pe Ne heb). THY LU aN KWU STEAM TURBINE GOVERNING AND PROTECTION SYSTEM - er TAG HN NATIONAL POWER TRAINING INSTITUTE An ISO 9001:2000 & ISO 14001 Organisation (Ministry of Power, Govt. of India) NPTI Complex, Sector-33, Faridabad - 121 003, IndiaNEED DDS Cegaua.,, KWU STEAM TURBINE GOVERNING AND PROTECTION S MV Pande MTech. (H. P.E.). DBM Dy, Director, NPT! (WR) Nagpur. MARCH 2002 YSTEM Si - go RS iKWU STEAM TURBINE GOVERNING & PROTECTION SYSTEM CONTENTS Chapter No. Te Tonic | Chapter t Concept of steam Turbine Governing 7a | ae Introduction ‘ 1.2 Theory of Turbine Speed Governing 1 Ae Methods of Governing 3 } 14 Steady State Regulation 6 | 15 || Transient Speed Rise (T.S.R.) 16 |) | 16 Dead Band ae F Chapter 2 Oil Supply Scheme [ 3 24 Function and specification | 19 2.2 } Main equipments 20 23 | Description of equipments 20 | Chapter 3 | Features of KWU Turbine Governing ya pete 2a | 34 Functional Areas of Governing System 23 3.2 Salient features 23 Chapter 4 | Governing System Overview aa? Bs = 31 44 General Description ! 25 42 Stop & Control Valve Scheme 25 ("Chapter 5 | Governing Oil Scheme re | 32-44 64 | Generation of various ols in governing scheme 32 Bo | Function of Governing oils 32 53 | Control and Trip oll circuit | 37 54 Secondary oil circuit | 42 | Chapter 6 4 ‘Stop & Control Valves Operation ae | 45-56 64 Main & Reheat Stop valve oil scheme 45 62 HP Control Valve (HPCV) Servomotor 50 63 Servomotor for IP Control Valve (IPCV) 52 64 Control Valve Opening Characteristics 56 ‘Chapter 7 Hydraulic Governing System B7-74 7A Function and limitations of Hydraulic Governing 87 72 Principal Components of Hydraulic Governing System 57 73 Working of Hydraulic control 58 74 Description of Main components 60 18 Governing Characteristics | n— Page No. | Chapter No. ae ota | Chapter 8 Electro-Hydraulic Governing System ! 75 | a1 Introduction al 82 Functional Requirements for the EHC ; | | | a3 Structure & Elements of Electro-hydraulic governing | a ! a4 Speed Control loop ! at 85 Load control loop ! 86 Pressure Control loop 96 | 87 Selection Circuit 98 88 Admission Control loop 14 89 | Electro-hydraulic Converter a | 8.10 Common Arrangement between EHC & HC (Linking) 106 ant | EHC Characteristics 113 Chapter9 Turbine Protection System 114-119 | 94 Funetion 114 i 92 Mechanical-Hydraulic Turbine Protection | ete 93 | Electrical-hydraulic Turbine Protection | dic Chapter 10 Hydraulic Protective Devices | 420-132 10.1 Trip Devices eer | 102 Main Trip Valve 120 | 103 Remote Trip Solenoid Valve 122 10.4 Overspeed Trip Device 1 & 2 / 124 10.5 Thrust Bearing Trip Device } 128 10.6 Low Vacuum Trip Device | 130 Chapter 11 Governing System Operation 133 — 145 144 Salient Operational Points 133 11.2 Turbine Start-up with various Governing modes 145 11.3 Response of EHC to load rejection 144 11.4 Important Governing System Annunciations & Indications 144 Chapter 12 Automatic Turbine Tester 146-166 | 12.4 Application of the Automatic Turbine Tester 146 12.2 ‘System Description 146 12.3 Automatic Turbine Tester-Protective Devices 147 12.4 ATT Sub-group for Stop & Control Valves 161 atKWU STEAM TURBINE GOVERNING & PROTECTION SYSTEM ILLUSTRATIONS mustration Description Page No. bigeye | Turbo-Generator Turning Moment Fig. 12 Nozzle Governing Method. =e Fig 1.3 [Throttle GoverningMethod Fig. 1.4 | Throttling of Steam. GBS) a Fig. 1.5 [Static Regulation Characteristic Fig 16 » Determination of Speed & Load Character! Fig. 1.7 {Grid Configuration < Fig 1.8 Load Sharing by Units with Same Droop Fig. 1.9 | Load Sharing by Units with Different Droops Fig. 1.10 Mechanical Speeder Gear Arrangement Lor aa Fig. 1.41 | Speeder Gear Operation ag) Fig. 1.12 Electrical Speeder Geat_ bee Fig. 1.13 [Speed Response fo Load Rejection 16 Fig 24 ‘Turbine Oil Supply Scheme! __-_ jeiese8 Eid ide: [Main Oil Tank Arrangement 19 [ieee oiproperios Fe 2 ‘Fig. 2.3 7 Main Oil Pump 22 "Hydraulic Equipment Rack of Governing System __ 26 [Steam Admission System for KWU Turbine 2 H.P. Stop & Control Valve 28 IP. Stop & Control Valve 30 Details of Governing Oils es Se Ue Governing & Protection Oil Scheme for KWU Turbine 35 Control Oil & Trip Oil Circuit 38 Emergency Shut-off Valve for ‘Control Oil Supply Secondary Oil Circuit e ‘[ Stop & Control Valve Oil Scheme Servomotor for HP & IP. Stop Valves = is Test Valve for HP& IP Stop Valves ‘Servomotor for Main Control Valve (HPCV) [iP Control Valve Servornotor : HP & IP Control Valve Characteristics "| Hydraulic Speed Governing Scheme Hydraulic Speed Transmitter Hydraulic Speed Transmitter Characteristics Constructional Details of Hydraulic Speed Governor & SLLD. Simplified Diagram of Hydraulic Speed Governor Relationship between Governor Bellows Stroke and Auxiliary Secondary Oil Pressure ee ‘Speeder Gear Arrangement Hydraulic Converter (Amplifier Piston) 6 +) Hydraulic Converter (Follow-up Piston) ~ 0 ~ Readings of lydraulic Govert ning Parameters fer ming Characteristics y ce 73 Control System B76 Turbine Controller — 16 ok Diagram 78 i 82Wilustration | Fig, 8.6 Fig 8.7 Fig. 8.8 Fig. 8.9 Fig: 8.10 “Fig. 8.17, Fig. 8.12 | Fig, 8.13 “Fig. 8.14 / Fig, 8.15(a,b)_ Fig. 8.19(c,d) Electro-Hydraulic Converter Fig. 8.16 Fig 8.17 __ Main Trip Vaive ___ Remote Trip Solenoid Va “ Actual Speed Measure! arrangement of Electric: “Hall Probe Connection Load Control Loop ___. die SE { Gharacteristic of Frequency Influence ‘Actual Generator Load Measurement ___ | Pressure Control Loo} election Circuit + Admission Control Loop _Electro-Hydraulic Converter “Hydraulic MIN-GATE Hydraulic Controller with Trackign Arrangement _EHC Readings for Typical 210 MW Unit _ | EHC Characteristics Turbine Protection Scheme _ _{ Main Trip Valve __Remote Trip Solenoid Valve _ | Arrangement of Overspeed Trip Mechanism Overspeed Trip Device Overspeed Trip TestValve Thrust Bearing Trip Device _ | Low Vacuum Trip Device Turbine Governing Control Module | Co-ordinated Master Control Module "Scheme ofProtection Devices | Changeover Valve __Bearing Trip ie | Overspeed Trip Hydraulic Trans Low Vacuum Trip _ Thrust Bearing Trip itter for Overspeed Trip pia Rest Solenoid ers ee gee _ Stop Valve and Control Valve Scheme (ATT) _ Hydraulic Test Transmitters for Low Vacuum Trip & Thrust Page No. 86 87 87 91 93 95 97 99 101 403 104 407 109 411 4112 1. 124 123 125 125 127CHAPTER-1 CONCEPT OF STEAM TURBINE GOVERNING 1.1 Introduction To govern means to control and regulate certain parameters 10 achieve expected functional requirements. Governing system can, therefore, be preliminary defined as t designed to achieve functional requirements of turbo-generator operation by controlling and regulating steam turbine input parameters, viz. turbine inlet pressure of steam, mass flow rate of steam ete are dependent Operational conditions of steam turbine have certain requirements which on the nature of driven machine. For example, in case of utility turbines, the AC generator is directly coupled to its shaft and therefore the speed of the steam turbine should be maintained in the narrow range so as to stabilize the grid frequency which keeps on fluctuating due to variation of Demand Load. As a matter of fact the output speed characteristic of steam turbine is not suitable for electrical generation purposes. Therefore, some additional form of control must be applied to ensure that dynamic changes in the consumers’ demand for electrical power are followed automatically without large deviation from the nominal electric frequency, ie. 50 eps. in our country. 1.2 Theory of Turbine Speed Governing 1.2.1 Function of Speed Governor The function of the speed governor is to sense the magnitude of the turbine speed and respond with a proportional output in the form of mechanical, hydraulic or electrical signal that is used for regulating the steam admission control valves of turbine. In addition to forming the desired load-speed characteristic of the turbine, the governing gear also provides : * Control of turbine speed at no-load to permit the unit to be synchronized with the grid or electrical network. © — Control of turbine load when running in parallel with other generating sets. * Protective gear (system) to ensure the safe operation of turbine, 1.2.2 Turning Moment Balance for turbo-generator In following Fig, 1.1, the turbine unit is directly coupled to AC generator, The balance of turbine output power in accordance with generator output and mechanical losses ean be explained as follows: 2 esGenerator Turbine Losses Mc: MMe Fig. 11 Turbo-Generator Turning Moment Balance As per fig. 1./,the equation for turning moments balance ean be expressed @s : Mr=Mg +Mi + (lr-+ Ig) a soe ® Turning moment at the turbine coupling (N.m.) Where : Mr M, Losses due to Breaking moment in the bearings arising ut of friction as well as windage and other generator losses (N.m.) Mo : Turbine turning moment conyerted in to electrical Power at generated terminals (N.m.) Ir ‘Moment of inertia of turbine (N.m. Sec”) Uj 8 ‘Moment of inertia of generator (N.m. sec”) o Angular velocity of turbo-generator shaft (rad/sec) When turbo-generator is operating at constant speed, the 2 =0 inequation (1) 7 v-Mr=Mg + Mi Q) Further equation (2) can be written as Myx ox 10°=Mgx ox 10° +M, xox 107 OR Nr=No +N; oo @ Where: Nr _Effective power developed by turbine at coupling (KW) Ne: Generator output power (KW) Ni: Power Lost (KW) In equation (3), No, ie, Generator output power is governed by the load requirements of the consumer, whereas Nr, i, power developed by the turbine is a function of steam flow rate, hheat drop across the turbine and efficiency of the machine, “Nr=f(G,H,n) Where :G: Steam flow rate or steam through put (kg/sec) HH: Heat drop across the turbine (Joules) 1): Efficiency of the machine.rr er YU YD OD. ae Now considering above factors, the power output of the turbine can be varied to match, with the consumer’s demand by varying either steam flow or heat drop or the combination of both. Hence, the governing system has to accomplish above functions in order to automaticall of the turbine restore the state of equilibrium between extemal load and power output matching constant speed as long as generator is not connected (0 the grid. Once the generator is synchronized with the grid, the turbo-generator speed is controlled by the system frequency and the generator as per preset load then function of the governing system is to control the loadii 1m admission control valves of the frequency characteristic by adjusting the position of stea turbine. ‘All modern turbo-generators are combined with steam generator (boiler) to operate as integral unit. The allowed load changes of the steam generator determines the load changes of tics of turbine and steam generator has made it the unit. The distinctly different character necessary to link their respective control system together. Since the load on the grid. /< demand, is constantly changing due to which there is always a mismatch between generator output and demand. If the demand is greater than generator output then the grid frequency falls, on the other hand if the demand is less than generator output the grid frequency rises. Hence the change in frequency, i.e. turbine speed is detected by speed governor and it takes the corrective action. Hence the response of the governing system to initiate the corrective action is utmost important factor to bridge-up the demand and supply gap and to stabilize the grid frequency as carly as possible. 1.3 Methods of Governing 41.3.1 Methods Adopted ‘As discussed in Chapter 1.2, it is evident that the final element regulated by the governing system is the group of steam admission control valves. Hence the way control valves are operated, depends on the method of governing adopted for turbine. Generally for utility steam turbines following two methods are popularly used. * Nozzle governing method « Throttle governing method In both the methods, the unit may be operating at constant steam pressure or yariuble steam pressure before stop valves or a combination of two (i. in constant pressure mode over a certain load range and variable pressure mode over a remaining load range). 31.3.2 Nozzle Governing n sets, each set In this method, as shown in fig: 1.2, n0721 decrease of load, required num! Fach valve may have its own relay Jes for steam inlet are made up 1 i ber of nozzles may be being controlled by a separate valve. With shut off, and same may be opened to regain the load. der may open the valves by the cylinder or pilot valve or a single relay governor in a particular or the nozzle area in the help of a cam shaft. This method is restricted to the first stage of turbine, other stages remains constant. It is suitable for simple impulse turbines and for large units which have an impulse stage as first stage followed by impulse-reaction stages. This method is mostly adopted in LMW design turbines. This method is more efficient than throttle governing method at part load operations. CV. eee ena Serre Nozzle Box Separately Welded to Turbine Casing Fig. 1.2 Nozzle Governing Method 433 Throttle Governing In this method (ig. 1.3) the mass flow rate of steam is controlled by throttling the st g the steam by simultancous operation o: yy which 1" 3 ri a control valve; ine inlet cai s by which 1" stage pressure at turbi t can be regulated to the extent of required load,POR edtts oi ee Oe AOD Control Valve CV.2 = Nozzle Ring Fig. 1.3 Throttle Governing Method eee eee A = — u ou w) Fig. 1.4 Throttling of steanjoverned turbine. In throttle 9 ieess of throttling for throttle gc a xi rocess of throttling “ig. 1-4 explains the pt oe e et Toad c« governing the mass flow of steam is reduced whenever there is a reduction of lo: mnomic or design load and vice-versa, As the load decreases, shaft speed tends to increase, th econom lo: v : less power steam inlet valve is partially closed to admit less steam to the turbine and to prod i ' Py to match the demand. Due to restriction of passage in the valve, steam is throttled; say from to Pm (Fig 14). The specific ideal output of turbine thus reduces from (by-hz,) to (hy-hys). With further closure of the valve, Pa, will still be less to produce a still lower output. In throttling, enthalpy of steam remains constant but the available energy for doing work reduces. This reduces the efficiency of the turbine at part load, ‘This method is mechanically simple resulting in less initial cost but thermodynamically less efficient than nozzle governing at part loads. In most of the KWU turbines, throttle governing is adopted. 4.34 Constant and Variable Pressure Mode Im constant pressure mode, the pressure upstream of control valves is kept constant through out entire load range while in variable pressure mode, the control valves are kept wide open and the pressure upstream of control valves varies proportionately with the load over a definite Yoad range (generally over 60% load). As the turbo-generator sets operating in Fequency control must react quickly even to moderate load changes, turbine control valves rmust be continuously throttled by a limited amount, This ensures that instant reserve output is made available. Boiler can not respond so quickly as to fulfill the necessary pressure changes, 14 Steady State Regulation 7.4.1 Definition 50% 100% Load % —» fig. 1.5 Static Regulation Characteristic: |Speed regulation is a measurement of the quickness with which the goveming system controls the change in speed. As shown in Fig. 1.5, the inherent relationship between load and speed for turbine driving an AC Generator is a linear drooping curve, i.c. speed falling with increase of load For example a turbo-generator serving captive load (isolated grid operation) is rolled to the rated speed or no load speed No (Ref. Fig. 1.5). Then the set is loaded to full load capacity and the full load speed Nj is noted. It is observed that the turbine speed falls by (Nz ~ Nu) when loaded from no load to full load. This percentage change in speed with respect to no load speed is called as steady state regulation or droop of the machine, 2-Nl Droop x 100% Where : N1 = speed at full load N2 speed at No load I The droop percentage at the machine decides the load sharing by the machine connected in the network during demand changes. This is elaborated in chapter in chapter J.4.3. 1.4.2 Derivation of speed-load Relationship The graphs shown in Fig. /.6 explain how the relationship between speed and load is determined. 1.4.3 Load sharing of Machines operating in grid It is well known fact that power generating sets of various capacities and unlike features are connected to common grid to fulfill the real time load demand. The demand fluctuations are reflected in the form of varying grid frequency which is sensed by speed govemors of the generating units which then will be proportionately loaded or unloaded. However, the additional demand sharing or load rejection characteristics for the machines operating in grid depends on two factors: 1. Capacity of the units 2. Load frequency (droop) characteristic of the machine.A Vaive arom, (D+ ———————$—$————— ‘cG ac 100% 0 Governor Travel oy load 100% ° Load Fig. 1.6 (a): (b): ©: @: 3 3 100% Valve Litt Valve Area {c) (a) () fe) (f) Fig. 1.6 Determination of Speed & Load Characteristics Governor Travel is inversely proportional to turbine speed Control Valve lift is proportional to governor travel as a non-linear relationship. Valve area is proportional to valve lift depending on profile of valve seat. Steam flow is proportional to valve area. This graph is single straight line for throttle-governed turbines, known as “Willian’s Line”, The load is directly proportional to the steam flow. The intercept on “Y” axis gives the no-load steam consumption. It is derived from graphs (a) to (e) that with fall in turbine speed governor travel is increased which increases the steam flow by opening the control valve and the load is increased. This graph explains that the speed falls with increased of load.Ne Se Whenever there is a change in demand, the percentage sharing of demand by each unit in the grid is directly proportional to its capacity & inversely proportional to the droop percentage. The grid generally comprises of Hydro turbines and gas turbines which can be loaded or unloaded frequently without much disturbing the dynamics of the process. Hence On the other hand, coal these units are called as peaking units preset with lower droop (3 - 4%). fired units, which contribute about 70% demand sharing in the grid, are adjusted with higher droop (5 ~ 8%) s0 as to work as base load units, Coal fired units can not be loaded or unloaded fat a rapid rate due to inherent limitations of boiler dynamics. Hence coal fired units should 1¢ as base load units for good stability of the system. normally run above 60% load and s The load sharing characteristics of the units operating in common grid can be computed as follows: graphically or mathematicall: Case (i) : Load sharing with units having similar droop but different capacities. Suppose for example, two units having 4% droop of capacity 200MW and 500 MW are loaded to 100 MW and 250MW respectively Unit -2 Unit -1 200 MW 500 MW 4% droop 4% droop, Total demand Grid = 350 MW, 50 cps Fig.1.7 Grid Configuration [At the grid demand of 350 MW, the grid frequency is suppose maintained at 50 eps. Now say grid demand has shoot-up to 525 MW from 350 MW instantaneously. As an effect grid frequency starts falling which causes the speed governors of unit 1 & 2 to act accordingly thereby loading Unit 1 and 2 further in the proportion of their capacity and droop. When the generation again matches with the current load demand, grid frequency stabilizes at lower value say 49.5 cps in this case. The load sharing between set 1 & 2 and resulting frequency can be calculated graphically as follows. In Fig. 1.8 Load frequency characteristics of Unit 1 & 2 are plotted where “X” axis is represented by load in MW and “Y” axis by grid frequency in eps.(Cycles Per Sec. ).ee Unit 1 __A% droop Unit 2 $1 50 49.5 47 Frequency cps 48, a7 s ) 50 100 150 200 250 300 350 400 450 500 550 600 650 700 Load MW Fig.1.8 Load Sharing by Units with Common Droop Method: 1. Draw the horizontal line at 50 cps while the grid demand being 350 MW. 2. Draw vertical line at 100 MW, 250 MW and 350 MW (Combined Load A+B) cutting to 50 eps line at poinis B,, C; & Dy. These points represent the generation of Unit 1 & 2 and combined load at 350 MW grid demand and 50 CPS frequency 3. Unit 1 & 2are set with 4% droop which can also be expressed as 100 MW/cps for unit 1 and 250 MWieps for Unit 2. Hence the full load values for unit 1 & 2 are achieved at 49 cps. Draw 49 cps horizontal line and then draw vertical line at 200 MW and S00 MW for Unit 1 & 2 respectively to get the point B & C at intersection with 49 cps line. Similarly, for combined full load of Unit 1 & 2, vertical line at 700 MW is drawn which cuts 49 cps line at point D. 4, The curve passing through points B1 and B which cuts “Y” axis at point A (51 eps) is drawn for Unit 1. Hence the curve A-Bj-B represent the 4% droop curve for Unit 1. Similarly, 4% droop curve for Unit 2 i.e, “A-C)-C” and for combined load of unit 1 & 2 (Curve A-D)-D) are drawn. Now the A-Dj-D representing the total capacity of the units is the droop characteristic curve for the grid. 10 ee ig for Unit 1 & 2 and 5. Now say grid demand has increased to 525 MW. The load shari resulting frequency can be found out as follows: Then draw MW load cutting the curve A-D1-D at point D2 525 MW Draw vertical line at horizontal line passing through point D2 which represent the resulting frequency at © curve at C2, load demand. As per Fig. 1.8, this horizontal line passing through Do cuts A-C axis at 49.Seps. Hence resulting frequency becomes 49.5 eps. Curve A-B,-B curve at Bz and “ is drawn from point Bo Now for calculating new load sharing for Unit 1, a vertical line ad of unit 1. Similarly the vertical line (curve A-B)-B). The intersection at “X” axis gives the lo passing through point C> (Curve A-Ci-C) gives the load of Unit 2 as per new demand, From Fig. /.8 the following values are obtained. Load Sharing at350MW Lond sharing at 525. Net change of load demand at 0 cps MW demand at 49.5 cps “Too MW i 1S0MW 50 MW 250 MW 37 MW 125 MW an additional demand of 175 MW from the grid is Now from above values it is pointed out that 2.5 which is nothing but the capacity ratio of Unit 1 and 2. Since the shared in the ratio of 1 it can be concluded that load sharing during droop percentage for both the units is same (4%), demand change is directly proportional to the capacit governed by speed governors, Therefore, the load sharing yy of the units employed in the grid and an be well expressed mathematically as follows for above configuration. PUULECELEUEUEY CUCLUCELOCCEETEE X+Y =Z @ C2 X+ == (X)=Z a a & Q) Where; X = Load sharing by unit 1 Y = Load sharing by Unit2 Z = Change in load demand (MW) C1 = Capacity of unit 1 (MW) = 7 C2 Capacity of Unit 20MW) Now substituting the values in equation (2), we get : IL500 X+ —— (KX) = 175 200 ealizar X = SOMW (Unit I load share) Y = 2.5x50= 125 MW (Unit 2 load share ) fore: E I in the grid which have Ee & 2.can well be extended to number of units employed in the gri. te : Equation can well be same droop characteristics. i aracteristics. Case (ii) : Load Sharing with same capacities but different droop characteristi 82 bnit2, 8% droop: 51 Unit-1, 4% droop 4 = & 50 = 3 é 349 f t 48 4” 50 100 150 200 250 300 350 400 450 500 Load MW —» Fig. 1.9 Load Sharing by Units with Different Droops Tf say two units of 500 MW Capacity having 4% and 8% droop respectively 250 MW load each at grid frequency 50 cps. are sharing The droop characteristics of Unit 1 and Unit 2 are plotted in Fig. 1.9, (as explained earlier), as curves “A-B-C” for Unit 1 (4% droop) and Curve “D-B-F” for Unit 2 (8% droop). The point “B” shows the load sharing of 250 MW each at SOeps for both the units, Now suppose due to increase in grid demand, the frequency has reduced by 1 cpsi.e. falling from $0 cps to 49 ¢ps. To find out present load sharing, a horizontal line at 49 eps is drawn which intersects curve “A-B-C” at point “C” and Curve “D-B-F” at Point “B,”. Then the vertical lines are drawn from points “B” & “C” to intersect at “X” axis. The load sharing is as follows : a gn MO O SB aNew Load Sharing Load Sharing at 50 “Loud Sharing at eps" Net change of load Droop eps feequency frequency 250MW, SOOMW. 250MW a% : 250 MW 375MW 125 MW 8% Unit 1 with 4% droop is From above table it is observed that Net change of load of double than the Unit 2 change of load at 8% droop. .d that the load sharing by Since the capacity of both the units are same, it ean be deduce The same can be mathematically the units is inversely proportional to their droops percentage. expressed as follows X4+Y=Z Di OR X+— (X)=Z 2) pe ) Where:X = Load sharing by Unit 1 (MW) Y= Load sharing by Unit 2 (MW) Z=Net change of Load Demand from Grid (MW) DI= Droop of Unit 1 (%) D2= Droop of Unit 2 (%) By substituting the values in equation (2) above, we get x4 ag=375 1.5X=375 X=250 MW Y=05x(X) Y= 125MW ‘The examples explained in case (i) and (ii) are typical cases. In fact in actual practice the grid comprises of units with different capacities, may be ranging from 10 MW to 500 MW and their Droops setting may vary from 3% to 8%, considering the peak load characteristics of the typical grid. The load sharing can be calculated for all the units by clubbing their capacity characteristics and droop characteristics as elaborated in Cases (i) and (ii). 13J with speed governor 444° Speeder Gear corporate s ye mechanism in ea 12 Gear is the me on of turbine cont es : nor to modify the posit Which can be operated in conjunction with govern valves. e he machine (© speeder gear is used to increase the speed of th a ibs ear is further used to load While rolling the machine, d, the speeder 2 rated 5 machine is synchronized, the spe’ cua oe as the speed of the machine is dictated by machine or to control the power output of the machine. the real time grid frequency with chanism in conjunction wil For explaining the function of speeder gear, a simple mechanism in conj mechanical speed governor is shown in Fig. 1.10 Speeder} Gear —teverd mony cS Speeder | Gear input ‘ Steam to Turbine tor Govemor input Speed ‘ontrol Valve Fig. 1.10 Mechanical Speeder Gear Arrangement AS shown in above Fig, 1.10, the speeder gear movement as well as speed governor ‘M™ovement is transferred to Control Valve actuation through the floating lever ‘D, Initially the control valve is in closed condition and turbine is stopped, The speeder gear is operated by hand Wheel due to which relative position of floating lever “D’ is changed by keeping point “Cc? (governor linkage) as a pivot. This will open the control valve and turbine is rolled to rated Speed. Now the governor assumes the control and regulate the turbine speed at rated value with reference to speeder gear position. This way the machine can be synchronized and the load can On the other be increased by further opening of control valve with the help of speeder gear. ingly load of hand whenever grid frequency varies, the governor position is changed and accord the machine is changed by modifying the control valve lift with reference to speeder gear Position. This time, point ‘A’ works as a pivot. The speeder gear acts in parallel with governor. 14 sprneeidehi tea ai ee ae neeNe ee ‘The result of adjusting the speeder gear is shown in Fig. J.17 04 104 Speeder Gear Operalion 94} Load > }00% Fig. L.11 Speeder Gear Operation In above figure Curve ‘A’ shows the governing characteristic (droop) when the speeder mchronizing position i.e. no load condition at rated (100%) speed. After gear is in the s synchronizing the machine, the speeder gear is operated to achieve full load (100%) of the machine. Now the machine is at rated speed and curve “B’ shows the new governing characteristic. This means the curve ‘A’ has been parallely shifted to position of curve 'B' This is because governor reference position is modified by speeder gear position with respect to 100% load. The curves *C’ and “D’ shows, the normal range of adjustment provided. Electrical Speeder Gear : In electrical governing system, the function of the speeder gear is simply achieved by means of a motor driven potentiometer and the speeder gear setting (position) is represented by a voltage that is added to the electrical speed governor signal. The arrangement is shown in Fig. 1.12. With some forms of electrical governing systems, the function of the speeder gear is performed by two components - one for controlling the speed when the machine is not synchronized, this can be termed as speed setting gear or speed reference, 15ee Ae virVo=Le eee ese aa pis See e To electro-hydraulie Speed Governor _| a Be esents —> & Motor driven Potentio Meter _| (Speed Reference) Tui Fig, 1.12 Electrical Speeder Gear Another contro! that adjusts the load on the set when the machine is synchronized, this gear is termed the load setting gear or load reference. This division of functions is adopted when 4 separate control loop is used to control the load. The arrangement also intend to the integration of the governor in to the Automatic Turbine Run-up System (A.T.R.S), 1.5 Transient Speed Rise (T-S.R.) Over Speed Trip Setting Level__ Ho TEP FT i 108 i bare & Speed Rise x Closing Steady state start speed rise e ’ So DS 3 Ui ccc eee « Fig. 1.13 Speed Response to Load Rejection r When the ul i a i : en the total load rejection takes place, turbine speed shoots up temporarily, before ¢ settling down to steady state valve. The Tesponse of the governor and turbine to a full load ( rejection is shown in Fig. 1.13. It is seen that turbine continues valves are closed (B), and turbine. to accelerate after the steam this is due to expansion of the steam entrained between the steam valves To restrict the value of TSR to reasonable value (7 to 8%) anticipatory govemnor or load rejection relay are provided to close the control valves before hand, the governing system tak: Ss system takes 16the corrective action. In case the control valves are located away from the turbine, then the TSR value may be higher than 8%. 1.6 Dead Band ‘The inertia of a machine resists any change in the present state. Response of the machine to the signal from governing system will be inversely proportional to the inertia of the machine Further due to friction present in governing system elements, certain motion of governing system The lost motion is called is lost, before corrective signal can actuate the control valves. d speed. Dead Band or Insensitivity of the system. This is expressed as the pereentage of rate For example, in case of mechanical speed governor the movement of the sleeve from he total steady state condition starts only when the force due to change of speed overcomes t It is noticed that the regulation curve with increasing frictional force of the governing system. load is slightly shifted when the load is reducing. For one and the same value of the power, the difference in r.p.m, between load increasing curve and reducing curve, i.e. AN ~ (AN) = 2AN, is called as spontaneous speed variation. This should be noted that AN is the speed interval Therefore 2AN necessary 10 overcome frictional forces before speed governor can move indicates the insensitivity of speed governor. (Where : No = Nominal or rated speed) ~. Dead Band = ga x 100%, No Maximum permissible value of dead band for steam turbine in no case be. more than .5%, For modern turbines where Electro-hydraulic governing is employed, this value is less than 0.1%. ‘The load on a turbine may vary spontaneously, if its governing mechanism have ¢ high degree of insensitivity and if its droop is less. -o0o-CHAPTER-2 OIL SUPPLY SYSTEM 2.1 Function and Specification 211 Functions ‘The turbine oil system serve the following functions a) Lubrication and cooling of bearings Jacking-up the shaft and provide hydrostatic lubrication during low speed operation (Less b) than 500 rpm) ie, start-ups & shut down of turbine) Driving the hydraulic turning gear ©) Supply of control oil to governing system @d) 212 Turbine Oil Specification The turbine oil should comply with the requirements given in the sable 2.1 below for Proper operation. Servoprime-46 oil supplied by Indian Oil Corporation fulfills these requirements. Table 2.1 Oil Properties Property” Kinematic Viscosity at 37.8°C Kinematic viscosity at 50° a) In ; __ >) Organic Acidityean 00 awe 2 oyna besira D HP wrome Emergency Shut-off Valve 4 Combi! ure ard tt baring | Control Oil< | 4 8.5 Kg/em™ 18 Exnector fr ot vapour suction Bae en tll ond my iary 08 pure Fe eet nen sandy fl oad axa oil ovme Be Elccaly grven standby (ll ong 2s Fig. 2.1 Turbine Oil Supply Scheme 1:10" pipe (inieetot) © suniiry ol eure. Ozo>>e B Riser section drain 8 Oil inet 10 Cover of entrance to rir section. 11 Insoectior: hole 13 O11 vapour acnausser 15 Inspection hale Fig. 2.2 Arrangement of Oil Pumps in M.O.T. 14 Connection for tui limit swdtch — SONAR V6 Connection tar tank level wsicatorFi m1 cated in Main Oil e ated in M ae in Fig. 2.1. whereas equipments Ios e is shown: : Purbine oil supply scheme is I ee a oS ‘The specifications of equipments are a5 To Tank are shown in Fig he 5} ae ty 32 m?( Normal Oil quantity 20 ™ ) Capacity 3: 1. Main Oil Tank (M.O.T.) 2. Oil Pumps Name No. Power © Capacity (se Na ; ot (MO eae fe Py) 1x10 or. 1 mp(MOP.) Ixl00% 115KW © 500m "| Turbine shaft driven : ee 2x100% = 7SKW | 267 mvhr. 6.11 ke/om 2, Auxiliary Oil Pump (A.0.P.) AC Motor driven imergency Lub Oil pump 1x100% | 7.3KW | 169 m‘/hr. : (E.0.P.) DC Motor Driven : Jacking Oil Pamps 2x100% = 3KW 454m%hr. 120 kg/em’ 5 (OP) AC Motor driven 3. Oil coolers (Water cooled) 2Nos. 4. Oil injectors for MOP Suction 2Nos. 5. Lub Oil Temperature Control Valve 1No 6 Oil Vapour Extractor Fans 2.Nos. 2.3 Description of Equipments 231 Main Oil Tank : The main oil tank, as shown in Fig. 2.2, contains the oil required for lubricating and control system of turbine. Apart from storage, the deaeration of oil is carried out The capacity of the tank is such that the full quantity of oil is circulated not more than 8 ‘times per hour so as to Provide retention time of approximately 7 to 8 minutes from entry into the tank to suction by the Pumps. This time allows sedimentation and detrainment of the oil. As shown in Fig. 2.2, oil Teturning to the tank from the oil supply system first flows here the first Stage of deaeration takes place as rough oil strainer (6) in to the adjacent section site side by the suction pipe of the oil pumps. chausters produce a slight vacuum in the tank, in through a submerged inlet (9) in to the riser tank wi the oil rises to the top of the tank. Oil overflows thy hot return oil is vented.=~ = =p => =~ => = = > > > > > ) 2.3.2 Oil Pumps ‘Main oil pump along with associated speed sensing elements are shown in Fig. 3, The M.OP. is situated in the front bearing pedestal and supplies the entire turbine oil requirement such as bearing lubrication, cooling the shaft journals and control oil for hydraulic governing system. The M.O.P. is driven direct from the turbine shaft (16) via the coupling (17). The double flow centrifugal type impeller (7) is mounted on the pump shalt (20) by means of the e (21), The feather key (8) and fixed axially by the bearing bushing (5) and the spaces sleeve ( caled off from each other by sealing rings which are split discharge and suction chambers are and secured against turning at the joint. The pump shaft (20) runs in the journal bearing (3) and the combined journal and thrust bearing (10). Both bearings are lubricated from the pressure chamber of the main oil pumps via. The oil lines (4, 15). When the over speed trip test device is actuated by ATT, the over speed trip test oil “a” flows to the over speed trip device via oil tube (23) installed in the pump shaft (20). ‘The pump shaft (20) also caries the hydraulic speed transmitter (14) which runs in the bearing (10) and in rings (11). This supplies the primary oil pressure signal proportional to the alls speed to hydraulic governor. Besides this electrical speed pick transmitted, named as Probe” is situated on the shaft. Halls probe, supply the electrical speed signal to the speed controller of electro-hydraulic governing system. ‘The M.O.P. draws the oil through a suction pipe (1) (Fig. 2.2) situated at the flow end of the tank. This suction pipe is constructed as an injector to aid the suction of the M.O.P. which has to overcome a certain suction head. Pressure oil conducted to the injector via and injection pipe. This injection pipe also fills the suction pipe of the M.O.P. with oil when the plant is being started-up. The discharge of the M.O.P. is connected to common discharge header of Auxiliary oil pumps. The A.O.P. (2, 3) and emergency oil pump (4) arranged on the M.O.T. are electrically driven rotary oil pumps. The jacking oil Pumps (5), also situated on the tank are electrically driven Jack-screw immersion pumps. All pumps immerse in the oil contained in the tank and draw oil from the deepest point in order to obtain oil as free of air as possible. The discharge header pressure to which A.O.P. & M.O.P. are connected is 6.5 - 8.8 Ke/om*, The control oil for turbine governing system is drawn from the header via, emergency shut-off valve. E.S.V. stops the control oil supply to governing whenever fire protection is operated. 21 aeduced by th the oil pressure is reduced DY regulates the quantity is ub oil temperature to 45°C For lubrication of the bearing: 4.5kg/em?. The temperature control valve F and balance oil is bypassed so as to regulate the I 2 flow required. supplied to turbine bearings by regulating the flow requi of oil passed thr e throttle device tO ‘ough oil coolers ‘The lub oil then 1 Threaded Ring 2 Pump Casing. Upper 14 Hydraulic Speed Transmitter 5 lournal Bearing (Governor Impelieri 4 Oil Pipe 15 Oil Line 5 Bearing Bushing 16 Turbine Shaft 6 Seat Ring 17 Coupling 2 Impeller 18 Etectrical Speed Transmitter & Foather Key 19 Permanent Magnet 9 Feather Key 20 Pump Shaft 10 Combined Journal ana 21 Spacer Sleeve Theust Bearing 22 Pump Casing, Lower 1 Ring 23 Oil Tube 12 Vent Pipe 13 Oil Inlet Vesset @ Overspeed Trip, Test Oi! Fig.1 Main O11 Pump Fig, 2.3 Main Oil Pump -000-ee ee MUSEU EL CUULUUUUele vagy 31 CHAPTER-3 FEATURES OF KWU TURBINE GOVERNING Functional Areas of Governing System ‘The increasing size of thermal units, plant complexity and operation of higher optimal steam pressures and temperatures, demand considerable increase in the role of sophisticated turbine control and instrumentation. The turbine control system developed for KWU turbine meets the demand of precise control with high response and safety. The KWU turbine governing and protection system has following functional areas: 1 2 3, 4. Be Blectro-hydraulic governing as the main Control System Hydraulic governing as the back-up control system Electrical turbine protection system as main system. Hydraulic protection system as back-up protection. Salient Features The types of governor used are Electro-hydraulic backed up by Hydraulic speed governor. Throttle governing method is adopted to control the turbine load. Regulation range of Electro-hydraulic governor can be adjusted from 2.5 to 8%, even while the machine is in operation, in steps of 0.5%. The normal regulation setting is 5%. Hydraulic speed Governor regulation is set at 5% Control valves open with varying secondary oil pressure and constant control oil pressure. Transient speed rise (TSR): i) When control valves are mounted near turbine casing : 8% ii) When control valves are mounted away from the turbine casing 28.5% : 100 livmin. Oil required for governing system Dead Band : a) Electro-hydraulic Governor: 0.01% b) Hydraulic Governor 20.1% Closing time of Servomotors a) ESV Servomotor £0.26 sec. b) HPCV Servomotor 20.4 sec. ¢) IV Servomotor 20.8 sec. d) IPCV Servomotor 10.8 sec. 23C, follow up piston block, SLLD, trip valve, EI ‘and assembled in the rack (fig.4.1)- ‘omponents such Hydraulic governor are kept out side turbine pedest s HP control valve controls from 0 to 100% load. Pt, : ralves % loa 1 controlling function along with HP control valves upto 20 1 Inall ypes of sta IP control valves have a nee is done PC valve. Above 20% load IP control valve opens 100% and control is done by HP Control is used for controlling the HP © The trimming device provided for the IP control valve: i it s as follows: exhaust hood temp., in case of low load operation condition occurs as follo 5 HP exhaust (CRH) pressure > 32 kg/cm? and load less than 20% of rated capacity. F i cl G The solenoid valve for load shedding relay operates through a load shedding relay, whi ; gets energized during major load throw off. The electrical signal is converted to hydraulic signal by actuation of load shedding relay during following conditions. i) Load throw off >. 50% ii) Balance load < 20% > 49eps iii) Grid frequency This measure prevents the over speeding of turbo-generator. is provided to check the operation of protective devices and ') Automatic turbine tester closing of ESV, IV,HPCV, IPCV while the machine is in service. G Precise load frequency droop with high sensitivity. Reliable operation in case of isolated power grid or islanding to block load, © Safe operation of turbine with induction of direct influence of Turbine Stress Evaluator (TSE) during load changes. Limiting values for protective devices actuation : _ Protection DeviceSCCCCUUOLeee gy, < > o - > > CHAPTER-4 GOVERNING SYSTEM OVERVIEW 4.1 General Description ‘As discussed earlier, KWU Governing scheme comprise of main Electro-hydraulic cctrical signals for governing system and back-up hydraulic governing system. The reference el turbine speed, generator load (MW) and MSS. Pressure are picked-up by field mounted sensors and provided to Electrical governing cabinet for processing. After processing by Hlectronic mitted to electro- Controllers and selection circuit, the signal in the electrical form is transi hydraulic converter for amplification and conversion in to hydraulic signal for positioning of control valves, Electro-hydraulic converter along with hydraulic governor and other hydraulic protection equipments are located in the governing system rack situated besides turbine. The ‘All hydraulic components are open layout of hydraulic equipment rack is illustrated in Fig. 4.1 d to and can be operated locally. The speed signal in the form of hydraulic pressure is provides hydraulic governor from hydraulic transmitter. ‘The hydraulic and electrical speed sensors are mounted on Main Oil Pump Shaft which is enclosed in the front pedestal of turbine. The oil pipelines, namely Control oil, trip oil and secondary oil, are extended to HP& IP stop and control yalve servomotors for operation. The protection scheme comprises of electrical protection and hydraulic protection devices such as Remote trip solenoid valve, main trip valve and low vacuum trip for shutting down the turbine during emergency condition, This governing and protection scheme facilitates the total operation of turbine from remote, i.e. from plant control room. 4.2 Stop & Control Valve Scheme 42.1 Valve Arrangement ‘As shown in Fig. 4.2, main steam from super heater is admitted to HP Turbine through two sets of combined HP stop valve and control valve (ESV & HPCV). Similarly hot reheat steam is admitted to IP Turbine through two sets of combined IP Stop Valve Control Valve (IV & IPCV), The exhaust of IP turbine is directly admitted to LP Turbine through two cross around pipes. The turbine load is controlled by throttle governing method as discussed in Chapter 1.3.3. The turbine start-up is always performed by admitting steam in to HP turbine first. During loading of the machine IP Centrol valves are throttled upto 20% load and then kept full ‘open for minimizing the throttling losses at normal operation of turbine. So after 20% load the turbine is controlled through HP Control Valves. 25Hlectro-Hycraulic Converter MAX45 BYO01 Followup, Pistons Hycroutie Govemoe Maxas BYO0r Storting ana Load timiting Device a), © Teued suewnzSH Converter, (Follow-up Pistons) MAX45 8YO1 Overspeed Vacuum Tip Tip Device Test Device MAGOI AON MAX62 AAOOI Changeover Valve MAGOI AA2] att Filters ‘MAX42 BT 002 So © Control Oilfiters MAX<42 BTOOI Fig. 4.1 Hydraulic Equipment Rack of Go verning System 26 ee eh A AD ADA oD DoD Di OD. Pao OD 2 2 2 2M. a eeSV UTLLUTULTT TTT TAG AH Ss we | | 5) IPT exnaust Main gleam 147 kalem®, 535°C v1 ‘Superheater A wevaseiy Esv2 ] coLp Rear Reheater (RH CONDENSER Fig. 4.2 Steam Admission System for KWU Turbine 42.2 HP Stop & Control Valve (ESV & HPCV) The main stop and control valve are combined in a common body. ‘The stop valve (ESV) is arranged vertically whilst control valve horizontally. The main stop valve provided between main steam circuit and HP turbine can interrupt the steam supply to the turbine extremely quickly during tripping. The function of the control valve is to control the mass steam flow rate by varying the first stage pressure of HP turbine in accordance with the load requirement of the unit. 4.2.2.1 LP. Stop Valve (ESV) The arrangement of stop and control valve is explained in Fig. 4.3. Steam enters the valve casing (14) via the inlet connections above the main stop valve disc (2). A pilot valve integral with the valve steam (10), operates inside the main stop valve disc. Packing rings (6) seal the valve stem where it passes through the valve body. The valve disc has a back seating arrangement which is forced against the base bushing (3) and when the valve is fully opened forms the seat at this point. This also provides additional sealing or the passage of the stem Stem and valve disc are prevented from rotating, The valve body (4) is secured in the valve casing (14) by means of the threaded ring (8), The sealing gasket is a U-section ring (5), the legs of which are flexibly expanded by steam pressure and forced against the associated sealing faces 271 Drain connections 2 Valve disc of stop valve 3 Bas bushing with screw jolnt 4 Valve booy 8 Seal ring 6 Packing ring 7 Glond Bushing & Thc ne 9 Bushing 10 Valve ic with pllot valve ht Frston roo. 2 Column 13 Servamotor for stop valve hs Vatve caring 5 Valve seat he Vatve seat 17 Vaive cise with valve stem 8 Valve boy, 3 Drain connection [20 Base bushing with screw joint [21 Packing ring [22 Seal cing [23 Threaded ring 2 Gland bushing 5 Sal ring 26 Flenge with bushing [27 Column Piston rod Actuator for control valve IL, Leakage sta I Uekage steam 13: 12. e212 0d ane an 26 25 24 23 22 2120 19 18 17 16 Fig.4.3 HP. Stop & Control Valve (ESV & HPCV) 28O ba aed Ss bi > qe = = ~ fF oes - D J D » D wy J fF - r Pp i _ — aeywi & of the casing. The main stop valve is opened hydraulically (Trip Oil) by servomotor (1 closed by spring force when trip oil is drained 4.2.2.2 HP. Control Valve (Fig. 4.3) The effort required to open the led by al with the stem (1 Valve dise and stem (17) are Additional sealing The control valve dise is integ valve is reduced by relief holes in the valve disc led by packing rings (21), bushings in the valve body (18), the stem bein; ing arrangement of the valve disc which lies against the base bushing is provided by the back sea (20) when the valve is wide open. As with the stop valve, the valve body(18) is secured in the valve casing (14) by a threaded ring (23) and sealed by the U-shaped seal ring (2). The control valve is operated by the piston of the actuator (29) which is opened hydraulically (secondary oil signal and control oil) and closed by spring force servomotor details are discussed in chapter 6.2. 4.2.3 Combined IP Stop & Control Valve (IV & IPCV) function Stop valve and control valve are combined in a common body with their stems arranged at right angles to each other. The stop valve can interrupt the supply of steam from the reheater to the IP & LP turbines extremely quickly. The Control Valve controls the steam flow rate to the IP & LP turbines during start- up (upto 20% load) or during bulk load rejection. The control valves remains full open above 20% to 100% load range to eliminate any throttling losses (HPCYV position being approx. 15%, IPCV opens 100%). 4.2.3.1 IP Stop Valve The assembly of valve is shown in Fig. 4.4. The stop valve is a single seat valve with integrated pilot valve. Steam enters via the inlet of the valve body (1) and remains above the valve dise(4) when the stop valve is closed. A pilot valve, integral with the valve stem (6) is provided for relieving, thereby reducing the force necessary for opening, ‘The valve disc (4) slides in the bushing of the valve cover (5) and has a bead on the back which lies against the base bushing (7) and provides additional sealing at this point. Metal packing rings (8) seal the valve stem. Both stem and valve disc are prevented from rotating, The stop valve is opened hydraulically (Trip Oil Pressure) and closed by spring force. 42,3.2 IP Control Valve The control valve assembly is shown in Fig. 44. The control valve has a pipe shaped valve disc (14) that is bolted to the valve stem (16) and slides in the bushing in the valve cover (18). The valve disc is provided with relieving holes to reduce the necessary actuating forces. A fing fixed in the bushing of the valve cover prevents the valve disc from rotating, ‘This valve disc also has a back-sealing that operates when the valve is fully ‘open, ‘Packing rings (07) seat 2 012 20 19 117 16 15 4 13 1 Valve casing 8 Packing ring 15 Drain connection 2 Valve seat 9 Gland bushing RE Walielseary 3 Drain connection 10 Piston rod 17 Packing ring 4 Valve disc 11 Column 1B Valve cover 5 Valve cover 12 Stop valve operator 19 Piston rod 6 Valve stem with pilot valve 13 Valve seat 20 Control valve operator 7 Base bushing 16 Valve disc i Ueatiacrs stuart Fig. 4.4 IP Stop & Control Valve (IV & IPCV)a = ier alae ee ate a COR ee te eee Che Cement cate oe eee erramnense (FR 4 8 get ett poms ape prenen ts Vaew teet eee tee creme of Betts te em tCHAPTER-5 GOVERNING OIL SCHEME 5.1 Generation of Various Oils in Governing Scheme fieieme isiooa (tis eile AUG Cones prehensive governing oil schem: ‘The yarious ©} oe i] circuits compmses of shown inte samc ae situate nthe gover ek oils as detailed in fable 5,/ with their source of generation. Table 5.1 Details of Governing Oils Oil source MOP/AOP discharge header a Filtered Control Oil Oil.” Filtered Control Oil w d ae Auxiliary Trip Oil Red-White Filtered Control Oil ‘Trip Oil ee [MAXSI Red Filtered Control Oil Primary Oil | MAK44 | Green Filtered Control Oil Auwsliary Secondary Oil Bhie-White Trip Oi! Secondary Oil Trip Oi Filtered Control Of Filtered Control Oil 5.2. Function of Governing Oils $21 Control Oil Control oil is supplied by main oil pump or auxiliary oil pump. Two control oil streams are initiated in the governing rack. Oil is filtered and then supplied to various governing system equipments at normal pressure of 6.5 ~ 8.5 Kg/em?. Control oil serves following functions : * Source oil for generation of all other oils such as trip oil, Aux. Trip oil, secondary oil, Auxiliary Secondary oil,Start-up and Test oil. * Supplied to amplifier piston of hydraulic converter and electro-hydraulic converter for actuation, Supplied to HP & IP control valve (HPCV & IPCV) servomotor pistons for actuation of control valves. 322 Auxiliary Start-up Oil 32 en oo 60 Oat fo. a: Ring Legend for Fig. 5.1, Governing Oil Scheme. Detals of Equipments 3 “visti be ie Ta Vac Tip se ae BS Line goten Net nae fe Limit Stet sre res . O9 Setid Nate tr Tesegatoy Veen ap — : Brees Vues ni Geet re ees Sa OP) rresresutotverum ~~ f [Pres Sic Noort MAVELAYOO] 9 Main OilPump 7 ae “| Presure Gouge, Const oT “Nome valve os “[ Sotenoid Vake, Aijustnent of Conval Vakes Fr PMaxairooi 902 Conrot outer Sine ies tins Exmaxes aront | Hydrate Sped Transmitor Fyepaaceso) Pressure Gauge, Prinury i rs Hs “J Presse Valve fr Load Sdng Rly a Setondary lv Reka Cont Vales _lcewo:Hiydraulic Converter Ss dh I Foapr Piston for Man Conrol Valves 12 Follow-up Piston for Reheat Control Vales Kagd [Skeve “Piston Helical Spring Pitot Valve Piston Ajusting Device Control Valves Remote Position Indiator | Remote Position indicator Moving Col Limit Switch, Pispac Hydraulic Convere _Follos-up Piston for ely nea leeve ch fiFrese aes eee | d Load Limit Device ees aA KADI © Handwhee! Mo emote Pasion Indeator Ret pene) [ Solenoid Vaive for Auxiliary Start-u See mac ctote Lo a el een Solna Valves MA MAXSIAADOL 002 Solenoid Valve for Remote Tp MAXSIAAODS #006 Main Trip Valve KAD! Local Trip MAXSECGG0S +006 Limit Switeh, Alorin E Limit Switeh, Alarm ATT G> Limie Switeh, Local Trip Alarm Lien Switch, Load Trip Alarm ATT. J ‘MAXSI‘AA201 1 202 Solenoid Valve for Control Oi) Supply During Test MAXS1.AA217 Changeover Valve MAXSICGT B Limit Switeh, Up-normal Position c Limit Switeh, Down-Test Position ‘MAXSI €PO1I +012 A ae ‘ MAXSI CPOL Pressure Switch for Trip Oil (Automatie Start-up MARS] cP20) Presi Sich fr Tip il Solenoid Valex MANS AAUOI 1002 MAXI CP203 rassure Switch for Trp oll ahead of Main Trip Valve MAXSI CP205 Pressure Switch for Trip oil between Solenoid Valves MAXS1 AA201 +202 MANSUCH2O7 | | 45° Pressure Switch for Trip oll between Changeover Valves MAXS1 AA2I1 MAXSI C200, Pressure Switch for Trip il between Changeover Valves MAXS1 A211 MAXGI CP501 Pressure Gauge, Ttip oil MAXS2 cP211 Pressire Switch for Auxiliary Trip Oil MAXS2.CPSO1 Pressure Gauge, Auxiliary Tip oil Solenoid Valve for Changeover from Trip Oil to Control Oit PMAX6I A201 MAX61 A702 Solenoid Valve for Testing of Thrust Bearing Trip MAXel crait Pressure Switeh for Testing of Thrust Beating Trp MAXG2AAOO), ——F OverspecdTip Te Desles KAQL | Valve for Test Oi KAO? | Valve for Auxiliary Start-up Oil KAO3 | Valve for Auxiliary Trip Oil e M Electrical Motor PMAXG2CG00L BY 21 Limit Switch Up-normal Positon ATT bie } Limit Switeh Down-Test Position ATT. es © Mae CERT 27 | Pressute Switch for Test oil of Overspeed Trip min 1 MAX02 C212. Pressure Switch for Test Oil of Overspeed Trip max. MAX69 CP213_ Preaite Switch for Test oil of Overspeed Trip Pressure Collapsed MAXG2 CPSO1 io Pressure Gauge Test Oil Overspeed Trip MAY10.AA001 +002 ©) Overspeed Trip ian RAQL' Releasing Device | MAYIO 66001-0026 Limit Switch, Alarm Peete Sh Limit Switch, Alarm ATT | Thtost Bearing Trip ie a MN Pee 01} Releasing Device Limit Switeh, Alarm Limit Switch, Alarm ATT Ub ee Bay ce ea MAYOLCSOI1 013. __ Pleetrical Speed Transmitter g 34OU CUUUU LETT This oil is generated by Starting and Load Limiting device when its p. Brough s position is brought to zero, Aux. Start-up oil pressure remains in the range of 5-6 kg/em®, This oil serve following functions: * _Latching of Main Trip valve during start-up so as to open the M.T.V. and gencrate the trip & oil pressure. This resets the Turbine trip condition. Latching of (Reset condition) Thrust bearing trip and over speed trip device while starting the turbine, if they have operated, so as to hold aux. trip oil pressure, When starting device position is raised, the aux. start-up oil pressure approaches to zero. 5.2.3 Start-up Oil This oil is also generated by starting and load limiting device when its position is brought to zero. The source oil being control oil and normal pressure would be 4.5 kg/m? The function of oil is to latching (ready for opening) the servo motor split pistons of HP & When IP stop valves (ESV & IV). This oil is supplied to the test valve of ESV & IV. starting device position is raised, the oil pressure approaches to zero, 5.24 Auxiliary Trip Oil This ofl is generated at Main Trip Valve and supplied to hydraulic protective devices. ‘The main trip valve is held in open condition by auxiliary trip oil pressure and is closed as soon ¢ to operation of any hydraulic protective devices. s oil mainly serves the following function. aring trip and vacuum trip devices, as auxiliary trip oil pressure is reduced du: Normal oil pressure remains 6 7.5 ke/em”. Thi Since this oil is connected to over speed trip, thrust bes cched in condition). they hold the oil pressure whenever they are in normal or reset (lat levice operates, then it drains out auxiliary trip oil and the pressure of auxiliary trip oil, the main trip valves (MTV & fast reducing the trip oil circuit In case any of the protective di is dropped rapidly. Due to dropping pressure MTV2) which are held open, are immediately closed thereby pressure and in tur, closing the turbine stop and control valves immediately. 5.25 Trip Oil This oil is generated at remote trip solenoid valve when it is held open. The souree oil is filtered control oil supplied from Control Oil filters of normal stream. The normal trip oil pressure is in the range of 5- 7.5 kg) © Toopen HP & IP stop valves (ESV & IV) © Source oil for generation of Auxiliary Secondary Oil om’, It serves following functions : and Secondary oil for operation of control valves.Wher iat Trip Si and connects the Trip oil to initiated, Remote Trip Solenoid operates and connects # : hen turbine trip is initiated, } Ee aa, drain tes the Trip oil pressure instantly. This in tur operate Main Trip Val iin which reduces the Trip oil pres drain the Trip oil circuit resulting in closure of HP 4 IP stop & control valves. rain the Trip oil circuit resul 5.26 Primary Oil This oil is generated at Hydraulic Transmitter f led on M.O.P. Shaft, The same source oil, ie. filtered c¢ is fed to hydra insmit im Primat sssure, which is I, ie. filtered control oil is fed to hydraulic transmitter. In tum Primary oil pressure, whic] er ional to turbine speed, is supplied to hydraulic sp. ee al. The bi , pI iydraulic speed governor as a speed sigt normal value of primary oil pressure is 1.3 - 2.4 kg/cm? for governor control 5.2.7. Auxiliary Secondary Oil This oll is generated at auxiliary follow up pistons of hydraulic speed governor. The Source oil is trip oil from main trip valves. The basic function of auxiliary secondary oil is to Provide control valve opening signal to hydraulic converter. Hydraulic converter amplifies the auniliary secondary oil pressure signal and generate proportionate secondary oil pressure. ‘The normal value of auxiliary secondary oil pressure is in the range of 2.3 ~ 4.2 k ‘e/em? 528 Secondary Oil This oil is generated at hydraulic converter and electro-hydraulic converter follow-up Pistons which are connected in parallel. The source oil for generation of secondary oil is trip oil fed to hydraulic and electro-hydraulic converter from tri ip oil circuit. The secondary oil pressure emerging from HP follow- 4p pistons and IP follow- up pistons drawn to HP & IP control valve Servomotors in two separate streams, Secondary oil pressure provides the proportional control omotors. perated by secondary oil pressure which in turn feeds ci Proportionate opening of control valve. The secondary oil kg/em* ( 0— 100% control valve stroke). valve opening signal to the control valve serv Infact the servomotor pilot valve is Pressure remains in the range 2.5 — 5 52.9 Test Oil and thrust bearing device, during test when turbine is running normal, 53 Control & Trip Oil Circuit 53.1 Control Oi supply eal oP [By manually operating the lever of MTV > By cutting of trip oil supply from RTV ® By reducing pressure of auxiliary trip oil when hydraulic protective devices are operated. Trip oil thus emerging from MTV-1 is passed through MTV-2 and then extended to trip il circuit through changeover valve. Change over valve is also fed with test oil through test oil supply solenoid valves from 2" control oil stream. The function of change over valve is to feed the trip oil circuit from test oil supply instead of trip oil from MTV during automatic turbine testing of protective devices is in progress so as to prevent the actual tripping of the turbine. (Change over from trip oil supply 0 Test oil supply in the trip oil circuit), ‘Trip oil cireuit is formed after Changerover Valve and then trip oil is fed to 1. Servomotors of HP & IP stop valves (ESV & IV) 2. Auxiliary pistons of hydraulic pressure through their respective test valves Speed governor for generation of auxiliary secondary oil Follow-up pistons of hydraulic and Electro-hydraulic converter for generation of secondary oil pressure. 5.3.5 Auxiliary Trip Oil Circuit As explained earlier, auxiliary-tip oil is generated by two main trip valves (MTV1 and Job of protection oil and therefore fed to hydraulic trip thrust bearing trip and vacuum trip devices. trip device operate due to abnormal condition for which they are employed, the auxiliary trip oil is connected to drain ther ing it devices, viz. over speed trip, Whenever any of the In turn, trip oil is connected to drain and the trip oil circuit is depressuri : ised. This causes the turbine to trip instantaneously. However, the auxiliary trip oil is supplied to Overspeed trip ie function of test valve is to bypass the auxil iary trip 4] ee ewnenenonenepeoet-t--7-0 92 5S A BdCEUUy yy — ee OE YY, so supplied ‘oil cirenit from over specd trip device during testing. Similarly auxiliary trip of to thrust bearing trip and low vacuum trip device 5.4 Secondary Oil Circuit 5.4.1 Hydraulic Governor Circuit Secondary Oil Circuit is shown in Fig. 5.4. Hydraulic speed governor is clubbed with starting and load limiting device in one cabinet in order to mechanically limit the travel of governor or in other words provide the load limiting action. ‘On one hand hydraulic speed governor receives the input, the actual speed signal in the form of primary oil pressure emerging from hydraulic speed governor, on the other hand it receives the reference input from speeder gear position. As a result governor position is decided which in turn adjust the auxiliary secondary oil pressure through auxiliary follow up pistons. Auxiliary secondary oil pressure forms the signal for generation of secondary oil pressure. The load shedding solenoid valve is connected in auxiliary secondary oil circuit. When it is opened by load shedding relay, it drains the the auxiliary secondary oil pressure and thereby limiting the secondary oil pressure to prevent the over speeding of turbine during bulk load rejection. The auxiliary secondary oil line is connected to hydraulic amplifier (located in hydraulic The hydraulic amplifier amplifies and converts the auxiliary secondary oil sure, The sleeves of HP converter cabinet). pressure signal in to mechanical signal with the help of control oil pre and IP follow-up pistons battery fed through trip oil cireuit, are operated by this mechanical signal from hydraulic amplifier to generate proportionate HP secondary oil pressure and IP However, IP secondary oil pressure is adjusted by adjusting device to secondary oil pressure. provide full opening of IP control valves approximately after 20% load. The HP & IP control valve lifi (stroke) is adjusted in proportion to their respective secondary oil pressures. $4.2 Electro-Hydraulic Governor Circuit As shown in Fig. 5.4, Electro-hydraulic governor comprising of speed controller, load controller and pressure controller loops receives Electrical input signals of speed, load and M.S. pressure, whereas respective reference signals are preset ftom the control desk. After processing, the signals are routed through selection logic and finally the electrical signal from selected controller is provided to Electro-hydraulic converter (EHC), The function of EHC is to convert the electrical governing signal in to amplified hydraulic signal, ie, secondary oil pressure. The functioning of hydraulic part of BHC is same as explained in Chapter 5.4.1 in respect of Hydraulic Converter. 42.FILTERED CONTROL Olt fasts —_—_>—— Hydraulic Transmitter Speeder Gear (Ref) Starting and Load Limiting Device (SLL) ‘Govermer Hydrauilc Speed Control Oi Electro- Hydraulic, Hydraulic Converter Electra Hycreutic Amplifier plata HP Control Valves! IP Control Valves Follow-up piston for Follow-up platon for ‘ollow-up piston for "Sp Control Valves IP Secondary Ol 2.5 ~ Skg/em? Hydrautie Minimum Signal Load Rejection Solenoid Vaive To IPCV Servomotor 2.5-5kg/cm? HP Secondary Oil 2.5-5 kg/cm? To HPCY Servomotor fig. 5.4 Generation of Secondary Oil - Circuit onto! on ee aeCHAPTER-6 VES OPE rION STOP AND CONTROL VALV ES OPERATIO! 6.1 Main & Reheat Stop Valve Oil Scheme and Equipments eee tec ofa pola cg oi ts om age a lining oe any lei nal hon tine in ied oon, Be caine pistons are latched-out (in split condition) and the test valve (MA x 47 AA a ' 212) in top most position. Hence start-up oil coming from SLLD (when at zero position) is fed {0 test valve so as to press it downwards. Due to this action, the trip oil which is available to test valve is fed to the servo motor pistons from the top side thereby servomotor pistons are latched: in (become composite). Further when SLLD (Starting & Load Limiting Device) position is raised, start-up oil pressure is reduced due to which the test valve is lifted. Now the trip oil from test valve flows to the bottom side of servomotor piston and top side is connected to drain through test valve, Due to this action stop valve opens against the compression of spring and remains in that position till the trip oil pressure persists. 61.2 HP and IP Stop valve (ESV &IV) Servomotor The constructional details of servomotor for stop valve are shown in Fig. 6.2. The operative part of the servomotor consists of a two part piston, the lower disc-shaped patt (6) which is connected via piston rod to the valve stem (8). The other part of the piston (2) is bell Shaped and moves within the housing which is in the form of a eylinder. ‘Two spiral springs (4) are placed between the two halves of the piston; at the lower end spring plate (5) is interposed between the spring the piston dise (6). When trip oil is admitted to the space above the bell-shaped part of the piston from connection “X;", it moves this half of the piston downwards, compressing the springs, until it Seats against the piston disc, The edge of the bell-shaped half of the piston is designed to Produce a fluid tight seal with the piston disc. Now the stop valve is prepared for opening or in other words it is latched-in, To open the valve, oil from the trip oil circuit is admitted to 1 Ihe space below the piston disc from connection “X” and simultaneously, the space above the bell shaped half of the piston 45 i ieee 4e 1 eo & £ ifauoyag 10 aapna lounog 7.4045: NIU dit apap 3QTWA TOULNOD dH GUSTSAIWA sous NW. =o “iO Appuesss ay lO dn-iavis : CELL aTAnatiaaeen...Legend for Fig. 6.1, Stop & Conny NX" —" Details of Eanipments Bescriotion coe beset ea ne fain Stop Valves (ESV), test val Maxeranzit-e2i2 [Solenoid Val ema MADsTAAZII +220 Solenoid Valve for Sarcyp oll Reveat Stop Valve MAX47.AAO11+ 012 | Test Valve for HP stop valves (ESV) ; for IP Stop Valves (IV) Mantrnniniitae | reayonerrm sy vobes IMAX6] AA2314222 _f Solenoid Valve or Tesng af HP Siop Valves (ESV) MAXI 4A2214292 Solenoid Valve for'Tesling of IP Stop Valves (IV) MAA 20 AAOOI — “THIPSiop Vale (ESV) KAdr | Piston KAD | Piston Dise MAAIO-+20 Can0i ‘Open Valve Position iS 1, Closed Valve position D Limit Switeh, Open Valve Position ATT B Limit Switch, Closed Valve Position ATT MAA10-+ 2.44002 | TIP Conirol Valves (iiPCV) KAO) Servomotor KAD2 ——} Pision KAOt | Pitot Valve KAO9 J Fland-whee! for Testing Device M lectrical Motor | MAAIO= 20 CGO02 A“ Remote Position Indicator oe. Limit Switch, Motor valve Testing Device 0% and 100% ATT cc Limit Switeh, Closed Valve position ATT MABIO+ 29 AA0ot KAgi” KAQ2 Limit Switch, Oper Valve positiin | Limit Swit Closed Valve positon e Lint Switch, Open Vave positon ATT Limit Switch) Open Valve poston ATT IP Conitoi Valves (PCV) ; Servemotor Piston Pilot Valve Hand-ivhee for Testing Device 3 Eletrcal Motor _ Remote Position Indicator 1 Limit Switch, Motor Valve Testing Device Ov and 100% ATP © Limit Switch, Closed Valve Position oa Pressure Gauge, Trip oil Sg Pressure Gauge, Trp oil above piston of HP Stop Valves (E Valves (ESV) Pressure Gauge, Trip oil below Piston Disc HP Stop cree 2 _| Pressure Gauge, Trip oil above Piston OfIP Stop Valves (IV) Pressure: Gauge, Trip oil below Piston Disc IP Stop Valves 47 - . 8g gg og on ff 02010100 AMAR RVU UU TUTTO ee MUU YY es of the piston to move together in is connected to drain through test valve, This causes both the upward direction which opens the valve. In order to reduce oil leakage past the bell-shaped inst which the part ofthe piston, when the valve is open, back seat is provided in the housing a collar of the piston can seat. When the turbine is tripped, the pressure in the trip oil circuit, and henee in the space below the piston disc falls. This results in separation of two halves of the piston due to ‘compressed spring force. The piston disc connected to the valve stem moves downwards to close the valve. Just before the valve disc seats, the piston disc enters a part of the cylinder This arrangement restricts the flow of oil past the All oil where the diametrical clearance is reduced. jon which cause the valve dise to seat gently Valve opening and closure operations can be piston dise and so produces a braking a connections are routed through a test valve as well as remotely from starting device and main trip valve controlled manually from test val 6.1.3 Test Valve for Operation of Stop Valve 6.1.3.1 Function The function of the test valve is to open and close the stop valve, either by start-up oil circuit or manual operation, especially when the stop valve is being checked for free movement. Each stop valve is served by one test valve. 6.1.3.2 Opening of the Stop Valve Fig, 6.3 shows the arrangement and oil connections of the test valve. In order to open stop valve, the valve (13) must first be forced downwards against the force of the spring (15). This can either be done by start-up oil (connection 21) or manually with the hand wheel (2). Trip oil (connection 20) can then flow to connection (16) and then over the top half piston (bell- shaped) of the servomotor (connection X; in Fig. 6.2). The test valve must be returned to the upper position, either by lowering the pressure in the start-up oil circuit or by manually turning the hand wheel (2). The trip oil can now flow from connection (18) to connection (12) and thus under the dise shaped piston dise of servomotor (connection X in Fig. 6.2). This opens the stop valve. 6.1.3.3 Testing the Stop Valve For testing the stop valve, the valve (13) is moved slowly downward by means of the hand wheel (2). In this way, trip oil is extended to connection (10) and then connection (12) linked to 48 a a% = 7 1 Cylinder 226 = 8 2 Pinon : 2 3 Gomoresion soring : 4 Gompresion spring Eins ce ¥ Teipoll under piston oie 2 pS : 7 Stop valve column Fr Tips sow ston ee = 8 Piston od ene a is Fig. 6.2 Servomotor for HP & IP Stop Valves S 4

. ww +FS See = S 12 i) eu 13 it =t-——_14 ah +$——15 16 17 peal 12 Trip cit to space 2 Hencatee! below , iston dis 2 Seicdia 13 Piston vaive soi 14 Spring plot. 5 Oil seal forse 8 Bushing soc Hee) 17 Bottom cover 8 Valvo cover 18 Trip oil, 9 Valve body 19 Desk fe 10 Trip oil to space above piston 11 Piston sieeve Fig. 6.3 Test Valve for HP & IP Stop Valves _ gin we .@ of) 000 2 2 f,Peewee © LEE Y SUUVULIVIITT drain (19) which closes the stop valve. Affer this, the hand wheel (2) is slowly turned back and the stop valve opens again. This procedure is accordingly the reverse of the elosing procedure 62 HP Control Valve (HPCV) Servomotor 6.21 Function The Control valve Servomotor is provided with Secondary oil pressure signal, accordingly filtered control oil is admitted to the piston of servomotor to open the valve proportionately. Hence, the flow of steam (0 the turbine is regulated by varying the lift of the means of its servomotor. The servomotor arrangement with oil connections is control valve by Fig. 6.4. The control valve is actually moved by the piston (2) which is loaded on explained in one side by the disc springs (3) and on the other side by hydraulic pressure. The position of the valve is determined by the secondary oil pressure which is controlled by the governor. The supply of secondary oil (connection “b”) controls the pilot valve (8) so that when the valve is being opened, control oil at approx. pressure 8.5 kg/em? from connection “a” is directed to the under side of piston (2). When the valve is being closed, oil drains through the pilot valve. 6.22 Opening Procedure When the turbine is running and the valve is steady at any particular value of lift, the pilot valve (8) will be in the centre position as shown in Fig. 6.4. In this position the force exerted by the spring (5) and the secondary oil pressure action on the pilot valve are in equilibrium. When the governor raises the secondary oil pressure to open the control valve, the pilot valve (8) is lifted. Control oil from connection “a” can flow in to the upper annulus “e” of the valve bushing (9) and through a duct in the casing of the underside of the piston (2), causing the valve to open. The movement of the piston thus directs the depressurized oil on the spring side of the piston in to the annulus “‘d” of the valve bushing (a) and further in to the drain above it. The straight feed back cam (7) mounted at the end of the servomotor piston rod (1) returns the pilot valve (8) to its position by means of a lever system (4) and spring (5) and checks the flow of control fluid from. connection “a”. 6.2.3 Closing Procedure On a reduction in the secondary oil pressure, the pilot valve is foreed downwards by spring (5), thus connecting the space on the underside of the piston with the intermediate flow back of the valve bushing (9) via the upper annulus (e). The spring (3) can now close the valve« Ona greater reduction in secondary oil pressure, the pilot valve moves so far downwards that the1 Piston rod 2 Servo piston 3 Dise springs 4 Feedback linkage 5 Spring 9 Valve bushing Control oil Secondary oil Return oll Connection to space above piston (2) (spring side) © Connection to space. below piston (2) Fig. 6.4 Servomotor for HP Control Valve (HPCV)CLUE UCT TTF y3 oil can flow back via the lower annulus “c” which is connected to the upper space “e” th accelerating the closing of the valve. ccondary oil pressure (e.g. load decreases oF tripping) the pilot ‘Ona sharp drop in the n. This separates annulus “d” from the flow back and at the same valve goes to its lowest pos “a” through the annulus on the spring side of the time allows control oil to flow from connection This additional closing force aids the spring force and ensures a proper closing of the piston ein the valve system. control valve even if abnormal frictional force: 6.2.4 Rotation and Oscillation of the Pilot Valve The pilot valve (8) is continuously rotated by the action of oil issuing from tangential drillings in a dise mounted on its spindle in order to ensure that the valve moves freely. In addition, a little secondary oil flows through a small bore in the lower part of the valve with each evolution, The slight control impulses thus caused keep the pilot valve constantly oscillating, thus increasing still further the sensitivity. 6.3 Servomotor for IP Control Valve (IPCV) 6.3.1 Function The purpose of the control valve servomotor is to adjust the lift of the control valve so the main steam flow corresponds to the desired generator output. 6.3.2 Construction and Mode of Operation The constructional details of IPCV Servomotor are shown in Fig. 6.5. The control valve servomotor consists essentially of the pilot valve (26), piston (3) and the feed back mechanism (15, 19, 37, 21). The control valve lift is determined by the position of piston (3) which is controlled by pilot valve (26). Secondary oil is supplied through connection “b” to the pilot valve at a pressure which is adjusted by the governor in proportion to the desired steam flow. This oil pressure acts on the bottom side of the pilot valve (26), which slides in the valve sleeve (25). If, when the ‘ol valve has assumed any amount of opening under steady state turbine is running, the contr conditions, pilot valve (26) is in the central position as shown. The secondary oil pressure below the piston is opposed by the weight of the pilot valve and the force of spring (39). When the overnor by increasing the secondary oil pressure, gives a control pulse to increase the amount o} &Section A-B 19 18 17 16 15 14 13 im 6 7¥s 910 11 1 Cylinder 2 Piston rod 3 Piston 4 Spring © Teper pin 6 Cover 7 Packing ring 8 Bushing 9 Screw plug 10 Threaded sleeve 41 Spring 12 Guide 13 Follow cam 14 Bolt 15 Follower 18 Bearing 17 Washer 18 Bushing 19 Teppet 20 Spring dite 21 Teppet 22 Brecker 23 Redial ball bearing 24 Wheel disc 1 —— 5 25 Velo sleove 26 Pilot velve 27 Slotted rourd nut 28 Scrow 29 Ball 50 Bushing 31 Gao 32 Tepper 33 Adjustment screw 34 Threaded sleeve 3 Cover 36 Spring . 6.5 IP Control Valve (IPCV) Servomotor SectionC=-D , t t © —— 37 Floating lover 33 cup 39 Spring 440 Spring disc 41 Cylinder cover Control olt Secondary oil Oitdrein Connection to space above biston (3) (spring side) © Connection to space below piston (3) ance 53ee aL eee CCUUUl LEY ey ye opening of the control valve, the pilot valve (26) is forced downwards, ‘Through connection “a” to the space below piston (3) resulting in the piston control oil will then flow via connection moving in the opening direction against the force of springs (11) and the valve opening force The oil on the reverse side (spring side) of piston (3) is discharged through the uncovered outlet port in the top annulus of the valve sleeve (25) to drain “e* in cover (41) The piston rod (2) is guided in bushings (8,18) and is coupled with the control valve stem. At one end, the follow-up cam (13) is attached to the outer end of the piston rod by means of'a hexagonal nut and locked to prevent rotation. The outer end of follower (15) engages tappet (19) and supports, through the floating lever (37), tappet (21), spring dise (26). and spring (39). Under steady state conditions are attained when the piston position corresponds to a specific secondary oil pressure. If the secondary oil pressure rises, pilot valve (26) is foreed upwards and spring (39) is compressed. Therefore, the piston is moved in the opening direction, moving the follower (15) on the follow up cam (13) in such a way that the pilot valve (26) is restored to its central position via the feedback mechanism. The initial tension of the spring (39) is therefore a function of the secondary oil pressure. If the secondary oil pressure is reduced, which corresponds to a closing pulse for the control valve, the pilot valve is forced downwards by spring (39).thus connecting the space below piston (3) via connection “e” to the middle drain of valve sleeve (25). The pressure below piston (3) decreases and piston (3) moves in the closing direction due to the force of springs (11). The follower (15) slides downwards, thereby reducing momentarily the initial tension of spring (39) to such a degree that the secondary oil pressure restores the pilot valve (26) to its contral position. In this position the secondary oil pressure, the weight of the valve, and the spring force are once more in equilibrium.100% OPEN 20 2.2 2.4 2.6 28 3.0 3.2 343638 4.0 4.2 44 4.6 48 5.0 Secondary Oil Pressure (kg/cm?) Fig. 6.6 HP &IP Control Valve Characteristicsjection or trip-out, the upper drain of valve sleeve (25) is closed by pilot valve (26) and load re ceeure ofl will then flow t0 the space above piston (3), Therefore, a relatively large additional pr losing foree is provided and thus positive elosing of the control valves is assured. 6.3.3, Rotation and vibration of Pilot Valve For reliable operation, minimum friction must exist between pilot valve (26) and valve sleeve (25), For this reason control oil is passed through a bore in the pilot valve to the wheel dise (24) from which it emerges through tangential passages, thus causing the pilot valve to rotate, Friction losses are also reduced with the use of a radial ball bearing (23) located between pt pilot valve (26) and spring disc (40). In addition to the rotating movement, the pilot valve is oscillating slightly. On each rotation a small quantity of oil is passed from the secondary oil circuit through a narrow passage in the lower land of the pilot valve (26) to the outlet port which is machined in the valve sleeve (25) and connected to the drain. Due to slight reduction of pressure resulting from the small loss of oil, the pilot valve scondary oil pressure is restored to its initial pressure due to closing moves downwards until the This brief up and down movement of the pilot valve (26) is sufficient to oe o of the outlet port. transmit, continuously, very small control oil pulses to piston (3). As a result, the piston, valve ee aaa ee 8 ee Stem, etc. constantly carry’ slight oscillations which serve to prevent seizing in the guides and at other sliding surfaces, 64 Control Valve Opening Characteristics ‘The opening characteristics of control HP and IP control valves (valve stroke) against secondary oil pressure are illustrated in fig.6.6 with respect to following data : Data: i) Stroke of HP control valve : 50mm ii) Stroke of IP control valve 95 mm. iii) Secondary oil pressure required to open the control valves to full stroke (100%) + Ske/em* -000- 56CHAPTER-7 HYDRAULIC GOVERNING SYSTEM 71 Function and Limitations of Hydraulic Governing ‘d controller and can perform all the full load, ic governor is basically a spec ing up to rated speed, loading the machine to Function = The bys functions of turbine control, viz. speed atid frequency variations ete. However, governing action of loading or unloading during asa back up control hydraulic governing is provided in parallel with Blectro-hydraulic governing G fails to control, thereby turbine which can readily assume turbine control at the point E tripping or over loading is prevented. Due to phenomenal advantages of EG over Hydraulic governing (HG) turbine is always controlled by EHG,but the hydraulic governor always keeps IG to HG without appreciable the tack of FHC set point. This helps in changing over from Toad change. Limitations : i tmitations + As the name suggests, hydraulic speed governor is inherently a speed governor. Though the speed governing is advantageous to peaking Meat one : (Gas and Hydro turbines), it is not ich serve as base load units. The grid frequency fluctuations are sensed by speed governor so as to effect loading or unloading of machine. ‘The coal fired steam generators cannot support or respond immediately to fast changes of load to maintain the steam Puameters, Secondly, the turbine stress evaluator influence, which protects the turbine from Overstresses during undue loading (as in EHG) is not incorporated in hydraulic governing system due to abse ical si nce of electrical signals. Hence hydraulic governing has no automatic control turbine stress level during its operation. eP 7.2 Princi| rincipal Components of Hydraulic Governing System (Ref Fig. No. 5.1 & 5.4) ee FLL Ul LESS A GS IP/IP P stoy ising the turbine (2400 rpm) thy© Generates auxiliary secondary oil pressure for adjusting the control valve lift to match the load conditions. Speeding up the turbine from 2400 to rated speed and controlling the speed while synchronizing the Hydraulic speed Governor MAX46 BYOOI machine. Controlling the machine load as per droop setting. Loading of unloading of the machine manually or remotely through speeder gear operation, | 4. Load shedding relay solenoid “Dray the auxiliary secondary oil circuit and closing the ‘control valves momentarily to prevent. over valve MAX46 AAOII speeding of the machine when load shedding relay has operated (bulk load rejection) 5. | Hydraulic Converter To amplify the auxiliary secondary oil signal MAX45 BYO11 sufficient for control valves actuation — by | generating HP & IP sccondary oil pressures. To adjust the relationship of IP control valve lift with respect to IP. control valve lift from the view oft | | 7.3 Working of Hydraulic Control The hydraulic governor oil scheme is explained in Fig 5. & 7.1. Main oil pump MAV21 APOOI supplies oil circuit with control oil whilst hydraulic speed transmitter MAX44 APOO1 acts as a pulse generator for the control circuit, providing primary oil pressure proportional to speed. This oil pressure can also be read directly from speed indicator pressure gauge MAX44 CP501. This primary oil pressure acts on diaphragm KA09 of hydraulic speed governor MAX46 BY001 against the force of speed setting spring KA02 which is tensioned by reference speed setter MAX46 BY001. The travel of diaphragm KA09, which can be limited by starting and load limiting device MAX47 BYOO1, is transmitted by linkage KAO to sleeves KA04 of auxiliary follow-up pistons KA08, the pistons KAS of which are held against the oil pressure by spring KA06. The trip oil controlled by orifice is fed to auxiliary follow-up pistons. The oil drains according to the amount of overlap between the piston and sleeve and the oil pressure corresponding to the tension of spring KA06 is built up, This auxiliary secondary oil pressure acts as a pulse generator via pilot valve KAO7 of hydraulic converter MAX 45 BYOI1. Piston KA08 of this hydraulic converter Position corresponding to the auxiliary secondary oil pressure and operates the s ? a> position of ed back system stabilizes the P For Aor wie a Tinie systema vA feed Dark + up pistons, anc i ter MAX45 BYOI! pilot valve KAOT and KAO of hydraulic converter Mi primary Oil Pressure (1.3-2.4 kg/erm?) mee. Speed Signal) Hes speeder Gear Pdstion | Hyd: Speed. Governor |g Loadimiing} $110 ae 0 i = Maxey Bv001 Tracking MAx4s a — sux Secondary EG Pressure | Co (73-42 ko/er) Load shedaing| Relay Solenoid valve Hydraulic Converter Trip Oo oe maxas aaoni | | Hydraulic Ampifier + - i = i HPAP Follow-up Pistons 65-7.5kg/cl Drain MAX 45 BYO1 ns O11 Circuit HP Sec. O + IP Sec. Oil 25-Skasem? Primary Ot 5 25-5kg/cm}| =a eee HPCVi2 IPCVi2 Load Shedding | Relay Sol. Valve Hyd. HPT PT Transmitter Drain Fig. 7.1 Hydraulic Speed Governing Scheme As already described for auxiliary follow-up piston KAO8, a secondary oil pressure corresponding to the position of the sleeves and to the rated spring tension builds-up in the follow-up pistons of hydraulic converter MAX45 BY011. Any change in the position of linkage KA03 results in a proportional change of the secondary oil pressures in the follow-up pistons of hydraulic converter. The secondary oil circuits and the auxiliary secondary oil circuits are supplied from the trip oil ciruit by way of orifices. The varying secondary oil pressure in the follow-up pistons of the hydraulic converter in turn effects changes in the positions of their associated control valves 59 — ‘ SS enaccmmanaaaaaaaag gg $49)7.4 Description of Main Components 7.4.1 Hydraulic Speed Transmitter (MAX 44AP 001 ) hanical 74.1.1. Function Hydraulic speed transmitter is the speed sensing clement. It converts the ns the input to. speed signal in to proportionate hydraulic pressure signal (Primary oil) which fo, the hydraulic speed governor. al 21 Primary oi Section A-B Fig. 7.2 Hydraulic Speed Transmitter 7.4.1.2 Working Principle Hydraulic speed transmitter is fitted on the main oil pump shaft located in the front pedestal of the turbine (Fig.2.3). ‘The cross sectional view is shown in Fig. 7.2. The hydraulic speed transmitter operates on the same principle as a centrifugal pump impeller, The variation of the pressure in the primary oil circuit ‘al’, due to speed variation, serves as a control impulse for the hydraulic speed governor. The hydraulic speed transmitter is supplied with control oil supplied from the hydraulic equipment rack via the oil supply reservoir at the centre of the impeller. An annular groove in the speed transmitter ensures that its inside is always covered with a thin layer of oil to maintain a uniform initial pressure, Excess oil drains in to the bearing pedestal, The speed x Primary oil pressure relationship for hydraulic speed transmitter is plotted in Fig. 7.3, When the turbine is speeded-up by raising the SLLD position, at 2400 rpm, shown as point “A” in Fig. 7.3, Hydraulic governor assumes control. The primary oil pressure, 1.4 kg/om? at this speed balances the governor bellows. The speed range 2850-3150 rpm shown as “B - C” 60.ea near and primary ed. The relationship is almost line f turbine spe' is the operating range of pressure varies from 1.92= 2.35 Kig/em in this rane. Overspeed Tip Speed f Linear i : Govemer | Relationship + i “Assumes Control ; for governing + i 2400 | Signal : 2300 i RAS ME2 3405: 1.6 17 NBS 1.9. 2002.1) 22 23242526 Primary Oil Pressure (Kg/em*) Fig.7.3 Hydraulic Speed Transmitter Characteristic 7.4.2 Hydraulic Speed Governor (MAX46 BY001) 7.4.21 Function The function of the hydraulic speed governor is to operate the control valves to give the appropriate turbine steam throughput for the particular load condition, 7.4.2.2 Construction The constructional details of hydraulic speed governor clubbed with starting and load Timiting device are shown in Fig. 7.4 and speed governor alone in Fig. 75. The principal components of the speed govemor (Fig. 7) are the bellows (7), the link (5), the speed setting Spring (4), the sleeve (10) and the follow-up piston (11). The primary oil supply from the hydraulic speed transmitter is available at connection aie The primary oil pressure is dependent onthe speed and determines the position of link (5) 61 ee a gp pap PPS SL 31 Electric position transmitter 2 Differential transformer 11 Follow-up piston 12 Tension spring 13 Adjusting screw 14 Pushrod 15 Reference speed setter motor 16 Trip test lever 17 Pitot valve 18 Motor for starting and load limiting device 19 Handwhee! 20 Limit switch for position indication 2. Control oit b Auxiliary secondary oil to converter © Return oil U_ Starting oil to stop valves ul Auxiliary starting oi! Fig. 7.4 Hydraulic Speed Governor & Starting & Load limiting Devicene (¢¢ &. & &, ELLE. err EE er ee are? Ss nvapsy fo wmasorcy parfiyduns: sowsason poads, uoysod ais a No dus yo Aud | usdo 2AjDA joquoa ADA pioi upig @—= 63dl ee ea Ue Se via the bellows (7) and the push rod (6). The speed setting spring (4) opposes the primary oil is pre-compression can be varied either by hand or remotely by the motor (15). The pressure. I sleeve (10) which can slide on the bottom end of the follow-up piston (11) is attached to the link (5), The follow-up piston is held against the auxiliary secondary oil pressure (connection “b") by the tension spring (12). ‘The follow-up piston and the sleeve have ports which at normal overlap jent oil to escape to produce equilibrium between the auxiliary secondary oil pressure allow su and the force of the tension spring (12). Bach steady state position of the Tink (5) and hence of the sleeve (10) corresponds to a specific force from the tension spring (12) and hence to a specific auxiliary secondary oil pressure which in turn determines the position of the control valves. 7.4.2.3 Mode of Operation If the primary oil pressure falls (as a result of increasing load and the resulting drop in speed), the link (5) and the sleeve (10) sliding on the follow-up piston (11) are moved downwards by the speed setting spring (4) so that the overlap of the ports in the sleeve and the follow-up piston is reduced, This causes the pressure in the auxiliary secondary oil space to rise and the follow-up piston follows the movement of the sleeve against the increasing force of the The lift of the tension spring (12) until normal overlap of the ports and equilibrium are restored. control valves is increased in this manner by the increased auxiliary secondary oil pressure. 222 24 26 28 30 3.2 36 38 40 4.2 4.4 Auxiliary Secondary Oil Pressure (Kg/em’) Fig. 7.6 Relationship between governor bellow stroke and auxiliary secondary oil pressure Ina similar but reverse manner a rise in primary oil pressure causes the lift of the control valves to be reduced. When the pre-compression of the speed setting spring (4) is varied with 64c primary Ol” ranges the relationship between the primary jer gear), it ch en speed and ee ete Cea the relationship between speed an i 1d hence ry oil pressure ant y hand to jink (5) to be depressed by ee Ae e machine for testing the overspeed pressure and the auxiliary seconde Bass Hows the power output. Lever (16) a : govemor, ©. 0 provide a second means of over speeding the trips in addition to the overspeed trip tester. lary oil pressure 18 The relation between governor bellow stroke and auxiliary secondary oN P shown in Fig 7.6 which is a linear graph 743 Starting and Load Limiting Device (SLLD- MAX47 BY001 ) 2. J Function st 2s (Prepared for To latch the protective devices (resetting) and to latch the HP & IP Stop valves (Prep: opening) when SLLD is brought to bottommost position (0%). 2 s s prevented till the F G To compress the governor bellows so that control valves opening is prevented till the & Ivs are opened fully at 56% SLLD position. Further raising of SLLD causes control valves to open and speeding up the machine to 2400 rpm (approx. 80% of _rated speed). }_ To provide the load limiting function as desired by the operator when machine is on load. 74.3.2 Mode of operation The starting and load limiting device is housed in the hydraulic governor body as shown in Fig. 7.4. The main components of SLLD are pilot valve (17), Motor (18), hand wheel (19), limit switches for position indication (20). Control oil from test oil stream is supplied at connection “a” to SLLD. SLLD generates Avxiliary start-up oil and start-up oil pressures (deseribed in Chapter 5.2) for latching of hydraulic protective devices and stop valves. Before start-up, the pilot valve (17) is brought to its bottom limit position either by hand or remotely by the motor (18). This causes the bellows to be compressed via the lever (9) and the pin (8) until the governor assumes the position “control valve closed”. With the pilot valve (17) in the bottom limit position contro! oil from connection “a” can flow simultaneously to the auxiliary starting oil circuit (connection U1) and as start g oil via connection "U" to the stop Yalves to prepare these for opening. When the valve (17) is moved upward, the pressure first falls in the auxiliary starting oil circuit and subsequently the starting oil connection “U is opened to drain “C”. This opens the stop valves, Further upward movement of the valve (17) auses the pin (8) to release the bellows as with negligible primary oil Pressure, the governor na - - =» «2 o @ eee‘Section C-C 1 Handwheet 15 Wormvtet 2 Washer 16 Handwhoel spindle 3 Roundhead screw 17 Limit ring 4 Bushing 18 Thrust ange B invet 19 Cover 6 Compression spring 20 Cover 7 Teper pil 21 Bushing 8 Grease cup ‘ 2Worm 9 Wormwheel with worm 23 Bushing 10 Flange bearing 24 Taper pio 11 Gear casing 25 Coupling 12 Bushing 28 Coupling 13 Cover 21 Flange 14 Limit ring 28 Motor Section AA 1312 Fig. 7.7 Speeder Gear Arrangement 66‘opens the ves. The release of the bellows can be limited by the pin hat the in (8) so the bellows can b y valves, releas control in primary oil pressure lift any further despite a further reduction in p control valves do not lift an ‘Speeder Gear (Adjusting Gear) 74.41 Function eration of ed for manual or motor operation 0 The speeder gear, also called as adjusting gear, is used for manual the reference speed setter and the starting and load limiting device. 74.4.2 Mode of Operation ee. speed load adjusting ‘The speeder gear arrangement is shown in Fig.7.7. The speed /lo: ee y movement of the motor operated either manually or by means of motor (28). The rotary mover transmitted to worm wheel(15 ‘worm wheel (9)and the worm attached to it. Worm wheel( my ert (5) and the gear is located axially on the threaded portion of the hand wheel spindle(16) by in oe easing(11). The spindle (16) is connected with bushing (4) by feather key so as to 5 pate spindle to slide axially in the bushing (4) which can rotate in cover (19), spring (6) fore : thrust rings (18) against bushing (4) which prevents bushing (4) and spindle (16) from turi rs Spindle (16) however, can be moved axially by turning the worm wheel (15). Spindle (16) can be moved up or down depending on which direction worm wheel (15) turns, The limit of travel ‘eset by limit rings (14 & 17). If cither stop has been reached the thrust rings operate as a slip coupling, The thrust rings also protect the motor (28) from overload in the event of rest movement within the speeder gear. 74.5 Hydraulic Converter(MAX 45 BY011) # 1 Function The function of the hydraulic converter is to amplify the signals from the hydraulic speed Sovemor connection b1) so that they are sufficient for the actuating devices, 7.4.5.2 Construction The assembly details of Hydraulic Converter components of the converter are : sleeves (3), are shown in Fig. 7.8. The principal er piston (1), Pilot vatve(7) follow-up piston (2) with ‘mechanical feed back system (6) and actuator (21), Bushings and follow. “A” (HP Secondary Oil Piston) are connected to each other via the adjusting screws ( amplifi up pistons 10), spring nd pieces and springs (11). Auxiliary secondary oil flows over the pilot valve via “PI”. In the steady state condition, the pilot val auxiliary secondary oil circuit and the force of Kept in rotation by control oil flowing from connection Ive is in its center position and the pressure in the Spring (8) are in equilibrium. The pilot valve is ‘he tangential holes in an integral collar to give Greater freedom of reciprocal motion and higher response sensitivity 67 eee Ss Sider A AAADASASIIS IDIee OOM ae When the pilot valve is deflected from its centre pos sition, control oi is admitted to the space above or below the amplifier piston (1) with t, piston opened to the oil drain, The resulting motion of the amplifier pisto, lever (6) to the sleeves (3) which, in tur, slide on the follow-up piston (2) circuits which are fed from the trip oil circuit via throttles and supply the Geviees, are connected at point “b”. The secondary oil pressures are determined by compression of the spring (11) which counter balance the oil pressures acting upon the & i ae pistons. Fach follow-up piston (2) and sleeve (3) has ports which control the secondary oil fos according to the overlap when the throttling area is cl anged by movement of the sleeve (3), it ‘also changes the pressure in the follow-up piston causing it to follow the movement of the sleeve. This varies the compression of the spring until equil spring foree and the new secondary oil pressure. Each position ) and the follow-up lary oil pressure at point “b”. The of the amplifier piston (1) corresponds to a specific position of the sleeve (3 piston (2). The position of the follow-up piston is the determining factor for the second: means of the adjusting screws pre-compression of the follow-up piston springs can be varied by (10,14) and the levers (15,16). 7.4.5.3 Controlling Action with Hydraulic Converter The pressure above the pilot valve (7) is varied by the hydraulic governor varying the auxiliary secondary oil pressure at connection “bl”, An increasing auxiliary secondary oil oil pressure at the connections “b” to rise and open the control pressure causes the secondary valves, where 5 reduction in the secondary oil pressure causes the actuating deviees to close. The motion of the amplifier piston produces a simultaneous feed back via le' 1 assume its center position when the new position of the amplifier piston is ver (6) and causes the pilot valve t reached, Each auxiliary secondary oil pressure cortesponds to a certain position of the piston (1) which, in turn, results in a certain secondary oil pressure at connection “b” with each auxiliary ondary oil pressure. The degree of proportionality of the hydraulic governor can be adjusted by varying the position of lever pivot (6) with the adjusting screw (9) 7454 Adjusting Device for Valves (IP Secondary Oil Pistons) : The follow-up pistons “B” and the lever (15) of the rotary shaft (12) situated above it are connected by the springs (11) of follow-up pistons “B”, the guide bolts (13) and the adjusting screws (14), During normal operation an excited solenoid valve allows control oil “a” to flow under the piston (20) of the actuator (21). The piston (20) is moved upwards against the force of the spring (19) and the initial tension of the tension springs (11) of the follow-up pistons “B” is 681 Amplifier piston 2 Followup piston 6 Foodback lever @ Control olf 3 Stoo 7 Pilot valve b it 4 Shaft 8 Compression spring by Auxiliary secondary oil 6 Lever 9 Adjusting screw cc’ Return olf Fig. 7.8 (a) Hydraulic Converter (Amplifier piston) SSSection 8-8 ee > m \ > > y ) 21 Actuator 22 Manual edjusting device 1, Controt oit 1B Socondary oil © Retum olf 12 Shaft 19 Compression spring ‘A. Follow-up pistons for actuators of main control valves 13 Guide bolt 20 Piston B Followup pistons for actuators of intercept control valves Fig. 7.8 (b) Hydraulic Converter (Follow-up Piston) 70io e HP control valve as ) which results in relation to the HP contro) 15, 16) which res adjusted by means of the lever ( intended for this operation. ae d TIP exhaust pres set minimum load an If the condition “Turbine Joad Jess than a set mi Ei, greater than e, after load sheddi a alue” is fulfilled, for example, I ter than a set maximum ¥: Z cemented, 1w of control oil to the actuator (21) and allows: Bos il to the ¢ he flow of control oi ize is blocks ves the in, The force of the spring (19) moves control oil under the piston (20) to flow in to the drain. The fore ae = ee piston into the lower end position and the tension springs (11) of the follow-up a ise tte Pom va P Ives are wider idjusted so that the IP control valves do not begin to open until the HP control valv‘ adjusted so that the IP control valves do n open. 75 Governing Characteristics Pace As discussed earlier, control valve lift is controlled by the magnitude of s a i respective pressure. The HP & IP control valves open 0 through 100% with the variation of z eivalbe lary oi | secondary oil pressure in the range of 2.5 — 5 kg/cm”, However, the value of secondary Pressure depends on signal oil, i.e he auxiliary secondary oil pressure which in turn depends on t! governor bellows movement (stroke) For typical 210 MW KW ‘Uturbine control system, the readings of governing parameters are recorded in table 7.1. Wi th these values the relationships of various parameters with Tespect to Below kecie loked in Fig. 7.9. The significances of tese graphs are as follows: Significance : It is observed from Fig. 7.9 that relationship between governor bellows travel (Stroke) verses auxiliary secondary oil pressure and HP secondary oil pressure clearly follows the equation y= mx +c, ile, linear relationship. But the IP secondary oil pressure initially when the bellows travel is less than 1.5 min build-u P slowly (non-linear) and thereafter sharply to the full value of 5 ke/em? (full opening of IPCV) within a shor range of 1.5 — 1.8 mm governor bellow travel Since control valve stroke is pro portional to secondary oil Pressure, HP & IP control valve opening follows the characteristic $ of respective secondary oil pressure. ‘The From the table 7.1, it is observed that when thi 1¢ HP control valves Start opening, valves are closed (Si IP control t. No. 1), Moreover, Percentage wise opening of IP control valves is less 1 seoes, aig wb v9 oe zo oe ies ee so. ose “él evs vse £09 Lee 0) 07's ore oss vie “OL 86y ye ess i S eLy see les EK4 iy ve vee Ls z t_ | os ove 4 86% wee Ost at sty. oe ez wet 4 sel i gee oor 991 19% vel THEUIDIDg BUILEAOD OYNDIPALY JO SBurpoay 1-7 aqoy Oot ¥ lr 9 Zt 7. 86T 06% eel x4 Srl 080 % al g ose, ave £60 osz €0'L 0) ie 0 + z 00 osz 0 ez 0 [aWl2/PX] | [e973] 2 rab) 3 ‘aus | ct824 | ainsoug [0t9/By) “ig eae sos wt He 228 d_| 40225 dH_| (usu) ayoys | yo 205 xny (usu) ax04s Bore sue|siy dn-mojoy (unui) Je1@AuoD SmnDIpAH eat P4015 moje, r US AN-Moyo “xn e on souIBA0D usBARRAAALD DI ee lle tun (Mx) MWV O12 10) WEISS BuluseAc5 2INBIBAH JO S2IsUeIODIOUD 620d ass LLU} [ADI] SMO}}9g JOWACS S'INDIPAH, s sy : Ri \ a s on “hiopuases mnssaig ‘Appu0325 4} vous aoa] ea MEPUEDOS Aap O1nS5944 5RAAAAAS "ARA*sagaaaaae oCHAPTERS e Pi STE ELECTRO-HYDRAULIC GOVERNING SYST! 8.1 Introduction ity turbo-generators and the ‘The large size of power distribution network, bigh capacity turbo-gen ae of Electro-bydrau! enhancement of automation in the operation of the plant make the use of Elec! control system mandatory and inevitable. The turbine is equipped with electro-hydraulic governing system [0 ce the ‘operation of the turbo-set in an interconnected grid system. The clectrical measuring and processing of signals offer the advantages such as flexibility, dynamic stability and simple representation of complicated functional relationship. ‘The processed electrical signal : introduced at a suitable point in the hydraulic circuit through the Electro-hydraulie Converter. The hydraulic-control provides the advantage of continuous control of large positioning forces for control valves actuation 8.2 Task and Advantages of EHC Electro-hydraulie controller is an integral part of EAST (Electronic Automation for Steam Turbine) supplied with KWU design turbines. The EHC has the task to control the steam flow to the turbine by positioning of the HP & IP control valves and accordingly the speed, during start-up and Joad of the turbo-generator after synchronization with the grid for any operating condition. As the name suggests, the integration of electrical and hydraulic system offers following advantages over conventional governor. » High operational safety and reliability by utilizing control modules with integrated circuits, as well as speed and load measurement in multiple channels, > Exact load-frequency droop with high sensitivity and provides the adjustment of droop in small increments while the machine is running, > Reliable operation in case of isolated power grid by automatic switchover of the load controller to speed controller. rereepsssgagagdogsgeddgg ddd sagas: 7, 75 nOEH.CONV Blecto- cL 7 Hydranlic 4 EHC Contoler ™ HYo HYDRAULIC : ACTUATION srst FOR CONTROL VAL HH-CONY POSITIONING i Mechanical HYD Hydray Fe Me Contlle HYD Fig. 8.1 Structure of Turbine Control System SPEED CONTROL LOOP. EH-CONVERTER SELECTION ADMISSION EL ae CIRCUIT CONTROL, ? CONTROL ifcon ; Loor. Ss HYD PRESSURE CONTROL Loop Fig. 8.2 Structure of Electro-Hydraulic Turbine Controller> Low Transi steady-state speed de id per lons. te speed deviation under all operational concitx 1 ww steady-state 5} yw Transient and > Sal rf rbine Stress Evaluator (TSE) by bine in conjunction with the Turbine Stress Eval 5 oe : L turbine parts below permissible limits. Due to this keeping the thermal stresses of ervative operation, life of the turbine is enhanced, > Support of the main steam pressure contro! system, 5 S) with EHC for turbine > Provision to interface Automatic Turbine Run-up System (ATRS) with F start-up and shut-down, 8.3 Structure & Elements of Electro-Hydraulic Control 83.1 Structure ystem e connected in ‘The Electro-hydraulic controller and Mechanical-hydraulic controller are ¢ i s the turbine. Parallel as shown in Fig. 8 . The controller with minimum set point controls the i 28. BHC The structure of electro-hydraulic controller is illustrated in Fig.82. The El comprises of following sub-control loops. a) Speed Control loop 6) Load Control loop ©) Pressure Control loop 4) Selection Circuit (Control Mode Selection) ©) Admission Control loop (Position Controller) The block diagram of Blectro-Hydraulic Controller is shown in Fig. 8.3. The electrical Signals processing modules are mounted inside a standard control cabinet. hydraulic Converter, which transforms the processed electrical signal in to hydr: located in hydraulic equipment rack as shown in Fig. 4.1. The Electro- aulic signal, is The Electro-Hydraulic Controller is an analog control} of the ISKAMATIC-A modular control system, All the control loops and elements of EHC are discussed in detail in further chapters, ler composed of control modules TDpapyy-00907] £8 Bd ab aaa a Sua 1USANOD 3sind ad SYOSN3S Ga3dS x Jinn 9NIENSV3N VOT AWT SaATVA 10NLNOD AD qVNOIS DIINVUGAH (NEDER) ‘oval pod aaNan isi AQNaNDawS [#4 Osaris 4 ae Wd YA1TOWINOD BuNSS3ud 300d prs age BONSNTANI si e | sajaa fash + y prover ee] MT bes) eg eae corn " 4ONIAOD. zl et “F aq a a z oeaa (ayonv09 wossiupy) NOllvoUNaaL | NOILvoIsuN3ar [xso/Ne pied a Ivnnen 2 eee eect ee iQ\s- Org Sauna sage t arisen, 05u3/0¥01 top 703 ao [qo bk ft a 32N3nqanr 2si/ast (oniseg 23) feed] Qi ‘MWGdIII SNITI0I 4a TOMI NOD + re dinow Bfomenclature i ghee Be e used in the description of various control loop ' Following abbreviations are relevant figures IL Physical Quantities : Z Elements : Abbreviation Description Abbreviation Description ee ‘Aes aes Ae ‘Admission Controller i Gaia eee fe : Blectro-Hydraulie Controtter sai cauibslicr: ae Eee SAY é brn : Output of speed contro > ~ > >= ~» js provided with the following display indieators and operating push-buttons mounted en the ~D 59 turbine control desk. Indicators: } The actual position of starting device (SLLD) of the hydraulic device. > The actual position of speed adjusting device (Speeder gear) of the hyd. governor. > ee value of speed (nr) in rpm (0~3300 rpm) , _» Thereference value of speed in rpm having display range 2700-3300 rpm (spread scale), > : > The time dependant reference value (nr Jim or nrtd) of speed in rpm. > Load reference value (Pr) in MW. > The time dependant load reference value (Prlim or Prtd) in MW > Load reference value of frequency influence in MW > Net effective reference of load value in MW (Prabs) > The load gradient desired in MW/Min > The reference value of maximum load (load limit) in MW > The steam pressure deviation in Kg/om* > The actual position of Electro-hydraulic converter in % > The actual position of HP & IP control valves in % Push Buttons: Push buttons tiles with pair of push buttons, one to initiate "Lower" command and the other for "Raise" command are located on control desk for operation of following. > The speed reference setter (SRS) 80> Load reference setter (LRS) > Load limit setter > Load gradient setter [ > ‘Starting device (SLLD) | ® Speeder wear (Hydraulic governor) > Load gradient ON-OFF > Load controller ON-OFF > Frequency influence ON-OFF > HPAP Trim Device ON-OFF > Tracking Device ON-OFF ® Selection between Initial Pr ressure mode and limit pressure mode, Mode Indications: The following LED indicators are provided on the control desk for displaying the status during operation. > Load gradient ON-OFF > Load control ON-OFF > Frequency influence ON-OFF > Tracking device ON-OFF > HPAP Trim device ON-OFF > Speed Controller in service > Load controller in service > Pressure controller in service > Speed/Power blocked > Limit pressure reached > Isolated Grid > ESV, IV Open/close, 84° Speed Control Loop 84.1 Function The speed controller performs following functions: ® To increase the turbine speed from baring Sear speed (150 rpm) to rated speed (3000 1pm) in a controlled ‘manner, > To assist auto synchronizer in synchronizing the machine ® To increase the urbo-generator load up to 100% load. But normally speed controller is used upto the block load, ive. 10% of rated power output, 81—_ oo INO tues O90 we OoeE-poyz 3ON3MUNI (951) ouLNoo SS auis SNiounL'o unload the turbo-generator ve wver-speeding of turbine e 1 a very fast rate in the event of over-specding . the turbo-generator at . ‘due to power grid separation or bulk load throw-off condition. ions (Re 84) The speed control loop consists of following sub-sections (Refer Fig. 8) Speed Reference Setter (SRS) for setting nr. A 5) Speed set point control or speed reference limiter (SRL) for derivation 0! ©) Actual speed measurement for providing nact 4) Speed Controller ©) Acceleration monitoring (dn/dt monitor) 84.2 Speed Set Point desk, ATRS As shown in Fig. 8 4, speed set point can be changed from Cabinet, control des! : ent of 2160 and auto synchronizer. This set point is called nr. The set point changes at a gradient This ‘pm/min upto 2820 rpm (47 cps) and at a gradient of 360 rpm/min. after 2820 rpm. din facilitate accurate setting of set point in the working range and also enables smooth loading after synchronization. ‘The reference value is displayed at the control desk by means of two indicators — i) 0-3300 rpm (Full range) ii) 2700-3300 rpm (Spread range at working speed) ‘Speed set point remains in follow mode during following conditions: 1) When turbine trips, speed set point nr follows 120 rpm less than actual speed while coasting down (i.e. if turbine speed is 2700 rpm, the nr = 2580 rpm). This feature ensures that set point always remains below the actual speed and speed controller output is always negative. Hence re-rolling will not be Possible till the turbine trip is reset and raise command given to speed reference setter (SRS). After synchronization when load controller takes over, the speed controller follows the actual speed between 49 Hz to $1 Hz. This ensures that during grid frequency variation in the above range, the speed controller does not interfere with load controller. $43 Speed Set Point Control (SRL) ‘The speed set point nr is only a desired speed and it ean not be passed on as itis to the speed controller. Speed set point control circuit decides the acceleration (speeding rate) of the tuPine depending on the temperature margins evaluated by the turbine stress evaluator (TSE), As shown in Fig. 8.5, the maximum permissible speeding rate is 600 rpm/min, TSE acquires gIFAIITIRIS IIS SD — oo . a ae 2 © feee MYM OY Ye temperatures at 50% and 90% depth and evaluator thermal str locations, * following, > UP stop valves (ESV) 7 > HP Control Valves (HPCV) J Admission zone > HP turbine casing > IP turbine shaft 'K then the output of SRL (nrlim) changes @ 600 If the above margins are more than 30 °K the SRL output will change at a rate decided by and if the margins are below 30° between rpm/min, 8.5 (ie. speeding rate is directly proportional to temp. margins the curve in Fig. 0 - 30°K). rpm/min 0 54 30 TSE Margins °&& ——— Fig.8.5 Influence of TSE Margins on Acceleration s nrlim or nrtd. The nslim indicat! 8. The output of this integrator circuit is known as t following extra facilities 1 desk (0-330 rpm). ‘The integrator has eo provided on the control low mode so that input nr will be equal to 1. Fast calibration (FM) during fo! 2. Integrator output will be blocked (ST 20 rpm before generator breaker is clo: re than 13% (27 MW). ') or steam parameters it will STOP/BLO! nrlim > nact by sed, This ensures that controller output will not be mor |. If there is some disturbance in TSE (Faulty; integrator output. ‘OP : will remain where it was) if the integrator ot e we ris nrlim very fast. utput speed CK thesynchronization 4, Generator signal > ios wo < in tn i GOOG AP Ke nota speed vale, act, A the taxthne is messmed di a : The , Sia, ‘ and processing circuit is sown im Piz, 46 wherees Fiz shows the measurement arrangement of clectrical speed pick-op. eis Speed measurement systems contains (ona maxnbers of "Hall Probes” Bis bearing pedestal on MOP shaft 2s shawn im Fig, 22 These probes ate mowed eo Aluminium disc containing 120 magnets. The leaance tetmeen probes and rotating Es maintained around 0% mun (G0 M-pohes and 60 Sqoles acranged alternately on the 7 Advantage of magnetic system is that one retation of disc with indace 60 positive pulses ( 4 2.0), s0 that by counting the pulses for one second can Gereatly determine the turbine speed in tpm. All the four Hall Probe sensors axe wized upto pedestal janction box, out of which three are used and one is kept as spase (redundzxt). The thece used sensors are wired upto three Pulse converter junction boxes, The Hall Probe contains 4 wines. A constead coment (10-£0 mi) is fed to the two wires and output is penerated across another two wives (as soon in Fig 24), When the magnetic Gite Tlsies around the Hall probes, dhe Hall robe outpes will be a sine wave with a peak voltage of + 300 my to + 400my. Pulse converter cead converts this sine wave in to a square Wave with a peak voltage of + 10. Each pulse converter card generates three isolated output (as shown in Fig ie 8.6) out of which so ontpets xr asd aad one is kept as spare. tn each EHC abinet there are two independent but identical measmrcmsent chamacls. One channel is used for Speed contro! loop and another for indication and linnit value monitor. voltage signal for intemal use and into current signal for external use. 845 Speed Controller (SC) ES. AAS aera es = eeeNousan3s THO SHO LAWN ee 1 waurane ass _2BNey9-213 GsiNDOW GTS oie 86J Clamping piece with sockets 2 Pump casing, upper half 3 Pump easing, lower half 4 Helcer 5 Hell probe 8 Permanent magnet eo 7 Bump shatt 8 Feather key 9 Hub ring 0 Non-magnetic disc 1 Hub ring Fig. 87 Arrangement of Electrical Speed Pick-up (Hall Probe) Input (30-80mA) -—|—|_ Hall Probe Output == «= (#300 - + 400mA) . Fig. 8.8 Hall probe Connections 87SS SS SS > ~ > >» Ss » » ww » » > > , ) ‘The control deviation forms the input signal for SC. This deviat ‘output signal of the SRL, nr lim and the actual speed signal, nact. ‘The controller dynamic response of the speed controller is adjusted to the r for speed control of the turbo-set. os Ifthe turbine is controlled by the load controller, the speed.controller is simultaneoush operated in a standby mode. 5: In case of load rejection with subsequent operation of the turbo-set in a islanding mode or supplying station load only, the speed controller assumes continuous control of the turbo set. The speed controller also temporarily controls the turbo-set during rapid, large frequency fluctuations. Jectro-hydraulic ‘The considerably improved speed control response due to the use of el If the speed of the turbo- control is demonstrated particularly during cases of load shedding, set rises slightly above synchronous speed then speed control action takes place and the speed is quickly reduced close to the synchronous speed ‘The speed controller exhibits a proportional differential — proportional (PD-P) i.e. the speed controller is a PD-Controller with a sloping characteristic. The output response, ional to the control deviation during signal of the speed controller remains always proporti stationary operation, This arrangement results in better load sharing by several turbo-sets as compared with the earlier mechanical or hydraulic controllers. The proportional characteristic of speed controller which. requires a difference between the nr im and nact to give an output signal to open the control valves, ie. if the turbine would be loaded with full load by means of the speed controller(with an adjusted droop of 5%), the limited speed reference nr lim must be set to 3150 rpm at an actual speed of 3000 rpm to open the turbine control valves fully as calculated below : 3150—3000 rpm = 150rpm = 5% of 3000 rpm ( 50c.p.s.) The range is0-3600rpm_ = 0-10.8V rpm = (0.003 V@mV) 150mm = 0.45: V (450 mV) ‘The range for valve lifting is 0 - 100% = 0 — 10V 88put deviation of 450 mV wi fi0V. Range beyond tis on V will give an output of 10V. Rang: So vviation of 450 mV wi 10Y__ 99.92. The output of valve is fully open at 10V itself. Gain of speed control loop ~ 455,77 speed controller is know as hrNC. No load correction : [As the speed controller loop is PD(P), so an error in the input is a must e ey a valves open for running the machine at the rated speed. To avoid this error between set Be and actual valve, a pressure dependent correction signal is given since the valve a a required for running the machine at rated speed is directly dependent on steam pressure: pee for correction purpose practical reading should be taken when the machine is running at rate: speed at different pressure. For example : Turbine running at 3000 rpm:~ Output of speed controller at 50 kg/cm? pr. = SV Output of speed controller at 150 kg/cm? pr. = 0.8 V The pressure transmitter range is 0 — 250 0-10V The corre n input is given with a gain of 0.05 and the overall gain of speed controller loop is 22.22, so net gain for correction signal = 0.05 x 22.22 = 1.11 “Correction input required at 50 kg/em? = 1,5/1.11 = 1.35 V And correction input required at 150. kg/em? = 0.8/1.11 = 0.72 V Hence above two equations can be derived with : Y=mX+e Where Y = Correction signal X = Pressure signal m =0.16 (gain) = 1.67 Bias) Above values of gain 'm! and bias'c' are adjusted by potentiometers in EHC cabinet, 44.6 Acceleration Rate (dn/d)) monitoring This control Joop detects low acceleration rate of turbine (less than 108 rpm/min) while tolling the turbine. The KWU turbine has two critical speeds (1545 rpm and 2126 rpm) between 700 rpm to 2850 rpm. Hence it is not advisable to run the turbine for prolonged period in this speed zone. This loop detects the low acceleration rate and generate a binary signal 89 pasts 5 3: —— lr hUvrathlc hae 8 2 PPwhich brings back the turbine speed to a safe speed of 600 rpm (w ArM-up speed)-The protection operates when following conditions are fulfilled i) BSVsare open fi) Generator Circuit breaker open es between 700 to 2850 rpm. S > ~~» => The dn/dt protection will be operated predominantly during speeding of turbine trom SS» we > => > > » > > {600 rpm to 2850 rpm in case of TSE upper temperature margin is very much less than 30°K (a shown in Fig. 8.5) 8.5 Load Control Loop 8.5.1 Function Load controller is used to maintain the load set by the operator or automatic load dispatch centre (optional), Load controller is also responsible for taking care of frequency changes and correcting the load accordingly. The load controller comes in to operation only after synchronization and the block load (10% of rated power) is achieved. Before that it remains in follow mode for taking over the control from speed controller in a smooth manner, The load control loop is illustrated in Fig. 8.9. The total loop can be divided in the 1. Load set point or load reference value (Pr. Value from LRS) Load gradient and TSE margin influence » » following sub-sections. > » > Load set point control or limiter (Pr lim value from LRL) > Pressure influence (PrAPR) Load Limiter Actual load acquisition (Pact) 2 3. 4, 5, Frequency influence (PrAf) 6. Z 8 Final Control Loop (Load controller, LC) 8.5.2 Load Set point ‘As shown in Fig. 89, Load setpoint can be changed from EHC cabinet, control desk, ATRS or from Auto dispatch centre (optional). The load set up point, called as load reference Pr, is set by potentiometer at a gradient of 100 MW/Min. The gradient remains same throughout the range. The load set point indicator is provided on control desk, with the range of 0-250 MW. 90PPPOE IEEE SS ee doo josuoy poo 68 Sut seijenuea, N =<) " soyeiguag, "2 = 128d Hs ! peor | MFiousg H= Ed 67 «20d vig ogy saisas Wirdsi0 aWo7 o1a! —>» > = te > <> > = > => > => => => => oe js ie VNU YY 45.3. Loud Gradient (dp/d) & TSE Influence Load gradient is an additional feature available in toad control loop, “The lond yeaa acts n parallel with TSE margin with a minimum selector (Fig. 8.9). Loud gradient ha sarge of 0-25 MWimin, While for TSE margin 0 ~ 30°K corresponds to 0-25 MWimin, (dire 4 TS) margin have got an ON-OFF switch, so if an: proportional). Both load gradient a jn desired to be taken out of service can be switched off If both are kept "OFF" then Prlim value changes at fixed rate of The one which remaing “ON! controls the output. MW/min . Load gradient setting Load gradient setting can be changed from desk or EHC cal in common for increasing as well as decreasing the load. However, TSE. upper margin controls reasing rate and lower margin control the load decreasi if the margins the load inc Jess than 30°K. The limiters for the margins are provided in such a way that positive upper margin {ig allowed to control Prim (hence it ean unload the machine) while negative lower margin isnot allowed to control the machine (hence it cannot load the machine) ly a block (STOP) influence is "ON" and TSE develops any fault, immedi wrong TSE margins are not allowed to control Prlim. To reset it, If TS! command is initiated so that F influence should be switched off from EHC cabinet, Before again switching on the the TS influence, the TSE fault should be rectified and acknowledged. $54 Load Set point Control (Prlim) ‘The function of this sub-section is similar to the one already described in speed control Joop. ‘The maximum rate of change here is 25 MW/min in both directions. ‘The follow mode and fast calibration (FM) signal are used for different purposes as explained below. The set point controller remains in follows mode. When generator breaker is "OFF" i) or load controller is "OFF" or load is less than block load (10% of rated load). During this mode Prlim follows actual load, This follow mode is must so that the Prlim is brought back to "Zero" after breaker opens. After synchronization Prim tracks the actual load (which is taken with speed controller) so that more time is not wasted in bringing the Prlim from zero value to working value, ii) During above follow mode fast calibration signal is given so that Prlim follows Pact without any delay. "STOP" command is generated if TSE fault appeats or any disturbance takes place in steam parameters, 92are not matching. 4 for TSE test when Prim and Pr are n snerator blocking command for iv) Generator i + Prlim is available in desk with a range of 0-250 MW. icator for Prlim is avai y) Indicator 4.5.5 Pressure Influence (Pr APR signal) Pi is ation of turbine in "Limit Pressure ‘A pressure influence signal PrAPR during operatio tur a wressure influence sign oe fo. Jdded in Prlim value ie. the output of load referencs limiter wh i I _ Mode" is added in Prlim value i« a ressure deviation. The correction of ++ 12 MW for the change of £4 kg/em® (linear relation. pressure deviation. The 1 ection allows the ise of MS. Pressure. This corre is implemented in order to prevent drop or rise of si sgure controller coming Joad controller to manage small pressure changes and prevents the pressta in to service in limit pressure mode. 8.5.6 Frequency Influence (PrA/ signal) int whenever drifts Frequency influence is used to correct the load set point whenever frequency Pr Af (load correction) 40 MW. Droop Characteristic Fig.8.10 Characteristic of Frequency Influence The frequency influence on load set point is shown in Fig.8.10. Depending upon the frequency deviation a load correction signal is generated. The frequency influence has got a droop of 5% (it can be changed from 2.5% to 8% in steps of 0.5% on line). Hence a deviation of + 0.5 Hz will cause a load change of + 40MW. The correction signal is limited at + 40MW. The circuit has got a filter so that normal hunting in frequency will not cause hunting in load. But if frequency drifts by even a small amount will cause load change. The frequency influence can be switched ON/OFF depending upon the requirement. Indicator for the correction signal is provided on control desk, with the range of 0-100 MW. 93 8.5.7 limit cme load% Load Limiter Final set point (after addition of Pi suggests if the Af to Prlim) is fed to a minimum selec\or more than load fi 85.7 final set point becom J for fast reduction of load i ‘As the name oad limiter. ‘The limiter also can be used 2 imiter will control the load. emergency cases. While doing so Pr (in tun Prid) should also be reduced, so that during XP oading load increases as per Prlim and not as per Joad limiter fare summed up with quency correction signal PrAy > Pressure correction signal PrAPR and fre Pr lim signal and find load setpoint Prabs 1s derived. This load setpoint (Prabs) forms the actual reference signal for load controller. 4.5.8 Actual Load Acquisition (Pact) ‘The actual generator load measurement 1S explained in Fig 611, Three load’ meaguring the actual Ioad. All the three transducers get signal ¢ for this transducer is 4-20 mA from PT & CT and give the output in mA. The ‘output rang 50 MW. These three signals are passed on 10 EHC cabinet for ue of the three is selected for further processing. If .d amount (5%) then a selective xb the working of the controller which corresponds to 0 - 2: n, The mean val alue by more than a certain fixes .d, The fault does not distur selection and fault indication any value drifts from other ¥ indicate is the defective channel. side on selection card once the faul fault alarm is generated and i ‘The fault generated can be ‘as the selection circuit discard It is rectified. acknowledged by switch available out $5.9 Final Controller Loop PI controller. The loop can be divided into two major Paris consisting 1y designed for this purpose. The final Joad set point (Prabs) The final loop is a of two clectronics cards special! > “> > > ™» Rp transducers are provided for \» S» ~» » ~»> > > > > > Y and actual load (Pact are entered into load controller Card. : From these two signals (Prabs and Pact) an error signal is generated. ‘The gain of the it frequency influence whose responsibility is in this card. This card has got an inbui ding of the turbine. Hence, ip it gives a correction signal to close th the frequency influence described this frequency influence acts only in one Joop is set i e valves. If to prevent the over-spee direction, ie. if frequency is shooting own, it will not take any action, Unlik d off, This card also detects the large error between set ond 51 Hz) and it changes the ake fast frequency is going d earlier, this influence cannot be switches point and actual value (if it exceeds 10% and frequency goes bey mode, the gain of the loop is increased to t controller to isolated grid mode. In this 94 a ll em mmm ROTI correction action.[avewosnsvoy peor go eTdeuTAE a i cs Gl ana Lk Sin AT 0A Su Gs & er geuTquo OHS geutquo] 2 abt [ LET PET, 2 seonpsuesz prot | [e sonpsuesy peoSo Se Se -) Ss » >» » » » o » » » » > > > > ’ J ) ‘The output of the above card is then fed to other card which provides th the imtegrator part af the loop. Apart from the integrator this card has also got a filter so that it doc ction if output of earlier card is hunting at higher frequency than the one set f oe! y cts a tor eard has also provision for follow mode. Two types of follow modes are availab indicat i) Follow above (hvo) + ‘This mode is in operation during following conditions a) Load Controller Off OR b) Generator Breaker off OR 1 ¢) Pact < Block load (21 MW) and AP > 5% During the above condition, the load controller output tracks the speed controller output 150 mV. This follow mode ensures that during above all the time with constant error of ot come into service. conditions, the load controller should n ii) Following Low (hvu) : nce the beaker is closed (synchronized) and speed This follow mode is present 6 1g this mode also the load controller output tracks the speed difference in this mode is that the load can take over) that due to this y delay after controller is still in service. Durin ¢ — 150mV, The only controller output with error of controller output ean go more than speed controller output (hence Joad controller but it cannot go 150mV below the follow mode, the load controller can be taken into service at any time without an: synchronization if desired. speed controller output. The advantage being The output of load controller is limited to +10v through first minimum selection circuit (explained in Chapter 8.7). The load controller output is known as hrPC. 8.6 Pressure Control Loop Pressure control loop is to maintain the pressure within the working range 861 Function of got two modes of operation, at all load, Pressure controller has i) Initial Pressure mode ii) Limit Pressure mode ‘The pressure contro! loop is shown in Fig.8.12 86.2 Initial Pressure Mode ‘A pressure deviation signal (difference of required pressure as per load and actu pressure) is fed to the controller. As long as the deviation is more than + 150m¥V (Actualsaad C19 ty doo7] jonuoy 24 YouINO) 991108 Hows Jenssdud I LOWML WHEY Yow1k0) wIT108 WoMs Fg WII ATe DeNss IEE Gee +! 001~ GOW auNssaud IWILINI Ieee ny awe ‘vo S115 DOTA over 97» » » o » » » » » » » > > y ) Pee ren et restore), the pressure) conoler ouput remains at satura fo the output of final minimum selection output (hence it is made ready to take over) ron fas the deviation becomes negative, the output of pressure controller starts decreasing. and it takes over the control, This mode should be used during start-up and initial loading of turbine. $6.3 Limit Pressure Mode ‘The function of this mode is similar to the initial pressure mode. ‘The only difference , pe eee ene ce being that a biasing of 10kg/em’ is given in this loop. pressure drops by more than 10kg/em?, This mode should be used once the Joad on turbine is stabilized. The output of pressure controller is known as hrPRC. 8.7 Selection Circuit When the turbine is running, one of the three controllers (speed, load or Pressure ¢ matched continuously for quick controller) will be exercising the control and others will b sfer of the control mode is transfer, ‘The selection of appropriate controller or the tran: ‘pesformed by the selection circuit. ler (hrNC), load ‘As shown in Fig. 8.13, this loop receives signals from speed control ler (hrPC) and Pressure controller (hrPRC) through a set of MAX/MIN selection and contro! selected is passed on to Admission Controller (Position Controller). The then the final value fanctioning of the system is as follows : > The signals h:NC and hrPC pass through a Maximum value selector and the value selected is passed on to first MIN value selection. 10.5 V is added in hNC and this value is also fed to first MIN value section, This is done to prevent over-speeding of the turbine. As soon as the turbine speed increases above the speed set point then the controller will give negative output, This output cannot passed through MAX value selector hence it limits the output through first Minimum value selector. The value selected in first MIN value selector is passed on to the second MIN value selector along with the output of pressure controller output (hrPRC). The value selected here is passed onto admission controller for positioning the control valves. All the three selectors (one MAX and two MIN Gates) have the provision to indicate that which value is selected. From this information, respective controller (which is in service) is indicated on control desk. The final output of selection circuit is known as hr. 98oe © bayjouu05 Jo Je)sU0N) {DID UONDeIa5 19 ‘Bly (Syau) 21-9 By AGING 5 (iu) pie 61g JB|ONUOD UORSWIpY OFi ion Controller) Admission Control Loop (Posi th 8.8 ‘Admission controller is the final control element in ELIC the admission derivative (PD) response of EH converter for the control deviation acquiir. For this controller input signal (hr) and the actual position of the turbine control valy As shown in Fig. 8,14, it received ( indirectly at the actuator piston of the E.H. Converter. signal (br) from selection circuit and the feed back signal from Collins transmi The output of the two ve and t s » S Sp purpose, two Collins transmitters are provided in the plunger coil Sy Collins passes through Min value selector (channel selection logic) as the range ism Ss the value selected is passed on to the controller. The controller compares the set point and the Sp _Bedback and then depending upon the error signal it bring the piston of Blectro-hydraulic hoe the desired position » fessure through the » up » y y The output signal of Admission Controller controls the secondary oil pr d the mechanically linked follo plunger coil of the EH Converter, the actuator piston an piston battery The balance point of ‘Some important points in this loop are as follows : Similar to an i) Plunger coil of electro-hydraulic converter is an integrator type the coil is — 1.0V (should be set anywhere between -0.8V to -1.2V). integrator if this voltage (-1.0V) is applied across the coil, the piston remains where it was. For moving the piston in open direction, the voltage has to be increased so if the voltage is made -0.9V (-0.9V is more than —1.0V) piston will keep on moving towards opening =1.0V. As soon as the voltage is restored to -1.0V, direction till the voltage is again made n is blocked. Similarly, if piston will remain in the position where it was, j.e. the positio voltage is made ~1.1V (-1,1V is less than -1.0V) the piston will keep on moving towards closing direction till the voltage is again brought back to -1.0V. ii) ‘The Collins transmitters used for a very accurate feedback of the piston position. The ‘output of the Collins varies from -8.0V to =10.0V, The 0,0V corresponds to position at which first control valve just starts opening and —10.0V corresponds to the position at which last control valve is just full open. A constant biasing of +200 mV is given for second Collins transmitter so as to avoid frequent changeover from one Collins to another. In case of wire breakage in any Collins transmitter, the respective card generates a fault alarm. If at any time the difference between the two Collins transmitters exceeds +700 mV, a fault alarm is generated. 100—-frow TORN 5 pee » DEVICE v ara i frre i lng 5 Ba 2 » er E eg 2 » nee Ct ae meals SELECTION -*#————} Is » 2 » g » FROM ADMISSION] BAT! €L * SELECTION ene > esl —el 4 CIRCUIT HYD (Fig. 8.13): ‘CONTROLLER “i EH-CONVERTER: HYDRAULIC « Ie |____|aCTUATION SYSTEM a > FOR CONTROL VALve| : POSITIONING HYD. CONVERTER Fig. 8.14 Admission Control Loopwate tidddd dd CONN TT ii alin “lla Lass. /) casera TL) Hi) There is « provision to switch ON/OFF the voltage supply plunger coil, I eee Sorc only eine oucut oF Admsion conser 5 more than (SV. This ensures that atthe time of switching OFF the piston of FHC is full open and sures that while switching ON, the command for there will not be any jump. Similarly, ite fall open is there. Hence, piston will not go down (hence valves will not close) once the coil is switched ON Il go to full during operation plunger coil wire breaks, the piston wil {As the piston goes to full iy) If at any time opening position and plunger coil fault alarm will be generated. igpen (position, the contol valves will also open fully. To control this, the hydraulic governor should be taken into service immediately. In this case tracking device is automatically switched off and load is blocked through limiting from SLLD and Hydraulic Governor Circuit (Ref: section 8.10.2). 8.9 Electro-Hydraulic Converter 8.9.1 Function ‘An electro-hydraulic converter is used as an interface device between the actuators of control valves and electronic control circuits. The EH-converter complies with stringent of the Electro-hydraulic turbine control requirements for actuating force and actuating speeds system. So the basic function of EH-Converter can be defined as the conversion of processed electrical control signal in to equivalent hydraulic signal to operate the control valves system. 8.9.2 Construction and Working Principle "he constructional details of EH-Converter are shown in Fig. 8.15. The principal components of the converter are Moving coil system (Plunger coil - 12) 2, Sleeve (10) 3. Pilot Valve (6) 4, Amplifier Piston (3) 5, Follow-up Pistons (21) Different transformer, LVDT (1) az Actuator (17) 102° ee=~ 3 ie 4 8 = 1 Differential transformer f 2 Amplifier casing 9 ion spring 3 Amplifier piston 10 Sleeve 4 Piston rod. 11 Casing suppor 5 Valve bushing 12 Moving coil system, 6 Pilot valve 7 Grooved tall bearing @ Control oit 8 Spring dics x Trip fluid Fig. 8.15 (a) Electro-Hydra: Section A-A ulic Converterana Fig. 8.15 (b) Electro-Hydraulic Converter Section DD “~» S| ae > |e Section D-D Oa ~ | > ~ | » > ae “> y i | a *» 7 pe ™ o> 2 LO atk, OD. o> eo ep > > > > ;16 Guide bott 20-3 | leave 21 Follow-up piston 22 Tension spring sae 23 Sleeve 24 Adjusting serew 1a, Control oil fc! Return oif for actuators of main control valves ch ‘A Follow-up piston A eehioteb piston for actuators of intercept control valves Fig. 8.15 (c) Follow-up Pistons Section C=C16 Guice batt 19 Lover 28 Sine 21 Follows piston Be ransion spring 24 Adoring sorew 2 feum ol! Seta Ol ston for actuators of main contol vies pt control valves ea A eee ae Pion for actuators of intara Fig. 8.15 (o) Follow-up Pistons age then oe Se Section C-C. 28 Lever 29 Limit switch 30 Adjusting screw ‘2, Control oif Secondary oi! © Return oit 104c via the adjusting screws istons “A* are connected 10 each othe Bushings and fotlow-up pistons “ ar Fig.8.15) (24, spring end pieces and the springs (22) (Refer Fis 6 eve (10) via the + operate the slee The control signals from the Electro-hydraulic converter ope! At en he control sign: eo i is sleeve slides up and down 07 a, moving coil system (12). This sleeve s ‘ oss d ea ines the position of the valve in the manner of a follow-up Pp and determines ition of the ing from ount of trip-oil flowing sleeve have ports which depending on the overlap, control the amount of trip connection "X". In the steady state condition, the pilot val ive is in its center position and the trip oil pressure acting on the face of the valve in equilibrium with the force of the compression : tangential holes in an spring (9). The pilot valve is kept in rotation by control oil flowing from tangen' i response sensitivity. integral collar to give greater freedom of reciprocal motion and achieve high respo! When the pilot valve is deflected from its center position, control oil from connection “al is admitted to the space above or below amplifier piston (3) with the opposite side of the piston ‘pened to the oil drain. The resulting motion of the amplifier piston is transmitted via lever (13) to the sleeves (20) which in tum can slide on the following up pistons (21). The secondary oil circuits, which are fed from the trip oil circuit via throttles (orifices) and supply the various actuating devices (HPCV & IPCV servomotors) are connected at point "b". The secondary oil Pressures are determined by the compression of the tension springs (22) which counter balance ‘he oil pressure acting on the follow-up pistons. Each follow-up piston and sleeve (20) has ports Which control the secondary oil flow according to the overlap. When the throttling area is changed by movement of the sleeve (20) it also changes the pressure in the follow-up piston causing it to follow the movement of the sleeve This varies the compression of the tension Spring (22) until equilibrium is regained between the spring force-and the new secondary oil Pressure. Each position of the amplifier Piston (3) corresponds to a specific position of the sleeves (20) and therefore the follow-up piston (21). ‘The position of the follow-up piston is the determining factor for the secondary oil pressure at point "b", BIZ Controlling Action with Electro-Hydraulic Converter When the Admission Controller gives a command to open the control valves, the sleeve (10) is moved upwards by the moving coil system (12), thus decreasing the oil drain area. This ‘auses the pressure below the pilot valve (6) to increase and the v alve moves upwards and opens he way for control oil from connection "a" to flow over the space below the amplifier piston (3), he following movement of the amplifier piston then slides the sleeves (2) down wards over the vers (13,19) reducing the drain area between the sleeves and the follow-up pistons, causing the -ssure in the follow-up pistons and secondary oil circuit to rise. 105 aeJoe Se Y We Ro > > ~ » » » » av y > y ) The motor of the amplifier piston (3) produces a simultaneous feed back action on th The sleeve (10) is moved back until the new pilot valve via. the differential transformers(1) position of the amplifier piston eauses the pilot valves to assume the oil pressure below the valve When @ command i and the compression spring force (9), piven to close the control valve controlling action is similar but in the reverse manner Adjusting Device for Valves ( Fig. 8.15-b, d) and the lever (14) of the rotary shaft (15) situated abo connected by the springs (22) of the follow-up pistons "B", the guide bolts (16) and the adjusting yws control oil a, to flow serews (30). During normal operation an energized solenoid valve allo The piston (25) is moved upwards against the forces nn springs (22) of the follow-up pistons "B' 8.9.2 c it are The follow-up pistons " under the piston (25) of the actuator (17). of the spring (26) and the initial tension of the tensio is adjusted by means of the lever (28, 14), which results in the IP control valves opening in relation to the main control valves as intended for this operation: 1PCV Trimming Condition : s than a set minimum foad and HP exhaust pressure ion, the solenoid If the condition ~ turbine load I greater than a set maximum value is fulfilled, for example after load rejecti 17) and allows valve will be de-energized. This blocks the flow of control oil to the actuator ( control oil under the piston (25) to flow into the oil drain pipe. The force of the spring (26) iston moves the piston into the lower end position and the tension springs (22) of the follow-up p "B are adjusted so that the intercept control valves do not begin to open until the HP control valves are wider open. This arrangement is also called as "IP Trim Device" which can be put into service by the operator on the turbine desk. 8.10 Common Arrangement Between EHC & HC (Linking) 8.10.1 Hydraulic MIN-GATE The two follow-up piston batteries ("A" & "B") of hydraulic converter and electro- hydraulic converter are connected in parallel to the respective secondary oil circuits, ie. HP secondary oil and IP secondary oil circuit. The governor with minimum set point control the turbine and secondary oil pressure with respect to this governor is developed through Hydraulic MIN-GATE as shown in Fig. 8.16. ‘ In fact there is no physical MIN-GATE in the secondary oil circuit. The follow-up pistons of the governor with highest set point allows constant oil draining rate through out the entire load range. However, the follow-up piston of the governor with minimum set point adjust 106 eesepPePPCPPOETEESS BOF! i AMA GIONSI05 (1007) UBHHOISNY HL WILN3uAs SIO = . SAS IO YSONMId $ WNLOV 7, Gin13 AuvaNooas @ ee Ton | 9 Glmy dieit p 1 NIV 9 s OIMS ABYONOORS AYTIKNY g = (91d 71H Gin AOWLNOD © (eee Ey s, Cy 19H26U09 ou nespyyaod aS Sy a ‘ “So > ~ ~ ng > ~~» ys » » » » > > > ) the draining rate with respect to other follow-up pistons in such a manner that the minim oil ire! secondary oil pressure with respect to controller in service is developed as per MIN-GATE in the seconda Therefore, this arrangement forms the hydraulic described in Fig. 8.16. ; 8.10.2 Tracking Device for Hydraulic Governor .d-by during normal the 100% When the EHC is in service and the hydraulic governor is Kep! jovernor is set to operation of the turbine, the speed set point of hydraulic speed es position (speeder gear position). ves of the turbine would tend to open fully EHC and to keep the In case of a failure of the EHC, the control val le of the 100%). To prevent this extreme response due to failure of turbine generator in the same magnituds "start-up and load (EHC positio: control valves and accordingly the load of the a tracking circuit is provided for the gh hydraulic load called for before the ENC failure, limiting device", limiting the set point for the position of the control valves throu governing circuit. ‘The functional block diagram of hydraulic speed governor with SLLD and wracking arrangement is described in Fig. 8.17. The tracking device maintains the set point for the position of the control valves of the hydraulic controller during stand by mode approximately 5 to 10% (adjustable) above the set point issued by the EHC. ‘a small transient load increase will occur Due to the slight difference in the set points, yy from upon transfer from EHC to HC. The tracking device can be switched on and off manuall: the turbine control desk. is automatically To prevent sudden load changes after certain failures, the tracking device i switched OFF in following cases : © In case of certain internal faults of the EHC (to avoid tracking of the HC when the BHC drifis to the 100% position). Incase of a turbine trip. 8.10.3 Load Rejection Relay (LRR) The Load Rejection (Shedding) Relay constitutes a supplement to the hydraulic controller (see Fig. 8.17) to ensure that the speed of the turbine generator is kept safely below the response value of the mechanical-hydraulic over-speed trip device during load rejections. 108PAAAEIO OEE ST © © JuaWIeBUoUY BULyoOI) YIM JE]ONUOD DINOIOAH Z1'9 ‘Old (yt'@'Sld) NOLISOd SH 3DIAIq ONDIOVAL uy, 19V avo ——— >} 2801 AVIRA NowSaray dVo1 NOUISOd 3AWA | OUND IN NO/440. JDIAIG ‘ONIN GVO7 GNV da-lawis | ONINONISOg aATWA 4 % 001-07 xsmor TOINOD., Asia 4x01 SANSS3Yd TO AIVWig 8V39 Ysaaaus + 30130 ONILYALOW 483183ANOO) — SNNWAGAH,‘The relay is mostly necessary when the hydraulic Governor is controlling, but is also Kept Ss in operation when the EHC controls the turbine generator. Upon action of the LRR, the HPCV & IPCY are closed completely for a short interval (1.4 sec. max), supporting the hydraulic control system, For activating the LRR following three conditions have to be fulfilled. io Mie) Load throw-off more than 50% of rated load Se i)__-Remaining load less than 20% of rated load RD i) Frequency more than 49 Hz » The LRR measures electrical load rejections of the generator. Any load rejection of the o ntaneously by the LRR and ~~ » » » y ) turbo-set, i.e. a Jarge negative load change, is therefore acquired instan is then transformed in to an electrical pulse, the duration of which is related to the magnitude of the load rejection (Percentage of full load). ‘This pulse energizes two solenoid valves © One solenoid valve connects the auxiliary secondary oil (hydraulic out put signal of hydraulic speed governor) supply line to a drain, causing a rapid drop of the pressure of that fluid and therefore closing of the HPCVs & IPCVs (Fig. 5.4) The second solenoid valve connects the secondary oil of IPCVs to a drain, causing those valves to close faster than only the action of the first solenoid valve (due to its hydraulic characteristics). Accordingly, all control valves of the turbine close at a maximum speed. The fast response of the LRR is caused by measuring the change of electrical generator load which precedes the later speed increase. The LRR acts therefore earlier on the hydraulic control system, i.e. before the HC takes action due to the speed increase. After the electrical pulse, issued by the LRR has ended the solenoid valves will close ‘Auxiliary secondary and secondary oil pressures will build-up again, by this time ion corresponding again. hydraulic governor will resume control of the turbine control valves to a pos to the new generator load. To prevent any response of the LRR at frequencies below rated frequency, a frequency ack out is employed. If the transmission system is operating below rated frequency while a load jection occurs, without this lock out, the LRR will issue its signal and cause the control valves close immediately. After its signal has disappeared, however, the hydraulic speed governor il find a big mismatch between the actual speed and the hydraulic speed set point causing the bine control valves to open rapidly and in turn accelerate the turbine that it most likely will 110( et or | ove 00's ool ae ai as oor ogy 06 : 3 98 ose osy 08 Oo ty 00 iy oz 004 — os ss Lot vee 09 00'9 a ws oe ost ove os 00's 9 004 O56 vey Ce TU ore or 00" = ve Ose ve St EE 806 Of coe y a su st a os 08% 0% 0% e eso so. “i » OZ ere ol z : ae : ie TRE on 0 Lodeiiers | aem anit | soowesesn | Sle, | “lowed vossupy) 200A A /nchno 5} seE)2944 10 AmpuCaES PARAAR AAA ~ a ioiz.0} 1onu09 2yncIpaH-O4 19 s9jo1u05 2OUSHIWPY! 19819 40 SoYuaLIOIOUD ge OH ) @BOYOA LOD OHA s y © a a 7 ulo/® uj eunesell NO AYepucoes ‘a'1 pus aH ot 4 os oz 06 % U] UoHIeod ‘OHSLRR signal below a, frequency relay blocks the jp. Therefore, the run in to an over speed tip ot ae « frequency is exceeded again A when this frequency 1S 9 eleases i adjustable value 49 HZ, 4 8.10.4 IP Trim Device ot takes place then governing dden drop offload of turbo-set takes P sration of turbine sudden dre If during operation 2 load while the IP contro) 1 valves immediately to control the loa p control valves ii y system will close the HP contr are maximum load out of his will cause the IP and LP turbine to share valves are still wide open. This wi . T exhaust pressure to rise the turbine, This will effectively cause HP the balance load on the tut . BR ea » "Trimming Device" is provi bnormally and also the exhaust hood temperature. Hence, the "Tr : wae abnormally and also o eee ‘ for IP control valves which is operated to control the HP exhaust hood temp for IP control valves which is c device will be operated if following condition is fulfilled: % -d load. HP exhaust pressure > 32Kg/em’ and generator load < 20% of rate When the trimming device is operated, IP control valves are closed and do not tend to open unless HP control valves are opened wide. Trimming device is operated through the solenoid operated actuator provided to adjusting device for IP control valves. The operation of adjusti device is already explained in Chapter 8.9.4. The facility to make the trimming device ON/OFF is. provided on turbine control desk. 8.11 ENC Characteristics The electro-hydraulic controller characteristics, i.e. EHC output voltage (0 — 10V) verses SHC position, HP/P secondary oil pressure and HP/IP control valve opening are plotted in Fig. 8.18. The readings of EHC for typical 210 MW KWU turbine are recorded in Table 8] -o0o->» » CHAPTER-9 » TURBINE PROTECTION SYSTEM 9.1 FUNCTION ‘The function of the turbine protection system is to trip the turbine by instantly closing » » stop and control valves of HP and IP turbine thereby cutting off the Steam supply. The obligatory » turbine protection covers following functions: » > Protection of the turbo-set from inadmissible operating conditions. SD > Itprevents consequently damage in case of plant failure. SD > Itrestricts occurring failure to a minimum. » 9.2 Mechanical-Hydraulic Turbine Protection ‘\» 9.2.1 Details ‘> The comprehensive Turbine protection schemes is explained in Fig. 9.1. The design of the: > mechanical-hydraulic protection devices are in accordance with the hydraulic break current y principle and consists of - » > two tripping devices (Turbine Trip Gear) i.e. Main Trip valves MAX 51 AA00S and MAX » 51 A006 with integral manual trip arrangement. > > Two overspeed trip devices 1 & 2, MAY 10 A001 and MAY 10 A002 > J ’ > One Thrust Bearing Trip Device MAY 10 AAOI1 Two solenoid Valves for trip initiation (Remote trip devices 1&2) MAX 52 AAOO1, MAX 52 > AA002. 9.2.2 Turbine Trip Initiation By means of the tripping devices trip oil pressure is rapidly reduced. During normal operation, control oil MAX 42 and trip oil MAX 51 (Ref. Fig. 5.1 and 5.2) are connected via the tripping devices which keep the stop valves open. The tripping devices remain in operating position by Auxiliary Trip Oil MAX 52. If the trip oil pressure is reduced (e.g, leakage) or the auxiliary trip oil pressure falls below a certain value (e.g. response of protective device operation), the pistons of Main Trip valve MAXS1 AAQOS & AA006 move to trip position(downward) by spring force. ‘Thereby the trip oil circuit get connected to the drain and trip oil pressure drops to zero, causing the stop valves and control valve to close by spring force. In order to start-up the turbine, the main trip valves are latched in (reset) by auxiliary start-up oil MAX 48 generated by bringing SLLD to "zero" position. 14Electrical Trip ‘Channel —1 2 Condenser Pressure > 0.3 kg/em’ abs Lube Oil Pressure < 1.2 ke/emt (are protection Operated OR M.O.T- Levelitoo Bre j <=Main Steam Temp. <460°C (latching at 510°C) i } Turbine Trip Push Button Operated (Turbine Desk) ! 225 mm) (Mech-Hydraulic Trippings) Electrical Trip Channel -2 / 0.35 kg/cm? abs). Tripping the turbine stops the steam flow to the condenser via the turbine. The alarm “Mechanical vacuum Trip” along with standard turbine trip alarms are initiated in the control room. Tripping of the turbine due to poor vacuum in the condenser occurs via electrical trip signal (cond. pr. >0.3 ke/om® abs) before the mechanical vacuum trip value is reached. 116" i 0.3. Eleetrical-Hydraulie Turbine Protec ion. jc: 93.1 Arrangement rough “OR steria (Fig. 9.1) routed throug! principle, All wip criteria (Fig: 9 fe a functioning on the operating current eae i / jergize turbine trip rela oe 3 Eee ed), The clectrical-hydra ee, | ated valves (solenoids are energized) ioe oT di valves (RIVI & 2) MAX 52 | > Two solenoid operated valves initiation. annels 1 & 2). trip contact cabinet (CJJ10 containing the trip chi > ‘The emergency trip contact c > Monitors with signal conditioning ine trip signals during ted transmission of eventual turbine trip sig 4 e uninterrupted transmiss > A special channel to assure uninterrup testing by the ATT. 9.32 Remote Trip Devices 1 & 2 The solenoid valves for trip initiation (RTV 1 & 2) serve as interfaces between lectrical turbine protection and the mechanical - hydraulic turbine protection. If these valves ai energized auxiliary trip oil is connected to the drain. The operation of any one channel is sufficient to trip the turbine, 235° Monitoring and Signal conditioning Transmitters that cause a trip in case of response are conditioned and monitored via the binary signal conditioning of the ATT (Automatic Turbine Tester) or via the central analog/binary signal conditioning, 234 Turbine Trip Equipment during test by the ATT During test by the ATT trip signals are simulated, Clo: by the change over valy. sure of the stop valves is prevented e which interrupts trip oil loo} AA005/6 and the stop valves ip between the tripping devices MAXS1 Protection of the turbo set during test is guaranteed by a special de-energizes two solenoid valves (solenoid valves during test 1 é& A202). Functioning on the break eurrent principle they switch trip oil loop over to drain and cause the stop valves to close. Chapter 12 dealing with ATT. logic in the ATT cabinet which 2 MAXS1 AA201, MAX 51 More details are provided in the 935 Turbine Trip Actuation Circuits The actuation circuits of the turbine protection equipment are sub-divided in : > Protective Circuits of the standard turbine protection equipment 7 eM els with redundancy, ependent chann .quipment features two indepen’ pine trip equip ‘The electrical turboe os » oe & w Sp Se ‘> ‘e ~ ~ ~» » » » » ) »& Protective criteria from other areas, 9.3.6 Electrical Low Vacuum Protection (Condenser Pressure high) If the pressure in the condenser is too high, turbine trip is initiated in order to protect the condenser and the LP blades. This is initiated at condenser pressure > 0.3 ke/em’ abs. Besides the hydraulic low vacuum trip device, the electrical condenser pressure switch is provided When the turbine is started-up, the pressure switch is interlocked against a pressure switch, which monitors this operating condition, in order to prevent trip initiation during condenser pressure is still high. 9.3.7 Lube Oil Pressure Protection Turbine trip is initiated if the lubricating ofl pressure is too low and therefore adequate supply of the oil to the bearing is not ensured. Hence the turbine is tripped when the lub oil During shut down of the turbine the auxiliary oil pump (AOP) pressure drops below 1.2 kg/em*. ensures sufficient oil supply to the bearings. 9.3.8 Fire Protection Tripping of the turbine during fire hazard can be initiated cither manually by means of fire protection push buttons 1 & 2 or through the M.0.T. level too low. With operation of fire protection, the control oil supply to the governing system is interrupted through the oil supply emergency shut-off valve (explained in Chapter 5.3.2.) thereby tripping the turbine. 9.3.9 Manual Turbine Trip This facility enables the operating personnel to trip the turbine by pressing the “Turbine Trip” push button provided on the desk during emergency. This protection is acted through the electrical trip channel. 9.3.10 Other Electrical Protections > Main steam temperature drops below 460°C. This protection comes in to service (Arming or Latching) when the main steam temp. crosses 510°C. After that if the temperature drops below 460°C, there will be danger of turbine metal cooling and the reversal of stresses. Hence turbine is tripped at this value. > Turbine tripped from ATRS. When the shut-down of the turbine is effected from ATRS shut down programme, at appropriate step turbine trip is initiated by ATRS. 118ens eon yesaecd a poo The oe when tewker eee we were 6 cmmtitnen is ther cqperatinn Seemttanccunly wartime wip a See datay o proven ile D> Rrwee tewel Very Migh If the dram level in greater than 22 mum, the turbine tip abowng wh Inodhes wep os ioetamedt Ths os an cinder te prevent catty over of ria ate> > > » > » » s) » y > S ma ~ = CHAPTER-10 HYDRAULIC PROTECTIVE DEVICES 4 s 10.1 Trip Devices ‘As diseussed in Chapter 9.2, mechanical-hydraulic protection $9516 comprises of following hydraulic Trip devices. 51 AAO0S and A006 1) Main trip valves 1 & 2, MAX & 2, MAX 52 A001 & A002 2) Remote trip solenoid valves 1 3) Overspeed trip device 1 & 2, MAY 10 AOD! & AA002 4) Thrust Bearing Trip, MAY 10 AAOIL 5) Low Vacuum Trip, MAGOIAAOI1 40.2. Main Trip Valve (MAXS1 A005 & 44006) 10.2.1 Function ‘The function of the main trip valve is to open the ‘op and contro! p oil circuit in event of abnormal I valves of turbine. conditions, thereby closing the Main and Reheat st 10.1. The assembly consists of ynes (1, 21). During normal d, Lower section 10.2.2. Construction and working ‘The assembly details of main trip val the valve (14), rod (7) and spring (18) and lever (3,4) with limit switel operation, valve (14) isin the position illustrated in Fig 10.1, ie. fully upwar a differential piston and the resulting oil pressure forces the crowned and the force of the Ive are shown in Fig. of valve (14) is designed as rim of the valve tightly against the body (16) over coming its own weight spring (18). pressure oil (Trip oil rom RTY) enters the body (11) through connection a” (Fig. 5.1) From there it flows up through the annular passage to trip oil connection "X" and on to the main Pressure oil flows to auxiliary trip oil circuit from ‘and reheat stop valve trip oil circuit. via passages drilled in body (11), which leads to the overspeed trip valve, the connection "X" thrust bearing trip and the vacuum trip (Refer Fig, 5.1) 10.2.3 Operation If for any reason the oj opening of auxiliary trip oil circuit or closing of RTV, 01 lownwards due to its own weight and the adjustable force of spring (18). This connects il pressure in the connected lines drops below a specific value (By 1 leakage in trip oil circuit), valve 14 moves di 120TT eS 1 Limit Switch (Manual Trip-out) 2 Ball Knob 3 Lever 4 Lever 5 Sewcrew 6 Nut 48 Compression Spring 19 Spring Dise 20 Bonnet 21 Limit Switch (urbine Tripouy) 22 Cylindrical Fin 23 Cylindrical Pin ket 25 Tension Spring 25 Hexagon haad screw 27 Protective shield U Auxiliary Startup Oil x Trip Oil x1 Auxiliary Trip Oi! Fig. 10.1 Main Trip Valve 121UO “» S> ~ ~» ‘> > ‘> ~» > » » » » > > » . 8X* and "Xi," connection with drain connection "C", thus de-pressuring the trip oil circuit ra 3 idly of hydraulic speed governor, hydraulic converter and EH Converter is shut off therefore causing HP and IP control valves to close. result in closing of HP and IP stop valves, Also, the trip oil supply to the follow-up piston ed manually by means of lever (3), thus opening the trip oi} »U") coming from “The valve (14) can be depress focal trip), When starting the unit, the auxiliary start-up (connection the valve (14) again to its upper oil keep circuit (l starting and toad limiting device ("zero position) brings operating position. ‘Then in the absence of auxiliary start-up oll pressure, auxiliary trip the valve in operating position. ‘out signals to the control Limit switches (1, 2) are provided to initiate electrical ip room, Limit switch (1) operate upon a manual trip out (by pressing lever (3)) and limit switeh @1) ona trip out caused by a collapse in pressure inthe trip ofl circuit 10.3. Remote Trip Solenoid Valve (MAX 52 AA001,AA002) ‘10.3.1 Function (Ref. Fig. $.1,5.2) pipe to the main trip valve. When this The solenoid valve is installed in the pressure oil ip signal from electrical protection system, valve is operated by energizing the solenoid due to i lve to close and rapidly valve interrupts the oil flow to main trip valve. This causes main trip vi reduce the trip oil pressure in the trip oil circuit. 10.3.2 Construction The assembly details of RTV are shown in Fig. 10.2. ‘The valve body (15) has three connections : 0 Pressure oil (Control oil from filters) inlet (2) 0 Oil to main trip valve (13) 1 Oil drain (17) ‘The directions of flow are indicated by arrows on the body. The vale1 Solenoid — 2 Magnetic snorteircur sleeve, complete 3 Compression spring 8 Stem with cone 9 Bushing 18 Oring 11 Pine 30 12 Stem with piston and i—n1 ‘nwo valve discs 12 13 Connection of main trip valve LEILA ZZ-RSSS ZNeN y14 21 Using 22 Ong 23 O-ring 18 24 Filter, complete 23 V-ning 26 Backing ving 16 27 Washer 28 Cirelip 29 Washer 20 Armature, complete Fig. 10.2 Remote Trip Solenoid Valve10.3.3 Operation When the solenoid (1) is not energized, the armature (30) is held down by the spring (2). lower valve seat in the three-way valve(7). Whe! Sy andthe stem @) seals the SS open, the space between the piston of stem (12) and the bushing (9) #8 linked with the oil drain Sine The piston is forced upwards by the incoming pressure oll, whereby the lower s valve aise ofthe stem (12) comes in contact with the ower valve seat(L4) and closes the oll Grain nn the valve seat (6) 1s te (17), The pressure ol can nov flow to the main tip valve through eennection (19) The armatureG0) is The solenoid valve is operated by energizing the solenoid(1) inst the force of the spring (3) and the valve dise of the steam (8) is forced against into the space between the attracted agai Ive seat(6). Pressure oil can now flow through the filter (24) is forced down wards, the uppet the val linked with oil piston on the stem (12) and the bushing (9). The steam (12) ‘The connection (13) is thus valve disc bearing down upon the upper valve seat. outlet, and the pressure in the pipe to the main trip valve collapses: 10.4 Over Speed Trip Devicel & 2 (MAY10 AA001,4A002) ‘10.4.1. Over Speed Trip Arrangement & Mechanism 10.411 Function & Arrangement ‘The function of the overspeed trip is to stop the turbine when the permissible speed is exceeded. In Fig, 10.3, the arrangement of overs wy _is ited in HP turbine shaft (7) located in front bearing the adjusting serew (6), the spring (5) and the sorew plug (1). peed trip mechanism is shown. Overspeed trip pedestal. It consists of eccentric bolt (4), ew (6). By appropriate The overspeed trip mechanism is set by the adjusting sc to the turbine » > ajustment ofthe serow, the centre of gravity of bolt (4) is positioned eccentrically > shaft so that below the tripping speed the bolt is held in the position shown by spring (5) against > J the centrifugal force. In this position, the bolt bears against the serew plug (1). If the turbine rotational speed exceeds the overspeed setting, the centrifugal force overcomes the force of the spring (5) and forces the bolt (4) out of the turbine rotor. This activates the turbine automatic stop mechanism. 104.2 Overspeed Trip Device 104,21 Function The function of the overspeed trip device is to open the auxiliary trip oil circuit and thereby shut down the turbine when an over speed is reached which would subject the rotor to dangerously high centrifugal force. 1248 Quran 9 bo 9 Shaft jo 10 Limit wach © Rewurnoit & Auxiliary on X Auxiliary trip ov. Fig. 10.4 Overspeed Trip Device% a AWS WL dig, ~> “> “> »> > > > > > > > > ) @ a valve body (5). ist 10.4.2.2 Construction “The trip device situated in the front bearing pedestal (1) consists of ‘and pawls (7). The spindles (2) resting against the pistons (4) actuate the limit switches (10). nal (©) 10.4.2.3 Shut down by Overspeed Trip wrates, the eccentric bolts fly out of the shaft jour The latches igainst the force of the springs (6). shaft (9) due to the The When the overspeed trip opei thereby striking the pawls (7) and rotating these aj celease the two pistons (4) which, in turn, move down wards the sl "xX and the spring loaded spindles (2) of the pawl r force of the auxiliary trip oil pressure connected to process opens the oil drain line "C” to the auxiliary trip off shut down due to the drop in trip oil pressure, 1 "x", thus causing the turbine to be 10.4.2.4 Electric Trip-out Signal s on trip-out, these spindles assist in ‘The spring loaded spindles (2) reset against the piston: (10) which transmit an electric trip out ‘moving the pistons inwards and actuate the limit switches signal to the control desk. 104.2.5 Testing the Overspeed Trips ‘The proper functioning of the overspeed trips is of the utmost importance °S severe The overspeed trip testing device (4 piston (4) and spindles (2) and permits alt in chapter of damage may result from excessive speeds. ATT), services for checking the overspeed trip bolts (8), the overspeed trip to be tested during operation of turbine 104.2.6 Latching-in of Device ‘After the turbine has been tripped out, the automatic trip gear must be latched in (reset) before the turbine is restarted, This is done by admitting auxiliary start-up oil from connection "U" (provided from SLLD) to the valve body (5) thereby forcing the respective piston (4) The supply of oil is then interrupted and the oil outwards until it engages the latch of the pawl. in the body drained via a bore into bearing pedestal (1). 104.3 Overspeed Trip Test Device 104,31 Function The function of the overspeed trip test device is to test and exercise the overspeed trip. The overspeed trip consists of an eccentric bolt which protrudes out against the force of a spring under the effect of centrifugal force during an overspeed condition. The bolt strikes a pawl and thus opens the trip oil circuit so that the stop and control valves immediately interrupt the 1261 Hancwheet 2 Limit switch 3 Reduction gear with motor 4 Guide piece 5 Coupling 6 Valve 7 Guide bushing 8 Valve block 9 Rod with ball knob 10 Guide piece 1 Compression spring 12 Valve 13 Rod with ball knob 14 Compression spring 15 Valve 4. Control oil a1 Test oil for testing overspeed trip © Drain U™ Auxiliary start-up oil from starting device 5 UT Auxiliary start-up oil for latching in overspeed trip 1 x Auxiliary trip oil x1 Auxiliary trip oil to overspeed trip valve Fig. 10.5 Overspeed Trip Test Device9 Rod with ball knob 10 Guide piece 11 Compression spring 12 Valve 13 Rod with ball knoo 14 Compression spring 15 Valve 2 Control oil 21 Test oil for testing overspeed trip Start-up oil from starting device start-up ail for latching in overspeed trip © D uA 110 overspeed trip valve Fig. 10.5 Overspeed Trip Test Device x A trip x1 Auxiliary trip oiadmission of steam to the turbine. It is therefore of major importance that the overspeed trip ‘operates reliably. ‘10.4,3.2 Construction & Test Operation Bs ‘The over speed test device is shown in Fig 10.5. It consists of three valves (6 combined in valve block (8). Valve (12) is held in the position by spring (11) which b against guide piece (10) and rod (9), In this position auxiliary trip oil can pass to the overspeed SS trip release valve via connection "x" and "x ". When knob (9) is pushed in and held, valve (12) ys is positioned so that connection "x" and "Xi" are separated from cach other, thus blocking the auxiliary trip oil circuit from the overspeed trip release valve. A small quantity of oil is permitted fo pass valve (12) during this operation which ensures a pressurized line fo the overspeed trip release valve after a test .Valve 6 performs the function of admitting test oil to the eccentric bolts of the overspeed trips,causing them to protrude from the turbine shaft during the overspeed test operation. Valve (6) is guided in guide picce (4) and bushing (7). A center bore with radial opening: is provided in valve (6) (see section "A-A"). A annular chamber in bushing (7)'is connected to control oil connection "a". In the position shown in the figure, oil is prevented from entering the bore of valve (6). By means of hand wheel (1), valve (6) can be moved inwards so that the passage from connection "al" is blocked from drain "c". Control oil can now flow from connection "a" via bushing (7) and valve (6) to connection "al" for testing the overspeed trip with the automatic turbine tester. Limit switches (2) are used for transmitting valve (6) position signals back to the control room. Valve (15) is used for resetting trip release valve after the test operation. When knob (13) is pushed in against the force of spring (14), valve (15) is positioned to provide control oil from connection "a" to "U1" thus latching-in the over speed trip valve. <» ~~» ~> “> ‘> “ » > > > » > > During start-up, connection "u" and "u1" provide a passage for auxiliary start-up oil for latching- in the overspeed trip release valve. Passage in valve block (8) are provided to carry any leakage oil from the valves to drain "c". 10.5 Thrust Bearing Trip Device 10.5.1 Function In the event of axial displacement of the shaft due to excessive wear of the thrust bearings pads, the function of the thrust bearing trip device is to open the auxiliary trip oil circuit, thus shutting down the unit to avoid damages. 128Section A~A Fig. 10.6 Thrust Bearing Ty rip Device 4 Compression spring 2 Bearing pedestal 3 Piston 4 Valve body 5 Turbine shaft 6 Pawi 7 Torsion spring 8 Piston 2 Compression sprin 10 Knob, u Test oil Return Auxiliary start-up Auniliary trip oil> » » » » » » » S % e » » ~» . » » » » > y Phe main parts of the trip device. 10.5.2 Construction On start-up, the ng trip device is shown in Fig, 10.6. phe thrust beat situated in bearing pedestal (2),are the valve hody (4). piston (3) and Pawl (6). 'u" moves the piston and pawl in to the latched position. auxiliary startup oil 10.5.3 Operation When the shaft (5) becomes axially displaced, the pawl (6), which is between the two ‘cams on the turbine shaft, engages one of these cams. The pawl (6) which is suspended to allow rotation, releases the piston (3) which moves in the direction of the shaft (5)due to the foree of The auxiliary trip oil "x" is thus pressure in the spring (1) and the unbalanced auxiliary trip oil pressure connected to the oil drain "c" via bores in the valve body (4). The resulting drop in the auxiliary trip oil circuit closes the turbine stop valves and shut down the unit isin 10.5.4 Test Device It is utmost importance for safe operation of the turbine that the thrust bearing trip It is therefore essential that the device be tested at regular proper working order at all times. intervals. This is done by admitting fest oil to the space above piston (8) through connection "a whereby the force of spring (7). The response of the thrust bearing trip is thereby tested 10.6 Low Vacuum Trip Dev 10.6.1 Function ‘The purpose of low vacuum trip is to operate the main trip valve when a failure of vacuum occurs in the condenser, thus tripping out the turbine stop and control valves and shutting off the supply of steam to the condenser via turbine within shortest possible time. 10.6.2 Operation The low vacuum Trip device is explained in Fig. 10.7. The condenser vacuum is * connected via "I" (connection to condenser) to the top side of the diaphragm (8). The space below the diaphragm is at atmospheric pressure. Upon failure of condenser to maintain proper vacuum, diaphragm (8) is forced downwards by the increase in pressure and the force of the spring (7) against the force of the spring (10), thus moving valve (9) downwards. This establishes a connection between "x," and drain "c" so that the auxiliary trip oil circuit is depressurized and the main trip valve operates. Concurrently, valve (11) actuates the limit switches (15), which initiates an alarm contact. 1301 Casing 2 Piston 3 Guise 4 Limit switch (condenser protection ready for operation) 5 Adjusting screw 6 Stem 7 Compression spring 8 Diaphragm 9 Auxiliary pilot valve 10 Compression spring 11 Valve 12 Casing 13 Compression spring 14 Diaphragm 15 Limit switch 2 Control oil © Drain 3. Primary oil x1 Auxiliary trip oil 1 Vakuum Fig. 10.7 Low Vacuum Trip Devicein ‘a ie te nina of MAL Drains AILM.S., CRH & HRH line drains open and SLC of M. 6. built-up. HPILP Bypass system charged and steam parameters are bui Ensure: © _HIP/L.P Bypass valves on "AUTO' e depending * Steam condition are built-up as per start-up procedure dep. on HP casing temperature. ¢ For Example, during cold start-up: M.S. Pressure = 32-35 ke/em? MS. Temp, = 330°- 350°C M.S. Flow =95— 100 vhr. HRH Pressure = 10-12 kg/em? HRH Temp. = 330°C -350°C Generator protections are reset Ensure: * Hp Pressure : 3 ke/em? * Seal oil system maintaining dp = 1.5 kg/em? * Stator Water system in service * All protection relays in reset condition Criteria for opening HP stop valve (ESVS) are fulfilled Ensure: * Main steam conditions are such that criteria Xi, Xo,X3 are "Fulfilled" Turbine Reset operation Refer Fig. 11.1 showing the governin Operation : Set Starting and Load Limiting Device (SLLD) to "zero" Position, Ensure: All ripping orters of turbine are cancelled (Reset) ¢ Turbine trip solenoid supply "OK" and Oil Pressures as follows : a) Control oil pr. + 6,5 Kelem? (> 5 kg/em?) 137 ee ew were se Jefe — FF 7. cg e284 SII IIIb) Trip oll pr. teed Giiges) ©) Start-up oil pr. = 6 ke/em* 4) Aux. start-up oil pr: 6 Kg/em* ) Aux. trip oil pr. = 5.5 kg/m? Note: Ifcontrol oil pr. is less, rotate the filters in governing & ATT oil circuit 10. TSE Margins normal Ensure: ‘¢ TSE is selected in Admission mode ‘+ TSE influence is "ON" ‘« TSE upper temp. margin » 30°C » a» » » ~ ‘11.2.2 Starting up turbine with EHC. S >» (After completion of procedure stated in Chapter 1.2.) 1. Keeping hydraulic Governor out of service Operation: Raise speeder gear position to 100%. “> 2. Opening of emergency stop valves (HP stop valve) ba Operation: _« Raise starting device (SLLD) position to 42% ~» Ensure = ¢ ESV Close indication Resets (disappear) “~ # SV Open LED Lamp glows ~> 3. Opening of Intercepter valves (IP Stop Valves) ; Operation: _* Raise starting device position to 56% * Make tracking device "ON" ( Ref Fig 11.1) Ensure: ¢ [V Open LED Lamp glows Trip oil pr. : 5.5 kg/em? © Start-up oil pr= 0 * Aux. Start-up oil pr. = 0 * Aux. Trip oil pr 5.5 kglem* “p “p> “» Control oil pr. 6.5 kg/em*™ ~» >o .O.Pil, "OF" at 5401 ‘Turbine speed stays at 600 P10 s are normal. «All turbovisory parameters &f° Observe following para appro’ 0 following values i ers approximately i serve following parameters em? Control Oil Pr. 6.2 kg/em Trip Oil Pr. 5.2 kg/em* Aux. trip oil pr. 5.5 kg/em HP Secondary oil pr. : 2.6 ke/em” FP Secondary oil pr. : 1.7 ke/em 6. Turbine trip healthiness test and re- ling Operation + Press "Turbine Trip" rush button Observe « Turbine trips and trip indications appears # ESV,IV closed, JOP and turning gear pick up e abov re. ‘Nore: Roll the turbine to 600rpm again by repeating the above procedti 7. Speeding up to Rated speed (3000 rpm) Ensure X¢ criterion (soaking of HP turbine) is fulfilled TSE upper temp. margin > 40°C Operation: Raise speed reference to 3000 rpm at a stretch Observe Vibration level at critical speed 1545 rpm é& 2126 rpm © Axial Shift < + 0.5mm © A.O.P. trips at 2800 rpm © M.O.P. discharge pr. 9.7 kg/cm? © Turbine speed stays at 3000 rpm © Governing oil pressures as follows : : 8.5 kg/cm? : 7.5 kp/em? - Aux. Trip Oil pr. : 7.5 kg/cm” - Aux, Sec. oil pr. : 3.8 kg/cm? - Control oil pr. - Trip oil pr. -HP Sec. oil pr. : 3 kg/cm? -IP Sec. oil pr. 2.8 kg/om? -Primary oil pr. ; 2.3 kp/em? 8, Synchronizing and load raising to block load Operation: Switch "ON" Load control 139* Set load reference 10 20 MW (Ref, Fig. 11.1) ‘ Sct load limit to 50 MW (Load reference setter) © Switch "ON" Load gradient Set load gradient to 20 MW/min. (dp/dt set.) ‘¢ Switch "ON" HP/IP trip device Select "Limit Pressure Mode” * X; criterion is fulfilled (IPT soaking) Ensure © All turbovisory parameters are normal Observe: * HPCV position 20% + IPCY position 5% Operation: — Synchronize the Generator ‘« Increase the speed reference pulse-by-pulse to load the turbo-generator to 20 MW Observe * Load controller comes in to service at about 20 MW Load (Speed control, LED "Of" and load Control "ON") Note Further loading can be done by raising the load reference the M.S. pressure & TSE upper load margins time-to-time supporting 11.23 Starting up with Hydraulic Governing (After completing the procedure stated in Chapter 10.2.1) Keeping Electro-hydraulic governor out of service. © Raise the speed reference (speed reference Operation : setter) corresponding the full load i.e. 3150 rpm # Keep the speeder gear position "0" (Ref. Fig. 11.1, Speeder Gear Module) Observe: _ ¢ EHC position goes to 100%, Opening of ESV & IV « Raise starting device to 56% Operatio (SLED module in Fig. 11.1) Observe : e ESV & IV opens 140eed) faren-up 8? ‘ 3. Speeding up turbine to 600 rpm (Ws Diao lar! Ii Operation; + Stowiy aie the SLD po Jed to 600 rpm. hoe 00 spr. rs + Turbine speed stays at 6 4. Speeding up to rated speed (3000 rpm) ere o 4 Altthe conditions of turbine shoul cee ‘ discussed in Chapter 11.2.2 during speed sp fiseussed in ‘ it 00% at a stretel | aise the SLD position to 1 g Operation: + Raise the S) Pn Obs Turbine speed is raised to 2400 rpm (80% of ral erve: —* Turbine a Note Hydraulie governor assumes control at this spee ne Raise spe ar position to increase speed to get 3000 rps Operation: + Raise 5 car Ensure: Turbine speed stays at 3000 rpm. Note further Afier generator synchronization, turbine can be loaded by fia 5 imiting 1¢ applied it limiting can be raising the speeder gear position. However, load i is not 4y lowering the position of SLLD. Since the TSE influence bine to incorporated in hydraulic governing, operator should load the turbi the extent of TSE upper load margins at that instant. 1124 Governing parameters at full load (210 MW) condition When EHC is performing EHC position 1 75-80% HP Secondary oil pr. : 4.34.5 kg/em? HP control Valve + 55% open IP Secondary oil Pr, : 6,5 kg/em? IP control valve + 100% open Trip oil pr. + 7.5 kp/om? Aux. Trip Oil pr. + 7.5 ke/em? Aux. Secondary oil pr.: 4.3 kg/cm? Primary oil pr. +2.1~2.2 kp/em? 44.2.5. Change over from EHC tp Hydraulic Governing Status before change over * Speeder Gear Position 7 100% * EHC position Z 75% * Load Control : Active * Tracking device t "ON" 141 tit