A

Presentation
on
“TG Speed and Load Controls”
INSTRUMENTATION DEPARTMENT
NATIONAL FERTIIZERS LIMITED,
PANIPAT

PREPARED BY :

NIKHIL KUMAR
 INTRODUCTION

• The 15 MW turbine-generator sets are to generate power at

11 KV and feed power into the 132 KV bus for further
distribution to the various area sub-stations through existing
11 KV distribution network.

• The plant is capable of operating either in isolation or in

parallel with the grid supply. Further it is possible to operate
either one or both the turbine generator sets running in
parallel with the grid.
 DESCRIPTION OF TURBINE

• The Turbine is fed with steam from the main steam header.
The main steam flows through the start up valve (main
steam emergency stop valve), the main steam control valves,
the nozzle groups and parallel to the turbine rotor through
the main steam casing.

• For economical use of its power potential, it passes through

several subsequent stages. In this way the enthalpy
difference of the steam is worked off.

Continued...
 DESCRIPTION OF TURBINE

• Then the exhaust steam is condensed in a condenser by

means of cooling water. When doing so, the heat differential
of the steam is utilised not only up to atmospheric pressure
but, due to high vacuum prevailing the condenser, up to that
vacuum. The resulting condensate is fed back in to the LP
heater or into the polishing water plant.

Continued...
FLOW DIAGRAM
FEED WATER TANK
BOILER FEED PUMP
LP HEATER
HP-1 Heater
HP-2 Heater
 DESCRIPTION OF TURBINE

• In accordance with the heaters in operation, steam is

extracted from the extraction points of the turbine at 18.1,
10.4, 4.3, 0.96 kg/cm2. This steam is used for stepwise
heating up of the condensate to the boiler by 2 HP heaters, 1
LP heater and feed water tank.
• Basically turbine output depends on steam flow and the
available heat differential.

Continued...
TURBINE BLEEDS
 Steam turbine governing is the procedure of controlling the flow rate
of steam into a steam turbine so as to maintain its speed of rotation as
constant. The primary objective in the steam turbine operation is to
maintain a constant speed of rotation irrespective of the varying load. This
can be achieved by means of governing in a steam turbine.

The steam flow through the control valve is proportional to the valve
opening in the operating range. So when valve position changes, turbine
steam flow changes and turbine power output also changes proportionally.
Thus governing system changes the turbine mechanical power output. In
no load unsynchronized condition, all the power is used to accelerate the
rotor only (after meeting rotational losses) and hence the speed changes.
 Nozzle Governing
In nozzle governing the flow rate of steam is regulated by opening and
shutting of sets of nozzles rather than regulating its pressure. In this method
groups of four nozzle set is controlled by a separate valve. The actuation of
individual valve closes the corresponding set of nozzle thereby controlling the
flow rate.

2nd Nozzle
1ST Nozzle

V1 V2 V3 V4

SIC

4th Nozzle
3rd Nozzle STEAM IN
 OIL SYSTEM of TG set
The oil system of TG is designed as combined
lubricating control and governing oil system with
pressure circulating lubrication.
Main oil pump, Auxiliary oil pump and emergency oil
pump discharge the lube oil flow to a common
piping(0.3 MPa). This supplies the bearings of the
whole Turbo-generator.
 OIL SYSTEM of TG set Contd.

The power oil piping is supplied with oil via its own
suction connection from the lube oil pipe. The oil
transported by the power oil pumps (2X100%) is
governed to 1.8 MPa and transported on to the controller
unit.
Pressure actuators (current/pressure convertor) are fitted
to the controller which convert power oil to control oil
pressure proportional to the electrical control parameter.
 TG TRIP RELAY LOGIC

Dcs +24v

R1 R2 R3

R2 R3 R1

TRIP TTL1

TRIP TTL2

R4(DCS TRIP RELAY)

SSC I/H SIC I/H

POWER R5 R5 R6 R6 POWER
SUPPLY SUPPLY

Dcs I/O com

 ELECTRO HYDRAULIC GOVERNING SYSTEM
Basically the controls can be described as i) speed control when
the machine is not connected to the grid or in isolation and ii) load
control when the machine is connected to the grid.

When the turbine generator unit is being started, governing

system controls the speed precisely by regulating the steam flow. Once
the unit is synchronized to the power system grid, same control system
is used to load the machine. As the connected system has very large
inertia (‘infinite bus’), one machine cannot change the frequency of the
grid.
 Speed Control
Speed control is the primary control loop for turbogenerator. Without speed
control the turbine cannot be started or operated safely.
Since the steam turbine has a steam flow metering device and the inlet
steam is being controlled by actuator i.e. governing valve, so a fundamental rule for
governing applies:
One steam control device can only control one parameter.
Functions of the speed control:
• Safe start up of turbine according to manufacturer’s speed gradient curve.
• Speed Controller will be switched on automatically in case grid breaker opens.
• After Synchronization, with load controller in service, the speed controller tracks
the actual speed.
• ISLANDING
During island operation, machine will be transferred to Speed
Control and load will be changed by changing speed set point. During
island operation, speed target will be set automatically to actual turbine
speed + speed set corresponding to droop rate and actual load on the
unit. This speed set keeps on varying while grid in line and gets hold for
1.25 sec on isolation. After 1.25 sec, new speed set is derived from
new load and acquired speed and speed is maintained thereafter for
10 sec by logic itself. After 10 sec., speed control is entirely left upon
operator.
 SPEED MEASURMENT
• Turbine speed measurement is be done by using 3 sensors.
• The mean of the three sensors is taken as actual speed.
CH A
<
CH B

<
<
CH C

< T
SELECTED SPEED

0 T ANY CH bad

CH A bad
<
T
CH B bad

T
CH C bad
 HOT, WARM & COLD
Hot Condition is achieved when-
TR-108 > 300 DegC
TR-111 > 135 DegC
TR-112 > 135 DegC
TR-100 > 450 DegC
ES-111 = 1 (i.e. TG is synchronized)
This Hot condition is changed to Warm Condition after 1.5
hours of TG comes on turning after trip.
And Warm condition changes to Cold Condition after 12.5
hours of TG comes on turning after trip.
 Rolling Speed Gradient chart
Speed targets, Ramp rate and Soaking time during rolling.
Rolling HOT Warm Cold
Conditions
Target Soaking Ramp Rate Soaking Ramp Rate Soaking Ramp Rate
Speed Time(Sec) Time(Sec) Time(Sec)
(RPM)
680 210 600 600 380 1050 265

1700 120 600 180 380 360 265

2500 120 1200 180 1200 360 1200

4400 120 600 240 380 300 265

5800 180 600 300 380 300 265

Rolling Trend
SPEED Control
 Load Control
Load Control On: Load Controller will be switched on automatically
if Turbine controller is kept on auto and connected to the grid under
“Turbine Latched” condition.

Load Control Off: Load controller will be switched off under

following conditions:
1. Manual control mode is switched on
2. The Generator has disconnected from the grid
3. The grid frequency has gone beyond allowable limits
4. Load Measurement faulty (2/3 sensors faulty)
5. M.S. Pres. measurement faulty (2V3 sensors faulty)
How Forward Load is generated?
As synchro control is put ON and generator breaker is
engaged, an integral control gets active with error
signal 4 and integral constant 15 to open governor
valves. This integral control becomes inactive after 15
sec or as soon as 2.5 MW forward load is achieved.
During this period, ‘LOAD CONTROL’ will remain ‘OFF’
and governor control will be in ‘VALVE MODE’.
 How Forward Load is generated?
Contd.

Operator has the flexibility to select either of the following

two operating modes:
- Valve Control Mode : Valve is opened by operator to
any position irrespective of any load. This mode appears
when generator is with grid and ‘Load Controller’ is off.
- Load Control Mode : Valve is positioned automatically to
achieve the desired load set by the operator.
Transfer between Valve Control and Load Control is bump-
less at any load after initial loading.
 How Forward Load is generated?
Contd.

But governor control will not come in operator’s hand

even in ‘VALVE Mode’ after synchronization till LOAD
Set-Point update control is released by logic (after 1
min of forward load/15 sec in hot condition, 5 min in
warm and cold condition).
This VALVE Mode will be shifted to LOAD Mode after
load controller is put on by operator.
LOAD Control