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This paper covers Controls for Turbine for a variety of functions and
therefore it would be natural to classify the turbines according to the
control parameters.
2) Inlet Pressure control where the turbine has the basic task to
maintain a constant pressure in its inlet header.
3) Back Pressure turbine where the turbine has a task to provide a low
pressure steam by expanding steam from the high pressure source.
All these basic types are used in many variations, including extraction
turbines with two or more extraction ports or combination of
extraction /induction turbines.
When the pressure drops, the control will open the inlet valve further
until the new flow matches the flow demand and pressure returns to
normal. However the increase in steam flow also increases the speed
or power output of the turbine.
The main task of the back pressure turbine is to provide low pressure
steam. The power available from the expansion of the steam in the
turbine is a by-product but for a single valve turbine, as a
backpressure turbine this power can not be controlled: the available
power depends solely on the demand for extraction steam.
Inlet Pressure Control: The inlet pressure turbine receives its steam
from a high pressure header which also provides steam to other users
such as other turbines. The flow in the header varies with the demand
by these users and rather than varying the flow from the boiler, the
inlet pressure turbine takes all these flow. Again, it is not possible to
measure flow demand by other users but the inlet pressure turbine
matches available flow to flow demand by maintaining constant
header pressure. When header pressure drops due to an increase in
flow demand, the controller closes the inlet valve. When header
pressure increases due to a drop in demand, the controller opens the
inlet valve further. Again, the available power is a function of steam
flow and can not be controlled in this application.
The back pressure and inlet pressure application work for generators
which operate in parallel with a grid and for variable speed
mechanical drives. These applications do not work for generators on
an isolated system as the control cannot maintain constant speed.
The inlet valve for backpressure turbine opens when the transmitter
indicates a drop in pressure. However, the inlet valve of the inlet
pressure turbine moves in the opposite direction: it closes when the
transmitter on the high pressure header indicates a pressure drop.
(3) The governor has an internal oil supply and pump. Therefore, the
servo does not have any power output until turbine speed has
increased sufficiently to provide adequate oil pressure from the pump.
(4) For stability reasons, there is a time delay between any changes in
the speed reference input and the reaction of the internal speed setting
mechanism.
In addition any decrease in the turbine speed below the 3 PSI level
such as turbine idle or a controlled shutdown must be accomplished
manually, again via the T/T valve.
The speed reference input moves a pilot valve (PV) via a bellows. The
PV directs oil to the piston on top of the speeder spring (SS) which
determines the actual reference setting. A restriction in the flow of oil
to this piston creates a time delay. This built-in time delay of 3 – 5
seconds is necessary for system stability but it prevents any fast
overriding action via the 3-15 PSI input when a limiter wants to affect
the steam valve instantly. A typical example is a steam driven pump
which is controlled on flow with an override when suction pressure
drops.
Electronic Governors:
(2) The control must recognize that there are certain limiting
parameters which may have to take over automatically when such a
variable reach a set point.
The digital control does not care what the input variables are. The 4 –
20 mA input to the cascade controller can be steam pressure such as
inlet pressure or back pressure or it can be a compressor parameter
such as suction pressure or discharge pressure.
2. Two Valves Turbines: With two valves, the control can modulate
two parameters simultaneously. For power plat, turbines in Generator
application, this can be a combination of maintaining constant turbine
speed and modulating extraction flow. For a variable speed drive
such as Compressor application, the two parameters typically are a
variable speed control combined with modulating extraction flow.
This type of turbine is called a Single Automatic Extraction (SAE)
turbine as it has a single extraction port with controlled extraction
flow.
The turbine can drive a compressor in which the turbine speed must
vary with compressor demand through a speed governor with the
input from a process controller. Another application is a generator
operating parallel with a commercial grid. In that case the speed is
constant and the control is designed in such a speed/power mode that
amount of power from the generator shall not be fluctuating.
Extraction Control:
Decoupling:
The back pressure turbine has a control which modulates the flow in
the back pressure header while speed or power is not controlled. The
SAE turbine is used in applications where both extraction flow and
speed or power needs to be controlled simultaneously.
Rationing:
All steam to provide power must travel from the HP valve, through
the HP turbine, through the LP valve and the LP turbine to turbine
exhaust with none of the steam travelling to the extraction port. All
steam to satisfy extraction demand must travel from the HP valve,
through the HP turbine to the extraction port without any of this steam
going through the LP section.
Induction Turbines:
The turbine has two inlets for steam, a High Pressure (HP) and an
Intermediate Pressure (IP) inlet. Many plants such as the ethylene
plant depend on the reformer to produce the high pressure
steam. During the start a boiler produces the intermediate steam and
the induction turbine starts on that source. When the process is well
on its way and high pressure is available, the turbine switches to high
pressure source. Other induction turbines use all the excess steam
available from an intermediate pressure header.
There are two separate control issues, determined by the nature of the
process to be controlled. These areas are: Plant control, Turbine
control.
Mechanical Input:
Mechanical Trip:
Over speed protection is the primary trip but other trips involving lube
oil and other parameters may be involved. Should the existing
mechanical trips be maintained and a new electrical trip mechanism
be added or should the existing trip mechanism be completely
replaced? If the existing mechanical system does not cause nuisance
trips, it can be retained as the secondary trip and a new electrical
system can be added as primary protection. Insurance regulation may
even require that the mechanical trip be retained.
Electric Trip:
The software for the protection can be in the digital turbine control as
long as a second, independent, trip is provided for the (very remote)
case that there is a failure in the turbine control. More common is to
have the overspeed protection as a separate device. The trip valves are
dormant all the time and periodic testing is essential to assure that
they operate when required. The two isolation valves are added which
can isolate one trip valve for testing while the other trip valve remains
active. Once the switch on the isolation valve indicates that the trip
valve is isolated, the operator can test the trip valve.