13 OCTOBER 2012 TS TIDINGS

FEED BACK NO.1

PROJECT:
PROBLEM: PROPORTIONAL SERVO BASED EHTC CONTROLS - ANALYSIS/
TROUBLE SHOOTING

The Electro hydraulic Turbine Controls is the heart of the turbine controls governing
the operation of turbine controls in order to control speed, load or pressure under
different modes of operation. Based on the machine stability conditions position set
points are derived from either the load controller output, speed controller output or
the pressure controller output. This position set point is given to an analogue output
buffer and hardwired to the position controller card. The position controller card is a
proportional controller operating from 4 mA to 20 mA for opening and closing and
remains at 12 mA at any equilibrium position based on the feedback from the EHG
feedback. This position controller card output operates a proportional servo valve
through an amplifier unit having a localised feedback from the servo through LVDT.
The overall drawing is as below:

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Let us know the individual components of the Proportional Governing controls

EHTC Position Set point

The EHTC Position set point is a 0- 100 % signal derived from the Governing controls
derived out of the 3 controllers namely Speed, load and pressure controllers. The 3
controllers operate in tandem with the load controller acting in foremost with
generator running on load and the speed controller tracking 10 percent house load
requirement in line with the droop of the turbine. The pressure controller acts as a
boiler stabiliser in case the boiler pressure starts dropping down. All the 3 controllers
have different soft PIDs and generate output as per the individual PID Gains,
integration time and differential constants. The selection of the position set point in a
single statement is Minimum of pressure controller and maximum of speed and load
controllers.

The position set point automatically change on the stability of the system in line with
the logics of EHTC and generates an analogue output through a AOB card (IOP 320 )
max module.
Position Controller Card (ARS + AVBAA)
The Position controller card is a simple PID card which operates with a single 4- 20
mA from the Analogue Output card and dual feedbacks of EHG in terms of 4- 20 mA.
The card has provision to select inputs in mA or Voltage modes and feedback selection
in minimum or maximum mode based on jumper settings in the card. The gain,
integration and derivative parameters and offsets can be directly adjusted by
potentiometers on the front face of the card. The following are the potentiometers :
P18- Offset range
P17- Proportional gain for PI controller
P20- Integration time
P19- Proportional gain for PD Controller
P16- Differential time
These pots, other switches are to be adjusted in line with the test reports (gains
adjusted to 12, Times adjusted to 7).
The position controller card gives an output based on the feedback from the EHG
balluff and once required feedback is achieved, the controller maintains the amplifier
unit output at around 12 mA to maintain the same position of servo. This maintaining
of 12 mA is an inherent equilibrium requirement for the amplifier unit and happens by
virtue of the proportional valve requirement to maintain status quo.

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Amplifier Unit ( VT17399) Rexroth make

An amplifier unit is erected near the proportional servo valve which takes input out of
the position controller card and gives command to the servo coil for allowing signal oil
(control oil) to the amplifier piston. The servo has a LVDT powered through an
oscillator connected to its plunger whose core moves giving a voltage output which is
demodulated and given as an input to the PID as one of the inputs, the command
comes as the other input. The balance between the input and output is given as a
command to the servo to maintain its position. The amplifier piston operates in either
of the direction for any command other than 12 mA. If the command is less than 12
mA it opens the servo and if the command is greater than 12 mA it closes the servo
and at12 mA it holds where it is. This point is called the null point and is adjusted
with the zero point adjusting POT.

This proportional nature of the controller helps it maintain a fine minimum error
operation. Once the signal oil operates the amplifier piston, the feedback of the
amplifier piston is taken thru balluff magnetic transducer to the position measurement
module (APM) which gives an output mA for use by the position controller card. There
are pots on the amplifier unit for adjustment of ramping time, range and command.
The following are the pots:
R1: Command value
R10: Ramp time
R21: Zero point (position transducer)
The amplifier unit is powered up through a capacitance module which takes care of
any power supply disturbances without damages to the amplifier unit. Note that the
amplifier unit should not be powered up without the capacitor unit as it might damage
due to voltage fluctuations
Erection/ Commissioning of the EHTC
Erection

1) Erect metallic JB in which the amplifier and capacitor unit along with TBs are
mounted.
2) Power supply cables are to be 1.5 sqmm at least for minimum line losses
3) Check for healthiness of servo coil ( 2.7 ohms) and healthiness of LVDT ( 116
ohms secondary, 136 ohms primary)
4) Check proper termination of cable and shield terminations in the TB.
5) LVDT shields are also to be terminated as per the suppliers diagram

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6) Check for polarity of supplies and polarity of mA, enabling signal healthiness
7) Ensure termination of cables in the MAX side as well as proper earthing of
shield wires.
8) Ensure the metallic JB is double earthed.
9) Ensure correct termination of balluff feedback and check healthiness of values
Commissioning

1) Create offset in the Position measurement module of one of the balluff

2) Disable EHG due to which amplifier piston moves to 100 percent feedback.
3) Adjust 100 percent in both the position measurement card.
4) Now enable EHG and check for indication at the local on the lamp.
5) Now force a zero percent command and because of higher offset in one Collins
the amplifier unit shall take the amplifier piston to extreme giving further
closing to the servo because of the created offset( maximum of position
measurement feedback will be selected and hence more positive offset feedback
shall be selected).
6) Fine adjust the other position measurement feedback. Check once or twice the
offset and the 100 percent feedbacks of the adjusted Collins enabling and
disabling the EHG
7) After adjustment of one of the position measurement card, with the adjusted
position measurement card as reference re-adjust the offset one and make it
almost equal to the originally adjusted one.
8) In this process there may be an overall error because of controller error making
the actual command of the controller to drift and hence the feedback to drift
too. This drift of feedback is a real drift.
9) Once the Collins have been adjusted and if a drift is observed, P18 pot on the
controller can be adjusted to produce a negative drift and can be verified under
various command conditions.
10) Try to the maximum not to tamper the Rexroth amplifier unit as well as the
PID controller unit other than the above said P18 adjustment. Take various
readings of the EHG and ensure linearity of operation and measure voltages at
the amplifier unit and test points.
11) It may be observed that the measurement voltages at amplifier unit are almost
the same at all conditions which are static. During dynamic conditions of
changes in command the voltages vary but then come back to the static
condition voltage values after equilibrium.

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12) Check out for saturation at the ends. Try setting to such an extent that
saturation is avoided near zero command and minimal saturation occurs near 100.
In this way faster response is ensured.
Problems faced during commissioning at Vallur

1) Dust entry into the amplifier piston area made the controller react very slow.
The amplifier piston was cleared in several occasions and covered with sheets.
2) The amplifier piston has a coupling plate with magnets mounted on it to move
over the balluff sliding over a stud placed on the EHG. Dust entry in the sliding
area made the feedback to vary erratically because of fulcrum action due to
dust and unit tripped on few occasions. The hole enclosing the stud was slightly
filed to allow a bigger gap for the above problem
3) Erratic variation of position feedbacks were observed on few occasions and it
was found that looseness of plug was found on the servo feedback and mere
pressing of the feedback plug made the servo to hunt. The plugs were tightened
and found EHG was operating very smooth
4) On few occasions it was observed that there were hunting’s in the EHG when
walkie talkies were taken near. All shield cables were connected properly on the
JB terminals, amplifier unit and earthed only on the panel side properly and
found no hunting was observed.
5) Once due to saturation problem position set point was limited to 98 percent. At
that time machine was running in hydraulic and EHG was disabled. When EHG
was enabled machine tripped because of servo going to extreme position. This
phenomenon occurred because of error in EHG command and feedback due to the
limitation of command to 98 percent and feedback being at 100 percent. This
error made the PID to take the command to 20 mA though the command was
not executed because of disabling of EHG. Once EHG was enabled, the servo
made the amplifier to go to zero and then slowly came back by PID action again,
in the meanwhile unit load reduced and speed controller came into action and unit
got tripped on low forward power. Hence do not limit the position set point
output to less than 100 percent for limiting saturation as hydraulic to EHG
changeover would be difficult and might lead to tripping when unit is running.
6) Do not mount lugs in the cables terminated on the amplifier unit/ capacitor unit
as termination is difficult and can damage the units permanently. Also looseness
can be avoided.
7) Ensure proper venting of the system after every service of amplifier piston for
dust

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8) Check up with mechanical commissioning group frequently for no froth formation

in the Control fluid tank as amplifier piston can misbehave due to air pockets.
Advantages of Proportional servo based EHTC Control

1) Proportional servo controls are the latest technological development and got huge
amount of procurement options (many vendors are available in the market).
2) Original plunger coil system involved physical adjustment of balance voltages
(approximately -1 V) and can again be disturbed due to mechanical vibrations/
stresses. Proportional servo controls do not have any such issues and all residual
voltages are in the electrical system and proper termination without lugs on the
amplifier unit can avoid such problems as in the original plunger coil system.
The above write up is just to provide an insight for young engineers and not a
specialising article. Kindly go through the individual manuals so as to understand the
essence of the entire system.

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