Hydraulic Fluid System Sonic Flow Analysis Services
Most power stations have instituted a program of periodic replacement and reconditioning of their turbine control system servo valves. By systematically changing out the servo valves the possibility of a failure is greatly reduced. Unfortunately most of the servo valves that are being reconditioned are in good working order. Barry Sibul Company provides a service where, with the unit on-line, worn servo valves can be identified and replaced as needed. This assures the utility that only servo valves that are in need of repair are sent out for service.
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The Hydraulic Fluid System Sonic Flow Analysis use...
The Hydraulic Fluid System Sonic Flow Analysis uses a sonic flow measuring device that is completely non-intrusive. There is no danger of fluid contamination or of causing the turbine to trip when using this process. The measuring equipment uses a 'transit time' method of determining flow. Two transducers are mounted externally to the pipe directly opposite one another, and the signal is passed directly between them. This way it is not necessary to have bubbles or impurities in the fluid to reflect the signal in order to give a flow reading, as with other forms of sonic measurement. The result is an accurate and safe way of taking flow measurements.
The flow analysis will be able to specifically isolate faulty components in an otherwise healthy system. Excessive flows can indicate leakage, and these can be traced to their source. The analysis can also measure aeration, which signals a bad pump or seal that is allowing air into the system. This can also be traced to the source of the problem. Testing will show if there is a build-up of any kind on the inside of the pipes. Any substance on the inside of the pipe that does not have the same sonic conductivity as the pipe material will indicate a problem on the computer monitor. The type of build-up can then be determined by the computer and compensated for so that an accurate flow reading can still be taken.
On hydraulic power units (HPUs), measurements are taken on the suction line of both 'A' and 'B' pumps, the discharge lines for both pumps, and the header pipe after the pump flows combine. Flows are also taken at each of the following Hydraulic Power Unit header lines: the fluid actuator supply (FAS), fluid trip supply (FTS), and fluid jet supply (FJS)-if so equipped. The flow from the header lines is totaled and compared to the reading at the pump discharge.
A difference of more than 1 gallon per minute indicates a possible problem. Testing continues by isolating the relief valves and the in-line filters to determine where the leakage is occurring.
The flow analysis continues by measuring the fluid flow at each of the valve actuators, including the control valves, main stop valves, and combined reheat valves. While the valves are at steady state, any flow in the supply lines is leakage. Depending on the specific configuration, measuring the FAS line shows the amount of leakage through the servo valve and/or the shut off valve, the emergency trip supply (ETS) line gives leakage through the fast-acting solenoid valve, and flow in the FJS line indicates leakage at the servo valve.
Following the analysis a detailed report is provided which explains the condition of the system and provides recommendations to correct any problems noted.
With the unit on-line in a steady state condition the on site flow analysis generally takes about 10 hours.
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