NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO.

01

WRITE UP ON ELECTROHYDRAULIC TURBINE CONTROLLER ( EHTC )

Reference Documents: 1.MPL for Steam Turbine Doc. No. :- 41330000488(TAPP3/64110/5516/SCH) 2.Scheme for speed measurement turbine and generator Doc. No. :- 41330098204(TAPP3/64110/5512/DN) 3.Write up on LRR for MSCV and AEOR Doc. No. :- 41330000481(TAPP3/64110/5661/DN) 4.OGA of TG control desk 6610 PL 9 Doc. No. :- 06560000403(TAPP3/64100/5724/GA) 5.OGA of TG control desk 6610 PL 10 Doc. No. :- 06560000404(TAPP3/64100/5725/GA) 6.Turbine controller CJJ01 Cubicle & Rack assembly diagram Doc. No. :- 36560001746(TAPP3/64100/5728/GA) 7.Turbine controller CJJ01 Signal Flow Diagram(SFD) Doc. No. :- ED-031027-SF-S105(TAPP3/64100/5729/WD) 8.Turbine controller CJJ01 Functional Diagram(FCD) Doc. No. :- ED-031027-FC-S105(TAPP3/64100/5729/WD)
NPC. DOC. NO. TAPP3/64110/5526/DN/R0

01 00 REV

1.10.02 17.11.02 DATE

REVISED AS PER BS RANA NPC COMMENTS FIRST ISSUE REMARKS V. KUMAR WORKED

BS RANA BS RANA CHECKED A. ALI APPROVED

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Electro-hydraulic turbine controller INDEX 1 2 3 3.1 3.2 4 4.1 4.2 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 6 7 8 8.1 8.2 8.3 8.4 9 Introduction Turbine Control System Hydraulic Controller Hydraulic Amplifier and Electro hydraulic Converter Load Rejection Relay Electro hydraulic Controller Control Requirements for Electro hydraulic Controller Structure of Electro hydraulic Controller Control Loops of Electro hydraulic Controller Speed Control Loop Speed Set point Adjuster Speed Set point Control Actual Speed Derivation Speed Controller Lift Set point control loop Lift Set point Adjuster Lift Set point Controller Actual Load Derivation Maximum Valve Lift Set point Adjuster Further Processing of Lift Set point Signal Activation and Deactivation of Lift Set point Pressure Control Loop Control Selection Circuit Valve Lift Control Loops Set point Derivation for Lift Control Loops Actual Lift Derivation position Controller Interaction of Electro hydraulic Controller and Hydraulic Controller Operator Control Devices Operating Concept, Operating Modes Start-up Loading/Power Operation Shutdown Load Rejection Alarms SH. NO. 4 4 5 5-6 6-7 7 7 7-8 8 8 8 9 9-10 10-11 11 11-12 11 12 12 12 13 13 14-15 15 16 16 16-17 17 17 18 18 18-19 19 19-20 20

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 Fig. -1 Fig.-2 Fig.-3 Fig.-4 Fig.-5 Fig.-6 Fig.-7 Fig.-8 Fig.-9 Fig.-10 Fig.-11 Fig.-12 Fig.-13 Fig.-14 Fig.-15 Fig.-16 Fig.-17 Structure of the turbine control system Mechanical Hydraulic Controller (MHC) structure of the EHC with Hydraulic Actuation Speed Control Loop Turbine Stress Control influence on ref limiter Actual Speed Measurement Lift Set point Control Loop Actual Load Measurement signal Exchange Speed Measuring Unit Minimum pressure Control Loop Control selection Circuit Function of Selection Circuit Valve Position Control Loop Characteristic Curve Of Plunger Coil Tiles On Control Panel Functional Diagram of EHC 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

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Introduction controller (EHTC) is realized as a part of

Electro-hydraulic turbine PROCONTROL system.

The Electro hydraulic turbine controller consists of two main components: 1. 2. An electronic controller which outputs valve lift set points. A hydraulic system which position the valves to match the valve lift signal.

This combines the advantages of electronic measurement and signal processing such as: high flexibility excellent dynamic response simple representation of complex functional interrelationships

With the advantages of hydraulic systems, i.e. continuous and precise control of large actuation forces.

A hydraulic controller is also provided. Under normal conditions, this controller is deactivated. In the event of failure of the Electro-hydraulic controller, the hydraulic controller can be activated from the main control room panel 6610-PL-10. Operation of the Electro-hydraulic controller and its interaction with the hydraulic controller is described below : 2 Turbine Control System

The standard configuration provides a hydraulic controller and an Electrohydraulic controller for control of the turbine generator. As can be seen in fig. 1, the hydraulic controller acts via a hydraulic amplifier, and the Electrohydraulic controller via Electro-hydraulic converters. The output of each of the Electro-hydraulic converters is linked via an hydraulic MIN gate (as shown in fig 3). This means that the lower control signal at any time takes affect for the hydraulic actuation system. This description in not intended to give detailed information on the hydraulic controller or on the hydraulic valve actuation system. These two systems are therefore described only to the extent required to assist in understanding Electro-hydraulic controller operation. ---------------------------------------------------------------------------------------------- Sheet no. 4 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01

Hydraulic Controller

The hydraulic controller (see fig . 2) comprises of hydraulic speed governor and a start-up and load limit device. These two devices are linked via a MIN gate, with the output from this acting on the hydraulic amplifier and thereby on the turbine control valves. If the hydraulic controller is to govern turbine start-up, the set point for the Electro-hydraulic controller must be set to 100% to allow the hydraulic controller to implement turbine control over the entire control range. The speed set point for the hydraulic controller is set to minimum for this. The set-point for the start-up and load limit device is then increased from 0%. This causes trip fluid pressure to build up and reset the protective devices of the turbine. Increasing the set point for the start-up and load limit device further in the open direction causes the turbine stop valves to open. After the turbine stop valves have opened, increasing the set point for the start-up and load limit device further results in gradual opening of the control valves, admitting steam to the turbine. This runs the turbine up to about 85 - 90 % rated speed. The hydraulic speed governor then takes over speed control of the turbine. Actual speed is derived from hydraulic speed transmitters. After this control takeover has taken place, the set point of the start-up load limit device has then to be set to the 100 % position.. For synchronization, turbine speed is run further by increasing the set point. After synchronization, the turbine is loaded by raising the set point further. As the hydraulic speed governor and the start-up and limit load device are linked via the downstream hydraulic Min gate, the output of the hydraulic controller and thereby turbine output can be limited by the start-up and limit load devices. If turbine start up is to be governed by the Electro-hydraulic controller, the set point for the start-up and limit load device has to be set to its max. value of 100% immediately after opening of the turbine stop valves. The set point for the hydraulic controller likewise has to be set to 100% to allow the Electro-hydraulic controller to take over speed control of the turbine above turning speed. The speed set point for the Electro-hydraulic controller must be set to 0% for this. 3.1 Hydraulic Amplifier and Electro hydraulic Converter

The hydraulic amplifier forms the interface between the hydraulic controller and the hydraulic valve actuation system. The output signal from the ---------------------------------------------------------------------------------------------- Sheet no. 5 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 hydraulic controller (secondary fluid pressure) acts on a piston via a sleeve, thereby acting on the follow-up piston block. This movements of the followup piston alters pressure of the secondary fluid. The secondary fluid pressure sets control valve lift. The Electro-hydraulic converters forms the interface between the Electrohydraulic controller and the hydraulic valve actuation system. Two analog electrical output signals are available from the Electro-hydraulic turbine controller. Each signal acts on a piston via a sleeve of the independent electro hydraulic converter(EHC). The position of the piston of each EHC is acquired by linear variable differential transmitters (LVDTs) and used as actual value for the valve lift controller. The piston acts on a followup piston block, the resulting movement of the follow-up pistons likewise altering secondary fluid pressure and thereby control valve lift. The output from the follow-up piston blocks of the hydraulic controller and Electro-hydraulic are linked via a MIN gate. This means that the system with the lower pressure output signal sets valve lift. In the event of failure of the output signal from the Electro-hydraulic controller to one of the two Electro-hydraulic converters, the other Electrohydraulic converter, sets the valve lift if selected though the MIN gate. 3.2 Load Rejection Relay

The load rejection relay (see Fig.2) assists the electro hydraulic controller to ensure that the speed of the turbine generator cannot reach the trip setting for the hydraulic overspeed trips under any circumstances. Sudden unloading of the turbine generator, that is , a negative step load change, are acquired promptly by electrical means via the load rejection relay and converted into an electrical pulse of adjustable duration. This pulse is used to actuate the solenoid valves in the control fluid circuit for the control valves, switching to drain and thereby causing a rapid drop in pressure. Response of the load rejection relay to the load rejection uses the change in electrical generator load before the subsequent increase in speed which results. This means that the load rejection relay acts on the turbine control system before the significant speed increase . After termination of the electrical pulse the solenoid valves which have switched to drain close again. At this stage , the electro hydraulic controller still holds the drain closed due to the speed increase which has occurred in the meantime. After this speed increase has stabilized , the electro hydraulic controller opens these valves again. Control fluid pressure then builds up again and the electro hydraulic controller opens the control valves to a position corresponding to the new generator load or to the speed set point. ---------------------------------------------------------------------------------------------- Sheet no. 6 of 37 STE, BHEL-HARDWAR

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The settings for the load rejection relay (load step magnitude, pulse duration) are made during initial commissioning and start-up of the turbine generator. To prevent response of the load rejection relay on under -frequency, a frequency monitoring circuit inhibits response of this relay if frequency drops to an adjustable under frequency limit. Without this feature , in the event of the load rejection on under frequency ,after termination of the CLOSE pulse the electro hydraulic controller would then open the turbine control valves very far due the large error caused by the frequency deviation. This in itself could lead to an overspeed trip. 4 4.1 Electro hydraulic Controller Control Requirements for Electro hydraulic Controller

The task of the electro hydraulic controller is to control steam flow by actuation of the control valves and thereby to control turbine speed as well as generator load under all operating conditions (start-up, loading, power operation, rundown, load rejection). The electro hydraulic controller meets the following requirements: High operational safety and reliability by utilizing modules with integrated circuits as well as multiple channels speed acquisition. Ability to ride through load rejections on disconnection from power system and the associated speed excursion due to rapid control action. Low stress operation of the turbine generator due to action of turbine stress evaluator (TSE) on set point controls, i.e., the rate at which speed and load changes are implemented is optimized on the basis of maximum permitted material stress criteria. Provision for automatic turbine generator start-up and shutdown by providing for signal input from an appropriate auto control. Structure of Electro hydraulic Controller(refer Fig. 3)

4.2

The electro hydraulic controller comprises the following control loops: Speed control loop Lift set point control loop Minimum pressure control loop

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 The separate loops are completely isolated from one another by means of a control selection circuit . The output signal of the control selection circuit sets the positions of the electro hydraulic converters pistons via the valve lift controllers, thereby setting turbine control valve lift. 5 5.1 Control Loops of Electro hydraulic Controller Speed Control Loop(refer Fig. 4)

The task of the speed loop is to meet closed-loop control requirements for the turbine generator during start-up and synchronization with the power system. During power operation the speed controller serves as an overspeed limit controller to ensure that speed increases caused by power system disturbances (such as load rejection) cannot result in speed reaching the trip setting for the mechanical overspeed trips (set to approx. 115% of rated speed) under any circumstances. The speed control loop consists of the set point adjuster, the set point control and the speed controller. 5.1.1 Speed Set point Adjuster The speed set point nr is governed by the position of the set point adjuster (refer Fig. 5). The set point can be adjusted over the range from 0 to 55 rps from the main control room panel 6610 PL - 10. To assist in fine adjustment of the speed set point for synchronization, the rate of change for the set point adjuster is decreased by a factor of 4 at set points above 47 rps. Further input are provided for adjustment of the speed set point by a synchronizing unit and an automatic start - up system. Manual set point change command take priority. The speed set point is displayed on two indicators on the turbine control panel , one for the overall speed range of 0 to 60 rps and the other for the narrow range from 45 to 55 rps. 5.1.2 Speed Setpoint Control The speed setpoint nr forms the input signal for the setpoint control which determiners the acceleration rate. For this, the setpoint control outputs a delayed setpoint nr del.

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 The maximum permissible speed acceleration rate is part of control software. This is set at 600 rpm/min. The turbine stress evaluators (TSE) acts via the setpoint control to limit the speed setpoint rate. Any limitation is based on acquisition and evaluation of thermal stresses measured at representative locations on the turbine .This prevents excessive thermal stressing of the turbine and at the same time allows turbine generators run-up at the maximum permitted acceleration rate. Depending on the thermal conditions in the turbine , the TSE can cause the acceleration rate to be reduced to zero or even to become negative (see Fig.5). In the event of a fault in the TSE, the momentary output signal of the speed setpoint control is "frozen" automatically until the fault has been cleared or the TSE control component has been deactivated using the ON/OFF switch in the electro hydraulic controller cabinet. The TSE is provided with a test program to allow checkout of the anolog calculation channel. To avoid any negative impact on turbine generator operations on testing , an interlock is provided which only permits testing when input and output of the speed setpoint control match. Due to the P- characteristic of the speed controller the setpoint must be corrected at no load operation. This can be done by an adjustable component added to the delayed speed setpoint .The value of this correction is optimized based on the operating pressure at the time of commissioning. 5.1.3 Actual Speed Derivation Actual speed is measured digitally .The end of the turbine shaft is fitted with a digital speed transmitter which consists of 3 Hall probes and a nonmagnetic disk with 120 permanent magnets positioned around its circumference (See Fig.6). During turbine operation , the poles of these magnets move past the Hall sensors separated by a slight air gap only (approx.0.8 mm). When the disk rotates , the probes output pulses which are converted into an AC voltage signal with a frequency proportional to rotational speed of the turbine. The output signal from each Hall probe is transmitted to a dedicated pulse converter in the vicinity of the turbine .Each of these pulse converters amplifies the Hall voltage and replicates this to give 3 floating- voltage, square -wave voltage signals of approx. 20 Vpp. Three (3) signals (one each from each pulse converter) of frequency which corresponds to the Hall voltage frequency (and thereby to turbine speed ) ---------------------------------------------------------------------------------------------- Sheet no. 9 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 are transmitted to pulse amplifiers mounted in the electrohydraulic converter cabinet. The 3 output signals from the pulse amplifiers are monitored continuously by the pulse monitor for failure. This is performed by cyclic scanning of the input signals, with the signal which is at any time the second in chronological order being selected as actual speed signal by the channel changeover circuitry and transmitted to the downstream frequency/ voltage converter. Within the frequency/ voltage converter the square-wave voltage is then converted into an analog signal appropriate for controller processing. Failure of a speed channel is detected by the pulse monitor. The actual valve signal is then selected from the two unaffected channels and this fault annunciated by an individual alarm in the cabinet as well as by a group alarm. As changeover of channel configuration is performed by solid-state switching devices, control system operation continues without interruption, even in the event of failure of a further channel. The remaining output signals from the three pulse converters is transmitted to other I&C system, e.g. to the speed measuring unit. 5.1.4 Speed Controller The speed controller features P+D (proportional + derivative) action to satisfy the dynamic requirements of the control system for start-up and shutdown, no-load operation and load rejection. The control deviation forms the input signal for the speed controller. The deviation is derived from the delayed speed setpoint nr delay (output of the speed setpoint control) and the actual speed signal nact (output by the frequency/ voltage converter). The output from the speed controller is applied to the control selection circuit and, when selected for output, forms the input signal for the valve lift controller ( see description of control selection circuit, Section 5.4).

5.2

Lift Setpoint control loop(refer Fig. 7)

The set point output of the lift set point control loop takes over control of the turbine immediately after synchronization of the turbine generator with the power system. This function allows valve lift and thereby turbine load to be ---------------------------------------------------------------------------------------------- Sheet no. 10 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 increased continuously up to the point at which the steam generator pressure controller deviation signal is zero. This function consists of the lift setpoint adjuster, the lift setpoint controller and an ON / OFF logic. 5.2.1 Lift Setpoint Adjuster The lift setpoint Lr is set by the output of the setpoint adjuster. The setpoint can be adjusted manually from the main control room panel 6610-PL-10. During auto mode of operation, the lift setpoint adjuster Lr follows the output of lift setpoint controller Lr del to enable bumpless transfer during

changeover back to manual. The lift setpoint is displayed on an indicator located on the turbine control panel in the control room. 5.2.2 Lift Setpoint Controller In manual mode, the output from the lift setpoint control Lr del follows the input signal Lr, with the preset rate and the rate of change governed by the lift setpoint rate adjuster. This set point rate can be adjusted from the main control room panel. The rate can be adjusted to anywhere between zero and maximum permitted lift rate (approx. 10% /min). During Auto mode of operation, the output of the lift setpoint controller is based on the adapted steam generator pressure controller output. Adapted steam generator pressure controller output is received in two channel . A minimum selection is formed of the two channel. The lift rate adjuster can be activated and deactivated from the main control room panel 6610 - PL -10. When the lift rate adjuster is deactivated, the maximum permitted lift rate becomes effective. The turbine stress evaluator (TSE) also acts on the lift set point controller. The TSE component acts on setpoint changes in both directions, with the upper margin acting on valve opening and the lower margin on valve closing. If the upper margin should become negative valve opening, the output valve of the setpoint controller is automatically reduced, thus leading to closure of valves instead of opening. This ensures loading and unloading at maximum possible rate, but without exceeding maximum permitted thermal stress limits. The effective rate of change for the lift setpoint is given by the MIN TSE component and the set lift setpoint rate.

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The output of the lift setpoint controller is inhibited on the following conditions: When the MIN-pressure controller takes over control of the turbine during loading of turbine When the TSE is faulty and the TSE component is activated.

The output from the lift setpoint controller is automatically set to zero under the following conditions: When the lift setpoint is deactivated for longer than 3 s ( see Section 5.2.6) After the speed controller has taken over control of the turbine during shutdown.

5.2.3 Actual Load Derivation Actual load is measured by three load transducers, with each system arranged as a two-wattmeter circuit. The three output signals are monitored for synchronism and the actual valve selected via a downstream mid valve selector. These load transducers are connected to a generator voltage and current transformers. The load transducers feature extremely short time constants (<10ms), as electronic multipliers are used to multiply currently and voltage. Load measurement is required to derive limit signals for automatic activation and deactivation. 5.2.4 Maximum Valve Lift Setpoint Adjuster The max. valve lift set point LMAX is set by the output of setpoint adjuster. The setpoint can be adjusted manually from the main control room panel 6610 PL -10 to limit the valve lift in case of necessity. 5.2.5 Further Processing of lift Setpoint Signal The output signal from the lift setpoint controller is passed on to a MIN gate and compared with the maximum valve lift set point LMAX . The output of this MIN gate is passed on to the control transfer circuit via a switch for " Lift setpoint controller ON / OFF".

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01

5.2.6

Activation and Deactivation of Lift Setpoint

Providing that the speed controller is in action, the lift setpoint can be activated or deactivated manually as required from the main control room panel 6610-PL-10. The lift setpoint should always be activated in normal operation, as selection of the controller to take control is implemented by the control selection circuit. The control selection circuit is described in Section 5.4. The output of the lift setpoint controller is automatically deactivated under the following operating conditions : When the generator breaker is open ( meaning that the generator is not synchronized with the power system) or When generator active power is below about 2 x station load and a sudden drop in generator active power is then registered ( meaning that load rejection has taken place)

Deactivation of this setpoint causes the speed controller to immediately take over control of the turbine generator and close the turbine control valves at maximum speed. This action ensures that the turbine generator speed will be held below trip speed under all conditions. If load on the power system picks up again within a short period(approx.3s), the lift setpoint is automatically reactivated. As the output signal prior to deactivation was stored this means that the status prior to load rejection is restored immediately. In the event that generator actual load becomes negative due to power system load swings ( generator synchronized to power system and supplying more than 2 % reverse power, i.e. generator is motoring ), the lift setpoint is then immediately reactivated. Such load swings in the power system can occur on reconnection of loads that were shed during a power system disturbance. 5.3 MIN Pressure Control Loop(refer Fig. 11)

The adapted pressure deviation signal from steam generator pressure control system is received in two channels. These two signals are compared in a MAX gate and fed to a pressure controller. The output of the pressure controller is fed to the control selection circuit and has got highest priority (see fig.12) The pressure controller tolerates small size deviations from the pressure setpoint. It does not take action until actual pressure drops more than a ---------------------------------------------------------------------------------------------- Sheet no. 13 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 certain limit value below the setpoint. The controller then throttles the turbine control valves. 5.4 Control Selection Circuit

The control selection circuit (see fig.12), a logic circuit comprising a MAX gate with downstream MIN gate, determines which of the three types of loop- speed control loop,lift set point control loop or minimum pressure control loop - takes over control of the turbine generator. This control selection circuit also ensures that only one of these 3 controllers will be active. The output signals from the speed controller and the lift setpoint controller are inputted to the MAX gate, i.e the higher signal value is always output by this gate, thereby setting turbine valve lift if this is also the lower signal valve present at the downstream MIN gate. During turbine generator startup, the output signal from lift setpoint formation is deactivated (as the generator breaker is not closed), so that the signal from the speed controller will be output by this logic and the speed controller will take control of the turbine generator. Minimum pressure controller output has got more priority and will takeover control to throttle valves if actual pressure drops more than a certain limit from set pressure valve. Once the generator is synchronized with the power system and the generator breaker is closed and lift setpoint control loop is activated, the lift setpoint control in line with the set lift set point. During this operation with the output signal from the speed controller set to a valve lift corresponding to about 10 % load by appropriate automatic adjustment of the speed setpoint. This setting for the speed controller output signal ensures that if the lift setpoint signal is deactivated in the event of power system disturbance, turbine generator speed is prevented from rising due to the setpoint set for the speed controller. In the event of a load rejection with a resulting increase in speed of the turbine generator, the output signal from the speed controller will become negative. This counteracts the perturbation by moving the turbine control valves in the closing direction, i.e. as soon as the output signal from the speed controller becomes negative, the sum signal then leads at the summing point ahead of the MIN gate where speed controller and lift setpoint controller outputs are compared. The minimum pressure controller takes over control via the MIN gate when this is lowest input signal to this gate.

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 The control loop that is in control of the turbine generator at any moment is signalled on main control room panel 6610-PL-10 by one of the following status indications: Speed controller in action Lift setpoint control in action Pressure controller in action

Fig. 13 serves to illustrate operation of the control selection circuit. The example given is for a load rejection down from 300% to 150% load. Here power input to the power system is from three generator so that this load swing amounts to a reduction in load from 100% to 50% for each turbine generator. With a droop setting for the speed controller of 5%, this results in a speed rise of nTurb= P = 50% = 2.5% =1.25 rps

K 20 Where Gain K= 1 = 1 =20 S 5% For a droop setting of 5%, the speed setpoint increase by 2.5 rps over the load range. As the speed setpoint is set to 10% lift, equivalent to 50.25 rps, this load rejection results in a speed rise to (50 + 1.25 + 0.25 ) rps =51.5 rps ( Point t2 on diagram n=f (P)). From this diagram it can be seen that lift setpoint controller is in control of the turbine up to time t1 . After this load is reduced to 50% of rated load by the negative speed controller output signal. The turbine then operates at an actual speed of 51.5 rps to match the new load demand of 50% only. Turbine speed can be returned to rated speed by lowering the lift setpoint to match the new power system load demand. 5.5 Valve position Control Loops

Two valve position control loops are provided for the turbine control valves. To improve the stability and dynamic response of the overall control system, the valve position controllers are implemented as slave control loops to the master controllers (speed controller, minimum pressure controller, lift setpoint controller). Both valve position control loops are operative normally but in case of fault in actual lift derivation of one loop, the valve position is decided by other loop which will now always remain operational . 5.5.1 Setpoint Derivation for Lift Control Loops ---------------------------------------------------------------------------------------------- Sheet no. 15 of 37 STE, BHEL-HARDWAR

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The signal by the control selection circuit is outputted in two sets of three channels. Middle of the three signals is selected by voting module. This acts as set point for both valve lift controllers. These two control loops do not differ so that the description which follows applies for both. 5.5.2 Actual Lift Derivation The lift of the servo piston in the electrophydraulic converter sets the lift of the turbine control valves. As a result, this can be used to derive control valve lift. Although this is an indirect measurement it is linear and accurate enough for this purpose. This is usually a more reliable method than direct measurement on the control valves. Even in the event of turbine trip with the resulting drop in trip fluid pressure, the servo piston moves in the "close valves" direction so that valve lift is correctly registered under these conditions. Each electrohydraulic convertor has got two LVDTs ( Linear variable differential transducers) , one as redundant to measure lift of the servo piston. The output signals from the LVDT of the electrohydraulic convertors are monitored for synchronism and given to valve lift controllers as actual lift signals hact1-1 and hact1-2 . In the event of a fault in the lift measurement

system an alarm for "fault in actual valve acquisition for lift is annunciated in cabinet thus issuing a group alarm ( Electro hydraulic controller fault"). 5.5.3 VALVE POSITION CONTROLLER

The valve position controllers feature PID characteristic. The control deviation derived by comparison of the position setpoint ( as described above) and actual lift ( lift signal as measured at servo piston of electrohydraulic convertor) forms the input signal to this controller. The output signals act on the plunger coil system of the electrohydraulic converters, thereby acting on control fluid pressure of the hydraulic valve actuation system. These converters thereby set the lift for the control valves. For further details see turbine manual. The characteristic of the electro hydraulic converter is shown in fig. 15. The position controller output signal can be deactivated electrohydraulic controller cabinet for maintenance purposes. in the

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 A monitoring functions within the valve position controller annunciates shortcircuits and ground faults for the plunger coil within the electrohydraulic controller. Faults are annunciated by means of the alarm "Plunger coil fault". In the event of an open circuit for the plunger coil of one electrohydraulic converter, the valve position is determined by other valve position controller which is always operative as back up. 6 Interaction of Electrohydraulic Controller and Hydraulic controller The electrohydraulic controller and hydraulic controller are redundant controllers. Either of the two controllers can take control of the turbine generator under the conditions described previously. Both controller use the same hydraulic actuation system to position the turbine control valves. The two controller are linked with this hydraulic system by the electrohydraulic converter in the case of the electrohydraulic controller and the hydraulic amplifier in the case of the hydraulic controller. As can be seen from fig. 1, the downstream MIN gate means that the controller with the lower output signal will take control under any condition. As a result, to make a controller take over control it is necessary to adjust the setpoint appropriatly for the two controllers. If the turbine is to be operated with the electrohydraulic controller, the setpoint for the hydraulic controller, has to be set to 100%. This allows the electrohydrualic controller to take over the control over entire control range. To transfer control to the hydraulic controller, the setpoint for this controller only needs to be set lower than that for the electrohydraulic controller. The lift setpoint for the electrohydraulic controller then has to be set to 100% to allow the hydraulic controller to exercise control over the entire control range. In normal operation the electrohydraulic controller controls the turbine, with the hydraulic controller on stand -by ready to assume control immediately in the event of failure of the electohydraulic controller. 7 Operator Control Devices

The operator control devices for operation of the turbine controller are intergrated into the main control room. The panel section for the electrohydraulic controller is shown in fig.17. This panel section comprises miniaturized control room equipment, consisting of pushbuttons indicators and indicator lamps on the appropriate tiles.

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8 8.1

Operating Concept, Operating Modes Start -up

It is a preconditions for turbine generator start-up that the electrohydraulic controller cabinet be ready for operation ( commissioned, cabinet power supply switched on). The turbine generator must be in turning operation, with the start-up and load limit device, hydraulic speed governor setpoint and electrical speed setpoint set to zero. After the turbine stop valves have been opened using the start-up and load limit device, hydraulic speed governor as well as the start-up and limit load device are then set to their upper limit positions ( 100% position). As the turbine has already been run up to a low speed (approx. 200 rpm ) by the hydraulic turning gear, the electrical speed measurement system supplies a voltage signal proportional to speed as actual speed. The speed setpoint nr is raised to make the speed controller take control, the turbine is then run up to rated speed by increasing the speed setpoint further and the generator synchronized with the power system. The TSE component ensures run-up of the turbine at an optimum rate and without exceeding permitted thermal stress limits. 8.2 Loading /Power Operation

The lift setpoint controls the turbine generator unit once the generator has been synchronized with the power system. After this, control valve lift is set by adjusting the lift setpoint manually to the appropriate level in manual mode. The output signal from the lift setpoint controller is increased and at the same time the speed setpoint is reduced to a value corresponding to approx. 10% unit load. In auto mode, the output of lift setpoint controller is determined by the adapted pressure deviation signal from steam generator pressure control system and lift setpoint Lr tracks the lift setpoint controller

output. The speed controller is inactive but is kept on stand-by to take over control of the turbine generator and maintain speed close to rated speed on full load rejection down to station load. The TSE ensures optimum power increase rates on turbine generator loading, but without exceeding permitted thermal stress limits.

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NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 The lift setpoint rate dL/dt is set on the main control room panel 6610-PL-10 to give the max. permitted rate of change for lift. After synchronizaiton in normal operation, the valve lift setpoint is determined by lift setpoint controller with the limitation set manually by the Maximum valve lift setpoint adjuster. Steam is admitted to the turbine by opening the turbine control valves. If the actual pressure drops below a certain preset limit from pressure setpoint, the minimum pressure controller then takes over control of the turbine and the lift setpoint controller is deactivated. If actual pressure increases again, the minimum pressure controller is deactivated and control of the turbine is transferred to the lift setpoint controller which then continues to open the control valves in line with the set rates. If valve opening is limited for any reason, the lift setpoint is lowered. This results in take-over of turbine generator control by the lift setpoint controller via the control selection circuit 8.3 Shutdown

The lift setpoint is set to zero on turbine generator shutdown. This causes unloading of the turbine generator in line with the set rates. The lift set point is lowered until all control valves are throttled such that the generator breaker opens via the anti-motoring protection ( this responding when the generator motors and takes up more than 2 or 3 % reverse power from the power system ) and the generator is de-excited. The turbine trip pushbutton is then pressed to initiate turbine trip, this resulting in closure of the turbine stop valves. The above operating procedure ensures that the turbine generator is not disconnected from the power system until the control valves have closed fully ( to avoid the risk of turbine overspeed). During rundown of the turbine generator after turbine trip push button is pressed, the speed setpoint nr is tracked to actual speed. This means that Load Rejection

the speed setpoint adjuster is already set to the correct value for restart. 8.4

On load rejection to station load or zero load (i.e., in the event of sudden disconnection of the loaded turbine generator from the power system), the lift setpoint signal is immediately deactivated. This results in a large magnitude deviation in the control valves in close direction for the lift ---------------------------------------------------------------------------------------------- Sheet no. 19 of 37 STE, BHEL-HARDWAR

NPC DOC. NO. TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ---REV. NO. 01 controller. The speed controller takes over control of the turbine generator unit. This results in closure of the turbine control valves at maximum speed, as the speed setpoint was set to a level equivalent to 10% load on turbine generator start-up and this signal now takes effect as input signal for the lift controller. Thanks to the above actions, controller action is taken immediately to counteract any speed rise on load rejection without the need to wait for a recognizable rise in speed to cause response of the speed controller. If load on the power system picks up again within a set period (approx. 3 seconds), the lift setpoint is reactivated and the turbine control valves are moved to the position they were at before the disturbance. The only difference between a load rejection to station load and a load rejection to zero load is in the magnitude of the resulting transient speed rise. The speed rise is less for load rejection to station load due to the load which remains. The electro hydraulic controller or hydraulic controller hold the speed of the turbine generator below the trip setting for the overspeed trips under all operating conditions. 9 Alarms

The group alarm "Electrohydraulic controller fault" is provided on window. The alarm " Electro hydraulic Controller Fault" is initiated in response to various alarms. Details of individual alarms are indicated in the COIS(Computerized Operator Information System).

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