Professional Documents
Culture Documents
GOVERNING SYSTEM
NOTE
EDC-Singrauli 1
TURBINE GOVERNING SYSTEM
In order to maintain the synchronous speed under changing load/steam conditions,
the KWU turbine supplied by BHEL is equipped with electro-hydraulic governor;
fully backed-up by a hydraulic governor. The measuring and processing of electrical
signal offer the advantages such as flexibility, dynamic stability and simple
representation of complicated functional systems. The integration of electrical and
hydraulic system has the following advantages:
• Adjustment of droop
droop in fine steps, even during
during on-load operation.
operation.
• Hydraulic amplifier.
• Test valve.
The remote trip solenoid operated valves are two in number and form a part of
turbine protection circuit. During the normal operation of the turbine, these
solenoids remain de-energised. In this condition, the control oil from the governing
rack is free to pass through them to the main trip valves. The solenoids gets
energised whenever any electrical trip command is initiated or turbine is tripped
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manually from local or UCB. Under energised condition the down stream oil supply
after the remote trip solenoids gets connected to drain and the upstream will be
blocked. By resetting
resetting Unit Trip
Trip Relays (UTR) from
from UCB, these solenoids can be reset.
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Under normal conditions, this oil flows into two different circuits, called as the Trip
Oil and Auxiliary Trip Oil. The Trip Oil is supplied to the Stop Valves (of HP Turbine
and IP Turbine),
Turbine), Auxiliary Secondary Oil circuit and Secondary Oil Oil circuits. The
Auxiliary Trip Oil flows in a closed loop formed by main trip valves and turbine
hydraulic protective devices (Over Speed trip device, Low Vacuum trip device and
Thrust Bearing
Bearing trip device).
The construction of main trip valves is such that when aux. trip oil pressure is
adequate, it holds the valves' spools in open condition against the spring force.
Whenever control oil pressure drops or any of the hydraulic protective 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.
The starting and load limit device is used for resetting the turbine after tripping, for
opening the stop valves and releasing the control valves for opening. The starting
device consists of a pilot valve that can be operated either manually by means of a
hand wheel or by means of a motor from remote. 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-up, 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 the auxiliary start-up circuit (to reset trip gear and
protective devices) and into the start-up oil circuit (to reset turbine stop valves). A
build-up of oil pressure in these
these circuits can be observed, while
while bringing the starting
device to zero position. When the pilot valve i.e. the starting
s tarting device position is raised,
the start-up 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 governor's spring tension and primary oil pressure
(turbine speed), and raises the aux. sec. oil pressure; closing the aux. follow-up
drains of hydraulic governor.
SPEEDER GEAR
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HYDRAULIC SPEED TRANSMITTER
TRANSMITTER
The hydraulic speed
transmitter runs in the MOP
bearing and operates on the
principle of a centrifugal
pump. The variation of
pressure in the discharge line
is proportional to the square
of the machine speed. This
primary oil pressure acts as
the control impulse for the
hydraulic speed governor.
The transmitter is supplied
with control oil via an oil
reservoir. An annular groove
in the speed transmitter
ensures that its inside is
always covered with a thin
layer of oil to maintain a
uniform initial pressure.
Excess oil drains into the
bearing pedestal.
pedestal.
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AUXILIARY FOLLOW-UP
FOLLOW-UP PISTON
PISTON VALVES
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 response
of main and reheat control valves. When the reheat pressure is more than 32
2
Kg/cm and load less than 20% the IP turbine tends to get loaded more than HP
turbine. The steam flow through HP turbine tends to fall to very minimum, causing a
lot of churning and excessive exhaust temperature. The trim device operates at this
moment trimming the IP turbine control valve. The control valves of HPT open more
to maintain flow of steam, reducing the HPT exhaust temperature.
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 pistons control valves,
draining the secondary oil. The IP control valves openings are trimmed down.
HYDRAULIC AMPLIFIER
Hydraulic Amplifier consists of a pilot valve and an amplifier piston. 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
the amplifier piston. The other side of amplifier is connected to the drain. The
movements of the amplifier piston are transformed into rotation of a Camshaft
through a piston rod and a lever assembly. A feedback linkage mechanism stabilises
the system for one particular aux. secondary oil pressure.
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HYDRAULIC AMPLIFIER
1. Amplifier piston
2. Follow-up piston
3. Sleeve
4. Shaft
5. Lever
6. Feedback lever
7. Pilot valve
8. Compression spring
9. Adjusting screw
a : Control
Control oil
oil
b : Secondary
Secondary oil
b 1 : Aux. Sec oil
c : Return
Return oil
A pair of solenoid
solenoid valves has been
been incorporated in the IP Sec oil
oil line on control
control valves
and Aux Sec. oil line, in order to prevent the turbine from reaching high 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
solenoid drains the IPCV secondary oil directly. Direct draining of IP Sec oil circuit
causes the reheat valves to close without any
a ny 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 stops valves controlled by IP secondary oil
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 reduce load builds-up in the HP and IP turbine secondary oil lines.
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 in all twelve follow-up piston valves. Six of them are associated with
hydraulic amplifier and six of them with EHC in the governing system. The follow-up
piston valves constitute a minimum value gate for both the governors. This means
the governor with lower reference set point, is effectively in control. This is also
termed as HYDRAULIC MINIMUM SELECTION of governors.
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FOLLOW-UP PISTON VALVES
TEST VALVE
1. Bolt
2. Hand wheel
3. Spindle
4. Cover
5. Oil Seal
6. Bushing
7. O-ring
8. Valve Cover
9. Valve Body
10. Trip Oil
11. Piston sleeve
12. Trip Oil
13. Piston valve
14. Spring plate
15. Spring
16. Spacer
17. Bottom cover
18. Trip oil
19. Drain
20. Trip oil
21. Startup oil
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Each of the HP and IP stop valves' servomotors receives trip oil through their
associated test valves. The test valves have got port openings for trip oil as well as
start-up oil. The test valves facilitate supply of trip oil pressure beneath the
servomotor disc. (Stop valve open condition, under normal operation). 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 the
stop valve servomotor 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 servomotor piston and building the trip oil pressure below the disc, thus
opening the stop valve. A hand wheel is also provided for manual operation of test
valves.
EXTRACTION
EXTRACTION N.R.VS AND EXTRACTION VALVE RELAY
Four pair of swing-check valves are provided in the extraction lines to the feed
heaters (LP Heaters No: 2,3, Deaerator and HPH No: 5) to prevent back flow of
condensed steam into the turbine from heaters on account of high levels in the
heaters. There are two NRVs provided in each of these extraction lines and is force
closing type. Both these valves are free-swinging check type, however the first valve
is equipped with an actuator. In case of flow reversals, both the valves are closed
automatically. The actuator assists the fast closing of the first valve. 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 spring force closes the valve when steam pressure
either falls or is lowered (reduced load).
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oil pressure through extraction valve relay assists closing movements of FCNRVs. In
both the cases the actuator is devoid of trip
tri p oil and its spring force closes
cl oses the NRV.
Extraction (4) FCNRV solenoid is also energised additionally by lower differential
pressure in the extraction line.
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VACUUM BREAKER
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Electro-Hydraulic
Electro-Hydraulic Governor (EHG)
The Electro-Hydraulic
Electro-Hydraulic Governor (EHG) is beneficial in
• Admission Control
Control mode,
• Speed Control mode,
• Load Control mode
• Pressure Control mode.
The Hydraulic governor and the EHG system have been designed such that the
governor with lower set point takes over or assumes the system control, as such
normally, the set point of the Hydraulic Governor must be set above that of the
Electro-Hydraulic Governor when EHG is effective. In cases, when EHG fails to cause
shut-off, the set point that is, affected is that of Hydraulic Governor.
In such situations the Tracking Device provides a revised set point of 5-10% above
the EHG set point and it causes increase in small load when the control is
transferred to Hydraulic-Governor. The tracking device is either switched on or off
manually but when EHG failure or turbine trip occurs, the tracking device is
switched off automatically thus tracking under faulted operation mode is prevented
or prohibited. More details on tracking actions are covered in the follow-up circuits
of the speed/load control modes.
Electro Hydraulic Converter converts the electrical signal in to the hydraulic signals
and large positioning forces are generated in control valves. The electrical signal from
governor control circuit operates the sleeve and pilot valve spool; this regulates the
trip fluid drain. Under steady state condition pilot is at central position; in deflected
position, the control oil is admitted above or below the amplifier piston. The motion
of the amplifier piston is transmitted via a lever to a camshaft, which actuates the
sleeves of follow-up piston valves, causing secondary oil pressure to change. The
speed, load, and pressure signals are measured and converted into conditioned
signal in electronic modules.
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1. Differnetial transformer
2. Amplifier casing
3. Amplifierpiston
4. Piston rod
5. Valve bushing
6. Piston valve
7. Grooved ball bearing
8. Spring dics
9. Compression spring
10. Sleeve
11. Casing support
12. Moving coil system
a. control oil
b. Trip Oil
The current in the plunger coil is increased for closing the HP /IP CV and vice versa
for opening of the HP /IP Control Valve. The reference signal therefore works in
reverse manner (rise in the coil current for low reference condition). By using two
Nos of differential transformer (housed in EHC), feedback signal from the valve lift is
derived to ensure proper stationing of plunger spool.
Whenever current
current through the plunger
plunger coil gets interrupted
interrupted or the electrical feedback
feedback
circuit gets faulted, the reference value of the Hydraulic controller determines the
actual valve position. Although the force to the plunger coil and to the control sleeve
is, considerably smaller, but the regulating signal to the secondary auxiliary oil flow
as transformed is quite large. The figure below gives various connections and
modules used in EHG.
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Actual speed (nact) Measurement:
Actual speed nact is acquired by three digital speed pickups (Hall probes) in the form
of pulses /frequency. Channel-2 is utilized while other two-channel pick-up remains
redundant; electronically switching ensures no affect in channel in service and also
a full - proof monitoring. The selected sensed speed channel signal is further divided
into three measuring signals (f/v of 0-60 Hz, low range 0-6 Hz & full range 0-60 Hz
and a quartz frequency standard) for various other applications in the EHG and
other circuits.
The difference of actual speed and time dependent speed signals ( nact - ‘nRTD) form
the input error of the Speed controller which outputs control signal (in the path as
explained in selection section) through the selection modules for driving the EHC
and finally establishing the EHG.
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TURBINE PROTECTION
PROTE CTION SYSTEM
SYSTE M
Turbine protection
protection system performs to cover
cover the following functions: -
a. Protection of turbine
t urbine from inadmissible operating conditions.
b. In case
case of plant failures,
failures, protection
protection against subsequent
subsequent damages.
Mechanical/hydraulic
Mechanical/hydraulic turbine protection.
Mechanical
Mechanical Hydraulic Turbine Protection
Th e design of me ch an ic a l hy dr a ul ic pr ot ec ti on eq ui pm en t is i n ac co rd an ce
with hydraulic
hydraulic break current
current principle and consists
consists of following:
following:
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a. Two manual
manual trip devices
devices (main
(main trip valves)
As explained earlier, turbine stop and control valves are tripped to close position if
the trip oil pressure is reduced below the minimum value. The main trip valves allow
rapid draining of trip oil in case they are operated either manually or automatically
by the reduction of aux. trip oil pressure. Aux. trip oil pressure can be drained
because of actuation of hydraulic low vacuum trip device, over speed trip device or
thrust bearing trip device. The principle of functioning of individual hydraulic trip
devices is explained in details under the chapter of Automatic Turbine Testing
System.
Remote trip solenoids act as interfaces between mechanical hydraulic and electro-
hydraulic protection equipment of turbine. Upon receiving the electrical trip
command, the solenoids get energised and close the valves. Thus control oil supply
to main trip values is cut off leading to their closure.
The electro-hydraulic
electro-hydraulic turbine protection
protection equipment
equipment features -
- Two solenoid operated valves for trip initiation (Remote trip solenoids).
solenoids).
The remote trip solenoids (RTS) have already been described. Operation of any one
channel causes energising both solenoid-operated valves leading to turbine trip
eventually. Transmitters that cause a trip in the case of any electrical tripping signal
are conditioned and monitored via binary signal conditioning of the ATT system or
via the central analog/binary
analog/binary signal conditioning.
conditioning.
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TURBINE PROTECTION
PROTECTION FOR 200MW KWU
KWU SETS
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Turbine Trip Actuation
Actuation Circuits
Circuits
Standard criteria are specified by the turbine manufacturer and are responsible for
full protection of turbine under various specific conditions, which are:
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1. Manual tripping devices (Turbine trip gear local operating lever)
7. Fire protection
Like low vacuum tripping (electrical) the low steam temperature protection also
comprises 'Arming' and 'Disarming' features to facilitate re-start of turbine, under
low main steam temperature
t emperature conditions.
conditions.
Two hydraulically operated over speed trips are provided to protect the turbine
against over speeding in the event of load coincident with failure of speed governor.
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When the preset
preset over speed is reached, the eccentric fly bolt activates the piston
piston and
limit switch via a pawl.
pawl. This connects
connects the auxiliary trip oil to draindrain thereby
thereby
depressurising
depressurising it. The loss of auxiliary trip medium
medium pressure causes the main trip
valve to drop,
drop, which in turn causes the trip oil pressure to collapse.
collapse.
In the hydraulic low vacuum trip device, a compression spring set to a specific
tension pushes downwards against diaphragm, the topside of which is subject to the
vacuum. If the vacuum is too weak to counteract the spring tension, the spring
moves valve 6 downwards. The pressure beneath valve is thereby dispersed and the
auxiliary trip medium circuit is connected to drain. The resultant depressurisation of
the auxiliary trip oil actuates main trip valves MAX51 AA 005 and MAX51 AA 006
thereby closing all turbine valves.
The electrical tripping on low vacuum occurs through a pressure switch on the
vacuum line to mechanical hydraulic low vacuum trip device also at the same
condenser pressure. When turbine is started up again, this pressure switch is
interlocked against a second pressure switch, which monitors this condition and
prevents continuation of tripping initiation when condenser pressure is high.
The function of the thrust bearing trip is to monitor the shaft position in the bearing
pedestal and, if a fault occurs, to depressurize the auxiliary trip medium and thus
the trip oil in the shortest possible time, thereby tripping the turbine.
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1. Compression
spring
2. Bearing pedestal
3. Piston
4. Valve body
5. Turbine shaft
6. Pawl
7. Torsion spring
8. Piston
9. Compression
spring
10. Limit switch
11. Knob
a: Test Oil
c: Return Oil
u: Aux. Startup Oil
x: Aux. Trip Oil
The two rows of tripping cams, which are arranged on opposite sides of turbine
shaft, have a specific clearance, equivalent to the permissible shaft displacement,
relative to pawl of the thrust-bearing trip. If the axial displacement of the shaft
exceeds the permissible limit, the cams engage pawl, which releases a piston to
depressurise
depressurise the auxiliary trip oil and at the same time to actuate limit switch.
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FIRE PROTECTION-1 CHANNEL-1
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FIRE PROTECTION-2 CHANNEL-1
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FIRE PROTECTION OIL TANK LEVEL MONITOR
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TRIP OIL
FUNCTION : To provide the position signal for the control val ve servomotor
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KWU LMW
The types of governor used is Electro-hydraulic The types of governor used is Hydro-
1.
backed up by Hydraulic governor mechanical
6. Dead band of Governing system: 0.01% Dead band of Governing system: 0.3%
Closing time of servomotors
a) HP i) ESV: 0.2 Sec a) HP ESV: 0.35 Sec
7. ii) Control
Control valve: 0.4 Sec
b) IP: IV: 0.4 Sec
b) IP i) IV: 0.8 Sec c) Control valve servomotor: 0.5 Sec.
ii) Control
Control valve: 0.8 Sec.
8. Control oil pressure – 8.0 Kg/cm2 Control oil pressure – 20.0 Kg/cm2
Size of control valves 1,2,3,4 (4 nos) –
Size of HP Stop valve (ESV)
125,150,150.150 mmφ
i) 160 mmφ - 2 nos
ii) zie of HP control valves 128 mmφ - 2 nos) (0.8
9.
times of ESV)
Size of IV valves – 320 mmφ (2nos)
iii) Size of IV valves - 320 mmφ (2 nos)
iv) Size of IP control valves - 256 mmφ (02 nos)
Size of IP control valves (4nos)
Automatic turbine testing is provided to check Automatic testing device is not provided
10. the protective devices while M/C is in to check the protective devices while
operation M/C is in operation
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In cold and warm start HP control valves
In all types of starts HP control valves
v alves control
control from 0 to 100%. There is no control
from 0 to 100%. IP control valves have
on IP control. In case of hot start, IP
13. controlling function along with HP control
c ontrol
control valves control the M/C up to
valve up to 40%, further control is done by HP
30MW. Further control is by HP control
control valves.
valves for HP & LP bypass system.
Actual over speed test is carried out by means Actual over speed test is carried out byby
of separate test lever provided in Hydraulic means of Speeder gear after selecting
14.
governor. Both over speed governor are the respective governor by means of
tested together. selector of emergency governor lever.
Initial steam pressure unloading (ISPUG)
Electrical pressure controller is provided to
hydraulic device has been provided to
unload the M/C in case
ca se the main steam
15. unload the M/C in case main steam
pressure drops by more than 10% of rated
pressure drops more than 10% of the
value.
rated value.
Load shedding Relay is provided to control the
The electrical signal is converted into
16. acceleration rate during sudden reduction in
hydraulic signal by actuation of EHT.
output load.
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PROBLEM
Change over
valve not getting
reset
OBSERVATION
Change over valve in trip
condition and control oil
pressure low
SOLUTION
On line full flow filter
self cleaning by knob
rotation
RECOMMENDATION
On line full flow filter self
cleaning by regular
knob rotation
PROBLEM
Emergency
Governor operating
within operating
speed range
OBSERVATION
Unit frequently tripping in
over speed during rolling at
speed lower than 3000 rpm.
SOLUTION
Check test oil pressure.
Check proper latching of
reset unit. Check the
position and mass of the
over speed bold
RECOMMENDATION
Period testing of O/S
Governor by simulation
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PROBLEM
LP By pass Not
Resetting
OBSERVATION
Getting reset after bypassing
condensate pressure
mechanical switch
SOLUTION
Open the switch found
bellow found damaged.
It was replaced. Normal
operation of LP BP
observed
RECOMMENDATION
Bellow changed OR If
operation required
before replacement.
Ensure temperature
switch working properly.
Replace bellow at the
earliest.
PROBLEM
Electro Hydraulic
Converter Hunting
OBSERVATION
Calibration of EHC checked
with Calibrator and found
oscillating
SOLUTION
Opened the EHC and one leaf out of
three leaves spring of electro hydraulic
converter found damaged. Spring was
replaced. Stabilization voltage set to
negative (-1 mV). Problem was solved.
PROBLEM
LP Bypass Water
Injection Valve Not
Closing
OBSERVATION
Signal Oil Pressure was low and
W I actuator drain line was hot
SOLUTION
Signal oil inlet was wrongly
connected with valve actuator.
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PROBLEM
HP CV Oscillating
(Hunting)
OBSERVATION
HPCV & HP Secondary Oil
Pressure Hunting
SOLUTION
Damping device was opened
and ball
ball was found missing. It was
put back, oscillation of valve
stopped.
PROBLEM
Startup Speed Not
Rising
OBSERVATION
Startup device and speeder
Gear liver link was broken
SOLUTION
Lever was changed,
problem was solved
RECOMMENDATION
Same problem was
repeated after about a
month. Spring setting was
set right and stroke of
starting device and
speeder gear was re-
adjusted. Problem solved
permanently.
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PROBLEM
HP Control Valve
Not Opening
OBSERVATION
HP Secondary oil pressure
was not building up. This was
checked in Hydraulic mode
as well as EHC mode
SOLUTION
Follow up pilot block
inspection cover was
opened and one of the
three control pilot was
found loose and fell down.
It was placed in position.
RECOMMENDATION
Pilot was tightened in
position with a small
screw and little glue
smooth operation of
HPCV
PROBLEM
HP Stop valve Not
opening
OBSERVATION
Test valve was checked and
found clearance of slide
and sleeve more.
SOLUTION
Test valve was
replaced. Problem
solved.
RECOMMENDATION
Quality of oil/FRF to be
maintained for no
corrosion / mechanical
pitting. Avoid frequent
operation of manual
testing devices.
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PROBLEM
IP Stop Valve Not
Opening
OBSERVATION
Test valve was checked and
found OK. Flow of Trip oil to
SV actuator was felt, as line
was hot.
SOLUTION
Actuator was opened
and a nut was found
in between piston
and disc
RECOMMENDATION
Fault at assembly shop
do not attempt to open
the Hydraulic Actuator
without the expert
guidance.
PROBLEM
CRH NRV not
opening
OBSERVATION
Supply and return line was
found hot.
SOLUTION
Servomotor was
opened and servicing
was done its seal was
found damaged. It
was replaced.
RECOMMENDATION
Change all the gasket
and seals if opened in
governing system and
control oil system.
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