Whether it’s an industrial turbine or a power turbine, a turbine generator or a turbocharger – when it comes to modernization to extend service life or improve performance, the task is invariably to upgrade the turbine control and protection system. It has become commonplace for modern mechanical engineering to equip machinery with modern measurement technology during production. The control logic is implemented on high-performance and highly reliable PLCs with the help of special software.

Our company solves such problems for units that have to a certain extent exhausted their design life, but can still be operated for a long time. Although such upgrades are inferior in technical effect to the installation of new machinery, they have a huge cost advantage. The necessary factor for a quality turbine modernization is an experienced team that knows how to correctly execute the solution for the electronic part of the turbine control system and its protection.

INTENGIN has extensive experience in modernizing not only industrial turbines, but also power turbines. This is a very important quality, since it is the power turbines that are tasked with the parameter accuracy, responsiveness and maneuverability described by the general ENTSO-E standard. In order to meet the requirements of ENTSO-E and the subsequent participation of the generating company in the ancillary services market, turbo generators must be equipped with modern systems that not only prolong their service life when replacing outdated hydraulic systems with electro-hydraulic ones, but also qualitatively improve the performance of these complex mechanisms.

The heart of regulation system offered by INTENGIN is a SIEMENS S7-400H series redundant controller, which forms the basis of our solution for regulation of steam turbines. It also provides input/output facilities from sensors and other control systems of the turbine unit as well as communication with the turbine’s automatic control system in accordance with the existing signal exchange design or existing control circuits based on relay schemes.

To ensure maximum operational reliability of the automatic control system of the turbines, we use measuring instruments and other components of the system only from high-tech manufacturers, whose reliability has been confirmed by years of successful operation in power plants around the world. This makes it possible to increase measurement accuracy and avoid unnecessary transformations.
After the implementation of the electronic control system, the turbine must necessarily undergo tests for compliance with the shunting characteristics of the standards. Our company helps to conduct these tests, participates in supporting and drawing up reports.

The proposed EHR of turbines will allow to perform the following functions:

• Automatic regulation of turbine speed and power in accordance with the static characteristic and the task received from the automatic control system or from the operator when the generator works both in the network and on an isolated load.
• Efficient frequency and power control by reducing speed insensitivity at a given irregularity in regulation.
• Limitation of speed overshoot below the safety controller trip setpoint at full (or up to auxiliary) load shedding with the generator disconnected from the mains.
• When operating in the mode of active power maintenance (sharp steam pressure), or stabilization of position of RC servomotors, the priority of speed control at its set deviation is provided. Transition from one control circuit to another is automatic and shockless.
• Limit values of active power, peak steam pressure, rate of increase or decrease of load are limited. It is possible to change the limit settings by the plant personnel.
• Automatic changeover to load limitation or unloading mode is performed if one of the limiting parameters has reached the limit value in the manual (remote) control mode.
• Выполняется прием и отработка аналоговых и дискретных сигналов от системы противоаварийной автоматики (ПАА), в том числе дискретных сигналов от ПАА на заданную разгрузку турбины с последующим заданным ограничением активной мощности блока.
• It is possible to test the electronic automatic safety device in all operating modes of the turbine, including the stopped turbine.
• The efficiency of regulation and protection is checked by steam reset and by disconnecting the generator from the mains.
• Automated turbine reversal is performed from any thermal state, taking into account fast and non-stop passage of critical rotor speeds.