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Governing systemGoverning system
System preparationSystem preparation
Parameters to followParameters to follow
GOVENING SYSTEM BLOCK DIAGRAM
PUMP
MAIN SOLENOID
VALVE
DUPLEX FILTER
OST TESTER
TRIPPING
DEVICE
ESV
STARTING
DEVICE
I / H CONVERTOR
SERVOMOTOR
GOV.
VALVE
OS GOVERNOR
CLEANING OF THE SYSTEM
Oil flushing:
- servomotor pilot pistons to be removed.
-cleaning of oil lines in the console.
- ESV cleaning and assembly.
Governor stroke check up:
preconditions
steam system should be completely isolated.
No vacuum
by pass trips coming from PLC/ DCS
check the the control valve movements vis a vis actuator signals.
Parameters
• Governing oil pressure : 8-10 atg
• Trip oil pressure : 7 -9atg
• Sec Oil Pr. : 1.5atg-4.5 atg
• signal : 4MA-20MA
• Valve Lift : 0 mm-full scale
• Governing oil temp : 50-60 deg c
• Max & Min Extr signal thro’ Governor & compare with diagram
Start up diagram
• Typical example
critical speed
zone
Time in minutes
Speed
in
rpm
Idle speed
Idle speed
COMMON GOVERNING PROBLEMS
- Hunting.
-Chattering.
-sudden rise /fall in the speed/ load.
-spurious tripping due to trip oil pr very low.
CHATTERING:
- Oil temperature, de aeration
- Oil pressure fluctuation
Hunting of control valves
1. Sec oil pressure VS valve lift calibration.
2. Oil purity
3. Sluggishness of the moving parts.
4. Frequent changes in steam inlet parameters.
5. Damage of control valve cones.
6. Tuning of electronic signals in case of electronic
Governor.
7.Programming of controllers as per start up curve /
extraction map / site conditions.
8. Problems of EHTC ( converters ).
9. Damage of Electronic components.
Hunting of control valves
Trip oil pressure very low trips
1.Mechanical problems with tripping device.
2.Tripping device lever radial and axial clearances not proper.
3.Turbine axial displacement very high (failure of T B).
4. Control oil pressure very low.
5. Heavy leakage through ESV drains due improper seating
of disk and cylinder.
6. Governing console duplex filter choking.
7.Choking of trip oil line.
8. Lube oil pump discharge pressure fluctuation.
9. Malfunctioning of trip oil pressure low- low switch.
10. Overspeed of turbine by pin actuation
SUDDEN RISE/ FALL IN SPEED/ LOAD
- control valves’ problems.
-servomotor pilot piston non rotation.
Control Valve Actuator
P
c
T
PILOT PISTON ASSEMBLY
Pilot piston top
Spurious tripping :
sudden drop in the trip oil pressure
malfunctioning of pressure switches
blocking of oil lines viz. Sec oil , power oil lines.
Lay out of the governing piping- should allow smooth
flow, should
posses less bends.
Loose connections, particularly at trip solenoid valves.
DO’S & DON’TS OF TURBINE
OPERATION (BEFORE START UP)
Do:
1. Check up the start of opening and full lift of the
servomotor.
2. WWG- ensure I/H converter manual knob is in min.
position.
3.Ensure the extraction valves are fully closed
before rolling.
4. . Check the operation of over-speed governor once
in 3 months.
DO’S & DON’TS OF TURBINE
DON’T….
1. Try to tune the servomotor while m/c in
operation.
2. Operate the m/c with the governor hunting.
3. Meddle with the manual knob of I/H converter
when m/c is in operation.
4. Raise the speed fast when MOP/ Governor
are taking over.
EMERGENCY STOP VALVE
OVERSPEED TRIP PIN ASSLY
CHANGEOVER VALVE FOR QCNRV
TRIP SOLENOID VALVE
Case study #1
FEED BACK ON CONTROL
VALVE SERVOMOTOR ASSLY
OBSERVATION:
• Speed raise immediately after opening
of Emergency Stop Valve
ANALYSIS
• Improper assembly of servomotor with
control valve lever
• Result in lift of valve cone
Preventive Action : Assly sequence to be followed
1. Fix the dampers (horizontal & vertical)
2. Fix the assembly fixture (Clamping
Device)
3. De-link Lever jointing Head & Control
valve lever.
4. Gently push the lever towards the Control
valve
5. Fix a dial gauge on the lever bracket and
the dial pointer on the pin towards the
control valve center.
Preventive Action : Assly sequence to be followed
6. Bring the power cylinder piston rod to the
top extreme position and hold it there.
7. With the help of the fixture, lift the control
valve lever by 1.5 and < 2 mm and hold
the position there.
8. Link the power cylinder piston and the
control valve lever head and lock the nut
of the lever jointing head.
Preventive Action : Assly sequence to be followed
HP GOVERNING VALVE ASSLY
Case study # 2
20 MW STG
PROBLEM:
EMERGENCY STOP VALVE NOT OPENING
DURING THE LOAD RUN TRIAL THOUGH IT WAS
NOT HAVING OPENING PROBLEM DURING NO
LOAD TRIAL.
ESV ASSEMBLY DRAWING
ESV REMOVED FROM THE POSITION WITH THE STRAINER
Scratch mark
Broken tack welding
DETACHED DISPENSER
RESOLUTION
1. Scratch mark removed by lapping.
2. The Piston was made free moving.
3. Dispenser tack weld in thee places in position
and fixed firmly.
4. ESV assembled and mounted back in position.
5. Opening of the ESV done from the remote (Control
Room)
and found satisfactory.
6. Load run trial of 20 MW STG completed successfully.
Problem:
Load hunting at various loads, but
not always. All of a sudden hunting
occurs at full load or even at partial
loads
Reasons:
pilot valve compression spring is
having lot of bent. (Refer Figure)
Action taken:
New compression spring supplied,
case study # 3
Sitapuram Power
PILOT VALVE ASSEMBLY
COMPRESSION SPRING LOCATION
STEAM TURBINES Governing System & TROUBLE SHOOTING

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STEAM TURBINES Governing System & TROUBLE SHOOTING

  • 1.
  • 2. Governing systemGoverning system System preparationSystem preparation Parameters to followParameters to follow
  • 3. GOVENING SYSTEM BLOCK DIAGRAM PUMP MAIN SOLENOID VALVE DUPLEX FILTER OST TESTER TRIPPING DEVICE ESV STARTING DEVICE I / H CONVERTOR SERVOMOTOR GOV. VALVE OS GOVERNOR
  • 4. CLEANING OF THE SYSTEM Oil flushing: - servomotor pilot pistons to be removed. -cleaning of oil lines in the console. - ESV cleaning and assembly.
  • 5. Governor stroke check up: preconditions steam system should be completely isolated. No vacuum by pass trips coming from PLC/ DCS check the the control valve movements vis a vis actuator signals.
  • 6. Parameters • Governing oil pressure : 8-10 atg • Trip oil pressure : 7 -9atg • Sec Oil Pr. : 1.5atg-4.5 atg • signal : 4MA-20MA • Valve Lift : 0 mm-full scale • Governing oil temp : 50-60 deg c • Max & Min Extr signal thro’ Governor & compare with diagram
  • 7. Start up diagram • Typical example critical speed zone Time in minutes Speed in rpm Idle speed Idle speed
  • 8. COMMON GOVERNING PROBLEMS - Hunting. -Chattering. -sudden rise /fall in the speed/ load. -spurious tripping due to trip oil pr very low.
  • 9. CHATTERING: - Oil temperature, de aeration - Oil pressure fluctuation
  • 10. Hunting of control valves 1. Sec oil pressure VS valve lift calibration. 2. Oil purity 3. Sluggishness of the moving parts. 4. Frequent changes in steam inlet parameters. 5. Damage of control valve cones.
  • 11. 6. Tuning of electronic signals in case of electronic Governor. 7.Programming of controllers as per start up curve / extraction map / site conditions. 8. Problems of EHTC ( converters ). 9. Damage of Electronic components. Hunting of control valves
  • 12. Trip oil pressure very low trips 1.Mechanical problems with tripping device. 2.Tripping device lever radial and axial clearances not proper. 3.Turbine axial displacement very high (failure of T B). 4. Control oil pressure very low. 5. Heavy leakage through ESV drains due improper seating of disk and cylinder. 6. Governing console duplex filter choking. 7.Choking of trip oil line. 8. Lube oil pump discharge pressure fluctuation. 9. Malfunctioning of trip oil pressure low- low switch. 10. Overspeed of turbine by pin actuation
  • 13. SUDDEN RISE/ FALL IN SPEED/ LOAD - control valves’ problems. -servomotor pilot piston non rotation.
  • 17. Spurious tripping : sudden drop in the trip oil pressure malfunctioning of pressure switches blocking of oil lines viz. Sec oil , power oil lines. Lay out of the governing piping- should allow smooth flow, should posses less bends. Loose connections, particularly at trip solenoid valves.
  • 18. DO’S & DON’TS OF TURBINE OPERATION (BEFORE START UP) Do: 1. Check up the start of opening and full lift of the servomotor. 2. WWG- ensure I/H converter manual knob is in min. position. 3.Ensure the extraction valves are fully closed before rolling. 4. . Check the operation of over-speed governor once in 3 months.
  • 19. DO’S & DON’TS OF TURBINE DON’T…. 1. Try to tune the servomotor while m/c in operation. 2. Operate the m/c with the governor hunting. 3. Meddle with the manual knob of I/H converter when m/c is in operation. 4. Raise the speed fast when MOP/ Governor are taking over.
  • 24. Case study #1 FEED BACK ON CONTROL VALVE SERVOMOTOR ASSLY
  • 25. OBSERVATION: • Speed raise immediately after opening of Emergency Stop Valve ANALYSIS • Improper assembly of servomotor with control valve lever • Result in lift of valve cone
  • 26. Preventive Action : Assly sequence to be followed
  • 27. 1. Fix the dampers (horizontal & vertical) 2. Fix the assembly fixture (Clamping Device) 3. De-link Lever jointing Head & Control valve lever. 4. Gently push the lever towards the Control valve 5. Fix a dial gauge on the lever bracket and the dial pointer on the pin towards the control valve center. Preventive Action : Assly sequence to be followed
  • 28. 6. Bring the power cylinder piston rod to the top extreme position and hold it there. 7. With the help of the fixture, lift the control valve lever by 1.5 and < 2 mm and hold the position there. 8. Link the power cylinder piston and the control valve lever head and lock the nut of the lever jointing head. Preventive Action : Assly sequence to be followed
  • 30. Case study # 2 20 MW STG PROBLEM: EMERGENCY STOP VALVE NOT OPENING DURING THE LOAD RUN TRIAL THOUGH IT WAS NOT HAVING OPENING PROBLEM DURING NO LOAD TRIAL.
  • 32. ESV REMOVED FROM THE POSITION WITH THE STRAINER
  • 36. RESOLUTION 1. Scratch mark removed by lapping. 2. The Piston was made free moving. 3. Dispenser tack weld in thee places in position and fixed firmly. 4. ESV assembled and mounted back in position. 5. Opening of the ESV done from the remote (Control Room) and found satisfactory. 6. Load run trial of 20 MW STG completed successfully.
  • 37. Problem: Load hunting at various loads, but not always. All of a sudden hunting occurs at full load or even at partial loads Reasons: pilot valve compression spring is having lot of bent. (Refer Figure) Action taken: New compression spring supplied, case study # 3