GE Infrastructure –Energy

Controls
Session 1- Control Logic and Applications

•Control Fundamentals
•Control Logic /Sequencing
•GT Control Schedules
•Next Generation

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2/9/2006
Control Fundamentals

Input System Output

r(t) G y(t)

Fuel/Air Gas Turbine Speed/Load

Or…
Set point Valve Flow
Or…
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Control Fundamentals
Considerations
Input Analog, Digital/Discrete,
Mechanical , Fluidic

System
G Linear, Non-linear system
Properties:Physical Gain, Inertia..
Time Invariant, or variant

Accuracy / Precisions
Outputs “Hard” or “Soft” limits boundaries
Outside Disturbance
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Control Fundamentals
Input Control System Output

r(t) K(s) G(s) y(t)

−
Feedback

Wiki Definition: “A control system is an interconnection of

components connected or related in such a manner as to
command, direct, or regulate itself or another system.”

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Show of hands?
Real world example:

“Cruise Control”

Logic: ON/ Off

Protection: Brake;Clutch;Speed
Setpoint: SET /COAST /RESUME
Feedback: Speed ; Throttle position
Output: Throttle Command 7/
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2/9/2006
Control- Boolean Logic
Logic: ON / Off Logic commonly shown as
Protection: Brake;Clutch;Speed “Rung Ladder Diagrams”
Set point: SET /COAST /RESUME
Feed back: Speed ; Throttle position Derived from physical electrical
Output: Throttle Command relay notation.

Boolean operations:

AND
A B Out
0 0 0
1 0 0
0 1 0
Normally Open contacts 1 1 1

Read as: 0= false or de-energized 8/

GE Title or job number /
1= true or energized 2/9/2006
 Control- Boolean Logic
NAND A B Out
0 0 1
1 0 1
0 1 1
1 1 0
Normally Closed contacts

OR A B Out
0 0 0
1 0 1
0 1 1
1 1 1

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Control- Boolean Logic
NOR A B Out
0 0 1
1 0 0
0 1 0
1 1 0

So back to cruise control… on /off

L_ON L_off Outlast Outnext

0 0 0 0
1 0 0 1
0 0 1 1
0 1 1 0
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Control Logic / Sequencing - Protection

Logic: ON/ Off Brake Clutch Throttle

switch switch actuator
Protection: Brake;Clutch;Speed
Set point: SET /COAST /RESUME
Feed back: Speed ; Throttle position
+
Output: Throttle Command
12V

Battery

Control and Protection are typically segregated to

improve reliability and minimize common mode
failures.….
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 Fundamentals- Linear controls
ON/OFF
Logic: ON/ Off
Brake/clutch
Protection: Brake;Clutch;Speed Throttle Command
Set/Accel
Set point: SET /COAST /RESUME Speed
Control
Feed back: Speed ; Throttle Position Throttle Position

Output: Throttle Command

How to control speed ???

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Fundamentals- Linear controls

K
Speed reference Throttle Command

K = Expressed as “% Throttle Command / Speed” or %/MPH

Could be a “constant” gain Linear ,or Array /table/ F(X) for Non linear

Linear Non linear

Throttle Position %

Throttle Position %

Speed MPH Speed MPH

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Fundamentals- Linear controls

r(t) K(s) G(s) y(t) r(t) K(s) G(s) y(t)

−

Closed Loop or Negative Feedback

Open Loop: Closed Loop:

• Simple
• Will “Always” will have an error
• Can have high gain if G (s) is large
• Variations in G(s) will cause change
in y
• y “tracks” r if stable and t=long
• Overall gain can be reduced
• More complex/expensive
• Possible instability if G(s) is large
• Variation in G (s) will have less
impact on y

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Fundamentals- Linear controls
+
K
Speed reference Throttle Command

- +
Speed measured

Throttle Position 1
Proportion +
1+TCs
Integral Action
Percent

First Order System

1TC = 67%
Time Constant

Time 15 /
GE Title or job number /
2/9/2006
Fundamentals- Linear controls
ON/OFF

Brake/clutch
Throttle Command
Set/Accel
Control
Speed
Throttle Position

Load..
Gear…
Uphill..
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You Ready ?
 GT Standard Droop Speed/Load Control
FSKRN2 FSKRN1
Fuel System MW
+ ++ FSRN FSR +
TNR X MIN Gas Turbine
- Generator N
Dynamics
TNH

Speed
I/O
Sensor

Rated
Base Load
100%
FSRN = FSKRN1 + FSKRN2(TNR - TNH)

FSKRN2
FSKRN1 = FSNL FSR

op
Rated

D ro
50%
FSKRN2 = Base FSR - FSNL FSR % FSR oo
p Load

op
2%
Dr

ro
% Droop 6%

D
Full Speed
FSKRN1 4% 0%
No Load

1% 2% 3% 4% 5% 6%
TNR - TNH
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Design Standard: http://inside-engineering.ps.ge.com/communities/engineering/case/desstds/GAS/SixX172/SevenX412/Bp1g/Bp1g.shtml
GT Constant Settable Droop Control
Constant Settable Droop Speed/Load

DWDROOP DWKDG
DWATT I/O
(DWKDTC)s+1

Fuel System MW
TNR TNRL FSKNG[(FSKNTC)s+1] Gas Turbine
FSRN MIN FSR
+
(FSKNTC)s Generator N
Dynamics

TNH

Turbine
I/O Speed
Sensor

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Analogous to cruise control ………….

TRIP SYSTEM …………….. Protection: Brake; Clutch ;Speed

http://inside-engineering.ps.ge.com/communities/engineering/case/desstds/GAS/SixX330/SevenX469/BP2H_TRIP/BP2H_TRIP.shtml

GT Load control ……………… Set point: SET /COAST /RESUME

http://inside-engineering.ps.ge.com/communities/engineering/case/desstds/GAS/SixX172/SevenX412/Bp5m/Bp5m.pdf

ST Isochronous control ……..Feed back: Speed ; Throttle position

Output: Throttle Command
http://inside-engineering.ps.ge.com/communities/engineering/case/desstds/LSTG/SixX85/SevenX241/Skcsi04/Skcsi04.shtml
A controls view

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 Critical Control Schedules
Legend: 99
How Controls sees/effects the World MWI (fuel temperature/composition) limits
10
10
Fuel supply pressure limits SPPM mode PM1 splits
IGV – critical 11
PPM mode PM1 splits
11 IGV Min/Max Schedule PPM mode D5 splits
effectors
88 PM mode PM1 splits
TTXM – critical
FPG2
IGV
(psig)
(F) sensors %
(Units) D5
SRV
TNHCOR
ATID
(F) PM1 TTRF1
AFPAP
(inHg) AFPCS
CTIM PM4
12
12 (inH2O)
(F) Comb
Rotor Torque Limit

~
Other Critical Control Parameters:
TTRF1 – surrogate for Tfire
C TNH T TNHCOR – inlet temp-corrected speed
(%) CPR – compressor pressure ratio

DWATT CPD
(MW) IGV (psig)
CTD TTXM
(F) (F)
11 IBH 77
Compressor OLL 33 Backup Exh T Curve
66 Peak Exh T Curve
Inlet Anti-icing
CPR
55 Part Exh T Curve
TNHCOR 22 DLN IBH schedule 44 Base Exh T Curve
IBH
IGV TTRX
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IGV 2/9/2006
CPR
11

Compressor Operating Limit

Physical Limits Defined:
- n% Stall Margin, implicit Cm/U Compressor OLL
Defined by:
Compressor Aero, defined in DM for engine
CPR
Adjustment:
No requisition-specific adjustment

Typically Limits:
Cold day base/part load heat rate
TNHCOR
Opportunities:
(For stall margin-limited engines like FB, reduce deteriorated stall margin by
taking advantage of Model-Based controls)
IGV
New EPROM GHD 1.8&2.8
First Action
CSGV CX7FXXXX

CPRLIMN CPRLIM + + CPRERR CPRERR < 0.00 Increase

X Operating Limit Bleed Heat
TNHCOR _ _ 0 - 5%

Second Action

CPRERR < -0.1 Bias TTRXGV

CPKRLIM G Operating Limit
(Open IGV)

CPD
CPRV2 Third Action
AFPAP CPR
CPRERR < -0.35 Bias FSR
AFPCS Operating Limit
(Lower FSR)

(CPR_MEAS) Forth Action

CPKERRO
CPRERR < -0.45 Trip Gas
Operating Limit 23 /
Turbine GE Title or job number /
2/9/2006
Compressor Operating Limit- IBH portion 100%
IBH Analog Select Green = IBH Floor Logic
H Blue = CPR ERR Logic
CX7FN940 CPR_FSR_LIM 100% IN1
CSGV CPR A
L3BHF3 L1
CPRLIMN csrih B CSRPRX0
IN2 OUT
A OUT 0% MAX
TNHCOR CPRLIM
3-D Lookup A*B C (B / (TC s +1)) + LCSRENI L2
(C - A – 0.25) *
CPKRLIMG B CSKRPRTC CSRBHFX
TC PG CSRPR IN3
(2 sec) CSRPRX1
PG
L L3
Interp
LTRUE
ABS (CPRERR) 1st True Sets Output
CSRPRX1
3%
CSKRPRGE CSKRPRG 100%
CSKRPRGV MAX
3-D Sched
H
CQBHP
PV
CSKBHFMNREF
(0,5%) CSRBFRTLM
SP P+I Reg
CSRBHFX
TNH_NORM Interp MAX CSRBHF1 csrih OUT
INT_IN
CSRBHF CSKBHF_G (10)
KTHNORM CSRPRX1
PG
KCSRBF CSKRBHF_TC (2) CSRPRX2 CSRPRX
3-D Sched
IG (0-100%)
CSRBHF1 L COPY

EN
0%
T CSRBHF2
CSRDLNX
MAX
INRATE
0 lbm/s F LIMIT
~L83FXP1 (DLN Trndwn
IN
-0,25 F/s Lower TD LCSRTRI IBH Req’mnt)

CSRBHF 30 s T
A 0,5 F/s Upper CSRIH
A>B
(hold last value during premix (0-100%)
L3BHF_EN
CSKBFMNSP (0.25%) B
transient mode + 30s) To valve
CSKBHFHYS (0.15%)
Hysteresis
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Compressor Operating Limit

EPIC tm
Implementation

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 Base Load Exhaust Temperature Control

Fuel Control for Base Load Operation

Target Firing Temperature
Performance vs. Emissions
Ambient Range
Hot Day
Isotherm
Exhaust Temperature

Rated Day

Cold Day

Compressor Pressure Ratio

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44

Base Load Exhaust Temperature Control

Physical Limits Defined:
- HGP temperatures (Tfire) Isotherm
- Exhaust duct & HRSG temperature limits Slope
Break Point
- NOx
- (On some engines, last stage bucket temp limits)
Break Point
Part 0
Defined by:
- Applications
- Performance
Part 1
- Combustion
- Turbine Engr. Part 2

Adjustment: Corner
- Requisition-specific curve (GTP-generated for site- Control Constants:
unique product configurations) TTK0_I = 1200 degF (Isothermal limit)
- Adjusted during integrated tuning TTK0_S = 26.757 degF/pr
TTK0_C = 13.321
Typically limits:
Base load output & heat rate TTKRXBP = 15.353
TTK1_I = 1200 degF (Isothermal limit)
Opportunities: TTK1_S = 22.772 degF/pr (Slope)
Improve cold day base load output by managing TTK1_C = 12.966 (Corner)
combustion boundaries by other means (splits).
TTKRBP2 = 16.511
TTK2_I = 1200 degF
TTK2_S = 41.176 degF/pr
TTK2_C = 14.550

TTKXCOEF_1 = 0.990 (Partload exhaust temp profile effect)

TTKXCOEF_2 = 1.000 (Baseload exhaust temp profile effect) 27 /
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 Part Load IGV Temperature Control
Independent IGV Control
DLN Considerations:
Emissions Turndown
Temperature Control Dynamics
Curve
Exhaust Temperature

Base
Load

Part Load Temperature Control

Compressor Pressure Ratio

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55

Part Load Exhaust Temperature Control

Physical Limits Defined:
- HGP temperatures (Tfire)
- Exhaust duct & HRSG temperature limits
- NOx
- Combustion dynamics (Pk1, Pk2)
Bias down setpoint for
Defined by: Tcd lower than 763.1
- Performance
- Combustion
- Turbine
- Customer (HRSG)

Adjustment:
- Requisition-specific curve
- Adjusted during integrated tuning Control Constants:

Typically limits: TTK0_I = 1200 degF (isothermal limit)

Cold day base/part load heat rate
TTKGVC_0 = TTKGVI_0 =
Opportunities: TTKGVC_1 = 13.8037 TTKGVI_1 = 1183.9 degF
Improve part load heat rate by opening IGV’s further TTKGVC_2 = 16.5467 TTKGVI_2 = 1120.143 degF
with Model-Based Control, managing combustion TTKGVC_3 = 17.000 TTKGVI_3 = 1115.4 degF
boundaries through other means
TTKGVTCDO = 763.1 degF (CTD offset)
TTKGVTCDG = 0.65 degF/degF (lower Tx by this much per
degree CTD below offset)

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New Directions….
ARES Model Based Controls
IGV Wf
Air Flow

Generator Compressor Turbine Exhaust Flow

DPin
CTD Tx DPex
DWATT CTIM Pamb
CPD
CMHUM

Fundamental Tuning Inputs

Inputs DWATT y
PAMB, DP-inlet, DP-exhaust, TTXM
On-Line Partial Derivative Calculation
SPHUM, TAMB, CTIM, CPD
IGV, XBH, W-FUEL, CTD Norm
Primary Outputs
u

Partial Calc.
T-FUEL, SPEED, DWATT_MOD
S1NA, PFACT TTXM_MOD
z ARES
a, h

Norm
CPD_MOD x̂ prt Model
u CTD_MOD
ŷ ẑ
+

ARES Norm _

x̂ Model ŷ ext
On-Line Filter Gain Calculation

P = a ⋅ P ⋅ aT + Q (Covariance of
Prediction Error)

x̂ + s = h ⋅ P ⋅ hT + R (Covariance of
Norm

Residual)
K
State Estimate
+ K = P ⋅ hT ⋅ s −1 (Gain Matrix)

KCMP_ETA (Covariance of
KCMP_FLW Z-1 P = P − K ⋅h⋅P Prediction Error)

KTRB_ETA
KF_FLW

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MPC Problem
HP & IP maximum rotor stresses
Final CC load

MPC controller GT load

reference
GT, HTSG, ST models Optimize Mark VI
HP & IP rotor stresses GT loading Controls
over next Update GT
hour reference
Adjust models every every 30 sec
State estimation 30 sec

Measurements Measurements
Steam & metal Temperatures, Steam Pressures

Calculate the optimal GT loading to minimize time

to reach 100% load Load

While 25 minutes
– HP rotor surface stresses at 1st stage < 100%
– HP rotor bore stresses at 1st stage < 100 %
– IP rotor surface stresses at 1st stage <100 %
– IP rotor bore stresses at 1st stage <100%
– GT load rate < 8 % /min
Stress
constraints
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Architecture for Model Based Sensor Selection
Common Approach Being Pursued by GEAE, GEE:
• Based on stochastic principles
• Address measurement noise
Real Engine
• Address modeling error
Sensor Output, Channel A, B • Provides on-line statistical information
control
signals
• Utilization of on-line cycle model to fuse all
u
sensors - more accurate predictions of sensed
outputs.
Engine Model Predicted
sensor
output
Sensor Selection
Logic Using
Model Outputs
To Control
Logic

Selected Sensor
Self-Tuning Filter - + Values & Fault Codes
State Estimation
& Tracking

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 MBC… Not Just For Gas Turbines
Incorporating Domain Smarts into Control

Gas Turbine Steam Turbine Wind Turbine

3Q05

MPC Model-Predictive Reduced

Control 3Q08 Start Time

Output, HR, A10

Gen II - Model /D11 4Q07
Reliability
Based Control 2Q06
MBC / 9FB
ACC Output & -2A Increased
Gen I - Model Energy Capture
2Q05 Heat Rate
Based Control
7FA 2.x
Expanded GE15
CPC Corrected
Compliance
Parameter Control 7FA
7EA
9FB-1A
Rules-based, Indirect 7FA A14/A15
Non-CPC
Boundary Control 9H 6B
9FA 9FB-1 9E

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Power Plant Configuration
HMI HMI
Operator Stations
• Unit Control <HMI>
• Historian
Plant Data Highway

Control Software
Historian • Cimplicity™
• Toolbox™
Unit Data Highway

Control Application
• Gas Turbine
Mark VI Mark VI EX2100 LS2100 GP2100 Mark VI EX2100 GP2100 • Generator
HRSG GT GT GT GT ST ST
ST • Static Starter
• Generator Protection
• Steam Turbine

G T GEN S T GEN

HRSG

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