DIVISION – E

HP BYPASS SYSTEM
VOLUME – E1
CONTROL VALVES, ACTUATOR AND ACCESSORIES
CONTENTS LIST

Location Description Ref. No./ Drg. No.

Tab1 Check Lists of Do’s & Dont’s for Material Receipt Pub. No: 7123
(1-46) and Storing, Transport Mounting and Layout,
Operation & Commissioning, Maintenance
General Instructions on Storage, Transport, CON: HP: 0032/00
Mounting, Heat Treatment & Cleanliness of
Control Valves
General Recommendations for the Layout & CON: HP: 0033/03
Arrangement of Bypass Stations with
Electro Hydraulic Actuators
General Maintenance and Assembly Instructions Pub. No: 7101
Control Valves
Lubrication Instruction for Bolts, Nuts & Tapped Pub. No: 7136
Holes used in BHEL Valves
Tab 2 Control Valve Data Sheet VSS: HP: 0046/01
(47-131)
Maintenance and Assembly Instructions BP ON-OFF BPE BDO
Sectional Drawings, Characteristic ARS 100 E32S E32S 6910
Curves and Dimensional Drawings.
General Instruction for Dismantling and the
Assembly of Actuators – Type ASM - 10 Pub. No: 7135
General Operation And Maintenance Actuators
ASM 63, 160, 250 And Accessories Pub. No: 7110

Electro - Hydraulic Servo Valve Pub. No: 7111

Blocking Unit Pub. No: 7112
Tab 3 Servicing of Servo Valves and Blocking Elements
(132-169) in HPLP ByPass System of Sulzer Design Pub. No: 7111 A
Solenoid Valve APL6 86-114
Installation Commissioning & Maintenance of Pub. No: 7116
Hydraulic System
Oil Supply System HP Bypass 1-22-100-01062
Oil Piping For HP Bypass System 1-22-600-01063

0358 & 0369 - CHANDRAPURA VOL- E1 Page 1 of 3

 DIVISION – E
HP BYPASS SYSTEM
VOLUME – E1
CONTROL VALVES, ACTUATOR AND ACCESSORIES
CONTENTS LIST

Location Description Ref. No./ Drg. No.

Piping Layout To SSB 3-22-100-15012

Flushing Device and Tank Filling Filter 4-22-889-40006
Tab 4 Oil Supply Unit OV 32 B-30-201 CON:HP:0031/02
(170-185)
Oil Supply Unit Parts List & Assembly 86-168
Oil Supply Unit 86-168
Air filter for OV 16 and OV 32 – Parts List 86-96

Pressure Line for OV 86-154

Flushing Device and Tank Filling Filter 3-22-100-15005
HP Oil Filter Type 6841– (HH 9600 C16 KP RBD) Pub. No: 7124A
General Instruction for SSB 6,10,16,32 0386-5/99/76-1e
Tab 5 HP Oil Filter Type 6840- (HH 9020 C12 KP SBD) Pub. No: 7124/B
(186-220)
Description of Accumulator Manifold SB 24 86-192
General Instructions for Pressure Relief Valves 6803/6804-200
and Filters
General Operation & Maintenance Instructions
for Oil System Accumulator 6803/6804-1
Instructions for the Pressure Stat 6803/6804-400
Connection Block with Pressure Reducing Valve 6803/6804-500
Tab 6 4/3, 4/2 & 3/2 Dir. Control Valves Type WE6 RE 23176
(221-237)
Dir. Operated Pressure Relief Valve DBD RE 25400
Tested Pressure Relief Valve Type DBD/B RE 25401
3/2 and 4/2 Poppet Valves RE 22054

Tab 7 Flow Control & Shutoff Valves-Flutec DV12 0386-5/99/80-10e

(238-260)
HP Hydraulic Filter 9000 Series 0386-5/99/80-3

0358 & 0369 - CHANDRAPURA VOL- E1 Page 2 of 3

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 DIVISION – E
HP BYPASS SYSTEM
VOLUME – E1
CONTROL VALVES, ACTUATOR AND ACCESSORIES
CONTENTS LIST

Location Description Ref. No./ Drg. No.

Block Type Ball Valve Series 302 0386-5/99-80 6e

Hand Tools List Pub. No: 7134

Spare Parts List CON: HP: 0096/00
List of Special Tools CON: HP: 0043/00
HP Bypass System – Check List for Commissioning Pub. No: 7121

OIL SUPPLY UNIT SETTING VALUES

Oil Supply Unit Type : OV 32 B-30-201

System Operating Pressure : 10 Mpa

Bladder Pressure : 8 Mpa

Pressure too low *No.3 : 7 MPa

Pump on Pressure *No.2 : 11 Mpa

Pump off Pressure *No.1 : 16 Mpa

Pressure too High *No.4 : 17 MPa

Blow off Pressure of Safety Valve : 18 Mpa

Notes: 1. *No. Indicates the Number of the Micro Switch of the Pressure Switch. The
Numbering Sequence (NOS:- 1 to 4) is from Left to Right when Looking at the Cable Glands of the
Pressure Switch.

2. Pressure Values are in Mpa. (1 Mpa = 10 bar)

0358 & 0369 - CHANDRAPURA VOL- E1 Page 3 of 3

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TAB - 1

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GO TO INDEX 0368&0369 VOL- E1 T01-1
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0368&0369 VOL- E1 T01-8
GO TO INDEX 0368&0369 VOL- E1 T01-9
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GO TO INDEX 0368&0369 VOL- E1 T01-11
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GO TO INDEX 0368&0369 VOL- E1 T01-19
 Pub.No. 7101

GO TO INDEX 0368&0369 VOL- E1 T01-20

GO TO INDEX 0368&0369 VOL- E1 T01-21
GO TO INDEX 0368&0369 VOL- E1 T01-22
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GO TO INDEX 0368&0369 VOL- E1 T01-30
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GO TO INDEX 0368&0369 VOL- E1 T01-32
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GO TO INDEX 0368&0369 VOL- E1 T01-34
GO TO INDEX 0368&0369 VOL- E1 T01-35
GO TO INDEX 0368&0369 VOL- E1 T01-36
GO TO INDEX 0368&0369 VOL- E1 T01-37
 GO TO INDEX
0368&0369 VOL- E1 T01-38
 GO TO INDEX
0368&0369 VOL- E1 T01-39
 GO TO INDEX
0368&0369 VOL- E1 T01-40
 GO TO INDEX
0368&0369 VOL- E1 T01-41
 GO TO INDEX
0368&0369 VOL- E1 T01-42
 GO TO INDEX
0368&0369 VOL- E1 T01-43
 Pub. N0. 7136-83
GO TO INDEX 0368&0369 VOL- E1 T01-44
GO TO INDEX 0368&0369 VOL- E1 T01-45
GO TO INDEX 0368&0369 VOL- E1 T01-46
TAB - 2

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GO TO INDEX 0368&0369 VOL- E1 T02-47
 VALVE DATA SHEET

Project : CHANDRAPURA 7&8 (2X250 MW)

Specification No: Quantity ONE
Valve Type E32S Valve Designation According to Schematic Diagram:ON-OFF
VALVE ACTUATOR
1 Design Pressure ata 291 35 Type Hydraulic
0
2 Design Temperature C 170 36 Designation / Size ASM 100-10
3 Calculation According to Code --- 37 Positioning time 10-12 SEC*
4 Body Material SA 105 38 Type of operation:Continual control/Step control/Openclose
5 Nozzle Material SA 105 39 Feed back transmitter R-4K
6 Valve ends edge preparation CON:HP:0091/01 40 Servo valve type ---
7 Cooling water connection No / Yes 41 Blocking unit type ---
8 Sealing water connection No / Yes 42 Solenoid valve type APL -6
9 Valve characteristic CON:HP:0028/01 43 Safety device ---
10 Dimensional sketch CON:HP:0027/00 44 Oil Supply Unit Quantity / Type 2xOV32B-30-201
11 Sectional view / Code sheet CON:HP:0024/03 45 Dimensional sketch of OSU CON:HP:0031/02
12 Material list CON:HP:0024/03 46 Connection between OV Yes / No
13 Positioning force 4108.4 Kg47 Hydraulic piping material With / Without tube
14 Required force '--- Kg 48 Tube Connection Welded & screwed
15 49 Additional Accumulator Yes / No
16 50 Dimensional sketch ---
51 Hydraulic Piping diagram CON:HP:0090/01
ACTUATOR REQUIREMENTS
52 Hydraulic System pressure 100 bar
17 Valve opens again Kg/sq.cm p1 p2 53
18 Valve is tight against Kg/sq.cm p1 291 p2 0 54
19 Valve remains close at Kg/sq.cm p1 p2 55
SELECTION DATA
20 Operating State 1 2 3 4 5 6 7
21 Medium Superheated Steam / Spray Water
22 Pressure before valve ata 171.5 171.5 113.0 191.0 116.0 185.0
O
23 Temperature before valve C 141.4 141.4 141.4 162.0 142.9 141.0
24 Pressure after valve ata 134.567 136.199 92.448 143.725 101.072 136.000
O
25 Temperature after valve / BDO C 141.4 141.4 141.4 162.0 142.9 141.0
26 Pressure after BDO ata - - - - - -
27 Pressure drop ata 36.933 35.301 20.552 47.275 14.928 49.000
28 Flow per valve tons/hr 65.338 63.878 48.660 73.226 41.446 75.300
29 Maximum flow tons/hr 68.028 66.506 56.896 75.414 43.622 78.400
2
30 Required valve control area cm 3.697 3.577 3.157 4.134 2.501 4.276
2
31 Maximum valve control area cm 5.000 5.000 5.000 5.000 5.000 5.000
32 Seat diameter mm 30.0 30.0 30.0 30.0 30.0 30.0
33 Required valve stroke mm - - - - - -
34 Maximum valve stroke mm 40 (STROKE LIMITED)
1 HPH 6 out 4 Trip from BMCR
2 HPH 6 IN 5 Sliding Pressure
3 Hot Start 6 House Load
Rev 00 Rev 01 Rev 02 Rev 03
Prepared: VSS:HP:0046 Rev 01
Reviewed & Approved:
Date 05.01.2006 Sheet 2 of 3

GO TO INDEX 0368&0369 VOL- E1 T02-48

 VALVE DATA SHEET

Project : CHANDRAPURA 7&8 (2X250 MW)

Specification No: Quantity TWO
Valve Type E32S Valve Designation According to Schematic Diagram:BPE1,BPE2
VALVE ACTUATOR
1 Design Pressure ata 291 35 Type Hydraulic
0
2 Design Temperature C 170 36 Designation / Size ASM 100-10
3 Calculation According to Code --- 37 Positioning time 10-12 SEC*
4 Body Material SA 105 38 Type of operation:Continual control/Step control/Openclos
5 Nozzle Material SA 105 39 Feed back transmitter RSG 15+4K
6 Valve ends edge preparation CON:HP:0091/01 40 Servo valve type St 10-4+R6
7 Cooling water connection No / Yes 41 Blocking unit type BL 10
8 Sealing water connection No / Yes 42 Solenoid valve type --
9 Valve characteristic CON:HP:0028/01 43 Safety device --
10 Dimensional sketch CON:HP:0026/00 44 Oil Supply Unit Quantity / Type 2xOV32B-30-201
11 Sectional view / Code sheet CON:HP:0024/03 45 Dimensional sketch of OSU CON:HP:0031/02
12 Material list CON:HP:0024/03 46 Connection between OV Yes / No
13 Positioning force 4108.4 Kg 47 Hydraulic piping material With / Without tube
14 Required force '--- Kg 48 Tube Connection Welded & screwed
15 49 Additional Accumulator Yes / No
16 50 Dimensional sketch ---
51 Hydraulic Piping diagram CON:HP:0090/01
ACTUATOR REQUIREMENTS
52 Hydraulic System pressure 100 bar
17 Valve opens again Kg/sq.cm p1 p2 53
18 Valve is tight against Kg/sq.cm p1 291 p2 0 54
19 Valve remains close at Kg/sq.cm p1 p2 55
SELECTION DATA
20 Operating State 1 2 3 4 5 6 7
21 Medium Superheated Steam / Spray Water
22 Pressure before valve ata 134.567 136.199 92.448 143.725 101.072 136.000
O
23 Temperature before valve C 141.4 141.4 141.4 162.0 142.9 141.0
24 Pressure after valve ata 86.333 85.049 49.677 101.765 44.603 97.841
O
25 Temperature after valve / BDO C 141.4 141.4 141.4 162.0 142.9 141.0
26 Pressure after BDO ata - - - - - -
27 Pressure drop ata 48.234 51.150 42.771 41.960 56.469 38.159
28 Flow per valve tons/hr 32.669 31.939 24.330 36.613 20.723 37.650
29 Maximum flow tons/hr 34.014 33.253 28.448 37.707 21.811 39.200
30 Required valve control area cm2 2.014 1.919 1.618 2.403 1.213 2.547
2
31 Maximum valve control area cm 3.200 3.200 3.200 3.200 3.200 3.200
32 Seat diameter mm 30.0 30.0 30.0 30.0 30.0 30.0
33 Required valve stroke mm - - - - - -
34 Maximum valve stroke mm 40 (STROKE LIMITED)
1 HPH 6 out 4 Trip from BMCR
2 HPH 6 IN 5 Sliding Pressure
3 Hot Start 6 House Load
Rev 00 Rev 01 Rev 02 Rev 03
Prepared: VSS:HP:0046 Rev 01
Reviewed & Approved:
Date 05.01.2006 Sheet 3 of 3

GO TO INDEX 0368&0369 VOL- E1 T02-49

 MAINTENANCE AND HIGH PRESSURE BYPASS VALVE
ASSEMBLY INSTRUCTIONS (VALVE TYPE ARS 100)

1. General Maintenance and Assembly

For details of Maintenance, Dismantling refer to Publication No. 7101-78 "Control Valves.
General maintenance and Assembly instructions " under the Sections.

1 Description
2.2 (Fig. 10) -- Replacement of the Gland Packing
2.3 (Fig. 5) - Dismantling and Assembling the Stem
2.4 (Fig. H) --- Adjusting the Stem

2. Technical Data

Valve Designation - ARS 100

Valve Type-- . - 6076/6078

Max. Valve Stroke -60mm

Max. Port area- 4760 sq.mm'

Weight of Valve 526.8 Kgs

3. Supplementary Instructions for ARS Valves

i. Installation of Spiral Wound Gaskets

Before inserting the gasket. care should be taken that the connection flange for spray
water is lined up parallel with the pressure seal plug (bonnet), in its unstressed state.

The contact surfaces must be clean and show no damage.

After inserting the prescribed gasket, carefully tighten the flanges crosswise. The
torques for tightening the bolts are shown either on the Code Sheet or on the Parts
List.

With these torques the flange must be evenly tight against the pressure seal plug
(bonnet) (check with feeler gauge) and the pressure seal plug is also lined up with the
housing.

ii. Dismantling and Reassembly of the Jet Cage

- Remove safety tack seams on the safety-ring halves, it possible, on a lathe. i

-- After exchanging the jet cage tighten the nut with stud (37) according to the torque
indicated in the code sheet.

- preheat ring halves, nuts and penstock [at the weld points] to 150 to 200 °C.

- Weld together ring halves and penstock with about 50 mm long tack seams, i.e. similar
to the original lengths.

- Weld screws on to the ring halves.

Bharat Heavy Electricals Limjted

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GO TO INDEX 0368&0369 VOL- E1 T02-51
GO TO INDEX 0368&0369 VOL- E1 T02-52
GO TO INDEX 0368&0369 VOL- E1 T02-53
 ON / OFF CONTROL VALVE
(TYPE E 32 S / E 45 S)

BHARAT HEAVY ELECTRICALS LIMITED

GO TO INDEX 0368&0369 VOL- E1 T02-54

 ON / OFF CONTROL VALVE
(TYPE E 32 S / E 45 S)
1. General Maintenance and Assembly

For details of Maintenance, Dismantilng refer to Publication No. 7101 "Control

Valves General maintenance and Assembly instructions" under the Sections.
1. -- Description

2.1. [ii] [Fig. 2] -- Dismantilng the Pressure Seal

2.1. [iii][Fig.2] -- Assembling the Pressure Seal

2.2. [ii] [Fig. 10] -- Replacement of the Gland Packing

2.3 [ii] [Fig.2] -- Dismantling and Assembling the Stem

2.4 [iii] [Fig. G] -- Adjusting the Stem 2. Technical Data

3. Valve Designation -- E 32 S /E 45 S

4. Valve Type -- 6094/6095/6092/6093

5. Max. Valve Stroke -- 40mm /45mm

6.. Max. Port area -- 320/500/630/1000 mm2

7. Weight of Valve -- 120 kg

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GO TO INDEX 0368&0369 VOL- E1 T02-56
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GO TO INDEX 0368&0369 VOL- E1 T02-60
GENERAL INSTRUCTION FOR
DISMANTLING AND THE
ASSEMBLY OF ACTUATORS -
TYPE ASM - 10

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB. NO. 7135

GO TO INDEX 0368&0369 VOL- E1 T02-61

 CONTENTS
INTRODUCTION
APPLICATION AND DESCRIPTION
REPLACEMENT OF SEALS
REPLACEMENT OF PISTON ROD PACKINGS
REPLACEMENT OF PISTON SEALS
FURTHER DISMANTLING OF THE ACTUATORS
ASSEMBLY OF THE ACTUATORS
FILLING AND VENTING THE ACTUATORS
FILLING THE ACTUATORS
VENTING THE ACTUATORS
SPECIAL DESIGNS
TECHNICAL DATA OF ACTUATORS-TYPE ASM

GO TO INDEX 0368&0369 VOL- E1 T02-62

1. INTRODUCTION
1.1 Application and description
Oil-hydraulic actuators are used as drives where the control organs (valve, dampers etc.)
have to be set accurately with considerable setting forces and positioning speeds. Basically,
the actuators consist of a cylinder and a piston with piston rod. (Exception: in the small
types, the piston rod and piston are in one piece).
A lantern is used to connect the actuator (active part) with the control organ (valve) and a
two-piece coupling to connect the piston rod with the valve spindle. In all the actuators the
stroke of the actuator piston can be limited on both sides by means of spacer rings. In the
majority of cases, the stroke of the actuator is limited by the valve in one direction. Valves
without sealing seats, however are limited on both sides by the actuator.
The piston and the piston rod are each provided with a compact sealing. To enable the respective
valve position to be determined, a position transmitter is mounted on the lantern. This transmits
the position of the valve spindle electrically to the controller and the control desk. An optical
stroke indicator is also provided on the lantern.
2. REPLACEMENT OF SEALS
If a seal has to be replaced, the following procedure is to be observed:
2.1 Replacement of piston rod Packings
- Thorough cleanliness is essential
- Before starting work on the actuator, make sure that no force from the valve or
actuator is present on the spindle.
- Drain off the additional accumulator of the safety device serving the corresponding
actuator
The actuators do not have to be dismantled for the replacement of piston rod seals.
- Disconnect the link with ball and socket 6223 from the coupling 6221.
- Dismantle the coupling.
- Measure and note the distance between the spindle and piston rod. (only for valve
spindles with thread)
- Undo screws 6036 and remove the outer bushing 6012 and the inner bushing 6013.
Open vent plug 6041 of the corresponding cylinder.
- Replace guide ring 6022, piston rod seal 602l, scraper ring 6023 and the O-ring
6028.
- Lubricate seal with hydraulic oil being used in the system.
- Note Sections. 3 and 4.2
Remarks :
When fitting the piston rod seal, make sure that the white ring rests on the outer bushing
6012.
2.2 Replacement of piston seals
Thorough cleanliness is essential.
- Before starting work on the actuator, make sure that no force from the valve or
actuator is present on the spindle.

GO TO INDEX 0368&0369 VOL- E1 T02-63

 - Drain off the additional accumulator of the safety device serving the corresponding
actuator.
- Drain off oil.
- Undo screws of cover 6011 and remove cover together with O-ring 6027.
- Support piston or hang same on a lifting device.
- Disconnect link with ball and socket 6223 from the coupling.
- Undo screws 6234 and remove coupling halves 6221.
- Measure and note distance between the spindle and piston rod. (only for valve spindles
with thread)
- Remove piston 6071, including piston seal 6078 and piston rod 6084 carefully.
- Now remove retaining ring 6072.
- Note: For piston to actuator ASM 100, undo the locking screw 6106 first and then
the nut 6085. With this piston, the O-ring 6080 is also to be checked and replaced if
necessary.
- after this, the piston seal 6078 can be replaced.
- The piston seal is to be lubricated with the hydraulic oil being used in the system.
2.3 Further dismantling of the actuators
Normally, the actuators need not be dismantled any further than that already described in the
previous section. If there is reason to believe that the O-ring 6080 is leaking, it is to be replaced.
This is effected in the following manner:
- Undo the locking screw 6106
- Undo nut 6085 ( do not lose the plastic pin 6095)
- Remove piston from piston rod
- Replace O-ring.
3. ASSEMBLY OF THE ACTUATORS
Prior to assembly, all the parts are to be cleaned thoroughly. The actuator is assembled in
reverse order to the dismantling operation.
- Maintain the measured distance between the spindle and piston rod.
- Check: with the valve closed, the mark on the guide bolt must line up with the
position on the scale. Irregularities can be corrected by turning the valve spindle.
Never move the scale.
4. FILLING AND VENTING THE ACTUATORS
4.1 Filling the actuators
The actuators are filled with oil from the oil supply unit. The oil level in the tank is to be
checked from time to time, and topped up if necessary.
4.2 Venting the actuators
When starting up for the first time or after an overhaul, the working and cavity spaces are to
be vented thoroughly. Vent the upper cylinder space with the plug 6041 and the lower one
with the plug 6107.

GO TO INDEX 0368&0369 VOL- E1 T02-64

 - Unscrew both plugs slightly to allow the air to escape.
- Move actuator up and down a few times by manual operation of the control element.
- Once only oil is emitted, tighten up the two plugs again.
Note: ASM 63 does not have any venting plugs.
5. SPECIAL DESIGNS
A special description will be supplied for actuators which deviate from the standard design.
6. TECHNICAL DATA OF ACTUATORS, TYPE ASM
ASM Type 63 100 160 200 250 320
Actuator piston dia. in mm 63 100 160 200 250 320
Max. service pressure MPa 16 16 16 25 16 16
Test pressure MPa 24 24 24 38 24 24
Large piston area cm² 31.2 78.5 201 314 491 804
Small piston area cm² 28 71.5 185 276 452 740
Mass ASM ...10 kg 23 39 87 140 180 350

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 L-ASM63-10-2

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6
0368&0369 VOL- E1 T02-66
Lantern for hydraulic actuator ASM 63-10 (Parts list)
6201 Lantern
6211 Scale holder
6212 Scale
6221 Coupling
6222 Guide bolt
6223 Link with ball and socket
6231 Screw with spring washer
6232 Screw with spring washer
6233 Screw with spring washer
6234 Screw with spring washer
6241 Lever
ASM Hydraulic actuator
MA Instructions for assembling the feedback transmitter, 0386-5/99/78-5
RG Feedback transmitter
SW Width across flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e.g.: ASM 63-10 / 6241

GO TO INDEX 0368&0369 VOL- E1 T02-67

 Servomotor ASM 100-10

Actuator ASM 100-10

Servomotor ASM 100-10

Servomotor ASM 100-10

8
0368&0369 VOL- E1 T02-68

ASM 100-10

GO TO INDEX
Actuator ASM 100-10 (Parts list)

6001 Cylinder
6004 Name plate
6011 Cover
6012 Outer bushing
6013 Inner bushing
6021 Piston rod seal
6022 Guide ring
6023 Scraper ring
6027 O-ring 94.84 x 3.53
6028 O-ring 47.22 x 3.53
6035 Screw with spring washer
6036 Screw with spring washer
6041 Plug
6071 Piston
6078 Piston seal
6080 O-ring 40.87 x 3.53
6084 Piston rod
6085 Piston nut
6090 Non return valve
6095 Plastic pin
6106 Locking screw
6107 Venting plug with ball
6151 Spacer ring, cover side.
6156 Screw with spring washer, cover side
6157 Screw with spring wwwasher, bottom side.
Ma Tightening torque in Nm
SW Width across flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e.g.: ASM 100-10 / 6151

GO TO INDEX 0368&0369 VOL- E1 T02-69

Lantern for hydraulic actuator ASM 100-10 (Parts list)

6201 Lantern
6211 Scale holder
6212 Scale
6221 Coupling
6222 Guide bolt
6223 Link with ball and socket
6231 Screw with spring washer
6232 Screw with spring washer
6233 Screw with spring washer
6234 Screw with spring washer
6241 Lever
86-206 Connection manifold ASM-ST 10
ASM Hydraulic actuator
MA Instructions for assembling the feedback transmitter, 0386-5/99/78-5
RG Feedback transmitter (See Register 8)
SW (blue) Width across flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e.g.: ASM 100-10/ 6241

10

GO TO INDEX 0368&0369 VOL- E1 T02-70

 GO TO INDEX
11
0368&0369 VOL- E1 T02-71
 L-ASM 160-10

GO TO INDEX
12
0368&0369 VOL- E1 T02-72
Lantern for hydraulic actuator ASM 160-10 (Parts list)

6201 Lantern
6211 Scale holder
6212 Scale
6221 Coupling
6222 Guide bolt
6223 Link with ball and socket
6231 Screw with spring washer
6232 Screw with spring washer
6233 Screw with spri ng washer
6234 Screw with spring washer
6241 Lever
Ma Tightening torque in Nm (1Nm =0.102 mkp)
86-206 Connecting manifold ASM-ST 10
ASM Hydraulic actuator
MA Instructions for assembling the feedback transmitter, 0386-5/99/78-5
RG Feedback transmitter
SW Width across flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e.g.: ASM 160-10 / 6241

13

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 ASM 250-10

GO TO INDEX
14
0368&0369 VOL- E1 T02-74
Actuator ASM 250-10 (Parts list)

6001 Cylinder
6004 Name plate
6011 Cover
6012 Back-up ring
6013 Guide bush
6021 Piston rod seal
6022 Guide ring
6023 Scraper ring
6027 O-ring ∅240.67 X 7
6028 O-ring 91. 67 x 3.53
6035 Screw with spring washer
6036 Screw with spring washer
6041 Locking screw
6042 Eyebolt
6071 Piston
6072 Retaining ring
6078 Piston seal
6080 O-ring ∅75. 8 x 3. 53
6084 Piston rod
6085 Piston nut
6090 Non return valve
6095 Plastic pin
6101 Screw with spring Washer
6106 Locking screw
6107 Venting screw with ball
6151 Spacer ring, cover side
6152 Spacer ring, bottom side
6156 Screw with spring washer, cover side
6157 Screw with spring washer, bottom side
Ma Tightening torque in Nm
SW Width over flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e. g.: ASM 250-10/6021

15

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 ASM 250-10-4

GO TO INDEX
16
0368&0369 VOL- E1 T02-76
Lantern for hydraulic actuator ASM 250-10 (Parts list)

6201 Lantern
6211 Scale holder
6212 Scale
6221 Coupling
6222 Guide bolt
6223 Link with ball and socket
6231 Screw with spring washer
6232 Screw with spring washer
6233 Screw with spring washer
6234 Screw with spring washer
6241 Lever
86-206 Connecting manifold ASM-ST 10
ASM Hydraulic actuator
Ma Tightening Torque in Nm(1Nm=0.102mKp)
MA Instructions for assembling the feedback transimitter, 0386-5/99/78-5
RG Feedback transmitter
SW Width across flats (AF) in mm
When ordering spare parts, please quote code sheet and part number,
e.g.: ASM 250-10/ 6241

17

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GO TO INDEX 0368&0369 VOL- E1 T02-78
GO TO INDEX 0368&0369 VOL- E1 T02-79
GO TO INDEX 0368&0369 VOL- E1 T02-80
GO TO INDEX 0368&0369 VOL- E1 T02-81
GO TO INDEX 0368&0369 VOL- E1 T02-82
GO TO INDEX 0368&0369 VOL- E1 T02-83
GO TO INDEX 0368&0369 VOL- E1 T02-84
GO TO INDEX 0368&0369 VOL- E1 T02-85
GO TO INDEX 0368&0369 VOL- E1 T02-86
GO TO INDEX 0368&0369 VOL- E1 T02-87
GO TO INDEX 0368&0369 VOL- E1 T02-88
GO TO INDEX 0368&0369 VOL- E1 T02-89
GO TO INDEX 0368&0369 VOL- E1 T02-90
 GO TO INDEX
0368&0369 VOL- E1 T02-91
 GO TO INDEX
0368&0369 VOL- E1 T02-92
 GO TO INDEX
0368&0369 VOL- E1 T02-93
 GO TO INDEX
0368&0369 VOL- E1 T02-94
 GO TO INDEX
0368&0369 VOL- E1 T02-95
 GO TO INDEX
0368&0369 VOL- E1 T02-96
GO TO INDEX 0368&0369 VOL- E1 T02-97
GO TO INDEX 0368&0369 VOL- E1 T02-98
GO TO INDEX 0368&0369 VOL- E1 T02-99
 GO TO INDEX
0368&0369 VOL- E1 T02-100
GO TO INDEX 0368&0369 VOL- E1 T02-101
GO TO INDEX 0368&0369 VOL- E1 T02-102
GO TO INDEX 0368&0369 VOL- E1 T02-103
GO TO INDEX 0368&0369 VOL- E1 T02-104
 GO TO INDEX
0368&0369 VOL- E1 T02-105
GO TO INDEX 0368&0369 VOL- E1 T02-106
GO TO INDEX 0368&0369 VOL- E1 T02-107
GO TO INDEX 0368&0369 VOL- E1 T02-108
GO TO INDEX 0368&0369 VOL- E1 T02-109
 GO TO INDEX
0368&0369 VOL- E1 T02-110
GO TO INDEX 0368&0369 VOL- E1 T02-111
GO TO INDEX 0368&0369 VOL- E1 T02-112
GO TO INDEX 0368&0369 VOL- E1 T02-113
GO TO INDEX 0368&0369 VOL- E1 T02-114
 GO TO INDEX
0368&0369 VOL- E1 T02-115
 GO TO INDEX
0368&0369 VOL- E1 T02-116
 GO TO INDEX
0368&0369 VOL- E1 T02-117
 GO TO INDEX
0368&0369 VOL- E1 T02-118
 GO TO INDEX
0368&0369 VOL- E1 T02-119
 GO TO INDEX
0368&0369 VOL- E1 T02-120
GO TO INDEX 0368&0369 VOL- E1 T02-121
GO TO INDEX 0368&0369 VOL- E1 T02-122
GO TO INDEX 0368&0369 VOL- E1 T02-123
GO TO INDEX 0368&0369 VOL- E1 T02-124
GO TO INDEX 0368&0369 VOL- E1 T02-125
GO TO INDEX 0368&0369 VOL- E1 T02-126
GO TO INDEX 0368&0369 VOL- E1 T02-127
GO TO INDEX 0368&0369 VOL- E1 T02-128
 GO TO INDEX
0368&0369 VOL- E1 T02-129
GO TO INDEX 0368&0369 VOL- E1 T02-130
GO TO INDEX 0368&0369 VOL- E1 T02-131
TAB - 3

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0368&0369 VOL- E1 T03-135
0368&0369 VOL- E1 T03-136
0368&0369 VOL- E1 T03-137
 GO TO INDEX
0368&0369 VOL- E1 T03-138
 INSTALLATION
COMMISSIONING AND
MAINTENANCE OF

HYDRAULIC SYSTEM

Bharat Heavy Electricals Limited

Tiruchirapalli

PUB.NO.7116

GO TO INDEX 0153&0154 VOL E1 T03-139

 CONTENTS

DESCRIPTION OF THE HYDRAULIC SYSTEM

OIL SUPPLY UNIT
SERVOVALVE
BLOCKING UNIT
ACTUATOR
POINTS TO BE NOTED DURING ERECTION AND COMMISSIONING
OIL SUPPLY UNIT
TECHNICAL DATA
OIL SUPPLY UNIT
VISCOSITY/TEMPERATURE DIAGRAM
PIPEWORK MATERIAL
PIPING
HOSES
PIPE COUPLINGS
FILTER
SUCTION STRAINER
PRESSURE FILTER (IN OIL SUPPLY UNIT 10 MICRONS)
AIR FILTER
PRESSURE FILTER (FINE 3 MICRONS ABSOLUTE).
ASSEMBLY
OIL SUPPLY UNIT
PIPE WORK
WELDING PROCEDURE OF TUBES OF HYDRAULIC POWER SYSTEMS
PRESSURE FILTER (FINE, 3-MICRONS ABSOLUTE)
PIPE COUPLINGS

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COMMISSIONING
FILLING THE OIL TANK WITH HYDRAULIC FLUID
CHECKING THE GAS-FILLING PRESSURE IN THE ACCUMULATOR
CHARGING THE ACCUMULATOR WITH NITROGEN
ACID CLEANING
FLUSHING
VENTING THE ACTUATORS
CHECKING THE OIL LEVEL
SETTING THE TRIPPING PRESSURE OF THE SAFETY RELIEF VALVE
RESETTING THE ACCUMULATOR OPERATING PRESSURES
RESETTING THE SYSTEM PRESSURE
MAINTENANCE
PERIODIC CHECKS
EXCHANGING THE ELEMENT OF THE 3 MICRON PRESSURE FILTER
FLUSHING PROCEDURE FOR OIL LINES OF QUICK STROKING DEVICE
(SSB UNIT)

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 INSTALLATION COMMISSIONING AND MAINTENANCE OF
HYDRAULIC SYSTEM

1. DESCRIPTION OF THE HYDRAULIC SYSTEM

The hydraulic system consists of the oil supply unit, the actuators with the corresponding
control valves(Servovalve, blocking unit, solenoid valves etc), the pipework and the filters.
i. Oil Supply Unit ( Fig. 2 and 3)
The oil supply unit provides the hydraulic actuation energy for the complete actuating system
and functions as follows :
An electric motor driven axial piston oil pump sucks the hydraulic fluid through a suction
strainer and pumps it through a pressure filter and via a non-return valve into the accumulator.
A safety relief valve protects the system against over pressure. The accumulator is of the
bladder type and consists of a steel pressure vessel containing a nitrogen filled rubber bladder,
which separates the oil from the gas. The accumulator supplies the system with pressurised
oil and covers all the peak supply requirements. The oil pump is therefore sized only for the
mean supply requirements and it is switched off when the accumulator is fully charged. From
the accumulator the oil is fed through the supply manifold with the pressure reducing valve
and the pressure switch. With the pressure reducing valve the system pressure is set and
controlled. The pressure switch monitors the oil pressure in the accumulator and provides the
signals to switch the oil pump motor. From the supply manifold the oil is fed through the
pipework and the 3 micron pressure filters to the appropriate control valves and the actuators.
ii. Servovalve ( Fig. 1 )
The two stage servovalve is actuated by the torque motor which is controlled from an analogue
positioning amplifier or from a manual desk control. The torque motor moves the control fork
( of the servovalve ) and operates the pilot stage ( 1 st stage) which controls the position of the
control piston ( 2nd stage ). A mechanical override acting directly on the control piston permits
local manual operation of the valve.
iii. Blocking Unit (Fig. 1)
The electro hydraulically pilot-operated blocking unit is mounted between the servovalve and
the actuator. It closes off both ports to the actuator if electrically de-energized or with insufficient
oil pressure and holds the piston of the actuator ( disregarding some leakage drift) in its last
position. A mechanical override on the blocking unit permits also local manual deblocking.
iv. Actuator (Fig. 1)
The actuator consists of a double acting cylinder with piston and piston rod. An intermediate
yoke connects this cylinder with the valve, and a solid coupling connects the valve stem with
the piston rod. A feedback transmitter unit is mounted onto the coupling yoke and is connected
to the valve stem by a linkage system.
A detailed description of the various components can be found in Publication No.7135 :
General instructions for the dismantling and assembly of Type ASM-10,-11,-20,-21.

GO TO INDEX 0153&0154 VOL E1 T03-142

2. POINTS TO BE NOTED DURING ERECTION AND COMMISSIONING
i. BYPASS VALVES INCLUDING PRDS AND SPRAY VALVES SHOULD NOT
BE INVOLVED DURING STEAM BLOW-OUT OPERATION.
ii. AFTER ACID CLEANING OPERATION ALL PACKINGS GASKETS AND
SEALS OF THE VALVES SHOULD BE CHANGED IF THE LINE ON TO
WHICH THESE VALVES ARE ASSEMBLED ARE ACID CLEANED.
iii. AFTER HYDRAULIC TESTING, IF LONG STORAGE IS EXPECTED, IT IS
ADVISABLE TO REMOVE THE STEM, PACKING AND COVER SUITABLY
THE OPENING CAUSED FOR THE ABOVE REMOVAL. SILICA JEL MAY BE
PUT INSIDE THE VALVE PACKED IN A COTTON BAG.
iv. THE THREADS MUST BE LUBRICATED WITH MOLYBDENUM
DISULPHIDE POWDER.
v. VALVES SHOULD BE THOROUGHLY CLEANED BEFORE THEY ARE PUT
INTO SERVICE.
vi. GLAND NUT TO BE TIGHTENED TO THE EXTENT NECESSARY TO STOP
THE LEAKAGE AND IT SHOULD NOT BE OVER TIGHTENED.
vii. FILLING OF OIL INTO THE TANK SHOULD BE DONE THROUGH A 3
MICRON FILTER.
ix. HYDRAULIC OIL SHOULD NOT CONTAIN ANY VISCOSITY INDEX
IMPROVER AND ANY CALCIUM.
x. WHEN LAYING OUT THE OIL SUPPLY UNIT, IT SHOULD BE NOTED THAT
THESE UNITS ARE LOCATED AT LEAST 1.5M BELOW THE LOWEST
ACTUATOR. WHEN ROUTING THE OIL HYDRAULIC PIPE WORK, IT
SHOULD BE ENSURED THAT NO STATIC HEAD OF OIL CAN OCCUR AT
ANY SERVO VALVE. OIL SUPPLY UNIT SHOULD BE LOCATED SUCH THAT
THE RUNNING LENGTH OF PIPE IS 15 TO 20M MAXIMUM FROM OIL
SUPPLY UNIT TO VALVE ACTUATOR
xi. WELDING BETWEEN TWO FLANGED SURFACES SHOULD NOT BE
RESORTED TO, IF SMALL LEAKS OF MEDIUM ARE FOUND THROUGH
THE GASKETED JOINTS.
xii. RUBBER HOSES SHOULD BE ERECTED WITH FAIRLY LARGE BENDING
RADIUS.
xiii. OIL PIPES MUST BE SUPPORTED EVERY 2 TO 3 METRES BY ‘U CLAMPS.
xiv. ALL OIL LINE BENDS TO BE OF SAME BENDING RADIUS.
xv. P, T, L FROM OIL SUPPLY UNIT CAN BE TAKEN LIKE THlS,

xvi. P, T, L OIL LINES TO BE FIXED NEAR HOSE END, (i. e.) NEAR THE HP
FILTER

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xvii. P, T, L OIL LINE BENDS TO BE SUPPORTED AT ENDS.
xviii. MAINTENANCE PLATFORM FOR ALL THE VALVES TO APPROACH
VALVES AND SERVOVALVES, TO BE PROVIDED.
xix. VALVES AND OIL UNITS TO BE LOCATED IN DUST FREE ATMOSPHERE.
xx. SUBSEQUENT SECTIONS OF THIS MANUAL WILL GIVE MORE DETAILS
ON OIL SUPPLY SYSTEM.
xxi. HIGH PRESSURE FILTER HH 9600 SHOULD BE RIGIDLY SUPPORTED.
xxiii. WARM UP LINE BEFORE HPBY BASS VALVES SHOULD BE KEPT OPEN
FOR CONTINOUS DRAINING DURING THE OPERATION OF THE PLANT.

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