4-13300-00-415-—
Rev. No.-01
WRITE-UP
ON
ELECTRO- HYDRAULIC
CONTROLLER
Project = _Rihand, STPP, Stage-II (2X500MW)
Package Main Plant Turnkey Package
Produ Steam Turbine
NTPC drg. no.-1230-001-03HW-PVM-W-024
To be resubmitted for approval
ler incorporating the comments.
For Information / Record.
cat - SS
eat
1 22.7.02 REVISED AS PER (V.KUMAR) (V.KUMAR) ( B.S.RANA)
MOM DT. 1-2/7/02
WITH NTPC.
Sd/- Sd/- Sd/-
0 30.8.99 (K.B.Batra) (K.B.Batra) (A.Ali)
Rev. Date Remarks Worked Checked Approved
STE, BHEL Hardwar1.0
2.0
3.0
STE.
- 1330-00-41 5.
Rev. No-01
INTRODUCTION:
The turbine is equipped with electro-hydraulic governing system to facilitate
the operation of the turbo set in an interconnected grid system, The electrical
measuring and processing of signals offer the advantages such as
flexibility, dynamic stability and simple representation of complicated
functional relationship. The processed electrical signal is introduced at a
suitable point in the hydraulic circuit through the electro-hydraulic converter.
The hydraulic controls provide the advantages of continuous control of
large positioning forces for control valves, The integration of electrical and
hydraulic system offers the following advantages -
- Exact load frequency droop with high sensitivity,
- Reliable operation in case of isolated power grids,
- Dependable control during load rejection,
- Low transient and low steady-state speed deviations under all
operational conditions,
- Excellent operational reliability and dependability,
- Safe operation of the turbo-set in conjunction with the
Turbine Stress Evaluator (TSE)/Controller(TSC).
ELECTRICAL EQUIPMENT:
The electrical equipment of the electro-hydraulic governing system
comprises of measuring devices, the electronic controllers, electro-hydraulic
converters etc. The electrohydraulic controller is realized in the
microprocessor based hardware system. It is configured as a local station with
input/output and processor modules housed in cabinet. The cabinet also
contains the solid state hardware for actual speed acquisition, position
measurement of electrohydraulic converter , speeder gear and starting device
and for the valve lift cantroller,
MEASURING DEVICES:
Digital speed monitoring devices with three speed measuring probes for
measuring rotational speed installed in bearing housing and three pulse
converters for amplifying and shaping of the signal from the speed
probes,
- Three measuring devices to determine the active electrical power of the
generator,
- Remote position transducers to determine the actual positions of electro-
hydraulic converters.
- One electro-hydraulic converter housed in the governing rack placed adjacent
to the main turbine.
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OPERATING EQUIPMENT;
To facilitate easy and efficient operation of the electro-hydraulic governing
system, it is interfaced with MMI system via the control system data bus and
with control tiles and indicators acting as back up operating equipment, The
system is provided with the following display indicators and control tiles to be
mounted on UCP and / or corresponding displays on the operator workstations.
For actual provision of control tiles and operator displays project specific
documents may be referred.
NOTE:-
All indicators/ Control buttons/Annunciations (as below) will be
realized in MMI. For Hardware realization please refer G.A. of control
tiles.
INDICATORS :
- The actual position of start-up device of hydraulic device,
- The actual position of speed adjusting device of the hydraulic device,
- The reference value of speed in rpm; range 2800-3300 rpm (spread scale).
- The reference value of speed in rpm; range 0-3600 rpm.
~The time dependent reference value of speed in rpm; range 0-3600 rpm.
- Load reference value of grid controller in MW,
- Load reference value in MW,
- The time dependent load reference value in MW,
- Load reference value of frequency control in MW,
- Net effective reference of load value in MW,
- The load gradient desired in MW per min,
- The reference value of maximum load in MW,
- The steam pressure deviation ( ONLY IN MMI ),
- The actual position of electro-hydraulic converters.
PUSH BUTTONS:
- 6 control tiles with one pair of push buttons (one to initiate "lower"
command and the other for “raise” command) for the following -
- The speed reference setter.
- Load reference setter.
- Maximum load reference setter.
- Load gradient reference setter,
- Load gradient ON/OFF,
- Frequency influence ON/OFF,
- Hydraulic start -up device setter.
- Hydraulic speed setting device setter.
One control tile with two control buttons and two indicating lamps for
load gradient command ON-OFF ( ONLY in MMI)
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- Two control tiles with one pair each of control buttons and one pair of
feedback lamps and one pair of fault indication lamps for load controller and
grid controller command ON-OFF ( ONLY IN MMI) ,
- One control tile with two push buttons and feedback lamps for “ Initial
Pressure Control” and“ Limit Pressure Control”,
ANNUNCIATION :
The following annunciations are also provided in the control desk -
One annunciation tile with two lamps for the status display “ Frequency
Influence ON/OFF".
Five annunciation tiles with horizontal linear windows, for status and fault
display of the following -
a) Speed controller in operation
b) Load controller in operation
c) Pressure controller in operation
d) Stop reference limiter
e) Limit pressure reached
CONTROL LOOP :
The electro-hydraulic governing system essentially consists of the
following control loops -
Speed Control Loop
Load control Loop
Pressure Control Loops
One of these three loops act selectively on the subordinate valve lift control
loop. The vaive lift controller actuates the plunger coil of the electro-hydraulic
converter which acts as an interface between the electrical and the hydraulic
systems.
SPEED CONTROL LOOP:
This loop is essentially formed by a speed reference limiter and speed
controller. The integrated functions of the two blocks is explained below.
The speed controller essentially compares the speed reference
generated by the speed reference limiter circuit and the actual speed of the
turbine and accordingly provides an output for the valve lift contraller.
The actual speed, nzq is acquired by three speed pick-up systems. The output
of each pick up is then processed in three different channels . The output
“SHEET NO. 4 OF [1~-4-13300-00-815
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from only one channel is used . In the event of failure of this channel, the
system is automatically switched onto the other channel and an alarm to
that effect is initiated. The switchover does not affect the operation. In case
the defective channel gets restored again , the same is automatically
made available to the selection circuit independent of any acknowledgement
of the alarm. The controller gain is matched to have a very precise control in
the vicinity of the rated speed.
The speed reference is generated by the speed reference limiter control
loop. The desired reference speed value can be set with the help of a
potentiometer remotely from control desk or manually at the cabinet. In the
speed reference limiter the reference speed signal is juxtaposed with the
output from the TSE/TSC at every instant and a time dependent limited
speed reference is generated corresponding to the highest permissible rate of
speed increase which Is consistent with the safe operation of the turbine. After
attaining the target reference speed the output of the speed reference
limiter is held constant, The TSE/TSC influence is made ineffective in those
segments of speed increase which cover the critical speed of rotors. The
output of speed reference limiter is automatically blocked in the event of
@ fault in TSE/TSC and the speed of the set cannot be changed until and
unless TSE/TSC is suitably disconnected
dn/dt monitoring
To avoid rolling of the turbo set at or near critical speeds, the acceleration of
the set is monitored in the range 700 rpm to 2850rpm. In case dn/dt goes
below the set value , the speed set paint is rolled back to the soaking value and
the set is returned to that speed. After further thermal stabilization, when
sufficient temperature margins are available , the speed is again increased
The speed controller exhibits a steady state proportional control to form the
necessary droop characteristics, The dynamic response is improved by the
addition of proportional integral and differential element. The speed
controller realises the following operations -
- Start up and shut down of the turbine
- Synchronisation of the generator
- Provides a minimum load operation
- Operation of the turbo-set in the complete power range in case load
controller is defective
5.2 LOAD CONTROL LOOP
- Load Reference Limiter
- Frequency Load Droop
- Load / Frequency Controller
The reference load is set by a motor -operated potentiometer which is
transmitted to the load reference limiter. The load reference set value and
SHEET NO. 5 OF I
STE, BHEL Hardwar13300-00415.
Rev. No.1
output signal from TSE/TSC are juxtaposed in the load limiter and
it generates the time dependent limited reference load setting depending upon
the influence of the TSE/TSC at the highest permissible rate consistent with
the thermal stresses of the turbine both during load increase and
decrease. After attaining the target load reference, the reference limiter
output is held constant. The TSE/TSC — influence is rendered ineffective upon
failure and the load reference limiter is held constant. It is only
possible to increase the load when TSE/TSC is disconnected. The load gradient
setter also influences the time dependent load reference signal but the actual
maximum permissible load rate is governed by the TSE/TSC.
The grid controller can also be activated to exercise control on the load
reference setter which in turn is effective via the load reference limiter and
TSE/TSC. This facilitates loading of the set from despatch centres.
The load controller receives the reference load signal from the load reference
limiter and also from the frequency controller depending upon the frequency
of the grid. These two signals are summed in the load controller and the
net value derived for controlling the valve position. The droop characteristics
of the frequency controller can be varied from 2.5% to 8% in steps of 0.5%.
To limit the total power delivered by the turbine, the system is equipped with
maximum load reference limit.
This acts directly on the valve lift controller and has priority over all other
influences acting directly or indirectly on the valve lift controller.
The actual load value is acquired in three independent channels and
transmitted to the load controller. In case of a deviation of more than 5% in
between the measurement channels, an alarm “actual load signal
faulty" is initiated.
The load controller exhibits a proportional. -integral action and has an excellent
dynamic response when the turbine is synchronised and the block loading
have been achieved. This controller and the speed controller signal are
transmitted to valve lift controller signal through maximum and minimum
selection circuits
Isolated grid operation
If the power plant together with a section of the power grid should become
isolated during load control, the configuration of the control is switchover to
frequency control. The PI characteristics of the load controller is switched over
to P characteristics with 5% droop.
Isolated grid operation is suitably annunciated and is reset manually.
SHEET NO. 6 OF I -
STE, BHEL HardwarLOAD SHEDDING
In case of sudden loss of export load, the output of the load controller is
immediately reduced below the output of the speed controller which is set at
station load, Due to maximum selection speed controller assumes control
and returns the turbine back to almost the rated speed
This provision improves the dynamic response of the closing of the steam
control valves and keeps the turbine speed from rising along the droop
characteristics.
5.3 PRESSURE CONTROL LOOP
The pressure controller controls the turbine load w.r.t. the main steam pressure
deviation and prevents a pressure drop e.g. during a quik load increase. Two
operational modes can be selected -
a) Initial Pressure control
b) Limit pressure control
5.3.1 INITIAL STEAM PRESSURE CONTROLLER
Operation of the initial steam pressure controller initiates the unloading of the
set in the event of initial steam pressure falling below a preset value. The
unloading of the set continues proportional to the available pressure. The
loading of the set begins only if the firing rate in the boiler is increased. In this
mode of operation load is controlled by the boiler and main steam pressure by
the turbine.
5.3.2 LIMIT PRESSURE CONTROL MODE
The boiler storage capacity is utilized in this mode of operation. The
controller influences MS control valves to support boiler pressure only when
@ preset minimum deviation is exceeded. This allows load controller to
handle small, quick load variations, until the pick-up limit of the limit pressure
control is reached.
5.4 VALVE LIFT CONTROLLER
The input of valve lift controller is continuously compared to actual valve lift
(feedback signal) and error signal is transmitted to the electro -hydraulic
controller.
The feedback signal representing the valve lift is derived from position of
the electro -hydraulic converter plunger as an analog value from the differen-
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tial transformer type transducer. There are two transducers continuously
scanning the position of the plunger. If the signal from any transducer
differs by more than predefined value an alarm is initiated. The
characteristics of valve lift controller are proportional, integral and differential
type and this ensures high overall sensitivity and improves _ transient
response. During operation of the turboset one of the controller is always in
control. The other standby controllers are matched continuously with the
active controller to allow quick transition without bumps. The outputs from
the speed control loop and load control loop are juxtaposed and tied to each
other by means of a maximum selection circuit. In a separate
circuit the output of speed control loop is summed with load reference
value, This signal is compared with the signal from maximum selection circuit
of the speed and load controller and minimum of the two
juxtaposed with the output signal from pressure control loop in yet another
minimum election circuit. The output of this minimum selection circuit is fed
to valve lift controller.
Normally the set is run on electro -hydraulic controller whereas the hydraulic
controller serves as a standby.
ELECTRO HYDRAULIC CONVERTER
The electro -hydraulic converter is used as an interface device between the
actuators of the main steam control valves and the electronic control
circuits. It converts the electronic signal received from the valve lift controller
to an appropriate hydraulic signal. The electro-hydraulic converter complies
with the stringent requirements for actuating force and actuating speed of the
electro -hydraulic governing system.
TRACKING DEVICE :
A tracking device is provided to achieve bumpless transfer of contro! to the
back-up hydraulic device in the event of failure of electro-hydraulic controller.
This device tracks the output of hydraulic starting and load limiting device to 5
to 10% more than the output of the electrohydraulic controller. During normal
operation, electro-hydraulic controller is in operation through a hydraulic
minimum gate. In case of failure of electro-hydraulic controller , it gives a
maximum opening signal for the valves and hydraulic controller takes over
through the minimum gate.
LOAD SHEDDING RELAY :
The load rejection relay assists the hydraulic controller to ensure that the
speed of the turbine generator can not reach the trip setting for the hydraulic
averspeed trip in case of load through off.
Hardwar1330-00-41
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The instantaneous power is compared with the last measured value
(scanning time 60 msec) which is stored throughout the length of scanning
time. In case a negative load transient is detected a control pulse is
generated.
This pulse is used to actuate the solenoid valve in the HP and IP secondary
fluid circuits, switching to drain and thereby causing a rapid drop in pressure.
The HP and IP turbine control valves close at maximum speed as a result,
thereby preventing overspeed. The length of the pulse which determines the
closure time of the valves, is dependent on the magnitude of the negative
load transient.
Upon termination of the control pulse the solenoid valve is deenergised, the
control fluid pressure increases again and the speed controller opens the
valves corresponding to the new load value. Since the turbine speed after a
load rejection is not only dependent on the magnitude of the load rejection
but also on the residual load after the load rejection, the control pulse is only
issued if the remaining load is also below a preset value. The setting for the
load rejection relay (magnitude of load drop, remaining load, duration of
pulse) may be adjusted during initial checkout/ commissioning and start-
up of the turbine generator. The default settings are as follow:
AP > 50%
Prog < 30%
scanning time 60 msec
length of pulse= 1.2 sec (max)
f< 49 Hz.
To prevent response of load shedding relay on under-frequency, a
frequency monitoring circuit inhibits response of this relay if frequency drops
to an adjustable under-frequency limit , Without this blocking (feature), the
turbine would accelerate too much (in the event of load rejection on
underfrequency, after termination of the close pulse the hydraulic controller ),
would open the turbine control valves very far due to the large error
caused by the frequency deviation. This itself would reach the overspeed trip
point.
SHEET NG, 9 OF 11
STE, BHEL HardwarLoan
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