-4-18000-35-415. Rev. No-01 K K igtaty signed by KK WRITE-UP Baner="=2—- i 2s ON ELECTRO- HYDRAULIC CONTROLLER (With FGMO) Project: FARAKKA STPP (1X5OOMW) STAGE-IIT Customer: NTPC Product: Steam Turbine C&I NTPC drg. no.-4140-108-110-03HW-PVM-K-017 29.9.07 _ | FGMO SCHEME ADDED | SASWATI | VINOD KR | KB BATRA, OL 0 [30.04.07 ‘SASWATI | VINOD KR | KB BATRA, REV | DATE REMARKS WORKED | CHECKED | APPROVED SHEET NO. 1 OF 11 CIE, BHEL HardwarRev, No-01 1.0 INTRODUCTION: The turbine is equipped with electro-hydraulic governing system to facilitate the operation of the turbo set in an interconnected grid system. The electrical measuring and processing of signals offer the advantages such as flexibility, dynamic stability and simple representation of complicated functional relationship. The processed electrical signal is introduced at a suitable point in the hydraulic circuit through the electro-hydraulic converter. The hydraulic controls provide the advantages of continuous control of large positioning forces for control valves. The integration of electrical and hydraulic system offers the following advantages - -Exact load frequency droop with high sensitivity, -Reliable operation in case of isolated power grids, -Dependable control during load rejection, -Low transient and low steady-state speed deviations under all operational conditions, - Excellent operational reliability and dependability, - Safe operation of the turbo-set in conjunction with the Turbine Stress Evaluator (TSE)/Controller(TSC). 2,0 ELECTRICAL EQUIPMENT: The electrical equipment of the electro-hydraulic governing system comprises of measuring devices, the electronic controllers, electro-hydraulic converters etc. The electrohydraulic controller is realized in the microprocessor based hardware system. It is configured as a local station with input/output and processor modules housed in cabinet. The cabinet also contains the solid state hardware for actual speed acquisition, position measurement of electrohydraulic converter , speeder gear and starting device and for the valve lift controller. 3,0 MEASURING DEVICES: = Digital speed monitoring devices with three speed measuring probes for measuring rotational speed installed in bearing housing and then taken to pulse converters in speed measuring unit in Braun system for hardwired realization , the output is received in 4-20 mA. With the help of input modules , the speed signal is further taken to Max processor (DPU) in median of three configuration for further processing for analog applications. - Three measuring devices to determine the active electrical power of the generator, = Remote position transducers to determine the actual positions of electro- hydraulic converters. = One electro-hydraulic converter housed in the governing rack placed adjacent to the main turbine HEET NO, 2 OF 11 CIE, BHEL Hardwar4,0 OPERATING EQUIPMENT: To facilitate easy and efficient operation of the electro-hydraulic governing system, it is interfaced with MMI system via the control system data highway s and with operator interface. The system is provided with the following display indications on the operator workstations. For actual provision of control tiles and operator displays project specific documents may be referred. All indicators/ Control buttons/Annunciations (as below) will be MMI. 4.1 INDICATIONS : - The actual position of start-up device of hydraulic device, - The actual position of speed adjusting device of the hydraulic device, - The reference value of speed in rpm; range 2800-3300 rpm (spread scale). - The reference value of speed in rpm; range 0-3600 rpm. ~The time dependent reference value of speed in rpm; range 0-3600 rpm ~ Load reference value of grid controller in MW, - Load reference value in MW, The time dependent load reference value in MW, - Load reference value of frequency control in MW, - Net effective reference of load value in MW, - The load gradient desired in MW per min. The reference value of maximum load in MW, The steam pressure deviation , - The actual position of electro-hydraulic converters. 4.2 (OWS/MMI) BASED OPERATOR INTERFACE: -6 face plates with one pair of push buttons (one to initiate "lower" command and the other for "raise" command) for the following - - The speed reference setter. - Load reference setter. -Maximum load reference setter. -Load gradient reference setter, -Load gradient ON/OFF, -Frequency influence ON/OFF, - Hydraulic start -up device setter. - Hydraulic speed setting device setter. -One control tile with two control buttons and two indicating lamps for load gradient command ON-OFF. -Two control tiles with one pair each of control buttons and one pair of feedback lamps and one pair of fault indication lamps for load controller and grid controller command ON-OFF SHEET NO, 3 OF 11 CIE, BHEL Hardwar-4-18000-35-415- Rey, No-01 One control tile with two ‘soft push buttons’ and feedback lamps for * Initial Pressure Control” and “ Limit Pressure Control” 4.3. ANNUNCIATION : The following annunciations are also provided in the control desk - - One annunciation tile with two lamps for the status display * Frequency Influence ON/OFF”, - Five annunciation windows in OWS for status and fault display of the following - a) Speed controller in operation b) Load controller in operation c) Pressure controller in operation d) Stop reference limiter e) Limit pressure reached 5.0 CONTROL LOOP : The electro-hydraulic governing system essentially consists of the following control loops - Speed Control Loop Load control Loop Pressure Control Loops One of these three loops act selectively on the subordinate valve lift control loop. The vaive lift controller actuates the plunger coil of the electro-hydraulic converter which acts as an interface between the electrical and the hydraulic systems 5.1 SPEED CONTROL Loop: This loop is essentially formed by a speed reference limiter and speed controller. The integrated functions of the two blocks is explained below. The speed controller essentially compares the speed reference generated by the speed reference limiter circuit and the actual speed of the turbine and accordingly provides an output for the valve lift controller. The actual speed, nsx is acquired by three speed pick-up systems. The output of each pick up is then processed in three different channels . The output from only one channel is used . In the event of failure of this channel, the system is automatically switched onto the other channel and an alarm to that effect is initiated. The switchover does not affect the operation. In case the HEET NO. 4 OF 11 CIE, BHEL Hardwar-4-18000-35-415- Rev, No-01 defective channel gets restored again , the same is automatically made available to the selection circuit independent of any acknowledgement of the alarm. The controller gain is matched to have a very precise control in the vicinity of the rated speed. The speed reference is generated by the speed reference limiter control loop. The desired reference speed value can be set with the help of a potentiometer remotely from control desk or manually at the cabinet. In the speed reference limiter the reference speed signal is juxtaposed with the output from the TSE/TSC at every instant and a time dependent limited speed reference is generated corresponding to the highest permissible rate of speed increase which is consistent with the safe operation of the turbine. After attaining the target reference speed the output of the speed reference limiter is held constant. The TSE/TSC influence is made ineffective in those segments of speed increase which cover the critical speed of rotors. The output of speed reference limiter is automatically blocked in the event of a fault in TSE/TSC and the speed of the set cannot be changed until and unless TSE/TSC is suitably disconnected. dn/dt monitoring To avoid rolling of the turbo set at or near critical speeds, the acceleration of the set is monitored in the range 700 rpm to 2850rpm. In case dn/dt goes below the set value , the speed set point is rolled back to the soaking value and the set is returned to that speed. After further thermal stabilization, when sufficient temperature margins are available , the speed is again increased. The speed controller exhibits a steady state proportional control to form the necessary droop characteristics. The dynamic response is improved by the addition of proportional integral and differential element. The speed controller realizes the following operations - ~ Start up and shut down of the turbine - Synchronization of the generator - Provides a minimum load operation = Operation of the turbo-set in the complete power range in case load controller is defective 5.2 LOAD CONTROL LOOP - Load Reference Limiter - Frequency Load Droop - Load / Frequency Controller The reference load is set by OWS, which is transmitted to the load reference limiter. The load reference set value and output signal from TSE/TSC are juxtaposed in the load limiter and _ it generates the time dependent limited reference load setting depending upon the influence of the TSE/TSC at the highest permissible rate consistent with the thermal stresses of the turbine both HEET NO. 5 OF 11 CIE, BHEL Hardwar-4-18000-35-415- Rev, No-01 during load increase and decrease. After attaining the target load reference, the reference limiter output is held constant. The TSE/TSC _ influence is rendered ineffective upon failure and the load_reference limiter is held constant. It is only possible to increase the load when TSE/TSC is disconnected. The load gradient setter also influences the time dependent load reference signal but the actual maximum permissible load rate is governed by the TSE/TSC. The load controller receives the reference load signal from the load reference limiter and also from the frequency controller depending upon the frequency of the grid. These two signals are summed in the load controller and the net value derived for controlling the valve position. The droop characteristics of the frequency controller can be varied from 2.5% to 8% in steps of 0.5% To limit the total power delivered by the turbine, the system is equipped with maximum load reference limit. This acts directly on the valve lift controller and has priority over all other influences acting directly or indirectly on the valve lift controller. The actual load value is acquired in three independent channels _and transmitted to the load controller. In case of a deviation of more than 5% in between the Measurement channels, an alarm “actual load signal faulty” is initiated. The load controller exhibits a proportional integral action and has an excellent dynamic response when the turbine is synchronised and the block loading have been achieved. This controller and the speed controller signal are transmitted to valve lift controller signal through maximum and minimum selection circuits. Isolated grid operation If the power plant together with a section of the power grid should become isolated during load control, the configuration of the control is switchover to frequency control. The PI characteristics of the load controller is switched over to P characteristics with 5% droop. Isolated grid operation is suitably annunciated and is reset manually. 5.2.1 FREE GOVERNING MODE OF OPERATION (FGMO) ‘As per the requirement of IEGC, a control scheme is provided to facilitate the operation of TG set in FGMO. There are two different loops as described below: For frequency band of 49,5 to 50.5 Hz ~ In this band a floating reference frequency is generated to enable better dynamic response to changing grid frequency. The floating frequency is derived from the previous cycle frequency and compared with the present frequency. Based on the deviation, a load reference change is HEET NO, 6 OF 11 CIE, BHEL Hardwargenerated which is summed up with the load reference. A dead band of 0.03 Hz is considered to avoid frequent fluctuations in load and the load change is limited to +/- 5%. After frequency stabilization, the load generated by the machine returns back to the original value in 4 to 5 minutes in a ramped fashion. For frequency below 49.5Hz and above 50.5 Hz - In this range, droop based frequency influence is provided. Load change is limited to +/- 10% to provide better support for frequency stabilization in the grid. Droop value is generally set as 5%. It is however adjustable between 2.5 to 8%. LOAD SHEDDING In_ case of sudden loss of export load, the output of the load controller is immediately reduced below the output of the speed controller which is set at station load. Due to maximum selection speed controller assumes control and returns the turbine back to almost the rated speed. This provision improves the dynamic response of the closing of the steam control valves and keeps the turbine speed from rising along the droop characteristics. 5.3 PRESSURE CONTROL LOOP The pressure controller controls the turbine load w.r.t, the main steam pressure deviation and prevents a pressure drop e.g. during a quik load increase. ‘Two operational modes can be selected - a) Initial Pressure control b) Limit pressure control 5.3.1 INITIAL STEAM PRESSURE CONTROLLER Operation of the initial steam pressure controller initiates the unloading of the set in the event of initial steam pressure falling below a preset value. The unloading of the set continues proportional to the available pressure. The loading of the set begins only if the firing rate in the boiler is increased. In this mode of operation load is controlled by the boiler and main steam pressure by the turbine. 5.3.2 LIMIT PRESSURE CONTROL MODE The boiler storage capacity is utilized in this mode of operation. The controller influences MS control valves to support boiler pressure only when a preset minimum deviation is exceeded. This allows load controller to handle small, quick load variations, until the pick-up limit of the limit pressure control is reached. SHEET NO, 7 OF 11 CIE, BHEL HardwarRev, No-01 5.4 VALVE LIFT CONTROLLER The input of valve lift controller is continuously compared to actual valve lift (feedback signal) and error signal is transmitted to the electro -hydraulic controller. The feedback signal representing the valve lift is derived from position of the electro -hydraulic converter plunger as an analog value from the differen- tial transformer type transducer. There are two transducers continuously scanning the position of the plunger. If the signal from any transducer differs by more than predefined value an alarm is initiated. The characteristics of valve lift controller are proportional, integral and differential type and this ensures high overall sensitivity and improves transient response. During operation of the turboset one of the controller is always in control. The other standby controllers are matched continuously with the active controller to allow quick transition without bumps. The outputs from the speed control loop and load control loop are juxtaposed and tied to each other by means of a maximum selection circuit. In a separate circuit the output of speed control loop is summed with load reference value. This signal is compared with the signal from maximum selection circuit of the speed and load controller and minimum of the two juxtaposed with the output signal from pressure control loop in yet another minimum election circuit. The output of this minimum selection circuit is fed to valve lift controller. Normally the set is run on electro -hydraulic controller whereas the hydraulic controller serves as a standby. 6.0 ELECTRO HYDRAULIC CONVERTER The electro -hydraulic converter is used as an interface device between the actuators of the main steam control valves and the electronic control circuits. It converts the electronic signal received from the valve lift controller to an appropriate hydraulic signal. The electro-hydraulic converter complies with the stringent requirements for actuating force and actuating speed of the electro - hydraulic governing system. 7.0 TRACKING DEVICE : A tracking device is provided to achieve bumpless transfer of control to the back-up hydraulic device in the event of failure of electro-hydraulic controller. This device tracks the output of hydraulic starting and load limiting device to 5 to 10% more than the output of the electrohydraulic controller. During normal operation, electro-hydraulic controller is in operation through a hydraulic minimum gate. In case of failure of electro-hydraulic controller , it gives a maximum opening signal for the valves and hydraulic controller takes over through the minimum gate. HEET NO. 8 OF 11 CIE, BHEL HardwarRey, No-01 8.0 LOAD SHEDDING RELAY: The load rejection relay assists the hydraulic controller to ensure that the speed of the turbine generator can not reach the trip setting for the hydraulic overspeed trip in case of load through off. The instantaneous power is compared with the last measured value (scanning time 60 msec) which is stored throughout the length of scanning time. In case a negative load transient is detected a control pulse is generated. This pulse is used to actuate the solenoid valve in the HP and IP secondary fluid circuits, switching to drain and thereby causing a rapid drop in pressure, The HP and IP turbine control valves close at maximum speed as a result, thereby preventing overspeed. The length of the pulse which determines the closure time of the valves, is dependent on the magnitude of the negative load transient. Upon termination of the control pulse the solenoid valve is deenergised, the control fluid pressure increases again and the speed controller opens the valves corresponding to the new load value. Since the turbine speed after a load rejection is not only dependent on the magnitude of the load rejection but also on the residual load after the load rejection, the control pulse is only issued if the remaining load is also below a preset value. The setting for the load rejection relay (magnitude of load drop, remaining load, duration of pulse) may be adjusted during initial checkout/ commissioning and start-up of the turbine generator. The default settings are as follow: AP > 50% Pres < 30% scanning time 60 msec length of pulse= 1.2 sec (max) £< 49 Hz To prevent response of load shedding relay on under-frequency, a frequency monitoring circuit inhibits response of this relay if frequency drops to an adjustable under-frequency limit . Without this blocking (feature), the turbine would accelerate too much (in the event of load rejection on underfrequency, after termination of the close pulse the hydraulic controller ), would open the turbine control valves very far due to the large error caused by the frequency deviation. This itself would reach the overspeed trip point. SHEET NO. 9 OF 11 CIE, BHEL Hardwar1 40 OT ON L43HS ere po 5 velvday + ‘ddd | Salva ‘SSWWaa Sty-S€-00081- ‘ON ‘300 M1 CONIA © ‘HO Logo's SHA NO dN JLIaM LLWMSWS | ‘ddd ‘Aa To SWSHIS WALNOD ITINVSAAH + T 'OI4 Teor saul S3AWA I IOAINOS OL! x0 1 SSTIOSLNGO | t t ' ; WOTALIATS L--------- TOOARL? 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