蓄能式液控缓闭止回蝶阀

Hydraulic Slow-Closing Check Butterfly Valve

Operation Manual
1400Dx7pk41XL-6NC
for Indonesia Lampung 2 X 100 MW Power Plant Project
Hongcheng Group Operation Manual of Check Butterfly Valve

SAFETY GUIDANCE

 When unloading, the lifting and storage of equipment shall strictly

follow the marks on the packing case.
 When long sotred, the valve, hydraulic station and electric cabinet
shall be put inside the shady and cool, dry and ventilating room. The
hydraulic station and electric cabinet shall be protected against
monisture and dust. All machined surfaces shall be coated with
anti-rust oil. All articles shall not be piled up in the open air.
 The valve shall be prohibited to be used as a blind.
 During the maintenance of the valve, the dismantling or replacement
of parts and components shall follow the operationa manual.
 Hongcheng Group Operation Manual of Check Butterfly Valve

Content
Part I Composition, Application and Maintenance of Mechanical Part
Part I Composition, Application and Maintenance of Mechanical Part ...................................................... 1
I. General ................................................................................................................................. 1
1. Composition of System ................................................................................................................... 1
2. Application and Characteristics....................................................................................................... 1
II. Valve Part ............................................................................................................................ 2
1. Structure: ......................................................................................................................................... 2
2. Installation: ...................................................................................................................................... 4
3. Application and Maintenance .......................................................................................................... 5
3.1 Valve Opening:.............................................................................................................................. 5
The valve opening is carried out with the water pump interlock. The interlocking start sequence of
the pump and the valve generally have the following cases. Selection shall be made according to the
actual situation..................................................................................................................................... 5
3.2 Valve Closing ................................................................................................................................ 6
3.3 Adjustment of Fully Opened and Fully Closed Positions of Valve ............................................... 6
3.4 Adjustment and Replacement of Disc Seal Ring ........................................................................... 8
3.5 Adjustment and Replacement of End Seal of Main Shaft ............................................................. 9
4. List of Wearing Parts..................................................................................................................... 10
Part II Installation, Operation and Maintenance of Hydraulic System ................................. 11
I. Composition of Hydraulic System ..................................................................................... 11
II. Installation of Hydraulic System ...................................................................................... 12
1. Installation Steps and Implementation Methods ........................................................................... 12
III. Principle & Function of Hydraulic System and Structure & Principle of Main
Components ........................................................................................................................... 13
1. Working Principle of Hydraulic System ....................................................................................... 13
2. Functions of Hydraulic System ..................................................................................................... 14
2.1 Oil Supplementation of Hydraulic System .................................................................................. 14
2.2 Hydraulic Control Circuit ............................................................................................................ 15
3. Structure and Working Principle of Main Components ................................................................ 17
3.1Oil cylinder ................................................................................................................................... 17
3.2 Accumulator ................................................................................................................................ 18
3.4 Oil Pump .................................................................................................................................................... 18
3.4 Electromagnetic Ball Valve ......................................................................................................... 19
3.5 Two-Way Cartridge Valve ........................................................................................................... 20
3.6 Hydraulic One-Way Valve ........................................................................................................... 21
3.7 Relief Valve ................................................................................................................................. 22
4. Matters and Attentions for Maintenance .................................................................................................. 25
I. Installation of Electric Cabinet ................................................................................................................... 28
II. Descrpition of Control Functions.............................................................................................................. 28
2. Control of Oil Pump Motor ........................................................................................................... 28
3. Valve Control ................................................................................................................................ 29
4. Acceptance and Feedback of Signals ............................................................................................ 30
III. Valve Operation ............................................................................................................... 30
1. Commissioning: ............................................................................................................................ 30
2. Operation and Control of Valve: ................................................................................................... 32
2.1 Local “Single Action” Operation (to be used when installation, commissioning and
maintenance): .................................................................................................................................... 32
2.2 Remote “Interlocking” Operation: .............................................................................................. 32
IV. General Faults and Analysis ..................................................................................................................... 33
V List of Electrical Elements and Electrical Drawings ......................................................... 34
1. List of Electrical Elements ............................................................................................................ 34
2 Electrical Drawings ........................................................................................................................ 34
 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Part I Composition, Application and Maintenance of Mechanical Part

I. General
1. Composition of System
The design, manufacture and acceptance of hydraulic slow-closing check butterfly valve with
accumulator are in accordance with JB/T5299-1998 “Hydraulic Check Valve”.
Hydraulic slow-closing check butterfly valve with accumulator is composed of three parts: valve,
hydraulic station and electric cabinet. Refer to Fig. 1.

1 2 3

1. Valve 2. Hydraulic Station 3. Electric Cabinet

Fig. 1

2. Application and Characteristics

Application:
The valve is installed at the outlet of water pumps in the urban water supply, drainage, irrigation
and other projects as well as the thermal power plants water pumps and circulating water pump,
used to prevent the pump reversing and eliminate and restrain the occurrence of water hammer.
Characteristics:
 The body and the disc are made of seawater resistant nickel-chrom alloy cast iron to

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

imporve the corrosion resistance of the cast iron in the seawater. The fasteners and the
fittings for the shaft, seal retaining plate and flow surface are made from stainless steel. In
order to ensure the better seawater corrosion resistance of the valve, the valve parts surfaces
touching with the seawater are painted with “ZF101” heavy-duty coating. This kind of
coating has good performance of chemicals resistance and seawater resistance, developed
and manufactured by the seventh research institute of China State Shipbuilding Corporation.
This kind of coating has been verified by the ministeral division, suitable for the situations
of seawater resistance such as the ship cabin, the water pipeline at the bottom of sea, etc.
 The main seal type is stainless to rubber, adopting double eccentric structure, of reliable seal
performance. The seal ring can be compensated and adjusted through the regulating screws
on the disc after being worn out.
 The bearing is lead-free, oil-free self-lubricated bearing, of strong bearing capacity, small
friction coefficient, good wear resistance and little friction resistance.
 Our patented technology of sand erosion resistance butterfly valve – double compensatory
movement seal structure is used for the shaft end seal.
 The body and disc are integrally cast by the resin sand-making and the finite element
analysis was applied in design and calculation with enough safety margin, sufficient
strength and rigidity. The disc is of the streamline design, with small flow resistance
coefficient.
 The hydraulic system adopts tccumulator to store energy, the circuit blocks adopt
high-voltage integrated design with compact structure and good performance of pressure
holding.
 The electric control system adopts PLC for control with reliable control.
 The control is flexibie. The valve and pump are interlock controlled and the interlock
control program can be adjusted based on the working conditions and pump characteristic.

II. Valve Part

1. Structure:
Refer to Fig. 2.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

1. Transmission case 2. Packing gland 3. Packing 4. Composite bearing

5. Body seal ring 6. Body 7. Adjusting plate 8. Disc seal ring
9. Composite bearing 10. End cover 11. Lower shaft 12. Disc
13. Pin 14. Upper shaft 15. Foundation bolt 16. Hydraulic oil cylinder
Fig. 2

1.1 Datasheet of Valve

Nominal Pressure 0.6
Shell Test Pressure 0.9 MPa
Seal Test Pressure 0.66
Working Temperature -10～65°C
Suitable Medium Seawater
Opening valve time at
20～60
constant speed (s)
Adjustable
Quick closing 70±8° 2.5~20
Closing valve time (s)
Slow closing 20±8° 6~60

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

1.2 Material List of Valve Parts

Parts Materials
Body Ni-Cr cast iron（STQNiCr+ZF101）
Disc Ni-Cr cast iron（STQNiCr+ZF101）
Shaft Stainless steel (316L)
Body seal ring Stainless steel (316L)
Disc seal ring Chloroprene rubber (CR)
Adjusting plate Stainless steel (06Cr18Ni11Ti)

2. Installation:

2.1 Hoisting Requirements of Valve: Refer to Fig. 3.

When lifting the valve, the sling is not allowed to tie on the valve end cap, valve neck, or the
transmission device. High strength and long enough steel sling shall be used to fix on the lifting
screw to ensure that the included angle of steel sling is less than 60 °. When lifting, smooth
movement shall be carried out to avoid impact when lifting.

Included angle of steel

sling less than 60°

Fig. 3
2.2 Installation Requirements of Valve: Refer to Fig. 4.
1) The distance from the valve center to the pump outlet must be more than 2000 mm. If such
requirement can not be met, then rectification measures shall be taken. In possible conditions,
this distance shall be increased as far as possible to reduce the adverse effects of turbulent flow

of the pump outlet on valve.

2) Some pumps still have one oviduct equipped at the pump outlet. When the valve is fully
opened, the disc should not be inside the oviduct.

3) The disc sealing plane shall face the water pump outlet and the disc lower back should be in

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

the downstream direction of the pump, as shown in Fig. 4.

4) The hydraulic station and the valve are connected together. The electric conntrol cabinet shall
be installed locally.

图 Outlet of water
pump

Disc back

Fig. 4

3. Application and Maintenance

Special Note:
The valve must be achieved coordinated control with the pump. Although the valve has the
function of local operations, but the feature is available only in the commissioning process of
valve or the pipe fillint water; after that, the start and stopping operations of pump are
coordinated controlled with the valve. The interlock start sequence of the pump and the valve
must be determined by user according to the characteristics of the water pump.

3.1 Valve Opening:

The valve opening is carried out with the water pump interlock. The interlocking start sequence
of the pump and the valve generally have the following cases. Selection shall be made according
to the actual situation.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Special Note:
(1) At the outlet of centrifugal pump, the pump starts first. After reaching the rated speed,
the valve opens uniformly, realizing the joint control of pump and valve.
(2) At the outlet of axial flow pump, the valve opens uniformly. When the opening angle is
up to 15 ° ± 5 °, the pump starts, realizing the joint control of pump and valve.
(3) At the outlet of mixed flow pump, as the case may be, if the condition of mixed flow
pump is close to that of centrifugal pump, implementation shall be carried out according to
program (1); if the condition of mixed flow pump is close to that of axial flow pump,
implementation shall be carried out according to program (2).

3.2 Valve Closing

Valve closure is also carried out with the water pump interlock. When closing, the pump-valve
interlock action sequence should be determined according to the characteristics of water pump.
The interlock action sequence of the pump and the valve generally have the following cases.
Selection shall be made according to the actual situation.

Special Note:
(1) At the outlet of centrifugal pump, the valve shall be closed while the pump is stopped.
(2) At the outlet of axial flow pump, the valve closes first to the set angle and then the
pump is stopped.
(3) At the outlet of mixed flow pump, as the case may be, if the condition of mixed flow
pump is close to that of centrifugal pump, implementation shall be carried out according to
program (1); if the condition of mixed flow pump is close to that of axial flow pump,
implementation shall be carried out according to program (2).

3.3 Adjustment of Fully Opened and Fully Closed Positions of Valve

Special Note:
The fully open and fully closed limit of valve is positioned mechanically. The limit switch
on the electrical control cabinet is used to detect the signals and send signals to DCS.

3.3.1 Adjustment of Fully Closed Position

The fully closed position of valve shall be adjusted through the adjusting bolts at fully closed
position on the gear box. The adjustment basis is to ensure that the rubber seal ring on the disc
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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

seated in the middle of body seal seat which has been adjusted well before delivery from the
factory.

Special Note:
For re-adjustment, set the electric control mode at local “single action” mode, close the
accumulator and open the oil pump. With the oil supplied by the oil pump, open the valve
slowly. When the crank leaves from the fully-closed position to the adjustable space (angle),
stop the oil pump from supplying oil and adjust the bolts as shown on the drawing.

Adjusting bolts at fully

closed position
Fig. 5

3.3.2 Adjustment of Fully Opened Position

The fully opened position of valve shall be adjusted through the adjusting bolts at fully opened
position on the gear box. The adjustment basis is to ensure that the disc plane is parallel to the
pipe axis which has been adjusted well before delivery from the factory. Re-adjustment shall be
made subject to change, referring to the regulation method of adjustment of fully closed
position.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Adjusting bolts at
fully opened position

图六

Fig. 6

3.4 Adjustment and Replacement of Disc Seal Ring

Body seal ring

The material of disc seal ring is chloroprene
rubber. As a result of long-term working, the seal
Disc seal ring
ring gradually loses its elasticity due to aging or is
Adjusting plate
worn in the work process, inevitably resulting in
destroying the valve sealing surface and causing Adjusting screw
leakage, then the seal ring needs to be adjusted; if
Disc
badly worn or damaged due to cuttingby the
foreign body or even aged completely, the seal
Fig. 7
ring must be replaced.

1) Adjustment of disc seal ring: As shown in Fig. 7.

Adjust and evenly tighten the adjusting screws corresponding to the fray of seal surface.
2) Replacement of disc seal ring of main valve: Refer to Fig. 8.

Loosen the adjusting screws on the adjusting plate, slowly remove the adjusting plate through
the screw holes on the adjusting plate, remove the damaged seal ring, replace with new seal ring,

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

reattach the adjusting plate and evenly tighten the adjusting screws.
Installation direction of seal ring:
Place the lower part of seal ring into into the groove of the seal ring according to Fig. 9.

Fig. 8
1. Disc 2. Adjusting screw 3. Adjusting plate 4. Body seal ring
5. Disc seal ring 6. Removal bolt

Fig. 9

3.5 Adjustment and Replacement of End Seal of Main Shaft

The valve journal seal is composed of packing and Yx seal ring. The material of packing is
PTFE; it will be worn due to the friction with the shaft during the working process, which will
result in the leakage from the shaft end. If serioudly worn out, exceeding the compression limit
of packing, the packing must be replaced.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Packing
Body Yx seal ring Packing gland Shaft

Fig. 10

3.5.1 Adjustment of Packing of Upper Shaft

Evenly tighten the adjusting nut on the adjusting stud and the adjusting gland extrudes the
packing to compress, thus to achieve the sealing effect of shaft end.

3.5.2 Replacement of Packing of Upper Shaft

Remove the cover of driving gear box and the crank, release the adjustment bolt, remove the
packing gland and remove the damaged packing, replace new packing, reattach the packing
gland, evenly tighten the adjustment bolt and put on the crank. The packing of shaft is composed
of total three types of packing: one upper packing, three intermediate packing and one lower
packing forming one group, the free height of about 40mm and the compression height of about
32mm. When replacement of packing, fill, one group must be replaced.

4. List of Wearing Parts

No. Name Model & Spec.

1 Disc seal ring DN1400 PN6
Packing Packing 125-40A-5
2 Shaft end seal
Yx seal ring Seal ring for Yx shaft d125
3 End cover O-ring O-ring 170X5.3G

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Part II Installation, Operation and Maintenance of Hydraulic System

I. Composition of Hydraulic System
The hydraulic system is composed of hydraulic station, oil cylinder assembly and high-pressure
hose.

1, 2
6

7
3

10

Fig. 1 Master Drawing of Hydraulic Station

(Refer to Table 2.1 for main component of hydraulic station)

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Table 2.1 Main Components of Hydraulic Station and Specifications of

Corresponding Seal Ring
No. Screws to be
Name Model Manufacturer
matched with
1 Motor Y100L1-4-B5 4-M10x45
2 Oil pump 2.5MCY14-1B Shaoyang Hydraulic 4-M8X65
3 Relief valve DBD-H6P315S1 Beijing Huade 4-M6X50
4 Electromagnetic
23QDF6B/31.5E24 Shanghai Hanghai 4-M6X30
ball valve
5 Hydraulic SV10PA1-30 Beijing Huade 4-M10x60
one-way valve
6 Pressure YTK-03 Shanghai Automation
controller Instrument Factory
7 Pressure gauge YN-100 Wuxi Xuehu

8 Accumulator NXQ2-L40/31.5-H Fenghua

9 Stop valve Self-made

10 Oil tank 70L Self-made

II. Installation of Hydraulic System

1. Installation Steps and Implementation Methods
Installation Steps Implementation Methods
The hydraulic station shall be fixed on the corresponding
1. Fastening foundation according to the plant site layout; the oil cylinder
of equipment assemblies shall be installed at the in the corresponding valve
position and fixed with a hinge pin and collar.
Pre-installation The high-pressure hoses shall be connected in accordance
with their corresponding adapters. The cylinder adapter near
2. Connection
to the trunnion is elbow. The length of high-pressure hoses
of hose
meet the distance requirements, maintain the relaxed state and
can swing.
Before installation, the interface shall be cleaned. When
formal installation, any sand or other dirt are not allowed enter
into the pipe. After the high-pressure hose, O-ring and
Formal Connection of combination washer are connected, tighten the nut and no
installation piping leakage is permitted. The high-pressure hose shall be fixed
with a tie to prevent the adapter from loosening due to the
swinging of hose when high-pressure instant starting and
opening and closing of valve.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

III. Principle & Function of Hydraulic System and Structure & Principle of
Main Components

1. Working Principle of Hydraulic System

Fig. 2 Hydraulic Principle Diagram

YV1 YV2

Valve opening + +

Valve closing - -

Table 2.2 Action Status Table of Solenoid Valve

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Table 2.3 List of Elements

No. Name of Elements Model & Spec. Qty.
1 Oil filter WU-63X180 1
2 Axial plunger pump 2.5MCY14-1B 1
3 Motor Y100L1-4-B5 1
4 Manual pump Self-made parts 1
5 Stop valve Self-made parts 1
6 One-way valve TJ016 3
Direct action type relief
7 DBD-H6P315S1 1
valve
8 Pressure gauge Y-100（0—25MPa） 1
9 Pressure controller YTK-03 1
10 Accumulator NXQ2-L10/31.5-H 2
11 Stop valve Self-made parts 2
12 Two-way cartridge valve TJ016-1/0215 1
13 Hydraulic one-way valve SV10PA1-30 1
14 Ball-type solenoid valve 23QDF6B/31.5E24 1
15 Two-way cartridge valve TJ016-1/0015 1
16 Throttle valve Self-made parts 1
17 Ball-type solenoid valve 23QDF6K/31.5E24 1
18 Switch of pressure gauge Self-made parts 1
High-pressure hose
19 16III-5000 2
assembly
20 Oil cylinder 125/63/325 1

2. Functions of Hydraulic System

The No. Of components described in the following sections are the same as that marked in the
hydraulic principle diagram.

2.1 Oil Supplementation of Hydraulic System

The hydraulic system is composed of a oil pump motor unit, a manual oil pump and a safety
valve used to prevent the system from excessive pressure. There are two ways for the oil
supplementing of system: manual and automatic.
2.1.1 Manual
The manual pump shall be used in case of emergency or when debugging without
electricity. When the manual pump switch is used, attentions shall be paid that the stop
valve below the the accumulator shall be closed.

2.1.2 Automatic Control by Pressure

The pressure of hydraulic system is controlled within the specified range by the pressure

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

controller (No. 9). Please refer to electrical control part for details of the pressure controller.
When the system pressure is lower than 14.5Mpa, the lower limit point of pressure controller is
connected and send a signal to start the pump while the oil pump fills oil to the accumulator.

Special Note:
1. The maximum pressure of system is controlled by the relief valve. The setting of relief
valve should be slightly higher than the upper limit of rated oil pressure of system, which
is usually adjusted to 18Mpa. If the system pressure is higher than this value, the system
pressure will be relieved by this valve to ensure that the system pressure does not exceed
the set value. When clockwise rotation of the valve, the system pressure increases; when
counterclockwise rotation, the system pressure reduces.
2. At the opening and closing moment of valve, the system pressure shown on the pressure
gauge is more than the rated lower limit, but the oil pump will be started due to the pulse
of the system pressure, which is a normal phenomenon.

When the pressure rises to 17Mpa, the upper limit point of the pressure controller is connected,
sending a signal to make the pump stop running.

2.2 Hydraulic Control Circuit

The hydraulic control circuit is mainly used to control the opening and closing of hydraulic
butterfly valve and the adjustment of its speed.

2.2.1 Opening and Closing of Hydraulic Butterfly Valve

The opening and closing of hydraulic butterfly valve is concerned with the action status of the
solenoid valve. When viewing the hydraulic principle diagram, please refer to the action status
table of solenoid valve. Please refer to Part 3 of this section for details of working principle and
structure of solenoid valve.

Special Note:
When the opening of main valve, the pressure oil is filled through the rodless chamber;
when the closing of main valve, the pressure oil is filled through the rod chamber.

2.2.2 Adjustment of Opening Speed

The opening speed can be adjusted by adjusting the throttle valve on the circuit block of
hydraulic station.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

Special Note:
1. The throttle governing of the hydraulic system is return oil governing.
2. When the throttle valve lever rotates clockwisely, the speed becomes slower; when the
throttle valve lever rotates counter-clockwisely, the speed becomes faster.

2.2.3 Adjustment of Quick and Slow Closing Angle and Speed

The two-stage closing speed and angle of oil cylinder can be adjusted by adjusting the adjusting
nut on the oil cylinder.
(1) Adjusting screw of quick and slow closing angle:
The quick and slow closing angle of valve can be
obtained by adjusting the screw 1.
When clockwise rotation of screw 1, the quick
closing angle reduces; when counterclockwise
rotation of screw 1, the quick closing angle increases.
Generally, the quick closing angles of hydraulic
butterfly check are valve angle 65 °, 70 ° and 75 °.
(2) Adjusting screw of quick closing speed:
3
The quick closing time can be adjusted by adjusting
the screw 2. When clockwise rotation of screw 2, the
quick closing time becomes longer; when
counterclockwise rotation of screw 2, the quick 2
1
closing time become shorter.
(3) Adjusting screw of slow closing speed:
Fig. 3 Two-Stage Adjustment Diagram
The slow closing time can be adjusted by adjusting of Valve Closing by Oil Cylinder
the screw 3. When clockwise rotation of screw 3, the slow closing time becomes longer; when
counterclockwise rotation of screw 3, the slow closing time become shorter.
The three adjusting screws are at the tail of oil cylinder and there is indication plate beside each
screw. The screws shall be adjusted to the specified quick and slow closing angles and times
according to the user’s requirements.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

3. Structure and Working Principle of Main Components

3.1Oil cylinder

1 2 3 4 5 6 7

Fig. 4 Structure Diagram of Oil Cylinder

(Refer to Table 2.3 for specifications of seal ring)
Table 2.4 Seal Ring of Oil Cylinder
No. Name Model Qty.
1 Dust ring DH-63 1
2 O-ring 118X3.55 GB3452.1 1
3 Yx seal ring D125 Q/ZB248-77 2
4 O-ring 118X3.55 GB3452.1 1
5 O-ring 6.9X1.8 GB3452.1 2
6 O-ring 25X3.55 GB3452.1 1
7 O-ring 15X3.55 GB3452.1 2

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

3.2 Accumulator

1) Internal Structure (Fig. 5)

The internal chamber of accumulator is separated
and splitted into the intracapsular part and
extracapsular part by the leather bag.
2) Working Principle
The intracapsular part is filled with nitrogen and
the extracapsular part is filled with hydraulic oil.
1
When the oil pump presses the hydraulic oil into
the shell (4) of accumulator, the leather bag will 2
deform and the gas volume reduces as the pressure
increases. The hydraulic oil is stored gradually. 3
When the hydraulic system needs hydraulic oil 4
for working, the accumulator discharges the
hydraulic oil.
Fill the nitrogen from the upper hole of accumulator.
First open the upper cover 1, then install the outlet
joint of the nitrogen-filling tool on the gas filling
Fig. 5 Structure of Accumulator
valve 2, open the stop valve on the nitrogen cylinder,
thus the nitrogen can enter the leather bag 3 of accumulator. The nitrogen-filling pressure is
8~9Mpa. Fill the nitrogen by the nitrogen-filling tool or the nitrogen-filling trolley and the
hydraulic oil will enter from the lower hole of accumulator.
3.4 Oil Pump
1) Structure: Refer to Fig. 6. 1 2 3 4 5 6
2) Working Principle: The driving shaft 6
actuates the cylinder of axial plunger pump
to rotate, enable the seven plungers 3 evenly
distributed on the cylinder to rotate around
the driving shaft center. The plunger head
is connected with the sliding shoes 2, which
presses on the retainer plate 1. The plungers
make reciprocating movement as the cylinder
rotates, thus to accomplish the oil absorption
and oil pressure action.

Fig. 6 Structure of Oil Pump

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

3.4 Electromagnetic Ball Valve

1) Internal Structure

Electromagnetic ball valve is one kind of change valve. The ball valve used for this system
is two three-way, normally open and normally closed type. Port P is pressure port and Port
B port is return oil port.

2 A

P B
1

4
Fig. 7 Structure Diagram of Electromagnetic Ball Valve

Table 2.4
No. Name Function
1 Electric lever Enlarge thrust
2 Magnet Give thrust
3 Valve core Change direction
4 Reset srping Reset
2) Working Principle
The electromagnetic force generated by the electromagnet through the amplification of leverage
promotes the valve core to change direction and achieve the cutting-off, connection and
changing direction (from the connection to the unconnection for the normally open type or from

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

the unconnection to the connection for normally closed type) of oil circuit .
3) Characteristics and Application
Electromagnetic ball valve has the characteristics of good sealing performance, quick reflecting
speed, use of high pressure, good adaptability of working medium and strong anti-pollution
ability.
Electromagnetic ball valve is used to control directly the connection and cutting-off of the main
oil line in the hydraulic system of small flow and used as pilot control components in the large
flow system.

3.5 Two-Way Cartridge Valve

1) Internal Structure

Control port K

Hole B
3

Hole B

Hole A

Hole A

Fig. 8 Structure Diagram of Cartridge Valve

Table 2.5
No. Name Function
1 Spring Control
2 Valve core Cutting off and connecting
3 Valve sleeve Oil circuit

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

2) Working Principle
The control of cover plate can achieved the control of direction, pressure and flow, achieve the
connection of Hole A and Hole B. When the oil pressure of control oil port disappears, Hole A
and Hole B can communicate with each other and the high pressure side flows to the low
pressure side.
3) Application
Two-way cartridge valve is used in the hydraulic systems of large flow,

3.6 Hydraulic One-Way Valve

1) Internal Structure and Function of Oil Port

Port P1: Inlet of forward oil and outlet of reverse oil
Port P2: Outlet of forward oil

2 P2 P1

3 Port K

P2

1
P1

Port K

图九 液控单向阀结构图

2) Working Principle
Hydraulic single-directional valve is one-way valve allowing reverse flow. When there is no
pressure oil through the control Port K, the role of the valve has the same function as that of the
single-directional valves, only allowing the oil fluid to flow in one direction P1 and P2 and cut
off in the reverse direction. When there is pressure oil through the control Port K, the valve
pushes the control piston 1 and lift the cone valve core 3 through the push rod, to remain the
valve at the open state and the oil liquid can flow reverse.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

3.7 Relief Valve

1) Internal Structure

1 2 3 4

Oil inlet port

Oil spill port

Fig. 10 Structure Diagram of Relief Valve

Table 2.6

No. Name Function

1 Adjusting lever Adjustment of relief pressure
2 Valve sleeve
3 Spring Pressure control element
4 Valve core Control

2) Working Principle
DBD direct action type relief valve is set with the maximum pressure of the system through the
adjustment of spring pressure. When the system pressure is higher than the set point, the excess
pressure is drained away through the relief valve channel, to ensure the security of the entire
system. As a safety valve in the hydraulic system, the relief valve is used to ensure the security
of the entire system.

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V. Commissioning, Operation and Maintenance of Hydraulic System

1. Commissioning Contents

1. Oil Filling
Fill the antiwear hydraulic oil L-HM46 or L-HV46 (cold regions) into the oil tank and
filter the hydraulic oil with the oil filter vehicle whose filtration accuracy is 20um. The
height of oil level is up to the upper limit of oil pointer.
2. Recharing Oil for System
1) All hydraulic elements are at the correct open or closed position.
2) Loosen the handle of relief valve, close the stop valve (11) under the accumulator and
open the stop valve (5) as shown on the hydraulic principle drawing.
3) Start the electric motor. If it’s the first time, then inching shall be adopted. Attentions
shall be paid to the correct direction of rotation. The correct direction is clockwise. After
the system runs normally, make the motor idle for several minitues, close the stop valve
(5) and adjust the handle of relief valve, the system will run for 5 minutes under the low
pressure of 2Mpa.
After the motor runs normally, gradually adjust the handle of relief valve and enable the
pressure rise step by step. The pressure will be stabilized for 2~3 minutes for every step
of pressure rise. After there is no abnormal noise, the pressure will rise to 18Mpa. Then
lock the adjusting rod of relief valve.
Open the stop valve (11) under the accumulator.
3. Setting of System Pressure
The setting of system pressure is mainly dealing with the adjustment of pressure
controller. Refer to the electrical control part for details.
Set value of system pressure:
Y 1 upper limit: 17Mpa; lower limit: 14.5MPa

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

2. Matters and Attentions for Operation

1) The ambient environment of the hydraulic system shall be kept clean, especially in the
early construction stage of power station, after the hydraulic station is hoisted to the
right position, the dust shall be avoided to scatter on the hydraulic station.
2) In the case of normal running, all selector valves are deenergized originally. The state of
every electromagnetic valve shall not be changed optionaly.
3) The set value of electromagnetic relief shall not be more than 18Mpa, so as to avoid the
overload of electric motor due to too high pressure.
4) The hydraulic system shall be filled in the specified grade of hydraulic oil. Different
grades of hydraulic oils shall not be used together. The pollution degree of hydraulic oil
used for the hydraulic system shall not be higher than the specified value. After the
system is put into operation for 3 months, the hydraulic oil shall be filtered once or
replaced, the oil tank shall be cleaned and the degenerative or polluted hydraulic oil
shall be replaced in time.
5) The control point of pressure controller shall not be changed optionally, so as to avoid
the influence to the normal working of system.
6) The leather bag inside the accumulator shall be filled with nitrogen, other gases such as
air or oxygen shall be strictly prohibitted to fill in.
7) The hydraulic station can work normally only after the commissioning according to the
commissioning procedure when the hydraulic station stops working for long time or the
hydraulic oil has been replaced.
8) When the repair of the valve, the control power supply shall not be switched off until the
pressure oil inside the accumulator is emptied, so as to prevent the formation of
differential pressure between the two chambers, resulting in the self-opening
phenomenon of the valve.

3. Maintenance Contents

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

1) The instruments and other elements shall be checked regularly to see whether their
functions are normal. If maintenance or replacement is necessary, attentions shall be paid
to the requirements for model and instructions.
2) When the hydraulic station is working, the pressure meter switch shall be switched on.
Attentions shall be paid to observe the pressure of pressure meter and the indication of
power supply. If there is any abnormality, the power supply shall be cut off promptly and
the corresponding treatment shall be adopted.
3) The pressure of nitrogen in the accumulator shall be checked regularly and the pressure of
nitrogen shall be ensured within the range of 8~9Mpa.
4) The height of oil level shall be checked every shift.
5) The ambient environment of hydraulic system shall be kept clean, the relative humidity of
ambient environment shall not be more than 85% and no erosioin of rain.
6) The hydraulic system shall be repaired periodically, the hydraulic oil shall be filtered or
replaced and the oil tank shall be cleaned.

4. Matters and Attentions for Maintenance

1) When dismanting, the yard shall be clean and the parts shall not be put on the floor directly.
2) When the hydraulic elements shall be dismantled during the maintenance of hydraulic
system, the oil pump shall be closed and the system pressure shall be released. When
unloading, the stop valve shall be opened, so that the pressure oil in the accumulator can be
discharged to the return oil tank.
3) When cleaning the hydraulic station and hydraulic elements, it shall be done in the clean
diesel oil and the cotton yarn mustn’t be used for wiping.
4) When dismanting the electric motor and coupling, the electric motor and the oil pump shaft
can not be attached hammered.
5) When dismanting, the seals shall not be installed by mistake or missed, and the damaged
seals shall be replaced.
6) Welding and machining shall not be made on the accumulator. Before dismanting the
accumulator, the stop valve under the accumulator shall be opened and the pressure oil in
the accumulator shall be emptied.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

5. Troubles Shooting
1) Serious Noise
Troubles Causes Troubles Shooting
The suction filter is blocked. Clean it or replace it with new oil filter.
The suction pipe has too many bends. Replace it with new pipe or install the
The oil pump pipe of larger inside diameter.
sucks air. The oil produces steam. Reduce the working temperature to the
suitable temperature.
The oil tank is airtight. The air filter is blocked.
The oil level in the oil tank is too low. Fill oil to the correct position.
The oil The used oil is wrong. Change suitalbe oil.
products The seals of oil pump shaft leaks air. Replace the seal ring.
foams. The joint sucked into the pipe leaks air. Fasten the joint or replace it with new
joint.
Mechanical The coupling is loose. Fasten the screw.
vibration The pipeline vibrates. Fasten or add pipe clamp.
The oil pump is worn out or damaged. Repair it or replace it with new oil
Oil pump
pump.
Electric The electric motor is worn out or Repair it or replace it with new electric
motor damaged. motor.
Overflow The overflow valve is not stable. Repair it or replace it with new
valve overflow valve.

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 Hongcheng Group Operation Manual of Turbine Inlet Butterfly Valve

2) Underpressure or No Pressure
Troubles Causes Troubles Shooting
The rotation The oil pump sucks air. Correct the rotation direction of oil
direction of oil pump pump.
is not correct.
The oil pump is worn out or Repair it or replace it with new oil
The oil pump damaged. pump.
overheats. The viscosity of oil is too low. Use the hydraulic oil of recommended
viscosity.
The overflow valve is adjusted Adjust to the correct positioin.
improperly.
Leakage from the The pressure relief stop valve is Close the pressure relief stop valve.
high pressure side to not closed.
the return oil side. The internal wall of oil cylinder, Repair it or replace it with new
piston rod or the seals of piston elements and seal rings.
rod are damaged.
The oil supply from The oil pump is worn out or Repair it or replace it with new oil
the oil pump is not damaged. pump.
sufficient.
3) Too Low Flow or No Oil
Troubles Causes Troubles Shooting
The suction filter is blocked. Clean it or replace it with new oil filter.
The suction pipe has too many Replace it with new pipe or install the
The oil pump sucks bends. pipe of larger inside diameter.
air. The oil produces steam. Reduce the working temperature to the
suitable temperature.
The oil tank is airtight. The air filter is blocked.
The oil level in the oil tank is too low. Fill oil to the correct position.
The oil products The used oil is wrong. Change suitalbe oil.
foams. The seals of oil pump shaft leaks air. Replace the seal ring.
The joint sucked into the pipe leaks air. Fasten the joint or replace it with new joint.
The oil pump is The oil pump is worn out or Repair it or replace it with new oil
worn out. damaged. pump.
The rotation The oil pump sucks air. Correct the rotation direction of oil
direction of oil pump.
pump is not correct.
The overflow valve is adjusted Adjust to the correct positioin.
Leakage from the
improperly.
high pressure side to
The pressure relief stop valve is Close the pressure relief stop valve.
the return oil side.
not closed.

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 Hongcheng Group Operation Manual of Check Butterfly Valve

Part III Functions, Operation and Troubls Analysis of Electrical Control System
I. Installation of Electric Cabinet
Special Note:
The overall dimensions of electric control cabinet is 500mm×300mm×1200mm. For the
convenience of commissioning and spot operation, the electric control cabinet shall be
installed near by the hydraulic station and fixed by expansion screws. The distance from the
electric control cabinet to the wall shall not be less than 1m.

II. Descrpition of Control Functions

1. Guarantee of Powr Supply
The hydraulic slow-closing check butterfly valve with accumulator is the protection measures
for preventing the water pump rotating reserse, restricting and eliminating the water hammer.
The reliability and controllability of control system are very important, in need of stable power
sources (the power sources of PLC and electromagnetic valve are DC24V). Therefore, the valve
control system adopts dual power sources, ie. one power supply is converted into DC24V output
by the internal AC220V power source via the switch power supply U1; another power supply is
converted into DC24V output by the DC110V power source supplied by the user via the switch
power supply U2. The dual power sources adopt the hot spare mode, ie. any one of the dual
power sources disappears, another one will realize undisturbed switching and will be switched
on automatically. Refer to Electric Principle Diagram I for the power supply and shift principle
of power source.

Special Note:
The power supply of valve must ensure to be of the same degree of reliability as the power
supply of water the pump motor!

2. Control of Oil Pump Motor

Place the oil pump switch SA3 at “On” position, the oil pump motor will automatically starts
and stops in accordance with the pressure setting valve of the hydraulic system. When the
system pressure is lower than 14.5Mpa, the oil pump motor starts; when the system pressure
reaches 17Mpa, the pump stops running.

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 Hongcheng Group Operation Manual of Check Butterfly Valve

Close Open

Pump motor

The adjustment of pressure controller is as follows:

The pressure controller shall be adjusted according to the sequence of setting value first and
switching difference later. Specific methods are as follows:
Insert the screwdriver into the orifice on the side of “pressure setting” and rotate the adjusting
screw located in the orifice according to the upper switching value of pressure (generally, every
one revolution can make the pressure change be only 40% of the upper limi within the pressure
range). After the adjustment is finished, the rotation direction of adjusting screw shall be made
in the clockwise state.
Insert the screwdriver into the orifice on the side of “pressure difference” and rotate the small
gear located in the orifice according to the inquired pressure difference (generally, every one
revolution can make the pressure difference change be only 10% of the upper limi within the
pressure range). In fact, the adjustment of pressure difference can obtain the lower switching
value of pressure desired to be controlled.

3. Valve Control
Electrical control system has two operating modes: local “single action” and remote
“interaction”. These two operation modes are separately independent and do not interfer each
other.
Local Remote

Selection of
control modes

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 Hongcheng Group Operation Manual of Check Butterfly Valve

When in the local “single action” state, the push buttons for “open”, “close” and “stop” on
the operation control cabinet control the valve actions.
When in the remote “interaction” state, the valve operation is operated and controlled by the
DCS.

Special Notes:
When in the remote “interaction” state, the pump must be interlocked with the valve.
The interlocking sequence of pump and valve must be determined by user according
to the characteristics of the pump.

4. Acceptance and Feedback of Signals

4.1 Acceptance of DCS Command by Valve Control System
(1) Interlocking signal for valve opening;
(2) Interlocking signal for valve closing.
4.2 Signal of Feedback from Valve Control System to DCS
(1) Control mode: local or remote;
(2) Valve status: fully opened and fully closed;
(3) Intermediate position of valve: 15° signal and 75° signal;
(4) Monitor of main power supply;
(5) Hydraulic failure;
(6) Opening failure of butterfly valve;
(7) Motor running monitoring.

III. Valve Operation

Before the electric cabinet is connected with power supply, please strictly check the correctness
of each grade power supply and the correctness of wiring according to the electrical control
principle and operate each switch in the electric cabinet ccording to the following process:
Switch on the line power switch the master switch of power supply in the
cabinet AC220V power supply switch DC24V air switch
respectively switch on the other group of switches

1. Commissioning:
Commissioning contents, steps and attentions

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 Hongcheng Group Operation Manual of Check Butterfly Valve

Results of
No. Steps Contents Precautions
implementation
The requirements of
Carry out the electrical wiring
technical information
Step 1: among the mechanical, electrical
should be met and the
1 Preparation for and hydraulic parts and the oil
correctness of wiring
commissioning pipe connection in accordance
and piping connections
with the technical information.
should be confirmed.
1. Before switching on the
next step of switch, please
check the correctness of
After all switches are next step of power supply.
Switch on the breaker in the
switched on, there shall 2. Especially PLC power
Step 2: electric cabinet step by step in
2 be no any short circuit supply, be sure to check
Power on accordance with the technical
or electric leakage and confirm the
information.
phenomenon. correctness of their
power supply (including
the polarity and voltage
level).
After the program is
When plugging the data
input, all indication
Step 3: cable between PC and
Input the PLC control program or lamps on PLC are shows
3 Program input PLC, the programming
adjust the program. normally and logical
and check cable must not be hot
display without any
plugged.
problems.
1. Commissioning of system Press the corresponding
without oil pressure means the buttons, the
After the contents involved
joint commissioning of hydraulic corresponding solenoid
in this step are confirmed
system with the electrical control valves act; simulated
to be entirely correct, the
Step 4: system without pressure, mainly motion of all detection
next step of work can be
Commissioning to further check the correctness of switches, the
4 directly proceeded.
of division wirings among the mechanical, corresponding indication

action electrical and hydraulic parts. lamps are on.

2. Commissioning of rated oil Set the system pressure
pressure: value according to the
(1) Setting of system oil pressure; requirements of
(2) Commissioning of actions. technical data.

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 Hongcheng Group Operation Manual of Check Butterfly Valve

2. Operation and Control of Valve:

The valve shall be accurately operated and controlled strictly in accordance with the markings of
the disc layout diagram of the electrical control cabinet.

2.1 Local “Single Action” Operation (to be used when installation, commissioning
and maintenance):
Place the change-over swtich SA2 for control modes at the “local” mode. At this mode, the
operation of push buttons on the local control cabinet can control the “open”, “close” and “stop”
of valve, determinte the fully open and fully closed limits and adjust the valve opening time and
quick and slow closing time as well as angle.

Special Note:
During the maintenance, when the valve needs closing, for safety reason, it’s better to
close the stop valve under the accumulator, adopting the oil pump supplying mode to open
or close the valve.

2.2 Remote “Interlocking” Operation:

In this control mode, the control system receives the pulse signals for the opening and closing of
valve from DCS and automatically control the interlocking of pump and valve.

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 Hongcheng Group Operation Manual of Check Butterfly Valve

IV. General Faults and Analysis

1. PLC Fault (to judge according to the corresponding indication lamps on PLC display panel)

Fault Display Possible Causes Handling

Re-communicate with PLC and
RUN lamp is flickering PLC stops running
transfer the data.
Check PC and PLC data
The data interchange is
TER lamp is off. configuration and the correctness
stopped.
of communication cables.
I/O point for procedure Use the spare point and change the
I/O point is broken.
running is dim light or is off. procedure.
Power failure or at least one
Check whether PLC module is
channel circuit is broken or
broken from the external circuit.
I/O module lamp is red. one module is lost, and the
Recommunicate with PLC and
configuration does not
transfer data.
match or shut down.
The CPU configuration of Recommunicate with PLC and
ERR lamp is red.
PLC is wrong. change CPU data.
The battery is undervoltage. Replace the old batterfy with new
one. If PLC is disenergized at that
Batterly lamp is red time, the replacement of batterfy
must be accomplished within 30
seconds.

2. Other Faults

Fault Display Possible Causes Handling

The electric wire Check whether the electric wire in the
The control system has
comes off and the electric cabinet comes off. Check the
no power source.
elements are damaged. breaker, switch power source, etc.
The hydraulic oil in the Replace the hydraulic oil and re-adjust the
The opening or closing
oil tank of hydraulic governor valve for opening or closing of
time of main valve is
station has run for too main valve, to enable the speed less than
more than 120 seconds.
long time. 120 seconds.
The oil pump motor has
The hydraulic system Check the hydraulic system and clean or
been running for more
leaks internally. repair the hydraulic elements.
than 10 minutes.

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 Hongcheng Group Operation Manual of Check Butterfly Valve

V List of Electrical Elements and Electrical Drawings

1. List of Electrical Elements

No. Code Name Model & Spec. Qty. Manufacturer Remarks

PLC and
Programmable
1 related FX1S-30MR-D 1 Mitsubishi
controller
accessories
2 SQ1-4 Travel switch XCKJ10541H29C 4 Schneider
Breaker 6.3A
3 QF1 Triple pole DZ108-20/211 2 Chint
AC380V
QF2
4 Breaker 10A
DZ47-60(D) 2 Chint
QF4 Single pole
QF3
5 Breaker 4A
DZ47-60(D) 3 Chint
QF5, QF7 Single pole
QF6,
6 Breaker 2A
DZ47-60(D) 4 Chint
QF8~10 single pole
7 KM1 AC contactor CJX2-0910 1 Chint
8 FR Thermal relay NR2-11.5 1 Chint
9 KA1~8 Intermediate
RXM4AB1BD 8 Schneider
relay
10 U1, U2 Switching power
2 Chint
supply
11 SA1 Knob swith XB2BD33C 1 Schneider
SA2,
12 Knob swith XB2BD25C 3 Schneider
SA3~4
13 SB1~3 Reset button XB2BA21C 3 Schneider

HL1, HL7 Indicator light XB2BVB1C 2 Schneider

14
HL5, HL6 Indicator light XB2BVB3C 3 Schneider
HL2~5 Indicator light XB2BVB4C 2 Schneider

2 Electrical Drawings

1) Electrical principle diagram

2) Electrical interconnection diagram
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Hongcheng Group Operation Manual of Check Butterfly Valve

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Hongcheng Group Operation Manual of Check Butterfly Valve

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