I&C – II

C.S.T.P.S. CHANDRAPUR
1
 AN ISOLATED TG SET
• Irrespective of variation in load, the generators are
required to run at constant speed. However when load on
generator varies there will be corresponding variation of
load on turbine also if the I/P to the turbine remains
same, the speed of the turbine tends to increase or
decrease depending on whether there is decrease or
increase in load. This will cause speed of generator also
vary. In order to maintain constant speed, the steam flow
through turbine need to be regulated.
• Such an operation of speed regulation is known as
GOVERNING.
• It is done automatically by means of Governor.
• All TG sets have got Hydraulic Governor.

2
 PRINCIPLE DIAGRAM OF GOVERNOR
PRINCIPLE OF SPEEDER GEAR &
FLY BALL GOVERNOR
Raised Lower
Lower Raised Load Load
Load Load
A B

Fly ball / Oil pump

Governor M
A – Normal Operating position Speeder
DRAIN
B – Relative Position when Gear Motor
Speeder Gear is set to nearly
max. position
Control Oil
3
4
 GOVERNOR DROOP
CHARACTERISTIC
• Purpose of a governor is to regulate steam input so
as to hold speed along droop characteristic.
• The percentage change in speed of an isolated
turbo generator when load on turbine generator is
increased from No load to full load (or decrease
from full load to No load) is called Governor Droop
No load speed – full load speed
% Droop = --------------------------------------- x 100
Rated speed
Rated Load Change in Frequency
= ----------------- x ---------------------------- x 100
Change in load Rated Frequency
5
 Lower Speeder Load increased
MECHANICAL GOVERNOR
Gear setting to from 50 % to 100
bring Load to % due to Turbine Follow Load drop from 100 % to
initial value Frequency Drop Mode Action 50% due to Freq.
Change ( Boiler Follow
A2 B1 B3
Mode In Service)
100

Raised Speeder
Gear setting to
bring load to
initial value
50
A1 B2
A3

Different Speeder
Gear Position

48 49 50 51 52

GOVERNOR CHARACTERISTIC WITH 4 % DROOP 6

 GOVERNOR FREQUENCY REGULATION
CHARACTERISTICS
LOAD

100

NO LOAD SPEED
RATED SPEED
FULL LOAD

50
SPEED

0
48 49 50 51 52
FREQUENCY HZ

2880 3000 3120 RPM

7
DROOP CHARACTERISTIC 500 MW UNIT
LOAD LOAD

500 MW
500 MW

DROOP 8%
250 250 MW DROOP 4%
MW

0 MW 0 MW
50 Hz 50 Hz
52 54 51 52 FREQU
Hz Hz Hz Hz ENCY

FREQUENCY

8
EFFECT OF CHANGING SPEED SET POINT
TG set at No load and unsynchronised
• Change in speed set point results in
change in frequency/ Speed
• Governor controls the frequency.
TG set synchronised to the grid
• Change in speed set point results in
change in load
• Governor controls the load.

9
EFFECT OF VARIATION OF SPEED SET POINT

c1 c2 b3
100 %

n g ing ed
LOAD f cha t Spe
ff ect o t poin se t t
E d se n
50 % s pe
e poi
h
b2 hig
ed
Spe
set t
poin
Low

0 a1 a2 a3

FREQUENCY

10
 ACTION OF SPEED GOVERNOR
FOR CHANGE IN GRID FREQUENCY
• load on the system is constantly changing
• If generation is more than demand
frequency will increased.
• Governor acts to reduce the steam input
• If generation is less than demand frequency
will decrease
• Governor acts to admit more steam.
• System settles at some new frequency
depending on speed – Load characteristic of
entire system.

11
 Lower Speeder Load increased
MECHANICAL GOVERNOR
Gear setting to from 50 % to 100
bring Load to % due to Turbine Follow Load drop from 100 % to
initial value Frequency Drop Mode Action 50% due to Freq.
Change ( Boiler Follow
A2 B1 B3
Mode In Service)
100

Raised Speeder
Gear setting to
bring load to
initial value
50
A1 B2
A3

Different Speeder
Gear Position

48 49 50 51 52

GOVERNOR CHARACTERISTIC WITH 4 % DROOP 12

 COMPARISION BETWEEN GOVERNING SYSTEM
OF KWU MACHINES AND RUSSIAN MACHINES
SR. SYSTEM ELEMENT GOVERNING GOVERNING SYSTEM (KWU)
NO. SYSTEM
(RUSSIAN)
1. HYRAULIC SPEED GOVERNOR YES YES
2 SPEEDER GEAR YES YES
3. LOAD LIMITOR & STARTING YES YES
DEVICE
4. CONTROL VALVES WITH YES YES
SERVOMOTORS
5. INTERFACE TO UPPER LEVEL THROUGH SPEEDER THROUGH SPEEDER GEAR IN
CONTROL SYSTEM GEAR IN BOTH MANUAL MODE ONLY &
AUTO & MANUAL THROUGH EHC IN BOTH AUTO &
MODE MANUAL MODE
6. SPEED AND LOAD CONTROL THROUGH SPEEDER THROUGH SPEEDER GEAR AS WELL AS
GEAR EHC

7. FREE GOVERNOR ACTION YES YES

THROUGH HYDRAULIC GOVERNOR

13
 FLYBALL SPEED LOAD LIMITOR SPEEDER
GOVERNOR 0 TO FULL LOAD GEAR
SIGNAL FROM
MECHANICAL LINK MECHANICAL CONTROL
LINK SYSTEM
FOLLOW PILOT VLV
SUMMATION LOAD SPEED
WITH 14 % OVER
PILOT VALVE CTRL PILOT VLV
SPEED PROTECTION

DIFFERENTIATOR
EMERGENCY
GOVERNOR
PILOT VALVE INTERMEDIATE IV STOP
S/D PILOT VALVE VALVE
Switch SERVOMOTOR
EMERGENCY CONTROL VALVE
GOVERNOR SERVOMOTOR
WITH MECH STRIKER EMERGENCY
STOP
VALVE
ISPUG HP & IP CONTROL SERVOMOTOR
VALVES THROUGH
CVSM LINKAGE 14
 LOAD LIMITER / STARTING SPEEDER GEAR ELECTROHYDRAULIC
DEVICE 0 – 100 % LOAD 0 – 100 % LOAD CONVERTER

HYDRAULIC SPEED
TRANSMITTER
SIGNAL
HYDRAULIC FROM
HYDRAULIC SPEED FOLLOWUP EHTC
GOVERNOR PISTON

ELECTRO HYDRAUPLIC
REMOTE TRIP HYDRAULIC AMPLIFIER CONVERTER FOLLOWUP
SOLENOID VALVE FOLLOWUP PISTON PISTON

HYDRAULIC SAFETY SELECT MINIMUM BETWEEN MHG/EHG

TRIP DEVICE
CONTROL VALVE SERVOMOTOR

MAIN TRIP VALVE EMERGENCY STOP CONTROL

VALVE VALVE
15
 ELECTRO HYDRAULIC GOVERNOR

LOAD
REF

16
 MAIN FUNCTIONS OF GOVERNING
SYSTEM OF A LARGE TG SET
The main functions of the governing system of a large TG
set used for power generation via an extensive power
network are :
• To control the initial run-up and synchronisation
of the TG unit..
• To control the steam valve lift (and hence the
load generated) in response to signals from the
operator or from an auto control system.
• To assist in matching the power generated to
that demanded by responding to grid frequency
changes.
• To restrict the speed rise within acceptable limits
in case of unit disconnected from grid.
17
 ELECTRO HYDRAULIC GOVERNOR

LOAD
REF

18
 ELECTRO HYDRAULIC TURBINE
CONTROLLER EHTC (KWU MACHINE)

• KWU machine are supplied with mechanical

hydraulic governing system and electro hydraulic
governing system called Electro Hydraulic Turbine
Controller (EHTC).
• Hydraulic governor will always be standby to EHTC
with hydraulic governor bypassed, hence hydraulic
governor droop will be ineffective.
• There is no dead band in hydraulic governor speed-
load characteristic. Upper load limit can be set by
load limiter. But there is no lower limit. Frequency
influence ON/OFF option is also not available in
hydraulic governor.

19
20
 ELECTRO HYDRAULIC TURBINE
CONTROLLER EHTC (KWU MACHINE)
• Hydraulic governor or EHTC, any one will be in
control through hydraulic minimum gate.
• In electro hydraulic governor frequency influence
can be made ON/OFF by operator. Characteristic
such as dead band, upper & lower load limit etc
can be configured as desired. Governor droop
can be set from 2.5 to 8.0 % in step of 0.5 in Unit
– 5 & Unit – 6. droop is freely configured in Unit –
7.
• Load, Speed and Pressure control loops are
implemented in EHTC. Each control loop will be
take over automatically as per plant conditions.

21
22
 ELECTRO HYDRAULIC
CONVERTER
• The Electro Hydraulic Governor was
succeeded on 660 MW machine installed from
1968 onwards by electronic governors.
• In 1980s a digital governor similar in principal
to the Electronic governor but with the
proportional action performed by a
microcomputer was developed.

23
24
25
26
27
28
29
 TYPES OF FLUID
36 BAR
1. HP CONTROL FLUID
12 BAR
2. LP CONTROL FLUID

3. START UP FLUID

4. AUXILIARY START UP FLUID

5. TRIP FLUID

6. AUXILIATY TRIP FLUID

7. AUXILIARY SECONDARY FLUID

8. HP SECONDARY FLUID

9. IP SECONDARY FLUID

10. PRIMARY OIL

30
 ROLLING THROUGH HYD GOV
 Reset Turbine by starting and load limiting
device.
 Keep EHC maximum or interconnection valve
close.
 Keep speeder gear (SPG) minimum.
 Raise SLLD slowly and open stop valve.
 Increase SLLD and roll the Turbine.
 At around 2800 rpm SPG will become active.
 Further raise the speed by SPG upto desired
speed.
31
32
 ROLLING THROUGH EHG

 Reset Turbine by starting and load limiting

device.
 Keep EHC minimum.
 Keep speeder gear (SPG) maximum.
 Raise SLLD slowly and open stop valve.
 Make tracking device ‘ON’
 Increase speed set point to desired speed.
33
 ELECTRO HYDRAULIC GOVERNOR

LOAD
REF

34
 EHG TO HYDRAULIC

 Make Tracking Device off and raised SLLD.

 Take M/C on load controller.
 Reduce SPG till load start decreasing.
 Raised load set point to 500 MW.
 EHC will slowly go to maximum.
 Close interconnection valve.
 Hydraulic Governor is active.
35
 ELECTRO HYDRAULIC GOVERNOR

LOAD
REF

36
 HYDRAULIC TO EHG
 Raised load set point to 500 MW.
 Ensure EHC is at maximum and load
controller active.
 Open interconnection valve.
 Reduce load set point till load starts
decreasing.
 Raise SPG slowly to maximum.
 Make Tracking Device ON
 Now M/C is on EHC with load controller
active.
37
 ELECTRO HYDRAULIC GOVERNOR

LOAD
REF

38
ELECTRO HYDRAULIC GOVERNOR

39
 EHC GOVERNING
CHARACTERISTIC
S. HREF HP SEC IP SEC. HPCV1 HPCV2 IPCV1 IPCV2
N. OIL OIL MM MM MM MM
PRESS PRESS
Kg/cm2 Kg/cm2
1 0% 3.0 3.0 0 0 0 0
2 10 % 3.25 3.50 2 2 5 5
3 20 % 3.48 3.98 5 5 30 20
4 30 % 3.70 4.42 7 9 70 67
5 40 % 3.95 4.45 10 11 120 130
6 50 % 4.10 5.33 14 14 170 170
7 60 % 4.35 5.62 19 18 170 170
8 70 % 4.55 5.72 30 30 170 170
9 80 % 4.79 5.78 63 65 170 170
10 90 % 4.98 5.78 90 92 170 170
11 100 % 5.15 5.80 100 100 170 170
40
 EHC CHARACTERISTICS
180 HPSEC
160
140 IPSEC
120
HPCV1
100
80 HPCV
60 2
40 IPCV1
20
0 IPCV2

EHC POSITION %
41
ELECTRO HYDRAULIC GOVERNOR

42
 SPEED CONTROLLER
The speed controller structure is designed for the “
Turbine torque – Turbine Speed” control loop and
used to control the operating mode.
• Start up and shut down the Turbine.
• Synchronised the TG set with the grid.
• Load control at min load rejection below
auxiliary power.
• Intercept the turbine before the over speed
trip response limit is reached.
• Load control of the TG set if necessary.
43
 SPEED GRADIENT
MONITORING DN/DT
• Turbine must be prevented from leveling
off in the range from 600 rpm to 2850
rpm (Blade vibration).
• If the acceleration less than 100
rpm/min occurs during run-up, DN/DT
will operate.
• Start up procedure will stop.
• speed set point will return to 360 rpm.
44
 TSE INFLUENCE

MINIMUM TSE MARGIN

SPEED CONTROLLER
30 0k  100 %
0 – 30 0k  0 – 100 %
 0 – 600 rpm/Min
15 0k = 50 % = 300 rpm / Min
LOAD CONTROLLER

0 – 30 0k = 0 – 100 %
= 0 – 50 mw /Min

45
ELECTRO HYDRAULIC GOVERNOR

46
 LOAD CONTROLLER
The load controller is designed for two functions.
1.Power operation on the grid, with PI transfer
function.
2.Isolated grid operation with P transfer
function.
3.Together with the other slave controllers it
acts via the control transfer circuit on the EHC
and hence on the turbine control valves.

47
 FREQUENCY INFLUENCE
 Reference Frequency is floating depending upon
the previous operating frequency between 49.0 Hz
to 50.5 Hz.
 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
correction.
48
 FREQUENCY INFLUENCE
 After this period the load value comes back to the
original value in a ramped fashion.
 For frequencies more than 50.5 Hz and less than
49.0 Hz load change is as per droop characteristic
and limited to +10 % of machine rating.
 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 Co-ordinated
Master Control.

49
FREQUENCY INFLUENCE INCORPORATED IN
EHC OF KWU MACHINES
LOAD 100 % = 500 MW

50
 LIMIT FREQUENCY MODE (EHTC)
HIGH FREQUENCY UNLOADING ABOVE 3090 RPM
• The frequency comparator of load controller only
takes effect on over frequency in order to prevent
hazardous turbine over speed under certain
disturbances.
• When frequency rises above 51.5. Hz i.e 3090 rpm
load starts dropping.
• Load will drop to 180 MW in case of 500 MW
machine.
• Ratio of power and frequency being 5 % i.e 5 % over
frequency reduces the power set point by 100 %.

51
 LIMIT FREQUENCY MODE
(EHTC)
8 % DROOP
500

350 LIMIT
LOAD FREQUENCY
MODE
250

180

50 Hz 51.2 Hz 51.5 Hz 52.35 Hz

FREQUENCY

52
 SPEED / LOAD SET POINT BLOCK

 EHC FAULT
SPEED SLOPE LOW
TSE MARGIN < ZERO
STEAM TEMPERATURE BEFORE LPBP <
15 k
X3 – 15K CRITERIA NOT FULFILLED

53
ELECTRO HYDRAULIC GOVERNOR

54
 PRESSURE CONTROLLER
• The pressure controller exhibits PI control action.
• When pressure controller is not in action, the
controller outputs a value corresponding to valves
fully open.
• When pressure error approaches zero, controller
output tracks load controller output.
• When pressure error is zero pressure controller
quickly assumes control of the valve.
• When pressure controller in action the load controller
tracks the valve lift signal of the pressure controller.

55
 THREE MODES OF OPERATION
1) LIMIT PRESSURE MODE (BOILER FOLLOW MODE)
During limit pressure operation, the storage
capacity of the steam generator is exploited and
the pressure controller intervenes only when an
adjustable pressure deviation is reached or
exceeded and acts to limit valve lift in order to
protect the steam generator. The pressure is
however hardly even reached during normal
operation as pressure is maintained by the steam
generator controls.

56
 THREE MODES OF OPERATION
2) INITIAL PRESSURE MODE (TURBINE FOLLOW MODE)
IN the initial pressure control mode the pressure
controller adjusts the control pressure difference 'P to
zero and the steam generator governs the turbine load
up to the value set on the load set point adjuster.
3) TRUE SLIDING PRESSURE MODE
In the true sliding pressure mode the load is falsified so
that the load controller outputs a max valve lift signal
and the control valves are fully open.

57
ELECTRO HYDRAULIC GOVERNOR

58
 CONTROL TRANSFER CIRCUIT
• The control transfer circuit gates the controllers
( Speed, Load & Pressure) and generates the lift set
point hR
• The speed and load are output via a maximum
selection gate.
• The combined speed /load signal is applied with the
pressure controller signal to a minimum selection
gate.
• This gating ensures bumpless transfer from speed
to load operation, load to pressure and pressure to
load operation.
59
 HP / IP TRIM DEVICE
• Turbine load < 100 MW and HPT exhaust Pr.
> sliding reference proportional to main
steam pressure.
• Solenoid MAX42AA051 will be de-energised.
• IP control valves do not begin to open untill
the main control valves are wider open.
• HPT exhaust steam temperature is lowered.

60
 EHC CHARACTERISTICS
OIL POSITION
7
6
5 NORMAL
4
3 HPSEC
TRIMMED
2 IPSEC
1
IPSEC
0

EHC POSITION
61
ELECTRO HYDRAULIC GOVERNOR

62
 ISOLATED GRID OPERATION
1.Load set point > actual load by 50 MW
2.Frequency > 50.6 Hz
3.Load controller “ON”
4.Speed controller not in action.
5.Pressure controller not in action.
Once isolated grid is detected, the parameters of load
controller will change and load set point deviation will no
longer be corrected.

63
ELECTRO HYDRAULIC GOVERNOR

GEN MW MS FLOW

GEN FREQ

GEN MVAR

64
ELECTRO HYDRAULIC GOVERNOR

65
 LOAD SHEDDING RELAY
The initial transient speed rise following a load
rejection, is primarily due to two factors.
• The stored energy of steam within
the turbine and its associated pipe
work.
• The time taken by the turbine valves
to close in response to sensed over
speed.
66
• To contain the over speed within the trip setting of 10 %
it is generally necessary to close the valves at maximum
rate.

Over Speed Trip Setting Level

110

Transient Over Speed

SPEED Valve Fully Closed

Fully closed Signal

100
TIME T
67
TURBINE RESPONSE TO LOAD
 LOAD SHEDDING RELAY
• The load shedding relay performs a support
function to the hydraulic turbine governor. Even
with large load rejections the load shedding relay
caused the turbine to be stabilized by the turbine
governor before trip speed is reached and the
turbine over speed monitor responds. By rapidly
applied the signal at the secondary oil pressure
output of the hydraulic governor. Turbine run up
is reduced in accordance with its Speed / Load
characteristic thus also reducing the maximum
over speed value.
68
 LOAD SHEDDING RELAY
CONDITION FOR LOAD SHEDDING RELAY
1. Step load Change > 300 MW
15 to 90 % ( 5 % step)
2. Residual load PA/PN < 120 MW
5 to 50 % ( 5 % step)
3. Frequency F > 50 Hz
4. Step load change within 100 msec.
69
 LOAD SHEDDING RELAY
MAX45AA001
MAX46AA011
dP/dt < LSR SOLENOID
P= VI COS  VALVE
-a
I P
dP/dt PULSE
V
-b
AND
X S
<

F<

70
ELECTRO HYDRAULIC GOVERNOR

71
 HOUSE LOAD OPERATION
1. Generator Circuit Breaker opens.
2. UAT will not change over.
3. Field breaker will not trip.
4. HP/LP Bypass will fast open.
5. Turbine control will change over to speed control.
6. LSR will operate if conditions are satisfied.
7. HPT evacuation valve will open.
8. DPSU solenoid valve will operate in TDBFPs.
9. 40% fuel will cutoff without any delay.
TG unit will continue to feed auxiliary load and frequency
can be corrected by changing speed set point. The machine
may be reconnected to the grid when required.
72
 HPT EVACUATION VALVE

 VALVE WILL OPEN WHEN

 LOAD LESS THAN 2 % OR
 TURBINE TRIP
 VALVE WILL CLOSE WHEN
 SPEED LESS THAN 2000 RPM

73
74
 HP/LP BYPASS SYSTEM
• Purpose of HPBP station is to allow steam pressure at
HP Turbine inlet to be controlled before and during
turbine startup, running as well as during trip out
conditions.
• HP/LP bypass capacity for KWU machine is 60
% of main steam flow and 30 % for LMW machines.
• Set pressure of HPBP opening is kept 8 Kg/cm2 above
normal rated pressure. In normal course turbine
pressure will be controlled by pressure control loops
i.e. combustion control or turbine control valve.
• If load drops suddenly due to FGMO, pressure may
rise beyond setting and HP/LP Bypass system will
immediately open to maintain pressure.
75
 HP/LP BYPASS SYSTEM
• With set synchronized , HP/LP Bypass operation is
desirable only in exclusive conditions and for
short duration.
• When HPBP valves are opened more than 2
% corresponding spray valves switch over to auto
and regulate to maintain downstream
temperature near to set temperature. In case of
excessive rise in down stream temperature HPBP
valves will get force closing commands.
• With BP1 or BP2 greater 2 % open, BD valve will
also open automatically.
76
 HP BYPASS SYSTEM
FAST OPEN & PUT TO AUTO
FROM
BOILER CLOSE
HPBP
PR ref PRactual
CONTROL DEV HIGH

GEN BREAKER HPBP

OPEN O PI VALVE HPT
TURB. LOAD R
SHADING RELAY CLOSE
OPERATED HPBP
TURBINE TRIPPED DE-SUPER SP
HEATER RA
HPBP DOWN STREAM Y
TEMP V.LOW
O
COND VACUUM R FEED
LOW WATER
TO
REHEATER 77