1 - Steam Turbine Control Basics

1
Turbine Control Basics
December 2018
Industrial Turbomachinery Systems

2
Steam Turbine Applications and

Turbine Components

3
High Pressure Boiler Supply (1500psi/103bar)
Main Supply (600psi/41bar)
(350psi/24bar)
HP Process (165psi/12bar)
IP Process (35psi/2.5bar)
LP Process
Condenser Header

4
Typical Single Stage Steam Turbine
ACTUATOR
PLANT BOILER

5
Single Valve Application

TURBINE CONTROL
ACTUATOR
T&T PT
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
LET DOWN
STATION
PLANT BOILER PT
TO PLANT
STEAM LOADS

6
Split Range Valve Application

TURBINE CONTROL
ACTUATOR
T&T PT
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
T&T
PLANT BOILER
ACTUATOR PT
LET DOWN
STATION
TO PLANT
STEAM LOADS

7
Single Extraction Application

TURBINE CONTROL
ACTUATOR
ACTUATOR
T&T PT
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
LET DOWN
STATION
PT
PLANT BOILER
TO PLANT
STEAM LOADS
LET DOWN PT
STATION
TO PLANT
STEAM LOADS

8
Single Extraction Turbine Performance Map
Performance Map Uses

• Parameter Relationships
• Turbine Load
• Inlet Flows
• Extraction Flows
• Turbine Limits
• Unit Protection

9
Double Extraction Application

TURBINE CONTROL
ACTUATOR
ACTUATOR
ACTUATOR
PT
T&T
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
LET DOWN
STATION
PT
PT
PLANT BOILER
PT
TO PLANT
STEAM LOADS
TO PLANT
STEAM LOADS
TO Condenser

10
Double Extraction Turbine Performance Map
Performance Map Use

• Parameter Relationships
• Turbine Load
• Inlet Flows
• Extraction Flows
• Turbine Limits
• Unit Protection
11
Power Plant Generator Application
ACTUATOR
ACTUATOR
T&T
PT
LET DOWN
STATION
PT
PLANT BOILER
TO PLANT
STEAM LOADS

12
Turbine Load and Flow Sharing Application

13
Steam Turbine Control Basics

14
Typical Steam Turbine System
• High pressure steam flows from the boiler at

approximately 600 psi and 850 degrees Fahrenheit to the
steam chest and onto the “Nozzles” or “First Stage”.
The control system governs the amount of this steam
flow.
• Nozzles then direct the steam flow to the rotating blades
or “Buckets”. Between each rotating “Stage” is a fixed
nozzle which directs the expanding steam to the next
row of blades.
• Exhaust steam, reduced in pressure and temperature to
about 35 psi and 340 degrees Fahrenheit is condensed
back to water and returned to the boiler.
• There are many other types of steam turbines; Single
Valve, Split Range, Extraction, Double Extraction,
Backpressure...

15
Single Stage Steam Flow
Nozzle
Blade
Single-Stage
Multi-Stage

16
Multiple Stage Steam Flow

17
Double Auto-Extraction Steam Turbine

18
Single Admission Steam Valve
Single admission Governor Valve

with trip valve
Trip valve to allow for positive shut off

on trip conditions

19
Single Admission Steam Valve
w/Governor
Single admission valve

with TG Governor
Back standard
Over speed Trip Valve
Governor linkage
Throttling Valve
Steam Chest inlet

20
Steam Rack Poppet Valves – Flow
Considerations
Internal Steam Turbine Admission Valves
8
6 4 2 1 3 5
7 Staggered lift
Lifting Bar
Poppet Valve

21
What is a Governor and Control
System???
• Governor Definition: An attachment to a machine for

automatic control or limitation of speed. b: A device
giving automatic control (as of pressure or
temperature).
• A Governor is a device which controls the energy
source to a prime mover to control its power for a
specific purpose.
• Basic governors sense speed and sometimes load of
a prime mover and adjust the energy source to
maintain the desired level.
• Governors are often referred to as Control Systems
and consist of an electronic control and an actuator.

22
Constant Load
DESIRED SPEED
ACTUAL SPEED

23
Increased Load

24
Decreased Load

25
Turbine Shaft Torque Balancing

TURBINE CONTROL
Apposing
ACTUATOR
Torques on Shaft
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
Shaft Speed Notes:

• Turbine Torque > Load Torque = Increase in Shaft Speed
• Load Torque > Turbine Torque = Decrease in Shaft Speed
• Turbine Torque = Load Torque = Constant Shaft Speed

26
Factors Affecting Turbine Speed
• Shaft Load
 As the load increases, the speed will be reduced
• Inlet steam Conditions
 Changes in the inlet pressure or temperature will change the
available energy in the steam
• Exhaust steam conditions
 Changes in the backpressure or condenser vacuum will change
the available energy in the steam
• Extraction flow
 Changes in the extraction flow and pressure will cause changes in
the speed

27
Closing the Loop
Control
Of The
Actual Speed Energy
or Load
Desired Speed or
Load Reference

28
Closing the Loop
• The governor functions the same as the car driver.

• It automatically changes the Fuel Flow to maintain
the desired speed or load.
• Closed Loop Definition: When used as an automatic
control system for operation or process in which
feedback in a closed path or group of paths to
maintain output at a desired level.
• If parameter(s) of the loop change, it will effect the
entire loop and fuel will automatically be corrected to
maintain the desired set point.

29
Example of a Steam Turbine

30
Force Balance
F(a) = F(d)
Actual Desired
Speed Speed
Force Force
F(a) F(d)
1000 lb 1000 lb
Decrease Increase
Fuel Fuel

31
Closed Loop Speed Control – Mechanical
Governor
Mechanical
Speeder Control
Adj
Spring
PI Actuator
Buffer Springs
& Needle Valves
Gen
Turbine
Turbine
Speed

32
Closed Loop Speed Control

• PID stands for Proportional, Integral, and Derivative
R Digital • A PID amplifier is used to calculate an appropriate
Speed
Turbine Control response to the output based on changes to the input
L Setpoint
PID Actuator
Steam
Turbine Gen
Speed
Frequency
to
Speed Converter Magnetic
Pickup
AC Sine Wave

33
Closed Loop Speed Control
R Digital
Speed Turbine Control
L Setpoint
3000 rpm
0 40% 40%
PID Actuator
3000 rpm
Steam
Turbine Gen
Speed
Frequency
to
Pickup
AC Sine Wave

34
PID Tutorial
• Proportional Gain is used to set the PID’s proportional

response to a summing junction error. This is a multiplier
typically used to match the control’s response to a transient
load change.
• Integral Gain is used to set the the PID’s integrator’s
response to a summing junction error. The PID’s integrator
integrates up or down at a the set rate until the summing
junction’s error is zero. Typically the integral gain term is
measured in repeats/second. This term is used to prevent
slow hunting at steady state and controls the time rate at
which the speed error returns to zero after a speed or load
disturbance.
• Derivative Gain is used to quicken/improve the PID’s
response by giving a boost to the PID’s output depending
on derivative or rate of change of the summing junction
error signal.

35
PID Basics
• PID stands for Proportional, Integral, and Derivative
R Speed • A PID amplifier is used to calculate an appropriate
L Setpoint response to the output based on changes to the input
Error Signal
X
P Gain
Actual Turbine Actuator

Speed I Gain
(Repeat / second)
D Gain
(Rate of Change)

36
PID Tutorial

37
PID Tutorial
Integral Gain
Adjustment
Proportional Gain
Adjustment
Derivative Gain
Adjustment
TIME
38
“Text Book” Dynamic Response

39
Actuator, Linkage, & Steam Chest

Considerations

40
Effects on unit Gain (Dynamics)

Actuators & Linkages affect:
• Loop Gain
• Loop Delay (Lag)
R Speed • Loop Stability
L Setpoint Effects Loop
Gain
Effects Loop
Gain
Effects Loop
Gain
PID Actuator
Effects Loop Effects Loop
Gain Gain
Steam
Turbine Gen
Speed Effects Loop
Gain
Frequency
to
Digital Converter Magnetic
Pickup
AC Sine Wave
41
Linkage Gain
Steam Valve
Steam
Valve
Steam Valve
Actuator
Demand
Steam Valve

42
Linkage Travel
Allow some over-travel to ensure steam valve
mechanical stops are reached.
0 – 100% Valve Demand must equal 0 – 100% Valve Flow

43
Common Linkage Problems
• Linkage connected improperly:

 Uses less than maximum range
(0-100% Demand = 0-75% flow)
• Binding or seizing Linkage (painted, worn, etc.)
• Loose Linkage
 Worn bearings, rod ends, etc.
• No over travel
 No positive shutoff
 Limited valve flow

44
Steam Rack Poppet Valves – Flow
Considerations
Internal Steam Turbine Admission Valves
8
7 Staggered lift
6 4 2 1 3 5
Lifting Bar
Poppet Valve

45
Steam Rack Flow Chart
Willans Line Controllers

Compensation
100%
Flow Curves
Valve Rack
Poppet Valve
Steam Chest
Flow Curves
Flow
0% Control Valve Demand 100%

(Horse Power)

46
Recommend Variable Gains in Control
Only
Actuators & Linkages affect:
• Loop Gain
• Loop Delay (Lag)
R Speed • Loop Stability
L Setpoint Effects Loop
Gain
Effects Loop
Gain
Effects Loop
Gain
PID Actuator
Effects Loop Effects Loop
Gain Gain
Steam
Turbine Gen
Speed Effects Loop
Gain
Frequency
to
Pickup
AC Sine Wave
47
Header Pressure Control Basics

TURBINE CONTROL
ACTUATOR
ACTUATOR
T&T PT
PT
LOAD:
PUMP
COMPRESSOR
GENERATOR
ETC.
LET DOWN
STATION
PT
PLANT BOILER
TO PLANT
STEAM LOADS
LET DOWN PT
STATION
TO PLANT
STEAM LOADS

48
Extraction Steam Turbine Basics

49
Extraction Turbine Horsepower and Flow
Relationships
Total Horsepower = HP Horsepower + LP Horsepower
Inlet Steam Flow - Extraction Flow = Exhaust Flow

50
Extraction Turbine Valve Interaction

Horsepower Increases
 Inlet Valve Opens
 Extraction Valve Opens
Extraction Increases
 Inlet Valve Opens
 Extraction Valve Closes

51
Typical Extraction Map

52
Extraction Turbine Control Equations
V1 = K1 * SPout + K2 * EXTout + K3
V2 = K4 * SPout + K5 * EXTout + K6
DV1
K1 =
D HP EXT CONSTANT
D V1
K2 =
D EXT HP CONSTANT
D V2
K4 =
D HP V1 CONSTANT
D V2
K5 =
D EXT HP CONSTANT
53
Extraction Control Three Arm Linkage

54
Single Extraction Steam Turbine Controller
HSS
N
Speed N 505E
Signals
N LSS Functional
Input AI
Raise Diagram
Lower -
Setpoint +
- PID
Remote AI Remote AI
-
Raise Setpoint +
- PID Speed
Lower E/D
Cascade
Load
AI LSS
Signal
Input AI
AO V1
Raise Limiter
Lower -
Setpoint +
- PID
Remote AI
Auxiliary E/D
Ratio/
Limiter
Input AI HSS
Ext/Adm
Raise
Lower Setpoint +
-
PID
AO V2
-
Limiter
Remote AI
E/D
Raise
Lower Manual
Setpoint
Remote AI

55
Single Extraction Turbine - Performance Map

Ratio/Limiter Algorithm’s Purpose
• Ensure decoupling of
parameters
 Speed/Load & Extraction
 Inlet & Extraction
 Exhaust & Extraction
 Speed & Inlet
• Protect turbine from operating
outside of its limits
• Ensure safe starting and
stopping
• Allows turbine operation to be
matched to the plant control
scheme
 Decoupled modes
 Plant priorities when in a limited
mode

56
Single Admission Turbine - Performance Map

57
Single Extr/Adm Turbine - Performance Map

58
Double Extraction Steam Turbine Controller

HSS
N
Speed N 505DE
Signals
N LSS Functional
Input AI
Raise Diagram
Lower -
Setpoint +
-
PID
Remote AI Remote AI
-
Setpoint + PID LSS
Raise - Speed
Lower E/D
Cascade
Load
Signal
AI AO V1
Limiter
Input AI
Raise
Lower -
Setpoint +
-
PID
Remote AI
Aux 1
Input AI E/D
Raise
Lower -
Setpoint +
-
PID
Remote AI
Aux 2 HSS
Ratio/
E/D
Limiter AO V2
Limiter
Input AI
Raise P-1
Lower -
Setpoint +
-
PID
Remote AI
Raise
Manual E/D
Lower
Setpoint
Remote AI
HSS
Input AI
Raise P-2 AO V3
Lower - Limiter
Setpoint +
-
PID
AI
Raise
Manual E/D
Lower
Setpoint
AI

59
Questions????

1 - Steam Turbine Control Basics

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1

Turbine Control Basics

Industrial Turbomachinery Systems

Steam Turbine Applications and

Industrial Turbomachinery Systems

High Pressure Boiler Supply (1500psi/103bar)

Main Supply (600psi/41bar)

Industrial Turbomachinery Systems

Typical Single Stage Steam Turbine

Industrial Turbomachinery Systems

Single Valve Application

Industrial Turbomachinery Systems

Split Range Valve Application

Industrial Turbomachinery Systems

Single Extraction Application

Industrial Turbomachinery Systems

Single Extraction Turbine Performance Map

Performance Map Uses

Industrial Turbomachinery Systems

Double Extraction Application

Industrial Turbomachinery Systems

Double Extraction Turbine Performance Map

Performance Map Use

Power Plant Generator Application

Industrial Turbomachinery Systems

Turbine Load and Flow Sharing Application

Industrial Turbomachinery Systems

Steam Turbine Control Basics

Industrial Turbomachinery Systems

Typical Steam Turbine System

• High pressure steam flows from the boiler at

Industrial Turbomachinery Systems

Single Stage Steam Flow

Industrial Turbomachinery Systems

Multiple Stage Steam Flow

Industrial Turbomachinery Systems

Double Auto-Extraction Steam Turbine

Industrial Turbomachinery Systems

Single Admission Steam Valve

Single admission Governor Valve

Trip valve to allow for positive shut off

Industrial Turbomachinery Systems

Single admission valve

Industrial Turbomachinery Systems

Industrial Turbomachinery Systems

• Governor Definition: An attachment to a machine for

Industrial Turbomachinery Systems

Industrial Turbomachinery Systems

Industrial Turbomachinery Systems

Industrial Turbomachinery Systems

Turbine Shaft Torque Balancing

Shaft Speed Notes:

• Load Torque > Turbine Torque = Decrease in Shaft Speed

• Turbine Torque = Load Torque = Constant Shaft Speed

Industrial Turbomachinery Systems

Factors Affecting Turbine Speed

Industrial Turbomachinery Systems

Closing the Loop

Industrial Turbomachinery Systems

Closing the Loop

• The governor functions the same as the car driver.

Industrial Turbomachinery Systems