TURBOMACHINERY

WELCOMES THE
DELEGATES ON A
GUEST LECTURE.

Date : 14 – Nov - 2011

Governing of Steam
Turbines
By
M.S. RAHMAN
General Manager
Turbomachinery,
Hyderabad.
STEAM TURBINE
AND
ITS FEATURES.
BACK PRESSURE TURBINE - 2
BACK PRESSURE TURBINE - 2
CONDENSING TURBINE - 2
EXTRACTION – BACK PRESSURE TURBINE - 2
EXTRACTION – CONDENSING TURBINE - 2
Back Pr. Turbine HG-25, Higher Parameters: 140 bar / 540°C
Turbine EHNK 90/2.8-4.
 PRINCIPLES OF
GOVERNING SYSTEM
AND
TYPES OF GOVERNORS
 Application of governing system
The purpose, types, and Selection of Governing System for
different applications
Single extraction
Double extraction
Back pressure And Condensing in steam turbines
for
 Driving Generators,
Blowers
Compressors and Boiler feed Pumps etc.
Types of Industries where gov.system
applicable
• Steel, Aluminum, Copper
• Fertilizers&Refineries
• Petrochemicals
• Paper
• Cement
• Chemicals and
• Sugar and Utilities
The main purpose of the Governing
System is to maintain:

Constant speed at variable loads

Constant speed at varying steam

inlet parameters
Constant speed at varying
extractions and exhaust steam
parameters
2.0 TYPES OF GOVERNORS USED IN
STEAM TURBINES:

I) CENTRIFUGAL FLY WEIGHT GOVERNOR

(MECHANICAL GOVERNOR)

II) HYDRO-MECHANICAL GOVERNOR.

III) HYDRO-DYNAMIC GOVERNOR.(SR-III,SR-IV).

IV) ELECTRO-HYDRAULIC (ELECTRONIC) GOVERNOR.

I -MECHANICAL GOVERNORS
MECHANICAL GOVERNOR

CENTRIFUGAL
GOVERNOR
LINKAGE

] [

SERVOMOTOR
OIL
PUMP
D
B
PILOT
THROTTLE VALVE
VALVE P0

C P1
A

] [

] [

S
GEAR
STEAM

EXHAUST TO CONDENSER
 II-HYDRO-
MECHANICAL
GOVERNOR
 III-HYDRO-DYNAMIC GOVERNOR
(SR-III & SR-IV)
SERVO MOTOR
STARTING
DEVICE SPEEDER GEAR
POWER OIL
LSR SOL.,
AMPLIFIER DRAIN
VALVE

PG
A
C
C SR-IV GOV.
COLOUR FLOW
U BELLOWS
VALVE(DAMPER)
M
U TRIP OIL
L
A
T PRIMARY OIL
O
R
FROM PRESSURE OIL TURBINE

GOVERNOR IMPELLER
IV-ELECTRONIC-GOVERNOR
ELECTRONIC GOVERNOR
 3.0 SELECTION OF GOVERNORS AS PER
PROCESS REQUIREMENT

i) SPEED / FREQUENCY CONTROL

ii) BACK PRESSURE CONTROL
iii) EXTRACTION PRESSURE CONTROL
iv) EXTRACTION BACK PRESSURE
CONTROL
BLOCK-DIAGRAM OF VARIOUS
GOVERNING SYSTEMS
I) SPEED/FREQUENCY CONTROL
INLET STEAM

SPEED
SETTING
MECHANISM
CONTROL
SPEED VALVE CONTROL
AMPLIFIER
GOVERNOR ACTUATOR VALVE

SPEED SENSOR TURBINE

S
S
GENERATOR

CONDENSOR
 II) BACK PRESSURE CONTROL

INLET STEAM
SPEED
SETTING ELECTRIC GRID
MECHANISM

CONTROL CONTROL
SPEED MIN AMPLI- VALVE
VALVE
GOVERNER SELECTION FIER ACTUATOR
OR
CHANGE
OVER
DEVICE G

SPEED
SENSOR
PRESSURE
TRANSDUCER
ACTUATOR PRESURE
CONTROLLER

SET PRESSURE
III) EXTRACTION PRESSURE CONTROL

INLET STEAM
SPEED CONTROL
SETTING VALVE H.P CONTROL VALVE
MECHANISM JUNCTION AMPLIFIER ACTUATOR
H.P H.P L.P
SPEED
+ - CONTROL
L.P L.P VALVE
GOVERNOR + +

S
SPEED SENSOR
DRIVEN
EXTRACTION MACHINE
PRESSURE

EXTRACTION
ACTUATOR PRESSURE PRESSURE
CONTROLLER TRNSDUCER

PRESSURE
REFERENCE
IV) EXTRACTION BACK PRESSURE CONTROL
INLET STEAM
SPEED CONTROL H.P CONTROL
SETTING VALVE VALVE
MECHANISM AMPLIFIER ACTUATOR
JUNCTION
H.P H.P
+ + L.P
SPEED CONTROL
MINOR
GOVERNOR L.P L.P VALVE
CHANGE
OVER

S
SPEED SENSOR

EXTRACTION
PRESSURE
EXTRACTION BACK
PRESSURE PRESSURE
ACTUATOR
CONTROLLER
TRNSDUCER

BACKPRESSURE
ACTUATOR CONTROLLER
TRNSDUCER
TURBINE GOVERNING&
PROTECTION SYSTEMS
TURBINE GOVERNING SCHEME
 PROTECTIONS
ELECTROMAGNETIC VALVE
LUBE OIL PROTECTION
EMERGENCY STOP VALVE
TRIPPING DEVICE
VACUUM PROTECTION
BACK PRESSURE PROTECTION
EXTRACTION PROTECTION
BEARING TEMPARATURE HIGH
VIBRATION LEVELS HIGH
GENERATOR VOLTAGE LQW/HIGH
GENERATOR AMPS HIGH
MAIN STEAM PRESSURE LOW/HIGH
FREQUENCY HIGH/LOW
REVERSE POWER PROTECTION
AXIAL, DIFFERENTIAL SHIFT PROTECTIONS
ELECTRO-
MAGNETIC
VALVE
LUBE OIL
PROTECTION
EMERGENCY STOP
VALVE
TRIP
DEVICE-2
TRIP
DEVICE-3
VACUUM PROTECTION
BACK PRESSURE/EXTRACTION PR.
PROTECTION
ELEMENTS OF GOVERNING SYSTEM

MAIN OIL PUMP

FILTERS
MAGNETEC VALVE
LUBE OIL PROTECTION
VACUUM PROTECTION
EXTRACTION PRESSURE PROTECTION
BACK PRESSURE PROTECTION
TRIPPINING DEVICE
STARTING DEVICE
EMERGENCY STOP VALVE
AMPLIFIER
SERVOMOTOR
CONTROL VALVES
OVER SPEED TESTER
OVER SPEED GOVERNOR
STARTING DEVICE
LOADING DEVICE
PRIMARY OIL SENCING ELEMENT
EXTRACTION PRESSURE CONTROLLER
BACK PRESSURE CONTROLLER
AXIAL SHIFT PROTECTION
DIFFERENCIAL ROTOR/CASING EXPANSION PROTECTION
AMPLIFIER
SR-4
GOVERNOR
CONTROL VALVES - 2
CONTROL SLIDE AND SLEEVE
CONTROL SLIDE AND SLEEVE ASSEMBLY
LUBE OIL SYSTEM
AND
ITS IMPORTANCE
 STARTING & LOADING OF TURBINE
STARTING OF TURBINE
 CHECKING OF LOGIC CIRCUITS, PROTECTIONS AND ALARMS
 STABILISING LUBE OIL SYSTEM AND RUNNING BARRING GEAR
 ESTABLISHING CW SYSTEM, CONDENSATE SYSTEM
 STARTING GOVERNING OIL PUMP
 HEATING PIPELINES AND KEEPING ALL STEAM DRAIN LINES IN OPEN CODITION
 PULLING VACUUM BY ESTABLISHING GLAND STEAM SYSTEM
 ROLLING OF TURBINE AS PER DESIGN CURVE
 TAKING OVER OF GOVERNOR AND THEN M.O.PUMP
 CHECKING PERFORMANCE AT RATED RPM
 PREPARATION OF SYNCRONIZATION AND SYNCRONISATION
LOADING
 LOADING THE TURBINE AS PER DESIGN CURVE BY O.E.M
 CHARGING EXTRACTION AT MINIMUM LOAD AND GOING TO REQUIRED EXTRACTION
 LOADING TURBINE UP TO FULL LOAD AND CHECKING AND RECORDING ITS PERFORMANCE
 SHUTDOWN OF TURBINE
PLANNED SHUT DOWN
 REDUCE THE LOAD TO MINIMUM LOAD , OPEN THE BREAKER AND THEN TRIP THE MACHINE
 OPEN ALL STEAM DRAIN LINES
 WATCH COASTING OF TURBINE AND OBSERVE LUBE OIL SYSTEM COMING IN SERVICE ELSE
START THE AUX.PUMP OR LUBE OIL PUMP OR EMERGENCY LUBE OIL PUMP OR O.H.TANK OIL
AND ESTABLISH LUBE OIL SYSTEM.
 KEEP THE BARRING GEAR IN SERVICE AFTER STOPPING AND KEEP RUNNING DURING
COOLING OF TURBINE
 ISOLATE ALL STEAM SUPPLY LINES, VACUUM CUTTING OFF , AND STOPPING CODENSING
SYSTEM AND CW WATER SYSTEM FOR LONG SHUT DOWNS

 EMERGENCY SHUTDOWN

 TRIP THE MACHINE AND DO THE OTHER SAME ACTIVITIES CARRIED IN PLANNED SHUT
DOWN
OVERHAUL SCHEDULES
OF
STEAM TURBINES
 OVERHAULING AND MAINTANANCE OF
INDUSTRIAL TURBO-MACHINES:
1. GENERAL
2. TYPES OF OVERHAUL(O/H)
- MINOR OVERHAUL
- INTERMEDIATE OVERHAUL
- MAJOR OVERHAUL
- MODULAR OVERHAUL
 OVERHAULING AND MAINTANANCE OF INDUSTRIAL
TURBO-MACHINES: contd.

3. CHOOSING MOMENT OF OVERHAUL

 BASIC FACTORS
 OPERATIONAL FACTORS
 EQUIVALENT OPERATING HOURS
 INTERVALS BETWEEN OVERHAULS
4. EXECUTION OF O/H’s AND SPARES STOCKING
5. INSPECTION DURING OVERHAUL
6. OVERHAULS AND THEIR SCOPE
7. RESULTS OF O/H AND THEIR CONSEQUENCES
RETROFITTING
OF ELECTRONIC
GOVERNOR
ADVANTAGES OF ELECTRONIC
GOVERNOR
ELECTRONIC GOVERNOR
1IT IS.MORE RELIABEL AND
MORE AVAILABLE
2. IT IS LOW COST OPERATION
AND MANITENANCE
3. MANY PARAMETES CAN BE
CONTROLLED.
4. IT CONTROLS WIDE RANGE OF
A PARAMETER.
5. DIFFERENTS SETTINGS OF
SAME PARAMETER CAN BE
POSSIBLE
HYDRO-MECHANICAL GOVERNOR
LESS RELIABE AND PERSIST
FREQUENT PROBLEMS
2. IT REQUIRES HIGH COST
OPERATION AND MAINTENANCE
UNDER EXPERT GUIDAINCE
LIMITED PARAMETERS ARE
CONTROLLED
4. IT CONTROLS LIMITED RANGE
OF A PARAMETER.
5. ONLY ONE SETTING OF EACH
DEVICE IS POSSIBLE.
 ACTIVITIES TO BE CARRIED FOR
RETROFITTING OF ELECTRONIC
GOVERNOR
MECHANICAL
1.FITTINGS OF PIPELINES. ISOLATING VALVES
2.FITTING OF E/H CONVERTERS
3.FITTING OF SPEED PROBES
4.FITTING OF TRANSDUCERS (PRESSURE, TEMP ETC)

ELECTRICAL
1. FIXING OF WOODWARD GOVERNOR 500E
2. CONNECTIONS OF ELECTRICAL CABLES FOR E/H
CONVERTERS, MONITOR, TRANSDUCERS, RELAYS ,
ANALOG METERS, ELECTROMAGNETS FROM
WOODWARD500E
3. GIVING POWER SUPPLY TO PANEL
 DO’S AND DON’TS
OF
STEAM TURBINES DURING OPERATION
DO’S AND DON’TS OF STEAM TURBINE DURING
OPERATION:
DO’S AND DON’TS OF STEAM TURBINE DURING
OPERATION: contd.
TROUBLE SHOOTING,
CASE STUDIES
AND
GROUP DISCUSSIONS
 4.0 TYPES OF PROBLEMS ON STEAM TURBINE
GOVERNING SYSTEM:
a) PROBLEMS USUALLY FACED:

Load Limitation.
Chattering of Control Valve Actuators
(Servomotors).
Low Primary Oil Pressure.
Spurious tripping of the unit.

Over Speeding of the unit on load throw offs.

 a) PROBLEMS USUALLY FACED:

Severe hunting of units at no-load & on loads.

Stalling of Control Valves in dynamic condition
Jerky movement of Control Valves
Emergency Stop Valve not opening with steam
charged in the chest
Main Oil Pump not taking over at normal rated
speeds
 b. PROBABLE CAUSES:

 Load limitation due to inadequate opening of Control

Valves / Valve cone damage / salt deposits on turbine
internals.
 Chattering of Control Valve actuators mainly due to
chocking of oil jets in pilot valve / mechanical
impurities in oil etc.
 Low primary oil pressure mainly due to inadequate
inlet oil supply / oil leakage through seals
 Spurious tripping mainly due to mechanical Turbine
projections without indications
 Over speeding of the unit on trip out is due to
additional steam entry onto Turbines
 b. PROBABLE CAUSES: contd
 Hunting of unit at no-load and on-load mainly at nodal
point of operation and Governing elements mal-
operation
 Stalling of Control Valves in dynamic condition due to
inadequate oil pressure of MOP / Jamming of Control
Valve
 Jerky movement of Control Valves – mainly due to
excessive gland packing, bent spindles etc.
 Emergency stop valve not opening with steam is due to
jamming of pilot in main cone etc.
 Main oil pump not taking over mainly due to higher
seal clearances on suction & discharge and improper
priming due to missing injector nozzle in MOP suction
pipe.
 Changeover from Main Control Valve to Auxiliary
Control Valve mainly due to mismatching of Governing
system calibration values
 CASE STUDIES:
CASE STUDY (1)
i) PROBLEM : There is lot of hunting in 3.5MW tg set on
load and also on no load. M/c was kept idle for 1.5 yrs. Many ex
perts even O.E.M. tried and could not able to success.
Site : M/s. KISCO MANGLORE
ii) OBSERVATIONS : Lot of hunting in MW meter is
observed
iii) ACTION TAKEN : Calibration of the tg set is carried.
All governing elements like oil transformer, droop setter
checked. Finally the secondary cup is in jam condition and the
same is made free.
RESULT : Turbine is run and loaded and the tg set running
smooth without any hunting in load and speed.
 CASE STUDIES: contd.
CASE STUDY (2)
i) PROBLEM : Tg set is over speeding soon after ESV is
opened
Site : M/s. CORAMANDAL VISAKHAPATNAM 5MW
BHEL SET
ii) OBSERVATIONS : Turbine is automatically going up to
over speed and tripping the M/c
iii) ACTION TAKEN : It is observed that the 1 st control
valve is in open condition. The same is made in close condition by
adjusting the servomotor spindle. Calibration of servomotor is
calibrated and set to design values
iv) RESULT : Turbine did not spin soon after the ESV opened.
Turbine speed was stable where ever we maintain.
 CASE STUDIES: contd.
CASE STUDY (3)
i) PROBLEM : HP and LP servomotors of unit-2&3 were
chattering.
Site : M/s. IOCL MATHURA EK1100 12.5MW
ii) OBSERVATIONS : There is lot of hunting in the speed
and extractions flow were not maintaining.
iii) ACTION TAKEN : HP &LP servomotors-2 does not
have secondary flow control in manufacturing. Hence the same is
rectified by providing extra orifices in secondary line and there
by controlled the chattering of servomotors.
iv) RESULT : After running the turbine the hunting in speed is
rectified. Extraction flows were achieved as required.
 CASE STUDIES: contd.
CASE STUDY (4)
i) PROBLEM : LP servomotor stuck and maximum is not
achieved.
Site : M/s. DCW GUJARAT EG300-2 3.5MW
ii) OBSERVATIONS : LP servomotor is stuck in position
due control valve links and spindles.
iii) ACTION TAKEN : LP servomotor and control valve
links are completely overhauled. During overhauling it is
observed that the control valve spindle locknuts are slipped and
the valves jerked down side and restricting the steam flow
towards back pressure side. The same is rectified and lifted the
valves properly.
iv) RESULT : After running the turbine LP servomotor start
working and increased the flow towards the LP side and there by
achieved the full load. This saved lot of budget and comfortable
in meeting the load demands
 SUMMARY OF GOVERNING SYSTEMS
The governing system by governing the turbines plays an
important role of controlling various parameters for the
smooth operation like extraction of steam, load and speed
of the turbines.
So control systems should always be monitored continouly
Proper maintenance of governors can minimize the outages
of turbines and thereby saves lots of energy
If the control system is not proper losses occur and even 1
% loss can be a loss of lacs in the budget
Thank you