DIGITAL ELECTROHYDRAULIC

CONTROL SYSTEM

Shanghai Turbine Ltd company

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 DEH CONTROL SYSTEM INDEX
1 DEH SYSTEM OVERVIEW
2 CONTROL SYSTEM
2.1 Sensor Input Summary for OA/OPC
2.2 Operate Modes
2.2.1 MANUAL Mode
2.2.2 OPERATOR AUTO Mode
2.2.3 AUTO SYNC Mode
2.2.4 REMOTE Mode
2.3 Feedback Control Loops
2.3.1 Speed Feedback Loop
2.3.2 Megawatt Feedback Loop
2.3.3 Impulse Pressure Feedback Loop
2.4 Limiters
2.4.1 Valve Position Limiter
2.4.2 High-Load Limiter
2.4.3 Low-Load Limiter
2.5 Valve Testing
2.6 Valve Management
2.7 Over speed Protection Control (OPC)
2.8 Startup Procedure
2.8.1 Startup Procedure Bypass Off
2.8.2 Startup Procedure Bypass On
3 AUTOMATIC TURBINE CONTROL (ATC)

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 1. DEH OVERVIEW
The DEH proposed to Indian power is an MAXDNA based Distributed Control
System(DCS). This system will be equipped with three controll cabinet(include
two redundant MAXDNA controllers), one operator workstation, one engineer’s
workstation ,power cabinet, for Indian power. The MAXDNA Control System
controllers and workstation drops are summarized below:
• 2 – Main Turbine Speed and Load Control controller, referred to as the
Operator
Automatic/Over speed Protection Control controller (OA/OPC), and supporting
automatic turbine control (ATC), and rotor stress monitoring (RSM)
• 1 – Engineering Station/Software Server/Power Tools Database Server
• 1 – Operator Workstations
All inputs for which median selection (three channel inputs) is performed, the
inputs are placed on separate input cards and on separate I/O busses to
minimize the effects of a card failure or removal.
Operator workstation is the main interface for the operator. This workstation
provides the capability for a full soft control interface and status graphics for
operating, controlling, and testing the turbine. The Operator workstation is
configured with a single LCD display, a QWERTY keyboard, and a mouse, and
are located in the main control room. The DEH will use a graphical operator
interface or soft control graphics, which are designed to be intuitive and easy to
navigate for a turbine operator. These graphics are accessed via the Operator
Workstation. The Operator Workstation allows system monitoring, point scan
removal/enable, interaction with performance calculations, alarms processing and
acknowledgment, data point process trending or historical trending, viewing
graphic displays, and system tuning if enabled. The system operational status
can be determined by the operator at any time by observing the status diagram.
which presents each system drop status (Normal, Offline, Failed etc) with
diagnostics capability down to the I/O card and channel. In addition to the
MAXDNA Operator Workstations, two hard control interfaces are also provided.
The trip is reset manually to ensure that the turbine can be safely restarted. A
desk mounted combined Engineering/Software Server/Power Tools/Database
Server Workstation is also provided to make engineering and configuration
changes to the control database, or graphic displays or generate new control
applications. The maxVUE/maxDpuTools/Point Browser also allows system
configuration changes such as controller programming, graphics generation and
modification, database changes, uploading and downloading controller
configurations, and equipment addition/deletion from these drops only. This
workstation should be located in a central and convenient location such as a data
logging or computer room. An HP printer are also supplied to print control builder
documentation, graphic builder displays, system documentation, screen dumps
and general system functions.
The communication network of the offered system is formed by two Fast Ethernet

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 root switches(primary and backup), which are fully redundant to each other. It is
recommended that the Fast Ethernet switches be powered from two separate and
independent power sources to provide maximum system fault tolerance. The
switches may be located in the network cabinets, or can be desktop mounted in
an appropriate location designated by SHANGHAI TURBINE. The root switch
pairs are dual attached to the workstation drops via network cables, using media
converters, to make the system immune to any EMI/RFI that may be present.
Each redundant half of the DEH controller is attached to one of the primary or
backup switches in the equipment area. All network cables and connectors
required for installing the new system are included. The MAXDNA control system
philosophy is to design the controller applications to the extent possible to be
independent of the Communications network. This approach ensures that the
controllers will continue to function and control the plant in the event of
catastrophic failure of the communications network due to human error.
The main turbine control system functions perform operator automatic (OA) and
over speed protection control (OPC). These functions position the turbine
steam-inlet governor valves according to the Operator’s speed and loading
commands. The DEH system main functions are signal selector logic, speed
control, load control, valve testing, feedback loop initiation, remote control and
over speed protection. All vital analog and digital inputs come into the OA/OPC
controller. Vital analog inputs such as Speed, Megawatt, Impulse Pressure, and
vital digital inputs such as auto stop latch (ASL), breaker close(BRA) status and
turbine runbacks are processed in this controller.
2.1 Sensor Input Summary for OA/OPC
The OA/OPC functions provide a fast and effective means of control and
protection against critical situations that might cause the unit to trip. The system
continuously monitors critical control turbine parameters on a multi-channel basis.
The following field parameters are monitored in the OA/OPC controller. The field
process devices are identified below.
• Turbine Speed (three speed pickups as input)
• Eight LVDT valve positions
• Auto Stop Latched (three contacts as input)
• Megawatts Transducers (three transducers as inputs)
• Impulse Pressure(three transducers as inputs)
• OPC Pressure (three pressure transmitters as inputs)
• Generator Breaker Closed (three contacts as input)
• Four contact outputs for RSV & IV closure
Vital analog inputs to the OA/OPC controller, such as the Main Turbine Speed,
MW, and Impulse Pressure have three input transducers. If three input
transducers are available, they are processed using a median selector algorithm.
This smart logic ensures accurate signal measurement by requiring at least two of
the three inputs to equal one another within a configurable tolerance. This logic
becomes particularly useful when one of the three inputs fails. In this instance, the
algorithm calculates the average of the remaining two good signals and an alarm

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 is triggered to inform the operator of the failed or unreliable input. The use of
three independent inputs provides improved reliability, because each of the three
inputs are read from a different I/O card electronic module on a different I/O
branch.
2.2 Operate Modes

The CTRL MODE performs all of the functions associated with basic turbine
speed and load control. The main function of the CTRL MODE is to select various
operating modes such as:
A. MANUAL Mode
B. OPERATOR AUTO Mode
C. AUTO SYNC Mode
D. REMOTE Mode
E. ATC MOD
Based on the selected mode, the control logic
in the OA/OPC controller calculates a Set point,
Target and Rate. Using the current set point,
the controller can correct the valve demand for
speed control and two separate load control
loops: Speed (Frequency) Correction Loop,and
MW Loop The Operator enters a Speed or
Megawatt Target (rpm or MW) on the main
Turbine Control System graphic by selecting
the set point button. Before accepting the

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 operator’s entry, data entry checks on desired speed target for resonance range
and valid acceleration rate are performed.
2.2.1 MANUAL Mode
In the MANUAL mode, the operator uses the
graphic display of the DEH manual Pop Up
panel to raise and lower the master station
which drives the control valves for the desired
turbine speed or megawatts. In MANUAL, the
OA controller uses flow demand to insure a
linear response with load.
2.2.2 OPERATOR AUTO Mode
Once OPERATOR AUTO turns from green to
red on the control mode graphic, then
OPERATOR AUTO mode may be selected. If
any control mode on the control mode graphic
is red, then that mode will not be initiated when
selected. When OPERATOR AUTO is selected, the flow demand tracking value
will be the new operator auto
target and reference. In
OPERATOR AUTO mode, the
operator sets the target or
demand value and the rate. If
GO is pressed, the controller will
increment or decrement the flow
value at the entered rate for
either load or speed control.
Once the OA controller has
calculated a flow demand, the
valve management program
calculates a valve position set
point based on the valve mode
(single or sequential).
2.2.3 AUTO SYNC Mode
Once in OPERATOR AUTO
mode, the operator may go to AUTO SYNC on speed control if the AUTO SYNC
permissive is present. In AUTO SYNC, the reference and target are the same
value and both are modulated up or down by the auto synchronizer raise/lower
pulses. The acceleration rate is fixed to 1 rpm per auto synchronizer pulse. In the
event that AUTO SYNC is rejected either by losing the permissive or closing the
generator main breaker, the system automatically goes to OPERATOR AUTO
mode. The auto synchronizer hardware external to the MAXDNA turbine control
system is not being proposed.
2.2.4 REMOTE Mode
The REMOTE mode allows an automatic dispatch to control the DEH load

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 reference directly to effect a coordinated control scheme. Either an analog input
( hardwire or across the data highway) or contact closures can be used to
increase and decrease the reference. The rate of change of the DEH reference is
determined by the interfacing signals. The contact closure interface can respond
on a pulse frequency or on a pulse duration. The DEH impulse pressure and
megawatt (MW) feedback loops can be utilized in this operating mode or may be
removed from service by the remote system. If required, a maximum load rate
monitor can be provided to always limit the remote demand to the capabilities of
the system. Using the pulse duration contact inputs, the time from the leading
edge of the pulse to the trailing edge is calculated and multiplied by the auto
dispatch system (ADS) rate constant. This value will be added to or subtracted
from reference demand. Using pulse frequency contact inputs, the pulses are
multiplied by the ADS rate constant. This value will be added to or subtracted
from the reference demand, if the ADS rate is less than a MAXRATE.
2.3 Feedback Control Loops
When the DEH is in any automatic
mode with no feedback loops in service
is at rated pressure and temperature,
the reference should match actual MW
if the governor valve (flow vs. lift)
curves are accurate. The OA controller
will use the governor valve (flow vs. lift)
curves to position the governor valves
in a feed-forward manner. The DEH
has two closed loop feedback
controllers: speed and MW — all of which are online tunable. Any feedback
control loop can be placed in or out of service as desired by the operator while in
load control with no disruption to the system. The MW loop is blocked from being
in service simultaneously since in the MAXDNA design these loops are
completely independent of each other.
2.3.1 Speed Feedback Loop
The speed feedback loop must be in service on speed control to go to
OPERATOR AUTO mode. Once in service, it cannot be taken out of service on
speed control. On load control, it can be taken in and out of service. The speed
control loop uses median selector logic applied to the three speed channel inputs.
If two-speed channels should fail, the speed loop will be rejected out of service,
which will put the system in MANUAL control. The speed error between reference
demand and actual speed is applied to the throttle valve (TV) or governor valve
(GV) proportional-plus-reset controllers (PIDs). The PIDs will modulate the valves
to reduce any speed error. On load control, the speed feedback loop is used for
frequency participation to help correct system frequency. The speed error is sent
to a function generator which generates a frequency correction factor.
2.3.2 Megawatt Feedback Loop
The Megawatt control loop uses median selector logic applied to the three

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 megawatt transducer inputs. The megawatt feedback loop will correct the MW
setting in the reference window to actual MW. When this control loop is placed in
service, the MW error between the corrected reference MW and the actual MW is
applied to a PID controller. The MW PID controller output will trim the GV control
signal up or down to reduce any MW error. This loop is also used for governor
valve test closure to allow the remaining control valves to compensate for the
required flow when comparing load setpoint to Megawatt feedback.
2.4 Limiters
2.4.1 Valve
Position Limiter
The valve position
limiter provides the
operator with
high-limiting action
on the final GV
controller output.
The valve position
limiter set point can
be raised or lowered
on the set limiter
graphic.
2.4.2 High-Load
Limiter
The high-load limiter
can be placed in service on the set limiter graphic if the following are true in any
of the automatic modes:
• Main generator breaker is closed
• DEH is not in MANUAL mode
• High-load limit greater than the reference demand
When the high-load limiter is in service, the operator may place the MW and
impulse pressure feedback loops in and out of service. This action may cause the
high-load limit set point to be set equal to reference demand if the new computed
reference demand is greater than high-load limiter. A limiting condition exists
when high-load limiter is true and reference demand is equal to high-load limit,
which will cause LIMITER LIMITING to display on the CRT. An INVALID prompt
will appear if the operator enters a value of high-load limiter which is less than
reference demand, less than the low-load limit, or is totally out of range of a
high-low monitor. If the operator tries to place the high-load limiter in service in a
limiting condition, the INVALID prompt message will appear on the CRT.
2.4.3 Low-Load Limiter
The low-load limiter can be placed in service on the set limiter graphic if the
following are true:
• Main generator breaker is closed
• DEH is not in the MANUAL mode

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 • Low-load limit is less than reference demand
When the low-load limit is in service, the operator may place the MW and impulse
pressure loops in or out of service. If a turbine runback occurs and the reference
demand is less than low-load limit, then the low-load limit will be set equal to
reference demand to prevent the low-load limiter from inhibiting the protection
system. INVALID will appear on the CRT if the operator enters a low-load limit
value greater than reference demand or high-load limit. If the operator tries to
place the low-load limiter in service when in a limiting condition, the INVALID
message will appear.
2.5 Valve Testing
The DEH
valve testing
is selected on
the DEH
overview
graphic only in
single valve
mode and on
load control.
The DEH can
perform stop,
governor, reheat stop valve tests safely and
efficiently. To initiate a valve test, the operator
must go to the DEH overview graphic, move
the cursor to the valve to be tested, and press the SELECT button on the mouse.
Once selected, the operator presses the CLOSE button on the special valve test
window, and the particular valve will begin to ramp closed. The message VALVE
TEST IN PROGRESS will appear on the graphic. Valve positions are constantly
displayed on the DEH overview graphic to monitor the valve closure. To complete
the valve test, the operator must press cancel and the valve will ramp open.

the DEH will automatically add additional

flow to the GVs not being tested to maintain
constant flow or load on the system. This is
accomplished in a feed-forward manner
using the GV (flow versus lift) curves. During
a reheat stop valve test, the intercept valve
will close and reopen simultaneously with
the reheat stop valve.
2.6 Valve Management
This page allows the operator to select the
control valve mode the turbine is in
operating in. The operator can select the
sequential or single governor valve mode or

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 initiate a transfer from throttle valve(TV) to governor valve control.
The TV-GV transfer is a one-directional transfer. Once the turbine from TV to GV the
operator cannot transfer back to TV control. Whenever a control valve transfer is in
progress, a message VALVE TRANSFER IN PROGRESS will appear on the overview
graphic. The exact text of the message will identify whether it is a TV –GV transfer or a
single to sequential , or a sequential to single valve transfer. On a TV-GV transfer, the
governor valve will move from fully open to the closed position. The governor valve will
remain closed for a brief interval until there is a slight decrease in speed, indicating that
the governor valve are in positive control of speed. Simultaneously the throttle valve start
moving toward the wide open position, and the governor valve open to a position to
control speed at the TARGET value.
In single valve operation ,all governor valves move together in sync. In sequential valve
operation the governor valve are not all opened simultaneously ,but in an preplanned
sequence. Sequential valve operation provides an improvement in the efficiency of the
turbine.

2.7 Over speed Protection Control (OPC)

Over speed Protection Control (OPC) is achieved by the Over speed function and
the Load Drop Anticipator (LDA) function. The DEH manual panel graphic display
also has the over speed protection control (OPC) test key-switch. The OPC test
key-switch requires a two-step pushbutton operation for safety, and is locked out
completely on load control.
OPC TEST Select the OPC TEST and press the IN pushbutton , make sure that
all GV and IV close rapidly and all GV and IV will reopen . then press the OUT
button , exit the test.
OVERSPEED TEST Raise the TARGET to 3100rpm. when the actual speed
reach 3090rpm, the OPC alarm will appear in the graphic and all the GV and IV
will close and all GV and IV will reopen. Decrease the target to 3000rpm.
Mechanical OVERSPEED TEST Depress the DIASBLE and then press the IN
pushbutton . Thus Disable the OPC function and raise the TARGET to 3300rmp.
When the actual speed reach to 3090rmp ,OPC will not happen. When the
Mechanical OVERSPEED TEST is accomplished ,make sure that DISABLE is
OUT.
Over speed function
The OA/OPC has three turbine speed channels, each with it’s own magnetic
speed pickup and tachometer. The OA/OPC controller applies two out of three
logic to the three turbine speed channels for Overspeed sensing and tripping. As
a result, a malfunction in any one of these channels will not cause an invalid trip
or prevent a valid trip. Logic is also provided in the controller to detect and identify
a malfunction in the speed pickups or tachometers. The over speed control using
2/3 logic will slow the turbine by energizing the OPC solenoids, which will in turn
close the governor valves and intercept valves when turbine speed exceeds,for
example 103%. The normal over speed protection control is designed to regulate
the turbine speed back to within normal range and avoid a turbine over speed

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 trip.
the Load Drop Anticipator (LDA) function
The Load Drop Anticipator function protects the turbine from over speeding when a
complete load loss occurs. The LDA function is enabled when the MW load is
greater than 30%. The LDA function will close the Governor and Intercept valves
immediately if the generator breaker opens. The LDA function will hold the Governor
and Intercept valves closed for a time delay and then reopen them as long as the
turbine speed is below 103%.
2.8 Startup Procedure
2.8.1 Startup Procedure Bypass Off
1. Put the controller in OPERATOR AUTO mode and make sure that the
BYPASS MODE is on BYPASS OFF.
2. Press and hold the LATCH pushbutton for two seconds. When the turbine is
latched, the TURBINE TRIPPED status lamp will go off and the TURBINR
LATCHED will become green. The valve position limits will reach 100 percent
automatically. Check to make sure that all IV and RSV are in the open position.
Check to make sure that all GV in the open position and TV in the closed
position.
3. The operator enters his desired speed and depress the ENTER pushbutton. The
operator enters his desired rate and depress the ENTER pushbutton. Press the
GO pushbutton.
When GO button is pressed, if the new TARGET is different from the current
SETPOINT value , a HOLD message will appear to the left of the SETPOINT
value. The HOLD message informs the operator the system is ready to make
the change from the current SETPOINT to the new TARGET at the RATE
shown. When the ramp is started , the HOLD message will change to go. This
go will stay on until SETPOINT equals the TARGET, or until a HOLD is
instituted by the operator. In addition , entering a speed in any of the blade
resonant ranges as a TARGET will not be accepted . During the blade resonant
ranges, the rate will become 300 automatically.
RULE :for the TARGET entry field to accept a new value of TARGET , the GO
indication must not be present.
4. Before the speed reach 2950 rpm , the speed is controlled only by TV. IV and
GV are on open position. When the speed reach 2950 rpm , press the VALVE
MODE button ,then depress the TV –GV TRANSFER button and the ENTER
button. Now the turbine is proceeding TV –GV TRANSFER. A message TV –GV
TRANSFER will be displayed in the overview graphic. The speed is not allowed
to reach 3000 rpm if the TV-GV transfer is not accomplished.
5. when the TV –GV TRANSFER is accomplished ,the speed is controlled only by
GV and TV is on open position , increase the speed to 3000rpm.
6. when a message AUTO SYNC MODE IS PERMISSIVE appear in the
graphic ,click the CONTROL MODE and choose the AUTO SYNC mode. The
speed will increase or decrease according to the signal AUTO SYNC UP and
AUTO SYNC DOWN.

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 7. With the closing of the generator breaker ,the TARGER and SETPOINT
windows will display a value in megawatts which will automatically position the
GV at a position equivalent to 5% load.
8. When the load has been increased above 10%load the MW loop can be in
service by means of the FEEDBACK graphic.
2.8.2 Startup Procedure Bypass ON
1. Put the controller in OPERATOR AUTO mode and make sure that the BYPASS
MODE is on BYPASS ON .
2. Press and hold the LATCH pushbutton for two seconds. When the turbine is
latched, the TURBINE TRIPPED status lamp will go off and the TURBINE
LATCHED will become green. The valve position limits will reach 100 percent
automatically. Check to make sure that all GV and RSV are in the open position.
Check to make sure that all TV and IV are in the closed position.
3. The operator enters his desired speed and depress the ENTER pushbutton. The
operator enters his desired rate and depress the ENTER pushbutton. Press the
GO pushbutton.
When GO button is pressed, if the new TARGET is different from the current
SETPOINT value , a HOLD message will appear to the left of the SETPOINT
value. The HOLD message informs the operator the system is ready to make
the change from the current SETPOINT to the new TARGET at the RATE
shown. When the ramp is started , the HOLD message will change to go. This
go will stay on until SETPOINT equals the TARGET, or until a HOLD is
instituted by the operator. In addition , entering a speed in any of the blade
resonant ranges as a TARGET will not be accepted . During the blade resonant
ranges, the rate will become 300 automatically.
RULE :for the TARGET entry field to accept a new value of TARGET , the GO
indication must not be present.
4. When the speed reach 600 rpm , the operator should wait for 4 minutes at
least and check the parameter.
5. When the speed reach 2800 rpm , the operator should wait for 2 minutes at
least and a message will appear in the graphic . when the
message disappear ,the operator can raise the TARGET.
6. When the speed reach 2950 rpm , the speed is controlled by IV and GV. When
the speed reach 2950 rpm , press the VALVE MODE button ,then press the TV
–GV TRANSFER button and the ENTER button. Now the turbine is proceeding
TV –GV TRANSFER. A message TV –GV TRANSFER will be displayed in the
overview graphic. The speed is not allowed to reach 3000 rpm if the TV-GV
transfer is not accomplished.
7. when the TV –GV TRANSFER is accomplished ,the speed is controlled only by
GV and TV is on open position , increase the speed to 3000rpm.
8. when a message AUTO SYNC MODE IS PERMISSIVE appear in the
graphic ,click the CONTROL MODE and choose the AUTO SYNC mode. The
speed will increase or decrease in according to the signal AUTO SYNC UP
and AUTO SYNC DOWN.

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 9. With the closing of the generator breaker ,the TARGER and SETPOINT
windows will display a value in megawatts which will automatically position the
GV at a position equivalent to 5% load.When the load has been increased
above 10%load the MW loop can be in service by means of the FEEDBACK
graphic.
3AUTOMATIC TURBINE CONTROL (ATC)
The Automatic Turbine Control (ATC) function utilizes the rotor stress information
from the RSM functions to automatically accelerate or load the unit at the fastest
possible rate without overstressing the turbine rotor. The ATC function includes
an expanded graphics package that includes turbine, generator and auxiliary
system pictorial displays.The ATC control mode can be selected if in Operator
Auto Mode and the following conditions are met:
• No ATC vital sensor has failed.
• No turbine trip condition exists
• HP stress calculations are valid
• Load does not equal demand on load control
On speed control, the ATC mode will automatically move the demand signal from
0 RPM to 1800 RPM, while monitoring vibration, metal temperatures, etc., and
holding speed when hold conditions occur. Transfer from Throttle Valve to
Governor Valve control is accomplished before synchronization speed is
achieved, when proper conditions are met.Upon initial breaker closure, control is
automatically transferred to the OPERATOR AUTO mode with Turbine
Supervision only. Once on load control and the operator enters a new demand,
the ATC control mode can again be selected and the reference is automatically
counted toward an operator-selected demand. Also on load control in ATC, the
REMOTE mode can be selected and all the ATC monitoring functions are
performed and load holds prevent REMOTE from moving the reference. ATC in
load control also chooses a load rate. This rate is compared with the plant load
rate and the operator-entered load rate, and the lowest value is selected.
ROTOR STRESS MONITORING (RSM)
The Rotor Stress Monitoring (RSM) functions perform turbine rotor stress
calculations and present information concerning the actual and anticipated rotor
stress to the operator. This information includes the recommended acceleration
and loading rates, and the maximum allowable instantaneous load changes.

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