hydraulic mechanical systems in power stations

Power Distribution Control Systems

Power Station Control Systems

Control Room Technology

Automation Equipment

Hydraulic Mechanical Systemsin Power Stations

3

Contents Page

Hydraulic and Mechanical Equipment Services 4

Turbine Protection 8

Turbine Operation Monitoring 10

Installation and Commissioning 11

4

Hydraulic Mechanical Systems

Mauell GmbH offers complete hydraulic and mechanical equipment services for the modernization of turbine hydraulic systems and HP, IP, LP bypass stations.

The scope of our services comprises:

• Planning and layout of hydraulic components and systems

• Design and delivery of hydraulic mechanical components

• Optimization tests of all hydraulic components in our own test bench before shipment

• Modernization of hydraulic systems (aggregates, pipelines, control modules) and adaptation on existing machines

• Commissioning of hydraulic systems and plants

• Delivery and installation of all measurement systems required for turbine expansion, vibration, speed, etc.

• Maintenance services after project completion

• Training of customer personnel for maintenance / monitoring

Our project engineers prepare hydraulic diagrams, define the component specifications and develop concepts for the constructing engineers. The project planning and design documentation is created with 3D (Solid Works Software (SW) and 2D (Auto CAD Software) systems.

8 bar

p0

trip valve

trip valve

measurement 4-20 mAredundant position

trip valve

E/H converter 4-20 mA

redundant position measurement 4-20 mA


3/2 solenoid valve

pi

EMERGENCY STOP

G

G

CONTROL VALVE

G

VALVE ESV

G

CV

PROTECTION BLOCK 1oo2

CONTROL VALVECV

I

IP

PSystem pressure p0 8 bar

Impulse pressure pi

Drain

3/2 solenoid valve

Combination of two control valves and one emergency stop valve

5

p0

8 bar

p0


trip valve

trip valve

trip valve

redundant position measurement 4-20 mA

pressuretransmitter

Emergency stop P. B.

ip

Emergency stop P. B.

STOP VALVE

SIL 3

Hydraulic safety block 2oo3

DESK

Servo motor

PI

GG

CONTROL VALVE

BP-ESVSTOP VALVEEMERGENCY EMERGENCY

ESVCVCVESV

CV full open < 12 sec.

HP-ESV

TCSOverspeedprotectionSIL 3 ON SITE

System pressure p0

8 bar

Impulse pressure pi

Drain

Combination of one control valve and two emergency stop valves

3D-model of hydraulic aggregate with three controllable radial piston pumps

6

Status checks of the hydraulic lines and components to modernization concepts, isometric diagrams, welding documentation and non-destructive testing will be carried out by qualified engineers according to time schedule.

Isometric diagram of the lines and components of a large-scale turbine

Isometric diagram of a hydraulic 2oo3 protection block, vacuum breaker control unit, and associated hydraulic accumulators

Isometric diagram of HP control valve and emergency stop valves

7

We are specialists in the design and manufacture of servomotors and special cylinders, if required with integrated control blocks, for steam turbine systems up to a capacity of 1100 MW.

Our scope of delivery and services fulfil the high quality standards for applications in nuclear power stations. Delivery and installation of our high-performance servomotors includes electro-hydraulic converters, position measuring devices, couplings or ball joints, and the provision of all specifications, material certificates, function test reports and performance records.

HP servomotor with integrated control block and coupling to steam valve spindle

BP servomotor with integrated control block and ball joint to the butterfly control valve

8

Turbine Protection

Core of every Mauell turbine protection concept is our own electronic overspeed protection system certified according to SIL 3 standard by the German Technical Control Board (TÜV). Three over-speed modules, each equipped with three integrated speed monitoring modules, operate on a subordinate protection level.

Two alternative concepts are implemented on this protection level:

• Central hydraulic turbine protection block 2oo3 (SIL 3 standard), which triggers the pressure release in the protec-tion pulse fluid circuit via three solenoid valves / cartridges and activates all emergency trip units.

Hydraulic protection block 2oo3 in operating mode

Hydraulic protection block 2oo3 in test mode

9

For new plants or modernization projects that include the hydraulic system and the servomotors, turbine protec-tion with decentralized hydraulic tripping will be the better solution for costs and efficiency.

• Electronic protection block 2oo3 with decentralized electronic activation of the subordinate solenoid valves and thus of the downstream cartridge valves for each regulating unit (steam shut-off valve and steam control valve)

Instead of the central 2oo3 hydraulic protection block, speed monitoring modules control the electronic 2oo3 protection modules (EAM 15A) and execute the protection commands via electronic ANS-MV control modules. The entire electronic protection system is certified according to SIL 3 standard.

Both protection concepts are fully integrated in our ME 4012 power station control system and can be tested automatically during plant operation.

Electronic 2oo3 protection block with decentralized tripping

Electronic / hydraulic tripping, 1oo2 for each regulating unit

# # #

Failsafeclosed-circuit

protectionDW module 1

Quartzcomp.

Quartzcomp.

Quartzcomp.DWDW DW DW DW DW DW DW DW

RS

AS

RS

AS

RS

AS RS

AS

RS

AS

RS

AS

RS

AS

RS

AS

RS

AS

& & &2oo3

&t 0 2oo3

&t 0

& & &2oo3

&t 0

& & &

Failsafeclosed-circuitprotection

DW module 2



OC protection (closed-circuit transmission)

Turbineshaft

Turbine controller(slave)

Turbine controller(master)

+L1 +L2

+L3

Activate turbine>3 revolutions min -1

24V +L124V +L224V +L3

from FG Turbine control

Emergency stop switch(turbine trip)

ElectronicdisconnectionSolenoid valves(2oo3)

Test programElectricaltripping devices

#

#

#

#

Mon

itorin

g

#

#

Mon

itorin

g

Mon

itorin

g

EAM 15A EAM 15A EAM 15A

Test programShut-off valves

Solenoid valveactivation(current controller)

G SV servomotor

2oo3-type electronic turbine protection with distributed hydraulic trip devices in 1oo2 logic

G SV servomotor

# Criterion-specific 2oo3 signal operations through permutation

MV

MV

MV

MV

Hyd

raul

ics

E

lect

roni

cs

=>1

=>1

=>1

C=>1

=>1

=>1

C=>1

=>1

=>1

C

Generatorprotection

SUB-NET

OCprotect. 1

OCprotect. 2

OCprotect. 3

Protection criteria and operation monitoring

# #

OC protection system

2 v 32oo32oo3

ANS-MV ANS-MV ANS-MV ANS-MV

Shut-off valve 1Channel 1

Shut-off valve 1Channel 2

Shut-off valve nChannel 1

Shut-off v. nChannel 2

Test Test Test Test

Power busbar 24V -

Test programOverspeed governor

Turbine protectionManual trip

2oo3LSN24

and control valves

# # #



Quartzcomp.

Quartzcomp.

Quartzcomp.DWDW DW DW DW DW DW DW DW

RS

AS

RS

AS

RS

AS RS

AS

RS

AS

RS

AS

RS

AS

RS

AS

RS

AS

& & &2oo3

&t 0 2oo3

&t 0

& & &2oo3

&t 0

& & &

Failsafeclosed-circuitprotection

DW module 2



OC protection (closed-circuit transmission)

Turbineshaft

Turbine controller(slave)

Turbine controller(master)

+L1 +L2

+L3

Activate turbine>3 revolutions min -1

24V +L124V +L224V +L3

from FG Turbine control

Emergency stop switch(turbine trip)

ElectronicdisconnectionSolenoid valves(2oo3)

Test programElectricaltripping devices

#

#

#

#

Mon

itorin

g

#

#

Mon

itorin

g

Mon

itorin

g

EAM 15A EAM 15A EAM 15A

Test programshut off valveand control valves

Solenoid valveactivation(current controller)

G SV servomotor

2oo3-type electronic turbine protection with distributed hydraulic trip devices in 1oo2 logic

G SV servomotor

# Criterion-specific 2oo3 signal operations through permutation

MV

MV

MV

MV

Hyd

raul

ics

E

lect

roni

cs

=>1

=>1

=>1

C=>1

=>1

=>1

C=>1

=>1

=>1

C

Generatorprotection

SUB-NET

OCprotect. 1

OCprotect. 2

OCprotect. 3

Protection criteria and operation monitoring

# #

OC protection system

2 v 32oo32oo3

ANS-MV ANS-MV ANS-MV ANS-MV

Shut-off valve 1Channel 1 Channel 2

Shut-off valve nChannel 1

Shut-off v. nChannel 2

Test Test Test Test

Power busbar 24V -

Test programOverspeed governor

Turbine protectionManual trip

2oo3LSN24

Shut-off valve1CP 1SOVCompact drives 1 SOV

CP 1 CV

CP 12 SOVCP 12 CV

CP 1CV

10

Turbine Condition Monitoring During Operation

Constant monitoring of the operation characteristics of the turbine is an essential contribution to the turbine‘s durability. Expansion, vibration and bearing temperature measurements are very important turbine protection measures. Trouble-free, non-stop turbine operation and preventive maintenance can only be achieved with an appropriate turbine monitoring system.

spee

d

HP G

Intermediate bearing 1 Intermediate bearing 2 Generatorbearing

TScenterbearing

Oil pump

ES

LP F

Fieldbearing

WS

RD

WP

WS

Key

Pha

ser

P

P

FD

IP

P

HZÜ

P

P

P

P

WS

RD

P

P

P

RD

WS

WS

WS

RD :WP :

Relativ expansionShaft position thrust bearing P

: Metall temperature / Steam temperature: Pressure measurement

ABS:Absolut expansionSpeed: Turbine speed 3-channelWS: Shaft vibration

Bearing HP front

VS: Valve positionLS: Bearing vibrations

M

Turn drive

Measuring point arrangement for turbine operation monitoring

Speed measurement with standstill moni-toring

Bearing vibration measurement Shaft position monitoring

Shaft vibration measurement Absolute expansion measurement Relative expansion measurement

Measuring Transducer Examples

11

Installation and Commissioning

We provide you with an experienced team of construction supervisors, hydraulic technicians, fitters and welders, for all tasks, from system analysis to delivery, installation, piping and system flushing, over pressure test and commissioning. We also offer a wide range of maintenance services.

Vacuum breaker and control unit for extraction check valve Servomotors for HP control valves

Emergency stop valve with new trip valve to enhance plant reliability

Hydraulic aggregate with radial piston pumps in redundant arrangement

Servomotor for BP control valve Hydraulic 2oo3 protection block

www.mauell.com

Head officeGermanyHelmut Mauell GmbHAm Rosenhügel 1-742553 VelbertGermany

BrazilHelmut Mauell do Brasil Ltda.Estr. Est. Salvador de Leone 299806850-000 ITAPECERICA DA SERRA SAO PAULOBrazil

NetherlandsHelmut Mauell B.V.Lorentzstraat 313846 AV HARDERWIJKNetherlands

SwitzerlandMauell AGFurtbachstraße 178107 BUCHSSwitzerland

USAMauell Corporation31 Old Cabin Hollow RoadDILLSBURG PA 17019USA

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U.A.E.

01_4012_39E12 Subject to change without notice.

hydraulic mechanical systems in power stations

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