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OPERATION & MAINTENANCE MANUAL Valve Cooling Equipment The Three Gorges – Shanghai ± 500 kV DC Transmission Project Yidu – Huaxin, CHINA

Pumpstation and valve hall

Spraywater arrangement and coolers

OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China LIST OF CONTENTS 1. GENERAL DESCRIPTION .......................................................................................... 10

1.1 SYSTEM DESCRIPTION ...................................................................................................................................... 10 1.1.1 Valve cooling system ................................................................................................................................................. 10 1.1.2 Spray water system..................................................................................................................................................... 10 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 SYSTEM DATA....................................................................................................................................................... 10 Cooling system data – YIDU ..................................................................................................................................... 10 Spray water system data – YIDU............................................................................................................................... 10 Cooling system data – HUAXIN ............................................................................................................................... 11 Spray water system data – HUAXIN......................................................................................................................... 11 GENERAL DESIGN STANDARDS...................................................................................................................... 11 Piping system.............................................................................................................................................................. 11 Expansion vessel ........................................................................................................................................................ 11 Pump motors............................................................................................................................................................... 11 Electrical cabinet ........................................................................................................................................................ 11 Material ...................................................................................................................................................................... 12

1.4 MECHANICAL FUNCTIONAL DESCRIPTION.............................................................................................. 12 1.4.1 Valve cooling system ................................................................................................................................................. 12 1.4.2 Spray water system..................................................................................................................................................... 20 1.5 SYSTEM CONTROL DESCRIPTION ................................................................................................................ 24 1.5.1 Valve cooling system ................................................................................................................................................. 24 1.5.2 Spray water system..................................................................................................................................................... 24

2.
2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.3

START-UP.................................................................................................................... 26
GENERAL ................................................................................................................................................................ 26 WARNINGS ............................................................................................................................................................. 26 General ....................................................................................................................................................................... 26 Lifting ......................................................................................................................................................................... 26 Noise........................................................................................................................................................................... 26 Resins ......................................................................................................................................................................... 26 Chemicals ................................................................................................................................................................... 26 Protective covers ........................................................................................................................................................ 26 Safety switches ........................................................................................................................................................... 27 Water sprayed coolers................................................................................................................................................ 27 Spare parts .................................................................................................................................................................. 27 ADDRESS ................................................................................................................................................................. 27

2.4 START CONDITIONS ........................................................................................................................................... 27 2.4.1 Valve cooling system ................................................................................................................................................. 27 2.4.2 Spray water system..................................................................................................................................................... 30

3.

OPERATION ................................................................................................................ 32
Approved Document No. Rev. Description Date Page

Produced

BO

KO/?I

8-5697-200

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Changed/removed sections marked with a line at the 2006-11-13 right margin.

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
3.1 GENERAL ................................................................................................................................................................ 32 3.1.1 Valve cooling system - starting .................................................................................................................................. 32 3.1.2 Valve cooling system - routines during operation ..................................................................................................... 32 3.1.3 Valve cooling system - make-up procedure............................................................................................................... 33 3.1.4 Valve cooling system - shut down procedure ............................................................................................................ 33 3.1.5 Valve cooling system - procedure with coolers: when the thyristors not are energized, the pumps not are running, the cooling control protection is off and it is risk for freezing............................................................................... 33 3.1.6 Spray water system - starting...................................................................................................................................... 33 3.1.7 Spray water system - routines during operation......................................................................................................... 34 3.1.8 Spray water system - shut down procedure................................................................................................................ 34

4.
4.1

CONTROL AND SUPERVISION ................................................................................. 35
VALVE COOLING SYSTEM - DESCRIPTION OF THE CONTROL AND SUPERVISION ................... 35

4.2 SPRAY WATER SYSTEM - DESCRIPTION OF THE E300 PANEL............................................................ 35 4.2.1 Key functions.............................................................................................................................................................. 35 4.2.2 Menus ......................................................................................................................................................................... 36

5.
5.1 5.2

SET-POINT LISTS ....................................................................................................... 47
SET-POINT LIST - VALVE COOLING SYSTEM ............................................................................................ 47 SET-POINT LIST – SPRAY WATER SYSTEM ................................................................................................ 47

6.
6.1

MAINTENANCE ........................................................................................................... 48
GENERAL ................................................................................................................................................................ 48

7. 8. 9.
9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.3 9.3.1 9.3.2 9.3.3

PREVENTIVE MAINTENANCE PROGRAM ............................................................... 49 SPECIAL TOOLS FOR MAINTENANCE .................................................................... 52 VALVE COOLING SYSTEM - MAINTENANCE.......................................................... 52
EXCHANGE OF ION EXCHANGE RESIN ....................................................................................................... 52 General ....................................................................................................................................................................... 52 Vessel E1.Z4 in operation and E1.Z3 for service...................................................................................................... 52 Filling new ion exchange resin................................................................................................................................... 54 Vessel E1.Z3 in operation and E1.Z4 for service...................................................................................................... 56 Maintenance ............................................................................................................................................................... 56 OXYGEN REMOVAL SYSTEM .......................................................................................................................... 57 General ....................................................................................................................................................................... 57 Quality of nitrogen ..................................................................................................................................................... 58 Adjustments................................................................................................................................................................ 58 Maintenance ............................................................................................................................................................... 59 CLEANING OF CONDUCTIVITY SENSORS................................................................................................... 60 General ....................................................................................................................................................................... 60 Service sensors E1.BQ1, E1.BQ2.............................................................................................................................. 60 Service sensor E1.BQ3. ............................................................................................................................................. 61

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
9.4 9.4.1 9.4.2 9.4.3 9.4.4 SERVICING THE MAIN PUMPS ........................................................................................................................ 61 General ....................................................................................................................................................................... 61 Mechanical sealing..................................................................................................................................................... 62 Bearing housing oil .................................................................................................................................................... 62 Vibrational control ..................................................................................................................................................... 62

9.5 SERVICING THE MAIN MOTORS.................................................................................................................... 63 9.5.1 General ....................................................................................................................................................................... 63 9.6 9.6.1 9.6.2 9.6.3 CLEANING OF FILTERS AND STRAINERS ................................................................................................... 63 General ....................................................................................................................................................................... 63 Filters in the water treatment circuit E1.Z5, E1.Z6, E1.Z7 ....................................................................................... 63 Strainers in the cooling liquid circuit E1.Z1, E1.Z2 .................................................................................................. 64

9.7 TEMPERATURE MEASURING .......................................................................................................................... 66 9.7.1 General ....................................................................................................................................................................... 66 9.8 LEVEL SWITCHES – EXPANSION VESSELS................................................................................................. 66 9.8.1 General ....................................................................................................................................................................... 66

10. SPRAY WATER SYSTEM - MAINTENANCE ............................................................. 67
10.1 EVAPORATIVE COOLERS ................................................................................................................................. 67 10.1.1 Coolers - general ........................................................................................................................................................ 67 10.1.2 Water spray system .................................................................................................................................................... 67 10.2 10.3 10.4 10.4.1 10.4.2 10.4.3 10.5 10.5.1 10.5.2 10.5.3 10.5.4 10.6 10.7 10.8 10.8.1 10.8.2 10.8.3 BLEED OFF SYSTEM E4.K4-K5......................................................................................................................... 67 MOTORISED BY-PASS VALVES E4.K1-K3..................................................................................................... 67 CHEMICAL SYSTEM - GENERAL.................................................................................................................... 68 Chemicals E4.C11-C14.............................................................................................................................................. 68 Dosage pumps E4.P11-P14........................................................................................................................................ 68 Flow guards E4.BF1-BF4 .......................................................................................................................................... 68 SAND FILTER - GENERAL.................................................................................................................................. 68 Sand filter E4.Z9 ........................................................................................................................................................ 68 Motorised valves to the sand filter E4.K6-K9 ........................................................................................................... 68 Filter pump E4.P6 ...................................................................................................................................................... 68 Pressure meter E4.BP1............................................................................................................................................... 68 Flow meter E4.BF11 ................................................................................................................................................ 68 CONDUCTIVITY METER E4.BQ1 ..................................................................................................................... 69 BASIN (SPRAY WATER)- GENERAL................................................................................................................ 69 Water quality in basin E4.C1 ..................................................................................................................................... 69 Level sensors E4.BL1-BL3, E4.BL5-BL8 ................................................................................................................ 69 Drainage pump E4.P7 ................................................................................................................................................ 69

11. MISCELLANEOUS - MAINTENANCE......................................................................... 70
11.1 11.2 ANNUAL SERVICE................................................................................................................................................ 70 CLEANLINESS........................................................................................................................................................ 70

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
11.3 WATER LEAKAGE ............................................................................................................................................... 70

12. FAULT TRACING SCHEDULE – VALVE COOLING EQUIPMENT........................... 71
12.1 12.2 12.2.1 12.2.2 12.2.3 12.3 12.3.1 12.3.2 12.3.3 GENERAL ................................................................................................................................................................ 71 HIGH COOLING WATER TEMPERATURE ................................................................................................... 71 Water sprayed air blast coolers .................................................................................................................................. 71 Temperature control ................................................................................................................................................... 72 Flow rate control ........................................................................................................................................................ 72 LOW FLOW IN THE COOLING LIQUID CIRCUIT ...................................................................................... 72 Flow meter malfunction ............................................................................................................................................. 72 Increased pressure drop.............................................................................................................................................. 72 Main pumps................................................................................................................................................................ 72

12.4 LOW FLOW IN THE WATER TREATMENT CIRCUIT ............................................................................... 72 12.4.1 Pressure drop .............................................................................................................................................................. 72 12.4.2 Flow meter.................................................................................................................................................................. 72 12.5 HIGH CONDUCTIVITY IN THE WATER TREATMENT CIRCUIT .......................................................... 72 12.5.1 After make-up............................................................................................................................................................. 72 12.5.2 Conductivity meter ..................................................................................................................................................... 72 12.6 12.6.1 12.6.2 12.6.3 12.7 12.7.1 12.7.2 12.7.3 12.7.4 HIGH CONDUCTIVITY IN THE COOLING LIQUID CIRCUIT ................................................................. 73 Water treatment circuit............................................................................................................................................... 73 Conductivity meter ..................................................................................................................................................... 73 Other ........................................................................................................................................................................... 73 LOW PRESSURE IN THE EXPANSION VESSEL ........................................................................................... 73 Pressure regulator....................................................................................................................................................... 73 Pressure relief valve ................................................................................................................................................... 73 Nitrogen bottles .......................................................................................................................................................... 73 Other ........................................................................................................................................................................... 73

12.8 LOW WATER LEVEL IN THE EXPANSION VESSEL .................................................................................. 73 12.8.1 Level meters ............................................................................................................................................................... 73 12.9 LOW/LOW WATER LEVEL IN THE EXPANSION VESSEL ....................................................................... 73 12.9.1 Level meters ............................................................................................................................................................... 73 12.10 HIGH PUMP VIBRATION.................................................................................................................................... 73 12.10.1 General................................................................................................................................................................. 73

13. FAULT TRACING SCHEDULE – SPRAY WATER SYSTEM..................................... 74
13.1 13.2 13.2.1 13.2.2 13.2.3 13.2.4 13.2.5 13.2.6 GENERAL ................................................................................................................................................................ 74 ALARMS .................................................................................................................................................................. 74 BF11 – Raw water flow ............................................................................................................................................. 74 BF11 - Sensor failure ................................................................................................................................................. 74 BL3 - Level basin....................................................................................................................................................... 75 BL3 - Sensor failure ................................................................................................................................................... 75 BL5 - Level basin....................................................................................................................................................... 75 BL6 - Level basin....................................................................................................................................................... 75

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
13.2.7 BL7 - Level pump pit ................................................................................................................................................. 76 13.2.8 BL8 - Level basin....................................................................................................................................................... 76 13.2.9 BQ1 – Conductivity filter circuit ............................................................................................................................... 76 13.2.10 BQ1 – Sensor failure ........................................................................................................................................... 76 13.2.11 P6 – Filter pump .................................................................................................................................................. 77 13.2.12 K6 (K7, K8, K9) – Filter valve ........................................................................................................................... 77 13.2.13 V37 – Drain valve................................................................................................................................................ 77 13.2.14 Z9 – Filter system ................................................................................................................................................ 77 13.2.15 P11 (P12) – Dosage pump................................................................................................................................... 78 13.2.16 P11-P12 – Dosage system 1 - Biosperse............................................................................................................. 78 13.2.17 P13 (P14) – Dosage pump................................................................................................................................... 78 13.2.18 P13-P14 – Dosage system 2 – Drew/Performax ................................................................................................. 78 13.2.19 K4 (K5) – Bleed-off valve................................................................................................................................... 79 13.2.20 Bleed-off system .................................................................................................................................................. 79 13.2.21 Main supply 1 (2)................................................................................................................................................. 79 13.2.22 Circuit breakers-failure ........................................................................................................................................ 79 13.2.23 DC/DC converter-failure ..................................................................................................................................... 79 13.2.24 PLC-failure .......................................................................................................................................................... 80 13.3 EXTERNAL COMMON ALARMS...................................................................................................................... 80 13.3.1 Common alarm no. 1.................................................................................................................................................. 80 13.3.2 Common alarm no. 2.................................................................................................................................................. 80 13.3.3 Common alarm no. 3.................................................................................................................................................. 80 13.3.4 Common alarm no. 4.................................................................................................................................................. 80 13.3.5 Common alarm no. 5.................................................................................................................................................. 81 13.3.6 Common alarm no. 6.................................................................................................................................................. 81 13.3.7 Common alarm no. 7.................................................................................................................................................. 81 13.3.8 Common alarm no. 8.................................................................................................................................................. 81 13.3.9 Common alarm no. 9.................................................................................................................................................. 81 13.3.10 Common alarm no. 10 ......................................................................................................................................... 81 13.3.11 Common alarm no. 11 ......................................................................................................................................... 81 13.3.12 Common alarm no. 12 ......................................................................................................................................... 81

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China REFERENCES
A. FLOW DIAGRAMS
A.1 Flow diagram – Three Gorges Shanghai Yidu & Huaxin pole 1.................................................................1-5697-001 A.2 Flow diagram – Three Gorges Shanghai Yidu & Huaxin pole 2.................................................................1-5698-001 A.3 Flow diagram – Normal operation – E1.Z3 first in series.........................................................................3-5697-002A A.4 Flow diagram – Normal operation – E1.Z4 first in series......................................................................... 3-5697-002B A.5 Flow diagram – Bypass, E1.Z3 for service................................................................................................ 3-5697-002C A.6 Flow diagram – Bypass, E1.Z4 for service................................................................................................3-5697-002D

B. LISTS OF COMPONENTS
B.1 Mechanical Spare Parts List - YIDU Converter Station, Pole 1&2.............................................................4-5697-040 B.2 Mechanical Spare Parts List - HUAXIN Converter Station, Pole 1&2.......................................................4-5697-045 B.3 Special Tools - YIDU Converter Station Pole 1&2 .....................................................................................4-5697-042 B.4 Special Tools - HUAXIN Converter Station Pole 1&2 ...............................................................................4-5697-047 B.5 Electrical Spare Parts List - YIDU Converter Station, Pole 1&2 ...............................................................4-5697-043 B.6 Electrical Spare Parts List - HUAXIN Converter Station, Pole 1&2 ..........................................................4-5697-048 B.7 List of Components - YIDU Converter Station Pole 1 ................................................................................4-5697-050 B.8 List of Components - HUAXIN Converter Station Pole 1 ..........................................................................4-5697-055 B.9 List of Components - YIDU Converter Station Pole 2 ................................................................................4-5698-050 B.10 List of Components - HUAXIN Converter Station Pole 2 ........................................................................4-5698-055

C. MECHANICAL DRAWINGS
C.1 Layout drawing - Cooling Room Arrangement - YIDU Converter Station Pole 1 .....................................1-5697-100 C.2 Layout drawing - Valve Hall Layout – YIDU Converter Station Pole 1.....................................................1-5697-110 C.3 Layout drawing – Cooler arr. and Spraywater treatment arr. – YIDU Converter Station Pole 1................1-5697-120 C.4 Pump unit drawing – Converter Station Pole 1............................................................................................1-5697-200 C.5 Treatment unit drawing – Converter Station Pole 1.....................................................................................1-5697-210 C.6 Rating Plate – YIDU Converter Station Pole 1............................................................................................1-5697-070 C.7 Layout drawing - Cooling Room Arrangement - HUAXIN Converter Station Pole 1 ...............................1-5697-105 C.8 Layout drawing - Valve Hall Layout– HUAXIN Converter Station Pole 1................................................1-5697-115 C.9 Layout drawing – Cooler arr. and Spraywater treatment arr. – HUAXIN Converter Station Pole 1..........1-5697-125 C.10 Rating Plate – HUAXIN Converter Station Pole 1....................................................................................1-5697-070 C.11 Layout drawing - Cooling Room Arrangement - YIDU Converter Station Pole 2 ...................................1-5698-100 C.12 Layout drawing - Valve Hall Layout – YIDU Converter Station Pole 2...................................................1-5698-110 C.13 Layout drawing – Cooler arr. and Spraywater treatment arr. – YIDU Converter Station Pole 2..............1-5698-120 C.14 Pump unit drawing – Converter Station Pole 2..........................................................................................1-5698-200 C.15 Treatment unit drawing – Converter Station Pole 2...................................................................................1-5698-210 C.16 Rating Plate – YIDU Converter Station Pole 2..........................................................................................1-5698-070 C.17 Layout drawing - Cooling Room Arrangement - HUAXIN Converter Station Pole 2 .............................1-5698-105 C.18 Layout drawing - Valve Hall Layout – HUAXIN Converter Station Pole 2.............................................1-5698-115 C.19 Layout drawing – Cooler arr. and Spraywater treatment arr. – HUAXIN Converter Station Pole 2........1-5698-125 C.20 Rating Plate – HUAXIN Converter Station Pole 2....................................................................................1-5698-075

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
D. ELECTRICAL DRAWINGS
D.1 Layout – MCC & Frequency converters -YIDU Converter station, Pole 1 ................................................3-5697-901 D.2 Component list - MCC & Frequency converters -YIDU Converter station, Pole 1....................................3-5697-902 D.3 Single line diagram - MCC & Frequency converters -YIDU Converter station, Pole 1 .............................3-5697-903 D.4 Cable diagram - MCC & Frequency converters -YIDU Converter station, Pole 1.....................................3-5697-904 D.5 Module Main supply - MCC & Frequency converters -YIDU Converter station, Pole 1 ..........................3-5697-911 D.6 Main pump - MCC & Frequency converters -YIDU Converter station, Pole 1..........................................3-5697-921 D.7 Module Spray pump - MCC & Frequency converters -YIDU Converter station, Pole 1 ...........................3-5697-924 D.8 Module Freq. fan- MCC & Frequency converters -YIDU Converter station, Pole 1 .................................3-5697-931 D.9 Module El-heater- MCC & Frequency converters -YIDU Converter station, Pole 1 .................................3-5697-941 D.10 Module Motor valve - MCC & Frequency converters -YIDU Converter station, Pole 1.........................3-5697-951 D.11 Module Solenoid valve - MCC & Frequency converters -YIDU Converter station, Pole 1.....................3-5697-952 D.12 Module Damper Cooling Tower - MCC & Frequency converters -YIDU Conv. st. Pole 1.....................3-5697-953 D.13 Connection box JB1 & JB2 - MCC & Frequency converters -YIDU Conv. st. Pole 1 ............................3-5697-961 D.14 Electrical system – Set-point list - YIDU Converter station, Pole 1..........................................................4-5697-910 D.15 Layout - YIDU Chemical dosage & Filter equipment, Pole 1...................................................................3-5697-971 D.16 Component list - YIDU Chemical dosage & Filter equipment, Pole 1 .....................................................3-5697-972 D.17 Circuit diagram - YIDU Chemical dosage & Filter equipment, Pole 1.....................................................3-5697-973 D.18 Cable diagram - YIDU Chemical dosage & Filter equipment, Pole 1.......................................................3-5697-974 D.19 Internal connection table - YIDU Chemical dosage & Filter equipment, Pole 1......................................3-5697-975 D.20 PLC Program - YIDU Chemical dosage & Filter equipment, Pole 1........................................................3-5697-976 D.21 Operating panel – YIDU Chemical dosing & Filter equipment, Pole 1....................................................3-5697-977 D.22 Function Interface - YIDU Chemical dosage & Filter equipment, Pole 1 ................................................3-5697-978 D.23 Layout - MCC & Frequency converters -HUAXIN Converter station, Pole 1 .........................................3-5697-906 D.24 Component List - MCC & Frequency converters -HUAXIN Converter station, Pole 1 ..........................3-5697-907 D.25 Single line diagram - MCC & Frequency converters -HUAXIN Converter station, Pole 1 .....................3-5697-908 D.26 Cable diagram - MCC & Frequency converters - HUAXIN Converter station, Pole 1............................3-5697-909 D.27 Module Main supply - MCC & Frequency converters - HUAXIN Converter station, Pole 1 .................3-5697-916 D.28 Main pump - MCC & Frequency converters - HUAXIN Converter station, Pole 1.................................3-5697-926 D.29 Module Spray pump - MCC & Frequency converters -HUAXIN Converter station, Pole 1 ...................3-5697-929 D.30 Module Freq. fan- MCC & Frequency converters -HUAXIN Converter station, Pole 1 .........................3-5697-936 D.31 Module El-heater- MCC & Frequency converters -HUAXIN Converter station, Pole 1 .........................3-5697-946 D.32 Module Motor valve - MCC & Frequency converters -HUAXIN Converter station, Pole 1 ...................3-5697-956 D.33 Module Solenoid valve - MCC & Frequency conv. -HUAXIN Conv. st., Pole 1 ....................................3-5697-957 D.34 Module Damper Cooling Tower - MCC & Frequency conv. - HUAXIN Conv. st., Pole 1.....................3-5697-958 D.35 Connection box JB1 & JB2 - MCC & Frequency converters -HUAXIN Conv. st., Pole 1 .....................3-5697-966 D.36 Electrical system – Set-point list - HUAXIN Converter station, Pole 1....................................................4-5697-915 D.37 Layout - HUAXIN Chemical dosage & Filter equipment, Pole 1.............................................................3-5697-981 D.38 Component list - HUAXIN Chemical dosage & Filter equipment, Pole 1 ...............................................3-5697-982 D.39 Circuit diagram - HUAXIN Chemical dosage & Filter equipment, Pole 1...............................................3-5697-983 D.40 Cable diagram - HUAXIN Chemical dosage & Filter equipment, Pole 1.................................................3-5697-984 D.41 Internal connection table - HUAXIN Chemical dosage & Filter equipment, Pole 1 ................................3-5697-985 D.42 PLC Program - HUAXIN Chemical dosage & Filter equipment, Pole 1..................................................3-5697-986 D.43 Operating panel – HUAXIN Chemical dosing & Filter equipment, Pole 1 ..............................................3-5697-987 D.44 Function Interface - HUAXIN Chemical dosage & Filter equipment, Pole 1...........................................3-5697-988

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
D.45 Layout – MCC & Frequency converters -YIDU Converter station, Pole 2 ..............................................3-5698-901 D.46 Component list - MCC & Frequency converters -YIDU Converter station, Pole 2..................................3-5698-902 D.47 Single line diagram - MCC & Frequency converters -YIDU Converter station, Pole 2...........................3-5698-903 D.48 Cable diagram - MCC & Frequency converters -YIDU Converter station, Pole 2...................................3-5698-904 D.49 Module Main supply - MCC & Frequency converters -YIDU Converter station, Pole 2 ........................3-5698-911 D.50 Main pump - MCC & Frequency converters -YIDU Converter station, Pole 2 .......................................3-5698-921 D.51 Module Spray pump - MCC & Frequency converters -YIDU Converter station, Pole 2 .........................3-5698-924 D.52 Module Freq. fan- MCC & Frequency converters -YIDU Converter station, Pole 2 ...............................3-5698-931 D.53 Module El-heater- MCC & Frequency converters -YIDU Converter station, Pole 2 ...............................3-5698-941 D.54 Module Motor valve - MCC & Frequency converters -YIDU Converter station, Pole 2.........................3-5698-951 D.55 Module Solenoid valve - MCC & Frequency converters -YIDU Converter station, Pole 2.....................3-5698-952 D.56 Module Damper Cooling Tower - MCC & Frequency converters -YIDU Converter st., Pole 2 .............3-5698-953 D.57 Connection box JB1 & JB2 - MCC & Frequency converters -YIDU Converter station, Pole 2..............3-5698-961 D.58 Electrical system – Set-point list - YIDU Converter station, Pole 2..........................................................4-5698-910 D.59 Layout - YIDU Chemical dosage & Filter equipment, Pole 2...................................................................3-5698-971 D.60 Component list - YIDU Chemical dosage & Filter equipment, Pole 2 .....................................................3-5698-972 D.61 Circuit diagram - YIDU Chemical dosage & Filter equipment, Pole 2.....................................................3-5698-973 D.62 Cable diagram - YIDU Chemical dosage & Filter equipment, Pole 2.......................................................3-5698-974 D.63 Internal connection table - YIDU Chemical dosage & Filter equipment, Pole 2......................................3-5698-975 D.64 PLC Program - YIDU Chemical dosage & Filter equipment, Pole 2........................................................3-5698-976 D.65 Operating panel – YIDU Chemical dosing & Filter equipment, Pole 2....................................................3-5698-977 D.66 Function Interface - YIDU Chemical dosage & Filter equipment, Pole 2 ................................................3-5698-978 D.67 Layout - MCC & Frequency converters -HUAXIN Converter station, Pole 2 .........................................3-5698-906 D.68 Component List - MCC & Frequency converters -HUAXIN Converter station, Pole 2 ..........................3-5698-907 D.69 Single line diagram - MCC & Frequency converters -HUAXIN Converter station, Pole 2 .....................3-5698-908 D.70 Cable diagram - MCC & Frequency converters - HUAXIN Converter station, Pole 2............................3-5698-909 D.71 Module Main supply - MCC & Frequency converters - HUAXIN Converter station, Pole 2 .................3-5698-916 D.72 Main pump - MCC & Frequency converters - HUAXIN Converter station, Pole 2................................3-5698-926 D.73 Module Spray pump - MCC & Frequency converters -HUAXIN Converter station, Pole 2 ...................3-5698-929 D.74 Module Freq. fan- MCC & Frequency converters -HUAXIN Converter station, Pole 2 .........................3-5698-936 D.75 Module El-heater- MCC & Frequency converters -HUAXIN Converter station, Pole 2 .........................3-5698-946 D.76 Module Motor valve - MCC & Frequency converters -HUAXIN Converter station, Pole 2 ...................3-5698-956 D.77 Module Solenoid valve - MCC & Frequency converters -HUAXIN Converter station, Pole 2...............3-5698-957 D.78 Module Damper Cooling Tower - MCC & Frequency converters - HUAXIN Converter st., Pole 2 ......3-5698-958 D.79 Connection box JB1 & JB2 - MCC & Frequency converters -HUAXIN Converter station, Pole 2........3-5698-966 D.80 Electrical system – Set-point list - HUAXIN Converter station, Pole 2....................................................4-5698-915 D.81 Layout - HUAXIN Chemical dosage & Filter equipment, Pole 2.............................................................3-5698-981 D.82 Component list - HUAXIN Chemical dosage & Filter equipment, Pole 2 ...............................................3-5698-982 D.83 Circuit diagram - HUAXIN Chemical dosage & Filter equipment, Pole 2...............................................3-5698-983 D.84 Cable diagram - HUAXIN Chemical dosage & Filter equipment, Pole 2.................................................3-5698-984 D.85 Internal connection table - HUAXIN Chemical dosage & Filter equipment, Pole 2 ................................3-5698-985 D.86 PLC Program - HUAXIN Chemical dosage & Filter equipment, Pole 2..................................................3-5698-986 D.87 Operating panel – HUAXIN Chemical dosing & Filter equipment, Pole 2 ..............................................3-5698-987 D.88 Function Interface - HUAXIN Chemical dosage & Filter equipment, Pole 2...........................................3-5698-988

E. MISCELLANEOUS INSTRUCTIONS
E.1 Flanged joint – Loose steel flange with pressed collar, PN10.................................................................. 4-1000-344/E

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
E.2 Water quality in pure water cooling systems .............................................................................................. 8-9900-009e E.3 Lubrication of electrical motors .................................................................................................................. 8-9900-010e E.4 Flanged joint tightening .............................................................................................................................. 8-9900-011e E.5 Alignment of pump and pump motor.......................................................................................................... 8-9900-012e E.6 Assembling instruction for expansion joints............................................................................................... 8-9900-013e E.7 Cleaning and reparation of surface treatment damage................................................................................ 8-9900-016e E.8 Vibrational control of pump units............................................................................................................... 8-9900-017e E.9 Procedure for analyze of basin water ............................................................................................................8-5697-210 E.10 Log book – Water quality control - Basin ..................................................................................................8-5697-211 E.11 Mounting/selection of Orifice plate S5 – Bleed off piping .......................................................................8-5697-110

F. COMPONENT INFORMATION - E1 - E4 - E4.E1-E4.E3 (coolers) - ELECTRICAL COMPONENTS G. TEST RESULTS H. TEST CERTIFICATE
This Manual is confidential and shall not be copied or reproduced in any way, entirely or in part, without the approval of SwedeWater.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China

1.
1.1 1.1.1

GENERAL DESCRIPTION
SYSTEM DESCRIPTION Valve cooling system The HVDC valve cooling equipment is a closed circuit cooling equipment. The converter valves are cooled via a flow of de-ionised water. A small portion of the valve cooling flow is by-passed through a water treatment circuit where the coolant is continuously deionised and filtered. Make-up water can be added to the valve cooling system via the water treatment circuit. The valve cooling equipment is automatically and controlled by a Mach 2 control system. To monitor the valve cooling system function there are meters for monitoring flow, pressure, temperature, coolant level and conductivity. Spray water system A spray water system supplies the HVDC valve cooling equipment with water for the evaporative coolers. The spray water is treated in a basin to which chemicals automatically are added in order to give a spray water of good quality – essential for reliable cooler performance. The spray water system also includes a bleed-off system and a sand filter. The system is automatically controlled by a local PLC control system. To monitor the spray water system function there are meters for monitoring level, flow and conductivity. SYSTEM DATA Cooling system data – YIDU System volume: Min nominal flow to converter: Flow through treatment circuit: Max. nominal water conductivity at 20°C: Max conductivity at max temperature: Max oxygen content: Design pressure: Cooling capacity: Max. coolant temp. to converter Max. indoor temp. Min. indoor temp. Design outdoor temp. (dry bulb) Max. outdoor temp. (wet bulb) Min. outdoor temp. (dry bulb) Main power supply

1.1.2

1.2 1.2.1

VAC VDC

20 000 litres 94.8 l/s 2.0 l/s 0.1 ?S/cm 0.5 ?S/cm 200 ppb 1.0 MPa 5346 kW 51.9 °C 50 °C 10 °C 40.8 °C 37.1 °C -13.8 °C 400±5% 50 +0.5, -1.0 Hz 110

1.2.2

Spray water system data – YIDU System volume: Min nominal flow to coolers: Max conductivity:

75 000 litres 45 l/s <3,0 mS/cm

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
Main power supply VAC VDC 1.2.3 Cooling system data – HUAXIN System volume: Min nominal flow to converter: Flow through treatment circuit: Max. nominal water conductivity at 20°C: Max conductivity at max temperature: Max oxygen content: Design pressure: Cooling capacity: Max. coolant temp. to converter Max. indoor temp. Min. indoor temp. Design outdoor temp. (dry bulb) Max. outdoor temp. (wet bulb) Min. outdoor temp. (dry bulb) Main power supply 400±5% 50 +0.5, -1.0 Hz 110

VAC VDC

20 000 litres 88.8 l/s 2.0 kg/s 0.1 ?S/cm 0.5 ?S/cm 200 ppb 1.0 MPa 4144 kW 55.4 °C 50 °C 10 °C 38.9 °C 35.9 °C -10.0 °C 400±5% 50 +0.5,-1.0 Hz 110

1.2.4

Spray water system data – HUAXIN System volume: Min nominal flow to coolers: Max conductivity: Main power supply

VAC VDC

75 000 litres 18 l/s <3,0 mS/cm 400±5% 50 +0.5, -1.0 Hz 110

1.3 1.3.1

GENERAL DESIGN STANDARDS Piping system - Design (stainless steel) - Flanges Expansion vessel - Design

SS-EN 13480-1/ISO 1127 ISO 7005-1

1.3.2

ASME Boiler&Pressure Vessel Code Section VIII

1.3.3

Pump motors - Electrically Electrical cabinet - Design - Equipment

IEC

1.3.4

IEC 439-1 applicable IEC standards

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1.3.5 Material - Piping and Pressure Vessel - Wetted parts, Pumps - Cast Steel, Ball-valves - Not Welded Stainless Steel AISI 304L/316L, SS2352, SS2353 AISI 304/316L ASTM A351 CF8M /AISI316L/ ASTM A276 T-316 AISI 304, AISI 316 or equal quality within norms

1.4 1.4.1 1.4.1.1

MECHANICAL FUNCTIONAL DESCRIPTION Valve cooling system Circulation pumps The main circuit is provided with two redundant stainless steel pumps. Each pump is powered over a frequency converter. The speed control is used to set the proper operating pressure needed to produce the required flow. See Figure 1.

Figure 1

1.4.1.2

Main circuit strainers A strainer with 0.6 mm mesh size is located after each pump and before the converter valves in the main circuit, see Figure 2. E1.Z2

E1.Z1

Figure 2

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.3 Shunt system The cooling unit is equipped with a shunting system (E1.K7, E1.K8), where the coolers can be bypassed at low ambient temperatures, in order to avoid condensation in the thyristor valve at low ambient temperatures, see Figure 3.

E1.K8

E1.K7

Figure 3

E1.K6

E1.K5

1.4.1.4

Heaters Four heaters are placed in the cooling equipment, they are started when the coolant temperature is too low although the coolers are by-passed. This in order to avoid condensation. See Figure 4 E1.E4 E1.E1

E1.E3 E1.E2

Figure 4

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.5 Coolers A low coolant temperature is maintained via three temperature controlled evaporative coolers. Each cooler is equipped with two fans and one electric motor, air inlet louvers and sound attenuators. Each fan group is powered over a frequency converter. The fan speed control is used to set the proper operating fan speed needed to produce the required cooling. The raw water used for spraying the coolers are pre-treated with chemicals. See Figure 5.

Figure 5

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.6 Cooling water treatment / Coolant conductivity Two ion-exchangers placed in the water treatment circuit maintains low conductivity of the cooling water. One conductivity meter located in the water treatment circuit provides information on when the ion-exchanger resin needs to be replaced. Two conductivity meters placed in the measurement circuit provides information on the conductivity in the main circuit. Three mechanical filters with a 3 ?m rating is placed after the ion-exchanger in the water treatment circuit, to prevent resin beads or fine material entering the system. Two of the three filters shall always be in operation. One flow meter E1.BF3 is located in the water treatment circuit after the ion exchangers. The flow can be adjusted using the valve E1.V59. See Figure 6.

E1.BF3 E1.Z4

E1.Z3

Figure 6

E1.Z5

E1.Z6

E1.Z7

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.7 Oxygen removal system The outlet water from the treatment circuit is led through the expansion vessel and there exposed to nitrogen to keep the oxygen content very low in the valve cooling equipment. See Figure 7.

Figure 7

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.8 Expansion vessel Two communicating expansion vessels are located in the water treatment circuit, on the suction side of the pump. These vessels are pressurised via a nitrogen cushion to achieve the system static pressure. The nitrogen cushion is pressurised automatically during operation by the pressure regulator which via the emptying equipment is connected to the nitrogen bottles. A safety valve is located on the top of the expansion vessel to protect the system from overpressure. Alarms will be given when the pressure in the expansion vessel is too low or too high. The coolant level in the expansion vessel can be monitored via a visual level meter. Redundant level-switches are provided for low/low level monitoring, this in order to protect the pumps for running dry. Redundant analogue level-switches gives signal for low and high level. The switches give also a signal for make-up and for the leak detection system. See Figure 8. E1.F1 E1.BL10 E1.C3 E1.BL1 E1.BL2 E1.C2

E1.C7 E1.C6 E1.C5 E1.C4

Figure 8

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.9 Main circuit flow One dual sensor flow meter of “vortex-type” is placed before the thyristor valves, see Figure 9.

E1.BF1/BF2

Figure 9

1.4.1.10 Water treatment circuit flow One flow meter is located in the water treatment circuit after the ion-exchangers. The flow can be adjusted using the valve E1.V59, see Figure 10.

E1.BF3

E1.V59

Figure 10

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.1.11 Make-up pump A moveable storage vessel is connected to the make-up pump, and the treatment circuit. see Figure 11 Filling up the system will be done manually from this vessel with the make-up pump.

E1.P3

Figure 11

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.2 1.4.2.1 Spray water system General A basin tank contains a buffer volume of water, which is used for spraying the coolers. This water needs to be treated with chemicals and a bleed-off from the basin has to be made so that the concentration of dissolved salts is limited. The raw water feed pump is located externally and supplied by others. The raw water is pretreated with chemicals in a basin tank before being sprayed over the coolers. The basin water is treated with anti-scalant and biocides. The dose of anti-scalant are made to prevent deposits of Calcium carbonate in the system, especially on the warm surfaces in the coolers. The anti-scalant chemicals help keeping the calcium in solution, so that it will follow with the bleed-off to drain. The dose of the biocides is made to prevent bacteria and algae to grow in the water system.
Chemical dosing ? Anti-scalant (Drew/Performax) ? Biocide (Biosperse) Example: 100 mg/l Cl Spray water Evaporation 8 m3/h 0 mg/l Cl

Raw water 12 m3/h 100 mg/l Cl

Evaporative Cooler

Bleed-off 4 m3/h 300 mg/l Cl Water basin < 300 mg/l Cl

Spray system over-view (figures are examples only, to show function).

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.2.2 Layout Layout over the spray water system, see Figure 12. Each vessel (total four) with chemicals are equipped with a dosing system, including a dose pump, a flow guard, a check valve, a strainer and level monitoring. The treatment also includes a tank filled with sand where a small amount of the spray water is filtered. A conductivity meter is also installed for in-line measurement, after the filter E4.Z9. The conductivity value is an indication of the amount of salts dissolved in the water and hence an indirect indication of the Chloride concentration. Four spray water pumps (one redundant) are connected to the basin and sprays the coolers. The basin water level is automatically controlled.

Figure 12

1.4.2.3

Feed pump The raw water feed pump is located externally and supplied by others. Raw water flow One electromagnetic flow meter is placed on the incoming raw water piping, see Figure 13. Basin The raw water is collected in a basin placed under the chemical system where it is mixed with the chemicals. Level in basin The level in the basin is monitored by several level meters. E4.BL1, E4.BL2 for low/low level, the analogue meter E4.BL3 gives start and stop signals to the raw water pump, E4.BL5 for low level and E4.BL6 for high level. Filter pump The filter pump E4.P6 pumps basin water to the sand filter. The filter pump is also used for daining the basin.

1.4.2.4

1.4.2.5

1.4.2.6

1.4.2.7

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.2.8 Drain pump The drain pump E4.P7 is placed in the spray water pump pit. E4.BL7 monitores the water level in the pump pit. Chemical Dosing Equipment Four plastic vessels, each equipped with a dose pump, flow guard, check valve, filter and level monitoring is individually connected to the basin, see Figure 13.

1.4.2.9

E4.BF11

Figure 13

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.2.10 Spray water pumps Four spray water pumps (one redundant) pumps water from the basin to the cooler spray nozzles. See Figure 14. (Note: the spray water pumps are controlled by the valve cooling control program)

E4.P4 E4.P3

E4.P2

E4.P1
Figure 14

1.4.2.11 Sand filter A small portion of the spray water is passed through the sand filled filter, see Figure 15.

Figure 15

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
1.4.2.12 Conductivity meter after sand filter After filtration the water conductivity is measured. Measurement of the conductivity gives an indication of chloride content in the sandfiltered spraywater. 1.5 1.5.1 SYSTEM CONTROL DESCRIPTION Valve cooling system The valve cooling equipment (including spray water pumps) is controlled and supervised by means of a computerized system, Cooling Control and Protection (CCP), and is a part of the overall Pole Control and Protection System, ABB Mach2. For further information about the CCP see ABB document “Functional Description Valve Cooling System”. Spray water system The spray water system is controlled and supervised by means of a PLC (programmable logic controller), with digital inputs/outputs and analogue inputs. Description of the Mitsubishi Ans PLC is found in section “Component information” and the application program is shown in section “Electrical drawings”. The system is designed with four dose equipments, sand filter, bleed-off valves and raw water pump. Running, failure and alarm signals are given on an operators’ panel located on the cubicle front door. A more extensive description of the function of the E300 control panel is given in chapter 5. System Condition The spray water system is ready for use when "CONTROL SYSTEM ON" is shown on the operators’ panel. This function indicates that: * The PLC is in ON and OK, * Circuit breaker ON, * Power supply OK, Raw water pump control MAN or AUTO mode of raw water pump can be selected on the operating panel (E300). In MAN mode the pump can be started/stopped on the operating panel. In AUTO mode the pump are controlled by the PLC-system, and is running depending of level sensors E4.BL3 (E4.BL5,E4.BL6). The pump can also be started/stopped on the operating panel (E300). 1.5.2.3 Filter pump control MAN or AUTO mode of filter pump can be selected on the operating panel (E300). In MAN mode the pump E4.P6 can be started/stopped on the operating panel. If drain valve E4.V37 is open the pump can be used as drain pump for the basin. In AUTO mode the pump are controlled by the PLC-system, see Filter system control. 1.5.2.4 Dosage pumps control MAN or AUTO mode of each pump can be selected on the operating panel (E300). 24

1.5.2

1.5.2.1

1.5.2.2

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
In MAN mode the pump can be started/stopped on the operating panel and the pumps are controlled by its own automatic. In AUTO mode the pumps are controlled by the PLC-system, and is running during preselected periods. The dosage pumps are controlled by its own automatic. The dosage pumps E4.P13/E4.P14 are only running if the raw water pump is running See Dosage system control. 1.5.2.5 Bleed-off valves control MAN or AUTO mode of the valves can be selected on the operating panel (E300). In MAN mode the valves can be open/closed on the operating panel. In AUTO mode the valves are controlled by the PLC-system. Valves E4.K4-E4.K5 are opened when raw water pump is running but always closed during dosage of biosperses and preset minutes after dosage has finished. 1.5.2.6 Filter valves control MAN or AUTO mode of the valves can be selected on the operating panel (E300). In MAN mode the valves can be open/closed on the operating panel. In AUTO mode the valves are controlled by the PLC-system, see Filter system control

1.5.2.7

Filter system control MAN or AUTO mode of filter system can be selected on the operating panel (E300). In MAN mode normal or backwash mode can be start/stopped. In AUTO mode the backwash mode is automatically started.

1.5.2.8

Dosage system control MAN or AUTO mode of dosage system can be selected on the operating panel (E300). In AUTO mode the dosage mode is automatically started. Dosage of Biosperse is done during preset times. During dosage the bleed-off valves are automatically closed and will automatically open after the dosage is stopped. The opening is time-delayed according to a preset time. Dosage of Performax/Drewsperse is done during preset times if raw water pump is running.

1.5.2.9

Failure indications The spray water system alarm indication levels are defined in the relevant Set point list, see chapter 5.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China

2.
2.1

START-UP
GENERAL This instruction should be followed when starting-up the valve cooling equipment for the first time. Applicable parts can also be followed during service of the cooling equipment. Following these instructions will ensure that the system is ready for operation. WARNINGS General The HVDC cooling equipment as supplied by SwedeWater is considered inherently safe, however, the risk for personal injury should never be discounted and all necessary precautions shall be taken when operating the system. The contents of the following instructions contained in this manual should be read and understood before work is carried out on the system. Lifting When lifting of heavy and/or awkwardly positioned items is necessary, extreme caution shall be exercised. Safe, reliable mechanical lifting equipment shall be used wherever possible. Under no circumstances shall items be lifted via straps, ropes, chains etc. connected to piping or other system components. Noise The valve cooling equipment as supplied by SwedeWater conforms to international standards for noise emission. However, suitable hearing protection should be worn if long exposure to the system during operation is necessary. Resins Care should be taken when handling ion exchange resin. Protective clothing including rubber gloves and safety glasses shall be worn at all times when handling the chemicals. Contact with the skin and eyes may result in minor irritation. Care shall also be taken to avoid spilling resin as flooring can become slippery, resulting in possible personal injury. For further information consult the component information. Chemicals Extreme care should be taken when handling the chemicals. Protective clothing including rubber gloves and safety glasses shall be worn at all times. The chemicals should only be handled in well-ventilated areas or with proper self-contained breathing equipment. For further information consult the applicable component information with the safety data sheet. Protective covers The rotating shafts between the pumps and pump motors have been equipped with protective covers to eliminate the risk of clothing etc. becoming caught in the rotating parts. SwedeWater does not accept liability for personal injury arising from accidents of this nature if the cooling equipment is operated without the covers fastened securely in place.

2.2 2.2.1

2.2.2

2.2.3

2.2.4

2.2.5

2.2.6

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
2.2.7 Safety switches To allow maintenance work to be performed during system operation, the pump motors and cooler fans have been equipped with local safety switches. Care shall be taken to ensure that the equipment has been electrically isolated via the safety switch prior to the commencement of maintenance work. Water sprayed coolers Be careful when near the cooling fans. The fans can suddenly start if the equipment has not been electrically isolated via the safety switch. Spare parts The valve cooling equipment has been designed for long life and high reliability. The components that form the system have been especially chosen with this goal in mind. Therefore, to ensure safe and reliable performance of the cooling equipment only original spare parts as detailed by SwedeWater shall be used. During the warranty period, any installation of material or components other than those supplied by SwedeWater will affect the warranty responsibility.

2.2.8

2.2.9

2.3

ADDRESS In the event that certain maintenance information is insufficient, missing or incorrect, then SwedeWater shall be contacted at the below listed address: SwedeWater P.O. Box 265 S-261 23 LANDSKRONA SWEDEN Phone: +46 418 450700 Fax: +46 418 12019

2.4 2.4.1 2.4.1.1 1. 2. 3. 4. 5.

START CONDITIONS Valve cooling system Valve cooling system - start conditions The cooling equipment shall be assembled complete in accordance with the installation instructions. Ensure that the piping system is internally clean. If it is suspected that the pipes are not thoroughly clean or that foreign objects such as loose end caps exist in the system, then a thorough check shall be performed prior to the system being filled with water. All electrical installations shall be complete. All electrical supplies shall be shut off. The main power switch to the system shall be in the "OFF" position. Check that the pumps in the main circuit have been filled to the correct level with oil. A simple method to ensure the level is correct is to slowly drain oil through the drain plug until air begins to bubble up through the oil in the oil reservoir. See also component information.

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2.4.1.2 1. 2. 3. 4. 5. 6. 7. 8. Check points prior to valve cooling system fill-up Set all valves to the "running" state. Information on the positions of all valves in this state can be obtained from the applicable flow diagram. All filled valve symbols indicate valves in the "shut" position. Make an additional check to ensure that all drainage valves or other valves open to atmosphere are shut. Valves on the nitrogen bottles shall be shut. Pressurizing the expansion vessel shall occur at a later stage. Open block valve E1.K6 and valves E1.V73 and E1.V74 Open by pass valves E1.K7 and E1.K8 to a half-open position. Open valve E1.V48. Open the bleed valves positioned on the highest points of the valve cooling equipment, as noted on the applicable drawings. Filling the valve cooling system Remove the filter bag in vessel E1.C8. Connect the tube between the valves E1.V79 and E1.V77 and open the valves. Fill de-ionised water into make-up vessel E1.C8. Fill de-ionised water by connecting the local water supply through the extra ion-exchange tube. Ensure that filling of the make-up vessel ceases before water overflows. Move three way valve E1.V52 to position "Make-up". Deaerate the make-up pump E1.P3 and thereafter start it via local motorstarter. Stop the make-up pump E1.P3 before the E1.C8 vessel is emptied. The make-up pump shall NOT be operated when dry. Check all open bleed valves for water flow. Repeat items 3 to 7 until water starts to trickle out of the bleed valves. Check via pressure gauge E1.BP5 or E1.BP6 that the pressure in the expansion vessel E1.C2 does not exceed 260 kPa. Shut the bleed valves in series as water appears. Fill the system with water until the service level in the expansion vessel marked with a red tape is reached. This can be seen via level gauge E1.BL10. The air pocket above the water in the expansion vessel will now be compressed. The pressure relief valve E1.V25 is adjusted to a recommended opening pressure of 260 kPa at SwedeWater prior to delivery, however, changes to this setting can occur during shipment. Therefore, should air be noticed to be leaking, check that the opening pressure is set at 260 kPa. The valve cooling equipment is now pressurized via compressed air. Deaerate the cooling system via the bleed valves. Start at the pumps and proceed through the entire system. Should the water level become low in the expansion vessel, then repeat the filling process as described in items 3 through to 14. When the entire system has been deaerated, deaerate the pumps E1.P1 and E1.P2 via the bleed valves E1.V81 and E1.V82 to ensure that no air remains in the pumps. Start one of the pumps via the MCC and allow it run for approximately 30 seconds. Check immediately that it rotates in the correct direction. Note: Care shall be taken when the pumps are in operation. Excessive exposure to noise can damage your hearing, therefore, it is considered advisable to wear hearing protection during long exposure to noise. Allow 5 minutes to pass before repeating the deaeration process. Repeat the above procedure for the other main pump.

2.4.1.3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20.

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21. 22. Repeat items 15 through to 20 until no air remains in the system. This can require 3-4 repetitions of the deaeration procedure. Restore the valve positions according to flow diagram and perform Pressure and Leakage test according to ABB document “Pressure and Leakage test of Valve Cooling System”. E1.BP6 E1.V25 E1.BL2 E1.F1 E1.BP5

E1.T1 E1.BL10 E1.BP5.1 E1.BP6.1 E1.BP7 E1.T2 E1.BP8

E1.C4

E1.C5

E1.C6

E1.C7

Figure 16

2.4.1.4 1. 2. 3. 4. 5. 6.

Pressurizing See Figure 16. The pressure regulating valve E1.T1 and the pressure relief valve E1.V25 are set to 200 kPa and 260 kPa respectively. Check on E1.BL10 that the expansion vessel is filled to the nominal level marked with a green tape. Check that one pair of the nitrogen bottles E1.C4-C7 is connected to the system. Open the valve on the nitrogen bottle. Evacuate the air cushion in the expansion vessel by pulling the handle on the safety valve E1.F1 until no air remains. Check the pressure in the expansion vessel and adjust the nitrogen pressure regulating valve E1.T1 to the recommended set point of 200 kPa. The pressure level can be read off either the pressure regulator E1.T1 or the pressure gauges E1.BP5.1, E1.BP6.1. The safety valve opening pressure needs to be checked to ensure correct function. Increase the system pressure by plugging the pressure relief valve outlet (?" female thread) and opening the pressure regulator valve until the safety valve opens. The correct opening pressure is 350 kPa.

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
7. 8. 9. 10. 11. 12. 13. 14. 2.4.1.5 1. 2. 3. 4. 2.4.1.6 1. 2. Be careful to avoid over pressure. The risk that this should occur is minimal as the safety valve is adjusted and checked by the supplier and then checked again by SwedeWater prior to delivery. Damage to the valve can, however, occur during transport. Release the pressure in the expansion vessel via the safety valve. Remove the plug from the pressure relief valve. Adjust the pressure regulator valve once again to the recommended set point of 200 kPa. Note: The pressure gauge on the pressure regulator shall indicate approximately 70 kPa over the pressure indicated on the pressure gauges E1.BP5.1 and E1.BP6.1. It may be necessary to release the system pressure several times before the correct adjustment has been obtained. Check using leakage detection spray, that no leaks exist in the gas system. Move the three way valve E1.V52 to position "Normal" and move the valves to running positions according to the flow diagram. The valve cooling equipment is now pressurized via nitrogen. Final deaeration Start one of the main pumps and allow it to run for approximately 5 minutes, check immediately the rotation direction of the pump. Stop the pump and allow the system to "settle" for at least 2 hours. Deaerate the system as described earlier. Repeat items 1 through to 3 until no air remains in the system. Final adjustment Start one of the main pumps in operation speed. Read the flow rate before and after the thyristor valves. Check that the flow rate exceeds 94.8 l/sec in Yidu and 88.8 l/sec in Huaxin. Should it not be possible to achieve the above noted flow rate, then this may be due to an excessive pressure drop in the system. Therefore, check the following: Valves: Check the position of all valves. All valves in the main and water treatment circuits shall be fully open unless otherwise marked on the flow diagram. Pumps: Check the rotation direction of the pumps. Filters: Check that filters are free from obstructions. Piping: A possible cause of excessive system pressure drop could be a constriction in the flow due to an pipe end cap for instance. This type of problem results normally in very low flow rates. Adjust the flow in the treatment circuit via valve E1.V59. The flow rate at meter E1.BF3 shall be 2 l/s ( ≈6 on meter) for Yidu and 2 l/s (≈6 on meter) for Huaxin. Check that the level in the expansion vessel is at nominal level marked with the green tape. Check all instrumentation to ensure that all alarm and trip set points are correctly adjusted. Spray water system Spray water system - start conditions The spray water system shall be assembled complete in accordance with the installation instructions. Ensure that the piping system is internally clean. If it is suspected that the pipes are not thoroughly clean or that foreign objects such as loose end caps exist in the system, then a thorough check shall be performed prior to the system being filled with water. All electrical installations shall be complete.

3. 4. 5. 2.4.2 2.4.2.1 1. 2. 3.

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4. All electrical supplies shall be shut off. The main power switch to the system shall be in the "OFF" position. Check points prior to spray water system fill-up Set all valves to the "running" state. Information on the positions of all valves in this state can be obtained from the applicable flow diagram. All filled valve symbols indicate valves in the "shut" position. Make an additional check to ensure that all drainage valves or other valves open to atmosphere are shut. Make an additional check that the dosage pumps and control has been set to correct settings according to Set-point list, see chapter 5.2. Make sure that an appropriate volume of the correct chemical is in each vessel. WARNING Extreme care should be taken when handling the chemicals. Protective clothing including rubber gloves and safety glasses shall be worn at all times. The chemicals should only be handled in well-ventilated areas or with proper self-contained breathing equipment. For further information consult the applicable component information with the safety data sheet. 6. Fill sand to sand filter or check that the sand filter has been filled with the correct sand and to correct levels. See component information. Filling the spray water system After the raw water has been found to be of acceptable quality, the basin tank shall be filled with raw water. The chemical system shall be activated and dosing of chemicals will be made automatically according to settings during filling of basin. Fill sand to sand filter or check that the sand filter has been filled with the correct sand and to correct levels. See procedure in component information 8-1000-383/E. Fill the sand filter with water from the basin by starting the sand filter pump E4.P6 manually, make thereafter a manual backwash of the sandfilter to drain for removing dust from the sand. Note: prime the sand filter pump before running it, running without water in the pumphouse will damage the mechanical seal. Final adjustment – spray water system Test the water in the basin according to instruction 8-5697-210. Note: Do not spray any water on the coolers before the chemicals have been added to the basin and the basin water test has been made with OK result. Prime the spray water pumps before running them (controlled by the valve cooling control system), running the pumps without water in the pump house will damage the mechanical seal. Verify that correct bleed-off orifice plate E4.S5 has been choosen. Instruction for selecting orifice plate see document 8-5697-110.

2.4.2.2 1. 2. 3. 4. 5.

2.4.2.3 1. 2. 3.

2.4.2.4 1. 2. 3.

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3.
3.1

OPERATION
GENERAL This instruction shall be followed during operation. It does not cover all details, only main recommendations. The instructions assume that the flow diagram, the drawings, the electrical diagrams and the component descriptions have been read thoroughly. Before the cooling equipment is to be set in operation, it shall be started up in accordance with the above detailed Start-up instruction. Valve cooling system - starting Energise the control cabinet and start the valve cooling control program. Reset all alarms. Check the coolant level in the expansion vessel. The level should be close to nominal level as indicated by the green tape on the level meter. If needed, perform a make-up to increase the coolant level to nominal. Refer to the applicable sections in the above detailed start-up instruction. Check the level in the spray water basin. The level should be well over min level. If needed add raw water and chemicals with the control program. Start of the pump (main circuit). Pumps are started manually at the frequency converter cubicle. The pump has 2 modes of operation, Local (manual/test) and Remote (operation). In local mode, the pump is started with setting the ref rpm to either “high speed” or “low speed” rpm with push buttons on the control panel. Neither start nor stop of the pump can be carried out by the control system program. In remote mode, the speed selection and stop of the pump can only be carried out by the control program The total system is started by selecting one of the systems. If the pump has been started in manual mode and the system is switched over to automatic, the pump will continue to run. Check flow, conductivity, pressure and temperature on each meter. The values should be acc. to the set-point list, see chapter 5. If the system has been standing unoperational for a while, the conductivity can exceed the acceptable limit. Only a small portion of the main flow is passing through the ion-exchanger, therefore, it can take considerable time before coolant conductivity reaches an acceptable level. Check the entire system for possible water leakage. Valve cooling system - routines during operation The system is normally operated in automatic mode. Control is then carried out from the control room. All faults are alarmed, serious failure will automatically trip the converter. It is recommended to check the cooling equipment weekly regarding at least the following points: Water leakage: If water leakage is detected at an early stage, it is normally easy to take steps to prevent failure or alarm. Noise: A pumping system working properly has a characteristic sound. If this sound changes it is often an early warning of a fault. Pumping systems always develop vibrations. These are normally far lower than acceptance limits. However, if the vibration starts to increase as

3.1.1

3.1.2

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
indicated by unusual and louder noise levels, this is generally a warning that something is wrong. Read all system meters, such as temperature, flow, conductivity, pressure and level, regularly. A change in measured values can provide an early warning and unnecessary alarms and failures can be avoided. For example: Increased conductivity: The ion exchanger resin needs to be changed in the near future. Decreased flow in main circuit: The strainers need to be cleaned in the near future. Decreasing coolant level in expansion vessel: There could be an undetected leakage. Keep the equipment clean and repair any damages to surface treatment promptly. This will decrease the risk of corrosion and increase the life of the equipment. 3.1.3 Valve cooling system - make-up procedure When necessary, make-up water should be added to the system using the same method as described in section 2.6 but it is not necessary to connect the local water supply through an extra ion-exchange tube. After refilling - reset the leakage detection system via the Mach2 system at the operators station. Valve cooling system - shut down procedure Pumps and fans are stopped manually at the control cabin, MCC (Motor Control Centre). To avoid unnecessary alarms to the operator control, the automatic cooling control, CCP (Cooling Control Protection) should also be turned off. The system will not be damaged when standing still during shorter stops. For general stops from one week up to six months, start the system and circulate the water once a week. Operate the system for 30 minutes. For stops longer than six months, drain the system of coolant and empty the ion exchanger of resin. Before refilling the system, clean the conductivity meter sensor. Proceed with the start-up procedure, same as for the first time the system was set into operation. Do not spray any basin water on the coolers until the chemical treatment of the basin water has been activated and water test from the basin is OK. Valve cooling system - procedure with coolers: when the thyristors not are energized, the pumps not are running, the cooling control protection is off and it is risk for freezing When the thyristors not are energized, the pumps not are running, the cooling control protection is off and the temperature falls down towards freezing point the following procedure must be done to protect the coolers from freezing: ? close valves E1.V11, E1.V12, E1.V13, E1.V14, E1.V15 and E1.V27 and open valves E1.V89 and E1.V92. ? open valves E4.V81, E4.V82, E4.V83 and drain the coolers at E4.V91, E4.V92 and E4.V93, E4.V94 and E4.V95. Spray water system - starting Energise the control cabinet and start the PLC-system. Reset all alarms. Start of the spray water system.

3.1.4

3.1.5

3.1.6

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
Each part of the spray water system has 2 modes of operation, manual and automatic. In manual mode, the system is started and stopped on the operating panel. Neither start nor stop can be carried out by the PLC automatically. Select automatic mode for all systems Raw water, Filter, Bleed-off and Dosage system. In automatic mode the PLC will start the raw water pump when water is needed according to level meter E4.BL3. If the raw water pump has been started in manual mode and the system is switched over to automatic, the pump will continue to run. Check basin level, flow, conductivity and sand filter pressure. Conductivity, level and flow values are displayed on the operator’s panel. The values should be acc. to the set-point list, see chapter 6. Check the entire system for possible water leakage. 3.1.7 Spray water system - routines during operation The system is normally operated in automatic mode, controlled by a local PLC. Initially it is recommended to check the spray water system daily/weekly regarding at least the following points: Chemical dosing: Make sure that the dosage of chemicals works, check plastic tubes, check the chemicals barrels and check that the dosage pumps operate properly. Water leakage: If water leakage is detected at an early stage, it is normally easy to take steps to prevent failure or alarm. Noise: A pumping system working properly has a characteristic sound. If this sound changes it is often an early warning of a fault. Pumping systems always develop vibrations. These are normally far lower than acceptance limits. However, if the vibration starts to increase as indicated by unusual and louder noise levels, this is generally a warning that something is wrong. Read all system meters, such as conductivity and sand filter pressure, regularly. A change in measured values can provide an early warning and unnecessary alarms and failures can be avoided. For example: Increased conductivity: The chemical treatment settings should perhaps be changed or the bleed-off should be increased. Increased sand filter pressure: The timing and length of backwash mode is pre-set in the PLC, make a note of sand filter pressure before backwash and after backwash, the pressure should drop after backwash. When backwash no longer has an effect on the pressure the first step should be to increase the backwash time in steps of 5 minutes, when backwash with extended length no longer enables the pressure to drop it means that the sand has been sautered and can no longer be cleaned by backwash. The sand has to be changed. Spray water system - shut down procedure The system will not be damaged when standing still during shorter stops. For general stops from one week up to six months, start the system and circulate the water through the sand filter once a week. Operate the system for a minimum of 30 minutes. Continue dosing of Performax/Drewsperse regularly even if the spray water system not is in operation, to prevent organic growth in the basin and in the piping. For stops longer than six months, drain the system of coolant and empty the basin of water.

3.1.8

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
Before refilling the system, clean the basin, the level meters in the basin and the conductivity meter sensor. Proceed with the start-up procedure, same as for the first time the system was set into operation. Do not spray any basin water on the coolers until the chemical treatment of the basin water has been activated and water test from the basin is OK. Spray water pumps and cooler fans are stopped manually via the valve cooling program at the control cabin, MCC (Motor Control Centre). To avoid unnecessary alarms to the operator control, the automatic cooling control, CCP (Cooling Control Protection) should also be turned off.

4.
4.1

CONTROL AND SUPERVISION
VALVE COOLING SYSTEM - DESCRIPTION OF THE CONTROL AND SUPERVISION See ABB document, Functional description valve cooling system. SPRAY WATER SYSTEM - DESCRIPTION OF THE E300 PANEL The E300 panel, hereafter called simply E300, is an operators’ panel for man-machine communication with the Mitsubishi AnS PLC. It consists partly of a display that can be programmed to show text with dynamic indication and alarm display, and partly a keypad for control. The E300 can be programmed either direct from the keypad or via a PC. A description of the ready programmed panel for the above referenced project follows below. Key functions

4.2

4.2.1

RAW WATER

FILTER Z9

DOS.1 P11/P12

DOS.2 P13/P14

BLEED-OFF K4/K5

RETURN

RESET

MAIN:

Return to the E300 main menu 35

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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
LIST: List all alarms Moves the cursor upwards Moves the cursor downwards Moves the cursor to the left Moves the cursor to the right Function keys linked to lower level menus No function Number keys for data entry Erases the character to the left of the cursor Alarm acceptance Moves to previous menu Enter data Reset

F2 – F7 F1 [ 0 ] - [ 9 ], [ - ], [ . ] ← ACK PREV ? RESET 4.2.2 4.2.2.1 Menus

Main menu A number of lower level menus can be reached by moving up and down from the main menu. If a "+" is shown in the bottom right hand corner of the menu, then more information exists below. The opposite is true if a "+" is shown in the upper right hand corner. The main menu appears as follows: MAIN MENU RUNNING CONDITION RAW WATER PUMP FILTER SYSTEM DOSAGE SYSTEM BLEED-OFF SYSTEM FLOW LEVEL CONDUCTIVITY DATE/TIME & PARAMETER SETTING

Running condition display Raw water pump menus Filter systems menus Dosage system menus Bleed-Off system menus Flow value display Level value display Conductivity value display Date/Time & Parameter setting menus

4.2.2.2

Menu RUNNING CONDITION General running condition can be read from this menu. RUNNING CONDITION RAW WATER PUMP MAN/AUTO FAIL OFF/ON/OFF DELAY/ON DELAY FILTER PUMP P6 – MAN/AUTO FAIL OFF/ON DOSAGE PUMP P11- MAN/AUTO FAIL OFF/ON

Displays the raw water pump position. Auto or Man mode, if failed and if on/off/on delay or off delay. Displays the filter pump (P6) position. Auto or Man mode, if failed and if on or off. Displays the dosage pump (P11) position. Auto or Man mode, if failed and if on or off.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
DOSAGE PUMP P12- MAN/AUTO FAIL OFF/ON DOSAGE PUMP P13- MAN/AUTO FAIL OFF/ON DOSAGE PUMP P14- MAN/AUTO FAIL OFF/ON BLEED-OFF VALVE K4- MAN/AUTO FAIL CLOSE/OPEN CL/OP Displays the dosage pump (P12) position. Auto or Man mode, if failed and if on or off. Displays the dosage pump (P13) position. Auto or Man mode, if failed and if on or off. Displays the dosage pump (P14) position. Auto or Man mode, if failed and if on or off. Displays the bleed-off valve K4 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the bleed-off valve K5 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the filter valve K6 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the filter valve K7 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the filter valve K8 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the filter valve K9 position. Auto or Man mode, if failed and if in position closed, opened or position in between closed and opened. Displays the current flow BF11 in m?/hour. Displays the current level BL3 in mm. Displays the current conductivity BQ1 in mS/cm Displays the status of the control system, if on or failed.

BLEED-OFF VALVE K5- MAN/AUTO FAIL CLOSE/OPEN CL/OP

FILTER VALVE K6-

MAN/AUTO FAIL CLOSE/OPEN CL/OP

FILTER VALVE K7-

MAN/AUTO FAIL CLOSE/OPEN CL/OP

FILTER VALVE K8-

MAN/AUTO FAIL CLOSE/OPEN CL/OP

FILTER VALVE K9-

MAN/AUTO FAIL CLOSE/OPEN CL/OP

BF11-FLOW BL3-LEVEL BQ1-COND CONTROL SYSTEM

____ m?/h ____ mm ____ mS/cm ON/FAIL

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
4.2.2.3 Menu RAW WATER PUMP MAN/AUTO FAIL OFF/ON/OFF DELAY/ON DELAY Displays the raw water pump position. [F2] MAN [F3] AUTO Information on which function keys are active for selecting the operational mode. [F6] STOP [F7] START Information on which function keys are active in manual mode for starting and stopping the pump. Menu FILTER SYSTEM FILTER SYSTEM FILTER SYSTEM FILTER PUMP FILTER VALVES Jumps to lower menu FILTER SYSTEM Jumps to lower menu FILTER PUMP P6 Jumps to lower menu FILTER VALVES

4.2.2.4

4.2.2.4.1Menu FILTER SYSTEM FILTER SYSTEM AAAA Day/time: Start day: Start time: Time set: Time actual

BBBBBBBBBBB DD EEEE GG/GG/GG/GG/GG/GG/GG II JJ/II JJ/II JJ LL m MM s OO m PP s

P6-CCC K6-FFF K7-HHH K8-KKK K9-NNN

Where: AAAA is either MAN/AUTO, showing the current mode for the filter system. BBBBBBB is either GO-TO-NORM, GO-TO-BACKW, NORMAL ON, BACKWASH ON, GO-TO-STOP, OFF, WAITING showing the current operation state for the filter system, GO-TO-NORM, means that valves K6 and K9 opens Pump P6 starts and on the operating panel E300 a red diod flashes, (valve V37 must be closed and BL8-level (normal) OK). NORMAL ON means that valves K6 and K9 are in open position, Pump P6 running and on the operating panel E300 a green diod is turned on. GO-TO-OFF (after normal) means that valves K6 and K9 closes and Pump P6 stops and on the operating panel E300 a red diod flashes. OFF means that the filter system is in OFF position (K6 and K9 has closed Pump P6 has stopped) and on the operating panel E300 a red diod is turned on. GO-TO-BACKW, means that the valves K7 and K8 opens Pump P6 starts and on the operating panel E300 a red diod flashes, (valve V37 must be closed and BL8-level (normal) OK). BACKWASH ON means that the valve K7 and K8 are open and Pump P6 running and on the operating panel E300 a green diod flashes. Backwash time is preset. GO-TO-OFF (after backwash) means that valves K7 and K8 closes and Pump P6 stops and on the operating panel E300 a red diod flashes, OFF means that the filter system is in OFF position and on the operating panel E300 a red diod is turned on. CCC is either ON/OFF, showing the operation state for the filter pump P6. DD is Day of the week, showing the current day of the week.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
EEEE is current Time, showing the current time. FFF is either OPEN/CLOSE or CL/OP, showing the current position of the K6 valve. GG is either Mo, Tu, We, Th, Fr, Sa, Su, showing which day or days the filter system shall be run in backwash mode. HHH is either OPEN/CLOSE or CL/OP, showing the current position of the K7 valve. II is the start hour for the filter system.(three different start hours can be set) JJ is the start minute for the filter system (three different start minutes can be set) KKK is either OPEN/CLOSE or CL/OP, showing the current position of the K8 valve. LL is minutes, showing how many minutes the filter system will run in backwash mode when started. MM is seconds, showing how many seconds the filter system will run in backwash mode when started. NNN is either OPEN/CLOSE or CL/OP, showing the current position of the K8 valve. OO is minutes, showing how many minutes that the filter system has run in backwash mode of the LL minutes. PP is seconds, showing how many seconds that the filter systems has run in backwash mode of the MM seconds. [F2] MAN [F5] STOP [F7] NORMAL [F3] AUTO [F6] BACKW Information on which function keys are active for selecting the operational mode. Information on which function keys are active for selecting the filter system action.

4.2.2.4.2 Menu FILTER PUMP P6 P6-FILTER PUMP MAN/AUTO OK/FAIL OFF/ON Displays the current filter pump position, auto or man mode if failed or ok and if on or off. [F2] MAN [F6] STOP [F3] AUTO [F7] START Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for starting and stopping the pump.

4.2.2.4.3 Menu FILTER VALVES FILTER VALVES K6-FILTER VALVE K7-FILTER VALVE K8-FILTER VALVE K9-FILTER VALVE Jumps to lower menu FILTER VALVE K6 Jumps to lower menu FILTER VALVE K7 Jumps to lower menu FILTER VALVE K8 Jumps to lower menu FILTER VALVE K9

4.2.2.4.3.1 Menu FILTER VALVE K6 K6-FILTER VALVE

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
MAN/AUTO FAIL OPEN/CLOSE/ OP/CL Displays the current filter valve (K6) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

[F2] MAN [F6] CLOSE

[F3] AUTO [F7] OPEN

Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for closing and opening the filter valve K6.

4.2.2.4.3.2 Menu FILTER VALVE K7 K7-FILTER VALVE MAN/AUTO FAIL OPEN/CLOSE/ OP/CL Displays the current filter valve (K7) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

[F2] MAN [F6] CLOSE

[F3] AUTO [F7] OPEN

Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for closing and opening the filter valve K7.

4.2.2.4.3.3 Menu FILTER VALVE K8 K8-FILTER VALVE MAN/AUTO FAIL OPEN/CLOSE/ OP/CL Displays the current filter valve (K8) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

[F2] MAN [F6] CLOSE

[F3] AUTO [F7] OPEN

Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for closing and opening the filter valve K8.

4.2.2.4.3.4 Menu FILTER VALVE K9 K9-FILTER VALVE MAN/AUTO FAIL OPEN/CLOSE/ OP/CL Displays the current filter valve (K9) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

[F2] MAN

[F3] AUTO

Information on which function keys are active for selecting the operational mode.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
[F6] CLOSE [F7] OPEN Information on which function keys are active in manual mode for closing and opening the filter valve K9.

4.2.2.5

Menu DOSAGE SYSTEM DOSAGE SYSTEM DOSAGE SYSTEM 1-P11/P12-BIOSPERSE Jumps to lower menu DOSAGE SYSTEM BIOSPERSE DOSAGE SYSTEM 2-P13/P14-DREW/PERFORMAX Jumps to lower menu DOSAGE SYSTEM DREW/PERFORMAX DOSAGE PUMPS Jumps to lower menu DOSAGE PUMPS

4.2.2.5.1 Menu DOSAGE SYSTEM BIOSPERSE DOSAGE SYSTEM 1-BIOSPERSE AAAA BBBBBBBBBBB Day/time: CC DDDD Start day: FF/FF/FF/FF/FF/FF/FF Start time: HH II Time set: JJ m KK s Time actual LL m MM s

P11-EEE P12-GGG

Where: AAAA is either MAN/AUTO, showing the current mode for the Dosage system 1-Biosperse. BBBBBBB is either GO-TO-DOS., DOS. ON, GO-TO-OFF, OFF, showing the current operation state for the Dosage system 1-Biosperse, GO-TO-DOS. means that bleed-off valves K4 and K5 closes, P11 or P12 starts and on the operation panel E300 a red diod flashes., DOS. ON means that that bleed-off valves K4 and K5 are closed and that either P11 or P12 has started and on the operting panel E300 a green diod is turned on, GO-TO-OFF means that the operating pump P11 or P12 stops and that the bleed-valves K4 and K5 after a time delay are opened and on the operating panel E300 the green diod will start to flash. OFF means that the dosage system is in OFF position and on the operating panel E300 a red diod is turned on. CC is Day of the week, showing the current day of the week. DDDD is current Time, showing the current time in hour and minutes. EEE is either ON or OFF, showing the current position for the pump P11. FF is either Mo, Tu, We, Th, Fr, Sa, Su, showing which day or days the Dosage system 1Biosperse shall run. GGG is either ON or OFF, showing the current position for the pump P12. HH is the start hour for the Dosage system 1-Biosperse. II is the start minute for the Dosage system 1-Biosperse. JJ is minutes, showing how many minutes the Dosage system 1-Biosperse will run when started. KK is seconds, showing how many seconds the Dosage system 1-Biosperse will run when started. LL is minutes, showing how many minutes that the Dosage system 1-Biosperse has run of the JJ minutes. MM is seconds, showing how many seconds that the Dosage system 1-Biosperse has run of the KK seconds.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
[F2] MAN [F6] STOP [F3] AUTO [F7] START Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for starting and stopping the dosage system 1-Biosperse.

4.2.2.5.2 Menu DOSAGE SYSTEM DREW/PERFORMAX DOSAGE SYSTEM 2-DREW/PERFORMAX AAAA BBBB Active time set: CC m DD s P13-EEE Active time actual: FF m GG s P14-HHH Passive time set: II m JJ s Passive time actual: KK m LL s Where: AAAA is either MAN/AUTO, showing the current mode for the Dosage system 2Drew/Performax. BBBB is either GO-TO-DOS/ DOS.ON/ GO-TO-OFF/ OFF/ WAITING, showing the current mode for the dosage system. CC is minutes, showing how many minutes the Dosage system 2-Drew/Performax will run when started. DD is seconds, showing how many seconds the Dosage system 2-Drew/Performax will run when started. EEE is either ON or OFF, showing the current position for the pump P13. FF is minutes, showing how many minutes that the Dosage system 2-Drew/Performax has run of the CC minutes. GG is seconds, showing how many seconds that the Dosage system 2-Drew/Performax has run of the DD seconds. HHH is either ON or OFF, showing the current position for the pump P13. II is minutes, showing how many minutes the Dosage system 2-Drew/Performax will be passive. JJ is seconds, showing how many seconds the Dosage system 2-Drew/Performax will be passive. KK is minutes, showing how many minutes the Dosage system 2-Drew/Performax has been passsive of the II minutes. LL is seconds, showing how many seconds the Dosage system 2-Drew/Performax has been passsive of the JJ seconds. [F2] MAN [F6] STOP [F3] AUTO [F7] START Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for starting and stopping the dosage system 2-Drew/Performax.

4.2.2.5.3 Menu DOSAGE PUMPS DOSAGE PUMPS P11-DOSAGE PUMP P12-DOSAGE PUMP
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OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
P13-DOSAGE PUMP P14-DOSAGE PUMP 4.2.2.5.3.1 Menu DOSAGE PUMP P11 P11-DOSAGE PUMP MAN/AUTO FAIL ON/OFF [F2] MAN [F6] OFF [F3] AUTO [F7] ON Displays the current dosage pump (P11) position, auto or man mode, if failed, if on or off. Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for turning the dosing pump P11 on and off. Jumps to lower menu DOSAGE PUMP P13 Jumps to lower menu DOSAGE PUMP P14

4.2.2.5.3.2 Menu DOSAGE PUMP P12 P12-DOSAGE PUMP MAN/AUTO FAIL ON/OFF [F2] MAN [F6] OFF [F3] AUTO [F7] ON Displays the current dosage pump (P12) position, auto or man mode, if failed, if on or off. Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for turning the dosing pump P12 on and off.

4.2.2.5.3.3 Menu DOSAGE PUMP P13 P13-DOSAGE PUMP MAN/AUTO FAIL ON/OFF [F2] MAN [F6] OFF [F3] AUTO [F7] ON Displays the current dosage pump (P13) position, auto or man mode, if failed, if on or off. Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for turning the dosing pump P13 on and off.

4.2.2.5.3.4 Menu DOSAGE PUMP P14 P14-DOSAGE PUMP MAN/AUTO FAIL ON/OFF [F2] MAN [F6] OFF [F3] AUTO [F7] ON Displays the current dosage pump (P14) position, auto or man mode, if failed, if on or off. Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for turning the dosing pump P14 on and off.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
4.2.2.6 Menu BLEED-OFF VALVES BLEED-OFF VALVES BLEED-OFF SYSTEM K4-BLEED-OFF VALVE K5-BLEED-OFF VALVE Jumps to lower menu BLEED-OFF SYSTEM Jumps to lower menu K4-BLEED-OFF VALVE Jumps to lower menu K5-BLEED-OFF VALVE

4.2.2.6.1 Menu BLEED-OFF SYSTEM BLEED-OFF SYSTEM AAAA BBBBBB Delay: OPENING Time set: CC h DD m Time actual: HH h II m CLOSING EE h FF m JJ H KK m K4-GGG K5-LLL

Where: AAAA is either MAN or AUTO, showing the current mode for the Bleed-off system. BBBBBB is either OFF/ ON/ GO-TO-OFF/ GO-TO-BLEED/ WAITING / CLOSE-DELAY showing the current operation state of the Bleed-valve system, OFF and ON means that the system is either off or on, GO-TO-OFF means that the valves K4 and K5 are being closed, GO-TO-BLEED means that the valves K4 and K5 are being opened, WAITING means that bleed-off is stopped during dosage of Biosperse and a preset time after the dosage has stopped. CLOSE-DELAY means that the bleed-off will continue although the raw water pump has been stopped CC is hours, showing how many hours the Bleed-off valves will wait before opening after dosage of Biosperses. DD is minutes, showing how many minutes the Bleed-off valves will wait before opening after dosage of Biosperses. EE is hours, showing how many hours the Bleed-off valves will wait before closing after that the raw water pump has stopped. FF is minutes, showing how many minutes the Bleed-off valves will wait before closing after that the raw water pump has stopped. GGG is either OPEN/CLOSE or CL/OP, showing the current position of the K4 valve. HH is hours, showing how many hours that the Bleed-off system has waited of the CC hours. II is minutes, showing how many minutes that the Bleed-off system has waited of the DD minutes. JJ is hours, showing how many hours that the Bleed-off system has waited of the EE hours. KK is minutes, showing how many minutes that the Bleed-off system has waited of the FF minutes. LLL is either OPEN/CLOSE or CL/OP, showing the current position of the K5 valve. 4.2.2.6.2 Menu BLEED-OFF VALVE K4 MAN/AUTO FAIL OPEN/CLOSE/ OP/CL

Displays the current bleed-off valve (K4) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

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[F2] MAN [F6] CLOSE [F3] AUTO [F7] OPEN Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for closing and opening the filter valve K4.

4.2.2.6.3 Menu BLEED-OFF VALVE K5 MAN/AUTO FAIL OPEN/CLOSE/ OP/CL

Displays the current bleed-off valve (K5) position, auto or man mode, if failed, if in open or closed or in position in between open-closed.

[F2] MAN [F6] CLOSE

[F3] AUTO [F7] OPEN

Information on which function keys are active for selecting the operational mode. Information on which function keys are active in manual mode for closing and opening the filter valve K5.

4.2.2.7

Menu FLOW FLOW BF11 BF11 meas. ___ m?/h low ___ m?/h Displays the current flow (BF11) in m?/hour. Displays the current low flow alarm set point in m?/hour.

4.2.2.8

Menu LEVEL LEVEL BL3 BL3 BL3 BL3 BL3 meas. ___ mm h/h ___ mm high low l/l ___ mm ___ mm ___ mm Displays the current level (BL3) in mm. Displays the current high/high level alarm set point in mm. Displays the current high level set point in mm. Displays the current low level set point in mm. Displays the current low/low level alarm set point in mm.

4.2.2.9

Menu CONDUCTIVITY CONDUCTIVITY BQ1 BQ1 meas. ___ mS/cm high ___ mS/cm Displays the current conductivity (BQ1) in mS/cm. Displays the current high conductivity alarm set point in mS/cm.

4.2.2.10 Menu DATE/TIME & PARAMETER SET LOGIN DATE/TIME & PARAMETER SET LOGIN DATE/TIME SETTINGS PROJECT MENU SWEDEWATER MENU Jumps to lower menu DATE/TIME SETTINGS Jumps to lower menu PROJECT MENU Jumps to lower menu SWEDEWATER MENU

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[F2] LOGIN [F3] LOGOUT Information on which function keys are active for login to specified security level and logout. Password level 1 gives access to DATE/TIME SETTINGS and PROJECT MENU, password level 2 gives access to SWEDEWATER MENU.

4.2.2.10.1 Menu DATE/TIME SETTING DATE/TIME SETTING WEEKDAY ___ DATE ___ TIME ___

Displays the current weekday. Displays the current day. Displays the current time.

4.2.2.10.2 Menu PROJECT MENU PROJECT MENU FILTER SYSTEM Jumps to lower menu FILTER SYSTEMSETTING DOSAGE SYSTEM 1-BIOSPERSE Jumps to lower menu DOSAGE SYSTEM 1-BIOSPERSE DOSAGE SYSTEM 2-DREW/PERFORMAX Jumps to lower menu DOSAGE SYSTEM 2-DREW/PERFORMAX BLEED-OFF SYSTEM Jumps to lower menu BLEED-OFF SYSTEM-SETTING 4.2.2.10.2.1Menu FILTER SYSTEM-SETTING FILTER SYSTEM Time settings: -Weekday: __ __ __ __ __ __ __ __ __ __ __ __ __ __ -Backw./day: __ -Start time: __ __/__ __/ __ __ -Time set: __m __s In the menu FILTER SYSTEM-SETTING all settings for backwash; active weekdays, start time and time set, can be changed.

4.2.2.10.2.2Menu DOSAGE SYSTEM - SETTING DOSAGE SYSTEM 1-BIOSPERSE Time settings: -Weekday: __ __ __ __ __ __ __ __ __ __ __ __ __ __ -Start time: __ __ -Time set: __m __s In the menu DOSAGE SYSTEM-SETTING 1-BIOSPERSE all settings, active weekdays, start time and time set, regarding the dosage system 1-biosperse can be changed.

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4.2.2.10.2.3Menu DOSAGE SYSTEM - SETTING DOSAGE SYSTEM 2-DREW/PERFORMAX Time settings: -Active time set: __m __s -Passive time set: __m __s In the menu DOSAGE SYSTEM-SETTING 2-DREW/PERFORMAX all settings, active and passive time, regarding the dosage system 2-Drew/Performax can be changed. 4.2.2.10.2.4Menu BLEED-OFF SYSTEM-SETTING BLEED-OFF SYSTEM Delay: OPENING CLOSING -Time set: __h __m __h __m In the menu BLEED-OFF SYSTEM-SETTING the setting, delay of opening after dosage can be changed and the delay of closing after raw water pump has been stopped can be changed. 4.2.2.10.3 Menu SWEDEWATER MENU Set points and parameter settings for Flow, Level and Conductivity can be changed via this menu. To be able to come into this section, a password must be entered. Any change of setpoints and parameters is only allowed after confirmation from SwedeWater and according to instructions from SwedeWater.

5.
5.1

SET-POINT LISTS
SET-POINT LIST - VALVE COOLING SYSTEM See ABB document, Setting list for valve cooling system. SET-POINT LIST – SPRAY WATER SYSTEM The Function Interface documents 4-5697-978 (Yidu pole 1), 4-5697-988 (Huaxin pole 1), 45698-978 (Yidu pole 2), 4-5698-988 (Huaxin pole 2) in section Electrical Drawings includes a complete list of all Items with: ? Description ? Signal Type ? Range ? Unit ? PLC Tag Name ? Nominal Value ? Set-point ? Alarm ? Function ? Individual Signal ? Common Warning Signal ? Common Alarm Signal ? Common Trip Signal ? Communication ? Remark

5.2

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6.
6.1

MAINTENANCE
GENERAL It is considered important to have a good, comprehensive preventive maintenance program to ensure faultless operation of the thyristor valve cooling equipment. The following maintenance instructions provide general guidance, however, maintenance routines shall be developed by those who operate the system to reflect user experience gained over time. Every cooling equipment operates differently based upon the project-dependant tailor-made design, differing environmental conditions and the people operating the system. SwedeWater has developed the following maintenance instructions based on many years of experience from previously delivered cooling systems and recommendations from subsuppliers. The following instructions include only certain relevant details taken from the technical documentation provided by the sub-suppliers. Detailed component documentation can be found in section "Component Information". A Preventive Maintenance Program has also been provided to serve as a guide regarding the recommended periodical maintenance for different system components.

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7.

PREVENTIVE MAINTENANCE PROGRAM
Period h d w m y Action Cooling Liquid Pumps E1.P1/M1-P2/M2 1 1 1 3 3 3 1 1 1 1 3000 - Check oil level - Check for noise - Check for shaft leakage - Check for leakage in pump - Check for excessive vibration - Regrease pump motor - Check threaded parts and couplings - Check mechanical sealing - Check alignment of pump and pump motor - Check condition on the anti-vibration mounts under pumpmotor bottom plate - Change oil 8-9900-012e Component Info. Component Info. Component Info. Component Info. Component Info. Chapter 9.5 Refer to: Data:

Cooling Liquid System E1 1 1 - Deaeration of vessels E1.Z3-Z4 - Check all flanged joints for tightness 8-9900-011e

Ion Exchange Vessel E1.Z3-Z4 1 5 - Exchange of ion exchange resin - Dismantle the bottom inserts and clean the inside of the vessels thoroughly Strainers and Filters E1.Z1-Z2, E1.Z5-Z7 1 - Cleaning of strainers and change of filters. Chapter 9.6 Chapter 9.1

Temperature Monitoring E1.BT1-BT6 1 - Check of Pt100 element Component Chapter 9.7 Info./

Hand Operated Valves 1 - Check function, Close-Open

Conductivity meters E1.BQ1-BQ3 1 - Check and cleaning of sensors Chapter 9.3

2-way and 3-way Remote Controlled Valves E1.K5-K8 1 - Check position indicator switch Component Info.

Automatic Deaeration Valve E1.V19 1 - Check function Component Info.

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
Period h d w m y Action Refer to: Data:

Safety valve E1.F1 1 - Manually operate the safety valve by lifting the lever on the valve and check function by following the steps in start-up instruction section 2.7. Pressure Relief Valve E1.V25 1 - Check function by following the steps in start-up instruction section 2.7 Pressure Regulator E1.T1 1 - Check function and set-point by following the steps in start-up instruction section 2.7 Level Switches E1.BL3-BL4 1 - Check function Component Chapter 9.8 Info./ Component Info./ Chapter 2.4.1.4 Component Info./ Chapter 2.4.1.4 Component Info./ Chapter 2.4.1.4

Level Sensors E1.BL1-BL2 1 - Check function Component Chapter 9.8 Info./

Solenoid Valves E1.K11 1 - Check function by simulating the valve operation Component Info.

Pressure Transmitter E1.BP1-BP6 1 - Check of zero adjustment Component Info.

Pressure Transmitter E1.B7-BP8 1 - Check function Component Info.

Expansion joints E1.W1-W4 3 1 10 - If necessary follow-up bolt/nut tightening of expansion joint and limit rods after start-up/ “open inspection” - Check bolt/nut tightening and that the extension limit rods not are loose - Change to new expansion joints Component Info. 8-1000-013e Component Info. 8-1000-013e 8-1000-013e

Heaters E1.E1-E1-E4 1 - Check function, turn on maually and make sure the piping temperature around the heaters increase Make-up Pump E1.P3 1 1 - Check function - Check for leakage Component Info. Component Info. Component Info.

Oxygen content in the cooling liquid E1.BO1 1 1 - Measure the oxygen content - Check, clean and calibrate sensor Chapter 9.2 Chapter 9.2/ Component Info

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Period h d w m y Action Refer to: Data: Component Info. Chapter 9.2

1

- Check gas level in the nitrogen bottles

Other 1 - Check for leakage in the system

Coolers 1 - Check according to maintenance program in Component information for the Coolers Chapter 10.1/ Component Info.

Spray Water System (E4) 3 1 1 - Check pumps for leakage and noise. - Check nozzles in spray water system. - Check bleed-off valves E4.K4-K5 Chapter 10.5.2/ Component Info. Chapter 10.1/ Component Info. Chapter 10.2/ Component Info.

Raw water flow 1 - Check flow meter E4.BF11 Chapter 10.6/ Component Info.

Chemical system 2 2 - Check dosage pumps E4.P11-P14 - Check flow guards E4.BF1-BF4 Chapter 10.4.2/ Component Info. Chapter 10.4.3/ Component Info.

Sand Filter (E4.Z9) 1 1 1 6 6 1 - Check and if necessary change sand - Check pressure over filter E4.BP1 - Check pressure meter function E4.BP1 - Check function of all motorised valves E4.K6-.K9 - Check and clean E4.BQ1 sensor - Check pump E4.P6 Chapter 10.5/ Component Info. Chapter 10.5/ Component Info. Chapter 10.5.4/ Component Info. Chapter 10.5.2/ Component Info. Chapter 10.7/ Component Info. Chapter 10.5.3/ Component Info.

Basin (water tank) 1 1 1 1 - Check water quality - High-pressure wash the basin. - Check level sensors E4.BL1-BL2, E4.BL3, E4.BL5-BL8 - Check drainage pump E4.P7 Chapter 10.8.1/ 8-5697-210 Chapter 10.8/ Component Info. Chapter 10.8.2/ Component Info. Chapter 10.8.3/ Component Info.

PLC 5 Change back-up battery (type - lithium) Component Info.

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Period h d w m y Action Refer to: Data:

Control Panel 1 4 - Change ventilation filter - Change cubicle ventilation fan (calc. life-time)

8.

SPECIAL TOOLS FOR MAINTENANCE
Dial instrument for alignment of pump motor shaft. Funnel and scoop for filling ion exchange resin. Analysis equipment and chemicals for spray water. Grease gun for lubrication of electrical pump motors.

9.
9.1 9.1.1

VALVE COOLING SYSTEM - MAINTENANCE
EXCHANGE OF ION EXCHANGE RESIN General The working principle of the ion exchange circuit is to have both ion exchange vessels running in series during normal operation. Always keep the vessel containing the most exhausted ion exchange resin first in series. The lifetime of the ion exchange resin shall normally be more than one year, however, if the system has been filled with large quantities of water with high conductivity, the lifetime of the resin can be greatly reduced. SwedeWater recommends that the ion exchange resin in the first vessel of the serie is exchanged once per year. Warning Care shall be taken when handling the ion exchange resin. Contact of the resin with the eyes and skin can lead to slight irritation. Protective clothing including rubber gloves and safety glasses should be worn. The Component Information Data Sheet provided should be consulted prior to the commencement of resin replacement work. Vessel E1.Z4 in operation and E1.Z3 for service Turn off the leakage detection system via the Mach2 system at the operators station. Increase the level in the expansion vessels E1.C2/C3 to the service level marked with a red tape by performing a manual make-up. Check that the level in the make-up vessel E1.C8 is half-filled and that the filter insert is in place, otherwise fill-up. Arrange the valves and hoses according to Figure 17 below. Filled valve symbols indicate that the valve shall be closed and non-filled open. Connect the hose between valves E1.V77 and E1.V79, and the hose between valve E1.V71 and vessel E1.Z3. Reposition valve E1.V53 so that E1.Z4 is first in series, close valve E1.V55 and E1.V61.

9.1.2 1. 2. 3. 4.

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Figure 17

5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15.

Attach the loose handle to valve E1.V71 and open the valve. Open valve E1.V79 and E1.V77. Deaerate the make-up pump E1.P3 and then start it. Open E1.V65 CAREFULLY. The exhausted ion exchange resin in E1.Z3 will now be pumped into the make-up vessel E1.C8. Note: The water drains slowly through the resin in the filter insert in the make-up vessel E1.C8. Due to this, two water levels will appear, one over the resin in the filter insert and one under the bottom of the filter insert. Check the two levels continuously during the whole operation, the lower level so that the pump doesn’t begin to suck air and the upper level so that the make-up vessel doesn't begin to overflow. If there is a risk of the above occurring, the make-up pump shall be stopped until an acceptable level is reached. The last section of the hose connection with the make-up vessel is transparent, making it possible to see when the ion exchange resin vessel has been emptied. SwedeWater recommends that the filter insert be emptied when half full. When the ion-exchange vessel has been emptied, stop the pump E1.P3. Shut valve E1.V65. Shut valve E1.V71 and REMOVE the handle. Empty the filter insert in the make-up vessel using a scoop or using the lifting eye bolts in the bag and lift the bag. When empty, rinse the bag with water. Restore the make-up vessel to operational mode i.e. close valve E1.V79, E1.V77 and remove the hose between E1.V71 and the make-up vessel E1.C8 . Connect a hose between valve E1.V71 and the closest drain.

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16. 17. 9.1.3 1. 2. Drain the ion exchange vessel by opening valve E1.V71 and bleed valve E1.V90. When the ion exchange vessel is emptied shut valve E1.V71. Filling new ion exchange resin Disassemble the pipe coupling connecting the inlet piping to the pipe elbow of the filter insert on the top of vessel E1.Z3. (pos. 1 in Figure 18) Lift out the filter insert together with associated piping as marked in Figure 18 below. Pos. 1

Pos. 2

Ion exchange resin

Ion exchange resin – Fill level

Figure 18

3. 4. 5. 6. 7.

8. 9. 10.

Fill the vessel with new ion exchange resin using a funnel and a scoop. Fill to a level equivalent to where the vessel end cap begins (weld line see Figure 18). Note: In principle, the screen of the filter insert shall lie directly over but not in, the resin. Open the screen of the filter insert (pos. 2 Figure 18) and clean it thoroughly. Reinstall the filter insert and reassemble the pipe coupling. Open valve E1.V62 CAREFULLY, approximately 30°. This to prevent the flow through the ion exchange vessel becoming too great. E1.Z3 will now be filled with water from the system. If the water level in the expansion vessel E1.C2 gets too low, shut valve E1.V62 and perform a manual make-up until the water level returns to the nominal level marked with green tape. Open valve E1.V62 carefully once again to approximately 30° and continue with the water filling process. Continue the filling process until the ion exchange vessel is full as noted when water starts to trickle out of bleed valve E1.V90. Shut valve E1.V62 and bleed valve E1.V90. Arrange the valves according to Figure 19 below i.e. E1.Z3 first in series.

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Figure 19

11. 12.

Maintain the system configuration with E1.Z3 first in series in for at least 24 hours. This configuration saves the filters in the treatment circuit since loose particles from the new resin is trapped in the E1.Z4 and not clogging the filters. When the conductivity value is below 0,1 μS/cm and at least 24 hour has past arrange the valves according to Figure 20 i.e. E1.Z4 first in series.

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Figure 20

13. 14. 15.

Ion exchange vessel E1.Z3 is now back in operation. Turn on and reset the leakage detection system via the Mach2 system at the operators station. Deaerate E1.Z3 and E1.Z4 after about a week after changing the ion exchange resin. Thereafter, deaeration should be done according to the preventive maintenance program. Ion exchange vessel E1.Z3 is now back in operation. Vessel E1.Z3 in operation and E1.Z4 for service The process for exchanging the resin in vessel E1.Z4 is in principle, exactly the same as for E1.Z3. The above procedure as described in sections 2 and 3, shall therefore be followed, substituting valve and vessel numbers where appropriate for those equivalent for vessel E1.Z4. Maintenance Every fifth year the bottom insert in the two ion exchange vessels shall be dismantled. This provides the opportunity to perform a thorough internal cleaning of the vessel. The most important operation to perform during this maintenance is to clean the bottom of the vessel from old resin residue.

9.1.4

9.1.5

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9.2 9.2.1 OXYGEN REMOVAL SYSTEM General To keep the oxygen content very low in the valve cooling circuit, the equipment has an oxygen removal system based on the use of nitrogen gas bubbling. The system is a part of the water treatment circuit. Circuit Design The outlet water from the treatment circuit is led through the expansion vessel and exposed to nitrogen, before it returns to the main circuit. The exposure is obtained in two ways. One is by sprinkle the water, via a nozzle at the top of the expansion vessel, into the nitrogen cushion used for the system pressurizing. The other is to inject nitrogen gas through a spreader at the bottom, which make the gas to bubble through the water volume in the vessel. A pressure relief valve V25, ensure that the pressure will not increase above allowed level. The following components are belonging to the nitrogen gas bubbling system (see Figure 21): ? A gas spreader (nozzle) in the bottom, E1.V44 ? A water inlet and spraying nozzle at the top, E1.V45 ? A gas flow meter with regulating valve, E1.BF11 ? A solenoid valve to dose gas, E1.K11 ? An oxygen meter, E1.BO1

9.2.1.1

Figure 21

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9.2.1.2 Control of the oxygen content By sprinkling the water into the nitrogen cushion the contact surface water - nitrogen is increased. The dissolved oxygen will then partly be transferred into gaseous phase. To renew the nitrogen gas cushion, when saturated with the amount of oxygen where the transfer of oxygen stagnates, nitrogen is injected through a spreader at the bottom of the expansion vessel. That makes the pressure to rise above the open limit for the pressure relief valve E1.V25 and the nitrogen/oxygen mixture is released to the surrounding atmosphere. Two parameters are used to control the oxygen content. The bubbling time and the gas flow. The bubbling time is controlled from the software by open orders to the solenoid valve E1.K11. The flow is adjusted by means of a valve on the gas flow meter E1.BF11. These parameters are set during an adjustment period, see section 11.3 Adjustment. Quality of nitrogen The nitrogen gas shall be of ordinary trade quality. Typical specification is AGA Nitrogen Plus: nitrogen > 99.99% water oxygen < 5 ppm < 5 ppm

9.2.2

hydrocarbons < 1 ppm 9.2.3 Adjustments To achieve acceptable low levels of oxygen in the cooling water, an adjustment period is needed after the system has been filled up with water for the first time, as well as after major refilling (not normally make-up). Levels Recommended levels: Oxygen content (ppb) <200 (150*) Nitrogen gas flow (l/min) 0.2-1.0 (0.3*) Bubbling time (minutes) 15-60 (20*) Non bubbling time (minutes) 15-60 (20*) * Typical levels. Actual levels are decided during the adjustment period. Measuring The oxygen content is shown on the BO1 oxygen meter, which is placed in the measurement circuit on the treatment unit. The oxygen meter shall during operation only be switched on when it is time for measuring the oxygen content. The response time for the sensor is 7.2 seconds but wait 30 seconds or until the value is stabilised before noting the result. During operation when no measurement is made the instrument shall be shut off but the coolant shall pass the sensor, according to the flow diagram. Handling Initially there is an adjustment period where the oxygen content in the filling water has to be removed. This will be done by a constantly bubbling with a higher gas flow for a couple of days. How many are depending of how large the system is and how much oxygen there is in the filling water. See Figure 22 for a representative inward curve. There will be a final adjustment period when the thyristor valve is in operation, and thereby the producing of oxygen due to the electrolysis process takes part. When the oxygen content 58

9.2.3.1

9.2.3.2

9.2.3.3

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level has come down to the wanted the gas flow has to be adjusted to the chosen level and the times for bubbling and non bubbling has to be set in the cooling control program.

Figure 22

9.2.4

Maintenance To prevent the nitrogen gas bubbling system from failures the following visual inspections have to be done: Check the nitrogen gas bottles, so that there are gas for the gas bubbling, as well as, to keep the system pressurised. When the nitrogen bottles has been changed the connection between the bottles and the tubes shall be checked with leakage detection spray and the valve marked PURGE should be opened until all the air in the tubes are released avoiding the air to enter the expansion vessel. Check that the gas flow and the flow in the water treatment circuit is correct. Normally, only the oxygen sensor requires service. If the indicating instrument is properly connected, is handled with reasonable care, and is kept clean, it should give no mechanical or electrical problems. Follow the instructions given in the component information for the oxygen meter and oxygen sensor.

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9.3 9.3.1 CLEANING OF CONDUCTIVITY SENSORS General The cleaning interval is normally one year. Check if there is any coating on the sensors. Both electrodes must be free from coating and grease. If necessary, wash the electrodes with alcohol. Inorganic coating (e.g. aluminium oxide) can be removed by washing with a weak solution e.g. 5% hydrofluoric acid. Service sensors E1.BQ1, E1.BQ2 See Figure 23. Shut valve E1.V42 before the conductivity sensors. E1.BO1.1 E1.BQ3.1 E1.BQ1.1 E1.BQ2.1

9.3.2 1.

E1.BO1

E1.V46 E1.BQ1

E1.V47

E1.BQ2

E1.V48 E1.V42

Figure 23

2. 3. 4. 5. 6. 7. 8.

Shut valve E1.V46 and make sure valve E1.V48 is closed after the sensors. Dismount the sensors. Check and clean the electrodes, see component information. Remount the sensors. Open fully valve E1.V46 after the conductivity sensors. Open valve E1.V42 before the conductivity sensors. Check that the flow measured on flow meter E1.BF3 is correct. If not, adjust the flow via flow regulating valve E1.V59.

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9.3.3 1. Service sensor E1.BQ3. See Figure 24. Shut the valves on both sides of the conductivity sensor, E1.V54 and E1.V61.

E1.BQ3

E1.V61

E1.V54

Figure 24

2. 3. 4. 5. 6.

Dismount the sensor. Check and clean the electrodes. Remount the sensor. Open the valve before (E1.V54 or E1.V61) the conductivity sensor. Open the valve after (E1.V54 or E1.V61) the conductivity sensors ensuring that the flow meter E1.BF3 indicates the correct flow rate. SERVICING THE MAIN PUMPS General The two components in the cooling equipment that require the most attention are the main pumps. The manufacturer's maintenance instructions should be read thoroughly. Warning To allow maintenance work to be performed during system operation, the pump motors have been equipped with local safety switches. Care shall be taken to ensure that the equipment has been electrically isolated via the safety switch prior to the commencement of maintenance work.

9.4 9.4.1

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9.4.1.1 Operation time – pump/motor Viewing the current operation time for the pump is done on the frequency converter control panel for the actual pump, if the motor run time not is presented on the display procedure as below: On the frequency control panel, move the cursor to desired line with single arrow. Press Enter. Choose from the list (43 = motor run time). Press Enter. On the frequency control panel the actual motor run time can be read in hours. Mechanical sealing The Pumps are equipped with mechanical sealings. These sealings are not 100% leak proof. There is always small leakage. For deionized water systems filled only with clean water, this leakage will quickly evaporate. Normal leakage is approximately 2-10 centilitres per day. The mechanical sealings ought to be changed if the leakage is noted to be greater. To minimize the risk for unacceptable leakage during operation, the mechanical sealing can be replaced every two years or after approximately 8000 working hours. To replace the mechanical sealing the shaft coupling needs to be dismounted. The coupling is equipped with a spacer, so the motor is not required to be dismounted from the bottom plate. Before service work on the pump is started, ensure the safety switch is in position "0" (OFF). Shut the isolation valves on both sides of the pump and drain the pump body. Follow the pump manufacturers instructions regarding replacement of the mechanical sealing (see "Component Information"). When the shaft coupling has been remounted, the alignment of the pump and motor shall be checked in accordance with SwedeWater Standard Instruction "Alignment of Pump and Pump Motor", See Miscellaneous Instructions. Before refilling the pump, increase the water level in the expansion vessel to the service level marked a red tape, by performing a manual make-up and shut off the leak detector via the Mach2 system at the operators station. Fill the pump body with water by carefully opening the valve on the suction side. Open the bleed valve on the pumps compression side and shut it again when water starts to trickle out of it. Open the isolation valves before and after the pump. Return the safety switch to position "1" ("ON"). Check for excessive noise and vibration and possible leakage once the pump is back in operation. Bearing housing oil After 300 working hours the oil needs to be changed for the first time, thereafter, every 3000 working hours. Normally the operating time of each of the pumps is equal during the year, so it is beneficial to change the oil in both pumps during the annual service stop. Always use the type of oil that the manufacturer specifies. Check the oil level regularly (see the Preventive Maintenance Program). Vibrational control A change in the vibration level often provides a forewarning that something is wrong. A regular vibration check is therefore beneficial (see the Preventive Maintenance Program). If the vibration level increases, check the following items: a) Check all fastening bolts on the pump and motor.

1. 2. 3. 4. 5. 9.4.2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

9.4.3 1. 2. 3. 9.4.4 1. 2.

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b) Check the alignment of the pump and motor. c) Check the temperature of the bearings. d) Turn the shaft manually and check for noise. e) Check all the rubber grommets in the shaft coupling. f) Check all the anti-vibration mounts under the pump/motor bottom plate. If they are worn or damaged, they shall be replaced. Should no faults be found, continue to check the vibration level regularly. SERVICING THE MAIN MOTORS General The main motors require very little maintenance. However a regular inspection is recommended to ensure minor problems do not escalate to breakdowns. The bearings should be re-greased according to preventive maintenance program always use the type of grease that the manufacturer specifies, if that is not available use a lithium-based high temperature grease. See grease information plate on the motor. See also component information for more specific information regarding grease quality/ amount/ grease outlet equipment and more. CLEANING OF FILTERS AND STRAINERS General There are three filters and two strainers installed in the system. All filters and strainers can be cleaned during operation of the cooling system. E1.Z5, Z6, Z7: E1.Z1, Z2 9.6.2 1. Filters in the Water Treatment Circuit. Strainers in the Cooling Liquid Circuit

3. 9.5 9.5.1 1.

9.6 9.6.1 1.

Filters in the water treatment circuit E1.Z5, E1.Z6, E1.Z7 The filters in the water treatment circuit have the function of collecting the residue from the Ion Exchanger vessels. Two of the three filters E1.Z5, E1.Z6, E1.Z7 shall always be in operation. Originally redundant filter E1.Z6 shall be taken in operation when the other filters needs service. The general service procedure is to open for the redundant filter and closing for the one of the two that shall be changed. Change the filter and thereafter put the newly serviced filter back in operation. Close for the second filter of the pair first in operation. Change and remount it and keep the other filters in operation until next service. Service on E1.Z5 and E1.Z7 Open the isolation valves before and after the redundant filter E1.Z6. Shut the isolation valves before and after filter E1.Z5. Drain the filter by unscrewing the drain plug and open the filter in accordance with the Figure 25 below, see also component information 8-1000-128/E.

9.6.2.1 1. 2. 3.

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Figure 25

4. 5. 6. 7. 8. 9. 10. 9.6.2.2 1. 9.6.3

Remove the old cartridge and install a new one. Remount the filter. Open the isolation valves before and after filter E1.Z5. Shut the isolation valves before and after filter E1.Z7. Remove the old cartridge and install a new one. Remount the filter. Filter E1.Z5 and E1.Z6 are now in operation and E1.Z7 is the redundant filter. Service on E1.Z6 or E1.Z7 Perform the above listed steps substituting Z5 for Z6 or Z7 and vice versa. Strainers in the cooling liquid circuit E1.Z1, E1.Z2 The risk for fouling in the strainers during normal operation is considered minimal. The strainers normally only requires to be cleaned after start-up. Service on E1.Z1/E1.Z2 Shut the valves on both sides of the strainer. Drain the strainer using the drain plug located on the strainers underside, see also component information 8-1000-016/E. Unfasten and remove the bolts around the strainer. Remove the strainer and clean the screen. Reposition the strainer between the flanges. Note: The flow direction shall be as shown by the arrow in the Figure 26 below.

9.6.3.1 1. 2. 3. 4. 5. 6.

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7. 8.

Figure 26 It is considered very important to centre the strainer and gaskets between flanges. Tighten the bolts.

9.6.3.2 1. 2. 3. 4. 5. 6. 7. 8.

Filling water Increase, if necessary, the water level in the expansion vessel to the nominal level marked with a green tape, by performing a manual make-up. Turn off the leakage detection system via the Mach2 system at the operators station. Open isolation valve E1.V16 (E1.V17) carefully. Deaerate by opening E1.V81 and E1.V83 (E1.V82 and E1.V84) until water appears. Open isolation valve E1.V3 (E1.V4). Strainer E1.Z1 (E1.Z2) is now back in operation. Check the level in the expansion vessel, it should be close to nominal, if not, perform a manual make-up. Turn on and reset the leakage detection system via the Mach2 system at the operators station.

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9.7 9.7.1 TEMPERATURE MEASURING General Check that the temperature monitoring from E1.BT1-BT4 and E4.BT5-BT6 are within limits, check that the temperature from the same measuring point gives the same results in both systems, if possible check against a reference. If any faults are noted the sensor and transducer has to be checked. Make a visual check that all wiring are OK. LEVEL SWITCHES – EXPANSION VESSELS General Check that the level switches E1.BL3-BL4 works properly by decreasing and increasing the water level in the expansion vessel and note if the switches gives the correct signals to the systems. Save the coolant in a suitable vessel when the lower level is checked so that it can be re-entered in the system. If the results not are OK, the switches has to be visually inspected , see also component information. Make a visual check that all wiring are OK. For the level sensor E1.BL1-BL2 check the probe insulation for damage, remove if necessary material build-up especially at the process connection, check the housing cover and the cable entry for tightness. Check that both sensors give the same result to the system. See also component information.

9.8 9.8.1

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10.
10.1 10.1.1

SPRAY WATER SYSTEM - MAINTENANCE
EVAPORATIVE COOLERS Coolers - general Check the water sprayed coolers regularly for debris and other minor malfunctions. Follow the manufacturers maintenance program in the component information. Water spray system Check that all pumps, E4.P1-P4, work properly.

10.1.2

10.1.2.1 General - Pumps The components in the spray water system that require the most attention are the spray water pumps and motors. See enclosed component information for the pump/motor. Check also that all spray nozzles and louvers on the coolers are working properly when the spray water pumps are running. Warning To allow maintenance work to be performed during system operation, the spray water pump motors have been equipped with local safety switch. Care shall be taken to ensure that the equipment has been electrically isolated via the safety switch prior to the commencement of maintenance work. 10.1.2.2 Vibration check – Spray water pumps A change in the vibration level often provides a forewarning that something is wrong. A regular vibration check is therefore beneficial. If the vibration level increases, check the following items: a) Check all fastening bolts on the pump and motor. b) Check the temperature of the bearings. Should no faults be found, continue to check the vibration level regularly. 10.2 BLEED OFF SYSTEM E4.K4-K5 Check that all valves and motors in the bleed off system works properly. Check also that the piping and the flow through the piping is OK. MOTORISED BY-PASS VALVES E4.K1-K3 The motorised by-pass valves after the spray water pumps shall be used when the redundant spray water pump shall be used, make sure that the motorised by-pass valves works properly.

10.3

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10.4 CHEMICAL SYSTEM - GENERAL WARNING Extreme care should be taken when handling the chemicals. Protective clothing including rubber gloves and safety glasses shall be worn at all times. The chemicals should only be handled in well-ventilated areas or with proper self-contained breathing equipment. For further information consult the applicable component information with the safety data sheet. 10.4.1 Chemicals E4.C11-C14 The four different vessels with different chemicals shall be replaced by new ones when empty. Remaining small quantities of chemicals shall not be moved/transferred to the new vessel. Personal protection, handling, disposal information and more is to be found in the applicable 16-point safety data sheet in the component information. Carefully unscrew and remove the suction assembly from the empty vessel and mount it in the new vessel. Dosage pumps E4.P11-P14 Check the dosage pumps according to preventive maintenance program, maintenance actions according to component information. Each dosage pump has a level guard. Flow guards E4.BF1-BF4 Check the flow guards according to preventive maintenance program, maintenance actions according to component information. SAND FILTER - GENERAL A portion of the water in the basin is continuously pumped by E4.P6 through the sand filter were it is filtered, pressure is measured. To avoid that the pressure drop over the sand filter gets to high, the sand filter is backwashed at pre-set timings. During backwash all water goes to drain. Sand filter E4.Z9 The sand filter is filled with three different types of sand. Keeping note of the sand filter pressure E4.BP1, before and after backwash, will give an indication on when initially the settings for backwash must be changed and finally a time for when the sand-filter is saturated and the sand has to be replaced, follow instructions in component information, 8-1000-383/E for filling new sand. Motorised valves to the sand filter E4.K6-K9 Make sure that the motorised valves works properly by running them manually. Filter pump E4.P6 The pump is a smaller version of the spray water pumps, same maintenance actions has to be done as earlier described in point 16.2.1-16.2.2. Pressure meter E4.BP1 No special maintenance required, keep the pressure meter clean. Flow meter E4.BF11 No special maintenance work required, keep the flow meter clean and check the wiring. See component information.

10.4.2

10.4.3

10.5

10.5.1

10.5.2

10.5.3

10.5.4

10.6

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10.7

CONDUCTIVITY METER E4.BQ1 Check the sensor for deposits every 6 month. Deposits on the sensor can be removed by a soft brush, e.g. a bottle brush. Hard-to-remove crusts and deposits can be softened and removed with citricacid or equivalent acid. Observe the safety regulations. BASIN (SPRAY WATER)- GENERAL The spray water quality in the basin shall be checked regularly. Once a year the basin shall be washed with high-pressure water. The filter pump E4.P6 should be used to drain the tank. Check at the that the level sensors are clean and works properly. Water quality in basin E4.C1 Until experience/know-how has been achieved for dosing of chemicals at different seasons and conditions the quality of the basin water shall be checked twice a week. Use the analysis equipment and chemicals supplied with the unit. The analyze procedure is described in document 8-5697-210 in Miscellaneous instructions. Level sensors E4.BL1-BL3, E4.BL5-BL8 For the level sensor E4.BL3 check the probe insulation for damage, remove material build-up especially at the process connection, check the housing cover and the cable entry for tightness. See also component information. For the level sensors E4.BL1-BL2 and E4.BL5BL8 check cabling and remove build-up on the regulator. See also component information. Drainage pump E4.P7 The drainage pump is maintenance-free, operational reliability will be improved by regularly checking the pump?s proper functioning. See also component information.

10.8

10.8.1

10.8.2

10.8.3

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11.
11.1

MISCELLANEOUS - MAINTENANCE
ANNUAL SERVICE An annual shut-down for service is recommended. During this shut-down, the valve cooling equipment shall be checked in accordance with the Preventive Maintenance Program. CLEANLINESS It is considered important for the long term reliability of the valve cooling equipment, that the equipment and general environment be kept clean. Repair all surface damages, regardless of size or nature at the earliest opportunity. WATER LEAKAGE The pump units, spray water system including the chemical system and piping system should be checked regularly concerning water leakage. When a flanged joint has been unfastened, it shall be checked and tightened where necessary after one or two months.

11.2

11.3

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12.
12.1

FAULT TRACING SCHEDULE – VALVE COOLING EQUIPMENT
GENERAL The first checks after an alarm will be carried out with the system in service. When tracing faults it may be necessary to work with the auxiliary supply switched on. The interlock between the main switch and the door to the frequency converter can be by-passed by inserting a pin on the side of the switch. Warning: This may only be done by authorised personal. After a failure has been located and rectified, the alarm shall be reset. MCC main power breaker If the spring for the stored energy motor is discharged, because of it has tripped or been manually turned off, it has to be recharged maually. Choose the other main breaker Q01 with the control switch S01 (A-B). Turn the main breaker Q01 in Manual mode on the front of the motor. Use the handle on the front of the motor to recharge the spring until it is fully charged. When fully charged, turn the main breaker Q01 back in Auto mode. Now it is in operation.

Warning:

- Never turn both breaker ON at the same time when they are in manual mode - Never work alone. - Always maintain sufficient distance from high voltage parts. - Do not touch live parts of the equipment.

Warning:

12.2 12.2.1

HIGH COOLING WATER TEMPERATURE Water sprayed air blast coolers Check that all valves are open. Check the fans for debris. Chech the fan belts. 71

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12.2.2 Check the cooler blocks for debris. Check the fan and spray-pump safety switches. Check the ambient temperature. Check cooler spray-pumps.

Temperature control Check the starting logic of the fans. Check the PT-100 temperature signal. Flow rate control Check the flow rate in the Cooling Liquid Circuit. LOW FLOW IN THE COOLING LIQUID CIRCUIT Flow meter malfunction Check the flow rate on both flow meters. Check that the flow meters are free from leakage. Increased pressure drop Check that all valves in the deionized circuit that shall be open are open. Check the pressure drop over the thyristor valve. Check the pressure drop over the coolers. Main pumps Check the pumps. Check the rpm. Check for jarring sound in the pump. Air in the pump will limit flow. LOW FLOW IN THE WATER TREATMENT CIRCUIT Pressure drop Check the positions all valves. Check filters for fouling. Check the upper distributor head of the ion exchangers for fouling. Flow meter Check the alarm set-point. Adjust the flow according to the Start-up instruction. HIGH CONDUCTIVITY IN THE WATER TREATMENT CIRCUIT After make-up Check the conductivity of the make-up water. Conductivity meter Check the sensor and instrument according to component information. Check the quality of the water.

12.2.3

12.3 12.3.1

12.3.2

12.3.3

12.4 12.4.1

12.4.2

12.5 12.5.1

12.5.2

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12.6 12.6.1 HIGH CONDUCTIVITY IN THE COOLING LIQUID CIRCUIT Water treatment circuit Check the conductivity in the water treatment circuit. Check the flow in the water treatment circuit. Conductivity meter Check the sensor and instrument according to component information. Check the quality of the water. Other Wait a while after filling-up and observe the conductivity value tendency. LOW PRESSURE IN THE EXPANSION VESSEL Pressure regulator Check the setting and adjust if necessary. Pressure relief valve Check the setting and adjust if necessary. Nitrogen bottles Check the bottles pressure. Check the regulating valve on the bottle. Other Check for leakage. LOW WATER LEVEL IN THE EXPANSION VESSEL Level meters Check level on both BL1 and BL2 level meter. LOW/LOW WATER LEVEL IN THE EXPANSION VESSEL Level meters Check level on both BL1 and BL2 level meter and BL3 / BL4 sensors. HIGH PUMP VIBRATION

12.6.2

12.6.3

12.7 12.7.1

12.7.2

12.7.3

12.7.4

12.8 12.8.1

12.9 12.9.1

12.10

12.10.1 General Check for air in the piping system. Check the alignment of the pump and motor.

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13.
13.1

FAULT TRACING SCHEDULE – SPRAY WATER SYSTEM
GENERAL The first checks after an alarm will be carried out with the system in service. When tracing faults it may be necessary to work with the auxiliary supply switched on. The interlock between the main switch and the door can be by-passed by inserting a pin on the side of the switch, see picture. Warning: This may only be done by authorised personal. After a failure has been located and rectified, the alarm shall be reset. Note: After power supply failure of DC-supply the day/time setting must be checked/adjusted. - Never work alone. - Always maintain sufficient distance from high voltage parts. - Do not touch live parts of the equipment.

Warning:

13.2 13.2.1

ALARMS BF11 – Raw water flow Fault indication - Low flow - Low flow alarm – operators panel. - External common alarm no. 4 after 60 sec. Action - Check the raw water pump. - Check all piping for fouling. - Check the alarm setting on the flow meter. - Reset alarm.

13.2.2

BF11 - Sensor failure Fault indication - Failure - Sensor failure alarm - operators panel. - External common alarm no. 4 after 5 sec. Action - Check flow sensor BF11. - Check 4-20 mA signal. - Check PLC analogue module.

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- Check circuit breaker. - Reset alarm. 13.2.3 BL3 - Level basin Fault indication - Low/low level - Low/low level alarm – operators panel. - External common alarm no. 6 after 60 sec. - Stop of spray pumps. Fault indication - High/high level - High/high level alarm – operators panel. - External common alarm no. 8 after 60 sec. Action - Check level sensors BL3. - Fill up with raw water. (low/low level). - Drain some basin water. (high/high level). - Reset alarm. 13.2.4 BL3 - Sensor failure Fault indication - Sensor failure - Sensor failure alarm - operators panel. - External common alarm no. 7. Action - Check level sensor BL3. - Check 4-20 mA signal. - Check PLC analogue module. - Check circuit breaker. - Reset alarm. 13.2.5 BL5 - Level basin Fault indication - Low level - Low level alarm - operators panel. - External common alarm no. 8 after 300 sec. Action - Check incoming raw water pump. - Check level sensors BL3 and BL5. - Fill up with raw water. - Reset alarm. 13.2.6 BL6 - Level basin Fault indication - High level - High level alarm – operators panel. - External common alarm no. 8 after 300 sec. Action - Check level sensors BL3 and BL6. - Drain some basin water.

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- Reset alarm. 13.2.7 BL7 - Level pump pit Fault indication - High level - High level alarm – operators panel. - External common alarm no. 9 after 30 sec. Action - Check drain pump. - Check level sensor BL7. - Drain some pit water. - Reset alarm. 13.2.8 BL8 - Level basin Fault indication - Low/low level - Low/low level alarm – operators panel. - External common alarm no. 8 after 30 sec. - Stop of filter pump P6. Action - Check incoming raw water pump. - Check level sensor BL8. - Check level sensors BL1 and BL2. - Fill up with water. - Reset alarm. 13.2.9 BQ1 – Conductivity filter circuit Fault indication - High conductivity - High conductivity alarm – operators panel. - External common alarm no.10 after 300 sec. Action - Check water quality for chloride content. - Check conductivity sensors BQ1. - Reset alarm. 13.2.10 BQ1 – Sensor failure Fault indication - Sensor failure - Sensor failure alarm - operators panel. - External common alarm no. 10 after 300 sec. Action - Check conductivity sensor BQ1. - Check 4-20 mA signal. - Check PLC analogue module. - Check circuit breaker. - Reset alarm.

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13.2.11 P6 – Filter pump Fault indication - Failure - Filter pump failure alarm – operators panel. - External common alarm no. 3. Fault indication – Man mode - Filter pump Man mode alarm – operators panel. - External common alarm no. 3. Action - Check power supply. - Check pump P6. - Check overload protection. - Check mode. - Reset alarm. 13.2.12 K6 (K7, K8, K9) – Filter valve Fault indication - Failure - Filter valve failure alarm – operators panel. - External common alarm no. 3. Fault indication – Man mode - Filter valve Man mode alarm – operators panel. - External common alarm no. 3. Action - Check power supply. - Check filter valves. - Check mode. - Reset alarm. 13.2.13 V37 – Drain valve Fault indication - Open - Valve open alarm – operators panel. - External common alarm no. 3. Action - Check valve V37. - Reset alarm. 13.2.14 Z9 – Filter system Fault indication – Man mode - Filter system Man mode alarm – operators panel. - External common alarm no. 3. Action - Check operation mode. - Check filter valves K6-K9. - Reset alarm.

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13.2.15 P11 (P12) – Dosage pump Fault indication – Man mode - Dosage pump Man mode alarm – operators panel. - External common alarm no. 1. Fault indication – Failure - Dosage pump failure alarm – operators panel. - External common alarm no. 1. Action - Check mode. - Check power supply. - Check level in dosage vessel. - Check flow sensors. - Check dosage. - Reset alarm. 13.2.16 P11-P12 – Dosage system 1 - Biosperse Fault indication – Man mode - Dosage system 1 – Biosperse Man mode alarm – operators panel. - External common alarm no. 1. Action - Check mode. - Check dosage pumps P11-P12. - Reset alarm. 13.2.17 P13 (P14) – Dosage pump Fault indication – Man mode - Dosage pump Man mode alarm – operators panel. - External common alarm no. 2. Fault indication – Failure - Dosage pump failure alarm – operators panel. - External common alarm no. 2. Action - Check mode. - Check power supply. - Check level in dosage vessel. - Check flow sensors. - Check dosage. - Reset alarm. 13.2.18 P13-P14 – Dosage system 2 – Drew/Performax Fault indication – Man mode - Dosage system 2 – Drew/Performax Man mode alarm – operators panel. - External common alarm no. 2. Action

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Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
- Check mode. - Check dosage pumps P13-P14. - Reset alarm. 13.2.19 K4 (K5) – Bleed-off valve Fault indication – Man mode - Bleed-off valve Man mode alarm – operators panel. - External common alarm no. 5. Fault indication - Failure - Bleed-off valve failure alarm – operators panel. - External common alarm no. 5. Action - Check mode. - Check power supply. - Check bleed-off valves. - Reset alarm. 13.2.20 Bleed-off system Fault indication – Man mode - Bleed-off system Man mode alarm – operators panel. - External common alarm no. 5. Action - Check mode. - Check bleed-off valves K4-K5. - Reset alarm. 13.2.21 Main supply 1 (2) Fault indication - Failure - Power supply 1 (2) –main supply failure alarm - operators panel. - External common alarm no. 11. Action - Check circuit breaker. - Check voltage supervision relay. - After power supply has returned all systems must be put into Auto mode and restarted. 13.2.22 Circuit breakers-failure Fault indication - Failure - Circuit breakers failure alarm - operators panel. - External common alarm no. 11. Action - Check circuit breakers. 13.2.23 DC/DC converter-failure Fault indication - Failure

8-5697-200, rev 2, 2006-11-13

79

OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
- DC/DC converter failure alarm - operators panel. - External common alarm no. 11. Action - Check DC/DC converter. - Check circuit breaker. 13.2.24 PLC-failure Fault indication - Failure - PLC failure alarm - operators panel. - External common alarm no. 12. Action - Check PLC indicating LED. - Check DC/DC converter. - Check circuit breaker. 13.3 13.3.1 1. 2. 3. 4. 5. 13.3.2 1. 2. 3. 4. 5. 13.3.3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.3.4 1. EXTERNAL COMMON ALARMS Common alarm no. 1 Dos. pump P11 Man mode Dos. pump P11 Fail Dos. pump P12 Man mode Dos. pump P12 Fail Dos. system 1 Man mode Common alarm no. 2 Dos. pump P13 Man mode Dos. pump P13 Fail Dos. pump P14 Man mode Dos. pump P14 Fail Dos. system 2 Man mode Common alarm no. 3 Filter pump P6 Man mode Filter pump P6 Fail Filter valve K6 Man mode Filter valve K6 Fail Filter valve K7 Man mode Filter valve K7 Fail Filter valve K8 Man mode Filter valve K8 Fail Filter valve K9 Man mode Filter valve K9 Fail Filter system Z9 Man mode Drain valve V37 Open Common alarm no. 4 Raw water pump Man mode

8-5697-200, rev 2, 2006-11-13

80

OPERATION & MAINTENANCE MANUAL
Valve Cooling Equipment The Three Gorges – Shanghai±500 kV DC Transmission Project Yidu - Huaxin, China
2. 3. 4. 13.3.5 1. 2. 3. 4. 5. 13.3.6 1. 13.3.7 1. 13.3.8 1. 2. 3. 4. 13.3.9 1. Raw water pump Flow sensor BF11 Flow sensor BF11 Fail Low flow Sensor fail

Common alarm no. 5 Bleed-off valve K4 Man mode Bleed-off valve K4 Fail Bleed-off valve K5 Man mode Bleed-off valve K5 Fail Bleed-off system Man mode Common alarm no. 6 Level sensor BL3 Low/low level Common alarm no. 7 Level sensor BL3 Sensor fail Common alarm no. 8 Level sensor BL3 High/high level Level sensor BL5 Low level Level sensor BL6 High level Level sensor BL8 Low level Common alarm no. 9 Level sensor BL7 High level

13.3.10 Common alarm no. 10 1. Cond.sensor BQ1 High conductivity 2. Cond.sensor BQ1 Sensor fail 13.3.11 1. 2. 3. 4. 5. Common alarm no. 11 Main supply 1-400V Fail Main supply 2-400V Fail AC circuit breaker Fail DC circuit breaker Fail DC/DC converter Fail

13.3.12 Common alarm no. 12 1. PLC-system Internal fail 2. PLC-system Battery fail

8-5697-200, rev 2, 2006-11-13

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