Gas Turbine

Gas Turbine
Control & Protection
Control & Protection
Systems
Systems
by David Lucier
PAL Engineering
Control Systems
Control Systems
What must be
What must be

controlled
controlled

on
on
GE
GE
gas turbines?
gas turbines?

Turbine Shaft Speed

Turbine Shaft Speed

Rate of Change of Speed

Rate of Change of Speed
(a.k.a. Shaft Acceleration)

Exhaust Temperature
Exhaust Temperature

Rate of Change of Temperature

Rate of Change of Temperature

Air Flow through Compressor

Air Flow through Compressor

TNH units: RPM or % speed

TNH units: RPM or % speed
Acceleration: RPM/second or
% speed/second

TTX units:
TTX units:
Degrees Fahrenheit (
Degrees Fahrenheit (

F )
F )
Exhaust Temperature Rate: F per second

Airflow: lbs
Airflow: lbs
-
-
air per hour
air per hour
(actual flow not measured)
What devices
What devices
do the controlling?
do the controlling?

Liquid Fuel Bypass Valve

Liquid Fuel Bypass Valve

Gas Stop Speed/Ratio Valve

Gas Stop Speed/Ratio Valve

Gas Control Valve

Gas Control Valve

Variable Inlet Guide Vanes

Variable Inlet Guide Vanes
Modern GE
Modern GE
Control Systems
Control Systems
Mark IV Control Panel, TMR
Mark IV Control Panel, TMR
(1982
(1982

1989 Era)
1989 Era)
<R>
<R>
<S>
<S>
<T>
<T>
Mark IV Operator Panel
Mark IV Operator Panel
Mark IV Screen
Mark IV Screen
Mark V Control Panel, TMR
Mark V Control Panel, TMR
(1989
(1989

2000 Era)
2000 Era)
Human Machine Interface
Human Machine Interface
Original <I> versus New <HMI>
Original <I> versus New <HMI>
Human Machine Interface
Human Machine Interface
(Close
(Close
-
-
up of HMI Main Screen)
up of HMI Main Screen)
Typical
Typical
HMI
HMI
Screens
Screens
(Mark V)
(Mark V)
Control Principles
Control Principles
Minimum Value Select:
Minimum Value Select:
The control sub
The control sub
-
-
system
system

calling for
calling for

the
the
least
least
fuel flow
fuel flow
will be in command.
will be in command.
Simplified
Simplified
Minimum Value Select
Minimum Value Select
(18) TC (18) TC s s
%TNH %TNH
FSR FSR
Limits Limits
%TNH/sec %TNH/sec
TTXM TTXM
Min & Max Value Gates
Min & Max Value Gates
MIN (6 inputs) MIN (6 inputs)
MIN MIN
MAX MAX

Liquid Fuel Bypass Valve,

Liquid Fuel Bypass Valve, BPV

Gas Stop Speed/Ratio Valve,

Gas Stop Speed/Ratio Valve, SRV

Gas Control Valve,

Gas Control Valve, GCV

Variable Inlet Guide Vanes,

Variable Inlet Guide Vanes, IGV
Triple Modular Redundant (
Triple Modular Redundant (
TMR
TMR
)
)
(Speedtronic
(Speedtronic

Mark IV thru VI)

Mark IV thru VI)
> BPV > BPV
> SRV > SRV
> GCV > GCV
> IGV > IGV
TMR TMR
<R> <R>
<S> <S>
<T> <T>
Temperature Profile Diagram
Temperature Profile Diagram
(Base Load Operation)
(Base Load Operation)
3000 F
<

T
f
=

2
0
2
0

F
TTX = 1000 F
<
5
0
0

F
59F
<
4
5
F
<

T
e
m
p
e
r
a
t
u
r
e

>
solid line graph > solid line graph >
INLET INLET
EXHAUST EXHAUST
Pressure Profile Diagram
Pressure Profile Diagram
(Base Load Operation)
(Base Load Operation)
1
5
0

p
s
i
a

>
<

1
4
9

p
s
i
a
14.7 psia
14.7psia
14.3 psia
<

P
r
e
s
s
u
r
e

>
dotted line graph > dotted line graph >
INLET INLET
EXHAUST EXHAUST
Gas Turbine Start
Gas Turbine Start
-
-
up Curves
up Curves
%TNH
Fuel Stroke Ref, FSR
T
T
X

=

9
0
0

F

>
26%
19.5%
TTX = 550 F S
p
e
e
d
E
x
h
.

T
e
m
p
Speed
Fuel Stroke Reference
Fuel Stroke Reference
(FSR constants for Start
(FSR constants for Start
-
-
up)
up)
%

F
S
R

>

>
TIME, Seconds > >
Start-up FSR Algorithms
Constants List Constants List
Liquid Fuel
Liquid Fuel
Control Principles
Control Principles
Fuel Control Principles
Fuel Control Principles
Fuel Flow is proportional to:
Bypass Valve Position
&
Fuel Pump Speed
FFN = (%FSR) x ( %TNH)
Liquid Fuel Flow
Liquid Fuel Flow
TNH measured 0 to 100 % speed
FFN measured in frequency
(measure speed of flow divider)
FSR measured 0 to 100 percent
of Bypass Valve (full open to closed)
FFN = (%FSR) x ( %TNH)
Liquid Fuel Flow Principles
Liquid Fuel Flow Principles
Fuel Pump is driven by Turbine through
Accessory Gear Box (% TNH)
By-pass Valve Position is controlled by
SpeedtronicPanel (% FSR)
Flow divider speed is proportional to fuel
flow (FFN, gal/min)
Liquid Fuel Control Fundamentals
Liquid Fuel Control Fundamentals
FFN = (%FSR) x ( %TNH)
%FSR > < %TNH
< FFN < FFN
70.7 cps/gpm
- - - - - -> > - - - - - -> > - - - - - -> >
- -
- -
- -
> >
< < - - - - - - - - - - - - > >
- -
- -
- -
> >
Roper Liquid Fuel Pump
Roper Liquid Fuel Pump
& Bypass Valve
& Bypass Valve
< < <
< < <
<

<

<
<

<

<
> > > > > >
>

>

>
>

>

>
<< Fuel Bypass Valve << Fuel Bypass Valve
>

>

>
>

>

>
> > > > > >
IMO Liquid Fuel Pump
IMO Liquid Fuel Pump
S
c
r
e
w

P
u
m
p
S
c
r
e
w

P
u
m
p
Liquid Fuel Bypass Valve
Liquid Fuel Bypass Valve
Servovalve 65FP > Servovalve 65FP >
Bypass Bypass
Valve Valve
Flow Divider
Flow Divider
Speed Pickup (
Speed Pickup (
77FN
77FN
-
-
1
1
)
)
77FN 77FN- -1 > 1 >
F
low
D
ivider
F
low
D
ivider
Flow Divider
Flow Divider
Speed Pickups (
Speed Pickups (
77FN
77FN
-
-
2, 3
2, 3
)
)
7
7
F
N
7
7
F
N
- -
2
,

3

>

>
2
,

3

>

>
Flow Divider Characteristic:
60-tooth wheel
4600 cps = 65 gallons/min
Therefore, 70.7 cps per 1.0 gpm
Liquid Fuel Flow Calibration
Liquid Fuel Flow Calibration
(from GE Control Specifications)
(from GE Control Specifications)
Fuel Flow = .0085 (%FSR) x (%TNH)
1. Assume for firing fuel:
%FSR = 14
%TNH = 16
Firing Fuel = .0085 (14) (19)
Firing Fuel Flow Rate = 1.90 gpm
Liquid Fuel Flow Calibration
Liquid Fuel Flow Calibration
(from GE Control Specifications, ISO conditions)
(from GE Control Specifications, ISO conditions)
Fuel Flow = .0085 (%FSR) x (%TNH)
2. Assume for full speed/no load fuel:
%FSR = 14
%TNH = 100
Firing Fuel = .0085 (14) (100)
FSNL Flow Rate = 12.0 gpm
Liquid Fuel Flow Calibration
Liquid Fuel Flow Calibration
(GE Control Specs, ISO conditions)
(GE Control Specs, ISO conditions)
Fuel Flow = .0085 (%FSR) (%TNH)
3. Assume for Base Load Operation:
%FSR = 66.6
%TNH = 100
Firing Fuel = .0085 (66.6) (100)
Base Load Flow Rate = 57.2 gpm
Liquid Fuel Flow Calibration
Liquid Fuel Flow Calibration
(GE Control Specs, ISO conditions)
(GE Control Specs, ISO conditions)
Gas Fuel
Gas Fuel
Control Principles
Control Principles
Gas Stop Speed/Ratio & Control Valve
Gas Stop Speed/Ratio & Control Valve
Gas Fuel Control Fundamentals
Gas Fuel Control Fundamentals
P2
P2
P1 P1
P3 P3
Gas Fuel Pressure Gages
Gas Fuel Pressure Gages
P1 P1
P2
P2
P3 P3
Gas Stop Speed/Ratio (
Gas Stop Speed/Ratio (
SRV
SRV
)
)
& Gas Control Valve (
& Gas Control Valve (
GCV
GCV
)
)
< SRV < SRV
GCV > GCV >
P2 Pressure Transmitter
P2 Pressure Transmitter
(
(
96FG
96FG
)
)
P2, Pressure Transducer > > P2, Pressure Transducer > >
P1 P1
Gas Stop Speed/Ratio (
Gas Stop Speed/Ratio (
SRV
SRV
)
)
& Control Valve (
& Control Valve (
GCV
GCV
)
)
< SRV < SRV
GCV > GCV >
< 90SR < 90SR
< 65GC < 65GC
Servovalves
Speed/Ratio Valve Calibration
Speed/Ratio Valve Calibration
(from GE Control Specifications)
(from GE Control Specifications)
P2 = Speed Ratio (
% TNH
% TNH) Preset
P2 = .49
(
(
%TNH
%TNH) .50 P2 in DC volts
P2 P2
Speed/Ratio Valve Calibration
Speed/Ratio Valve Calibration
P2 = Speed Ratio (
% TNH
% TNH) Preset
96FG transducer calibration
96FG transducer calibration
0 to 5.0 DC volts = 0 to 300 psig
0 to 5.0 DC volts = 0 to 300 psig
P2 = 2.95 (%TNH) 30 in psig
Speed/Ratio Valve Calibration
Speed/Ratio Valve Calibration
(from GE Control Specifications)
(from GE Control Specifications)
P2 = 2.95 (%TNH) 30 in psig
At 100% shaft speed
At 100% shaft speed
P2 = 265psig, constant
P2 P2
Inlet Guide Vane
Inlet Guide Vane
Control Principles
Control Principles
Variable Inlet Guide Vanes
Variable Inlet Guide Vanes
(
(
VIGV
VIGV
)
)
I
n
l
e
t

G
u
i
d
e

V
a
n
e
IGV Actuator & Position Indicator
IGV Actuator & Position Indicator
<

I
G
V

A
c
t
u
a
t
o
r

>
<

I
G
V

A
c
t
u
a
t
o
r

>
I
G
V

A
n
g
l
e

>
I
G
V

A
n
g
l
e

>
IGV Control Fundamentals
IGV Control Fundamentals
Servovalve 90TV >
<

<

<

<

L
V
D
T
,

9
6
T
V
-
1
,

2
,

2
IGV Control
IGV Control
(Control air flow into compressor)
(Control air flow into compressor)
Servovalve 90TV >
R
V
D
T
R
V
D
T
20TV >
<

<

I
G
V

M
o
d
u
l
a
t
i
n
g

>

>
<

<

I
G
V

M
o
d
u
l
a
t
i
n
g

>

>
Summary of
Summary of
Control Principles
Control Principles
Summary of Control Systems
Summary of Control Systems
(System calling for
(System calling for

least
least

fuel controls FSR)

fuel controls FSR)
MVG MVG
<

6

I
n
p
u
t

S
i
g
n
a
l
s
<

6

I
n
p
u
t

S
i
g
n
a
l
s
FSR FSR
Min Fuel Min Fuel
Protection Systems
Protection Systems
Four Primary Protections:
Overspeed
Overtemperature
Loss of Flame
Vibration
Four Primary Protections (typical settings):
Electronic Overspeed: 110 % TNH
Mechanical Overspeed: 112% TNH
Overtemperature (~ 1000 F)
Loss of Flame
Vibration (1 inch/second, 5 mils peak-peak)
Triple Modular Redundant (
Triple Modular Redundant (
TMR
TMR
)
)
(Speedtronic
(Speedtronic

Mark IV & V)
Mark IV & V)
> BPV
> GCV
> SRV
> IGV
TMR TMR
Logic 0 or 1
<R> <R>
<S> <S>
<T> <T>
2/3 Voting
Many Secondary Protections including:
Low Lube Oil Pressure
High Lube Oil Header Temperature
Low Hydraulic Pressure
Generator Lockouts
Customer Added Protections
Other, as required
Protection Systems
Protection Systems
(High
(High
-
-
pressure Hydraulics)
pressure Hydraulics)
1200 psig
25 psig
L 4 trips >
Protection Systems
Protection Systems
(20 FG energize to run, de
(20 FG energize to run, de
-
-
energize to trip)
energize to trip)
Solenoid Valve
Deenergizes !
<

S
t
o
p

V
a
l
v
e
C
l
o
s
e
s

!

!
< L 4 trips
1200 psig
Redundancy by Association
Redundancy by Association
(Control & Protection Systems)
(Control & Protection Systems)
If operating on Liquid Fuel:
when stop valve closes,
the bypass valves goes to
full recirculation.
Protection Systems
Protection Systems
(If a trip occurs, BPV goes
(If a trip occurs, BPV goes
to 100% fuel recirculation)
to 100% fuel recirculation)
< < < <
<

<

<

<
>

>

>

>
>

>

>

>
1
0
0

%

f
u
e
l

r
e
c
i
r
c
u
l
a
t
i
o
n

>
S
t
o
p

V
a
l
v
e

C
l
o
s
e
s



>
> > > >
Flow Divider
Stops
[zero flow]
Redundancy by Association
Redundancy by Association
(Control & Protection Systems)
(Control & Protection Systems)
If operating on Gas Fuel:
when stop valve closes,
gas control valve also closes
immediately.
Protection Systems
Protection Systems
(If a trip occurs, both valves close)
(If a trip occurs, both valves close)
C
l
o
s
e

>
>
>
C
l
o
s
e

>
>
>
Redundancy by Association
Redundancy by Association
(Control & Protection Systems)
(Control & Protection Systems)
Inlet Guide Vanes:
When a trip occurs, IGV go toward
the closed position immediately
to prevent compressor surge.
Protection Systems
Protection Systems
(If a trip occurs, IGV Close)
(If a trip occurs, IGV Close)
2
0
T
V
d
e
-
e
n
e
r
g
i
z
e
s

>
<

<

<

I
G
V

C
l
o
s
e
R
V
D
T
Summary
Summary
(Control & Protection Systems)
(Control & Protection Systems)
Shaft Speed Control
Shaft Acceleration Control
Overspeed Protection
Exhaust Temperature
Rate of change of Temperature
Overtemperature Protection
Vibration
Loss of Flame
All Other Protective Devices
The End
The End
Thank you for
Thank you for
your attention!
your attention!
Questions ?
Questions ?