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1.0 INTRODUCTION

In petrochemical and refinery complexes, gas compressors are extensively used. There are mainly three types of compressors i.e centrifugal, reciprocating and screw. The centrifugal

compressors are used widely due to the high pressure and volume delivered by them. Prime mover for these centrifugal compressors can be either electrical motor or steam turbine. Steam turbines are preferable over the electrical motors where the steam is available. It is easier to increase/decrease speed of steam turbine for load control purpose where as electrical motors are fixed speed. A governor is a device, which is used to control the speed of the turbine. The mechanical governors are used for turbine control of small pumps .An electronic governor measures the speed of the machine and manipulates the steam flow to the turbine to maintain it at the desired speed. In some cases pumps (Boiler feed water/Lube oil) or fans are also driven by steam turbines.

2.0 PRINCIPLE OF OPERATION: CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 1 of 10 : 00 : 01 : 09/03/2002 : BSB

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Turbine consists of a casing containing rotor and stator. The steam passes through the stationary nozzles and is directed at high velocity against the rotor buckets causing the rotor to rotate at high speed. The following events take place in the nozzles: The steam pressure decreases. The enthalpy of the steam decreases. The steam velocity increases The volume of the steam increases.

There is a conversion of heat energy to kinetic energy as the heat energy from the decrease in steam enthalpy is converted into kinetic energy by the increased steam velocity. Steam at high pressure is allowed to expand through stationary nozzles, the result is drop in the steam pressure and an increase in steam velocity. In fact, the steam is issued from the nozzle in the form of a high-speed jet. This high velocity steam is applied to properly shaped turbine blades .It will change direction due to the shape of the blade. The effect of this change in direction of the steam flow is to produce an impulse force on the blade causing it to move. The blades are attached to the rotor of a turbine. The low-pressure steam comes out of the turbine.

Most commonly used turbines in industry are the backpressure turbines. CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 2 of 10 : 00 : 01 : 09/03/2002 : BSB

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The two general types of governors used are the speed sensitive governor and the pressure sensitive governor. Speed sensitive governors are applied to all kinds of turbines. Pressure sensitive governors are applied to back pressure and extraction turbines in connection with the speed sensitive governor. The speed sensitive governor (Steam Turbine Controller) may be: a) Mechanical Governor c) Electronic Governor Mechanical Governors use the fly balls with speed adjustment by the spring. The rotating motion revolves the fly balls causing displacement of the connecting rod and thereby of steam inlet valve. The speed of turbine increases till the spring tension force balances the centrifugal force of the fly balls. Electronic Governor uses the electronic module for controlling the start up/shut down sequence and speed control of the turbine. Steam inlet valve is in the form of a multi port valve, which is hydraulically operated by the signal from electronic module.

Jamnagar Complex has the following installations of Steam Turbine Controllers: A) Woodward (WW505) for: CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 3 of 10 : 00 : 01 : 09/03/2002 : BSB

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1) Wet gas compressors-2 nos in FCC 2) Recycle gas compressors-2nos in VGO HT 3) Heat pump compressor in PRU 4) Coker gas compressor in Coker B) Triconex Forced Draft Fan Steam Turbine Governor for: FD Fan of Auxiliary Boilers CPP C) Woodward PEAK 150 for: Boiler Feed Water Pumps---3 nos 4 nos

This SDM gives the details of the Wooward505 governor. Triconex Governor and Woodward Peak150 Governor are covered in other SDM.

3.0

Woodward the

Electronic steam

governor (prime

WW505 movers

is for

used the

for gas

controlling

turbine

compressors) operation at Jamnagar refinery complex. Steam turbines are used for driving the gas compressors in process plants. The basic function includes load variation by controlling the speed of rotation of compressor. The final controlled variable can be discharge/suction pressure of compressor or flow through the compressor. CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 4 of 10 : 00 : 01 : 09/03/2002 : BSB

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Magnetic speed pickup probes measure speed of the turbine. Output of the Woodward governor controls steam input to turbine and hence speed of the turbine. The Startup, operation and shutdown of turbine is controlled by Woodward make Steam Turbine Controller. Starting the Turbine (Automatic): Turbine speed is raised gradually to the operating speed by ramping. Speed is held at intermediate set points called low idle and high idle. The timings and ramp rates are user configurable. Turbine vendor normally sets these during commissioning.

Critical Speeds: During start up, turbine passes through the speeds at which vibration of the turbine may increase beyond dangerous levels. So it is essential to cross these speeds as quickly as possible. The speed ramp rate is configured to be very high in these ranges of speed.

Operation of Turbine: Figure 1 shows the schematic of a Turbine Control loop for controlling the compressor load:

CHECKED HSG APPROVED BY DGS

PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR

: 5 of 10 : 00 : 01 : 09/03/2002 : BSB

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Woodward 505 Turbine Controller Programmable Logic Controller (Compressor logics) Start Turbine Stop Turbine Remote set point Enable Turbine Speed signal from field To Turbine Steam Inlet Valve (Hydraulic Governor)

Remote set point from DCS

PID loop is implemented in Turbine controller. It receives the Turbine speed input from magnetic speed pickups. Remote set point is available from DCS, which gives the command to increase or decrease the Turbine speed depending on the compressor loading.

CHECKED HSG APPROVED BY DGS

PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR

: 6 of 10 : 00 : 01 : 09/03/2002 : BSB

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Stopping of the Turbine: After Turbine Stop Command is issued the Turbine is stopped in a controlled manner with speed ramping to zero at a configured ramp rate. Various parameters such as ramp rates, timings are configured during commissioning of the Turbine and recorded in Configuration Worksheet. Changing of parameters is password protected and should be carried by competent persons only with proper approval. 4.0 For Further details of Woodward505 refer following sections of Woodward Digital governor for extraction steam

turbines Volume-1 & 2 Refer to the following sections in the WW505 manual: Sr.No 1 2 3 4 5 6 7 Topic Starting features Turbine start Electrical connections Speed sensor inputs Basic control overview Speed control Speed set point Emergency shutdown/Controlled shutdown Over speed test function/procedure Section No 2-1 4-5 Vol.1 3-7 Vol.1 3-12 Vol.1 4-1 Vol.1 4-15 4-18 Vol.1 4-44 Vol.1 4-45/6-11 Vol.1 CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 7 of 10 : 00 : 01 : 09/03/2002 : BSB

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Configuration procedures Configuration Worksheet Trips and alarms Service Mode Procedures Hardware specifications System faults/diagnostics

5-1 Vol.1 A-3 Vol.1 6-29/6-30 Vol.1 4-1 Vol.2 A-3 Vol.2 6-1 Vol.2

5.0 For Triconex Governor TRI-SEN TS310 refer to the following sections: Sr.No 1 Topic Section Title and number Turbo machinery controller Extraction /Admission Basics Control Actions Function configuration 2 operation Section3 Section4 Section5 Installation , Configuration, Operation, and CHECKED HSG APPROVED BY DGS PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR : 8 of 10 : 00 : 01 : 09/03/2002 : BSB

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Maintenance System Description Hardware Installation Operating functions Maintenance Spare parts Specification Configuration 6.0 For Woodward Peak 150 governor refer to the following sections of the Instruction Manual PEAK150 DIGITAL CONTROL FOR STEAM TURBINES Sr.No 1 Topic Section Title and number Digital Control for Steam Turbines Control Description Wiring Functional Description Operating procedures Programming Service Menus Configuration Menus Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 : 9 of 10 : 00 : 01 : 09/03/2002 : BSB Section2 Section3 Section4 Section5 Section6 Section7 Section8 Section9

Functional Block Diagram Chapter 10 CHECKED PAGE HSG ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE APPROVED BY SELF DEVELOPMENT MODULE DATE DGS ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR

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Modbus communications Trouble shooting Replacement Procedures Program mode worksheet and

Chapter 11 Chapter 12 Repair Chapter 13 Chapter 14

CHECKED HSG APPROVED BY DGS

PAGE ENGINEERING & MAINTENANCE REV INSTRUMENTATION ISSUE SELF DEVELOPMENT MODULE DATE ELECTRONIC STEAM TURBINE AUTHOR GOVERNOR

: 10 of 10 : 00 : 01 : 09/03/2002 : BSB

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