Pressure

United States Patent 119]
1111
4,201,924
Uram
[45]
May 6, 1980
Primary Examiner-Gene Z. Rubinson
[54] COMBINED CYCLE ELECTRIC POWER

PLANT WITH A STEAM TURBINE HAVING
A SLIDING PRESSURE MAIN BYPASS AND
CONTROL VALVE SYSTEM
[75] Inventor:
Robert Uram, East Pittsburgh, Pa.

Pittsburgh, Pa.
1111. cm ............................................. .. 1102p 9/04
[52] us. c1. ................................ .. 290/40 R; 364/494;
60/660; 60/3918 B
[58] Field of Search ................. .. 290/2, 4, 40; 60/660,
60/667, 39, 18 B; 415/15, 17; 364/492, 494, 495

References Cited
7/1968
6/1973
3,762,162
10/1973
steam is supplied by one or both of the steam generators

for operating the steam turbine. The control system is of
the sliding pressure type and maintains a predetermined

steam pressure as a function of steam flow according to
a predetermined characterization depending on the

number of steam generators in service to limit the maxi
mum steam velocity through the steam generators, and
reduce the probability of water carryover into the
steam turbine. Such control is always maintained by the

bypass valve. The turbine control valve responds to the
U.S. PATENT DOCUMENTS

3,741,246
3,391,539
ABSTRACT
gas turbines has an exhaust heat recovery steam genera

tor connected to a common header from which the
[211 App]. N0.: 497,503

[22] Filed:
Aug. 13,1974
[56]
[57]
A combined cycle electric power plant includes two gas

turbines, a steam turbine, and a digital control system
with an operator analog or manual backup. Each of the
[73] Assignee: Westinghouse Electric Corp.,
[51]
Assistant Examiner-John W. Redman

Attorney, Agent, or Firm-H. W. Patterson
Dimitroffetal.
Braytenbatt ..
speed/load demand only, except when the bypass valve
Miura m1. .................... ..
is closed and the rate of steam generation is insufficient

to maintain a predetermined pressure ?ow relationship.
FOREIGN PATENT DOCUMENTS

0718179
9/1965
16 Claims, 55 Drawing Figures
Canada .................................... .. 60/660
IOI C
I |Qoc
PROCESS
SENSORS
MONITOR
COMPUTER
3e
SIN'
VA NES
44
STEAM
GENERAT
TURBINE
BYPASS
VALVES
02c:
[ l 100
DAEIWI 206
1'8
5C
IE]
see
>_.:[
jcggggtgg
OPERATOR
PANEL
me
as
iiiCONTROL I
AFTERBURNER
,as
AFTERBURNER
AB
CONTROL
l
'3
GENERATOR
so
mac
r2e
HRSG l l HRSG H CONTROL

BOILER
- GAS TURBINE
246
CONTROL
'
mac
OAS TURBINE
SEOUENCER
flZSC
AUXILIARY
EQUIPMENT
G! s
l2 TURBINE l
rLEL VALVES
AND
CONMS
GUIDE
VANES
Gl
TURBIEEZ
22
*
FU EL VALVES
AN
CONTRQS
GENERATOR
lNLE 1'
GUI DE
V?NES
US. Patent
May, 6, 1980
Sheet 2 of 53
6/67
4,201,924
502\ 32
358
VENT
64
i8_
515
5|
577
576
507
EXTRACTION
STE AM
DEAER ATO
506
5|O
508
520
44
N .
547 575
54a 51a 54
79
574
580
VENT
572
573
MOISTURE
SEPERATOR
FEEDWATER
RESERVOIR
70
700
585
7
555
557 556
250/ 25l
572
353
>
58|
582
595
U.S. Patent
May, 6, 1980
sheetaofsg
4,201,924
CONDENSTATE
435
434
EXTRACTION STEAM
424
425
CH3
423 CH2
432
448
447
444
WATER
445
Ml ERALIZER 44o
44|
WATER
STORAGE
STEAM
FIG. 2B.
U.S. Patent
May, 6, 1980
Sheet 4 of 53
4,201,924
88/89
378%
90
DEAERATOR
609?
607
620 608
e2|
@41 /
376
3775
610
LOW
PRESSURE
623622@ STORAGE
TANK
6%
92b)
MOISTURE
SEPERATOR
FEEDWATER
RESERVOIR
644*? 643 642

(
COOLING
WATER
66.7
36]
654 656
657
36O
U.S. Patent
May, 6, 1980
Sheet 6 of 53
4,201,924
US. Patent
May, 6, 1980
Sheet 7 of 53
4,201,924
mL
N
mm
s
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US. Patent
May, 6, 1980
Sheet 8 0f 53
4,201,924
FIG.6A
Mw TRANSDUCER
_____J
FAIL COMPUTER cc0w_o-$w

70|
THROTTLE PRESSURE
SIGNAL FROM XMTR
.N
IPFAIL
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HRSG#ISUP<ERHEAT O
OUTLET STEAM FLOW
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SIGNAL FROM XMTR
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704,
U.S. Patent
May, 6, 1980
___._______.___
Sheet 9 of 53
4,20LQ24
FIG.6B
T0 ANNUNCIATOR 'bEII
TRANSDUCER FAILuREa
COMPUTER CCI'DEH
TRANSDUCER FAILURE
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BLOCK VALVE CLOSED
US. Patent
May, 6, 1980
Sheet 10 of 53
4,201,924
FIG.6C
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HRSG 2 IN
SERVICE
COMPUTER CCI
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BLOCK VALVE CLOSED
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CCI
,',
TPL'I
US. Patent
May, 6, 1980
Sheet 11 of 53
4,201,924
FIG. 7A
BTG BOARD
CV RAISE P8
are BOARD
VALVE TEST OPEN

VALVE TEST OPEN
are BOARD
cv LOWER
TPL
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FIELD CONTACT
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CC
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PB
SET CV To
BTG BOARD
OPERATOR
AUTO
MANUAL
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COMPUTER COMP
PER. FAIL
BTG BOARD
TURBINE MANUAL
SCC
COMPUTER SET
CV #2 TEST
COMPUTER "0A
AUTO PB LITE"
.'
U.S Patent
May, 6, 1980
Sheet 12 of 53
4,201,924
COMPUTER
DIRECT CHANI/O 'NT'

~
INPUT DATA
FIG.7B
ouTPuT DATA
a0|u\
BITS (M3
I INPUT
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US. Patent
May, 6, 1980
Sheet 13 of 53
4,201,924
FIG. 7C
S/LV DT
LVDT POS. F. B.
LVDT POS- E B.
AC TO DC
00
AC TO DC
CONVERTER CONVERTER
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SUPPLY
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B
(XCV#Z DEMAND)
>~ CCI TO COMP TURBINE MANUALISTATUS)
LD
BTG BOARD
AUTO PB LIGHT
,,
VALV E
#2
US. Patent
May, 6, 1980
Sheet 15 Of 53
4,201,924
FROM BTG PB
"MAIN BY-PASS
MBPV cLOsE PB
vALvE cLOsE"
RATEO PRESSURE
cOMPARATOR I
PREss FB__ H
86"
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/863
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864'
30o
L
COMPARATOR
FROM BTG P8
"MAIN BY-PASS
MANUAL"
853'
344'
MBPV MANUAL P8
sET MAIN BY-PASS vALvE TO MANUAL
~ssI
FROM BRO PB
MAIN BY-PASS
VALVE OPEN"
MBPV OPEN PB
FROM HRSG LOGIC
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FROM HRSG LOGIC
FROM
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OR HI cONOENsOR PREss
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PRESS LO"
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(FOR 2 BY-PAss VALVE LOGIC a.

TOTAL FULL TRIP LOGIC)
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FROM CONDESATE SYSTEM
L_SCC
"DESUPEIBHEATEROUTLET
FROM BTG "cONOENsER TRIP

RESET PB"
To
Is I---
R 0
FIG. 9A
US. Patent
May, 6, 1980
Sheet 16 of 53
4,201,924
COMPUTER
DIRECT CHAN 1/0
r";m
8OIB'\
,862'
N
860 8?2
F, ,,
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SET PT
.eNNUClATOR
"
ST BY-PASS VALVE TRIPPED
ENERGIZE MAIN
STEAM BY-PASS
VA LVE SOLENOID
850
U.S. Patent
May, 6, 1980
Sheet 17 of 53
4,201,924
INT
A
LD
,a4I'
r840
7T0 MAIN BY-PASS VALVE

1
4MA T0 20MA CURRENT
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LIGHT
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"AuTo"
BTG LIGHT
"A"
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Iv"
BTG LIGHT
I "READY"
FIG. 9C
US. Patent
May, 6, 1980
Sheet 18 of 53
4,201,924
I
(
701
TS"TU.LSEOSR%EWY
Q To ,JQV
I
Lo 1mm
SET POINT (-0.5V)
BIO
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BIO
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HRSG#I MAIN STEAM

BLOCK VALVE CLOSED
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:P#2 FAIL LOW

AC8
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HRSG# 2 SUPERHEAT
OUTLET PRESSURE?
0 oTO I500 PSIG
HRSG#2 MAIN STEAM

BLOCK VALVE CLOSED
706,
B09
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US. Patent
TP FAIL HI
I FAIL HIGH
May, 6, 1980
Sheet 19 of 53
4,201,924
RETROFITTING STEAM
TURBINES WITH MODERN
CONTROL PLATFORMS
Ronald Hitzel
Global Business Development Manager
Instrumentation & Controls
Siemens Westinghouse Power Corporation
Fred Block
I&C Engineer
Siemens AG 2003. All rights reserved.
PowerGEN 2003 LasVegas, Nevada Dec. 9-11
RETROFITTING STEAM TURBINES WITH MODERN CONTROL PLATFORMS

Abstract
Steam turbine owners are being confronted with complex operating processes brought
on by deregulation. In order to compete in todays electrical power market place and
meet these complex operating conditions, steam turbine owners have begun to retrofit
their steam turbine control systems with modern control platforms. Because these
modern control platforms provide better control of the steam turbine, the flexibility to
meet the demands of the market can be obtained. The control system design is critical
to optimize availability and reliability while minimizing impact on maintenance and
capital budgets. Issues such as turbine performance, controls integration and future
upgrades are sometimes overlooked when implementing a turbine control system
modification. This paper presents examples of steam turbine control system design and
integration and offers recommendations for a successful steam turbine control upgrade.
RETROFITTING STEAM TURBINES WITH MODERN CONTROL PLATFORMS
Ronald Hitzel
Global Business Development Manager Instrumentation & Controls
4400 Alafaya Trail, MC 250, Orlando, FL 32826-2399
Telephone: (407) 736-2553; Fax: (407) 736-5025; E-mail: ron.hitzel@siemens.com
Fred Block
I&C Engineer
1345 Ridgeland Drive, Suite 116, Alpharetta, GA 30004
Telephone: (678) 256-1606; Fax: (678) 256-1558; E-mail: fred.block@siemens.com
Introduction
Better performance throughout the steam turbines operational life improves cost
efficiency. Today, better control is even more important then before, as older turbines
operate beyond their original life expectancy. Since the early 1980s digital controls
have been the accepted standard in many North American and European
manufacturing and process industries. Recent developments in digital processing
technology (i.e. faster processing speeds, lower cost, and smaller sizes) make digital
turbine control the preferred technology of power plant operators.
Traditional steam turbine controls were accomplished with a fly-ball governor for
speed indication, mechanical linkages, and low-pressure turbine lube oil. Although
these systems are fairly reliable, they are becoming costly to maintain, as many of the
original control devices are now obsolete. Replacement parts, if available, are becoming
expensive with long delivery times. Maintenance of these systems required a certain
degree of familiarity and knowledge of the instrumentation of its era. The knowledge
base involving implementation of controls on mature steam turbines has diminished
over the years, which directly affects unit availability and reliability.
Turbine Control Philosophy
The modern digital turbine control system (TCS) is designed to control the main
steam flow to the steam turbine in all operational conditions by means of the turbine
throttle, governor, admission, and or extraction control valves. The control functions are
conducted through the use of simplex or redundant electronic functions incorporated
within the TCS software and hardware, integrated through the use of servo coil
actuators.
Master controllers automatically engage when required to ensure the appropriate

rates of change match the mode of operation of the turbine. Setpoint controls, open
and closed-loop control functions, as well as continuous monitoring functions associated
with the TCS system prevent the turbine generator from assuming inadmissible
operating conditions, thus avoiding the necessary response of the turbine protection
equipment and possible damage to the machine. This is the predominant operating
philosophy surrounding the high availability criteria of the turbine generator.
The vendor should provide each of these functions within their standard turbine
control packages. Each of these functions can be inhibited as necessary to facilitate
proper integration within the existing Distributed Control System (DCS) as required.
The principle features of the TCS system are summarized as follows:
Speed Control
Inlet/Admission Pressure Control-two channel selection which facilitates initial

pressure (boiler follow mode) and limit pressure (turbine follow mode) functions
Load Control-via either a load setpoint command from a DCS, or can be configured
to receive MW input for utilization of the load control function developed within the
system, or can be configured stand-alone as a MW or Speed Droop function.
Turbine Stress Influence
Frequency Influence
ADS (Automatic Dispatch System) Influence
Valve Lift Control
The TCS system ensures stable operation throughout all operational phases, i.e.
during unit start up, shutdown, parallel operation, Island mode, etc. In generation
applications, full load rejections created by a sudden separation from the grid (lightning
strike in the field, etc.) are controlled through the TCS thereby preventing an over-speed
condition and collateral damage from occurring.
Within the standard design of the TCS system, individual device inputs within the
master controller algorithms developing a 1 of 2, 2 of 3, and or 2 of 4 cross configuration
voting functions can be deselected through the use of an optional password protected
engineering client/server Operating Terminal (OT) station. In certain critical systems,
automatic de-selection is implemented upon a loss of the device-input signal, with the
system automatically returning to a normal state upon correction of the issue. What
this means is that the system senses each device input signal, monitoring it for quality,
in the event the device input falls outside of the pre-selected, configurable threshold (for
example, one of the active speed pick-ups just failed high), then the device is removed
from its associated algorithm. An alarm is issued, alerting the operator of the device
malfunction, and the control algorithm automatically transfers to the next assigned
device redundancy level. Upon correction of the malfunction, the control system will
automatically transfer to the next device redundancy level to ensure the maximum
availability and protection of the system.
The TCS should provide automatic and manual shutdown. In automatic
shutdown, the system must lower the load until the generator breaker opens on reverse
current. On manual shutdown, the operator will open the generator breaker manually
once the turbine is at minimum load.
The TCS Software System Comprises the Following Standard Master Controllers:
1. Speed Control
The speed control function provides the operational control involving the speed
limiting and acceleration functions of the unit over the entire operating speed range.
The speed control system is fully integrated with the load rejection and load anticipatory
functions as required, as well as the turbine trip system. The speed control function is
designed to receive up to three speed inputs. These inputs feed a 1 of 2, 2 of 3, and or
2 of 4 voting algorithm which issue an overspeed trip command. If one of the channels
fail, that channel is automatically deselected, an alarm is issued alerting the operator of
the malfunction, and the unit shifts to the next available comparison algorithm. In the
event the speed channel is repaired (the operator found a loose wire connection in the
junction box on the ST), then the unit automatically detects the correction, and shifts
back automatically into the pre-configured algorithm.
In generation applications, when the generator is on the grid and the turbine
controller is in the load control mode, the speed control function continues to provide a
speed error (influence) input for use in frequency regulation. Comparing the speed
reference with the actual speed derives the speed error signal. The frequency detection
accuracy is within 10 mHz, with tunable variables controlling deadband and droop
characteristics.
The desired speed reference is selectable manually from the client Operating Station
(OS). The speed acceleration rate (ramp rate) can be selected either manually or
automatically through the client OS station. Proportional speed regulation,
acceleration/deceleration ramp rates, and turbine/boiler runback functions are entirely
configurable through the Engineering Station (ES). Discrete values are provided for
selecting steady state operation at lower speed holds, as well as for operation at rated
speed. Four predominant modes of start-up while under speed control are provided as
standard solutions within the TCS system:
A speed setpoint is keyed into the system via the client OS, and the operator hits
go, and the unit ramps at a pre-determined ramp rate (which is programmable via
password protection) to the desired setpoint and holds at the selected value until
another command is issued.
The operator manually raises and lowers the speed via a soft-key selector (up or
down gradient key). In this function, if the operator selects a stop function during a
transient condition through the predetermined critical bands, the unit will continue to
either increase or decrease to the next available threshold. What this means is that if
the operator is telling the unit to ramp up, and then stops the command during a
critical state, the unit will not stop until after achieving the high end of the critical range.
The same occurs during a downward gradient change.
Depending on the particulars of the steam turbine itself and its application use, the
unit can be configured to open the governor valve(s), and modulate the stop valve in
order to warm the unit without breaking turning gear speed. After the unit has gone
through its initial thermal soak period (which can be configured via either thermal
inputs-RTDs/Thermocouples or via a time-based sequence), the stop valve will
continue to open, bringing the unit up to the minimum governor speed (typically 95%
rated speed/synchronous speed). This function is completely programmable and
generally depends on specific unit requirements. At this point in time, the unit will bring
the Governor Valve down below the Stop Valve (in order to shift the control from the
stop valve- full arc, to the governor valves-partial arc control), and issues a synch
command enable, facilitating generator breaker closure.
Another standard function utilized by many customers to facilitate automatic start-up
is the configuration of the system according to the units Standard Operating Procedure.
Each unit is issued with a Standard Operating Procedure (SOP), which typically is
modified in writing and issued by the customer as the operations guide governing the
machine. The vendor provides for configuration of the unit to operate based on the
time- based sequence issued under the SOP. In other words, the unit would be ramped
to a pre-determined setpoint, held at that point on a timer, and then ramped to the next
point and so and so forth. At no point would the unit be allowed to stop within the
critical bandwidths.
The TCS employs a configurable, operator controllable, proportional regulation
controller to ensure a bumpless transfer from full arc and partial arc admission.
A separate function is employed which, when password enabled through the
Engineering Station (ES), enables a manually controlled overspeed test. Configurable
acceleration rates and gradient ceiling facilitate controlled testing of the mechanical
overspeed protection devices. In the event the unit reaches the gradient ceiling prior to
the units mechanical devices activating, or the operator disables the function, the unit
will automatically coast down to rated speed.
Upon achieving synchronous speed, the controller accepts raise and lower impulses
from the auto synchronization circuitry. Standard provisions are made within the TCS to
facilitate the incorporation of both manual and automatic command and control.
2. Inlet/Admission Pressure Controller

The inlet/admission pressure control provides two channel selection which facilitates
initial pressure (boiler follow mode) and limit pressure (turbine follow mode) functions.
This automatic control function is activated when the inlet-steam pressure drops to a
pre-determined configurable setpoint. This gives the operator the ability to perform
sliding pressure control for lower MW minimums.
3. Load Control
Once the turbine is on the grid, the TCS can either be transferred automatically or
manually into the load control mode of operation. The load control function produces
steam flow demand signals via the position controller of the associated servo valve
actuators. Logic signals derived from the units load control system (ULCS) indicate
operating conditions, such as power load imbalance.
The load reference (setpoint) value corresponds to the current desired load as
compared to the rated main steam pressure. To initiate a change in desired load, the
operator dials in the selected desired setpoint and hits go, and the unit ramps at a predetermined ramp rate (which is configurable via password protection) to the desired
setpoint and holds at the selected value until another command is issued. The load
reference (setpoint) may be changed by either raising or lowering the desired target
load at the operator control panel, or from the increase or decrease signals generated
by the Generator synchronization functions.
Turbine runback control functions reside within the load control logic. This function
exists as designed to provide a controlling medium during abnormal conditions whereby
an engagement of automatic ramp rates bring the unit down to predetermined values.
These predetermined runback ramp rates and setpoint limits are configurable via
password protection.
Standard turbine runback features designed within the system are:
Loss of boiler feed water pump
Loss of condenser vacuum
Loss of primary coolant/pump (generator H2 coolant circulating water pump)
A load limiter is embedded within the load control function to limit the steady state
opening of the control valves thereby limiting the flow of steam to the turbine. The load
limit function interfaces to the runback function so that an adjustment of the load limit
automatically causes a runback of the load reference setpoint to a level 2% above the
predetermined load limit. This desirable function prevents a sudden increase in load
when the load limiting function is corrected (for example; the boiler feed water pump
circuit breaker was inadvertently turned off, and has been re-energized). The load limit
is configurable through the entire range of operation via password protection. The TCS
is designed to provide an indication of deviation percentage from the load limit and
issue an indication when the load limit is activated.
A load rejection occurs when the generator breaker opens at load. This situation
should be handled by the TCS by rapidly shutting the governor valves thereby
minimizing the pending overshoot. This is an anticipatory function triggered by the
generator breaker position indication. The governor valves then reopen to achieve preconfigured load rejection speed.
A megawatt (MW) feedback loop embedded within the TCS load control function
which automatically adjusts the megawatt reference setting to correspond with the
actual real load (MW). Through selection of this control loop function through the client
OS, the MW error value developed between the relationship of the corrected reference
MW and the actual MW is applied to a PI controller, which will automatically adjust the
control valve signal to reduce any MW deviation.
An initial load pickup (Min-load) function embedded within the TCS load control
function provides a configurable (typically 3-5%) step increase that occurs each time the
generator is initially synchronized to the grid. This Min-load function is used during
initial loading of the machine in order to prevent reverse power conditions upon synch
enable and is configurable through password protection at the Engineering Station (ES).
An impulse pressure feedback loop is embedded within the TCS load control
function to correct the megawatt reference versus the actual megawatt value based on
actual Impulse pressure. The impulse pressure error derived from the corrected
reference impulse pressure (in MW units) and the actual impulse pressure is applied to
the controller, which will trim the control valve signal to reduce any impulse pressure
error.
4. Turbine Stress Influence
The TCS system is designed to accept influencing from a turbine stress evaluation
(TSE) system thereby limiting the acceleration and load ramp gradients. During start-up
and shutdown, a TSE would provide an input generated from the algorithm delta
created between two thermocouples embedded within the main stop valve (MSV or
throttle valve) and main control valve (MCV or governor valve). This value would limit
the acceleration and or deceleration limit applied to the turbine via the master
controllers. Under normal loading operations, a TSE would provide an input generated
from the algorithm delta created between thermocouples embedded within the casing
(typically HP and IP, which can be utilized to generate a HP/IP shaft deviation
algorithm). This deviation signal is utilized within the master controllers to limit the load
gradient applied.
5. Frequency Influence
When the generator is on the grid and the turbine controller is in the load control
mode, the speed control function continues to provide a speed error (influence) input for
use in frequency regulation. Comparing the speed reference with the actual speed
derives the speed error signal. The frequency detection accuracy is within 10 mHz, with
tunable variables controlling deadband and droop characteristics.
6. ADS (Automatic Dispatch System) Influence
The TCS system is designed to accept influencing from an ADS controller, facilitating
the remote dispatch loading and unloading of the machine along predetermined ramp
gradients. The load limit gradients are configurable through the entire range of operation
via password protection.
7. Valve Lift Control
The valve lift controller integrates the min-gated valve demand reference versus
valve actual (setpoint) functions. Some vendors have standard applications oversampling rates of greater than 20 samples per cyclic event throughout the stroke of the
valve to achieve the fastest possible response time.
The Turbine Control System (TCS) Processor
The brain of the steam turbine controller should be a high-speed digital processor.
One example is the S7 Programmable Logic Controller. The S7-416 is a high availability
processor with the performance required for applications such as steam turbine control.
It acquires measured values and status signals from the I/O, carries out open- and
closed-loop control functions, transfers the resulting commands to the I/O and performs
all the functions of the group and individual device levels. Clearly structured and
vigorously tested control concepts should be available for various configurations of plant
control tasks. One example of a specific application would provide a modular-based,
fan-free, cost-effective solution with a high degree of expansion and communication
options. This user-friendly system provides for the easy implementation of distributed
structure that is capable of handling the most sophisticated tasks in the high-end
performance range. In your application, this processor will automate the total turbine
package.
Look for a vendor to configure the TCS to allow push button valve calibration and
tuning. This significantly reduces commissioning and startup times. Operating alarms
and trends should be easy to see and configure in the TCS operator interface graphics.
The Turbine Protection System (TPS) Processor

A critical part of the steam turbine control system upgrade is the protection system.
The protection system must have a robust controller to safely shutdown the turbine in
the case of emergency. One such controller is the S7-314C-2DP. This is a high
availability processor with the performance required for applications such as steam
turbine protection systems. It acquires measured values and status signals from the onboard I/O, carries out open- and closed-loop control functions, transfers the resulting
commands to the I/O and performs all the functions of the group and individual device
levels. Clearly structured and vigorously tested control concepts are available for
various configurations of plant control tasks. This user-friendly system provides for the
easy implementation within a distributed architecture that is capable of handling the
most sophisticated tasks in the high-end performance range. In the TPS application,
these processors will automate the turbine trip system (TPS) package within a triplemodular, 2 out-of-3 voting architecture.
Mechanical / Hydraulic Engineering And Modifications
The vendor should manage the coordination between the mechanical and hydraulic
modifications and the electronic control system requirements, so that the complete
control system retrofit is a successful project.
Mechanical/Hydraulic Trip Subsystem
All new steam turbines are being supplied with electronic trip systems without
mechanical bolts for overspeed protection. Many customers have requested upgrades
to the existing Mystery Box and mechanical bolt style systems. The mechanical
upgrade completely replaces the original equipment within a 2-out-of-3, 2-out-of-4
algorithm voting architecture. A prefabricated panel incorporating triple redundant field
devices for each of the associated parameters facilitates on-line testing and calibration.
Many of the components are designed within the system architecture to facilitate on-line
repair and or replacement. In the new electronic control logic, each parameter input is
read and compared to a trip limit. If the values (for any parameter) exceed the trip limit,
the controls will trip all of the turbine valves. In addition to the normal trip limit
comparison, the controls will also compare the values of the like parameters (such as
bearing oil pressure), will alarm if the deviation between signal levels exceeds a predetermined threshold limit, or if all signals are trending toward the trip limit. In this way,
potential problems can be avoided before a trip condition actually occurs, and on-line
maintenance can be performed to correct the problem and avoid a trip. Because the
transmitters can be compared, monitored and alarmed, on-line testing of the
transmitters is not required. The TPS maintains the inputs for tripping the unit from the
auxiliary devices. This input mimics the trip solenoid in the existing trip block assembly.
A trip-reset input is necessary to clear any latched trips. The trip output of the TPS
consists of six- (6) discrete outputs, two- (2) from each processor. This matches the
six- (6) emergency trip oil dump solenoids configured in a 2-out-of-3 to trip
arrangement.
Field Device Parameter Sensing Assemblies
This instrumentation upgrade is a 2-out-of-3, 2-out-of-4 voting design. Each transmitter
has a local LED readout, and is plumbed with an isolation valve and calibration port.
The transmitters are pre-wired to an on-board junction box with ring lug terminal strips.
This proposal includes 2-out-of-3 sensing assemblies for the following functions:
The following items are installed in place of the trip block assembly and provide inputs
to the TPS.
Vacuum Pressure. The new panel has three- (3) vacuum pressure measurement
devices that provide discrete contacts and analog 4-20mA signals. They may be
connected to the TPS as either. Upon sensing a high exhaust pressure (low
vacuum) the TPS will issue a trip command.
Bearing Lube Oil Pressure. The new panel has three- (3) pressure measurement
devices that provide discrete contacts or analog 4-20mA signals. They may be
connected to the TPS as either. Upon sensing a low bearing oil pressure the TPS
will issue a trip command.
Turbine Thrust Pressure Sensing. While retaining and monitoring the existing oil
pressure based thrust-sensing system, this modification incorporates four- (4)
independent, pressure measurement devices that provide discrete contacts or
analog 4-20mA signals. Two- (2) of the transmitters facilitate monitoring of the
active thrust position, and two- (2) of the transmitters facilitate monitoring of the
inactive thrust position. The transmitter outputs may be connected to the TPS as
either discrete contacts or as 4-20mA signals. Upon sensing turbine thrust the TPS
will issue a trip command.
Turbine Trip Solenoids. This modification incorporates the installation of three- (3)
new sets of turbine trip solenoids to facilitate a 2-out-of-3 voting algorithm within the
TPS system functionality. Included within this modification is the Auxiliary Governor
Function, which will consist of a single set of solenoids. A manual trip handle (Local
E-Stop) with an associated limit switch is provided for a local hand trip function.
Simplex discrete output generated by each TPS processor in a 2-of-3 algorithm for
the Auxiliary Governor solenoid function. A set of solenoids that is in same
configuration as the turbine trip solenoids.
Trip Solenoid Testing

The six- (6) solenoids (typically) are piped to the throttle valve emergency trip fluid
header. They are organized in sets of three- (3) pairs. Each pair is comprised of two(2) solenoids plumbed in series, with the three- (3) pairs plumbed in a parallel
configuration. The three- (3) TPS processors actuate the solenoids to generate a 2-outof-3 algorithm. Each solenoid may be independently tested. Pressure switches located
between each pair of solenoids indicate when a solenoid has been tripped. Similarly,
these pressure switches indicate when a failure of a particular solenoid has occurred.
The following permissive conditions must be met prior to testing of any solenoid:
All TPS processors are operating normally.
All solenoid panel pressure switches indicate a normal status.
No TPS processor is sensing a trip and or fault condition.
Tests are conducted from the DCS via a communication link or locally via the HMI.
Speed Sensing
The Magnetic Pick Up (MPU) bracket provides for primary speed control and electronic
overspeed protection will be designed to incorporate multiple new speed probes. Within
the confines of a base scope of supply, the vendor should provide four- (4) new active
magnetic speed probes for software based zero speed detection, measurement, and
overspeed protection.
Three- (3) of these probe slots are dedicated for software overspeed measurement
and protection.
Three- (3) of these probe slots are dedicated for hardware overspeed protection.
Two- (2) of these probe slots are dedicated for installed spares.
Zero speed detection is accomplished directly through the use of the installed
software based system.
The system senses turbine speeds from 0 rpm through overspeed. All inputs are
individually processed through a 2 of 3 algorithm-generating outputs to perform speed
control functions as well as overspeed trip functions utilizing a field proven MPU voting
scheme. The overspeed trip function will be implemented within control logic and
becomes the primary form of overspeed protection.
Mechanical Overspeed Trip Assembly

The mechanical overspeed trip assembly is not very high tech. These systems use a
bushing, adjustment nut, plunger, and spring arrangement. As the spring is
compressed, the force to overcome the spring force is increased. The weight of the
plunger, spring force, speed, and the distance from the plunger to the trip lever defines
the trip speed. Since the desired trip speed, the weight of the plunger, and the distance
the plunger must travel to strike the trip lever are fixed, the only adjustment that can be
made is the spring force. Adding or removing shims, or repositioning the spring
compression adjustment nut, changes the trip speed. The only way to change the trip
speed is to shutdown the turbine to make the mechanical adjustments. Multiple runups
are not unusual. This is time consuming and introduces a potential for human or
mechanical error. Owner / Operators have experienced many problems over the years
with the setting of mechanical governors. A list of some actual issues follows here:
Trip plunger improperly machined, a grooved finish on the bore of the plunger guide
bushing
The end of the plunger was flared out preventing the trip plunger from moving. This
was the result of a millwright physically pushing on the end of the plunger with a
center punch.
The plunger and guide bushing had a buildup of varnish.
The installed spring was too strong.
The installed spring was too weak from either an old spring that had lost some of its
force or a spring with too low a spring constant.
The millwright turned the adjustment nut in the wrong direction.
Table: Comparison of Mechanical Overspeed Trip System versus Electronic Overspeed

Trip System
Mechanical Overspeed Trip System
General trip speed range, +/- 50 rpm
Trip speed will change over time
Does not interface with anything
Does not provide any trip indication
Must have mechanical trip lever interface
Oil varnish buildup will keep the
mechanical trip plunger from functioning
Not fault tolerant
Cannot be tested except when uncoupled
from the driven equipment, which requires
a shutdown
Must be initially set in a spin test pit
Requires multiple runs of the turbine to
adjust the trip set point in the field
Electronic Overspeed Trip System

Precise trip speed, digital set point
Trip speed will not change over time
Provides DCS interface
Provides first out trip indication
No physical contact with shaft or
mechanical trip lever is required
Oil varnish does not affect the trip function
Fault tolerant
System can be tested periodically with a
signal generator with minimal or no risk to
the operation of the turbine
Set by a signal generator
Does not require any extra runs of the
turbine in the field
Redundant Interface to Valve Positioners

The vendor should provide drivers for redundant servomotor coils, expecting the
existing servomotors to have dual coils. They should also provide redundant LVDTs, as
the LVDT represents a single point of failure in a system that has redundancy built into
nearly every other area. This design provides redundancy all the way to the valve.
Failure of any module, power supply, servomotor coil, LVDT or wiring will not interrupt
operation in any way, and will only result in an alarm for the operator.
Electrical Auxiliaries
Several auxiliary items should be looked at when performing the upgrade. Vibration
monitoring equipment should be added or upgraded to monitor the health of the rotor
and associated bearings. Ensure the TCS vendor provides the capabilities to integrate
vibration monitoring data into the TCS operating graphics.
Adding more sensors to monitor bearing lube oil and metal temperatures, valve
metal temperatures, steam chest temperatures and any other temperatures as
applicable should enhance temperature monitoring. These indications should be added
to the TCS graphics.
For the purpose of vibration monitoring, a system to monitor the status of the
bearings should be made available. It should provide highly reliable turbomachinery
information for improved protection. The system should continuously measure and
monitor a variety of parameters, which are vital to turbine protection. When any of
these parameters begin to indicate weakness in the turbine components, such as
imbalance, bearing failures, misalignment, and shaft crack conditions, the operator
should be alerted. Engineering information should be provided that includes mechanical
modification instructions to install probes in the turbine.
The communications to the existing DCS should be a non-proprietary open protocol.
Many plant sites have multiple protocols that increase maintenance. The ability to
communicate with one common protocol to devices such as generator protective relays,
automatic voltage regulators, Turbine Stress Evaluator, vibration monitoring, etc will aid
operations and maintenance capabilities.
It would be prudent for a customer to chose a vendor that can provide all of the
basics plus auxiliaries utilizing a common control platform. This includes generator
protective relay and automatic voltage / excitation systems. Having systems that
communicate with the same protocol and contain similar hardware will reduce
operating, training, and maintenance costs.
Conclusion
Because of their age, design, and lack of maintenance, todays steam turbine
governor control systems are operating in a manner far different than the original
manufacturers designed them. They are also operating in an order of magnitude less
efficient in performance than that of similar sized turbines operating with the latest
digital controls. Typically these older steam turbines drift, control has a sluggish
response caused by multiple individual servo motors connected by antiquated linkages
and connectors, or does not operate in a coordinated fashion. These problems are
costing your operation and maintenance teams time and money better spent on
improving the operation rather than just keeping it running. Find a vendor that can
implement an innovative solution for modernizing your steam turbine controls and that
can integrate this upgrade into your current or future plant systems using a scalable,
standardized, proven platform. Upgrading to a state-of-the-art turbine control system will
generate true long-term benefits for operations, maintenance, and service of your steam
turbine.
References
API Standard 612, 1995, Special Purpose Steam Turbines for Petroleum, Chemical,
and Gas Industry Service, Fourth Edition, American Petroleum Institute, Washington,
D.C.
API Standard 670, 2000, Vibration, Axial-Position, and Bearing Temperature
Monitoring Systems, Fourth Edition, American Petroleum Institute, Washington, D.C.
Clark, E. E., 2002, Steam Turbine Overspeed Incidents, The Hartford Steam Boiler
Inspection and Insurance Company.
Rutan, C.R., 2003, Turbine Overspeed Trip Protection, Lyondell/Equistar Chemical,
LP, Proceedings of the Thirty-Second Turbomachinery Symposium.
Clark, B.E., 1992, Steam Turbine Generator Equipment Westinghouse Electric
Corporation.
Simatic Catalog ST 70, 2000, Components for Totally Integrated Automation,
Siemens.
Nov. 19, 1968

Filed May
3,411,300
w. G. SCHUETZENDUEBEL ETAL
METHOD AND APPARATUS FOR SLIDING PRESSURE OPERATION OF A

VAPOR GENERATOR AT SUBCRITICAL
AND SUPERCRITICAL PRESSURE
2 Sheets-Sheet 1
31, 1967
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INVENTORS:
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BY
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NOV- 19, 1968
W.G.SCHUETZENDUEBEL ETAL
3,411,300
METHCD AND APPARATUS FOR SLIDING PRESSURE OPERATION OF A
VAPOR GENERATOR AT SUBCRITICAL

AND
Filed May 31, 1967
SUPERCRITICAL PRESSURE
'
2 Sheets-Sheet 2
INVENTOR3=
WOLFRAM G. SCHUETZENDUEBEL
BY JOHN l. ARGERSINGER
@340, @217
AGENT
3,411,300
,.
United States Patent 0 we
Patented Nov. 19, 1968
3,411,300
pressure at the turbine by manipulating the turbine valves.

This operation at lower than maximum loads, however, is
METHOD AND APPARATUS FOR SLIDING

PRESSURE OPERATION OF A VAPOR
GENERATOR AT SUBCRITICAL AND
very ine?icient. The reason is that at these loads the vapor
is ?rst raised to the high normal pressure of the vapor

generator and is then throttled down to the turbine throttle
pressure required at the lower load. This results in an in~
SUPERCRITICAL PRESSURE
Wolfram G. Schuetzenduebel, Avon, and John I. Arger
singer, Simsbury, Conn., assignors to Combustion En
gineering, Inc Windsor, Conn., a corporation of
Delaware
Filed May 31, 1967, Ser. No. 642,478
8 Claims. (Cl. 60-104)
e?icient use of the boiler feed pump power.

Attempts have been made to combine in one unit the
physical characteristics of a vapor generator operating in

the subcritical range with those of a vapor generator op
erating in the supercritical pressure range. This is exempli

?ed in US. Patent 3,242,911 as issued to W. W. Schroedter
on Mar. 28, 1966. It is generally known to operate a vapor
ABSTRACT OF THE DISCLOSURE

A method and apparatus for operating and controlling
a supercritical vapor generator with sliding pressure, with
15
generator individually either in the subcritical or in the

supercritical pressure range by sliding pressure, i.e. with
the turbine inlet valve wide open or at a ?xed opening.
The present invention, however, discloses a method of op
the pressure of the vapor varying between a low sub

critical pressure at a low vapor output rate and a high
supercritical pressure at a high vapor output rate. The
erating a single vapor generator with sliding pressure

whereby the transition from the subcritical to the super
critical pressure range or from the supercritical to the sub
critical pressure range is accomplished in a continuous,
output of the vapor generator in the subcritical pressure

range is controlled with sliding pressure, with the work
ing ?uid following a controlled circulation ?ow system,
i.e., passing through a vapor and liquid separator. The

output of the vapor generator in the supercritical pressure
range is controlled with sliding pressure with the working 25
smooth operation.
Summary of the invention
?uid following a once-throug flow system, i.e., by
The invention is embodied in a method and apparatus

for operating and controlling a supercritical pressure vapor
passing the vapor and liquid separator. Transition from

sliding pressure operation in the subcritical pressure range
generator with sliding pressure over at least a portion of

the load range. The invention is characterized by a unique
mode of sliding pressure operation over that portion of

to sliding pressure operation in the supercritical pressure
range is preceded by switching from the controlled cir 30 the load range which includes the transition from sub
or supercritical pressure to super- or subcritical pressure,
culationf?ow system to the once-throng ?ow system

before the critical pressure is reached, and with the work
respectively. This is accomplished during a rising load op

eration, for example, by bypassing the vapor and liquid
ing ?uid leaving the vapor generating section preferably

being slightly superheated, however, possibly having a
separator, which conventionally is required during sub

critical pressure operation, within a speci?cally selected
small liquid content up to approximately 10% .
transfer zone. This transfer zone is located in the sub
critical pressure region. The preferred lower limit of the

transfer zone is de?ned by a heat content of the working
?uid corresponding to a small liquid content. The con
Background of the invention

The invention generally relates to a vapor generator
dition of the ?uid at the actual point of transfer, however,
operating at normal top load in the supercritical pressure
may vary between approximately 10% moisture and a
range. It is particularly concerned with a method and ap

paratus for operating and controlling such a generator
with sliding pressure throughout at least a partial load
range thereof including the load range at which a trans
state of slight superheat. The advantages accruing from

this operation are manifold, and the objects of the inven
45
fer from snbcritical pressure to supercritical pressure, or

vice versa, takes place.
The critical temperature of a gas is generally de?ned
as the temperature at which the gas may just be liqui?ed
tion, accordingly, include the following:

(1) Reduction of boiler feed pump power consumption
resulting from sliding pressure operation at lower than
maximum load.
(2) Ability to match vapor temperature to the turbine
metal temperature by eliminating the need for throttling
at its critical pressure. For water and steam this pressure
in the turbine valves during start-up and low loads.

(3) Reduction of the wear of the turbine valves and
boiler valves during start-up and low loads because no
critical pressure drop orrhigh pressure drop duty is re
quired of the turbine valves or other valves in the boiler.
is 3206.3 >p.s.i.a (pounds per square inch absolute) and the

critical temperature is 705.34 P. When heating water at a
pressure below the critical pressure, it passes from the
liquid state to the vapor state at a constant temperature,
the so-called saturation temperature. A certain amount of
(4) Design of the separator vessel and recirculating
heat is required to change the water from the liquid state
piping can be restricted to partial load ?ow of the work

ing medium and a subcritical pressure.
to the vapor state. This heat is called heat of evapora

tion. It decreases with an increase in pressure and becomes
zero at the critical pressure. When heating water at the
critical pressure or at a supercritical pressure with Zero
(5) Simpli?cation of the control system by the elimina

tion of the control to maintain furnace wall pressure.
Brief description of the drawings
heat of evaporation, a single phase condition therefore
prevails, with the temperature constantly increasing while
Other objects and advantages of the invention will be

come apparent from the following description of an illus
heat is added. When heating water at subcritical pressure,
a two-phase condition prevails during the evaporation
trative embodiment thereof when taken in conjunction

with the accompanying drawings wherein:
FIGURE 1 is a simpli?ed diagrammatic representation
of the ?ow circuit of a vapor power plant embodying the
process, with the temperature rising to the evaporation
point, remaining constant until all water is evaporated

to steam and then rising again in the process of super
heating the steam.
It is known to operate separate individual vapor genera
tors either in the subcritical pressure range or in the super
critical pressure range by maintaining a maximum pres
sure in the vapor generator and by controlling the throttle
invention;
70
FIGURE 2 is a diagram illustrating sliding pressure op
eration with the pressure of the working ?uid plotted
against percentage of load;
3,411,300
FIGURE 3 is an enthalpy-pressure diagram for steam

and water upon which is plotted a typical sliding pressure
characteristic as disclosed herein; and
FIGURE 4 is a basic control diagram for operating
the vapor power plant of FIG. 1 in accordance with the
throttle may be 1000 p.s.i. The operating pressure at the

boiler outlet would be somewhat higher due to pressure
especially of those furnishing power to industrial plants,
point somewhat higher, for example, 2500 p.s.i.a. at which

pressure the working ?uid will be slightly superheated (ap
drop through the superheater and steam piping. During
this low load operation, valve 45 in bypass 44 is closed and

the steam and water mixture leaving evaporator tubes 24
herein disclosed method.
?ows to separator 35 by way of conduit 32 and valve 34.
The steam separated from the water in separator 35 then
Description 09 the preferred embodiment
?ows through conduit 42 and valve 43 to superheater 26a,
The inventive apparatus and operating and control
while the water is returned to the main circuit at point 31
method will now be described in connection with a vapor
by way of conduit 36 and valve 38. The unit therefore
10
power plant in which water and steam are utilized as the
operates at low load in the conventional manner of a
working medium. As shown in FIG. 1, during normal
controlled circulation steam generator.
operation, feedwater is obtained from a source such as hot
With a rising load characteristic the unit is operated in
well 10 of condenser 11. The water is delivered at relative
this manner with the pressure increasing with load as in
ly low pressure by condensate pump 12 through demin
dicated by curve 46 of FIG. 2 until the transfer zone 59
eralizer 14, low pressure feedwater heater 16 and deaera
is reached. In the enthalpy-pressure diagram of FIG. 3
tor 18 to the suction side of boiler feed pump 20. Pump
this subcritical phase of low load operation is indicated
20 raises the pressure of the feedwater a substantial
by curve 60 which shows the enthalpy of the working ?uid
amount and forces it through high pressure feedwater
at the outlet of the evaporator tubes 24 when plotted
heater 21, economizer 22, conduit 23, furnace water wall 20 against pressure. Also shown are curves of the enthalpy
or evaporator tubes 24, conduit 25, superheaters 26a and
of the feedwater and of the steam at the inlet of super~
26b, and conduit 27 into high pressure steam turbine 28,
heater 26a and the outlet of superheater 26b. The trans
reheater 29 and low pressure steam turbine 30. After ex
fer zone 59, in accordance with the invention, extends in
pansion of the steam in turbine 30, the steam is condensed
the herein described particular case from approximately
in condenser 11 and returned to hot well 10 to complete 25 2200 p.s.i. to 2500 p.s.i. as indicated in FIG. 3 by the cross
the working ?uid cycle.
hatched area. This transfer zone, however, could be lo
A recirculating circuit is provided around the furnace
cated anywhere within the subcritical pressure range. The
Wall or evaporator tubes 24 to protect these tubes espe
heat content of the working ?uid within the transfer zone
cially at partial loads by recirculating a portion of the
59 can ?uctuate between liimts characterized by a small
working ?uid from the outlet of the water wall tubes 24 30 moisture content and a state of slight superhe'at such as
to a point 31 upstream thereof in the main ?ow circuit.
10 F. Within this transfer zone 59 and at a point below
This recirculating circuit comprises a conduit 32 includ
the critical pressure (point 61) the ?ow of the working
ing valve 34, a steam and water separator 35, a return
?uid is transferred from a combined circulation ?ow
conduit 36 including valve 38, and a recirculating pump
path to a once-through ?ow path. This is accomplished
40 preferably located in conduit 23. There is also pro
by bypassing separator 35 by way of bypass 44 and valve
vided a conduit 42 and valve 43 connecting separator 35
45, with valves 34 and 43 being closed (see FIG. 1).
with the inlet of superheater 26a. Furthermore, the por
As earlier set fort-h, the transfer can take place with
tion 44 of conduit 25, which lies between the intersection
the working ?uid still containing a slight amount of
points of conduits 32 and 42 with conduit 25, functions
moisture, such as would be the case at a pressure of
as a bypass bypassing separator 35, with this bypass 44 40 approximately 2200 p.s.i.a. in the described example. This
including a valve 45.
is indicated in FIG. 3 by line 62. However, a preferred
During the operation of steam generating power plants,
operation is desirable to raise the pressure at the transfer
it is often required that the generation of steam or load

during weekends or in some cases even during nighttime
be substantially reduced. It has been customary in the

past during such low load operation to maintain the pres
sure in the steam generating portion vat maximum value
and to throttle this pressure by way of a turbine throttle
valve 46 so as to accommodate the reduced load require
ments of the turbines 28 and 30. Such operation requires

considerable boiler feed pump power to maintain the
pressure in the steam boiler. This power, however, is
partially lost by the throttling of the steam in the turbine

valves. To avoid this loss, sliding pressure operation is
resorted to. Thus the furnace wall operating pressure is
not controlled with throttling valves at the outlet, but is

allowed to slide with the superheater and turbine throttle
pressure as a function of through-?ow and of turbine
valve position.
The above is illustrated in FIG. 2, wherein throttle

pressure is plotted against percentage of load, with the
throttle pressure as indicated by curve 46 rising or falling
with load from zero load and Zero pressure to full load or
partial load and maximum pressure. Sliding pressure op

eration can be practiced throughout the entire load range
or partial load range. FIG. 2 illustrates a case wherein
sliding pressure operation prevails throughout the major

portion of the load range, i.e., from zero load to approxi
mately 75% of maximum load. During the remaining

upper 25% of the load range, the unit is operated with
constant maximum operating pressure of, for example,

3500 p.s.i.
When operating at low load such as 20% of maximum
load, for example, the required pressure at the turbine
" proximately 10 F.) as indicated by line 63. After trans
fer from controlled circulation ?ow to once-through ?ow,

sliding pressure operation continues with once-through ?ow
of the working medium and with rising load and rising
pressure. After passing the critical pressure line at 64,
FIGS. 2 and 3, sliding pressure operation continues up
to the maximum operating pressure at, for example 75%
of maximum load. At this point the pressure at the inlet
of turbine valves 46 remains constant while the load in
creases to maximum load with the pressure at the turbine
inlet being regulated boiler input as will later here-in be

described and by the turbine valves 46 as indicated by
line 65 of FIG. 2. As earlier mentioned herein, the steam
generator can be operated with sliding pressure-load opera
tion throughout its entire load range as indicated by
60 broken line 66 of FIG. 2.
When operating with a falling load characteristic, the

above described procedure is reversed. Thus in the ex
ample illustrated, when dropping the load in the region

between 100% and 75 % of maximum load, the pressure
at the inlet of turbine valves 46 remains constant being
controlled as hereinbefore described. When reducing the
load to a value below 75%, sliding pressure operation
takes over with the working ?uid bypassing the separator
35 until the transfer zone 59 is reached. Within this trans
fer zone and preferably while the working ?uid leaving
water wall tubes 26 is slightly superheated but preferably
not having a moisture content of more than 10%, trans
for from a once-through path (bypassingv separator 35)

to a controlled circulation ?ow path (passing through
separator 35) is accomplished by manipulation of valves
3,411,300
changes in the basic control pattern of the unit as indicated

in dash-dash lines in FIG. 4. These changes are initiated
34, 43, and 45. Thereafter sliding pressure operation con

tinues with reducing load and reducing pressure to any
by actuating switch 90 so as to make contact with contact

point 90a instead of 90b, and switch 83 so as to make
desirable lower load as indicated by line 46 of FIG. 2.

Since the transfer from controlled circulation ?ow
to once-through ?ow, and vice versa, can be made
contact with point 83a instead of 83b thereby utilizing

control of ?ring rate to feedwater ratio for regulating
the superheater outlet temperature in response to signals
received from controller 82. Operation of the unit is then
within a zone rather than at a ?xed point, such transfer
can be accomplished smoothly without interrupting the

normal sliding pressure operation of the unit.
FIG. 4 shows the basic control system for operation
established for once-through ?ow, with sliding pressure
of a supercritical pressure boiler with sliding pressure 10 load operation being maintained until the maximum pres
sure, such as 3500 p.s.i., is reached (see FIG. 2).
versus load operation. A load control signal coming from
Above this point of the operation of the steam gener
the load controller 67 will be transmitted to the turbine
ator herein described the pressure at the turbine valve in
input controller 69 by way of conduit 70. It is also trans
let may be maintained constant for the upper range of
mitted to the boiler input controller 71 by way of conduit
load. Control of the turbine input must therefore now
72. The turbine input controller 69 is connected with the
be accomplished by manipulation of turbine valves 46.
turbine governor 74 by way of switch 75 having contact
point 75a. The boiler input controller 71 regulates feed

water, fuel, and air input by transmitting a signal to
regulators 76, 78, and 80 by way of conduits 77, 79 and
81, respectively.
This mode of operation is indicated in FIG. 4 by dot-dot
lines. Switches 75 and 96 are closed to make contact with
contact point 75a and 96a, respectively. Signals emitted

20 from load controller 67 are now transmitted to the turbine
A signal from the superheater outlet temperature con

troller 82 is received via switch 83 at the valve controller
84 and determines the amount of spray water that must
be sprayed by way of valve 85 into the superheater steam

at 86 (see FIG. 1) to obtain the desired steam tempera
ture. The controller 82 indicating correction of the tem
perature of the steam at the superheater outlet is also
connected to a ?ring rate-feedwater ratio controller 88
by way of contact point 90a of switch 90'. While the
superheated steam temperature can be controlled by spray 30
water as above described, other conventional means to
control the steam temperature may be used such as by
tilting burners or gas bypass.

The other contact point 90b of switch 90 is connected
to water level controller 92 of separator 35. There is also '
provided a fuel-air ratio controller 94 to maintain the
correct fuel-air ratio for ef?cient and safe combustion of
governor 74 via turbine input controller 69 in addition to
boiler input controller 71, with supplementary control

superimposed by the throttle pressure controller 95 upon
the turbine input controller 69 via switch 96.
While control of the steam generator with a rising load
characteristic has been described herein above in detail,
control with a falling load characteristic takes place in a
similar manner, only in the reverse order of the individual
steps. Therefore, a detailed description thereof does not
seem to be necessary.
Having illustrated and described a preferred embodi

ment of our invention, it is to be understood that such
is merely illustrative and not restrictive and that variations

and modi?cations may be made therein without departing
from the spirit and scope of the invention. We there
fore do not wish to be limited to the precise details set
forth but desire to avail ourselves of such changes as fall
within the purview of our invention.
the fuel. The throttle pressure at the turbine inlet as indi

We claim:
cated at 95 communicates with the turbine input con
1. In a steam generating plant having a steam generat
troller 69 and the boiler input controller 71 via switch 40 ing section, a valved conduit including a steam and water
96 during the higher load range as will later herein be
separator, a superheating section and a turbine connected
described.
\
for series ?ow therethrough, and a valved bypass conduit
During low load operation, control signals are sent to

the various control elements as indicated in solid lines.
Switches 75 and 96 are in the open position as shown in
FIG. 4. Switch 83 is making contact with contact point
bypassing the separator, the method of operating the

steam generating plant by sliding pressure operation
83b permitting regulation of steam temperature by spray
sure at a low steam output rate and a maximum super
water as will later herein be described. Switch 90 is
critical pressure at a high steam output rate, the im
making contact with contact point 90b permitting regu
throughout the load range thereof, in which the pressure

of the steam varies between a minimum subcritical pres
lation of the water level in separator 35 by means of
provement
controlling
comprising
operationthe
of steps
the steam
of: generating plant with
?ring rate-feedwater ratio controller 88. With switches

96, 75, 83, and 90 placed as above indicated during low
load operation, signals from the load controller 67 travel
to the boiler input controller 71 for regulating feed
water, fuel and air at 76, 78 and 80, respectively, with
the ratio of ?ring rate to feedwater additionally being
adjusted by ?ring rate-feedwater ratio controller 88 in
sliding pressure while operating in a subcritical pres
response to water level controller 92 and the ratio of

fuel to air by fuel-air ratio controller 94. With the turbine
throttle valves 46 maintained wide open or at a ?xed 60
opening, the pressure varies with load. Wit-h switch 83
closed as shown in FIG. 4 signals indicative of deviations
of superheated steam temperatures emitted from super

heater outlet temperature controller 82 are received by
valve 84 and regulate the ?nal steam temperature by
controlling the amount of spray water permitted to pass
through valve 85 and injected into the superheated steam

at 86.
The above method of control prevails with rising load

until the transfer zone 59 is reached (FIG. 2). The opera
tion of the unit then is changed from controlled circula
tion to once-throug ?ow by opening valve 45, and
sure range up to a pressure point below the critical
pressure, with the" working ?uid ?owing through the

valved conduit and separator, and the moisture con
tent thereof being diminished with rising pressure;
controlling operation of the steam generating plant

with sliding pressure while operating in a higher pres
sure range between said subcritical pressure point
and a pressure in the supercritical pressure range,
with the working ?uid ?ow being transferred from

the separator to said bypass conduit at said sub
critical pressure point; and
transferring the working ?uid flow from the separator to
said bypass conduit when the moisture content of the
working ?uid at said subcritical point is below a
value of approximately 10 percent.
2. The method as de?ned in claim 1 in which the work

ing ?uid is transferred at said subcritical pressure from the
separator to said bypass conduit when the working ?uid
has attained a measure of superheat below approximately
50 degrees.
3. The method as de?ned in claim 1 in which the
working ?uid is transferred at said subcritical pressure

by subsequently closing valves 34 and 43, to cause by
passing of separator 35. Such ?ow transfer also requires 75 from the separator to said bypass conduit when the heat
3,411,300
content of the working ?uid at said subcritical pressure

point lies between the limits of 10 percent moisture con
tent and 50 degrees superheat.
4. The method as de?ned in claim 1 including the step
of:
ler, a water level controller and a superheater outlet
temperature controller, and means for sending con

trol signals from said water level controller to said
?ring rate-feedwater ratio controller when operating
controlling operation of the steam generating plant with

sliding pressure while operating in the supercritical
pressure range up to maximum steam generating
load.
5. The method as de?ned in claim 1 including the steps
of:
said means for operating the steam generating plant

with sliding pressure throughout a selected load
range including a ?ring rate-fcedwater ratio control
in said subcritical pressure range, and means for

10
controlling operation of the steam generating plant with

sliding pressure while operating in the supercritical
pressure range up to a partial steam generating load;
and
controlling the operation of the steam generating plant

in the load range above said partial steam generating
load while maintaining substantially constant oper
ating pressure at the steam generating section outlet
sending control signals from said superheater outlet

temperature controller to said ?ring rate-feedwater
ratio controller When operating in said higher pres

sure range.
7. The combination as de?ned in claim 6, wherein said

means for operating the steam generating plant with slid
ing pressure throughout a selected load range includes a
spray Water valve and controller, and means for sending
control signals from said superheater outlet temperature

controller to said spray water controller when operating
in said subcritical pressure range.
and throttling the steam to the turbine to accommo 20
8. The combination as de?ned in claim 6 wherein said
date required turbine loading.
means for operating the steam generating plant with slid
6. In a steam generating plant having a steam gen
ing pressure throughout a selected load range includes a
erating section, a valved conduit including a steam and
load controller, a throttle pressure controller, a boiler in
water separator, a superheating section and a turbine con
put controller and a turbine input controller, a turbine
nected for series ?ow therethrough, a valved bypass con
governor, and means for sending control signals when
duit bypassing the separator, and means for operating the
operating in a load range above said selected load range
steam generating plant with sliding pressure throughout
(1) from said load controller to said turbine throttle
a selected load range thereof, in which the pressure of the
controller and said boiler input controller,
steam varies between a minimum subcritical pressure at
(2) from said throttle pressure controller to said tur
a low steam output rate and a maximum supercritical 30
pressure at a high steam output rate, the improvement
comprising in combination:
,means for operating the steam generating plant with
sliding pressure while operating in the subcritical
bine input controller, and

(3) from said turbine input controller to said turbine
governor.
References Cited
UNITED STATES PATENTS
pressure range up to .a selected pressure point, in
cluding means for ?owing the working ?uid through
3,225,748
12/1965
Schuetzenduebel __ 122-406 X
the valved conduit and separator;

means for operating the steam generating plant with
sliding pressure while operating in a higher pressure
range between said subcritical pressure point and a 40
3,262,431
7/ 1966
Hanzalek _________ __ 122-406
3,286,466
3,313,111
11/1966
4/1967
3,338,053
8/1967
point in the supercritical pressure range, including

means for ?owing the working ?uid around the sepa~
rator and through said bypass conduit above said
subcritical pressure point; and
Stevens ____________ __ 60105

Strohmeyer ________ __ 60-105 .
Gorzegno et a1. ____ __ 60-105
EDGAR W. GEOGHEGAN, Primary Examiner

C. B. DORITY, Assistant Examiner.
ited States Patent [191

Eggenberger et al.
[54] TURBINE CONTROL SYSTEM FOR
SLIDING OR CONSTANT PRESSURE
BOILERS
[11]
4,253,308
[451
Mar. 3, 1981
Between Steam Turbine and Steam Generator Opera
[75] Inventors: Markus A. Eggenberger; Patrick C.

Callan, both of Schenectady, N.Y.
tion, P. Martin and L. Holly.

Primary ExaminerAllen M. Ostrager
Assistant ExaminerStephen F. Husar
Attorney, Agent, or Firm0rmand R. Austin; John F.
Ahern
[73] Assignee: General Electric Company,

Schenectady, N.Y.
[57]
[21] Appl. No.: 46,865

[22] Filed:
ABSTRACI
An automatic control system enabling comprehensive

operation of a reheat steam turbine with sliding or con
stant pressure boilers. The control system includes an
Jun. 8, 1979
HP control valve for regulating steam ?ow to the high
[51]
Int. Cl.3 ............................................ .. F01K 13/00
pressure turbine according to load and speed demands,
[52]
US. Cl. ...................................... .. 60/664; 60/663;
an intercept valve for regulating steam ?ow to the low

pressure turbine and for reheater pressure control, and a
bypass flow system for bypassing excess boiler steam
60/680
[58]
Field of Search ............... .. 60/646, 652, 657, 660,
60/662, 663, 677, 679, 680, 664
[56]
References Cited
U.S. PATENT DOCUMENTS
3,097,488
7/1963
3,488,961
1/1970
Eggenberger et a1. .......... .. 60/660 X
3,699,681
10/1972
Frutschi ..
60/682
3,919,846
11/1975
Lecocq ..... ..
60/657
3,928,972
12/1975
Osborne .... ..
60/646
4,118,935
10/1978
Andersson ..
60/662
4,132,076
l/ 1979
Weiss ........ ..
,. 60/ 646
Gerber .............. ..
60/662 X
OTHER PUBLICATIONS
during periods of low loading. The bypass system in

cludes. a high-pressure bypass sub-system and a low
pressure bypass sub-system, each having a ?ow control
valve and provision for desuperheating the steam. A
signal indicative of actual load demand (ALD) and
proportional to the product of boiler pressure and main
control valve ?ow demand is produced. From the ALD
signal, reference functions are generated to effect con
trol of the bypass valves. The intercept valve is con
trolled directly by the ALD signal with a regulation

factor inversely proportional to the minimum allowable
reheat pressure. Coordinated valve control is effected
during all principal phases of turbine operation.
Proceedings of the American Power Conference, vol. 35,

12 Claims, 5 Drawing Figures
pp. 365-376, Bypass Stations for Better Coordination
33'\
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32\ DcA
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DESUPER
HEAT
CONTROL
l5
AMP
VP
DE?llZER
CONTRBL
CONTROL
CONDENSER
US. Patent
Mar. 3, 1981
4,253,308
Sheet 1 of 3
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4,253,308
from which reference setpoints are generated for con
trol of the high-pressure and low-pressure bypass
TURBINE CONTROL SYSTEM FOR SLIDING OR

CONSTANT PRESSURE BOILERS
valves. There are no provisions, however, for directly
This invention pertains to control systems for steam
coordinating the bypass valves with operation of the

main control valve, which must be responsive to speed
turbines and more particularly to a control system en
and load requirements, nor for coordination with other
abling comprehensive operation of a reheat steam tur
valves of the system. Furthermore, it is recognized that
bine with constant or sliding pressure boilers.
?rst stage pressure is not a valid indicator of steam flow
BACKGROUND OF THE INVENTION
under all prevailing conditions.
In another known sliding pressure control system, a

?ow measuring ori?ce in the main steam line provides a
signal indicative of total steam flow, forming the basis
for a pressure reference signal for control of the high
with constant or sliding pressure boilers. This mode of
operation permits the steam boiler to be maintained at a pressure and low-pressure bypass valves. The flow mea
surement thus made requires an intrusion into the steam
high steam production rate independently of the load
flow path, a corresponding pressure drop, and addi
demand on the steam driven turbine and is attained by
tional equipment not normally available.
using a bypass arrangement to divert the excess steam
The fundamental signals upon which these and other
around the turbine directly to the condenser during
prior art systems depend for control are derived from
periods of low turbine loading. As load on the turbine is
increased, more steam ?ow can be apportioned to it and 20 sources other than the controller responsible for main
taining turbine speed and load. Thus, in these previous
less bypassed until a point is reached at which all of the
systems there has been a group of somewhat indepen
steam is devoted to the turbine and none bypassed.
dent control loops; one for speed and load, others for
Once the bypass is completely shut off the boiler pres
Certain advantages may be realized by operating the

steam turbines of electrical power generating stations
sure may be allowed to increase, or slide upward, to its
rated pressure in support of the turbine demand for

steam. Conversely, with a lessening of turbine load, the
boiler pressure may be allowed to slide down to some
acceptable minimum level, followed, if necessary, by

again bypassing the excess steam. Among the principal
advantages of this kind of operation are (l) shorter
turbine startup times; (2) use of larger turbines for cy
cling duty where there must be a quick response to
the bypass valves. An object of the present invention,

therefore, is to provide a comprehensive control system
for turbines in the sliding or constant pressure mode of
operation wherein the speed and load control means is

incorporated into a uni?ed system for control of all
valves, and wherein operation is coordinated with con
trol of boiler and reheat pressures by automatically
positioning the main control valve, the intercept valve,

and the high- and low-pressure bypass valves.
Another object of the invention is to provide an im

changes in load; and (3) avoidance of boiler trip-out
proved and uni?ed control system for reheat steam
with sudden loss of load. A general discussion of the
sliding pressure mode of operation appears in Vol. 35, 35 turbines operable in conjunction with sliding or con
stant pressure boilers and wherein automatic control is
Proceedings of the American Power Conference, Bypass
effective during all phases of turbine operation.
Stations for Better Coordination Between Steam Tur
bine and Steam Generator Operation, by Peter Martin
SUMMARY OF THE INVENTION
and Ludwig Holly.
Contrasted with the more conventional mode of tur 40
The invention provides an improved control system
enough steam for immediate use and where there are no
for a reheat steam turbine operating from sliding or

constant pressure boilers by producing an actual load
bypass valves), the sliding pressure mode necessitates
demand (ALD) signal from which two independent
bine operation (wherein the boiler generates only
pressure reference functions are generated. Serving as

uni?ed control of a more complex valving arrangement.
The control system must provide precise coordination 45 setpoint values, the pressure references are compared
with actual boiler and reheat pressure to regulate the
of the various valves in the steam ?ow paths and do so
high-pressure (HP) bypass and low-pressure (LP) by
under all operating conditions while maintaining appro
pass valves accordingly. The ALD signal, with a gain
priate load and speed control. There are three principal
inversely proportional to the minimum allowable reheat
phases to consider in the operation.
1. With the turbine down and the boiler at reduced 50 pressure, is applied directly to position the intercept
valve. The main control valve is positioned by speed
pressure, or being started up, steam must be bypassed
and load signals as is disclosed in U.S. Pat. No.
from the main steam line to the cold reheat line, and
3,097,488 to M. A. Eggenberger et al, which disclosure
from the hot reheat line to the condenser by means of
is incorporated herein by reference thereto. The ALD
pressure-controlled bypass valves;
signal is the yield of a multiplier element, and is the
2. Upon turbine startup, the control and intercept
product of boiler pressure and the HP control valve
valves should open according to a relationship that
maintains reheat pressure at a predetermined level re
gardless of main steam pressure and in coordination

with the bypass valves for uni?ed control of the boiler
and reheater pressures; and,
3. At a predetermined turbine load the bypass valves
should become fully closed, the control valves held in
positioning signal which is derived from the speed and

load control loop. Valid under all operating conditions
as an indication of actual load demand, a continuous
readout of the ALD signal is provided.

BRIEF DESCRIPTION OF THE DRAWINGS
While the speci?cation concludes with claims partic
approximately constant position, and the boiler pressure

ularly pointing out and distinctly claiming the subject
ramped up to rated pressure by increasing steam ?ow.
Various control systems have been developed for 65 matter regarded as the invention, the invention will be
better understood from the following description taken
reheat steam turbines operating in a sliding pressure
in connection with the accompanying drawings in
regime. In one known scheme, pressure in the ?rst stage
which:
of the turbine is used as an indicator signal of steam flow
4,253,308
FIG. 1 schematically illustrates, in block diagram
zero so that the output of second summing device 28 is
format, a preferred embodiment of the turbine control
a signal representative of the load setting. This signal,
system according to the present invention;
referred to as BL, is applied to CV control unit 30.

Control unit 30 may include a power ampli?cation de
FIG. 2 is an example of the high-pressure reference

signal (PREF Hp), generated as a function of the actual
load demand signal;

FIG. 3 is an example of the low~pressure reference
signal (PREF LP), generated as a function of the actual
load demand signal;
FIG. 4 graphically illustrates the relationship be
vice'to operate control valve 11 in accord with EL, and

may also include means to linearize the flow character
istics of the control valve 11. The speed and load con
trol branch of the system is substantially the same as was
and position of the intercept valve with changes in load,
disclosed in the aforementioned patent, US. Pat. No.

3,097,488 to Eggenberger et al.
Control of the HP bypass valve 12, the low~pressure
bypass valve 21, and the intercept valve 16 is deter
all as functions of the turbine load signal and at constant

boiler pressure; and
mined by a signal indicative of turbine actual load de

mand (ALD) and designated as EL. EL is formed by
tween HP control valve steam ?ow, reheater pressure,
taking the product of EL (the output of the second sum

ming device 28) and PB (the boiler pressure as measured
by pressure transducer 32) in multiplier 33. The ALD
cept valve and the HP control valve to maintain mini
signal E1, is applied to a load demand readout 34 in
mum reheater pressure at lower load and, taken with
addition to control loops for regulating the HP bypass
FIG. 4, illustrates that valve coordination is indepen
20 valve 12, the LP bypass valve 21, and the intercept
dent of boiler pressure.
FIG. 5 is a graphic illustration similar to FIG. 4
showing the coordination of control between the inter
DETAILED DESCRIPTION OF THE

INVENTION
In the electrical power generating plant shown in
valve 16 as mentioned above. The HP bypass control
loop includes PREF Hp function generator 35, mode

selector 41, rate limiter 36, third summing device 37,
boiler pressure transducer 32, proportional plus integral
FIG. 1 a boiler 1 serves as the source of high-pressure 25 controller 38, manual/automatic selector 39, and HP
steam, providing the motive fluid to drive a reheat
bypass valve 12; the LP bypass control loop includes
steam turbine generally designated as 2 and including
PREF Lp function generator 40, fourth summing device

42, reheater pressure transducer 43, proportional plus
integral controller 44, manual/automatic selector 45,
and LP bypass valve 21; and the intercept valve control
high-pressure (HP) turbine 3, intermediate-pressure (IP)

turbine 4, and low-pressure (LP) turbine 5. The turbine
sections 3, 4, and 5 are coupled in tandem and to electri
cal generator 7 by a shaft 8.
loop includes adjustable gain ampli?er 46, intercept
The steam flow path from boiler 1 is through conduit
valve 16, and IV control unit 47 which may include
9, from which steam may be taken to HP turbine 3

through main stop valve 10 and HP control valve 11. A
means to linearize the flow characteristics of valve 16.
high-pressure bypass sub-system including HP bypass

valve 12 and desuperheating station 13 provides an
alternative or supplemental steam path around HP tur
bine 3. Steam ?ow exhausting from HP turbine 3 passes
through check valve 14 to rejoin any bypassed steam,

and the total passes through reheater 15. From reheater
15, steam may be taken through the intercept valve 16
and reheat stop valve 17 to the IP turbine 4 and LP
turbine 5 which are series connected by conduit 18.
Steam exhausted from the LP turbine 5 flows to the
condenser 19. A low-pressure bypass sub-system includ

ing LP bypass valve 21, LP bypass stop valve 22, and
In the HP bypass control loop, PREF Hp function

generator 35 provides a reference signal, or setpoint,
against which the boiler pressure P5 as measured by
transducer 32 is compared in third summing device 37.
The HP bypass valve 12' is positioned in accord with the
output signal from summing device 37, being caused to

40 open more or less as Pg is greater or lesser than PREFHP,
the signal from function generator 35. An example of

the function produced by PREFHP function generator 35
is shown in FIG. 2 wherein PREFHpis a function of B1,.
In the example shown, PREF Hp at low values of E1, is
a constant equal to a minimum selected boiler pressure
PB MIN, then is ramped upward to a second constant
value PREF Hp MAX, selected to be just greater than the
desuperheater 23 provides an alternative or supplemen

tal steam path around IP turbine 4 and LP turbine 5 to
rated boiler pressure, with higher values of BL. Func
condenser 19.
tion generator 35 includes adjustments 50 and 51 pro
Rotational speed and output power of the turbine 2 50 vided, respectively, to select PB MIN and the value of a,
are related to the admission of steam by control valve 11
the slope of the ramped portion of the function PR E1: Hp.
In terms of valve operation, the HP bypass valve 12 is
which, although referred to herein as a single valve for
throttling at the lower values of EL to maintain P3 MIN,
the purpose of explaining the invention, is actually a
plurality of valves circumferentially arranged about the
then is fully closed as the function PREF HP is ramped
inlet to the high-pressure turbine to achieve full or par 55 up. Function generators operative as described, and as
tial arc admission of steam as desired. A speed and load
will hereinafter be described in conjunction with the LP
bypass control loop, are well known in the art and may
control loop, operative to position control valve 11,
includes speed transducer 24 providing a signal indica
generally be of the type described in US. Pat. No.
tive of actual turbine speed, a speed reference unit 25 by
3,097,488.
which the desired speed may be selected, and a ?rst
Rate limiter 36 prevents PREFHP from declining at an
summing device 26 which compares the actual speed

with the desired speed and supplies a speed error signal
proportional to the difference. The error signal from
excessive rate with a sudden drop of EL as may occur

with a sudden loss of load. This prevents the occurrence
of a large error signal which would tend to rapidly
summing device 26 is ampli?ed by gain element 27 to

swing the bypass valve 12 from closed to opened, caus
provide one input to second summing device 28 65 ing shock to the boiler 1 from the quick release of steam
wherein the ampli?ed error signal is compared with a
pressure. Proportional plus integral controller 38 ac
load reference RI, supplied by load reference unit 29.
cepts the error signal from third summing device 37 to
Under steady-state conditions, the speed error signal is
produce a signal proportional to the error and its time
4,253,308
integral so as to position HP bypass valve 12 accord
of pressure with all of the steam being bypassed through
ingly. The manual/automatic selector 39 provides for

disengaging the HP bypass valve 12 from automatic
control so that it can be manually positioned, and allows
the bypass system around turbine 2 to the condenser 19.
control to be readily switched from automatic to man

ual and vice versa. Mode selector 41 allows control
cause steam ?ow through the control valve 11 and the
according to the PREFHP function (sliding pressure) or,

by substituting a constant value for PREF Hp, at a con
stant pressure.
In the LP bypass control loop, PREFLP function gen

erator 40 provides a reference pressure signal or set
point based on the value of BL, for example, as shown

in FIG. 3. The function PREF Lp is a constant at lower
values of EL, representing the minimum allowable
The turbine 2 is then started by appropriately setting

speed reference unit 25 and load reference unit 29 to
intercept valve 16. For example, when the load refer

ence signal RL is increased to 0.3 units, assuming no
speed error, EL also equals 0.3 and ?ow to the high

pressure turbine 3 is 0.12 units (0.3ELX0.4P5=0.l
2E[,'). The actual load demand (ALD) readout 34 will,
at this point, display 0.12 units of demand, numerically

equal to the steam ?ow into the high-pressure turbine 3.
Furthermore, if the minimum allowable reheat pressure
setting PREH MIN is 0.3 units, then ?ow through the
intercept valve 16, intermediate pressure turbine 4, and
low-pressure turbine 5 will also be 0.12 units
(0.3PREHX 0. l2EL/0.3PREH MIN). The latter paren
thetical expression results from multiplying the reheater
reheat pressure PREH MIN, then is ramped upward with

slope B as EL increases. The PREFLP function genera
tor 40 is provided with adjustment 52 to select the de
sired valve of PREH MIN, which is determined by the
operating speci?cations of the reheater boiler 15. The
pressure by the ALD signal and multiplying that prod
PREF Lp value is compared with actual reheater pres 20 uct by the gain (I/PREHMIN) of intercept loop ampli?er
sure, as measured by transducer 43, in fourth summing
device 42 and the error signal therefrom applied to
If, at this point, R1, is increased to 0.7, the ALD signal
proportional plus integral controller 44 which automati
will move to 0.28 and, from the graphs of FIGS. 2 and
cally directs operation of LP bypass valve 21 to mini-> 3 as examples, the HP and LP bypass valves 12 and 21
mize the error signal. Manual/automatic selector 45
will become very nearly closed with PREFHp and PREF
allows the LP bypass valve 21 to be operated manually
LP on the verge of being ramped up. Flow through the
or automatically as was described above for the HP
intercept valve 16 will be 0.28 units (0.3PREHX 0.
bypass valve 12.
28EL'/0.3PREH MIN) and the valve 16 will be very
The intercept control loop provides for throttling the
intercept valve at reduced load to maintain the mini 30 nearly wide open (0.28EL'/0.3PREH M1N=l.0 units,
where a value of 1.0 in the intercept control loop results
mum allowable reheater pressure PREH MIN. This is
achieved by passing the EL signal through ampli?er 46

whose gain is selected to be inversely proportional to
PREHMIN. The output from ampli?er 46 is applied to IV
control unit 47 providing a proportional power signal
for operating intercept valve 16. The coordinated oper
in intercept valve 16 being fully open). Since the gain of

the intercept loop is matched to the inverse of PREH
MIN, coordination of the control valve 11 and intercept

valve 16 is assured as illustrated by the graphs of FIGS.
4 and 5.
At higher loads the RL signal can be fixed, or held
ation of control valve 11 with intercept valve 16 is
constant, and if conditions are steady-state with respect
illustrated graphically in FIGS. 4 and 5, each ?gure
to speed, RL will equal EL. Thus the control valve 11
showing the results with a different boiler pressure PB.
The plots of FIGS. 4 and 5 are in normalized units 40 will be ?xed in position and the boiler pressure may be
allowed to slide upward to satisfy increasing load de
covering a range of 0 to 1.0 representing generally, 0 to
mands on the turbine 2. The ALD readout 34 will dis
100% of the possible span of a particular variable. For
play the actual load demand under all conditions, show
example, a boiler pressure P); stated to be 0.5 units may
ing an increasing value as boiler pressure slides upward.
be taken as a boiler pressure of 50% of rated pressure.
Thus in referring to the plot of intercept valve opening
Above 0.7 units of actual load, as illustrated in the exam
as shown in FIGS. 4 and 5, a normalized value of 1.0

indicates the valve is fully open, a value of 0.5 that the
valve is one-half open, and so on. This permits descrip
and control of the turbine 2 will be as is conventional

for a turbine not having a bypass valving arrangement.
ples of FIGS. 2 and 3, the boiler will be at full pressure
As load is reduced, mode selector 41 may be-orought

tion of the control system independent of the limiting
parameters of any given system component, e.g., boiler 50 into play, permitting the boiler 1 to be operated at a
constant elevated pressure. In this constant pressure
capacity or pressure. The graphs show that the inter
mode, mode selector 41 negates the effect of a changing
cept valve throttles over the range of BL necessary to
value of EL on the output of function generator 35 by
maintain the minimum reheater pressure in accord with
substituting a constant value for PREF Hp. At constant
EL and the steam ?ow through the control valve 11,
pressure, intercept valve 16 operates in coordination
but independently of the main boiler pressure.
with control valve 11 as load is reduced; the HP bypass
OPERATION
valve 12 controls the pressure of the boiler 1 at a se
lected constant value of PREF Hp; and the LP bypass
Operation of the invention can best be explained in
valve, with the intercept valve, controls reheater pres
terms of numerical values assigned to the various oper
ating parameters to serve as illustrative examples. For 60 sure.
If turbine load is reduced while in the variable pres
that purpose, and for signal manipulation, the parame
sure mode, and unless there is very sudden loss of load,
ters can be expressed in terms of normalized units as was
operation of the system is the reverse of that obtained
explained above. For the following description of dif
during the loading process, and the boiler and reheater
ferent phases of turbine operation, reference is made to
FIGS. 1-5.
65 pressures are allowed to slide down to the minimum
preselected values. With a sudden loss of load, rate
Just prior to startup of the turbine, the boiler 1 is
limiter 36 prevents a precipitous drop in the signal ap
operated at some minimum steam ?ow and pressure.
There may, for example, be 0.3 units of flow at 0.4 units
plied to third summing device 37, avoiding a rapid
4,253,308
opening of the HP bypass valve 12 and causing a sudden

blowdown of the pressure of boiler 1.
While there has been shown and described what is
considered to be a preferred embodiment of the inven
tion, and there has been set forth the best mode contem 5
plated for carrying it out, it will be understood that
various modi?cations may be made therein. It is in
tended to claim all such modi?cations which fall within
the true spirit and scope of the present invention.
10
What is claimed is:
1. A comprehensive control system for a steam tur
bine operating in conjunction with a boiler generating

steam pressure, the turbine having a high-pressure (HP)
section, at least one lower pressure (LP) section, a steam
an LP error signal for controlling the positioning of
said LP bypass valve to maintain equilibrium be

tween said second reference signal and said re
heater pressure signal.

4. The control system of claim 3 wherein:
said HP function generator is adapted to provide said

first reference signal at a ?rst constant value for
lower values of said ALD signal and to linearly

increase said reference signal at slope at to a second
constant value at higher values of said ALD signal,

said HP function generator having means for se
lecting said ?rst constant value and means for se
lecting said slope at; and

said LP function generator is adapted to provide said
conduit interconnecting the HP section to the LP sec
second reference signal at a third constant value for
tion through a steam reheater, at least one admission
lower values of said ALD signal and to linearly

increase said reference signal at slope at at higher
values of said ALD signal, said LP function gener
control valve for regulating the flow of steam to the HP

section, and an intercept valve for regulating the ?ow
of steam to the LP section, comprising:
an HP bypass sub-system for passing steam around 20
ator having means to select said third constant

value.
5. The control system of claim 4 wherein said HP

bypass control loop includes means for limiting the time
including an HP bypass valve for regulating steam
rate of change of said first reference signal so that the
flow;
opening rate of said HP bypass valve is limited.
an LP bypass sub-system for passing steam around
said lower pressure section, said bypass sub-system 25 6. The control system of claim 5 further including
means for displaying the magnitude of said ALD signal.
including an LP bypass valve for regulating steam
7. The control system of claim 6 wherein said HP
flow;
bypass control loop includes means to selectively trans
a load and speed control loop for operating said ad
fer between a sliding pressure control mode and a con
mission control valve to maintain preset turbine
stant pressure control mode, said transfer means having
speed and load, said control loop having an admis
means for disengaging said ?rst reference signal and
sion control valve position signal;
substituting therefor a selectable constant valued signal.
a multiplying means for providing an actual load
demand (ALD) signal representing the product of
said HP bypass control loop includes an HP manual
boiler steam pressure and the admission control
/automatic selector, said selector effective to trans
35
valve position signal;
fer said HP bypass valve between an automatic
an HP bypass control loop for operating said HP
mode of operation wherein said valve is operated
bypass valve to control boiler steam pressure in
in response to saidHP error signal and a manual
accord with a ?rst reference signal determined
from said ALD signal;
in response to a ?rst manual operating means; and,
an LP bypass control loop for operating said LP
said LP bypass control loop includes an LP manual
bypass valve to control reheater steam pressure in
/automatic selector, said selector effective to trans
accord with a second reference signal determined
fer said LP bypass valve between an automatic
from said ALD signal; and,
an intercept control loop for operating said intercept
in response to said LP error signal and a manual
45
valve in response to said ALD signal.
2. The control system of claim 1 wherein said inter
in response to a second manual operating means.
cept control loop includes means for providing an inter
cept valve signal proportional to the product of said
said HP bypass control loop includes means for pro
ALD signal and the inverse of a preselected value of
ducing an HP bypass valve position signal accord
reheater pressure for controlling the position of said 50
ing to the sum of said HP error signal and the time
intercept valve.
integral value of said HP error signal; and,
3. The control system of claim 1 or claim 2 wherein:
said LP bypass control loop includes means for pro
said HP bypass control loop includes an HP function
said high-pressure section, said bypass sub-system
generator for providing said ?rst reference signal

as a preselected function of said ALD signal, a 55
transducer providing a boiler steam pressure signal,
means for comparing said ?rst reference signal

with said boiler pressure signal to produce an HP
error signal for controlling the positioning of said
HP bypass valve to maintain equilibrium between
said ?rst reference signal and said boiler pressure
ducing an LP bypass valve position signal accord

ing to the sum of said LP error signal and the time
integral value of said LP error signal.
10. A reheat steam turbine for operation with a slid
ing or constant pressure boiler, comprising:

a high-pressure (HP) turbine section, at least one
lower-pressure (LP) turbine section, steam conduit
generator for providing said second reference sig
means connecting the HP and LP sections, means

reheating the steam between the HP and LP tur
bine sections, at least one control valve for control
ling the ?ow of steam to the HP section, an inter
nal as a preselected function of said ALD signal, a 65

transducer providing a reheater steam pressure
cept valve for controlling the flow of reheated

steam to the LP section, an HP bypass for passing
signal, means for comparing said second reference

signal with said reheater pressure signal to produce
steam around the HP turbine section, an HP bypass

valve for controlling the flow of steam in the HP
signal;
said LP bypass control loop includes an LP function
4,253,308
bypass, an LP bypass for passing steam around the

LP turbine section, an LP bypass valve for control
ling the ?ow of steam in the LP bypass, a control
10
of steam to the LP section, a comprehensive control

system enabling sliding or constant pressure boiler oper
ation comprising:
loop for positioning the control valve to maintain
an HP bypass sub-system for passing steam around
preset turbine speed and load and for supplying a (II

. control valve position signal, means for supplying a
said high-pressure section, said bypass sub-system

including an HP bypass valve for regulating steam
signal representative of boiler steam pressure,
?ow;
means for generating an actual load demand
an LP bypass sub-system for passing steam around
(ALD) signal as the product of the boiler pressure
said lower pressure section, said bypass sub-system
signal and the control valve position signal, an HP

bypass control loop having means for generating a
first preselected reference signal as a function of
the ALD signal and means for positioning the HP
bypass valve to maintain equilibrium between the
boiler pressure signal and the ?rst preselected ref
erence signal, means supplying a signal representa
including an LP bypass valve for regulating steam
flow;
a load and speed control loop for operating said ad
mission control valve to maintain preset turbine
speed and load, said control loop having an admis
sion control valve position signal;

a multiplying means for providing an actual load
tive of reheated steam pressure, an LP bypass con
trol loop having means for generating a second

preselected reference signal as a function of the
ALD signal and means for positioning the LP by 20
pass valve to maintain equilibrium between the
reheated steam pressure signal and the second pre
selected reference signal, and an intercept valve
control loop having means for amplifying the ALD
signal by a factor proportional to the inverse of a 25
preselected value of reheated steam pressure to
supply an ampli?ed ALD signal and means to posi
tion the intercept valve in accord with the ampli
?er signal.
11. In combination with a reheat steam turbine oper 30
ating in conjunction with a boiler generating steam

pressure, the turbine of the type having a high-pressure
(HP) section, at least one lower pressure (LP) section, a
demand (ALD) signal representing the product of

boiler steam pressure and the admission control
valve position signal;

an HP bypass control loop for operating said HP
bypass valve to control boiler steam pressure in
accord with a ?rst reference signal determined
from said ALD signal;

an LP bypass control loop for operating said LP
bypass valve to control reheater steam pressure in
accord with a second reference signal determined
from said ALD signal; and,

an intercept control loop for generating said intercept
valve in response to said ALD signal.
12. The combination of claim 11 wherein said inter
cept control loop includes means for providing an inter
cept valve signal proportional to the product of said
ALD signal and the inverse of a preselected value of

steam conduit interconnecting the HP section to the LP
section through a steam reheater, at least one admission 35 reheater pressure for controlling the position of said
intercept valve.
control valve for regulating the ?ow of steam to the HP
I
section, and an intercept valve for regulating the flow
45
50
.55
65

Pressure

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United States Patent 119]

Primary Examiner-Gene Z. Rubinson

[54] COMBINED CYCLE ELECTRIC POWER

Robert Uram, East Pittsburgh, Pa.

1111. cm ............................................. .. 1102p 9/04

[52] us. c1. ................................ .. 290/40 R; 364/494;

60/667, 39, 18 B; 415/15, 17; 364/492, 494, 495

steam is supplied by one or both of the steam generators

the sliding pressure type and maintains a predetermined

a predetermined characterization depending on the

steam turbine. Such control is always maintained by the

U.S. PATENT DOCUMENTS

gas turbines has an exhaust heat recovery steam genera

[211 App]. N0.: 497,503

A combined cycle electric power plant includes two gas

[73] Assignee: Westinghouse Electric Corp.,

Assistant Examiner-John W. Redman

speed/load demand only, except when the bypass valve

Miura m1. .................... ..

is closed and the rate of steam generation is insufficient

FOREIGN PATENT DOCUMENTS

16 Claims, 55 Drawing Figures

Canada .................................... .. 60/660

HRSG l l HRSG H CONTROL

644*? 643 642

PCPROE0NRl TTAERT COI

FLOW % MAX/ HRSG

FAIL COMPUTER cc0w_o-$w

SIGNAL FROM XMTR

SIGNAL FROM xMTR

OUTLET STEAM FLOW

SIGNAL FROM XMTR

LIMIT sw. MAIN

VALVE CLOS ED L0' SOC

STEAM BLOCK <>

HRss#2 MAIN STEAM

HRSG #l MAIN STREAM

VALVE TEST OPEN

ASL($T NOT TRIPPED)

DIRECT CHANI/O 'NT'

\. CONTROL D" CONTROL

83' CLOCK 0")

DIRECT CHAN I/O

805G ' M ALO

H SET MAIN BYPASS

I _J [__.,. >TG0To 825/

OUTPUT DATA Nam); gAlgA

LVDT PRI. PWR. o

LVDT PRI. PWR.

>~ CCI TO COMP TURBINE MANUALISTATUS)

sET MAIN BY-PASS vALvE TO MANUAL

FROM HRSG LOGIC

"HI HOTWELL TRIPV

"BOTH C'RC WATER PUMPOFF/WSCC

FROM CONDENSATE sYsTEMj=-- scc

>10 HRSG LOGIC

(FOR 2 BY-PAss VALVE LOGIC a.

FROM CONDESATE SYSTEM

FROM BTG "cONOENsER TRIP

DIRECT CHAN 1/0

2am GATES BITS O I

7T0 MAIN BY-PASS VALVE

4MA T0 20MA CURRENT