2.

2M PENSTOCK PROTECTION VALVE DESIGN PHILOSOPHY

Valve provided with 2 sets of seals. Service seals. Maintenance seals. Both seals are on periphery of valve disc and on downstream of the valve Maintenance seal operated using external water pressure. Disc of Lattice design. Valve operated by 2 nos. single acting servomotor oil pressure to open and counter weight to close the valve. Servo motor oil pressure supplied from a separate oil pressure unit. Valve provided with locking pin for valve maintenance purpose.

BYPASS ARRANGEMENT:
- Provided with a 200mm dia hydraulically operated bypass valve (needle type) for balancing pressure across the valve before opening. - Bypass provided with guard gate valve for isolation of bypass valve

UPSTREAM PIPE:
PPV provided with fabricated upstream pipe with one end suitable for welding with the penstock and downstream end with flange suitable for connecting to the valve. - Upstream pipe has provision for following connections, Bypass valve pipe Penstock drain pipe

DISMANTLING JOINT AND DOWNSTREAM PIPE:

Downstream side of PPV provided with dismantling joint to enable removal of valve. Downstream pipe section suitable for welding to penstock at one end and the other end suitable for receiving the dismantling joint. Downstream pipe has provision for following connections. a) Bypass valve pipe. b) Air release cum vacuum valve.

AIR RELEASE CUM VACUUM BREAKER VALVE:  Provided on downstream pipe to expel the air during penstock filling and
admit air during penstock downstream watering.  Antivacuum valves will also admit air in the penstock during penstock rupture or should sub atmospheric conditions prevail in the penstock.  Additional air release provided on top of downstream penstock pipe for air release after above antivacuum valve inlet openings are covered in water during penstock filling through bypass arrangement.

VALVE FOUNDATIONS AND SOLE PLATE:

Valve foundation fasteners and sole plates are provided. The valve is free to slide on sole plate.

DESIGN CRITERIA:
 PPV is designed to open under balanced head conditions.  Valve is designed to close under, a) Balanced head conditions, during normal operation. b) Close against full flow of 21 m3/s. c) Close against partial penstock rupture condition considering worst possible location of penstock burst.  Valve is opened with hydraulic oil pressure.  Valve held by mechanical latch mechanism in fully open position.  Valve closed by counter weight.  Latch mechanism is released by operating trip cylinder via a solenoid operated valve.  Penstock water pressure is used to operate trip cylinder.

MATERIAL OF CONSTRUCTION FOR PPV:

1. 2. 3. 4. BODY DISC SHAFT BEARING BUSH - CAST STEEL (BS 3100 Gr A4) - CAST STEEL (BS 3100 Gr A4) - FORGED STEEL (BS29 ) - STAINLESS STEEL CARRIER WITH LEADED BRONZE MATRIX - EPDM - NITRILE RUBBER - ASTM A479 TYPE 316 - ASTM A240 TYPE 316

5. 6. 7. 8.

VALVE SEAL HOSE SEAL SEAT RING CLAMPING RING

OPERATION OF PPV:
1. NORMAL OPENING:
OPEN COMMAND FROM LOCAL PUSHBUTTON OR REMOTE

BYPASS VALVE OPENS

PRESSURE ON DOWNSTREAM SIDE EQUALISED

DIFFERENTIAL PRESSURE SWITCH GIVES SIGNAL TO OPEN THE VALVE

SOLENOID ENERGISED AND MAIN PUMP ON

VALVE OPENS FULLY ACTUATING LIMIT SWITCH

PUMP STOPS AND SOLENOID DE-ENERGISED

CRANK ARM OF VALVE IS MECHANICALLY LATCHED

2. NORMAL CLOSING:
 Delatching by activating the trip mechanism.  Closing by counterweight.  Closing requires energizing solenoid valve on trip cylinder.  Normal closing takes place in dual speed, a)First 90% in about 20% of the closing time, b)And balance 10% in about 80% of the time.  This is site adjustable, achieved by additional return flow path activated by limit switch adjusted at 90% travel through different solenoid valve.

3. EMERGENCY CLOSING:
Initiated by one of the following;  Burst penstock !!!  Turbine rejects load and MIV fails to close.  Water velocity through fully open valve exceeds preset value.  Increase sensed by over velocity trip mechanism which will delatch the valve held in fully open position. Except for closing time, sequence will be the same. -Closing time comes down by 50% due to higher hydrodynamic torque.

Sequence of events in penstock system, leading to complete emergency closure of PPV.

Occurrence of emergency condition. Velocity of water through Penstock rises instantly- static pressure starts falling. .Velocity increase passes through a preset value over velocity sensing device is activated. Annunciation starts. Solenoid valve on trip mechanism gets energised. Trip mechanism operates and delatches valve blade. BFV starts closing rapidly aided by hydrodynamic torque. Oil in the main servo cylinder is forced out to sump in hydraulic power pack.

-Oil pressure in servomotor rises rapidly, well above the normal delivery pressure of the hydraulic power unit.When flow separation starts in downstream line, antivacuum valve opens to admit air.

At about 15% from fully closed position, energizes another solenoid valve in return flow oil path with more restricted passage and valve closure slows down. Internal cushion in cylinder comes into effect and closing slows down further. Virtual flow isolation takes place at 95% of fully closed position.

Valve closes fully, close limit switch activated.

Annunciation stops.

FAULT INDICATING SIGNALS AUDIO VISUAL ANNUNCIATION:

 RUNNING PUMP FAILED  STANDBY PUMP FAILED  WATER FILTER CHOKED  TANK OIL LEVEL LOW  OIL FILTER CHOKING  OIL PRESSURE HIGH  OIL TEMPERATURE HIGH

LOCKING PIN ENGAGED BYPASS VALVE FAILS TO OPEN BFV FAILS TO OPEN BFV FAILS TO CLOSE WATER VELOCITY HIGH.

 LOW WATER PRESSURE FOR TRIP CYLINDER

SYSTEM STATUS INDICATORS - INDICATING LAMPS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Power supply on Indication Hydraulic Pump Tripped DC Supply ON Heater ON Bypass valve open Bypass valve closed Penstock Valve open Penstock Valve closed Penstock Valve 90% closed Phase Indication Lamps Hydraulic Pump Running

LOGIC MODES INTERLOCKS

Valve opening precluded unless pressures on U/S and D/S are balanced. Low oil level in the reservoir prevents hydraulic power unit motor start. Locking pin engaged will prevent valve opening sequence. After emergency closure valve cannot be opened unless reset push button is operated. Over velocity automatically closes the valve. Standby pump starts automatically on failure of main pump. High oil pressure will stop hydraulic pump motor. High oil temperature will switch off heater.

OVER VELOCITY SENSING DEVICE

PRIMARY FUNCTION:
To monitor flow velocity through the valve and generate a signal in the event the flow velocity exceeds the preset value.

REQUIRED ACTION:
Convert signal into mechanical force large enough to be able to release the latch mechanism so as to initiate valve closure.

ADDITIONAL REQUIREMENT:
Accurate flow measuring for turbine efficiency test.

MAIN INLET VALVE

DESIGN PHILOSOPHY
MIV PROVIDED WITH 2 SETS OF SEALS; a) Service seal on downstream side b) Maintenance seal on upstream side. Both seals are sliding metallic seals. Seals operated using penstock water pressure Double acting servomotor to open and close the valve Servo motor mounted directly on valve body Locking pins provided for valve closed position for maintenance

BYPASS ARRANGEMENT:
 Valve provided with external bypass for balancing pressure across MIV.  An oil pressure operated needle valve and Guard valve.  Oil pressure for needle valve operation supplied from main oil pressure unit.

 Needle valve provided with dismantling joint. UPSTREAM PIPE

 MIV provided with Upstream pipe.  U/S pipe has provisions for following , a) Bypass valve pipe connection b) Penstock dewater drain pipe with energy diffuser.

DOWNSTREAM PIPE
 MIV provided with Downstream pipe with dismantling joint.  Bypass valve pipe connection  Air release valve  Pipe tap off.

DESIGN CRITERIA
MIV designed to open under balanced pressure head conditions But close at rated discharge of 10.5 m3/s, And maximum turbine flow of 11.05 m3/s under emergency condition Valve controls arranged so that valve may be automatically opened or closed.

MATERIAL OF CONSTRUCTION
1. 2. 3. 4. 5. 6. 7. BODY ROTOR TRUNNION SERVICE SEAL MAINTENANCE SEAL SEAT BEARING CAST STEEL (BS 3100 Gr A4) CAST STEEL (BS 3100 Gr A4) FORGED STEEL (BS29 WITH SS SLEEVE) ASTM A 217 Gr CA15 ASTM A 217 Gr CA15 ASTM A 217 Gr CA15 SELF LUBRICATING

MIV HYDRAULIC CONTROL FEATURES

Servomotor double acting (requires oil pr for operation) Maintenance seal & service seal operated by penstock water pr. Bypass valve operated by double acting hydraulic cylinder. Oil pr system (including accumulator) available exclusively for inlet valve operation.

OIL PRESSURE SYSTEM - IMPORTANT FEATURES

 pumps operate under pr switch control.  Two pumps one acting as main and other standby.  Accumulator designed to cater for 3 strokes without assistance from pumps.  Main oil pump motor operates automatically under action of pr switch.  Standby pump operates automatically.  Directional control valves Poppet type

LOGIC MODES - INTER LOCKS

Prevent opening of rotor in case maintenance seal is closed. Prevent opening of rotor in case service seal is closed Prevent closing of service seal in case rotor is open. Interlock valve provided to prevent application of service seal.

Valve opening precluded unless pressure on U/S and D/S are balanced. Low oil level in oil reservoir will prevent hydraulic power unit motor to start High oil pr will stop hydraulic pump motor Low oil pr will start the pump
Single phase preventer for motor protection

SPHERICAL VALVE
FAULT INDICATING SIGNALS - AUDIOVISUAL ANNUNCIATIONS
1. 2. 3. 4. 5. 6. 7. 8. Service seal fails to open Service seal fails to close Bypass valve fails to open Bypass valve fails to close Rotor fails to open Rotor fails to close Both pumps fail Entire opening process does not open in preset time, contacts give alarm in main control room. 9. Entire closing process does not close in preset time, contacts give alarm in main control room.

SYSTEM STATUS INDICATORS - INDICATING LAMPS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Maintenance seal closed Maintenance seal open Service seal closed Service seal open Bypass valve open Bypass valve closed Rotor open Rotor closed Rotor creep Pump-1 ON Pump-2 ON

12. 13. 14. 15. 16. 17.

Oil pressure low Control supply healthy Pressure Balanced Hydraulic oil level low Indication for local mode Indication for remote mode

AUTO SEQUENCE
OPEN:
Bypass valve opens

Pressure equalizes

Service seal is withdrawn

Open rotor

Bypass valve closes CLOSE: Close rotor

Service seal is applied