Chapter 4

Turbines and Auxiliaries Chapter 4
Department of Electrical and Electronics Engineering Page 23

Chapter-4
TURBINE GOVERNING SYSTEM
1. INTRODUCTION:-
In order to maintain the synchronous speed under changing load/grid or steam
conditions the KWU turbine is equipped with Electro-Hydraulic governor; fully
backed up by a hydraulic governor. Hence the speed of turbine generator set can be
controlled either by hydraulic governing system or by Electro-hydraulic governing
system. Change over from one governing system to the other is possible during
operation. When Electro-hydraulic governing is controlling the speed of the set,
Hydraulic speed governing system acts as back up and comes into operation
automatically in case former fails.
A Hydraulic/ Hydraulic converter for the Hydraulic governing system and an
Electro/hydraulic converter for the Electro-hydraulic governing system is provided.
The measuring and processing of electrical signal offer the advantage such as
flexibility, dynamic stability and simple representation of complicated functional
system. The integration of electrical and hydraulic system is an excellent combination
with following advantages:
a. Exact load frequency droop with high sensitivity.
b. Avoids over speeding of turbine during load throw off.
c. Adjustment of power frequency droops in fine steps, even during on load
operation.
d. Reliable operation in case of isolated power grid.
e. Dependable control, during load rejection.
f. Low transient and low steady speed deviation under all operating conditions.
g. Safe operation of the turbo set in conjunction with the turbine stress Evaluator
(TSE).

2. Different governing Oils and their purpose :-
In the 210 MW KWU turbine single oil is used for lubrication of bearings,
control oil for governing and hydraulic turbine turning gear. During start-ups, aux. oil
pump (2Nos) supplies the control and control oil. Once the turbine speed is more than


90% of rated, the main oil pump (M.O.P.) takes over. It draws oil from main oil tank.
The lubricating oil passes through oil cooler.
2.1 Control Oil:-
Tapped from MOP discharge header through emergency shut off valve
and is used for turbine controls.
2.2 Startup Oil:-
This is developed from control oil at SLL device. The purpose is to press
the piston of test valve to downward position there by permitting trip oil flow
to the space above the piston of stop valve servomotors to resetting the stop
valve servomotor.
2.3 Auxiliary Startup Oil:-
Which is developed from control oil at SXLL device, the purpose is to
lift the piston of main trip valve ther by trip oil flow will establish in main trip
valves.
2.4 Trip Oil:-
Which is developed from control oil by main trip valves 1 & 2purpose
is for opening and closing of stop valves servomotors and the source for
auxiliary secondary oils.
2.5 Auxiliary Trip Oil:-
Which is developed from trip oil at main trip valves, purpose is to hold
the main trip valve piston against spring tension.
2.6 Auxiliary Secondary Oil:-
Is developed from trip oil at hydraulic speed governer, purpose is signal
oil to hydraulic amplifier.
2.7 Secondary Oil:-
Is developed from trip oil at follow up piston of hydraulic amplifier,
purpose is to open or close the HP and IP control valves.
2.8 Primary Oil:-
It is developed by governor impeller at MOP shaft from control oil,
purpose is signal oil to hydraulic governor.



3. Components Of The Governing System:
The main components of the governing system and the brief description of their
functions are as follow:

1. Remote trip solenoids.
2. Main trip valves.(turbine trip gear)
3. Starting and load limit device.
4. Speeder gear (Hydraulic governor).
5. Aux. follow up piston valves.
6. Hydraulic amplifier.
7. Follow up piston valves.
8. Sequence trimming device.
9. Solenoids for load shedding relay.
10. Test valves.
11. Extraction NRVs and Extraction valve relay.
12. Cold reheat swing check valve.
3.1 Remote Trip Solenoids:
The main trip valves (2 in numbers) are the main trip gear of the turbine
protective circuit. All turbine tripping take place through these valves. The
control oil from remote trip solenoids is supplied to them. Under normal
condition this oil flows into two stop valve and aux. trip oil circuit. The oil is
supplied to the stop valve and aux. secondary oil circuit.
The aux. trip oil flows in a closed loop formed by main trip valves and
turbine hydraulic protection devices.
The construction of main trip valves is such that when aux. trip oil
pressure is adequate, it holds the valves spool in open condition against the
spring forces. Whenever control oil pressure drops or any of the hydraulic
protection devices are actuated, the main trip valves are tripped. Under tripped
condition, trip oil pressure is drained rapidly through the main valves closing
turbine stop and control valves.
3.2 Starting and Load Limit Devices:-
The starting and load limit devices are used for resetting the turbine after
tripping, for opening the stop valves and releasing the control valves for


opening. The starting device basically consists of a pilot valve that can be
operated either manually by means of a hand wheel or from remote by means
of a electric motor. It has got port connections with the control oil; start up oil
and auxiliary start up oil circuits. The starting device can mechanically act
upon the hydraulic governor bellows by means of a lever and link arrangement.
Before start IP the pilot valve is brought to its bottom limit position by
reducing the starting device to 0% position. This causes the hydraulic governor
bellows to be compressed thus blocking the build up of secondary oil pressure.
This is known as Control valve close position. With the valve in the bottom
limit position (starting device 0%) control oil flows into auxiliary start up
circuit (to reset protective devices) and the start up oil circuit (to reset turbine
stop valves).
A build up of oil pressure in these circuits can be observed, while
bringing the starting device to zero position. When the pilot valve i.e the
starting device position is raised, the startup oil and auxiliary start up oil
circuits are drained. This opens the stop valves, ESVs open at 42% and IVs
open at 56% positions of the starting device. Further raising of the starting
device release hydraulic governor bellows which is in equilibrium with
hydraulic governors spring tension and primary oil pressure(turbine speed),
and raises the aux. sec. oil pressure; closing the follow up drains of hydraulic
governor.
3.3 Speeder Gear:-
The speeder gear is an assembly of a bellow and spring, the tension of
which can be adjusted manually from PCR by an electric motor or locally by a
hand wheel. The bellow compression depends upon the position of the starting
device and the speeder gear position which alters the spring tension on the top
of the bellow. The bellow is also subjected to the primary oil pressure which is
the feedback signal for actual turbine speed.
The speeder gear position determines the hydraulic governor set point. The
zero position of position of speeder gear corresponds to 2800rpm i.e. hydraulic
governor comes into action after 2800 rpm. The bellow and spring assembly is
rigidly linked to the sleeves of the auxiliary follow up piston valves. The
sleeves position changes with the equilibrium position of the bellow.



3.4 Auxiliary Follow-up Piston Valves:-
These are two in number and are in parallel. The trip oil is supplied
through orifices to the aux. follow-up valves. The sleeves of these valves are
attached to the speeder gear bellow link. The sleeve position determines the
drain of trip oil through the aux. follow up valves. Accordingly the trip oil
pressure, upstream of these valves changes. Upstream of circuit is termed as
Aux. SECONDARY OIL CIRCUIT. Hence, aux. follow up piston valves can
be said to control aux. secondary oil pressure.
3.5 Hydraulic Amplifier:-
It consists of pilot valve and amplifier piston valve. The position of the
pilot valve spool depends upon the aux. secondary oil pressure. Depending
upon the pilot spool position, the control oil is admitted either to the top or the
bottom of movements of the amplifier piston. The other side of amplifier is
connected to the drain. The movements of the amplifier piston are transformed
into rotation of camshafts through a piston rod and a lever assembly. A
feedback linkage mechanism stabilizes the system for one particular aux.
secondary oil pressure.
3.6 Follow up Piston Valves:-
The trip oil is supplied to the follow up piston valves through orifices and
flows in the secondary oil piping to control valves. The secondary oil pressure
depends upon position of sleeves of follow up piston valves, which determines
the amount of drainage of trip oil.
There are twelve follow up piston valves. Six of them are associated with
hydraulic amplifier and six of them with Electro hydraulic converter in the
governing system. The follow up piston, valves constitute a minimum valve
gate for both the governor does. This means the governor with lower reference
set point, is effectively in control. This is also termed as hydraulic minimum
selection of governors.
The drain port opening of follow-up piston of hydraulic amplifier
depends on auxiliary secondary oil pressure, upstream of aux. follow up piston,
and that of Electro-hydraulic converter, on the piston of pilot spool valves of
the Electro-hydraulic converter. ( i.e. EHC output).



3.7 Sequence Trimming Device:-
The function of the sequence trimming device or HP/IP trim device is to
prevent any excessive HP turbine exhaust temperature due to churning. It
changes the time and setting response of main and reheats control valves.
When the reheat pressure is more than 32kg/
and load less than 20% the IP

turbine tends to get loaded is more than HP turbine. The steam flow through
HP turbine tends to fall very minimal, causing a lot of churning and excessive
exhaust temperature. The trim device operates at this moment trimming the IP
turbine control valve. The control valve of HPT open more to maintain flow of
steam, reducing the HPT exhaust temperature.
It consists of a spring loaded piston assembly which is supported by
control oil pressure from beneath, under normal conditions. The control oil is
supplied to trim device via an energized solenoid valve. When the turbine load
is less than 50 MW and hot reheat pressure is more than 32Kg/
the
solenoid valve gets de-energized cutting out the control oil supply to the trim
device.
The trim device trips under spring pressure. The trim device is connected to the
follow up piston valves of IP control valves by means of a lever. Upon tripping
the trim device alters the spring tension of follow up pistons of IP piston
control valves, draining the secondary oil. The IP control valves openings are
trimmed down.
3.8 Solenoids for Load Shedding Relay:-
A pair solenoid valves have been incorporated in the secondary oil lines
on the control valves in order to prevent the turbine from reaching dangerous
speed in the event of sudden turbine load throw-off. The control valves are
operated (closed) by the load shedding relay when the rate of load reduction
exceeds a certain value. The solenoids drain the IPCV secondary oil directly.
Direct draining of IP secondary oil circuit causes the reheat valves to close
without significant delay. The HP control valves are closed due to draining of
aux. secondary oil before the hydraulic amplifier, by the second solenoid valve.
The extraction stop valves controlled by IP acting through extraction valves
relays also get closed. After an adjustable time delay(approx. 2 seconds) the
solenoid valves are re-closed and secondary oil pressure corresponding to
reduced load build-up in the HP & IP turbine secondary oil lines.


3.9 Test Valves:-
Each of the HP& IP stop valves servo motors receive trip oil through
their associated test valves. The test valves have got port opening for trip oil as
well as start up oil. The test valves have got port opening for trip oil pressure
beneath the servo motor disc.(stop valve open condition) under normal
conditions for the purpose of resetting stop valves after a tripping, start up oil
pressure is supplied to the associated test valves which moves their spool
downwards against the spring force. In their bottom most position the trip oil
pressure starts building up above stop valve servo-motor piston while the trip
oil beneath the disc gets connected to drain. When start up oil pressure is
reduced the test valve moves up draining trip oil above the servo-motor piston
and building the trip oil pressure below disc, thus opening the stop valve. A
hand wheel is also provided for manual opration of test valves.
3.10 Extraction NRVs and Extraction Valve Relay:-
Swing check valves (2x4 no.) are provided on the extraction lines to feed
heaters (LP heaters 2,3 and HPH No.5) tp prevent back flow of condenser
steam into the turbine from heaters on account of high levels in heaters.
There are two extraction line NRVs provided on each of the extraction
lines to LPH -2/3 and HPH -5. Both these valves are free swinging check
valves. The first valve is equipped with an actuator. In case of flow reversals,
both the valves are closed automatically. The closing movement of the valve is
assisted by the actuator. These are force closing type valves.
The mechanical design of force closed valves is such that they are
brought into free swinging position by means of trip oil. They are open as soon
as differential pressure is sufficient. If the trip oil pressure falls, the valve is
closed by the spring force; steam pressure either falls or is lowered (reduced
load).
The trip oil to each of the actuators of force type valves is controlled by
the extraction valves relay, its changeover valve and its solenoid valve.
Extraction valve relay actuates the FC NRVs in proportion to secondary oil
pressure. By suitable adjustment of its spring, the secondary oil pressure at
which the FCVRVs will also open without the release action if the steam
pressure is more than the spring force. But in this case the pressure loads shall
be more leading to loss of efficiency.


Closing movements of FCNRVs are assisted by draining of trip oil pressing
through extraction valve relay or because of turbine trip conditions, by
energizing the associated solenoid valve. In both the cases the actuator is
devoid of trip oil and its spring force closes the NRV. Extraction (4) FCNRV
solenoid is also energized additionally by lower differential pressure in the
extraction line.
3.11 Cold Reheat Swing Check Valve :-
On swing check valve is provided on the cold reheat lines from which the
extraction steam is drawn for HPH-6. These NRVs prevent charging of steam
in turbine when tripped. The CRH NRVs are operated by their pilot valves via
their rotary servo motor in proportion to secondary oil pressure. They open out
fully when main control valves open up corresponding to 5-10% of maximum
turbine output. Only when the control valves are closed to this threshold again,
the NRVs return into steam flow by the hydraulic actuator, so that when the
steam flow ceases in the normal direction they are closed by the torque of
rotary servo motor this preventing back-flow of steam into turbine from CRH.
Even when the pressure of secondary oil has not built up sufficiently,
NRVs can be opened up like safety valves when the upstream pressure rises the
down steam side pressure by one bar.
4. Electro Hydraulic Controller:-
The parameters to be controlled i.e. speed, load and turbine throttle pressure
measured are converted into electrical signals by means of suitable transducers. These
signals are then fed to various control loops where they are processed as per
requirement of the operator reference value signal set points and turbine conditions
(monitoring signals). The control signal generated is then fed to the Electro-Hydraulic
converter where it is converted into hydraulic signals for actuating the hydraulic
operated final control elements. i.e. the control valves. The electrical turbine controller
basically consist of subsidiary controllers for main steam control valve off (valve
position controller), speed, load and boiler pressure are superimposed to main steam
control valve position loop, efficiency of turbine and working of turbine as well.



5. Speed Controller:
The speed controller is used for starting the turbine up to synchronization and
block loading. It can also operate over full load range, during emergency such as
generator tripping from full load to house load operation or during rapid load throw-
off and or severe frequency fluctuations. The speed controller is always kept it
readiness for operation even when it is not directly controlling the turbine by tracking
the signal generated by the other controller in service. The speed reference value can
be changed from-
(a) Cabinet
(b) VPC/ Back up Desk
(c) ATRS and
(d) Auto Synchronizer.
5.1 Speed Control Loop:
Speed set point changes at a gradient of 2160 rpm up to a setting of 2800
rpm. After 2800 rpm the set point changes at a gradient of 360 rpm to facilitate
exact adjustment of speed. The speed reference value is indicated on two
instruments, one with a range of 0-3300 rpm and other with range of 2800-
3300 rpm (for finer adjustment).
The control device for the speed reference value generates the time
dependent speed reference value NRTD / NRLIM which influence the speed
controller. NR is fed to a high gain DC amplifier. The subsequent integrator
responds to very small imbalance of the inputs of DC amplifier. Output of the
integrator is NRTD / NRLIM which changes like a ramp. The speed of
reference value is tracked depending on two operating conditions:
(a) After turbine trips speed controller follows the actual speed with a
difference of 120 rpm. This follow mode ensures that the set point is
below the actual speed, once the turbine is tripped and rolling does not
take place till raise command is given to speed set point.
(b) After synchronization, when load controller takes control, speed
reference follows the actual speed between 48.5 Hz to 51.5 Hz. This
ensures that speed controller does not interfere with load controller as


output of speed controller will remain close to 0% (0.0V). The gradient
of signal NRTD however is modified accordingly to available TSE
margins.
The TSC influence is introduced between DC amplifier and the integrator
to limit the input voltage to the level corresponding to the available margin.
The NRTD during start up allows a rise of turbine speed at highest possible
rate consistent with the conservative permissible operation of turbine on
account of the level of thermal stresses.
The freezing of the speed reference value can occur for the following two
cases:
(a) If TSC becomes faulty the reference value is blocked and integrator
stops. The integrator can again be enabled after the TSC influence is
switched off and master set point release push button is reset. Since the
stress evaluator monitors the dynamic margin on fault detection, the fault
is stored in the turbine governor. The memory is reset by the command
Stress evaluator limitation off.
(b) On transition from barring to rolling by electric speed controller, a
transition period occurs as a result of under modulation of the speed by
speed controller. The reference value is blocked at NRTD NACT > 50
rpm in order to prevent occurrence of excessive control deviation. The
NRTD signal is transmitted to the speed controller where it is compared
with actual measured speed signals and thus generates final controller
output of speed controller.

5.2 No load speed correction:
As a result of proportional control behavior of the speed controller, a
control error exists between the actual value & the reference value. A pre-feed
which is influenced as a function of boiler pressure is provided to achieve
identical speed at synchronizing point.
5.3 Droop of speed controller:
5% i.e. 2.5 Hz above & below 50 Hz. So for a changing of 150 rpm of
reference speed, the speed controller output will vary from 0 to 10 volts.



5.4 Stopping of speed reference value control:
If stress evaluator fault occurs and the generator circuit breaker is open
and NR > NRTD the speed reference value control is stopped.
When the generator circuit breaker is closed stopping of the speed
reference value control is inhibited. The speed reference value control is also
stopped in an analogous manner to that described above when the unit is
operating in pressure control mode.
5.5 Speed measurement and processing:
For speed measurement, four numbers of stationary Hall probes are
mounted around a disc containing 120 magnets (60 N-pole and 60 S-pole
placed alternatively) in front bearing pedestal. By means of these probes the
magnet pulses of the passing magnets are converted into an AC voltage with a
frequency proportional to the rotational speed of the TG. An advantage of this
system is that in one rotation of disc 60 ve pulses will be generated. So, by
counting the pulses for one second we can directly determine the turbo set
speed in rpm.
All the four hall probes are wired up to pedestal Junction box. Out of
these four hall probes, three probes are used for measurement purpose and one
is kept as spare. The gap between the hall probes and disc should be
maintained around 0.8 mm.
The hall probe contains 4 wires. A constant current (30-80 mA) is fed to
two wires and across output wires a voltage is generated in EHC cabinet the
speed measurement is done in two independent but identical channels. One
channel is used for controller and another for indication and limit value
monitors.
5.6 DN / DT Monitoring:
During rolling of the turbine, if between the speeds 600 rpm to 2850 rpm
the rate of speed rise is very low i.e. less than 108 rpm/min then dn / dt
monitoring operates giving appropriate alarms in the pms / soe .it blocks any
further rise speed and bring back the speed reference to 600 rpm. This is
incorporated to avoid low acceleration rates when the turbine speed lies in the
critical speed range (600-2850 rpm).s



6. Load Controller:
The load controller is used for controlling turbine during load operation. For
selecting the load controller a push button module load controller, on/off is provided.
The load controller must be switched on if it has to come into action. For final load
control, several factors like load reference (Pr), load limiter set point (Pr max), TSC
influence, frequency influence and pressure influence are considered and a final
reference (Pr) is developed. An induction load controller active is provided on the
turbine control panel when this lamp glows, which shows that the load controller is in
service. The power reference value can be changed by:
a. From VPC / backup desk.
b. From CMC / UDC control desk.
c. From control cabinet.
The loading and unloading gradients are influenced by:
a. Wall stress evaluation.
b. Rate of power changes reference value from the desk.
The reference value is limited by the absolute output reference value.
The load controller is designed for two modes of operation.
a. Power operation is conjunction with power system with PI control
characteristics.
b. Isolated grid operation with P control characteristic based on the frequency
of the isolated power system. Isolated power system operation is based on
power control deviation.
6.1 Load Control Loop:
Load reference value is from a reference setter module on turbine panel,
by means of a motorized potentiometer and the output of the reference setter Pr
is displayed by the UCB desk indicator. The device for the load reference valve
contains a proportional (P) channel parallel to first channel. On account of this
addition the response of the device is proportional to small changes of the load
reference value e and for large changes it is proportional to integral. Control
device for load reference value generates time dependent load reference value
PRTD / PRLIM which influence the load controller. This signal rises during
start up at a rate (MW/min) selected through load gradient setter until the final
load reference value PR has been reached.


The rate of change of PR limitation is also subjected to additional limits
because of influence of TSC margin of the same is in switched on condition.
The indications for PR limitation and gradient setter are provided on the UCB
panel. If the rate of rise of PRTD is limited by load gradient setter the
proportional channel automatically switches off and response of PRTD is
purely integral.
6.2 Load Gradient and TSC influence:
Load gradient is an additional feature available in load controller. The
load gradient acts in parallel with TSC margin via a minimum selector. Load
gradient range is 0.25 MW/min. while TSC margin have got on/off switch, so
if anyone is desired to be taken out of service it can be switched off. If both are
off then PRTD changes at a fixed rate of 25 MW/min.
Load gradient setting can be changed from desk or cabinet. TSC upper
margin controls the increasing rate and TSC lower margin controls the
decreasing rate. If TSC influence is on and TSC develops any fault
immediately block command is initiated so that wrong TSC margins are not
allowed to control PRTD. To reset it, TSC influence should be switched off.
Before switching it on again, the TSC fault should be rectified and
acknowledged.
6.3 Load Reference Value Control:
By means of reference value control, the maximum permissible gradient
for the turbo set is introduced. This gradient is limited by means of stress
evaluator or by gradient limit.
If the turbo set is not synchronized with the power system, tracking to the
value (PR-Pct) is effective in order that the controller is capable of taking over
control of the turbo-set independent of the actual reference value which has
been set.
The reference value control has PI control action i.e. small changes in
reference value leads to proportional action and large changes to proportional
integral action. Stress evaluator limiting is effective irrespective of the type of
control action.
If the load gradient limit is effective, the proportional action switches off.
The output signal of the integrator is continuously with P-act (actual power
output) by means of an automatic circuit as long as the generator circuit


breaker is not closed this provision facilitate smooth transition from speed
control mode to load control mode. The load controller is equipped with load
limiter module. The output of the load limiter limits the sum of reference value
(Pr) transmitted to load controller to the pre selected value. Even the reduction
in the grid frequency cannot cause the turbo-set to exceed the present power
level. The output of load limiter PR max is adjusted by means of a setter on the
UCB and also indicated on the console.
If the actual power falls below the station auxiliary load, the reference
value of the power controller is tracked to match the output of the speed
controller so that the latter assumes the control of the turbo-set.
The load controller consists of two plug in modules:
a. The first module accommodates the isolated grid detection and the
indicating system.
b. Proportional of the load controller as well as speed dependant
correction of the load control deviation.
c. The second module houses the dynamic system, the load controller as
well as the tracking inputs (the output signal of the load controller is
tracked according to output signal of active controlling the load i.e.
speed of the pressure controller).
The signal of component of CMC (Coordinated Master Control), PRADS
which is load reference for control device from ALDS (Automatic Load
Dispatch Signal) is limited by maximum and minimum load limits CMC
console and is displayed on the desk in MW in case of fault in CMC the
PALDS signal component is switched off. The load reference and the PRTD
which have been matched automatically to PRADS which is on standby,
assume control of the turbo generator.
The required dependence of load on frequency in accordance with the
frequency v/s load characteristics is achieved by means of additional load
reference value PRDF furnished by frequency unit. The unit is high linear. The
sensitivity of the response with respect to change in power grid frequency is
less than 5 m Hz.
The proportional component of load control may be adjusted during the
operation of turbo-set in steps of 0.5% between 2.5% to 8%. In the case of


failure of quartz frequency normal, a monitoring circuit automatically
disconnects the influence signal.
The frequency dependant load reference (PRDF) value can be connected
and disconnected by means of a push button switch inside controller cabinet.
The status of operation mode (frequency influence on/off) is displayed on the
desk / PMS. An indication displays the PRDF in MW.
All load reference values described so far totally in summing amplifier of
the load controller. The total load reference value as it is limited by load limiter
is displayed on the control desk in MW as PR.
If the power plant together with a section of the power grid becomes
isolated during the load control, the load controller automatically switches to a
proportional response with 5% drop. This arrangement permits safe operation
of turbo-set under these conditions. The status of operation of load under these
conditions described above is displayed on the control desk.
7. Pressure Controller:
The signal of the actual pressure and the reference pressure are furnished by
boiler load control system.
Pressure influence signal is generated by a proportional integrator (PI) pressure
controller and affects directly the lift of the main steam control valves via a section
circuit.
The pressure controller controls the turbine load with respect to the main steam
pressure deactivation, and prevents large pressure drop during a quick load increase.
There are two modes of operation on pressure controller.
7.1 Initial Pressure Mode:
It may be selected from the control panel. In initial mode pressure
controller tries to maintain initial pressure. Turbine inlet (throttle pressure) i.e.
reduces the difference between set (reference) pressure and actual pressure to
zero by sacrificing load.
The power delivered by the turbo set is determined by the boiler
capability up to a maximum of power level set by load controller. Load
increase above this level is blocked.



7.2 Limit Pressure Mode:
In the limit pressure mode the boiler storage capacity is utilized. The
pressure controller influences the MSCV to support the boiler pressure control
only if a preset main steam pressure deviation is exceeded. This provision
allows the load controller to handle small quick load variation until pick up
limit of the limit pressure control is reached. This pick up limit is seldom
reached in the usual frequency supported load control mode since boiler
pressure control holds pressure a deviation within narrow limits. The DP is
displayed on the desk.
If the alarm limit pressure reached is present additional load increase is
blocked by means of control unit for reference value load.
8. Valve Position Controller:
The outputs from the speed controller and load controller are compared in a
MAX-MIN selector and the output from this is again compared with the pressure
controller output in a minimum selector. The output from this is fed to the valve
position controller. Therefore the signal from the speed controller, load controller are
super imposed and selected to give an output to the valve position controller.
The feedback signal from the valve lift controller (i.e. the actual valve lift signal)
is derived from the differential transformers which are housed in the electro-hydraulic
converter and measure the position of power piston in amplifier.
9. Electro-Hydraulic Converter:
The electro-hydraulic converter or EHC is the connecting link between
electrical/electronic and hydraulic parts (actuators) in electro-hydraulic governing
system. The electrical signal from the valve position controller is taken to the electro-
hydraulic converter, which is processed and gives a command to the actuators. It
consists mainly of a moving coil system, sleeve a pilot valve assembly, amplifier
piston and a differential transformer.
The electrical signal from governor control circuit operates the sleeve and pilot
valve spool. The sleeve slides up and down on spool, changing the relative overlap
between them, this varies the trip fluid drain. Under steady position the pilot is in
central position. When it is deflected from its position, the control oil is admitted
above or below the amplifier piston, as in case of hydraulic amplifier. The motion of
the amplifier piston is transmitted via a lever to cam shaft which actuates the sleeves


of follow up piston valves, which regulate the secondary oil pressure to the HP and IP
turbine control valves separately.
10. Hydraulic Governor:
On the shaft of the main pump, a specially designed primary oil pump is
provided. The changes in the primary oil pressure can be taken as proportional to
small changes in the turbine speed.
This primary oil pressure acts on diaphragm of the hydraulic speed governor
against the seat of speed setting spring which is tensioned by speeder gear. Travel in
diaphragm is limited by a start up and load limiting device. The movement of the
diaphragm is transmitted by a link mechanism to the auxiliary follow-up drain valves.
The piston of auxiliary follow-up drain valves is held in service by a spring against oil
pressure, known as auxiliary secondary oil. The oil is essentially trip oil fed from trip
circuit and drained through a port formed between the piston and the sleeve.
Depending upon the piston opening, oil pressure gets established corresponding
to the initial displacement of the piston and initial spring tension in the auxiliary
follow-up valves. The auxiliary secondary oil pressure provides a signal to hydraulic
converter through its pilot. The piston of the hydraulic converter assumes a piston
corresponding to auxiliary secondary oil pressure. A secondary oil pressure
corresponding to the piston of the sleeve related spring tension built up in the follow-
up pistons of the hydraulic converter.
Any change in the piston of link results in proportional change of secondary oil
pressure in the follow-up piston of the hydraulic converter. The secondary oil circuit is
also fed from trip oil circuits through reducing valves orifices. It is necessary that
while operating on hydraulic governor mode the follow up drains on secondary oil of
the electro-hydraulic converter are closed fully i.e. EHC output is 100%.
The varying secondary oil pressure in the follow-up pistons of the hydraulic
converter operates the control valve.
11. Change over From EHG To HG Control:
If the turbine is to be rolled on hydraulic governor, the speeder gear is kept in
minimum position and EHC output is adjusted to its 100% position. The turbine is
rolled up to 2800 rpm by means of starting devices alone. Afterwards for further speed
raising speeder gear is raised. Isolating valves on the secondary oil lines coming from
EHG are to be closed while operating on the hydraulic governor mode.


The change over from Electro-hydraulic to hydraulic governor on load
conditions is done in the reverse sequence as mentioned in the earlier section. First
speeder gear position is lowered until secondary oil pressure drops slightly. This is an
indication that the hydraulic governor has taken over the control. Then reference set
points of the electric controller oil lines from EHG are closed. Now hydraulic
governor is fully effective and can operate over the entire load range.
12. Changeover From HG to EHG Control:
Change over from one control system to the other one is possible during normal
operation of turbine, since the two systems are brought into parallel connection, after
associated follow up pistons which represent a minimum value selection open
sufficient to start draining secondary oil to control valves, meaning that the system
with lower reference value always becomes the controlling one.
When bringing in the electro-hydraulic control system, the reference set point of
electrical controller should be reduced slowly until secondary oil pressure drops
slightly. When this occurs, the electro-hydraulic converter has taken over. The speeder
gear of the hydraulic converter is now fully effective and can operate over the entire
output range. The hydraulic speed governor acts as a speed/load limiter even in the
event of electrical controller developing a fault. In this case operation of the turbine
may be immediately changed over the hydraulic governor.
13. Starting Procedure:
The turbine is started and brought up to synchronization speed by means of main
steam control valves and reheat steam control valves. Reference speed setter is set to
minimum speed at this point if the hydraulic speed governor is to be used. In this case
the speed reference of the electro-hydraulic controller is set to maximum. If on the
other hand, start up is to be affected with electronic controller, hydraulic reference
speed setter is set at maximum and the speed reference of the electro-hydraulic
controller is at maximum.
The stop and control valves are in the closed position as the trip coil circuit is
not yet pressurised. But turning hand wheel clock-wise or by operating motor of SLL
in close direction, spring in auxiliary follow up piston is relieved by the linkage action,
thereby preventing a build up when the main trip valves are latched in.
By further turning hand wheel of starting and load limiting device is moved
downwards whereby control oil is admitted first into the start up oil circuit and then


into auxiliary start up oil circuit. The start up oil flows to the space above the piston of
test valves and forcing them down against the action of the return springs. The
auxiliary start up oil raises the piston of main trip valves, thereby permitting trip oil to
flow to that test valve and to the main and reheat stop valves.
The trip oil can now flow to the space above the pistons of the main steam stop
valves and reheat stop valves pressing them on the lower piston disc. Operation of the
start up and load limiting is continued until it attains lowest position.
Subsequently by turning back the hand wheel or by operating the motor of SLL
device in the open direction, the pressure oil is first discharged from auxiliary start up
oil circuit and then from the start up oil circuit. The piston of the test valves move
upwards by the springs and as a result trip oil builds up in space below the piston and
is slowly discharged from the space above the piston. The pressure difference thus
occurring lifts both the pistons together into their upper end positions thus causing the
main and reheat stop valves to open. Main trip valves are now held their upper
position by the oil pressure of the trip oil under their stepped, differential positions.
After the stop valves have opened, further turning of hand wheel in the open
direction after certain amount certain amount of dead range will enable the speed
governor diaphragm to move downwards causing increase in the auxiliary secondary
oil pressure. This would cause the increase in secondary oil pressure above the
hydraulic converter with follow up pistons and will gradually open the control valves.
This will run the turbine up to approximately 85%-90% of the rated speed. At this
point hydraulic speed governor will take over the control and maintains the speed.
Starting and load limiting device is the set at maximum position.
Further speed increase, synchronizing and loading of the turbine are
accomplished by adjusting reference speed setter. By turning hands wheel, additional
tension is applied to the speed setting spring, which results in increase in speed.

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Turbines and Auxiliaries Chapter 4

Department of Electrical and Electronics Engineering Page 23

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