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Technical Feedback

FEED BACK NO. 42
PROPORTIONALITY OF THE HYDRAULIC CONTROL SYSTEM
GENERAL
For years the turbine of the utilities have been operated to a large extent in parallel in large scale interconnection.
This large-scale interconnection is of advantage to all partners, especially as regards the reliability of system
management and economic employment of power plants. In the three phase grid the frequency is the criterion for
accurate matching of generation to consumption at any time. Each load change immediately becomes apparent in
the form of a change in speed and, resulting from that, a change in frequency. This shows that system operation
with a stable frequency is one of the main functions of the turbine governor. Through its intervention the turbine
generator unit participates in the balancing and maintenance of the frequency according to its proportional range
in the case of frequency changes that may be caused by scheduled or unforeseen step load change and the
proportional range will occur following the participation of the turbine generator in a frequency stabilization, the
loading rate of the turbine generator in a frequency stabilization, the loading rate of the power plants connected
will have to be changed by the load dispatching center in such a way that the normal frequency will be stored in
the system.
The proportionality of the control system, previously also called droop characteristic, indicated the difference in
speed related to the output range from O to max. As there is practically a linear connection between a
frequency change and an output change, the proportionality determines the gradient of the output-frequency
characteristic curve of the turbine governor and thus its share in the frequency stabilization. Excessive
proportionality leads to little participation of the turbine generator in the case of frequency changes and too small a
proportionality leads to fluctuations and unstable system conditions.
The proportionality of generator drive turbines is therefore set at a value between 4.5 and 5.5% of the rated
speed, related to a range from no-load operation to guaranteed maximum output.
Checking and setting during standstill with hydraulic governor
To enable the total proportionality of the turbine control system during standstill to be checked and set (especially
in the case of new plants) control oil will have to be passed under the diaphragm of the SR III governor (primary oil
connection) via a throttle valve. The pressure of the control oil must be accurately adjusted with the throttle valve.
The pressure of the control oil must be capable of being read from a pressure gauge (see fig. 1). This test line
shall be installed especially for the purpose of this verification.
The hydraulic speed transducer (previously called control impeller or impeller) converts the actual speed value
into an oil pressure (primary oil pressure). The transducer is designed in such a way that at rated turbine speed it
will produce a primary oil pressure of 2.5 kp/cm.
Corresponding to the proportionality of the governor and thus to the difference in speed from 0 to maximum load 0
to max. HP valve travel (first through last valve), the primary oil pressure will rise with the square of the speed.
p = K.n
p = primary oil pressure
K = constant
n = speed
The primary oil pressure is built up to 2.5 kp/cm with the aid of the two throttle valves to match the rated speed
and then the secondary oil pressures are set via the reference speed setter to match the maximum valve travel.
Subsequently the primary oil pressure will be increased with the speed setting remaining constant until the
secondary oil pressures have dropped to 0 mm HP valve travel (= HP valves are starting to open).
The primary oil pressure is built up to 2.5 kp/cm
with the aid of the two throttle valves to match the
rated speed and then the secondary oil pressures
are set via the reference speed setter to match the
maximum valve travel. Subsequently the primary
oil pressure will be increased with the speed setting
remaining constant until the secondary oil
pressures have dropped to 0 mm HP valve travel
(=HP valves are starting to open).
The Dp primary oil required for this reproduces the
difference in speed corresponding to 0 to max.
output.
The total proportionality of the control system
according to the primary oil pressures measured can be seen from the family of curves in Fig. 2 prepared
according to an approximation equation. Should the proportional range determined not correspond to the set value
( as a rule 4.5 /5.5%), resetting will have to take place.
Resetting of the proportionality of the hydraulic control system is usually achieved by changing the relation of the
difference in the secondary oil pressure (DPsec) corresponding to 0 to max. HP valve travel by means of shifting
the center of rotation or the gradient of the return mechanism. The proportionality may, however, also be changed
by using a speed setting spring with a different characteristic or valves with a throttle collar.
Adjustment of the proportional range of turbine
with HP control shaft valve actuators
Turbines with control shaft valve actuators either
have in the servomotor a rotable restoring cam
whose gradient will vary (Fig. 3) or the ratio of the
restoring linkage from the can follower to the valve
spool is variable (Fig. 4). By rotating the rotatable
restoring cam or by changing the restoring linkage
the relation of the secondary oil pressure and valve
travel and thus the total proportionality is changed
in each case.
If there is a hydraulic or electro-hydraulic converter
(Figures 5 and 6) the total proportionality can be
influenced by rotating the cam follower or by
adjusting the restoring linkage.
The local proportionality can only be changed by additional throttle collars or by an overriding output and
frequency control system superimposed on the speed governing loop.

Adjustment of the proportionality for turbines
with individual HP control valve actuators
Each individually actuated control valve has its
own, nonrotatable cam follower (see fig. 7).
For this reason a change in the total proportionality
can, with these turbines, only be performed by
adjusting the restoring element in the hydraulic or
electro-hydraulic converter (Fig. 5 and 6).
Should it be necessary to change the local
proportionality this can only be achieved by means
of a different design of the cam follower of a control
valve or, as is the case with valve group actuators,
by means of valves with throttle collars.

Checking of the total proportionality during no-load operation
The proportionality indicates the speed change in percent of the normal speed during a gradual load change of
the turbine from no load rated load at a constant position of all setting of the governing system.
As the increase of the primary oil pressure is not linear but parabolic in relation to the
speed (p = K.n), the gradient of the speed curve changes slightly depending on the
speed setting. For this reason the proportionality of the hydraulic speed governor also
changes slightly across the speed adjusting range. The deviation, however, is so
minimal across the small speed adjusting range that it can be neglected (see Fig. 8).
During the checking of the proportionality the speed setting may not be changed as otherwise the Dp range will be
shifted in a parallel direction and the initial speed can thus no longer be used for the determination of the
proportional range.
The position of the speed setting between no-load operation and maximum load is, however, of no consequence.
There is a correspondence between Dp and the proportionality, the associated Dn becoming smaller, however,
with increasing pretension of the speed setting spring.

Change in primary oil pressure

Dp = p
2
p
1
= k (n
2
n
1
)



As k is a constant, the difference (n
2
n
1
) must be equal if Dp is constant. The equality results from the
differing squares of the speed.
Checking with back-pressure and condensing turbines
To begin with, the turbine is run up to no-load under design steam conditions and the starting device is turned to
the open position. If there are several emergency stop valves, they are, except for one, slowly brought to the
closed position through the test slide valves. Then the open emergency stop valve is slowly moved to the closed
position and the drop in the speed dependent on the HP valve travel or the associated secondary oil pressure is
recorded, until the maximum valve position or the associated secondary oil pressure has been reached. From the
above-mentioned formula d = . the proportional range shall then be calculated.
Checking with reheat turbines
After the no-load speed has been reached, all HP emergency stop valves are put into the closed position. Then all
reheat stop valves, except for one, are closed. Subsequently the last open reheat stop valve is slowly moved to
the closed position and the drop in speed as a function of the HP valve travel or of the secondary oil pressure is
recorded, until the maximum position of the last HP control valve or the associated secondary oil pressure have
just been reached.
The slow closing of the control valve associated with the still open reheat stop valve constitutes a more elegant
method. This can take place either by slowly throttling the secondary oil isolating valve or possibly by turning the
bolt on the IP follower piston. The latter possibility should, however, only be used in exceptional cases as the
governor setting is changed by this. From the values obtained n
min
and n
max
., the proportionality shall then be
calculated.
During checking care shall be taken that for one the pressure upstream of the IP valves does not rise during the
bypass operation to such an extent that the safety vales open (which is possible depending on the boiler load
carried and the design of the bypass valves), and secondly that the HP exhaust steam temperature does not
exceed its maximum permissible value which could occur because of windage if the duration of the test is too
long.
Checking of the proportionality as a function of output
1
st
possibility (Normal reheat turbines)
At design steam conditions close all HP emergency stop valves and then all reheat stop valves except for one.
Then by closing the reheat stop valve or the associated control valve still open, take a reading of the pressures
building up of the auxiliary follower pistons as a function of the pretabulated speed drops until the maximum
auxiliary piston pressure the maximum valve travel is reached.



Following that, the valve travel to speed association is
obtained immediately. Subsequently synchronize the
turbine generator and apply load in steps according to
steam design data and record output associated with the
auxiliary follower piston pressures obtained previously
With that, the change in speed can be plotted across the
output and thus the turbine proportionality as a function of
the output and also of the valve travel is obtained.
By placing a tangent in the respective output point (e.g.
50 MW/point A) the speed difference (DnA) related to 100% load is obtained and with that the proportionality at
the respective load point. See also points B and DnB.
2
nd
possibility
Run turbine up to 3000 min
-1
, synchronize turbine
and load in steps according to steam design data.
After each load increase the travel of the speed
adjuster (possibly also of the linkage) and most
preferably in the case of the valve opening points,
too, the secondary oil auxiliary pressure or the
valve travel at the respective load shall be
recorded.
At no-load (generator isolated from system) the
turbine shall be run up in steps via the speed
adjuster, the speed resulting at the travel of the
speed adjuster with the respective loads being
recorded.
The drops in the speed as a function of the output
and thus of the valve travel can be represented and
the proportionality is in this way obtained via the
output as with possibility 1.
The second method is not only a little more
complicated, but also a little less accurate insofar
as the transmission of the speed adjuster gears
and rods is not completely without backlash (or lost
motion).
On the other hand the first method has the
disadvantage that in the case of oil turbines with
control shaft drive not all valves without steam
pressure will open and consequently the
secondary oil pressure of the secondary oil the
valves do not open any further -, the restoring
mechanism does not return the valve spool and
thus over travel occurs and a possible drop in the
secondary oil caused by it. Should this occur, this
method can be applied by means of spring
balancing.


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