ELECTRO

HYDRAULIC
TURBINE CONTROL
IN
TRIPPLE MODULE
REDUNDANCY
CONFIGURATION
R.N. MANIK
INTRODUCTION
The development of technology is increasing day by day towards
high availability of closed and open loop in critical control.
Previously mechanical hydraulic control was used very extensively
& now because of the development of electronics, reliability of
electronic control has increased many folds. This resulted in
replacement of hydraulic control by electronic control.
The new technology implemented in our unit 2 & 3 of turbine
control is named as Triple Modular Redundant Control on
EHTC and Turbine Protection. The new technology demands
modern Electro hydraulic actuator i.e. high-pressure actuators.
DEMANDS OF TMR CONTROL
NO BACKUP MECHANICAL GOVERNER
NO BACK UP PROTECTION
SIMPLIFIED HYDRAULIC / GOVERNING SYSTEM
(ONLY ONE OIL LINE)
FUNCTION OF LSR,HP/IP TRIM DEVICE AND ATT
DEVICES ARE CHANGED FROM HYDRAULIC TO
ELECTRONIC SYSTEM
IMPROVED AVAILBILITY AND RELIABILITY
INDEPENDENT CONTROL FOR EACH VALVE
(CONTROL AND TRIP)
CONFIGURATION OF TURBINE CONTROL IN UNIT # 2 & 3
IPB-2(DUAL LINE)
BACK UP
PANEL
WS POSE
TSE
CJJ01
CCA
02 &
03
CCA
01
TP
CJJ32
EHTC
MON
CJJ31
CCA
05
CCA
04
LPBP
&
GSPC
CJJ03
TMR-1
CJJ21
TMR-2
CJJ22
TMR-3
CJJ23
POS.
CNT
CJJ24
TRIP
SOV
CJJ34
ANALOG
DIGITAL
SIGNAL
RLTD TO
EHTC/TP
TRIP
SOLENOID
FOR SV s &
CVs
SERVO
VALVE FOR
CVs
TMR-1
CJJ21
TMR-2
CJJ22
TMR-3
CJJ23
SGNL
COND
CJJ07
SGNL
COND
CJJ33
TMR PHILOSOPHY
1. INPUT SIDE
A. SIGNAL FROM FIELD IS ACQUIRED FIRST IN SIGNAL DISTRIBUTION
PANEL, FROM WHERE THESE SIGNALS ARE DISTRUBATED TO
INDEPENDENT TMR
EXAMPLE :
MAIN STEAM TEMPERATURE -1
SIGNAL CONDITIONING PANEL
TMR-1 TMR-2 TMR-3
MAIN STEAM TEMPERATURE -2
SIGNAL CONDITIONING PANEL
TMR-1 TMR-2 TMR-3
MAIN STEAM TEMPERATURE -3
SIGNAL CONDITIONING PANEL
TMR-1 TMR-2 TMR-3
UA 374
TMR CH-1
+ ANALOG SIGNAL
DISTRIBUTION TMR CH-2
- CARD
SENSORS ( 4 - 20 MA ) TMR CH-3
UT 371 TMR CH-1
NC
DIGITAL SIGNAL TMR CH-2
COM DISTRIBUTION
CARD TMR CH-3
NO
TMR CH-1
TMR CH-2
TMR CH-3
SIGNAL DISTRIBUTION TO TMR CHANNELS
ARRANGEMENT OF SPEED PROBE SIGNAL DISTRIBUTION FOR EHTC SPEED ACQUISITION IN TMR
AND OVER SPEED PROTECTION TRIP
CH-A TURBINE TRIP
EI05 EI05 EI05
CH-B TURBINE TRIP
EI05 EI05 EI05
EHTC TMR-1 EHTC TMR-2 EHTC TMR-3
TP TMR-1 TP TMR-2 TP TMR-3
TURBINE
SHAFT
SPEED
PROBE-1
2
3 4
5
6
O/S RLY LT RLY COIL
O/S RLY LT RLY COIL
POSITION
CONTRO
LLER
REF-1
POSITION
CONTRO
LLER
REF-2
S
E
L
S
E
L
EHTC
TMR-1 / TMR-2 / TMR-3
SERVO SERVO
COIL-1 COIL-2
HPCV1, HPCV2
IPCV1 AND IPCV2
CHANGEOVER LOGIC OF TMR
POSITION SET POINT OUTPUT MODULE FAULTY
POSITION SET POINT OUTPUT MONITORING
MODULE ( ASABA13 ) DISCREPANCY FAULT
PROCESSOR FAULT ( BOTH MASTER & SLAVE)
COMMUNICATION FAULT ( PROPOSED )
EHTC control consisting of the
following main components
turbine start up and lift limiter
speed controller
load controller
pressure controller
TSLLE RAISE/LOWER
STARTING FUNCTION TMR
DEVICE GENTR FAULT CHANGEOVER
STATION
SPEED SPEED SPEED SLC HPCV1
REFERENCE REF. DLD ERROR HPCV1 M SWITCHING POSN SERVO
S I CKT CONTLLER
SPEED W CHART N
ACTUAL I CKT
T POSN ACT
C SLC HPCV2
LOAD LOAD LOAD H PD HPCV2 M SWITCHING POSN SERVO
REFERENCE REF. DLD ERROR I CONTRO I CKT CONTLLER
N LLER CHART N
G CKT
LOAD POSN ACT
ACTUAL C SLC IPCV1
I TRACKING IPCV1 M SWITCHING POSN SERVO
R FROM I CKT CONTLLER
C 2 & 3 CHART N
PRESSURE PRES. U TMR CHNL CKT
REFERENCE ERROR I POSN ACT
T SLC IPCV2
PR. IPCV2 M SWITCHING POSN SERVO
ACTUAL I CKT CONTLLER
CHART N
CKT
POSN ACT
FUNCTIONAL BLOCK DIAGRAM OF EHTC IN TMR IMPLEMENTATION
TURBINE SART UP AND LIFT LIMITING EQUIPMENT
( TSLLE )
SIMILLAR TO STARTING DEVICE OF UNIT NO-1, THE TSLLE CAN BE OPERATED FROM
THE TURBINE CONSOLE OF CONTROL ROOM
THE FOLLOWINGS ARE THE STEPS ON TSLLE RAISE
TSLLE > 7.5 %
ONE OF THE TURBINE PROTECTION RELEASED
TSLLE > 12.5 %
TURBINE PROTECTION RESET IN LOGIC SIDE
TSLLE > 22.5 %
PARTIAL TRIP RESET FOR STOP VALVE.
TSLLE > 32.5 %
PARTIAL TRIP RESET FOR CONTROL VALVE.
TSLLE > 42.5 %
STOP VALVE OPENING
TSLLE > 50 %
START INCREASE OF CONTROL OUTPUT FROM ZERO
RELEASE TO INCREASE THE TSLLE
1. EHA OIL PRESURE ADEQUATE i.e. CONTROL OIL PR > 150 KG/CM2
TSLLE POSITION REFERENCE VS TSLLE OUT PUT TOWARDS CONTROLLER OUTPUT
T
S
L 100%
LE
O
U
T
P 50 %
U
T
-10%
25% 50% 75% 100%
TSLLE POSITION REFERENCE
( 68 %, 47.5 % )
( 46 %, -10% )
( 90 %, 105 % )
TSLLE OUTPUT(%) V/S HPCV1 POS
(MM)
0
10
20
30
40
50
60
1
2
.
5
3
2
.
5
5
0
5
5
.
9
7
5
9
.
4
6
7
1
.
1
3
8
0
.
3
8
6
.
8
9
8
8
.
0
1
TSLLE OUTPUT(%)
H
P
C
V
1

P
O
S

(
M
M
)
TSLLE O/P( %) V/s HPCV2 POS. ( MM)
0
10
20
30
40
50
1
2
.
5
3
2
.
5
5
0
5
5
.
9
7
5
9
.
4
6
7
1
.
1
3
8
0
.
3
8
6
.
8
9
8
8
.
0
1
TSLLE OUTPUT in %
H
P
C
V
2

P
O
S
.

I
N

M
M
TSLLE O/P (%) V/S IPCV1 POS. (MM)
0
20
40
60
80
100
1
2
.
5
3
2
.
5
5
0
5
5
.
9
7
5
9
.
4
6
7
1
.
1
3
8
0
.
3
8
6
.
8
9
8
8
.
0
1
TSLLE O/P (%)
I
P
C
V
1

P
O
S
.

(
M
M
)
TSLLE O/P (%) V/S IPCV2 POS.(MM)
0
20
40
60
80
100
120
1
2
.
5
3
2
.
5
5
0
5
5
.
9
7
5
9
.
4
6
7
1
.
1
3
8
0
.
3
8
6
.
8
9
8
8
.
0
1
TSLLE O/P (%)

I
P
C
V
2

P
O
S
.
(
M
M
)
SPEED CONTROLLER ACTIVE
UNDER FOLLOWING CONDITION
LOAD WITH SPEED CONTROL SELECTED AND LOAD ACTUAL IS LESS THAN
15 MW
LOAD ACTUAL WILL INCREASE/DECREASE THROUGH LOAD REF.
IN NORMAL OPERATION (i.e. TURBINE IS IN LOAD CONTROLLER ), IF
1. LOAD SHED DETECTED SIGNAL APPEARS OR
2. GCB OFF
3. DVC ISOLATED (UNIT-2 ONLY )
SPEED REFERENCE BLOCK
UNDER FOLLOWING CONDITIONS:
GENERATOR CIRCUIT BREAKER OFF
AND
( Nrtd Nact ) > 36 rpm
OR
GENERATOR CIRCUIT BREAKER OFF
AND
SPEED/LOAD SP BLOCK FROM SGC TURBINE
AND
SPEED REFERENCE Nr > N rtd
AND
SPEED REFERENCE Nr < 2850 rpm
DN/DT MONITORING
GENERATOR CIRCUIT BREAKER OFF
AND
RATE OF CHANGE OF SPEED ACTUAL 5 RPM / 3 SEC
AND
CONTROLLER O/P MORE THAN 1%
AND
SPEED ACTUAL BETWEEN 725 TO 2850
ON DN/DT OPERATION SPEED ACTUAL WILL BE LOWERED
AUTOMATICALLY BELOW 725 RPM
LOAD CONTROLLER ACTIVE
UNDER THIS CONDITION
LOAD WITH LOADCONTROL
SELECTED
AND
GCB ON
BARE SPEED CONTROLLER ACTIVE
UNDER FOLLOWING CONDITION
GCB ON , LOAD SET POINT OFF ( TURBINE CONTROL IS IN SPEED
CONTROLLER)
AND
LOAD SHED DETECTED
GCB ON , LOAD SET POINT OFF ( TURBINE CONTROL IS IN SPEED
CONTROLLER)
AND
FRQUENCY > 53 HZ
ON BARE SPEED ACTIVE WITH LOAD SHED DETECTED
1. SPEED REFERENCE BECOMES 3000 RPM FOR 5 SEC
AFTER THAT LOAD CAN BE INCREASED AND DECREASED THROUGH SPEED
REFERENCE ONLY.
ON BARE SPEED ACTIVE WITH FREQUENCY > 53 HZ
2. LOAD CAN BE INCREASED AND DECREASED THROUGH SPEED
REFERENCE ONLY.
BARE SPEED CONTROL
1. GCB ON
2. LOAD SP OFF
3. LOAD SHED DETECTED OR FREQUENCY MORE THAN 53 HZ
SPD ACT
M
A
S
T
E
R
C
O
N
T
R
Nr
Nrtd
Speed
controller
LOAD SHED DETECTED
UNDER FOLLOWING CONDITION
LOAD ACTUAL IS LESS THAN 15 MW AND FREQUENCY IS MORE THAN 53 HZ
( DURING SYNCHRONISATION & FREQUENCY >53 HZ)
ARMING :- LOAD I S MORE THAN 15 MW ONCE
LOAD REFERENCE IS MORE THAN LOADACTUAL BY 5 MW AND LOAD
ACTUAL IS LESS THAN 15 MW
(THIS CAN HAPPEN IN CASE OF SUDDEN LOAD THROW OFF IN THE GRID)
EXAMPLE: - LOAD REFERENCE = 13 MW
LOAD ACTUAL = 7 MW
LOAD REJECTION ACTIVATED
UNDER THIS CONDITION
LOAD ACTUAL THROWN OF MORE THAN 60 MW
AND
RESIDUAL LOAD ACTUAL < 22.5 MW
ON LOAD REJECTION ACTIVATED
SPD/LOAD CONTROLLER OUTPUT TO ALL CONTROL VALVES
(HPCV1/2 AND IPCV1/2) BECOMES ABSOLUTELY ZERO FOR 1SEC.
AFTER THAT COME BACK TO CONTROLLER OUT PUT ACTUAL.
EXAMPLE: LOAD ACTUAL = 85 MW
THROWN LOAD = 65 MW
RESIDUAL LOAD = 20 MW
FREQUENCY VS PR MAX
120
100
80
LOAD
MW 60
40
20
0
52.50 52.6 52.7 52.8 52.9 53 53.1 53.2
FREQUENCY
HP EXHAUST TEMPERATURE CONTROLLER
MIN HP EXHAUST REFERENCE
HP SHAFT MEAN TEMP.
HP EXHAUST
TEMPERATURE
FLANGE TEMP. CONTROLLER CONTROLLER OUTPUT
HP EXHAUST TEMP. TO IPCV
30% HIGH
0% LOW
FKG
FKG
DVC ISOLATION SCHEME
ON DVC ISOLATION THE
FOLLOWING ACTIVITIES WILL
TAKE PLACE
Load controller will switch over to speed
controller
Speed reference will be changed to calculated
value with respect to last load reference to hold
the load.
Valve lifting will instantly change and come to
original valve lifting after correction of
frequency ( which will be approximately 51.5
Hz)
To maintain the frequency and load as per
requirement, LOAD REFERENCE has to be
adjusted by the operator (not through speed
ref.).
TO MAINTAIN ACTUAL SPEED
AROUND 51.5 HZ DURING DVC ISOL
SPEED ACTUAL SELECTED
ON "LOAD SP ON" FOR SPEED REF TRACKING
ADS UMS
51.5 HZ
50 HZ
OPERATOR SET SPD REF.
SMU
FOR BLOCK LOAD SWITCH
FLIP FLOP
LOAD SETPOINT ON
OR
FOR SYNC.
FOR DVC ISO
0.09
0.05
SEL 2
2
1
S
R
GCB OFF
TURBINE TRIP
INT
T
>
<
2
1
SEL2
OR
GCB ON
AND
DVC ISOLATED(0.5SEC)
SPEED ACTUAL
K
EFFECTIVE LOAD REFERENCE
60M
LOAD ACT MORE THAN 15 MW
AND
UMS
1
2
SEL2
UMS
1
2
SEL2
Nr O/P
LOAD SP OFF
OR
UNIT -2
SPEED CONTROLLER
1. WHEN MACHINE IS SYNCHRONISED AND LOAD ACTUAL IS LESS THAN 15 MW, THE SPEED REFERENCE WILL BE
CHANGED FROM LOAD REFERENCE ONLY.
2. WHEN LOAD ACTUAL IS REACHED MORE THAN 15 MW AND MACHINE IS IN SPEED CONTROLLER, THE SPEED
REFRENCE CAN BE INCREASED AND DECREASED THROUGH SPEED REFERENCEN ONLY.
3. ONCE DVC IS ISOLATED AND LOAD CONTROLLER SHIFTED TO SPEED CONTROLLER. THE SPEED REFERENCE WILL
BE CHANGED THROUGH LOAD REFRENCE ONLY AS LONG AS DVC ISOLATION IS THERE.
LOAD ACTS
< 15 MW
M
A
S
T
E
R
C
O
N
T
R
Pr Prtd
Load
controller
Nr
Nrtd
Speed
controller
AFTER DVC
ISOLATION
Nr
Nrtd
Speed
controller
M
A
S
T
E
R
C
O
N
T
R
Pr Prtd
Load
controller