MOV

MAINTENANCE
KUDGI SUPER THERMAL POWER PLANT, 3X800 MW NTPC

DURGESH KUMAR VERMA

CHANDAN TIWARY
MOV USED
1. ROTORK
2. AUMA INDIA
3. AUMA GERMANY
1. ROTORK MOVs
Total 5 nos. of Rotork MOVs are used in each
individual unit. The locations are
MCW INLET A
MCW INLET B
MCW OUTLET A
MCW OUTLET B
SERVICE WATER INLET ISOLATION FOR ATMOSPHERIC
FLASH TANK
 2. AUMA GERMANY MOVs

Total 14 nos. of Auma Germany MOVs are used in

each individual unit. The locations are
TDBFP A/B Discharge Outlet and its IBVs
MDBFP A/B Discharge Outlet and its IBVs
30% feedwater control station Inlet/Outlet and its
IBVs
Feedwater control station Main Valve and its IBVs

3. AUMA INDIA MOVs

Rest All MOV in Turbine is Auma India MOV i.e Total
153 nos. MOVs are used in individual unit. Total 172
numbers of MOVs have been used in a single unit in
Turbine area .
 Actuator E-Pac

Limit switch
Limit Switch counter gear Reverse
Logic Card Contactor

Local Indicator

TSD
Tranformer

Limit switch gear

arrangement
Limit switch
Counter gear
 Block Diagram
LSO/LSC
TSO/TSC
Electrical
3Phase Supply

Logic card Reversing

DCS Contactors TOLR Motor
(K1/K2)

E-Pac Unit
Single Line Diagram

Power Supply

DCS Logic Board

COMMAND
Interlock Torque switch

Limit Switch

Thermal Switch

TOLR

Reversing
Contactors (K1/K2)

M
Display Card
Its Show the current status of MOV as its corresponding LED
glows. Total 15 LED is provided.
Open/Close Command.
LSO/LSC Limit switch feedback
TSO/TSC Torque switch feedback
TH-S & Thermal over load relay trip feedback
Local/Remote feedback.
Single phase, 11V, 23V and 24V healthiness feedback.
Fault signal .
 Non-
Inching
Operation
Type
Inching

Inch-Local ON/OFF

ESD Open ON/OFF

ESD Close ON/OFF

LSO Bypass ON/OFF

Dip Switch INH Open ON/OFF

Setting in
MOV INH Close ON/OFF

Inch Remote ON/OFF

LSC Bypass ON/OFF

Dos and Doesnt
1.Improper methods of declutch mechanism leading to premature
failure of tripping arm

2.Re-set torque by loosening the adjustment screw.

3.Improper tightening of covers or missing of O-ring during fitment

4.In the events of interchangeability check for the e-

pac wiring diagram number.
5.Do not press mechanical interlock of reversing contactors manually
Setting of limit Switch

Operate valve away from end-position to account for

over-run or to the desired switch tripping point.
Push thrust bolt inward and turn the bolt
counterclockwise and clockwise for setting open and
close limit respectively.
For close position turn spindle marked and for open
position turn spindle marked Continue turning the
spindle until the cam operates the switch. At this stage
the spindle should not click anymore and should not be
turned any further.
Turn thrust bolt till it snaps back into its original
position by spring action.
Limit Switch Gear
Arrangement
Counter Gear for Limit Swich
Torque Switch Gear
Arrangement
TSD Internal gear connected to MOV shaft
TSD damage
TSD damage due to overtightening of valve using F-
Rod
DCS Signal Interface
Power Supply Interface
Commissioning Check Point

Mechanical freeness of the actuator to be ensured by

operating the valve manually.
Check the direction of rotation and observe arrow at
limit switch gear, if incorrect then immediately stop.
Before energizing the MOV check for correct phase
sequence of R, Y and B.
Operate actuator manually to open position and set the
open limit switch (at the same time check for open LED)
similarly set the close Limit.
Important points

Before interchanging the logic card, transformer card,

Counter gear etc. Please check the e-Pac code (MOV
TYPE).
Do not interchange the e-Pac without checking OLR
rating.
Do not bypass the thermo-switch connection in the loop
Please check the input voltage rating of motor before
giving supply.
Condition for Faults Signal

Thermoswitch trip signal active.

Torque switch trip signal active(when MOV is set for
limit operation )
Thermal over load relay trip signal active.
Power supply failure/signal phasing fault signal active
Modification In MOV Wiring

Single DI Signal is used for Local/Off/Remote selection

of MOV.
Loop in T.B no. 11(local) and 12(off).
General troubleshooting
encounter
TSD damage
Declutch mechanism failure
Limit switch disturbed
Limit Switch Counter Gear not Failue
Logic Card Not working
POINTS TO PONDER

1. How Torque acting mechanism works.

2. How Open/Close mechanism work.
3. What happen if Torque switch or Limit switch fail.
4. How Much % is to set for safe operation
5. How to operate MOV if power fail.