Technical Description of The Digital Turbine Governor

Voith Siemens Hydro
Power Generation
GmbH & Co. KG
Heidenheim
Turbine Governor HyConTM Series 400

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Buan Kuop
Technical
Description
of the
Digital Turbine Governor
TM
HyCon G C 431
g:\projekte\buan kuop\regler\doku\2007-10-11-1e-techbes-govs431 buan kuop.doc
Technical changes reserved
The quotation is decisive for

the hardware and functions delivered
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A Voith and Siemens Company
Vertraulich, alle Rechte vorbehalten DIN 34
Confidential, all rights reserved DIN 34
Confidencial, reservados todos os direitos DIN 34
Voith Siemens Hydro
Power Generation
GmbH & Co. KG
Heidenheim

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Contents
1 Hardware 4
1.1 Programmable Logic Controller PLC 4
1.2 Operating Panel 5
1.3 Output Amplifiers for Proportional Valve or Moving Coil Control 5
1.4 Additional Devices 5
1.4.1 Power Supply 5
1.4.2 Buffer Amplifiers 6
1.4.3 High Quality and redundant Speed Detection 6
1.4.4 Position Transmitters 6
1.4.5 Signal Exchange 6
2 Control Loops 8
2.1 Speed Control 8
2.2 Opening Control 8
2.3 Bumpless Changeover 8
2.4 Setpoint Ramp 8
2.5 Isolated Grid Detection 9
2.6 Limitations 9
2.6.1 Opening Limitation 9
2.6.2 Maximum Opening 9
2.6.3 Minimum Opening 9
3 Description of Additional Standard Functions 10

3.1 Automatic Start and Stop Sequences 10
3.1.1 Start-up 10
3.1.2 Stopping 10
3.1.3 Quick shutdown 10
3.2 Parameter Input / Parameter Indication 11
3.3 Limit Value Generation 11
3.4 Monitoring 11
4 Options 13
4.1 Load Detection 13
4.2 Net Head Signal 13
4.3 Power Control 13
4.4 Acceleration Control 14
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4.5 Limitation of the Operation Area 14

4.6 Shut down Options 14
4.6.1 Stepped Closing Law 14
4.7 Governor-independent Overspeed Detection 14
4.8 Creep Detection 15
4.9 Running Out Simulation 15
4.10 Adaptive Parameters for Speed and Power Control Loop 16
4.11 Redundant Governor 16
4.12 Remote Diagnosis 17
5 Operating Panel 18
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Voith Siemens Hydro
Power Generation
GmbH & Co. KG
Heidenheim

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1 Hardware
The hardware of the digital turbine governor consists of the programmable logic
controller (PLC), the operating panel for local operation, the output amplifiers as well
as the additional equipment for measured-value detection, signal decoupling or
signal conversion. These individual groups are described in the following.
1.1 Programmable Logic Controller PLC

The PLC consists of standard, high-quality industrial grade components (see
technical data):
¾ power supply
¾ CPU with program and data memory
¾ binary input / output modules
¾ analog input / output modules with counter
For safety reasons no storage devices with moving parts are used. In order to be
able to operate the governor without problems even after a power failure, the actual
status of all adjustable parameters is stored in resident memory and on a non-
volatile storage volume (FEPROM, MMC).
The required input and output modules are assigned according to the specific plant
functions.
In order to detect breakdown or disturbances of the digital governor a watchdog

relay is provided to release protective functions (emergency shut down).
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1.2 Operating Panel

The operation of the turbine governor is done by an operating panel. This unit
includes a liquid crystal display (LCD) with graphics capability and a membrane
keyboard with programmable function keys and a numerical input field. The
operating panel is connected to the governor controller via bus interface (MPI).
1.3 Output Amplifiers for Proportional Valve or Moving Coil Control

If the positioning devices don’t have integrated electronic amplifiers, external digital
output amplifiers for the control of the positioning devices can be provided. On them
the opening setpoint is compared with the opening actual value (4-20 mA) and,
depending on the difference, the pertinent servo valve is controlled via an adjustable
gain (positioning control loop). An alternating current is superimposed on the signal
thus preventing static friction in the valve.
For wicket gate control during and after inspection, manual emergency control by
means of an adjustable setpoint control is provided on the output amplifiers. The
opening of the actuator follows the position of the manual amplifier setpoint
independently of the setpoint of the governor. I.e. manual emergency control is
possible without operative governor. In this mode of operation there is no speed
control.
1.4 Additional Devices

External sensors are provided for speed detection, servo motor position
measurement etc. Possibly required additional amplifiers, measuring transducers
etc. are integrated in the governor cabinet.
1.4.1 Power Supply

The governor requires an earthed 24V DC power supply. This will be made by a
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DC-converter in redundant version.
1.4.2 Buffer Amplifiers

The buffer amplifiers have a galvanic isolation between input and output as well as
between power supply and input or output. The load at the output has no influence
on the input.
1.4.3 High Quality and redundant Speed Detection

For the three speed detection inductive proximity switche with a tooth disc is used.
Tow of the speed singals are connected to a counter input of the PLC. The speed is
calculated out of the time period of the square wave signal. This solution supplies an
exact measurement for nearly the whole range.
The third signal is fed to a frequency-current converter. The current signal is used in
the governor for backup (automatic transfer) in the case of a failure of the main
speed signal and for low ranges down to standstill.
For redundant overspeed detection an external overspeed trip device (separate

frequency-current converter with relay output or overspeed pendulum) is used.
1.4.4 Position Transmitters

The position of the wicket gates is detected by capacitive angle measuring

transducers in two-wire-connection or by transsonar linear position transducers.
Usually the closed position corresponds to an output signal of 4 mA, the open
position corresponds to a signal of 20 mA.
1.4.5 Signal Exchange

For signal exchange with outside supplies, floating contacts are made available.
Analog signals are decoupled via buffer amplifiers. Signals made available from
outside supplies must also be floating. On request the galvanic isolation of the input
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Voith Siemens Hydro
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GmbH & Co. KG
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Buan Kuop
signals can also be effected in the governor cabinet.

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GmbH & Co. KG
Heidenheim

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2 Control Loops
2.1 Speed Control

The speed governor is a PID(P) governor (governor parameters variable according
to the operating condition). There are 3 sets of parameters: one for no-load
operation (optimized for synchronization), one for isolated operation (high damping)
and one for network parallel operation (low damping).
2.2 Opening Control

Opening control is possible in network parallel operation only , i.e. the circuit breaker
must be closed and the speed has to be within speed band.
The opening control corresponds to a setpoint entry to the positioning control loop
for the wicket gates. In opening control the wicket gates follow immediately this
setpoint. The value of the opening setpoint is compared with the opening limiter and
the lower value is transferred to the position control loop (minimum selection).
2.3 Bumpless Changeover

All control loops currently not active are followed up in order to guarantee a
bumpless changeover at any time, e.g. in case of any governor mode changes the
servomotor position does not change and thus the output fed to the grid is kept
constant.
Special demands for isolated grid operation may require a fixed speed setpoint
instead of a follow-up speed setpoint.
2.4 Setpoint Ramp

For all control modes the actual valid setpoints will follow the external setpoints
using parameterizable ramps. So during normal operation there will be no setpoint
jumps.
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2.5 Isolated Grid Detection

In case of network parallel operation the turbine governor checks permanently if the
adjustable speed band is violated. This function guarantees a safe and reliable
detection of grid disturbances. If the speed band is violated the governor switches
automatically to speed control with isolated mode parameters.
The width of the speed band can be adjusted by means of the parameter input
function.
2.6 Limitations
2.6.1 Opening Limitation

The opening limitation can be adjusted at will, e.g. to limit the generator load
temporarily, but usually it is set to 100 %. The opening limitation is effective in all
control modes, even during start-up of the turbine.
2.6.2 Maximum Opening

The wicket gate opening can be limited by a fixed maximum value (adjustable via
the parameter input).
2.6.3 Minimum Opening

Additionally, a minimum limitation is possible that becomes effective after closing
the circuit breaker (adjustable via the parameter input).
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Voith Siemens Hydro
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3 Description of Additional Standard Functions
3.1 Automatic Start and Stop Sequences
3.1.1 Start-up
The turbine start-up is controlled via 2 head dependent starting openings in such a
way that the machine can be synchronized to the grid as fast as possible without
respect to boundary conditions (e.g. changing head).
Via two adjustable speed limits the commands for switching on the excitation and
the synchronizer are issued.
3.1.2 Stopping
In case of a normal stop the wicket gates are closed at an adjustable rate down to
closed position. When the circuit breaker has been opened the wicket gates are
closed at maximum hydraulic closing speed to closed position.
After reaching the no-load position a signal is issued that can be used to open the
generator circuit breaker.
3.1.3 Quick shutdown

In case of an external failure a separate input for quick shutdown is activated. By
this the governor is set to stop too, but wicket gates are closed at maximum speed.
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3.2 Parameter Input / Parameter Indication

Without programming unit this function allows the indication and editing of
parameters, ranges, limit values and tabulated points for curves (e.g. Cam curves).
This function offers a powerful but still easy to handle tool to perform most of the
maintenance work ever necessary during operation of the digital governor. This can
be done without using a complex programming device.
If necessary all parameters can be changed using this function - provided the user
has appropriate access rights (controlled by password input).
The parameters can be changed from the local operating panel.
The parameters such adjusted are also maintained in the event of a power failure.
3.3 Limit Value Generation

The limit values of shaft speed and wicket gate position required by the power plant
automation system are generated by the governor. All limit values can be adjusted
via the parameter input.
Additional limit values from any signal can be output by the governor on request.
3.4 Monitoring
All analog signals read into the governor are 4-20 mA signals and are monitored for
signal failure. The speed signal is checked as a function of the wicket gate position,
i.e. if the wicket gates have been opened for a certain time, a speed signal must be
available. In this way a failure of the speed sensor is also monitored. Furthermore
the setpoint-actual value deviations of the wicket gate position is monitored, i.e. a
failure of the opening control loop as well as a failure in the hydraulic positioning
devices are detected and a fault signal is issued.
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The function of the governor program is monitored by a watchdog relay.
Failure signal outputs:

The turbine governor issues a collective warning as well as a collective alarm. The
latter generally causes the machine to be shut down via the protection system.
If required additional individual alarm outputs can be issued.
Detailed alarm messages are available in the local operating panel.

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4 Options
4.1 Load Detection

The load actual value is usually supplied as 4-20 mA signal .
4.2 Net Head Signal

The net head signal or pressure signals for calculation of the net head in the
governor are usually delivered by the customer as 4 to 20 mA signal. On request
pressure transducers can be included in the scope of delivery.
4.3 Power Control

In order to achieve a quick response to alterations of the power reference value a
pilot characteristic (wicket gate opening as function of power) is included which may
be head dependent if a head signal is available. The output of this characteristic is
added to the output signal of the power controller without delay. By this means the
actual output value follows the setpoint as fast as admitted by the control elements
and the typically relatively slow PI power controller has just to balance the
inaccuracies or influences not acquired. If required, power control is activated
automatically after closing the generator circuit breaker.
Due to an adjustable frequency power droop, the machine may participate in

maintaining the network frequency. To meet ambitious requirements in case of a
weak grid the governor uses a solution with an extra speed control loop and power
control loop additively connected, i.e. both controllers are active at the same time.
External analog power setpoint:

For fast response to the demands of a dispatch center or a joint (group) controller
an external analog power setpoint input may be switched on. This is used instead of
higher / lower commands to control the unit output.
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4.4 Acceleration Control

Usually as described in chapter 3.1.1 the machine is started using 2 starting
openings (optionally being head dependent). However, if high fluctuations of the
starting torque at the turbine shaft are expected a significant improvement may be
achieved using an acceleration control.
In this mode instead of adjusting calculated fixed opening values the wicket gate is
adjusted in such a way that the acceleration is kept constant. This results in a very
smooth start-up of the machine with a lower vibration level. Furthermore the time for
accelerating the turbine from 0 to 100 % speed is always constant independent of
mechanical or hydraulic constraints.
4.5 Limitation of the Operation Area

In order to consider the overload limits of the generator or cavitation limits of the
turbine the maximum value of wicket gate opening is calculated as a function of the
operation point. For this purpose the maximum opening is programmed as a
function of head. The tabulated points may be changed at will using the parameter
input function. This module helps to use the full admissible operation area of the
machine in any case.
4.6 Shut down Options

4.6.1 Stepped Closing Law

For optimization of the speed curve after load rejection without protective shutdown,
a stepped closing law is provided. In the first stage, depending on turbine type, the
wicket gates close with their hydraulic closing time. However, in the second stage
the closure is effected at a lower rate.
4.7 Governor-independent Overspeed Detection

If there is no external overspeed trip device (e.g. overspeed pendulum) available,
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with a second speed sensor and a separate speed relay a redundant overspeed
detection and indication takes place in addition to the governor-internal monitoring.
With the help of the analog output of the overspeed relay it is monitored by the
governor for plausibility (see 3.4). In case of a failure of the first speed signal this
second speed signal can be used for speed control.
4.8 Creep Detection

Usually standstill of the turbine is detected by means of the speed signal and a time
delayed switching point. If a more accurate creep detection is necessary, a special
governor module can be provided that uses the pulses of the speed sensor directly
to form an accurate creep detection.
4.9 Running Out Simulation

To ensure a proper process of the stop sequence in case of failure in the speed
measurement the governor can simulate the running out curve approximately. By
this way the machine control unit gets a qualitatively correct indication on the
response of speed limit values. Thus the brake control and other automation
modules can be operated properly.
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4.10 Adaptive Parameters for Speed and Power Control Loop

In case of complicated water passages and/or special grid conditions adaptive
parameters for the speed control loops may contribute to a significant improvement
of the transient properties of the controlled system. Additional to the three parameter
sets for no-load, network parallel or isolated grid operation, which are supplied as
standard solution, the parameters of the PID(P) controller for network parallel
operation and for isolated grid operation are determined as a function of the actual
head and gate opening.
On request a similar function for the power and level controller is available.
4.11 Redundant Governor

The digital governor HyConTM series 400 offers an extraordinary high availability due
to the exclusive application of high-grade industrial quality devices. Nevertheless, a
system failure cannot be totally excluded. For extremely high requirements in a fail-
safe operation of the governor on request a real hot standby solution with complete
hardware and software redundancy is available.
The degree of redundancy is scalable. Redundancy of only power supply and CPU
is possible as well as a complete duplication of the digital governor with the
exception of the control panel, i.e. as well CPUs, storage devices, power supply as
all input, output and counter devices are installed twice.
The governor software installed in the redundant unit, which is the same as in the
main PLC, is permanently active. Both CPUs work with the same process image,
same internal data and are synchronized all the time. If a failure happens in the
active PLC, power supply or associated I/O (depending on degree of redundancy)
automatically a bumpless changeover to the hot standby PLC is initiated without any
disturbance for the machine.
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4.12 Remote Diagnosis

The digital governor HyConTM series 400 provides a remote interface. Using this
interface the governor can be connected online via modem to the Voith Siemens
Hydro diagnosis center. The remote communication link offers identical functions as
a developing system directly connected to the governor at site. So full access to all
internal data and debugging functions is available for fast and efficient trouble
shooting.
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5 Operating Panel
The following screens are examples. The contents of the screens may vary
depending on turbine type and functions delivered.
Front display of the Operation Panel
For the LCD operation panel a separate technical description is available.
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Control screen
Trend screen
Alarm screen
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Alarm history screen
Parameter screen
Maintenance screen
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Technical Description of The Digital Turbine Governor

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Technical Description of The Digital Turbine Governor

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Voith Siemens Hydro

Turbine Governor HyConTM Series 400

Digital Turbine Governor

Technical changes reserved

The quotation is decisive for

Turbine Governor HyConTM Series 400

3 Description of Additional Standard Functions 10

Turbine Governor HyConTM Series 400

4.5 Limitation of the Operation Area 14

Turbine Governor HyConTM Series 400

1.1 Programmable Logic Controller PLC

In order to detect breakdown or disturbances of the digital governor a watchdog

Turbine Governor HyConTM Series 400

1.2 Operating Panel

1.3 Output Amplifiers for Proportional Valve or Moving Coil Control

1.4 Additional Devices

1.4.1 Power Supply

Turbine Governor HyConTM Series 400

DC-converter in redundant version.

1.4.2 Buffer Amplifiers

1.4.3 High Quality and redundant Speed Detection

For redundant overspeed detection an external overspeed trip device (separate

1.4.4 Position Transmitters

The position of the wicket gates is detected by capacitive angle measuring

1.4.5 Signal Exchange

Turbine Governor HyConTM Series 400

signals can also be effected in the governor cabinet.

Turbine Governor HyConTM Series 400

2.1 Speed Control

2.2 Opening Control

2.3 Bumpless Changeover

2.4 Setpoint Ramp

Turbine Governor HyConTM Series 400

2.5 Isolated Grid Detection

2.6.1 Opening Limitation

2.6.2 Maximum Opening

2.6.3 Minimum Opening

Turbine Governor HyConTM Series 400

3 Description of Additional Standard Functions

3.1 Automatic Start and Stop Sequences

3.1.3 Quick shutdown

Turbine Governor HyConTM Series 400

3.2 Parameter Input / Parameter Indication

The parameters can be changed from the local operating panel.

3.3 Limit Value Generation

Turbine Governor HyConTM Series 400

The function of the governor program is monitored by a watchdog relay.

Failure signal outputs:

Detailed alarm messages are available in the local operating panel.

Turbine Governor HyConTM Series 400

4.1 Load Detection

4.2 Net Head Signal

4.3 Power Control

Due to an adjustable frequency power droop, the machine may participate in

External analog power setpoint:

Turbine Governor HyConTM Series 400

4.4 Acceleration Control

4.5 Limitation of the Operation Area

4.6 Shut down Options

4.6.1 Stepped Closing Law

4.7 Governor-independent Overspeed Detection

Turbine Governor HyConTM Series 400

4.8 Creep Detection