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Overview of Turbine Concept of Governing System Functioning of EHC Circuits Turbine Start Up Procedure TSI & TSC System Turbine Protection System

Turbine Extractions
Ext. No Source Of Extraction Destination Equipments

1 2 3 3 4 5 6 7 8

13th stage of HPT CRH 3rd stage of IPT 3rd stage of IPT 6th stage of IPT 8th stage of IPT 11th stage of IPT 2nd stage of LPT 4th stage of LPT

HPH-8 HPH-7 HPH-6 * TDBFP DEAERATOR LPH-4 LPH-3 LPH-2 LPH-1

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Turbine: HPT, IPT, LPT1 and LPT2 Turbine Bearings: 08 Generator / Exciter Bearings: 04 Turbine Stop Valves: 04 (HPSV-1&2, IPSV-1&2) Turbine Control Valves: 08 (4 HPCV & 4 IPCV) CRH Check Valves: 02 ( With Bypass lines for warm up) Motor driven Shut Off valve in non-stabilized oil line to Check Valve Motor driven warm up Shut Off valves for HPCV-3 & 4 Governing Box

Motor operated Control Gear to generate resetting / protection oil & control oil for S.V./ Summators Two Manual trip devices Two Over Speed Governor Slide valves (110 % & 111 %) Two Remote Trip Solenoids Slide Valve for ATT with two solenoids

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Combination of throttle & nozzle governing IP Turbine has throttle governing all four control valves open simultaneously HP Turbine has nozzle governing all four control valves open in preset sequence Resetting of Turbine is done by Control Gear operation Operation of Stop & Control Valves and CRH Check Valves are done by spring type hydraulic servomotors Servomotors are closed by spring action during loss of oil pressure

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HPT control valves open only after achieving preset load (12% of 660 MW) Opening time of control valve is 1.5 sec Closing time of Stop valve in case of operation of protection is 0.3 sec Turbine maximum speed is restricted to 108% in case of generator disconnected from grid Over speed protection system stops steam supply in HPC in < 0.5s Speed Controller Droop is adjustable from 2.5% to 8% (with dead band of 0.04%)

Stabilized oil pressure of 50 Ksc is supplied to Control Gear The control gear (AE001) is moved from closed position (0 degree) to open position (90 deg) Oil is first supplied to reset the over speed governor slide valves Subsequently Protection Oil is generated and supplied to protection devices Finally, Control Oil for Stop Valves servomotors & Control Oil for EHC-summators are generated

Control Oil pressure in S.V. servomotor moves up slide valve, providing Header Pressure Oil under the piston for S.V. opening Header Pressure Oil is supplied to C.V. valve servomotors via locking pilot valve & traction/bush arrangements. Opening of C.V. is governed by Control Oil from EHC-Summator During loss of Header Pressure Oil, the servomotors are closed by spring action During loss of Control Oil pressure, Bush & Traction of Pilot valve travels up shutting off head pressure oil supply to C.V. servomotors, resulting control valve closing During S.V. ATT, bush & Traction do not travel up due to slide valve downward movement by ATT motor

EHC comprises of following controllers: 1. Speed Controller 2. Pressure Controller 3. Load Controller 4. Position Controller

EHC can be kept in Manual / Auto Mode as per operators choice Manual mode can be selected only when Generator is connected to grid In Manual Mode, operator can directly open / close the control valves Controllers can be selected in auto mode through P.B provided on operators console or through interlocks Controller output in auto mode depends on set point and actual value

R L

+ Speed Set Point Rate Logic Speed - Controller O/P

Logic - 2 Logic-1 Speed Set Point = 0 Actual Speed (Mv3)

Logic 1: Turbine protection operated / 2v4 stop valves closed / 2v3 speed

measuring channels faulty / Deviation between actual speed and set point during run-up exceeded allowable value* Logic 2: Speed gradient is controlled by minimum of TSE margin & gradient from selected Start up curve, given by the Turbine Manufacturer
Contd.

Rolling Speed Gradient Curve

Speed gradients as per Manufacturers start up curve are as follows:
Rolling Condition Target Speed Preset Time Min. Halt Time

3 - 500 rpm Cold Startup ( > 72 H ) 1200 rpm* 3000 rpm 3 - 500 rpm Between 36H 72H Between 8H 36H Between 2H 8H 3000 rpm 3 - 3000 rpm 3 - 3000 rpm

150 sec 550 sec 630 sec 75 sec 240 sec 360 sec 300 sec

300 sec 300 sec -------120 sec ----------------------

Speed Controller will be switched on automatically in case generator breaker opens (with Turbine controller on auto) or Turbine trips Turbine speed measurement is be done by using 3 sensors (eddy current type) The mean* of the three sensors is taken as actual speed Incase of one sensor fault, maximum of rest two sensors will come in service Incase of two sensor fault, Turbine trip signal is generated to trip the turbine

Speed Ref Tracking:

After Synchronization, with other controller in service, the speed controller tracks the actual speed between 49HZ to 51HZ (adjustable)

Islanding Mode:
If actual speed exceeds speed reference by a preset limit under Generator Breaker in closed condition, Islanding mode occurs Transferring Turbine to Speed Control mode

Load Control On: Load Controller will be switched on automatically if Turbine controller is kept on auto and connected to the grid under Turbine Latched condition. Load Control Off: Load controller will be switched off under following conditions: 1. Manual control mode is switched on 2. The Generator has disconnected from the grid 3. The grid frequency has gone beyond allowable limits 4. Load Measurement faulty (2/3 sensors faulty) 5. M.S. Pres. measurement faulty (2V3 sensors faulty) 6. Unit is in Pressure Control mode

R L Load Ref

STOP

Delay Element
Fast Tracking

Correction C.K.T Freq. Corr

O/P -

Actual Load 6

2 1

Press. Corr

Max.Load Lim. Min.Load Lim. Logic - 4

Logic-1: CMC ON, when load ref. will come from CMC circuit, where TSC Margin calculation controls the gradient Logic-2: The Load reference tracks actual load for bump less transfer once it is connected to the grid.
Contd

Logic-3: Load Reference will be

stopped

under

the

following

Conditions: 1. TSC Margin is less than permissible value* 2. The difference between the actual and reference value is not in allowable range Logic-4: Maximum and minimum load set points, set by the Operator Logic-5: External Frequency Influence ON - actual frequency will be tracked at a predefined delayed rate, with an adjustable droop to help in loading and unloading of the machine within a band of frequency
Contd

Logic 6: The Pressure correction is divided into two Parts: 1. Before the HPC On is generated, the pressure correction will be calculated with R.H. pressure 2.After HPC On is generated, the pressure correction will be calculated with M.S pressure

HPC On: The point at which the HP Control Valves starts Opening (12% of full load)

Load Measurement: Three Transducers with mean* value selection Incase of one of the transducer failed, maximum of rest two.will be selected

Pressure Control is switched ON by the operator or automatically through Turbine Control on auto when HPC is in operation Pressure Controller is automatically deactivated under the following conditions: 1. GCB Open 2. The frequency is more than allowable value* 3. M.S. pressure transducers failed (2V3) 4. Manual Control switched on 5. Load control is On 6. HPC is out of operation

Actual Pr. Value M. S. Pr. Set Point

+ Adder Block -

PI Controller

MIN

MAX

O/P

Minimum Pr. Controller

Control Stage Max Pr. Controller

M.S. pressure set point is dictated by Boiler Master Limitation of pressure drop to impermissible value is ensured by minimum pressure controller Limitation of pressure rise to impermissible value is ensured by a protective control stage maximum steam pressure controller, which comes into operation through maximum value selector

+
Control Signal From TC

O/P- (0-150mA)

+
Posn. F/B - 1 Posn. F/B - 2 MV2

PI

MIN

TO I/H CONVERTOR

Limiter

Biasing Current 0.8 to 1A

A PI controller is used to generate the signal to the current amplifiers through Limiter Command to HP control valves extends under HPC ON condition Loss of current signal to I/H Converter results in closing of the C.V.

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I/H Converters control the opening and closing of the corresponding control valves Individual I/H converters get command from Turbine controller 50 Ksc Header Pressure Oil holds the piston (2) up against spring action As the slide valve (1) moves as per I/H converter, 35 Ksc control oil output is regulated for C.V. servomotor operation When 50 KSC Governing oil pressure collapses, piston (2) travels down due to spring action thus draining the oil line of C.V. servomotor

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Start Turbine rolling with Speed Control on from barring speed to 500 rpm After achieving desired criteria, raise speed set point to 1200 rpm* and subsequently to 3000 rpm After synchronization Load Controller gets switched On raise load > 80MW when HPC ON signal is generated Turbine Pressure Control will be automatically switched On After HPCV demand crosses 80%, switch ON Position controller to hold 80% as the o/p to control valves for raising pressure to rated value Switch ON Pres. Controller to raise load to rated value Switch ON Load Control after load reaches the rated value

START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT

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To S.H Live steam temperature. Trh R.H steam temperature Po S.H outlet steam pressure Prh R.H. steam pressure Go Electrical Load of TG Ne Live steam flow from boiler N Turbine rotor speed A Steam Admission B Synchronization C HPC switch on D HPCV open with 20% Throttle reserve & Loading with constant HPCV position & HP heaters charged E HPCV no-3 opening. Throttle pressure reduced F Full Load

START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT

START UP CURVES OF TURBINE AFTER SHUTDOWN OF THE UNIT

Turbo Generator consists of 12 bearings 8 for Turbine & 2 for Generator & 2 for Exciter For Bearing no. 1-10, abs. brg. vibration is measured in 3 components (Horizontal, Vertical & Horizontal axial) For Bearing no. 11 & 12, abs. brg. vibration is measured in 2 components (Horizontal & Vertical) Absolute shell vibration is measured for all the bearings in 2 components (Horizontal & Vertical)

Turbovisory Instruments
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Rotor Relative Vibration is measured in all the bearings in 2 components Absolute Rotor Vibration is derived from Absolute Bearing Shell Vibration and Rotor Relative Vibration for all the bearings Axial Shift measurement is done in Bearing no. 3 Eccentricity measurement is done in Bearing no. 1 Turbine Speed sensors and Key phasor are Installed in Bearing no. 1

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Turbovisory Instruments
Brg. No. Abs. Brg. Vib. 3 Comp 2 cmp Abs.Shel Vib. (2Comp) Rel.Rotor Vib. (2 Comp) Ang. Dis. Brg. Shell (2 Comp) Casing Exp. Rotor Exp.

1 2 3 4 5 6 7 8 9 10 11 12

Y Y Y Y Y Y Y Y Y Y N N

N N N N N N N N N N Y Y

Y Y Y Y Y Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y Y Y Y Y

N N N Y Y Y Y Y Y N N N

Y (HPC)

Y (IPC)

Y (LPC-1)

Y (LPC-2)

The Stress Margin of the Turbine is calculated by measuring the temperatures of following components: 1. HPC Rotor and Outer Casing 2. IPC Rotor and Outer Casing 3. 2 HP Stop Valves 4. 2 IP Stop Valves 5. 4 HP Control Valves 6. 4 IP Control Valves

Turbine protection system consists of Two Independent channels, each operating the corresponding solenoid (220V DC) to trip the Turbine in case of actuation of remote protection Hydraulic Protection: Apart from the Electrical Trip, Turbine is equipped with the following Hydraulic Protections: 1. Local Manual Trip (1V2) 2. Over speed Trip #1 at 110% of rated speed 3. Over speed Trip #2 at 111% of rated speed 4. Governing oil pressure < 20 Ksc
Contd..

Contd

Turbine Protection System

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Axial shift Very High (2V3) [-1.7mm, +1.2mm] Turbine bearing vibration : Very High (2V10 including X & Y directions)* >11.2mm/sec (Td=2 sec) Lube oil tank level very Low (2V3)* Td=3sec (Arming with two stop valves open) Lub oil pressure Very Low (2V3) < 0.3 Ksc; Td =3 sec (Arming with two stop valves open) Condenser pressure Very High (2V3) > - 0.7ksc (Arming with condenser press < 0.15 ksc Abs)
Contd..

M.S. temp Very Low (2V3) < 470 deg C (arming > 512 deg C)* M.S. temp Very High (2V3) > 565 deg C* HRH temp Very Low (2V3) < 500deg C (arming > 535 deg C)* HRH temp Very High (2V3) > 593deg C* HPT outlet temperature Very High (2V4) > 420 deg C
Contd

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Gen seal oil level of any seal oil tank Very Low (2V3)* < 0 mm;Td=15 sec (Arming with any two stop valves open) All Generator seal oil pumps OFF (3V3)* Td: 9 sec (Arming with any two stop valves open) Generator Stator winding flow Very Low (2v3) < 17.3 m3/hr; Td =120 sec (Arming with any two stop valves open) Generator hot gas coolers flow Very LOW (2V3)* : <180m3/hr; Td=300sec(Arming with any two stop valves open) Generator cooler hot gas temp. Very High(2V4) > 85 deg (Td = 300sec
Contd

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MFT operated: (2V3) Deareator level Very High (2V3) > 3400 mm* HP heater level protection operated (2V3)* Generator Electrical protection operated (2V3) Turbine over speed protection operated (114%) Turbine Controller failure protection operated (2V3)
Contd