FGMO CONTROL LOGIC

Write up on Free Governor Mode Operation (FGMO) Control logic modifications

As per the discussions held the FGMO implementation is first targeted on KWU design 200/210/250/500 MW turbines installed at various power plants in India. BHEL team of engineers have developed the control scheme. The scheme so developed was reviewed by members of Steering committee and was incorporated at Simhadri STPP Unit 2 for field trial. Fine-tuning of the control logic was done based on the performance at Simhadri STPP. The control logic finalized is shown in the block diagram in annexure 1. A brief description of the control scheme is given below. Modification in control logics of Electro Hydraulic Turbine Controller (EHTC) have been made to fulfill following requirements of FGMO 1. Reference frequency is floating depending upon the previous operating frequency between 49.0 Hz to 50.05Hz. 2. Load changes are made whenever the frequency changes from operating frequency. This change is limited to + 5% of machine rating. The load change so made is sustained for approximately 5 minutes (dynamic time delay). If the frequency varies during this period, dynamic time delay becomes zero and count starts again. However small changes up to +/- 0.03 Hz are ignored for load corrections. 3. After this period the load value comes back to the original value in a ramped fashion. 4. For frequencies more than 50.5 Hz and less than 49.0 Hz load change is as per droop characteristics and limited to +10 % of machine rating. 5. To take care of the load change, fuel firing is to be increased in the boiler system by giving a feed forward signal to combustion control system through Boiler Master control or Coordinated Master Control. In order to meet the above requirements the EHTC logic has been modified. The enclosed block diagram details the functional diagram of the frequency influence circuit to meet FGMO guidelines 1. Floating frequency set point: The speed actual signal is used to generate the floating signal. The time delayed set point generated by the actual value of speed. In the event of any change in frequency, the set point changes to a value equal to the new frequency (speed) value. This change happens in a slow ramp and the time taken is set to about 2 mins. 2. For frequency changes more than +/- 0.03 Hz, for a duration varying between minimum 3 minutes to a maximum of 6 mins (proportional to frequency change) a HOLD signal is generated. This signal forces the floating frequency set point to the last set value held. This is done to ensure a proportional correction for sufficient duration to effect changes in boiler parameters. 3. The proportional controller compares the set value and actual value and generates a frequency influence signal with a proportional gain corresponding Date 5 Sept 2004 Page 1 of 5

BHEL EDN

FGMO CONTROL LOGIC

4.

5.

6.

7. 8.

to droop setting. This proportional component is given in full magnitude at the beginning (limited to + 5%) and starts coming down as the deviation reduces on account of frequency set point slowly approaching the new actual value. The proportional values of frequency influence (limited to + 5%) is added to the load set point to form the final load set point (Sigma Pr) going to load controller. This will increase the load signal. This signal is in addition to the pressure dependent load correction (already available) After the frequency stabilizes to a value (fluctuating within +/- 0.03 Hz) then the hold signal is removed. After the removal of hold signal the set point will now settle to the new frequency value and proportional frequency influence starts coming down as the deviation reduces. With this the system is now available for the next frequency change. In the frequency range beyond FGMO limits i.e. blow 49.0 Hz & above 50.5 Hz the frequency influence as per droop characteristic will become effective and drives the frequency influence signal to + 10% (this limit can be decided as per site conditions). While the frequency influence acts on turbine load set point a signal is given to Boiler control to make changes in fuel firing with a feed forward action for a quick response. The pressure controller of EHTC in Limit Pressure mode ensures that the load is reduced to maintain the boiler header pressure, in the event of a sudden pressure drop more than set limit value (10Kg/cm2 for 500MW unit).

The performances of the boiler parameters are to be monitored and the controls have to be tuned for optimum performance to ensure that t5he load changes do not cause any disturbances in the boiler parameters. Depending on the other conditions of the plant the limitations of load change can be adopted keeping the regulatory requirements for FGMO. IMPLEMENTATION METHODOLOGY : As the Turbine controls systems supplied to various power plants over a period of 20 years in different hardware platforms, implementation of the control scheme has to be accordingly addressed. 1. In the sets supplied since 1995 the Turbine controller is based on the software based system of BHEL PROCONTROL. Implementation of the additional logics is possible by revising the software without the need of any hardware being added. Only additional signal exchange with Boiler control system is required to trigger the necessary change in fuel firing in the boiler to ensure the change in steam generation. 2. The first supplied sets were based on hardwired analog control schemes using Siemens design ISKAMATIC hardware. The control functions in this are fixed and the dedicated modules are used for special functions. So implementation of the FGMO logics is proposed to be done in an electronic interface rack taking the necessary signal outputs from EHTC system. The Date 5 Sept 2004 Page 2 of 5

BHEL EDN

FGMO CONTROL LOGIC

Correction signal is generated in this unit and wired back to EHTC. The speed signal (representing the grid frequency) is taken directly from the probe pulse output to ensure required accurate signal for frequency corrections. The Interconnection diagram shows the typical interconnection between EHTC system and Interface rack. 3. The interface rack is based on the maxDNA hardware and can be easily fitted in the existing Turbine control cabinets using the available 24V DC power supply. The signal exchange between the EHTC system and interface rack is using current signals. Necessary modifications in the EHTC cabinet will have to be done. Additional signals required to trigger the necessary change in fuel firing in the boiler to ensure the change in steam generation are also originated from the interface rack.

Date 5 Sept 2004

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BHEL EDN

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HOLD TIME DELAYED ACT.FREQ (SPEED) FREQ.SET POINT ABS LIMIT VALUE

TIME LIMITER - 4% + 4% + 0.03 - Hz Kp

PULSE WIDTH EXTENSION MIN 3mins

+
TIME

Kp

< >
SIGNALS TO BOILER CONTROL

* see note

5% DROOP CIRCUIT FOR <49.01Hz >50.5Hz

LIMITER - 4%

FREQ.INFLUENCE SIGNAL B

10% + 4% 10% * see note

FEED FORWARD SIGNAL

< >

SELECTION CIRCUIT

FEED FORWARD SIGNAL TO COMBUSTION CONTROL (BOILER MASTER)

FREQ. INFLUENCE PRESSURE DEP. LOAD CORRECTION LOAD SETPOINT LOAD ACTUAL

+ + +

LOAD SETPOINT FOR LOAD CONTROL ( PR) PrMAX

M I N

LOAD CONTROLLER

SPEED ACTUAL

36560002227-02

+ +

SPEED REF

SPEED CONTROLLER

M A X M I

PRES.REF(FROM BC) PRES. ACT

PRESSURE CONTROLLER

+ POSITION - CONTROL
POS.ACT

EHC

GOV VALVE

*NOTE: LIMITS REFER TO % OF RANGE VALUE (4% OF RANGE = 5% OF RATED VALUE)

01 16.08.04 DRG.REVISED & REDRAWN. AS IMPLEMENTED IN SIMHADRI-U2

PD SKR BSV -sd-

02
-sd-

02
-sd-

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EHTC CABINET (ISKAMATIC HARDWARE)

FREQ.INFLUENCE SIGNAL FOR LOAD SET POINT CORRECTION

INTERFACE RACK FEED FORWARD SIGNAL-1 TO BOILER CONTROL

LOAD ACTUAL BOILER MASTER ON AUTO

FEED FORWARD SIGNAL- 2 TO BOILER CONTROL

CMC ON

FREQ.INF.DISABLE SPEED SIGNAL INPUT

FAULT SIGNAL

SPEED SIGNAL

+
24 V DC

SPEED PULSE SIGNAL

SPEED MEASURANT UNIT (2700-3300RPM)

PD SKR BSV

INTER CONNECTION DETAILS BETWEEN ISKAMATIC BASED EHTC & INTERFACE RACK FOR FGMO
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