ModelingofGasTurbineandIts ControlSystem

DrMSRMurty

GasTurbineScheme

Brayton Cycle
Thecycleismadeupoffourcompletely irreversible processes:
12Isentropic Compression; 23ConstantPressureheataddition; 34IsentropicExpansion,and 41ConstantPressureheat T rejection

TemperatureEntropydiagram

Brayton Cycle
Airisfirstcompressedinanadiabaticprocesswithconstant entropywithinthecompressor(process12),usuallyanaxial compressor.Pressureof1320timesthatofatmosphericis achievedafterthecompressionstage. Fuel,eitherliquidofgasisthenmixedwiththecompressed airandburntinthecombustor(process23).Afterwhich,the hotgassesisallowedtoexpandthroughtheturbine(process 34).Thisgasexpansiondrivesthebladesoftheturbineand consequentlytheshaftofthegeneratorconnectedtoit.

TransferFunctionBlockDiagram: Rowens Model

GTControlsmodelled
Therearefourblocksrelatedwithspeed/load control,temperaturecontrol,fuelcontrol,and aircontrol. Speed/loadcontrol:determinesthefuel demandaccordingtotheloadreferenceandthe rotorspeeddeviation Temperaturecontrol: restrictstheexhaust temperaturenottoinjurethegasturbine.The measuredexhausttemperatureiscomparedwith thereferencetemperature.Theoutputisthe temperaturecontrolsignal.

GTControls
Thefueldemandiscomparedwiththe temperaturecontrolsignalinthefuelcontrol block.Thelowervalueisselectedbythelow valueselector,anditdeterminesthefuelflow Theaircontrolblockadjuststheairflow throughcompressorinletguidevanes(IGV) soastoattainthedesiredexhaust temperature.Theexhausttemperatureiskept lowerthanitsratedvalue(say1%).

AirflowControl
Theadjustableairflowisabout30%ofthe ratedairflow.Theadjustingspeedisslow comparedwiththefuelflow. Theairflowisproportionaltotherotorspeed.

GTOperatingparameters

Wf=fuelflow, W=theairflow,Te=Exhausttemperature, Tr =referencetemp.Tf =turbineinlettemp

GenerationofValveControlsignal

PowerOutput

Temperaturecontrol

RotorInertia

SimplifiedGTModel

PIDGovernorDetailedModel

Thedroopcircuitincludesan intentionalfiltertimeconstant, Td,of0.8s.

GTModelsinPSS/E

GASTGasturbinegovernormodel Simplemodel GAST2AGasturbinegovernormodel SimilartotheRowen model GASTWDGasturbinegovernormodel SuitableforWoodwardgovernors

GASTModelinPSS/E
Fuelvalveopening Flow

ExhaustTemp

R (speed droop)

T1 (>0) (sec)

Ambient temperature T2 (>0) (sec) T3 (>0) (sec) load limit, AT KT

VMAX

VMIN

Dturb

0.05

0.4

0.1

0.95

-0.05

StepchangeinSpeedReference

Eachdivision10Seconds

Eachdivision10Seconds

TwinShaftGT

PermanentDroopusingCDP
CompressorDischargePressure(CDP)rather thanvalvepositionorelectricalpower feedbackisusedforpermanentdroopsetting onsomeunits TypicalvaluesofCDPversusoutputpoweris showninthetable

Thediscontinuitybetween25% and40%poweriswhenthewater injectionandinletguide vanesgointoservice.

OnlineStep response

OfflineStepresponse

Typicalfrequencyresponsecurves

OUTERLOOPCONTROLS: Loadcontrol
Someunitsareoperatedwithanouterloop activepowercontroller.DigitalUnitController producesapulsetothegovernorraiseor lowerinputthatisproportionaltothe distanceawayfromtheMWsetpoint. Thegovernorisprogrammedtorampthe referenceatarateof0.3%/swhenreceiving thesepulses.

OuterLoopControl:pf/VAr Controller
Manygasturbineunitsareequippedwitha pf/VAr controllerwhichisinservicewhenever theunitisonline.Thisisanouterloopcontrol, whichmonitorsgeneratorstatorreactivecurrent andcontrolstoafixedVAr orpf setpoint. Thecontrollerisoftenusedinpf mode, controllingtounitypowerfactor. Thecontrolstructureisanintegratorwithgain feedbacktotheAVRsetpoint.

Pf/VARController
Toridethroughsystemtransientdisturbances, thecontrolshouldbeasslowaspossible, however,toolongasettingwillresultin operatorinterventionandovershootinthe resultingunitoperatingpoint.

Simulink Model
Ka T a.s+1 Step T ransfer Fcn Ke T e.s+1 T ransfer Fcn2 1 s+1 T ransfer Fcn1 Scope

Vt Kf.s T fa.s+1 T ransfer Fcn3 T o Workspace

Kr T r.s+1 T ransfer Fcn4 Clock t T o Workspace1

SIM ULAT ION OF AVR

AVR1_dat.m required

1.0
In1

1.0 Aligv
In1 Out1 In2

0.2 T re -KFuel T emp Control 0.3/T t

Out1

Tr1 1 s IGV T emp Control T hermo couple

In1

0.46 IGV limits

Out1 In2

0.46 IGV actuator Radiation sheild Txm1

In1 Out1 In2 In3

Wx

Scope1

Tx1
Out1

Tx3
Out1 In1

1 s

1/Tt Tre Fsrt Tm

Out1 In2

Tx
In1

Tx2
Out1 In2 In1 Out1 In2

Xnr Fsr
In1

0.23

VALVE POSITIONER
In1 Out1 In2

GAS FUEL SYST EM

In1 Out1 In2

min -KFUEL LIMITS Fb Fa Fc

Wg Xne

In2 Out1 In3

Fsrn Zg SPEED GOVERNOR ROT OR SPEED

Akf ROTOR 1 s n To Workspace1 T load

In1

Wf

1/T 1

Out1 In2

F2

FIG NO.

BLOCK DIAGRAM OF A GAS TURBINE

Scope t Clock To Workspace

SIMULATION OF GT GOVERNOR SYSTEM 1.009 Different positioner gains 1.008 1.007 1.006 Speed(p.u) 1.005 1.004 1.003 1.002 1.001 1 0.999

10

20

30

40

50 60 Time(Sec)

70

80

90

100

Combinedcycle
Heatenginesareonlyabletouseaportionof theenergytheirfuelgenerates(usuallyless than30%).Theremainingheatfrom combustionisgenerallywasted. Combiningtwoormore"cycles"suchasthe Braytoncycle (GasCycle)andRankinecycle (SteamCycle)resultsinimprovedoverall efficiency.

SimpleGTcycle
FUEL

AIR INLET

COMBUSTOR
EXH AU ST G AS

DRIVEN EQUIPMENT

COMPRESSOR

TURBINE

Combinedcycleplant

CombinedCycle(Brayton&RankineCycles)
EXHAUST GAS LOW PRESSURE STEAM (For Deaeration) AIR INLET FUEL INTERMEDIATE PRESSURE STEAM (To Intermediate Pressure Steam Turbine) COMBUSTOR GENERATOR HIGH PRESSURE STEAM (To High Pressure Steam Turbine) HEAT RECOVERY STEAM GENERATOR GENERATOR ELECTRIC POWER COMPRESSOR TURBINE

ELECTRIC POWER

HIGH INTERMEDIATE PRESSURE PRESSURE STEAM STEAM

STEAM EXHAUST

GAS TURBINE

STEAM TURBINE

CONDENSATE RETURN TO HRSG

HRSG
Steamisgeneratedbyfiring hotexhaustgasesfromGas turbines(GTs) Remainingsteamrequiredis generatedbyfiring Supplementaryfuel.

TypicalIndustrialCogenerationSystem
EXHAUST BYPASS SILENCER AIR INLET FILTER GENERATOR EXHAUST SILENCER DIVERTER VALVE

HEAT RECOVERY STEAM GENERATOR (HRSG) GAS TURBINE SUPPLEMENTARY BURNER

PROCESS STEAM

SteamTurbine

CombinedCyclePowerPlant

Captive Power Plant - General Overview

AUX BOILERS

NAPHTHA GAS OIL 8X30MW

4 x 125 TPH

Refinery Fuel Oil

GAS TURBINE

NAPHTHA GAS OIL

11KV

8 X 125 TPH

HRSG

33KV

TOREFINERY 11KV

4 X 30 MW STEAM TURBINE

TOGEB132/220kV

33KV

HPsteam42Kg/cm2 Power INSTALLED CAPACITY PRESENT GENERATION EXPORT TO GEB CAPABILITY 360 MW 269 MW 80 MW Steam MPsteam17Kg/cm2 1500 TPH 979 TPH -----------To Refinery

GAS TURBINES
5 Nos, GE Frame-6 machines supplied by BHEL, Hyderabad 3 Nos, GE Frame-6 machines supplied by NP, Italy. GT # 1 & 4 are having BLACK START CAPABILITIES. All gas turbines are capable to run at base load with spread well within the limit : MachineDesignoutputDesignoutputSiteoutput MW(ISO)MW(350C)(MW)

PG 6541 PG 6551 PG 6561

37.52 38.48 38.82

32.64 33.48 33.77

28.7 28.7 28.7

HRSG
HRSGloadwithGTatbaseloadinunfiredmode: HHPSteam(TPH) BHELHRSGs(06nos.) 5355 DBPSHRSG(01No.) 5355 ThermaxHRSG(01No.) 5355 HRSGloadwithGTatbaseloadinfiredmode: Steam(TPH)Design(TPH)Max(TPH) BHELHRSGs(06Nos.) 125 125NA DBPSHRSGs(01No) 125 125NA ThermaxHRSGs(01No.) 125 125134* (*Steamflowforonehourin08hrs.shift)

Steam Turbine
All 4 STGs are tested to deliver 30 MW of power. Steam turbines are provided with HP and MP extractions Maximum steam flow through one steam turbine shall be as follows
262 TPH HHP steam (Max) Pr: 109 Kg/CM^2 @ 505 DegC

MP 133 TPH

LP 60 TPH

60 TPH to Condenser (Max.) 20 TPH to Condenser (Min.)

180 TPH HP steam (Max) 149 TPH HP steam (Normal) Pr: 44.8 Kg/CM^2 @ 383 DegC 80 TPH MP steam (Max) 53 TPH MP steam (Normal) Pr: 18.8 Kg/Cm^2 @ 282 DegC

Normal steam flow HP section =15.27 MW MP section = 5.73 MW LP section = 11.81 MW

Auxiliary Boilers

All 4 Auxiliary Boilers are capable to deliver 125 TPH , at 115 KG/CM2(g) and 510 Deg C. 10 % overload margin i,e 137 TPH at 110 KG/CM2 (g) and 5100 C also tried for 01hr.

PRDS
Six PRDS are provided to supply HP, MP & LP steam to the process. PRDS is sized to meet the demand normally met by two steam turbines on the basis that one trips whilst another is out of service for maintenance. Design flow rates (TPH) of PRDS are : Min.NormalMax. HHPtoHP 21.480186.3 HPtoMP 24.947.4138 MPtoLP 9.134.9120 Startup&letdown 12.525 (HHPtoHP)

STEAM SYSTEM
BoilersNos.Nos.inoperationGeneration(TPH)
AuxiliaryBoilers HRSGs Total 4 8 12 4 8 12 500 880 1380

Auxiliary boilers able to ramp up 9 MT /Min/boiler in case of emergency without much pressure variation at HHP level Able to meet steam demand when both PRTs trip. Able to supply HP and MP steam, without pressure drop, if STG trips.

CPPGenerationandDistributionOverview
X 1321 1323 132kVRPLBUS 1322 132kVGEBBUS

1324 RIL

1325 RPL

1326

1327

GTG#8 G

GTG#3 G

GTG#2 G

STG#2 G

GTG#1 G

STG#1 G

STG#3 G

GTG#4 G

GTG#5 G

GTG#6 G

GTG#7 G

STG#4 G

A3 A4 A7 B4 B8 ESEE94101 A5 A6 B7

B10 B11 ESEE94102 A12

A4 A3 B5 B4 ESRU77201 A12

A7 A3 B11 B3 ESRU77202

MRS#1:BOARD#1

MRS#1:BOARD#2

MRS#2BOARD#1

MRS#2BOARD#2

RIL
BUSA
1.AROM.733CTA 2.PPSTRMA/BA 3.PPSTRMCA 4.AROM.PX.TR.1A 5.AROM.PX.TR.2A 6.AROM.TATORYA 7.AROM.PX.TR.3A 8.CPP941A

RPL
BUSB BUSA
1.SULPHERA 2.UTILITY2A 3.HYDRGNA 4.CRUDE14.4MWM 5.HYDJN5.75MWM 6.CRUDE1B 7.PLATFMR7.3MW

RPL
BUSB BUSA
1.CRUDE2A 2.RTFS/S2A 3.COKERB 4.RRTFA 5.PLATFMR7.3MW 6.CPP772A

RPL
BUSB BUSA
1.FCCB 2.HYDRJNB 3.UTILITY1B 4.CPP772B 5.RRTFB 6.PRT2FCC 7.FCC10MWM

BUSB
1.HYDJN5.75MWM 2.TNSHIPB 3.UTILITY2B 4.HYDJN5.75MWM 5.MTFL2C1 6.MTFL2C2 7.RTFS/S1B 8.FCCA 9.PLATFMR7.3MW

1.AROM.PX.TR.1B 2.AROM.PX.TR.2B 3.AROM.PX.TR.3B 4.PPSTRMA/BB 5.PPSTRMCB 6.AROM.TATORYB 7.AROM.733CTB

1.CRUDE2B 2.UTILITY1A 3.CRUD2,4.4MWM 4.SULPHERB 5.PLATFMR/HNUUB 6.RTFS/S2B 7.CPP941B

1.COKERA 2.TNSHIPA 3.PLATFMR/HNUUA 4.PRT1FCC 5.MTFL1C1 6.MTFL1C2 7.CRUDE14.4MWM 8.RTFS/S1A 9.CRUDE1A 10.CRUD2,4.4MWM

PowerPlantControl
Plantparametersaretobemaintainedby closedloopcontrol Boiler:Steamparameterslikepressure, temperature,otherprocessparameterslike furnacepressure,drumlevel Turbine Generator:Power(MW),speedor frequency

NeedforControl
Mismatchingenerationandconsumption causesdeviationinplantparameter Mismatchinsteamflow:pressurechange Mismatchinheatflow:temperaturechange Mismatchinpower:speedchange Mismatchingasflow:furnace.pr.change

ControlSystems
GTGControlSystem(GEMarkV) STGControlSystem(GHHBorsig) BurnerManagementSystem(ABPLC):48 FoxboroDCS

ControlSystems
DistributedcontrolSystem(Foxboro) 38nodes EmergencyShutdownSystem(Triconex) 26no. Fire&GasSystem(Wormald) 35no. MachineConditionMonitoringSystem(Bentley Nevada) 23no. AutomaticTankGaugingSystem(SAAB) 259no.

ElectricalLoadDistributionManagementSystem
Two major functions Load management System (LMS) Electrical Distribution Management System (EDMS) LMS functions: Load shedding Active/Reactive power control Synchronisation EDMS main functions: Data logging & reporting circuit breaker control Power System Event Recording & Alarm Annunciation's

CombinedCyclePlant:Schemefor Modeling

ModelofCombinedCycle PowerPlant