Actuator Filter DP6SH201EA10V/-W: Guarding the Last Safety Line of the Main Steam Valve

Problems in a power plant’s main steam valve electro-hydraulic servo system can lead to downtime for maintenance at best, or even a safety incident at worst. In this system, the actuator filter is the final “gatekeeper.” In particular, the DP6SH201EA10V/-W actuator filter, used at the main steam valve actuator inlet, effectively filters impurities from the oil. Its ability to remove impurities directly impacts the lifespan of critical components like the servo valve and actuator, and can even affect the safe operation of the entire turbine. Today, we’ll discuss why the actuator filter is so critical and how to ensure the quality of the actuator filter we purchase.

I. First, let’s understand: What exactly does the actuator filter do in the main steam valve system?

The main steam valve electro-hydraulic servo system is driven by high-pressure oil, requiring extremely high oil cleanliness. Even metal particles or dust a few microns in size can, if they enter the servo valve, jam the valve core, preventing the main steam valve from opening or closing properly. The core function of a actuator filter is to remove impurities from the oil entering the actuator . This is especially true for actuator filters like the DP6SH201EA10V/-W, installed at the inlet. These filters act as a “pre-protection” for the servo valve. As long as the actuator filter is functioning properly, it can block most impurities.

I previously encountered a case at a power plant where, due to using a low-quality actuator filter, the filter layer failed after only three months of operation. Iron filings in the oil flowed directly into the servo valve, preventing the main steam valve from closing promptly. Consequently, an emergency shutdown and overhaul cost over 300,000 yuan, including the servo valve replacement and downtime. This explains why actuator filters aren’t just “small parts” but the bottom line of the main steam valve system’s safety: if the actuator filter fails, the safety of the entire system is compromised.

II. Why shouldn’t you choose just any actuator filter? Keep these key reasons in mind

The importance of the actuator filter is driven by its operating environment and function. Specifically, there are three core reasons:

First, the main valve electro-hydraulic servo system requires extremely high precision. The clearance between the spool and sleeve of the servo valve is only a few microns. Any impurities larger than 10 microns in the oil can seize the spool, causing operational delays. Common actuator filters, however, have a filtration accuracy of around 10 microns, accurately intercepting these dangerous impurities. If the actuator filter’s filtration accuracy falls short, even a difference of 2-3 microns will allow impurities to penetrate.

Second, the actuator filter must withstand system pressure. The operating pressure of the main valve motor is typically 10-16 MPa. If the actuator filter is not strong enough, the filter cartridge may deform and the filter layer may rupture under high pressure. Not only will this prevent impurities from being filtered, but it may also allow filter fragments to fall into the oil line, causing secondary contamination. A power plant previously encountered a problem with its actuator filter element, which failed to meet crack resistance standards and cracked during operation, clogging the entire actuator system and requiring two days of downtime for cleaning.

Third, the actuator filter element’s seal must be flawless. If the seal ring of the actuator filter element is aged or the interface is not tightly sealed, oil can bypass the filter element through the gap and enter the actuator directly without being filtered. This “short circuit” is more dangerous than a failed filter element, as the O&M personnel may believe the actuator filter element is working, when in reality, impurities have already begun to wear out the components.

III. Purchasing an actuator filter element requires foolproof assurance?

When purchasing actuator filters, don’t just focus on price; quality must be controlled from the source. Following these six steps will essentially avoid pitfalls:

1. Step 1: Choose the right actuator filter supplier, preferably one with power plant experience.

Don’t blindly choose a supplier; consider their experience in power plant parts. For example, a manufacturer specializing in steam turbine accessories, like YOYIK, will be more familiar with the actual operational requirements of actuator filters—for example, they must withstand high pressure and vibration, and the filter layer must be free of debris. Avoid small-scale, off-the-shelf manufacturers, as this will compromise the quality of the actuator filters.

2. Step 2: Focus on the technical specifications of the actuator filter; no mistakes are made.

The actuator filter’s specifications must be perfectly matched to the system, focusing on three key factors: filtration accuracy, operating pressure, and operating temperature. A power plant previously failed to check temperature parameters when purchasing, resulting in the seal of the actuator filter freezing solid in winter, causing leakage and requiring emergency replacement.

3. Step 3: A test report for the actuator filter is essential, focusing on these two items.

A reliable supplier will provide detailed test reports. We should focus on two test results: 1. A filtration efficiency test, which must comply with ISO 16889 standards and ensure a filtration efficiency exceeding 99% for 10-micron particles; 2. A burst resistance test, which must comply with ISO 2941 standards, proving that the actuator filter element will not burst under the system’s maximum pressure. If the supplier cannot provide these two reports, simply pass them and do not use them.

4. Step 4: Confirm actuator filter compatibility.

The actuator filter element must perfectly match the original filter housing. For example, for the DP6SH201EA10V/-W actuator filter element, verify its outer diameter, height, port specifications, and seal size. A power plant previously purchased the wrong actuator filter element. The incorrect port size caused damage to the filter housing, resulting in additional repair costs. Therefore, when purchasing, be sure to confirm that the supplier can produce filter elements that meet original manufacturer standards, and avoid buying low-quality imitations from small workshops.

5. Step 5: Establish a replacement cycle for the actuator filter and perform regular maintenance without skimping on it.

Even high-quality actuator filters cannot be used indefinitely. The replacement cycle must be determined based on actual conditions. Generally, under normal operation, they should be replaced every 6-12 months. However, if the oil cleanliness is poor (for example, if the particle count exceeds the standard during oil testing), they should be replaced earlier. Furthermore, during each overhaul of the unit, regardless of the length of service, the actuator filter should be removed and inspected. If significant accumulation of impurities is observed in the filter layer, it should be replaced even before the due date. In the past, one power plant used an actuator filter for 18 months to save costs, resulting in wear on the servo valve and increased repair costs.

IV. How serious are the consequences of an actuator filter failure?

Once an actuator filter fails, the consequences are more than just a simple filter replacement. It often triggers a chain reaction:

The most common problem is a stuck servo valve. The main steam valve either won’t close properly, causing a risk of turbine overspeed, or won’t open, preventing the unit from starting properly. A power plant previously experienced a failure in the hydraulic actuator filter, which caused the main steam valve to stick and the unit’s speed to lose control during startup. Fortunately, the timely activation of the protection system prevented a more serious accident.

Another issue is that the hydraulic motor system’s pressure fluctuates, resulting in unstable output. This causes the main steam valve to open and close at different speeds, affecting the turbine’s load regulation. While this situation doesn’t cause a shutdown, it can lead to unstable unit operation and increased wear on other components.

Even more seriously, impurities entering the hydraulic motor can wear the piston and cylinder, causing internal leakage. This requires not only replacement of the hydraulic motor but also cleaning of the entire oil circuit, a maintenance period of at least 3-5 days. This significantly impacts the power plant’s power generation, with losses potentially reaching hundreds of thousands of yuan.

V. Choosing a high-quality actuator filter may seem like an extra expense, but it actually saves money.

Some may think that high-quality actuator filters are tens or even hundreds of yuan more expensive than standard ones, making them uneconomical. However, let’s consider the long-term implications:

For example, a high-quality actuator filter like the DP6SH201EA10V/-W, while initially costing slightly more, lasts for 12 months, while a standard actuator filter only lasts for six months. The average annual cost is actually similar. More importantly, a high-quality actuator filter prevents wear on the servo valve. A servo valve costs tens of thousands of yuan, while a actuator filter only costs a few hundred yuan. If a servo valve is damaged due to a actuator filter failure, the loss is far greater than the filter cost.

There’s also the issue of downtime. A single downtime caused by a actuator filter problem can cost tens of thousands of yuan in lost power, or even hundreds of thousands. Choosing the right actuator filter can minimize this risk. Therefore, choosing a high-quality actuator filter isn’t about spending more money; it’s about buying “insurance” for your equipment.

Finally, let me be honest. The safety of the main steam valve system depends entirely on the actuator filter element, the last line of defense. When purchasing and maintaining actuator filters, don’t skimp on effort or cost. While purchasing a professional actuator filter element like the DP6SH201EA10V/-W requires some careful attention to parameter verification and supplier selection, it provides peace of mind and can avoid unnecessary trouble.

When looking for high-quality, reliable transmitter & display, YOYIK is undoubtedly a choice worth considering. The company specializes in providing a variety of power equipment including steam turbine accessories, and has won wide acclaim for its high-quality products and services. For more information or inquiries, please contact the customer service below:
E-mail: sales@yoyik.com
Tel: +86-838-2226655
Whatsapp: +86-13618105229

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