Knowledge Sharing Program in C & I

• Turbine Electro Hydraulic Governing

System (EHTC)

Date: 21 April 2008 Amol Mahalle

 Major Groups in Turbine Controls

• Automatic Turbine Testing

• Automatic Turbine Run-up System
• ETS (TTS)
• HPLP Bypass
• Turbovisary Instrumentation.
• TSI
•Turbine Governing System
 Discussion objectives

• To understand the concept of Turbine Governing System

• Types of Turbine Governing System
• What are major Control Loops in GS.
• How is control transfer circuit.
• What are Major Field Instrumentation
• What is Admission Controller.
• What is major difference in BHEL (EHG) and SEC (DEH) supplied system.
• What are Point of control.
• Interface with DDCMIS
• EHG Tracking
• What is limit pr. Mode
• What is initial pr. Mode
• Issue of integral system with DDCMIS.
 Turbine Governing System

• Hydraulic Governing System

• Electro Hydraulic Governing System
• Digital Electro Hydraulic System (DEH)
• Throttle Governing
• Nozzle Governing
Major Control Loops in Turbine Governing

• Speed Controller
• Load Controller
• Pressure Controller
 Controller Selection criteria
Condition Speed Load Pressure
Controller Controller Controller

(I) Start-up  x x
a) Speeding up (Rolling )
600 rpm, 3000 rpm
b) Synchronization  x x

c) Initial loading  x x
immediately after
synchronization
(II) Loading Can be used  Can cut in limit
More than house hold as backup pressure mode or
initial pr. Mode.
(III) Tripped  X X
(IV) Load shedding  Can be x
backup
 Control Transfer Circuit

AE131X12 AH011 XII AH011 AH018 XII

Speed hs
Controller MAX M min2 M Final o/p of
O/P I I controller
N N
Load X21
Controller
O/P /724

+
+
+
AH27 X21
X22
2V
Pressure
Controller
O/P
 Major Field Instrumentation

• Speed Measurement
• Pressure Measurement
• Load Measurement
• Temperature Margins
• Valve Lift Position Feedback
• Collins Transmitter
• Electro Hydraulic Convertor
• Plunger Coil
 Redundant DEH WH – SEC Design
Redundant
Processor
Conceptual Diagram (Control Part)

SP PR 1 PR 2 EHC-2
EHC-1

EHC-5

EHC-3
LVDT-2
LVDT-1
HPCV-1 HPCV-2

LVDT-5
EHC-6
AI AI AI LVDT-3 IPCV-1
HPCV-3 EHC-4
Triple Redundant

MW MW MW
LVDT-6
SPEED SPEED SPEED
LVDT-4 IPCV-2

PR PR PR HPCV-4
Note: EHC is electronic module (MOOG)
 REDUNDENT DEH– Alternative DESIGN
Conceptual Diagram (Control Part)
Redundant
Processor
Plunger Coil
EHC-2

S PR 1 PR 2
P LVDT-2
EHC-1 IPCV-2

LVDT-1

Pilot valve & Follow-up Piston Assembly

HPCV-1
AI AI AI IPCV-1

HPCV-2
Triple Redundant
MW MW MW HPCV-3
SPEED SPEED SPEED
HPCV-4
PR PR PR Note.- Feedback OF Individual CV is not used in control. Used
only for indication purpose. EHC is electronic module.
 Key Technical Comparison

WH SEC Design Alternative Design (REL Plant)

Each CV has dedicated LVDT used for Redundant LVDT at follow up piston is
control. used for control of group of control valve.
10 nos. of LVDT used in DEH control. 2 nos. of LVDT used in DEH control.

Redundant Processor Redundant Processor

Each CV has dedicated EH converter Redundant EH converter (ARS) used for

(MOOG)
Total 10 nos. EH converter (MOOG).
Triple redundant measurement for key
control parameter
control of group of control valve.
Redundant EH converter (Throttle and
Nozzle). Further backed up by hydraulic.
Triple redundant measurement for key
control parameter

Advantages VS Disadvantages
 VALVE Position (Admission)
Controller

The signal from speed controller, load controller and pressure controller are
superimposed and selected for valve position controller.

LVDT measures the valve lift i.e. position of power piston in the amplifier.

EH conversation is done by plunger arrangement which is common for all

control valve. It is connected to follow up piston which regulate secondary oil
pressure to the HP turbine control valve and IP turbine control valve.

Throttling of oil pressure to differential opening of control valve OR Individual

valve control i.e. EH conversation is done independently for control valve.
Regulate oil pressure to the HP turbine control valve and IP turbine control
valve separately
 Admission Controller

PID
 6V
SP EHC
Controller Amplifier
ARS12 AVC12

-7.5 to 7.5V

AKC
M
A
X
hr , actual AKC
LVDT 1 Follow up Piston
LVDT 2

Concerns
Oil Lines
1. Loss of power to Plunger Coil
2. Switching ON Plunger Coil
3. Plunger Coil Wire Break
 Speed Controller

Function:
During following situation

– Start up
– Shutdown
– Synchronizing
– Raising to house lead operation.
– Lead shedding (Islanding condition)
– Limitation of speed before reaching over speed.
 Speed Controller

Speed ref + Speed Control

Controller Transfer ckt

Actual speed

Speed controller is PD loop an error in the input is must to keep valve open for running
the m/c at rated speed. To eliminate this offset pressure dependent correction signal is
given as valve operation for required speed is directly proportional to pressure system.

Settings of Speed Controller

Droop in speed controller (5 %)
Speed controller is PD controller with droop of 5%.
Deviation of 150 rpm  full opening of valve.
Input deviation of 450 mV will give o/p 10V 0-3600 rpm = 0-10.8 V o/p
speed controller (1 rpm = 3 mV.)
 Speed Controller

 Speed Controller is PD loop.

 Gain of the loop is 10/0.45 = 22.22. (Response adjustment)

 Gain adjustment is made at AE131/R26.

 The adjustment of system response is done at AE131, R12 & R 13.

 Speed Controller- Set point control

Panel 0-3000 nR limit

nref (0-3000 rmp) n ref (2800-3300 rmp)

HMI
Speed nR
Reference Limit
2160 rmp /

Speed Ref TSC

desk (If backup) Inf.
ON
Interlock &
SGC Protection
Turbine

Auto Synchronization
 nRTD
n RTD nRTD

1800

1200

600

1 mm 2 mm 3
mm
Min req. speed 100 RPM
 TSE INF on SC

n RTD nRTD

600

300

100

5k 15K 30K

TSE Margin
 TSE Inf on SC

• Maximum desired rate of change with minimum most upper margin

= 600 rpm/min.

• Fast Calibration during follow up mode.

• Zero acceleration ( blocking integrator output) if deviation between

Nrtd & nact is greater than 45 rpm before generator breaker is
closed. This is to ensure speed controller will not give output more
than about 30%
150 rpm = 100%
30% = 45 rpm

Up to 2820 Nr – 2160 rpm

Above 2820 – 360 rpm
 nRTD vs nREF

n Ref

2160 rmp

n RTD

600 rpm

1m t
n ref Vs n RTD
 Speed Measurement
A 027 -X13
Hall Probe

U
AE051
U AE051 AE099
nact
A IA 11 -X13
AWI11 MV3 F1 F
A E035 Freg.
Setting
ADA 11 U
F2

AWI11 A 043 -X13

U 0 to –10.8 V
U
AWI11
AC003 AB099 Nact120-120

AIA 11

A C011

AIA 11 AB115
Spare Nact
A C019
AIA 11
For
Follow up
Speed ref generation Value
 Measurement of Speed

• Disk contain 60N/ 60S (120 Magnet ) mounted on a shaft.

• Mounted at front bearing pedestal on MOP shaft.
• Hall probe Principle: emf is generated when electric current is passed
through rotating magnetic field.
• Hall probe resistance : 33 
• Sine wave o/p is converted to sequence wave  10V
• Each converter card generate 3 output. Two output are used and one is
spare.
• Nowa days BHEL is supplying Jacket Probes

Is 30-80mA
Sensor Volt output  700to  900mV
 Hall Effect

A Hall effect
probe measures
the magnetic
field by making
use of the
Lorentz
force, on the
electrical current
in a
semiconductor.

If an electric current flows through a conductor in a magnetic field, the magnetic

field exerts a transverse force on the moving charge carriers which tends to push
them to one side of the conductor. A buildup of charge at the sides of the
conductors will balance this magnetic influence, producing a measurable voltage
between the two sides of the conductor. The presence of this measurable
transverse voltage is called the Hall effect
 Speed Sig. Conditioning

• In EHC cabinet speed measurement is done in two independent

channel (identical) one is for controlling and other for indication and limit
value monitoring.

• AIWII Pulse converter module is in Enclosure JB.

• AIA II frequency generator and pulse matching unit. I/P Pulse train o/p
sq. Wave pulse. Measurement x13 w.r.t. x22 = Max 11V.
Green light up > 12 Hz (quartz freq, std.)

• ADA11- Used to form a mean signal relative to the phase relationship

from 3 speed signal.
To Monitor I/ p signal.
Max. value of o/p signal =  15V
If input freq < 12 Hz fault indicated.

• If one signal is defective next design higher order selected.

• Principle of max. value is followed.
• If I/p freq > 12 Hz high D26.
Speed Signal Measurement and Diagnostic

•S11 cancelled annunciation on .

-H11 Group alarm (red)
- H12 Red D06 defective.
- H23 Red D12 defective.
- H24 Ch3 defective D22
- H12
- H13
-H14
AFU Output –3mV = 1rpm  3600 rpm = -10.8V
Measurement point AEO99 x 21 / x12
AE067 x 21 / x12
 Speed Controller

Speed 3000 150 rpm

Droof steady state
Load throw

Steady state droop on load throw off from full load to no load
Rate of change of speed set point R.
Up to 2820 rpm – at a rate at 2160 rpm/min
Beyond 2820 rpm – at a rate of 360 rpm / min (1/6 rate)
2160 rpm/min
Nr rate
360 rpm/min
nR measurement – AB035 : x11
2820 nR
 Load Controller

• What is load reference

• Where do we set load reference
• What are inhibiting factors on change in load reference.
• What are influencing factors on change in load reference.
• What is load limiter.
• What is load reference limited.
• What is dP/dt
• When load controller in service.
• What are two main regime of load controller in operation.
• What is frequency influence.
• What is TSE influence on load reference.
• How load controller functions in isolated grid mode operation.
 Load Set Point Control

Turbine Governing - In response to change in the load set point

• Load SP changes at the gradient of 100 MW / min.

• Load gradient act parallel with TSE influence.

• Load gradient 0-25 MW.

• TSE margin 0-30°K  0-25 MW/min.

Load controller is designed for two mode of Opera ration

1. PI Power operation in conjunction with power system
with.
2. P operation on isolated grid operation.
 Load Measurement

CJJ08 BH043 X21 X25

0-10 V Pact
4-20mA ASI
LMU1 M
112 BE115
V
3
X22
Pact <30%
ASI
LMU2
112 BH067

X11 Pact >STL

ASI
LMU3
112 BP035
 Load Reference

ADC Gen ckt br. Off

TSE
Fault PRF
Unf.
Stop
Lower
PR raise
T
H Load SP Control + M
I Load M
A
- N Controller
X
PR

Pr (lim)
T h rnc (AE131 x 12)
Load Limit H
Min
ADC/UNIT
PR MAX
T TSE Fault
H
TSE inf
dP/dt
PRF
Pr (Lim)
dp /dt hRPc
TSE inf
Load Limiter
Pr Limited
 Load Controller
TSE GB
Fult OFF

Frequency
BB19 Isolated
influence
Grid Mode
Panel PRF
XII
L
O XII XII
Desk Stop
A
PB Pref PR _ Normal
D
(Optional) Y Limit PRTD hrpc
+ MIN BH075 Islanded
X25 EPR Mode
R BE083 BE163 X12
HMI
E MIN
XII PRMAX X12
F
SGC Pack Speed signal
Turbine BE115 BH043 5% droop
73080

X24

Load BE75
TSE
Gradent

dp/dt CJJ01
BE083, X25 DA10
Operator set
 Load Controller
Gradient of Load reference Max

•PRMAX can be raised @ 20V/min i.e. 600MW/min.

• This means 100 MW in 10 sec. (careful)
• PR is minimum of P RMAX 1 (PRTD – P R f)
• Deviation of 5% in input give annunciation.

How is load controller output (hrpc) Tacking

•Selection through max gate with speed controller

•Selection through min gate with pressure controller.
• Output of 1mV higher than hrprc when Pressure Controller is in service.
• Load controller cannot go 1mV higher than hrprc.
• Output is kept 150 mV less than hrnc when S.C. in service and m/c sync. and
nCia and load < station load. Load controller o/p cannot go lower than (sp
controller o/p –150)
• Tracking prior to synchronization, after sync. and load < 12 MW to keep
deviation (P R-Pact) seen by load controller to zero to cut in load controller
(BB099).
 Load Controller

• PI controller

• ARL 12 card.

a) Error generation (set point and actual)

b) In build freq. Influence, 5% droop above 3080 rpm.
c) Freq. Influence can’t be made off.

• Changes to isolated grid mode if deviation exceed 10% and freq.

> 51Hz. Fast corrective action is envisaged.
 Load Set Point Control

• Any change in PR
Max, PRTD changes by 5% of full load immediately
and remaining by TSE influence.

• Set point in follow up mode.

a) GB off or.
b) Load controller off or.
c) Load less than that of station load.

• Follow up mode must so that Prtd can brought back to zero after GB open.
• PRTD tracks actual load after synchronization.
• Fast calibration provided for follow up.
• PRTD block on TSE fault / margin.
• Prtd block on steam parameter not OK (SGC).
 Load Controller

ARL 13 Card

• Integrator part
• Filter to ward out fluctuation in ARL 12 o/p.
• Hunting adjustment (filter ) pot R11/R12
• Follow up mode
Load controller off \generator Bkr off\pact < STl and  P > 5%
then output is made to follow the speed controller by 150 mv.
 Load controller o/p tracks speed C. with error 150 mV.
GB closed and Speed control in servise (Following low hvu)
 LC tracks speed controller o/p by 150 mV.
 Can not go below 150 mV of speed controller o/p.
 LC output can go more than speed controller o/p.
 Fast calibration is provided to mach the Prtd with actual load.
 Freq influence PRf

• PR  f to correct load set point.

• Droop can be changed 2.5% to 8.0%

• Freq. influenceMf. ON/OFF provision.

• PR f ineffective below 2800 rpm.

• Limitation  40 MW.
 Freq. influence ckt.

• Oscillator in BL011 x 21 is running at a freq. Of 1400 Hz fo= 1400  2800 rpm.

• AFV11 BL043 card. Comparator  f and nact.

Actual M/c Fact Fo f AFU 12

speed BL051 / x 21
2800 1400 1400 0 0
3000 1500 1400 10 -5.00 V
3200 1600 1400 200 -10.00 V
 Pressure Controller

• As long as deviation is > 15 mV (actual and required) The pressure

controller o/p remains at saturation > 10V (> 100%).
• If deviation falls between 0 to 150 mV the o/p of pressure controller
jumps from saturation to the output of last minimum of control transfer ckt.
(Ready to take over).
• As soon as deviation becomes negative the o/p of controller starts
decreasing and takes over the control.
• Two mode of operation
(a) Initial Pressure mode:
Used during cold startup for initial heading of turbine. Controller loads or
unloads machine to maintain desired pressure set by the separator.
(b) Limit Pressure mode:
• Same as above. Only difference is bising is given such that action starts
only after pressure changes by 10 kg.
• Used once the load on turboset is stabilized.
 Admission Controller

PID
 6V
SP EHC
Controller Amplifier
ARS12 AVC12
Col 1
-7.5 to 7.5V

AKC
M
A
X
AKC
Col 2
hr , actual Follow up Piston

Concerns
Oil Lines
1. Switching OFF Plunger Coil
2. Switching ON Plunger Coil
3. Plunger Coil Wire Break
 Collins Transmitter

Yellow + ve

+ Red
-7.5 V to + 7.5 V
24 V DC Supply Plunger
Linear w.r.t.Positive
Concerns - Black

1. Voltage diff. in two Collins tr.

- Ve Blue
EHTC fault.
• -7 V to +7 V = -10 V TO 0 V
• 0 V Corresponds to just
opening of first control valve.
2. Opening of the termination in
TB at transducer end.

Scope Reliability Soldering

Improvement
 Plunger Travel

+ 7.5 V

0 50 mm travel
25 mm = 0 V

- 7.5 V
 LVDT Principle of Operation

Measurement

• Phase Angle
• Amplitude
 Admission Controller

• Nozzle- Hydraulic Governing.

• EHC- Throttle and Nozzle.
• Measurement of valve lift Collins transmitter (MIN) selection.
• Biasing of 200 mV for second cooling transmitter.

 EHTC fault if difference in Collins T. > 700mV. (adjustable)

 Plunger coil is integrator type. Balance voltage is –1V.
 If voltage –1V is applied to coil no change in piston.
 Plunger keeps on moving till coil voltage = -1V.
 Plunger coil supply can be made ON/OFF.

a) Ensure o/p of admission controller > 5V (P.C. OFF)

b) Piston will full open.
c) Same while switching ON plunger coil.
d) During operation of plunger coil wire break piston will go for full open.
 Plunger Coil Response

Error +ve
Balance Condition
Plunger Coil 1V
V

Error -ve

Time

• Min selection logic for cooling (MAX gate)

• hact1 > hact2 alarm generation adjustable.
 Electro-hydraulic Transducer
Termination Detail

External Inner Description

Gray 1 Black - 24 V DC PS
Yellow 2 Red + Collins
Orange 3 Blue -
Feedback Collins
Brown 4 Yellow +
Brown 5 Red (1.5 mm) +
Plunger Coil
Green 6 Black (1.5 mm) -
Blue 7 Black - 24 V DC PS
Red 8 Red + Collins

Green 9 Blue -
Feedback Collins
Yellow 10 Yellow +
 Hydraulic To Electro Hydraulic Control

While bringing in the Electro Hydraulic control system, the reference set point
of EHC should be reduced slowly until secondary oil pressure drops slightly.
When this happen Electro Hydraulic converter has broken over. The speeder
gear of hydraulic speed governor is then set at max. position.
 Changeover from Electro Hydraulic
to
Hydraulic Control

If the turbine is to be rolled on Hydraulic Governing the speeder gear is set to

zero. And EHTC o/p is adjusted to 100% position. The turbine is rolled to 2800
rpm by means of starting device alone. Afterward for further speed raising
speeder gear is raised.
To change to EHG from hydraulic speeder gear position is lowered until
secondary oil pressure drops slightly. This is the indication the hydraulic
governor has taken over the control. Then EHTC reference is set to maximum
and isolating valve on sec oil line from EHG are closed.
 dn/dt Monitoring
dN /dt < 108 rpm/min

act
n
dN /dt  nact < 2850
nact > 700
GCB off

Stop valve open

& dr/dt acted

Bring speed reference to 600 rpm

1. Minimum acceleration required 100 rpm / min.
 Droop In Speed Controller

Load
5% droop

50.2 51.33
freq
 Stop on Set Point Generator

TSE inf ON

& Stop set point for speed

and Load controller
TSE faulted
 No Load Correction
•As speed controller is PD+P loop an error in the input is must to keep valve
open for running the m/c at rated speed. To eliminate this offset pressure
dependent correction signal is given as valve operation for required speed is
directly proportional to pressure system. This correction is given by gain of 0.05
and overall gain of speed is 22.
•Net Gain = 22 X.05 = 1.11
•Correction input required for 50 KG = 1.35
•Correction input required at 150 KG = 0.8/1.11 = 0.72
• Gain Adjustment at AB099/R11 & BSING AT AB155/R13
•No load correction to keep speed reference close to
speed actual at 3000 rpm.
• As soon as the turbine trips, speed increases above
speed set point. Speed controller will give negative
output. This negative output cannot pass through MAX
gate but will pass through second minimum gate.
• (hrpc+hrnc+2V) is given to prevent over speeding of
turboset.
 EHG Tracking
(Not applicable in SEC unit)
• Tracking device is only on Electronic circuit acting on HG.

• Gets auto off on any of the following conditions.

• EHTC Fault OR Starting Device Position feedback

faulty.

OR

• Turbine Tripped.

OR

• Throttle Select.

OR

• EHTC Throttle < 100%.

-10% M

A
50% 
50%
X
M
50%
I
N
+
60%
+
+

20%
-30% M
A
50%
X
M
40%
I
N
+
+
+

20%
 PROBLEM

M/C speed was not raising

while starting after unit tripping

OBSERVATION

Ball bearing below plunger coil

found jammed. Attended then plunger coil
starts operating and speed raised
 PROBLEM

Diff. Characteristics is getting

with Gov. system every time

OBSERVATION
Plug at the bottom of pilot of
plunger coil was found loose

ACTION TAKEN
Plug tightened then characteristics found ok.
Also plug fixed with locktite 270 to
avoid repetitive failure
 PROBLEM

At Korba unit tripped due to

failure of one hall probe

ACTION
After replacement of one hall
probe, Unit synchronized

ANALYSIS
M/C should not trip on failure of one hall probe
as speed is sensed by 3 hall probes. Suspected
problem was in mean value selection logic or
malfunctioning of selection logic card
 PROBLEM
Multiple cracks of 4 mm depth observed in
LPBP stop valve and control valve. Also
typical layer observed there. Problem
observed during overhaul at Khaperkheda

OBSERVATION
Attended by BHEL
 At Ramagundam frequent problem observed in speed
measurement because of frequent failure of DC to DC
converter circuit on AIW 11 card mounted in DIW10B
field JB for speed measurement. As 3 separate card
are there for 3 speed channels, m/c not tripped due to
mean value selection circuit.
 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 RECOMMENDATION
knob rotation On line full flow
filter self
cleaning by
regular knob
rotation
 PROBLEM
Electro Hydraulic
Converter Hunting

OBSERVATION
Callibrator of EHC checked with
callibrator and found oscillating

SOLUTION

Opened the EHC and one

leaf out of three leaves
spring of electro
hydraulic converter found damage.
Spring was replaced. Stabilization
voltage set to negative (-1 mv)
Problem was solved
4. Two Stop & Control Valves are provided for HP and IP
Turbine.
5. Valves are operating with hyd. System with the pressure
Of 160 kg/cm² like in HPBP system.

6. Mech. Overspeed trip / bolt arrangement on rotor shaft is

Removed and overspeed trip / testing is taken from electrical
Signal. 06 Jacket probes are provided instead of 03. 03 probes
for monitoring and control & 03 for over speeding tests &
trips.
1. BHEL Hardwar is now supplying jacket probes instead of
hall probes for speed measurement.

2. Since 1994 BHEL EDN has stoped supplying iskematic

Hardware based siemens panel.

3. As per BHEL Hardwar, In newly designed TG sets no

separate gov. rack / system is provided.