WELCOME TO

THE PRESENTATION ON

STEAM TURBINE
PROTECTIONS AND
GOVERNING SYSTEMS
AT

ESCI, HYDERABAD
BY

BHEL PS SR, CHENNAI

8-9 Dec, 2004

CONTROLS OF LARGE
UTILITY TURBINES
Presentation By

Srinivasan Selvaraj

Main Control Systems

Electro-Hydraulic Governing System (EHTC)

Turbine Stress Evaluator (TSE)
LP Bypass Control System (LPBP)
Gland Steam Control System (GSC)
Protection System
Turbovisory System (TSI)
Automatic Turbine Tester (ATT)

Electro-Hydraulic Governing
System (EHTC)

EHTC: Advantages

Safe Operation of Turbine in

conjunction with Turbine Stress
Evaluator (TSC)
Excellent Operation Reliability and
Dependability
Low transient and steady state speed
deviations

EHTC: Advantages

Dependable control during load

rejection
Reliable Operation in case of Isolated
Grid

Critical Measuring Devices

Speed Probes (3 Nos.) and associated

circuit elements
Load Transducers (3 Nos.)
Electro-hydraulic Converter housed in
Governing Rack (1 No.)
Position Feedback Transmitter of EHC

Control Loops

Speed Control
Load Control
Pressure Control

Speed Control: Main Functions

PD Controller
Start Up & Shut Down of Turbine
Synchronizing with grid
Providing Min. Load
Operation of Turbine over entire range
of Load in case of Load Controller
Failure

Load Control: Main Functions

PI Controller
Provision of load reference limiter
Frequency influence option

Pressure Control:Main Functions

PI Controller
Initial pressure control
Limit pressure control

Nr

Nrtd

+
Nact

Pr

Prtd

+
+

Pmax
+

Prsu
m

SPEED
CONT. PD
M
I
N

_
+

LOAD
CONT. PI

M
A
X

M
I
N

M
I
N

EL
HYD

Pact
Fact

_
+
Fref

pREF

_
+

PRESSURE
CONT. PI

pACT
0
P
LIMIT PRES.

INIT. PRES.

Governing Scheme for

KWU Turbines

FROM ELEC
CONTROLLER
EL
HYD
STARTING
DEVICE

MIN
M
I
N

TO CONTROL
VALVES

HYD
HYD

SPEEDER
GEAR

Governing Scheme for

KWU Turbines

Additional Functions

Tracking device option

Load shedding relay
Auto Synchronizer
Isolated grid operation

Tracking Device Functions

The starting device keeps varying
automatically with variation in the
position of EHC. In case the EHC fails
the starting device will restrict the
raise in the load.

Load Shedding Relay Functions

During sudden load throwoff conditions,
there will tendency for the speed to raise
rapidly. To avoid such conditions the LSR
gives a close command for closure of the
control valves for a brief moment. The
magnitude of load throw,time duration of
closure of control valves are settable in
the LSR.

Auto synchronizer Functions

The auto synchronizer accepts Gen and Grid
Potential transformer signals. To match the
frequency and voltage of the Generator, the
auto. Sync. Unit gives Speed raise/lower
command to EHTC and voltage raise/lower
command to AVR.
After parameter matching the auto sync. Unit
generates a command for Synchronizing the
unit

Auto synchronizer Functions

After parameter matching the auto sync.
Unit generates a command for
Synchronizing the unit

Turbine Stress Evaluator

(TSE)

Turbine Stress Evaluator

Compares thermal stress in the

monitored components with the
permissible limits and generates
margins.
The temperature margin is fed to the
set point controller speed and load.
Derives start up criteria for ATRS

TSE: Components Monitored

Emergency stop valve.

HP control valve.
HP casing.
HP shaft.
IP shaft.

TSE: Measuring Points

Surface and mid wall temperatures of

(Ti & Tm)
Surface and mid wall temperatures of
Surface and mid wall temperatures of
casing.
Derived value for HP and IP shaft
temperatures from specified locations
respective casings.

ESV
HPCV
HP

in

TSE: Operating Modes

Three modes viz., fast, normal, slow

available.
The increased fatigue rate associated
with fast mode can be compensated by
more slow mode operation.

TSE: Margins

For any component, the difference Ti Tm

represents the actual thermal stresses.
Depending on the value of Tm and
operating mode the permissible value of
thermal stress is determined.
From the difference between the
permissible stress and prevailing actual
stress the margin is derived.

TSE: Margins

The margins of different components are

provided in the Bar graph form in the
TSE monitor.
The reference variable derived from the
minimum margin acts directly on the
turbine control system.

LP Bypass Control System

(LPBP)

LPBP system: Main Features

Enables alternative path for dumping
steam from RH outlet to condenser
bypassing IP and LP turbine.
Maintains RH pressure from a criteria
representing the HP turbine flow.
Works in conjunction with HP bypass
systems and when necessitated by the
system.

LPBP system: Main Features

Provides fixed and variable set point.
Protects the condenser by water
injection.
Hydraulically protects the system when
the water injection press. is v low or
condenser press. is v high

LPBP system: Pressure control

Process variable for control loop is
acquired from Press. Transmitter in RH
line.
Two set values viz. Fixed set point and
variable set points are formed and
maximum value is used as reference.

LPBP system: Pressure control

Fixed set point is varied with push
button in the control desk.
Variable set point is derived from I stage
pressure of HP turbine which is an
indicative parameter of steam flow.
Manual operation of valves is possible
with push buttons in the control desk.

I stg.
press

PT

f(x)
Fixed
setpoint

M
A
X

PI
Cont.
From EHC LVDT
-

PT

Valve
Lift PID

To EHC

RH press

LPBP Scheme for KWU turbines

Gland Steam Control System

(GSC)

Gland Steam Pressure Control

Maintains the Gland steam header

pressure at required value.
Provided with two control valves viz.
seal steam control valve and gland
steam control valve.
Process variable is the header pressure
from a transmitter.

Gland Steam Pressure Control

The electro-hydraulic actuator have

inbuilt pump and it is powered by
separate power supply.
In the event of pump failure,the valve
remains stay put.

Seal steam valve

Set
point.

+
-

PI
Cont.

f(x)

EHC

PT
Leak steam valve

GS header
press

100

EHC

Leak steam valve

Seal steam valve

Command
To
Valve

f(x)

Cont.output

100

GSPC Scheme for KWU turbines

Protection Systems

Protection Systems

Electrical Protection Systems

Hydraulic Protection Systems

Electrical Protection Systems

Emergency PB (UCB)
Lub Oil Pressure Very Low (2 out of 3)
Fire Protection Trip
Turbine Trip from ATRS
Axial Shift Very High (2 out of 3)
Over-speed Trip
MFT Relay Acted from Boiler (2 out of 3)

Electrical Protection Systems

Generator Protection Trip

Vacuum Low Trip
HP Exhaust Temperature Very High(2 out of 3)
Generator Cold Gas Temperature Very High
Exciter Hot Air Temperature Very High
Liquid Level in Generator Bushing Very High
(2 out of 3)

Hydraulic Protection Systems

Over-speed Trip 1 & 2

Vacuum Low Trip
Axial Shift
Hand Trip Lever 1 & 2

Features of Protection Systems

Cyclic Test done periodically for each

Trip input
Fault at input level will be annunciated
Testing can be done online
2 out of 3 logic ensures reliability and
avoid spurious trippings
2 separate Processor Units realize the
Protection Logic with dedicated IOs.

Features of Protection Systems

Data of both processors matched

through Serial Communication and
discrepancy annunciated
2 separate Solenoids provided in
Hydraulic System for redundancy
First cause of trip will be annunciated
Online Testing of Final Tripping
elements through ATT

Resetting of Protection
Turbine Trip Solenoid stays in energised
condition until the following conditions
are fulfilled.
Command from individual Trip ceases
Both ESVs Closed
Trip Oil Pressure less than 2 kg/sq.cm

Turbovisory System (TSI)

Turbovisory Instruments

Absolute bearing vibration

Absolute shaft vibration
Axial shift
Relative expansion HP
Relative expansion IP
Relative expansion LP
Overall expansion

Automatic Turbine Tester

(ATT)

ATT : Features

Individual testing of each turbine

protective devices.
Pretest ensures substitute devices.
Monitoring of program steps for
execution within a certain time.
Interruption if trip is initiated.
Automatic reset of program after a
fault.

Automatic Turbine Tester

Sub group Safety Devices.
Sub group HP/IP valves.

ATT: Safety devices

Remote trip device 1 & 2.

Over speed trip device 1 & 2.
Low vacuum trip device.
Thrust bearing trip.

ATT: HP/IP Valves

HP stop & control valve 1

HP stop & control valve 2
IP stop & control valve 1
IP stop & control valve 2

ATT: LOGICS for safety devices

Release condition for start
All protective device in operating
condition.
1st step command
Checking of Provision of control fluid for
enabling test

ATT: LOGICS for safety devices

Release condition for 2nd step
Pressure before changeover valve > 5
kg/sq cm.

2nd step command

Takes care of over speed trip-1 during
test.

ATT: LOGICS for safety devices

Release condition for 3rd step
Pressure before changeover valve < 2
kg/sq cm.
Pressure between sol. valve >5 kg/sq cm.

3rd step command

Takes care of over speed trip-2 during
test.

ATT: LOGICS for safety devices

Release condition for 4th step
Pressure between sol. valve <2 kg/sq
cm.
4th step command
Provision of control fluid.

ATT: LOGICS for safety devices

Release condition for 5th step
Pressure before changeover valve >5
kg/sq cm.
5th step command
Changeover valve to test position.

ATT: LOGICS for safety devices

Release condition for 6th step
Trip oil Pressure >5 kg/sq cm.
Changeover valve test position.
Aux startup fluid < 2 kg/sq cm.

6th step command

Testing of remote trip device 1 & 2.

ATT: LOGICS for safety devices

7th step command
Testing of over speed trip device 1 & 2.
8th step command
Testing of low vacuum trip device
9th step command
Testing of thrust bearing trip device

ATT: LOGICS for valves

Start conditions
All stop valves 100 % position
Load controller in action
Load < 66.6 %
Trip oil pressure > 2 kg

ATT: LOGICS for valves

Step I command
Control valves - HP & IP
Step II command
Stop valves HP & IP

Automatic Turbine
Run-up System
(ATRS)

Automatic Turbine Run-up

System (ATRS)

Acquisition, analysis and collation of

various parameters during Startup
Sequential Control of Drives
Unit Synchronization and Minimum Load
Operation
Organised and hierarchically arranged
as Sub Group Control (SGC), Sub-loop
Control (SLC), and Control Interface

ATRS: Functional Group

ATRS

SGC (Oil)

SGC (Cond & Evac)

SGC (Turbine)

SLC (Turning Gear)

SLC (CEP)

SLC (Drains)

SLC (AOP1)

SLC (Vac. Pump)

Warm Up Controller

SLC (AOP2)

SLC (Vac. Brkr)

Starting Device

SLC (EOP)

Set Point Device

(Speed & Load)

SLC (JOP)

Autosynchroniser

THANK YOU !