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g Power Systems University

Governing Basics

Governing Basics

Objective: To gain an understanding of control fundamentals.

Slide 1
g Power Systems University
Governing Basics

Safety Information

WARNING!
The engine, turbine or other type of prime mover
should be equipped with an overspeed shutdown
device, that operates independent of the prime mover
control device to protect against runaway or damage to
the prime mover with possible personal injury or loss of
life should the mechanical-hydraulic governor or
electric control, the actuator, fuel control, the driving
mechanism, the linkage, or the control device fail.

Slide 2
g Power Systems University
Governing Basics

What is a Governor ???


z Governor Definition: a: An attachment to a machine
for automatic control or limitation of speed. b: A
device giving automatic control (as of pressure or
temperature).
z A governor is a device which controls the energy
source to a prime mover to control it for a specific
purpose.
z Basic governors sense speed and sometimes load of
a prime mover and adjust the energy source to
maintain the desired parameter.
z Advanced governors are often referred to as Control
Systems.
Slide 3
g Power Systems University
Governing Basics

Why do we need Governors ?


Prime movers must be controlled to do useful
work. Common control parameters include:
z Speed
z Load (torque or MW)
z Pressure
z Temperature
z Valve Position
z Speed Derivative
z Pressure Derivative
z Any parameter that can be converted into a 4-20 milliamp
signal.

Slide 4
g Power Systems University
Governing Basics

Prime Mover Introduction

Slide 9
g Power Systems University
Governing Basics

Prime Mover Introduction


z Prime Mover Definition: An initial source of motive power
(as a waterwheel, turbine, or engine) designed to receive
and modify force and motion as supplied by some natural
source and apply them to drive machinery.
z Before we can understand what a governor is or how a
governor works, here is a quick introduction of the prime
movers that use governors.

Slide 10
g Power Systems University
Governing Basics

Basic Control Loop

Woodward
Actuator Control
System
Energy
Source

Prime Load
Mover
Metering
Valve
Exhaust
Slide 11
g Power Systems University
Governing Basics

Basic Control Loop

zA basic prime mover control loop consists of


the following pieces:
„ Energy/Fuel Source - Steam, Diesel, Gas, Water...
„ Fuel Metering Valve - Gas Valve, Steam Valve,
Gate Valve, Injector...
„ Load - Generator, Compressor, Propeller...
„ Control System - Governor, Electronic Control
System and Actuator.

Slide 12
g Power Systems University
Governing Basics

Example of a Gas Turbine

Slide 15
g Power Systems University
Governing Basics

Example of a Gas Turbine


z A simple gas turbine is comprised of three main sections; a
compressor, a combustion assembly and a power turbine.
z Air is drawn in the front of the turbine and compressed. The
compressed air is then mixed with fuel, and burned. The control
system governs the amount of fuel being burned.
z The resulting hot gas expands and is forced through the power
turbine creating horsepower or work.
z The power turbine section is connected to the load.
z There are many other types of gas turbines; Aero Derivative, 2-
Shaft, 3-Shaft ...

Slide 16
g Power Systems University
Governing Basics

Speed Control: Constant Load


DESIRED
SPEED
z The driver of the car is the ACTUAL
SPEED
control or governor.
z The speed limit sign is the
desired speed setting.
z The speedometer senses
actual speed.
z The driver compares desired speed to actual speed, If they are the
same, fuel is held steady.
z If desired speed and actual speed are different, the fuel setting is
adjusted by the driver to make actual speed equal desired speed.
z Fuel is held steady until a speed or load change occurs.

Slide 19
g Power Systems University
Governing Basics

Speed Control: Increased Load


SPEED
LIMIT
z The car starts up the hill, 60
load increases, speed Increase
decreases. Fuel

z The actual speed is less


than desired speed.
z Driver increases the fuel
to increase the speed,
which returns the actual
speed to the desired
speed.
z Before the actual speed reaches the desired speed, the driver
reduces the fuel to prevent overshoot of speed. This is called
Compensation and is adjusted to match the response time of the
prime mover.
z It takes more fuel to pick up load than to maintain load. Slide 20
g Power Systems University
Governing Basics

Speed Control: Decreased Load


z The car starts down the hill, load
decreases, speed increases.
z Actual speed is greater than
desired speed.
z Driver decreases fuel to
decrease speed, which returns
the actual speed to desired
speed.
z Before the actual speed reaches the desired speed, the driver
increases the fuel to prevent undershoot of speed. This is called
Compensation and is adjusted to match the response time of the
prime mover.

Slide 21
g Power Systems University
Governing Basics

Closing the Loop

Control
Of The
Actual Speed Energy
or Load

Desired Speed or
Load Reference
Slide 23
g Power Systems University
Governing Basics

Closing the Loop

z The governor functions the same as the car driver.


z It automatically changes the Fuel Flow to maintain the desired
speed or load.
z Closed Loop Definition: When used as an automatic control
system for operation or process in which feedback in a closed
path or group of paths to maintain output at a desired level.
z If parameter(s) of the loop change, it will effect the entire loop
and fuel will automatically be corrected to maintain the desired
setpoint.

Slide 24
g Power Systems University
Governing Basics

Early Mechanical Governor

Early Mechanical Governor


Slide 25
g Power Systems University
Governing Basics

Force Balance

Actual Desired
Speed Speed
Force Force
F(a) F(d)

1000 lb 1000 lb

Increase Decrease
Fuel Fuel

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g Power Systems University
Governing Basics

Force Balance

z In the governor, Actual Speed and the Desired Speed are


converted to a force that represents their respective
actions.
z These forces must be balanced in order to maintain the
speed/load constant.
z If they are not balanced, the governor will increase or
decrease fuel until they are balanced.

Slide 27
g Power Systems University
Governing Basics

Simple Flyweight System

Simple Flyweight System

z F(a) = Actual Measure of the Centrifugal force = Actual Speed.


z F(d) = Actual measure of the compressed speeder spring =
Desired Speed.
z F(a) = F(d) for a balanced system.
z In other words, when the force of the compressed speeder spring
equals the centrifugal force, the system is in equilibrium.
z The forces are summed together in a thrust bearing. Slide 28
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Governing Basics

Flyweights and Pilot Valve

Thrust
Bearing Speed
Adjust Output
Servo

Pilot Valve Pilot


Valve
Plunger
High
Pressure
Oil
Control Land
Control Increase
Land Fuel
Pilot Valve
Bushing Sump
Control Port Oil Pump

Slide 29
g Power Systems University
Governing Basics

Pilot Valve Bushing and Porting

z Pilot Valve Bushings are


cut differently to Round
compensate for different Slot Hole
size prime movers and
prime mover responses.
z Pilot Valve Bushings are
cut with holes or slots.
Pilot Plunger
z Very tight tolerances are
required on both the pilot Valve and
valves and pilot valve Plunger Bushing
bushings for exact
controlling.

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Governing Basics

Unstable Governor
Speed
z As load is added, speed Adjust Output
Servo
decreases. Fuel is added,
increasing speed until speed
equals speed setpoint.
z Due to the acceleration and lag Pilot
Valve
time of the prime mover, speed
High
overshoots thus decreasing the Pressure
Oil
fuel. Control Increase
Land Fuel
z Speed decreases until speed
Sump
equals speed setpoint. Oil Pump
Unstable Governor

z Due to the deceleration and lag Prime Mover


Acceleration Actual
time of the prime mover, speed Speed
Load
undershoots thus decreasing the Added
fuel.
SPEED

Time
z Process is repeated remaining
unstable or in some conditions
becoming more and more Desired
Speed
Prime Mover Setpoint
unstable. Deceleration
Slide 31
g Power Systems University
Governing Basics

Droop Governor
Feedback Arm

A droop governor
allows the feedback Output
Servo

arm to increase or
decrease the force High
Pressure
on the speeder Oil

Increase
spring, thus Fuel

increasing or Sump

decreasing the speed


reference with a
Speed Setpoint

Load
Added

change in load (fuel


demand) or speed.
Load
Removed
Droop Governor
Time Slide 32
g Power Systems University
Governing Basics

Droop Curve
Droop Definition:
A decrease in
desired speed
setpoint for an
increase in load
or output servo
position
(feedback). 0%
LOAD 50% 100%

Slide 33
g Power Systems University
Governing Basics

Droop Calculation
No Load Speed - Full Load Speed
% Droop = X 100
Rated Speed
Example of 5% Droop

3600 RPM (no load speed) 3600 RPM - 3420 RPM X 100 = 5% Droop
(rated speed) 3600 RPM

3420 RPM (full load speed)

0% LOAD 100%
Mechanical Load or Gen. set loaded by a Load Bank

3780 RPM 63 Hz
(no load speed)

3600 RPM 60 Hz (full load speed) 3780 RPM - 3600 RPM X 100 = 5% Droop
(rated speed) 3600 RPM

0% LOAD 100%

Generator Set Loaded to Utility Bus or Other Generator Sets Slide 34


g Power Systems University
Governing Basics

Droop Calculation
Example of
5% Droop

100 RPM Mechanical Load


(no load speed)
(rated speed)

95 RPM 100 RPM - 95 RPM


X 100
(full load speed) 100 RPM
0% = 5% DROOP
LOAD 100%

105 RPM
63 Hz
(no load speed) Example of
5% DROOP

100 RPM GEN SET


60 Hz Loaded to Utility Bus
(full load speed)
&
(rated speed)

105 RPM - 100 RPM


X 100
0% LOAD 100% 100 RPM
= 5% DROOP
Slide 35
g Power Systems University
Governing Basics

Speed / Droop Calculation


Speed Setpoint
(63 Hz) 105%
5% Droop Curve Intersection of Droop Curve
(62.4 Hz) 104%
And Actual Speed Determines
(61.8 Hz) 103% Wicket Gate Position / Load
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
Actual Speed
(59.4 Hz) 99% “Fixed” When Tied
Large system
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Wicket Gate Position / Load Slide 36
g Power Systems University
Governing Basics

Speed / Droop Calculation


Speed Setpoint
(63 Hz) 105%
Lower Speed Setpoint Intersection of Droop Curve
(62.4 Hz) 104% By 2.5% And Actual Speed Determines
(61.8 Hz) 103% (Shifts Droop Curve) Wicket Gate Position / Load
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Wicket Gate Position / Load Slide 37
g Power Systems University
Governing Basics

Speed / Droop Calculation


Speed Setpoint
(63 Hz) 105%
Increase Speed Setpoint Intersection of Droop Curve
(62.4 Hz) 104% By 1% to 103.5% And Actual Speed Determines
(61.8 Hz) 103% Wicket Gate Position / Load
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%

Load Increases
By 20%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Wicket Gate Position / Load Slide 38
g Power Systems University
Governing Basics

Speed / Droop Calculation


Speed Setpoint
(63 Hz) 105%
(62.4 Hz) 104%
If System Frequency Shifts,
(61.8 Hz) 103% Load Will Shift According
To Droop Curve Intersection
(61.2 Hz) 102%
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Wicket Gate Position / Load Slide 39
g Power Systems University
Governing Basics

Speed / Droop Calculation


Speed Setpoint
(63 Hz) 105%
5%
Dro
(62.4 Hz) 104% op C
urve
(61.8 Hz) 103%
(61.2 Hz) 102% 2% Droop
C ur v e
(60.6 Hz) 101%
(60 Hz) 100%
(59.4 Hz) 99%
30%

40%

50%

60%
10%

20%

70%

80%

90%
0%

100%
Wicket Gate Position / Load Slide 40
g Power Systems University
Governing Basics

Dashpot Compensated Governor

Slide 41
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Governing Basics

Dashpot Compensated Governor

z The dashpot compensated governor was the first governor


designed to be an isochronous governor.

Slide 42
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Governing Basics

Isochronous Definition

ISOCHRONOUS
(ISO+CHRONOS = SAME +TIME)

CONSTANT SPEED
No change in speed setting
with an change in load

Slide 43
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Governing Basics

Isochronous Curve
Speed / Speed Setpoint

0% LOAD 50% LOAD 100%

Slide 44
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Governing Basics

Pressure Compensated Governor

Slide 45
g Power Systems University
Governing Basics

Pressure Compensated Governor


Response
Speed / Speed Setpoint

Slide 46
g Power Systems University
Governing Basics

Electronic Governor Basics

Slide 47
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Governing Basics

Review of Basic Governor Elements

z Speed Sensor
z Speed Reference
z Summing Point
z Stabilizing Method
z Hydraulic Pressure Source
z Output Servo
z Controlling Amplifier

Slide 48
g Power Systems University
Governing Basics

Actuators

z The part of an electronic governing system that converts the


electrical output signal of the electronics into a mechanical
movement which positions the throttle, steam valve, fuel metering
valve etc.
z An ACTUATOR is a hydraulic, or pneumatic, or electrical device
that converts an electrical signal to a mechanical position.
z A SERVOMOTOR is a hydraulic cylinder assembly controlled by a
pilot valve and usually directly connected to the prime mover's
energy-medium control (fuel valve, steam valve, etc.).
z Woodward electro-hydraulic actuators usually convert 20 -160
milliamps to zero to ~45 degrees of rotation, or zero to one inch,
depending on the actuator.
z Other manufacturers (Valtec, Vickers, Fisher, etc.) convert 4-20
milliamps to zero to full stroke.
Slide 49
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Governing Basics

Proportional Actuator
Level Adjustment

Centering
Screw Increase
Fuel

Coil
+
Demand
From Governor
_
Coil
Permanent
Magnet

High Pressure
Control Oil

Control Land Control Port


To Sump
Slide 50
g Power Systems University
Governing Basics

Integrating Actuator
Null Current LVDT LVDT
Adjustment Excitation Feedback

Centering Centering
Springs Screw
Increase
Fuel
+ Coil
Demand N N
CL
From Governor
S S
- Coil
Magnet
(-) High Pressure Oil
Power Servo
Control Pressure
CL
Control Port
Control Land
To Sump
Slide 51
g Power Systems University
Governing Basics

Speed Sensing
• Speed of the prime mover is
sensed using Magnetic Pickups
(MPU).
• An MPU generates a frequency
signal that is directly proportional
to the speed of the prime mover.
• Single pole, alternating current,
electric generator.
• Single magnet, attached to a pole
piece which is wrapped with
multiple layers of copper wire.
• The ferrous gear teeth and the magnet creates a path for the magnetic lines of force.
• Making and breaking of the flux lines induces an alternating voltage into the coil around the
pole piece.
• Each pulse is represented by a gear tooth passing by the Magnetic Pick-up.
• The Impedance of a Magnetic Pick-up is approximately 220 ohms.

Slide 52
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Governing Basics

Magnetic Pick-Up’s
Magnetic Lines Ferrous Gear
of Force

1.5 V RMS Gap


Minimum
Jam Nut

s s S

MPU Bracket Coil Pole Piece


mpu Permanent
Magnet

z The voltage amplitude output is dependent on the air gap of the


MPU. A decrease in air gap equals an increase in voltage.
z MPU voltage must be >1.5 V RMS, at the lowest control speed.
Slide 53
g Power Systems University
Governing Basics

MPU Generated Waveforms

Slide 54
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Governing Basics

MPU Generated Waveforms


z The output waveform of the MPU depends on the
following items:
„ Speed of the gear and number of teeth.
„ The air gap between the pole piece and the gear tooth.
„ The dimensions of the MPU and the type of gear.
„ The impedance connected across the output coil.

z MPU Advances per turn:


„ 16 Threads Per Inch = 0.0625 inch.
„ 18 Threads Per Inch = 0.0550 inch.
„ 20 Threads Per Inch = 0.0500 inch.
„ 24 Threads Per Inch = 0.0415 inch.
„ 28 Threads Per Inch = 0.0357 inch.
Slide 55
g Power Systems University
Governing Basics

MPU Frequency Calculation


MPU Frequency(cycles/sec) = Gear Speed(revolutions/min) x Number of
Teeth 60(sec/min)

OR

Gear Speed(revolutions/min) = MPU Frequency(cycles/sec) x 60(sec/min)


Number of Gear Teeth

For a 60 Tooth Gear:

Gear Speed(revolutions/min) = MPU Frequency(cycles/sec)

Slide 56
g Power Systems University
Governing Basics

Proximity Probes

z Proximity Probes or Proximity Switches are active devices usually used where slow
rpm or a large air gap is required. This is necessary due to the large runout of the
monitored gear and the slow speeds of large engines or turning gears on turbines.
These have a slower surface speed which an MPU cannot detect.
z Proximity probes require an external power supply, usually 24 Vdc to operate.
Slide 57
g Power Systems University
Governing Basics

Hydraulic-Mechanical vs. Electrical

Hydraulic- Electrical
Mechanical Analog Digital
z Speed Fly Weights Magnetic Pick Up or Magnetic Pick Up or
Sensing Proximity Probe Proximity Probe

z Speed Speeder Spring Speed Potentiometer Software Ramp Block


Setting

z Summing of Thrust Bearing Summing Amplifier Software Add Block


Forces
Reset
z Stability Needle Valve Capacitor/Potentiometer Software PID Block

z Gain Buffer Springs Gain Potentiometer Software PID Block

z Reaction to Error Pilot Valve Porting PID Amplifier Software PID Block
Signal Slide 58
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Governing Basics

Speed Control Summing Junction


Speed Reference or
Desired Set - Point

Error
PID Feedback
Output Output
To To
Other Inputs Amplifier Actuator
(Load Sensor)
(Synchronizer) PID
(Droop Signal)
(Etc.)

Actual Speed

The Set-point or reference is where you would like the actual measurement to be.
Error is defined as the difference between the set-point and actual measurement
Slide 59
g Power Systems University
Governing Basics

Summing Point

z The summing point is where all signals in a control loop add


up.
z The input signals must sum up to zero for precise steady
state control.
z The summing point is electronically the same as the thrust
bearing in a hydraulic / mechanical control where all the
forces balance to zero.
z Many parameters can be added into the summing point.
z The PID block and feedback block represent a special type of
amplifier.

Slide 60
g Power Systems University
Governing Basics

Analog Electronic Speed Control

Desired Speed
+DC Volts PID Feedback

Error Signal PID


Summing Junction

Actuator

Actual Speed
- D.C. Volts Prime Generator
Mover

Frequency
to
Voltage Converter Magnetic
Pickup
AC Sine Wave
Slide 61
g Power Systems University
Governing Basics

Digital Control System Block Diagram


Setpoint (+)

PID Feedback

Summing Junction
+
Adjustable Dynamics Output To
+ Error Signal and Amplification
Fuel Valve
-
-
PID

The
Thesetpoint
setpointisisthe
theonly
onlyparameter
parameteraccessible
accessibleininthe
theclosed
closedloop
loop
Actual (-) system.
system.
The
Thecontrol
controlwill
willforce
forcethe
theactual
actualparameter
parametertotomatch
matchthe the
setpoint
setpointby
byactuating
actuatingthethefuel
fuelvalve.
valve.
Slide 62
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Governing Basics

Closed Loop Speed Control


Speed
Reference Feedback

Generator

Servomotors

Valve

Droop (Gate Position)


Prime Mover

D.C. Volts ZVPU


Interface
Module 15V Zero Velocity
0V Pickups
Pulse Train Slide 63
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Governing Basics

Closed Loop Speed Control


z Actual speed is converted to a DC voltage that is
proportional to the speed of the prime mover.
z Speed reference is compared to the actual speed.
z An error signal is produced if the actual speed voltage and
the speed reference are not matched.
z An increase fuel or decrease fuel signal is then given to the
actuator.

Slide 64
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Governing Basics

Mechanical / Electrical Governor Comparison


Pivot Points Needle
Speeder Mechanical
Valve
Spring
Gain Reset Electrical
Rated
Speed
Pot

Generator

Summing
Point Error Servomotors
Signal
Valve

Prime Mover
Thrust Flyweights
ZVPU
Bearing
Interface Module
Zero Velocity
Pickups

Pilot Valve Porting Slide 65


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Governing Basics

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Slide 66
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HSS - LSS
LSS
Speed Control
HSS
Temperature Control

Accel Control
Output
To
High Limit
Actuator

Decel Control
Low Limit
Slide 67
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Governing Basics

HSS - LSS
z LSS = Low Signal Select. Whichever input is the
lowest, will be sent to the output.
z HSS = High Signal Select. Whichever input is the
highest will be sent to the output.
z These Hardware or Software algorithms allow
different items to be in control as they are needed.
z Only one input can be in control at any one time.

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Governing Basics

Example of Temperature Limiting LSS

Slide 69
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Governing Basics

Example of LSS
z The two inputs on the LSS are speed and
temperature.
z If the temperature input ever exceeds the speed,
then the fuel would be limited by temperature.
z Exhaust Gas Temperature, Compressor
Discharge Pressure, Manifold Air Pressure, Lube
Oil Temperature, Multiple Speeds, are examples
of LSS Inputs.

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Governing Basics

Example LSS

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Example of HSS

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Example of HSS

z Redundant Magnetic Pickups are often used in


control systems.
z Both inputs to the HSS are the same, yet coming
from different MPU’s.
z If either MPU should fail and the input go to zero,
the good MPU will send its output to the summing
point.

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Governing Basics

Example HSS

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What is a PID ?

If you don’t understand the following


equation / algorithm, then continue on.
1 d e(t)
OUTPUT = Kc e(t) + e(t) dt + D
I dt
e=error, Kc = gain, I = integral, and D = derivative settings

Slide 77
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Governing Basics

PID Tutorial
z The Set-point or reference is where you would
like the actual measurement to be. Error is
defined as the difference between the set-point
and actual measurement.

Speed Reference or
Desired Set - Point

Feedback
Error Output
Other Inputs To Amplifier Output
(Load Sensor) PID To
(Synchronizer) Actuator
(Etc.)

Actual Speed
Slide 78
g Power Systems University
Governing Basics

PID Tutorial

z PID stands for Proportional, Integral, and Derivative.


z A PID amplifier is used to calculate an appropriate response to
the output based on changes to the input.
z Controllers use PID’s to eliminate the need for continuous
operator attention.

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Governing Basics

PID Tutorial

z Question: Why are dynamic adjustments


necessary in a governor or control system?
z Answer: Control Systems must be matched to the
prime movers, in order for them to operate
properly.

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g Power Systems University
Governing Basics

PID Tutorial

Slide 81
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Governing Basics

PID Tutorial

z The output of a PID controller will change in


response to a change in measurement or set-point.
z PID - Combinations of Proportional, Integral, and
Derivative will provide the best type of process
control required.

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Governing Basics

PID Tutorial
z Gain - The gain is the proportional gain term in the
PID controller.
z With Proportional Gain, the control output is
proportional to the error in measurement or set-
point.

Slide 83
g Power Systems University
Governing Basics

PID Tutorial
z Reset - The reset is the integral term in the PID
controller.
z With integral action, the controls output is
proportional to the amount of time the speed error is
present.
z It prevents slow hunting at steady state and controls
the time rate at which the speed error returns to zero
after a speed or load disturbance.

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Governing Basics

PID Tutorial
z Compensation - The compensation is the derivative
term in the PID controller.
z With Derivative action, the controls output is
proportional to the rate of change of the
measurement or error.
z The controls output is calculated by the rate of
change of the measurement with time.
z Compensation is used to avoid overshoot.

Slide 85
g Power Systems University
Governing Basics

PID Tutorial
RESET
ADJUSTMENT
SPEED

GAIN
ADJUSTMENT
COMPENSATION
ADJUSTMENT

TIME
Slide 86
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Governing Basics

“Text Book” Dynamic Response

Slide 87
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Governing Basics

“Text Book” Dynamic Response


z Characteristics of correctly tuned prime mover:
„ Stable control at no load.
„ Stable control over all load ranges.
„ Minimum overshoot with no ringing or instability.

Slide 88
g Power Systems University
Governing Basics

Governor Assumptions

• Consistent fuel quality


ƒ Steam pressure, gas pressure, BTU value, etc.
• Control of valves
ƒ Valves must be calibrated for zero to 100 percent travel
• Linkage
ƒ Smooth travel
ƒ No lost motion
• Linearity
ƒ Linear flow for zero to 100 percent travel
ƒ Power output linear with valve position
• Consistent machine geometry
ƒ No change in dynamic response

Slide 89

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