GOVERNING SYSTEM OF STEAM TURBINE

NECESSITY OF GOVERNING SYSTEM

-Turbine speed (i.e.-electrical frequency) is a function of electrical
load(i.e-consumers demand).
-The lower the load higher the speed due to accelerating torque. The
load may not remain the same for example sometimes full,
sometimes half as per consumer demand and under this condition
the electrical frequency will vary with the load. This is not at all
desirable as all the electrical machines & appliances are designed for
a nominal frequency.
-This suggest that some additional form of control must be applied
to ensure that the changes in the consumer demand for electrical
power are followed automatically without large deviation from
frequency.
-In addition to this, an excessive increase in speed may endanger the
rotating parts of the turbine& therefore needs some form of control
device. For these reasons all turbines are fitted with speed
governors. In short the function of a governor is to maintain the
shaft speed constant as the load varies.
FUNCTIONS OF GOVERNING SYSTEM
 To control the initial run up and synchronization of
the machine
 To control the turbine load when running in parallel
with other generating sets.
 To obtain the speed rise within acceptable limits in
case of the unit getting disconnected from the load.
 To provide protective gears to ensure the safe
operation of the turbine
Thus the TG governing system imply a need to
 Provide appropriate contributions to system frequency
control
 Withstand a full load rejection safely
 Governor Characteristics
The main characteristics of a governing system is therefore the
relationship between the generated load of the machine and its
speed which is the prime governor input. This is known as the
speed-loop droop or frequency regulation characteristics of the
governor.
Considering NR: Rated speed,
NL : Speed at full load
NO: Speed at No load

The steady state overall frequency regulation or droop of the

machine is defined as
N  N  100
0 L

N R
% of frequency change ( % of RPM change) will lead
to full travel of Governing valves or full load change.
5% droop means: 5%*50 Hz= 2.5 Hz
Will change 500MW. In terms of output total change
should take place is 100%
 Droop of KWU Machine
output

+100%

2790 2940 3060 3210

0%
RPM

-100%
THE EFFECT OF REGULATION
This regulation permits a machine to share load with other machines in a stable
manner. Generally the droop of a turbine used for electric power generation
varies between 4-7%.
Typical governor frequency regulation characteristics is shown here as
USE OF VARIABLE DROOP SETTINGS FOR CLOSED LOOP LOAD CONTROL
Closed loop control of turbine electrical load by use of proportional and integral load
controllers is added to the basic governing system to facilitate the provision of variable
droop settings. The frequency range over which the load loop is operative is limited so that
even when the load loop droop is set to high or infinite values the unit response any large
frequency errors in a manner matched to the characteristics of the normal droop of the
basic speed governor.
Governing Of Large Reheat Machines
• On reheat machines it is necessary to control not only the hp
valves but also the interceptor (IP) valves because on a full
load rejection the stored steam in the reheater and the
associated pipe lines could be sufficient to overspeed the
machine to destruction. The characterstics of the IP valves are
such that they usually remain fully open over the normal low
range of the machine and the governing action is achieved by
throttling of the HP valves. This operating regime is known as
HP governing & is achieved by giving a fixed bias to the IP
valves.

• However, the reheater control valves comes into action during

certain abnormal conditions like fast load rejection or low
load conditions with excessively high reheater pressure, with
the help of over riding controls provided by features like load
sheding relay, IP trimming device etc.
TYPES OF GOVERNOR

BASED OF STEAM FLOW:

 NOZZLE GOVERNOR
 THROTTLE GOVERNOR
 BYPASS GOVERNOR
 THROTTLE GOVERNING
 We know that as the load decreases, shaft speed
increases, the stop valve is partially closed to admit less
steam to the turbine & to produce less power according
to the demand. Due to restriction of passage in the valve,
steam is throttled. The specific ideal output of turbine
thus also reduces. With further closer of the valve,
throttle pressure will still be less to produce a still lower
output. The throttle & stop valves are located in the
steam supply line to the turbine. The stop valve is a
hydraulically operated quick opening & shutting valve
designed to be either fully open or shut. For a small
turbines the stop valve may be manually operated. The
throttle valve is used to regulate steam flow during
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 allowed to pass through a
restricted passage thereby reducing its pressure across the
governing valve.[
 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,
 Low initial cost and simple mechanism makes throttle
governing the most apt method for small steam turbines.
 The valve is actuated by using a centrifugal governor which
consists of flying balls attached to the arm of the sleeve,
hydraulic governor, electro hydraulic governor.
THROTTLE GOVERNING
THROTTLE GOVERNING: LOAD IS GOVERNED BY MUDULATING THE OPENING
OF CONTROL VALVE. IF PERCENTAGE OPENING OF CONTROL VALVE IS
CHANGED THEN 1) AVAILABLE HEAT DROP CHANGES, 2) QUANATITY OF
STEAM FLOW CHANGES. BY THESE MECHANISMS LOAD CHANGES
THROTTLE GOVERNING
THROTTLE GOVERNING
THROTTLE GOVERNING
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.
 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. Since no regulation to the pressure is applied.
NOZZLE GOVERNING
 In the nozzle control governing, the nozzles
of the turbines are grouped in two, three or
more groups & each group of nozzles is fed
with steam controlled by valves. For low
loads instead of using throttle governing, we
use nozzle governing
 To increase the turbine efficiency. With the
decrease of load, the required no of nozzles
may be shut off.
NOZZLE GOVERNING: Figure shows the mechanism of nozzle
governing applied to steam turbines. As shown in the figure the
three sets of nozzles are controlled by means of three separate
valves.
NOZZLE GOVERNING
NOZZLE GOVERNING: ONE SET OF NOZZLE BOX IS FULL OPEN AND
THROTTLES FROM 1 TO 2 (LESS THROTTLING LOSS). ANOTHER SET
OF NOZZLE IS PARITIALLY OPEN TO MAINTAIN THE LOAD AND
THROTTLES TO 4 (HIGH THROTTLE LOSS). STEAM FROM THE EXIT
OF TWO NOZZLE BOX MIX AND FINAL CONDITION IS 6.
BYPASS GOVERNOR
 PRINCIPLE OF BY PASS GOVERNING IS TO BYPASS
SOME EXTRA STEAM TO THE FAR DOWN
STREAMS STAGES WHEN THE LOAD IS MORE
THAN ECONOMIC LOAD.
 OWING TO SMALL HEAT DROP IN THE FIRST
STAGE OF HIGH PRESSURE TURBINE, IT IS NOT
ADVISABLE TO EMPLOY NOZZLE CONTROL
GOVERNING.
By Pass Governing
 PRINCIPLE OF BY PASS GOVERNING IS TO BYPASS
SOME EXTRA STEAM TO THE FAR DOWN
STREAMS STAGES WHEN THE LOAD IS MORE
THAN ECONOMIC LOAD.
 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 FIGURE.
 d

A
By Pass Governing
 The total amount of steam entering the turbine passes
through the valve A which is under the control of
speed governor.
 B is a nozzle box or steam chest .
 For all loads greater than the economic load , a by pass
valve c is opened, allowing steam to pass from the first
stage nozzle box in to the steam belt D and so in to the
nozzle of downstream stage.
 The valve c is designed such that it is not opened until
the lift of the valve a diminishes.
 The by pass valve c remains under control of a speed
governor for all loads within its range.
 COMPARISON BETWEEN THROTTLE AND NOZZLE
GOVERNING
S.NO THROTTLE GOVERNING NOZZLE GOVERNING
1. SEVERE THROTTLING LOSS NO THROTTLING LOSS ( ACTUALLY
THERE IS SLIGHT THROTTLING
LOSSES IN NOZZLE VALVES WHICH
ARE PARTIALLY OPEN)

2. LESSER PARTIAL ADMISSION MUCH PARTIAL ADMISSION LOSSES

LOSSES
3. LESSER HEAT DROP AVAILABLE LARGER HEAT DROP AVAILABLE

4. EMPLOYED IN IMPULSE AND EMPLOYED IN IMPULSE AND

REACTION TURBINE BOTH REACTION TURBINE IF INITIAL
STAGE IS IMPULSE
EMERGENCY GOVERNOR
Types of Governors
There are three types of speed Governors
 Mechanical
 Hydraulic
 Electrical
 Combination of Hydraulic & Electrical

With the increasing amount of automatic control equipment

employed in a power plant greater demands are being made
on turbine governing system with regard to their response
sensitivity & speed of operation.
An electro hydraulic governing system as thus been developed
which needs these stringent requirements.
Mechanical Governor
 It is a force balanced
system, the centrifugal
force of the rotating
weight is balanced by
the elastic force of a
spring and the radial
position taken by the
weight is dependent on
the speed of the
rotation
Hydraulic Governor
 A hydraulic Governor for a turbine consists
of a centrifugal pump driven from the main
shaft which supplies oil to a cylinder
containing a spring loaded piston or
bellows. The pressure is proportional to the
square of the speed, so the position of the
piston or bellows is a function of speed.
HYDRO MECHANICAL GOVERNOR
 HYDRAULIC GOVERNING
 On shaft of the main oil pump, the “Hydraulic Speed Transmitter” is
provided ,which provides primary oil pressure . The change is absolute &can
be taken as proportional to small changes in speed .This primary oil pressure
acts on diaphragm of “Hydraulic Speed Governor” against the force of speed
setting springs , which is tensioned by speeder gear. Travel of the diaphragm is
limited by start up &load limiting device . The movement of the diaphragm is
transmitted by link mechanism to “Auxiliary follow –up pistons”. The pistons
of “Auxiliary follow –up pistons” is held by a spring against oil pressure ,
known as auxiliary secondary oil.
 The oil is essentially trip oil fed from trip oil circuit & drained from a port
formed between the piston & the sleeve . Depending upon port opening ,oil
pressure gets stabilised corresponding to initial displacement of the piston &
initial spring tension , the secondary auxiliary oil pressure provides signal to
“Hydraulic Converter” through its pilot The piston of the hydraulic
converter assumes a position corresponding to secondary auxiliary oil
pressure.
 A secondary oil pressure corresponding to the position of the sleeve & the
related spring tensions built up in the “Follow-up Pistons” of the “Hydraulic
Converter”. Any change in the position of link results in a proportional
change of secondary oil pressure in the ” Follow -up Pistons” of “Hydraulic
Converter”. The secondary oil circuit is also fed oil from trip oil circuit
through reducing valves.
 IMPORTANT EQUIPMENTS & PARTS
 Hydraulic speed governor with and load limiting device
 Speed/load adjusting device.
 Electro hydraulic converter.
 Hydraulic amplifier.
 Electrical speed pick up.
 Servomotor for main stop valves and reheat stop valves.
 HP control valve servomotor.
 IP control valve servomotor.
 Pilot valve of bypass control valve.
 Pilot valve of bypass stop valves
 SPEED/LOAD ADJUSTING GEAR
 The speed and load adjusting gear can be used to set
the limits of variation of speed.
The gear is operated manually by hand wheel or by
motor from remote. At the start up, the hand wheel is
moved downwards by imparting clockwise motion by
operating the motor in closed direction. These prepares
stop valve for opening. At this condition the governor
diaphragm is in fully compressed condition which
ensures control valve fully closed.
Again by operating hand wheel in open direction the
governor diaphragm is released gradually, which
corresponds to gradual pressure builds up of auxiliary
secondary oil and thereby increase in turbine speed.
Thus through this gear the travel of diaphragm is
restricted which limits turbine speed/load.
HYDRAULIC AMPLIFIER
Speeder Gear
 Speed Governors are fitted with stops which limit the
speed range above and below which they operate. The
normal operating range is ± 6% of the nominal speed.
Within this range the speed may be controlled by an
operator making an adjustment to the relationship
between the radius of the governor weights and the
position of the governor weights. The adjusting gear known
as speeder gear acts in parallel with the speed governor.
After an initial run up the speeder gear is used to bring the
machine to rated speed before synchronization. After the
machine is synchronized the speeder gear controls its
power output. In electrical governing system function of
speeder gear is achieved by means of a motor driven
potentiometer. As the speeder gear setting is represented
by a voltage that is added to the electrical speed governor
signal.
Speeder Gear
Electrical governor
• Common design incorporates a permanent type shaft driven
permanent magnet generator producing an a.c. wave having
frequency of shaft speed. This wave is fed into an electric
filter that resonates at a frequency corresponding to rated
speed and the output is rectified to produce a d.c signal
proportional to difference between rated and actual speed.
This signal is amplified to form required speed correction
signal.
• Another design utilizes digital signals from a shaft driven
square wave generator, the output is compared with a
reference square wave signal generated by an oscillator. The
output of the comparator is rectified and amplified to form
required control signal.
ADVANTAGES OF ELECTRICAL GOVERNING SYSTEM
1. House load operation is possible within acceptable range of
frequency.
2. Provision of load controller - Proportional + Integral
control action as against pure proportional action of
Mechanical/Hydraulic governors.
3. Provision of taking aspects of thermal stresses of different
parts of the turbine during startup, shutdown and normal
load operation. This is valuable for enhancing life of the
Turbine.
4. Accurate control of the desired acceleration of the machine
during rolling.
5. Accurate control of the load gradient while loading the
machine.
 ELECTRO-HYDRAULIC GOVERNOR
 The parameters to be controlled i.e. speed, load & turbine
throttle pressure are measured & converted into electrical
signals by means of suitable transducers. These signals are then
fad to various control loops where they are processed as per
requirement of the operator (reference value signals/set-
points) & the turbine condition (monitoring signals). The final
control signal generated is then fed to the Electro-hydraulic
Converter where it is converted to hydraulic signals for
actuating the hydraulically operated final control elements i.e.
the control valves.
 The Electrical Turbine controller basically consists of the
subsidiary controllers for main steam control valve lift (Valve
Position Controller) , speed , load , throttle , pressure &
frequency influences. The control loops fir speed , load &
boiler pressure are superimposed to main steam control valve
position loop .
HYDRAULIC SPEED TRANSMITTER-PRIMARY OIL PUMP
ELECTRICAL SPEED PICK UP
 It is located in the front bearing pedestal. It
indicates the exact speed of turbine through all
speed ranges. Major components of the system are
shown in the figure. There are 120 permanent
magnets of alternate polarity fitted in the non
magnetic disc around its circumference. The non
magnetic disc is mounted on the main oil pump
shaft. On rotation of disc the pole faces of the
magnet move past the hall probes and develop a
output frequency proportional to turbine shaft
speed. The signal is transmitted to the speed
measuring unit for further utilization.
ELECTRO HYDRAULIC SPEED SENSOR: HALL PROBE
HALL PROBE
MAIN OIL PUMP
MAIN OIL PUMP
 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 PRIMARY OIL:
 On the control and governing rack the primary oil lines are coloured
in ‘Green’. Primary oil emerges from the hydraulic transmitter
mounted on the Main Oil Pump shaft and supplies to two points:
 Hydraulic Speed Governor
 Low vacuum tripping device mounted on governing rack
 Its main function is to transmit hydraulic signal proportional to speed
of turbine to the hydraulic governor. The hydraulic speed transmitter
works on the principle of centrifugal pump. It develops a pressure
proportional to turbine speed. The signal actuates the hydraulic
governor bellow and develops another proportional signal for further
processing. The hydraulic speed transmitter is supplied from the
control oil header from the governing rack.
TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 SECONDARY OIL:
 Secondary oil is coloured in ‘Navy Blue’ on the control and governing
rack. For maintaining a steady speed of turbine this oil acts as a
continuous signal to the main and intercept control valves for its
proportional opening according to the quantity of steam needed at a
particular moment. Six auxiliary follow up pistons are arranged in
parallel, three each for main and interceptor control valves. The
secondary oil emerges from these follow up pistons carrying a signal
proportional to follow up piston movement which is guided by the
hydraulic or electro-hydraulic converter. This oil is also supplied to
check the opening of extraction steam valves through extraction valve
check relay. This oil is supplied from trip oil circuit through orifices.
 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM

 AUXILIARY SECONDARY OIL:

 Auxiliary secondary oil is coloured in ‘Navy Blue and
White’ in the drawings. It works as a link to transmit signal
in the form of varying pressure, from the hydraulic
governor to hydraulic converter. Pressure in this oil is
generated by an auxiliary follow up piston, which is guided
by hydraulic governor bellow piston. This oil is also
replenished from trip oil circuit through orifices.
 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 TRIP OIL:This oil is coloured in ‘Pink’ and emerges from the
main trip valves and supplied to the main and interceptor stop
valves, secondary and auxiliary oil requirements and EHC. Its
main function is to cut off the steam supply to the turbine by
closing the main stop valves and the control valves, whenever a
protective device is actuated or a trip signal is given either from
local or remote. It remains in a pressurised state during normal
operations keeping the stop valves open. When any trip signal is
generated, the trip oil is needed to be drained, depressurising
the circuit, results in closure of stop valves. Control oil makes up
any loss caused after drainage of the oil in the trip valve itself.

 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 AUXILIARY TRIP OIL:
 Auxiliary trip oil is coloured ‘White & Pink’. It links all the protective
devices with the trip valve. In main trip valve it keeps the valve in such
a position so that the trip oil circuit remains pressurised. Its main
function is to transmit signal to the main trip valve when any of the
protective device is actuated. In the trip valve, it causes to open the
drain port of trip valve. In this way trip oil circuit is depressurised
thereby main and interceptor valves are closed. This oil stays at a set
pressure during normal condition.
 The actuation of any protective device depressurises the circuit. Any
loss in the oil is supplied by control oil through main trip valve.

 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM

 START- UP OIL:
 This oil is coloured ‘Blackish Red’ on the governing rack.
The oil emerges from starting and load limiting device and
links the solenoid valve s putting up the main & reheat stop
valve with the same oil. Its main function is to prepare the
stop valves for opening before start up. It is supplied from
control oil to the starting and load limiting device pilot
valve.

 TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 AUXILIARY START-UP OIL:
 The identification of this oil is done by ‘White-Violet’ lines.
The oil emanates from the pilot valve of starting and load
limiting device. It is supplied to the main trip valves
through solenoid valves. It also carries signal for resetting
protective devices. Its function is to reset main trip valve
and protective devices in normal operating position. By
resetting the main trip valve it rebuilds the collapsed trip
oil pressure, which is responsible for opening the stop valve
at the start up. At the same time it resets the activated
protective devices.

TYPES OF OIL AND THEIR FUNCTIONS IN
GOVERNING SYSTEM
 OVERSPEED TRIP TEST OIL:
 This oil is coloured ‘Red and Pink’ on the governor control
rack. It carries signal from the over-speed trip test device to
over-speed trip device when testing of device is intended. It
is supplied from the pilot valve of the over-speed test
device from a control oil line connected to the valve.
Speed Controller
 The Speed Controller is used for starting the
turbine upto synchronisation & block
loading . it can also operate over the full
load range during an emergency such as
turbine tripping from full load to no load ,
house load operation or during rapid or
severe frequency fluctuations . the speed
controller is always kept in readiness for
operation even when it is not directly
controlling the turbine by tracking the
signal in service
 Speed Controller Loop
 The turbine is sensed by digital speed pick up (hall probe) mounted on
the shaft in the Front Bearing pedestal & fed to the speed controller as
the actual speed signal (N.act.) .The speed reference, signal (NR) is
formed as a constant voltage from a contactless potentiometer which can
be adjusted automatically by motor (eg. during ATRS operation, auto
synchronisation etc.) or manually from the control room (by operating a
push button console on turbine panel) . The reference value is indicated
on two instruments one with range 0-3500 r.p.m and the other with
2800-3300 r.p.m (for finer adjustments) .The in- coming speed
reference signal is fed into high gain D.C. voltage amplifier .The turbine
condition is reflected by T.S.E signal is introduced in the loop at this
point .The signal then passes into the integrator which generates the
LIMITED SPEED REFERENCE (NR,LIM). NR,LIM is transmitted to the
speed controller module where it is compared with actual speed (N act.)
to generate the final out put signal of the speed controller.
 Load Controller
 The load controller is used for controlling turbine
output during on-load operation .For selecting the load
controller, a push button module LOAD CONTR.
ON/OFF is provided . The load controller must be
switched ‘ON’ if it has to come to action . For final load
control several factors like the Load Reference PR ,Load
limiter set point PR MAX ,TSE influence ,frequency
influence are considered & a final reference EPR is
developed. An indication ‘LOAD CONTR ACT’ is
provided on the Turbine Control Desk. When this lamp
glows it shows that the Load Controller is in service.
 Load Control Loop
 The load is measured with a load measuring unit comprising two
mutually independant systems. The unit is connected to the generator
voltage transformer & to the generator current transformer.
 The LOAD REFERENCE (PR) is set from a reference setter module on
turbine panel in the control room. The rate of change of this reference
value (PR) is conditioned by the TSE influence &the load gradient set in
sub-assembly “LOAD REFERENCE LIMITER”.
 In order to protect the turbine generator set from overload or to limit any
desired value ,turbine controller contains a limiter for maximum load .
This MAXIMUM LOAD REFERENCE value (PR MAX) limits the sum of all
the reference values acting on the load controller to the set level.
 The required dependence of load on frequency is obtained by means of an
additional load reference value PR df. This is known as the FREQUENCY
INFLUENCE.

 In the load control loop, the limited load signal & the frequency
influence are added & the sum compared with PR MAX in a minimum
selector &the resultant is fed to a control frequency controller block.
Pressure Controller
 A pressure dependant load reference value PR df is formed
by a proportional action pressure controller . it readjusts
the turbine load reference depending upon the initial
steam pressure deviation dp & prevents too large a pressure
drop when the turbine demand exceeds the boiler load .
 The pressure controller normally operates in a LIMIT
PRESSURE MODE .When the pressure deviation dp is less
than 10 kg/cm2.when the pressure falls beyond that the
limit pressure is reached & the pressure controller
automatically goes to INITIAL PRESSURE MODE. This
blocks any further load in the load reference limiter & the
indication ‘Limit Pressure Reached’ appears.
Valve Position Control
 The output from speed controller &the load
controller are compared in a max-min selector
& the output from this is again compared with
the pressure controller output in a minimum
selector .The output from this is fed to the valve
position controller. Therefore, the signals from
the speed controller , load controller &
pressure controller are super- imposed &
selected to give an input for valve position
controller.
 ADVANTAGES OF EHC
• i) Increases the life of turboset by conservative
operation with the aid of TSE
• ii) Reliable operation of isolated power grid by
Automatic Switchover of the load controller to
frequency control.
• iii) Precise maintenance of the rated frequency of
the power grid by means of an exact frequency load
curve.
• iv) Low speed deviation under all operational
conditions.
• v) Support of the pressure control system
Parallel Systems
Modern day turbines are equipped with two parallel
governing systems a) Hydraulic
(b) Electro Hydraulic – Both independent of each other.
Although only one of them comes into control action at
any given point of time, the other governor acts as a
backup and its output is in the ready- to- takeover
mode(tracking mode).
 CHANGEOVER FROM HYDRAULIC (HC) TO ELECTRO-
HYDRAULIC (EHC) CONTROL

 Changeover from one control system to another is possible during normal

operation of turbine, since the two systems are brought into parallel connection
after associated follow-up pistons which represent a minimum value selection,
meaning that the system with the lower reference value is always the controlling
one.
 If the turbine is to be run under hydraulic control, the reference speed of the
electrical controller is at “Max. Speed”, which prevents the electro-hydraulic
system from coming into action.
 When bringing in the electro-hydraulic control system, the reference speed of the
electrical controller should be reduced slowly until the secondary oil pressure
drops slightly. When this occurs, the electro-hydraulic controller has taken over.
The speed changer of the hydraulic speed governor is then set at maximum speed.
 The electro-hydraulic controller is now fully effective and can operate over the
entire output range.
 The hydraulic speed governor also acts as a speed limiter in the event of electrical
controller developing a fault. In this case, operation of turbine may immediately
be continued by means of hydraulic speed governor.
 CHANGEOVER FROM ELECTRO-HYDRAULIC (EHC)
TO HYDRAULIC (HC) CONTROL
 This changeover is done in the reverse sequence
mentioned above. First, the speed changer is
actuated in the “Decrease” direction until secondary
oil pressure drops slightly. This is an indication that
hydraulic speed governor has taken over the control.
Then, reference speed limit of electric controller is
set at “maximum”. Now, the hydraulic speed
governor is fully effective and can operate over the
entire load range.
Speed measurement-EHC
• Hall probes are mounted around a disc (fitted at the
turbine shaft) containing 120 magnets (60 N-pole &
60-S pole alternatively) . An advantage of the same is
that one rotation of disc will generate 60 positive
pulses & So, by counting the pulses for one second
we can directly determine the turbo set speed in
rpm.
Speed Controller
 Speed Controller is used to increase turbine speed
from barring speed to rated speed in a controlled
manner and to assist Auto synchronizer in
synchronizing the machine and taking the
blocking load. After synchronization speed
controller can be used for taking load up to 100%
but as a normal practice approx. 10% of load
should be taken and then load controller should
be taken into service. It is done because during
speed controller mode a small frequency change
will cause corresponding opening in valve opening
( hence in load)
Speed controller can be divided into sub section:
Speed set point,
Speed set point control, Dn/Dt monitoring,
Speed control Loop, No load correction.

 a) Speed set point can be changed from cabinet,

desk, auto Synchronizer and SGC turbine. The set
point is called nR. The set point changes at a
gradient of 2160 rpm/min up to a setting 2820
rpm. After 2820rpm speed set point changes at a
gradient of 360 rpm/min which enables accurate
setting of set point in the working range
b) Speed Set Point control
 Speed Set Point control :- The set point fixed in the
earlier section cannot be passed to speed control loop
directly as it is only the desired value which can be
changed at a very fast rate and it does not take care of
turbine stress margin. To incorporate the above
facilities an integration (closed loop) is used.
 TURBINE STRESS EVALUATOR (TSE)
 It is important for the operator to know how quickly his turbine can be
started up and what changes in load he can make without the fear of over-
stressing the turbine components; thereby causing excessive fatigue.
Whenever steam inlet temperature changes within the turbine, the metal
temperature follows the steam temperature with a certain delay. This
causes differential thermal expansions within the turbine casing and shaft
& corresponding stress in the metal. Thermal over-stressing can reduce
the useful operational life of turbine and its components.
 Turbine Stress Evaluator measures and calculates the relevant
temperature values and evaluates them in an analog computing circuit
and determines the allowable conditions of operation so that useful life of
the turbine shall not be unduly reduced. Thus it allows the operation
of the turbine at the highest possible rates of load/speed change while
limiting the stresses within permissible values. The results of TSE, which
are the appropriate operating instructions, are displayed by means of an
indicating instrument.
 TASK OF TSE
 If the turbine is to be operated so that there is no undesirable
material fatigue, these thermal stresses must be kept within
acceptable limits. The optimum balance between longevity on one
hand and material flexibility of operation on the other is achieved
when the permissible range of material stress can be utilized to
the fullest extent.
 The turbine stress evaluator provides the basis of continuously
calculating permissible values for desired changes in operating
conditions at all times and under all operating states and by
displaying temperature margins, within which the speed/load can
be changed during loading/unloading of the machine.
 Signals from the TSE are also fed to the speed and load reference
limiter of the turbine controller for use in set point and gradient
(speed and load) control.
2B) Load gradient and TSE
influence
 Load gradient is an additional feature available in
load controller. The load gradient acts in parallel
with TSE margin with minimum Selector. Load
gradient range is 0-25MW/ min : 200MW & 0-
60MW/min (500MW).
 While for TSE margin 0-30 degree K corresponds to
0-25 MW/min –200MW, 0-60MW/min(500Mw)
 Both load gradient and TSE margin have got an
ON/OFF switched, so if any one is desired to be
taken out of service can be switched off.
c) Dn/Dt MONITORING
 Speed controller is used to increase turbine speed from
barring speed to rated speed in a controlled manner. And
a Dn/Dt monitoring operates during turbine rolling,
between the speeds of 600 r.p.m. to 2800 r.p.m. the rate of
speed rise is very low i.e less than 100 r.p.m/min. it blocks
any furher rise inspeed and brings backs the speed
reference to 600 r.p.m. this incorporated to avoid slow
acceleration rates within the range of critical speeds.
 Speed set point for 200 MW is more than 700 r.p.m & for
500 MW set point is >400 r.p.m and Dn/Dt is <108 r.p.m.

2.Load Controller
 Load controller is used to maintain the load set by
the operator ( at turbine control or at CMC console
) or automatic load dispatch Centre (optional ).
Load controller is also responsible for taking care
of frequency changes and correcting the load. The
controller comes into operation only after
synchronization, before Synchronization it
remains in the follow mode .The total loop can be
divided in the following sub-sections
Sub-sections of Load controller
 2A) Load set point (PR)
 2B) Load Gradient and TSE Margin Influence.
 2C) Load Set Point Control (PRTD)
 2D) Frequency influence.
 2E) Load Limiter
 2F) Actual Load Acquisition
 2G) Final Control Loop

2A)Load Set Point:-
 Load Set Point:- Load set point can be changed from
cabinet, desk, SGC or CMC or from Auto dispatch
Centre (optional).The set point changes at a
gradient of 100 MW /Min for 200MW &
250MW/min for 500MW). The gradient remains
same through out the range. The load set point
indicator is available at desk. The range of the
indicator is 0-250 MW for 200 MW M/c & 0-600MW
for 500MW M/c.
 2C) Load set point Control(PRTD
)
 If load gradient is off and any change in PR is
made PRTD changes by 5%
 The function of PRTD is similar to the NRTD in
speed controller The maximum rate change here is
25MW /min or 60MW in both directions
 The set point controller remains in follows mode
in generator breaker is off or load controller is off
or load is less than station load& MW error>10%.
During this mode PRTD follows actual load
without delay
 STOP command is generated if TSE fault appears
2D) Frequency Influence
 Frequency influence is used to correct the load set
point. The frequency influence has got a droop of 5%
 The frequency influence can be switched on/off from
Frequency Influence module
 Indicator for the correction signal is available at desk
of range +/- 100MW for 200MW M/c & +/- 200 MW
for 500MW M/c.
 IN all NTPC stations this has been kept off.
2E) Load Limiter
 Final Set point (addition of PRTD and PR F ) is
fed to a minimum selector with the load limiter
 Load limiter will limit the actual load and it also
can be used for fast reduction of load in emergency
cases.
 PR (in turn PRTD )also should be reduced, so that
during load increase as per PRTD and not as per
load limiter
2F) Actual Load Acquisition /Load
measurement
 The actual load is measured by three load
transducers which get the signal from PT and CT
and give out put 0-250MW (or 0-500MW M/c)
corresponds to 4-20 mA
 The middle value of the three load measurement is
use for processing
 If any value drifts from the other value by more
than 5%, a selective alarm is generated
2G) Final Controller Loop
 The final loop is a PI controller
 Two major parts consisting of two cards ARL 12&
ARL 13 specially designed for this purpose
 Error signal is generated from the final set point
and actual load in ARL 12 card. It has an inbuilt
frequency influence whose responsibility is to
prevent the over speeding of the turbine. Hence,
this frequency influence acts only to reduce the
out put of the controller
 The output of ARL 13 card provides the integrator
part of the loop. Apart from the integrated, ARL
13 has also got a filter
3 Pressure Controller :-
 3a) Initial Pressure Mode A Pressure deviation
signal (difference of required pressure as per load
and actual pressure ) is fed to the controller .As
long the deviation is more than + 150mV (Actual>
required ) the pressure controller output remains as
maximum saturation. If the deviation fall between
0 to +150mV, the output of the pr. controller comes
out from saturation & match to the output of final
minimum selection output
 As soon as the deviation becomes negative, the
output of the pressure control starts
 This mode comes when runback action comes into
picture or it is selected from console
Pressure controller
3b Limit pressure mode
 The function of this mode is similar to the initial
pressure mode .The only difference being that
biasing of 10Kg/Cm2 is given in this loop. Hence,
all the action start after the pressure drops by more
than 10Kg/Cm2.
 This mode is used when m/c is in load control; a
small pressure correction signal is also applied +/-
side to load set point control.
 This mode should be used once the load on turbo
set is stabilized.
 MIN

PI controller EHC
HP sec. oil
Plunger
Admission Coil
controller IP sec oil

AND

PLUNGER COIL
EHC>1
ON/OFF PB
00%
 CONTROL TRANSFER LOGIC & ADMISSION CONT
ACTUALPR –SET
THROTTLE PR.

MIN
SUMMER
PI CONTR
COLLINS

10 KSC EHC
PI
MIN CONT. CONV
INITIAL PR. MODE

LOAD CONT

MAX MIN
SPEED CONT
100% -0-+100%

OVER SPEED LIMIT

105%
 LOAD SHEDDING RELAY OPERATION
 Load shedding is used to support the function of the turbine governor.
The relay ensures that even in case of a large load rejection, the governor
re-gains control before the over-speed trip is reached. A quick correction
value input to the hydraulic governor output and secondary oil pr. of
IPCVs, minimizes the speed building up according to m/c droop
characteristic. The sudden unloading of the of the turbine i.e. negative
jump in load is detected instantly by the load shedding relay. This pulse
will actuate to a solenoid valves in turn to close the HP & IP CVs as soon
as the pulse ceases the solenoid vales drops causing the secondary oil pr.
to build up and hydraulic speed governor to open HP & IP CVs in new
reduced load condition.
 200MW: load through off >40% & residual load <15% & frequency
>49Hz.
 500MW: load through off >50% & residual load <35% & frequency
>49Hz in a response time of 100 mili seconds.
 LOAD SHEDDING RELAY
 LOAD shedding relay is used to support the function
of the turbine governor. A quick correction value
input to the hydraulic governor output & secondary
oil pr. of IPCV min speed building
 When acceleration time constant is very small or
when governor under load or pressure control.
 Sudden negative jump in load is detected electrically
instantaneously by the load shedding relay
 200MW: Load throw off>40% & residual load<15% &
frequency>49 Hz
 500 MW: Load throw off>50% & residual load<30%
& frequency>49 Hz in a response time of 100mili
seconds. Full load through off <6% the total
interrogation time for solenoids to energize is 1.25
seconds.
 STEAM TURBINE PROTECTIVE DEVICES

 It is the function of the turbine protective system to put

the turbine out of operation by closing the turbine
emergency stop and control valves as soon as operating
conditions occur that can no longer be maintained within
the admissible limits of the protective equipment and thus
endanger the life of the plant. For direct protection and
tripping of the turbine, the following protective devices are
provided
 EMERGENCY GOVERNORS
TURBINE TRIP
– LOW VACUUM TRIP
– HIGH AXIAL SHIFT/THRUST BEARING TRIP
– OVERSPEEDING OF TURBINE
– MAIN OIL TANK LEVEL LOW
– TURBINE REMOTE PUSH BUTTON TRIP
– TURBINE HAND TRIP FROM MOT ROOM /
TG FLOOR (FIRE PROTECTION)
–
 MAIN TRIP VALVE
 The valve’s function is to open the trip oil circuit in the event of
abnormal conditions thereby closing the main and reheat stop and
control valves and thus shutting of admission of steam to the turbine.
In the main trip valve, connections are provided for control oil,
auxiliary start-up oil, trip oil, auxiliary trip oil, drain oil. The auxiliary
start-up oil is used to reset the trip valve (i.e. to return the valve to it’s
upper operating position) after a trip-out condition. The auxiliary
trip-oil connection leads to the hydraulic trip devices viz. the
overspeed trip, the thrust bearing trip and the low vacuum trip.
Actuation of any one of these protective devices will depressurize the
auxiliary trip oil circuit and operate the main trip valve. The main trip
valve can also be operated manually by depressing the lever provided
which opens the trip oil circuit to drain. Two limit switches are
provided alongwith the main trip valve for initiating the electrical
trip-out and the other on depressurization of the trip-oil circuit.

MAIN TRIP VALVE
 SOLENOID VALVE FOR REMOTE OPERATION OF MAIN TRIP
VALVE

 The solenoid valve is installed in the pressure

oil pipe to the main trip valve and when
operated, interrupts the oil flow. This causes the
tripping oil circuit to be drained thus cutting of
steam flow to the turbine. The solenoid valve is
remote-controlled electrically, eg. from the
control room or the protective devices (eg. SGC
Turbine, Fire Protection etc.).
REMOTE TRIP SOLENOID
 OVERSPEED TRIP DEVICE
 The function of the overspeed trip mechanism is to stop the
turbine when the permissible speed is exceeded. This device is
located within the front bearing pedestal on the turbine rotor
and consists of an eccentric bolt, adjusting screw, spring and
screw plug.
 The overspeed trip mechanism is et by adjusting the screw by
means of which the centre of gravity of bolt is positioned
eccentrically to the turbine shaft so that below the tripping
speed, the bolt is held in the position by the spring against the
centrifugal force. If the turbine rotational speed exceeds the
overspeed setting, the centrifugal force overcomes the force of
the spring and forces the bolt out of the turbine rotor. This
depressurises the auxiliary trip oil circuit and operates the main
trip valve. There are two such eccentric bolts, one set at 11% and
the other slightly above that.
OVERSPEED TRIP BOLTS IN BEARING NO. 1 PEDESTAL
OVERSPEED TRIP
OVERSPEED TRIP
OVERSPEED TRIP
BOLTS IN TURBINE
ROTOR
OVERSPEED TRIP
RELEASING DEVICE
OVERSPEED TRIP TEST DEVICES
 THRUST BEARING TRIP DEVICE

 A This device is mounted in the number 2 bearing

pedestal If the axial shift of HPT rotor exceeds
permitted value of 0.5 mm as either side, the pawl
comes in contract with the projected portion of the
shaft collar and the valve is activated. Auxiliary trip oil
area is then connected with drain. Consequently, the
trip oil pressure, in the circuit from trip valve collapses.
This brings closure of stop valve and after a little delay,
closure of control valve. The device is latched again
when auxiliary start up oil is made to flow in the space
provided in the device
THRUST BEARING TRIP
 LOW VACUUM TRIP DEVICE (HYDRAULIC)

 The purpose of the low vacuum trip is to operate the main

trip valve when a failure of vacuum occurs in the
condenser. On initiation of this device, the auxiliary trip oil
circuit is depressurised anfd limit switches are operated
which convey the alarm ‘Hydraulic low vacuum trip
operated’ to thr control room. This device is set to operate
when the condenser back-pressure increases above 220
mm Hg.
LOW VACUUM TRIP
LOW VACUUM TRIP
Free Governing Action
Such large variation of output will require a matching change
in boiler output. This will lead to large and quick changes in
boiler fuel firing rate (oil support, if needed, for low load
operation), air flow, attemperation quantity etc. But the
boiler response is not as fast as that of the changes in the
electrical load of the generator. This gives rise to fluctuations
in the drum level, furnace instability and temperature
excursion.
So, sustained operation under this regime would lead to
frequent equipment failures and less reliability of the system.
Hence , free governing should be used only for trimming
purpose after the frequency has been brought down to a band
range of ±0.25 Hz, for which the boiler response time would
not come into the picture to a great extent.
HYDRUALIC DRIVEN EMERGENCY SHUT OFF VALVES
AUTOMATIC TURBINE TESTER
 AUTOMATIC TURBINE TESTER
HEALTHINESS OF FOLLOWING COMPONENTS IS CHECKED ONLINE (WITHOUT TRIPPING
OF TURBINE)

 PROTECTION DEVICES
- FUNCTIONING OF REMOTE TRIP SOLENOID
- FUNCTIONING OF OVERSPEED TRIP FLYBOLTS
- FUNCTIONING OF HYDRUALIC LOW VACUUM TRIP
- FUNCTIONING OF THRUST BEARING TRIP

 TURBINE STOP & CONTROL VALVE

- FREE MOVEMENT OF ALL HP / IP STOP VALVES
- FREE MOVEMENT OF ALL HP / IP CONTROL VALVES
AUTOMATIC TURBINE TESTER FOR STOP VALVES AND CONTROL VALVES
 SCHEDULE OF TESTING
ATT FOR PROTECTION DEVICES
-TWICE IN A WEEK

ATT FOR TURBINE STOP & CONTROL VALVE

-ONCE IN A MONTH

ATT FOR PROTECTION DEVICES IS CONDUCTED AT FULL LOAD CONDITION WHEREAS FOR
TURBINE STOP & CONTROL VALVE IT IS CONDUCTED AT PART LOAD CONDITION
CHANGEOVER VALVE
FOR AUTOMATIC
TESTING DEVICE
THRUST BEARING TRIP DEVICE
HYDRAULIC TEST SIGNAL
TRANSMITTER FOR OVERSPEED
TRIPS
MAIN TRIP VALVE
REMOTE TRIP SOLENOID VALVE
1

II

RESET SOLENOID
SOLENOID VALVES FOR ATT OF VALVES
STOP VALVES AND CONTROL VALVES
TEST VALVE STOP VALVE SPRING ASSEMBLY
CONTROL VALVE
THANK YOU