Proportional valve for electro hydraulic governing control supplied by

M/S Rexroth Bosch (500MW)

The EHTC system with Proportional valve is used for the control of direct operated high
response valves STW and uses two stage position controls. In first stage demand signal from
speed /load, controller is compared with EHC piston position and a difference is applied as
differential input command value to Amplifier module. In second stage actual value of pilot valve
spool position is measured through inductive position feedback transmitter and compared with
the externally applied command value. Any differences between the actual and command
values drive the proportional valve.

System Overview –

The movement of proportional valve allows control fluid to admit

in the space above or below the piston with the opposite side of the piston
opened to the fluid drain. The resulting motion of the piston is transmitted to the
sleeves via lever which in turn slides on the follow-up pistons, as a result
secondary oil pressure varies and changes the control valve position accordingly.
 ANNEXURE-A

Standard checks to be carried out during Erection & Commissioning:

1) House the Amplifier and capacitance module in a JB and locate near the Governing rack
(1<Distance< 5 meters) .It is advised to use metallic JB and ensure that the body
and cover of the JB is properly grounded with Plant Earth.
2) Enabling signal and supply of Capacitance module shall be extended through an isolator
/MCB from system power supply TBs of max EHTC cabinet. System power supply 0V
line TB shall be connected to dedicated electronic earth pit. In KTPS Power supply is
taken from X31:32 of CJJ02 panel & enabling signal to Pin 3 of Amplifier module is from
X31. (X32 is electronically earthed)
3) Command value cables and inductive position transducer cable shall be separately
screened .It is recommended by manufacturer to use Screened 1.5 mm2 cables for
solenoid command .In KTPS 3C x 2.5 Sqmm Cu cable is used for the power supply to
capacitance module and 1mmsq cable is used from amplifier to proportional valve
solenoid.
4) Check the Command output from EHTC cabinet is 20 to 4 ma with respect to 0 to 100 %
command.
5) Supply to amplifier module and enabling signal should be 24V dc, with M having Zero
potential.
6) Two independent shielded cables with conduits, for Proportional Valve Solenoid and
LVDT portion (Feed back portion of the Proportional Valve) shall be laid from Amplifier
Unit to the Proportional valve. Avoid bunching of the Power cables and the Feedback
cable of the valve inside the JB.
7) Main cable shield from EHTC JB to EHTC cabinet (CJJ02) in DCS room, shall be
connected to 'A' BUS at panel end & and shall be kept open at the junction
box end.
8) Shield wires of Spool position FB (LVDT Portion of the Proportional Valve) to be
connected at the Z point of Power supply, only at the amplifier module end (Pin 2 of
Amplifier module).
9) Ensure that voltage at the input of capacitance module should not drop below 21 V.
10) Avoid multiple junctions in the flow path of the signal from CJJ02 to proportional valve
via amplifier JB.In KTPS connection cables were directly terminated from amplifier
module to proportional valve and similarly cable from CJJ02 TO Amplifier module was
directly terminated at amplifier end without marshalling TBs.
11) Shielded cables for the command lines (Proportional Valve Solenoid) shall be kept
floating at both ends.
12) Null point adjustment of the Proportional Valve and the Amplifier module shall be carried
out as per the data sheet. In Amplifier Module it is possible to adjust externally : The
ramp time up to approx. 1 s (tmin approx. 1 ms), & the command value reduction up to
approx. 20% and 3) the actual value zero point within the range ± 30% through trimming
potentiometers.
Standard tuning procedure for amplifier module:

12a). Differential Input (4-20mA or ±10V) from the DCS module is applied to the Amplifier Card
(Pin 4 & 5), which can be measured in voltage form ±5V at the front panel of the Amplifier
Card.

12b). With hydraulics and the Electronics/Power supply “ON” apply Differential Input of
12mA or 0V from the DCS module to the Amplifier card, correspondingly measure the
Voltage at ports 2(Voltage point on the Multi meter) and 3 or 4 (Common point on the
Multi meter) given on the front panel of the Amplifier Card. The voltage reading on the
Multi meter should be 0V; if not tune the R1 potentiometer till it reads 0V.
12c). With Differential input of 12mA or 0V from the DCS module to the Amplifier card the
Voltage measured at ports 1(Voltage point on the Multi meter) and 3 or 4(Common
point on the Multi meter) given on the front panel of the Amplifier Card should be 0V,
else tune the R21 potentiometer till it reads 0V or the zero point on the valve is
achieved.

12d). Apply the Differential Input (4-20mA or ±10V) in steps from the DCS module to the
Amplifier Card and correspondingly measure the Voltage at the Ports on the front
panel of the Amplifier card. Command value should match the Actual Value.

Scaling of Differential Input applied and the Voltage measured on the front panel of the
Amplifier Card.
Differential Input.
4mA 12mA 20mA
-10V 0V +10V
Voltage on the Front Panel of the Amplifier Card (Command Value & Actual Value).
-5V 0V +5v
The supplied position valve is susceptible to Signal interference. Hence utmost care
shall be taken during power supply and earth checks of the system.
 Annexure –B

Value of gain, derivative

gain and time constants
A4 - 11 can be set at front panel
as per this instruction.
Description Engg. Test Commi- Mainte-
Dept. Dept. ssioning nance

POSITION CONTROLLER

Check Link S1, S2 & S3 Pos. 2-3

Check Link S5, S6 & S7 OUT
S8 IN

Check at R3M6 Switch SW1.1, SW1.3 ON

Check for MAX Output selection of
EHC 1 & 2 Pos. at R3M6 jack-A4.

Set Link S11 at R3M6 IN

Simulate 0.0 V at pins P3-10,

Ref I/p (P3-1, 2) to 0 mA
and Actual I/p’s (P3-3, 6 & 8) to 0 V
Set at R3M6 at Jack- B5
By POT VPIR (P18 -offset) 0.000V
Set POT PDT (P16-Der.Time Constant) 7h
Set POT PDK (P19-Der. gain) 12h
Set POT PIT (P20-Int. times) 7h
Set POT PIK (P17-PI. gain) 12h

Set at R3M6 JACK B3 (Upper Limit) -10.000V

by POT P22 (Internal Pot- not on front plate)
Set at R3M6 JACK A3 (Lower Limit) +10.000V
by POT P21 (Internal Pot- not on front plate)

Controller action to be checked by Polarity

Reversal of controller O/P