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Feature of Fully Automatic
1
Chapter
Electronic Governor for HEP
A comprehensive Hydro Electric Plant’s automation and
governing system.
Features
Built in Auto-synchronizer.
Fuzz 9800 is a stand alone governor with its own user friendly
man machine interface which includes four displays, 35 push
button keys and 50 LED indications on the front facia. This
configuration increases the reliability of the governor because
it does not depend on any other system like PC’s for command
input and displays.
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supports industry standard MODBUS SLAVE RTU protocol.
Any other custom protocols also be implemented in C-
Language
Mechanical details
Environmental Specifications
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Digital output signal details
1. No of channels : 8 Nos.
2. Input range : 4 - 20mA
3. Input resistance : 100Ω
4. Resolution : 12bits
5. Common mode voltage : ±12V
1. No of channels : 8 Nos.
2. Output range : ±10mA
3. Resolution : 12bits
4. Type of output : Referenced to fixed Ground.
1. No of channels : 3Nos.
2. Type of input : 0/24v pulse I/P(1 No.)
110V PT input (2 Nos.)
3. Resolution : 0.01 Hz
4. Pulse rate for 24V : 750/ 1500 pulse per sec. at
50Hz
(Selectable through software)
1. No of channels : 3 Nos.
2. Type of Output : 0 /24V Pulse
3. Output Frequency : 50Hz (2Nos.)
750/1500 Hz (1 No.)
Selectable through software.
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Governor Mounting Details
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The figure above shows the rear panel view of the Governor.
The cards staring from the left are Analog I/O-2, Analog I/O-1,
Digital I/O-2, Digital IIO-1, Auto-Synchronizer, CPU and Power
Supply. Field terminations are provided on the connectors of
the respective cards. Five Cables are supplied along with the
Governor, one for each card. Five cables are supplied along
with Governor, one for each card with a length of 2.5 meters.
One side of the cable is terminated with 25-pin “D” type
connector and the other side is crimped with 2.5mm Lugs.
Power supply connections are provided on a terminal strip as
shown in the figure above. The power supply is protected with
a fuse of 2.5 Amp for 110 Volts Power Supply Input.
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NC. 19.
NC. 20.
SP TST-3 Violet 21. A8 Speed test O/P, Simulated speed
NC. 22.
NC. 23.
NC. 24.
SP TST-1 Brown 25. A7 Speed test O/P, Simulated GEN PT
26.
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SL. Description
No.
7. NC
9. NC
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User Interface of the Governor
The Governor has four function keys namely F1, F2, F3 and F4.
These are used as hot keys to change the display pages and the
function of corresponding increment and decrement keys. By
default, when the governor is powered on, the main page
corresponding to "F1" key press is displayed. Displayed
parameters and function of the corresponding increment and
decrement keys are explained below.
Actual Speed is derived from the 'Speed Pulse Signal' and the
frequency measured from the Generator PT signal. Most
consistent speed of the two is used as the actual speed of the
turbine. In this way the speed loop will function even if any of the
speed input signal falls. The corresponding Alarm LED on the
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front face of the Governor indicates failure of any of the speed
signal.
speed set point to any value within the permissible limits using
the increment and decrement keys.
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Function of “Needle/ Deflector Opening Limit Set Point”
display and increment/decrement keys on the governor is
determined by the Auto/Manual selection of the governor. In
Auto mode and manual mode, the “Needle/Deflector Opening
Limit Set Point" display and Increment/ decrement keys
correspond to the both the Needle opening Limit Set points. In
Auto the deflector is automatically controlled according the
actual speed. In manual mode, when 'F2" page is displayed, the
display and Increment/decrement keys will correspond to
Deflector Opening Limit Set Point. It is therefore possible to
control Deflector independently through governor in manual
mode.
The Governor has several special purpose keys on the front face.
These keys and their functions are explained below.
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This key or the START push button is used to start the
Governor. In auto mode, if all conditions for starting the
2. START machine are met, the Governor will start to rotate the
Key turbine and match the speed to the Grid frequency.
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The two modes of operation are summarized below.
START key is used for starting the turbine. If the Machine Ready
to Start Input to the Governor is active and the Governor is in
Auto made and "Auto synchronizer ON" is selected on the unit
control panel, it performs the starting sequence, synchronization
and loading of the turbine to a preset value. However if "Auto
synchronizer ON' is not selected, the governor performs the
starting sequence and matches the frequency of the Generator to
that of the Grid and waits for manual synchronization. Auto
synchronization can still be done at this moment by selecting
“Auto Synchronizer ON” from the unit control panel. Auto/
Manual mode can also be selected with the AUTO and MANUAL
keys. Mode of the operation of the Governor (AUTO/MANUAL) is
indicated with an illuminated LED on the respective switches.
After all the pre-conditions for starting the turbine has been met,
START key or START push button has to be pressed so that the
Governor will permit to vary its set points in Manual mode.
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The deflector can be opened to a comfortable value for rotating
the machine. This can be achieved by pressing F2 key to display
deflector opening limit set point and deflector actual position.
Then the deflector be opened to approximately 50% by using the
increment and decrement keys on the governor.
After opening the Deflector, Needle Opening Limit set point can
be slowly increased by using the increment/decrement keys from
page F1, so that the machine starts rolling and picks up speed.
The speed set point can be set to the desired speed so that the
unit can be synchronized. The speed set point will not be
automatically set depending on the Grid frequency in this mode of
operation. The unit can then be manually synchronized.
The Needle Opening Limit set point and Speed set point are both
active in the manual mode also. The difference from the auto
made before synchronization is that the Speed set point will not
follow the grid frequency and the Load Limit set point will not be
automatically incremented to attain the no load speed. Both the
Speed set point and the Load limit set point has to be adjusted by
the operator in manual mode. The actual guide vane opening is
limited by the Needle opening limit set point or the Needle
opening required for attaining the speed set point, whichever is
lower.
S. Push
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No Button Input Description
.
1. LOAD LIMIT RAISE This push button is used as LOAD LIMIT RAISE Push
PB Button.
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The Governor OK signal indicates the health of the Governor. The
main Processor runs the built in test to check its RAM and Flash
memory and the processor. It also periodically triggers the built
in watchdog timer. If the processor and its memory are healthy
and the watchdog does not time out, the governor holds the
Governor OK signal in the digital I/O card to active state. If the
processor does not update the Governor OK signal within 2
seconds, the Digital I/O card will automatically withdraw the
Governor OK signal. The Governor OK signal will be withdrawn
also during programming of the Governor.
The speed control loop has a permanent speed droop that can be
set from 0-10% and a temporary droop compensates the speed
control loop against water hammer effect and machine inertia.
PID values, permanent droop and temporary droop parameters
can be set in the field through software. The State detection logic
detects the state of the Governor from the system dynamics
(Starting/Synchronised). It accordingly modifies the Speed PID
parameters for robust control under all circumstances.
Apart from these basic blocks the Governor has an auto loop to
perform automatic functions, Auto Synchroniser loop, Logic and
alarm processing, diagnostic loops, SCADA functions and user
interface programs.
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Tuning of the Governor to reduce hunting:
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Tuning of the Governor parameters is not provided through the
governor keyboard and display interface. The tuning parameters
will not change for the same machine, as the inertia and other
plant parameters cannot change significantly enough to effect the
tuning. This will also prevent any unauthorised change in the
tuning parameters. Tuning of the unit needs careful matching of
the Needle Control loop Gain, Deflector control loop gain, Speed
Control loop gain, derivative time constants, Integral Time
Constant and temp droop settings.
CPU Card :
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allows easy update of the firmware and software so that any
future requirements can be added to the system with ease.
Apart from the governor functions, the CPU is also capable of
performing logic functions, which are useful for automating the
control of turbine auxiliaries. The main CPU also performs
extensive self-diagnostic checks. In case of any failure in the
governor software or hardware, the "Governor OK" signal will
be withdrawn so that the turbine will be shut down
immediately with the help of an emergency trip relay.
Programmable data is stored in a non-volatile flash memory in
the main CPU card. The data is well protected against 'any
inadvertent write operations with the help of hardware security
features. The CPU with the help of extensive CRC checksums
also periodically monitors integrity of the configuration data.
The Analog I/O card measures the feedback signals from the
held and drives the actuators to control the speed and other
parameters of the turbine as per the governor control scheme.
Analog inputs are measured as 4 to 20mA signals. Since
current signals are used for measurement, noise pickup will be
very less. This improves the controllability of the turbine.
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Feedback signals generally used are Guide vane and Runner
Blade position feedback and Head Race and Tail Race water
levels. Any other signals like Active power; Reactive power,
Power-factor etc can also be feedback using appropriate
transducers with 4 to 20 mA outputs. Output signals are 10
mA. Output signals are generally used for actuating the servo
control valves of Guide vane and Runner Blades. Outputs can
also be used for driving inputs to other PLC systems and for
metering. Fuse protection (F1 to F4) is provided for all analog
input channels. Potentiometer P1 and P2 are used for Offset
and 'Gain control of analog input channels respectively.
Potentiometer P3 is used for Gain control of analog output
channels.
Detecting Fuse Blown Condition in Analog I/O card :
The fuse (F1-F4) provided on the Analog Input channels is
meant to protect the PCB in case of any inadvertent wrong
connection being made to the respective channel. This could
happen if +24 Volt field power supply is bypassed in any of the
field transducers and given directly to the Analog input
channel. This will cause excessive current to flow in the card.
In this condition, the fuse will blow and protect the governor
PCB. The fuse blown condition can be detected when the
governor does not read the corresponding channel (indicates
minimum value) even though the input is present. Fuse F1
corresponds to channel 1 and fuse F4 corresponds to channel 4
respectively.
Digital I/O card :
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Figure 6, Digital I/O Card layout diagram
The governor senses the discrete inputs from the field through
the digital I/O card. This includes push buttons from the panel,
Circuit breaker Open/Close status inputs, limit switch inputs,
and other user selections. All inputs are optically isolated from
the governor power supply and operate at 24 volts DC.
The Governor also actuates discrete outputs through this card.
This includes, indicators, alarms, circuit breakers, relays, and
inputs to other PLC systems. Digital outputs are electrically
isolated from the governor power supply using relays. Each
digital output channel of the 8-channel card is capable of
switching a current of 0.5 Ampere at a maximum voltage of 230
volts AC or 110 Volts DC.
Digital outputs are protected against overload with help of
fuses (1 Ampere). Fuse F1 is used for channels 1 & 2, F2 for
channels 3 & 4, F3 for channels 5 & 6 and F4 for channels 7 &
8 respectively.
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Figure7, Auto Synchroniser Card layout diagram
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Similarly SP TST-2 and SP TST-3 are 5QHz signals, which in be
used to test generator and grid frequency input signals.
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c. Temporarily bypass the remaining emergency trip signals if
they can be safely
ignored while the turbine is stationary.
5. Actuator signals can now be forced from proportional valve
amplifier cards as given below.
a. Ensure that 24 volts power supply is made available to the
proportional amplifier card for its operation. This can be
confirmed by the indication on the front panel of the card.
b. Short the MANUAL OPEN signal to the SlG_POS input of the
card to open the Needle proportional valve.
c. Short the MANUAL CLOSE signal to the SIG_POS input of
the card to close the Needle proportional valve.
d. If the Needle does not move, analyse the hydraulic circuit
and ensure that the Needle moves when the actuator signal is
applied.
Needle Position Feedback :
After ensuring that the Needle actuator circuitry is functional,
Needle position feed back from Needle position transducer is
to be checked and calibrated. Follow the procedure given
below to achieve this.
a. Keep Needle fully closed by applying the Manual close signal
from proportional amplifier card as explained in para 18.2
point 5.
b. Observe the reading on the Governor for "Actual Load'
(Actual Needle opening). “Actual Load" should read close to
0.00. If the reading defers by more 2% than loosen the angle
transducer coupling and adjust the shaft rotation of the Angle
transducer so that the Actual Load reading is close to 0.00.
c. Using the Offset trim potentiometer in the transducer (refer
transducer manual), finer adjustments can be made, so that the
"Actual Load' can be adjusted to 0.00.
d. Now the Needle shall be opened fully by applying the
Manual open signal from proportional amplifier card as
explained in
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para 18.2 point 5.
e. Adjust gain potentiometer so that "Actual Load" reads 100%.
f. If it is not possible to attain the full range (0 to 100%) using
the offset and gain potentiometers, further adjust the
transducer shaft as mentioned in point above and repeat the
steps to “b” to “e”.
19. Checking Needle position control loop :
1. Ensure that the Needle actuator output from the governor is
connected to the proportional card (SlG_POS and SlG_RET).
2. Ensure that the Needle Position Feed Back from the angle
transducer is connected to the Governor.
3. Power ON the Governor.
4. Press Manual Button from the Governor. (If already in
Manual mode, skip this step).
5. Increment Load Limit set point from the Governor Facia or
control desk.
6. Observe the 'Actual load' value (Actual Guide Vane opening)
on the governor. The Actual Needle opening should follow the
set point
7. Observe the Needle opening Servomotor for any hunting. It
the Needle Position control loop is hunting, reduce the gain of
the Needle position control loop till the hunting stops. (Please
note that the gain can be adjusted only if the MENU key is
enabled in the Governor), In this governor, MENU key is not
enabled and the gain in already tuned during commissioning.
This gain is not expected to change because the machine
characteristics will not change considerably during the life of
the machine.
8. Ensure that the Needle closes when the Emergency stop
push button is pressed. Press the emergency stop push button
on the unit control panel, when the Needle is fully open. The
Needle should close immediately.
20. Deflector actuator testing and position control loop:
Follow the same procedure as Needle control loop as given
above and check the Deflector control loop.
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21. Initial spinning of machine:
The following procedure shall be followed for initial spinning of
the machine.
1. Emergency shutdown logic has to be checked. This ensures
that the turbine will trip when Emergency stop push button is
pressed from the unit control panel. This will protect the
turbine from over speeding in case of any failure.
2. Switch ON all the Governor accessories and make sure that
all warnings disappear from the alarm annunciator panel.
3. Ensure that Manual mode is selected on the Governor.
4. Press Start button from the Governor or the unit control
panel.
5. Increment the Load Limit set point to approximately 10% or
till the machine starts to rotate.
6. When the machine starts to rotate, decrease the load limit
set point to the no load value so that the machine does not over
speed.
7. By adjusting the Load Limit set point, rotate the machine to
approximately 40 Hz. Check speed of the machine using a
tachometer.
8. At this point correlate the speed indicated by the Governor
to the tachometer reading. For a rated generator speed of 750
RPM, 40 Hz. Frequency will be obtained at 600 RPM.
9. If there is any jump in the speed signal reading or the speed
signal does not indicate, check the wiring of the speed
transducer and the gap between the speed transducer and gear
tooth.
10. Then the full rated speed of 50 Hz can be obtained if
required.
11. All the turbine vibration checks, gearbox, and bearing heat
checks can be carried out at this moment.
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12. The polarity and phase sequence of the generator PT signal
to the Governor and synchronization panel can also be
checked.
22. Governor operating procedure (Manual Mode) :
The Governor can be operated in the following manner to run
the Machine in the manual mode.
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15. The frequency and phase of Grid and Generator can be
matched by using the Load Limit increment and decrement
buttons.
16. Synchroscope in the synchronisation panel can be switched
ON for synchronisation.
17. When all the Generator Voltage, frequency, and phase are
matched, on the Synchroscope, synchronisation of the unit can
be done.
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9. AVR can be energized and Auto-Synchroniser can be
switched ON at this moment to enable Auto-Synchronisation.
10. Governor will match the voltage, phase and frequency of
the Grid and Generator.
11.When the Generator Voltage, frequency, and phase are
matched, the governor will automatically synchronize the unit.
24. Normal shut down of the Turbine :
Normal shut down is used to shut down the turbine normally.
Normal shut down can be initiated by pressing the "Normal
shut down” push button from the unit control panel. When
Normal shut down is initiated, the governor takes the following
actions.
1. Load limit set point is gradually reduced to the no-load
value, so that the generator is brought to no-load condition.
2. When the actual Needle opening reaches the no-load value,
the governor generates a two second pulse on the "Circuit
Breaker open command output", which intern trips the circuit
breaker.
3. The Needle and deflectors are then completely closed to
bring the machine to a complete halt.
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26. Governor Trouble Shooting Guide :
S. Indication Check Replace /Action
No
.
1. Field Power +24V a. Input Power. If not available, check
Fuse in the Input supply
Indication LED not b. Check Fuse on to the Governor.
Governor
glowing on Power supply If blown, replace Fuse
Governor with 2.5mAmp glass fuse.
c. Check +24V
front panel. power on the If voltage not present,
rear connector replace Governor Power
of Governor. supply card.
If frequency is indicating
zero, replace the speed
sensor.
Fuse F2 corresponds
to channel 3 and
channel 4.
Fuse F3 corresponds
to channel 5 and
channel 6.
Fuse F4 corresponds
to channel 7 and
channel 8.
Channel 9 to 16 are
provided in Digital
I/O Card.
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INDEX OF DRAWING
SCHEMETICS
WIRING DIAGRAMS
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