NOVEL DIGITAL GOVERNOR FOR HYDRAULIC TURBINES

Dane D. Depeski, Jelena S. Pavlovi, Duan B. Arnautovi, Slobodan S. Bogdanovi

Electrical engineering institute Nikola Tesla, Koste Glavinia 8a, 11000 Belgrade, Serbia
Abstract: In this paper novel digital governor for hydraulic turbines is presented. Its structure and
its advanced features that improve speed and power control quality and robustness are described.
Additional functions of the turbine governor, whereby auxiliary systems are controlled, are also
described. Digital simulator with nonlinear mathematical model of the turbine governor
surroundings, where the hydro turbine exploitation characteristics are realized in fuzzy technique, is
presented. Test results of the novel digital turbine governor on the simulator are shown. These
results are verified in comparison to measurement results on real machine.
Key words: turbine governor, hydraulic turbine, digital simulator, fuzzy logic
1. INTRODUCTION
Development of the novel digital turbine governor is result of realization of innovation project
of contemporary control system for station service power generator in HPP Bistrica. This project
was funded and supported by Ministry of Science and Technological Development of Republic of
Serbia. Novel digital governor represents only one part of this project, which also includes control
system, synchronizer and excitation system for aforesaid machine. During the governor
development modern design and production techniques and knowledge are used, as well as decadeslong experience of expert team of Electrical Engineering Institute Nikola Tesla in tasks of
parameter calculations, putting into operation, adjusting and testing of the turbine governor system
in power plants of Electric Power Industry of Serbia. For the purpose of governor development and
testing, unique digital simulator of, so called, turbine governor surroundings is developed. Under
the term of turbine governor surroundings hydrosystem, hydraulic turbine, generator and generator
load are meant. For needs of one formerly large hydraulic turbines producer the Institute developed
simulator of governor surroundings based on nonlinear mathematical model, which was realized in
analogue technique. Following contemporary courses, the novel simulator is based on real time
computer application. Special attention is paid on forming of the hydraulic turbine model. The
model of the turbine is based on fuzzy logic. Fuzzy logic, with its inherent property of the result
value decision, as the most likely value from set of more or less likely values, represents the most
convenient utility for modeling of sometimes extremely nonlinear water flow and turbine efficiency
dependencies of head and guide vane opening. Such turbine model enables the simulation of the
turbine and governor work in all possible modes that may appear in the power plant, including the
transient processes caused by sudden machine loading and unloading.
2. DIGITAL TURBINE GOVERNOR
During realization of novel digital governor for hydraulic turbine, it was started from
satisfying the basic functions which one turbine governor must perform [1], [2]. Speed control
function and active power control function are realized in digital form and represent the framework
on which the novel digital turbine governor is developed. The implementation of these functions is
provided by guide vane opening control, as to servomotor, whereby governed value of guide vane
opening is directly realized. By upgrading of the basic governor functions, quality improvement and
improvement of robustness in speed and active power control are accomplished [3-5]. Also,
automatization of oil pressure system and control of machine auxiliary systems in start and stop
sequences are achieved. Moreover, the communication of turbine governor with synchronizer,

excitation system and machine control system is realized. The implementation of turbine governor
in power plant process network and chronological recording, data acquisition, of the events and
relevant variable values are enabled. The basic set of input and output signals which turbine
governor exchanges with other systems is shown on fig. 2.1 [6].
INPUT SIGNALS
start command
stop command
control mode
(speed or active power control)
speed reference value
active power reference value
guide vane opening reference value
servomotor position measurement
speed measurement
active power measurement
way of control
(automatic or manual)
OUTPUT SIGNALS
o servomotor position (control signal)
o governor malfunction
(general signal of governor error)

Start
Stop
Auto/Man
Ref. speed

TURBINE
Ref. power
Ref. opening

GOVERNOR

Servomotor
position
Error

Speed meas.
Power meas.
Servomot. meas.

Figure 2.1 Basic signal set required for turbine governor algorithm implementation

Basic set of input and output signals represent necessary and sufficient set of information for
turbine control algorithm execution. The governor states and controlled values measurements are
included. The governor is by its nature proportionalintegralderivative (PID) controller of parallel
structure (see Figure 2.2). Parallel structure of the governor enables certain advanced governor
functions, as to numerical results of their execution, can be inserted in some of the branches without
any influence on the other branches. Numerical result of water hammer compensation function is
dominantly brought into derivative branch of governor, power feedforward signal is inserted only in
integral branch, integrator limitation function is also referred only to integral branch of the governor

Figure 2.2 Block diagram of governor structure

Governor parallel structure also enables neutralizing or total exclusion of influence of a certain
branch of governor, if necessary. Active power regulation of the governor can be performed by
using only PI regulator, since derivative action is negligible, or is excluded completely. Moreover,
parallel structure enables, in relatively simple way, creating conditions for governor testing, both in
the test field and in the plant. Customization of the governor structure, as well as its upgrade for
needs of certain machine, driven by Pelton, Francis or Kaplan turbine, can be realized by governor
program editing. Digital technology provides to the governor designer and the governor
programmer almost unlimited number of possible changes in the executive program, and thereby
those changes have almost no influence to the hardware platform on which the program is executed
[7], [8]. In this case the platform of programmable logic controller (PLC) is chosen, as a platform
which supports standard hardware components and it is of modular structure easy to upgrade, robust
with large mean time between failure, resistant to electromagnetic interference, with a lot of built-in
communication protocols, easy and inexpensive for maintenance.
Beside basic functions of the governor, speed and active power control, more functions that
improve governing quality, resistance against failures in turbine governing system and to sudden
changes which are coming from turbine governor surrounding are added to the governor. Function
for communication with elements of the turbine governing system and with machine control system,
as well as function for gathering and archiving of data about turbine governor performance is also
appended.
The governor has possibility of automatic switch from state when generator is on network,
machine works in parallel with other machines in a unique network, to state when it works in
isolated network. Automatic switch from active power control to speed control is activated if the
criterion that the speed deviation is beyond allowed limits is fulfilled. Also, the governor can switch
from speed control mode to active power control mode if the network frequency is stable and close
to its reference value. The network frequency must be stable and close to the reference value within
previously defined time interval.
Possibility of recognition of failures within turbine control system, like error in speed
measurement, error in active power measurement, error in the servomotor positioning subsystem, as
well as possibility of governor adjusting to emerging operation circumstances is also part of the
turbine governor executive program. Depending on the failure type, an appropriate part of the
program is executed. The failure can be such that further work of the governor is possible, but this
state must be followed with unique signalization to the machine control system that an error has
appeared. In case that one of three inductive sensors which are used for speed measurement breaks
down, governor will continue with work, but way of measured speed signal processing will be
altered and governor will send a warning signalization to the machine control system. When sensor
for generator active power measurement breaks down, it is possible to switch to servomotor
position control or control of estimated value of active power based on information of the head and
current servomotor position. Governor will continue with its work in this case too, and warning
signalization will be sent to the machine control system. When two or all three inductive sensors
break down or an error in subsystem for servomotor positioning occurs, the governor gives a
command for emergency stop and sends an alarm signalization to the superior control system.
These are only some of cases which illustrate execution of program modules which improve
governor resistance to possible error appearance in measurement and executive elements of the
turbine government system.
Matching of the governor into technological process of hydroelectric power plant is realized
in several hierarchical levels. The highest level represents the machine control system and the
operator himself. At the same hierarchical level with the turbine governor are synchronizer and
excitation regulator. Oil pressure system, different kinds of converters and actuators in turbine
control system represent subordinate hierarchical level. The connection to the process is brought out
with communication channels.
The communication can be carried out by wire, through voltage free contact of the signal
relays, or by using of standard communication protocols (Profibus), or by a process network of the

power plant (Ethernet, Profinet). Combination of different ways of communication listed above is
desirable. Both, serial and network communication can be physically realized by using of optical
link which preserves relatively large data transfer rate even in long distances and in environment
with distinguished electromagnetic interference is accomplished. Communication with the machine
control system allows bidirectional data exchange. Although always being active, this
communication channel is of great importance when the distance control mode of the turbine
governor is activated. Set of exchanged data contains information about the state of governor,
measured values, warning and alarm signals and commands from the machine control system. This
data set is not strictly defined. Readjustments of the data set are possible in accordance with project
requests. Communication with the synchronizer is brought down to sending orders for start and stop
of synchronizer and receiving orders for increasing, or decreasing of machine speed. Also, the
turbine governor must have the information about an error occurrence in the synchronizer. The
turbine governor, like as in case of synchronizer start and stop commands, generates command for
excitation regulator start using digital outputs of its speed relay. The number of output, as well as
the activating threshold of the corresponding speed relay output is adjustable.
Exchange of turbine governors data and commands with the process, the governor states, as
well as protection signals activations are memorized in the event and alarm archive. Also, the
current values of the measured variables speed, servomotor position and generator active power are
recorded. The memory, in which the event and alarm archive is stored, is permanent and resistant to
sudden governor power switch off. The recordings are successive and with time resolution better
then 500ms. The records overview is available through the graphical interface which is realized on
the touch panel. The touch panel is integral part of the governor, and, beside tasters, switches and
analog measuring instruments has also a purpose of local control of turbine governor. It is possible
to view records in the real time or to overview the previous records by calling of the corresponding
file from the governor memory. The appearance of the graphic interface for the user is shown on
figures 2.3 and 2.4. The records can be viewed and processed on the personal computer, by reading
the content of the governor memory card. The existence of chronological data registration gives the
user and the producer of the governor the insight into the event sequence and considerably
facilitates their analysis, enables quick defect revelation and provides the base for possible
intervention on the governor.

Fig. 2.3 Basic screen of the operator panel

Fig. 2.4 Speed monitoring and reference setting

Control of the auxiliary systems and the systems which are classified, partially from
technological reasons, and mostly conceptually, with the turbine control system are also joint to the
novel turbine governor. Digital technology enables the realization of many functions related to the
turbine control system on a unique hardware platform, in a single device. Chronologically observed,
earlier, these functions were not implemented in one device, but in separate units within the turbine
control system. Todays market demands, thereby having in mind demands for, above all, low

prices of devices, especially concerning low power hydro units, impose the need that the majority of
the functions related to the turbine control system should be realized on the same hardware platform
on which the turbine governor itself is implemented. In contemporary turbine control systems it is
relatively often that within the same device in which the turbine governor is realized, also the
functions like speed relay, control of the oil pressure system, bearings lubrication system and
cooling system control, bearings temperature monitoring, etc. are implemented. This is probably
one of the basic reasons why there is not, or at least is not so recognizable, the boundary between
the subsystems which contemporary turbine control system is made of.
3. DIGITAL SIMULATOR OF TURBINE GOVERNOR SURROUNDINGS
In purpose of the turbine governor testing in the laboratory conditions the simulator of turbine
governor surrounding is developed [9], [10]. By the turbine governor surrounding are meant hydro
system, hydraulic turbine, hydraulic servomotor, generator and power system. The model is
particularly developed for testing of the novel turbine governor for Pelton hydro turbine of station
service power generator in HPP Bistrica, but is easily adjustable for other types of turbines.
The model is nonlinear and can be applied for both, large and small deviations from nominal
values [11], [12]. It consists of several submodels: submodel for servomotor and valve, submodel
for turbine and electromechanical submodel. In modeling of servomotor and valve the dynamic and
maximum rate limit of servomotor are taken in concern. Also, the limit of the maximum opening of
the valve is modeled. The dynamic of servomotor is considered first-order transfer function 1/(1+
Tys). Rate limits and saturation limits make this submodel nonlinear.
The submodel of the turbine is realized in fuzzy technique [13], [14]. The technique is used to
represent and extrapolate turbine q characteristics. The calculated dependencies are nonlinear
functions q=q(H,) and = (H,), where q represents water flow, turbine efficiency, H head
value and guide vane opening. Since these functions are graphically represented and therefore
accurately determined only in intersection points, fuzzy technique is convenient for their modeling.
In fuzzy decision logic meanings of terms equality and belonging are not discrete (1,
meaning yes, or 0 meaning no), but continual. That implies that each known value or statement
has a membership function attached to it. For example, if membership function of statement is
number A is f(x)=1/|x-A|, then statement is number 3 is more valuable for number 2 then for
number 5, but has a certain nonzero value for both. The process of attaching a membership function
to each number from the predefined set and deciding how much is given number one of the
numbers from the predefined set is called fuzzification.
Values or statements from the predefined set which have membership functions are organized
in strictly defined decision rules. For example, when statements input1 is number A and input2
is number B are true, the decision would be output is number C. But concerning membership
functions, many statements are more or less true at the same time, so there are many rules that can
be applied simultaneously. Then all these candidates for output value are pondered by membership
functions values of the input statements and the final output value is calculated. This process is
called defuzzification.
This technique enables making decisions and predictions of values without knowing the exact
analytical rules using the similarity concept with some experienced examples programmed as
decision rules. In this model of turbine nonlinear functions decision rules are defined at intersection
points of the hill chart, and membership functions, which determine interpolation, are linear.
Nonlinear membership functions give more accurate model of nonlinear functions, but reduce the
calculation speed. Calculating surfaces are given in Figure 3.1. This submodel is nonlinear, but can
be linearized in some special conditions.
1 t
The base of electromechanical submodel is electromechanical equation
( p g pl )dt ,
Ta 0
where is normalized speed deviation, Ta time constant of inertia of hydro generator, pg power of
the generator and pl is load. Power of the turbine is: pt=qh, and power of the generator can be

modeled as: pg= pt- ploss. With some simplifications ploss can be modeled as a constant. However,
integrator limits of type saturation are included in the submodel, which makes it nonlinear, too.

Figure 3.1 Calculating surfaces of nonlinear functions q=q(H,) and = (H,) in turbine submodel

Electromechanical equation is valid only when the generator is working on isolated mode.
Then the pl can be changed in order to test the speed control during loading and unloading of the
machine. When the virtual switch for network is on, the speed is constant and is forced to zero, so
this submodel has no significance.
Water hammer is modeled as correction of head depending on water flow time derivation
dq
where Tw is water starting constant.
H Tw
dt
The model is of incremental type, which means that input signal represents scaled difference
between temporary and desired servomotor position. The output signals of the model are speed of
the turbine, power of the generator and servomotor position. The connection between servomotor
position and guide vane opening is considered linear =Ky. Generator switch is represented by a
hardware switch which position is also recognized in the model. The presence of electrical network
is modeled by a virtual switch.
The model is realized in Matlab Simulink as a real-time application with sample time
significantly smaller then the smallest time constant in the model. The realization of the model is
shown in Figure 3.2. The connection to the hardware, A/D and D/A conversions are obtained by an
interface card. The analog input signal from governor and output signals that represent power of the
generator and servomotor position are connected directly to the PLC. Analog output representing
the speed of the turbine is first transformed into the set of impulses of variable frequency, and then
sent to the counter module of the PLC.
The parameters used in the model are to represent the turbine governor surrounding for hydro
turbine of station service power generator in HPP Bistrica. They are obtained directly or
experimentally during previously preformed measurements in HPP Bistrica. Also, some time
diagrams are taken as test examples in order to prove the accuracy of the model.

Figure 3.2 Model of the turbine governor surrounding

4. DIGITAL TURBINE GOVERNOR TESTING ON SIMULATOR

The simulator parameters are calculated from experimental measurements, available diagrams
and data from HPP Bistrica. Also, a number of diagrams are recorded in purpose of verification
of the model. Only the records when the effect of the currently installed turbine governor on HPP
Bistrica is known or negligible can be used in this purpose. However, many verification tests
have been performed, and Figures 4.1 and 4.2 are examples of those results. These figures show
compliance of the digital model with the electro-hydraulic system. On the Figure 4.3 starting of the
hydro unit is shown. It can be seen that starting procedure is realized with two fixed positions of the

Figure 4.1 Stopping of the machine simulated

and measured diagram

Figure 4.2 - 250 kW unloading - simulated and

measured diagram

servomotor. These positions can be adjusted in the program, but remain fixed during machine
starting. The first position enables the turbine to pass over undesired state quickly, and the second

one leads the turbine slowly to the desired speed. The moment when PID controller takes over the
turbine is also noticeable. It can be seen that the transitions between different servomotor positions
and turning on of the PID controller do not cause any sudden undesired changes of values of
interest.
In the Figure 4.4 work on insulated load of the hydro unit is presented. Therefore the governor
was in the speed control mode. The model of the unloaded hydro unit was first loaded with 250 kW
(31% of nominal active power) and then unloaded again. The speed deviations were 3.8% under the
nominal value and 4.2% over the nominal value. The asymmetry in responses of the speed when
loading and unloading is consequence of asymmetry of the system itself. Namely, the servomotor
position for nominal speed of unloaded turbine is only 2%. Hence, when unloading, the servomotor
stroke is close to zero and the speed drops off slowly. To prevent the integral windup governor
works in the special mode during this period and continues with its normal work when the speed is
close to its nominal value.

Figure 4.3 Simulation of hydro unit starting

Figure 4.4 -Governor testing in speed control mode

Setting of the governor parameters is of essential importance to the quality of control. Figure
4.5 illustrates how inadequate parameter setting can lead to oscillatory regime of the hydro unit.
The same experiment as in previous figure is taken, but the derivative action time was changed
42%. The results are substantially different. Due to emphasized derivative action the governor
responses with too strong control signal and leads the system to the oscillations. Therefore, special
attention is paid to governor parameter settings for each working mode separately.

Figure 4.5 - Inadequate settings of governor

parameters

Figure 4.6 - Governor testing in power control

mode

Finally, Figure 4.6 shows work of the governor in the power control mode. The turbine was
simulated to be connected to the electrical network and the reference of the power was changed in
the regulator to values 0 kW, 200 kW, 350 kW, 600 kW, 800 kW, 500 kW, 400 kW, 150 kW and 0
kW respectively. It can be noticed that active power follows the given reference with acceptable
response dynamic and without errors in steady state.
5. CONCLUSION

The novel digital turbine governor, which properties and performance fulfill criterions of
control quality set by actual international regulation is developed. Also, by consolidating of
auxiliary turbine systems control functions and speed and active power control functions, the novel
turbine governor is applicable for implementation on all power range hydrounits. The governor
execution program adaptability enables its implementation on every hydrounit regardless of the
turbine type. Also, it is shown that the turbine governor surroundings simulator is very important
element in governor testing on large disturbances in laboratory conditions. By governor testing on
simulator a set of appropriate governor parameters is formed, which, with more or less changes, can
be implemented in the hydro power plant.
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