Turbine Governors

By: FIA
November 6, 2007.
INTRODUCTION

What is governor?
• The governor controls the speed of turbine by controlling the
amount of steam supplied to the turbine with respect to variation
in loads.

Why need a governor?

• While in operation, when ever there is some variation in load over
turbine it tends to slow down or speeds up . For example
• Consider a steam turbine running at 5100 rpm and is generating
3MW load. Suppose a load of 0.5 MW taken off the turbine. Now
since power produced by turbine is greater than consumption the
result will be increase in speed. An intelligent system is required
which tells turbine to reduce quantity of steam to bring back
speed to normal otherwise turbine may trip due to OST
mechanism.
 2 MW
0 MW

Steam out

3600 rpm
6000 rpm
3600

Steam turbine Generator

175# ; 85% valve opening 5 MW

85% valve opening
175# ; 65% 3 MW

Steam in
 2 MW
5 MW

Steam out

3600 rpm
1600 rpm
3600

Steam turbine Generator

175# ; 85% valve opening 5 MW

85% valve opening
175# ; 95% 8 MW
BASIC DEFINATIONS
Governor Valve
The valve through which governor mechanism controls the
speed of turbine by opening or closing hence allowing increase
or decrease in quantity of steam.

Governor regulation
When ever turbine tends to speedup or slow down, governor
regulates speed. The limit within which governor could manage
speed control is called governor regulation. With no difference
between the speeds at full and no load, regulation is zero. 10%
regulation means if a turbine full load speed is 1000 rpm then
its no load speed would be 1100 rpm ((1000 * 10/100) + 1000)
BASIC DEFINATIONS (cont’d)

Narrow governor
A governor that tends to keep changes in speed as small as
possible is called narrow governor. A narrow governor normally
allows as much as 4% speed regulation without any speed
correction.

Broad governor
A governor that tends to keep changes in speed a bit larger as
compared to narrow governor is called broad governor. A broad
governor normally allows as much as 10% speed variation without
any speed correction.
BASIC DEFINATIONS (cont’d)
Hunting of governor
When ever governor tends to regulate speed its mechanism every time
have to overcome frictional and unbalance forces before it can move
the governor valve.

Tends to overcome these forces sometime governor causes valve to

over travels and thus overshooting constantly governor never finds the
operating speed preciously. This alternate speeding up and down is
Hunting.

Normally a narrow governor is more likely to “Hunt” than a broad

governor.

☺ WHY ?
Types of governors

Types of governors

Hydraulic governor Oil relay governor

Mechanical shaft
governor
Mechanical shaft governor

• Mechanical shaft governors are also called “fly ball governors”.

• Fly weight are mounted on shaft and takes their rotation from shaft.
• Centrifugal force of flyweights is balanced by spring.
• With increase in shaft speed fly weights move outwards because of
centrifugal force and compresses spring.
• At turbine operating speed centrifugal forces equals spring force.
• As the speed further increases it causes spindle assembly to move
which in turn moves governor lever.
• Governor lever is pivoted from centre and gives travel to governor
valve.
• As the speed decreases it causes flyweights to move inwards and hence
opposite to what happened in case speed is increased.
Mechanical shaft governor (Cont’d)
Mechanical shaft governor (Cont’d)

Advantages
• Simple in operation.
• Long life.
• Easy to maintain.
• Less likely to hunt.

Disadvantages
• Are broad governors.
• More wear parts.
Mechanical shaft governor (Cont’d)

Mechanical shaft governor regulation control

Mechanical shaft governors regulation can be done by following two ways

• Through hand operated speed changer

• Through governor adjusting nut.

Mechanical shaft governor (Cont’d)
Mechanical shaft governor (Cont’d)
Through hand operated speed changer

• The hand operated speed changer

permits accurate speed adjustment of
20 percent of the maximum full load
turbine speed.
• The speed changer assembly is attached
to the steam end bearing case through
bracket on one end and to the governor
lever on the other end.
• In start mechanical shaft governor
should be set for minimum specified full
load speed with hand wheel backed off
having no tension on spring.
• When hand wheel in turned in clockwise
direction, the turbine speed is
increased.
Mechanical shaft governor (Cont’d)
Through hand operated speed changer (Cont’d)
• When hand wheel is turned in counterclockwise
direction, the turbine speed is decreased.
• A pin is placed in stem with nut to act as stop for
hand wheel. The hand wheel should not move beyond
this point as undue strain will be placed on the
governor spindle bearing adversely affecting his
life.
Mechanical shaft governor (Cont’d)
Through governor adjusting nut
• Speed can also be adjusted by adjusting governor adjusting nut.
• By tightening the nut will cause increase in compression force over
spring.
• This will change the balance of forces between flyweight
centrifugal forces and spring force.
Mechanical shaft governor (Cont’d)
Through governor adjusting nut (Cont’d)
• The increased spring force will move spindle to move downward and
hence decrease in speed of turbine.
• Now flyweight will need more force to move spindle against spring
force.
• Similarly by loosening the nut will cause decrease in spring
compression force over spindle and hence increase in speed due to
upward movement of spindle.
Mechanical shaft governor (Cont’d)
Governor valve
• Governor controls speed of turbine through governor valve which is
placed on main steam line.
• The travel of governor valve is important and should be maintained
accurately.
• In order to measure governor valve travel, stop turbine.
• With unit standing still measure from inside of face of valve stem jam
nut to the face of gland follower and record this dimension.
Mechanical shaft governor (Cont’d)
Governor valve
• Loose jam nut slightly and turn valve stem clockwise until the
valve seats.
• With valve in seated position, again take the measurement as
above.
• The difference between these two measurements is the
governor valve travel.
Mechanical shaft governor (Cont’d)
Maintenance tips
• Pin 1 should be an easy
fit in governor lever and
connections. Fig 5 ; page
11
• Governor weight
assemblies should be
well seated and NO
CLEARANCES should
exist between weights
and bearing case.

• The slightest motion of

the weights should be
transmitted to the
spindle assembly without
any play.
Mechanical shaft governor (Cont’d)

Maintenance tips (Cont,d)

• Governor lever pins should be kept clean and well oiled. A good
sliding fit should be maintained at all times and when wear is
excessive parts should be replaced.
• Governor valve stem at all times should move freely in packing.
• WHY????
Mechanical shaft governor (Cont’d)
Maintenance tips (Cont,d)
• When steam turbine with
mechanical shaft governor acts as
standby to motor driven equipment
it is always advisable to give a
turbine no-load speed slightly less
than the motor full load speed.

• If the motor fails and the turbine

takes the load, bring the turbine
speed up to normal full load speed
with the speed changer. When the
motor again takes the load, reduce
the turbine speed with the hand
speed changer.

• Oil level in oiler should be

monitored and maintained.

• PM frequency should be followed

religiously.
Mechanical shaft governor (Cont’d)
Maintenance tips
(Cont,d)

• Oil level in oiler should be

monitored and maintained.

• PM frequency should be followed

religiously.
Mechanical shaft governor (Cont’d)
Trouble shooting

Problem: Governor fails to control speed.

Solution: Speed adjustment through hand wheel uptill locking pin
and then from adjusting nut.

Problem: Despite adjusting, governor fails to control speed.

Solution; Replace spring / weight assembly.

Problem: Governor is hunting.

Solution: If governor shows tendency to hunt, there are many
things to look in to
• One of the stems rubbing in a sleeve.
• Lost motion between the governor and governor valve.
• Linkage pins have excessive clearance.
• Governor valve glands are over tighten.
Hydraulic governor
• In hydraulic governor, an oil pump is coupled with turbine shaft.

• This pump in turn is attached to governor valve through hydraulic

piping and relieve valve.

• As the shaft of turbine rotates it causes pump to rotate thus making

hydraulic oil pressure.

• This pressurized oil after relief valve reaches governor valve which
is diaphragm operated.

• Increase in oil pressure causes increase in pressure over diaphragm

which is usually held in position against spring force.

• As the turbine reaches operating pressure the oil pressure equalizes

spring force. Now any slight increase in turbine speed causes
governor valve to close and hence decrease in turbine speed.
Hydraulic governor (Cont’d)
Advantages
• Consist of less mechanical parts hence less wear and tear.
• For high speed turbines hydraulic governors are more suitable than
fly ball governors.
• Speed can be regulated from control room.

Disadvantages
• Any increase or decrease in oil temperature causes viscosity of oil to
change any hence turbine speed setting.
• If pressure in hydraulic system is lost due to any reason, the
governor valve will become fully open hence causing turbine to over
speed.
• Since temperature changes can affect the adjustment of the
hydraulic governor, they are usually broad governors
Hydraulic governor
Hydraulic governor Cont’d

Governor regulation control (Cont’d)

• For hydraulic governors without air operated

control valve, speed regulation can be done
through needle valve

• By closing the needle valve decreases

the turbine speed.

• By opening the needle valve increases

the turbine speed.

• Note: The upper limit of needle valve opening

must always be set for the maximum full load
speed of the turbine.
• WHY ???
• Thus the speed change is always downward
from this setting.
Hydraulic governor Cont’d

Governor regulation control (Cont’d)

• For hydraulic governors with air operated control valve speed regulation
can be done through needle control valve

• By closing the needle valve decreases the turbine speed.

• By opening the needle valve increases the turbine speed.

• Note: The upper limit of control valve opening must always be set for
the maximum full load speed of the turbine. Thus the speed change is
always downward from this setting.
Hydraulic governor
Hydraulic governor Cont’d
Maintenance tips

• The governor is set and adjusted at the factory setting for

turbine design condition and those settings should not be
changed unless absolutely necessary.
• The pressure over diaphragm should be adjusted in the startup
to attain turbine optimum speed.
• It is important to have complete oil system free of air or vapour
all the times. Turn handle of oil filter occasionally to relieve
trapped air.
• The relief valve setting should be checked and adjusted as per
factory setting.
• All links should be well lubricated to ensure trouble free
operation.
• Oil temperature should be monitored and maintained.
• PM frequency should be followed religiously.
Hydraulic governor Cont’d
Trouble shooting

Problem: Governor fails to control speed.

Solution: There might be following reasons
• Governor pump might have lost priming.
• Oil filter is chocked.
• Pump have excessive clearance.
• Oil leakage in piping.
• Stop nut of needle valve need adjustment.

Problem: Governor is hunting.

Solution: If governor is hunting, following might be the reason / reasons
• Valve diaphragm need adjustment.
• Relief valve setting need adjustment.
• Air trapped in oil circuit.
• One of the stems rubbing in a sleeve.
• Lost motion between the governor and governor valve.
• Governor valve glands are over tighten.
Oil relay governor
• An oil relay governor combines
the features of Mechanical
shaft and hydraulic governor.

• An oil pump provide pressurized

oil in governor hydraulic circuit
which operates a piston.

• The amount of oil coming in to

and going out from hydraulic
circuit is controlled by a pilot
valve which in turn is operated
by flyweights that are mounted
over turbine shaft.
Oil relay governor
Over view of PG-PL governor
Oil relay governor
Over view of PG-PL governor

•The PG governor is bolted and dowelled to governor drive

housing that is attached to the steam end bearing housing.

•The governor oil pump, flyweight head and pilot valve

assembly are driven through a worm gear and worm wheel
arrangement.

• The worm gear is mounted on the trip body and is driven by

the turbine rotor shaft. The worm wheel is attached to the
governor drive shaft and meshes with worm gear.

•The governor valve level and linkage connect the governor

power cylinder assembly (servo motor) to the governor valve.
Oil relay governor
Principle of operation.

•The governor driveshaft worm wheel is driven at a speed directly

proportional turbine rotor speed.

•The governor uses mechanical force to sense the turbine speed and
hydraulic force to correct the speed.

•The hydraulic pressure is generated by an internal governor oil pump.

•The pump draws oil from the governor reservoir and discharges it to
spring loaded accumulators which store high pressure oil to help
maintain the full work capacity the governor.

•Relief valves built into the accumulators, maintain the correct

operating oil pressure in the governor oil passages.

•A spring loaded, rotating flyweight head sense the turbine speed.

When the speed changes, centrifugal force causes the flyweight to
pivot outward or inward.
Oil relay governor

Principle of operation (Cont’d)

•. The flyweight movement actuates a pilot valve plunger that opens or
closes a control port and directs control oil to or from the servo motor
power piston.

•The power piston motion is transmitted mechanically through the

governor valve lever and connecting linkage, to open or close the
governor valve and control the steam flow to the turbine nozzle ring.
Oil relay governor
PG-PL governor lubrication system:
Oil relay governor

• With increase in turbine speed

flyweights move outward
causing more oil to come inside
hydraulic circuit and forcing
governor valve to close and
reducing amount of steam.

• For decrease in speed the

mechanism works vise versa.
Oil relay governor
Advantages

• Accurate in control.
• Narrow regulation.
• The governor speed could be adjusted from control room.

At ECPL almost all oil relay governors are of Woodward make. Some of
the most common types installed are
– PG governors
• PG-PL governors
• PGD governors
• TG-13 governors
• TG-17 governors

PG governors:
PG or pressure compensated governors use hydraulic oil pressure to
compensate for change in speed. Out of most of its types PGD and
PG-PL are most commonly used.
 In case load on
turbine increases ;
speed will decrease

As the
AS fuelupward
forces
supplyare
balanced with
increases fly
speeder spring
weights
force pilotwill
Moves
valve plunger
move
inward
will move
outwards
upward.
Oil relay governor (Cont’d)
Oil relay governor (Cont’d)
Speed adjustment
– By Air control mechanism
– By manual speed setting mechanism
By Air control mechanism
– Direct speed setting arrangement
– Reverse speed setting arrangement

Direct speed setting arrangement

In Direct speed setting arrangement speed setting increases upon increase
in air pressure and vice versa.

Reverse speed setting arrangement

In reverse speed setting arrangement speed setting increases upon
decrease in air pressure and vice versa.
Oil relay governor (Cont’d)
Air control speed setting working principle

Pivot point
Oil relay governor (Cont’d)
Manual speed setting

The manual speed setting

mechanism can be used to
adjust the speed setting of
the governor to any point
within the normal speed
setting range when the
control air pressure is nor
available.
With no air signal the
restoring spring holds the low
speed adjusting screw in
contact with the pin on the
restoring lever.
Oil relay governor (Cont’d)
Manual speed setting

The loading spring continuously

urges the bearing and speed
setting screw in downward
direction.
Turning the manual speed
adjusting knob in C.W direction
(to increase the governor
speed|) lowers the stop collar
under the speed adjusting nut.
The speed setting screw with
the ball bearing will move down
with the stop collar until the
high speed stop adjusting screw
hits the high speed stop pin.
Further C.W direction will make
no effect on h’e speed screw
posiion.
Oil relay governor (Cont’d)
Manual speed setting

As the speed setting assy and

the bearing pivot are lowered,
the left end of the restoring
lever pushes the low speed
adjusting screw down and in
doing so lowers the speed
setting pilot valve plunger. Oil
flows to the speed setting
cylinder to push speed setting
piston down and raise the
governor speed setting
Oil relay governor (Cont’d)
Manual speed setting (Cont’d)
The manual speed setting mechanism can be
used to adjust the speed setting of the
governor to any point within the normal speed
setting range when the control air pressure
is nor available.
With no air signal the restoring spring holds
the low speed adjusting screw in contact with
the pin on the restoring lever.

The loading spring continuously urges the

bearing and speed setting screw in downward
direction.
Turning the manual speed adjusting knob in
C.W direction (to increase the governor
speed|) lowers the stop collar under the
speed adjusting nut.
The speed setting screw with the ball
bearing will move down with the stop collar
until the high speed stop adjusting screw hits
the high speed stop pin. Further C.W
direction will make no effect on governor
speed.
Oil relay governor (Cont’d)
Routine maintenance:

Because of the simplicity of the PG governor system, a minimum of

maintenance is required. Make the following checks:
• Check the governor oil level daily.

• Frequently sample of the governor oil. Change oil if sample

shows sign of contamination.

• Checks the governor linkage for binding, excessive play and

loose jam nuts or setscrews.

• Keep governor linkage clean and will lubricated with a high

temperature, water resistance silicone grease.
Oil relay governor (Cont’d)
Worm wheel replacement:
Remove cotter pin (12, figure6-4) and castle nut from the governor
driveshaft.
• Remove bottom shim (19), worm wheel (5), key and top shim (19)
from the governor driveshaft.
• Assemble in reverse order.
Oil relay governor (Cont’d)
Worm wheel tooth contact
adjustment:
• Remove cover (7) or oil pump (40) and
adapter (33,49) if applicable.

• apply a thin coat of Prussian blue to the

worm gear(4)

• Rotate the turbine shaft by hand to

transfer bluing from worm gear (4) to worm
wheel teeth (5).

• Observe the blued surface of the worm

wheel teeth. Contact point should be at the
center of teeth.

• If necessary, correct the contact by adding

or removing shims (14 & 15) between the
governor base and drive housing (2).

Note
• Add shims if contact points is above center
of teeth. Remove shims if contact point is
below center of teeth.
Oil relay governor (Cont’d)
Worm wheel backlash
adjustment:
• Adjust the worm wheel tooth contact as outlined
in worm tooth contact adjustment section.

• Work through the opening provided by removing

end cover (7) from drive housing (2) and mount a
dial indicator so that the indicator contact point
rests against one of the worm wheel teeth (5).

• Move worm wheel back and fourth while holding

rotor stationary to measure the clearance
between the worm wheel and worm gear mesh.
(This clearance is called “backlash”).the backlash
must be set at .006 to .008 inch (0.15mm to -
.20mm).

• Loosen bolts (16), remove dowels (18) and move

the governor (1) latterly on the drive housing (2)
to adjust the backlash.