Steam turbine governing is the procedure of controlling the flow rate of steam to a steam turbine so

as to maintain its speed of rotation as constant. The variation in load during the operation of a steam
turbine can have a significant impact on its performance. In a practical situation the load frequently
varies from the designed or economic load and thus there always exists a considerable deviation
from the desired performance of the turbine.[1] The primary objective in the steam turbine
operation is to maintain a constant speed of rotation irrespective of the varying load. This can be
achieved by means of governing in a steam turbine.There are many types of governors.

Contents

1 Overview

2 Throttle governing

2.1 Throttle governing – small turbines

2.2 Throttle governing – big turbines

3 Nozzle governing

4 By pass governing

5 Combination governing

6 Emergency governing

Overview

Steam Turbine Governing is the procedure of monitoring and controlling the flow rate of steam into
the turbine with the objective of maintaining its speed of rotation as constant. The flow rate of
steam is monitored and controlled by interposing valves between the boiler and the turbine.[2]
Depending upon the particular method adopted for control of steam flow rate, different types of
governing methods are being practiced. The principal methods used for governing are described
below.

Throttle governing

In throttle governing the pressure of steam is reduced at the turbine entry thereby decreasing the
availability of energy. In this method steam is passed through a restricted passage thereby reducing
its pressure across the governing valve.[2] The flow rate is controlled using a partially opened steam
control valve. The reduction in pressure leads to a throttling process in which the enthalpy of steam
remains constant.[1]
2-D schematic of throttle governor

Figure1: 2-D schematic of throttle governor

Throttle governing – small turbines

Low initial cost and simple mechanism makes throttle governing the most apt method for small
steam turbines. The mechanism is illustrated in figure 1. The valve is actuated by using a centrifugal
governor which consists of flying balls attached to the arm of the sleeve. A geared mechanism
connects the turbine shaft to the rotating shaft on which the sleeve reciprocates axially. With a
reduction in the load the turbine shaft speed increases and brings about the movement of the flying
balls away from the sleeve axis. This results in an axial movement of the sleeve followed by the
activation of a lever, which in turn actuates the main stop valve to a partially opened position to
control the flow rate.[2]

Throttle governing – big turbines

In larger steam turbines an oil operated servo mechanism is used in order to enhance the lever
sensitivity. The use of a relay system magnifies the small deflections of the lever connected to the
governor sleeve.[2] The differential lever is connected at both the ends to the governor sleeve and
the throttle valve spindle respectively. The pilot valves spindle is also connected to the same lever at
some intermediate position. Both the pilot valves cover one port each in the oil chamber. The
outlets of the oil chamber are connected to an oil drain tank through pipes. The decrease in load
during operation of the turbine will bring about increase in the shaft speed thereby lifting the
governor sleeve. Deflection occurs in the lever and due to this the pilot valve spindle raises up
opening the upper port for oil entry and lower port for oil exit. Pressurized oil from the oil tank
enters the cylinder and pushes the relay piston downwards. As the relay piston moves the throttle
valve spindle attached to it also descends and partially closes the valve. Thus the steam flow rates
can be controlled. When the load on the turbine increases the deflections in the lever are such that
the lower port is opened for oil entry and upper port for oil exit. The relay piston moves upwards
and the throttle valve spindle ascend upwards opening the valve. The variation of the steam
consumption rate ṁ (kg/h) with the turbine load during throttle governing is linear and is given by
the “willan’s line”.[1]

The equation for the willan’s line is given by:

ṁ=aL+C

Where a is the steam rate in kg/kWh, 'L' is the load on turbine in KW and C is no load steam
consumption.

Nozzle governing

In nozzle governing the flow rate of steam is regulated by opening and shutting of sets of nozzles
rather than regulating its pressure.[3] In this method groups of two, three or more nozzles form a set
and each set is controlled by a separate valve. The actuation of individual valve closes the
corresponding set of nozzle thereby controlling the flow rate. In actual turbine, nozzle governing is
applied only to the first stage whereas the subsequent stages remain unaffected.[1] Since no
regulation to the pressure is applied, the advantage of this method lies in the exploitation of full
boiler pressure and temperature. Figure 2 shows the mechanism of nozzle governing applied to
steam turbines.[2] As shown in the figure the three sets of nozzles are controlled by means of three
separate valves.
2-D schematic of nozzle governor

Figure2: 2-D schematic of nozzle governor

By pass governing

Occasionally the turbine is overloaded for short durations. During such operation, bypass valves are
opened and fresh steam is introduced into the later stages of the turbine. This generates more
energy to satisfy the increased load. The schematic of bypass governing is as shown in figure3.
2-D schematic of bypass governor

Figure3: 2-D schematic of bypass governor

Combination governing

Combination governing employs usage of any two of the above mentioned methods of governing.
Generally bypass and nozzle governing are used simultaneously to match the load on turbine as
shown in figure 3.

Emergency governing

Every steam turbine is also provided with emergency governors which come into action under the
following condition.[2]

When the mechanical speed of shaft increases beyond 110%.

Balancing of the turbine is disturbed.

Failure of the lubrication system.

Vacuum in the condenser is quite less or supply of coolant to the condenser is inadequate.
1966_jachens_steam turbines their construction.pdf –“Steam Turbines: Their Construction, Selection
and Operation”. W. B. Jachens (Proceedings of the South African Sugar Technologists Association -
1966

“Thermal engineering” Rathore and Mahesh. M (2010) Tata McGraw-hill.p.739.

“Turbines, compressors and fans” S M Yahya (fourth edition) Tata McGraw-hill.p.393.

Categories: Steam turbines Mechanical power control

General industrial steam turbine prefers a steam source of 42 Kg/Cm2 (600 PSI) at 482 OC (900 o
F). Steam turbines for industrial applications are often classified in two (2) categories, according to
the basic design-

1) Condensing turbine where the steam exhausts into a condenser. A vacuum in the condenser
provides the optimum pressure drop from turbine inlet to turbine exhaust. The steam condenses to
water and a pump returns this water to the boiler.

2) Back pressure turbine is the turbine where the exhaust of the turbine is above atmosphere. The
low pressure exhaust stream is utilized to some other section of the plant. Typical pressure is 2 to 4
kg/cm2 for heating a process or heating a building.

This paper covers Controls for Turbine for a variety of functions and therefore it would be natural to
classify the turbines according to the control parameters.

Classification according to Control Function:

1) Condensing turbine, the most common application for driving generator and for mechanical drive
(compressor) if no other turbine parameter needs to be controlled.

2) Inlet Pressure control where the turbine has the basic task to maintain a constant pressure in its
inlet header.

3) Back Pressure turbine where the turbine has a task to provide a low pressure steam by expanding
steam from the high pressure source.

4) Extracting Turbine for applications requiring an intermediate source of steam pressure at a

controlled flow.

5) Induction Turbine, also called Admission Turbine where an intermediate source of pressure is
available to drive the turbine, in addition to high pressure source.

All these basic types are used in many variations, including extraction turbines with two or more
extraction ports or combination of extraction /induction turbines.

Classification according to the number of Valves:

In past during the era of analog controls, the functional classification was natural classification.
Actually it was analog controls which was hardware intensive requiring significant design work for a
particular application or function. But now all is digital control which is software intensive. This
software control eliminated much of this hardware design. For example, the digital control does not
care whether a 4 -20 mA input signal is pressure, power or any other parameter because all the
scaling is done in software. Therefore from a control point of view we can simplify the system by
classifying the turbine according to the number of control points on the turbine with each control
point having one or more control valves. Each location can have multiple valves, such as a turbine
with multiple inlet valves but these valves operate at a single point: the inlet of the turbine. These
valves can operate simultaneously or in sequence but in the classification these valves are
considered as a single control point. Large, single extraction turbines may have more than one LP
valve to handle the steam volume but for this classification all extraction valves at one location are
considered as one valve.

1. Single Valve Turbines: Because there is only one controlled (inlet) port, only one parameter can
be controlled simultaneously. This single parameter can be speed, inlet pressure, back pressure, or
for a compressor drive, that parameter can be a compressor function such as suction pressure or
discharge pressure. The control may have additional control functions such as speed and valve
opening limiter and the control can switch from one control mode to another which is typical during
a start when the control switches from speed control to pressure control. At any given time only one
parameter can be in control.

Condensing Turbines: in Condensing Turbines Steam enters the turbine through the inlet valve and
exhausts to the condenser. A vacuum pump maintains vacuum of typically 4 inch Hg in the
condenser, giving the turbine the pressure drop between inlet and exhaust for optimum efficiency.
Cooling water flowing through the condenser converts the exhaust steam to water and a pump
returns this water to the boiler. The controlled parameter for the turbine is speed and for Generator
drives this is the only parameter. For mechanical drive the controlled parameter shall be also on
Compressor, such as compressor suction pressure or compressor discharge pressure.

A single valve condensing type turbine may have an extraction port or even more than one
extraction port but this extraction flow is not controlled.

Backpressure Control: Here in this type of turbine, high pressure steam is expanded to low pressure
steam. Another technique is to use expansion valves with a pressure regulator but this method is
inefficient because it is a waste of heat energy during expansion. The back pressure turbine recovers
this energy by driving a useful load.

The steam in the back pressure header is used in a process or for heating purposes, usually at a
variable flow demand. There is no instrument available to measure demand but it is known that at
constant turbine speed the back pressure would vary with demand. An increase in demand results in
an initial decrease in pressure while a decrease in flow demand initially will result in an increase in
pressure. Therefore, the control on the backpressure turbine modulates the inlet valve and matches
steam flow to steam demand by maintaining constant pressure in the backpressure header.

When the pressure drops, the control will open the inlet valve further until the new flow matches
the flow demand and pressure returns to normal. However the increase in steam flow also increases
the speed or power output of the turbine.
The main task of the back pressure turbine is to provide low pressure steam. The power available
from the expansion of the steam in the turbine is a by-product but for a single valve turbine, as a
backpressure turbine this power can not be controlled: the available power depends solely on the
demand for extraction steam.

Inlet Pressure Control: The inlet pressure turbine receives its steam from a high pressure header
which also provides steam to other users such as other turbines. The flow in the header varies with
the demand by these users and rather than varying the flow from the boiler, the inlet pressure
turbine takes all these flow. Again, it is not possible to measure flow demand by other users but the
inlet pressure turbine matches available flow to flow demand by maintaining constant header
pressure. When header pressure drops due to an increase in flow demand, the controller closes the
inlet valve. When header pressure increases due to a drop in demand, the controller opens the inlet
valve further. Again, the available power is a function of steam flow and can not be controlled in this
application.

The back pressure and inlet pressure application work for generators which operate in parallel with a
grid and for variable speed mechanical drives. These applications do not work for generators on an
isolated system as the control cannot maintain constant speed.

The inlet valve for backpressure turbine opens when the transmitter indicates a drop in pressure.
However, the inlet valve of the inlet pressure turbine moves in the opposite direction: it closes when
the transmitter on the high pressure header indicates a pressure drop.

Mechanical Hydraulic Governors:

Governor is the basic speed control which receives a pneumatic speed reference signal from a
process control. Commonly this is a 3 – 15 PSI signal. This process controller can control any variable
such as back pressure, turbine inlet pressure, compressor suction pressure or discharge pressure
depending on the operation of the turbine. As the governor is completely mechanical-hydraulic it is
intrinsically safe in all hazardous environments. In addition it is completely self-contained as it has an
internal oil supply. However, from an operational point this type of governor has some operational
limitations as follows.

(1) If the 3- 15 PSI speed reference signal represents compressor operation, the 3 PSI is equivalent to
minimum compressor operating speed and 15 PSI represents maximum compressor operating
speed.

(2) The dynamics of the governor are determined by mechanical components and the speed range
over which the governor will control with acceptable stability is limited.

(3) The governor has an internal oil supply and pump. Therefore, the servo does not have any power
output until turbine speed has increased sufficiently to provide adequate oil pressure from the
pump.

(4) For stability reasons, there is a time delay between any changes in the speed reference input and
the reaction of the internal speed setting mechanism.
(5) Because the 3 PSI signal determines the minimum speed (equivalent to minimum compressor
speed) where the governor will control, the start procedure, upto that speed, must be manual
through the Trip &Throttle(T&T) valve (installed in steam inlet line). The operator cracks the T&T
valve open and the turbine starts rotating. As soon as the oil pump in the governor produces
sufficient pressure, the governor senses an under speed condition and it moves the controlled valve
(CV) to maximum. CV is installed in the downstream of TT valve in the steam inlet line. Any ‘Hold’ for
warm up and any fast acceleration through a critical must be controlled manually through the T/T
valve. This process continues until the turbine reaches a speed corresponding to the 3 PSI reference
setting at which point the governor takes control of the turbine through the control valve CV. The
Trip & Throttle (T/T) valve can be opened completely and the compressor loading process stars.

In addition any decrease in the turbine speed below the 3 PSI level such as turbine idle or a
controlled shutdown must be accomplished manually, again via the T/T valve.

The speed reference input moves a pilot valve (PV) via a bellows. The PV directs oil to the piston on
top of the speeder spring (SS) which determines the actual reference setting. A restriction in the flow
of oil to this piston creates a time delay. This built-in time delay of 3 – 5 seconds is necessary for
system stability but it prevents any fast overriding action via the 3-15 PSI input when a limiter wants
to affect the steam valve instantly. A typical example is a steam driven pump which is controlled on
flow with an override when suction pressure drops.

Electronic Governors:

This governor was introduced in old days. It is vintage category now. The speed reference for this
type of governor was a combination of a remote reference 94 -20 m A) from a process controller and
a manual potentiometer, with the later used to control speed below the minimum compressor
operating speed corresponding to 4 m A. The electronic governor allowed the operator to control
turbine speed through the control valve (CV) over a much wider speed range and also allowed
remote control of speed.

Benefit of the electronic speed governor over mechanical hydraulic includes the reaction time and
some additional flexibility. The electronic speed control reacts faster than the mechanical – hydraulic
equivalent if combined with a fast actuator. It also operates with a wider speed rage.

Digital Controls: Basic control mode-

(1) The normal mode of operation which can be speed, power, pressure, or any other variable as
long as it is understood that for a single valve turbine only one parameter can be in control at any
given time at any given type although the control must be able to switch from one single control
parameter to another.

(2) The control must recognize that there are certain limiting parameters which may have to take
over automatically when such a variable reach a set point.

Cascade Control Mode:

Speed is the basic control parameter for both generator and mechanical drive. Any other control
parameter such as a process controller acts as a reference input to the speed controller. The output
of the process control modulates the reference of the speed control.

Inlet Pressure Control:

Let us consider a turbine connected a constant pressure steam header. When there are other users
connected with the steam header, the header pressure drops and the control close the turbine inlet
valve which makes more steam available to other users. The main task is to maintain header
pressure while the power is a by-product which depends on the amount of steam through the
turbine.

Back Pressure Control:

Back pressure can be controlled as above, except the inversion of the signal must beaded as the
turbine control valve moves in the opposite direction: a drop in back pressure indicates an increase
in demand which requires the inlet valve to be opened. For the inlet pressure control a drop in
pressure requires the valve to move in the close direction.

Minimum Inlet Presser Limiter: In simple speed control of steam turbine, the steam pressure may
drop due to a sudden demand or trouble with the source of steam. Low pressure may cause water
carry-over from the boiler which can cause severe damage. Therefore this controller has a low
limiter on steam pressure. During normal operation when pressure exceeds the set point of the
limiter, the output of the limiter is high and the speed control operates the turbine control valve.

Compressor Control: For the majority of compressor applications the controlling parameter is either
compressor inlet pressure or compressor discharge pressure. For compressor the process to be
controlled is upstream, hence the compressor inlet pressure controller operating as a cascade
control on the speed controller. This application could be, say, a gas separation plant where the
compressor must remove all available gas. An increase in pressure causes the control to increase
turbine speed. If the process is downstream, it is more likely that the controlling parameter is
compressor discharge pressure. However, the action is opposite from the inlet pressure control: an
increase in pressure indicates a decrease in flow demand which requires a decrease in turbine
speed.

The digital control does not care what the input variables are. The 4 – 20 mA input to the cascade
controller can be steam pressure such as inlet pressure or back pressure or it can be a compressor
parameter such as suction pressure or discharge pressure.
The user has to configure the details of the control requirements which involves selecting the
various control modes and entering the details of the inputs and outputs. The Woodward 505 has a
alpha-numerical display and an integral keyboard for this task. The newer generation of standard
controls will have the configuration done by computers such as PC or laptop.

All the Woodward standard controls are configured by answering questions which appear on the
display by entering yes/no answers or entering numerical values.

Standard controls cover the majority of applications of mechanical drives. However, for more
complex applications of large turbines having an extensive protection system or more complex
applications such as a train of steam turbine/compressor, the requirements do not fit in a standard
control and a custom programmed control is needed.

Controls with a standard program usually are less expansive because the application program does
not have to be functionally tested for every control.

2. Two Valves Turbines: With two valves, the control can modulate two parameters simultaneously.
For power plat, turbines in Generator application, this can be a combination of maintaining constant
turbine speed and modulating extraction flow. For a variable speed drive such as Compressor
application, the two parameters typically are a variable speed control combined with modulating
extraction flow. This type of turbine is called a Single Automatic Extraction (SAE) turbine as it has a
single extraction port with controlled extraction flow.

1) Single Automatic Extraction:

Turbines with one extraction port are called Single Extraction turbines. The turbine can have control
valves on the HP inlet only in which case the extraction flow is not controlled and flow as well as
pressure in the extraction header can vary. However if it is important to control the flow in the
extraction header, the turbine shall have two valves, one on the HP inlet and a second LP valve
downstream of the extraction port. This type of turbine is a Single Automatic Extraction (SAE)
turbine. For the majority of SAE turbines, there is only one HP and one LP valve although the design
may involve more than one HP and/or more than one LP valves.

Speed / Power Control:

The turbine can drive a compressor in which the turbine speed must vary with compressor demand
through a speed governor with the input from a process controller. Another application is a
generator operating parallel with a commercial grid. In that case the speed is constant and the
control is designed in such a speed/power mode that amount of power from the generator shall not
be fluctuating.

Extraction Control:

The second controller is the extraction controller which must modulate the amount of flow in the
extraction header. This flow is determined by the demand from the user.

Decoupling:

The back pressure turbine has a control which modulates the flow in the back pressure header while
speed or power is not controlled. The SAE turbine is used in applications where both extraction flow
and speed or power needs to be controlled simultaneously.

The modern digital control allows de-coupling of the two control modes by making them
independent. De-coupling requires the speed/power controller and the extraction controller both
operate the HP and LP valves simultaneously.

Rationing:
All steam to provide power must travel from the HP valve, through the HP turbine, through the LP
valve and the LP turbine to turbine exhaust with none of the steam travelling to the extraction port.
All steam to satisfy extraction demand must travel from the HP valve, through the HP turbine to the
extraction port without any of this steam going through the LP section.

Any change in flow demand in the extraction header requires the pressire controller operates both
valve simultaneously. The steam does expand in the HP section on its way to the extraction port and
that changes the power level. Therefore he LP valve must move in the opposite direction. An
increase in extraction demand requires that the HP valve opens but the P valve close to reduce the
power produced by the LP valve in an amount equal to the power increase by the HP section of the
turbine.

Induction Turbines:

The turbine has two inlets for steam, a High Pressure (HP) and an Intermediate Pressure (IP) inlet.
Many plants such as the ethylene plant depend on the reformer to produce the high pressure steam.
During the start a boiler produces the intermediate steam and the induction turbine starts on that
source. When the process is well on its way and high pressure is available, the turbine switches to
high pressure source. Other induction turbines use all the excess steam available from an
intermediate pressure header.

Digital Controls for Large, Base Load Utility Steam Turbines:

Utility power plants are complex arrangements of machinery requiring sophisticated control systems
to keep all equipment working in harmony and to keep the overall plant operating at its optimum
efficiency. Traditional control system includes control of boilers, burner controls, turbine controls
and various sections of the balance of plant control. The operator supervises all these different
controls from the central control room. Digital technology offers more integration of control
functions and improved operator interface but there shall be additional economic benefits for the
justification of replacing existing controls.

There are two separate control issues, determined by the nature of the process to be controlled.
These areas are: Plant control, Turbine control.

Major improvements in efficiency can be made by changing the operating mode of the plant with
turbine control being an important part of this.

In addition to the improvement of the basic operating efficiency there is a secondary efficiency
improvement in the increased availability of the turbine. The controls manufacturer can use digital
technology in the design of fault tolerant systems which allow a failure in the control hardware
without tripping the turbine. It is a truly fault tolerant control, the operator can make repairs and
replaces components while the turbine is operating which vastly improves the availability of the
turbine.

Steam Turbine Interfaces

The decision to replace an existing control on a steam turbine with a new digital control is only one
aspect in the process. The selection of the proper interface between the new control and the
existing steam valve is just as important for the success of the project. The majority of the vintage
controls are mechanical or electro-mechanical and the interfaces with the steam valve servo are
mechanical linkages or hydraulic pressures. The new electric control has a voltage or current output
representing steam demand. For the older turbines this electric signal must now interface with
existing mechanical devices which operate the steam valve. Some of the problems with the existing
governor, leading to the decision to replace the control may be a combination of governor problems
and servo deficiencies. Therefore, the incorrect interface may affect the performance of the turbine-
control combination regardless of the improvements from the new electronic control.

Mechanical Input:

Small Turbine may have a mechanical governor or mechanical-hydraulic governor directly operating
the steam valve. Larger turbines require more force to operate the valves and these turbines have
multiple stage servos. Most basic designs have a single pilot valve which modulates the flow of oil to
the power piston which, in turn, operates the steam valve(s). (Governor, pilot valve, power piston,
steam valve). Occasionally, very large turbines may have several stages of amplification with two or
more pilot valves in series.

Mechanical Trip:

Over speed protection is the primary trip but other trips involving lube oil and other parameters may
be involved. Should the existing mechanical trips be maintained and a new electrical trip mechanism
be added or should the existing trip mechanism be completely replaced? If the existing mechanical
system does not cause nuisance trips, it can be retained as the secondary trip and a new electrical
system can be added as primary protection. Insurance regulation may even require that the
mechanical trip be retained.

Electric Trip:

The software for the protection can be in the digital turbine control as long as a second,
independent, trip is provided for the (very remote) case that there is a failure in the turbine control.
More common is to have the over speed protection as a separate device. The trip valves are
dormant all the time and periodic testing is essential to assure that they operate when required. The
two isolation valves are added which can isolate one trip valve for testing while the other trip valve
remains active. Once the switch on the isolation valve indicates that the trip valve is isolated, the
operator can test the trip valve.

Lube Oil Consoles:

Manufacturers manufacture Hydraulic Power Units (HPU) with single and duplex electric motor
driven pumps. These are standard designs and provide pressure oil to the electro-hydraulic
actuators. Manufacturer also can design custom designed lube oil consoles providing low pressure
oil for the turbine and high pressure oil for the servo.