Gas Turbine Instrumentation

A.GNANASEHARAN, B.E.,
ASSISTANT EXECUTIVE ENGINEER/ C&I,
KUTTALAM GAS TURBINE POWER STATION,
TANGEDCO.
GAS TURBINE
A machine which transfers fuel energy into mechanical energy
AIR FUEL TO EXHAUST

SD LOAD
Starting
device HEAT WORK
COMPRESSION ADDITION EXPANSION DONE

By heating up compressed air expanding it in nozzles

mechanical/rotational energy is obtained
GAS TURBINE CYCLE (BRAYTON)
3
2 3

P T 2

4
4
1
1
V S

1 -2 COMPRESSION (COMPRESSOR)
2 - 3 HEAT ADDITION (COMBUSTION CHAMBER)
3 - 4 EXPANSION (TURBINE)
4 - 1 HEAT REJECTION
 WHY GT
GT is a mechanical driver can be used for driving,

Compressor
Generator
Ships
Air crafts
Pumps
Single shaft machines

Compressor & turbine are coupled to common single shaft

Normally used in process where less speed variation is required

Extremely suitable for generator drives

Due to large rotor mass the speed can easily be kept constant
 Two shaft machines
Nozzle

High pressure (HP) turbine & compressor are attached to one shaft

Low pressure (LP) turbine are attached to another

These machines provide wide speed range with sufficient power & efficiency

By varying nozzle angle speed control is achieved considerably

Well suited for mechanical drive (compressors & pumps )

More complex than single shaft machines (Ex. More no. of bearings)
GT should be protected from,
*Over temperature
*Over speed
*Loss of flame
*Vibration
*High pressure
*Fire

Hence control system plays vital role for safe running of GT

Any control system should be designed

# To crank the turbine

# Bring it to purging speed
# Fire it (Heat addition )
# Bring the unit to operating speed
# Synchronize the GT to Power Grid

These sequences must occur automatically

> A dedicated control system designed by General Electric (G.E ), U.S.A
> First Speedtronic system introduced in 1968
> The latest version of GE control system is Speedtronic Mark-V

Speedtronic system takes care of,

* Startup control
* Speed control
* Temperature control
* GT protection
* Control sequencing
* Smooth shutdown &
* power supply
 Objective of Speedtronic system
* Improved application flexiblity

* Enhanced operator interface

*A substantial decrease in GT outage rate

* Softening of the startup cycle

* High availability & reliability

This is achieved by distributing control functions among powerful

microcomputers.

These computers continuously monitor GT performance round the clock

Control concepts
Speedtronic system uses triple redundant configuration

There are 3 identical sections to carryout diagnostics

If one section fails the turbine continuous to run under control of

remaining sections

The failed section can be serviced and put back into service

The fourth section is for communication purpose

The 3 identical sections are named as <R>, <S>, & <T> which are powerful
microcomputers

The fourth section is named as <C> as communicator

Speedtronic Functional description

Analog Memory Analog

inputs outputs
Input Output
hardware Processor hardware Logic
Logic unit unit outputs
inputs
(contacts) Software CRT

Turbine mounted sensors monitors turbine operating conditions.

The input hardware unit converts the analog & logic signals from these sensors
into digital data for computation by the processor .
The processor(CPU) calculates the analog & logic signals,required control,
protection & sequencing of Gas turbine. The software (I.e. compute
program)defines this computation.
The output hardware unit then converts the digital results of these computations
to physical analog & logic signals to activate devices like solenoids
In general analog signals position servo valves and logic signals energize relays.
 SPEEDTRONIC SCHEMATICS
F *Each computers <R>,<S> & <T>
I are connected independently.
E <R>
L Contact * These computers are generally
D output mentioned as <RST> signifying that
Relay they are identical.
module
S <S>
I * All the critical sensors are distri-
G -buted among <RST> such that each
N section has an independent assessment
A of turbine conditions.
Valve
L <T> Servos * Sensors that are not critical to
control
S operations are brought directly into
<C> ,to avoid extra I/O and
processing in <RST>.
<C>
*GT will continuous to run even if
<C> computer fails.
OP. X-FACE
Voting function
*Output from 3 computers must be voted ordinarily 2 out of 3 are required
* Critical outputs (like trip command )will be issued only if 2 or all 3 of
<RST> computers indicates trip status.
<R> 1 1
AND 0 1
<S> 0 1
Trip command
<S> 0 1 00
AND 10
00 OR
<T>
<T> 0 0 00
<R> 1 1 AND
# If only one computer (Ex. <R>= 1 ) gives trip command output will be ‘0’
It will not do any trip function.
# If 2 computers ( Ex. <R>= 1,<S>= 1) give trip command output will be ‘1’
which will trip the GT.
* This configuration is called 2 out of 3 voting
 Logic voting
CIM 1-2 RELAY
RDM
OI <R> 2/3
OI <S> RD NO
Field NC
OI <T>
contact COM.
1/ 1
OI <C> RD
NO
CIM 3-6
NC
CIM - Contact Input Module. COM.
RDM - Relay Driver Module.

After logic execution output from <RST> computers going to relay driver module
Where it is getting hardware voted.
If 2/3 voting is true,trip command goes to de-energize the relay coil.Contacts from
this relay is used for final trip in the field.
There is no 2/3 voting for contacts from <C> computer.
Sequential control

CIM <RST> RDM

Switch

CIM : Contact Input Module RDM : Relay Driver Module

* The sequential control is achieved by ladder logic (like PLC system )

* Contact input module (CIM ) receives close or open status from GT

* Relay driver module ( RDM ) receives command signal from <RST>

computers and sends it to the final control element (like solenoid valves,
pumps etc.
 Sequential control
CIM 1-2 RELAY
RDM
OI <R> 2/3
OI <S> RD NO
Field NC
OI <T>
contact COM.
1/ 1
OI <C> RD
NO
CIM 3-6
NC
CIM - Contact Input Module. COM.
RDM - Relay Driver Module.
OI - Optical isolator.
Totally there are 6 contact input modules (CIM) .CIM 1-2 are used for <RST>
computers.Remaining CIM 3-6 are used for <C> computer.
All digital signals are isolated from the field by optical isolators, Where the
signals also triplicate.
Analog control

D/A SERVO
<RST>
VALVE

* Analog / continuous control is achieved by servo valves which has 3 coils

* Each computer drives one coil of 3 coil servo valve

* Digital signals from <RST> computers are converted into analog signals
by A/D converters before going to servo valves

# TWO coils are enough to operate the servo valves

Analog control

LVDT
Vibration Analog <R>
Pressure I/O
module
Speed Servo
<S>
valve
TCM<R>
T/C’s <T>
TCM<S>
Analog
TCM<T> <C> I/O
module
TCM
C1 -C3

All analog & Thermocouple (T/C) signals are connected to <RST> &
<C> computers via analog I/O & thermocouple cards.

Analog control takes place in <RST> computers. <C> computer gives

corrective or bias value for analog computation.
1.Maximum selector gate
A
A>B C
B

Analog input signals A & B are compared with one another.The logic output
C becomes ‘1’ if A is greater than B, else C becomes ‘0’.

2.Minimum selector gate

A
A<B C
B

Here C becomes ‘1’ if A is less than B else it becomes ‘0’

3.multiplier

A
AXB C
B

Analog signals A & B are multiplied , the result equals C

4.Divider
A
C
A/B
B

The output C equals the division of the inputs A & B

5.Median gate

A
Median Y
B
selector
C gate

This gate outputs intermediate value of inputs , I.e. it neglects minimum and
maximum value.In median gate minimum and maximum value is defined by user.
Control system

SPEEDTRONIC system consists of 4 major controls,

Fuel affecting control

Special control (Nozzle control, IGV control etc.)

Protection system ( speed, temperature, pressure, etc.)

Startup & shutdown sequence

 Protections : Flame,temp,pressure etc.
Protection DW
system Tx
FSR TNH
algorithm
Trip CPD
algorithm.
GCV
control
SRV TNH
control
T
N
P2 H

Fuel
SRV P2 GCV
Inter
valve
pressure
 SRV control
Fuel affecting control
GCV control

Fuel To combustion chamber

SRV GCV
SRV - Speed / Stop Ratio Valve
GCV - Gas Control Valve

Both SRV & GCV are SERVO VALVES which are operated by high pressure
hydraulic oil.

GCV is responsible for maintaining desired fuel flow.Basically it is a fuel

control valve
SRV does two functions,
1.It acts as a pressure regulating valve. Basically it is a pressure control valve
2.During emergency / normal shutdown it will be in full tight off position
in order to to stop any further flow.
Principle of SRV control

SRV TNH
control
software

Fuel P2 To combustion chamber

SRV Inter GCV
valve
pressure
SRV maintains downstream pressure P2, (called as inter - valve pressure) constant

‘SRV control software’ receives ‘TNH’ signal and maintains P2 according to

control algorithm.

If any trip occurs (TNH becomes zero) SRV becomes full tight shut off position
and does not allow any further fuel flow.
Nozzle angle control
Why do we need nozzle angle control ?

In single shaft machines depends upon the load condition turbine shaft speed
can be adjusted by modulating fuel flow & air flow.

But in 2 shaft machines HP & LP turbines are isolated.output hot gasses from
HP turbine enters into LP turbine through nozzles.

Hence by varying nozzle angle the amount pressure drop across each turbine
can be varied .

But nozzle angle control associates with these 2 algorithms to control exhaust
temperature.

This is achieved by controlling pressure drop across HP & LP turbines.

Protection system
Protection system takes care of safe running of gas turbine

It continuously monitors various GT parameters, if any parameter reaches

near danger limit it will give alarm to alert the operator. When it reaches
a predefined danger limit it will trip the GT.

Protection system takes care of

* flame detection

* over speed protection

* over temperature protection

* vibration protection

* combustion monitoring
Protection system schematics
Master Servo GCV
protection
Over speed valve
<R> 2/3
Over temp. Servo
SRV
<S> valve
Vibration 2/3

Flame out 2/3 SV

<T>

Master protection system for <R>,<S> & <T> computers receives

all the critical parameters from the field.
If the master protection system found any abnormalities it will give
trip command individually.
This trip command from all 3 computers voted 2 out of 3.
 Overspeed protection
Overspeed system is designed to protect the GT against possible damage
caused by overspeed of the turbine shaft.

Under normal operating conditions the speed of the shaft is the under the
control loop.

Overspeed protection

electronic overspeed protection (primary)

mechanical overspeed protection(secondary)

Electronic overspeed system
LATCH
TNH
A
A>B set Overspeed trip command
Overspeed
B
setpoint
Master reset reset

Electronic overspeed is achieved by computer software

Turbine shaft speed is measured by three magnetic pick up speed sensors

connected to <R> ,<S>&<T>, individually.
When the turbine speed (TNH) exceeds over speed set point it will issue trip
command through latch circuit.

Output will remain in trip status until master reset is done

Mechanical overspeed (secondary) system
It acts as a back up for electronic overspeed system

Since it is a back up system overspeed setpoint will be greater than electronic

overspeed setpoint

The mechanical overspeed trip system consists of

* overspeed bolt assembly

* overspeed trip mechanism

Overspeed bolt assembly acts as a sensing and feed back mechanism

Centrifugal force is used as a measure of force. Set point is adjusted by spring
force adjustment.

When the overspeed occurs centrifugal force will overcome spring force. The
resultant force will activate trip mechanism
This trip mechanism drains all the hydraulic oil from the servo valve circuit to
stop further fuel flow.
Flame detection

Fuel should not be allowed without flame existence.Other wise

GT should be tripped.

Flame detectors (Ultra violet scanners) monitor on the turbine and

generate logic signals depends upon flame condition
Flame detectors are utilized both in start up sequence and running
Totally there are 4 flame detectors mounted on the GT
If one flame detector detects flame the stressing sequence is allowed
to proceed. Conversely if one flame detector fails it allow the unit
continue to run but will alarm.
If both detectors detecting loss of flame the unit is immediately
shut down
Flame detection
<RST>
Flame
detector-1 Honey well
flame
Flame detector
To start up
detector-2 Flame
and
detector protection
Flame software
detector-3 Honey well
flame
Flame detector
detector-4
Analog
FIELD input/output
module
Flame detectors
Vibration protection

The vibration protection system of a GT composed of several

independent vibration measuring channel.
Each channel detects excessive vibration by means of vibration
pick up mounted on the bearing houses.

If a predetermined vibration level is exceeded the vibration

protection system trips the GT.
Vibration <RST>
pickup A/D Transducer
A A<B fault alarm
Analog Fault B
I/O
A A<B Alarm
Alarm B
A A<B
Latch Trip
Trip B
Master reset

Millivolt signal from vibration pickup <RST> computers via A/D

converter.
This vibration signals are compares with predefined constants to
generate trip and alarm signals.
Trip command is issued through latch circuit.Master reset
command is used to reset the system.
SPEEDTRONIC MARK - V
It is an advanced version of Mark-IV, introduced by general Electric in 1991.

The Speedtronic Mark-V control & protection system is based on microcomputers.

This system can be used for both single shaft & double shaft machines.

Triple redundancy I.e.3 redundant computers (<R>,<S> &<T> )is applied

for the essential control & protections.

A fourth non-redundant computer <C>,is used for the communication with

the operator interface <I>.
 MARK V - AN OVERVIEW

•3 Redundant computers <R> , <S> & <T> denoted by <Q>.

•<C> for communication.

•<P> for protection.

•<I> for operator interface.

•<BOI> for backup operation.(communication via backup net)

•Data exchange between <R> , <S> , <T> & <C> is done by DE net.
•Digital inputs &outputs are transferred to the respective locations
via IO net.
•Only one computer votes and if it fails another computer takes
over immediately.
 Functional description of Mark-V

Arithmetic
unit

Control
From
unit To
field A/D D/A
field
Memory

All the field signals are converted into digital form and then stored in the memory.
The memory also contains the program for Gas turbine control & instructions of
the system software.
The control unit executes all the programs with the help of Arithmetic unit.
The result of this digital operation is stored in the memory and then converted
into analog signals.
 Principle of Mark-V system

Logic inputs
Mark-V system uses Software Implemented Fault Tolerance(SIFT) technique.

This means all the 3 computers individually vote all 3 corresponding logic inputs.

Logic output
Logic output value is software voted by one redundant computer (the voter).
Only for the master protection system a hardware 2 out of 3 voting with relays
is executed in the protection module <P>.
The voted master protection signal (=trip signal) controls the power of trip
relays and solenoids.

Analog values
Analog inputs are converted into digital form , processed by the processor and then
converted back into analog form to actuate servos.
Principle of Mark-V

Analog I/P A/D D/A Analog O/P

<R>
Digital I/P 2/3 2/3 Digital O/P

A/D D/A
,, <S> ,,
2/3 2/3

A/D D/A
,, ,,
<T>
2/3 2/3

A/D D/A
,, <C> ,,
1/1 1/1
DE net
Mark-V system configuration

The major component of mark-V are,

<I> Computer
It is the operator interface,just like personal computer (PC) with color screen.

<BOI> Module
The backup operator interface communicates via a backup net with the redundant
computers <RST>.The malfunctioning of <C> or a unpowered <C> does not
affect this communication.

<C> Communicator
It is a common non-redundant computer.Mainly dedicated for communication
with <I> computer.Though if <C> fails the turbine can still be operated from
the <BOI>and is controlled by <RST> computers.

<RST> computers
These are 3 identical redundant computers.
<P>Module
This module is called protective module which acts as interface between
<RST> computers and field solenoids.
This module receives trip command from <RST> computers and performs
2 out of 3 voting . Then it issues trip command to field solenoids.

<CD> module
It is a digital I/O module of which digital input & output signals are routed
to/from <C> communicator.
This module provides 96 contact inputs and 60 contact outputs.

<QD1> Module
The digital I/O module of which the digital inputs & output signals are
routed to/from <RST> computers.
This module provides 96 contact inputs & 60 contact outputs .

* Analog inputs & outputs for <RST> are connected to terminal boards of
<RST>computers
MARK-V System configuration
<I>

<CD> Analog <C>

I/O

Analog <R>
I/O
Logic
Input/ <QD> <P>
output Analog <S>
I/O

Analog <T>
I/O
DE net