ELECTRO HYDRAULIC CONTROLLER

HEMANT KUMAR

EHC
Speed measurement Speed controller Load controller Pressure controller Controller Selection Position controller

SPEED MEASUREMENT

Four Nos of hall probes mounted around a disk containing 120 magnets (alternative 60 N-pole & 60 S-pole) One rotation will produce 60 pulses. Three probes are used for measurement 0.8 mm gap is maintained b/w hall probe and disc. Hall probe output is a sine wave with peak voltage 700 to 800 mV.

SPEED MEASUREMENT

Pulse converters will convert the sine waves to square wave of peak 10 V. Each pulse converter card will generate three isolated output out of which two are used. Speed measurement is done in two different channels. Both channels will receive signal from each pulse converters. One channel is used for indication and LVM & the other one for controller. nACT is shown in digital indicator provided in UCB range: (0- 3300 rpm)

SPEED CONTROLLER

SC is used for increasing speed from Barring speed to rated speed & to assist auto synchronizer in synchronizing the m/c. SC can be used to load the m/c fully but it is used only for loading upto 10% as frequency variation will affect the v/v opening. v/v opening is directly proportional to the diff. b/w grid freq and speed set point.

SPEED CONTROLLER

Speed set point Set point Tracking Speed set point controller Droop dn/dt monitoring No load pressure correction Speed controller loop.

SPEED CONTROLLER
Turbine trip

UCB ATRS C&I panel Auto sync AVR panel

-120 rpm bias

Stop fast balance

No load pressure correction

nR

15 rpm bias
49<f<51 & PC or LC in action

Speed set Point Controller

Gradient
TSE influence

nRTD nACT

Speed controller

SC output -10V to +10V

Speed set point

Speed reference nR Can be changed from desk, auto synchronizer, ATRS, C&I cabinet & AVR console. The set point changes at a gradient of 2160 rpm/min up to a setting of 2820 rpm. After 2820 rpm it changes at a rate of 360 rpm/min to have accurate control. Speed set point indicator is available in two ranges 1) 0-3300 rpm 2) 2700-3300 rpm

Set point Tracking

If the frequency is between 49 Hz & 51 Hz and LC or PC in action speed set point will track grid speed by +15 rpm. This ensures that SC will not interfere in normal operation when frequency changes. After turbine trips speed set point will follow the actual m/c speed by -120 rpm. This ensures that speed set point is less than actual speed (barring speed). So nxt time during rolling n has to be increased.

Speed set point controller

nR which is a step signal will be converted to time delayed ramp signal nRTD or nRLIM by an integrator for which gradient is decided by TSE upper margin. nRlim indicator is available in ucb(0-3300 rpm) This has three parts
1. 2. 3.

Gradient Stop reference Fast balance

Speed set point controller

1.Gradient This is the rate at which the out put of SSPC changes. Max rate is set at 600 rpm/min. The rate also depends on TSE upper margin. If it is 30ok then rate is maximum. Rate reduces as margin comes below 300k linearly. Min rate is 108 rpm/min. This is to ensure minimum thermal stress during rolling.

Speed set point controller

2.Stop reference The output of the SSPC will be blocked under certain condition given below. Though nR can be changed no change will be there in nRTD. The controller can be enabled again after the TSE influence is switched off and fault reset by C&I. Then made on and SPD set point release push button is pressed in UCB.

Speed set point controller

Stop reference logic

Speed set point controller

3. Fast balance When the set point is in tracking mode (follow up mode) there will be instantaneous change in nRTD value for a change in nR. The controller doesnt see the gradient in this mode.

Droop

After synchronization if nR is increased then actual speed will not increase. Instead the control will open more. The droop is set at 5%. As the rated speed is 3000 rpm,5% is 150 rpm. The deviation of 150 rpm will correspond to full opening or full closing of control v/v (with the assumption that full opening of CV will give full load at rated parameters).

Droop

3150 3000 Droop= X 100 5% 3000

dn/dt monitoring

KWU turbine got critical speeds between 700 rpm and 2850 rpm. It is not advisable to run turbine for prolonged time in this speed zone. For preventing low acceleration rate dn/dt monitoring is provided. When following conditions satisfy dn/dt monitoring actuates and will bring the speed to 600rpm.

dn/dt monitoring

nR is more than 600 rpm ESVs open G. bkr NOT ON nact less than 2850 rpm dn/dt less than 108 rpm/min SC in action

No load pressure correction

As the speed controller loop is PD(P) controller an error in input must be there to keep the control V/Vs open. As the v/v opening required for running m/c at rated speed is directly proportional to steam pressure, a pressure dependent correction signal is give to the speed controller loop. Correction is approximately 20 rpm for 100 bar.

Speed controller loop

The nRTD value is compare with nact and depending on the deviation the PD(P) controller will give out put. For a change of 150 rpm SC will produce an out put of 10 V. During steady state condition SC is always proportional (P) controller.

LOAD CONTROLLER

Load controller is used to maintain load set by the operator or load dispatch center (optional) LC comes into action only after synchronization. LC is also responsible for taking care of frequency changes and correcting load if frequency influence is ON. It is divided into following subsections.

LOAD CONTROLLER

Load set point Load set point controller Frequency influence Load limiter Actual load measurement Load controller loop Isolated grid

LOAD CONTROLLER
FI ON/OFF

UCB ATRS C&I panel CMC

Frequency influence

PRf

Load limiter

nACT droop

set freq(51Hz)

CMC ON

Stop fast balance

PR

PRCMC

Load set Point Controller

PRTD

M I PR + N _
PACT

Load controller

Gradient
Pressure correction

LC output 0 to +10V

TSE & load gradient

Load set point

Load set point can be changed from desk, C&I cabinet, ATRS & CMC Set point changes at a gradient of 250 MW/min The gradient remains the same throughout the range Load set point PR ,indicator is available UCB . range(0-600 MW).

Load set point controller

PR which is a step signal will be converted to time delayed ramp signal PRTD or PRLIM by an integrator for which gradient is decided by load gradient and TSE influence . PRLIM indicator is available in ucb (0-600 MW) LSPC has three parts
1. 2.

Load gradient and TSE influence Stop reference

Load set point controller

1) Load gradient and TSE influence Load gradient acts in parallel with TSE margin with a minimum selector. Load gradient range is 0-60 MW/min and can be set from UCB TSE margin 0-30 0 k corresponds to 0 to 60 MW/min Both are having individual ON/OFF switch. The one which is ON will control the output.

Load set point controller

If both are OFF then PRTD changes at a fixed rate of 60 MW/min. If both are ON min of two will be selected for controlling the output. Load gradient setting is common for increasing as well as decreasing. But in case of TSE , upper margin controls the increasing rate and lower margin controls the decreasing rate. If TSE fault occurs, the gradient will be 30 MW/min (50%)

Load set point controller

2) Stop reference
The PRTD will freeze on any of following conditions. i) TSE is ON and it develops fault. It can be reset by switching OFF TSE influence and fault reset by C&I. Then made ON and Load set point release push button is pressed in UCB. ii) Limit pressure reached AND PC in action AND Load set point raised. iii) Load set point controller disabled

Load set point controller

3) Fast balance In this mode output of LSPC, PRTD , will follow the actual load if any of the following condition exists i) generator breaker is OFF ii) Load controller OFF iii) Load shedding to less than station aux load AND MW error> 5%

Load set point controller

This ensures PRTD brought down to zero after GB opening. After synchronization PRTD tracks the actual load so that more time is not wasted in bringing PRTD from zero to working value

Frequency influence

Frequency influence is used to correct PRTD. The MW correction corresponding to frequency deviation is added to PRTD. FI has a droop of 5% (it can be changed 2.5% to 8.0% in steps of 0.5%). ie, a deviation of 0.5 Hz will cause a load change of 100 MW. FI can be switched ON/OFF from UCB. UCB indicator for the correction signal is known as PRf.(range:-200 to +200 MW). Pressure correction is similar as that of SC

Load limiter

Load limiter is used to limit the load to a certain value set by the operator. Load limiter value is shown in UCB indicator. (range: 0-600 MW) Final set point (sum of PRTD & PRf )is fed to a minimum selector with the load limiter. As load limiter acts after PRTD it can be used for fast reduction of load in case of emergency. Final set point after load limiter is know as PR

Actual load measurement

Three load transducers are used for measurement. Actual load 0-600 MW corresponds to 4-20 mA. Median value of the three will be selected for processing. If any value drifts from the other value by more than 5%, the selective card discards the defective channel.

Load controller loop

Final control loop is a PI controller. error signal= PR PACT. Error is fed to a PI controller which produces an output of 0 to +10V which corresponds to 0-600MW. LC has provision for two follow modes i) follow above ii) follow low

Load controller loop

Follow above mode is in operation during following

conditions, 1) Load controller OFF OR 2) Generator breaker OFF OR 3) Pact<STL and P>5% and generator breaker closed. During the above condition LC output will track the SC output with a constant error of -150mV. This ensure that during the above conditions the LC does not come into action.

Load controller loop

Follow low mode is present when the GB is ON

and speed controller is still in action During this mode LC tracks the SC out put with an error of -150mV. The LC output can go more than SC output and hence LC can be taken into service. Due to this follow mode, the LC can be taken into service anytime without any delay after synchronization.

Isolated grid

Isolated grid operation will act If, i) PR Pact >10% (50MW) AND ii) frequency > 51 Hz AND iii) LC in action In this condition the controller will be changed to proportional (P) type for fast corrective action. This condition can be eliminated by adjusting load set point near to actual load and pressing the Isolated grid reset button in UCB desk.

PRESSURE CONTROLLER

Pressure controller maintains the throttle pressure within working range at all loads. Deviation= actual (PrAct) - set pressure (PrR) The operating range of deviation is 0 to+150mV As long as deviation is more than +150mV , the PC output remains at max saturation(+12V). ie, for a deviation of 0 to+150mV, PC will produce an output of 0 to+12V. PC has two modes of operation. PC is a PI controller

PRESSURE CONTROLLER
Pr PrR PrAct
Limit pressure selected

15ksc

Limit pressure selected

Limit pressure reached

+ _

&

15ksc

+
_

Pressure controller

PC output 0V to +12V

PRESSURE CONTROLLER
1)Initial pressure mode In initial pressure mode PC will try to maintain the throttle pressure. Any deviation in pressure will be adjusted by opening or closing the control v/v. 2)Limit pressure mode In limit pressure mode boiler storage capacity is utilized. There wont be any change in PC out put till Pr deviation becomes -15 ksc.

PRESSURE CONTROLLER

Once the throttle pressure falls below the set value (15 kgc) then further fall in pressure is prevented by varying the control v/v position and hence load. p indicator is provided in UCB Range:(-30 to +30 kgc) Minimum EHC output is set at 30% to avoid complete closing of the control v/v when deviation is ve.

PRESSURE CONTROLLER

Limit pressure mode will be selected on following conditions.

1. 2. 3.

Boiler follow mode CMC selected LP mode selected from console

Initial pressure mode will be selected on following conditions.

1. 2. 3.

Boiler control on manual Turbine follow mode IP mode selected from console

CONTROLLER SELECTION
PC out put 0V to +12V SC out put -10V to +10V LC out put 0V to +10V M A X M I N M I N

+10V

A D D

CONTROLLER SELECTION

SC output is -10V to +10V for 0 to 150 rpm. LC out put is 0 to +10V for 0 to 600MW. PC output is 0V to +12V for 0 to +150mV. SC output and LC output passes through a MAX gate. The value selected is passed to MIN-I gate. The other input to the MIN-I gate is the adder output got by adding 10V(100%) to SC output. The MIN-I output is fed to MIN-II gate for which the other input is PC output.

CONTROLLER SELECTION

The MIN-II gate out put is fed to the position controller. Adder is provided to prevent over speeding of the turbo set. In normal condition SC output will be +1V as nR is tracking grid speed by 15 rpm. During over speeding, nR will stop tracking at 3060 rpm(51 Hz). At this point nR will be 3075 rpm.

CONTROLLER SELECTION

If frequency further increases at 51.25 Hz (3075 rpm) SC output will become 0V. From this point onwards SC output will be ve for increase in frequency which will reduce adder output. Suppose if m/c is at 500MW (LC active), LC output will be 8.33 V. If adder output comes less than this value SC will become active and m/c will start unloading. At 53.75 Hz (3225 rpm) SC output will be -10V and adder output will be 0V. ie, m/c will be fully unloaded.

POSITION CONTROLLER

Position controller is a PID controller Error signal is generated by comparing the selection circuit output with the position feedback obtained from Collins transformer. There are two Collins transformers which gives output voltage corresponding to piston position. The output of the two Collins transformer passes through a MIN gate (logical max selector as its out put is ve) and the selected value is fed to the controller.

POSITION CONTROLLER

POSITION CONTROLLER

Plunger coil is an integrator type. The balance position of the pilot v/v piston is achieved if -1.0V is fed to the plunger coil. For moving the piston in open direction the voltage has to be increased. Say -0.9V is fed to the coil, then piston will keep on moving towards opening direction till the voltage again made -1.0V. Similarly if the voltage is made -1.1V, then the piston will keep on moving towards closing direction till voltage is again brought back to -1V.

POSITION CONTROLLER
Plunger coil

POSITION CONTROLLER

Collins transformer is a differential transformer and produces output from -8.0V to +8.0V which is converted into 0.0 to -10.0V. 0.0V output corresponds to the position at which first control v/v just starts opening. -10.0V corresponds to the position at which last control v/v is just full open. A constant bias of +200mV is given for second Collins txr so as to avoid frequent changeover from one Collins to the other.

POSITION CONTROLLER

If at any time the difference b/w the two Collins exceeds 700mV a fault alarm is generated. There is provision to switch ON/OFF the voltage supply to plunger coil. This can be done only if the output of position controller is more than +5.0V. This ensures that at the time of switching OFF, the piston is full open and there will not any jump after switching OFF.

POSITION CONTROLLER

If at any time during operation plunger coil wire breaks, the piston will go to full open position and plunger coil fault alarm will be generated. As the piston goes to full open position, the control v/vs also will open fully.

POSITION CONTROLLER

EHC fault will occur on following condition

1. 2. 3. 4. 5. 6. 7. 8. 9.

Starting device faulty Collins-1 faulty Collins-2 faulty Plunger coil faulty nAct-1 ~ nAct-2 >5% Turbine tripped Power supply faulty EHC faulty Speed acquisition faulty