TC 1703 Gobernador

TC 1703
SLC Turbine Governor

Commissioning Manual
Turbine Governor
Identification TC 1703 ACP\DEM TC 1703 ACP
Version.Revision DEM TC 1703 ACP
Date of issue 04.08.2015
This document is applicable to the following product(s):
TC 1703 SLC From V4.0
© 2015 by ANDRITZ HYDRO GmbH, All rights reserved.

Any kind of disclosure and reproduction whatsoever of this document or of parts thereof is permitted only upon prior written
consent by ANDRITZ HYDRO. Technical specifications are used for purposes of product description only and are no
guaranteed specifications in legal terms. Subject to modifications - also in terms of technology.
2 / 39 DX7-082-3 Commissioning Manual

Common Information
Table of Contents
1. Common Information ............................................................................................ 5

1.1. Control loops ............................................................................................................................... 6
2. Dry test................................................................................................................... 6
2.1. Calibration of the position sensors .............................................................................................. 6
2.2. Valve characteristics.................................................................................................................... 8
3. Noload test .......................................................................................................... 12

3.1. Turbine start with start opening ................................................................................................. 12
3.2. Head calculation ........................................................................................................................ 14
3.3. First Turn ................................................................................................................................... 14
3.4. Speed selection ......................................................................................................................... 15
3.5. Speed switches ......................................................................................................................... 17
3.6. Overspeed test .......................................................................................................................... 18
3.7. Speed controller at noload operation ........................................................................................ 19
4. Load test .............................................................................................................. 21

4.1. Operation and grid modes ......................................................................................................... 21
4.2. Commands and set points ......................................................................................................... 21
4.3. Opening/Power/Flow controller ................................................................................................. 22
4.4. Flow calculation ......................................................................................................................... 26
4.5. Load rejections .......................................................................................................................... 26
4.6. Isolated grid operation ............................................................................................................... 27
4.7. Level controller .......................................................................................................................... 30
5. Parameter list ...................................................................................................... 32
Commissioning Manual DX7-082-3 3 / 39

Common Information
Figures
Figure 1: PID feedback control .................................................................................................................. 5

Figure 2: Speed control loop ..................................................................................................................... 6
Figure 3: Wicket gate with servomotors .................................................................................................... 7
Figure 5: 250SCALA Display for feedback calibration .............................................................................. 7
Figure 6: Servo valve and Proportional valve (Manufacturer Bosch-Rexroth) .......................................... 8
Figure 7: Position control loop of wicket gate/runner/needle/deflector ..................................................... 9
Figure 8: Position control loop main control valve ..................................................................................... 9
Figure 9: the signal to the servo valve is superposed by an offset ......................................................... 11
Figure 10: Touchpanel – Positioning – Wicket gate ................................................................................ 10
Figure 11: Touchpanel: Opening limiter .................................................................................................. 13
Figure 12: Speed acquisition ................................................................................................................... 16
Figure 13: Touchpanel: Commissioning – Overspeed test ..................................................................... 18
Figure 14: Speed control – noload mode ................................................................................................ 19
Figure 15: Touchpanel: Speed controller ................................................................................................ 20
Figure 16: Old Standard .......................................................................................................................... 23
Figure 17: New Standard ........................................................................................................................ 24
Figure 18: Touchpanel – Power controller .............................................................................................. 25
Figure 19: Stop control ............................................................................................................................ 27
Figure 20: Isolated grid mode old standard ............................................................................................. 28
Figure 21: Isolated grid mode new standard ........................................................................................... 29
Figure 22: Level control ........................................................................................................................... 30
Figure 23: Touchpanel: Level controller .................................................................................................. 31

Common Information
1. Common Information
The digital turbine controller serves for controlling the speed (at idle and isolated grid operation) and
also the load (at grid operation).
For guaranteeing a reliable control the controlled quantities shall be measured directly and processed
cyclically. The difference between set point and measured value is input to the PID algorithm.
Controller Td
Set point Actuator

System
- Kp
Ti
Measured value
Figure 1: PID feedback control
The PID algorithm consists of a proportional part with proportional gain Kp, an integral part with the
integral action time Ti and a derivative part with the derivative action time Td. The derivative action
vanishes after a step with the delay time Tf.
The sum of the parts give the actuator set point.
The PID algorithm is used for all control loops in the turbinegovernor. Depending on the loop the integral
part and the derivative part may not be used.
Increasing the gain Kp results in faster response but higher overshooting. At a certain Kp the control
loop oscillates without damping. The Ziegler-Nichols rule tells to choose 60% of this critical gain. The
integral time constant should be half of the oscillating period Pu.

Dry test
1.1. Control loops
The speed control loop resp. the load control loop (SLC) calculates an actuator set point, which is then
controlled by the positioning loop. In this way 2 control loops are switched one after the other.
Speed controller Td Position controller

Signal to
servovalve
Speed Position set

set point point Wicket gate/
Turbine
- Kp - Kp needle
Position
Ti measured
Interfaces
Speed
measured
Figure 2: Speed control loop
The control loops are set up one after the other starting with the lowest level, the positioning loop. The
set up shall be done only under dry conditions (resp. without water pressure). Depending on the plant
the closing and opening of the waterway can be quite affordable (spherical valve, butterfly valve, dam
inserts).
2. Dry test
2.1. Calibration of the position sensors
The servomotors move the wicket gate blades with a common ring.

Dry test
Figure 3: Wicket gate with servomotors
The opening of the wicket gate blades can be measured by a linear way-sensor of the servomotor or by
a rod with an angular sensor.
For defining the range between the complete closed and complete opened position, the sensor must be
calibrated.
For that issue the function „Turbine controller – Commissioning – Feedback calibration“has to be
selected.
Figure 4: 250SCALA Display for feedback calibration
For starting the calibration the turbine must not turn and the local-remote switch must be set to „local“.
Otherwise the calibration will be discarded, as well as after a determined time delay of 200 seconds
(parameter P_LOG;nMAX_TEST_ACTTON).

Dry test
The calibration is started with the corresponding button. The button is enlightened in green. With the “+”
and “-“buttons the servo valve can be moved directly with the set value. In this way the main control
valve or the servomotor can be moved to the end positions. The current value is stored as “0.0%” and
“100.0%”.
The analogue input signal l HWI;WG_SIGNAL will be converted to a percentage POS;WG_PC inside of
the function block HY_TC_POS.
The linear relation is determined by the parameters P_POS;WG_OFS and P_POS;WG_RNG:
POS;WG_PC = (HWI;WG_SIGNAL + P_POS;WG_OFS)*P_POS;WG_RNG
Parameter Name Standard value

P_POS;WG_RNG Range 1.0
P_POS;WG_OFS Offset 0.0
The settings are the same also for
- Runner RU_
- Distribution valve for wicket gate DVWG_
- Distribution valve for runner DVRU_
- Needle NDL_
- Deflector DFL_
2.2. Valve characteristics
Figure 5: Servo valve and Proportional valve (Manufacturer Bosch-Rexroth)
Servo valves have a small pre control hydraulic loop which is controlled by a small needle. This has less
mass and can be driven very dynamically. The position of the piston is controlled internally. Also an
internal dither signal prevents the piston from getting stuck.

Dry test
The piston of proportional valves is driven directly by a coil. Therefore they are less dynamic, but also
cheaper. Furthermore they have solidity, i. e. the piston must be moved a certain distance until the oil
can flow through the channels. Position control
In the function block HY_TC_MANOP the operation mode of the actuator is defined. The operation
mode can be switched between calibration mode , manual mode and the corresponding set points are
switched to the output.
Td
OfsNeg OfsPos
Position
Set point Servovalve signal
- Kp
Reset
Position
Meas. Ti
Alarm
IntAlmLim >
Figure 6: Position control loop of wicket gate/runner/needle/deflector
The position control loop is set by the PD parameters P_POS;KP_WG and P_POS;TD_WG. The
integral action serves for compensating a drift and raises an alarm, if the value is drifting.
Main control valves can be controlled by the turbine controller, too, if the parameter
P_POS;DVWG_SEL is set to TRUE. In order to prevent the valve from sticking a dither signal can be
added to the control signal ((P_POS;DVWG_DITHOFS > 0.0, DVWG_DITHFRQ > 0.0). The maximum
frequency is 50Hz, as the cycle time of the controller is 10ms.
Td
Control signal
Main control valve servovalve
set point
- Kp
Main control valve

position measured
DithOfs DithFrq
Figure 7: Position control loop main control valve

P_POS;KP_WG Proportional gain 5.0
positioning loop
P_POS;TI_WG Integral action time 0.0
positioning loop [s]
P_POS;TD_WG Derivative action time 0.0

Dry test
positioning loop [s]
For safety reasons the valve can be trimmed in the way, that it automatically closes when it is
unplugged or when the power supply fails.
For that reasons an offset is added to the signal to the servo valve. This offset compensates both the
solidity and the closing tendency. It must be adjusted on each valve individually; otherwise the position
loop would have a control deviation.
In the Touchpanel the position loop can be set up.
Figure 8: Touchpanel – Positioning – Wicket gate

Dry test
OUT
-Zone
OfsPos
OfsNeg IN
Zone
Figure 9: the signal to the servo valve is superposed by an offset
The parameter P_POS;DVWG_OFSPOS is used for compensating the solidity and the closing
tendency. It can be set by checking the positioning loop for a control error.
If the servo valve has a different solidity in negative direction, also the negative Offset
P_POS;DVWG_OFSNEG can be set to a value not equal to zero. Between the switching from negative
to positive offset, a zone has to be determined to avoid a permanent switching between the two offsets.
If the zone P_POS;DVWG_OFSZONE is set to 0, the negative Offset is not applicable.

P_POS;DVWG_OFSPOS Offset in positive direction 0.0
P_POS;DVWG_OFSNEG Offset in negative 0.0

direction
P_POS;DVWG_OFSZONE Switching zone for offset 0.0
The maximum control signal for opening and closing are set by the parameters pDvWg_FSPT.MaxRst
und pDvWg_FSPT.MinRst.
The settings are the same also for
- Distribution valve for wicket gate DVWG_
- Distribution valve for runner DVRU_
- Needle NDL_
- Deflector DVDFL_

Noload test
3. Noload test
3.1. Turbine start with start opening
During the start the speed controller is always active. The start and stop is controlled only by the
opening limiter. It limits the output of the main controller.
But the output is set to the opening limit anyway. This is achieved by setting the I-part to the limit
subtracted by the P-, the D-part and the feed forward part.
At the moment of starting, the I-part therefore is set to a negative value (Lim=0, P=-100, D=0). When
the limiter is set to the start opening, the output equals to this opening, which results in a smooth
starting, because the P-part is decreasing, when the speed rises and the I-part has to recover from the
negative initialization. When the sum is smaller the limit, the actuator starts closing although the desired
speed is not reached yet.
The turbine controller is ready for start, if no QSD or Stop signal is received. Furthermore the opening
limiter must have reached the lower limit, which is “-5” and the actuator has to be ready for start. In case
of Kaplan turbines this means, that the runner has reached his prestart opening.
As soon as the start command is received, the opening limiter rises to the first start opening
P_OPL;OPN_START and lets the speed controller open the wicket gate.
River plants often have a wide range of the head. Therefore the start opening has to depend on the
head, otherwise it could happen that the turbine does not reach the speed set point for synchronizing.
The variety of the head can be parameterized by two points, where the head and the start opening are
defined. Based on these two points the actual start opening is calculated by linear interpolation.
When the speed reaches the threshold P_OPL;OPN_START_ACTLIM, the start opening will be
switched to this head dependent value.

Noload test

P_OPL;STRPT1_HEAD Head point 1 4.0
P_OPL;STRPT2_HEAD Head point 2 10.0
P_OPL;STRPT1_OPN Start opening for head 12.0

1
P_OPL;STRPT2_OPN Start opening for head 20.0
2
P_OPL;OPN_START_ACTLIM Speed switch for 80.0
second start opening
P_OPL;OPN_START Initial start opening 15.0
Figure 10: Touchpanel: Opening limiter
For Kaplan turbines, the runner is controlled with the optimal relation with the wicket gate. This depends
also on the head. The optimal curves are gathered to a map, called CAM.
For starting it is useful to use another runner position, off the CAM, in order to achieve better speed
regulation. The runner is set to a determined position before starting, set by the parameter
P_POS;RUSPT_PREOPN. While synchronizing the runner is hold at the position
P_POS;RUSPT_SYNC.
As soon as the runner reaches the position P_POS;RU_STRLIM the start is allowed for the wicket gate.

Noload test
3.2. Head calculation
If the net head is signal is acquired by an analogue input, it is low pass filtered.
But it can also be calculated either from the level signals or pressure sensors.
The net head results from the difference of the level sensors also called the gross head or static head.
In addition the velocities at the input and the output must be taken into account as well as the friction
losses, which depend on the second power of the velocity resp. the discharge.
(p1-p2) Q2 1 1 2∙ 𝑄2 1 1 𝑄2
H = (z1-z2) + φ∙g
+ 2∙g ∙ (A 2 - A 2) -Q k 𝐻 = (𝑧1 − 𝑧2 ) + 2∙𝑔 ∙ (𝐴2 − 𝐴2 ) − 𝑄2 ∙ 𝑘
1 2 1 2 𝑟𝑒𝑓
𝑧1 …headwater level or pressure at inlet 𝑧1 = 10.2 𝑝1
𝑧2 …tailwater level or pressure at outlet 𝑧2 = 10.2 𝑝2
𝑄…discharge
𝑄𝑟𝑒𝑓 …nominal discharge
𝑘…friction coefficient (P_CSV;HEAD_LOSS)
𝐴1 …inlet cross section area (P_CSV;HEAD_LOSS)
𝐴2 …outlet cross section area (P_CSV;HTW_AREA)
The head calculation is found at 120_CSV.

P_CSV;HEAD_CALC Head is calculated FALSE
P_CSV;HHW_AREA Cross section area 237.0

headwater level [m2]
P_CSV;HTW_AREA Cross section area 141.0
tailwater level [m2]
P_CSV;HEAD_LOSS Head loss by friction [m] 0.2
3.3. First Turn
There are 2 possibilites to turn the turbine for the first time:
1. Setting the maximum opening limit to 1%. After receiving the start command, the opening limiter
can be stepped up with the touch panel, the turbine can be turned smoothly.
2. By usage of the manual position loop.
As soon as the turbine starts turning, the speed pickups can be checked and calibrated.
There are four speed signals preconfigured:

Noload test
- HWI;n1_SIGNAL: period duration measurement in steps of 50ns
- HWI;n2_SIGNAL: count operation for standstill and creep detection
- HWI;GEN_SIGNAL: Generator frequency
- HWI;GRD_SIGNAL: Grid frequency
The analogue inputs are converted to values in percentage of the nominal grid frequency. In the type
instance 120_CSV there is a function block HY_TC_SMS for each speed input. The output of each
block is HZ the speed in Hz and PC in %.
The conversion factor is calculated from the nominal revolutions per second nNom and the number of
teeth equal to the speed monitor configuration:
P_CSV;n1_NOM = z * nNom [U/s]
The nominal frequency of the grid is set with the parameter Unit_HTUR.SpdRtg (50 or 60 Hz).
Furthermore the speed signal is limited in its gradient by the acceleration time constant
Unit_HTUR.UntAccTms.

P_CSV;n1_NOM Nominal frequency 1. 100.0
pickup [Hz]
P_CSV;n2_NOM Nominal frequency 2. 0.0
pickup [Hz]
P_CSV;GEN_NOM Nominal frequency 50.0
generator frequency
sensor [Hz]
P_CSV;GRD_NOM Nominal frequency Grid 50.0
frequency sensor [Hz]
P_CSV;GRDFRQ Grid frequency [Hz] 50.0
P_CSV;TA Acceleration time 5.0
constant of the turbine [s]
The following test can be done (same procedure for pickup or SI 1010L):
- Disconnection of supply voltage: no SW error will be detected, the analogue signal switches to the
counter value and after 1 s the maximum period duration 166666.7 is output.
- Disconnection of impulse signal: the analogue signal switches to the counter value and after 1 s to
the maximum period duration 166666.7. After 500ms a SW error will be raised.
3.4. Speed selection
The turbine controller reads the impulses of 2 pickups by the peripheral module TE6420. Additionally
the generator frequency is converted from a sinusoid signal to an impulse signal by the converter
SI1010L XE of the company Hirt. The same is done with the grid frequency and both signals are read by
the module TE6420 too.
Therefore the speed control has 3 speed signals available.

Noload test
The inputs of the module TE6420 can be parameterized in different ways:
- Period measurement
- Counter operation
Pickup 2 will be set to counter operation, because only in this mode reliable standstill detection is
possible. The number of impulses is supervised not to change within time duration.
Pickup 1 and the generator frequency are configured with period duration measuring and provide a
reliable speed measurement.
The following criterions are followed:
1. The generator frequency normally is less noisy, because the number of poles is smaller than the
teeth on the tooth wheel. Therefore it is used for synchronization and in grid operation for primary
control.
2. The module TE6420 detects an error, if the current circuit of the impulse is broken. If the supply
voltage is interrupted, no error is detected, but no impulses will be detected neither, which results to
a speed measurement of 0.
Because of 1. The generator frequency is selected, if
- No error of the generator signals is detected AND

- The difference between pickup 1 and generator frequency is smaller than
P_CSV;nGEN_ACTLIM AND synchronization speed is reached OR
- The circuit breaker is closed OR
- An error of pickup 1 is detected.
SI1010L Generator frequency

Pickup 1 8 - XE
11 V+ 9+
(passiv/
13 IN C0 HALL)
14 V-
TM1703ACP
16 IN C0/AS SI1010L Grid frequency
Pickup 2 18 V- (aktiv/ 8 - XE
NAMUR)
9+
Pickup 1 … period duration measurement

Pickup 2 …Counter operation
Figure 11: Speed acquisition

P_CSV;nGEN_ACTLIM Maximum difference 2.0
between pickup and
generator frequency for
switching to generator
frequency
P_CSV;nGEN_ACTHYS Hysteresis between 0.5

Noload test
pickup and generator

frequency for switching to
generator frequency
3.5. Speed switches
For detecting standstill the number of impulses shall not change anymore in the time
P_CSV;nSTDSTL_TOF. If standstill is detected and a number of impulses is detected within the time
P_CSV;nCREEP_TOF, the creeping signal arises (equal to the TC1703mic speedmonitor).

P_CSV;nSTDSTL_TON Standstill speed threshold 0.0
P_CSV;nSTDSTL_TOF Standstill detection time 10.0

[s]
P_CSV;nCREEP_TOF Creep detection time [s] 5.0
P_CSV;nCREEP_CNT Number of impulses for 5

creep detection
The speed switch for overspeed detection is set by the threshold P_CSV;nOVR1_ACTLIM
. An additional but delayed overspeed is used to avoid operating the turbine at a higher speed for a
longer time. The time delayed threshold P_CSV;nOVR2_ACTLIM therefore shall be set lower than the
absolute one but with the delay P_CSV;nOVR2_ACTTON.
Additional speed switches are prepared for brakes (speed switch down) and synchronizing (speed
switch up). These are not set if a failure of the speed sensors is detected.

P_CSV;nOVR1_ACTLIM Overspeed threshold up 140.0
P_CSV;nOVR2_ACTLIM Delayed overspeed 130.0

threshold up
P_CSV;nOVR2_ACTTON Time delay for delayed 20.0
overspeed [s]
P_CSV;nBRAKE_ACTLIM Speed threshold down for 40.0
the brakes
P_CSV;nSYN_ACTLIM Speed threshold up for 98.0
the synchronizing
P_CSV;nSTART_ACTLIM Speed threshold up for 10.0
starting speed reached
P_CSV;nSWITCH_ACTHYS Hysteresis for speed 0.5
thresholds

Noload test
3.6. Overspeed test
The overspeed test is available at the Touchpanel “Turbine control – Commissioning – Overspeed test”.
It is only available, if
- the turbine controller is in local mode

- the circuit breaker is not on
- no quickshut down active
When the turbine is running at idle mode, the overspeed test is set to be ready. With starting the
electrical (internal) overspeed test, the Opening Limiter is set to the actual position of the actuator and
the actuator setpoint is set to P_POS;nMAX_TEST_SPT. In this way the overspeed is reached by
manually rising the opening limiter with the step size P_OPL;OPLSPT_STEP.
For the mechanical (external) overspeed test the electrical (internal) overspeed threshold is temporarily
set to P_CSV;nMAXTST_ACTLIM.

P_POS;nMAX_TEST_SPT Actuator set point for 40.0
overspeed test
P_OPL;OPLSPT_STEP Step size opening limiter 2.0
[%/s]
P_CSV;nMAXTST_ACTLIM Overspeed limit for 150.0
testing the mechanical
overspeed
Figure 12: Touchpanel: Commissioning – Overspeed test

Noload test
3.7. Speed controller at noload operation
The speed is controlled by the PID main controller. Increasing the gain Kp results in faster response but
higher overshooting. The oscillation period can be set by the integral action time. For damping
permanent oscillation the D-part shall be used.
Speed
Speed control Position control
meas. Td Signal
Servovalve
Speed Position
set point - set point Wicket gate/
Turbine
Kp - Kp needle
Position
Ti meas.
Figure 13: Speed control – noload mode

P_SLC;KP_SPD_N Proportional gain speed 1.0
control noload mode (0)
P_SLC;TI_SPD_N Integral action time 10.0
speed control noload
mode (0)
P_SLC;TD_SPD_N Derivative action time 0.0
for speed control noload
mode (0)

Noload test
Figure 14: Touchpanel: Speed controller
For starting the turbine the speed set point is set to 100%. The main controller is limited by the opening
limiter. It is raised to the start opening when the start command is received.
The set point can be changed by varying the set point limits P_SLC;SSPT_HILIM and
P_SLC;SSPT_LOLIM.
When the circuit breaker is closed (CSV;CBR_ON=TRUE), the grid mode will change from 0 (noload) to
3 (grid mode). If the speed exceeds the thresholds for isolated network detection, the mode is switched
to 2 (isolated network). See also chapter 4.6.

Load test
4. Load test
4.1. Operation and grid modes
The default for the operation mode LOG;OPMODE is opening control (0). But the operation mode can
be selected also before switching to the grid. This is done by command or the default value has to be
changed in the logics.
The 3 operation modes opening, power and flow control are equivalent. At opening control the set point
is not sent directly to the positioning loop, whose dynamics can vary from the positioning control. This
enables the control to behave different for primary control.
The step size for set point impulses is set by the corresponding parameter P_SLC;xSPT_STEP. Any set
point change will be limited in its gradient by the parameter P_SLC;OxSPT_GRD.
4.2. Commands and set points
Commands and set points can be transmitted by the network (IEC 60870 – 5 – 104) or by hardwired
peripheral modules. If the same commands or set points are transmitted by the Touchpanel and the
network from other stations, the signals are filtered by the originator.
In the parameters the MODES consist of elements, which define the range of the originator for local and
remote operation. The filter is set active with the element MODES.FilterAct.

MODES.FilterAct Originator filtering active FALSE
MODES.LocalIdMax Max local originator 99
MODES.LocalIdMin Min local originator 0
MODES.RemoteIdMax Max remote originator 255
MODES.RemoteIdMin Min remote originator 100
Parameters of the turbine control which are set on the Touchpanel are also treated as set points, but
there is no originator filtering. All parameters are processed by the type instance 220_PAR, the set
points as well as the feedback signals, for each a function block in order to hold them consistent.
If set points shall be transmitted by hardwired modules, the corresponding parameter

P_CSV;xSPT_SEL must be set TRUE.

Load test

P_CSV;OSPT_SEL Opening set point TRUE
hardwired
P_CSV;PSPT_SEL Power set point hardwired TRUE
P_CSV;FSPT_SEL Flow set point hardwired TRUE
The set point is always transmitted as physical value (not percentage). The function block HY_TC_SPT
choses, whether the set point is transmitted by network or hardwired.
The internal Variable CSV;PSPT_MW and CSV;FSPT_M3S gets the set point as physical value. In the
type instance 140_SLC, function block HY_TC_FSPT the set point is converted to percentage, is
increased and decreased by Higher/Lower commands are copied to SLC;PSPT_PC resp.
SLC;FSPT_PC.
Set points are only accepted, if the Preset-Bit is set to TRUE, e .g. CSV;PSPT_SET=TRUE. When the
set point is transmitted by network, the preset bit is set by the spontaneous –bit (S-Bit). If the set point is
transmitted by hardwired modules, the preset bit is set, when the value changes for a certain amount
(1%). This avoids the controller to follow the noise of the analogue transmission.
4.3. Opening/Power/Flow controller
In fig. 15 the old and the new algorithm are shown. Instead of selecting between the different PID
controllers, there is only one PID controller, whose inputs and parameters are selected by the grid mode
and the operation mode.
One feature of the new algorithm is the changed feed forward of the set point, if the parameter
P_SLC;COMBICTRL_x is set to TRUE. The signal flow shows, that the speed resp. frequency deviation
will not be added to the feed forward branch because it is added after the calculation of the power
deviation (multiplied with the droop factor 1/Rp, e. g. 1/0.04 = 25).
If the parameter P_SLC;COMBICTRL_x is set to false, the frequency deviation will be added to the
power set point as in the old standard. This method can increase frequency oscillations in weak grids,
because deviations are directly fed back to the opening of the turbine.
For low grid frequency oscillations an additional integral action can be parameterized by the dead band
P_SLC;LOFRQ_DB and the integral action P_SLC;LOFRQ_TI.

Load test
Speed Speed controller

Td
meas.
Speed
set point -
- Kp
Ti
1/FOD 1/FPD
bp
Opening Position
set point - set point
Sel
Opening controller
Power
set point - lin
Kff
Power Net head

meas.
- Kp
Ti
Power controller
Flow
set point
Flow
calculated
-
Kp
Ti
Flow controller
Figure 15: Old Standard

Load test
Speed SLC – Speed Load Controller

meas. Td
Net head
CombiCtrl Position
Speed
set point - 1
lin set point
db 1/Rp 0 Kp
LFdb LFTi Ti
bp
Opening
Meas.
Power
Flow - 1 0
Sel
CombiCtrl
Opening
Set point
Power
Flow Sel Kff
Figure 16: New Standard
An additional feature of the new algorithm is the linearization of the whole controller output, not only the
feed forward branch. The map opening – power or opening – flow keeps the same, but also the PI part
is linearized. In this way the PI controller can operate in a linear way over the whole power range
(input/output – linearization).
The linearization is dependent on the head. To avoid a continuous feedback by the head to the
controller output, the head will only be taken into account, when the set point changes.

P_SLC;KP_POC_C Proportional gain 0.5
Power controller at grid
operation
P_SLC;TI_POC_C Integral action time 8.0
operation [s]
P_SLC;KFF_POC_C Feed forward gain 1.0
operation

Load test
Figure 17: Touchpanel – Power controller
As soon as the circuit breaker is closed, the grid mode changes to grid operation and the turbine
controller raises to the minimum load. The minimum opening is defined by the parameter
P_SLC;OPN_MIN as well as the minimum power by P_SLC;PA_MIN_MW and the minimum flow by
P_SLC;FLW_MIN_M3S.
Another possibility is to set the duration of a set point impulse P_SLC;MINLOAD_ACTTON. If the
duration is set to 0, the minimum value will be used.

P_SLC;PSPT_GRD Gradient 1.0
Power set point [%/s]
P_SLC;PSPT_STEP Step size 1.0
Power set point [%/s]
P_SLC;PA_MIN_MW Minimum power [MW] 2.0
P_SLC;MINLOAD_ACTTON Duration of minimum 10.0

load impulse [s]
The measured active power is filtered by a low pass, because the signal is attached with noise. The
filter time constant influences the control quality significantly, therefore it should be set small.

P_CSV;PA_TFLT Low pass filter 0.5

Load test
time constant [s]
The linearization power-opening is calculated internally from the map P_SLC;POWLIN. It is a

3dimensional curve in dependency on the head.
4.4. Flow calculation
The flow is calculated from the wicket gate position and the head from the 3-dimensional map
P_POS;FLW_CALC. The result FCA;FLW_M3S [m3/s] is also converted to percentage SLC;FLW_PC
[%].
As an alternative the flow can also be calculated by the VOLCAL module, which works like in the old
standard software. The parameters of this module must be supplied by model tests.
4.5. Load rejections
The closing of the wicket gate is limited by a gradient for Francis and Kaplan turbines. This avoids
undershooting of the speed after a load rejection. For Kaplan turbines the runner blades are opened
during a load rejection in order to decelerate the runner. This is also called “stop control”.
There are 2 possibilities to activate the stop control:
1. When the circuit breaker is opened, the wicket gate is closed immediately to the start opening. The
speed rises and when it reaches the maximum, the closing of the wicket gate is limited by a
gradient in order to avoid undershooting.
2. With units with small inertia and a fast wicket gate it can happen, that the wicket gate is already
closed, when the speed has reached the maximum. This causes undershooting. To prevent this, the
wicket gate is limited in the closing gradient, after a certain time after the circuit breaker is opened.

Load test
Figure 18: Stop control

P_POS;WG_GRD_nMAX Wicket gate closing 1.0
gradient limit [%/s]
P_POS;STC_RUOFS Runner additional 20.0
opening for stop
control
P_POS;STC_RUMAX Maximum runner 100.0
opening while stop
control
P_POS;STC_RUFIX_ACTTON Duration of runner 60.0
additional opening [s]
P_POS:STC_RUGRADIENT Runner closing 2.0
gradient limit [%/s]
4.6. Isolated grid operation
If only one unit supplies the isolated grid, there is no need for the droop. The controller will control the
speed and if the load changes, the controller will open or close the wicket gate if necessary. For this
case grid mode 1 is determined, it is denominated with “black start”.

Load test

P_SLC;KP_SPC_A Proportional gain 2.0
speed controller
(single unit)
P_SLC;TI_SPC_A Integral action time 8.0
speed controller [s]
(single unit)
P_SLC;TD_SPC_A Derivative action time 0.0
(single unit)
If more units supply the isolated grid, the units would control one against the other without droop.
Therefore the output of each controller is fed back again by the droop action. If one unit would raise to
the maximum this feedback holds it back to a constant and stable output resp. a steady state wicket
gate position. The disadvantage of the droop is that the controller will always remain with a steady state
control error. This can be compensated by an increased speed set point.
The new standard provides an alternative. Instead of increasing the speed set point the load of the
isolated grid can be set as load set point, see fig. 19 and 20.
Drehzahl
Drehzahlregler Positionsregler
Istwert Td Stellsignal
Servoventil
Drehzahl Position
Sollwert Sollwert Leitapparat
Turbine
- Kp - Kp /Nadel
-
Position
Ti Istwert
bp
Figure 19: Isolated grid mode old standard
The steady state result is the same, if the actuator set point has reached its steady state and if the load
set point is equal to 0. But the speed control error will be the same.
This can be compensated in the old and in the new standard by a higher speed set point. The raising
results from the isolated grid load multiplied by the droop, e. g. 30%*0.04 = 101,2%.

Load test
Drehzahl
SLC – Speed Load Control Positionsregler
Istwert Td Stellsignal
Servoventil
Drehzahl Position
Sollwert - Sollwert Leitapparat
Turbine
- Kp - Kp /Nadel
Ti
Öffnung bp
Sollwert
Position
- Istwert
Figure 20: Isolated grid mode new standard
The new standard allows setting the load set point directly instead of raising the speed set point. In this
way the steady state control error of the speed vanishes also. This works for power control, opening
control or flow control, for each operation mode a dedicated parameter set can be determined. The grid
mode has index 2.

P_SLC;KP_SPC_B Proportional gain 2.0
speed controller
(isolated grid)
P_SLC;TI_SPC_B Integral action time 8.0
(isolated grid)
P_SLC;TD_SPC_B Derivative action time 0.0
(isolated grid)
The turbine controller switches to isolated grid operation due to an external signal or detects
automatically isolated grid if the thresholds pUnit_HUNT.IslDetHiLim or pUnit_HUNT.IslDetLoLim are
exceeded. Isolated grid operation is reset when a new operation mode is selected.

P_LOG;ISLAND_HILIM Isolated grid detection 100.4
upper limit [%]
P_LOG;ISLAND_LOLIM Isolated grid detection 99.6
lower limit [%]
P_LOG;ISLAND_ACTHYS Isolated grid detection 0.1
hysteresis [%]
P_SLC;DRPGAIN_B Isolated grid droop 4.0
P_SLC;COMBICTRL_B Selection speed set TRUE

point/load set point
change due to isolated

Load test
grid operation
If the parameter pMain_HGOV2.CombiCtrl is switched to TRUE, the load set point can be defined for
letting the control error go to zero. Otherwise the droop will be switched like in the old algorithm and the
speed set point has to be changed.
4.7. Level controller
The level controller is cascaded and calculates a set point for the flow controller or, if not available, the
opening controller.
Pegelregler SLC + Positionsregler

Td
Öffnung/ Stellsignal
Pegel Durchfluss Servoventil
Sollwert Sollwert
- Kp
Leitapparat Turbine +
Regler
Q /Nadel Reservoir
Ti
Position
Istwert
Pegel
Istwert
Figure 21: Level control

P_LEC;KP Proportional gain 2.0
level controller [%/cm]
P_LEC;TI Integral action time 8.0
level controller [s]
P_LEC;TD Derivative action time 0.0
level controller [s]

Load test
Figure 22: Touchpanel: Level controller

Parameter list
5. Parameter list
Parameter Type Longtext

P_CSV;FSPT.SEL TRUE Flow set point is read by analogue input
Offset for calculate flow the set point in percent from
P_CSV;FSPT_OFS 0.0 the analogue input in mA, SPT[%]=SPT[mA]*Rng+Offs
Range for calculate flow the set point in percent from
P_CSV;FSPT_RNG 1.0 the analogue input in mA, SPT[%]=SPT[mA]*Rng+Offs
P_CSV;FSPT_SEL TRUE Flow set point is read by analogue input
P_CSV;GRADIENT_TFLT 0.1 Speed gradient detection filter time constant [s]
P_CSV;GRDFRQ 50.0 Rated frequency of unit [Hz]
P_CSV;HEAD_CALC FALSE Head is calculated from tailwater and headwater level
P_CSV;HEAD_LOSS 0.2 Head loss [m] in relation to rated flow
P_CSV;HEAD_SEL TRUE Penstock pressure is read by analogue input
P_CSV;HEAD_TFLT 0.0 Power measurement filter time constant [s]
P_CSV;HHW_AREA 237.0 Cross section area headwater level [m2]
Offset for calculate flow the headwater level in meter
from the analogue input in mA,
P_CSV;HHW_OFS 0.0 LEV[m]=SPT[mA]*Rng+Offs
Range for calculate flow the headwater level in meter
P_CSV;HHW_RNG 1.0 LEV[m]=SPT[mA]*Rng+Offs
P_CSV;HHW_SEL TRUE Headwater level is read in by analogue input
P_CSV;HHW_TFLT 10.0 Headwater level low pass filter time constant [s]
P_CSV;HTW_AREA 141.0 Cross section area tailwater level [m2]
P_CSV;HTW_OFS
P_CSV;HTW_SEL TRUE Tailwater level is read in by analogue input
P_CSV;HTW_TFLT 1.0 Tailwater level low pass filter time constant [s]
P_CSV;LSPT_SEL TRUE Level set point is read by analogue input
Speed pickup 1 frequency conversion factor (with
number of teeth Z and nominal speed NOM)
P_CSV;n1_NOM 100.0 RNG=Z*NOM[1/s]
Speed pickup 2 frequency conversion factor (with
number of teeth Z and nominal speed NOM)
P_CSV;n2_NOM 0.0 RNG=Z*NOM[1/s]
P_CSV;nBRAKE_ACTLIM 50.0 Speed switch for break (low)
Number of impulses detected within time for creep
P_CSV;nCREEP_CNT 5 detection after standstill
P_CSV;nCREEP_TOF 5.0 Creep detection delay time [s]
Speed gradient detection limit for decreasing speed
P_CSV;nDECR_ACTHYS 0.1 [%/s]
Speed gradient detection hysteresis for decreasing
P_CSV;nDECR_ACTLIM -1.0 speed [%/s]
P_CSV;nGEN_ACTHYS 1.0 Generator frequency selection hysteresis
P_CSV;nGEN_ACTLIM 5.0 Generator frequency selection limit
P_CSV;nGEN_ACTTON 0.0 Generator frequency selection delay time [s]
Generator frequency conversion factor or nominal
P_CSV;nGEN_NOM 50.0 frequency 50 or 60 [Hz]
Grid frequency conversion factor or nominal frequency
P_CSV;nGRD_NOM 50.0 50 or 60 [Hz]
Speed gradient detection hysteresis for increasing
P_CSV;nINCR_ACTLIM 1.0 speed [%/s]
P_CSV;nMAXTST_ACTLIM 160.0 Speed set point for mechanical overspeed device test
P_CSV;nOFFSET_mHZ 0.0 Speed resp. frequency offset for primary control test

Parameter list
P_CSV;nOVR1_ACTLIM 150.0 Speed switch for overspeed (high)

Speed switch for backup overspeed with time delay
P_CSV;nOVR2_ACTLIM 140.0 (high)
Speed switch for backup overspeed with time delay
P_CSV;nOVR2_ACTTON 20.0 (high)
P_CSV;nSTART_ACTLIM 10.0 Speed switch for start ok detection (high)
P_CSV;nSTDSTL_ACTHYS 0.0 Speed switch for standstill (low)
P_CSV;nSTDSTL_ACTLIM 0.0 Speed switch for standstill (low)
P_CSV;nSTDSTL_TOF 10.0 Detection time for standstill (counter mode) [s]
P_CSV;nSTDSTL_TON 1.0 Delay time of standstill detection [s]
P_CSV;nSWITCH_ACTHYS 0.5 Hysteresis for all speed switches
P_CSV;nSYN_ACTLIM 98.0 Speed switch for synchronisation on (high)
P_CSV;OPLSPT_SEL TRUE
P_CSV;OSPT_SEL TRUE Opening set point is read by analogue input
P_CSV;PA_SEL TRUE Power measurement is read by analogue input
P_CSV;PA_TFLT 2.0 Power measurement filter time constant [s]
P_CSV;PSPT_SEL TRUE Opening set point is read by analogue input
P_CSV;PSPT_TFLT TRUE Power set point is read by analogue input
P_CSV;SSPT_SEL TRUE Opening set point is read by analogue input
P_CSV;TA 05.Sep Unit acceleration time [s]
P_FCA;FLW_HILIM 40.0 Flow calculation high limit [m3/s]
P_FCA;FLW_LOLIM 1.0 Flow calculation low limit {m3/s]
Circuit breaker delay time for activation of flush
P_FCO;CBR_ON_ACTTON 10.0 control
Theoretical power calculation coefficient
P_FCO;P_CALC_a0 0.7856 POW=COEFF0+COEFF1*WG+COEFF2*WG^2
Calculation method for theoretical power (TRUE = map,
P_FCO;P_CALC_METH TRUE FALSE = polynom)
P_FCO;PA_MIN 1.0 Minimum power for activation of flush control
P_FCO;PA_MIN_MW 0.5 Minimum power for activation of flush control
Power difference hysteresis for activation of flush
P_FCO;PADIFF_ACTHYS 0.1 control
Power difference threshold for activation of flush
P_FCO;PADIFF_ACTLIM 0.5 control
Power difference delay time for activation of flush
P_FCO;PADIFF_ACTTON 10.0 control [s]
P_FCO;QUEUE_ACTTON 1000.0 Time delay until next flush run [s]
Runner set point gradient limit for moving the runner
P_FCO;RU_GRD 1.0 blades during flush control
P_FCO;RU_MAX 35.0 Maximum runner position during flush control
Runner set point gradient limit for moving the runner
P_FCO;RU_SPT_GRD 10.0 blades during flush control
P_FCO;SELECT TRUE Activation of flush control
Wicket gate gradient limit during flush control in the
P_FCO;WG_GRD1 10.0 second phase
Wicket gate gradient limit during flush control in the
P_FCO;WG_GRD2 10.0 first phase
P_FCO;WG_MAX 70.0 Maximum wicket gate position during flush control
Maximum time duration for opening the wicket gate
P_FCO;WG_MAX_ACTTON 20.0 during flush control
P_FCO;WG_MIN 30.0 Minimum wicket gate position during flush control
Minimum time duration for opening the wicket gate
P_FCO;WG_MIN_ACTTON 20.0 during flush control
Minimum time duration for opening the wicket gate
P_FCO;WGCLS_ACTTON 10.0 during flush control
P_FCO;WGOPN_ACTTON 20.0 Maximum time duration for opening the wicket gate

Parameter list
during flush control
P_LEC;FSPT_HILIM 35.0 Flow calculation high limit [m3/s]

P_LEC;FSPT_LOLIM 1.0 Flow calculation low limit [m3/s]
P_LEC;KP 20.0 Level control, proportional gain
P_LEC;LSPT_GRD 10.0 Level set point gradient limit [m/s]
P_LEC;LSPT_HILIM 600.0 Level set point gradient limit [m/s]
P_LEC;LSPT_LOLIM 500.0 Level set point gradient limit [m/s]
P_LEC;LSPT_STEP 0.1 Level set point impulse step size [m/s]
P_LEC;TD 0.0 Level control, derivative action time
P_LEC;TF 0.0 Level control, derivative action time
P_LEC;TI 0.0 Level control, integral action time
P_LEC;WITH_OPN FALSE
Supervision of ESD and primary signal failure delay
P_LOG;FAIL_ACTTON 0.5 time [s]
Frequency deviation detection frequency upper
P_LOG;FRQDEV_ACTHYS 0.0 hysteresis [%]
Frequency deviation detection frequency upper limit
P_LOG;FRQDEV_ACTLIM 0.3 [%]
Frequency deviation detection frequency gradient
P_LOG;FRQDEV_ACTTON 30.0 hysteresis [%/s]
Frequency deviation detection frequency gradient
P_LOG;FRQGRDDEV_ACTHYS 0.0 hysteresis [%/s]
P_LOG;FRQGRDDEV_ACTLIM 0.6 Frequency deviation detection delay time [s]
P_LOG;GRIDDIST_AUT FALSE Frequency deviation detection activated
P_LOG;ISLAND_ACTHYS 0.1 Isolated grid detection hysteresis [%]
P_LOG;ISLAND_ACTTON 0.1 Isolated grid delay time [s]
P_LOG;ISLAND_HILIM 100.4 Isolated grid detection high limit [%]
P_LOG;ISLAND_LOLIM 99.6 Isolated grid detection low limit [%]
P_LOG;LEC_WOPC FALSE Level control with opening
P_LOG;nDB_C 0.4 Grid operation, speed resp. frequency deadband [%]
disturbed grid operation, spedd resp. frequency
P_LOG;nDB_D 0.01 deadband [%]
P_LOG;nGRADIENT_HILIM 1.0 Frequency gradient high limit [%]
P_LOG;nGRADIENT_LOLIM -1.0 Frequency gradient low limit [%]
P_LOG;nGRADIENT_T1FLT 0.00418 Frequency gradient filter time constant [s]
P_LOG;nGRADIENT_T2FLT 0.094 Frequency gradient filter time constant 2 [s]
P_LOG;nMAX_TEST_ACTTON 180.0
Timer on delay of start signal (2nd start opening must
P_LOG;START_ACTTOF 10.0 be switched within) [s]
P_LOG;START_FAIL_ACTTON 20.0 Delay time for detection of start failure [s]
P_MOD;A_TW 1.0
P_MOD;C0_eg 1.0
P_MOD;C1_eg 0.0
P_MOD;C2_eg 0.0
P_MOD;GRD_Q 1.0
P_MOD;H_MAN FALSE
P_MOD;H_MAN_VAL 405.0
P_MOD;HEAD_NOM_M 10.0 Rated head of unit [m]
P_MOD;HTW_OFFSET 401.0
P_MOD;LIH_HHW 407.5
P_MOD;LIL_HHW 401.5
P_MOD;MODEL_ON FALSE
P_MOD;N_SYM [0.0,0.0,0.0,0.0,0.0,0.0,0.0]
P_MOD;P_ISNET 1.0

Parameter list
P_MOD;q_PROP_HTW 0.0
P_MOD;Q_RUN_IN 40.0
P_MOD;TI_HHW 100.0
P_MOD;TI_SM [1.0,1.0,1.0,1.0,0.0,0.0,0.0]
P_MOD;TW 2.11
Opening limiter set point, impulse response step size
P_OPL;OPLSPT_GRD 10.0 [%/s]
P_OPL;OPLSPT_HILIM 105.0 Opening limiter set point maximum restriction [%]
P_OPL;OPLSPT_LOLIM -5.0 Opening limiter set point minimum restriction [%]
Opening limiter set point, impulse response step size
P_OPL;OPLSPT_STEP 1.0 [%/s]
P_OPL;OPN_START 25.0 Opening lmiter set point for start, first phase
Speed limit for switching to 2nd head dependent start
P_OPL;OPN_START_ACTLIM 40.0 opening
P_OPL;STRPT1_HEAD 2.0 NetHd 1 for interpolation
P_OPL;STRPT1_OPN 20.0 Start opening for net head 1
P_OPL;STRPT2_HEAD 12.0 NetHd 2 for interpolation
P_OPL;STRPT2_OPN 15.0 Start opening for net head 2
Closing gradient for runner set point during stop
P_POS:STC_RUGRADIENT 10.0 control
Dither frequency for additional dither on distribution
P_POS;DITHFRQ_RU 0.0 valve of runner signal (max. 50 Hz)
Dither frequency for additional dither on distribution
P_POS;DITHFRQ_WG 0.0 valve of wicket gate signal (max. 50 Hz)
Dither offset on distribution valve of runner signal
P_POS;DITHOFS_RU 0.0 (max. 10 %)
Dither offset on distribution valve of wicket gate signal
P_POS;DITHOFS_WG 0.0 (max. 10 %)
Distribution valve of runner, offset for calculate the
position in percent from the mA signal
P_POS;DVRU_ACT FALSE Pos[%]=Pos[mA]*Rng + Offs
Detection hysterersis of positioning failure of DV for
P_POS;DVRU_FAIL_ACTHYS 0.0 runner blades
Detection limit of positioning failure of DV for runner
P_POS;DVRU_FAIL_ACTLIM 100.0 blades
P_POS;DVRU_FAIL_ACTTON 0.0 Positioning failure detection delay time
P_POS;DVRU_FAIL_TFLT 1.0 Positioning failure detection delay time
Gradient limit for manual set point of distribution valve
P_POS;DVRU_GRD 100.0 of runner
Maximum restriction for manual set point of
P_POS;DVRU_HILIM 105.0 distribution valve of runner
Minimum restriction for manual set point of
P_POS;DVRU_LOLIM -105.0 distribution valve of runner
Distribution valve of runner, offset for calculate the
P_POS;DVRU_OFS 0.0 Pos[%]=Pos[mA]*Rng + Offs
Solidity offset or closing tendency compensation in
P_POS;DVRU_OFSNEG 0.0 negative direction
P_POS;DVRU_OFSPOS 0.0 positive direction
Distribution valve of runner, range for calculate the
P_POS;DVRU_RNG 1.0 Pos[%]=Pos[mA]*Rng + Offs
P_POS;DVRU_SEL FALSE positive direction
P_POS;DVRU_SELECT FALSE positive direction
P_POS;DVRU_TCLS 5.0 Closing time of distribution valve for runner blades
P_POS;DVRU_TOPN 5.0 Opening time of distribution valve for runner blades
P_POS;DVRU_ZONE 0.0 positive direction
Detection hysterersis of positioning failure of DV for
P_POS;DVWG_FAIL_ACTHYS 0.0 wicket gate
P_POS;DVWG_FAIL_ACTLIM 100.0 Detection limit of positioning failure of DV for wicket

Parameter list
gate
P_POS;DVWG_FAIL_ACTTON 0.0 Positioning failure detection delay time

P_POS;DVWG_FAIL_TFLT 1.0 Positioning failure detection delay time
Gradient limit for manual set point of distribution valve
P_POS;DVWG_GRD 100.0 of wicket gate
Maximum restriction for manual set point of
P_POS;DVWG_HILIM 105.0 distribution valve of wicket gate
Minimum restriction for manual set point of
P_POS;DVWG_LOLIM -105.0 distribution valve of wicket gate
Distribution valve of wicket gate, offset for calculate
the position in percent from the mA signal
P_POS;DVWG_OFS 0.0 Pos[%]=Pos[mA]*Rng + Offs
P_POS;DVWG_OFSNEG 0.0 negative direction
P_POS;DVWG_OFSPOS 0.0 positive direction
Distribution valve of wicket gate, range for calculate
P_POS;DVWG_RNG 1.0 Pos[%]=Pos[mA]*Rng + Offs
Distribution valve of wicket gate, offset for calculate
P_POS;DVWG_SEL FALSE Pos[%]=Pos[mA]*Rng + Offs
Distribution valve of wicket gate control, proportional
P_POS;DVWG_SELECT FALSE gain
P_POS;DVWG_TCLS 5.0 Closing time of distribution valve for wicket gate
P_POS;DVWG_TOPN 5.0 Opening time of distribution valve for wicket gate
P_POS;DVWG_ZONE 0.0 positive direction
Feedback calibration is withdrawn automatically, if this
P_POS;FBC_ACTTON 200.0 time is exceeded.
Manual deflection of servovalve when feedback
P_POS;FBC_DEFLECTION 2.0 calibration is active
P_POS;FBC_HIVAL 100.0 Open limit or upper value for feedback calibration
P_POS;FBC_LOVAL 0.0 Closed limit or lower value for feedback calibration
P_POS;HEAD_HILIM 05.Mai Open limit or upper value for feedback calibration
P_POS;HEAD_LOLIM 02.Mai Low limit of head input to CAM curve
P_POS;KP_DVRU 01.Mai Distribution valve of runner control, proportional gain
Distribution valve of wicket gate control, proportional
P_POS;KP_DVWG 5.0 gain
P_POS;KP_RU 4.0 Runner positioning, proportional gain
P_POS;KP_WG 8.0 Wicket gate positioning, proportional gain
Opening limiter set point during automated overspeed
P_POS;nMAX_TEST_SPT 40.0 test
P_POS;RU_CLSLIM 1.0 Detection limit of closed position of runner blades
P_POS;RU_FAIL_ACTHYS 2.0 Detection hysterersis of positioning failure of runner
P_POS;RU_FAIL_ACTLIM 10.0 Detection limit of positioning failure of runner
P_POS;RU_FAIL_ACTTON 20.0 Positioning failure detection delay time of runner [s]
P_POS;RU_GRD 100.0 Runner set point, gradient limit [%/s]
P_POS;RU_HILIM 100.0 Maximum restriction of runner set point
P_POS;RU_LOLIM 0.0 Minimum restriction of runner set point
Offset for calculate the runner position in percent from
P_POS;RU_OFS 0.0 the analogue input in mA, SPT[%]=SPT[mA]*Rng+Offs
P_POS;RU_OPNLIM 99.0 Opening limit of runner blades
Range for calculate the runner position in percent from
P_POS;RU_RNG 1.0 the analogue input in mA, SPT[%]=SPT[mA]*Rng+Offs
P_POS;RU_STRHYS 2.0 Detection hysteresis for runner start position
P_POS;RU_STRLIM 35.0 Detection limit for runner start position
P_POS;RU_TCLS 30.0 Closing time of runner blades [s]
P_POS;RU_TFLT 1.0 Position sensor failure time constant
P_POS;RU_TOPN 30.0 Opening time of runner [s]

Parameter list
P_POS;RUGRD_SYNC 02.Mai Open limit or upper value for feedback calibration

P_POS;RUSPT_HILIM 100.0 CAM output high limit
P_POS;RUSPT_LOLIM 0.0 CAM output low limit
P_POS;RUSPT_PREOPN 40.0 Opening set point of runner before starting
P_POS;RUSPT_SYNC 9.0 Open limit or upper value for feedback calibration
Wicket gate fixing delay time when ramp detected stop
P_POS;STC_ACTTON 0.1 control is active
P_POS;STC_EN TRUE Acitivation of stop control
P_POS;STC_nACTLIM 120.0 Speed limit for activation of stop control
Detection hysteresis of minimum wicket gate position
P_POS;STC_NOLOAD_ACTHYS 10.0 for activation of stop control
Detection limit of minimum wicket gate position for
P_POS;STC_NOLOAD_ACTLIM 10.0 activation of stop control
Runner offset during stop control is added for this
delay time, then set point is ramped down to CAM set
P_POS;STC_RUFIX_ACTTON 20.0 point.
P_POS;STC_RUMAX 100.0 Maximum runner set point during stop control
P_POS;STC_RUOFS 30.0 Offset added tp runner set point during stop control
Minimum wicket gate position for activation of stop
P_POS;STC_WG_ACTLIM 10.0 control
P_POS;STC_WG_OFS 0.0 Wicket gate offset of ramp detected stop control
P_POS;STC_WG_RNG 0.0 Wicket gate range of ramp detected stop control
Distribution valve of runner control, derivative time
P_POS;TD_DVRU 0.0 constant
Distribution valve of wicket gate control, derivative
P_POS;TD_DVWG 0.0 time constant
P_POS;TD_RU 0.0 Runner positioning, derivative action time constant [s]
Wicket gate positioning, derivative action time
P_POS;TD_WG 0.0 constant [s]
P_POS;TI_RU 0.0 Runner positioning, integral action time constant [s]
Wicket gate positioning, integral action time constant
P_POS;TI_WG 0.0 [s]
P_POS;WG_CLSHYS 2.0 Closed position detection hysteresis of wicket gate
P_POS;WG_CLSLIM 1.0 Closed position detection limit of wicket gate
Detection hysterersis of positioning failure of wicket
P_POS;WG_FAIL_ACTHYS 0.2 gate
P_POS;WG_FAIL_ACTLIM 2.0 Detection limit of positioning failure of wicket gate
Positioning failure detection delay time of wicket gate
P_POS;WG_FAIL_ACTTON 20.0 [s]
P_POS;WG_GRD 100.0 Manual set point for wicket gate, gradient limit [%/s]
Closing gradient for wicket gate set point after load
P_POS;WG_GRD_KXD 0.8 rejection
Closing gradient for wicket gate set point during stop
P_POS;WG_GRD_nMAX 3.0 control
P_POS;WG_HILIM 105.0 Maximum restriction of manual wicket gate set point
P_POS;WG_INTALM 1.0 Integrator alarm limit for drifting compensation
P_POS;WG_LOLIM -5.0 Minimum restriction of manual wicket gate set point
Offset for calculate the wicket gate position in percent
P_POS;WG_OFS 0.0 POS[%]=POS[mA]*Rng+Offs
P_POS;WG_OPNLIM 99.0 Opening limit of wicket gate
Range for calculate the wicket gate position in percent
P_POS;WG_RNG 1.0 POS[%]=POS[mA]*Rng+Offs
P_POS;WG_TCLS 5.0 Closing time of wicket gate [s]
P_POS;WG_TFLT 1.0 Position sensor failure time constant
P_POS;WG_TOPN 5.0 Opening time of wicket gate [s]
P_SLC;COMBICTRL_C TRUE New algorithm used for grid operation mode
P_SLC;COMBICTRL_D TRUE New algorithm used for disturbed grid operation mode
P_SLC;DRPGAIN_B 4.0 Isolated grid operation, permanent droop gain

Parameter list
P_SLC;DRPGAIN_C 4.0 Grid operation, permanent droop gain

P_SLC;DRPGAIN_D 4.0 disturbed grid operation, permanent droop gain
P_SLC;FLW_MIN_M3S 10.0 Rated flow of unit [m3/s]
P_SLC;FLW_NOM_M3S 60.0 Rated flow of unit [m3/s]
P_SLC;FRQDB_A TRUE New algorithm used for isolated mode
Isolated grid operation, speed resp. frequency
P_SLC;FRQDB_B 0.0 deadband [%]
P_SLC;FRQDB_C 0.1 Grid operation, speed resp. frequency deadband [%]
disturbed grid operation, spedd resp. frequency
P_SLC;FRQDB_D 0.01 deadband [%]
Frequency matching is on (synchronize on grid
P_SLC;FRQMATCH_EN FALSE frequency plus offset)
Frequency matchin offset (for synchronisation with
P_SLC;FRQMATCH_OFS 0.5 grid frequency)
P_SLC;FSPT_GRD 1.0 Flow set point gradient limit [%/s]
P_SLC;FSPT_HILIM 100.0 Flow set point gradient limit [%/s]
P_SLC;FSPT_LOLIM 0.0 Flow set point gradient limit [%/s]
P_SLC;FSPT_STEP 1.0 Flow set point impulse response step size [%/s]
P_SLC;HEAD_NOM_M 100.0 Rated head of unit [m3/s]
Flow controller at grid operation mode, feedforward
P_SLC;KFF_FLC_C 0.0 gain
Flow controller at disturbed grid operation mode,
P_SLC;KFF_FLC_D 0.0 feedforward gain
Opening controller at grid operation mode,
P_SLC;KFF_OPC_C 1.0 feedforward gain
Opening controller at disturbed grid operation mode,
P_SLC;KFF_OPC_D 1.0 feedforward gain
Power controller at grid operation mode, feedforward
P_SLC;KFF_POC_C 0.0 gain
Power controller at disturbed grid operation mode,
P_SLC;KFF_POC_D 1.0 feedforward gain
Flow controller at grid operation mode, proportional
P_SLC;KP_FLC_C 4.0 gain
P_SLC;KP_FLC_D 0.0 proportional gain
Opening controller at grid operation mode,
P_SLC;KP_OPC_C 0.0 proportional gain
P_SLC;KP_OPC_D 0.0 proportional gain
Power controller at grid operation mode, proportional
P_SLC;KP_POC_C 0.1 gain
P_SLC;KP_POC_D 0.1 proportional gain
Speed control at isolated grid operation, proportional
P_SLC;KP_SPC_A 3.0 gain
Speed control at isolated grid operation, proportional
P_SLC;KP_SPC_B 0.0 gain
P_SLC;KP_SPC_N 3.0 Speed control at noload operation, proportional gain
P_SLC;LOFRQ_DB 0.2 Low speed integrator, frequency deadband
P_SLC;LOFRQ_TI 0.0 Low speed integrator, integral gain
P_SLC;MINLOAD_ACTTON 10.0 Minimum load time when circuit breaker is on [s]
P_SLC;OPN_MIN_PC 20.0 Rated power of unit [MW]
P_SLC;OSPT_GRD 10.0 Opening set point gradient limit [%/s]
P_SLC;OSPT_HILIM 100.0 Opening set point maximum restriction
P_SLC;OSPT_LOLIM 0.0 Opening set point minimum restriction
P_SLC;OSPT_STEP 1.0 Opening set point impulse response step size [%/s]
P_SLC;OUTGRD_HILIM 100.0 Main control algorithm, high limit for output
P_SLC;OUTGRD_LOLIM 100.0 Main control algorithm, high limit for output
P_SLC;PA_MIN_MW 1.0 Rated power of unit [MW]
P_SLC;PA_NOM_MW 02.Mai Rated power of unit [MW]

Parameter list
P_SLC;PSPT_GRD 1.0 Power set point gradient limit [%/s]

P_SLC;PSPT_HILIM 100.0 Power set point maximum restriction
P_SLC;PSPT_LOLIM 0.0 Power set point minimum restriction
P_SLC;PSPT_STEP 1.0 Power set point impulse response step size [%/s]
P_SLC;SPC_STRFAC 0.5 Start factor for speed control
P_SLC;SSPT_GRD 100.0 Speed set point gradient limit [%/s]
P_SLC;SSPT_HILIM 110.0 Maximum restriction of speed set point
P_SLC;SSPT_LOLIM 80.0 Minimum restriction of speed set point
P_SLC;SSPT_STEP 0.1 Speed set point impulse response step size [%/s]
Flow controller at grid operation mode, derivative time
P_SLC;TD_FLC_C 0.0 constant [s]
P_SLC;TD_FLC_D 0.0 derivative time constant [s]
Opening controller at grid operation mode, derivative
P_SLC;TD_OPC_C 0.0 time constant [s]
Opening controller at weak grid operation mode,
P_SLC;TD_OPC_D 0.0 derivative time constant [s]
Power controller at grid operation mode, derivative
P_SLC;TD_POC_C 0.0 time constant [s]
P_SLC;TD_POC_D 0.0 derivative time constant [s]
Speed control at isolated grid operation, derivative
P_SLC;TD_SPC_A 0.0 action time constant [s]
Speed control at isolated grid operation, derivative
P_SLC;TD_SPC_B 0.0 action time constant [s]
Speed control at noload operation, derivative action
P_SLC;TD_SPD_N 0.0 time constant [s]
Flow controller at grid operation mode, integral time
P_SLC;TI_FLC_C 20.0 constant [s]
P_SLC;TI_FLC_D Jun.66 integral time constant [s]
Opening controller at grid operation mode, integral
P_SLC;TI_OPC_C 0.0 time constant [s]
P_SLC;TI_OPC_D 0.0 integral time constant [s]
Power controller at grid operation mode, integral time
P_SLC;TI_POC_C 5.0 constant [s]
P_SLC;TI_POC_D 5.0 integral time constant [s]
Speed control at isolated grid operation, integral
P_SLC;TI_SPC_A 8.0 action time constant [s]
Speed control at isolated grid operation, integral
P_SLC;TI_SPC_B 16.0 action time constant [s]
Speed control at noload operation, integral action time
P_SLC;TI_SPC_N 8.0 constant [s]

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TC 1703

SLC Turbine Governor

Version.Revision DEM TC 1703 ACP

Date of issue 04.08.2015

This document is applicable to the following product(s):

TC 1703 SLC From V4.0

© 2015 by ANDRITZ HYDRO GmbH, All rights reserved.

2 / 39 DX7-082-3 Commissioning Manual

1. Common Information ............................................................................................ 5

3. Noload test .......................................................................................................... 12

4. Load test .............................................................................................................. 21

5. Parameter list ...................................................................................................... 32

Commissioning Manual DX7-082-3 3 / 39

Figure 1: PID feedback control .................................................................................................................. 5

4 / 39 DX7-082-3 Commissioning Manual

Set point Actuator

Figure 1: PID feedback control

The sum of the parts give the actuator set point.

Commissioning Manual DX7-082-3 5 / 39

1.1. Control loops

Speed controller Td Position controller

Speed Position set

Figure 2: Speed control loop

2.1. Calibration of the position sensors

6 / 39 DX7-082-3 Commissioning Manual

Figure 3: Wicket gate with servomotors

Figure 4: 250SCALA Display for feedback calibration

Commissioning Manual DX7-082-3 7 / 39

The linear relation is determined by the parameters P_POS;WG_OFS and P_POS;WG_RNG:

POS;WG_PC = (HWI;WG_SIGNAL + P_POS;WG_OFS)*P_POS;WG_RNG

Parameter Name Standard value

The settings are the same also for

- Distribution valve for wicket gate DVWG_

- Distribution valve for runner DVRU_

2.2. Valve characteristics

Figure 5: Servo valve and Proportional valve (Manufacturer Bosch-Rexroth)

8 / 39 DX7-082-3 Commissioning Manual

Figure 6: Position control loop of wicket gate/runner/needle/deflector

Main control valve

Figure 7: Position control loop main control valve

Parameter Name Standard value

Commissioning Manual DX7-082-3 9 / 39

positioning loop [s]

In the Touchpanel the position loop can be set up.

Figure 8: Touchpanel – Positioning – Wicket gate

10 / 39 DX7-082-3 Commissioning Manual

Figure 9: the signal to the servo valve is superposed by an offset

If the zone P_POS;DVWG_OFSZONE is set to 0, the negative Offset is not applicable.

Parameter Name Standard value

P_POS;DVWG_OFSNEG Offset in negative 0.0

The settings are the same also for

- Distribution valve for wicket gate DVWG_

- Distribution valve for runner DVRU_

Commissioning Manual DX7-082-3 11 / 39

3.1. Turbine start with start opening

12 / 39 DX7-082-3 Commissioning Manual

Parameter Name Standard value

P_OPL;STRPT2_HEAD Head point 2 10.0

P_OPL;STRPT1_OPN Start opening for head 12.0

Figure 10: Touchpanel: Opening limiter

Commissioning Manual DX7-082-3 13 / 39

3.2. Head calculation

𝑧1 …headwater level or pressure at inlet 𝑧1 = 10.2 𝑝1

𝑧2 …tailwater level or pressure at outlet 𝑧2 = 10.2 𝑝2