, and then decrease the air. When increase the load, firs, increase the air,
and then increase the coal; when control the air volume, increase the oxygen correction.
b. Fuel volume control:
The fuel volume control of our plant adopts the method that the volume of coal which enters into the
furnace is controlled by the volume of primary air. The system accepts the boiler load order, after limited by air
volume signal cross as total fuel order, output the order to coal order through fuel-control unit, add bias to the
coal order, then calculate the deviation Xd with the opening of primary air baffle, and Xd is the control
deviation of primary air baffle, regulate the primary air baffle opening, control the volume of powder which
enters into furnace, regulate the fuel volume.
c. Coal mill primary air control:
According to the coal volume, deviation of outlet temperature of separator and the primary air volume,
control the opening of bypass air baffle, and control the total volume of primary air which enters into the
furnace.
d. Coal feeder rotating speed control:
The system controls the volume of coal which enters into the coal mill and the coal level of coal mill
through controlling the rotating speed of coal feeder. When the boiler load changes, the system treats the change
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of primary air as leading signal, and it increases the rotating speed of coal feeder in advance and increases the
coal quantity and maintains the coal level of coal mill.
e. Coal mill outlet temperature control:
Control the coal mill outlet temperature through regulating the opening of cool and hot primary air baffles,
control the outlet temperature of coal mill separator in certain temperature. When start the mill, control the
outlet temperature of coal mill, heat the mill slowly.
f. Seal air fan baffle control:
According to the deviation of inlet pressure of coal mill and the set value, regulate the opening of seal air
fan baffle, control the outlet pressure of seal air fan in certain set value.
g. Fuel oil pressure control:
According to the average value (two pressure measure points) of pressure of main fuel oil pipe (behind the
tone) and the deviation of fuel oil pressure set value, the system regulates the opening of valve and maintains
the set value of fuel oil pressure.
h. Primary air fan static blade control:
According to the pressure set value (the pressure set value is calculated in accordance with main steam
flow by function) and air pressure of hot air pipe, the system regulates the opening of primary air fan static
blade and maintains hot air pipe air pressure as pressure set value.
i. Secondary air fan baffle control:
According to the deviation of air bellow/furnace differential pressure and set value (the set value is
calculated in accordance with main steam flow by function) , the system regulates the opening of secondary air
fan baffle and maintains the air bellow/furnace differential pressure as a set value.
j. Fuel air baffle control:
According to the value within 0 to 100% calculated in accordance with the air volume in each adjusting
valve of coal mill by function and comparison between the value and order output of regulator, the system
regulates the opening of secondary air fan baffle and maintains a certain secondary air volume.
k. Overfire air baffle control
According to comparison between the baffle opening of main steam flow calculated by function (the
opening which is not over 70% is 0, and the opening over 70% increases as the linear) and output order of
regulator, the system regulates the opening of overfire air baffle in accordance with the deviation to make the
overfire air volume match with the load.
l. Air supply control system
According to comparison between the output total air volume order (Can be put into the oxygen correction)
of main control of boiler and actual air volume, the system regulates the opening of forced air fan static blade in
accordance with the deviation and controls the total volume of air which enters into the furnace.
m. Furnace pressure control
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According to the deviation of furnace pressure and set value, the system regulates the opening of forced air
fan inlet dynamic blade and maintains the furnace pressure as set value. At the same time, the system add
differential of forced air fan even order signal as leading signal to guarantee that when the air supply volume
changes, the inlet dynamic blade act in advance to decrease the pressure surge in furnace.
n. Feed water control system
Under normal working condition, the system controls the rotation speed of steam pump and feed water
flow. Under startup or halt and abnormal condition, regulate the scoop of electric pump and the opening of
bypass feed water valve in outlet pipe to change the feed water volume.
o. Boiler water level control
Feed water control system of our plant adopts grading control of single-element and three-element. When
the unit starts or halts or bears low load (load <30%) , the system adopts single-element control. The system
regulates the rotating speed of feed water pump and feed water volume with deviation of boiler water level and
set value as the input signal of regulator. Under normal working condition (load >30%) , the system adopts
cascade three-element control (boiler water level is the regulated variable, and feed water flow is the feedback
signal of water level control, and steam flow is the feed forward signal) .
p. Feed water pump minimum flow recycling control
In order to prevent the feed water pump from cavitation, each pump is equipped with recycle. According to
comparison between the rotating speed of each feed water pump and the flow of pump, the system controls the
opening of recycle valve to make the cycle flow be over the flow limiting value.
q. Steam temperature control system
r. Overheating steam temperature control
It adopts two-level water-spraying regulating. Outlet temperature of overheater is the regulated variable
and temperature behind desuperheater is the leading steam temperature signal. The overheating steam
temperature is calculated from main steam flow by function to control the opening of water-spray valve and
maintain the steam temperature as a set value.
s. Reheating steam temperature control
⑴ Reheating smoke baffle control
In normal operation, the regulated variable of system is the average value of steam temperature of right and
left sides of reheater outlet, and the set value is the value calculated from main steam flow by function (operator
can add bias to correct in accordance with conditions) . According to the deviation, the system regulates the
position of reheating smoke baffle and regulates the temperature of reheating steam.
⑵ Reheater water-spraying temperature-reducing control
According to the deviation of outlet temperature of right and left sides of reheater and set value (it is
calculated from main steam flow by function, and operators can add bias to correct in accordance with
conditions) , the system regulates the valve opening of right and left sides, controls the water-spray flow and
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adjust the temperature of reheating steam.


t. Air preheater cool end temperature control:
The system regulates the cool end temperature of air preheater through regulating the volume of steam
which enters into the air heater, and it controls the inlet temperature of secondary air and outlet smoke
temperature of air preheater in a set value (manually set) .
u. Deaerator water level control:
The system adopts single-element, three-element and main valve, auxiliary valve to control alternatively.
When the load is less than 30%, the system adopts single-element. When the load is over 30%, it adopts
three-element.
v. Deaerator pressure control:
The system adopts single loop feedback control system to keep the deaerator pressure be over the
minimum pressure. The system regulates the volume of auxiliary steam which enters into the deaerator to
control the deaerator pressure with the auxiliary steam regulating valve.
6.4.2 Maintenance items and quality standards
6.4.2.1 General inspection
1) General inspection of transmitter of MCS
a. Clean the transmitter and inspect the mark. Clean the inner and outside of transmitter. Name board and
nameplate shall be complete.
b. Inspect the connection of transmitter and test the insulation resistance. The connection line of transmitter
shall be firm, orderly without abrasion. Insulation resistance shall be over 50MΩ.
c. When reassemble the transmitter, installation shall be firm, and terminals shall be sealed well.
d. Inspect the secondary door of transmitter. The door shall be sealed well without leakage.
2) General inspection of thermocouple element and thermal resistance element of MCS system
a. Clean the element and inspect the mark. Clean the thermocouple element and thermal resistance element.
Mark of element shall be clear and complete, and the installation shall be firm.
b. Inspect the connection and test the insulation resistance. Before installing the element, test the
connecting cable insulation resistance, and the insulation resistance shall be over 50MΩ.
3) General inspection of pneumatic actuator of MCS system
a. Clean the actuator and inspect the mark. Clean the pneumatic actuator control cabinet and connection
box. The connection shall be firm and orderly. Each name board and nameplate shall be complete.
b. Inspect the mechanical part. Connection of actuator mechanical part shall be firm. Travel switch shall be
installed firmly.
c. Inspect the seal. The diaphragm air cylinder and air pipe of actuator shall have no air leakage.
4) General inspection of electric actuator of MCS (see electric actuator maintenance rules for details)
a. Clean the actuator and inspect the mark. Clean the electric actuator control cabinet and connection box.
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The connection shall be firm and orderly. Each name board and nameplate shall be complete.
b. Inspect the mechanical part. Connection of actuator mechanical part shall be firm. Travel switch shall be
installed firmly.
5) General inspection of AP control cabinet and relay cabinet
a. Clean the cabinet and inspect the mark. Clean the inner and outside of AP cabinet and relay cabinet of
MCS system. The relay shall have no dirt. Mark shall be complete.
b. Connection shall be firm. Inspect the coil resistance of relay. The connection shall be orderly and firm
without damage. Coil resistance of relay shall be consistent basically.
6) General inspection of oxygen volume measurement system (see oxygen volume measurement system
maintenance rules)
a. Clean the system and inspect the mark. Clean the zirconia probe and oxygen volume transmitter cabinet.
The connection shall be firm and each name board and nameplate shall be complete. Zirconia probe shall be
installed firmly.
b. Inspect the connection. The oxygen volume measurement system shall be installed firmly.
6.4.2.2 Maintenance items and technical standards of MCS system
1) Debugging of transmitter of MCS system. Debugging items are same with transmitter maintenance
rules.
2) Debugging items and technical standards of thermocouple and thermal resistance of MCS system.
Debugging items of thermocouple and thermal resistance are same with thermocouple and thermal resistance
maintenance rules.
3) Debugging items and technical standards of pneumatic actuator of MCS system. Debugging items of
pneumatic actuator are same with pneumatic actuator maintenance rules.
4) Debugging items and technical standards of electric actuator of MCS system. Debugging items of
electric actuator are same with electric actuator maintenance rules.
5) Debugging items and technical standards of card, relay and separator of MCS system. Debugging items
of clamping pieces, relay and separator maintenance rules.
6) Debugging items and technical standards of oxygen volume measurement system of MCS system.
Debugging items of oxygen volume measurement system are same with oxygen volume measurement system
maintenance rules.
7) MCS control system test
a. Preparation before test
⑴ Handle work tickets
⑵ Contact the maintenance department to ensure that all maintenance work has been finished.
⑶ Deliver power for regulating valve and baffle actuator of related system.
b. Test content
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⑴ Coordinated control system


 Locally add 4~20mA signal to primary air adjusting valve (A1, A2) of coal mil A inlet, primary air
adjusting valve (B1, B2) of coal mill B inlet, primary air adjusting valve (C1, C2) of coal mill C inlet, primary
air adjusting valve (D1, D2) of coal mill D inlet, primary air adjusting valve (E1, E2) of coal mill E. 4mA
corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the actual
action of actuator matches the theory. If not, then adjust the zero position and measuring range.
 At the operator station, conduct full open and full closed test with primary air adjusting valve (A1, A2)
of coal mil A inlet, primary air adjusting valve (B1, B2) of coal mill B inlet, primary air adjusting valve (C1, C2)
of coal mill C inlet, primary air adjusting valve (D1, D2) of coal mill D inlet, primary air adjusting valve (E1,
E2) of coal mill E. Observe whether the position of regulating valve corresponds to the order output. If not, then
adjust the zero position and measuring range until they correspond to each other.
⑵ Main steam temperature control system: Ⅰlevel temperature-reducing; Ⅱ level temperature-reducing
 Locally add 4~20mA signal with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with water-spray valve of Ⅰ level
temperature-reducing and Ⅱ level temperature-reducing respectively. Observe whether the position of
regulating valve corresponds to the order output. If not, then adjust the zero position and measuring range until
they correspond to each other.
 Linkage test: at operator station, open the adjusting valve to an opening, trigger the MFT manually to
observe that whether the valve is fully closed.
⑶ Fuel oil pressure control system
 Add 4~20mA signal with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with fuel oil control valve. Observe whether
the position of regulating valve corresponds to the order output. If not, then adjust the zero position and
measuring range until they correspond to each other.
 Test: at operator station, open the adjusting valve to an opening, trigger the MFT manually to observe
that whether the valve is fully closed.
⑷ Coal mill outlet temperature control system
 Locally add 4~20mA respectively to cold air baffle and hot air baffle of coal mill A, cold air baffle and
hot air baffle of coal mill B, cold air baffle and hot air baffle of coal mill C, cold air baffle and hot air baffle of
coal mill D and cold air baffle and hot air baffle of coal mill E with signal generator. 4mA corresponds to the
opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the actual action of actuator
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matches the theory. If not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed action test respectively with cold air baffle and hot
air baffle of coal mill A, cold air baffle and hot air baffle of coal mill B, cold air baffle and hot air baffle of coal
mill C, cold air baffle and hot air baffle of coal mill D, cold air baffle and hot air baffle of coal mill E and cold
air baffle and hot air baffle of coal mill F. Respectively observe whether the position of regulating valve
corresponds to the order output. If not, then adjust the zero position and measuring range until they correspond
to each other.
 Linkage test: at operator station, respectively open cold air baffle and hot air baffle of coal mill A, cold
air baffle and hot air baffle of coal mill B, cold air baffle and hot air baffle of coal mill C, cold air baffle and hot
air baffle of coal mill D, cold air baffle and hot air baffle of coal mill E and cold air baffle and hot air baffle of
coal mill F to an opening, manually trigger the primary air gate of coal mill A, B, C, D, E, F closure feedback,
observe whether the cold air baffles of coal mill A, B, C, D, E, F are fully opened and whether hot air baffles of
coal mill A, B, C, D, E, F are fully closed.
⑸ Coal mill bypass air volume control system
 Locally add 4~20mA respectively to A1 side bypass air baffle and A2 side bypass air baffle of coal mill
A, B1 side bypass air baffle and B2 side bypass air baffle of coal mill B, C1 side bypass air baffle and C2 side
bypass air baffle of coal mill C, D1 side bypass air baffle and D2 side bypass air baffle of coal mill D and E1
side bypass air baffle and E2 side bypass air baffle of coal mill E. 4mA corresponds to the opening of 0%, and
20mA corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If
not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test respectively with A1 side bypass air baffle
and A2 side bypass air baffle of coal mill A, B1 side bypass air baffle and B2 side bypass air baffle of coal mill
B, C1 side bypass air baffle and C2 side bypass air baffle of coal mill C, D1 side bypass air baffle and D2 side
bypass air baffle of coal mill D and E1 side bypass air baffle and E2 side bypass air baffle of coal mill E.
Respectively observe whether the position of regulating valve corresponds to the order output. If not, then
adjust the zero position and measuring range until they correspond to each other.
⑹ Forced air fan control system
 Locally add 4~20mA signal respectively to dynamic blade of forced air fan A and B with signal
generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe
whether the actual action of actuator matches the theory. If not, then adjust the zero position and measuring
range.
 At operator station, conduct full open and full closed test respectively with dynamic blade of forced air
fan A and B. Respectively observe whether the position of dynamic valve corresponds to order output. If not,
then adjust the zero position and measuring range.
 Linkage test: at operator station, respectively open the dynamic blade of forced air fan A and B to an
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opening. Manually trigger the forced air fan stopping feedback, observe whether dynamic blade of forced air
fan A and B are fully closed. Manually trigger the full closed signal of two forced air fan to observe whether
dynamic blade of forced air fan are fully opened. (delay 5 minutes) .
⑺ Induced air fan control system
 Locally add 4~20mA signal respectively to dynamic blade of forced air fan A and B with signal
generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe
whether the actual action of actuator matches the theory. If not, then adjust the zero position and measuring
range.
 At operator station, conduct full open and full closed test respectively with dynamic blade of induced air
fan A and B. Respectively observe whether the position of dynamic valve corresponds to order output. If not,
then adjust the zero position and measuring range.
 Linkage test: at operator station, respectively open the dynamic blade of induced air fan A and B to an
opening. Manually trigger the forced air fan stopping feedback (it must ≥operation of one forced air fan) ,
observe whether dynamic blade of induced air fan A and B are fully closed. Manually trigger the full closed
signal of two induced air fan to observe whether dynamic blade of induced air fan are fully opened. (delay 5
minutes) .
⑻ Deaerator pressure regulating system
 Locally add 4~20mA signal respectively to deaerator pressure regulating valve with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with deaerator pressure regulating valve.
Respectively observe whether valve position of deaerator pressure regulating valve corresponds to order output.
If not, then adjust the zero position and measuring range.
 Linkage test: at operator station, open the deaerator pressure regulating valve to an opening, manually
trigger (PG PRESSUR HH) to observe whether the deaerator pressure regulating valve is fully closed.
⑼ Deaerator water level regulating system
 Locally add 4~20mA signal respectively to deaerator water level regulating valves (main valve and
auxiliary valve) with signal generator. 4mA corresponds to the opening of 0%, and 20mA corresponds to the
opening of 100%. Observe whether the actual action of actuator matches the theory. If not, then adjust the zero
position and measuring range.
 At operator station, conduct full open and full closed test with deaerator water level regulating valves
(main valve and auxiliary valve) . Respectively observe whether valves position of deaerator water level
regulating valves (main valve and auxiliary valve) correspond to order output. If not, then adjust the zero
position and measuring range.
 Linkage test: at operator station, open the deaerator water level regulating valves (main valve and
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auxiliary valve) to an opening, manually trigger high water level signal of deaerator to observe whether the
deaerator water level regulating valves (main valve and auxiliary valve) are fully closed.
⑽ Reheater water-spraying temperature-reducing regulating system
 Locally add 4~20mA signal to reheater water-spraying temperature-reducing regulating valve (valve in
left side and valve in right side) with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with reheater water-spraying
temperature-reducing regulating valves (valve in left side and valve in right side) . Respectively observe
whether valves position of reheater water-spraying temperature-reducing regulating valves (valve in left side
and valve in right side) correspond to order output. If not, then adjust the zero position and measuring range.
 Linkage test: at operator station, open the reheater water-spraying temperature-reducing regulating
valves (valve in left side and valve in right side) to an opening, manually trigger MFT signal to observe whether
the deaerator water level regulating valve (main valve and auxiliary valve) are fully closed.
⑾ Air bellow furnace differential pressure regulating system
 Locally add 4~20mA signal respectively to secondary air baffles (6) , auxiliary air baffles (3) , fuel air
baffles (6) and overfire air baffles (2) . 4mA corresponds to the opening of 0%, and 20mA corresponds to the
opening of 100%. Observe whether the actual action of actuator matches the theory. If not, then adjust the zero
position and measuring range.
 At operator station, conduct full open and full closed test with secondary air baffles (6) , auxiliary air
baffles (3) , fuel air baffles (6) and overfire air baffles (2) . Respectively observe whether valves position of
secondary baffles (6) , auxiliary air baffles (3) , fuel air baffles (6) and overfire air baffles (2) correspond to
order output. If not, then adjust the zero position and measuring range.
 Linkage test: at operator station, open the secondary air baffles (6) , auxiliary air baffles (3) , fuel air
baffles (6) and overfire air baffles (2) to an opening, manually trigger MFT signal to observe whether the
secondary air baffles (6) are fully opened, manually trigger all secondary air baffles to open feedback to observe
whether auxiliary air baffles (3) are fully opened.
⑿ Air preheater cold end temperature regulating system
 Locally add 4~20mA signal respectively to control valve of air preheater A and B with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with control valve of air preheater A and B.
Respectively observe whether valves positions of control valve of air preheater A and B correspond to order
output. If not, then adjust the zero position and measuring range.
⒀ Primary air pressure regulating system
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 Locally add 4~20mA signal to static blade of primary air fan (A, B) with signal generator. 4mA
corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the actual
action of actuator matches the theory. If not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with static blade of primary air fan (A, B) .
Respectively observe whether valves positions of static blade of primary air fan (A, B) correspond to order
output. If not, then adjust the zero position and measuring range.
 Linkage test: at operator station, open the static blade of primary air fan (A, B) to an opening, manually
trigger primary air fan A stopping feedback signal to observe whether static blade of primary air fan A is fully
closed; manually trigger primary air fan B to stop the feedback signal to observe whether static blade of primary
air fan B is fully closed.
⒁ Seal air pressure regulating system
 Locally add 4~20mA signal respectively to outlet baffles of seal air fan (A, B) with signal generator.
4mA corresponds to the opening of 0%, and 20mA corresponds to the opening of 100%. Observe whether the
actual action of actuator matches the theory. If not, then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with outlet baffles of seal air fan (A, B) .
Respectively observe whether valves positions of outlet baffles of seal air fan (A, B) correspond to order output.
If not, then adjust the zero position and measuring range.
⒂ Minimum flow recycle valve control system
Locally add 4~20mA signal respectively to recycle valve of electric pump, recycle valve of steam pump
A and recycle valve of steam pump B with signal generator. 4mA corresponds to the opening of 0%, and 20mA
corresponds to the opening of 100%. Observe whether the actual action of actuator matches the theory. If not,
then adjust the zero position and measuring range.
 At operator station, conduct full open and full closed test with recycle valve of electric pump, recycle
valve of steam pump A and recycle valve of steam pump B. Respectively observe whether valves positions of
recycle valve of electric pump, recycle valve of steam pump A and recycle valve of steam pump B correspond
to order output. If not, then adjust the zero position and measuring range.
 Linkage test: at operator station, open the electric pump, recycle valve of steam pump A and recycle
valve of steam pump B to an opening, manually trigger the inlet flow <50t/h signal of steam pump A or B to
observe whether the recycle valves of steam pump A or B are fully closed.
6.4.2.3 Operation and maintenance of MCS control system
1) Carefully inspect the on-site equipment and its control equipment before delivering power for MCS
control system. Guarantee that the equipment is in good condition, and then deliver power for it.
2) After delivering power for MCS control system, carefully inspect that all signal of system is right, and
then conduct relevant operation with the equipment.
3) When the equipment is in operation, carefully monitor the operation of equipment. When the equipment
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has abnormal conditions, carefully inspect the equipment and handle the corresponding conditions.
4) In the process of operation, regularly inspect and clean the on-site equipment and control equipment of
MCS system to guarantee the operation of equipment is in good condition.
5) Common fault causes and their settlement methods
a. Remote operation does not act.
⑴ First, judge that whether the present signal has forced signal.
⑵ Inspect whether the local actuator is jammed and whether connecting lever and connecting rod have
falling-off.
⑶ Inspect whether the servo power supply is normal, whether the fuse is burnt, whether the air switch
trips and whether MCC delivers power.
⑷ Inspect whether the 4~20mA signal has been given out and whether closure of limit switch is normal.
b. Feedback indication is abnormal
⑴ Inspect whether the feedback potentiometer is normal.
⑵ Inspect whether the servo is normal.
⑶ Inspect whether the cable has grounding.
⑷ Inspect whether the feedback gear is worn.
c. Maloperation of limit switch
⑴ Inspect whether the adjustment of limit switch is appropriate.
⑵ Inspect whether the limit switch is worn.
6.5 Attendance Instruction for the maintenance and operation of automation system
6.5.1 Overview
6.5.1.1 Scope
This standard regulates the standards for the contents, methods and technical management of the
maintenance and operation of thermal automation system.
This standard is applicable for the maintenance and daily operation of thermal automation system in units which
have been put into production in power plant.
6.5.1.2 Standard reference documents
Technical Supervision Provision of Thermal Meter and Control Device in Thermal Power Plant (State
Power Safety Operation (1998) No.483)
Attendance Instruction for the Maintenance and Operation of Thermal Automation System in Thermal
Power Plant (DL/T 774-2004)
On-line Acceptance Test Instruction for Modulating Control System in Thermal Power Plant
(DL/T657—1998)
6.5.1.3 Preface
To ensure that automatic regulatory system stably operates before units start working, according to the
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standards regulated in Technical Supervision Provision of Thermal Meter and Control Device in Thermal Power
Plant (State Power Safety Operation (1998) No.483) , automatic regulatory system of operating units shall go
through inspection and maintenance, and regular disturbing test, and the automatic regulatory system after
maintenance, after main equipments are put into operation, shall act in time. The quality of regulation shall
comply with the requirements of regulatory system operation quality index. According to the real situation of
Daihai Company, main automatic regulatory system of operating units is checked every day. For regulatory
quality not compliant with requirements, disturbing test shall be conducted, and modify parameters in time to
reach maximum regulatory quality. Under other circumstances, disturbing test shall be conducted once a season,
and once after major repair of maintenance units. At present, according to standards regulated in Attendance
Instruction for the Maintenance and Operation of Thermal Automation System in Thermal Power Plant (DL/T
774-2004) and On-line Acceptance Test Instruction for Modulating Control System in Thermal Power Plant
(DL/T657—1998) , attendance instruction for the maintenance and operation of each automatic regulatory
system is therefore specially formulated.
6.5.2 Maintenance items and quality standards
6.5.2.1 Basic maintenance items and requirements
1) Inspection and check items:
a. Inspection after modulating control system hardware blacks out:
⑴Inspection of control module setup;
⑵Inspection of I/O module setup;
⑶Inspection of binding and setup of backup M/A (manual/automatic) ;
⑷Inspection of terminal board setup;
⑸Inspection of ground system before charging
b. Inspection and test after charging modulating control system hardware:
⑴Inspection of power module main/backup switching;
⑵Inspection of communication module main/backup switching;
⑶ Inspection of control module main/backup switching;
⑷Inspection of backup M/A operation station switching.
c. Inspection and test of modulating control system software:
⑴Inspection of coefficients and compensating parameters of flow signals;
⑵Inspection of exception report range and alarm limiting values;
⑶Inspection and simulation test of control software logic, set value, and parameter setup of each system;
⑷Inspection of relevant pictures of each control system
d. Inspection of peripheral equipments:
⑴Verification and confirmation of transmitter range;
⑵Confirmation of the schedule and direction of executing agency
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6.5.2.2 Feed water control system


Feed water control system of drum boiler refers to: single/three impulse feed water control system made up
of bypass adjusting valve at the exit of feed pump, electric speed regulating feed pump and steam-driven speed
regulating feed pump, and feed pump minimum discharge recirculation control system.
Test items and quality requirements before putting into operation:
1) Measurement of boiler water level signal:
a. Boiler water level signal is from three independent differential pressure transmitters after choosing logic
judgments among them, and this signal has gone through pressure and temperature modification.
b. The position of balancing vessel of differential pressure water level measuring equipment shall be
correct.
c. Sampling pipe, sampling valve and communicating pipe on the side of soda water shall be under good
heat preservation; pipes of balancing vessel or pipes with reference water column on top of vessel shall not be
under heat preservation; two sampling pipes causing differential pressure transmitter shall be laid with heat
preservation in parallel, and take anti-freezing measures as required.
2) Dynamic characteristic test of boiler water level (conduct if necessary) :
a. The purpose of dynamic characteristic test of boiler water level is to get the soaring characteristic curve
of boiler water level change when feed water flow changes. Test shall be separately conducted under high and
low load, and test under each load shall not be less than two times.
b. Basic methods for dynamic characteristic test of boiler water level when feed water flow changes:
⑴Keep unit load stable and boiler combustion ratio unchanged; feed water is manually controlled and stay
at stable operation under lower limit water level for about 2min.
⑵ Quickly change the opening of feed water adjusting valve for one-time, and make feed water flow
undergo a step increase of about 15% of rated flow; keep its disturbing unchanged, and record test curve.
⑶ When water level rises to around upper limit water level, manually operate and keep stable operation
around upper limit water level.
⑷ Quickly change the opening of feed water adjusting valve for one-time, and make feed water flow
undergo a step decrease of about 15% of rated flow.
⑸Keep its disturbing unchanged and record test curve
⑹When water level drops to around lower limit water level, end test.
⑺ Repeat the above mentioned test for 2-3 times, and analyze the soaring characteristic curve of boiler
water level change under step disturbing of feed water flow, and get (soaring speed) and (delay time) of its
dynamic characteristic parameter.
3) Characteristic test of adjusting valve at the exit of feed pump:
a. Adjusting valves newly put into operation or after maintenance shall meet the following quality
requirements:
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⑴The maximum flow when adjusting valve of feed pump exit shall meet maximum load requirements of
single feed pump, and there shall be a 10% surplus capacity;
⑵ When adjusting valves are all closed, leakage flow shall be smaller than 10% of maximum flow of
adjusting valve.
⑶Linear working segment of adjusting valve’s characteristic curve shall be over 70% of the whole journey,
and the hysteresis error shall not be larger than 3% of maximum flow of adjusting valve.
⑷Adjusting valve’s dead schedule shall be less than 5% of the whole journey.
b. Basic methods of characteristic test of feed water adjusting valve flow:
⑴ Before test, check when adjusting valve is wide open, whether feed water pressure has reached rated
value. Otherwise, adjust to elevate water pressure.
⑵During test, adjust feed water regulation to manual control; when unit is under stable operation condition,
manually opens adjusting valve discontinuously in one direction, and each time shall be best with 10% of
amplitude till adjusting valve is wide open.
⑶And then close adjusting valve with the same manner till it is completely closed up.
⑷Each closing or opening operation must be conducted after flow is stable.
4) Characteristic test of electric liquid speed regulating feed pump: electric liquid speed regulating feed
pump newly put into operation shall undergo test of relation characteristic between feed water exit pressure and
feed water flow under different rotating speed (speed regulating pump scoop pipe’s position and opening) . The
quality requirements are:
a. Regulating range of hydraulic coupling shall reach 25%-100%;
b. The relationship between the position and opening of hydraulic speed regulating pump scoop pump and
feedback voltage shall be linear, and its hysteresis error shall not be larger than 2%;
c. Within speed regulating range, feed pressure of pump exit and feed water flow characteristic shall
comply with the technical requirements of manufacturer.
5) Characteristic test of steam-driven speed regulating feed pump: steam-driven speed regulating feed
pump newly put into operation shall undergo test of relation characteristic between feed water exit pressure and
feed water flow under different rotating speed. The quality requirements are:
a. Adjusting range, according to the range confirmed by small steam engine, shall be set as 1-100%;
b. The relationship between feed water flow and load command shall be linear, and its hysteresis error shall
not be larger than 2%;
c. Within speed regulating range, feed pressure of pump exit and feed water flow characteristic shall
comply with the technical requirements of manufacturer.
6) Characteristic test of feed pump minimum flow recirculation control door: feed pump minimum flow
recirculation control door newly put into operation shall undergo test the quality requirements are:
a. Recirculation control flow shall be higher than feed pump minimum design flow;
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b. Recirculation valve could instantly improve valve opening (adjustable) to 30%;


c. When recirculation flow is cut off, recirculation valve could be instantly closed and 10% of recirculation
flow could be segregated.
7) Control system input condition:
a. Boiler normally operates and reaches the condition to send steam for steam turbine;
b. Main feed water pipe in under normal operations state;
c. Main parameters, such as boiler water level, steam flow and feed water low, etc. are under normal
operation, correctly indicated and clearly recorded;
d. Water level signal of boiler electric contact is under normal operation and correctly indicated.
e. Relevant protective device of boiler water is put into operation.
f. M/A operation station is under normal operation, tracking signal is correct, and there is no signal for
switching to manual operation;
g. Recirculation control and protection system of feed pump minimum flow is put into operation with
relevant feed pump;
h. When load is below 30%, single impulse feed water regulation shall be put into operation, and when
load is above 30%, three impulse feed water regulation shall be put into operation. The system shall be capable
of automatically switching between single and three impulse feed water regulation.
8) Quality index:
a. When control system is under normal operation, feed water flow shall under dramatic change with steam
flow; when boiler water level is normal, feed water flow and steam flow shall be basically equal.
b. Stability quality index: ±25mm; executing institute of control system shall not frequently function.
c. Water level set value disturbing (disturbing value: ±60mm) : attenuation rate of transient process
~;Stable time: less than 5min.
d. When units are started and stopped, the dynamic quality index of boiler water level control; when load is
below 30%, operate by means of single impulse, and the allowable dynamic deviation of boiler water level is
±80mm; when load is between 30% - 70%, under three impulse feed water control operation, the allowable
dynamic deviation of boiler water level is ±60mm; When load is between 70% - 100%, under three impulse
feed water control operation, boiler water level dynamic quality index is shown in Table 1.
e. Dynamic condition and stability quality index under boiler-turbine coordinated control mode are listed in
Table 1.
9) Maintenance acceptance check; after boiler major repair, the following test reports shall be provided:
a. For feed pump exit adjusting valve, electric liquid adjusting feed pump characteristic, steam-turbine
speed regulating feed pump, and feed pump minimum flow recirculation control door newly put into operation,
test compliance report shall be provided;
b. Dynamic characteristic test report of boiler water level (if required) ;
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c. Dynamic condition and stability quality compliance report of boiler water level control.
10) Operation maintenance:
a. According to boiler water level, steam flow, and feed water flow, record curve every day and analyze
working condition of control system. If problems occur, they shall be eliminated in time;
b. Regularly compare boiler water level, steam flow, and feed water flow, and the output value of triplex
level redundancy transmitter. For transmitter out of tolerance, failures shall be eliminated in time;
c. Regularly check sampling measuring point, and the validity of measuring signals;
d. Regularly check characteristics of executing institutes and adjusting institutes;
e. Regularly check control quality recording curve of system under various working conditions. In case of
abnormalities, they shall be dealt with in time, and system shall be ensured to be intact.
11) Tests during operation: when stability quality index in operation is out of tolerance, disturbing test of
boiler water level shall be conducted.
12) Removal of control system:
In case of the following conditions, system could be automatically removed:
a. Feed pressure is lower than allowable minimum pressure;
b. When boiler load is in stable working condition and boiler water level exceeds alarm value;
c. Feed water control system breaks down.
6.5.2.3 Steam temperature control system
Steam temperature control includes control system of overheating steam temperature and reheating steam
temperature.
1) Test items and quality requirements before putting into operation:
a. Dynamic characteristic test of overheating steam temperature (conduct if necessary) : test contents
mainly include main steam temperature class under the disturbing of class two de-superheating water, dynamic
characteristic of class two steam temperature before circulating, temperature of intermediate point under the
disturbing of class one de-superheating water, and dynamic characteristic of class one steam temperature before
circulating, etc.; tests shall best be done under two kinds of load of 70% and 100%, and tests under each test
shall not be less than two times.
Thermo-reduction shall be controlled by manual operation. When units are under stable operation,
manually turn down (step change) the opening of de-superheating water’s adjusting valve for one time. The best
reduction (increase) range is 10% of de-superheating water flow. Record main steam temperature changes, and
end tests when main steam temperature rises (drops) and stay at new values.
b. Dynamic characteristic test of reheating steam temperature (conduct if necessary) : test contents include
dynamic characteristic of reheating steam temperature of swinging combustor inclination angle, or under the
swinging of rear smoke channel control baffle, and dynamic characteristic of reheating steam temperature under
the disturbing of re-heater de-superheating water; tests shall best be done under two kinds of load of 70% and
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100%, and tests under each test shall not be less than two times.
c. Characteristic test of de-superheating water adjusting valve: adjusting valves newly put into operation
shall undergo this test, and the quality requirements are as follows:
⑴ Maximum flow of adjusting valve shall meet the requirements of maximum load with about 10%
surplus capacity;
⑵Leakage volume of adjusting valve shall be less than 10% of the maximum flow;
⑶Adjusting valve characteristic curve is linear, working section shall be over 70%, and its hysteresis error
shall be less than 3% of the maximum flow;
⑷Dead schedule of adjusting valve shall be less than 5% of the whole journey.
When unit is under stable operation condition, manually turn up de-superheating water adjusting valve
discontinuously in one direction, and each time shall be best with 10% of amplitude till adjusting valve is wide
open; and then turn down valve in the same way till it is completely closed; turning down or up each shall be
conducted after flow is stable.
During test, when steam temperature is lower than allowed range because of excessive flow of
de-superheating flow, to ensure the safety of unit, characteristic test shall be conducted in different sections and
under various operation conditions according to the above mentioned methods. To prevent steam temperature
exceeds allowed range, test procedure shall be strongly monitored. If steam temperature is severely out of limit
or out of control, test shall be stopped immediately, and quickly resume valve opening to the position before test
till parameters are stable.
d. Swing characteristic test of smoke channel control baffle: After smoke channel control baffle major
repair, conduct rear smoke channel control baffle test under thermal state. Mechanical parts are required to
move flexibly without jam.
2) Control system input conditions:
a. Temperatures at each level and reheating steam temperature of main steam shall be correctly indicated
and clearly recorded;
b. De-superheating water adjusting valve and rear smoke channel control baffle shall have enough
adjusting surplus;
c. M/A operation station shall normally operate. Tracking signal shall be correct, and there is no switching
signal for manual operation.
3) Quality index (load range 70%-100%) :
a. Stability quality index: overheating temperature is ±3℃; reheating steam temperature is ±4℃; Actuator
shall not frequently operate.
b. When set value of overheating steam temperature and reheating steam temperature undergo a change of
±5℃, transient procedure attenuation rate is 0.75~1, and stability time is less than 20mins.
c. Dynamic condition and stability quality index under boiler-turbine coordinated control mode are listed in
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Table 1.
4) Maintenance acceptance check; after boiler major repair, the following test reports shall be provided:
a. De-superheating adjusting valve newly put into operation shall be provided with characteristic test
compliance report;
b. Rear smoke channel control baffle after major repair shall be provided with characteristic test
compliance report;
c. Dynamic condition and stability quality index compliance report of over-heating steam temperature and
reheating temperature control;
d. Dynamic characteristic test report of overheating steam temperature/reheating steam temperature (if
necessary)
5) Operation maintenance:
a. Get to know overheating and reheating steam temperature recording curve from operator on duty every
day, and according to the curve, analyze the operation condition of control system. If problems are found,
eliminate in time;
b. Regularly check the validity of measuring signals;
c. Regularly check the characteristics of executing institute and adjusting institute;
d. Regularly check control quality recording curve of the system under various operation conditions. In
case of abnormalities, they shall be dealt with immediately to ensure that system is intact.
6) Tests during operation:
a. If necessary, conduct disturbing test of de-superheating water flow;
b. If necessary, conduct swinging test rear smoke channel control baffle;
c. If necessary, conduct disturbing test of overheating steam temperature and reheating steam temperature
set value.
7) Removal of control system; in case of the following conditions, automatic removal could be considered:
a. When boiler is stable operation, and overheating steam temperature and reheating steam temperature
exceeds alarm value;
b.De-superheating water adjusting valve is wide open, but steam temperature still keeps rising, or
de-superheating water adjusting valve is completely closed, and steam temperature still keeps dropping;
c. Control system operation is not stable, de-superheating water flow undergoes great fluctuation, and
steam temperature shows regular attenuation fluctuation;
d. Leakage flow of de-superheating water adjusting valve is larger than 15% of the maximum flow;
e. Boiler operation is abnormal, and overheating steam temperature and reheating steam temperature
parameters are lower than rated value.
6.5.2.4 Combustion control system
Combustion control system includes furnace pressure control, air volume and oxygen volume control
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(secondary air register and air volume control, secondary air pressure control, oxygen volume correction, and
after-combustion air control) , primary air pressure control, and coal mill control (primary air volume control,
exit temperature control, and coal feed control) etc.
1) Furnace pressure control system:
a. Test items and requirements before putting into operation:
Dynamic characteristic test of furnace pressure (conduct if necessary) : after boiler major repair, if
necessary, conduct dynamic characteristic test of furnace pressure, and tests shall include dynamic characteristic
of blowing-in air volume, and furnace pressure change under induced air volume change, which shall be
conducted under different load sections.
b. Conditions for control system input:
⑴Boiler operation is normal, combustion is table and furnace pressure signal is correct and reliable;
⑵Protection circuit input such as Furnace pressure is under directivity lock, furnace pressure is under low
override control, and MFT override control;
⑶ Induced air volume of induced draft fan baffle, under maximum opening, shall meet boiler maximum
load requirements with enough surpluses;
⑷ M/A operation station operates normally, tracing signal is correct, and there is no switching signal for
manual operation.
c. Quality index (Load range 70%~100%) :
⑴Stable quality index: ±100Pa.
⑵ Furnace pressure set value disturbing (±150Pa) : transient procedure attenuation rate is 0.75~0.9, and
stability time is less than 1min.
d. Maintenance acceptance check; after boiler major repair, the following test reports shall be provided:
⑴Furnace pressure dynamic characteristic rest report (if necessary) ;
⑵Compliance report of furnace pressure control system quality index.
e. Operation maintenance:
⑴Furnace pressure sampling tube shall be continuously blown to ensure smoothness.
⑵Compare output value of furnace pressure triple level redundancy transmitter every day. For transmitter
out of tolerance, failure shall be eliminated immediately.
⑶ Get to know furnace pressure recording curve from operator on duty every day, and according to the
curve, analyze the operation condition of control system. If problems are found, eliminate in time;
f. Tests in operation: during operation, when stability quality index is out of tolerance, disturbing test of
furnace pressure set value shall be conducted.
g. Removal of control system: in case of the following conditions, automatic removal could be considered:
⑴Boiler combustion is not stable;
⑵Control system operation is not stable, and furnace pressure undergoes great fluctuation;
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⑶Protective device of furnace pressure shall withdraw from operation.


2) Air volume and oxygen volume control system shall include: secondary air register air volume control,
secondary air pressure control, oxygen volume correction, and after-combustion air control system.
a. Test items and quality requirements before putting into operation:
Dynamic characteristic test of air volume control (conduct if necessary) :
Secondary air register air volume control system, before putting into operation, shall conduct dynamic
characteristic test secondary air register air volume control. During test, secondary air pressure control shall be
set as automatic.
b. Conditions for control system input:
⑴Boiler operation is normal, combustion is stable, load is larger than 50%, and secondary air register air
volume control system is put in;
⑵ Air output of secondary air register, under maximum opening, shall meet the maximum load
requirements of boiler with about 5% surplus;
⑶Air volume and oxygen volume signals are correct and reliable, and records are clear;
⑷Furnace pressure control system is put into operation;
⑸M/A operation station normally operates, tracking signal is correct, and there is no switching signal for
manual operation;
⑹Furnace pressure is under directivity lock, and anti-surge protection circuit is put in.
c. Quality index (load range 70%~100%) :
⑴Oxygen volume stability quality index is ±1(%) .
⑵When combustion ratio order increases, air volume shall be able to change in 30s, and oxygen volume in
1min.
⑶ Air pressure set value disturbing (±150Pa) : transient procedure attenuation rate is 0.75 ~ 0.9, and
stability time is less than 50s.
d. Maintenance acceptance check: after boiler major repair, the following test reports shall be provided:
⑴Dynamic characteristic test of air volume control (if necessary) ;
⑵Compliance report of air volume and oxygen volume control system quality index.
e. Operation maintenance:
⑴Air volume signal sampling tube shall be regularly blown to ensure smoothness;
⑵According to recording curve of parameters, such as air volume, oxygen volume, coal volume, and load,
etc, analyze operation condition of control system. If abnormalities are found, eliminate them in time.
f. Tests during operation: if necessary, conduct disturbing test of air volume and oxygen volume set value.
g. Removal of control system; in case of the following conditions, automatic removal could be considered:
⑴Boiler operation is abnormal, and combustion is unstable;
⑵Control system is unstable, and air pressure has great fluctuation;
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⑶Furnace pressure control system withdraws from operation.


3) Primary air pressure control system:
a. Test items and requirements before putting into operation: if necessary, conduct primary air pressure
dynamic characteristic test:
⑴For one air volume change, observe and record the dynamic characteristic of air pressure change;
⑵Tests shall be separately conducted under high and low load;
⑶Tests under each load shall not be less than two times.
b. Conditions for control system input:
⑴ Air volume of primary air baffle, under maximum opening, shall meet maximum load requirements of
boiler with enough surpluses;
⑵Primary air pressure had correct signal indication and clear recordings;
⑶M/A operation station normally operates, tracking signal is correct, and there is not switching signal for
manual operation;
⑷Anti-surge protection circuit input.
c. Quality index (load range 70%~100%) :
⑴Stability quality index: ±100Pa.
⑵When primary air pressure set value changes by 300Pa, transient procedure attenuation rate is 0.75~1,
and stability time is less than 50s.
d. Maintenance check: Every time boiler major repair, the following test reports shall be provided: primary
air pressure dynamic characteristic test report (if required) ;
e. Operation maintenance:
⑴Primary air pressure tapping and sampling tube shall be regularly blown to ensure smoothness;
⑵ According to primary air pressure recording curve, analyze operation condition of control system. If
abnormalities are found, eliminate in time.
f. Tests during operation; during operation, when stability quality index is out of tolerance, primary air
pressure set value disturbing test shall be conducted.
g. Removal of control system: in case of the following conditions, automatic removal could be considered:
⑴Under stable operation, primary air pressure exceeds ±200Pa of set value;
⑵Control system operation is not stable, and primary air pressure undergoes great fluctuation.
4) Coal mill control system includes: primary air volume control, exit temperature control, and coal feed
volume control system;
a. Test items and requirements before putting into operation:
⑴Primary air register air volume characteristic test (conduct if necessary) : Primary air register air volume
characteristic test is conducted in coal miller system cold state ventilation test. Manually turn up primary air
flow adjusting baffle discontinuously in one direction, and each time shall be best with 10% of amplitude till
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adjusting baffle is wide open; and then turn down valve in the same way till it is completely closed; turning
down or up each shall be conducted after flow is stable.
When coal miller is under operation, choose to conduct when coal miller is started and grounded, and
stopped and cleansed; under other circumstances, opening-flow check could be conducted in sections according
to the above-mentioned methods, but primary air volume characteristic test for a whole journey shall not be
conducted.
⑵Dynamic characteristic test of temperature at coal miller exit (conduct if necessary) : tests include under
coal volume and hot wind air volume change, dynamic characteristic of temperature change at coal miller exit.
b. Condition for control system input:
⑴Coal miller system operation is normal, and there is enough desiccation output;
⑵Adjusting baffle opening shall have enough adjusting range;
⑶Signals of primary air volume, coal miller exit temperature, and coal feed volume, etc. It shall be correct
and reliable, and clearly recorded;
⑷Protection interlock circuit input between control system, and FSSS, and SCS system.
⑸Air and coal crossed and limited circuit input;
⑹M/A operation station normally operates, tracking signal is correct, and there is no switching signal for
manual operation;
⑺Primary air pressure control system is put into operation.
c. Quality index (load range 70%~100%) :
⑴Stability quality index: coal miller entrance primary air volume is ±5%; coal miller exit temperature is
±3℃.
⑵When primary air volume set value change by 5%, transient procedure attenuation rate is 0.75~0.9, and
stability time is less than 20s.
⑶Coal miller exit temperature set value change by 3℃, transient procedure attenuation rate is 0.75~0.9,
and stability time is less than 5min.
⑷ When opening change of high temperature air (or low temperature air) baffle change by 10%, control
system shall be capable to removal disturbing within in 3min, and maximum deviation of coal miller exit
temperature shall not be larger than 5℃.
d. Maintenance and acceptance check: after boiler major repair, the following test reports shall be
provided:
⑴Compliance report of primary air register air volume characteristic test;
⑵Dynamic characteristic test report of coal miller exit temperature (if required) ;
⑶Compliance report of control system quality index of primary air volume, exit temperature and coal feed
volume.
e. Operation and maintenance:
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⑴Regularly blow flow sampling tube to ensure smoothness;


⑵Regularly check temperature measuring element to prevent protection casing from wearing out;
⑶According to recording curve of primary air volume, coal miller exit temperature and coal feed volume,
and analyze operation condition of control system. If abnormalities are found, eliminate them in time.
⑷Regularly check characteristics of executing institute and adjusting institute.
f. Tests during operation:
⑴If necessary, conduct disturbing test of primary air volume set value;
⑵If necessary, conduct coal miller exit temperature set value.
g. Removal of control system; in case of the following conditions, automatic removal could be considered:
⑴Coal pulverizing system abnormal operation;
⑵Control system operation is unstable, and air volume undergoes great fluctuation;
⑶Coal miller desiccation output is not enough;
⑷Coal miller exit temperature exceeds alarm value.
6.5.2.5 Auxiliary equipment control system
Modulating control system of auxiliary equipment include modulating control system of de-aerator water
level, pressure, heater water level, condenser water level, shaft seal pressure, condensation water recirculation
flow control, and other auxiliary equipments, etc. Among these, modulating control system of other auxiliary
equipments mainly include the following single circuit control system: condensation water recirculation flow
control, fuel pressure control, auxiliary steam temperature control, steam air heater drain tank water level
control, sealing air pressure control, closed water temperature control, closed water expansion tank water level
control, steam turbine lubricating oil control, generator cold water temperature control, and generator hydrogen
temperature control system, etc.
1) De-aerator water level control system:
a. Test items and quality requirements before putting into operation:
⑴ Dynamic characteristic test of de-aerator water level (conduct if necessary) : tests shall include under
change of feed water flow and condensation water flow, the dynamic characteristic test of de-aerator water level
change.
⑵Characteristic test of de-aerator water level adjusting valve; for adjusting valve newly put into operation,
characteristic test shall be conducted, and its quality requirements shall be:
 Under rated condensation water bus bar pressure, maximum flow when adjusting valve is completely
open shall meet the maximum feed water volume of boiler with a surplus around 10%;
 When adjusting valve is completely closed, leakage volume shall be smaller than 10% of maximum
flow of adjusting valve;
 Linear working segment of adjusting valve characteristic curve shall be larger than 70% of the whole
journey, and its hysteresis error shall not be larger than 3% of the maximum flow of the adjusting valve;
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 Dead schedule of adjusting valve shall be smaller than 5% of the whole journey.
b. Conditions for control system input:
⑴De-aerator water level, feed water flow, and main condensation water flow shall be correctly indicated
and clearly recorded;
⑵Adjusting valve of de-aerator water level shall have enough adjusting range;
⑶De-aerator water level protection shall be put into operation;
⑷Condensation water recirculation flow control system shall be put into operation;
⑸M/A operation station normally operates, tracking signal shall be correct, and there shall be no switching
signal of manual operation;
⑹ Single impulse and three impulse adjusting performance shall be complete to realize no disturbing
switching.
c. Quality index (load range 70%~100%) ;
⑴ Stability quality index: ±20mm.
⑵ When water level set value change by 100mm, transient procedure attenuation rate is 0.7 ~ 0.8, and
stability time shall be less than 20min.
d. Operation maintenance; according to recording curve of de-aerator water level, analyze operation
condition of de-aerator water level control system. If abnormalities are found, eliminate them in time.
e. Tests during operation; when stability quality index during operation is out of tolerance, disturbing test
of water level set valve shall be conducted.
f. Removal of control system; when operation condition is stable and de-aerator water level exceeds set
value by ±200mm, automatic removal could be conducted.
2) De-aerator pressure control system:
a. Conditions of control system input:
⑴De-aerator normally operates, and operation mode complies with requirements of automatic adjustment;
⑵Adjusting valve shall have enough adjusting range;
⑶De-aerator pressure shall be correctly indicated and clearly recorded;
⑷De-aerator pressure protective device shall be put into operation.
b. Quality index (load range 70%~100%) :
⑴Stability quality index: ±20kPa.
⑵When de-aerator pressure set value change by 50kPa, control system shall stabilize pressure at new set
value within 1min, and transient procedure attenuation rate is 0.75~1.
c. Operation maintenance: if necessary, conduct disturbing test of de-aerator pressure set value.
d. Removal of control system: in case the following conditions, automatic removal could be considered:
⑴When operation is stable, de-aerator pressure exceeds alarm valve;
⑵ When adjusting valve is completely open and pressure continuously decreases, or adjusting valve is
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completely closed, and pressure shall continue to be increased;


⑶When de-aerator operation mode changes, it doesn’t comply with requirements of automatic adjustment.
3) Control system of heater water level:
a. Conditions of control system input:
⑴Heater normally operates;
⑵Drain adjusting valve shall have enough adjusting range;
⑶Water level protection shall be put into operation.
b. Quality index:
⑴Stability quality index: ±10mm.
⑵Under set value disturbing, ( ±30mm) transient procedure attenuation rate is 0.75~1.
c. Operation maintenance: if necessary, conduct disturbing test of water valve set valve.
d. Removal of control system: in case the following conditions, automatic removal shall be considered:
⑴ Adjusting valve is completely open, and water level continues rising, or adjusting valve is completely
closed and water level shall continue to be dropped;
⑵When operation is stable, water level shall exceed ±150mm of set valve;
⑶Heater operation mode changes and requirements of automatic adjustment couldn’t be satisfied.
4) Control system of steam-turbine condenser water level:
a. Conditions of control system input:
⑴Steam-turbine normally operates, and condenser is under operation mode with water level;
⑵Condenser operation mode is reasonable, and adjusting valve has enough adjusting range;
⑶Condenser water level is correctly indicated.
b. Quality index:
⑴Stability quality index:
⑵When condenser water level set value change by 50mm, transient attenuation rate at rising direction is
0.75~1, and stability time is less than 5min.
c. Operation maintenance: if necessary, conduct disturbing test of water level set value.
d. Removal of control system: in case of the following conditions, automatic removal could be considered:
⑴When operation condition is stable, condenser water level exceeds ±200mm of set valve;
⑵Condenser operation mode changes, and doesn’t comply with automatic adjustment.
5) Modulating control system of other auxiliary equipments:
a. Conditions of control system input:
⑴Auxiliary equipments normally operate;
⑵Adjusting valve shall have enough adjusting range;
⑶Adjusted parameter shall be correctly indicated.
b. Quality index:
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⑴Stability quality index: near set value, there shall be no vibration.


⑵Under set value disturbing, attenuation rate of control system is 0.75~1.
c. Operation maintenance: if necessary, conduct disturbing test of set value.
d. Removal of control system: when operation condition is normal and the deviation between control value
and set value exceeds regulated value, automatic removal could be considered.
6.5.2.6 Turbine-boiler coordinated control system
Coordinated control system includes: control system of unit load command setup, steam turbine main
control, boiler main control, pressure setup, pressure setup, heat value calibration (BTU) , auxiliary failure load
reduction (RB) etc.
1) Test items and quality requirements before putting into operation:
a. Functionality test and mode switching test of coordinated control system. After modifying control
system software, conduct functionality test and mode switching test of coordinated control system.
⑴Manual adjustment (rising and falling) of unit load order, adjustment of load high/low limit value, and
set functionality test of load change rate;
⑵ Switching test among three methods of boiler following, steam-turbine following, and coordinated
control;
⑶No disturbing switching test of automatic generation control (AGC) distance and local control modes;
⑷Switching tests of constant voltage/sliding pressure operation mode;
⑸Functionality tests of load increase and decrease lock (block Increase/block Decrease) .
b. RB (run back) function simulating test: after modifying control system software and when unit operation
is stopped, conduct simulating test of coordinated control system’s R function to confirm that RB control circuit
and parameter adjustment are reasonable and actions are correct. During test, according to designed functions,
simulate conditions for the occurrence of RB in order, and mainly check the following contents:
⑴When RB with difference causes takes place, DI passage shall correctly action;
⑵ RB control parameters, such as load calculation circuit and load command change rate, etc. They are
correctly set;
⑶DO passage of CCS output to FSSS shall correctly action;
⑷FSSS coal mill shall have correct logic control and meet the requirements of DL/T655;
⑸CCS shall switch to TF (steam-turbine following) operation mode;
⑹During RB, methods to stabilize pressure/reduce pressure adopted by main steam pressure shall comply
with design requirements, and generally operation shall switch to reducing pressure mode;
⑺During reducing pressure mode, rate parameter of reducing pressure shall be correctly set according to
the characteristics of RB.
c. Load dynamic response characteristic test (conduct if necessary) : Tests shall be conducted under
different load sections, and test items shall include:
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⑴ For load dynamic response characteristic test (conduct if necessary) of stabilizing pressure operation
mode, test shall be conducted under two load sections of 60% and 90%;
⑵ Load dynamic response characteristic test of sliding pressure operation mode shall be conducted during
the load section of 70%~80%.
2) Conditions for control system input:
a. Boiler operation is normal, and furnace combustion is stable;
b. Main and key parameters of unit power, load command, main steam pressure, speed regulating pressure,
total air volume, total combustion volume, etc. are correct and reliable, and clearly recorded;
c. DEH system function is normal, and could switch into CCS control mode;
d. Main control system of combustion, feed water, overheating steam temperature, reheating steam
temperature, and de-aerator, etc. have been put into operation;
e. Coordinated control system’s control modes and each parameter are correctly set and M/A operation
station of steam-turbine main control and boiler main control, etc. normally operates, tracking signal is correct,
and there is no switching signal for manual operation.
3) Quality index:
a. Load change test: under boiler-turbine coordinated control mode, within the load range of 70%~100%,
load command has a change rate of 2% Pe/min or 3%Pe/min, and load change volume is P=15% Pe. Load
unidirectional change test shall be separately conducted; trends and stability quality index of mainly adjusted
parameters of unit are shown in Table 1.
b. AGC load following test: under AGC control mode, and within the load range of 70 % ~ 100 % ,
bidirectional change test with continuous increase and decrease (or decrease and increase) shall be conducted
when load command is under declination mode with a change rate of 1.5% Pe/min and a load change rate of
P=10%Pe; Trends and stability quality index of mainly adjusted parameters of unit are shown in Table 1.
Table 1 Trends and stability quality index of mainly adjusted parameters of unit are shown in Table 1.

Controlled parameters Qualification index Excellent index Static deviation


Pressure before engine ±0.6MPa ±0.5MPa ±0.3MPa
Main steam temperature ±10℃ ±8℃ ±3℃
Reheating steam temperature ±12℃ ±10℃ ±4℃
Boiler water level ±60mm ±40mm ±25mm
Furnace pressure ±200Pa ±150Pa ±100 Pa
Generator power ±3%MCR ±3%MCR ±1.5%MCR

4) Maintenance and acceptance check. After unit major repair, the following test reports shall be provided:
a. After modifying control system software, coordinated control system functionality check and mode
switching test report shall be provided;

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b. After modifying control system software, RB function simulating test report of coordinated control
system shall be provided;
c. Test report of load dynamic response characteristic (if required) ;
d. Under boiler-turbine coordinated control mode, qualification report of trends and stability quality index
of main adjusted parameters.
5) Operation maintenance; according to mainly adjusted parameters of unit power, load command, main
steam pressure, total air volume, total combustion volume, main steam temperature, reheating steam
temperature, boiler water level, furnace pressure, and smoke oxygen content, etc., analyze operation condition
of coordinated control system and each sub-systems. In case of abnormalities, eliminate them in time.
6) Test in operation; during operation, when stability quality index is out of tolerance, each sub-system
shall undergo set value disturbing test.
7) Removal of control system; in case of the following conditions, automatic removal could be considered:
a. Main measuring parameters, affecting coordinated control system decision, such as unit power, main
steam pressure, speed regulating pressure, total air volume, and total combustion volume, etc. have great signal
deviation or lose redundancy.
b. Mainly adjusted parameter severely exceeds limits, for example: main steam temperature deviation
exceeds ±15 ℃ ; reheating steam temperature deviation exceeds ±15 ℃ ; boiler water level deviation exceeds
±100mm; main steam pressure deviation exceeds ±1MPa.
c. Coordinated control system breaks down.
d. Computer control system has partial failure, and unit operation condition is deteriorated.

7. Thermal control system maintenance (DEH/MEH/ETS system maintenance rules)


7.1 DEH system maintenance rules
7.1.1 System overview
Steam-turbine digital electro-hydraulic control system (hereby briefed as DEH) adopts distributed control
system of Symphony by ABB Company, and control system is advanced and reliable.
The DEH control system of this unit mainly contains the following contents: one module cabinet 21B, two
terminal cabinets of 21A and 21C, one DEH operator station, and one engineer station. Share the same
communication network with DCS, which is convenient for usage. Power system is provided by two alternating
uninterrupted power supply as backup.
Control system is designed according to the design idea of distributed control, contributing to the
automatic control system of speed control, power control and protection function, and realizing automatic
control over unit by hydraulic service institute. And realize unit coordinated control (CCS) of DCS system.
7.1.1.1 DEH completes the following main protection functions:
OPC protection
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Over speed closing down (sent to ETS)


Failure closing down (sent to ETS)
7.1.1.2 DEH completes the following main control functions:
Rotating speed and power adjustment
Test function
Electric simultaneous interface
RUNBACK
Power load imbalance
Monitoring calculation of each parameter
Communication with DCS
Data alarming and tracking
Steam-turbine adopts high pressure main steam valve and medium pressure adjusting valve methods for
impulse starting. When rotating speed reaches 2900RPM, switch to high pressure adjusting valve to control
raising speed with load. Each unit is equipped with two high pressure main steam valves (TV) , four high
pressure adjusting valves (GV) , two medium main steam valves (RSV) and four medium pressure adjusting
valves (IV) .
Unit starting operation method: Stabilizing- sliding- stabilizing operation and high and medium pressure
are joined for starting.
Load quality: Have basic load, and peak load operation
Variation range of cyclic wave: 47.5~51.5Hz
Unit rated output: 622.819MW
Rated steam pressure before main steam valve: 16.67 MPa
538 ℃ Rated steam pressure before main steam valve: 538 ℃
7.1.1.3 Module type and amount:
No. Equipment name Specifications and models Quantity Unit
1 Redundant bridge controller module SPBRC410 4 Set
Redundant network interface module and
2 SPNIS21/SPNPM22 2 Set
terminal
3 Digital input sub-module and terminal SPDSI14 4 Set
4 Digital output sub-module and terminal SPDSO14 4 Set
5 Simulating input sub-module and terminal SPASI23 7 Set
6 Simulating input sub-module and terminal SPFEC12 4 Set
7 Simulating output sub-module and terminal SPASO11 1 Set
8 Hydraulic serving sub-module and terminal SPHSS03 10 Set
9 Rotating speed module and terminal SPTPS02 3 Set

7.1.1.4 Principles of DEH control system

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Main purpose of DEH control system is to control rotating speed and power of steam-turbine generator
unit to meet the requirements of power supply in power plant.
When unit is started and normally operates, DEH receives CCS command or operators, through human
machine interface, send out increasing and decreasing command. Collect signals of steam-turbine generator
unit’s rotating speed and power, and position feedback of adjusting valve, analyze and treat for comprehensive
calculation. Output control signals to hydraulic serving valve, and change the opening of adjusting valve to
control unit operation.
When unit is rising (namely units are not synchronized) , DEH, by means of acceleration control circuit
and speed control circuit, controls unit rising and rotating speed till actual rotating speed and target rotating
speed are equal. When DEH receives synchronous command, actual rotating speed undergoes periodic swinging
at around rated rotating speed and with certain amplitude and frequency till synchronization is completed.
After unit is synchronized, first by means of ring opening directly set flow command to control valve
opening with load. Input power at the side of DEH or pressure closed-loop for adjustment, or by means of CCS
input to control load.
DEH has valve management function, capable of realizing mutual switching from single valve to sequence
valve or from sequence valve to single valve.
DEH has valve action test function. When one high pressure adjusting steam valve action is under test,
main steam compensator produces load compensatory command and controls the opening of other high pressure
adjusting steam valve, which makes the actual load remains the same during high pressure adjusting steam
valve action. Besides, there are high pressure main steam valve and medium pressure steam valve action test
function.
When unit trips, set valve opening set signal as 0%, and close all valves.
DEH control system is set with valve limitation, quick release load, steam-turbine protection, and primary
frequency modulation, etc. Multi-DEH control system is set with operation modes of CCS coordinated control,
ATC self-starting, automatic control, and manual control, etc.
When DEH enters ATC control mode, according to thermal stress calculation result, automatically set
target, and choose appropriate speed rising rate or load rate to conduct automatic control of unit.
7.1.2 DEH engineer station
7.1.2.1 Overview
Engineer station adopts DELL Precision T3600: interface module adopts the latest IET800. IET800 could
be compatible with former Modbus communication through rear panel and through Ethernet communication on
front panel. It is widely applied with simple usage. Communication rate is improved and performance is stable.
Operation system is Windows7 64 bit in English professional version, and configuration software is
S+Engineering: Composer Harmony System 6.0.
Engineer station has the following functions:
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● System software server


● High performance tool data base
● High performance tool storage room
● Operator function
● Each engineer function, etc.
7.1.2.2 Common failure and treatments
1) Common failures
a. Printing service failure
b. Image point is connected by mistake.
c. Machine opening window failure
2) Treatments:
a. Check whether alarm printer is normally connected, printer power is normal, and confirms alarming.
b. Modify picture connection, and re-download pictures.
c. Log in as super user, and restart machine.
7.1.2.3 Test items
1) Check main machine, CRT, keyboard, and mouse appearance, make use of each downtime opportunity
to cleanse inner dust in machine;
2) Check operating desk and cabinet appearance, and make use of each downtime opportunity to cleanse
interior and exterior of operating desk;
3) Function test of operation pictures, trend chart, and alarm log, etc;
4) Check connection cable between engineer station and interchanger, and network communication;
5) Take engineer station as printer server, and test printing function;
6) Take engineer station as historical station, call historical alarm and data recording, and check the state of
magneto optical drive;
7) Engineer station configuration function test;
8) Power cable insulation test;
9) Power switching test;
7.1.2.4 Maintenance process standard
1) Main engine, CRT, keyboard and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, and cabinet door shall be complete and well sealed;
3) Check whether functions of operating pictures, trend chart, and alarm log are normal, and record check
results;
4) Check the communication connection between engineer station and interchanger, and conduct network
redundancy switching, and record test conditions;
5) Check the connection of printer, test printing functions, and record test conditions;
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6) Call historical alarm and data, check the operation condition of magneto optical drive, and record test
conditions;
7) Open each test group, each configuration software function is normal, and make records;
8) After modifying some configurations, download database configuration or image configuration, and
record modifications;
9) Power cable insulation test: adopt 500V mage meter to measure insulation between lines and ground
insulation, and record test results;
10) Turn on two routes of power, and then turn off one power, and check whether another power has
automatically switched, and whether the operation state of engineer station has been affected. Otherwise, turn of
the other power, and check the operation state of system, and record switching results.
7.1.2.5 Quality standards of acceptance check
1) Main engine, CRT, keyboard, and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, cabinet door shall be complete and well sealed, and environment
temperature is required with load;
3) Check records and examine whether functions of operating image, trend chart, alarm log, etc. comply
with requirements;
4) Check test records, engineer station and interchanger shall be normally connected, system state diagram
displays that network communication is normal, and conduct real-time monitoring of network redundancy
switching, which shall not affect engineer station;
5) Check test records, and engineer station shall have no printing failure display;
6) Check test records, take it as historical station, the function to call historical alarm and data is normal,
and magneto optical drive operation is normal;
7) Check record condition, and each software configuration function of engineer station shall be normal;
8) Check configuration modification records with complete standards;
9) Power cable insulation test: adopt 500V mega meter to measure insulation between lines and ground
insulation, and insulation resistance shall be larger than 20 megger;
10) Check record results, and two routes of power are required to be completely redundant, and switching
time complies with requirements;
7.1.3 DEH operator station
7.1.3.1 Overview
Operator station adopts DELL POWEREDGE R420, client adopts DELL precision T3600, and interface
module also adopts the latest IET800. Operation system is Windows7 64 bit in English professional version, and
operation software is S+Operation 1.1.1.
Operator station has the following functions:
● Procedure chart monitoring and operation
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● Alarm management
● Trend display
● Measuring point information/measuring point check
● Operator event report
7.1.3.2 Common failure and treatments
1) Common failures
a. Printing service failure
b. Image point is connected by mistake.
c. Machine opening window failure
2) Treatments:
a. Check whether alarm printer is normally connected, printer power is normal, and confirms alarming.
b. Modify picture connection, and re-download pictures.
c. Log in as super user, and restart machine.
7.1.3.3 Maintenance items
1) Check main machine, CRT, keyboard, and mouse appearance, make use of each downtime opportunity
to cleanse inner dust in machine;
2) Check operating desk and cabinet appearance, and make use of each downtime opportunity to cleanse
interior and exterior of operating desk;
3) Function test of operation pictures, trend chart, and alarm log, etc;
4) Check connection cable between engineer station and interchanger, and network communication;
5) Check the connection between operator station and alarm printer, and test printing function;
6) Power cable insulation test;
7) Power switching test;
8) System data backup
7.1.3.4 Maintenance process standard
1) Main engine, CRT, keyboard and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, and cabinet door shall be complete and well sealed;
3) Check whether functions of operating pictures, trend chart, and alarm log are normal, and record check
results;
4) Check the communication connection between engineer station and interchanger, and conduct network
redundancy switching, and record test conditions;
5) Check the connection of printer, test printing functions, and record test conditions;
6) Power cable insulation test: adopt 500V mage meter to measure insulation between lines and ground
insulation, and record test results;
7) Turn on two routes of power, and then turn off one power, and check whether another power has
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automatically switched, and whether the operation state of engineer station has been affected. Otherwise, turn of
the other power, and check the operation state of system, and record switching results.
7.1.3.5 Quality standards of acceptance check
1) Main engine, CRT, keyboard, and mouse functions are normal, and label is complete and clear;
2) Operating desk shall be clean and tidy, cabinet door shall be complete and well sealed, and environment
temperature is required with load;
3) Check records and examine whether functions of operating image, trend chart, alarm log, etc. comply
with requirements;
4) Check test records, operator station and interchanger shall be normally connected, system state diagram
displays that network communication is normal, and conduct real-time monitoring of network 5.5 redundancy
switching, which shall not affect engineer station;
5) Check test records, and operator station shall have no printing failure display;
6) Power cable insulation test: adopt 500V mega meter to measure insulation between lines and ground
insulation, and insulation resistance shall be larger than 20 megger;
7) Check record results, and two routes of power are required to be completely redundant, and switching
time complies with requirements;
7.1.4 DEH power cabinet
7.1.4.1 Overview
DEH power cabinet accepts two routes of 220VAC power, from security section and UPS. Un-switched
power is directly sent to power switcher with a small power, and two routes of power are output to ensure
normal operation of two interchangers. Un-switched two routes of power are separately sent to control cabinet
and two power modulates to conduct redundancy power supply for controller. OPC magnetic valve accepts two
routes of 220VDC power from electric 220VDC direct current screen 1 and electric 220VDC direct current
screen 2.
7.1.4.1 Failure treatment
Common failure: cable insulation declines and power switch trips.
Treatment method: turn off relevant power switch, check the insulation condition of output lines, replace
backup line for recovery, and after insulation is tested to be qualified, turn on power to check whether power has
been restored.
7.1.4.3 Maintenance items
1) Power supply state and supply voltage check;
2) Contact operation, turn off upper-end power, and clean up;
3) Fasten terminal connection;
4) Insulation test of 220VAC power supply cable;
5) Turn off each output switch, charge for on-load test, and power is switched to another circuit;
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6) Charge with load and conduct power switching test.


7.1.4.4 Maintenance process standards
1) Check power supply state, power supply voltage, and make records.
2) Clean up dust in each contactor, switch, and terminal.
3) Check and fasten connection, make records.
4) Insulation test of 220VAC power supply cable: adopt 500V mega meter to measure insulation between
lines, and record test results.
5) Turn on two routes of 220VAC power, turn off all power switches at each station and interchanger,
conduct on-load power circuit test and switching, and record test and switching results.
6) Turn on two routes of 220VAC power, turn on the power of controller, engineer station, operator station
and interchanger, etc. conduct power circuit switching, and record switching records.
7.1.4.5 Quality standards of acceptance check
1) Check records, and whether power circuit operation is normal;
2) Power circuit electric components are regularly cleaned, and appearance is tidy without dust;
3) Connection is fastened without loosening;
4) Power cable insulation test: adopt 500V mega meter to measure insulation between lines and ground
insulation, and insulation resistance shall be larger than 20 megger;
5) Check test and switching records, and power circuit on-load test shall be normal;
6) Check switching results, two routes of power are required to be completely redundant, and switching
time comply with requirements.
7.2 MEH system maintenance rules
7.2.1 Overview
7.2.1.1 System introduction
Boiler feed pump steam-turbine digital electro-hydraulic control system is SYMPHONY PLUS by ABB
company. It could receive commands of feed water control system, and conduct rotating speed closed-loop
control of small steam-turbine. At the same time, logics, such as ETS protection and test of small feed pump, etc.
are also included. This system has convenient and flexible configuration function, and could share networking
information with power plant DCS control system.
Steam of drive steam turbine comes from two routes of steam sources. Backup steam source is boiler high
pressure steam source (cold and then hot steam source) , and working steam source is four-section steam
extracting steam source of main steam turbine. On each route, there is one control valve, and steam comes out
from control valve, gathers and enters into main steam valve. Each steam pump’s speed regulating range is
2800 ~ 6000r/min. When main steam-turbine operates with set pressure with a load below 40%THA (during
sliding operation, below a load of 30%THA) , conduct low pressure steam source for steam supply. Adopt low
profile governing valve LPGV to control the steam flow that enters steam-turbine. When the load of main
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steam-turbine reaches 30%~ 40%, high pressure steam source and low pressure steam source jointly provide
steam. At this time, low profile governing valve LPGV follows feed water command and is completely opened,
and then adopt high profile governing valve HPGV to control.
Control system has three operation modes: boiler automation, rotating speed automation and manual
operation. Switching among three modes is realized by software.
7.2.1.2 Main functions of control system, also technical requirements after equipment maintenance.
1) Automatic control of boiler feed water volume.
2) Automatic control of feed pump steam-turbine rotating speed
3) Regulating valve position control
4) Normal operation and monitoring
5) Over speed protection and test
6) ETS tripping protection of small steam-turbine feed pump
7.2.1.3 System hardware configuration:
MEH is procedure control unit (PCU) . Its node number on control loop is 22, and unit plant has two
cabinets. Terminal cabinet number is 22A, and module cabinet number is 22B. The type and quantity of this
module adopted in this system are as follows:
No. Equipment name Specifications and models Quantity Unit
Redundant network interface module, terminal and
1 SPNIS21/SPNPM22 1 set
cable
2 Redundant bridge controller module and cable SPBRC410 2 set
3 Digital input sub-module, terminal and cable SPDSI14 4 set
4 Digital output sub-module, terminal and cable SPDS014 4 set
5 Frequency calculating sub-module, terminal and cable SPFCS01 6 set
6 Simulating input sub-module, terminal and cable SPFEC12 2 set
7 Simulating output sub-module, terminal and cable SPAS011 2 set
8 Hydraulic serving sub-module, terminal and cable SPHSS03 4 set
9 III type power MPSIII 1 set

7.2.1.4 System software configuration:


Engineer station adopts operation system of Windows7 64bit in English professional version, and
configuration software is S+Engineering: Composer Harmony System 6.0.
Operator station adopts operation system of Windows7 64bit in English professional version, and
configuration software is S+Operation 1.1.1.
7.2.2 Maintenance items and their quality requirements
7.2.2.1 General check of MEH control system
1) For MEH control cabinet general check, check whether there is any damage, deformation, and abrasion,
etc of machine cabinet, check each printed board of cabinet, preset cable, whether relay or others shall be burnt,
damaged, check fan inside cabinet normally operates, and record check results.
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2) For general check of MEH system local equipments, check MEH sensors, including each sensor and its
extension cord, front-end machine, transmitter, electro-hydraulic convertor, etc. Check site magnetic valve,
secondary valve, and whether each measuring point of oil system has leakage point. At the same time, check
whether there is evident damage and burning, etc at cabinet switches. Check each cable, relay and transformer
inside local control box has any damage and burning, etc. Record test results.
7.2.2.2 Maintenance procedure
1) MEH cabinet maintenance
a. Make maintenance work ticket. Stop plant UPS, and send plant security power to the two routes of
power controlled by MEH.
b. Stop each route of power and security inside each MEH cabinet.
c. Inner check of cabinet and clean up dust
d. Use hairbrush and vacuum cleaner to clean up fan.
e. Clean up dust in terminal strip, and check whether connection is fastened.
f. Check rotating speed passage and shielded line.
g. Appearance check of preset cable inside cabinet, check whether plugs are loosened, fasted, and set
screws are complete.
h. SG inside cabinet, and CG ground check is normal.
i. Clean printed board inside cabinet: use hairbrush and silk to clean each card. When cards are plugged in
and pulled out, adopt appropriate force. After maintenance, connection on printed board shall be firm.
2) Control cabinet power transmission
a. Provide MEH control cabinet with two routes of 24VDC power, check whether 24VDC power from
CUM01/CUM02 cabinets and voltage of power switching diode are balanced. If normal, check whether 24VDC
of electro-hydraulic convertor is normal.
b. After power is checked to be normal, close mini fuses on terminal strip under MEH cabinet. Send
module and turn on power switch of DPU control power module, confirm whether power indicator light on
DPU is normal and SPU indicator light is normal.
c. Observe whether indication of each MEH cabinet module is normal. By means of engineer station lower
computer, observe operation condition of DPU and I/O cards, and confirm that their operation is normal.
3) Local equipment maintenance
a. Make maintenance work ticket; turn off lubricating oil system of small engine, and turn off local panel
power of small engine.
b. Adopt multi-meter to test power, and confirm that there is no electricity in local panel.
c. Pressure switch maintenance
⑴ Appearance check; Switch connector has no leakage of oil. Switch contact normally actions, set value
calibration is correct, and switch is cleaned up.
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⑵ Insulation test; in local panel, disconnect each switch connection, and adopt 500V megger to measure
ground resistance value against each line, which shall be over 10MΩ.
⑶ Record switch connection, disconnect switch, wrap wires with insulating tape, and wrap up sampling
tubes.
⑷ Switch re-installation
d. Magnetic valve maintenance
⑴Check magnetic valve appearance
⑵Check magnetic valve plug, and whether connection is firm, and connection shall be fasted.
⑶Test direct current resistance of magnetic valve, and resistance value shall comply with values indicated
in nameplate and comply with its working requirements.
⑷ Conduct magnetic valve power-on test, and slide valve inside valve shall move flexibly without
jamming.
e. Relay maintenance
⑴Clean up relay, and connection shall be checked to be fastened.
⑵ Check relay output contacts. Adopt multi-meter to measure its closed resistance value. If resistance
value is larger than 0.1Ω, relay is taken as unqualified. Polish contact to make the resistance value less than
0.1Ω, or change relay.
f. Switch maintenance at valve position
⑴For switch maintenance at valve position , first conduct appearance check of switch at the position, and
check whether set screws are loose, and connection are firm.
⑵ Use hand to move each moving parts, which shall be flexible without jamming; At the same time,
adopt multi-meter to measure each contact, and closed resistance shall be below 0.1Ω.
g. Local panel charging, and rotating speed indication is normal.
h. Valve LVDT check; conduct appearance check of LVDT, and whether set screws are loose, connection
are firm, and whether snakeskin casing pipe has worn out. The position of LVDT shall be correct, iron core
connecting rod moves flexibly without jamming.
4) Static joint debugging and performance test of MEH control system
a. Installation debugging of speed measuring passage
⑴The installation of speed measuring probe requires that the space between gear and speed measurement
shall be δ=1.2±0.1mm, stand and speed measuring probe shall be fastened, and gear shall not have burr.
⑵Check speed measuring cable, and shielding layer shall be grounded with “single point” at MEH.
⑶Connection requirements
 Connection between local terminal box and MEH cabinet shall adopt cable with shielding layer, and the
shielding layer has ground insulation. At MEH terminal strip, shielding layer is connected with terminal “I”.
Local terminal box is not connected, but shall be wrapped and fastened.
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 Speed measuring probe introduces line to local terminal box, and shielding cable, signal line and
shielding layer could be installed at the terminal of connection box.
 The three speed measuring probes of MEH shall adopt three cables to avoid mutual disturbance. Passage
test: adopt frequency generator signal to simulate speed measuring probe signal. Untie speed measuring probe
line at local terminal, connect simulating signal, change signal frequency and fill the following table:

F
50 100 500 1000 2000 3000 4000 4500 5000 5500 6000 6500 7000
(Frequency)
N

According to actual requirements, separately test electric over speed value f=5800 and backup electric over
speed value 5920, the value of n, and f is frequency generator frequency, and n is the rotating speed display of
engineer station or operator station. Required control precision: f=n±1%f.
b. Static joint debugging operation: signals of each pressure switch correctly transmit, the action of LVDT
whole journey is linear without jamming, and the display of zero and full point correspondently shown on upper
machine are 0~100%. Adopt laboratory table frequency signal to correspond with tachometer and display shall
be correct, and correspond with upper machine and rotating speed shall be correctly displayed.
c. When valve is actually latched, pressure of starting oil and quickly closing oil are normally established,
action time is correct, and the time of valve latching is within design range. When valve is locally latched, valve
is quickly closed, and valve closing time shall not exceed 2s.
d. Serve circuit adjustment
⑴Static test of serve system ring opening
 Adjustment of LVDT amplifier zero point and gain adjustment; after confirming the mechanical zero
position of LVDT, adjust the zero position potentiometer of amplifier to make the valve indication of DCS
indicate at 0, and then confirm the full scale of LVDT. Adjust gain potentiometer, and make the valve indication
of DCS indicate at 0.
 Repeat for several times till the value stays the same.
⑵Adjustment of electro-hydraulic converter
 Switch position adjustment of electro-hydraulic converter:
The command of electro-hydraulic converter output from DCS is 0, the current of correspondent
electro-hydraulic converter is 4mA, and conduct professional maintenance, and adjust electro-hydraulic
converter’s oil circuit to change valve position till it is completely closed.
Adjust valve opening with the same methods.
 Position record of adjusting valve:
After small machine is latched, DCS system controls the output command of valve, and at the same time,
record command of valve, position feedback and the actual position of local valve.
In the table, four special operation conditions are: tripping, latched, medium and wide open. Each valve:
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command A, position signal P, and local position valve’s actual position S.


Tripping Latched Medium Wide open
P A S P A S0 P A S1 P A S2
High
profile
Low
profile

⑶Conduct MEH system latching and tripping test


Check whether latching and tripping connection is according to the construction drawing. If correct, press
“LATCH” button, steam-turbine shall be latched, and press “TRIP” button, steam-turbine shall be tripping.
⑷ Check MEH till main steam valve test signal is correct. If it is correct, press quick-closing valve test
button. Quick-closing valve test action shall be normal.
7.2.2.3 Check whether test signals from MEH to main steam valve are correct. If so, press quickly
closing valve test button and the valve actions normally.
1) MEH system starting and operation
a. Start MEH control system and operation station
b. On operation station, point out “MEHA CONTROL” image
c. Through “ETS RESET”,“LATCH”,“OPEN HPMSV” and “OPEN LPMSV” on the image of “MEHA
CONTROL” in operator station, latching and resetting of unit could be realized.
d. Through “MAN/AUTO” on the image of “MEHA CONTROL” in operator station, place control system
under AUTO.
e. Through “TARGET” on the image of “MEHA CONTROL” in operator station, enter expected rotating
speed.
f. Through “ACCEL RATE” on the image of “MEHA CONTROL” in operator station, change the current
rising speed.
g. When boiler automatic control system allows, control “BOILER AUTO” button and conduct switching
of operation mode.
h. If manual operation is needed, through “MAN/AUTO” on the image of “MEHA CONTROL” in
operator station, switch system to manual operation mode and through “MAN REF on the image to control
valve position.
2) MEH stopping procedure
a. According to unit operation state, under any operation state, adopt engineer station and operator station
or small engine control panel to stop small steam-turbine.
b. When rotating speed decreases below 500rpm, input small engine panel, monitor small engine zero
rotating speed, and lubricating oil pressure.
c. Stop small engine and lubrication pump of pumping set.
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d. Stop MEH cabinet, and stop small engine local panel power.
3) Under live state, it is strictly forbidden to remove cards or disassemble components on cards.
4) Cabinet shall be kept clean and dry.
5) Regularly conduct light test on control panel.
6) Regularly check whether each light indication is normal, and whether state indication on passage board
is normal.
7) Note operation state and mode of MEH controller.
8) Regularly conduct quickly closing valve test.
9) If MEH breaks down, MEH could be maintained by professionals.
7.2.2.4 Item list of MEH major repair and minor repair
1) MEH system power and cabinet cleaning
2) MEH system card dust cleaning and maintain, and partial adjustment
3) MEH logic check
4) Small engine local equipment, and magnetic valve maintenance and cleaning
5) Maintenance of temperature measuring elements, pressure switch, valve journey switch, and LVDT in
small engine
6) MEH function test
7.3 Maintenance rules of big machine ETS system
7.3.1 Overview
7.3.1.1 Technical regulations
1) Vinh Tan power plant ETS adopts PLC system from Schneider and redundancy configuration. Through
communication, connect to DCS system factory main bus, and conduct resetting and test operations on image.
But signals of all protection function adopt hardwiring connection.
2) ETS system monitors some important signals of steam-turbine to ensure the safety of steam-turbine
equipment, in accordance with ASME standard TDP-1-1985 and other requirements.
3) By adopting proper redundancy technology and independent control system, ensure the high reliability
of ETS system. Any system failure shall not affect the operation of the whole system.
4) Adopt the method of “power loss tripping”.
5) Control system has complete self-diagnostic function, and the condition for action to send SOE to DCS
system.
6) ETS provides information at key point to DCS system to give alarm and display.
7) All functions of ETS meet the technical requirements put forward by steam-turbine manufacturer.
8) Control system has independent power, supplied by DCS system. DCS power is provided by two routes
of UPS and security section.
7.3.1.2 Fundamental working principle of ETS
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1) ETS system, under dangerous operation condition, could make emergency trip magnetic valve AST lose
power and steam-turbine trip. Its main function is to check the validity of the signal for tripping, and make sure
that tripping action immediately reacts to effective tripping command signal, so as to reduce equipment damage
to the great extent.
2) ETS shall meet the following requirements:
a. Each tripping function is designed with proper delay and limit condition to make sure that tripping
action is correct and to reduce tripping by mistake as much as possible.
b. Important signals and simulating tripping function could be tested on-line. During function test or
maintenance, if protection conditions are not compulsory, protection still works.
c. Tripping source of all electric signals comes from contacts without source.
d. Provide two outputs for each tripping input, and one for steam-turbine tripping, and one for SOE of DCS
system.
e. The first emitted tripping signal shall be used for identifying the main cause for tripping, and this signal
shall be sent to the initial image of DCS system.
7.3.1.3 Steam-turbine emergency tripping system ETS shall include the following tripping conditions:
1) EH oil pressure is lower than 9.30MPa (two points on one side or given again) ;
2) Lubricating oil pressure is lower than 0.048MPa (two points on one side or given again) ;
3) Condenser vacuum (high pressure side) is lower than -20.3KPa (two points on one side or given again) ;
4) Condenser vacuum (low pressure side) is lower than -20.3KPa (two points on one side or given again) ;
5) Axial displacement is larger than 1.0mm or smaller than -1.0mm (two points on one side or given
again) , and at every point of TSI, there is 1S delay;
6) 110% over speed (take 2 out of 3) ;
7) Mechanical backup 114% over speed (take 2 out of 3) ;
8) Bearing vibration is larger than 254μm, and bearing vibration alarm of upper nearby tile is larger than
127μm, and at every point of TSI, there is 3S delay.
9) DEH power loss (take 2 out of 3)
10) Bypass operation without synchronization (DEH signal) and high bypass tripping (bypass signal) has a
1min delay;
11) Boiler MFT protection;
12) Manual shut-down;
a. Press two buttons on operating desk at the same time, normally closed contacts of each button are in
parallel connection to form four groups of normally closed contacts and connect with four AST magnetic valve
power circuit, which is hardwiring tripping;
b. Press two buttons on operating desk at the same time, normally open contacts of each button are in
parallel connection to form four groups of normally open contacts, and send ETS with logic tripping of 2 in 3,
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which is logic tripping valve.


13) Generator tripping
14) High pressure cylinder expansion difference is larger than 10.2mm or smaller than -4.8mm, and after
3S delay in TSI, there is another 20S delay;
15) Low pressure cylinder expansion difference is larger than 23.3mm or smaller than -1.4mm, and after
3S delay in TSI, there is another 20S delay;
16) Local tripping
As long as there are no other tripping conditions and among three latching signals, two is taken out of the
three and 5S impulse is not taken, local manual tripping could be considered.
17) High trip pressure ratio is low (when the following conditions are all met, and in DEH, there is a delay
of 20 minutes)
a. High trip pressure ratio (for regulating stage pressure, take 2 out of three, and take the one larger in the
two high trip pressure) is lower than 1.7;
b. Synchronization (For three contacts of 5012 oil switch, take 2 out of 3, or For three contacts of 5013 oil
switch, take 2 out of 3)
c. Load (take among three) is lower than 60MW;
d. For high and low bypass valves, there is at least one not at off-position;
e. Steam-turbine with bypass starting or without bypass starting, and high trip pressure is not lower than
0.027MPa
18) High trip temperature is high (meet all of the following conditions) . (DEH signal)
a. High trip temperature (two points are both with high temperature) is higher than 424℃
b. Load (take one from the three) is lower than 60MW
19) Power load is unbalanced (meet all of the following conditions) . (DEH signal)
a. For 0.12 times medium trip pressure, take one from the three, and reduce 0.16 load, and the one from the
three is larger than 40%;
b. Synchronization
c. Three points of medium strip are all without failure.
7.3.1.4 Generator water supply cut-off protection: (ETS sent to generator)
1) Stator cooling water flow is lower than 125KPa (take 2 out of 3) , and there is a delay of 30S;
2) Two stator cooling water pumps are all stopped with a delay of 30S.
7.3.1.5 Steam-turbine distance latching
Steam-turbine distance resetting latching magnetic valve controlled relay is in ETS system; however,
steam-turbine distant resetting latching button is designed in DEH image and connected to ETS system by DEH
system hardwiring, so as to realize the function of steam-turbine distant resetting latching. At the time when
distant resetting latching magnetic valve is electrified, four AST magnetic valves are electrified. If two in the
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three latching signals fail to come in 1 minute, namely steam-turbine is not latched, the four AST magnetic
valves’ electrification will lose power.
7.3.2 Maintenance items and quality standards
7.3.2.1 ETS system power cut
1) Cut ETS system power.
2) In ETS cabinet, measure power input, and start operation after confirming that there is no voltage.
7.3.2.2 Local equipment maintenance
1) Pressure switch verification
a. Close pressure switch secondary valve, dismantle pressure switch connection, wrap thread residues with
insulation tape, make marks, and get back to pressure switch.
b. Pressure switch appearance check: mark shall be clear, correct and tidy. Appearance shall be intact.
c. Clean up dust, and there is not dust inside and outside switches.
d. Pressure switch verification: verify according to pressure switch verification regulations.
2) Maintenance of axial displacement and vibration are introduced in TSI.
3) Magnetic valve maintenance
a. For appearance check, mark shall be clear, correct and tidy. Appearance shall be intact.
b. Resistance value test of magnetic valve coil and R is regulated value.
c. Insulation test of magnetic valve coil and shell, and insulation resistance is larger than 50MΩ.
d. While magnetic valve stops power supply, feel magnetic valve and the difference of sending or stopping
power supply.
4) Maintenance of ETS over speed measuring probe
a. Check connection in local junction box, and whether there is short-circuit and local, connection is in
good state, cable from junction box to speed measuring probe is intact, and whether there is heated cable
insulation damage;
b. Adopt multi-meter to measure whether the resistance of over speed measuring probe is normal around
160Ω;
c. Check whether speed measuring probe has serious abrasion, and if so, it shall be replaced.
d. When speed measuring probe is fit back, it shall pair with the tooth on axle, and the space between teeth
shall be between 1.2mm and 1.5mm.
7.3.2.3 ETS cabinet maintenance
1) Relay verification
a. The resistance of relay contact against shell is larger than 20MΩ. Resistance value test of contacts is
smaller than 0.1Ω.
b. The starting value of relay, and verify release value.
c. Adopt multi-meter to measure coil resistance value. Dc resistance is 100Ω.
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2) Check and verification of over speed card: circuit board is intact, elements are firmly welded, and both
are clean and tidy. Check whether the connection and state of pre-amplifier are normal.
3) Check 24VDC cabinet power, AST power, and test magnetic valve power:
a. Check whether 24VDC cabinet power fuse is intact, and whether each connection is grounded or in poor
contact;
b. Check that the insulation of AST power and test magnetic valve power shall be qualified, and each air
switch shall comply with requirements.
7.3.2.4 Local cable insulation test and space insulation test, and insulation resistance shall be larger than
20MΩ.
7.3.2.5 Terminal strip and label plate check, connection shall be firm and number shall be clear.
7.3.2.6 Local equipments installation shall be correct and connection shall be correct.
7.3.2.7 Button and connection check of manual latching operating desk
7.3.2.8 System circuit check, and if there is no error, power could be sent.
7.3.2.9 I/O module check
1) Check the module state in ETS system, and whether the state of ETS, communication module, and I/O
module indicator light are normal.
2) Test whether the precision and accuracy of I/O module passage are normal.
3) Check whether communication point display of all ETS in DCS image are normal.
7.3.2.10 Check the logic configuration of ETS system carefully, and if there is no error, conduct the following
test.
7.3.2.11 Steam-turbine latching test
1) Latching conditions:
EH oil pressure and lubricating oil pressure shall be normal, start seal oil pump, and relieve condenser
vacuum low signal. Press “Steam-turbine latching” button on DEH image, then steam-turbine shall be latched,
and “Latching” is displayed on DEH image.
2) If turbine couldn’t be latched during the period, check whether each magnetic valve in AST is electrified.
If so, it means that ETS system is normal .Otherwise, conduct overall check of ETS system.
3) After steam-turbine latching, press latching button again, then steam-turbine leaks oil and trips, and on
DEH image, “Trip” is displayed.
7.3.2.12 Test magnetic valve
In logic, force control relay to close, and magnetic valve shall be electrified. Otherwise, check circuit, relay
and power circuit.
7.3.2.13 Transmission check of protection circuit
1) Relieve current tripping conditions, and when steam-turbine latching conditions are met, steam-turbine
shall be latched.
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2) Check the display state of all points in ETS image, and if all are normal, start transmission.
3) Conduct passage test. Conduct test for four test blocks of EH oil pressure low, lubricating oil pressure
low, high, and low pressure condenser vacuum low and eight magnetic valves. During test, mainly check
whether EH oil pressure low, lubricating oil pressure low, high, and low pressure condenser vacuum low and
ASP1, and ASP2 switch action are normal. Check whether the actions of group 1 of AST1 and AST 3, and
group 2 of AST2 and AST4 are normal, and whether after resuming electrification, ASP oil pressure is normal.
Normal ASP oil pressure is around 7MPa and ASP1 is larger than 9.3MPa. ASP1 action shows that group 1 of
AST1 and AST3 (one or two) has power loss or is not closed; ASP2 is smaller than 4.14MPa, and ASP2 action
shows that group 2 of AST2 and AST4 (one or two) has power loss or is not closed.
4) Protection logic transmission from local simulating signal; On TSI cabinet or terminal, simulate signal;
in DEH logic, simulate enforcement, on bypass terminal, add signal, check each tripping condition, check
whether steam-turbine could normally trip, delay time is correct, and the first image is correct.
7.3.2.14 Operation and maintenance:
1) Daily maintenance:
a. Local pressure switch and magnetic check; Pressure tap is without leakage, and switch connection is
intact. Secondary valve mark is clear without leakage.
b. Cabinet relay check: relay mark is intact, and action is normal. Lines are firmly impressed.
2) General failure maintenance:
False switch off; steam-turbine switch off mainly because of the following accident causes
a. Power cabinet loses all power or is instantly switched off, which causes relay failure and efficacy loss.
b. At least each passage has one switch-off relay or switch-off relay breaks down and loses efficacy.
c. One pressure switch of each passage breaks down and loses efficacy, or one medium relay breaks down
and loses efficacy.
d. Local switch contact 24VDC is grounded, which causes module power fuse breaks. In this module, if
there is a single protection condition, tripping condition could be met.
e. Noise is added with sensor input.
f. Element breaks down.
g. SI module circuit breaks down.
h. Relay breaks down and loses efficacy.
3) Test valve won’t move:
a. Valve element is jammed.
b. Coil is not electrified, and there is something wrong with the control circuit.
4) Pressure gauge indication of test block is not right, and pressure meter breaks down.
5) Check PLC system state, and check and inspect the state of each point in image. In case of any problem,
treat it in time.
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7.3.2.15 Major repair items:


1) Clean up dust, and relay check.
2) ETS system switch, electric over speed probe check and verification
3) Terminal ash removal, rust protection, and insulation check.
4) Magnetic valve coil maintenance
5) Connector ash removal and check
6) Operating switch undergoes button ash removal and check.
7) Power system joint debugging.
8) PLC system test
9) ETS functions test
7.3.2.16 Minor repair items
1) Clean up dust, and relay check.
2) Terminal ash removal, rust protection, and insulation check.
3) Magnetic valve coil maintenance
4) Connector ash removal and check
5) Operating switch undergoes button ash removal and check.
6) Power system check
7) Test joint debugging.
7.4 Small engine ETS system maintenance rules
7.4.1 Overview
7.4.1.1 Technical regulations
1) Steam-turbine protection system of steam feed pump could make magnetic valve electrified when
steam-turbine is not under normal operation condition, cut off pressure oil which enters emergency security
device, and trigger emergency security device to action, so as to quickly close quick-closing valve, immediately
stop steam-turbine, and protect unit safety.
2) Working principles:

Two tripping Figu


Tripping signal MEH Output relay magnetic valve
Cabinet re 1:
terminal 2.PL of small engine
ETS
strip
C sche
mati
c
diagr
SOE am

Initial
image

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7.4.1.2 Protection tripping conditions for small engine


1) Manual shut-down, and press TRIP button during image;
2) Local latching;
3) Supply pressure of lubricating oil in small engine shall be smaller than 0.08MPa (take 2 out of 3) ;
4) Small engine quick-closing oil pressure shall be lower than 0.15MPa (take 2 out of 3) ;
5) Small engine exhaust steam pressure shall be larger than 70kPa (take 2 out of 3) ;
6) Small engine axial displacement shall be larger than 1.2mm or smaller than -1.2mm (take 2 out of 3) ;
7) Small engine over speed shall be larger than 6017 rpm (take 2 out of 3) or mechanical over speed back
up over speed shall be larger than 6300r/min;
8) Small engine front bearing vibration shall be larger than 125μm (take 2 out of 2);
9) Small engine rear bearing vibration shall be larger than 125μm (take 2 out of 2);
10) Feed pump non-driving end vibration shall be larger than 180μm (take 2 out of 2);
11) Feed pump driving end vibration shall be larger than 180μm (take 2 out of 2);
12) Small engine thrust bearing temperature shall be higher than 105℃ (take 2 out of 6);
13) DSC tripping small engine (under any of the following conditions):
a. Booster pump of steam pump trips
b. Thrust bearing temperature of steam pump is higher than 110℃ (take 2 out of 2);
7.4.2 Maintenance items and quality standards
7.4.2.1 Shut-down magnetic valve and latching magnetic valve power shall be hung with nameplate of “No
Switching on”.
7.4.2.2 Relay verification
1) Appearance check: label is clear and shell is intact.
2) Measure relay operate value, return value and they shall be correct and reliable.
3) Measure contact resistance, and it shall be smaller than 0.1Ω.
7.4.2.3 Magnetic valve maintenance
1) Appearance check: label is clear and shell is intact.
2) Coil resistance measurement: conform to regulated value.
3) Coil outer shell insulation test to be larger than 20MΩ
7.4.2.4 Pressure switch verification: see pressure switch maintenance rules.
7.4.2.5 PLC check: connection shall be complete, shell shall be intact, and functions shall be normal.
7.4.2.6 Cable insulation test: measure the insulation resistance between cable and ground, line and ground,
and between lines, and they shall be larger than 20MΩ.
7.4.2.7 Terminal strip dust removal and check: label shall be clear and lines are firmly imposed.
7.4.2.8 Local primary element resetting: element installation shall be firm, contact shall be without leakage,
and connection shall be correct.
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7.4.2.9 Power system check:


Power system gets power supply from ac 220V. Ac 220V power is used by magnetic valve with
electrification. Check power connection and opening and closing switch action.
7.4.2.10 Protection circuit logic check
7.4.2.11 Protection circuit static test:
1) Send power to magnetic valve and small engine shall meet latching conditions and small engine shall be
latched.
2) Conduct local simulation of actual analog quantity and switching valve. If possible, conduct actual
simulation of rotating speed. Others could under logic simulation. Confirm each tripping condition to ensure
correct action.
7.4.2.12 Operation maintenance
1) Local primary element resetting: appearance shall be complete without leakage, connection shall be firm,
and label shall be correct and clear.
2) Cabinet relay check; relay label shall be correct, connection shall be firm, and relay shall normally
actions.
3) General failure maintenance:
a. Pressure switches failure or set value drifting.
b. Medium relay breaks down and loses efficacy.
c. Tripping magnetic machine won’t work, and coil is without electrification or valve element is jammed.
7.4.2.13 Major repair items
1) Relay and circuit check test.
2) System pressure switches verification.
3) Terminal dust removal, rust protection and insulation check.
4) Magnetic valve maintenance
5) PLC tripping logic check
6) Power system check
7) System function test
8) Protection circuit transmission
7.4.2.14 Minor repair items
1) Cabinet dust removal and relay check.
2) System pressure switches verification.
3) Terminal dust removal, rust protection, and insulation check.
4) Magnetic valve maintenance
5) Power system check
6) Protection circuit transmission
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7.5 Schneider series PLC maintenance rules


7.5.1 System overview
Programmable controller could also be named as programmable process logic controller, briefed as PLC. It
is an electronic system operated by digital operation, especially designed for industrial environment. It could
adopt programmable memory to conduct internal storage and operation of commands, such as logic operation,
sequence control, time setting, calculation and digital operation, etc., and through digital and analogous input
and output to control each production process.
7.5.1.1 CPU module: used for controlling the output process input value, and the main module are 140CPU
65160S, and 65150, etc.
7.5.1.2 I/O module: convert input circuit signal to backup panel level signal, or convert back panel signal to
output circuit signal, and models are 140 SDI 95300S, SDO 95300S, DDI 35300, and DRA84000, etc.
7.5.1.3 Communication module: provide a terminal for communication with computer, other PLC processors
or I/O adapters at other position. In the I/O frame far away from processer, communication module could
provide one module to connect the I/O module on back panel to processer in another position.
7.5.1.4 Power module: provide direct current of 1.2V, 3.3V, 5V, and 24V for rack back panel and main models
are 140 CPS 12420 and 11420, etc.
7.5.2 Maintenance installation items and quality requirements
7.5.2.1 Installation of rack
Rack is used for installing processer and I/O module. Schneider’s PLC rack mainly has 6 types, ranging
from 2 grooves to 16 grooves.
7.5.2.2 Maintenance of rack
Keep rack clean so that backboard pin on rack could be normally used. Adopt groove cover plate to cover
grooves that are not used to avoid fragments or dust from falling into rack.
7.5.2.3 Installation of power module
Generally, power module is installed on the left of rack. Along rack guide rail, power module could be
inserted into rack.
7.5.2.4 Maintenance of power module
Keep power module clean. During normal operation, uncover seals at heat emission hole to make sure that
power module could normally emit heat.
7.5.2.5 Installation of processer
Processer always takes the first groove on the first rack. Align circuit board with frame. Along guide rail,
plug module into frame and confirm that module has reliably connected with frame base plate. When processer
and power or other installed module are aligned, and the spring key on the top and bottom match, processer is
then installed. If needed, memory extension panel could be installed.
7.5.2.6 Processer maintenance
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Don’t touch connector or connector on elements board. Don’t touch circuit elements in processer. When
not used, all elements shall be stored in special anti-static packing bags. When plugging and pulling processer,
electrostatic discharge device shall be adopted to connect with grounding conductor to release potential static
electricity.
7.5.2.7 Installation of I/O module
Align module circuit board with guide grove on rack. Slightly slide module forward till the alignment pin
at the top and bottom are firmly stuck. Install wire stab to fasten connection or use wiring arm to keep
connection clean. Adopt groove cover plate to cover grooves that are not used to avoid fragments or dust from
falling into rack. Before dismantling module, first cut off power to avoid module from damaging or other
failures. While dismantling module, press the alignment pin at the top or bottom, and then pull the module out.
7.5.2.8 Maintenance of I/O module
Don’t touch circuit elements inside module. Keep I/O module clean.
7.5.2.9 Meaning of I/O module indicator lights:
Table 1
DI (95300S)
LED indication Display state Meaning Solutions
OK Green light on Input is under normal operation state
Green light Module passes internal diagnosis, but there
OK Configure module
flashing is not input from multi-point transmission
Module has undergone unrecoverable
OK Red light on Change module
mistake
Check whether
communication between
OK Red light flashing Initially established communication time out
controller and base plate is
normal
Passage state light (with
Yellow light on Input activation
number)

When module is charged, there will be the following phenomena:


1) “OK” indicator light keeps turning red for 1s, and if self-inspection is passed, then “OK” light shall be
turned into “Flashing green”.
“Passage indicator light” will be on for 2s to the maximum and then goes out.
Table 2
DO(95300S)
LED indication Display state Meaning Solutions
OK Green light on System processer controls output
Green light Module passes internal diagnosis, but output
OK Configure module
flashing is not under the control of CPU
OK Red light on Module has undergone unrecoverable Change module

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mistake
Check whether
communication between
OK Red light flashing Initially established communication time out
controller and base plate is
normal
Passage state light (with
Yellow light on Input activation
number)

When module is charged, there will be the following phenomena:


2) “OK” indicator light keeps turning red for 1s, and if self-inspection is passed, then “OK” light shall be
turned into “Flashing green”.
“Passage indicator light” will be on for 2s to the maximum and then goes out.
7.5.3 Test items and technical standards
7.5.3.1 DI module
In control system, normally sued DI modules are two types of SDI95300S and DDI35300. Except input
points, other performance parameters basically are the same. Here take DDI35300 as an example to illustrate
performance parameter.
Table 3 DDI 35300 basic performance parameter table
Input point 32 points
Backboard current Under 24VDC, it is 2mA (total power of backboard is 0.81W)
Power consumption Under 60 degree centigrade, it is 4.5W
On-state voltage range 10-31.2VDC
Normal input voltage 24VDC
Maximum off-state voltage 5VDC
Maximum off-state current 1.5mA
Maximum input impedance is 31.2VDC 5.76kilo-ohm
Maximum injected current 250mA
Reversed polarity protection Yes
RTB Lock User-defined mechanical lock
Screwdriver width for RTB 3.2mm

Characteristics Default value Remarks

OFF-ON: enable
(COS) Change of state
ON-OFF: enable
Detailed description could refer to
OFF-ON:1ms
Software configurable filter time performance manual
ON-OFF:1ms
Communication format Input data

7.5.3.2 DO module
In control system, normally sued DI modules are two types of SDI95300S and DRA84000. Except input
points, other performance parameters basically are the same. Here take DRA84000 as an example to illustrate
performance parameter.
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Table 4 Basic technical index of DRA84000


Input points 16 points
Back plate current Under 24VDC, it is 2mA (back plate total power is 1.32W)
Power consumption Under 60 degree centigrade, it is 4.1W
Output voltage range 10-31.2VDC
Maximum load current 2A
Working temperature 0-60 Degree centigrade
Reversed polarity protection Non
Screwdriver width for RTB 8mm
RTB lock User-defined mechanical lock

7.5.4 Operation and maintenance


To make sure the normal operation of system, PLC system must be regularly checked and maintained, and
general failure diagnosis and elimination methods shall be familiarized.
7.5.4.1 Regular check and maintenance of programmable controller
Working environment has great effect on PLC. Normally, PLC shall under regular check every half a year.
If PLC’s working conditions are not up to regulated standards, emergency treatments shall be conducted to
make PLC operate under regulated standard environment.
7.5.4.2 Daily maintenance
Except lithium battery and relay output contact, PLC basically has no other vulnerable elements. Because
random access memory (RAM) for storing user procedures, counter, and auxiliary relay with hold function, etc.
all adopt lithium battery, and lithium battery has a service life of around 5 years and when lithium battery
voltage gradually decrease to a certain degree, indicator light of battery voltage drop on PLC basic unit shall
be on. Users shall be noted that procedures supported be lithium battery could still go on for about a week, and
battery must be changed, which is the main content of daily maintenance.
7.5.4.3 Abnormalities and treatments
Table 5 Periodic check table
Check items Check contents Standards
Alternating 1 Measure whether the voltage added on PLC is at 1 Power voltage must within the range of
current rated value. working voltage.
1 voltage 2 Whether there is frequent and rapid change of power 2 Power voltage fluctuation must be within the
2 stability voltage. range.
Environment
conditions Is temperature and humidity is relevant range? 0~55℃
Temperature When PLC is installed on dash board, temperature on Relevant humidity is below 85%
Humidity dash board could be deemed as the environment Vibration is smaller than 0.5mm(10~55Hz)
Vibration temperature of PLC. There isn’t much dust, salt content and scrap iron.
Dust
Installation Basic unit and extension unit shall be firmly installed. Installed screw must be fastened.
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conditions Whether the tie cable of basic unit and extension unit Tie cable must not be loose.
is well plugged. Tie screw must not be loose.
Whether winding screw becomes loose. Internal connection must not have any abnormity
Whether internal connection is damaged. at appearance.
1 Lithium battery pressure reduces or not. 1 Service life of around 5 years
Service life
2 Relay output points 2 Service lift for 3 million times (above 35V)

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Table 6 Failure treatment table of CPU device and I/O extension device
No. Abnormalities Possible causes Treatments
1Voltage switching terminal is not
(POWER) LED light is not Correctly set up switching device.
1 well set up.
on
2 Fuse is blown. Change fuse tube.
1Voltage switching terminal is not
Fuse tubes are blown for Correctly set up
2 well set up.
several times
2line short-circuit or burnt. Change power unit.
1 Program is wrong change program
2 Power circuit is not in good
Change CPU
condition
3 (RUN) LED light is not on
3I/O unit number is repeated Modify I/O unit number
4 Distant I/O power is off without
Connect power
terminal
(Output during
transmission) terminal is not
4 Power circuit is not in good condition Change CPU unit
switched off (POWER) and
light is on
Relay after a certain number
5 I/O main bus is not in good condition Change base plate unit
won’t work
(output) connection of
6 I/O main bus is not in good condition Change base plate unit
specific replay number
All relays in specific unit are
7 I/O main bus is not in good condition Change base plate unit
not connected

Table 7 Failure treatment tale of input unit


No. Abnormalities Possible causes Treatments
1.Outer input power is added. Power supply
2. Outer input voltage is low. Outer added rated power voltage
Input are all not
1 3. Terminal screw is loose Fasten
connected
4. Terminal plate connector is not Plug in terminal board and lock. Change
well connected. terminal board connector.
Input are all cut off
2 (action indicator lights Input circuit is not in good condition Change unit
are all off)
3 All inputs are not cut off. Input circuit is not in good condition Change unit
1. Input devices are not in good
Change input devices
condition
Input of specific relay 2. Input wiring breaks Check input wiring
4
number is not connected 3. Terminal screw is loose Fasten
4.Electric board connector is not well Plug in terminal board and lock. Change
connected. terminal board connector.

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No. Abnormalities Possible causes Treatments
5. Contact time of outer input is short Adjust input devices
6. Input circuit is not in good
Change unit
condition.
7. OUT command in program adopts
Modify program
input relay number
1 Input circuit is not in good
Change unit
Input of specific relay condition.
5
number is not cut off 2.OUT command in program adopts
Modify program
input relay number
1. Outer input voltage is low Make outer input voltage within rated range
Noise resistance measure: install insulation
2. Malfunction caused by noise transformer and spike killer; adopt shielded
Input irregular ON/OFF
6 wiring, etc.
action
3. Terminal screw is loose Fasten
4. Terminal plate connector is not Plug in terminal board and lock. Change
well connected. terminal board connector.

Table 8 Failure treatment table of output unit


No. Abnormalities Possible causes Treatment
1. Without load power Add power
2. Load power voltage is low Make power voltage as rated voltage
3. Terminal screw is loose Fasten
4.Terminal plate connector is not well Plug in terminal board and lock. Change
1 All outputs are not connected connected. terminal board connector.
5. Fuse is blown Change fuse tube
6. I/O main bus is not well connected. Change unit
7. Output circuit is not in good
Change unit
condition
2 Outputs are all not cut off Input circuit is not in good condition Change unit
1. Output connection time is short Change output devices
2. Output wiring breaks Check output wiring
3. Terminal screw is loose Fasten
Output of specific relay number 4. Terminal board connector is not Plug in terminal board and lock. Change
3 is not connected (action indicator well connected terminal board connector.
light is off) 5.Output circuit is not in good
Change unit
condition.
6. Relay output is not in good
Change relay
condition.
1 Relay output is not in good
Change relay
Output of specific relay number condition.
4
is not cut off 2. Because of leakage or residue
Change load or add load resistance
voltage, it couldn’t be cut off

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No. Abnormalities Possible causes Treatment
1. Power voltage is low Make power voltage within rated range
Noise resistance measure: install
2 Malfunction caused by noise insulation transformer and spike killer;
5 Output irregular ON/OFF action adopt shielded wiring, etc.
3. Terminal screw is loose Fasten
4. Terminal plate connector is not well Plug in terminal board and lock. Change
connected. terminal board connector.
Output indicator light is not good
6 LED light is broken Change unit
condition
1.COM terminal screw is loose Fasten
2. Terminal connector is loose Plug in terminal board and fasten.
7 Relay action abnormality
3. Fuse is blown. Change fuse tube
4.CPU is not in good condition Change CPU module

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