KWU Electro-Hydraulic governing

Governor is a device to control speed /load to a set point. Type: Hydraulic & Electro-hydraulic Advantages & disadvantages

ADVANTAGES OF EHC
i) Increases the life of turboset by conservative operation with the aid of TSE ii) Reliable operation of isolated power grid by Automatic Switchover of the load controller to frequency control. iii) Precise maintenance of the rated frequency of the power grid by means of an exact frequency load curve. iv) Low speed deviation under all operational conditions. v) Support of the pressure control system

kwu
EHC can be divided into following sub-sections: 1 Speed measurement and Speed controller 2 Load controller and Load measurement 3 Pressure controller 4 Control transfer of Speed, Load and Pressure Controller 5 Admission /Position Controller

Droop of kwu m/c

output +100%

2790 0%

2940

3060

3210 RPM

-100%

What is Droop?
% of frequency change ( % of RPM change) will lead to full travel of Governing valves or full load change. 5% droop means: 5%*50 Hz= 2.5 Hz Will change 500MW. In terms of output total change should take place is 100%

TURBINE DROOP 5% & NO DEAD BAND 2700 +100% 2850 3000 RPM 3150 3300

0 -100% +100%

-150 RPM

+150 RPM

+300

2790 DROOP5% & DEAD BAND +/-2%

0% 2940 -100% 3060 3210

1a Speed measurement
Hall probes are mounted around a disc (fitted at the turbine shaft) containing 120 magnets (60 N-pole & 60-S pole alternatively) . An advantage of the same is that one rotation of disc will generate 60 positive pulses & So, by counting the pulses for one second we can directly determine the turbo set speed in rpm.

1b Speed Controller
Speed Controller is used to increase turbine speed from barring speed to rated speed in a controlled manner and to assist Auto synchronizer in synchronizing the machine and taking the blocking load. After synchronization speed controller can be used for taking load up to 100% but as a normal practice approx. 10% of load should be taken and then load controller should be taken into service. It is done because during speed controller mode a small frequency change will cause corresponding opening in valve opening ( hence in load)

Speed controller can be divided into sub section: Speed set point, Speed set point control, Dn/Dt monitoring, Speed control Loop, No load correction.
a) Speed set point can be changed from cabinet, desk, auto Synchronizer and SGC turbine. The set point is called nR. The set point changes at a gradient of 2160 rpm/min up to a setting 2820 rpm. After 2820rpm speed set point changes at a gradient of 360 rpm/min which enables accurate setting of set point in the working range

b) Speed Set Point control

Speed Set Point control :- The set point fixed in the earlier section cannot be passed to speed control loop directly as it is only the desired value which can be changed at a very fast rate and it does not take care of turbine stress margin. To incorporate the above facilities an integration (closed loop) is used.

c) Dn/Dt MONITORING
A Speed controller output (hr n c) should be more than 0.0 V (with a time delay of 10 seconds) B E S Vs open. C Generator circuit breaker in open condition. D Actual speed (n a c t) < 2850 rpm. E Speed set point (nR) more than 700 RPM for 200MW. For 500MW,set point is > 400 rpm. F Dn/Dt < 108 rpm M/c will bring back to soaking speed 600rpm/360rpm

d) Speed Controller Loop: Speed Controller loop is PD (P) loop with a droop of 5%. As the rated speed of the turbine is 3000 rpm hence 5% is 150 rpm. A deviation of 150 rpm will correspond to full opening of the control valve (with the assumption that full opening of control valve will give full load at rated parameters)

e)No Load Correction

As the speed controller loop is PD (P) so an error in the input is a must to keep the valves open for running the at the rated speed .To avoid this error between set point and actual value a pressure dependent correction signal is given, as the valve opening required for running the machine at rated speed is directly dependent on steam pressure. Hence, for correction purpose practical reading should be taken when the machine is running at rated speed at different pressure

2.Load Controller
Load controller is used to maintain the load set by the operator ( at turbine control or at CMC console ) or automatic load dispatch Centre (optional ). Load controller is also responsible for taking care of frequency changes and correcting the load. The controller comes into operation only after synchronization, before Synchronization it remains in the follow mode .The total loop can be divided in the following sub-sections

Sub-sections of Load controller

2A) Load set point (PR) 2B) Load Gradient and TSE Margin Influence. 2C) Load Set Point Control (PRTD) 2D) Frequency influence. 2E) Load Limiter 2F) Actual Load Acquisition 2G) Final Control Loop

2A)Load Set Point: Load Set Point:- Load set point can be changed from cabinet, desk, SGC or CMC or from Auto dispatch Centre (optional).The set point changes at a gradient of 100 MW /Min for 200MW & 250MW/min for 500MW). The gradient remains same through out the range. The load set point indicator is available at desk. The range of the indicator is 0-250 MW for 200 MW M/c & 0-600MW for 500MW M/c.

2B) Load gradient and TSE influence

Load gradient is an additional feature available in load controller. The load gradient acts in parallel with TSE margin with minimum Selector. Load gradient range is 0-25MW/ min : 200MW & 0-60MW/min (500MW). While for TSE margin 0-30 degree K corresponds to 025 MW/min 200MW, 0-60MW/min(500Mw) Both load gradient and TSE margin have got an ON/OFF switched, so if any one is desired to be taken out of service can be switched off.

2C) Load set point Control(PRTD )

If load gradient is off and any change in PR is made PRTD changes by 5% The function of PRTD is similar to the NRTD in speed controller The maximum rate change here is 25MW /min or 60MW in both directions The set point controller remains in follows mode in generator breaker is off or load controller is off or load is less than station load& MW error>10%. During this mode PRTD follows actual load without delay STOP command is generated if TSE fault appears

2D)Frequency Influence
Frequency influence is used to correct the load set point. The frequency influence has got a droop of 5% The frequency influence can be switched on/off from Frequency Influence module Indicator for the correction signal is available at desk of range +/- 100MW for 200MW M/c & +/- 200 MW for 500MW M/c. IN all NTPC stations this has been kept off.

2E) Load Limiter

Final Set point (addition of PRTD and PR F ) is fed to a minimum selector with the load limiter Load limiter will limit the actual load and it also can be used for fast reduction of load in emergency cases. PR (in turn PRTD )also should be reduced, so that during load increase as per PRTD and not as per load limiter

2F) Actual Load Acquisition /Load measurement

The actual load is measured by three load transducers which get the signal from PT and CT and give out put 0-250MW (or 0-500MW M/c) corresponds to 4-20 mA The middle value of the three load measurement is use for processing If any value drifts from the other value by more than 5%, a selective alarm is generated

2G)Final Controller Loop

The final loop is a PI controller Two major parts consisting of two cards ARL 12& ARL 13 specially designed for this purpose Error signal is generated from the final set point and actual load in ARL 12 card. It has an inbuilt frequency influence whose responsibility is to prevent the over speeding of the turbine. Hence, this frequency influence acts only to reduce the out put of the controller The output of ARL 13 card provides the integrator part of the loop. Apart from the integrated, ARL 13 has also got a filter

Following Above (hvo)

This mode in operation during following conditions 1Load Controller Off 2Generator Breaker Off 3Pact <STL & P>5% and Generator breaker closed. During the above condition the load controller output tracks the speed controller output all the time with a constant error of-150mV. This follow-mode ensure that during above conditions, the load controller should not come into action.

Following Low (hvu)

This mode is present one the breaker is synchronized and speed controller is still in action. During this mode the load controller output tracks the speed controller output with error of 150mV load controller output can go more than speed controller output (hence load controller can take over) but it cannot go 150 mV below the speed controller output. load controller can be taken into service anytime without any delay

Pressure Controller :-

3a) Initial Pressure Mode A Pressure deviation signal (difference of required pressure as per load and actual pressure ) is fed to the controller .As long the deviation is more than + 150mV (Actual> required ) the pressure controller output remains as maximum saturation. If the deviation fall between 0 to +150mV, the output of the pr. controller comes out from saturation & match to the output of final minimum selection output As soon as the deviation becomes negative, the output of the pressure control starts This mode comes when runback action comes into picture or it is selected from console

Pressure controller
3b Limit pressure mode The function of this mode is similar to the initial pressure mode .The only difference being that biasing of 10Kg/Cm2 is given in this loop. Hence, all the action start after the pressure drops by more than 10Kg/Cm2. This mode is used when m/c is in load control; a small pressure correction signal is also applied +/- side to load set point control. This mode should be used once the load on turbo set is stabilized.

4 Control Transfer: This loop receives the signal from speed controller (hrnc), load controller(hr PC) and pr. controller a set of Max & Min selection and then final value selected is passed on to position /admission controller hrnc> and <hr PC> pass through a maximum value selector and the value selected is passed on to first MIN value selection. 10.5v is added in <hrnc> and this value is also fed to first Min value selector The value selected in first Min value selector is passed on to the second MIN value selector along with output of pressure controller output (hr PRC) The value selected here is passed on the position / admission controller.

Position/admission Controller:

Position Controller is the final control element in EHC. It receives the signal from control transfer It receives feedback signal from Collins transmitters.Two Collins transmitters are provided Selection one of two is through MIN value selector (logic MAX selector) Plunger coil supplied in EHC is an integrator type. The balance point of the coil is 1.0V Provision to switch ON/OFF the voltage supply to plunger coil. Switching ON /OFF can be done only if the output of position controller is > 100%.

PLUNGER COIL RESPONSE STEP INPUT OF ORDER OF 2 VOLT DC COLLINS RESPONSE AT INPUT OF CARD ( 1 ,2) EHC COIL RESPONSE HPCV RESPONSE, DELAY BY 1 SEC

MIN

PI controller
Admission controller

EHC Plunger Coil

HP sec. oil IP sec oil

AND

EHC> 100%

PLUNGER COIL ON/OFF PB

Response of plunger coil/EHC

Step I/n

collins1or2

EHC coil Volt

HPCV1 opening

LOAD SHEDDING RELAY

LOAD shedding relay is used to support the function of the turbine governor. A quick correction value input to the hydraulic governor output & secondary oil pr. of IPCV min speed building When acceleration time constant is very small or when governor under load or pressure control. Sudden negative jump in load is detected electrically instantaneously by the load shedding relay 200MW: Load throw off>40% & residual load<15% & frequency>49 Hz 500 MW: Load throw off>50% & residual load<30% & frequency>49 Hz in a response time of 100mili seconds. Full load through off <6% the total interrogation time for solenoids to energize is 1.25 seconds.

EHC: SPEED CONTROLLER

EHC: Load controller

ACTUALPR SET THROTTLE PR. SUMMER

CONTROL TRANSFER LOGIC & ADMISSION CONT

MIN PI CONTR COLLINS 10 KSC INITIAL PR. MODE MIN EHC CONV

PI CONT.

LOAD CONT MAX SPEED CONT 100% -0-+100% OVER SPEED LIMIT 105% MIN

LOAD SHEDDING RELY SOLENOID VALVES IN OIL CIR

For example :- Turbine running at 3000 rpm Output of speed controller at (50Kg/Cm2)=1.5V Output of speed controller at (150Kg/Cm2)=0.8V The pressure transmitter ranges is 0=250Kg/Cm2 = 0-10V for 4 to 20mA The correction input as given with a gain of 0.05 and the overall gain of speed controller loop is so net gain for correction signal =0.05x22.22=1.11 Hence correction input required at 50Kg Cm2 =1.5/1.11 =1.35v and correction input required at Y=m x +C Y= Correction Signal X = Pressure Signal ( 50 kg/cm2=2v, 150 kg/cm2=6v) 1.35=M x 2+C. .(1) 0.72=M x 6 +C. .(2)

By solving above two equation M = -0.16 C= 1.67 Gain (M) should be adjusted by potentiometer AB 099/R11 negative polarity of (M) is taken ca

CONTROL TRANSFER LOGIG & ADMISSION CONTROLLER