NPC DOC. NO.

TAPP-3/64110/5526/DN/R0---------------------------------4 13300 00 486 ----

REV. NO. 01

WRITE UP
ON
ELECTROHYDRAULIC TURBINE CONTROLLER ( EHTC )

Reference Documents:
1.MPL for Steam Turbine
Doc. No. :- 41330000488(TAPP3/64110/5516/SCH)
2.Scheme for speed measurement turbine and generator
Doc. No. :- 41330098204(TAPP3/64110/5512/DN)
3.Write up on LRR for MSCV and AEOR
Doc. No. :- 41330000481(TAPP3/64110/5661/DN)
4.OGA of TG control desk 6610 – PL – 9
Doc. No. :- 06560000403(TAPP3/64100/5724/GA)
5.OGA of TG control desk 6610 – PL – 10
Doc. No. :- 06560000404(TAPP3/64100/5725/GA)
6.Turbine controller – CJJ01 – Cubicle & Rack assembly diagram
Doc. No. :- 36560001746(TAPP3/64100/5728/GA)
7.Turbine controller – CJJ01 – Signal Flow Diagram(SFD)
Doc. No. :- ED-031027-SF-S105(TAPP3/64100/5729/WD)
8.Turbine controller – CJJ01 – Functional Diagram(FCD)
Doc. No. :- ED-031027-FC-S105(TAPP3/64100/5729/WD)

NPC. DOC. NO. TAPP3/64110/5526/DN/R0

01 1.10.02 REVISED AS PER BS RANA BS RANA

NPC COMMENTS
00 17.11.02 FIRST ISSUE V. KUMAR BS RANA A. ALI
REV DATE REMARKS WORKED CHECKED APPROVED

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Electro-hydraulic turbine controller

INDEX SH. NO.

1 Introduction 4

2 Turbine Control System 4

3 Hydraulic Controller 5
3.1 Hydraulic Amplifier and Electro hydraulic Converter 5-6
3.2 Load Rejection Relay 6-7
4 Electro hydraulic Controller 7
4.1 Control Requirements for Electro hydraulic Controller 7
4.2 Structure of Electro hydraulic Controller 7-8
5 Control Loops of Electro hydraulic Controller 8
5.1 Speed Control Loop 8
5.1.1 Speed Set point Adjuster 8
5.1.2 Speed Set point Control 9
5.1.3 Actual Speed Derivation 9-10
5.1.4 Speed Controller 10-11
5.2 Lift Set point control loop 11
5.2.1 Lift Set point Adjuster 11-12
5.2.2 Lift Set point Controller 11
5.2.3 Actual Load Derivation 12
5.2.4 Maximum Valve Lift Set point Adjuster 12
5.2.5 Further Processing of Lift Set point Signal 12
5.2.6 Activation and Deactivation of Lift Set point 13
5.3 Pressure Control Loop 13
5.4 Control Selection Circuit 14-15
5.5 Valve Lift Control Loops 15
5.5.1 Set point Derivation for Lift Control Loops 16
5.5.2 Actual Lift Derivation 16
5.5.3 position Controller 16-17
6 Interaction of Electro hydraulic Controller and Hydraulic 17
Controller
7 Operator Control Devices 17
8 Operating Concept, Operating Modes 18
8.1 Start-up 18
8.2 Loading/Power Operation 18-19
8.3 Shutdown 19
8.4 Load Rejection 19-20
9 Alarms 20

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Fig. -1 Structure of the turbine control system 21

Fig.-2 Mechanical Hydraulic Controller (MHC) 22
Fig.-3 structure of the EHC with Hydraulic Actuation 23
Fig.-4 Speed Control Loop 24
Fig.-5 Turbine Stress Control influence on ref limiter 25
Fig.-6 Actual Speed Measurement 26
Fig.-7 Lift Set point Control Loop 27
Fig.-8 Actual Load Measurement 28
Fig.-9 signal Exchange 29
Fig.-10 Speed Measuring Unit 30
Fig.-11 Minimum pressure Control Loop 31
Fig.-12 Control selection Circuit 32
Fig.-13 Function of Selection Circuit 33
Fig.-14 Valve Position Control Loop 34
Fig.-15 Characteristic Curve Of Plunger Coil 35
Fig.-16 Tiles On Control Panel 36
Fig.-17 Functional Diagram of EHC 37

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1 Introduction

Electro-hydraulic turbine controller (EHTC) is realized as a part of

PROCONTROL system.

The Electro hydraulic turbine controller consists of two main components:

1. An electronic controller which outputs valve lift set points.

2. A hydraulic system which position the valves to match the valve lift
signal.

This combines the advantages of electronic measurement and signal

processing such as:

- high flexibility
- excellent dynamic response
- simple representation of complex functional interrelationships

With the advantages of hydraulic systems, i.e.

- continuous and precise control of large actuation forces.

A hydraulic controller is also provided. Under normal conditions, this

controller is deactivated. In the event of failure of the Electro-hydraulic
controller, the hydraulic controller can be activated from the main control
room panel 6610-PL-10.

Operation of the Electro-hydraulic controller and its interaction with the

hydraulic controller is described below :

2 Turbine Control System

The standard configuration provides a hydraulic controller and an Electro-

hydraulic controller for control of the turbine generator. As can be seen in
fig. 1, the hydraulic controller acts via a hydraulic amplifier, and the Electro-
hydraulic controller via Electro-hydraulic converters. The output of each of
the Electro-hydraulic converters is linked via an hydraulic MIN gate (as
shown in fig 3). This means that the lower control signal at any time takes
affect for the hydraulic actuation system.

This description in not intended to give detailed information on the hydraulic

controller or on the hydraulic valve actuation system. These two systems are
therefore described only to the extent required to assist in understanding
Electro-hydraulic controller operation.
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3 Hydraulic Controller

The hydraulic controller (see fig . 2) comprises of hydraulic speed governor

and a start-up and load limit device. These two devices are linked via a MIN
gate, with the output from this acting on the hydraulic amplifier and thereby
on the turbine control valves.

If the hydraulic controller is to govern turbine start-up, the set point for the
Electro-hydraulic controller must be set to 100% to allow the hydraulic
controller to implement turbine control over the entire control range. The
speed set point for the hydraulic controller is set to minimum for this.

The set-point for the start-up and load limit device is then increased from
0%. This causes trip fluid pressure to build up and reset the protective
devices of the turbine. Increasing the set point for the start-up and load
limit device further in the open direction causes the turbine stop valves to
open.

After the turbine stop valves have opened, increasing the set point for the
start-up and load limit device further results in gradual opening of the
control valves, admitting steam to the turbine. This runs the turbine up to
about 85 - 90 % rated speed. The hydraulic speed governor then takes over
speed control of the turbine. Actual speed is derived from hydraulic speed
transmitters. After this control takeover has taken place, the set point of the
start-up load limit device has then to be set to the 100 % position..

For synchronization, turbine speed is run further by increasing the set point.
After synchronization, the turbine is loaded by raising the set point further.

As the hydraulic speed governor and the start-up and limit load device are
linked via the downstream hydraulic Min gate, the output of the hydraulic
controller and thereby turbine output can be limited by the start-up and limit
load devices. If turbine start up is to be governed by the Electro-hydraulic
controller, the set point for the start-up and limit load device has to be set to
its max. value of 100% immediately after opening of the turbine stop valves.
The set point for the hydraulic controller likewise has to be set to 100% to
allow the Electro-hydraulic controller to take over speed control of the
turbine above turning speed. The speed set point for the Electro-hydraulic
controller must be set to 0% for this.

3.1 Hydraulic Amplifier and Electro hydraulic Converter

The hydraulic amplifier forms the interface between the hydraulic controller
and the hydraulic valve actuation system. The output signal from the
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hydraulic controller (secondary fluid pressure) acts on a piston via a sleeve,

thereby acting on the follow-up piston block. This movements of the follow-
up piston alters pressure of the secondary fluid. The secondary fluid pressure
sets control valve lift.

The Electro-hydraulic converters forms the interface between the Electro-

hydraulic controller and the hydraulic valve actuation system.

Two analog electrical output signals are available from the Electro-hydraulic
turbine controller. Each signal acts on a piston via a sleeve of the
independent electro hydraulic converter(EHC). The position of the piston of
each EHC is acquired by linear variable differential transmitters (LVDTs) and
used as actual value for the valve lift controller. The piston acts on a follow-
up piston block, the resulting movement of the follow-up pistons likewise
altering secondary fluid pressure and thereby control valve lift.

The output from the follow-up piston blocks of the hydraulic controller and
Electro-hydraulic are linked via a MIN gate. This means that the system with
the lower pressure output signal sets valve lift.
In the event of failure of the output signal from the Electro-hydraulic
controller to one of the two Electro-hydraulic converters, the other Electro-
hydraulic converter, sets the valve lift if selected though the MIN gate.

3.2 Load Rejection Relay

The load rejection relay (see Fig.2) assists the electro hydraulic controller to
ensure that the speed of the turbine generator cannot reach the trip setting
for the hydraulic overspeed trips under any circumstances.

Sudden unloading of the turbine generator, that is , a negative step load

change, are acquired promptly by electrical means via the load rejection
relay and converted into an electrical pulse of adjustable duration. This pulse
is used to actuate the solenoid valves in the control fluid circuit for the
control valves, switching to drain and thereby causing a rapid drop in
pressure.

Response of the load rejection relay to the load rejection uses the change in
electrical generator load before the subsequent increase in speed which
results. This means that the load rejection relay acts on the turbine control
system before the significant speed increase .
After termination of the electrical pulse the solenoid valves which have
switched to drain close again. At this stage , the electro hydraulic controller
still holds the drain closed due to the speed increase which has occurred in
the meantime. After this speed increase has stabilized , the electro hydraulic
controller opens these valves again. Control fluid pressure then builds up
again and the electro hydraulic controller opens the control valves to a
position corresponding to the new generator load or to the speed set point.
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The settings for the load rejection relay (load step magnitude, pulse
duration) are made during initial commissioning and start-up of the turbine
generator.

To prevent response of the load rejection relay on under -frequency, a

frequency monitoring circuit inhibits response of this relay if frequency drops
to an adjustable under frequency limit. Without this feature , in the event of
the load rejection on under frequency ,after termination of the CLOSE pulse
the electro hydraulic controller would then open the turbine control valves
very far due the large error caused by the frequency deviation. This in itself
could lead to an overspeed trip.

4 Electro hydraulic Controller

4.1 Control Requirements for Electro hydraulic Controller

The task of the electro hydraulic controller is to control steam flow by

actuation of the control valves and thereby to control turbine speed as well
as generator load under all operating conditions (start-up, loading, power
operation, rundown, load rejection).

The electro hydraulic controller meets the following requirements:

- High operational safety and reliability by utilizing modules with

integrated circuits as well as multiple channels speed acquisition.

- Ability to ride through load rejections on disconnection from power

system and the associated speed excursion due to rapid control action.

- Low stress operation of the turbine generator due to action of turbine

stress evaluator (TSE) on set point controls, i.e., the rate at which
speed and load changes are implemented is optimized on the basis of
maximum permitted material stress criteria.

- Provision for automatic turbine generator start-up and shutdown by

providing for signal input from an appropriate auto control.

4.2 Structure of Electro hydraulic Controller(refer Fig. 3)

The electro hydraulic controller comprises the following control loops:

- Speed control loop

- Lift set point control loop
- Minimum pressure control loop

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The separate loops are completely isolated from one another by means of a
control selection circuit .

The output signal of the control selection circuit sets the positions of the
electro hydraulic converters pistons via the valve lift controllers, thereby
setting turbine control valve lift.

5 Control Loops of Electro hydraulic Controller

5.1 Speed Control Loop(refer Fig. 4)

The task of the speed loop is to meet closed-loop control requirements for
the turbine generator during start-up and synchronization with the power
system. During power operation the speed controller serves as an overspeed
limit controller to ensure that speed increases caused by power system
disturbances (such as load rejection) cannot result in speed reaching the trip
setting for the mechanical overspeed trips (set to approx. 115% of rated
speed) under any circumstances.

The speed control loop consists of the set point adjuster, the set point control
and the speed controller.

5.1.1 Speed Set point Adjuster

The speed set point nr is governed by the position of the set point adjuster
(refer Fig. 5). The set point can be adjusted over the range from 0 to 55 rps
from the main control room panel 6610 – PL - 10. To assist in fine
adjustment of the speed set point for synchronization, the rate of change for
the set point adjuster is decreased by a factor of 4 at set points above 47
rps.

Further input are provided for adjustment of the speed set point by a
synchronizing unit and an automatic start - up system. Manual set point
change command take priority.

The speed set point is displayed on two indicators on the turbine control
panel , one for the overall speed range of 0 to 60 rps and the other for the
narrow range from 45 to 55 rps.

5.1.2 Speed Setpoint Control

The speed setpoint nr forms the input signal for the setpoint control which
determiners the acceleration rate. For this, the setpoint control outputs a
delayed setpoint nr del.

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The maximum permissible speed acceleration rate is part of control software.

This is set at 600 rpm/min.

The turbine stress evaluators (TSE) acts via the setpoint control to limit the
speed setpoint rate. Any limitation is based on acquisition and evaluation of
thermal stresses measured at representative locations on the turbine .This
prevents excessive thermal stressing of the turbine and at the same time
allows turbine generators run-up at the maximum permitted acceleration
rate. Depending on the thermal conditions in the turbine , the TSE can cause
the acceleration rate to be reduced to zero or even to become negative (see
Fig.5).

In the event of a fault in the TSE, the momentary output signal of the speed
setpoint control is "frozen" automatically until the fault has been cleared or
the TSE control component has been deactivated using the ON/OFF switch in
the electro hydraulic controller cabinet.

The TSE is provided with a test program to allow checkout of the anolog
calculation channel.

To avoid any negative impact on turbine generator operations on testing , an

interlock is provided which only permits testing when input and output of the
speed setpoint control match.

Due to the P- characteristic of the speed controller the setpoint must be

corrected at no load operation. This can be done by an adjustable component
added to the delayed speed setpoint .The value of this correction is optimized
based on the operating pressure at the time of commissioning.

5.1.3 Actual Speed Derivation

Actual speed is measured digitally .The end of the turbine shaft is fitted with
a digital speed transmitter which consists of 3 Hall probes and a non-
magnetic disk with 120 permanent magnets positioned around its
circumference (See Fig.6).

During turbine operation , the poles of these magnets move past the Hall
sensors separated by a slight air gap only (approx.0.8 mm). When the disk
rotates , the probes output pulses which are converted into an AC voltage
signal with a frequency proportional to rotational speed of the turbine. The
output signal from each Hall probe is transmitted to a dedicated pulse
converter in the vicinity of the turbine .Each of these pulse converters
amplifies the Hall voltage and replicates this to give 3 floating- voltage,
square -wave voltage signals of approx. 20 Vpp.

Three (3) signals (one each from each pulse converter) of frequency which
corresponds to the Hall voltage frequency (and thereby to turbine speed )
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are transmitted to pulse amplifiers mounted in the electrohydraulic converter

cabinet.

The 3 output signals from the pulse amplifiers are monitored continuously by
the pulse monitor for failure. This is performed by cyclic scanning of the
input signals, with the signal which is at any time the second in chronological
order being selected as actual speed signal by the channel changeover
circuitry and transmitted to the downstream frequency/ voltage converter.

Within the frequency/ voltage converter the square-wave voltage is then

converted into an analog signal appropriate for controller processing.

Failure of a speed channel is detected by the pulse monitor. The actual valve
signal is then selected from the two unaffected channels and this fault
annunciated by an individual alarm in the cabinet as well as by a group
alarm.

As changeover of channel configuration is performed by solid-state switching

devices, control system operation continues without interruption, even in the
event of failure of a further channel.

The remaining output signals from the three pulse converters is transmitted
to other I&C system, e.g. to the speed measuring unit.

5.1.4 Speed Controller

The speed controller features P+D (proportional + derivative) action to

satisfy the dynamic requirements of the control system for start-up and
shutdown, no-load operation and load rejection. The control deviation forms
the input signal for the speed controller.

The deviation is derived from the delayed speed setpoint nr delay (output of
the speed setpoint control) and the actual speed signal nact (output by the
frequency/ voltage converter).

The output from the speed controller is applied to the control selection circuit
and, when selected for output, forms the input signal for the valve lift
controller ( see description of control selection circuit, Section 5.4).

5.2 Lift Setpoint control loop(refer Fig. 7)

The set point output of the lift set point control loop takes over control of the
turbine immediately after synchronization of the turbine generator with the
power system. This function allows valve lift and thereby turbine load to be

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increased continuously up to the point at which the steam generator pressure

controller deviation signal is zero. This function consists of the lift setpoint
adjuster, the lift setpoint controller and an ON / OFF logic.

5.2.1 Lift Setpoint Adjuster

The lift setpoint Lr is set by the output of the setpoint adjuster. The setpoint
can be adjusted manually from the main control room panel 6610-PL-10.

During auto mode of operation, the lift setpoint adjuster Lr follows the output
of lift setpoint controller Lr del to enable bumpless transfer during
changeover back to manual. The lift setpoint is displayed on an indicator
located on the turbine control panel in the control room.

5.2.2 Lift Setpoint Controller

In manual mode, the output from the lift setpoint control Lr del follows the
input signal Lr, with the preset rate and the rate of change governed by the
lift setpoint rate adjuster. This set point rate can be adjusted from the main
control room panel. The rate can be adjusted to anywhere between zero and
maximum permitted lift rate (approx. 10% /min). During Auto mode of
operation, the output of the lift setpoint controller is based on the adapted
steam generator pressure controller output. Adapted steam generator
pressure controller output is received in two channel . A minimum selection is
formed of the two channel.

The lift rate adjuster can be activated and deactivated from the main control
room panel 6610 - PL -10. When the lift rate adjuster is deactivated, the
maximum permitted lift rate becomes effective.

The turbine stress evaluator (TSE) also acts on the lift set point controller.
The TSE component acts on setpoint changes in both directions, with the
upper margin acting on valve opening and the lower margin on valve
closing. If the upper margin should become negative valve opening, the
output valve of the setpoint controller is automatically reduced, thus leading
to closure of valves instead of opening.

This ensures loading and unloading at maximum possible rate, but without
exceeding maximum permitted thermal stress limits.

The effective rate of change for the lift setpoint is given by the MIN TSE
component and the set lift setpoint rate.

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The output of the lift setpoint controller is inhibited on the following

conditions:

- When the MIN-pressure controller takes over control of the turbine

during loading of turbine
- When the TSE is faulty and the TSE component is activated.

The output from the lift setpoint controller is automatically set to zero under
the following conditions:

- When the lift setpoint is deactivated for longer than 3 s ( see Section
5.2.6)
- After the speed controller has taken over control of the turbine during
shutdown.

5.2.3 Actual Load Derivation

Actual load is measured by three load transducers, with each system

arranged as a two-wattmeter circuit. The three output signals are monitored
for synchronism and the actual valve selected via a downstream mid valve
selector.

These load transducers are connected to a generator voltage and current

transformers. The load transducers feature extremely short time constants
(<10ms), as electronic multipliers are used to multiply currently and voltage.

Load measurement is required to derive limit signals for automatic activation

and deactivation.

5.2.4 Maximum Valve Lift Setpoint Adjuster

The max. valve lift set point LMAX is set by the output of setpoint adjuster.
The setpoint can be adjusted manually from the main control room panel
6610 –PL -10 to limit the valve lift in case of necessity.

5.2.5 Further Processing of lift Setpoint Signal

The output signal from the lift setpoint controller is passed on to a MIN gate
and compared with the maximum valve lift set point LMAX . The output of
this MIN gate is passed on to the control transfer circuit via a switch for " Lift
setpoint controller ON / OFF".

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5.2.6 Activation and Deactivation of Lift Setpoint

Providing that the speed controller is in action, the lift setpoint can be
activated or deactivated manually as required from the main control room
panel 6610-PL-10. The lift setpoint should always be activated in normal
operation, as selection of the controller to take control is implemented by the
control selection circuit. The control selection circuit is described in Section
5.4.

The output of the lift setpoint controller is automatically deactivated under

the following operating conditions :

- When the generator breaker is open ( meaning that the generator is

not synchronized with the power system) or

- When generator active power is below about 2 x station load and a

sudden drop in generator active power is then registered ( meaning
that load rejection has taken place)

Deactivation of this setpoint causes the speed controller to immediately take

over control of the turbine generator and close the turbine control valves at
maximum speed. This action ensures that the turbine generator speed will
be held below trip speed under all conditions.

If load on the power system picks up again within a short period(approx.3s),

the lift setpoint is automatically reactivated. As the output signal prior to
deactivation was stored this means that the status prior to load rejection is
restored immediately.

In the event that generator actual load becomes negative due to power
system load swings ( generator synchronized to power system and supplying
more than 2 % reverse power, i.e. generator is motoring ), the lift setpoint is
then immediately reactivated. Such load swings in the power system can
occur on reconnection of loads that were shed during a power system
disturbance.

5.3 MIN Pressure Control Loop(refer Fig. 11)

The adapted pressure deviation signal from steam generator pressure control
system is received in two channels. These two signals are compared in a
MAX gate and fed to a pressure controller. The output of the pressure
controller is fed to the control selection circuit and has got highest priority
(see fig.12)

The pressure controller tolerates small size deviations from the pressure
setpoint. It does not take action until actual pressure drops more than a
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certain limit value below the setpoint. The controller then throttles the
turbine control valves.

5.4 Control Selection Circuit

The control selection circuit (see fig.12), a logic circuit comprising a MAX
gate with downstream MIN gate, determines which of the three types of
loop- speed control loop,lift set point control loop or minimum pressure
control loop - takes over control of the turbine generator. This control
selection circuit also ensures that only one of these 3 controllers will be
active.

The output signals from the speed controller and the lift setpoint controller
are inputted to the MAX gate, i.e the higher signal value is always output by
this gate, thereby setting turbine valve lift if this is also the lower signal
valve present at the downstream MIN gate. During turbine generator start-
up, the output signal from lift setpoint formation is deactivated (as the
generator breaker is not closed), so that the signal from the speed controller
will be output by this logic and the speed controller will take control of the
turbine generator. Minimum pressure controller output has got more priority
and will takeover control to throttle valves if actual pressure drops more than
a certain limit from set pressure valve.

Once the generator is synchronized with the power system and the generator
breaker is closed and lift setpoint control loop is activated, the lift setpoint
control in line with the set lift set point. During this operation with the output
signal from the speed controller set to a valve lift corresponding to about 10
% load by appropriate automatic adjustment of the speed setpoint.

This setting for the speed controller output signal ensures that if the lift
setpoint signal is deactivated in the event of power system disturbance,
turbine generator speed is prevented from rising due to the setpoint set for
the speed controller.

In the event of a load rejection with a resulting increase in speed of the

turbine generator, the output signal from the speed controller will become
negative. This counteracts the perturbation by moving the turbine control
valves in the closing direction, i.e. as soon as the output signal from the
speed controller becomes negative, the sum signal then leads at the
summing point ahead of the MIN gate where speed controller and lift setpoint
controller outputs are compared.

The minimum pressure controller takes over control via the MIN gate when
this is lowest input signal to this gate.

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The control loop that is in control of the turbine generator at any moment is
signalled on main control room panel 6610-PL-10 by one of the following
status indications:

- Speed controller in action

- Lift setpoint control in action
- Pressure controller in action

Fig. 13 serves to illustrate operation of the control selection circuit. The

example given is for a load rejection down from 300% to 150% load. Here
power input to the power system is from three generator so that this load
swing amounts to a reduction in load from 100% to 50% for each turbine
generator.

With a droop setting for the speed controller of 5%, this results in a speed
rise of

nTurb= P = 50% = 2.5% =1.25 rps

K 20
Where Gain K= 1 = 1 =20
S 5%
For a droop setting of 5%, the speed setpoint increase by 2.5 rps over the
load range. As the speed setpoint is set to 10% lift, equivalent to 50.25 rps,
this load rejection results in a speed rise to
(50 + 1.25 + 0.25 ) rps =51.5 rps
( Point t2 on diagram n=f (P)).

From this diagram it can be seen that lift setpoint controller is in control of
the turbine up to time t1 . After this load is reduced to 50% of rated load by
the negative speed controller output signal.

The turbine then operates at an actual speed of 51.5 rps to match the new
load demand of 50% only. Turbine speed can be returned to rated speed by
lowering the lift setpoint to match the new power system load demand.

5.5 Valve position Control Loops

Two valve position control loops are provided for the turbine control valves.
To improve the stability and dynamic response of the overall control system,
the valve position controllers are implemented as slave control loops to the
master controllers (speed controller, minimum pressure controller, lift
setpoint controller). Both valve position control loops are operative normally
but in case of fault in actual lift derivation of one loop, the valve position is
decided by other loop which will now always remain operational .

5.5.1 Setpoint Derivation for Lift Control Loops

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The signal by the control selection circuit is outputted in two sets of three
channels. Middle of the three signals is selected by voting module. This acts
as set point for both valve lift controllers.

These two control loops do not differ so that the description which follows
applies for both.

5.5.2 Actual Lift Derivation

The lift of the servo piston in the electrophydraulic converter sets the lift of
the turbine control valves.

As a result, this can be used to derive control valve lift. Although this is an
indirect measurement it is linear and accurate enough for this purpose. This
is usually a more reliable method than direct measurement on the control
valves. Even in the event of turbine trip with the resulting drop in trip fluid
pressure, the servo piston moves in the "close valves" direction so that valve
lift is correctly registered under these conditions.

Each electrohydraulic convertor has got two LVDTs ( Linear variable

differential transducers) , one as redundant to measure lift of the servo
piston. The output signals from the LVDT of the electrohydraulic convertors
are monitored for synchronism and given to valve lift controllers as actual lift
signals hact1-1 and hact1-2 . In the event of a fault in the lift measurement
system an alarm for "fault in actual valve acquisition” for lift is annunciated
in cabinet thus issuing a group alarm ( “Electro hydraulic controller fault").

5.5.3 VALVE POSITION CONTROLLER

The valve position controllers feature PID characteristic. The control

deviation derived by comparison of the position setpoint ( as described
above) and actual lift ( lift signal as measured at servo piston of
electrohydraulic convertor) forms the input signal to this controller.

The output signals act on the plunger coil system of the electrohydraulic
converters, thereby acting on control fluid pressure of the hydraulic valve
actuation system. These converters thereby set the lift for the control
valves. For further details see turbine manual.

The characteristic of the electro hydraulic converter is shown in fig. 15.

The position controller output signal can be deactivated in the

electrohydraulic controller cabinet for maintenance purposes.

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A monitoring functions within the valve position controller annunciates short-

circuits and ground faults for the plunger coil within the electrohydraulic
controller. Faults are annunciated by means of the alarm "Plunger coil fault".

In the event of an open circuit for the plunger coil of one electrohydraulic
converter, the valve position is determined by other valve position controller
which is always operative as back up.

6 Interaction of Electrohydraulic Controller and Hydraulic controller

The electrohydraulic controller and hydraulic controller are redundant

controllers. Either of the two controllers can take control of the turbine
generator under the conditions described previously. Both controller use the
same hydraulic actuation system to position the turbine control valves. The
two controller are linked with this hydraulic system by the electrohydraulic
converter in the case of the electrohydraulic controller and the hydraulic
amplifier in the case of the hydraulic controller.

As can be seen from fig. 1, the downstream MIN gate means that the
controller with the lower output signal will take control under any condition.
As a result, to make a controller take over control it is necessary to adjust
the setpoint appropriatly for the two controllers.

If the turbine is to be operated with the electrohydraulic controller, the

setpoint for the hydraulic controller, has to be set to 100%. This allows the
electrohydrualic controller to take over the control over entire control range.

To transfer control to the hydraulic controller, the setpoint for this controller
only needs to be set lower than that for the electrohydraulic controller. The
lift setpoint for the electrohydraulic controller then has to be set to 100% to
allow the hydraulic controller to exercise control over the entire control
range.

In normal operation the electrohydraulic controller controls the turbine, with

the hydraulic controller on stand -by ready to assume control immediately in
the event of failure of the electohydraulic controller.

7 Operator Control Devices

The operator control devices for operation of the turbine controller are
intergrated into the main control room. The panel section for the
electrohydraulic controller is shown in fig.17.

This panel section comprises miniaturized control room equipment, consisting

of pushbuttons indicators and indicator lamps on the appropriate tiles.

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8 Operating Concept, Operating Modes

8.1 Start -up

It is a preconditions for turbine generator start-up that the electrohydraulic

controller cabinet be ready for operation ( commissioned, cabinet power
supply switched on).

The turbine generator must be in turning operation, with the start-up and
load limit device, hydraulic speed governor setpoint and electrical speed
setpoint set to zero.

After the turbine stop valves have been opened using the start-up and load
limit device, hydraulic speed governor as well as the start-up and limit load
device are then set to their upper limit positions ( 100% position).

As the turbine has already been run up to a low speed (approx. 200 rpm )
by the hydraulic turning gear, the electrical speed measurement system
supplies a voltage signal proportional to speed as actual speed.

The speed setpoint nr is raised to make the speed controller take control, the
turbine is then run up to rated speed by increasing the speed setpoint further
and the generator synchronized with the power system. The TSE component
ensures run-up of the turbine at an optimum rate and without exceeding
permitted thermal stress limits.

8.2 Loading /Power Operation

The lift setpoint controls the turbine generator unit once the generator has
been synchronized with the power system.

After this, control valve lift is set by adjusting the lift setpoint manually to
the appropriate level in manual mode.

The output signal from the lift setpoint controller is increased and at the
same time the speed setpoint is reduced to a value corresponding to approx.
10% unit load. In auto mode, the output of lift setpoint controller is
determined by the adapted pressure deviation signal from steam generator
pressure control system and lift setpoint Lr tracks the lift setpoint controller
output. The speed controller is inactive but is kept on stand-by to take over
control of the turbine generator and maintain speed close to rated speed on
full load rejection down to station load. The TSE ensures optimum power
increase rates on turbine generator loading, but without exceeding permitted
thermal stress limits.

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The lift setpoint rate dL/dt is set on the main control room panel 6610-PL-10
to give the max. permitted rate of change for lift.

After synchronizaiton in normal operation, the valve lift setpoint is

determined by lift setpoint controller with the limitation set manually by the
Maximum valve lift setpoint adjuster. Steam is admitted to the turbine by
opening the turbine control valves. If the actual pressure drops below a
certain preset limit from pressure setpoint, the minimum pressure controller
then takes over control of the turbine and the lift setpoint controller is
deactivated.

If actual pressure increases again, the minimum pressure controller is

deactivated and control of the turbine is transferred to the lift setpoint
controller which then continues to open the control valves in line with the set
rates.

If valve opening is limited for any reason, the lift setpoint is lowered. This
results in take-over of turbine generator control by the lift setpoint controller
via the control selection circuit

8.3 Shutdown

The lift setpoint is set to zero on turbine generator shutdown. This causes
unloading of the turbine generator in line with the set rates.

The lift set point is lowered until all control valves are throttled such that the
generator breaker opens via the anti-motoring protection ( this responding
when the generator motors and takes up more than 2 or 3 % reverse power
from the power system ) and the generator is de-excited.

The turbine trip pushbutton is then pressed to initiate turbine trip, this
resulting in closure of the turbine stop valves.

The above operating procedure ensures that the turbine generator is not
disconnected from the power system until the control valves have closed fully
( to avoid the risk of turbine overspeed).

During rundown of the turbine generator after turbine trip push button is
pressed, the speed setpoint nr is tracked to actual speed. This means that
the speed setpoint adjuster is already set to the correct value for restart.

8.4 Load Rejection

On load rejection to station load or zero load (i.e., in the event of sudden
disconnection of the loaded turbine generator from the power system), the
lift setpoint signal is immediately deactivated. This results in a large
magnitude deviation in the control valves in close direction for the lift
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controller. The speed controller takes over control of the turbine generator
unit. This results in closure of the turbine control valves at maximum speed,
as the speed setpoint was set to a level equivalent to 10% load on turbine
generator start-up and this signal now takes effect as input signal for the lift
controller.

Thanks to the above actions, controller action is taken immediately to

counteract any speed rise on load rejection without the need to wait for a
recognizable rise in speed to cause response of the speed controller. If load
on the power system picks up again within a set period (approx. 3 seconds),
the lift setpoint is reactivated and the turbine control valves are moved to
the position they were at before the disturbance.

The only difference between a load rejection to station load and a load
rejection to zero load is in the magnitude of the resulting transient speed
rise. The speed rise is less for load rejection to station load due to the load
which remains.
The electro hydraulic controller or hydraulic controller hold the speed of the
turbine generator below the trip setting for the overspeed trips under all
operating conditions.

9 Alarms

The group alarm "Electrohydraulic controller fault" is provided on window.

The alarm " Electro hydraulic Controller Fault" is initiated in response to

various alarms. Details of individual alarms are indicated in the
COIS(Computerized Operator Information System).

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