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RTS1
RTS2
EMERGENCY
TRIP DEVICE
Trip oil
Soaking
Once this condition is achieved soaking of turbine is done by selecting HEAT SOAK from the
desk. In ATS mode Heat soak is automatically selected. This raises the set point to 1080 rpm at a rate
depending on the mode of operation. If under certain conditions metal matching conditions are not satisfied
a hold signal will be generated which will not allow the turbine to increase the speed. There is another
feature called the Run Down Operation .It takes care of the fact that turbine speed increases above a
certain rate to avoid unnecessary vibrations during critical speeds. If the rate of actual increase of speed
falls below 100 rpm/min during rolling from 400 rpm to 1080 rpm this action will be triggered and the
turbine will be brought down to turning speed.
The turbine is kept at soaking speed depending on the mode of rolling.
Rated
After necessary soaking RATED is selected from the desk, which brings the turbine at rated
speed i.e. 3000 rpm. There are three critical speed zones
1) Range-1:
1260-1610 rpm
2) Range-2:
1710-2185 rpm
3) Range-3:
2295-2800 rpm
If rate of increase falls below 100rpm/min during these speeds Run down becomes active and turbine is
brought down to soaking speed.
Hardware
Three hall probes mounted on bearing 1 of the turbine sense the speed. They generate pulse
signals, which are fed to Pulse Input Cards in the PLC.They are converted into corresponding digits by
these cards, which are used by the processor for processing. The mean value of the three signals are taken
and the deviation from the set point generated from the speed secondary setter is processed by a PI Control
loop to give appropriate signal to the E/H converter.
Target
Speed
Speed
2ndary
Setter
Speed
Setter
PI
CONTROL
Output
To valve controller
Speed Sensors
Pulse
Input
Card
Mean
Value
Speed setter generates required set points, which are fed to speed 2ndry setter, which determines
the rate of change of the speed set points according to the selected rate of change of speed.
POWER CONTROL
The Power controller ensures smooth loading of the turbine. It is active when the Generator circuit
breaker (GCB) closes. Various features are incorporated in this controller, which includes
1) Initial Load Concept
2) Governor free operation
3) Limiting Pressure Operation
4) Frequency Influence
5) Interfacing with Coordinated Master control (CMC)
Initial Load
When Generator is synchronized the power set point automatically becomes 5% of rated load i.e.
10.5 MW. Since the turbine goes on power control with an initial load of 10.5 MW, this ensures that
generator never goes on motoring which was one of the synchronization problems. It should be noted that
this set point goes directly to secondary setter; hence no influence of rate is present.
Governor Free Operation
In the Governor Free Operation, turbine responds directly with speed even though the turbine is on
power controller. In Bakreswar, the Governor Free Operation has a droop of 4.5% .The present dead band
of this circuit is 0%, i.e. loading and unloading of machine starts just as it crosses 50 Hz.However this is a
variable quantity and can be changed as desired. The droop and the maximum load change can also be
changed as desired.
Presently the maximum load change from Governor free operation is 50% i.e. 105 MW. The
response of the load change can be controlled by proper setting of time constant for an integrator circuit.
+105 MW
Frequency (Hz)
51.125
50
48.875
-105MW
Presently it is very difficult to have governor free operation owing to the large variation of
frequency in the grid, which leads to large load changes.
Load
Limit Press Setting
__
A
Actual Pressure
B
Press.
Dev
Continuous: -Present
Dashed: Designed
As discussed above the final set point for the power controller is influenced by Governor Free
Control, Limiting Pressure Control and Droop Control (Frequency Influence).
+
LPC output
+
Governor Free Control Output
PI
Controller
Actual Load
Final
Output
to valve
Control
Actual Speed
PI
Controller
3000 rpm
PRESSURE CONTROL
There is a pressure controller within the EHG system, which maintains constant pressure at HP
turbine inlet. The pressure setting value is given from the CMC desk. This controller becomes active only
in the turbine follow mode (TFM). In this mode, the EHG is in AUTO and no set point for load can be
given. The power controller tracks at 5% higher value i.e. 10.5 MW higher than the original load. If due to
certain reason the pressure controller output reaches a value below 50% then the output is limited to 50%
.In this condition the pressure controller will not work properly. This is done to ensure that boiler has
sufficient energy to give desired load.
PI
Controller
Load
Limit
Setter
Load Limit
2ndry
Setter
Controller output
+
10%
ALFC ON
Minimum
Value
Selector
Minimum
Value
Selector
Power
Control Output
100%
Pressure
Control Output
Pressure Control ON
S
E
L
1
E/H
Converter
HARDWARE: The valve position controller gives command to the E/H convertor in voltage. The output card
generates a voltage of 0- -10V which is used for lifting the pistons within the E/H convertor. If 0V is
applied to the E/H convertor the piston is lifted and the auxiliary secondary oil pressure is maximum
leading to opening of control valves. At a voltage of around 5.5V the lift is 0% and the auxiliary
secondary oil pressure is negligible leading to closing of control valves. A graph showing the piston lift and
oil pressures in relation to voltage output from E/H converter is given below:
LIFT/VOLTAGE
50
40
LIFT
30
Series1
20
10
0
-6
-4
-2
VOLTAGE
PRESSURE
LIFT/OIL PRESSURE
8
7
6
5
4
3
2
1
0
-1 0
Series1
Series2
Series3
Series4
Series5
10
20
30
40
LIFT
50
Valve Pos
Command
+
5%
65M position
__
Auto
Follow Up
Controller
Command
to 65M
F1
(x)
valve Position
65M Position
50%
Due to large variations of frequency the autofollow up circuit is not functioning properly at
BkTPP and hence the normal practise here is to keep 65M at 100%. MHG droop curve changes as 65M is
lowered and if there is a fluctuation in frequency it may so happen that MHG sometimes come into action
which is undesirable.The disadvantage of this is that if due to certain reason the EHG fails the control
valves will suddenly go to 100% causing accidents and damage in certain conditions.
Starting device (77M) and Speeder Gear (65M) for Electrohydraulic Governing
The starting device or 77M is used as a mechanical load limiter and also to generate start up oil for
resetting the stop valves and auxillary start up oil for resetting all trip devices.Control oil is the main source
of start up oil and auxillary start up oil .This oil is generated when the starting device is brought to 0%.
If all trip conditions are removed, the turbine resets when starting device goes to 0% as trip oil pressure
becomes available once emergency trip device is reset.Under normal operation the starting device is kept at
100%.However these can be used to decrease load as this also acts as the mechanical load limiter.
Start Up Oil for restting stop valves
Control Oil
Starting
Device
0%
Thus during Electro hydraulic governing, the starting device is used as the resetting device.
Speeder gear or 65M is the mechanical governor and we can control the load when MHG is
selected. If Auto follow up feature is selected then this follows the E/H valve position with a 5% higher
value. Otherwise the normal practice is to keep it at 100% so that mechanical governor does not influence
the EHG system. One thing must be mentioned here that 65M have certain droop characteristics and this
droop depends on frequency.
210 MW
65M position
100%
75%
50%
0MW
51.75
53.75
Above figure shows the droop characteristics of 65M. Presently the mechanical droop is set at
7.5% and turbine can generate 210 MW without the influence of 65M droop up to a frequency of 51.75 Hz.
This should be noted that this is the case when 65M is 100%. If 65M position is decreased the droop
characteristics will also fall parallely i.e. at 75% 65M position we can supply 210 MW at relatively lower
frequency. If there is a frequency fluctuation and auto follow up of 65M is made on then there may be a
position where 65M falls below EHG command and comes into action which may be undesirable. So for
smooth running of 65M we should maintain a constant frequency.
Series1
Series2
10
11
Series1
Series2
10
11
Series1: - EHG
Series2: - MHG
During House Load Operation the GCB is opened and in this case the turbine goes on speed
control. That means auxiliary power for the plant is supplied by the turbine at a constant frequency of 50
Hz. Load can be increased or decreased by the speed set point.
There are two Load Shedding Relays, which are activated if load rejection rate goes above a
certain limit. This type of situation takes place when GCB is opened and protects the turbine from over
speeding at that instant. Load shedding relays activate two solenoid valves. One of them present in the
auxiliary secondary oil line and the other present in the secondary oil line of the ICVs.If load shedding
relays operate they drain the auxiliary secondary oil and secondary oil for ICVs so that all control valves
closes. After two seconds they again open and maintain load according to the given command. This activity
mainly takes place in house load operations. When GCB opens, sudden load throw off take place, which
initiates the load shedding relay without tripping the turbine. The turbine goes on speed control while the
control valves closes for 2 seconds due to the draining of auxiliary secondary oil at that instant and then
again opens to maintain the load at that condition (House Load).
50%
MCV Position
10%
House Load
0%
Load Shedding
ON
2 Seconds
In the Governor Free operation Turbine responds directly with speed even though the turbine is on power
controller.In Bakreswar the Governor Free has a droop of 4.5% .The present deadband of this circuit is
0%,i.e. loading and unloading of machine starts just as it crosses 50Hz.However this is a variable quantity
and can be changed as desired.The droop and the maximum load change can also be changed as desired.
Presently the maximum load change from Governor free operation is 50% i.e. 105MW.
+105 MW
Frequency(Hz)
51.125
50
48.875
-105MW
Circuit Details:The Governor free circuit uses the speed detection circuit(midvalue of the three sensors) of the range 018,000 digits corresponding to 0-3000rpm.This value is subtracted from 18000 digits to get the speed
deviation in the range 0-18000 digits.A dead band circuit is present which presently has 0 dead band.
18000
DB
__
ACTUAL
SPEED
0%
INT
POWER
SET
+
LPC
OUTPUT
10
4.5
LIMIT