GOVERNING SYSTEM OF STAGE-1 200 MW TURBINE

This write-up consists of four parts as follows: 1. Brief functions of Hydraulic system 2. Oil circuit description a) Hydraulic oil b) Emergency trip oil c) Lubricating oil 3. Hydraulic power cylinder operation: a) Main steam stop valve MSV No. 1/MSV No. 2 power cylinder b) IP turbine stop valve RSV No. 1/RSV No. 2 power cylinder c) HP turbine control valve power cylinder d) Combined reheat valve IV1/IV2 power cylinder 4. Summary

1. FUNCTIONS OF HYDRAULIC CONTROL SYSTEM:

Stage-I M/S ANSALDO 200 MW turbines are equipped with HP turbine stop valves MSV no. 1 (left) and MSV No. 2 (right), IP turbine stop valves RSV No. 1 (left) and RSV No. 2 (right) to cutoff steam flow to turbine in case of turbine trip. HP turbine is equipped with single hydraulic power cylinder operated six control valves to regulate steam flow into it and IP turbine is equipped with two regulating valves IV no. 1 and IV No. 2 with independent hydraulic power cylinders to regulate steam flow into it. The stop valves are non-regulating type and they will be fully opened when turbine is reset and fully closed when turbine is tripped. Regulating valves also will be fully closed in turbine tripped state. When turbine is reset they will be operated by commands from EHC.

2. OIL CIRCUIT DESCRIPTION

The three important oil circuits are Hydraulic oil circuit, emergency trip oil circuit and lubricating oil circuit. The oil used for control and lubrication is same. Naming of oil as hydraulic oil, lubricating oil or emergency trip oil depends on the name of header it is present and function. The oil pumps, auxiliary oil pump (AOP) and Main oil pump (MOP) can individually meet all these requirements. All the oil sections are described

a. Hydraulic oil
The AOP discharge and MOP discharge are joining into a header marked with black arrow after passing through non-return valves. This is called Hydraulic oil or Governing oil or Control oil. Reference drawing control mechanism TG 152400.

The functions of hydraulic oil are, 1. Lifting of MSV No. 1 and MSV No. 2 and lifting of HP turbine CV power cylinder and IV 1 and IV 2 power cylinders to the extent demanded by EHC. However this can be done by hydraulic oil only when turbine is in reset state. 2. Hydraulic oil charges into emergency trip oil header when trip devices MTD and ETD are in reset state and pressurizes the header. 3. Main trip device reset and also test are done by this oil.

b. Emergency trip oil

Turbine has two trip devices MTD and ETD. These two devices are bistable. When the devices are given reset commands they reset if no trip causes are present and continue to be in reset state till trip commands are given. If they are in tripped state they continue to be in tripped state till reset commands are given. When these trip devices are reset MTD charges oil into emergency trip oil header and pressurize the header. Pressurization occurs because ETD is also in reset state. Is ETD is in tripped state pressurization doesnt occur. In brief, emergency trip oil header gets pressurized only when MTD and ETD are reset and get depressurized when MTD or ETD is tripped. Both the trip devices have commands by EHC from trip or on local hand lever trip. Local reset facility is available for the trip devices. The trip commands from remote are initiated by EHC for all turbine protections , axial shift very high, oil temperatures from coolers very high, bearing oil pressure very low, condenser vacuum very low, boiler tripped, generator tripped, 112% electrical over speed trip and main oil tank level very low. Reset commands will be able to reset both the devices (ETD & MTD) only when no trip causes are present. Main trip device: Reference control mechanism TG 152400 top left hand corner MTD. The main trip device has a body having ports 1, 2, 3 and 4, lockout sleeve 7 and piston having islands 5 and 6. The ports are connected as below. Port 1 - hydraulic oil through a orifice Port 2 - emergency trip oil header Port 3 - drain to MOT Port 4 - RSOV output When MTD is in tripped condition piston will be towards turbine shaft closing port 1 with island 5 and island 6 goes towards shaft and clears port 3 so that emergency trip oil from port 2 will get drained through port 3. trip of MTD can be caused by hand lever movement towards left or by energisation of MTS (main trip solenoid). In both cases rod 9 moves towards right and hence piston slips off from shoulder of trip finger 8. The spring which is in compression between lock out sleeve and piston drives piston towards shaft. The trip can also occur at 110 % mech. over speed by moving of trip finger 8 on top towards left by emergency governor, a dynamically unbalanced device.

Lock out sleeve 7 is a port of MTD which is having small ports when compared to ports in body of MTD. This permits testing of 110 % over speed protection device and MTD will be as seen in the diagram. When turbine is in reset state the MTD will be as seen in the diagram. When a test is to be made lockout sleeve is moved towards right by admitting oil in port 10. This oil can be admitted by pulling manual lever named exclusion for test in front pedestal and locking it by rotating 90o or by pushing lockout push button on EHC desk and energizing the solenoid valve LVS. Pressurized oil comes out at port 3 of LVS from port 1 in case of trip test from remote and from port 2 in case of trip test from local. The output of solenoid valve not only moves sleeve but also operates a hydraulic relay H by entering through port 1 and compressing spring. Then bearing oil entering port 2 will come out through to be available for trip test. The manual hand wheel counter clockwise rotation or the solenoid OTS actuation by pushing OIL TRIP push button from remote will impinge bearing oil on mech. over speed trip device on turbine shaft. With this unbalance the mech. Over speed trip device acts at nominal operating speed and actuates trip finger 8. MTD piston moves towards right as in case of a real turbine trip and indication in UCB will be MTD TRIPPED. In spite of a real movement of piston towards right as in real turbine trip emergency trip oil header pressure will not drop because of lockout sleeve which was moved towards right before oil admission for trip test. As sleeve moved towards right port 1 will not be cleared by island 6. so trip oil header continues to maintain pressure to keep all stop valves in full open state. When MTD is found tripped in test firstly oil trip test valve must be closed if the test is done I local (this is very important), oil trip push button must be released if the test is done from remote. MTD can be reset by pulling reset lever and rotating it by 90o or by energizing solenoid valve RSOV. Oil comes out with pressure at port 3 of RSOV from port 2 of RSOV in case of local reset operation or from port 1 in case of reset push button operation from remote. This oil enters at port 4 of MTD and tries to push piston towards left. As piston starts moving port 4 cant get linked to drain port 3 because of lockout condition. Whenever resetting of MTD is to be done lockout must be done. This interlock automatic ally gets satisfied in case of local and also remote. In local as reset lever R is pulled out port 1 and 3 of it gets connected and lockout lever port 3 gets pressurized to act against spring and connects ports 1 and 2 of lockout lever to bring locked out state. In case of remote whenever reset push button is pressed RSOV and also LVS are energized simultaneously. LVIS and OTS are limit switches to give indications regarding state of MTD and lockout sleeve. When a trip test is being done from remote, i.e. MTD is in locked out is 112 % electrical over speed trip cause occurs lockout gets automatically released to effect trip from MTD also. Emergency trip device: Emergency trip device is operated by two coils called trip coil and reset coil. Trip coil must be continuously energized to keep the device in reset state. Momentary deenergisation of trip coil causes trip. When no trip causes are present this coil gets energized. Reset coil will be energized when reset push buttons are pressed and resets ETD. When ETD is reset it gets mechanically latched and hence reset coil of ETD will be de-energized when reset push buttons are released. If reset coil is energized first and trip coil is energized next ETD will not reset.

ETD has two ports. The input port is connected to emergency trip oil header the output port is drain port. When ETD is in tripped condition ports 1 and 2 are connected and emergency trip oil pressure goes low. When ETD is in reset state port 1 gets isolated from drain and emergency trip oil pressure will not be dropped by ETD. It should be noted that ETS is not charging the trip oil header in any case.

c) Lubricating oil
Hydraulic oil drives the oil turbine driven booster pump. The exhaust of oil driven turbine is connected to one pressure relief valve set at 1.8 kg/cm2.The oil goes through oil coolers and from outlet of coolers it goes through magnetic filters and comes into a header called bearing oil header. Turning gear oil pump (TGOP) and emergency oil pump (EOP) discharges after passing through non-return valves are getting connected to booster pump discharge line going to coolers. Bearing oil is used in lubricating bearings, turning gear and in mechanical over speed trip test.

3. Hydraulic power cylinders operation

a. Main steam stop valves MSV No. 1 / MSV No. 2 power cylinders
Reference drawings: TGM 908/1, TG142306, Control mechanism TG 152400 The hydraulic power cylinder has spring 18 on one side of piston 15 and on the other side port 7 for hydraulic oil entrance. One relay dump valve having piston 14, spring 17, islands 13 and 12 on piston. Port 4 is connected to drain. Relay dump valve is to give path to governing oil to lift MSV No. 1/MSV No. 2 power cylinders piston when turbine is in reset condition. When turbine trips relay dump valve closes path of hydraulic oil and drains oil stored in hydraulic cylinder faster to close MSV No. 1/ MSV No.2. A test pilot valve provides hydraulic oil input to relay dump valve when test is not being done. In case of test pilot valve cuts off hydraulic oil input to relay dump valve and slowly drains oil stored in power cylinder to close MSV No. 1/MSV No. 2 in test. When turbine is in tripped state emergency trip oil is not present and relay dump valve piston 14 touches bottom because of spring 17. Hydraulic oil coming from port 3 of test pilot valve to port 4 of relay dump valve cannot go to power cylinder port 7 because island 12 will be as shown in diagram TG142306. As island 12 is down port 6 of relay dump valve drains oil from hydraulic power cylinder and hence vale will be in fully closed state only. When turbine is reset emergency trip oil coming with pressure enters port 1 of relay dump valve and lifts piston 14 against spring 17. So island 12 moves up, to isolate drain 6 from cylinder. Governing oil from port 2, port 3 of test pilot valve entering port 4 flows through relay dump valve and enters port 7 of hydraulic power cylinder and lifts piston 15 against spring 18. when turbine trip is actuated trip oil pressure goes low immediately and spring 17 brings piston 14 down and drain 6 gets connected to power cylinder to drain oil stored on power cylinder in around 500 milli

seconds. It must be noted that relay dump valve island 12 is not only connecting drain port 6 to power cylinder but also disconnecting the governing oil from power cylinder. Test pilot valve will be as shown in control mechanism diagram TG152400 when test is not done. Hence governing oil will be able to go to dump valve port 4. in hydraulic cylinder main stop valve drawing TG142306 island 11 must be imagined below port 3. When MSV test is done solenoid gets energized and air will reach port 2 from port 1and enters port 8 of pneumatic power cylinder and moves piston 9 upwards. Test pilot valve piston moves up because of linkage and hence island 11 cuts off the connection between ports 2 and 3 and connects port 3 to drain port 5 to drain slowly the oil stored in power cylinder through port 7 , port 4, port - 3 and port 5. After releasing test PB solenoid valve de-energizes and test pilot valve goes back to its original position charging oil through port 2, port 3, port 4 and port 7. When the turbine is tripped the oil stored in power cylinder is getting drained within 500 milli seconds. To decrease the speed of power cylinder in the fag end of the stroke so that valve seat and stem dont make a big collision dash port 19 is provided. On nearing end of the stroke dash pot is reducing port 7 size to reduce the rate of discharge of oil from power cylinder.

b) IP turbine stop valve RSV No. 1/RSV No. 2 power cylinders

Reference drawings: Control mechanism TG152400, Reheat stop valve power cylinder drawing TG 141311. The hydraulic power cylinder has a spring 12 on one side of piston 11 and on the other side a big port for emergency trip oil entry to lift the piston against the spring. A relay dump valve is present with port 1 and piston having islands 7 and 6 and port 2. When turbine is in tripped state at port 1 emergency trip oil pressure is not present and island 7 touches body 15 because of spring 14 and the bottom part of hydraulic power cylinder is connected to drains 3, 4 because islands 7 and 6 clear the ports. Port 2 (5 mm dia. hole of piston) also will be exposed to drain. When turbine is reset and emergency trip oil pressure builds up to a threshold level piston moves to the state shown in the drawing and the big drain ports are closed by islands 7 and 6 and port 2 slowly charges power cylinder with pressurized oil which lifts piston 11 against spring. The movement of piston with islands 6 and 7 is restricted accurately irrespective of trip oil pressure because of body 15 and rod 33 so that piston islands go to the exactly same position required. Test pilot valve has spring 13 which always keeps piston pushed towards test pilot body to keep ports 8 and 9 in disconnected condition. Hence power cylinder remains in full open position. When test push button is pressed pressurized oil will come from AOP discharge through 20 CRVI solenoid valve to port 10 of test pilot valve. So piston moves by 23 mm (stroke limited by body of pilot valve on both sides) and connects port 8 and 9. So oil gets drained from power cylinder through ports 8 and 9 and piston H comes down because of spring 12. In this time of test also port 2 of relay dump valve tries to charge power cylinder but however discharging predominates as test drain hole port 8 is bigger than port 2. When test push button is released CRV1/CRV2 solenoid cuts off AOP discharge to port 10 of test pilot valve and piston returns to the position shown in the drawing disconnecting ports 8 and 9. Oil that continuous to enter

from port 2 of relay dump valve lifts power cylinder again slowly. Incase of trip RSV1/RSV2 close in 350 milli seconds.

c. HP turbine control valves power cylinders

Reference drawings: Control mechanism TG 152400 and HP turbine control valve hydraulic power cylinder drawings TG141422 pages 1 and 2. This is the only double action power cylinder in this hydraulic power system. This power cylinder position is controlled by a pilot valve operated by a pilot valve actuator which is given commands by EHC. Pilot valve port 1 is connected to emergency trip oil, port 2 is connected to governing oil, port 3 is connected to lower side of CV power cylinder, port 4 is connected to upper side of CV power cylinder and pilot valve is rigidly coupled to pilot valve actuator. Emergency trip oil entering in port 1 lifts the piot valve by 35 mm by acting on piston 11 against spring 10 and enables pilot valve actuator to regulate oil flow to power cylinder to take it to the required opening. When turbine trip actuates emergency trip oil pressure oil goes low and spring 10 pushes pilot valve down allowing oil to go from port 2 to port 4 and to power cylinder port 6 to close power cylinder. However in case of trip pilot valve actuator also gets command from EHC to drive pilot down. When turbine is reset as seen earlier pilot valve lift by 40 mm and comes to the position shown in the drawing. Island 8 will be closing port 3 and island 9 is closing port 4. In this position pilot valve is said to be in closed ports position. Oil can neither enter nor come out of power cylinder. From this position pilot valve can go up by 15 mm (said to be open stroke) and go down by 35 mm (said to be close stroke). When pilot valve actuator takes pilot valve upwards port 2 gets connected to port 3 and port 4 gets connected to drain port 6. So hydraulic oil enters power cylinder lower port 5 and the oil other side of piston flows through port 6 and drain port 12. so power cylinder piston goes up, when the required position feedback is reached from PT OCA and PT OCB pilot valve will be brought back to the closed ports position by actuator A. when V is to be closed actuator A takes pilot valve piston down and connects ports 2 and 4, ports 3 and 7; so hydraulic oil flows from port 2 to port 4 and to port 6 of power cylinder. The oil on the other side of power cylinder flows from port 5 through port 3 to drain port 7. CV power cylinder piston moves downwards. When required position is reached actuator A brings pilot valve to the required position again. Actuator total stroke is 50 mm: 15 mm open stroke, and 35 mm close stroke. CV power cylinder stroke is 330 mm. The drain ports 7 and 12 are not connected to MOT since HP turbine CV power cylinder is double action power cylinder. Both sides of piston must be completely filled with oil irrespective of position to avoid hunting of the valve. Hence the drain line from ports 7 and 12 are combined and through a pressure relief valve set at 1.1 kg/cm2 and non return valve oil is going to MOP suction.

d. Combined reheat valve IV1 and IV2 power cylinder

Reference drawings: control mechanism TG 152400 and interceptor valve hydraulic power cylinder assembly TG141314.

This is a single action power cylinder with piston 11, spring 10 and port 6 and drain port 12. a relay dump valve is present with spring 13, piston with islands 14, 15 and 16 and port 1 is connected to emergency trip oil, port 2 connected to governing oil port 3 to pilot valve port 7 connected to port 6 of hydraulic power cylinder and port 8 to drain. When turbine trip is actuated trip oil pressure goes low and spring 13 moves piston down disconnecting governing oil to pilot valve and simultaneously connects power cylinder port 6 to port 8 a drain port through which oil stored in power cylinder gets drained and piston 11 moves up faster to close IV1/IV2 because of spring 10. A dash pot arrangement is present on top of piston which limits rate of oil discharge at the fag end of stroke to reduce speed. When turbine is reset emergency trip oil enters port 1 and moves piston up against spring 13 by 36.5 mm and connects ports 2 and 3 and with island 14 disconnects ports 7 and 8. So, governing oil will reach port 4 of pilot valve through ports 2 and 3 of relay dump valve. The relay dump valve piston stroke is limited to 36.5 mm on one side by body of dump valve and on the other side by rod 33. When turbine is reset governing oil reaches port 4 of pilot valve. The pilot valve piston coupled to actuator will be as shown in diagram when actuator is at full close stroke(actuator shaft is out by 50 mm) the drain port 9, 28 mm in height is open to power cylinder port 6 and oil stored in power cylinder gets discharged. When pilot valve actuator shaft moves up by 28 mm island 16 is completely closes drain port 9 and also keeps port 5 (22 mm in height) still closed. In this position oil neither enters nor leaves the power cylinder. Hence valve IV1/IV2 continues to remain in same position. When actuator B receives command to open valve its shaft moves up from ports closed position, port 9 continues to be closed by island 16 which starts clearing port 5 connecting it with port 4. Governing oil enters port 5 and goes to port 6 of power cylinder and pushes piston 11 down against spring 10 opening IV1/IV2. When the required position is reached as per position transmitters PT IV1A, IV1B, PT IV2A, IV2B, actuator B will be driven to take piston again to ports closed position to keep valve in same position. When actuator B receives command to close valve its shaft moves down from ports closed position, port 5 continues to be closed and port 9 gets opened to port 6 of power cylinder and drains oil from cylinder. Piston moves up and IV1/IV2 closes. Once required position is reached as per position transmitter actuator B will be driven to take pilot valve to closed ports position. When turbine trips oil stored in power cylinder gets drained through relay dump valve, however pilot valve actuator is also driven to full close stroke. It is to be noted that the rate of change of valve position is proportional to pilot valve piston movement from ports closed position. Pilot valve total stroke is 50 mm: open stroke is 22 mm and close stroke is 28 mm. valve stroke is 150 mm, power cylinder stroke is 305 mm. the valve stroke and power cylinder stroke are not same as they are not directly coupled. Drain port 12 is to drain leak off from piston rings. This is necessary to eliminate reaction forces from the oil on the bottom side of piston.

Summary:
1. A simple hydraulic system. No mechanical movement is proportional to pressure of oil. 2. Incompressibility of liquid is taken as main principle in regulating valves control. 3. The stop valves close in less than 1 sec time and the regulating valves close very fast irrespective of commands from EHC to the actuators in case of turbine trip. 4. Governing oil is used only as working oil to lift main hydraulic cylinder pistons. Emergency trip oil is the control oil however only for reheat stop valves it is used as working oil also. 5. Except for HP turbine control valves, all have test facility to close online. HP turbine CV test facility is not present since power generation will be greatly reduced. 6. Concealed piping. 7. Main trip device test facility from local and remote. 8. Emergency trip oil system, on turbine trip cuts off air supply to extraction non-return valve power cylinders.

Above Paper ON STAGE I GOVERNING System Was Presented By MR.PDMV PRASAD On 17.08.2002 To Progress Professional Circle Members