WELCOME TO

THE PRESENTATION ON

STEAM TURBINE
PROTECTIONS AND
GOVERNING SYSTEMS
AT
ESCI, HYDERABAD
BY
BHEL – PS SR, CHENNAI

8-9 Dec, 2004

CONTROLS OF LARGE
UTILITY TURBINES

Presentation By
Srinivasan Selvaraj
Main Control Systems
 Electro-Hydraulic Governing System (EHTC)
 Turbine Stress Evaluator (TSE)
 LP Bypass Control System (LPBP)
 Gland Steam Control System (GSC)
 Protection System
 Turbovisory System (TSI)
 Automatic Turbine Tester (ATT)
Electro-Hydraulic Governing
System (EHTC)
EHTC: Advantages
 Safe Operation of Turbine in
conjunction with Turbine Stress
Evaluator (TSC)
 Excellent Operation Reliability and
Dependability
 Low transient and steady state speed
deviations
EHTC: Advantages

 Dependable control during load

rejection
 Reliable Operation in case of Isolated
Grid
Critical Measuring Devices
 Speed Probes (3 Nos.) and associated
circuit elements
 Load Transducers (3 Nos.)
 Electro-hydraulic Converter housed in
Governing Rack (1 No.)
 Position Feedback Transmitter of EHC
Control Loops
 Speed Control
 Load Control
 Pressure Control
Speed Control: Main Functions
 PD Controller
 Start Up & Shut Down of Turbine
 Synchronizing with grid
 Providing Min. Load
 Operation of Turbine over entire range
of Load in case of Load Controller
Failure
Load Control: Main Functions

 PI Controller
 Provision of load reference limiter
 Frequency influence option
Pressure Control:Main Functions

 PI Controller
 Initial pressure control
 Limit pressure control
 _
Nr Nrtd
+

Nact
SPEED
CONT. PD
M
A M
Pmax M _
+ LOAD X I M
I EL
Pr Prtd + Prsu + CONT. PI N I
N
+ m N HYD

Pact
_
Fact
+
_ _
pREF PRESSURE
Fref CONT. PI
+ +
pACT
0
P

LIMIT PRES. R

INIT. PRES.

S
Governing Scheme for
KWU Turbines
 FROM ELEC
CONTROLLER

EL
HYD
TO CONTROL
VALVES
STARTING MIN
DEVICE
M HYD
I
N HYD
SPEEDER
GEAR

Governing Scheme for

KWU Turbines
Additional Functions

 Tracking device option

 Load shedding relay
 Auto Synchronizer
 Isolated grid operation
Tracking Device Functions
The starting device keeps varying
automatically with variation in the
position of EHC. In case the EHC fails
the starting device will restrict the
raise in the load.
Load Shedding Relay Functions
During sudden load throw–off conditions,
there will tendency for the speed to raise
rapidly. To avoid such conditions the LSR
gives a close command for closure of the
control valves for a brief moment. The
magnitude of load throw,time duration of
closure of control valves are settable in
the LSR.
Auto synchronizer Functions
The auto synchronizer accepts Gen and Grid
Potential transformer signals. To match the
frequency and voltage of the Generator, the
auto. Sync. Unit gives Speed raise/lower
command to EHTC and voltage raise/lower
command to AVR.
After parameter matching the auto sync. Unit
generates a command for Synchronizing the
unit
Auto synchronizer Functions
After parameter matching the auto sync.
Unit generates a command for
Synchronizing the unit
Turbine Stress Evaluator
(TSE)
Turbine Stress Evaluator
 Compares thermal stress in the
monitored components with the
permissible limits and generates
margins.
The temperature margin is fed to the
set point controller – speed and load.
 Derives start up criteria for ATRS
TSE: Components Monitored
 Emergency stop valve.
 HP control valve.
 HP casing.
 HP shaft.
 IP shaft.
 TSE: Measuring Points
 Surface and mid wall temperatures of ESV
(Ti & Tm)
 Surface and mid wall temperatures of HPCV
 Surface and mid wall temperatures of HP
casing.
 Derived value for HP and IP shaft
temperatures from specified locations in
respective casings.
TSE: Operating Modes
 Three modes viz., fast, normal, slow
available.
 The increased fatigue rate associated
with fast mode can be compensated by
more slow mode operation.
 TSE: Margins
 For any component, the difference Ti –Tm
represents the actual thermal stresses.
 Depending on the value of Tm and
operating mode the permissible value of
thermal stress is determined.
 From the difference between the
permissible stress and prevailing actual
stress the margin is derived.
 TSE: Margins
 The margins of different components are
provided in the Bar graph form in the
TSE monitor.
 The reference variable derived from the
minimum margin acts directly on the
turbine control system.
LP Bypass Control System
(LPBP)
LPBP system: Main Features
Enables alternative path for dumping
steam from RH outlet to condenser
bypassing IP and LP turbine.
Maintains RH pressure from a criteria

representing the HP turbine flow.

Works in conjunction with HP bypass

systems and when necessitated by the

system.
LPBP system: Main Features
Provides fixed and variable set point.
Protects the condenser by water

injection.
Hydraulically protects the system when

the water injection press. is v low or

condenser press. is v high
LPBP system: Pressure control
 Process variable for control loop is
acquired from Press. Transmitter in RH
line.
Two set values viz. Fixed set point and

variable set points are formed and

maximum value is used as reference.
LPBP system: Pressure control
Fixed set point is varied with push
button in the control desk.
Variable set point is derived from I stage

pressure of HP turbine which is an

indicative parameter of steam flow.
Manual operation of valves is possible

with push buttons in the control desk.

I stg.
press

PT
f(x)
M
- PI
A
X Cont.
Fixed +
setpoint
From EHC LVDT

-
Valve
PT + Lift PID
To EHC
RH press

LPBP Scheme for KWU turbines

Gland Steam Control System
(GSC)
Gland Steam Pressure Control
 Maintains the Gland steam header
pressure at required value.
 Provided with two control valves viz.
seal steam control valve and gland
steam control valve.
 Process variable is the header pressure
from a transmitter.
Gland Steam Pressure Control
 The electro-hydraulic actuator have
inbuilt pump and it is powered by
separate power supply.
 In the event of pump failure,the valve
remains stay put.
 Seal steam valve
Set + PI f(x)
point. Cont. EHC
-

PT
Leak steam valve
GS header
press f(x)
EHC

100
Leak steam valve
Seal steam valve
Command
To
Valve

0 Cont.output 100

GSPC Scheme for KWU turbines

Protection Systems
Protection Systems

 Electrical Protection Systems

 Hydraulic Protection Systems

Electrical Protection Systems
 Emergency PB (UCB)
 Lub Oil Pressure Very Low (2 out of 3)
 Fire Protection Trip
 Turbine Trip from ATRS
 Axial Shift Very High (2 out of 3)
 Over-speed Trip
 MFT Relay Acted from Boiler (2 out of 3)
 Electrical Protection Systems
 Generator Protection Trip
 Vacuum Low Trip
 HP Exhaust Temperature Very High(2 out of 3)
 Generator Cold Gas Temperature Very High
 Exciter Hot Air Temperature Very High
 Liquid Level in Generator Bushing Very High
(2 out of 3)
 Hydraulic Protection Systems

 Over-speed Trip 1 & 2

 Vacuum Low Trip
 Axial Shift
 Hand Trip Lever 1 & 2
Features of Protection Systems
 Cyclic Test done periodically for each
Trip input
 Fault at input level will be annunciated
 Testing can be done online
 2 out of 3 logic ensures reliability and
avoid spurious trippings
 2 separate Processor Units realize the
Protection Logic with dedicated IOs.
Features of Protection Systems
 Data of both processors matched
through Serial Communication and
discrepancy annunciated
 2 separate Solenoids provided in
Hydraulic System for redundancy
 First cause of trip will be annunciated
 Online Testing of Final Tripping
elements through ATT
Resetting of Protection
Turbine Trip Solenoid stays in energised
condition until the following conditions
are fulfilled.
 Command from individual Trip ceases

 Both ESVs Closed

 Trip Oil Pressure less than 2 kg/sq.cm

Turbovisory System (TSI)
 Turbovisory Instruments
 Absolute bearing vibration
 Absolute shaft vibration
 Axial shift
 Relative expansion – HP
 Relative expansion – IP
 Relative expansion – LP
 Overall expansion
Automatic Turbine Tester
(ATT)
 ATT : Features
 Individual testing of each turbine
protective devices.
 Pretest ensures substitute devices.
 Monitoring of program steps for
execution within a certain time.
 Interruption if trip is initiated.
 Automatic reset of program after a
fault.
 Automatic Turbine Tester

 Sub group – Safety Devices.

 Sub group – HP/IP valves.
 ATT: Safety devices

 Remote trip device 1 & 2.

 Over speed trip device 1 & 2.

 Low vacuum trip device.

 Thrust bearing trip.

ATT: HP/IP Valves
 HP stop & control valve 1
 HP stop & control valve 2

 IP stop & control valve 1

 IP stop & control valve 2

ATT: LOGICS for safety devices
Release condition for start
 All protective device in operating

condition.

1st step command

 Checking of Provision of control fluid for

enabling test
 ATT: LOGICS for safety devices
Release condition for 2nd step
 Pressure before changeover valve > 5

kg/sq cm.

2nd step command

 Takes care of over speed trip-1 during

test.
 ATT: LOGICS for safety devices
Release condition for 3rd step
 Pressure before changeover valve < 2

kg/sq cm.
 Pressure between sol. valve >5 kg/sq cm.

3rd step command

 Takes care of over speed trip-2 during

test.
ATT: LOGICS for safety devices
Release condition for 4th step
 Pressure between sol. valve <2 kg/sq

cm.

4th step command

 Provision of control fluid.
 ATT: LOGICS for safety devices
Release condition for 5th step
 Pressure before changeover valve >5

kg/sq cm.

5th step command

 Changeover valve to test position.
 ATT: LOGICS for safety devices
Release condition for 6th step
 Trip oil Pressure >5 kg/sq cm.

 Changeover valve test position.

 Aux startup fluid < 2 kg/sq cm.

6th step command

 Testing of remote trip device 1 & 2.
 ATT: LOGICS for safety devices

7th step command

 Testing of over speed trip device 1 & 2.

8th step command

 Testing of low vacuum trip device

9th step command

 Testing of thrust bearing trip device
ATT: LOGICS for valves
Start conditions
 All stop valves 100 % position

 Load controller in action

 Load < 66.6 %

 Trip oil pressure > 2 kg

ATT: LOGICS for valves

Step I command
 Control valves - HP & IP

Step II command
 Stop valves – HP & IP
Automatic Turbine
Run-up System
(ATRS)
Automatic Turbine Run-up
System (ATRS)
 Acquisition, analysis and collation of
various parameters during Startup
 Sequential Control of Drives
 Unit Synchronization and Minimum Load
Operation
 Organised and hierarchically arranged
as Sub Group Control (SGC), Sub-loop
Control (SLC), and Control Interface
ATRS: Functional Group
ATR S

S G C ( O il) S G C (C o n d & E v a c ) S G C ( T u r b in e )

S L C ( T u r n in g G e a r ) S L C (C E P ) S L C ( D r a in s )

S L C (A O P 1 ) S L C (V a c . P u m p ) W a r m U p C o n t r o lle r

S L C (A O P 2 ) S L C (V a c . B rk r) S t a r tin g D e v ic e

S L C (E O P ) S e t P o in t D e v ic e
(S p e e d & L o a d )

S L C (J O P ) A u t o s y n c h ro n is e r
THANK YOU !