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GOVERNING OPEARTION OF 2x15MW Turbine

The l5MW turbine Startup is based upon the Two Valve Algorithm. For the reference in Logic and Write-ups the Nomenclature is given as MV to the Main Stop valve (Safety Valve) and GV to the Governing valve. The Speed Measurement is done through 2 out 3 measurement logic

Standard Parameters of Turbines are given here under,

Turbine Rated Speed at 50 Hz

6789

RPM

Electrical Overspeed Trip Setting

7468

RPM

Mech. Overspeed Trip Setting

RPM

Baring Gear Speed

600

RPM

Max Governing Speed

51Hz

6925

RPM

Min Governing Speed

48.5Hz

6586

RPM

Min Critical Speed

3100

RPM

Max. Critical Speed

3300

RPM

Following Physical input/output are considered for Turbine Control Logic.

Card No FCS Card #1

FCS Card #2

FCS Card #3

FCS Card #4

CIS22 Card # 1

DIS13 Card #l

Type Pulse

Description

Input

Speed Probe #1

Pulse Input

Speed Probe #2

Pulse Input

Speed Probe #3

Pulse Input

Speed Probe #4

Multi I/O type

AIl-MW Input

AI2-Spare

AI3-Spare

AI4-Spare

A01-MV Control OIP A02-GV Control OIP DI1-Gen Breaker I/P DI2-Grid Breaker I/P DI3-Extemal Trip I/P DO1-Trip OIP to Interlock D02- Trip OIP to I/H Power Supply

D03-Spare

D04-Spare

DI1-Speed/KW Raise PB DI2-Speed/KW Lower PB DI3-0verspeed Trip Test PB

. Starting Conditions

The Operator should check that at the time of starting there should not any external trip

coming from the trip interlocks. If the Machine is in "Shutdown" conditions the "Shutdown" and "Shutdown mode" indication will appear. Once the external trip goes off

the operator can reset the machine by pressing the Reset PB from the HMI. An indication

will come at the HMI for "Ready to Roll". Once the "Ready to Roll" indication comes the

operator can select the mode of startup from the Auto/Man Selection Pushbuttons which

was made in the ASL logic (Please refer Master Documents) . It should be noted that

once the machine in selected in either of the mode it can not be switched to other mode

while startup is initiated. After selection of mode of startup the machine can be ready to start. Here under the mode of startup is given below.

Auto Mode (Ramp Mode)

By visualizing the indication of Auto mode Enabled the Automatic Turbine

Start/Hold/Runup ASL of turbine can be initiated from the HMI. (For the complete Auto Sequence Logic refer ASL Logic) The start command of turbine rolling to the governor

logic will comes from the ASL. Also the Setpoint to the MV and GV PID will comes from the MOD 13 and MOD12 logic on starting.

Once the start command initiated from the ASL GV valve starts opens at the rate of 01 %/Sec also the setpoint to the GV PID will go to the 5750 RPM and a mode of indication of "Ramp mode" comes. The GV setpoint will process to further at 6789 RPM in predefined step (for Step no. refer ASL logic). In the predefined step from ASL MV Target setpoint of 720 RPM will go to the MV PID at a rate of 10 RPM/Sec. To maintain the speed on the basis of Target setpoint, the MV

PID

will starts open the MV Valve which will maintain the desired speed i.e. 720 RPM.

The

speed setpoint will be remaining at the 720 RPM for a time which will be adopted

trough Cold/Warm/Hot Hold time in the ASL (for Hold details refer ASL Logic). After delay of Hold time and getting the other process condition of turbine the next step will be initiated (For other process conditions refer ASL logic) by which setpoint will automatically processed further to the next setpoint of 1625 RPM at a rate of 10

RPM/Sec. Once again speed will hold for a certain time at setpoint of 1625 RPM based upon process conditions. This operation will be active at different steps again 1725, 4900, RPM. Once the setpoint will start moves to 4900 RPM, and after reaching the setpoint of

MV at 4900 RPM and actual speed at 4850 RPM the Speed Control will transfer to GV

from the MV. In this mode if SP and PV of speed come in between range of critical speed the Set Point Change ramp rate changed from 10 to 20 RPM /sec in the critical speed band.

Manual Mode Startup (Ramp Mode)

By visualizing the indication of Auto mode Enabled the start command can be given from

the HMI by operator after meeting the other process requirement. Once the start

command initiated from the HMI the GV valve starts opens at the rate of 01 %/Sec also

the setpoint to the GV PID will go to the 5700 RPM and a mode of indication of "Ramp mode" comes.

The operator will gives a desired Target setpoint of based upon its requirement say 720 RPM, that will go to the MV PID at a rate of 10 RPM/Sec. To maintain the speed on the basis of Target setpoint, the MV PID will gives the output to the MV Valve which will maintain the desired speed i.e. 700 RPM. The speed setpoint will be remaining at the 700 RPM unless and until the new setpoint will not given by the operator. The operator should decide the next setpoint and enter it after meeting the other process requirement. Once the MV setpoint of 4900 will be given by the operator and after reaching the setpoint of MV at 4900 RPM and actual speed at 4850 RPM the Speed Control will transfer to GV from the MV.

In this mode operator should avoid to keep the MV setpoint in between critical band of range 3100 to 3300 RPM. Also in this mode the Set Point Change rate is changed from 10 to 20 RPM /sec in the critical speed band.

Towards Transfer of startup completion Once the speed reaches at 4850 RPM either in Auto or Manual mode startup. The control will transfer to GV, means the Main Valve (MV) start open to 100% irrespective of setpoint of MV at a rate of 0.5 %/Sec

In the Auto mode GV will goes to some percentage of OIP to maintain speed of

6789.

In the Manual mode once the MV will go to 100% open that will make an initial command to jump speed from 5700 to 6789 RPM means the Set point (SP) of GV PID will move to 6789 RPM at a rate of 10 RPM/Sec.

Main Range Mode Once the speed setpoint reaches 6789 RPM in Ramp mode and actual speed at 6700 the mode of turbine will shift to main range mode. At this mode the turbine speed can be Raised or Lowered by pressing the push buttons at HMI, from field from auto synchronize unit, from the Electrical Panels etc. In this mode the turbine can be rolled in between a frequency of 48.5 to 50 Hz.

Only in this mode the overspeed testing of turbine can be done. For overspeed testing the PB overspeed pressed continuously and speed can be controlled upto 110% of rated speed by Raise Lower PB. It should be noted that in load condition O/S testing can not be made.

Droop Mode:

While turbine running at main range mode the speed can be changed and can be synchronized with Grid or other TG. Once the synchronization condition is fulfilled, auto synchronization unit can do synchronization, or manually from the Electrical panel by operator. When the synchronization means generator breaker closes system will come into the droop mode. In this mode block load of 1.5 to 2 MW will come on the turbine to avoid the reverse power. Now the machine will be into the droop mode unless & until the Generator breaker switched off.

In the mode the load on the turbine can be Raised or lowered by pressing the same Raise/Lower Push Button on HMI.

KW / load control mode In the Droop mode the load can not be controlled if it is with the grid. As when machine is in droop mode the load on the machine will be decided by the grid frequency. So to avoid this more function/mode called as load control has been implemented.

By enabling the KW mode from HMI load can be controlled, when the machine is running with the grid. When grid Breakers is 'IN' and KW enabled by operator the machine will go to the KW mode. Means the operator can increase or decrease the setpoint of MW. Then the load controller PID OIP will give a reference to the speed controller to maintain the load irrespective of grid frequency.

In this mode the operation can go back to droop mode once the Grid Breaker goes off.

It should be noted that KW mode can only be enabled when the Grid breaker is in ON condition.

If two machines are running in KW mode and the Grid is ON. And due to some reason grid fails the both machine will automatically comes to the droop mode and share equal load even before going out of the Grid breakers the KW setpoint of two machines are different. (To avoid the same sharing the operator should decided the Droop percentage as per requirement of plant)

Shutdown Mode When machine is running in any mode and a shutdown condition comes the following action will takes place. All the speed setpoint will goes to zero. Also the MY & GV output will comes to zero and valve closes immediately.

In this condition operator should check the condition of Trip/Shutdown. Once all the trip condition checked, once again the machine can be ready for roll again.

Fail Safe Logic Mode When the Turbine starting from zero rotation i.e. from STOP condition fail safe logic works. It monitors the speed of the turbine and check whether the speed reaches 250RPM within 180 seconds. If the speed doesn’t reach the limit within the time frame that means there must be a fault so the Turbine is then tripped by the logic circuitry. We have to press reset button to start the turbine from beginning.