Domestic Imported 300 Unit DEH Oil Station Upgrade
1. Foreword The Zhujiang Power Plant has installed four domestic imported 300 units. Its control system adopts the DEH control system produced by Shanghai Xinhua Company. The DEH oil station adopts the EH300 type. The EH oil pump uses a variable vane pump and the oil pressure alternates between 12.2 and 14.8 MPa. It is vulnerable to oil leakage under the system stress under the alternating stress. For example, the #2 machine EH oil pump outlet tubing welding port, EH oil pressure gauge section The head leakage must be stopped before it can be disposed of. At the same time, each machine must be regularly replaced with a bladder, which has an adverse effect on the safe operation of the unit.
2. The necessity of upgrading the DEH oil control system The original EH300 oil supply device was imported from the American Westinghouse Corporation. The device was operated at an alternating load between 12.2 and 14.8 MPa in the EH system, resulting in instability of the system's hydraulic pressure. Accumulator Poor operating conditions will degrade the quality of the EH oil. At the same time, the pump suction filter is installed at the bottom of the tank. When the oil level is reduced, cavitation may occur.
The Zhujiang Power Plant # 1 machine overhaul fueling device transformation using Xinhua's original equipment technology based on the improved EH1000, the original quantitative vane pump to piston variable pump, the original variable pressure conditions changed The constant-pressure working condition eliminates the fatigue damage caused by the alternating oil pressure to the accumulator and the pipeline, so as to prolong the life of the accumulator, reduce the oil pollution at the same time, and facilitate the replacement of the filter element; an independent cooling system is added and The oil filter system device can effectively reduce the damage to the oil quality caused by the rise of EH oil temperature and ensure the long-term qualified operation of EH oil.
3. Modification of EH Oil Station 3.1 Modification of Engine Part First of all, the oil in the original oil supply device is put clean, and the thermal and electrical co-operation remove the cable connection of the oil supply device and mark it (Note: ER terminal box The hot terminal wires still have to be fully utilized). Unscrew the connecting port of the precision oil filter and the main oil pipe, remove the cooling water pipe joint, knock down the floor of the oil tank and knock off the part of the floor tile, and remove the screw that is connected with the oil supply device. The EH tubing must be wrapped and the EH oil system must not be contaminated. Remove the original oil supply device and clean the site. The size of the original position measurement is consistent with the size of the drawing equipment for the new oil station. If there is any inconsistency, the ground should be treated first to meet the installation size of the new oil station, and then the new oil supply device should be positioned as required. After positioning the fuel tank, connect the five interfaces of the oil station to and from the oil pipe. Then, connect the oil filter device and the regeneration device by high pressure argon arc welding, and then connect the oil supply device with the precision oil filter device interface. Because the height of the fuel tank of the new oil supply device is increased and the position of the interface is different, the original connection port must be re-welded, the cooling water pipe should be connected, and the original water pipe should be used for re-welding. The interface of the regeneration device provided by the new oil supply device, if not used, must be blocked with a plug and fixed by spot welding. During construction, the interior of the tubing and the weld must be cleaned to avoid contamination of the EH oil system.
3.2 Renovation of power supply for new oil supply device The new EH oil station shall be provided with a power supply line. The original two EH oil pumps are 23kW/380V/50Hz, and the power supply required for the EH1000 oil supply device is 30kW/380V/50Hz. EH oil pump cable capacity, AC contactors, and related electrical circuit protection settings should be accounted and determined, whether the capacity is sufficient, whether it can meet long-term safe operation, and whether or not to update the cable, AC contactors, and protection settings.
It is required to provide a new power cord with a three-phase four-wire capacity of not less than 3 kW for one oil filter pump and one cooling pump. Two pump control power circuits have been integrated in the new petrol station control box and only need to provide power.
The electric heater of the new oil station requires 5kW/220VAC/50Hz single-phase power. The same power as the original EH petrol station heater can be used with the original heater power. The original heater is at the top of the fuel tank and the new EH station is now heated. The device is at the bottom of the tank.
3.3 Thermal control of the oil station The thermal control shall be installed in accordance with the design drawings and the installation of the thermal control circuit should be completed to restore all terminal connections of the ER terminal box. According to the "EH1000 oil supply device operating instructions" requirements, the thermal control settings. The EH oil pump linkage test solenoid valve is originally connected to the top of the original EH tank and is now connected to the bottom of the new EH tank.
4. Post-upgrade trial run and overall acceptance 4.1 Prior to trial operation, tighten the live nut of each oil supply device with a spanner wrench to prevent the system from leaking due to vibration during transportation. After all the connection ports of the oil supply device are connected, the electrical power line of the electrical professional is well equipped. After the insulation of the pump motors is tested, the filter pump and the cooling pump power are sent to the forward and reverse directions and the idle current is recorded.
4.2 Fill the oil tank with the oil pump. When the oil is refueled, the four liquid level alarm indicators are measured by the thermal professional. The system needs to add four barrels of anti-fuel oil. Under the condition that the whole system does not have the overall oil circulation, the internal oil circulation of the oil tank is performed by using the oil filter device and the fine oil filter device on the oil station. Or the short engine oil drive and the engine on the oil engine interface with the short-circuit method, the entire system oil circulation.
4.3 Before the oil circulation in the entire system, the direction of main oil pump test A and B is correct. Oil pump can be run simultaneously with two pumps. The system pressure is controlled between 2.5~3.5Mpa. The oil temperature is between 45°C and 55°C. The upper limit of the digital thermometer is 55°C and the lower limit is 35°C. Press the automatic Cooling button is put into automatic operation.
4.4 When the system recovers, the oil quality must reach the NAS level 5 standard, and then replace all the filter elements of the EH system. After the filter element is replaced, the main oil pump is started again to continue the oil circulation. If the time is sufficient, the cycle is 24 hours, and the minimum is not less than 8 hours.
4.5 After the whole system recovers, adjust the system pressure on the A pump to 18MPa, loosen the DB-10 relief valve handle to the system pressure to 17MPa, and then adjust the screw to adjust the system pressure to 14.5MPa, stabilize for three minutes, and finally Stop pump A, start pump B, use the same adjustment method to make the oil pressure is 14.5 MPa, other various tests by DEH debugging, during commissioning, should pay attention to the pressure changes in the system when the oil motive action.
5. Operation after oil station renovation After the overhaul of Unit #1, after repeated tests and multiple start-stops, the EH oil pressure can be stabilized at 14.6 MPa, which can fully meet the requirements for long-term safe operation of the unit, and the EH oil quality test is qualified. The operating conditions of the two EH oil supply units are compared as follows:
6. Conclusions The upgrade of the 6.1EH1000 oil station is successful and necessary. It can effectively avoid the damage caused by the alternating stress of the EH oil piping system, improve the reliability of the system, increase the service life of the system, and reduce the The maintenance workload of the system also has a certain energy saving effect due to the drop of the EH pump current.
6.2 Through the EH oil analysis test, the EH1000 oil supply device is beneficial to improve the EH oil quality, in particular, it can effectively prevent the EH oil acid content from exceeding the standard.
6.3 EH petrol station should strengthen the cleaning work in the fuel tank at the time of delivery. At the same time, the operation control of the recirculating oil pump and the cooling oil pump carried by the oil station should also be integrated into the DCS for centralized control.
2. The necessity of upgrading the DEH oil control system The original EH300 oil supply device was imported from the American Westinghouse Corporation. The device was operated at an alternating load between 12.2 and 14.8 MPa in the EH system, resulting in instability of the system's hydraulic pressure. Accumulator Poor operating conditions will degrade the quality of the EH oil. At the same time, the pump suction filter is installed at the bottom of the tank. When the oil level is reduced, cavitation may occur.
The Zhujiang Power Plant # 1 machine overhaul fueling device transformation using Xinhua's original equipment technology based on the improved EH1000, the original quantitative vane pump to piston variable pump, the original variable pressure conditions changed The constant-pressure working condition eliminates the fatigue damage caused by the alternating oil pressure to the accumulator and the pipeline, so as to prolong the life of the accumulator, reduce the oil pollution at the same time, and facilitate the replacement of the filter element; an independent cooling system is added and The oil filter system device can effectively reduce the damage to the oil quality caused by the rise of EH oil temperature and ensure the long-term qualified operation of EH oil.
3. Modification of EH Oil Station 3.1 Modification of Engine Part First of all, the oil in the original oil supply device is put clean, and the thermal and electrical co-operation remove the cable connection of the oil supply device and mark it (Note: ER terminal box The hot terminal wires still have to be fully utilized). Unscrew the connecting port of the precision oil filter and the main oil pipe, remove the cooling water pipe joint, knock down the floor of the oil tank and knock off the part of the floor tile, and remove the screw that is connected with the oil supply device. The EH tubing must be wrapped and the EH oil system must not be contaminated. Remove the original oil supply device and clean the site. The size of the original position measurement is consistent with the size of the drawing equipment for the new oil station. If there is any inconsistency, the ground should be treated first to meet the installation size of the new oil station, and then the new oil supply device should be positioned as required. After positioning the fuel tank, connect the five interfaces of the oil station to and from the oil pipe. Then, connect the oil filter device and the regeneration device by high pressure argon arc welding, and then connect the oil supply device with the precision oil filter device interface. Because the height of the fuel tank of the new oil supply device is increased and the position of the interface is different, the original connection port must be re-welded, the cooling water pipe should be connected, and the original water pipe should be used for re-welding. The interface of the regeneration device provided by the new oil supply device, if not used, must be blocked with a plug and fixed by spot welding. During construction, the interior of the tubing and the weld must be cleaned to avoid contamination of the EH oil system.
3.2 Renovation of power supply for new oil supply device The new EH oil station shall be provided with a power supply line. The original two EH oil pumps are 23kW/380V/50Hz, and the power supply required for the EH1000 oil supply device is 30kW/380V/50Hz. EH oil pump cable capacity, AC contactors, and related electrical circuit protection settings should be accounted and determined, whether the capacity is sufficient, whether it can meet long-term safe operation, and whether or not to update the cable, AC contactors, and protection settings.
It is required to provide a new power cord with a three-phase four-wire capacity of not less than 3 kW for one oil filter pump and one cooling pump. Two pump control power circuits have been integrated in the new petrol station control box and only need to provide power.
The electric heater of the new oil station requires 5kW/220VAC/50Hz single-phase power. The same power as the original EH petrol station heater can be used with the original heater power. The original heater is at the top of the fuel tank and the new EH station is now heated. The device is at the bottom of the tank.
3.3 Thermal control of the oil station The thermal control shall be installed in accordance with the design drawings and the installation of the thermal control circuit should be completed to restore all terminal connections of the ER terminal box. According to the "EH1000 oil supply device operating instructions" requirements, the thermal control settings. The EH oil pump linkage test solenoid valve is originally connected to the top of the original EH tank and is now connected to the bottom of the new EH tank.
4. Post-upgrade trial run and overall acceptance 4.1 Prior to trial operation, tighten the live nut of each oil supply device with a spanner wrench to prevent the system from leaking due to vibration during transportation. After all the connection ports of the oil supply device are connected, the electrical power line of the electrical professional is well equipped. After the insulation of the pump motors is tested, the filter pump and the cooling pump power are sent to the forward and reverse directions and the idle current is recorded.
4.2 Fill the oil tank with the oil pump. When the oil is refueled, the four liquid level alarm indicators are measured by the thermal professional. The system needs to add four barrels of anti-fuel oil. Under the condition that the whole system does not have the overall oil circulation, the internal oil circulation of the oil tank is performed by using the oil filter device and the fine oil filter device on the oil station. Or the short engine oil drive and the engine on the oil engine interface with the short-circuit method, the entire system oil circulation.
4.3 Before the oil circulation in the entire system, the direction of main oil pump test A and B is correct. Oil pump can be run simultaneously with two pumps. The system pressure is controlled between 2.5~3.5Mpa. The oil temperature is between 45°C and 55°C. The upper limit of the digital thermometer is 55°C and the lower limit is 35°C. Press the automatic Cooling button is put into automatic operation.
4.4 When the system recovers, the oil quality must reach the NAS level 5 standard, and then replace all the filter elements of the EH system. After the filter element is replaced, the main oil pump is started again to continue the oil circulation. If the time is sufficient, the cycle is 24 hours, and the minimum is not less than 8 hours.
4.5 After the whole system recovers, adjust the system pressure on the A pump to 18MPa, loosen the DB-10 relief valve handle to the system pressure to 17MPa, and then adjust the screw to adjust the system pressure to 14.5MPa, stabilize for three minutes, and finally Stop pump A, start pump B, use the same adjustment method to make the oil pressure is 14.5 MPa, other various tests by DEH debugging, during commissioning, should pay attention to the pressure changes in the system when the oil motive action.
5. Operation after oil station renovation After the overhaul of Unit #1, after repeated tests and multiple start-stops, the EH oil pressure can be stabilized at 14.6 MPa, which can fully meet the requirements for long-term safe operation of the unit, and the EH oil quality test is qualified. The operating conditions of the two EH oil supply units are compared as follows:
6. Conclusions The upgrade of the 6.1EH1000 oil station is successful and necessary. It can effectively avoid the damage caused by the alternating stress of the EH oil piping system, improve the reliability of the system, increase the service life of the system, and reduce the The maintenance workload of the system also has a certain energy saving effect due to the drop of the EH pump current.
6.2 Through the EH oil analysis test, the EH1000 oil supply device is beneficial to improve the EH oil quality, in particular, it can effectively prevent the EH oil acid content from exceeding the standard.
6.3 EH petrol station should strengthen the cleaning work in the fuel tank at the time of delivery. At the same time, the operation control of the recirculating oil pump and the cooling oil pump carried by the oil station should also be integrated into the DCS for centralized control.
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