AUTOMATION OF STEAM TURBINE (EAST)

A CASE STUDY

A
DISSERTATION
Submitted in partial fulfillment of the requirements
for the award of the degree
of
Master of Technology

In

Electrical Engineering
(Control Systems Specialisation)
of
Kwiksbetra University,
Knrakshetra

Submitted
by
ASHOK KUMAR MAHESHWARI

ELECTRICAL ENGINEERING -DEPARTMENT

REGIONAL ENGINEERING COLLEGE
KURUKSHETRA -136119
(HARYANA)

Roll. No. 295731 Regn. No. 92-RC/360

 CERTIFICATE

Certified that the dissertation entitiled “Automation of Steam Turbine (EAST)-A Case

Study” which is being submitted by Mr. Ashok Kumar Maheshwari, Roll No. 295731, in

partial fulfillment of the requirements of the Degree of Master of Technology (Electrical

Engineering) in Control Systems of Kurukshetra University, Kurukshetra, is a record of

his own work carried out by him under our supervision and guidance. This matter

embodied in this report has not been submitted to any other University or Institution for

the award of any degree.

Lecturer Professor
D ept of Electrical Engg. Dept, of Electrical Engg.
REC Kurukshetra REC Kurukshetra
 ACKNOWLEDGEMENT

I express my profound sense of gratitude and indebtedness to my guides,

Dr. Krishna Gopal, Professor, Electrical Engg. Dept, and Sh. J. S. Lather, lecturer,

Electrical Engg. Dept., Regional Engineering College, Kurukshetra, for valuable

guidance and consistent help given at every stage of this dissertation work. I am

extremely grateful to Er. Amod Jindal and Er. P.N. Tripathi, AEE, Panipat Thermal

Power Station, who provided me with really rich and nourishing food for thought on the

topic of my dissertation, a fair amount of credit must go to them.

I am highly indebted to my parents, for their enormous love and affection

showered at me. Their faith in my capacity to achieve things has always stood me in

good stead.

I would be failing in my duty if I don’t acknowledge support and encouragement

received from my wife Anu Maheshwari,

ASHOK KUMAR MAHESHWARI

ROLL NO. 295731
M.Tech. ( Control Systems)
Department of Electrical Engg.
REC Kurukshetra
 AUTOMATION OF STEAM TURBINE (EAST)
A CASE STUDY

CONTENTS

CHAPTER-1. INTRODUCTION

CHAPTER-2. EAST PACKAGE

2.1 Introduction
2.2Turbine Stress Evaluator (TSE)
2.3Electro-Hydraulic Controller(EHC)
2.4Automatic Turbine run-up Systems(ATRS)
2.5LP Bypass and Gland Seal Steam Control
2.6Automatic Turbine Tester (ATT)
2.7Turbine Protection
2.8 Vibration & Expansion Measurement
2.9 Load shedding Relay
CHAPTER-3. Discussions and Suggestions

3.1 Frequency Influence Remains Off

3.2Fluctuations in Boiler parameters
3.3Stoppage of Barring Gear

References
 CHAPTER-I
INTRODUCTION
Panipat Thermal Power Station (PTPS) is located 10 km away from

Panipat on Panipat-Jind Road. First unit of PTPS was commissioned in 1979, now it

has five generating units with total generation capacity of 650 MW (Four units of 110

MW each and one unit of 210 MW), one more unit of 210 MW capacity is under

construction which is likely to start generating in June 2001. The area occupied by

the power station is about 744 acres in addition to 640 acres for ash disposal. The

power generated at this station is transmitted at 220kV/400kV to grid substation at

Sewah ( near Panipat) from where it is fed to the transmission network of Haryana.

The raw water supply for various plant usages and condenser cooling (circulating

water) is obtained from Western Yamuna Canal. Five operating units are divided into

three stages as below:

Stage-I includes Unit-I and Unit-2 with capacity 2X110=220 MW. Unit I and

Unit-2 were commissioned in 1979 and 1980 respectively.

Stage-11 includes Unit-3 and Unit-4 with generating capacity of

2xll0=220MW. Unit-3 and Unit-4 were commissioned in 1986 and 1987

respectively.

Stage-m includes Unit-5 with generating capacity of 210 MW. This unit was

commissioned in 1990.

Similarly Unit-6 of 210 MW capacity which is under construction is named as

 The station consists of five steam generators with their own turbine, generator

exciter and other auxiliaries on unit basis. The steam generators are of direct fired,

reheat type designed for pulverized fuel (coal) with provision of HSD/HFO/LSHS

firing at startup and low load conditions. Steps have been taken to minimize the

atmospheric pollution due to the boiler flue gases by employing mechanical

separators and employing Electrostatic Precipitator (ESP). Three RCC Chimneys of

91.5m, 120m, 180m height serve the boilers of stage-1, stage-11 and stage-in

respectively and ensure dispersion of pollution over vast area.

The classical static excitation system with AVR has been employed in Unit-I

and Unit-11 while U nit-in, Unit-IV &Unit-V have been provided with complete solid

state excitation system with AVR for smooth voltage regulation.

Unit-I - Unit-4 are each of 110MW and have almost identical constructional

features. A brief technical specification of these 110MW units is as follows.

Each unit can generate upto maximum 26.4 lakh units o f electricity per day (if the

plant load factor is 100%). At average 1800MT o f coal and 350MT o f DM water

used every day in each unit.

Boilers and Auxiliaries

Main Boiler: Boiler supplied by BHEL , Tiruchirapalli, TN has the capacity of 375

t/hr with max design pressure of 158.2 kg/cm2 and temperature 540°C.

Coal Mills: Each unit has five coal mills, four remain in service (for full load) and

one stand by. Each coal mill has Raw Coal feeder (RC feeder) with 20t/hr capacity
and Coal pulverizer with 16.5 t/hr capacity. As a change of design Stage-II (i.e. Unit­

Ill & Unit-IV) has been provided with six coal mills out of which five remain in

service.

Induced Draft Fans (ID Fans): Unit has three ID fans, two remain in service and

one stand by. Each has the capacity of 132 m3/sec. Fan motor is of 600 kW, 6.6 kV

rating.

Forced Draft Fans (FD Fans): Unit has two FD fans. Each with capacity 58m3/sec.

Fan motor is of 300kW, 6.6 kV rating.

Primary Air Fans (PA Fans): Unit has two PA fans. Each with capacity 40m /sec.

PA fan motor is of 750 kW, 6.6 kV rating.

Dust Collecting System: Each Unit has a Electrostatic Precipitator (ESP) for

collecting dust from the emission. Each ESP has a capacity of Gas flow 200 m3/sec

and two parallel gas path. Efficiency 99.52% and treatment time 24.68 sec.

Turbine and Auxiliaries:

Main Turbine:

Make: BHEL, Hyderabad

Rated Speed: 3000 rpm

No. Of Cylinders 3 (HP, MP, LP)

At 110 MW- steam flow at inlet is 364.5 t/hr (pressure -130 atm., Temp. 535°C R/H

535°C cooling water 32°C)

Main OS Pump (Shaft Driven)

Quantity of Discharge 4500 lt./min.

Delivery Head 10-12 atm.

Starting Oil Pump

Number 2Nos. (Each for 100% capacity)

Quantity of Discharge 2000 lt./min.

Head 138 mmWC

Driven Unit Motor 95kW, 3 phase, 1480 rpm.

Emergency Oil Pump

Number Two (each for 100% capacity)

Discharge Quantity 800 lt/min.

Head 23 mmWC

Jacking Oil Pumps

Number 7

Quantity Delivered 10.5 m3/hr

Head 50 atm.

One Common Drive Unit 30 kW, 415 V, 1465 rpm.

Condensate Pumps

Number 3 (2 +1 one standby)

Capacity 160 t/hr

 Motor Rating 225 kW, 6.6 kV, 1450 rpm.

Generator

The rating of main generator is as under

Output 110 MW

Power Factor 0.8 lagging

Rated Vohage 11000 V

Rated Speed 3000 rpm

Phase connection Double Star

Rated Frequency 50

Short Circuit Ratio 0.5

Generator Cooling System Hydrogen Cooled-Rated pressure 2 kg/cm2.

PERFORMANCE ABSTRACT FOR LAST FIVE YEARS OF UNIT I-IV

Table 1.1 Generation (in MU)

Year Unit-I Unit-D Unit-HI Unit-IV

1995-96 257.4 255 237.5 319.10

1996-97 318.2 276.5 274.3 326.74

1997-98 261.7 289.44 403.2 371.35

1998-99 211.2 307.9 268.2 551.68

1999-2000 429.6 - 490.7 490.7

Table 1.2 Plant Load Factor (PLF) in %ge

Year Unit-I Unit-E Unit-Ill Unit-IV

1995-96 26.47 26.47 24.58 32.02

1996-97 33.02 28.70 28.44 33.91

1997-98 27.17 30.4 41.83 38.54

1998-99 21.90 31.96 27.84 57.25

1999-2000 44.47 - 32.81 50.79

Table 1.3 Specific Oil Consumption (kl/MU)

Year Unit-I Unit-H Unit-Ill Unit-IV

1995-96 27.78 38.35 42.16 30.29

1996-97 36.17 44.57 35.08 33.72

1997-98 34.72 38.12 21.64 17.66

1998-99 39.73 32.10 17.28 21.32

1999-2000 13.36 - 14.22 13.57

Table 1.4 Number of Tripping

Year Unit-I Unit-II Unit-Ill Unit-IV

1995-96 54 56 58 46

1996-97 67 84 85 42

1997-98 58 102 80 76

1998-99 110 117 57 135

1999-2000 101 - 70 94
 Unit-5 can generate 50.4 Lac unit every day (corresponding to 100% PLF).

At an average 3500 MT of coal and 650 MT of DM water consumed everyday. A

unit overview of Unit-5 is shown in fig. 1.1 . Brief Technical specifications of this

unit are as below.

Boiler and Auxiliaries:

Main Boiler: Boiler is Natural Circulation, Wet bottom, Tangential fired, balanced

draft, Radiant Re-heat type with direct fired pulverized coal system. Boiler is

equipped with superheater, Economizer and air heaters to improve its efficiency.

Coal Mills: Unit has 6 coal mills (A, B, C, D, E, and F). As per design 4 should

remain in service one standby and one for maintenance but practically 5 coal mills

remain in service. Every coal mill has a Raw Coal feeder of 37.5 t/hr capacity.

ID Fans

Number 3 (2+1 standby)

Capacity 176.8 m3/sec

Pressure 260 mmWC

Motor Rating 1300 kW, 6.6 kV, 750 rpm

FD Fans

Number 2

Capacity 81.2 m2/sec

Pressure 340 mmWC

Motor Rating 750 kW, 3phase, 6.6 kV, 1490 rpm.

 Number 2

Capacity 42.1 m3/sec

Pressure 844 mmWC

Motor Rating 1250 kW, 3 phase, 6.6 kV, 1500 rpm

Dust Collecting System: Electrostatic Precipitator (ESP) has been used to collect

the dust from the emission before it reaches the stack. The rating of the ESP

installed are as under

Gas Flow rate 350 m3/sec

Temperature 140 C

Dust Concentration 32.83 gm./Nm3

Number of Precipitator 2 Nos.

Number of parallel gas path 4

Number of field in series in each gas path 7

Heavy Oil Guns:

Boiler is equipped with 12 number of Heavy Oil guns to support the coal mills

. These HFO guns are tilting, tangential, Steam atomized, air cooled type. 12 Guns

are located in Four Corners of three elevations (Elevation AB, CD & EF). Oil firing

rate is 750 to 1000 kg/hr/gun and the pressure is 4.5 to 6.0 kg/cm2.
Turbines and Auxiliaries:

Main Turbine: The turbine is of Tandem Compound design. It consists of modules

for HP, IP and LP Turbine. The HP turbine is single flow type whereas the IP & LP

are of double flow type. It is basically engineered on reaction principle with throttle

governing.

Make: BHEL (KWU design)

Rated Speed 3000 rpm

Rated Power 210 MW

Overall Length 16.975 mt.

Overall width 10.5 mt.

Turbine Oil System:

Servo prime 46 oil is used for Governing and lubrication system where as

Servo Vonvel 46 for HP bypass system. Specific gravity for this oil at 50 C should

0.852.

Auxiliary Oil Pumps:

No. of AOP 2

Capacity 282 m3/hr

Discharge Pressure 6.8 bar

Motor details 90kW, 415 V, 1480 rpm

Jacking Oil pumps:

 Capacity 4.54 m /hr

Discharge pressure 120 kg

Motor details 30kW, 415 V, 2950 rpm

DC Emergency Oil pump:

No. of EOP 1

Capacity 108 m3/hr

Discharge pressure 2.3 bar

Motor Details 13 .6 kW, 220 V DC, and 1450 rpm

Main oil pump(Shaft Driven):

No. of MOP 1

Capacity 500 m3/hr

Discharge Pressure 8.5 kg/cm2

Condensate System

Condenser

Design CW Temp 36°C

CW flow quantity 28,500 m3/hr

Condensate Extraction Pump

No. of pumps 2 (1+1 standby)

Design capacity 634 t/hr

Motor rating 435 kW, 3phase, 6.6 kV, 1480 rpm

 Circulating Water Pump (CWpump)

Number 3 (2+1 standby)

Capacity 15000 m3/hr

Discharge Head 23.5 mmWC

Motor Rating 1265 kW, 3 phase, 6.6 kV, 500 rpm

Boiler Feed pump (BFP)

Number of pumps 3 (2+1 standby)

Capacity 389 m3/hr

Differential head 2096 mm

Motor rating 3500 kW, 3 phase, 6.6 kV, 1485 rpm

Regenerative System: To improve the efficiency of the system one Drain

cooler, Three LP heaters, Two HP heaters, one Gland steam condenser, one Dearator

used as a part of close condensate cycle. Their purpose is to increase the temperature

of the water, which is taken from the hot well and fed back to the boiler drum.

ELECTRICAL SYSTEM

Generator:

Max. Continuous kW rating 210 kW

Rated terminal voltage 15.75 kV

Power Factor 0.85 lagging

Excitation current at MCR condition 2600 Amp

Excitation voltage at MCR condition 310 V

Phase connection Double Star

 Cooling Medium Rotor-Hydrogen cooled

H2 pressure 3.5 kg/cm2

Stator-Water cooled (27m3/hr &

3.3 kg/cm2 of DM water)

Generator Transformer

Make BHEL

Type of cooling OFAF

Capacity 240 MVA

Voltage rating 15.75 k V /240 kV

Connection symbol Y -n d l

Oil Quantity 65,805 kl.

Station Transformer

Make BHEL

Type of Cooling ONAF

Rating 40 MVA ^

Voltage Rating 220 kV / 7 kV

Unit Auxiliary Transformer (UAT)

Number 2

Make BHEL

Type of Cooling ONAF

MVA Rating 15 MVA

Voltage Rating 15.75/7 kV

The performance abstract of Unit-5 for the last five years is tabulated as below:

TaWe 1.5

Year Generation PLF (%) Sp.Oil No. of Auxiliary

(MU) consp. Tripping Consp (%)

1995-96 1196.21 64.87 7.48 53 10.35

96-97 1558.10 84.0 5.40 65 11.03

97-98 1543.10 86.89 2.56 47 11.05

98-99 1317.18 71.6 2.35 37 . 10.62

99-2000 1618.64 87.75 1.71 33 10.27

From the statistics of last five years (Table 1.1-1.5) it is very much clear that the

performance of 210 MW Unit is much better as compared to 110 MW units (i.e. unit

1-4). For example yearly PLF of 110 MW units is around 35% whereas that of 210

MW is more than 80%, specific oil consumption for 110 MW unit is around 30

KL/MU where as that of 210 MW is 3-4 kl./MW, No. of Tripping for a 110 MW unit

is around 100 per year and that of 210 MW unit is 40 per year. Auxiliary

consumption of 110 MW unit is around 13% where as Auxiliary consumption of 210

Table 1.6 Comparison

110 MW Unit 210 MW Unit

PLF (%ge) Around 35% More than 80%

Specific Oil Consumption 30 kl/MU 3-4 kl/MU

No. of Tripping (per year) About 100 About 40

Auxiliary Consumption (%) 13% 10-11%

Reasons of better performance of 210 MW Unit-V as compared to other units of

PTPS are technological advancement, greater degree of automation. However, aging

factor may also be playing its part in the performance of old 110 MW units.

One main area of the technological advancement is in the field of Control and

Instrumentation (C&I). Electronic Automation of Steam Turbine (EAST) is the result

of technological advancement in C&I. 210 MW, Unit-V is being provided with

EAST package.

This work is carried out to study the various aspects of EAST package such as

Construction, Working principle, performance, problems faced and their solution.

Chapter 2 is devoted to study the EAST package starting with the Introduction

of this Package. Chapter deals with all the important features of this package such as

Turbine Stress Evaluator (TSE), Electro-Hydraulic Controller (EHC), Automation

Turbine Run-up System (ATRS), Automatic Turbine Tester (ATT), LP bypass and

gland steam controller, Turbine protection, Turbo Supervisory system and load

shedding relay.

In chapter 3, Few problems faced in the operation of the system are

discussed. Suggestions for the solution of these problems and results there of are also

briefly discussed.
DIAGRAM NUMBER * 2000 VERSION
 CHAPTER-2

EAST Package

2.1 INTRODUCTION: The ever increasing size of Thermal Units, plant complexity

and operation at higher optimal steam pressure and temperature demand considerable

increase in the role of control and instrumentation. The C&I system being provided

along-with steam turbine to KWU design has been developed to meet such demands.

The system was earlier called ATRS (Automatic Turbine Run-up System). It

includes only binary control like alarms, protection, interlock and above all automatic

run up system for barring gear, vacuum pulling and Turbine rolling. All these

function called ISKAMATIC B. Later on advance features like

S Turbine Stress Evaluator (TSE)

S Electro-Hydraulic Turbine Control (EHC)

S LP Bypass and Seal Steam Control

were introduced. These features are called ISKAMATIC A functions.

Both ISKAMATIC-A and ISKAMATIC-B are integrated as ISKAMATIC

and given a trade name as EAST (Electronic Automation of Steam Turbine).

EAST as an integrated system for power station automation offers

miniaturization, greater security and reliability and simplicity of operation and

maintenance. The system consist of followings

1. Turbine Stress Evaluators (TSE)

2. Electro-hydraulic Controller i.e. (EHC)

3. Automatic Turbine Run-up System (ATRS )

4. LP bypass and Gland seal steam controls

5. Automatic Turbine Tester

6. Turbine Protection

7. Vibration and Expansion measurements Load Shedding Relay

8. Load Shedding Relay

2.2 TURBINE STRESS EVALUATOR (TSE)

rT i* n< '

During Startup and loading operations of the steam turbine,^required to attain

full load keeping the stresses on the turbine components within permissible limits is

of prime importance. TSE is specifically designed for achieving the above objectives.

During changes in operation of the turbine, the internals of the turbine are subjected

to temperature fluctuations resulting in thermal stresses. The maximum thermal

stress is proportional to the difference in the temperature at the surface on the steam

side and the mid wall temperature. This difference is compared with the permissible

temperature difference, which is determined, on the basis of estimated load cycle on

turbine, thermal fatigue, strength of material, and the geometry of the components.

The difference between permissible temperature difference and the actual temperature

difference is known as permissible temperature margin. The margins are evaluated in

an analogue computing circuit and displayed on the instrument as upper and lower

temperature margins upto the stage of synchronization, and as load margins during

subsequent loading. The display also indicates the component, which is critical at
TSE system consists of following five computing channels

> Main stop valve

> Intermediate pressure shaft

> High pressure casing

> High pressure shaft

> Control Valve

Channels 1 & 5 are from the steam admission area and channels 2,3 &4 are

from the turbine area.

NiCr-Ni thermocouples are used for measuring the surface temperature near

steam 0; and mean temperature (midwall temperature) 0m for the above five channels

mentioned. But for the channels 2 & 4 the mean shaft temperature 0m is derived by

computation from 0*. The output of thermocouple is fed for analog signal

conditioning. Where it is converted into 4-20 mA signal and fed to TSE. The actual

load of the turbine generator set Pad is measured separately and a current signal of 4­

20 mA is available for load indication and computation of load margin . The speed is

also measured separately and 4-20 mA signal is available for display in the TSE

indicator.

The thermal stress of HP Shaft and IP shaft is monitored indirectly by

computing the mean shaft temperatures. The steam temperature representing the

surface temperature of the shafts are measured at suitable locations and they are

further processed electronically to derive the mean shaft temperatures. The

schematic arrangement of mean shaft temperature derivation by simulation is shown

in fig 2.1.

The temperature margin for turbine shaft is computed from the difference in

shaft surface temperature and simulated mean shaft temperature. Turbine stress

evaluator predetermines the constraints only from thermal stress consideration. Other

vital turbine parameters like differential expansion axial shift etc. are to be considered

separately before deciding on steps to be taken in actual operation.

The permissible temperature margins are converted into permissible load

margins with the help of mechanical stress calculations for on load operation of the

TG set. The available temperature margins are converted into corresponding load

margins by TSE circuitry with the help of mathematical algorithms. These load

margins are the guiding factors to further load or unload the TG set on both manual

and auto mode.

Principal of Operation:

In each computing channel the difference between 0m and 0i (0m is actual

temp.at 50% depth and 0i is actual temp, at 100% depth) is calculated as D0 and this

is compared with the permissible upper and lower temperature difference D0uper and

D0i per which are dependent on the midwall temperature and are derived from the

function generators. The difference of D0uper or D0iper and D0 are the available

temperature margin D0u and D0j. The lowest of the respective upper and lower

temperature margins of admission area and turbine areas are selected for display and
for further processing. Fig above gives the maximum permissible temperature

difference allowed versus Bm- These curves depend upon the thickness of the material

at the point where we are calculating margins and as well as on material composition.

Hence all the five channels of the TSE have different curves. The basic philosophy

for computing the margins remains the same. For example refer figure above

0i = 280°C -> Actual temperature at 100% depth

em= 250°C -> Actual temperature at 50% depth

so e=(e,-em)=280- 250=30°C

From the curves when 0mis 250°C

Maximum upper permissible difference=60°C

Maximum lower permissible difference=80°C

The maximum upper margin=60-30=30°C

The maximum lower margin=-80-30=-l 10°C

9imaX-280+30=310°C

©**,=280-110=170°C
It means that 0j can be increased by 30°C safely. This is known as upper margin.

Similarly 0; can be decreased by 110°C safely and this is known as lower margin.

Temperature margin for all the five channels are calculated in the similar way and the

minimum upper margin and minimum lower margin of all the five channels is

selected separately and fed to EHC for controlling the rate of rise of speed and rate of

rise/fall of load (rate of fell of speed can not be controlled as it will come down on its

own after trip out or closing the valves).

Influence of margin during Rolling:

The rate of rise of speed is controlled by TSE margin

0 to 30°C = 0 to 600 rpm/min

If margin is more than 30°C speed increases at a constant rate of 600rpm/min,

between 0-30°C rate of change of speed is directly proportional to margin.

Speed increases 600 rpm/min if margin > 30°C

Speed increase a margin if margin<30°C

Influence of Margin during Load: During loaded condition the rate of rise of load

depends upon upper margin and rate of decrease of load depends upon lower margin

0 to 30°C = 0 to 25 MW/min

If margin is more than 30°C load will increase / decrease at a constant rate of

25MW/min, between 0 - 30°C of margin the rate of change of load is directly

proportional to margin.

Rate of increase of load = 25 MW/min if margin >30°C

Rate of increase of load a margin if margin < 30°C

TSE Display

The TSE indicator has two separate sections one for starting upto

synchronization stage and other for on load conditions (Fig.2.2 ). The sections are

illuminated according to the operating mode. The sector shaped aperture formed by

two semi circular disc displays margins. The top rectangles get illuminated and

indicate the component, which is the cause for imposing the minimum margin. The

upper boundary of the transparent sector indicates the upper margin for startup /

increasing load and the lower boundary indicates lower margin for decreasing load /

lowering of speed.

During speeding up and upto synchronization, the marking on the white scale

indicate the actual speed of the set. The aperture formed by the red disc indicate the

safe temperature margins (in Kelvin) in which components remain stressed within the

permissible level only. These indicated margins along with the actual metal

temperature help to assess the matching steam temperature requirements prior to

rolling correcting action has to be taken when the margin narrows down or becomes

zero.

During on load operation the display indicates the load range in which the

output can be altered without any restriction on the rate of load change.

2.3 ELECTRO HYDRAULIC CONTROL (EHC)

KWU design steam turbines are provided with hydraulic as well as Electro

hydraulic governing systems. The addition of EHC enables the operation of the turbo

set in interconnected grid system, with precise maintenance of rated frequency of the
grid by means of exact frequency load characteristics with good response, reliable

operation of isolated power grid, reliable control during load rejection, low speed

deviation under all operation conditions, safe operation in conjunction with Turbine

Stress Evaluator etc. Normally EHC will be in action while hydraulic controller

serves as a back up system.

EHC mainly consists of

S Equipment for obtaining various inputs i.e. measuring devices

S The electrical control system incorporating the power supply, sub controller for

valve position, speed, load and steam pressure.

Principle of Operation: The functioning of the speed control are, start up and shut

down of the turbine, synchronizing, bringing to house load operation on load

shedding, limitation of turbine speed before reaching the overspeed protection limit

and for load control when necessary. 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 output.

The EHC governing system essentially consists of following three control loops

• Speed control loops

• Load control loop

• Pressure control loop

These control loops essentially influence the steam control valves actuated by

Electro-hydraulic converter and valve lift controller. Fig.2.3 Shows the schematic

diagram of Electro-hydraulic Controller.

 Speed control loop is formed by a speed reference limiter and speed

controller. The integrated function of the blocks is explained below:

Speed Controller:

The speed controller 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 value lift controller.

The actual turbine speed rw ai is acquired by three digital speed pickup

system based on the hall probe principle. The output of each pick up is 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 on to the other channel.

The speed reference is generated by the speed reference limiter control loop. The

desired reference speed is set with the help of a potentiometer remotely from control

desk or manually from the panel. In the speed reference limiter the reference speed

signal is juxtaposed with the output from the turbine stress evaluator 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 separation

of the turbine. After attaining the target reference speed the output of the speed

reference limiter is held constant. The output of the speed reference limiter is
automatically blocked in the event of a fault in the turbine stress evaluator and the

speed of the set cannot be changed until and unless TSE is suitably disconnected.

The speed controller exhibits a steady state proportional control to form the necessary

droop characteristic. The dynamic response is improved by the addition of

Proportional Integral (PI) and differential (D) elements.

Load Control:

The load control loop consists of load reference setter, frequency load droops and

load controller. The load controller is designed for two modes of operation

• Operation in conjunction with power system with PID characteristics and

• Isolated operation with PI control characteristics based on the frequency of the

isolated power system. .

The output of the power controller acts along with other controllers in a selection

mode on the Electro hydraulic converter and thus acts on the turbine control valves.

Measurement of Load:

The measuring system consists of three independent channels and transmitted

to load controller via a selection circuit. The system is connected to PT’s and CT’s of

the generator. Solid state multiplicator based upon Hall effect are used for

multiplication in the device.

Load reference signal PR is generated in potentiometer module similar to

speed control. The load reference limiter generates the time dependent load reference

signal PRiim, which is fed to the load controller. The signal rises (during building up
of load) at a rate MW/min selected through load gradient setter until PR is reached.

The rate of change is subject to limiting by TSE margins.

The PR controller consists of a proportional channel parallel to PI channel. This

enables the response of the controller to be proportional for small changes of load

reference signal and PI for large changes. TSE limiting is effective irrespective of the

type of control action. To limit the total power delivered by the turbine the system is

equipped with maximum load reference limit Pmax which has priority over all other

influences acting directly or indirectly on the valve lift controller. To enable smooth

transition from speed controller (during start up) to load controller (after

synchronization) matching of the integrator output signal with actual power output is

done by an automatic circuit.

Frequency Influence:

Frequency dependent load variation based on frequency versus load curve is

achieved by means of adding additional signal PRAf is generated by the frequency

unit. The droop characteristic of the frequency controller can be varied from 2.5 to

8% in the steps of 0.5%.

Isolated grid operation: The load controller automatically switches to a proportional

response with 5% droop during isolated grid operation.
All load reference signals described so far are summed up in the load controller
(ZPR). The load controller comes in to action only when the turbine is synchronized
and the block loading have been achieved. Speed controller and load controller
signals are transmitted to valve lift controller through Max and Min selection circuits.
Pressure Control:
 Pressure control can be operated on initial pressure control mode or limit
pressure control mode by selection from desk. When the pressure controller is not
effective, its output corresponds to maximum valve opening . As the steam working
condition approaches the working range of controller, tracking to a preset take over
margin is effected, so that the pressure controller can rapidly assume control of the
valve. When the pressure controller controls the valves the load controller is tracked
as per pressure controller. The power delivered by the Turboset is decided by the
boiler steam pressure.
In the initial pressure control mode the set pressure is predetermined with
respect to load in a characteristic form. During initial startup, for example, for a
pressure of 30kg/cm2 20MW load is maintained and for change of 30kg/cm2 to
150kg/cm2 a change of load from 20MW to 150 MW is envisaged. Any deviation
between the reference pressure valve and actual pressure valve is corrected by
regulating the power output.
In the limit pressure control mode, the pressure controller influences the main
steam control valve to support boiler pressure control, only if a preset MS pressure
deviation is exceeded say by 10kg/cm2 as per the characteristics. This provision
allows the load controller to handle small quick load variations until the pick up limit
of limit pressure control is reached.
When the turbine is in operation, one of the three controllers (Speed, Load and
pressure) will be exercising the control and other will be matched continuously for
quick transfer. The speed and load controllers are tied up to a maximum selector
circuit. The output of this circuit is compared with the sum of speed and 100% load
signal via a Min selection circuit to avoid erroneous load control signal. The speed/
load control signal is compared with pressure control via a Min selection circuit.
In case of sudden separation of the loaded Turboset from grid 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 the speed controller assumes control
and returns the turbine back to the reference speed. This provision improves the
dynamic response of the closing of the main stream control valves and keeps the
turbine speed form rising along the droop characteristic.
Valve Lift Controller The input of the valve lift controller is continuously
compared to actual valve lift (feedback signal) and error signal transmitted to the
EHC
The feed back signal representing the valve lift is derived form position of the
Electro-hydraulic converter plunger as an analogue valve from the differential
transformer type transformer. 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 the valve lift controller
are proportional integral and differential type (PI-D) and this ensures high over all
sensitivity and improves transient response.
2.4 Automatic Turbine Run-up System (ATRS)
A successful startup of the turbine normally requires acquisition analyzes and
collation of wide variety of information pertaining to various parameters like speed,
steam temperature, vacuum, oil pressure, warm up condition of turbine and pipe lines.
Apart from this, it is important to know whether vital auxiliary equipment is on
automatic control loop or not. It is an ardous task for the operator to handle and
collate so many bits of information swiftly and correctly. Automatic run-up system
relieves the operator of arduous tasks of operating large number of equipment in
surveying and analyzing various parameters and this enables him to effectively attend
to performance of main equipment. .
ATRS- in conjunction with Turbine Stress Evaluator (TSE) and Electro-hydraulic
Controller (EHC) accomplish the various functions. TSE computes permissible
temperature margins and control the acceleration rate, duration of hold at lower speed
and rate of loading on the basis of actual metal temperature of the critical
components. ATRS takes into account the dynamic condition as existing at any given
point of time or thermal state of turbine and provides a continuous control signal to
EHC.
Auto turbine Run-up system is based on functional group philosophy i.e. the mam
plant is divided in to clearly defined sections called functional groups such as oil
system, vacuum system, and Turbine system. Each functional group is organized and
arranged in sub group control (SGC), Sub-loop control (SLC) and control interfaces
(Cl). Fig 3,4 Shows hierarchy of control. Functional group continues to function
automatically all the time demanding enable criteria based on process requirements
and from neighboring functional groups if required. In the absence of desired criteria,
the system will act in such a manner as to ensure the safety of the main equipment.
Sub-Group Control:
A Sub-group Control(SGC) executes commands to bring the equipment upto a
particular defined state, and contains the start up and shut down programme of the
respective group. SGC issues commands either to control interfaces level or switches
on SLC. Desired number of criteria act as precondition before the SGC can take off
to execute its defined programme. F igi5 Shows subgroup control structures. Fig^L6
Shows operator interface to subgroup. The program comprises of steps. For each
step there is a provision for monitoring time and waiting time. Waiting time implies
that the subsequent step could not be executed unless the specified time elapsed. The
time between command signal and appearance of check back signal is known as
monitoring time and when it is exceeded alarm is initiated and the program is not
proceeding further. In addition execution of any step is also permitted only if the
conditions specified for that particular step are completed certain tasks manually if so
desired. In addition to the normal sequential start up, the following modes are
possible
> Operator Guide Mode
> Step Mode
Operator Guide Mode: This mode receives the data from the plant but issues no
commands. The commands to the control interface must be issued manually. Useful
for commissioning and training.
Step Mode: This mode enable thie programme to be executed on set at a time, even if
step criteria are absent, and the automatic mode is malfunctioning. This is useful,
when system criteria have been met and cannot be processed due to transmitter
malfunctioning.
Control Interface: (Cl)
The control interface is the keystone in a modular control system, whose
primary purpose is to provide reliable and accurate control with self checking of all
essential functions. The control interface modules forms the link between the
individual commands and the power plant. Each remote controlled drive has a
control interface module. The module consists of command section, monitoring
section, power supply and alarm section. The command section processes the control
commands according to their priority and validity and passes actuation signals to the
interposing relays in the switchgear. Solenoid valves can be actuated directly upto
certain capacity (36W). The monitoring section mainly checks the command
functions, the position of the drive and the check back signals and transmitters to the
desk, protective logics and SGC.
Sub-Loop Control: (SLC)
Subsidiary functions within technological subgroups are automated employing
sequence control. Sub loop control contains only a part of the automatic operation of
a subgroup. The design is based on exclusive logical functions and suitable for
simple sequential procedures where short times are involved. Normal operation is
also possible. When SLC is switched on, it actuates the connected mechanical
equipment to the required operating condition as per the process condition. No
sequence logic is involved. SLC can be switched ON/OFF either manually or
through SGC.

At P.T.P.S Unit-V automatic turbine run-up system (ATRS) consist of three subgroup

controls (SGCs) viz.

 1. Condensate and Evacuation system

2. Oil supply system

3. Turbine system

SGC for Condensate and Evacuation System

The logics of Sub-Group Control (SGC) for condensate and evacuation

system accomplishes its task which comprises of keeping at least one of the two

condensate pumps in operation, evacuation of non condensible gases from the system,

maintaining the desired level of condenser pressure when the turbine is in operation

and breaking the vacuum as and when required by the mechanical process through

sub-loop control (SLC) namely

SLC Drains

SLC condensate pumps

SGCfor Oil Supply System

The logics of sub groups control for oil supply system perform its task

comprising starting relevant oil pumps ensuring turning of the Turbine as and when

demanded by the process and ensuring lubricating oil at a predefined temperature

under various conditions. The programme is accomplished through a number of steps

and seven SLCs namely

a) SLC Auxiliary Oil Pump-I

b) SLC Auxiliary Oil Pump-II

c) SLC Emergency Oil Pump-I

d) SLC Jacking Oil Pump-I

 e) SLC Jacking Oil Pump-11

f) SLC Auxiliary Oil Pump-1

g) SLC Oil temperature controller

h) SLC Turning Gear

SGC for Turbine:

The logics of subgroup control for turbine during start up execute the task

which comprise of warming the turbine, speed increase, synchronization and

subsequent block loading through a number of sequential steps and sub loop controls

(SLC) namely

SLC fo r Drains

SLC fo r warm-up controller

This subgroup control also shutdown the turbine, which comprises unloading, closure

of steam supply to turbine, isolation from grid and bringing the turbine drains to the

desired position.

SGC Condenser & Evacuation(Startup Program)

Permissive

Any Seal Steam Condenser Exhaust ON

Hot well level Normal > 100mm

Main ejector-A Air inlet valve Open

Main ejector-B Air Inlet Valve Open

Air Header - 1 IV Open

STEP-14

Condenser Vacuum <0.88 kg/cm

STEP-15

Main Ejector-A Steam IV Open

Main Ejector-B Steam IV Open

The program will return back to Step-12 if condenser vacuum > 0.88 kg/cm

SGC OIL SUPPLY (Startup Program)

Permissives:

Any Oil Vapor extraction Fan ON

MOT level or OK

Oil Pressure >4.8 kg/cm2

STEP-1

Waiting Time Over

STEP-2

Any Auxiliary Oil pump (AOP) ON

Or

Turbine Speed >2850rpm

Oil Pressure >4.8 kg/cm2

STEP-3

SLC Oil temerpature control ON

Generator Seal Oil Gas DP >0.9 kg/cm2

Generator Seal Oil Pressure-TS >3.8 kg/cm2

Generator Seal Oil Pressure-ES >3.8 kg/cm"

H2 Purity >97%

Generator Gas Pressure >3.4 kg/cm'

Liquid in Generator Not Present

STEP-4

Gate Valve gearing, or Open

Turbine Speed >250rpm

SLC Turning Gear ON

STEP-5

SLC AOP-I ON

SLC AOP-II ON

SLC EOP ON

SLC JOP-I ON

SLC JOP-II ON

Turbine Speed >15rpm

STEP-6

Turbine Speed >540rpm

STEP-7

JOP-I OFF

JOP-H OFF

Gate Valve gearing Close

STEP-8

Turbine speed >2850rpm

Oil Pressure >7.0 kg/cm2

STEP-9

Both the AOPs OFF

STEP-10

Waiting Time -10 secs., or Over

Generator Load > 10%

AOP-I OFF

AOP-II OFF

EOP OFF

COMPLETE

The SGC program will revert back to step no. —1 if the turbine speed

510 rpm at step no. 8 or the speed is less than 2800 rpm at step no. 11.

TURBINE SGC (Start-Up Program)

Permissives:

Starting Device 0%

Generator Field Breaker OFF

Generator Circuit Breaker OFF

MAL-11 Drain Not Closed

MAL-12 Drain Not Closed

Limit Pressure Operation ON

Load Controller ON

Synchronizer OFF

AOP Header pressure >7.2 kg/cm

STEP-1

SLC Drains ON

All ESV’s Closed

HPCV-1 Close

HPCV-2 Close

IPCV-1 Close

IPCV-2 Close

NRV, CRH, L/H Close

NRV, CRH, R/H Close

Extraction Values A2 to A5 <5%

STEP-2

Trip Fluid Pressure >5 kg/cm2

Turbine Speed >15rpm

CEP’s Discharge Pressure >22 kg/cm'

SLC Drains No Fault

DT HP casing Top/Bottom <+40K

DT IP casing Front Top/Bottom <+40K

-do- >-40K

DT IP Casing Rear <+40K

-do- >-40K

STEP-3

MAL-11 Drain Close

MAL-12 Drain Close

SLC warm up control OFF

STEP-4

Fire (Boiler lighted up) ON

Steam before HPBP-I -S/H >30K

Steam before HPBP-2 -S/H >30K

Steam before LPBP-I -S/H >30K

Steam before LPBP-2 -S/H >30K

DT HPBP -1 Control Valve >X 1.1

DT HPBP -2 Control Valve >X 1.2

Total Steam Flow >15%

Drain Values before HPESV’s Not Closed

Drain Values before IPESV’s Not Closed

Oil Temperature after cooler >35°C

STEP-5

Starting Device >42%

HPESV1/HPESV2 Not Closed

STEP-6

HPESV-1 Open

HPESV-2 Open

STEP-7

Total Steam Flow >15%

Steam before HPBP-I -S/H >3 OK

Steam before HPBP-2 -S/H >3 OK

Steam before LPBP-I -S/H >3 OK

Steam before LPBP-2 -S/H >3 OK

Fire ON

DT HPBP -1 Control Valve >X 1.2

DT HPBP -2 Control Valve >X 1.1

Condenser Pressure <0.5 kg/cm

STEP-8

SLC warmup control ON

STEP-9

Tracking Device ON

IPESV-1 Open

IP ESV-2 Open

Step-10

SLC Drains Not Fault

Speeder Gear 100%

Gland steam pressure control ON

SLC oil temperature control ON

Any oil vapor extraction fan ON

H2 purity >97%

Generator gas pressure >3.4 kg/cm'

Generator seal oil gas DP >0.9 kg/cm'

Generator seal oil TS Pressure >3.8kg/cm'

Generator seal oil ES pressure >3 .8kg/cm

Oil Level in pre chamber of seal oil tank <max

Generator stator cooling water flow >21 m3/hr

Stator Water pressure >2.4 kg/cm

Stator water Inlet temperature <44°C

H2 cooler CW pressure >2.5 kg/cm'

Liquid in Generator Casing NO

Conductivity of Distilled water <5 no

STEP-11

Generator Conditions Fulfilled

Steam before HPESV1 -S/H >X 4.1

Steam before HPESV2-S/H >X4.2

DT HPESV-1 HP casing >X 5.1

DT HPESV-2 HP casing >X 5.2

Turbine Speed > 15rpm

DT LPBP-1 -IP Casing >3 OK

DT LPBP-2 -IP Casing >3 OK

Steam temperature before LPBP-1 >400°C

Steam temperature before LPBP-2 >400°C

MAC-11 Drain Not Closed

MAC-II Drain Not Closed

Power Set Point > 10%

Condenser Pressure <0.2 kg/cm2

Relative Expansion Casing IF <+8mm, >-2mm

Relative Expansion 2RE <+8mm, >-2mm

Relative Expansion 3RE <+8mm, >-2mm

STEP-12

Turbine Speed Set point >650rpm

STEP-13

Turbine Speed >600rpm

STEP-14

Wall temperature HP casing >200°C

DT HPBP -1 HP shaft <X 6

Turbine Stress margin >3 OK

Bearing Vibration Casing IF <35 micron

Bearing Vibration Casing 1 RE <35 micron

 Bearing Vibration Casing 2 RE <35 micron

Bearing Vibration Casing 3 RE <35 micron

Bearing Vibration Generator FV < 50

Bearing Vibration Generator FH <50

Bearing Vibration Generator RE V <50

Bearing Vibration Generator RE H <50

Vibration HP Shaft FR <120jj.

Vibration HP Shaft RE < 1 20jn

Vibration LP Shaft FR <120|u

Vibration LP Shaft RE < 120(j.

Relative expansion < max

STEP-15

SLC Warm-up control OFF

STEP-16

Turbine speed set-point >3036 rpm

STEP-17

Turbine speed >2950rpm

Vibration Bearing Generator < max

Vibration Shaft < max

STEP-18

MAL-11 Drain C]osed

MAL-12 Drain CIosed

STEP-19

Both AOP’s OFF

DT LPBP-1 IP Shaft <X7

Generator Condition Fulfilled

Field Flash supply ON

AVR Control supply ON

AVR protection supply ON

STEP-20

Waiting time -15 sec. Over

Generator field breaker ON

Generator Voltage > 95%

STEP-21

Generator Breaker ON

COMPLETE

SGC TURBINE (Shutdown Programme)

STEP-51

SLC Drain ON

STEP-52

Speed Controller ON

Power Set-point, or <0%

Generator Breaker OFF

STEP-53

Turbine speed set-point reduced for lOOsec

STEP-54

Synchronizer OFF

Trip fluid pressure <5 kg/cm'

Generator field breaker OFF

All stop valves Closed

Tracking device OFF

STEP-55

Drain Bef. HPCV-I (MAL-11) Open

Drain Bef HPCV-2 (MAL-12) Open

Starting Device 0%

SLC Drains No Fault

SLC Warm-up controller OFF

STEP-56

COMPLETE

2.5 LP Bypass System & Gland Steam Control

Low pressure bypass system enables to establish an alternative path for

dumping the steam from reheater outlet directly into condenser at suitable steam

parameters bypassing the IP and LP turbines

 LP bypass controls are engineered to dump the excess steam present in the

reheat circuit due to its large time constant during transient non steady state. LP

bypass valves get opened and dump steam to condenser to such an extent as to

maintain the reheater pressure at a value derived form the criteria representing the HP

turbine flow conditions at any given instant during load changes. This control

criterion ensures that only the requisite flow is maintained through the IP and LP

turbines. The control of LP bypass system is hooked up by same control oil /fluid

which is envisaged for the turbine governing system.

LP bypass system works in conjunction with HP bypass system as and when

necessitated by system requirements such as warming up stage or dumping of large

quantity of steam following a heavy load rejection.

LP bypass control system is to regulate the pressure in the reheat system under

specified operating conditions. The schematic of LP bypass system is given in fig2.7.

Since the reheat pressure is a function of steam flow, tie referdnce varkable fop the

elgctronic controloer is ddrived fsom the pressure#before the HP wkeel chalber.

Dwring st'rtup ang shut dlwn a fixed set point is employed instead of variable set

point. If the reheat pressure exceeds the set#value the electsonic coltroller#actuatep

the Elgctro-hydraulic convertes to opesate and initiatg bypass operatimn.

Prespure traosducers are useg for acruisitioo of rehdat pressure (actual valve) and mf

the psessure 'head of#HP drum!blading#for derhvation mf the sdt-point/ The

pqessure wransducdr generctes a ctrrent skgnal 4-00 mA proportion' 1to the pressure.
The set point values ( a fixed set point and a sliding set point) which are selected

depending on the operating condktions, 're utilkzed whepeby the higher of the two

values acts on the controller. The fixed set point can be adjusted from the control

room between zero and 20% of the maximum reheat pressure/ The sliding set point is

deriwed from the pressure bedore the#HP drump blading by meals of mawching

alplifier#and a ftnction generatop. A vasiable upper pressure lilit for vhe set point

is#also prlvided b{ the me ns of wkich the set poiot is lilited a walue below the

setting If the rgheat sadety valwes.

To protect whe conddnser agcinst exaessive steam innet tempgrature tnder bysass

condition, whe bypaps values are cllsed wheo the sev permissible telperature is

excdeded. Whe wall temperawure of the condenser is measured by two

thermocouples If the temperature exceeds 90°C, a memory is latched and solenoid

valve in the signal fluid line of the LP bypass is moved to reset position, as a result of

which the bypass stop valve is closed. As a measure of additional protections,

protection devices, causing the closure of! bypass ptation kn case If following

eveltualitifs

• Condelser Vacwum low

• Ppray wawer prespure is oow

• Contpol faulw

Gland Peal Stecm Contrll Systeo

This pystem eosures the sealiog of gl'nds in KP, IP aid LP tusbines ulder

varkous load conditions.

Tfad turbine glands are self seal type upto 40% load steam from auxiliary source

through steam supply valve (MAW-10) is taken to seal the HP, IP and LP glands.

During this period the valve (MAW-50) connecting this header to condenser is kept

closed. After 40% load, valve (MAW-50) open and MAW-10 closed. System is so

designed that leak off steam from front and rear end of HP turbine goes to the

condenser through valve MAW-50 while steam from the two IP glands is utilized for

sealing the LP glands.

Fig 2.8 Shows the schematic diagram of Gland Seal Steam Control system. This seal

steam header pressure is sensed by the pressure transmitter and converted into 4-20

mA (-10 to +30m bar). The reference value for steam pressure can be set by means of

potentiometer on the controller (0-20mbar). This is compared with the actual value.

The deviation is fed to the PI controller via progressive static characteristics (not

shown). This enables fast action in the event of large disturbance e.g. a load throw

off. For small deviation upto lmbar, the characteristic is chosen to ensure stable

control under all operating conditions. Remote control manual operation of the valve

is possible when the controller is switched off. Bumpless transfer from auto to

manual and vice-verse is possible due to provision of tracking circuit.

The output of the controller is used for deriving valve position reference through a

valve position reference module. When the controller is off the output signal of the

manually operated setter is used for valve position reference value.

For a positive input voltage, the module gives out the position reference value for the

steam supply valve (MAW-10). For a negative input voltage the modules gives the
position reference value for leak steam valve. An overlap is given for stable

operation in the transition zone between steam input and extractions.

The output of the pressure controller is applied through valve position reference

module. Each valve has a PDD position controller in its loop. The difference between

valve position reference valve and the value of the actual valve position is the control

deviation for one position controller. The actual valve position is measured by a

Hall-Effect potentiometer located at the control valve. The output of the position

controller (0-4.8V) is applied to the EHC after power amplification which determines

the position of the valve (0-100%).

2.6 AUTOMATIC TURBINE TESTER (ATT)

Functional groups have been developed for testing at regular intervals the

functioning of stop valves, control valves and protection devices while the turbo set is

in operation. This facility increases the reliability at the same time without

interrupting operation of the Turboset. The ATT has been divided into two subgroups

• Subgroup Safety devices

• Subgroup Stop and Control Devices

Only one subgroup can be selected at a time. The test programme will be

discontinued in case of a fault and automatically revert back (reset)

Subgroup safety devices incorporate subgroup test for testing

• 1st remote trip device (solenoid Valve 1)

• 2nd remote trip device (Solenoid Valve 2)

• Over speed trip devices

• Hydraulic vacuum trip

• Thrust bearing trip devices

An alternative trip oil circuit is established for the duration of testing of the

safety devices in order to ensure tripping of the turbine if called for during testing.

The successful completing of the tests are concluded from the check back signals of

oil pressure and other conditions. Associate annunciation are also activated enabling

alarm testing also

Subgroup Stop and Control Valves: HP/IP stop and control valves are the final

control elements of the safety devices and hence their serviceability is important as

that of safety devices.

Their subgroup consist of subsets

• HP Stop and Control valve -1

• HP Stop and Control Valve-2

• IP Stop and Control Valve-1

• IP Stop and Control Valve -2

One of the major test requirements is that the output of the Turboset must be

less than maximum load as it calls for closing of one valve at a time.

2.7 TURBINE PROTECTION SYSTEM:

The function of the turbine protection system is to close the turbine

emergency stop and control valves as soon as any condition occurs which causes

danger to the turbine. The command from the protection system goes to the trip
solenoids, which reduces the trip oil pressure to zero. Reduction in trip oil pressure

closes the stop and control valves. The pressure of the trip oil can also be reduced

directly be means of hydraulic protection devices. Turbine electrical protection

system has two independent channels, which gives command to two independent

solenoids. The response of one of the solenoid valves is sufficient to trip the turbine

The protection system is a combination of two subsystems.

1. Hydraulic/Mechanical Trip

2. Electrical Tnp

Hydraulic / Mechanical Trip: Hydraulic / Mechanical trip devices directly reduce

the Auxiliary trip oil pressure which in turn reduces the trip oil thus closing stop and

control valves.

Hydraulic /Mechanical trip includefollowing trips

Over-Speed Trip: This protective device is used to prevent inadmissible high

over speed. The turbine trip is initiated when an admissible speed limit (approx.

111%) is exceeded. Trip initiation takes places with the assistance of mechanical

overspeed governors.

Low-Vacuum Trip: In the event of deteriorating vacuum, the turbine trip is initiated

to protect the condenser from over pressure. In this way the steam supply through the

turbine to the condenser is interrupted. Trip initiation occurs when the admissible

pressure limit (540-mm Hg) is reached.

Axial-Shift Displacement high: When axial shift displacement of the rotor is too

great, which can occur as a result of unacceptable wear of the axial bearing pads, the
turbine is put out of operation in order to avoid damage. Turbine trip is initiated by

the thrust-bearing trip when an inadmissible displacement (1mm) of the rotor in

relation to axial bearing occurs.

Electrical Trips: As mentioned earlier electrical trip system has two independent

channels, which operates two independent solenoid valves. Both the channels are

similar and include following trip conditions

Lubricating Oil pressure low: The supply of the oil to the bearing in endangered

whenever the lubricating oil pressure drop. Hence to prevent damage to bearings

machine is tripped (<1.1 kg /cm2)

Low Vacuum Trip: As explained in Hydraulic vacuum falls below admissible value

(540 mm Hg.) an electrical signal is also generated.

Fire Protection: Turbine trip is initiated with in the framework of the fire protection

measures to stop delivery of oil from the main oil pump (turbine driven) as quickly as

possible.

Fire Off: When “Boiler Fire off“ signal appears, turbine trip is initiated to protect the

steam generator by preventing an admissible drop in steam pressure.

Electrical Generator Protection: Turbine trip is initiated together with the response

of the electrical generator protection, in order to prevent the turbine over-speeding.

Manual Trip: This initiation device enables the operating personnel both during

operational shut down or in the event of detection of failure to trip the stop and

control valve from control room.

Drum level VHI: In the boiler drum - lower half is filled with water and upper half

stores steam. If drum level will become Very High then there may be chances of

intermixing of water into steam which may result into wet steam entry in the turbine

causing serious thermal stresses in turbine metals.

2.8 VIBRATION AND EXPANSION MEASUREMENT

In the operation of large steam turbines certain vital parameters are required to

be continuously supervised and monitored in order to provide information related to

the operational conditions of the turbine during various stages of operation like start

up, loading, load changes and coasting down.

Measurement system for this includes all necessary sensors mounted on the

turbine with flexible leads for connection to junction boxes, circuits for processing

the sensor signal alongwith power supply monitoring , signal level monitors, test

circuits etc., in a cabinet to generate information about the following parameters.

• Absolute bearing vibration

• Absolute Shaft vibration

• Axial shaft position of the rotor

• Relative Expansion

• Absolute Expansion

• Valve position
Absolute Bearing Vibrations Measurement

The seismic mass type pickup is mounted on the bearing pedestal. The

bearing vibrations are transmitted directly to the seismic device.

The device operates on the plunger coil principle. A coil is suspended in an

airgap in resilient way by a spring. The magnetic flux in the airgap remains constant.

The permanent magnet if firmly connected to the housing and to the magnetic return

path. Above the natural frequency, the plunger coil is steady in space due to its mass

- inertia. Thus a fixed point in space is created and vibrations can be referred to this

point. The relative motion between the coil and magnet generates a voltage, which is

proportional to the rate of vibration.

The measurement system is designed to operate satisfactorily over a frequency

range of 16Hz to 200 Hz and measures the amplitude of the vibrational displacement.

The output voltage of the sensor is amplified in a differential amplifier, which

suppresses any interference voltage picked up by the cable. Then the signal is

integrated in an active integrator to form a signal proportional to the vibrational

displacement. It is then rectified and displayed. The range of measurement is 0-100

micron peak to peak.

Absolute Shaft Vibration Measurement:

Measurement of absolute shaft vibration is done by the measuring the relative

shaft vibration with respect to the bearing pedestal and adding the absolute bearing

vibration with it.

 The measurement of relative shaft vibration is carried out in a contactless

manner according to the Eddy Current method. The measuring range is 0-400

microns peak to peak.

Axial Shaft Position of the Rotor Measurement:

This measurement yields information on the position of the shaft in the thrust

bearing on an wear of the bearing. It is imperative to continuously monitor the

position of the shaft as axial shift beyond permissible limit would lead to mechanical

interference and surface rubbing.

The measuring principle is based on the fact that the impedence of a coil with

iron core depends upto the sized of the air gaps in the magnetic circuit. There are two

such coils mounted on the either side of the measuring disc, and connected to form a

bridge, the output of which changes proportionally to the change in air gap, the bridge

output voltage is rectified by phase selection and modified. The range of

measurement is -0.5 to +0.5 mm.

Relative Expansion Measurement:

When steam turbines are in operation relative displacement occurs between

casings and rotors of the turbine due to their different thermal inertia. This is the case

particularly during start up and in case of major load changes. These expansions are

monitored continuously by contactless measurement.

Relative expansions of HP, IP and LP turbines are monitored in the same way

as described earlier for axial shaft position measurement. The difference lies in the

size of the measuring discs and the sensor arrangements. For the large range of
relative expansion in LP turbine, the measuring disc is in the form of double cone to

produce less change in air gap due to large change in expansion. As the bridge output

for a large air gap change becomes nonlinear a linearizing network is also used in the

electronic processing. The range of measurement are

For HP turbine = -5 to +16 mm

For BP turbine =-5 t o +16 mm

For LP turbine = -10 to +32 mm.

2.9 LOAD SHEDDING RELAYS

The function of load shedding relay is to assist governing system during

sudden load throw off. Whenever a large load throw off takes place the turbine speed

increases. To prevent the turbine from reaching overspeed trip value the Emergency

Stop valves are closed for a short time by load shedding relay. Three conditions have

to be fulfilled for operating the load shedding relays. •

a) Load throw off more than 50%

b) Remaining load less than 20%

c) Frequency more than 49Hz.

If any of the above condition is not fulfilled load shedding relay will not

operate as governing itself is sufficient to take care of small disturbances. If all the

three conditions are satisfied in that case load-shedding relay operates for short time

and closes the control valves for the same time. The time for which load shedding
relay operates depends upon the amount of the load thrown off. Maximum time of

operation is 1.4 sec.

60
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 Chapter-3
DISCUSSIONS AND SUGGESTIONS

EAST (Electronic Automation of Steam Turbine) package is performing quite

satisfactorily at 210 MW unit -V of Panipat Thermal Power Station, which is quite

clear from the performance abstract of this unit (Table 1.5). However, a few

problems/ Deficiencies/ Deviations from design were observed by the author while

working as operation engineer in this plant.

In this chapter some such problems are discussed. Suggestions for the

solution of these problems are also presented after consulting the maintenance

engineers of this unit.

PROBLEM #1: Frequency Influence remains off while unit is in operation.

As we studied (refer Article #2.3) that while raising the speed of the turbine

and till house loading is achieved system remains in speed control mode. After house

loading is achieved load control mode comes into picture and frequency influence

remains ON. But practically ‘Frequency Influence’ remains OFF during normal

running of the unit and system remains in pressure control mode only.

Reason: Frequency Influence Scheme (Free governing operation) is theoretically in

order but these are practical difficulties in implementation of this scheme.

The grid conditions are highly fluctuating. There are very rapid and heavy

fluctuations in the system frequency and in case the load is allowed to change with

these fluctuations in frequency, the system parameters do not respond so fast

particularly because the control of fuel and air to the boiler is not in the automatic
control mode- even when on the auto-mode, there is inbuilt process delays in

regulation of coal flow, its burning and the resultant system pressure.

In P.T.P.S, Unit V is being run with ‘Frequency Influence’ ON as a part of

exercise for Frequency Control. The Coordinated Master Control (CMC) is not

functional in this unit. The effect of frequency Influence was set in such a way that

the machine gets automatically deloaded / loaded to a maximum extent of 10MW.

When the frequency varies by 0.33 Hz. From 50 Hz.

Even with the limited variation of load (upto 10MW) due to frequency

variation a difficulty is being experienced because in case the frequency increases in

the range of 49.67 to 50.33 Hz. or beyond there is a sudden fluctuation of 20MW in

load that causes appreciable variation in the steam parameters even if the action for

regulating the fuel is taken simultaneously.

The free govemer operation with a droop of 4% to 5% (as recommended by NREB)

is not considered feasible till such time as the grid condition near stabilization
because otherwise it would cause heavy fluctuation in load and instability in
operation. As stated above under the trial exercise the PTPS Unit-V is being operated
with ‘Frequency Influence’. This corresponds to a droop of about 14%. In case the
droop setting is increased the range of response of frequency variation shall have to
be increased from 10MW which is not feasible at this time. As in most of the Power
plants in PTPS Unit-V also Coordinated Master ControlJCMG) is not operative. The
boiler control have not been put on auto as the signal CT^nng rate, (fuel rate) which is
obtained from RC feeder speed, is not correctly available due to the following
constraints J ] ■
Changing / Variable quantity of Coal: V o '
For the same volume of coal (determined by RC feeder speed) the energy
input is different depending upon the calorific value of coal which is varying.
Variable Size of Coal:
The coal is sometimes in powdery form. The quantity (mass) of the coal
delivered through RC feeder at the same speed varies from time to time depending
upon its size etc. Thus, RC feeder speed does not correctly reflect the coal quantity.
This provides incorrect and inconsistent signal of fuel due to which the control
system cannot work properly.
Mill Conditions:
The conditions of the grinding rolls play a great part in early loading of the
mill and increasing rejects. The increased rejects falsify the fuel flow signal, because
flow although reflected in the RC feeder speed, does not entirely pass on the furnace.
Moreover, these get overloaded at low RC feeder speeds and operational / Control
margins are reduced.
Shearing of RC feeder Pins:
In case of shearing of the pins of the RC feeders, coal flow stops but false
signal continues through RC feeder speed.
SUGGESTIONS:
It is quite difficult to run the system with ‘Frequency Influence’ ON in such a heavy
fluctuating grid conditions as it will cause instability in the operation of the unit.
Control frequency controlling agency (such as NREB) should devise means to
enforce its instruction regarding frequency control at all the power station to absorb
the fluctuations, only then fruitful results from ‘Frequency Influence’ can be
achieved.
It is also quite difficult to keep ‘Frequency Influence’ ON while Coordinated Master
Control (CMC) is not operative as because of this fuel firing rate and air flow rate are
being controlled manually. It has limitation to absorb sudden and heavy fluctuations
in load partly because of the human elements involved in the manual operation and
partly because the process itself has high response time. To get the correct signal of
fuel firing rate Volumetric RC feeder should be replaced by Gravity RC feeders (This
modification has been incorporated in Unit-VI, which is under construction).
PROBLEM #2: Heavy Fluctuations in the Boiler Parameters just after
Synchronization
As we know that to roll the machine from Barring gear (i.e. 120 rpm) to the rated
speed (i.e. 3000 rpm) speed controller is used (speed controller remains in action upto
house loading).
Output of speed controller a (speed reference -actual speed)
One of the important requirement of speed raising is that increase in speed
should be smooth , fast and non-interrupted specially in the critical speed zone (i.e.
700 rpm to 2800 rpm)
Speed reference, n«> is set by a motorized potentiometer. Command to
increase nR may come from any of the following:
• From Control desk
• Functional group control
• Auto Synchronizers
• From EHC cabinet (through Push button on card itself)
In the critical speed zone the acceleration should be 8-10 rpm/sec, as a result
of this machine passes the critical speed zone in 4-5 minutes. But once the critical
speed zone is over and machine get synchronized. the raising command (i.e.
acceleration) to nR of same magnitude (i.e. 8 to 10 rpm/sec) causes heavy fluctuations
in the load (which may be around 10-15 MW/sec) on the system. As a result of these
heavy fluctuations in the load boiler parameters such as Boiler drum level, steam
pressure and temperature etc. got disturbed. This situation has resulted into increased
tripping of the unit.
SUGGESTIONS: Crossing the critical speed zone as soon as possible is
necessary, therefore acceleration setting of 8-10 rpm/sec is all right. But this setting
causes heavy fluctuations in the load on the system and therefore in the Boiler
parameters after unit synchronization. So, the rate of rise in speed (acceleration) after
synchronization should be of smaller magnitude.
As a solution there can be two different setting for rate of rise as under
• One for critical speed zone i.e. when speed of the machine is between 700 to 2800
rpm, a setting of 8-10 rpm. /sec is adequate.
• Second setting when the critical speed zone has been crossed i.e. speed above
2800 rpm, this setting can be smaller in magnitude say 2-3 rpm/sec.
Result: These suggestions have been incorporated in the system and results are quite
satisfactory. Fig. 3.1 shows the schematic diagram of the original system (system
before modification whereas) Fig. 3.2 shows the modified system.
Basically Reference speed, nR is set through a motorized potentiometer. A
preset voltage will be available across the motor of the motorized potentiometer as
long as the switch S/Si, remains closed. Switch S/Si, got closed when a raising /
lowering of nR command is given. The preset voltage decides the acceleration. In the
original system this voltage was set to 1.35 V which corresponds to acceleration of 8­
10 rpm/sec.
In the modified system instead of this one preset voltage two different preset
voltages will be available depending upon the status of the turbine. First a voltage of
1.35V (same as in the original scheme) will be available when the turbine is rolling
and speed is in the critical speed zone (i.e. speed below 2800 rpm). This results into a
acceleration of 8-10 rpm/sec. Secondly a voltage of 0.3V will be available when the
critical speed zone is over (i.e. speed above 2800 rpm)
To incorporate this modification a Limit-Value monitor (AGS-11) card is
used. LVM is basically s Schmitt-Trigger, which gives the output when a preset limit
is reached. In our case a limit of 2820 rpm (8.46V) is set, hence when nR reaches
2820 rpm a signal along with a indicating lamp appears. This signal operates a relay,
which causes the change in contact from a to b. Due to this change over a lower
voltage (0.3 V) will be available across the motor of the motorized potentiometer as a
result of this a lower acceleration 2-3 rpm/sec is achieved.
After implementing the above discussed modification it has been observed
that system behaves quite satisfactorily in the transistion period with manageable
fluctuations in the Boiler parameters just after synchronization.
b l&

p - f ( p - 3-%
PROBLEM #3: Stoppage of Barring Gears:
It has been observed many times that machine coast down to rest position
during the hot shut down period.
Reason: It has been well noticed that the speed of the turbine on barring gear, comes
down slowly whenever there is a wet steam entry into the turbine glands instead of
the usual superheated gland sealing steam supply through auxiliary PRDS.
Suggestion/Action Taken: To prevent entry of water into the turbine following steps
were taken.
1 For gland sealing steam valve (MAW-10) a protection (close) provided if
temperature before the valve is <195°C. This protection was provided through
ATRS
2 Auxiliary PRDS temperature which was maintained at 200°C now it kept >210°C
ensuring 15 to 20°C superheat (minimum)
3 The motorized drain valve for MAW-10, calibration for auto open temperature
<195°C and closes for temperature >200°C, has been rechecked and set right.
After these adjustments the problem has been more or less eliminated.
Further there are few suggestions for retaking the machine on barring gear if coasted
down to rest in hot condition.
1 Cut-off gland sealing steam supply and kill the system vacuum
2Reduce the turbine lubricating oil temperature to 40°C
3 With one AOP, JOP and gate valve gearing valve in open position, try for hand
barring.
4 If hand barring is not possible, on no account must force be used for shaft
rotation.
5 Readjust the jacking oil header pressure > 120 kg/cm2 using the pressure
regulating valve or take second JOP if required.
6 Reduce the jacking oil pressure for the individual bearing

66
 REFERENCES

1 Operation and Maintenance (O&M) Manual - Vol. 1 & Vol. 2 For 210 MW,
Unit-V, by Design India Limited.
2 Instruction Manual for 210 MW plant by BHEL.
3 Power Plant Operation Manual by National Power Training Institute.
4 Control and Instrumentation Vol. I, II & HI by National Power Training
Institute.
5 Thermal power Plant Familisation Vol. H & HI by national Power Training
Institute.
6 J. Arogyaswamy, “ Power Station Practice”, 1985, IBH Publication.
7 E.B. Jones, “ Instrument Technology” 1985 New-Butterworth Publication.
8 Charles H. Becker, “ Plant Manager”, Hand Book, 1981, Prentice hall
Publication.

68
 REFERENCES

1 Operation and Maintenance (O&M) Manual - Vol. 1 & Vol. 2 For 210 MW,
Unit-V, by Design India Limited.
2 Instruction Manual for 210 MW plant by BHEL.
3 Power Plant Operation Manual by National Power Training Institute.
4 Control and Instrumentation Vol. I, II & HI by National Power Training
Institute.
5 Thermal power Plant Familisation Vol. II & HI by national Power Training
Institute.
6 J. Arogyaswamy, “ Power Station Practice”, 1985, IBH Publication.
7 E.B. Jones,MInstrument Technology” 1985 New-Butterworth Publication.
8 Charles H. Becker, “ Plant Manager”, Hand Book, 1981, Prentice hall
Publication.

68