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Emerson Process ManagementPower & Water Solutions
Upgrading Turbine Governor Controls to Improve Performance and Maintainability
Ross Papilla, Sr. Consulting Engineer
April 7, 2016
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 2
Presentation Outline
• Market Trends and Operating Environment
• Turbine Governor Challenges
• Turbine Governor Upgrade Options
• Considerations for Overall Plant Control System Architecture
• Integrated & Redundant Turbine Control System
• Turbine Control Algorithms
• Hydro-mechanical Turbine Protection System
• Turbine Governor Upgrade Specification Standards
• Hydro-mechanical System Upgrade (Animation files)
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 3
Market Trends and Operating Environment
• Growth of Renewables
– Mandated and incentivized by States
– Bulk of capacity additions in the West are renewables
– Renewables are generally “must take”
– Generation from Renewables is intermittent
– Renewables don’t have “rotational inertia” for grid stability
• Electricity Market Evolution
– Economic allocation of generation and AS
– Entities: Generators, SC’s, BA’s, ISO’s
– Sell to market vs firm commitments
– Energy: Day-ahead, realtime, EIM
– Ancillary Services: Reserves, RAS/AGC, Ramping, Frequency
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 4
Turbine Governor Challenges
• Hydro Turbine Generators are Dispatch More
– More load changes to mitigate impact of renewables
– More accurate load response to meet market requirements
– More usage for Regulation AS (AGC) due to fast response
– More and deeper cycling, and faster ramping
– More frequent start/stops, and faster starts
– More accurate response for frequency regulation
• Many Hydro Turbine Governors Are Old or Obsolete
– Performance for more and new dispatch requirements is poor
– High reliability, failure tolerance, availability not in design
– Maintenance decreased: obsolescence, part, new personnel
• There Are New and Specific Operating Rules & Stds
– Grid reliability & security requirements: WECC, NERC, ISO
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 5
Turbine Governor Upgrade Options
• Hydraulic Power Unit Options
– Replace w High-Pressure system, Retain Low-pressure system
• Digital Control Upgrade Options
– Special-purpose, Standalone (interfaced), Integrated
– Simplex, Redundant
• Instrumentation Upgrade
– Speed, frequency and position sensing; Actuation upgrade
• Tripping System Upgrade
– Single, redundant, two-out of three/on-line testable
• Protection System Upgrade
– Standalone, integrated, supervised
• Options Evaluaded on a Case-by-Case Basis
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 6
Digital Control Architecture – Standalone Simplex (interfaced)Turbine Control
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 7
Control Room Consoles and HSR
• Highly reliable and fault-
tolerant
•Global database
•Self-diagnosing
•Auto-documenting
•Easy to maintain
Unit & Turbine Controllers Config Console BOP Controller
Digital Control Architecture –Integrated Redundant Turbine Control
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 8
Integrated Redundant Turbine Governor
Power Supply
120V AC/ 24 V DC
120V AC
Primary
Redundancy Power for
All sensors and devices
Redundant Controller
DI, DO,
AI, AO
modules
Modules for
Speed and Frequency
measurement
Power Supply
125V DC/ 24 V DC
125V AC
Secondary
Toothed wheel
Fgrid
Fgen
Servomotor of WG
Command
Position
Module(s) for
Speed measurement
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 9
Algorithm for Speed Measurement
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 10
Francis turbine. General view• Power production depends on guide vanes opening P= f[Y=f(a0), H]
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 11
Francis turbine.Typical algorithm for Power and Frequency Control
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 12
Kaplan turbine. General view
Power production depends on guide
vanes opening (a0) blades angle (φ)
and water head (Н)
Active power P= f[Y=f(a0), φ, H]
Optimal combination function φ = f(a0, H)
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 13
Kaplan turbine.Typical algorithm Power and Frequency Control
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 14
Pelton turbine. General view
Power production depends on nozzles opening deflector opening and water head
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 15
Pelton turbine.Typical algorithm Power and Frequency Control
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 16
Algorithms Summary:
• Generator speed measurement. Before switch on generator circuit breaker – using 3 speed probes (2 out-of 3), after that using signal from voltage transformer.
• Grid frequency measurement. Signal from voltage transformer used for synchronizing the generator with the grid.
• Use typical solution for Frequency Control for all main type of turbine (Francis, Kaplan, Pelton) excluding principle of actuators control.
• Automatic adjustment of frequency for synchronization mode.
• Automatic switching from Power mode to Frequency mode by emergency frequency deviation.
• Optimizing the control by using a feed-forward algorithm.
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 17
Hydro-mechanical Protection Design• Overspeed Protection Schemes
– Triple-redundant speed modules generate 2-out-of-3 trips independently and directly to shutdown system
– Same as above, but completely separate system with SIL3 rated speed modules
• Turbine shut-down using main valve “FAST SHUT-DOWN”:
– Decreased water flow to turbine bearing
– Generator bearing and pilot bearing incremental temperature monitoring
– Oil system accumulator pressure monitoring
– Electrical protections signal
• Turbine shut-down using emergency stop valve “SLOW SHUT-DOWN”:
– Over speed @115% rated power and main valve do not respond to close guide vanes
– Over speed @ 145% rated power
– Failure of all servo motor control loops
– Speed measurements failure
– HPU pressure decrease
– Emergency stop button is pulsed
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 18
Hydro Turbine Retrofit Specification
• Applicable standards:
IEC 61362: 1998
Guide to specification of hydraulic turbine control systems
IEEE 1207: 2011
Guide for the Application of Turbine Governing Systems for Hydroelectric Generating Unit
IEC 545: 1976
Guide for commissioning, operation and maintenance of hydraulic turbines
ISA 18.2 EMMUA 191
Alarm Management Tools to assess and manage data information
IEC 61131
Use of graphical function blocks for control logic configuration
[File Name or Event] • Emerson Confidential • 4/7/2016 • Slide 19
Questions & Animation show
• Hydro-mechanical System Upgrade (Play Animation Files)
• Q&A
• Contact info:
– Ross Papilla, Sr. Consulting Engineer
– +1 (909) 896-6160
