Gas Turbine Control System

Speedtronic Mark IV
Kawas Gas Power Project NTPC Limited

GAS TURBINE CONTROL SYSTEMS

Gas Station Auriya Anta Jhanor Dadri Faridabad

GT Control System MIDAS 8000 (MHI) Procontrol-P (ABB) Procontrol-P (ABB) Teleperm-ME (Siemens) Teleperm-XP (Siemens)

Kawas
Kayamkulam

Mark-IV (GE)
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 TEMPERATURE REF. (TTRX) CALCULATION

Exhaust Temp. Reference

600 590 580 570 560 550 540 530 520 5 6 7 8 CPD
Isothermal Limit
585.752

593 578.202 570.652

593

593

563.102 555.552 548.002 540.452 536.677

10

11

Exhaust Temp. Reference

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). VA 13-1,2 inter valve gas pressure High (>3 Bar, Time delay 40 Sec) Transfer to HSD 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 Transfer To HSD

88-BT ventilation fan trouble.

<C> computer failure

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 ).

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