This is a presentation of research in the field of automation of steam turbines power upon 200MW of the group of Process Automation at Institute Mihajlo Pupin, Belgrade. In short, this is a model of steam turbine, which is used during the development of control algorithms steam turbine, power plant personnel training and optimization of steam turbine operation. The model has been adapted to work in real time and is applied in the form of hardware in the loop (HIL) simulation.

1. One Solution for Simulation
of Steam Turbine Power
Upon 210MW
Vesna Petkovski, Nikola Krajnović, Miloš Stanković, Nebojša Radmilović
Institute ’’Mihajlo Pupin’’, Belgrade, Serbia
www.pupin.rs
Željko Gagić
Thermal Power Plant ’’Nikola Tesla A’’, Obrenovac , Serbia
www.tent.rs

2. Idea About Simulator
The global industry trend is to reduce all costs regardless of their origin. In electrical industry, one
part of solutions for reducing the number of plant dropouts is system optimization and good
personnel training.
• Simulators and training systems represent a modern method of training staff that operates in various
sectors of a power plant (production, maintenance etc.) An inadequate training often leads to non-
professional reactions in critical situations.
• Some of the advantages of such training systems are the possibility of a thorough analysis of a
recorded event, the possibility to set the simulator to a state preceding a turbine trip or another
critical situation and the analysis of various influences on the plants stability.
• The price of the insurance policy significantly diminishes if the personnel have been trained on a
certified training system.

3. Simulator Usage
The turbine simulator consists of several hardware and software components and it is used for testing of
turbine governor and turbine protection:
• in the phase of installation
• during design and optimization of the algorithm
• for factory acceptance test
• during testing and putting into operation a complete integrated system on facility
• training of staff with the new system of regulation before the first turbine startup

4. Steam Turbine
Qshs
Pcrs
Pshs
Phrs
Plpbp Qlpbp
Qhpbp
Low pressure
bypass station
High pressure
bypass station Start up
bypass station
Condenser
High
pressure
chamber
Inter-
mediate
pressure
chamber
Low
pressure
chamber 1
Low
pressure
chamber 2
Reheater
Boiler
(superheater)
To Generator
Shaft
Qlpt
Pacs
N
IP valves
IP valvesHP valves
HP valves
QB, PB
Condensate steam turbine of 350MW, type 18-K-348, manufacturer ZAMECH
(Elblag, Poland) is considered for the modeling approach. This turbine installed
at Unit B2 of TPP “Kostolac B”, Drmno, Serbia.
Turbine parameters:
Nominal power 350MW
Rated speed 3000rpm
Steam pressure in front of turbine 180bar
Intermediate pressure 42.4bar
Pressure behind LP chamber 6bar

5. Generator
SG
Generator
P
Generator
breaker
Main circuit
breaker
Auxiliary unit
breaker
Auxiliaryunitgrid
Networkline
From Turbine
Shaft
Unit
transformer
Auxiliary unit
transformer
Generator (nominal voltage 410kV, nominal power P = 410MW, cosφ=0.85) over
generator breaker, unit transformer (nominal power 410MW, incoming voltage 410kV,
outgoing voltage 22kV) and main circuit breaker is connected with network. Auxiliary unit
transformer is connected at generator voltage.

6. Turbine Model
Turbine model is designed so that it can fully complete simulation of important
real process parameters. Overall model contains:
Boiler model,
HP, LP and start-up bypass station model,
Electro-hydraulic servo drive,
Model of control valves,
Reheter model,
Turbine mechanical power model,
Generator model

7. Turbine Model
Structure of turbine-generator model

8. • Boiler model of this type is developed and used only for turbo-plant simulation and it considered that
the pressure at the outlet of boiler PB and steam production QB are constant values. Change in
pressure Pshs or flow Qshs in front of HP turbine, depends only on change in
position of control HP valve and flow through HP bypass station
Turbine Model – boiler with HP valves & HP ByPass

9. Turbine Model – steam flow characteristic
0 10 20 30 40 50 60 70 80 90 100
0
10
20
30
40
50
60
70
80
90
100
HP/IP valves position [%]
[%]
high-pressure flow characteristic
intermediate-pressure flow characteristic
Nonlinear functions define
the flow of steam through HP valves
depending on the HP valve position.
Similarly, flow of steam through IP
valves is showed also These nonlinear
function are the most important part of
model, since it defines steam flow
linearization through turbine. Values of
these functions are obtained from
measurements of steam flow and valve
position, taken during different turbine
operating conditions.

10. HP bypass station
Turbine Model – other turbine parts
Electro-hydraulic drive model
Reheater model with IP valves and LP bypass stationStart-up bypass station

11. Turbine Model – generator & operating modes
Control logic for genertator
operating modes

12. 0 1000 2000 3000 4000 5000 6000 7000 8000 9000
0
500
1000
1500
2000
2500
3000
- max absolute error 1.8687%
- mean absolute error 0.37665%
turbine speed SIM
turbine speed ARH
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
0
10
20
30
40
50
time [s]
position[%]
HP valve position
IP valve position
LP bypass position
The comparison of the
obtained parameters by the
simulation showed satisfactory
matching with real data.
Increasing turbine speed
from a cold state with
position of HP valves, IP
valves and LP bypass station
Results – model VS real plant (verification)

13. Increasing turbine power
after sinhronization to power
grid
Results – model VS real plant (verification)
0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4
x 10
4
0
20
40
60
80
100
120
140
160
180
200
time [s]
electricpower[MW]
electric power SIM
electric power ARH

14. Comparative analysis of
simulated and real turbine
speed during turbine droopout
and speed reducing
Results – model VS real plant (verification)
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
x 10
4
0
500
1000
1500
2000
2500
3000
time [s]
speed[rpm]
- max absolute error 1.9185%
- mean absolute error 0.56801%
turbine speed SIM
turbine speed ARH

15. Hardware – for real-time simulations
To operate the model in real time it is used National Instruments PXI-1044 platform which
consists of:
• Embedded controller PXI-8105, that satisfies demands for real-time work. The used operating system is
LabView® 2009 Real Time v.9.0.
• Multi-function acquisition card M-Series, type PXI-6289 has four 16-bit analog outputs, 16 differential analog
inputs, 48 digital bidirectional channels and two pulse outputs with maximum output frequency of 80MHz.
• Multi-function acquisition card M-Series, type PXI-6723 has 32 analogue outputs, 8 digital bidirectional
channels and two pulse outputs with maximum output frequency of 20MHz.
Simulator user interface is situated on the computer, PC with MS Windows® operating
system, which is separated from the real-time controller and it communicates with the
real-time controller through a local area network.

16. Simulator
Connection
Turbine governor & Simulator
Turbine
governor

17. Opeartation Panel for Simulation
The operation panel is used to:
• start or stop the real-time simulation
• set some digital or analog input variables
• turn on certain system parts (bypass stations, generator breaker,...)
• monitoring simulator output signals such as electric power, rotation speed of the turbine or steam
turbine pressure

18. Conclusion
• Complete training system realistically reflects the behavior of the real system in all operating modes,
• Simulator enables training and testing of the plant personnel without any risk to the actual turbine
equipment and it is possible to simulate certain incidental states that rarely occur,
• More convenient to train staff how to behave in critical situations in the simulator than on real plant,
• This model can be integrated into other simulator tools,
• Further development of the described simulator will be reflected in the modeling of mechanical
measurements on the turbine (vibrations and shifts) and the temperature of the material in some parts of
turbine.

19. Thanks for attention
You may contact us at:
• Vesna Petkovski, Researcher
vesna.petkovski@pupin.rs
• Nikola Krajnović , Researcher
nikola.krajnovic@pupin.rs
• Miloš Stanković , Researcher
milos.stankovic@pupin.rs
• Nebojša Radmilović , Researcher
nebojsa.radmilovic@pupin.rs
• Željko Gagić, Main engineer for turbine facility
zeljko.gagic@tent.rs