A WRITE-UP ON ELECTRO-HYDRAULIC ACTUATORS &

HPSU SYSTEM FOR TURBINE VALVES

STEAM TURBINE
(SUPERCRITICAL RATING)

Steam Turbine Engineering

REPARED BY : (LAKHMI SINGH) AGREED BY: (SHEETAL SINGH)

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1. HYDRAULIC SYSTEM FOR TURBINE VALVES :

The steam turbine is controlled by adjusting steam mass flow rate by turbine inlet cont rol valves. These
control valves are hydraulically actuated. In the case of a turbine trip, turbine stop valves, which are also
hydraulically actuated, interrupt the steam flow into the turbine instantly.

Hydraulic Power Supply Unit (HPSU) for the turbine valves supply the high-pressure control fluid to the
Electro-hydraulic actuators. Electro-hydraulic actuators mainly consist of hydraulic pistons, disc springs &
control unit ( comprising of servo directional valve, pilot valve, trip solenoid valves & logic cartridge valves).
Servo directional valves converts the electrical input signal received from turbine controller, into a hydraulic
signal and amplify it. Further it controls the fluid flow to position the hydraulic actuators so that the required
steam flow rate is adjusted precisely.

Logic cartridge valves are mounted on the control blocks of actuators assemblies so that hydraulic actuators
can close the steam valves within a very short time.
Governing system is capable of controlling the stability of turbine speed between zero to m aximum power
output, during no-load operation and parallel operation.

1.1. HYDRAULIC CONTROL SYSTEM:

A- The high pressure hydraulic system (MAX01) is responsible for the actuation of the
turbine stop and control valves and it mainly consists of the following components:
- HPSU with adjustable high pressure control fluid pumps, electric motor, control fluid tank, pressure
relief valves, circulation pump, control fluid cooler, control fluid heater, filters,
accumulators, temperature regulator and control fluid regeneration circuit;
- Control fluid supply line;
- Control fluid return line;
- Control fluid.
B- The high pressure hydraulic control system (MAX01) of Steam Turbines has the following
functions:
- Generation & supply of a high pressure control fluid to turbine valve actuators;
- Collecting leakage and return fluid from the valve blocks and actuators;
- Continuous cooling of the control fluid;
- Continuous cleaning of the control fluid;
- Conversion of the electrical output signal of the turbine controller into a hydraulic
signal;
- Amplification of the hydraulic signal and changing into a control fluid flow which is
proportional to the electrical input signal;

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 - Positioning of the steam control valves according to the required steam flow rate.
From the HPSU, Pressurize fluid flows to actutors & return fluid flow back into the tank via SS tubes.
As the control blocks are directly mounted on the acuators, hydraulic fluid directly flow to the
actuator for opening & closing of Steam control valve as required .
Control fluid used is Fire resistant fluid (FRF).

1.2. CONTROL VALVE ACTUATOR ( Figure shown at page 4 of 9):

The control valve actuator is an Electro-Hydraulic Actuator with control fluid supply from HPSU (MAX01). The
actuator comprises a hydraulic cylinder, control unit and displacement transducers (10MAA12CG151 & 10MAA12
CGA152). Turbine control valve is coupled with the control piston of hydraulic cylinder. The control piston which
is pressure loaded in opening direction and pressure relieved on the opposite side, moves in hydraulic cylinder. The
closing force is supplied to the control piston by a cu p – spring stack housed inside the actuator. The actuator is
connected to the HPSU (MAX01) through control fluid supply and return lines. A pressure filter (10MAA12
AT021) is fitted in pressure line (upstream side) to prevent ingress of contamination from the pipe lines.

1.2.1. CONTROL UNIT:

The control unit comprises of servo directional valve (10MAA12AA012), trip solenoid valves (10MAA12AA013,
10MAA12 AA014), main logic cartridge valves (10MAA12 AA023, 10MAA12 AA024) and pilot logic cartridge
valves (10MAA12AA025 & 10MAA12AA026). In add ition a pressure filter (10MAA12AT022) is also fitted to
the pilot control of servo directional valve. All these control elements are connected via a control plate to the power
cylinder through internal fluid ducts.

1.2.2. MODE OF OPERATION:

The servo directional valve (10MAA12 AA012) is a high response continuously operating directional control valve
with good steady state and dynamic characteristics and high amplification. Servo directional valve
(10MAA12AA012) which also has good position monitoring controller, controls the flow of fluid to both s ides of the
control piston of actuators as a function of the output signal from the controller, thereby positioning the actuator.
Feedback in terms of analog position of the actuator is given to the controller by displacement transducers
(10MAA12CG151 & 10MAA12CGA152). In the event of rapid closure, trip solenoid valves
(10MAA12 AA013, 10MAA12 AA014) are de-energized and thus the pressure over the pilot logic cartridge
valves (10MAA12 AA025, 10 MAA12AA026) is reduced, causing it to open. Due to that, pilot pressure from top
of the main logic cartridge valves (10MAA12AA023, 10MAA12AA024) also gets drained to tank; thereby initiating
the opening of main logic cartridge valves. Main logic cartridge valves are opened with minimum travel time and the piston
chamber is connected to the drain, thereby ensuring the rapid closure of the control valves.

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 SCHEMATIC OF CONTROL VALVE ACTUATOR

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TYPICAL
1.3. STOP VALVE ACTUATOR (Figure shown at page 6 of 9):

The stop valve actuator is an Electro-Hydraulic Actuator with control fluid supply from HPSU (MAX01). The
actuator comprises a hydraulic cylinder, control unit & displacement transducer (10MAA11CG051) to monitor the
opening and closing of the actuator/valve. Turbine stop valve is coupled with control piston of hydraulic cylinder.
The control piston which is pressure loaded in opening direction and pressure relieved on the opposite side, moves in
hydraulic cylinder. The closing force is supplied to the control piston by a cup – spring stack housed inside the
actuator. The actuator is connected to the HPSU (MAX01) through control fluid supply and return lines. A pressure
filter (10MAA11AT021) is fitted in the pressure line (upstream side) to prevent ingress of contamination from the
pipe lines.

1.3.1. CONTROL UNIT:

The control unit is mounted on the hydraulic cylinder and comprises of the Pilot valve (Poppet direct valve,
10MAA11 AA011), trip solenoid valves (10MAA11 AA013 & 10MAA11 AA014), main logic cartridge valves
(10MAA11 AA023 & 10 MAA11 AA024) and pilot logic cartridge valves (10MAA11 AA025 & 10 MAA11
AA026). All these control elements are connected via a control plate to the hydraulic cylinder through internal fluid
ducts.

1.3.2. MODE OF OPERATION:

For the opening of turbine stop valve, the trip solenoid valves (10MAA11 AA013 & 10MAA11 AA014)
are energized with the help of output current signal from the controller. Pressuirze fluid keep the pilot logic cartridge
valves (10MAA11AA025 & 10MAA11AA026) & main logic cartridge valves (10MAA11AA023 & 10MAA11
AA024) in closed condition. Fluid from main pilot valve (10MAA11AA011 - with de-energized state), is fed to the
hydraulic cylinder and pushes the piston in opening direction against the spring force, thereby opening of stop valve.
Stop valve is rapidly closed by de-energizing the trip solenoid valves (10MAA11 AA013 & 10MAA11 AA014),
resulting in the reduction of pressure over the pilot logic cartridge valves (10MAA11AA025 & 10MAA11AA026),
causing it to open. Due to that pilot pressure from top of the main logic cartridge valves (10MAA12AA023,
10MAA12AA024) also gets drained to tank ; thereby initiating the opening of main logic cartridge valves.
Main logic cartridge valves are opened with minimum travel time and the piston chamber is connected to the drain,
thereby ensuring the rapid closure of the stop valves. Pilot v alve (10MAA11 AA011) remains in d e-energized state
during opening or rap id closing of the turbine stop valve. Pilot valve (10MAA11AA011) is energized only in case of
normal closing of the turbine stop valves, keeping trip solenoid valves (10MAA11AA013 & 10MAA11AA014) in
energized state.

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 SCHEMATIC OF STOP VALVE ACTUATOR

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TYPICAL
1.4. HYDRAULIC POWER SUPPLY UNIT ( Figure shown at page 9 of 9):

The main function of Hydraulic power supply unit (HPSU, MAX01) is to supply Control Fluid at 160 bar pressure
with a predetermined flow rate to operate respective Electro-Hydraulic Actuators (EHAs), coupled with main turbine
valves (stop, control and overload valve ). HPSU (MAX01) comprises of major components i.e. control fluid pumps
(Axial Piston Pump, MAX01 AP001/AP002), filters (MAX01 AT011/AT012/AT013/AT014/AT016), control fluid
regeneration unit (MAX01 AT015), control fluid cooler (MAX01 AC010/AC020), control fluid heater (MAX01
AH001), Accumulators (MAX01 BB011/BB012/BB013/BB014), Temperature regulator
(MAX01 AA151 AA152) etc.. These components are mounted on the control fluid tank of HPSU. All the piping /
component coming in contact with FRF are made of stainless steel or the material which is compatible with FRF as
per vendor's standard practice.

For the redundancy and to prolong the service life of the unit, two 100% control fluid pumps (MAX01
AP001/AP002) are provided for control fluid supply. Fluid flows from pumps to manifold block reaches to safety valve &
further flows to accumualtor via filters. Contamination gets removed from pressure line filters (mesh size 10 micron).
The filters (MAX01 AT011/AT012) are equipped with clogging indicator (MAX01 CP011/CP012) for alarm, in case
of choke. Pressure can be measured at pressure gauge (CP501) mounted on the panel. Pressurised fluid charge the
accumulator up to system pressure 160 bar. Once accumualtor gets fully charged, 160 bar is maintained constant
in the system & Pump come to distroke condition. Finally fluid at 160 bar from terminations P1 to P5 flows to Actuators.
The electric motors and pressure relief valves (MAX01 AA061/AA062) for system pressure adjustment are mounted
on the control fluid tank cover.

The accumulators system (MAX01 BB011/BB012/BB013/BB014), which is to supply the fluid quantity required for
control movements of power piston, comprises a group of bladder-type accumulators with isolating valves and safety
valves.
The supply unit is of compact design. It comprises a tank made of stainless steel with fluid level monitoring devices
(MAX01 CL501) as well as breather filter (MAX01 AT001). Moreover, a drip tray is provided at the bottom, which
is at the lo west point. All electric devices (Except elec. motor) are wired to a terminal strip in the terminal box
(MAX01 GF001). There are total 5 nos. pressure connections (P1, P2, P3, P4 & P5) and 5 nos. return connections
(T1, T2, T3, T4 & T5) have been provided is the HPSU for further connecting the control fluid pipe to various actuators.

Separate cooling-cum-filtration circuit is provided in order to maintain the cleanliness of the system and to ensure
proper cooling. Separate circulation pumps (MAX01 AP011/AP012) supply fluid to this circuit. On the tank cover a
console is mounted which contains the local pressure gauges, pressure switches and nipples for commissioning
measurements. The recirculation pumps (MAX01 AP011/AP012) supply the control fluid to the cooler (MAX01
AC010/AC020) through temperature regulator (MAX01 AA151/AA152). The temperature regulator (MAX01
AA151/ AA152) is set on 45 deg C. Only in case the control fluid temperature is greater than 45 deg C, the

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temperature regulator allows the control fluid to be passed through the cooler (MAX01 AC010/AC020), else it
supplies the control fluid directly to the tank via fine filter (MAX01 AT013/AT014).

A separate regeneration circuit is provided in th e HPSU with 2X100 % capacity AC driven regeneration pump
(MAX01 AP011/AP012). The regeneration unit pumps (MAX01 AP011/AP012) supply the control fluid from tank
to regeneration unit (MAX01 AT015). In control fluid regeneration unit (MAX01 AT015), control fluid
gets reconditioned and return back to t ank via a filter (MAX01 AT016). The regenerat ion circuit is designed to
purify at least 2% of the total fluid charge in the system per hour on continuous basis.

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 SCHEMATIC OF HYDRAULIC POWER SUPPLY UNIT

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TYPICAL