TURBINE GOVERNING SYSTEM

In order to maintain the synchronous speed under changing load/grid or steam

conditions, the KWU turbine supplied by BHEL at NTPC Korba is equipped with
electro-hydraulic governor; fully backed-up by a hydraulic governor. The measuring
and processing of electrical signal offer the advantages such as flexibility, dynamic
stability and simple representation of complicated functional systems. The
integration of electrical and hydraulic system is an excellent combination with
following advantages:

• Exact load-frequency droop with high sensitivity.

• Avoids over speeding of turbine during load throw offs.

• Adjustment of droop in fine steps, even during on-load operation.

Elements of Governing System

The main elements of the governing system and the brief description of their
functions are as follows:

• Remote trip solenoids (RTS).

• Main trip valves (Turbine trip gear).

• Starting and Load limit device.

• Speeder Gear (Hydraulic Governor).

• Aux. follow-up piston valves.

• Hydraulic amplifier.

• Follow-up piston valves.

• Electro-Hydraulic Converter (EHC).

• Sequence trimming device.

• Solenoids for load shedding relay.

• Test valve.

• Extraction valve relay.

• Oil shutoff valve.

• Hydraulic protective devices.

KORBA SIMULATOR 101

REMOTE TRIP SOLENOIDS (RTS)

The remote trip solenoid operated valves are two in number and form a part of
turbine protection circuit. During the normal operation of the turbine, these
solenoids remain de-energised. In this condition, the control oil from the governing
rack is free to pass through them to the main trip valves. The solenoids gets
energised whenever any electrical trip command is initiated or turbine is tripped
manually from local or UCB. Under energised condition the down stream oil supply
after the remote trip solenoids gets connected to drain and the upstream will be
blocked. By resetting Unit Trip Relays (UTR) from UCB, these solenoids can be reset.
Refer to Figure.

REMOTE TRIP SOLENOIDS

MAIN TRIP VALVES

The main trip valves (two in numbers) are the main trip gear of the turbine protective
circuit. All turbine tripping take place through these valves. The control oil from
remote trip solenoids is supplied to them.

Under normal conditions, this oil flows into two different circuits, called as the Trip
Oil and Auxiliary Trip Oil. The Trip Oil is supplied to the Stop Valves (of HP Turbine
and IP Turbine), Auxiliary Secondary Oil circuit and Secondary Oil circuits. The
Auxiliary Trip Oil flows in a closed loop formed by main trip valves and turbine
hydraulic protective devices (Over Speed trip device, Low Vacuum trip device and
Thrust Bearing trip device).

The construction of main trip valves is such that when aux. trip oil pressure is
adequate, it holds the valves' spools in open condition against the spring force.
Whenever control oil pressure drops or any of the hydraulic protective devices are
actuated, the main trip valves are tripped. Under tripped condition, trip oil pressure
is drained rapidly through the main valves; closing turbine stop and control valves.
Refer to the figure below.

KORBA SIMULATOR 102

 MAIN TRIP VALVES

STARTING AND LOAD LIMIT DEVICE

The starting and load limit device is used for resetting the turbine after tripping, for
opening the stop valves and releasing the control valves for opening. The starting
device consists of a pilot valve that can be operated either manually by means of a
hand wheel or by means of a motor from remote. It has got port connections with the
control oil, start-up oil and auxiliary start-up oil circuits. The starting device can
mechanically act upon the hydraulic governor bellows by means of a lever and link
arrangement.

Before start-up, the pilot valve is brought to its bottom limit position by reducing the
starting device to 0% position. This causes the hydraulic governor bellows to be
compressed thus blocking the build-up of secondary oil pressure. This is known as
control valve close position. With the valve in the bottom limit position (starting
device = 0%) control oil flows into the auxiliary start-up circuit (to reset trip gear and
protective devices) and into the start-up oil circuit (to reset turbine stop valves). A
build-up of oil pressure in these circuits can be observed, while bringing the starting
device to zero position. When the pilot valve i.e. the starting device position is raised,
the start-up oil and auxiliary start-up oil circuits are drained. This opens the stop

KORBA SIMULATOR 103

valves; ESVs open at 42% and IVs open at 56% positions of the starting device.
Further raising of the starting device release hydraulic governor bellows which is in
equilibrium with hydraulic governor's spring tension and primary oil pressure
(turbine speed), and raises the aux. sec. oil pressure; closing the aux. follow-up
drains of hydraulic governor.

STARTING DEVICE ACTING ON SPEEDER GEAR

KORBA SIMULATOR 104

SPEEDER GEAR

The speeder gear is an assembly of a bellow and a spring, the tension of which can
be adjusted manually from UCB by an electric motor or locally by a hand wheel. The
bellow compression depends upon the position of the starting device and the speeder
gear position, which alters the spring tension on the top of the bellow. The bellow is
also subjected to the primary oil pressure, which is the feedback signal for actual
turbine speed. The zero position of speeder gear corresponds to 2800 rpm i.e.
hydraulic governor comes into action after 2800 RPM. The bellow and spring
assembly is rigidly linked to the sleeves of the auxiliary follow-up piston valves. The
position of the sleeve changes with the equilibrium position of the bellow.

SPEEDER GEAR

KORBA SIMULATOR 105

HYDRAULIC SPEED TRANSMITTER
The hydraulic speed
transmitter runs in the MOP
bearing and operates on the
principle of a centrifugal
pump. The variation of
pressure in the discharge line
is proportional to the square
of the machine speed. This
primary oil pressure acts as
the control impulse for the
hydraulic speed governor.
The transmitter is supplied
with control oil via an oil
reservoir. An annular groove
in the speed transmitter
ensures that its inside is
always covered with a thin
layer of oil to maintain a
uniform initial pressure.
Excess oil drains into the
bearing pedestal.

CURVE SHOWING TURBINE SPEED Vs PRIMARY OIL

PRESSURE

KORBA SIMULATOR 106

AUXILIARY FOLLOW-UP PISTON VALVES

Two Auxiliary Follow-up

pistons are connected in
parallel and the trip oil is
supplied to them through
orifice. The sleeves of these
valves are attached to the
speeder gear bellow link. The
position of the sleeve
determines the draining rate
of trip oil through the ports.
Accordingly the trip oil
pressure downstream of
these valves changes. Oil
downstream of auxiliary
follow-up pistons circuit is
termed as AUXILIARY
SECONDARY OIL. Hence,
aux. follow-up piston valves
can be said to control
auxiliary secondary oil
pressure.

SEQUENCE TRIMMING DEVICE

The function of the sequence trimming device or HP/IP TRIM DEVICE is to prevent
any excessive HP turbine exhaust temperature due to churning. It changes response
2
of main and reheat control valves. When the reheat pressure is more than 32 Kg/cm
and load less than 20% the IP turbine tends to get loaded more than HP turbine. The
steam flow through HP turbine tends to fall to very minimum, causing a lot of
churning and excessive exhaust temperature. The trim device operates at this
moment trimming the IP turbine control valve. The control valves of HPT open more
to maintain flow of steam, reducing the HPT exhaust temperature.

It consists of a spring-loaded piston assembly, which is supported by control oil

pressure from beneath, under normal conditions. The control oil is supplied via an
energised solenoid valve. When the turbine loads is less then 40 MW and hot reheat
2
pressure is more than 32 kg/cm the solenoid valve gets de-energised cutting out the
control oil supply to the trim device.

The trim device trips under spring pressure. The trim device is connected to the
follow-up piston valves of IP control valves by means of a lever. Upon tripping, the
trim device alters the spring tension of follow-up pistons of IP pistons control valves,
draining the secondary oil. The IP control valves openings are trimmed down.

KORBA SIMULATOR 107

HYDRAULIC AMPLIFIER

Hydraulic Amplifier consists of a pilot valve and an amplifier piston. The position of
the pilot valve spool depends upon the aux. secondary oil pressure. Depending upon
the pilot spool position, the control oil is admitted either to the top or the bottom of
the amplifier piston. The other side of amplifier is connected to the drain. The
movements of the amplifier piston are transformed into rotation of a Camshaft
through a piston rod and a lever assembly. A feedback linkage mechanism stabilises
the system for one particular aux. secondary oil pressure.

1. Amplifier piston
2. Follow-up piston
3. Sleeve
4. Shaft
5. Lever
6. Feedback lever
7. Pilot valve
8. Compression spring
9. Adjusting screw

a : Control oil
b : Secondary oil
b1 : Aux. Sec oil
c : Return oil

HYDRAULIC AMPLIFIER

SOLENOIDS FOR LOAD SHEDDING RELAY

A pair of solenoid valves has been incorporated in the IP Sec oil line on control valves
and Aux Sec. oil line, in order to prevent the turbine from reaching high speed in the
event of sudden turbine load throw-off. The control valves are operated (closed) by
the load-shedding relay when the rate of load reduction exceeds a certain value. The
solenoid drains the IPCV secondary oil directly. Direct draining of IP Sec oil circuit
causes the reheat valves to close without any significant delay. The HP control valves
are closed due to draining of aux. secondary oil before the hydraulic amplifier, by the
second solenoid valve. The extraction stops valves controlled by IP secondary oil
acting through extraction valves relays also get closed. After an adjustable time delay
(approx. 2 seconds) the solenoid valves are re-closed and secondary oil pressure
corresponding to reduce load builds-up in the HP and IP turbine secondary oil lines.

KORBA SIMULATOR 108

FOLLOW-UP PISTON VALVES

The trip oil is supplied to the follow up piston valves through orifices and flows in the
secondary oil piping to control valves. The secondary oil pressure depends upon
position of sleeves of follow-up piston valves; which determines the amount of
drainage of trip oil.

FOLLOW-UP PISTON VALVES

There are in all twelve follow-up piston valves. Six of them are associated with
hydraulic amplifier and six of them with EHC in the governing system.

The follow-up piston valves constitute a minimum value gate for both the governors.
This means the governor with lower reference set point, is effectively in control. This
is also termed as HYDRAULIC MINIMUM SELECTION of governors.

The drain port openings of follow-up pistons of hydraulic amplifier depends on

auxiliary secondary oil pressure, upstream of aux. follow-up pistons; and that of
electro hydraulic converter, on the piston of pilot spool valve of the elector-hydraulic
converter (i.e. EHC output).

KORBA SIMULATOR 109

TEST VALVE
Each of the HP and IP stop
valves' servomotors receives
trip oil through their
associated test valves. The test
valves have got port openings
for trip oil as well as start-up
oil. The test valves facilitate
supply of trip oil pressure
beneath the servomotor disc.
(Stop valve open condition,
under normal operation). For
the purpose of resetting stop
valves after a tripping, start-
up oil pressure is supplied to
the associated test valves,
which moves their spool
downwards against the spring
force. In their bottom most
position the trip oil pressure
starts building up above the
stop valve servomotor piston
while the trip oil beneath the
disc gets connected to drain.
When start-up oil pressure is
1. Bolt 12. Trip Oil reduced the test valve moves
2. Hand wheel 13. Piston valve
3. Spindle 14. Spring plate up draining trip oil above the
4. Cover 15. Spring servomotor piston and
5. Oil Seal 16. Spacer building the trip oil pressure
6. Bushing 17. Bottom cover
7. O-ring 18. Trip oil
below the disc, thus opening
8. Valve Cover 19. Drain the stop valve. A hand wheel
9. Valve Body 20. Trip oil is also provided for manual
10. Trip Oil 21. Startup oil
11. Piston sleeve
operation of test valves.

EXTRACTION N.R.VS AND EXTRACTION VALVE RELAY

Four pair of swing check valves are provided in the extraction lines to the feed
heaters (LP Heaters No: 2,3, Deaerator and HPH No: 5) to prevent back flow of
condensed steam into the turbine from heaters on account of high levels in the
heaters. There are two NRVs provided in each of these extraction lines and is force
closing type. Both these valves are free-swinging check type, however the first valve is
equipped with an actuator. In case of flow reversals, both the valves are closed
automatically. The actuator assists the fast closing of the first valve.

The mechanical design of force-closed valves is such that they are brought into free-
swinging position by means of trip oil. They are open as soon as differential pressure
is sufficient. If the trip oil pressure falls, the spring force closes the valve when steam
pressure either falls or is lowered (reduced load).

KORBA SIMULATOR 110

The extraction valve relay, its changeover valve and its solenoid valve control the trip
oil to each of the actuators of force closing type valves. Extraction valve relay
actuates the FCNRVs in proportion to secondary oil pressure. By suitable adjustment
of its spring, the secondary oil pressure at which the FCNRVs will be released for
opening can be set. However, swing check FCNRVs will also open without the release
action, also if the steam pressure is more than the spring force. But in this case the
pressure loss shall be more leading to loss of efficiency.

In case of turbine trip or sudden load reduction, by energising the associated

solenoid valve, draining of trip oil pressure through extraction valve relay assists
closing movements of FCNRVs. In both the cases the actuator is devoid of trip oil and
its spring force closes the NRV. Extraction (4) FCNRV solenoid is also energised
additionally by lower differential pressure in the extraction line.

KORBA SIMULATOR 111

 b : Control Oil c : Return Oil

b1 : Secondary Oil x : Trip Oil

b2 : Secondary Oil x1 : Trip Oil

COLD REHEAT SWING CHECK VALVE

Two numbers of swing check valves are provided on the CRH lines from which the
steam is drawn for HPH-6. Their pilot valves via their rotary servomotor in proportion
to secondary oil pressure operate the CRH NRVs. They open out fully when main
control valves open up corresponding to 5-10% of maximum turbine out-put. Only
when the control valves are closed to this threshold again, the NRVs return into
steam flow by the hydraulic actuator, so that when the steam flow ceases in the
normal direction, they are closed by the torque of rotary servomotor. Even when the
pressure of secondary oil has not built up sufficiently, NRVs can be opened up like
safety valves when the upstream pressure rises above the downstream side pressure
by one bar.

KORBA SIMULATOR 112

VACUUM BREAKER

The function of the vacuum breakers is to cause an increase in condenser pressure

by conducting atmospheric air into the condenser together with the steam flowing
from the LP Bypass. When the pressure in the condenser increases, the ventilation
of the turbine balding is increased, which causes the turboset to slow down so that
the running down time of the turboset and the time needed for passing through
critical speeds are shortened.

KORBA SIMULATOR 113

HYDRAULIC AND ELECTRO-HYDRAULIC GOVERNING OF TURBINES

Power produced by any power plant is sent out on utility grid (Transmission line and
control equipments) together with power from other plants through process of
synchronization with the grid and to distribution systems and then to the consumer.
Control of system frequency on the grid or interconnected grid/pool is a major
responsibility of load dispatchers. When a Turbo-generator is connected to grid, the
speed of each machine in the grid remains same to all other machines connected to
the grid. When an increase of load is required, more steam is admitted by
opening/controlling the steam control valves. A basic understanding of turbine speed
governors is necessary to maintain the central control of system parameters like
speed, frequency, load, system voltages etc.

In the paragraphs that follow, the turbine governing has been explained using
theoretical information, figures and descriptions of governing systems.

All turbines are equipped with speed governors. The purpose of the governor is to
sense the instantaneous speed of the turbine in revolutions per minute, and to
transmit a signal to the turbine control valves to open or close and maintain the
desired speed. Most governors do not hold absolutely constant speed as load
changes, but are designed to permit the speed to drop as the load is increased. As
load is increased on the generator, the turbine speed tends to slow down. The speed
governor spins slower (control arm moves toward “LOW” position), which results in
the control mechanism in increasing steam flow to the turbine (control valve opens).
The governors therefore control the steam supply to the turbine as well as ensure
maximum safety of the machine and to the operating people when the turbine is on
load.

Basically, the governors perform functions such as: -

• Parallel operation/working of machines with other turbine-generators

connected together in a grid.
• Output of each individual unit is controllable due to governing actions.
• The governor enables the electrical grid system to be to some extent self-
compensating to changes in load demand.
• The governor enables the turbine-generators not connected together, in a
grid, run as single unit. (Before synchronisation), and also enables speed of
turbine, kept under control.
• The governor controls the rise in speed of all turbines irrespective of duty,
in instances of losing its’ electrical loads.

KORBA SIMULATOR 114

Turbine Governor System type-1

Governors of the turbines basically control the steam flow to the turbine. The
governor usually takes the form of spring-loaded weights mounted on a shaft
assembly that is driven by a worm & worm wheel from end of the H.P. shaft.

The weights, which are held by springs, tend to move outwards due to centrifugal
force and this movement is dependent upon the speed of the turbine shaft. The
movement of the weights is arranged to operate on oil relay valve and this valve
through an oil pressure relay system, opens or closes valves that admit steam to the
turbine. When an increase of load is required, more steam is admitted to the turbine
by opening the steam valves.

Simple turbine governor type-2

The governor (A) is driven from the turbine shaft. An arm pivoted at (B) has attached
to it, the governor weights and a moveable sleeve (C). Sleeve (C) is connected to a
floating lever (D) to which is attached the spindle (E) of the pilot relay valve and the
spindle (F) of the main steam valve.

If the turbine shaft speed increases, the governor weight will move outwards causing
sleeve C to lift; this also tilts floating lever (D). These movements uncover the port (G)
of the pilot valve thereby allowing oil pressure to act on the top of the power piston
(H). At the same time port (I) in the pilot valve, allows oil to drain from the bottom (J)
of the power piston. Due to this operation, the steam valve will move towards the
closed position, thus admitting less steam to the machine. During installation and
also afterwards, the governor springs are adjusted periodically, so as to keep the
range at which the governor operates between limits.

KORBA SIMULATOR 115

Loading on the machine is done/carried out by operating the hand wheel (K) thus
opening the steam valve. The hand wheel (K) is normally on remote operation from
the control panel by means of a reversible motor known as the “speeder motor”. Such
governors do not use the electro-hydraulic governors, which control the operation by
electrical interfacing units i.e. the electro-hydraulic converter. For detailed working of
Governor, the drawing as shown below should be referred.

The percentage of control valve opening on each turbine depends upon the electrical
output from that individual T.G, and in turn the entire system at the same speed
(frequency). The system frequency decreases, as more electrical load is required. To
regain the previous frequency/speed, the amount of fuel fed to the steam generator is
increased adequately. Since with more customer load on the system, the frequency
tends to decrease then the governors on all the system turbines need to operate (to
open) the control valves to admit more steam to Turbine and allow the system to
supply the extra load.

Mechanical –Hydraulic System Block Diagram:

The speed acts on the radial spring governor, this in turn, affects the hydraulic relay
and also, the anticipatory derivative system (acceleration component). Local or
remote adjustment on the speeder gear output is algebraically summed to act with
the speed component, thus the gain that is also regulated by local adjustment of
governor reputation through the pilot oil regulating valve, passes through a
minimum selector that has been provided with another signal of locally/remotely
controlled load limiting device; minimum signal thus obtained from here is acted
upon the Auxiliary and main relays of governor valves of H.P and I.P control valves
and the pressure switching & relaying that effects to operate the release and bled
steam check valve. The feedback signal of S.V pressure, vacuum unloading gear and
anti-motoring device act on check valve and also for differential pressure switching (it
compares the minimum selector O/P as explained above); this forms the speeder gear

KORBA SIMULATOR 116

runback as the feedback also. H.P and I.P control valves’ position are derived for
valve offset adjustments.

The figure below shows the block diagram of mechanical-hydraulic system.

The hydraulic oil used in the governor system is at a pressure up to 20 Bar. Better
control can be achieved by increasing this pressure (more than 35 Kg/cm2 pressure)
but this leads to leaks and fires. For this reason some turbines in use today utilize
the Fire Resistant Fluid (F.R.F) system and thus the pressures can be increased
without the risk of fires.

Turbine bearings are lubricated with oil at between 0.3 and l.4 bar pressure
depending upon the make and type of machine. A high-pressure oil pump normally
supplies this oil and then pressure of oil is reduced as above.

Emergency governors (often referred as the Over speed Governor): -

The emergency governor is the final line of defense to protect the turbine from
dangerous over speeds. This device, when actuated rapidly closes all valves
associated with steam supply to the turbine. Emergency governors are normally set
to operate instantaneously if turbine speed reaches 110% of rated (3300 rpm on a
two pole turbine generator) or higher speeds. The emergency governor shuts off the
steam supply in the event of rotor speed increasing by more than 10% above its
normal speed. A sliding bolt or an eccentric ring is attached to the shaft. These are
held in position by means of a retaining spring.

KORBA SIMULATOR 117

The bolt or the ring flies out of the normal position .In doing so, it operates a trip and
releases the relay oil pressure, which is holding the emergency, valve open. The
emergency valve then shuts off the steam supply .

The emergency governor is tested at periods by deliberately over-speeding the

machine when the load has been taken off. Each of the twin bolts or rings is operated
in turn. The one not being tested is made inoperative by a selector lever.

Droop of Turbo-generators:

Speed regulations of turbine also called the Droop, (or the proportional band), is
defined as the amount of speed change from no load to full load divided by the rated
speed. Turbine Droop can be set in turbines either mechanically or electrically (In
KWU turbines the provision of droop is made to range from 2.5% to 8.0% and to
match the grid frequency, chosen setting is 5%). If the governor speed regulation is
required to be set at 5% then for a 3000 rpm turbine, the control valves will be open
wide at a speed of 2925 rpm or 2½ % below 3000 rpm. And likewise in other side of
50 Hz frequencies, the control valves will be fully closed, at a speed of 3075 rpm, or
2½ % above 3000 rpm. The droop setting in electronic system of EHG has been
incorporated in a module connected in series which receives input as the load
controller/comparator forming the error (MV-DV), and the droop
corrected/incorporated signal is fed to the final load controller module of the load
control loop.

The amount of the inherent decrease in speed from no load to full load is called
speed regulation, droop, or proportional band. The Droop is necessary in the control
system in order to sense a change in speed and thus to reposition the valves. In KWU
turbine (of SSTPS droop is set at 5%, i.e. = ±2.5% from 3000 rpm, or 50 Hz

KORBA SIMULATOR 118

frequency), the droop is set such that a biased zone is maintained from 3000 r.p.m to
3075 rpm. Beyond this speed until 3225 rpm, the droop gets affected automatically
for unloading.

Most grids operate automatically, to sense a change in system frequency as load goes
up or down and to provide continuous signal to the controlled generating units in
order to maintain the desired 50 Hz system frequencies. If the cost of generation at
given moment on the grid is such that a load of 100 MW should be generated by that
unit, that is the load that the automatic control will attempt to maintain The
frequency bias of all controlling turbine generators on the grid is added up to
determine the system frequency bias.

In order to view the economical loading on the sets connected in parallel an example
of a single unit can be considered for understanding the cost controlled situation. If
the cost of generation at given moment on the grid is such that a load of 100MW
should be generated by that unit, that is the load that the automatic control will
attempt to maintain. The frequency bias of all controlling turbine generators on the
grid is added up, to determine the system frequency bias.

Our single unit example was being cost controlled to provide 100MW and it went to
104MW when system frequency dropped 1/10th of a cycle. With a 0 bias setting, as
soon as the load increased to 104MW, the cost control would close the control valves
to restore 100MW. At this point, the cost control is acting to oppose frequency
correction back to 50 Hz.

Further, let us review the frequency effects and the frequency bias on a particular
unit , if it has been set to 4 MW per 0.1 Hz deviations. As soon as the system
frequency drops to 49.9 Hz, the cost signal representing desired generation from this
unit changes from 100 MW to 104 MW, under the added influence of frequency bias.
If we can again assume that the turbine governor would again have picked up 4 MW,
no control action occur to reduce generation back to 100 MW and system frequency
should return to 50 Hz.

Of course, if no automatic load frequency control is being used, then the dispatcher
must manually direct an increase or decrease in generation from the units under his
control, in order to restore system frequency to 50 Hz. In this case, the dispatcher
“corrects” system frequency in order to provide the correct frequency on a 24-hour
basis. This is usually done fairly close to midnight of each day. Instrumentation will
advice him how far above or below 50 Hz the system has been operating for the past
24 hours. Knowing his system frequency bias, the dispatcher can then order more or
less load to be generated for a given period in order to restore system frequency to an
average of 50 Hz for the past 24 hours. This phenomenon is particularly important
for controlling system frequency specially in view of controlling power generation with
ABT.

KORBA SIMULATOR 119

 Transient speed rise (TSR):
When load rejection takes place,

Å
speed shoots up temporarily before 8-

TSR
settling down to steady state value 6-
TSR gives the % speed rise on full 4-
load throw-off 2-

Æ
O- Steady state
TimeÆ

Steady State Regulation: nmax.

It is defined as the Ratio of % speed nmin.

change (from no load to Full load) to

the nominal rated speed.
%Regulation=100x(nmax– min)/nnom
0% Load 100%

Load Frequency Control is shown in the figure below; it shows the single turbo-
generator system supplying an isolated load. Main component are;

1. Fly ball Speed governor system

2. Hydraulic Amplifier
3. Linkage Mechanism
4. Speed changer

Increase in frequency Ʀf causes the fly balls to move outwards so that B moves
downwards by a proportional amount k2’Ʀf. The net movement of C is therefore ƦyC
= k1 kC ƦPC + k2 Ʀf and movement D, ƦyD= k3 ƦyC + k4 ƦyE. The movement
ƦyD depending upon its sign opens one of the ports of the pilot valve admitting high-
pressure oil into the cylinder thus moving the main piston & opening the steam valve
by ƦyE.

KORBA SIMULATOR 120

In KWU turbines, the stop valve & control valve (one set) share a common body. The
piston of the servomotor is subjected to disc spring force in the close direction and
Hydraulic pressure in the opening direction. Hydraulic Governor controls the steam
supply by operating the control valves. The fluid pressure under the piston
determines the position of the valve; this is controlled by pilot valve of the turbine
governor & the secondary fluid oil system.

Electro-Hydraulic Governor (EHG)

Electro-Hydraulic Governor (EHG) works in parallel with Hydraulic governor at all

times of requirements. Basically the Electro-Hydraulic Converter (EHC) is the
connecting element between the electrical and hydraulic parts of the turbine
governing control system for carrying out the Electro-Hydraulic Governing of the
turbine.

The Electro-Hydraulic Governor (EHG) is beneficial in:-

• Offering the flexibility, dynamic stability, dependability, excellent

operational reliability, Low transients and steady-state speed deviations at
all instances.
• Maintaining exact load frequency droop with high sensitivity.
• Providing reliable operation at times of grid isolation conditions.
• Operating the turbo-generator Safely in conjunction with TSE.

In KWU turbines, Electro-Hydraulic Governing has been achieved through various

electronic / selector modules configured in four modes of controls:

KORBA SIMULATOR 121

 • Admission Control mode,
• Speed Control mode,
• Load Control mode
• Pressure Control mode.

The Hydraulic governor and the EHG system have been designed such that the
governor with lower set point takes over or assumes the system control, as such
normally, the set point of the Hydraulic Governor must be set above that of the
Electro-Hydraulic Governor when EHG is effective. In cases, when EHG fails to cause
shut-off, the set point that is, affected is that of Hydraulic Governor.

In such situations the Tracking Device provides a revised set point of 5-10% above
the EHG set point and it causes increase in small load when the control is
transferred to Hydraulic-Governor. The tracking device is either switched on or off
manually but when EHG failure or turbine trip occurs, the tracking device is
switched off automatically thus tracking under faulted operation mode is prevented
or prohibited. More details on tracking actions are covered in the follow-up circuits of
the speed/load control modes.

Electro Hydraulic Converter details:

Electro Hydraulic Converter converts the electrical signal in to the hydraulic signals
and large positioning forces are generated in control valves. The electrical signal from
governor control circuit operates the sleeve and pilot valve spool; this regulates the
trip fluid drain. Under steady state condition pilot is at central position; in deflected
position, the control oil is admitted above or below the amplifier piston. The motion
of the amplifier piston is transmitted via a lever to a camshaft, which actuates the
sleeves of follow-up piston valves, causing secondary oil pressure to change. The
speed, load, and pressure signals are measured and converted into conditioned
signal in electronic modules.

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Admission Valve (spool) Controller

Admission Valve (spool) Controller also referred as the position controller is Common
for all three modes of EHG, and it supplies the operating current for driving the
plunger coil. The Position controller loop uses a PID control mode for processing
outputs that provide the driving current signal to the plunger and regulate the oil
drains of HP/IP control valves (CV) ; thereby it controls steam supply into the
turbine.

The current in the plunger coil is increased for closing the HP /IP CV and vice versa
for opening of the HP /IP Control Valve. The reference signal therefore works in
reverse manner (rise in the coil current for low reference condition). By using two Nos
of differential transformer (housed in EHC), feedback signal from the valve lift is
derived to ensure proper stationing of plunger spool.

Whenever current through the plunger coil gets interrupted or the electrical feedback
circuit gets faulted, the reference value of the Hydraulic controller determines the
actual valve position. Although the force to the plunger coil and to the control sleeve
is, considerably smaller, but the regulating signal to the secondary auxiliary oil flow
as transformed is quite large. The figure below gives various connections and
modules used in EHG.

Control Transfer of various controllers:

Three selectors have been used for specific functioning Speed controller output (hrnc)
and the load controller output (hrpc) are passed through a Maximum selector (MAX-

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1) and the selected signal passes to a minimum selector (MIN-1) in such a fashion
that at times of over-speeding of turbine (during load throw-off situations), the input
to the minimum selector: MIN–1: takes care of transient condition of the load throw-
off and is sufficient to check the turbine from over speeding. (During sudden load
throw-off, over speeding of turbine is effected and since 10.5 V is generated by a
potentiometer that gets algebraically summated with hrnc then it outputs voltage
which is less than that of the speed/load signal as selected from the MAX-1:)

The signal from the Minimum selector: MIN–1: passes through another Minimum
selector: MIN–2: that receives the Pressure Controller output (hrPrc) signal as
explained in pressure controller loop. Finally through the last minimum selector:
MIN–2:, the control signal connects the Admission Valve (spool) Controller loop which
outputs the driving current for the EHC plunger coil.

Operation of EHG in various modes

Start-up

Switching the supplies ON and setting the speed/load setter to zero puts the EHG in
Operational condition. The hydraulic speed control eqpt and the start up eqpt of the
hydraulic controller are set in upper end position. The actual speed is sensed since
turbine already is in barring gear and by slow rising of speed reference the speed
controller works /is in service; the turbine speed is then brought up situation for
synchronising TG with grid using speed controller.

Operation under load

Load controller can be taken in service after turbine is synchronised to control load
in quick response and high linearity either as per LDC/AFDC or using various
modes/sub loops explained in Load control. Frequency change is selected via the
integral action load controller to corresponding droop values and a sensitivity of 5
Milli-Hz is obtained which meets the operational requirements of the present day
large grid. The output signal of the speed controllers is automatically matched to the
output signal of load controller from rated power on down to station load. The speed
controller then remains in standby mode only and stands ready to provide station
load in of load shading.

Shutdown

During normal shut down operation, the load controller is set to zero value. After the
speed controller has assumed control of TG set, the unit can be disconnected from
the grid.

Load shedding

In case of load shedding i.e. sudden separation of the generator, from the grid, the
output signal of the load controller is immediately reduced to value below that of
speed controller. Consequently due to minimum selection, the speed controller
assumes control and returns turbine back to the set reference speed.

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This reference speed practically coincides with the rated speed, since the speed
controller is set to provide the station load during the start of operation under load.
This provision improves the dynamic response of the closing of the main steam stop
valve /control valve and keeps the turbo set speed from rising along the droop
characteristic. An additional effect is the reduction of the speed oscillations. In case
of automatic reclosing of the generator CB, the reduction of the load controller
output signal below the speed controller output signal below the speed controller
output signal is cancelled and the initially selected load level restored.

Speed Control Mode

Speed Control Mode works during

• Rolling (start-up or shut-down of the turbine),

• Speeding up of turbine until synchronisation,
• For effecting block loading & full loading of TG set at exceptional emergency
situations House-loading operation during fast load throw-off
• For Controlling the TG set during rapid/large frequency fluctuations.
• Regulating during Over-speeding;(When the speed of the TG set rises slightly
above synchronous speed, the control action in speed control mode quickly
reduces the turbine speed very close to synchronous speed)
• During load shedding with subsequent operation of the TG set in an isolated
grid situation, (The speed controller assumes continuous TG set control in
such situations)

Speed reference signal (nR) is varied (In the range of 0-3600 rpm):

• Manually by Raise/Lower push buttons (using motorized potentiometer,

• By the synchronizer (when selected) or
• By follow up signal (explained separately). The speed reference (nR) can not be
raised when follow-up condition exists and dn/dt is less than monitoring (in
this situation lowering of nR gets slowed down.

The reference nR is varied in the range of 0-3600 rpm and for minute operation
during synchronizing, above the speed of 2800 rpm; a reducing gear lowers the speed
of the motorized potentiometer to ¼ rate for exact speed adjustment. The speed
reference (nR) cannot be raised when follow-up condition exists and dn/dt is less than
monitoring rather in this condition raising or lowering phenomena of nR gets slowed
down when the speed reference (nR) is less than 2800. Two indicators have been
provided in UCB panel for monitoring speeds; of narrow range (2700-3300) and wide
range (0-3600).

The Time-dependent speed reference signal ( nRTD )

The Time-dependent speed reference signal (nRTD) also referred as nR lim. influences
the speed reference nR considerably. During start-up of turbine this nRTD allows
rising of the turbine speed at the highest permissible rate consistent with the
conservative operation as decided by the TSE computed margin signal introduced
between a DC amplifiers. The Integrator module performs this function rising with
time like a ramp. The slope of the integrator ramp can be adjusted over a wide range

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and is optimized during commissioning. Fast mode or the stop action facility, modify
the final nR .The output nRTD of the integrator module, is transmitted to the speed
controller and displayed on the desk in the range 0-3600 rpm.

Quantum of Follow-up signal is the difference between actual speed (nact) and offset
of 120 rpm and is effected (switched automatically) if load controller is operative,
final load reference (hrpc) is more than final speed reference (hrnc) by 10% and
frequency is between 49-51 Hz OR if turbine is tripped (time elapsed) and speed
reference (nr) is equal to actual speed (nact) minus 60 rpm. During follow up, the
quantum of the follow-up signal is derived from the actual less the off-set (60-120
rpm) speed reference (nR) and difference is further added or subtracted as per the
magnitude to cause change in speed reference (nR ).

‘Blocking ‘ or the ‘Stop nRTD ‘ of the speed signal is generated by an AND module in
conditions i) speed >2850rpm, ii) nR is more than nRTD by 300 rpm and iii) an OR ed
output of many conditions as given below:-

1. TSE influence gets faulted (goes out of order or switched off) or EHC fault
condition appears AND turbine speed is more than 2950rpm. .
2. During the transition of control from electric to Hydraulic, the speed reference
signal becomes less than actual speed and if is more than 50 rpm, i.e. (nR -
nact ) < 50 rpm.;
3. If nR > nRTD; pressure controller is in action OR Generator breaker not ON.

This Block signal stops the integration (further) function of time dependent speed
reference integrator, it blocks the already generated nRTD , and thus the speed
controller input signal remains stay-put during stop action.

During rolling of the turbine, if between the speeds of 600-2820 rpm the rate of
speed rise is very low i.e. less than 100 rpm per minute, then the dn/dt is less than
monitoring signal appears to alarm the operator; it also blocks any further rise in
speed and brings back the speed reference to 600 rpm. dn/dt less than monitoring
alarms the operator and takes care of low acceleration rate in turbine during rolling
by suitable output from the speed reference setting module, and at the critical
speeds (between 600-2829 rpm) of the turbine.

The dn/dt is less than monitoring is derived from an AND gate module, its conditions
are i) nR is more than 600 rpm, ii) nact is less than 2850 rpm, iii) MSV is open (>0%),
vi) speed controller is selected & in action, v) Generator breaker is not on and a
feedback signal of dn/dt <108 rpm per rpm (0.03 sec –2).
Refer block diag. for details.

Actual speed (nact) Measurement:

Actual speed nact is acquired by three digital speed pickups (Hall probes) in the form
of pulses /frequency. Channel-2 is utilized while other two-channel pick-up remains
redundant; electronically switching ensures no affect in channel in service and also a
full - proof monitoring. The selected sensed speed channel signal is further divided
into three measuring signals (f/v of 0-60 Hz, low range 0-6 Hz & full range 0-60 Hz
and a quartz frequency standard) for various other applications in the EHG and
other circuits.

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The difference of actual speed and time dependent speed signals (nact - ‘nRTD) form
the input error of the Speed controller which outputs control signal (in the path as
explained in selection section) through the selection modules for driving the EHC and
finally establishing the EHG.

ACTUAL SPEED MEASUREMENT / FORMATION

The speed controller is poportional+derivative (P-D) action controller, with sloping

characteristics. During steady-state condition, the speed controller outputs for better
load sharing by more nos. of turbo-generators connected in the grid as compared
with purely mechanical and Hydraulic Governor run T-G sets. Due to proportional

KORBA SIMULATOR 127

control, a control error (off-set) is obvious in the speed reference but it does not
matter much. An identical speed at synchronising point is possible to be achieved
due to a Pre-feed function of pressure.

No load correction of speed is achieved by a feed forward signal that is obtained from
Boiler pressure controller during synchronising the T.G. set.

Load Control Mode

Load reference value pR is generated by means of a reference value setter module as

described in speed control mode and is derived manually by the operator adjusted
(lower/raise) values by means of a remote driven motorized potentiometer, Load
controller is switched ON for bringing load controller in service., it can also be varied
by the Automatic dispatch control (When switched ON ) ; it is also termed as pR ADS
,and is basically the MW demand generated by the Coordinated Master Control
loop(CMC). The load demand signal is restricted within upper and lower MW loading
limits as detailed in CMC loop description.

ADC influence ‘ON’ appears when there is NO ADC fault if is selected. In case if, CMC
or ADC gets faulted, it is automatically switched OFF; at this situation, matching or
the follow up is automatically taking place and loading of the TG set is subsequently
made in standby basis.

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KORBA SIMULATOR 129
Load reference pR as obtained from the potentiometer in voltage signal, is fed to the
high gain amplifier whose gain is adjusted by the rate of loading dp/dt or the load
margins (In order to load the turbo-generator at highest possible rate consistent to
permissible level of thermal stress, the upper/lower load margins are computed by
TSE, explained separately.). The Load gradient (load rate dp/dt.) is selected either by
On/Off push button or by follow-up command, for inclusion and it either modifies
the high gain amplifier slope in both negative and positive sides of the amplifier or
the TSE computed margins as explained above modify the high gain amplifier
through minimum selector. Upper release margin can result reduction of generated
power and lower release margin can result unloading.

Time dependent reference signal also referred as ‘pRLIM’’:

The Time dependent reference signal also referred as ‘pRLIM’’ is generated through a
high gain amplifier and an integrator functioning in fast, normal and stop modes. It
follows the ramp characteristic. The proportional leg of the response of the pRLIM can
be adjusted between 0-20% of MCR power of the TG Set. The response of the pRLIM is
purely integral, if the rate of rise of the pRLIM is limited to the load gradient selected,
and at this situation the proportional channel is switched off.

This pRLIM rises during start-up at a rate (Mw/min ) selected through load gradient
setter until final value. The pRLIM module is continuously allowing matching of the
actual power output as long as the generator breaker is open (not synchronized) and
ensures smooth transition of speed (during start-up) to load controller (after
synchronization).

The characteristic of pRLIM is linear 0-10v rising in 04 minutes. And it (pRLIM) acts
directly on the load controller without any intermediate control device. At conditions
when TG is not synchronised, power error (Pr-Pact) signal governs the follow-up
/tracking as explained below.

Tracking or the follow-up conditions in the load controller:

When the generator C.B. is on but the speed controller has taken over (due to
conditions of follow-up) and speed controller remains in action until load controller
signal (pr) < (nr) of speed controller; then tracking gets released as soon as (pr) = (nr)
and

When load shedding is less than station auxiliary power (p act < station load) and
Mw error reaches to more than 5 % or the generator circuit breaker is not made on;
the load controller output, tracks to speed signal.

Stop signal in load control:

A ‘Blocking’ or STOP command gets initiated at conditions shown below then the
integrator stops further integrating and pRLIM (the load demand) remains steady until
the blocking signals are cleared or restored. The block conditions are met at
conditions as given below: -

• TSE switch is ON (selected) and it goes out of order (got faulted); it is enabled
again after the TSE is reset and it becomes O.k..

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• The load reference signal has been raised and the pressure controller
goes/switches to limit pressure mode of operation.

• The STOP set point binary condition is/gets introduced.

A highly and sensitive linear response with respect to power grid frequency is effected
by having the additional load reference component pR∆f (this can be set as low as
possibly up to 5 milli Hz); it can be included for operating the load controller with
frequency influence included in the system.

This frequency influence was being excluded in the system sometimes in nineties,
because the units were been operated at very high differentials of frequencies when
frequency used to rise to approx 52 Hz at off-peak hours (in night hours) or
reduce/decline as low as 47.5 Hz at peak load hours. But now due to insistence by
Load Dispatch Center (LDC) to regulate the grid frequency at very tight margin and in
order to run systems on ABT mode, the frequency influence inclusion have become
mandatory. This is being referred as FGMO operation of units.

The load reference thus derived is fed to a minimum selector, which also is fed with
the load limiter output. In order to restrict loading, Load limiter is preselected; the
Load limit value (due to plant conditions) can be adjusted by the load limiter
potentiometers and can also be seen on control desk. Even the reduction in grid
frequency cannot cause the TG set to exceed the preset power level due to load
limiting.

The output signal from the load limiter at the minimum selector in the form of the
™pR , that is the sum of all reference values acting on the load controller as reference
signal or the desired value.

Actual Load signal is acquired threefold by means of the load measuring device and
transmitted to the controller comparator module but in case the signals of the three
parallel cannels deviate by more than 5% an alarm ‘ACTUAL LOAD SIGNAL FAULTY’
along with group alarm of ‘Turbine Controller Faulty’ appears.

The difference of the actual measured power signal (pact) and the ™pR form the input
of the load controller that outputs control signal and passes through a selection
module for driving the EHC as explained in the admission control and selection
diagram.

Load Controller consists of two plug-in modules first one to accommodate isolated
grid detection and the second to accommodate dynamic loading of the generators &
to housing the tracking module. Load Controller is a proportional (P) + integral (I)
controller to take care of small changes of load in Proportional mode and large
changes in Integral mode operation. Due to this addition, the response of the
controller is proportional for small changes of the load reference value but for the
large changes of reference value proportional plus integral mode refines the system
operation.

In order to effect smooth transition from speed controller to Load Controller

(Generator breaker open condition i.e. turbine not synchronised with grid) ™pR is

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compared continuously with pact and control signal is matched ensuring bump less
switching.

During the time the speed controller is in control for start-up, shut-down or no load
operation of TG set, the starting time constant of the TG set remains in dominating
whereas during synchronised operation, the transfer functions of generator and the
power grid become of vital importance for controller optimisation.

Pressure Control Mode

The pressure controller controls the turbine load with respect to the main steam
throttle pressure and prevents the large pressure drop during fast loading (Quick
load increase). The actual steam throttle pressure is measured in turbine area and
pressure reference is derived from CMC loop, after comparison the deviated control
signal (hRprc) is fed to the Proportional +Integral (PI) action type Pressure controller
and its final output is fed to the minimum selector-2 as described earlier in speed
controller and load controller loops.

The Pressure Controller functions in two modes of operation:

• Initial pressure mode
• Limit pressure mode

Initial Pressure Mode:

In Initial pressure mode of operation, constant initial pressure (turbine inlet throttle
pressure) is maintained and acts in proportional to pressure setting by minimizing
the pressure error (Actual-Ref) even up to zero value. The power delivered by the TG
set is determined by the boiler capability up to a maximum of power level as set by
load controller; increase of load above this is blocked thus, because it is connected to
a minimum selector. The difference pressure ∆p between the reference and actual
value, is controlled up to a value of 10 Kg/cm2 which is equal to the pressure drop of
steam flow from boiler to the turbine control valve; it therefore ensures natural
differential pressure of the steam flowing from boiler to the turbine. A preset
potentiometer equivalent to this pressure generates negative voltage to the controller
input and it biases the pressure differential ∆p thus in the controller.

Limit pressure mode:

Limit pressure mode uses the boiler storage capacity and is effected either by push
button or gets automatically selected as soon as the pressure deviates to 10 Kg/cm2
from normal running pressure to operate the controller in Limit pressure mode. This
deviation of 10 Kg/cm2 pressure signal already subtracted in the in the input of
Pressure controller, as described in the initial pressure mode, gets neutralized by
automatic switching.

Introducing the Limit Pressure Operation is therefore possible to regulate boiler

pressure beyond a pre-set pressure of main steam and load in small or quick
variations, and is controlled until pre-set pressure is reached that is not possible in
normal frequency based load control.

KORBA SIMULATOR 132

In fact the normal ∆p from boiler to turbine (as explained in initial pressure mode) is
not persisting either due to increase in pressure at turbine side due to load throw,
vacuum drop, extractions’ closure etc or due to pressure drop in boiler side by non-
availability/reduced loading of mills, of coal feeders or any other causes. At this
situation due to equating/reducing of differential pressure ∆p , an alarm is generated
so as to warn/alarm the operator of the discrepancy. When Limit pressure engaged
alarm appears, the stop signal in the load control loop is also generated for blocking
the pRLIM signal from increasing/reducing.

All the three controllers are operative in such a manner that the governing of T.G is
ensured full proof and speeding or loading of the T.G. is best maintained as per the
pressure in the system and Boiler or turbine follow mode is achieved with full
reliability and safety.

Co-ordinated Master Control (CMC) ensures co-ordination between Boiler & Turbine.
The Co-ordinated Master Control (500 Mw) block diagram has been given below, we
find that the Unit master receives load demand signal from load dispatcher (ALC). A
GNI computer/SPCM is provided with the system to decide target value Z0, Run
Back load limits & load rate required for proper generation, Boiler master controller,
Turbine load set-point etc., through which the CMC is ensured. The load demand
signal as generated in CMC, for turbine control reaches to point ‘D’ of EHG block
diagram (refer the load control mode) and is switched for inclusion to operate the

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EHG in coordination with grid dispatch ADC demand. Boiler Follow or Turbine follow
modes are decided by switching suitably and loaded TG operation is achieved as
explained in details of CMC mode of integrated control in C&I , ACS section.

KORBA SIMULATOR 134

KORBA SIMULATOR 135
KORBA SIMULATOR 136
KORBA SIMULATOR 137
KORBA SIMULATOR 138