LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 1

(262) 542-9061
LOVEJOY CONTROLS CORPORATION http://www.lovejoycontrols.com

Copyright 1998, 1999, 2000 Lovejoy Controls Corporation, All rights reserved.
Issue : Rev.1 7/10/2000

INTRODUCTION

The Lovejoy Controls Corporation (LCC) Series-2 Small Turbine Modular Governor is a
state of the art PLC-interfacing or direct operated turbine electro-hydraulic control
system designed to provide low maintenance and superior performance for small steam
turbines.

The Series-2
Governor electronics
are mounted in a
nitrogen purged
housing with
redundant Peltier
thermoelectric
cooling modules
which maintain
operating internal
electronic
temperature in the
optimum life range
under ambient
external temperatures
up to 175E F (80EC).
With the flexibility
enabled by solid state
cooling, the governor
housings may be
mounted either wall
or rail-mounted in
proximity to the
turbine units or in
existing electronics
cabinets. Virtually no
further ventilation is
required.
Thermoelectrically Cooled Series-2 Governor Enclosure
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 2
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Series 2 Enclosure, 19" Rack-Mount

The application range of the Series-2 includes:

# GENERATION TURBINES

# FEEDWATER PUMP DRIVE TURBINES

# FORCED DRAFT FAN TURBINES

# INDUCED DRAFT FAN TURBINES

# OTHER small turbine applications of Westinghouse, General Electric, De

Laval, Worthington, Seimans, ABB, Alsthom, both Mechanical and
Generation drive.

Multiple Series-2 Governor configurations permit very cost-effective solutions to turbine

control. Standard configurations can provide both PLC (Programmable Logic
Controller) or DCS (Distributed Control System) serial interfacing along with dedicated
operator control station options. An economical configuration can be found for each
application which provides required interfaces and/or control stations without the
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 3
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expense of additional unused equipment.

With a rich design heritage of governors controlling vital nuclear applications, LCC has
applied a twenty-year experience in turbine control to the Series-2.

ARCHITECTURE

The electronic design architecture of the LCC Series-2 Governor can be summarized
as Parallel Microcontroller. Just as advanced super-computer designers have learned
that multiple, smaller computers dedicated to specific tasks operating simultaneously
makes a much faster and more reliable computer, LCC has been applying parallel
processing to electronic governors since 1986. LCC alone offers parallel processor
control technology for small governor systems.

There are some excellent reasons for using a collection of small microcontrollers rather
than a single exotic microcontroller:

< By assigning dedicated tasks to separate microcontrollers, the speed

control loops are closed more quickly, improving governor response and
turbine control.

< The microcontrollers used by LCC, the Motorola HC-11 (or Hitachi
equivalent) are the standard automotive engine control computer used by
American and Japanese automakers. It is therefore widely available, low
cost, and most important of all guaranteed future availability for renewal
parts. Lower volume production exotic microcontrollers can have
production ceased overnight due to electronic market whims rendering
designs immediately obsolete.

< An excellent library of turbine control algorithms, proven in hundreds of

unit-operating years, has been developed by LCC for known bug-free
operation. Manufacturers using trendy exotic processors must constantly
develop new software with unproven validation and verification. LCC's
algorithms have been accepted by the US nuclear plants for reliable,
precise turbine control.
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 4
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The Series-2 Governor Block Diagram is shown below.

SERIES-2 GOVERNOR ELECTRONIC BLOCK DIAGRAM

Combining the array of signal I/O and the library of associated LCC governor control
algorithms, the Series-2 Governor provides a flexible turbine control package.

Field tuning and setup is performed by connecting a laptop personal computer

operating a LCC-supplied Configuration Program. The serial communication link
established allows adjustment of the Governor Characteristic Parameters (GCPs) for
each unit.

The valve-positioning design architecture will vary with applications. For turbine
applications requiring a servomotor pilot pressure to be generated, the LCC LPEHC
(Low Pressure Electro-Hydraulic Converter) is optioned. In these applications the
Pulse Width Modulated (PWM) drive output of the Series-2 Governor directly drives the
LPEHC which in turn develops the pilot control oil pressure to position the governor
servomotor.
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 5
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Other applications, Such as the REXA Type L Actuator, utilize the 4-20 mA drive
output.

In addition, Series-2 Governors have configurable actuator feedbacks for precise

positioning. Either pressure feedback or linear position (stroke) feedback may be
implemented, optimized for the application.

Series-2 Governor speed feedback is accomplished by either simplex or duplex speed

probes mounted in proximity to almost any size or tooth-count gear on the turbine shaft.
RS-422 transmitters insure RFI/EMI-free speed feedback to the governor.

APPLICATION CONFIGURATION with REXA ACTUATOR

Configurations are determined by specifying Demand Control, Positioner Drive/

Feedback, and Control Algorithm options to perfectly fit the target steam turbine. When
utilizing a REXA Actuator the interface is very straight-forward. The analog governor
valve drive output (4-20 mA) of the Series 2 provides the REXA Controller position
setpoint input. Further links between the REXA Actuator and the Series 2 Governor
combine alarm and diagnostic information, making it available at the OCS and/or the
DCS workstations. One such configuration is presented in the following figure.

TYPICAL SERIES-2 GOVERNOR SYSTEM CONFIGURATION DIAGRAM

LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 6
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1.0 Demand Control Options

1.1 Serial Interface

For applications where a plant (or OEM) PLC or DCS is present for
coordinated systems control, the most logical design is to interface the
turbine governor directly to the PLC or DCS as a distributed drop. The
PLC/DCS operator control stations may then be utilized to provide manual
or automatic speed/load demands to the Series-2 Governor. The serial
interface may be:

1.1a. RS-485, RS-232, or priority Serial Ports

1.1b. Master/Slave or Networked

1.1c. Choice of Protocols, including but not limited to:

< ModBus TM RTU
< ModBus TM ASCII
< GE Fanuc GENIUS TM BUS

ModBus TM is a registered trademark of Modicon Corporation.

GENIUSTM BUS is a registered trademark of GE Fanuc Automation N.A.

The serial interface supports communication of demand setpoints, alarms,

and special runbacks between the host PLC/DCS and the Series-2
Governor. Because the Series-2 Governor performs the high-speed loop
closure of valve position and turbine speed (much too fast for PLCs or
DCSs to control), it frees the host system to optimize demands and
provide operator control stations or screens.

1.2 Operator Control Station

When required, the Series-2 Governor is fitted with an Operator Control

Station (OCS) to provide a panel from which operators may input speed
and load control commands. The OCS is typically opted when a PLC or
DCS system is not resident in the plant or when a local hard-panel station
is desired as a backup or turbine startup station.

Physically, the station consists of a dedicated pushbutton panel with

LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 7
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demand and real-time displays and

status indicators. Pushbuttons are tactile
("clicking") and backlighted behind a
membrane cover. Membrane
identifications and legends may be
printed in any language.

Multiple configurable digital displays,

bar-graph displays, and indicators, allow
simultaneous monitoring of both turbine
speed/load and process parameters for
knowledgeable operator control beyond
conventional governor displays.

Typical OCS Layout

1.3 External Discreet Switch Control

On simple, basic installations using hard-wired control panels, external

switches may be wired to the Series-2 Governor providing basic governor
raise, lower, and emergency stop command inputs. When using this
configuration, an external tachometer and/or process display must be
available at the control switches' location for operator view.

When the existing displays exist and no "automatic" speed or load

positioning is required, this eliminates the expense of an OCS.

2.0 Positioner Drive/Feedback Options

Positioners for turbines vary greatly both by manufacturer, type, and vintage.
The Series-2 Governor may be configured to provide closed-loop positioner
control of most designs of steam, gas, and hydro turbine inlet governing valves.
The following configurations are most commonly utilized:
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LPEHC CONVERTER CROSS-SECTIONAL VIEW

2.1 LCC LPEHC Converter for Servomotor Pilot Pressure Control

The Series-2 Governor produces a Pulse Width Modulated (PWM) drive

output which drives the LCC Low Pressure Electro-Hydraulic Control
Converter (LPEHC Converter). The LPEHC Converter is an advanced
electronic to hydraulic pressure converter designed by LCC and currently
employed on over one hundred turbines providing nuclear plant reactor
and steam generator level control.

The LPEHC Converter produces a field-configurable linear pilot-

positioning control oil pressure to precisely stroke steam and hydro
turbine servomotors over their active range.

The figures on the following page depict the LPEHC Converter, which
establishes a force balance between the torque of the rotary solenoid
and the output control oil pressure working on the valve area. Existing
lube oil supplies are tapped to feed the LPEHC Converter from dual inlets
each protected with an orifice guard screen monitored for differential
pressure and maintainable on-line.
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LPEHC Converters are mounted in C-N-C machined hydraulic feed

blocks. The Series-2 Governor LPEHC kit consists of one LPEHC
Converter, two inlet guard screens with isolation valves and differential
pressure switches, and fittings for connection to servomotor ports. The
assembly mounts easily and provides leak-free connections.

Positioning feedback may be employed as LPEHC Converter pressure

output (via pressure transmitter) or position feedback from an LVDT or
linear potentiometer tracking the driven servomotor stroke. Each
application is analyzed for optimum feedback method.

LPEHC CONVERTER

2.2 REXA Actuator (Analog 4-20 mA Positioner Drive)

On many turbine units, the existing oil supply system is not reliable or
contains too much contamination to be used for control hydraulics. In
these instances the REXA Actuator may directly (or through mechanical
fulcrums) position the governor valves thus eliminating the oil system as a
failure point.
LCC works closely with REXA for the best possible retrofit alignments.
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 10
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3.0 CONTROL ALGORITHMS

According to the type of turbine, a set of control algorithms are provided which
utilize Governor Characteristic Parameters (GCPs) to define the particular unit
control functions. The laptop PC LAT may be used to change the GCPs at any
time, even during turbine operation, due to bumpless transfer buffering. The
following discussion covers basic control functions common to all types of
applications.

3.1 Operating Modes

Three operating modes are supported:

MANUAL MODE employs demand speed or load control strictly on the

basis of operator input commands, either from an Operator Control
Station (in MANUAL MODE) or from discreet switch inputs enabled. This
is a full-feedback closed loop control mode.

AUTO MODE uses an external demand signal for speed/load setpoint.

The signal may be received from the PLC/DCS serial interface, a 4-20 mA
analog input, or a pulse-coded input to the Series-2 Governor. This is a
full-feedback closed loop control mode.

DIRECT VALVE POSITION MODE ignores all speed/load feedback and

causes the operator input commands, either from an Operator Control
Station (in DVP MODE) or from discreet switch inputs enabled, to induce
immediate open or closed ramping of the inlet governor valve position.

The Series-2 Governor permits transfers between modes at all times

without demand or speed "steps" due to complete bumpless transfer
capability.

3.2 Intelligent Backup Control

In the event of a loss of an AUTOMATIC signal input, control is

immediately transferred to MANUAL without speed or load loss. In the
event of a loss of both speed feedback channels, control is immediately
transferred to DIRECT VALVE POSITIONING MODE without speed or
load loss.
LCC SERIES-2 SMALL TURBINE GOVERNORS TECHNICAL DESCRIPTION PAGE 11
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LOVEJOY CONTROLS... A LONG USER LIST, A REPUTATION OF EXCELLENCE

LCC has manufactured and installed turbine governor systems at the following plants:

Arkansas Power & Light McGuire Nuclear Generating Station

White Bluff Plant Entergy Operations, Inc.

Arkansas Nuclear One
Baltimore Gas & Electric
Calvert Cliffs Nuclear Power Plant Mississippi Power & Light
Baxter Wilson Generating Station
Central Illinois Public Service
Newton Generating Station Nebraska Public Power District
Cooper Nuclear Station
Cincinnati Gas & Electric
East Bend Station New York Power Authority
Indian Point 3 Nuclear Power Plant
Cincinnati Gas & Electric
Miami Fort Station New York Power Authority
Charles Poletti Generating Station
Commonwealth Edison Company
Joliet Generating Station Northern Ireland Electricity
Kilroot Unit 2
Commonwealth Edison Company
Kincaid Generating Station Otter Trail Power Company
Big Stone Generating Station
Commonwealth Edison Company
LaSalle Nuclear Generating Station PacifiCorp
Centralia Generating Station
Commonwealth Edison Company
Will County Generating Station Pacific Gas & Electric
Diablo Canyon Nuclear Power Plant
Commonwealth Edison Company
Zion Nuclear Generating Station PSI Energy
Cayuga Generating Station
Compania Sevillana de Electricidad
Estacion Bahia de Algeciras Tennessee Valley Authority
Shawnee Fossil Plant
Consolidated Edison Company
Indian Point 2 Nuclear Station Northwest Energy
Columbia Nuclear Plant
Dairyland Power Cooperative
Genoa 3 Generating Station

Duke Power Company