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Write Up ON Electrohydraulic Turbine Controller (Ehtc) : Reference Documents
Write Up ON Electrohydraulic Turbine Controller (Ehtc) : Reference Documents
01
WRITE UP
ON
ELECTROHYDRAULIC TURBINE CONTROLLER ( EHTC )
Reference Documents:
1.MPL for Steam Turbine
Doc. No. :- 41330000488(TAPP3/64110/5516/SCH)
2.Scheme for speed measurement turbine and generator
Doc. No. :- 41330098204(TAPP3/64110/5512/DN)
3.Write up on LRR for MSCV and AEOR
Doc. No. :- 41330000481(TAPP3/64110/5661/DN)
4.OGA of TG control desk 6610 PL 9
Doc. No. :- 06560000403(TAPP3/64100/5724/GA)
5.OGA of TG control desk 6610 PL 10
Doc. No. :- 06560000404(TAPP3/64100/5725/GA)
6.Turbine controller CJJ01 Cubicle & Rack assembly diagram
Doc. No. :- 36560001746(TAPP3/64100/5728/GA)
7.Turbine controller CJJ01 Signal Flow Diagram(SFD)
Doc. No. :- ED-031027-SF-S105(TAPP3/64100/5729/WD)
8.Turbine controller CJJ01 Functional Diagram(FCD)
Doc. No. :- ED-031027-FC-S105(TAPP3/64100/5729/WD)
NPC. DOC. NO.
01
1.10.02
TAPP3/64110/5526/DN/R0
BS RANA
NPC COMMENTS
00
17.11.02
FIRST ISSUE
V. KUMAR
BS RANA
A. ALI
REV
DATE
REMARKS
WORKED
CHECKED
APPROVED
SH. NO.
Introduction
2
3
3.1
3.2
4
4.1
4.2
5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.3
5.4
5.5
5.5.1
5.5.2
5.5.3
6
4
5
5-6
6-7
7
7
7-8
8
8
8
9
9-10
10-11
11
11-12
11
12
12
12
13
13
14-15
15
16
16
16-17
17
7
8
8.1
8.2
8.3
8.4
9
17
18
18
18-19
19
19-20
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Introduction
Electro-hydraulic turbine
PROCONTROL system.
controller
(EHTC)
is
realized
as
part
of
2.
A hydraulic system which position the valves to match the valve lift
signal.
high flexibility
excellent dynamic response
simple representation of complex functional interrelationships
The standard configuration provides a hydraulic controller and an Electrohydraulic controller for control of the turbine generator. As can be seen in
fig. 1, the hydraulic controller acts via a hydraulic amplifier, and the Electrohydraulic controller via Electro-hydraulic converters. The output of each of
the Electro-hydraulic converters is linked via an hydraulic MIN gate (as
shown in fig 3). This means that the lower control signal at any time takes
affect for the hydraulic actuation system.
This description in not intended to give detailed information on the hydraulic
controller or on the hydraulic valve actuation system. These two systems are
therefore described only to the extent required to assist in understanding
Electro-hydraulic controller operation.
---------------------------------------------------------------------------------------------- Sheet no. 4 of 37
STE, BHEL-HARDWAR
Hydraulic Controller
The hydraulic amplifier forms the interface between the hydraulic controller
and the hydraulic valve actuation system. The output signal from the
---------------------------------------------------------------------------------------------- Sheet no. 5 of 37
STE, BHEL-HARDWAR
The load rejection relay (see Fig.2) assists the electro hydraulic controller to
ensure that the speed of the turbine generator cannot reach the trip setting
for the hydraulic overspeed trips under any circumstances.
Sudden unloading of the turbine generator, that is , a negative step load
change, are acquired promptly by electrical means via the load rejection
relay and converted into an electrical pulse of adjustable duration. This pulse
is used to actuate the solenoid valves in the control fluid circuit for the
control valves, switching to drain and thereby causing a rapid drop in
pressure.
Response of the load rejection relay to the load rejection uses the change in
electrical generator load before the subsequent increase in speed which
results. This means that the load rejection relay acts on the turbine control
system before the significant speed increase .
After termination of the electrical pulse the solenoid valves which have
switched to drain close again. At this stage , the electro hydraulic controller
still holds the drain closed due to the speed increase which has occurred in
the meantime. After this speed increase has stabilized , the electro hydraulic
controller opens these valves again. Control fluid pressure then builds up
again and the electro hydraulic controller opens the control valves to a
position corresponding to the new generator load or to the speed set point.
---------------------------------------------------------------------------------------------- Sheet no. 6 of 37
STE, BHEL-HARDWAR
The settings for the load rejection relay (load step magnitude, pulse
duration) are made during initial commissioning and start-up of the turbine
generator.
To prevent response of the load rejection relay on under -frequency, a
frequency monitoring circuit inhibits response of this relay if frequency drops
to an adjustable under frequency limit. Without this feature , in the event of
the load rejection on under frequency ,after termination of the CLOSE pulse
the electro hydraulic controller would then open the turbine control valves
very far due the large error caused by the frequency deviation. This in itself
could lead to an overspeed trip.
4
4.1
4.2
The task of the speed loop is to meet closed-loop control requirements for
the turbine generator during start-up and synchronization with the power
system. During power operation the speed controller serves as an overspeed
limit controller to ensure that speed increases caused by power system
disturbances (such as load rejection) cannot result in speed reaching the trip
setting for the mechanical overspeed trips (set to approx. 115% of rated
speed) under any circumstances.
The speed control loop consists of the set point adjuster, the set point control
and the speed controller.
5.1.1 Speed Set point Adjuster
The speed set point nr is governed by the position of the set point adjuster
(refer Fig. 5). The set point can be adjusted over the range from 0 to 55 rps
from the main control room panel 6610 PL - 10. To assist in fine
adjustment of the speed set point for synchronization, the rate of change for
the set point adjuster is decreased by a factor of 4 at set points above 47
rps.
Further input are provided for adjustment of the speed set point by a
synchronizing unit and an automatic start - up system. Manual set point
change command take priority.
The speed set point is displayed on two indicators on the turbine control
panel , one for the overall speed range of 0 to 60 rps and the other for the
narrow range from 45 to 55 rps.
5.1.2 Speed Setpoint Control
The speed setpoint nr forms the input signal for the setpoint control which
determiners the acceleration rate. For this, the setpoint control outputs a
delayed setpoint nr del.
The output from the speed controller is applied to the control selection circuit
and, when selected for output, forms the input signal for the valve lift
controller
( see description of control selection circuit, Section 5.4).
5.2
The set point output of the lift set point control loop takes over control of the
turbine immediately after synchronization of the turbine generator with the
power system. This function allows valve lift and thereby turbine load to be
---------------------------------------------------------------------------------------------- Sheet no. 10 of 37
STE, BHEL-HARDWAR
The output from the lift setpoint controller is automatically set to zero under
the following conditions:
-
When the lift setpoint is deactivated for longer than 3 s ( see Section
5.2.6)
After the speed controller has taken over control of the turbine during
shutdown.
5.2.6
Providing that the speed controller is in action, the lift setpoint can be
activated or deactivated manually as required from the main control room
panel 6610-PL-10. The lift setpoint should always be activated in normal
operation, as selection of the controller to take control is implemented by the
control selection circuit. The control selection circuit is described in Section
5.4.
The output of the lift setpoint controller is automatically deactivated under
the following operating conditions :
-
The adapted pressure deviation signal from steam generator pressure control
system is received in two channels. These two signals are compared in a
MAX gate and fed to a pressure controller. The output of the pressure
controller is fed to the control selection circuit and has got highest priority
(see fig.12)
The pressure controller tolerates small size deviations from the pressure
setpoint. It does not take action until actual pressure drops more than a
---------------------------------------------------------------------------------------------- Sheet no. 13 of 37
STE, BHEL-HARDWAR
The control selection circuit (see fig.12), a logic circuit comprising a MAX
gate with downstream MIN gate, determines which of the three types of
loop- speed control loop,lift set point control loop or minimum pressure
control loop - takes over control of the turbine generator. This control
selection circuit also ensures that only one of these 3 controllers will be
active.
The output signals from the speed controller and the lift setpoint controller
are inputted to the MAX gate, i.e the higher signal value is always output by
this gate, thereby setting turbine valve lift if this is also the lower signal
valve present at the downstream MIN gate. During turbine generator startup, the output signal from lift setpoint formation is deactivated (as the
generator breaker is not closed), so that the signal from the speed controller
will be output by this logic and the speed controller will take control of the
turbine generator. Minimum pressure controller output has got more priority
and will takeover control to throttle valves if actual pressure drops more than
a certain limit from set pressure valve.
Once the generator is synchronized with the power system and the generator
breaker is closed and lift setpoint control loop is activated, the lift setpoint
control in line with the set lift set point. During this operation with the output
signal from the speed controller set to a valve lift corresponding to about 10
% load by appropriate automatic adjustment of the speed setpoint.
This setting for the speed controller output signal ensures that if the lift
setpoint signal is deactivated in the event of power system disturbance,
turbine generator speed is prevented from rising due to the setpoint set for
the speed controller.
In the event of a load rejection with a resulting increase in speed of the
turbine generator, the output signal from the speed controller will become
negative. This counteracts the perturbation by moving the turbine control
valves in the closing direction, i.e. as soon as the output signal from the
speed controller becomes negative, the sum signal then leads at the
summing point ahead of the MIN gate where speed controller and lift setpoint
controller outputs are compared.
The minimum pressure controller takes over control via the MIN gate when
this is lowest input signal to this gate.
K
20
Where Gain K= 1 = 1 =20
S 5%
For a droop setting of 5%, the speed setpoint increase by 2.5 rps over the
load range. As the speed setpoint is set to 10% lift, equivalent to 50.25 rps,
this load rejection results in a speed rise to
(50 + 1.25 + 0.25 ) rps =51.5 rps
( Point t2 on diagram n=f (P)).
From this diagram it can be seen that lift setpoint controller is in control of
the turbine up to time t1 . After this load is reduced to 50% of rated load by
the negative speed controller output signal.
The turbine then operates at an actual speed of 51.5 rps to match the new
load demand of 50% only. Turbine speed can be returned to rated speed by
lowering the lift setpoint to match the new power system load demand.
5.5
Two valve position control loops are provided for the turbine control valves.
To improve the stability and dynamic response of the overall control system,
the valve position controllers are implemented as slave control loops to the
master controllers (speed controller, minimum pressure controller, lift
setpoint controller). Both valve position control loops are operative normally
but in case of fault in actual lift derivation of one loop, the valve position is
decided by other loop which will now always remain operational .
5.5.1 Setpoint Derivation for Lift Control Loops
---------------------------------------------------------------------------------------------- Sheet no. 15 of 37
STE, BHEL-HARDWAR
The signal by the control selection circuit is outputted in two sets of three
channels. Middle of the three signals is selected by voting module. This acts
as set point for both valve lift controllers.
These two control loops do not differ so that the description which follows
applies for both.
5.5.2 Actual Lift Derivation
The lift of the servo piston in the electrophydraulic converter sets the lift of
the turbine control valves.
As a result, this can be used to derive control valve lift. Although this is an
indirect measurement it is linear and accurate enough for this purpose. This
is usually a more reliable method than direct measurement on the control
valves. Even in the event of turbine trip with the resulting drop in trip fluid
pressure, the servo piston moves in the "close valves" direction so that valve
lift is correctly registered under these conditions.
Each electrohydraulic convertor has got two LVDTs ( Linear variable
differential transducers) , one as redundant to measure lift of the servo
piston. The output signals from the LVDT of the electrohydraulic convertors
are monitored for synchronism and given to valve lift controllers as actual lift
signals hact1-1 and hact1-2 . In the event of a fault in the lift measurement
system an alarm for "fault in actual valve acquisition for lift is annunciated
in cabinet thus issuing a group alarm ( Electro hydraulic controller fault").
5.5.3
in
the
The operator control devices for operation of the turbine controller are
intergrated into the main control room.
The panel section for the
electrohydraulic controller is shown in fig.17.
This panel section comprises miniaturized control room equipment, consisting
of pushbuttons indicators and indicator lamps on the appropriate tiles.
8.1
Start -up
The lift setpoint controls the turbine generator unit once the generator has
been synchronized with the power system.
After this, control valve lift is set by adjusting the lift setpoint manually to
the appropriate level in manual mode.
The output signal from the lift setpoint controller is increased and at the
same time the speed setpoint is reduced to a value corresponding to approx.
10% unit load. In auto mode, the output of lift setpoint controller is
determined by the adapted pressure deviation signal from steam generator
pressure control system and lift setpoint Lr tracks the lift setpoint controller
output. The speed controller is inactive but is kept on stand-by to take over
control of the turbine generator and maintain speed close to rated speed on
full load rejection down to station load. The TSE ensures optimum power
increase rates on turbine generator loading, but without exceeding permitted
thermal stress limits.
Shutdown
The lift setpoint is set to zero on turbine generator shutdown. This causes
unloading of the turbine generator in line with the set rates.
The lift set point is lowered until all control valves are throttled such that the
generator breaker opens via the anti-motoring protection ( this responding
when the generator motors and takes up more than 2 or 3 % reverse power
from the power system ) and the generator is de-excited.
The turbine trip pushbutton is then pressed to initiate turbine trip, this
resulting in closure of the turbine stop valves.
The above operating procedure ensures that the turbine generator is not
disconnected from the power system until the control valves have closed fully
( to avoid the risk of turbine overspeed).
During rundown of the turbine generator after turbine trip push button is
pressed, the speed setpoint nr is tracked to actual speed. This means that
the speed setpoint adjuster is already set to the correct value for restart.
8.4
Load Rejection
On load rejection to station load or zero load (i.e., in the event of sudden
disconnection of the loaded turbine generator from the power system), the
lift setpoint signal is immediately deactivated.
This results in a large
magnitude deviation in the control valves in close direction for the lift
---------------------------------------------------------------------------------------------- Sheet no. 19 of 37
STE, BHEL-HARDWAR
Alarms