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INSTRUCTION
Dear Customer, Thank you for your trust and your selection of Wuhan Strong Automatic Control Technology Co. Ltd. Please read this manual carefully, especially items on safety and attention before your installation, circuit connection, operation and maintenance to ensure your correct operation and usage .Items needing attention in this manual have been divided into two grades warning and be careful.
Safety Guidance
According to related regulations, be careful and warning items shall be read carefully before the installation and operation. Thus please read this manual and instruction as well as documents on controllers. Whats more, the installation and operation only can be started until you are familiar with related knowledge. Human death or injury and property loss may be caused if any violation of this manual.
Warning
The equipment is with dangerous voltage and also controls the dynamic components which have dangerous voltage. Human death or injury and property loss may be caused if any violation of this manual. The equipment is with dangerous voltage and also controls the hydraulic components which have dangerous voltage. Human death or injury and property loss may be caused if any violation of this manual. Only technicians who have been familiar with guidelines on safety, installation, operation and maintenance can operate this equipment.
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The component which is connected with dynamic equipment directly operates under the dynamic voltage. Only constant input is allowed to connect and this equipment shall be earthing reliably. Be careful of the externally exposed component and no touch if you open the cabinet. Under normal condition, power terminal is also with dangerous voltage even if it does not work. , , Please do not draw any component during its work in order to not influence its normal work. Only qualified people can connect, start up this system and eliminate malfunction and those people must completely understand all warning and operation regulations in this manual. If any parameter setting operation, please do not modify the original setup randomly and shall contact with the supplier first. External power shall cut and warning plate also shall be hung before check and repair. The control power shall be cut and warning plate also shall be hung before operating electric or mechanical part of any equipment or machine.
Be careful
This mark will appear when installation error happens and it may bring mid or slight injury, or equipment damage. Please prevent the close of non-professional people to the equipment. The equipment shall be operated in the light of the suppliers
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regulation. Any mismatch or non-performance of random change or usage of parts which are recommended not by the supplier may cause fire, electric attack, burn or property damage. , . Please screw down the screw of the terminal and any loose may cause break or fault. ,, Please keep it clean. Keys of governor cabinet and oil pump control cabinet shall be kept by related person. Please pay much attention to all mentioned above, which must be obeyed. Please take care of this manual for your future convenience. ISO90012000 ISO90012000 ISO90012000 The quality management system of this equipment complies with the requirements of ISO90012000.
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CHAPTER I GENERAL DESCRIPTION ............................................................... 12 ........................................................................................ 16 CHAPTER II SYSTEM STRUCTURE OF GOVERNOR ....................................... 16 2.1 BLOCK DIAGRAM OF THE SYSTEM STRUCTURE ........................... 16 2.2 BLOCK DIAGRAM SPECIFICATIONS .................................................... 17 2.3 SYSTEM WORKING PRINCIPLES .................................................. 18 ........................................................................................ 23 CHAPTER III GOVERNOR SYSTEM CONFIGURATION .................................... 23 3.1 CONFIGURATION OF THE ELECTRICAL SYSTEM............................ 23 3.1.1 Hardware Configuration ......................................................... 23 3.1.2 Software Basic Configuration.......................................... 25 3.1.3 Functional strengthen Software Configuration ......... 25 3.1.4 Equipments and Software for Debugging (not belong to Governor equipments) ........................................... 26 3.1.5 Equipments for Test (not included in Governor equipments) .................................................................................... 26 3.2 MECHANICAL SYSTEM CONFIGURATION ..................................... 26 .............................................................................. 27 CHAPTER IV MAIN FUNCTIONS AND FEATURES OF GOVERNOR ................ 27 4.1 MAIN FUNCTIONS ............................................................................ 27 4.1.1 Regulation and Control Functions ............................... 27 4.1.2 Diagnostics and Tolerance Functions.......................... 30 4.1.3 Developing and Debugging Functions ............................ 32 4.2 MAIN FEATURES.............................................................................. 33 ............................................................... 35 CHAPTER V MAIN TECHNICAL DATA AND PERFORMANCE INDEX OF GOVERNOR ......................................................................................................... 35
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5.1 MAIN TECHNICAL DATA ............................................................. 35 5.2 MAIN PERFORMANCE INDEX ...................................................... 39 ........................................................................................ 41 CHAPTER VI HARDWARE CONFIGURATION ................................................... 41 6.1 PLC PLC HARDWARE CONFIGURATION ............................................. 41 6.1.1 Q PLC Japanese Mitsubishi Q series PLC..................... 41 6.1.2.S7-300 PLC S7-300 Series PLC .................................................... 42 6.1.3 Modicon TSX Premium PLC / Modicon TSX Premium Series PLC43 6.2
OPERATING TERMINAL
..................................................................... 44
6.3 ELECTRO-HYDRAULIC TRANDUCER PART ................................. 45 6.3.1 Step-by-step motor and Step-by-step motor driver module ............................................................................................................ 45 6.3.2 servo motor and driver module............................. 51 6.3.3 servo proportional valve and the amplifier ....... 56 6.4 FREQUENCY MEASUREMENT MODULE .............................................. 60 6.5 POWER SUPPLY SYSTEM .................................................................. 64 ................................................................................. 67 CHAPTER VII SOFTWARE PROGRAM SPECIFICATIONS................................ 67 7.1 FLOW BLOCK DIAGRAM OF MAIN PROGRAM............................. 67 7.2 REGULATING MODE ......................................................................... 69 7.3 STARUP AND SHUTDOWN RULES ............................................ 71 7.4 DIGITAL COORDINATION.................................................................... 72 7.4.1 coordination features of wicket and runner blade for Kaplan turbine.................................................................................. 72 7.4.2 Coordination interpretation arithmetic ............................ 73 7.5 MECHANICAL ,AUTO,ELECTRICAL /MANUAL
OPERATION AND BUMPLESS TRANSFER ....................................................
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..................................................................................... 75 CHAPTER VIII PANEL DESCRIPTION ................................................................ 75 8.1 PANEL DESCRIPTION OF THE SEPERAT CUBICLE OF
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ELECTRO-MECHANICS
........................................................................................... 75
........................................................................................... 75
............................................................................................ 77 CHAPTER IX MECHANICAL HYDRAULIC SYSTEM.......................................... 77 9.1 GENERAL DESCRIPTION .......................................................................... 77 9.2 INTRODUCTION OF
MAIN COMPONENTS ....................................
81
9.2.1 ZL 00 2 24552.3 Oil-free Electro Hydraulic Transducer (patent NO. ZL 00 2 24552.3) .................................................. 81 9.2.2 Servo Proportional valve .................................................... 83 9.2.3. Main Distributing Valve ........................................................... 83 9.2.4 Emergency Stop solenoid valve .................................. 86 9.2.5 Displacement Sensor ........................................................ 87 9.2.6 Oil Filter ..................................................................................... 88 9.2.7 () Closing Device with serval rates(optional)............. 88 9.2.8 () Emergency distributing valve(optional)................... 90
9.2.9 mechanic-hydraulic cabinet ................................................ 92 9.2.10 Assemble and adjustment ................................................ 92 HYZ YZ ................................................................ 95 CHARPTER10 USAGE OF HYZ AND YZ OIL PRESSURE DEVICE................... 95 10.1 GENERAL DESCRIPTION ....................................................................... 95 10.2 MAIN PARAMETERS ....................................................................... 99 10.2.1 HYZ Basic parameters for HYZ oil pressure device ........................................................................................................................ 99 10.2.2 YZ Basic parameters for YZ oil pressure device . 99 10.3 WORK PRINCIPLE .......................................................................... 99 10.4 DESCRIPTION OF OIL DEVICES MAIN COMPONENTS .106 10.4.1 Pressire tank cnfiguration ................................................106 10.4.2 Oil return tank configuration............................................107 10.4.3 /Oil pump group .....................................................................110
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10.4.3.1 Screw oil pump ............................................................. 111 10.4.3.2 Internal & straight tooth gear pump ...... 111 10.4.4 combined valve.......................................................................112 10.4.4.1 General description ..............................................................112 10.4.4.2 main parameters ...........................................................113 10.4.4.3 structure features ..........................................................113 10.4.4.4 Working principle ...........................................................114 10.4.4.5 The Adjustment and Checkup of the Combination Valve ...........................................................................................................117 10.4.5 Brief introduction of main automatic, test and ontrol components ..........................................................119 10.4.5.1 Oil level meter of pressure tank ( It is not included in the bladder accumulators)..........................................119 10.4.5.2 () Automatica air replenish device(optional).....120 10.4.5.3 oil level singal indicator of oil return tank(Optional) .............................................................................................121 10.4.5.4 oil mixing water signal device(optional) ....................................................................................................................122 10.4.5.5 Pessure meter, pressure controller and pressure transmitter(Optional)..............................................122 10.5 INSTALLATION OF OIL PRESSURE UNITS...............................123 10.5.1 Installation of oil return tank .........................................124 10.5.2 Installation of pressure oil tank.....................................125 10.5.3 Installation of motor......................................................126 10.5.4 Installation of valves and accessories of the pressure oil tank.............................................................................................127 10.5.4.1 Installation of the filling valve .................................127 10.5.4.2 Installation of release valve....................................127 10.5.4.3 Installation of main pressure oil valve .........128 10.5.4.4 Installation of assistant port valve ...............128
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10.5.4.5 Installation of oil level shut-off valve............128 10.5.4.6 Installation of air safety valve ......................128 10.5.4.7 Installation of air filler valve.............................129 10.5.4.8 Installation of shelf.....................................................129 10.5.5 Installation of valves and accessories of oil return tank .................................................................................................129 10.5.5.1 Installation of oil discharging valve of the oil return tank...................................................................................................129 10.5.5.2 Installation of double oil-filter screens ..............130 10.5.6 Installation of Automatic components .....130 10.5.6.1 Installation of by-pass level indication and thermometer of the pressure tank ....................................................130 10.5.6.2 Installation of by-pass level indication and thermometer of the oil return tank ....................................................130 10.5.6.3 Installation of automatic air filler device ....130 10.5.6.4 Installation of manometer, electro connecting pressure gauge, and pressure transducer .................131 10.5.7 Installation of oil and air ducts ...........................131 10.5.7.1 Installation of the oil duct from the oil pump to the pressure tank.................................................................................132 10.5.7.2 Installation of the air duct from the automatic air filler device to the air filler hole of the pressure tank. ........................................................................................................132 ................................................................................133 CHAPTER XI USAGE OF OIL LEAKAGE DEVICE(OPTIONAL) .......................133 11.1 Note to installation...............................................................133 11.2 Technology parameters .......................................................134 11.3 The main accessories......................................................135 ......................................................................140 CHAPTER XII DESCRIPTION OF INSTALLING, DEBUGGING AND
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MAINTAINING .....................................................................................................140 12.1 MECHANIC INSTALLATION AND DEBUGGING ..............................140 12.1.1 Assembling.................................................................................140 12.1.2 Zero setting .........................................................................140 12.2 ELECTRIC INSTALLATION AND DEBUGGING ...............................140 12.2.1 Installation ..................................................................................141 12.2.2 Debugging..................................................................................142 12.3 GOVERNOR INPSECTION AND MAINTENANCE.................150 12.3.1 Pay attention to following items while daily checking .....................................................................................................150 12.3.2 Pay attention to following items while daily maintaining .......................................................................................................................152 12.3.3 Breakdown Diagnosis ......................................................153 12.3.4 easily-abrasive spare parts .....................................................158 .............................................................................159 CHAPTER XIII OPERATING INSTRUCTION ......................................................159 13.1 GOVERNOR POWER UP OR RESET...................................159 13.2 CHANGING MODE .........................................................................160 13.3 INCREASING AND DECREASING OPERATION .........................161 13.4 MECHANIC OPERATION ..........................................................162 13.5 GOVERNOR OPERATION .....................................................162 13.5.1 necessary conditions before governor startup ............................................................................................................162 13.5.2 Automatic Starting and Synchronize ............................163 13.5.3 Load Increasing/Decreasing ...............................................164 13.5.4 phase modulation.......................................................................165 13.5.5 releasing phase modulation ................................................165 13.5.6 Automatic Stop....................................................................165 123.5.7 Start and Synchronize by Mechanical Manual ....166 13.5.8 Switching from Mechanical Manual to Auto ..............167
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13.5.9 Mechanically manual stop ...............................................167 13.5.10 Electrically manual startup and synchronization .168 13.5.11 Electrically manual stop .................................................169 13.5.12 // Switch of mechanically manual/automatic/electrically manual ............................................................169 13.5.12.1 Mechanically manual operation conversed into automatic one: ............................................................................................169 13.5.12.2 automatic operation switching into mechanically manual operation ........................................................................................170 13.5.12.3 automatic operation switching into electrically manual operation ........................................................................................170 13.5.12.4 electrically manual switching into automatic ........171 13.5.13 The operation of the Runner blades is same as the guide vane .................................................................................171 13.5.14 Emergent stop...................................................................171 13.5.15 Power Operation ...............................................................172 13.5.16 Lubricate Oil-free Electro-hydraulic Transducer .......................................................................................................................172 .......................................................................................173 CHAPTER XIV OIL PUMP SYSTEM ...................................................................173 14.1 GENERAL DESCRIPTION .......................................................................173 14.2 INSTALLATION AND HARDWARE CONFIGURATION OF
OIL PUMP SYSTEM ................................................................................................175
14.2.1 Mechanical installation .........................................................175 14.2.2 Conditions ............................................................................177 14.2.3 Electric installation ...............................................................178 14.2.3.1 Main control circuit ........................................................178 14.2.3.3 Power supply ........................................................................178 14.2.3.4 Panel arrangement ........................................................178 14.2.3.5 There are several relays
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and several peripheral wiring terminals. ..................................................179 14.3 CONTROL PRINCIPLE DIAGRAM OF OIL PUMP SYSTEM ..........................................................................................................................179 14.4 OPERATION DESCRIPTION OF OIL PUMP SYSTEM.........180 14.4.1 Oil pump automatic way..............................................180 14.4.2 OiI pump manual way................................................181
14.4.3 Oil pump Switchover way.............................................181 14.4.4 supplys air control ...............................................................182 14.4.5 Emergency stop ..................................................................183 14.4.6 Display .......................................................................................183 14.5 COMMISSIONING AND MAINTENANCE OF OIL PUMP
SYSTEM ..............................................................................................................184
14.5.1 System commissioning .......................................................184 14.5.2 System maintenance ...........................................................186 14.6 MAINTENANCE OF OIL PUMP SYSTEM .........................187
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microcomputer-based Governor overcomes the breakdown that the Governor exists at present, and is really power cut-off keeping, completely digit and maintenance-free, its reliability and regulation performance have completely come up to the national standard GB/T9652-2007.2. The governor developed by STRONG Company has gained many national patents.
With many years efforts, our Hydraulic Turbine microcomputer-based Governors have been applied successfully to operating on over hundreds units in thousands of hydraulic power plants all over China, including Baishan, Xijin, Fuchunjiang, Fengman ,Lushui ,gutianxi, bapanxia etc.We are highly appraised by a great number of power plants for high-quality product and first-class service. Basing on
this , the products have been successfully put into use in many countries such as NORWAY. Afghanistan, Macedonian ,Ethiopia and so on W(Z)T (PLC) W(Z)T Series Hydraulic Turbine microcomputer-based governor is a new type of Hydraulic Turbine governor, with imported programmable logical controller (PLC) as the control core, oil-free electro-hydraulic transducer or Proportion servo valves as electro-hydraulic transducer link, and mechanical hydraulic system as actuator. W(Z)T-AA-BB-SC CD -D2- P The model of the W(Z)T-AA-BB-SC CD-D2-P Hydraulic Turbine
microcomputer-based governor is defined as follows: WT WTGovernor for Francis turbine; WZT WZTGovernor for Kaplan turbine;
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AA WT mm WZT mm/ mm AA : number of size, as For WT governor for Francis turbine, it represents the diameter (mm) of wicket gate main distributing valve of wicket gates . For WZT governor for Kaplan turbine, it represents the diameter (mm) of main distributing valve of wicket gates/ the diameter (mm) of main distributing valve of runner blades.If the diameter of the two main distributing valves are the same, It is not necessary to show the diameter of main distributing valve for runner blade. BB 2.5Mpa4.0Mpa6.3Mpa
BB rated oil pressure code.There are main following codes: 2.5Mpa 4.0Mpa6.3Mpa SC SC: code of the manufacturer, that means Technology Co., Ltd C 0 1 2 3 4 5 6 7 8 + C: product characteristic code (electric conversion code), o means step-by-step motor type; 1 means servo motor type; 2 means servo proportional valve type; 3 means digital valve type; 4 means step-by-step double oil free electric conversion type; 5 means servo double electro-hydralic type; 6 means guide vane adopting oil free oil free Wuhan Strong Automatic Control
electro-hydralic and
proportional servo valve type; 8 means proportional servo valve plus oil free electro-hydralic type D: PLC 0 FX2N 1 Q 3 PREMIUM 4 OMRON 5 S7-200
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6 S7-3007 D: product characteristic code (PLC code),0 for Mitsubishi FX2N series; 1 for Mitsubishi Q series; 3 for Schneider PREMIUM series; 4 for OMRON series; 5 for Siemens S7-200, 6 for Siemens S7-300; 7 for Taida Series. D2 D2 PLC, PLC D2: product characteristic code (redundancy); D2 means double PLC , single PLC can be omitted, P P
P: product characteristic code (unit type); p means pump storage governor , if not ,it can not be omitted. WZT-80-4.0-SC 00 80 4.0Mpa FX2N PLC Taking WZT-80-4.0-SC 00 for example: it is blade type governor, diameters of both guide vane and the blade are 80, oil pressure is 4.0Mpa, manufactured by Wuhan Strong Automatic Control Technology Co., Ltd; step-by-step double oil free electric conversion type; the controller is FX2N, single PLC; W(Z)T The advantages of W(Z)T Series Hydraulic Turbine microcomputer-based
governor are: simple but reliable structure, with a low oil consumption, few starting times of oil pump, low requirement for oil quality, no occlusion, current opening holding of servomotor on power cut-off , easy accessibility, and convenient for human-machine to dialogue. W(Z)T Series , With LCD touch panel as human-machine interface, W(Z)T
microcomputer-based Governor displays various data, status, and performs various kinds of operation, test, record, alarm, print and communication functions.
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WT series
fg fn
Kf
Fg Fn
Ef
Kp YP
(D)
Kf
KDS YD + 1T + IVS + + +
(I)
+ -
fc
+ + Kf Fc
I Y 1
KI YI S
Ey Y bp
Yc
Ky Kpg Kpg
yc
Yc
+ + P
p e
A/D
Pc
pc pg
Ep
Kp
Pg
++
P
Ep
+
p
KI F
pc
16
Upper computer
fg
Frequency
Kf Kf
Fg Fn
fn
Net frequency
KDS YD + ++ + 1 + T IVS
(I)
fc
Frequency reference
+ + Kf Fc
Ey
I Y 1
KI YI S
Digital amplifier
Y bp
Opening reference
Wicket gate
Yc
Ky Kpg
Power measure
yc
Open loop increment
+
Yc
Frequency
A/D module
Pc
Power reference
pc pg
+ -
P dead band p Ep e
p
Kp
Pg
Unit power
++
P
Unit power Water level signal Stepping Wicket gate motor feedback feedback
Kpg
Ep
+
p
KI F
pc
2.2 Block Diagram Specifications 1 f Frequency Differencef 1) When the oil switch is shut, or when the oil switch is open with an abnormal net frequency, or when the oil switch is open with tracking frequency setter. f=fG-fJ 2) When the oil switch is open with normal net frequency, and net frequency is traced. f=fW-fJ 3) E Frequency dead band E (its value can be set)
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Servomotor
(D)
Frequency measure
Ef
Kp
YP
Electric limiter
E=0
E=0.2Hz
Difference value between Setter and Actual Value 1) Frequency /Opening regulating mode 2) Power regulating mode 3) Ep Power dead band Ep Frequency/Opening regulating mode Power regulating mode 4) Permanent speed droop 1 Frequency regulating mode 2 Opening regulating mode 3 Power regulating mode bp=010 bp=010 bp=0% bp Ep=0~5%PN Adjustable Ep=0 =PG-P =YG-YPIG
2.3 system working principles CPU The whole regulator employs types of CPU modules, each of which has different
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functions, and block module is adopted for the structure. The way that divides complex missions into different parts makes the system reparable and reliable; it is not only useful for single soft upgrade but also for the upgrade of the whole regulator system with good compability. (1) CPU PLC Frequency module is made of high-quality CPU to measure the frequency and send unit and net frequency to PLC by communication bus for the software upgrade. (2), A/D A/D Guide vane feedback device send the sampled guide vane opening signals and
active power signals to A/D module,and A/D module transfer these simulation into digital signals. (3) The switchgear input module collects secondary startup, shutdown, increase and decrease commands. (4) CPU CPU All above input signals will be sent to CPU module, which then will analyze and calculate corresponding guide vane control signal and status signal (including failure) according to regulating rule, which then will be sent to switching value output module or analog output module to complete the control output and status output. (5) The switchgear output moduel is to output the digital mechanical hydraulic
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systems oil free clockwise and anti-clockwise movemet on the basis of the corresponding width pulsing open or close signal by calculated control valueIf the electro hydraulic convertor adopts oil free electro-hydraulic tansducer,then
simulation quantity output moduel is used to control the servo valve on calculated value to make the guide vane acts in the light of regualtion rules and sends signals when fault happens. (6) Communication unit is responsible for the communication with upper computer, and send or receive commands to or from the upper computer. (7) Touchable panel is human-computer interaction interface in Chinese to finish field operation orders of Governor and status data display, and also to remotely communicate through connection. PID PID , PID The hudraulic turbine regulating system whose control index and stability has attracted more attention of the public is a non-linear, changable and non-min phase system. The controlling rules of turbine speed regulating system has been perfecting with the development of controlling technology. Although in recently years, the study of controlling modes and methods based on modern controlling system (e.g. Automatic controlling, parameters self- perfection when changing
the structure, multi-quantity and best-controlling of modular reference) has begun, PID controlling principles have also wildely used presently since the turbine regulating system is a system with variation and compared quick-speed. However,
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the common PID controlling system needed precise mathematical modes is only suitable for linearity system whose dynamic quality can not be secured with common PID. PID , , 9 , , ,, , , ,, , Herein, we adopt a new PID controller ---basic and logical controller (also called nine-point controller) which can be abstracted into nine operating points (strong plus, weak plus, plus, little plus, remaining, weak minus, miuns and heavly minus) to control aoocrding to the tolerance and its changing rate. Its fundamental principle is to continually change or adjust controlling methods in order to make the controlling rules of controller itself satisfy the system requests for good capacity according to the features of controlling system operating modes. As the controller works only influenced by the operating conditions of controlled objects, it is largely used by controlled objects. However, different operating points with different contolling methods, the new controller can change parameter, structure and control with non-linearity. Simple calculating in controlling makes its engine application come true. The stable controlled objects can simultaneaously obtain good static and dynamic qualities, even though it has effects on unstable ones, thus basic and logical controller can apply to water turbine speed regulating system to improve performance.
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PI AGC PI PID Governor has frequency regulation, opening regulation and power regulation three kinds of control modes, which can be chosen according to the practical needs. The change of them can be done through the touch key on terminal or secondary circuit contact, or through the digital communication interface. Frequency regulating mode has tracing frequency and network frequency. The mode of frequency regulating insures that unit frequency conforms to net frequency for synchronous operation. Power regulating mode utilizes PI link to regulate units according to the power difference for the constant output power. It is quite easy to realize the whole plant AGC (Automatic Generation Control) when units operating in this mode. Power setter is utilized to regulate units by PI link and, meanwhile, directly output by open-loop control to improve the increasing and decreasing speed. The power setter could be digital signal, which is set by upper computers . Electric limiter link limits the output of PID to make sure output not exceeding Electric limiter . PLC Digital amplifier compares the PLC output with the data sampled by servomotor feedback, amplifies and output. Dual closed loop structure is adopted for the control of servomotor, besides servomotor feedback, there is a motor feedback or Proportion servo valve feedback for the control of oil-free electro-hydraulic transduceror or Proportion cylinders accurate loacting, the compensation of various kinds of mechanical errors and abrasion etc.
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As
for
frequency
measurement,
it
adopts
residual
voltage
frequency
measurement. Anyhow, double frequency measurements consisting of residual voltage and tooth-gear also can be selected and they are backup for each other. The electric feedback can select absolute encoder, linear replacement transducer and potentiometer etc. The human-machine interface is LED touchable screener.
3.1.1 Hardware Configuration 1 Cubicle Body (1) The separate cubicle of electro-mechanics 8006002260mm Dimensions8006002260mm
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Colorselectable (2) The united cubicle of electro-mechanics 8006001860mm DimensionsSingle8006001860mm 12008001860mm Double12008001860mm Colorselectable
2 Power Supply System 1 1+24V Switch1 power supply +24V which is specialized for relay, operation terminal. 2 2+24V Switch power supply 2 +24V which is specialized for motor drive.
4 Control part W(Z)T PLC, Q S7-300 PREMIUM / As for the control part of W(Z)T Series Hydraulic Turbine microcomputer-based governor, imported PLC such as Mitsubishi Q series, Siemens S7-300 series, Schneider PREMIUM series can be chosen if required by the client. The hardware is consisted of the following parts which can be increased or decreased according
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to the real condition. 1 Power module 2CPU CPU module 3 Input simplifying module 4 Output simplifying module 5AD AD module 6 Communication module 7 Motor driver or proportional valve amplifier 8 Motor or proportional servo valve
3.1.2 Software Basic Configuration (1) PID Paralled connecting PID program adopts basic logical controller (2) Real-time graphic display, note and monitoring software (3) Real-time breakdown diagnosis program (4) Sub-program of double digital cooperation (5) Operation subroutine such as unit start, stop etc.
3.1.3 Functional strengthen Software Configuration (1) Communication software with upper computer (2) Power regulation Software with a closed control loop
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3.1.4 Equipments and Software for Debugging (not belong to Governor equipments) (1) PC (2) The software programming Mitsubishi, Siemens or Schneider (3) HG-II HG-II Simulation and Testing Instrument of the Hydraulic Turbine Governor (4)89C51 89C51 Single-Chip assembler
3.1.5 Equipments for Test (not included in Governor equipments) (1) HG-II HG-II Simulation and Testing Instrument of the Hydraulic Turbine Governor (2) PC
3.2 Mechanical System Configuration (1) Step-by-step oil-free electro-hydraulic transducer (with automatic center-return mechanism) or Proportion servo valves
(2) Piston and body of main distributing valve (3) Mechanical manual operation (4) Emergency stop solenoid valve, double oil filter
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and software, it is diagnostics and breakdown tolerant. The unit frequency is measured by Two-circuit frequency measurement which can be measured by residual voltage and tooth-plate. 2 At no Load, there are two types of control modes trace frequency setting and trace net frequency. For latter mode, unit frequency automatically conforms to system frequency. 3 PID , 9 PID adopts basic logical controller which abstract actual operating conditions into 9 operating points (strong plus, weak plus, plus, little plus, remaining, weak minus, miuns and heavly minus) according to the tolerance and its variable rate so that efficient control can be done in the light of corresponding manners. 4 AGC Assure units work stably in every operation conditions No-load, isolated operation, parallel operation, AGC operation. 5 With open loop control in power setting regulating, unit output power is increased and decreased rapidly and accurately. 6 Touchable panel is adopted for real-time human-machine interface, which makes operators convenient to get Governor operating condition. 7 Real-time diagnose, display and alarm, and all breakdowns recorded 8 Recording operation for consultant 9 Analog signals sampling
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function for water head, unit power, etc. 10 It addopts closed-loop stratup rules to supervise the unit speed all the time during startup to make sure water turbine reach rated speed fast and smoothly. With serial communication interface, this communicates with upper computer and realizes plant automatic operation 11 Double regulating unit can cooperate digits according to water head change and improve working efficency of motor units. 12 It is convenient to input cooperating data and store in the programmable controller by terminals in Chinese after cooperating curves offline qualification. 13 Realize power closed loop control (provided by the ouside if there is power in units), and power setting signals could be digital for the sake of connection with monitoring system. 14 Three types of operation mode automation and manual and electric manual, and no perturb switch between them. With computer automatically traces manual or electric manual operation, it realizes no warranty and no disturbing switch. 15 Water head signal may be input automatically or manually. 16 Different process monitoring and tests
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dynamic
process
monitoring,
static
characteristics
test,
no-load
frequency disturbing, no-load frequency swing, load rejection test. 17 Set parameters by operation terminal in Chinese. 18 / As input/output is completely digital, it is easy for debugging and setting. 19 Security function Different operators access to different interface operation by unique passwords. 20 Have help function with integral instruction 4.1.2 Diagnostics and Tolerance Functions W(Z)T PLC CPU A/D The W(Z)T Series Hydraulic Turbine Governor is of the function of powerful Diagnostics and Breakdown Tolerance, which not only includes the diagnostics function of PLC for CPU module, A/D module, communication module and application software, but also includes those of governing system for measured frequency signal, power and water head signal, feedback signal, and of mechanical system and communication system. All breakdowns are displayed on terminal and recorded; meanwhile, comprehensive contact signals are sent out. 1 Breakdown tolerance of unit frequency signal (1) In the event of unit frequency signal error with no Load, it would automatically cut off frequency tracing, and close opening to the safety no-load position, and be ready to receive stop command. (2)
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In the event of net frequency signal error in generating casenet frequency signal is used instead of the unit frequency signal, without load disturbing, if unit frequency returns to normal, it would join to help regulate, without load disturbing. (3) In the event of unit frequency and net frequency signal errors in generation case, Governor would maintain the current load, and regulate units output by power setter or increasing/decreasing operation. (4) 20HZ 20HZ Two-curcuit frequency measurement Residual voltage and gear frequency measurements are supplement with each other. Normally, residual volatage frequency measurement will be adopted automatically if units frequency is higher than 20HZ, otherwise, it will be gear frequency measurement. If residual voltage requency measurement has broken, the other one will be used automacally, vice versa. 2 Breakdown tolerance of net frequency signal In the case of net frequency signal error at No Load, it would automatically track frequency setter. In generation operation, net frequency would not join regulation. 3 In the case of guide vane feedback error, motor feedback error, or driver module error, make servomotor maintain the current opening. And switch to mechanical manual if needed. 4 In the case of power signal error, Governor would not perform power closed loop regulation, it would automatically switch to opening regulating mode, and control units output by upper computers or
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regular control. 5If any error occurs at water head signal, it would maintain the current water head value, and wait to be switched to manual command. 6 PLC In the case of PLC system error, and made servo motor maintain the current opening. Switch to mechanical manual if needed. 7PLC Even if error occurs at operation terminal, PLC performs the control functions, for instance, start, stop, load increase/decrease, breakdown protection, etc 8 When A/C, D/C breaks simultaneaously, mechanical hydraulic system will become zero automatically and no change to servometer. 9 Twin filter is made of two sets of foldable and stainless meshes one for working and the other for spare, and both can be converted and cleaned in operation without disturbance. 4.1.3 Developing and Debugging Functions 1 PLC PLC is extremely specialized for developing and debugging. 2 software Programming provides various man-machine interfaces, with which it
is quite convenient for users to develop and debug. 3Ladder diagram makes it easy for user to master. 4It is convient to equip and record on the terminal
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PID GB9652-2007 ID regulator adopts basic-logical controller which makes Governor used in different units and different operating in the same unit with well controlling results. And its functions have met or excelled the national standard GB9652-2007. 2 High reliability
30 The body of Governor hareware is the programmable controller of Q Series from MITSUBISHI, and its zero breakdown in more than 300,000 hours (on average) makes operation reliable.Electro-hydraulic transducer has automatic reset position device , the servomotor can keep current opening when D/C and A/C break at the same time. 3 Digitalization
Governor is digitalization, which improves data processing, filtering, amplifying and anti-interference capacities. Closed-loop positioning control of
electro-hydraulic transducer absolute postion can be realized by the way of pingpang-digital and opaque controlling. 4 Strong anti-interference capacity
PLC The PLC depending on industrial standards and application software has the function of self-diagnosis and breakdown tolerance, thus Governor has the anti-interference ability to withstand extreme circumstances in power plant.
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5 FlexibilityIt can be applied to control and regulate various types and capacities of hydraulic turbines. 6 PowerfulIt establishes normal control and upper computer control; including start, stop operation, etc. Furthermore, it establishes functions for debugging, test, and remote
communication, etc. 7 Convenient human-machine dialogue. Operator can know the real-time operation situation of the Governor by industrial-class Touched LCD. 8 Strong function for expanding Special function may be added if power plant needs. Only need to add corresponding hardware and software into the original system by not making large change to original system. 9 Its test, maintenance and use are better than traditional one with easier installation, adjustment and maintenanceis.
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(1)Mode residual voltage and tooth-plate frequency measurement (2)Input voltage signal (3)Pulse modulation time1~20mSec (4)Frequency Test range 5~100Hz 0.0015Hz remanent voltage 0.3V~200V, tooth-plate 24V pulse
2 Setting Range of Regulating Parameters bp=0~10% bt =0~200% Td=1~20 ( 1%) ( 1%) ( 1 ) ( 0.1 )
Tn=0~3
bp
=0~10%
(resolution 1%)
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For the governor adopted KP, KI,KD , the setting range of regulating Parametres is as follwing : Proportion: KP=0~20.00 Integral: KI=0.5~10.00 Differential: KD=0~5.00 3 Control Parameter Range Opening setter Frequency setter PG=0~100% FG=45~55Hz E=0~0.5Hz Ep=0~5%PN L=0~100% P=0~120% PN PG =0~100% FG =45~55Hz (resolution 1%) (resolution 0.01Hz) (resolution 0.01Hz) ( 1%) ( 1%) ( 0.01Hz) ( 0.01Hz)
Artificial frequency dead band range E =0~0.5Hz Power dead band Opening limiter Power setter E p =0~5% PN L =0~100% P=0~120% PN
(resolution 1%)
Parameter of Step-by-step motor Step-by-step motor model and manufacturer Model No103H8222 Manufacturer Japan Sanyo Corporation
Parameter of servomotor
servomotor model and manufacturer Model No34S42 Manufacturer Germany Kinco Corporation Holding torque 3.5NM
(2) max. 25VA (3) <10% (4) <0.1% (5) <0.2% (6) (0~100%)<10ms (7) 40<1%
Type and manufacturer Type: 0811 Diameter: 6 Structuer: Plate structure Control voltage: DC24V Pmax=315 bar Norminal flow Qnom=40L/min(valve port pressure P=35ba) Leakage(100bar/H): 1.1L/min Magnetic current: max. 2.7A 1Wiring resistance: 2.5 2Power consumption: max. 25VA 3Max flow tolerance: <10% 4Repeat accurancy: <0.1% 5Dead band: <0.2% 6Responding time(0~100%)<10ms 7Temperature float: zero float <1% when temperature difference larger than 40 6 Power (1) 50Hz220V15%<550
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50Hz220V15%<550VA
0.25%0.3% When the governor is automatically operating at no-load condition, the relative
values of speed swing of unit:0.15% for large governors; 0.25% for mid-small governors; 0.3% for mini-governors. 100% 3%
After 100% rated load rejection, the wave peaks surpassing 3% rates speed
t M 8 12 15 0.9 The specific value between the regulating time t E of the units from load counting from
load rejection to speed raising to the top speed less than 8 for middle,low water head pressure turbine , for axial flow turbine whose closing time is long less than 12,for high water head pressure turbine and impulse water turbine less than 15, for the uints which supply power to power station after network splitting, the lowest relative speed no less than 0.9 after load rejection. ( tubular turbine whose surge control and blade closing time is long is not included)
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0.2S The speed or command signals are changed by the stipulated forms, and the
0.06%0.10%0.20% The static characteristic curve is close to a line; and the speed dead band, is 0.06% for middle governor, 0.10% for small
1% For Kaplan turbine governor system, the inaccuracy of runner blade servo
system shall be no more than 0.8%; and the deviation between actual coordinating curve and theoretical coordinating curve shall be mo more than 1% of the total stroke of the runner blade servomotor.
1%0.5% Under steady state operation, for multi-needle Pelton turbine, the position
tolerance between needles shall be no more than 1% in the whole scope, and the tolerances between every needle opening and average value of all needles openings shall be 0.5%. 1%
0.5%. For the pumped storage units whose wicket gate is individually controlled, the
position tolerance bewteen any wicket gate servomotors shall be no more than 1%; and the tolerances between every wicket gate servomotor opening and average value of all wicket gate servomotors openings shall be 0.5%.