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    Gas Turbine Control System1 Nema

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    JJ
    The document describes the Speedtronic Mark IV gas turbine control system used at the Kawas Gas Power Project. Some key details: - The Speedtronic Mark IV system was developed by GE in 1982 and uses triple redundant microprocessor-based controllers to monitor, control, and protect the gas turbine. - It governs the turbine electro-hydraulically using signals from instrumentation like sensors, transmitters, and actuators. - The control system manages processes like startup, speed/load control, and temperature control to achieve the desired turbine output while keeping equipment safe.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Gas Turbine Control System1 Nema

    Uploaded by

    JJ
    835 views50 pages
    The document describes the Speedtronic Mark IV gas turbine control system used at the Kawas Gas Power Project. Some key details: - The Speedtronic Mark IV system was developed by GE in 1982 and uses triple redundant microprocessor-based controllers to monitor, control, and protect the gas turbine. - It governs the turbine electro-hydraulically using signals from instrumentation like sensors, transmitters, and actuators. - The control system manages processes like startup, speed/load control, and temperature control to achieve the desired turbine output while keeping equipment safe.

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    gas turbine control system

    Original Title

    72513718 Gas Turbine Control System1 Nema

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    The document describes the Speedtronic Mark IV gas turbine control system used at the Kawas Gas Power Project. Some key details: - The Speedtronic Mark IV system was developed by GE in 1982 and uses triple redundant microprocessor-based controllers to monitor, control, and protect the gas turbine. - It governs the turbine electro-hydraulically using signals from instrumentation like sensors, transmitters, and actuators. - The control system manages processes like startup, speed/load control, and temperature control to achieve the desired turbine output while keeping equipment safe.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    835 views50 pages

    Gas Turbine Control System1 Nema

    Uploaded by

    JJ
    The document describes the Speedtronic Mark IV gas turbine control system used at the Kawas Gas Power Project. Some key details: - The Speedtronic Mark IV system was developed by GE in 1982 and uses triple redundant microprocessor-based controllers to monitor, control, and protect the gas turbine. - It governs the turbine electro-hydraulically using signals from instrumentation like sensors, transmitters, and actuators. - The control system manages processes like startup, speed/load control, and temperature control to achieve the desired turbine output while keeping equipment safe.

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    © All Rights Reserved
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    Gas Turbine Control System

    Speedtronic Mark IV
    Kawas Gas Power Project
    NTPC Limited

    GAS TURBINE CONTROL SYSTEMS

    Gas Station

    GT Control System

    Auriya

    MIDAS 8000 (MHI)

    Anta

    Procontrol-P (ABB)

    Jhanor

    Procontrol-P (ABB)

    Dadri

    Teleperm-ME (Siemens)

    Faridabad

    Teleperm-XP (Siemens)

    Kawas

    Mark-IV (GE)

    Kayamkulam

    Mark- V (GE)

    CONTROL SYSTEM WORKS ?

    CONTROL SYSTEM FUNCTIONS


    Monitoring (Supervisory) :
    Provides measurement of all the process parameters like
    Pressure, position of valves , temp. , flow etc. It also provides
    alarms to the operator when required.
    Control (CLCS) :
    Controls the process parameters to achieve the desired
    output while keeping the equipments operating under
    designed limitations.
    Interlock/ Sequencing/Protection (OLCS) :
    Ensures safe and automated start-up logic. All the equipments
    do have certain limitations for operating parameters. If it
    crosses the limits, the system should trip / stop to prevent
    any damages.

    CONTROL SYSTEM SIGNALS


    Information and commands are transmitted in form of
    electrical signals. There are two types of electrical signals
    Analog signals
    Analog electrical signals have continuous values. They
    convey process information within a defined range. Normal
    industry standards are 4-20 mA current or voltage signals.
    These signals are employed in a CLCS.
    They follow arithmetic algebra for calculation of results.
    Logic Signals
    Logic signal are discrete values normally a 0 or 1. In
    electrical terms it can be attributed to presence or absence of
    voltage. These signals are employed in an OLCS. Boolean
    algebra is applicable for logic signal.

    GT Instrumentation

    Servo- valves (analog) and solenoids (logic)


    Speed Sensors (analog)
    LVDTs (analog) and Limit switches (logic)
    Spark plug (logic) and flame detectors (logic)
    Pressure transmitters (analog) and Pressure Switches
    (logic)
    Actuators (analog and logic)
    Thermocouples (analog) and temperature switches (logic)
    Level switches (logic)
    Fire sensors (logic) and Leak detectors (logic)
    Vibration sensors (logic)

    GT CONTROL SYSTEM AT KAWAS

    Control system used for Gas Turbines at Kawas is


    SPEEDTRONICS MARK IV. This system was developed by
    M/s GE, USA in 1982.
    The mark IV system is based on TMR control philosophy.
    INTEL 8086 & 80286 microprocessor based controllers
    ( microcomputers ) perform calculations required for the
    control , protection & sequencing of the gas turbine.
    For governing of the turbine electro-hydraulic technology
    is used.

    CONTROL PHILOSOPHY

    The main concept behind three redundant (TMR)


    controllers is for two-third voting concept.
    The design of each computer contains circuitry to achieve
    fail safe condition.
    On loss of power or when Trip condition occurs, it
    removes power from the coil.

    SPEEDTRONIC HARDWARE
    The SPEEDTRONIC panel comprises of following components.
    Three redundant controllers < R >, < S >, & < T >.
    These controllers are exactly identical in hardware &
    software.

    One communicator < C >.


    Signal processing/conditioning I/O modules
    Operator interface/Communication modules
    Relays
    Power distribution module and power supplies

    < R > < S > < T > CONTROLLERS

    Perform sequencing of auxiliaries to allow fully


    automated startup, shutdown, and cool down.

    Control of liquid, gas, or both fuels as per the


    requirements of
    Start-up and shutdown conditions.
    Speed or load control under part-load conditions.
    Temperature control under base load conditions.

    Inlet guide vanes and water injection control.

    Turbine protection against adverse operating situations.

    C- COMMUNICATOR

    Monitors the healthiness of the voting controllers


    < R >, < S > & < T > and initiates an audio visual alarm
    when there is disagreement between any control
    parameter / logic signal in <R>, <S> & <T>.

    Provides User-interface like CRT, Printer & Input


    commands.

    It contains diagnostic software, interface with logic and


    analog input & provides RS 232 link for remote interface.

    LOGIC INPUTS
    All the critical logic inputs from field are wired to Contact
    Input Module (CIM ) 1 or 2, where this signal is paralleled
    to the three optical isolators & fed to separate digital input
    cards in the < R >, < S > & < T > controllers.
    Communicator < C > feed these informations to the CRT.
    Logic i/p which are not critical, are fed to communicator
    < C > through CIM 3 to 6 after optical isolation.
    Optical isolation : A semiconductor device consisting of
    an LED & a phototransistor in close proximity. Current
    through the LED causes an internal light emission that
    forces current to flow in the phototransistor.

    LOGIC OUTPUTS
    2 out of 3 ( 2/3 ) logic voting for output signal is
    performed by Relay Driver Module (RDM).Here fail safe
    logic is implemented, means no power will result in safe
    condition.
    Non voted logic outputs are available through <C>.

    ANALOG INPUTS
    In Gas turbine control system all the analog inputs like,
    LVDT, pressure, vibration etc are fed to analog input ,
    output modules, AIO 1,2 & 3.
    For temperature measurement TCM modules are used.
    There is one module each for <R>, <S> & <T> controllers
    and two modules for communicator < C >.

    ANALOG OUTPUTS
    There are two types of analog outputs

    DC milliamp current from controllers,<R>, <S> & <T> to


    servo valves for functions such as liquid/gas fuel flow
    control and IGV control. If any controller fail remaining
    two will be able to drive the servo valve.

    4-20 mA and 0-10V DC analog outputs are also available.

    BRIEF DESCRIPTION OF HARDWARE


    The cards used in Mark-IV Speedtronic control system
    are as follows:

    HAFA: 16 Analogue and 32 Digital input cards.


    HAIC: 16 analogue input and [OPM] interface.
    HCMC: RS232 interface
    HCVA: Analogue output card (2)
    HIOD: 32 Digital I/O Board
    HPRB: 4 pulse rate input,
    HMPK: Microprocessor Card.
    HVDB: Video Driver Board, interface with CRT
    HXPD: CPU expander,PROM,16 digital I/O,8 interrupt
    NTCF: 14 thermocouple input per card
    NVCD: 6 vibration input per card

    BRIEF DESCRIPTION OF HARDWARE

    HSAA: Servo-amplifier,2 LVDT/servo channel per card.


    It is a interface between turbine control system and
    hydraulic actuator that positions the valve.

    Contact Input Module (CIM): 16 voting input connected


    to R/S/T and 32 nonvoting input to C.

    Analogue I/O module: It is used for remote analogue


    interface and passive filtering

    Thermocouple input module (TCM): TCM.R/S/T provides


    14 voting input to R/S/T. TCM.C1/C2/C3 gives 14
    nonvoting input to C.
    First input provides cold junction reference.

    FUEL STROKE REFERENCE (FSR)

    FSR is a fuel demand signal calculated by the control


    system to regulate the amount of fuel injection in the
    turbine. Independent FSR values are calculated for the
    following controls.
    1.
    2.
    3.
    4.

    Start up Control (FSRSU)


    Acceleration Control (FSRACC)
    Speed/Load Control (FSRN)
    Temperature Control (FSRT)

    All these FSR values are compared and the minimum value is
    passed to the fuel control valves.

    START - UP + ACCELERATION CONTROL


    This is an open loop
    controller which
    increases the
    FSR , as the
    turbine start-up
    sequence passes
    through
    pre- assigned states
    of Firing, Warm-up
    and acceleration.

    PART LOAD OPERATION


    During part load Gas Turbine is controlled by Speed/Load
    control algorithm.
    FSRN=(TNR-TNH)*Droop gain+ FSR FSNL

    where
    TNR- Speed Reference.
    Rate of change 0.4 or 0.8 % N/min
    TNH- Actual Speed
    FSNL FSR-14.5 %
    Droop Gain- 10.5 %/%N

    BASE LOAD OPERATION


    At base load the turbine control shifts to temperature control
    algorithm where
    FSRT (TTRX-TTXM)

    Where
    TTRX Exhaust Temperature Control Reference
    TTXM Actual Exhaust Temperature

    Exhaust Temp. Reference

    EXHAUST TEMPERATURE REF. (TTRX) CALCULATION


    600

    593

    590
    580

    593

    593

    585.752
    578.202

    570
    560

    570.652
    563.102
    555.552

    550
    540

    548.002
    540.452
    536.677

    530
    520
    5

    10

    CPD
    Isothermal Limit

    Exhaust Temp. Reference

    11

    FUEL SPLITTER

    FSR1 = FX1 * FSR (liquid fuel)


    FSR2= [100 FX1] * FSR (Gas Fuel)
    FX1= Fraction of Liquid Fuel [Range 0 100%]
    FX1=0% Means Total Gas Fuel.
    FX1=100% Means Total Liquid Fuel.
    Rate of change of FX1 i.e. ramp rate = FXK1 =
    1.6%/Sec (1 Minute for fuel changeover)

    Auto Fuel Change-over conditions


    UNIT RUNNING ON GAS FUEL
    Gas pressure low (17.5 Bar Before
    Stop Ratio Valve).

    Transfer to HSD

    VA 13-1,2 inter valve gas pressure


    High (>3 Bar, Time delay 40 Sec)

    Transfer to HSD, if not


    S/D after 45 Sec.

    UNIT RUNNING ON HSD


    HSD tank level low (2.0 Meters).

    Transfer to NGL/ARN

    Auto Fuel Change-over conditions


    UNIT RUNNING ON NAPHTHA FUEL
    Naphtha fuel pressure low - <3.0 Bar
    Naphtha tank level very low - <1.1 M
    Naphtha fuel flow low 1.8 Kg/Sec
    Both high tech pumps not running
    Hi-Tech tank level low 10 Min Delay
    Purge manifold liquid leak detection
    Atomizing air compressor DP low - <1.06 Bar

    88-BT ventilation fan trouble.


    <C> computer failure

    Transfer
    To
    HSD

    Tripping vs Normal Shutdown


    Tripping
    As soon as a tripping condition is detected, L4 i.e Master
    Protective logic signal gets dropped leading to immediate
    closing of the fuel valves and hence fast deceleration of the
    turbine.
    Normal shutdown
    In case of a normal shutdown order/condition, TNR (FSR)
    value decreases gradually to unload the unit till generator
    breaker opens at reverse power.
    FSR decreases further as per FSRMIN and fuel is totally cut off
    at the blow-out speed of 35%.

    INLET GUIDE VANE


    The guide vanes are installed at inlet to the compressor.
    They are used to direct and control the air flow to the first
    stage of the axial flow compressor.
    Variable compressor inlet guide vanes provide protection
    against compressor pulsation during turbine start - up and
    shut down.
    It facilitates proper exhaust temperature for combined cycle
    operation during partial loading of Gas Turbine.
    This variable inlet guide vane actuator is an hydraulically
    actuated assembly having a closed feed back control loop , to
    control the guide vanes angle.

    IGV TEMPERATURE CONTROL


    Variable compressor Inlet Guide Vanes modulate to maintain
    high exhaust temperature during part load for combined
    cycle operation.
    Initially during normal start-up the IGV is full closed, i.e.
    34 Deg. as proper temp corrected speed is reached IGV will
    open to a preset value, i.e.54 DEG, mini & remain at this
    position, until exhaust temp. condition asks for more opening
    If IGV temperature control is OFF, it starts opening from
    54 deg. To 84 deg at approximately 25 MW.
    If IGV temperature control is ON, up to 81 % load it
    remains 54 deg. , after that it is full open.

    SERVO VALVE DRIVER SYSTEM


    The gas turbine fuel control system will change fuel flow to
    the combustors in response to FSR.
    The servo system controls the fuel flow rate by means of
    an electro - hydraulic servo valve which ports high
    pressure hydraulic oil to either side of piston of an
    actuator as per signal. It is used to open & modulate or to
    close fuel passage in the fuel circuit.
    Thus servo valve is the interface between the electrical
    control system & the mechanical system. It converts an
    electrical signal to hydraulic output ( movement ).

    Thank You

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