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Gas Turbines
Can be split into two main areas, Industrial Single Shaft Two Shaft Tend to be larger, less efficient but less maintenanceintensive. More robust. Aero-derivatives Multi-shaft (up to three) Typically very high speed Highly efficient High maintenance
Combustion Chamber
This section injects the fuel (gas or liquid) at the rate determined by the Control System, mixes it with the air from the compressor, and passes the resultant combustion gas (approx. 1200 degC) into the turbine section, where it is converted into mechanical work.
Brayton Cycle
This describes the chemical-mechanical energy conversion carried out by a gas turbine. The chemical energy in the fuel is converted into mechanical work by the compressor/combustion/turbine sections
Compressor
Power Turbine
Fuel Control Valve Trip Valve Basket Gas Generator Turbine
Combustor
Aero-Derivative Turbine
Combustor
Housing
Liner
Transition Duct
Fuel Nozzle
Fuel
Combustion Air
1000
5000
tT_XD_1 800 4000 tT_XD_3 tT_XD_4 tT_XD_5 600 3000 tT_XD_6 tT_XD_7 tT_XD_8 400 2000 tT_XD_9 tT_XD_10 tT_XD_12 200 1000 tT_XDT_1 tT_XDT_2 Spread rSPEED 0 33:12.889 34:39.289 36:05.689 37:32.089 38:58.489 40:24.889 0 41:51.289
Control Elements
Fuel Valves Modulate fuel flow to turbine fuel nozzles to control required parameter, eg acceleration, speed, load, temperature, etc. Variable Turbine Nozzles Not the same as fuel nozzles. These nozzles act to redirect first stage turbine exhaust gas onto second and third stage nozzles to change power distribution between the turbine stages. Typically utilised on twoshaft mechanical drive turbines
Control Inputs
Speed: Magnetic Pickups Passive Active Provide speed feedback to the control system for startup, speed control and on-line control Exhaust Temperature thermocouples Provide control and protection for the turbine to prevent the turbine internals from being too stressed and possible failing Compressor Discharge Pressure and Temperature Used typically to calculate the operating condition of the turbine, and to provide a reference for the exhaust temp control limit
What Is A Governor?
A device to provide accurate speed control for rotating machinery Older governors utilized rotating fly-balls with manual adjustments for frequency control Digital governors utilize electrical speed feedback devices such as magnetic speed pickups The actual speed is compared to a speed setpoint to provide tight speed control Once synchronized, a digital governor will provide accurate speed / load control over the full range of turbine operations
Startup Control
Main Features: 1. Bringing the machine to a minimum firing speed 2. Purging the compressor / turbine / exhaust plenum to ensure no fuel (liquid or gas) remains from the previous shutdown 3. Injecting minimum fuel and igniting (Firing). Flame is selfpreserving from this point onwards. Possibly utilize specific ignition fuel (eg Propane bottles) if primary fuel is difficult to light (eg some liquids) 4. Fuel limiting to prevent excessive internal turbine temperatures (Warming up) 5. Bringing turbine to minimum operating speed in preparation for synchronizing (connecting to the grid)
Speed Control
Main Features: 1. Run turbine shafts (HP and LP) such that minimum operating speed is maintained when off-line 2. Adjust turbine speed to match system frequency for Automatic Synchronisation 3. Speed adjustment for Overspeed Test utility
On-Line Control
1. 2. 3. Control split into three main types: Droop Isochronous MW PID Control
Droop Control
Most common mode of on-line control for Industrial Gas Turbines when paralleled with a utility Provides assistance to grid in the event of upset conditions that cause the system frequency to either increase or decrease (droop) Digital governors provide easily adjustable droop regulation Typical droop regulation is 4 ~ 6 % For a 4% droop regulated system, a decrease in system frequency of 4% will cause the governor to increase load by 100% The operator typically adjusts the droop speed setpoint to adjust the steady state load on the turbine, or adjusts a load setpoint, and the governor automatically adjusts the speed setpoint to attain the desired load
50 HZ
Isochronous Control
This mode means Constant Speed In this mode, the governor will attempt to keep the turbine frequency at the speed setpoint (typically Synchronous Speed) Except in special circumstances, it is not possible to run more than one machine in Isochronous when paralleled, otherwise one machine will pick up all the load, while the other unloads completely This mode is normally used by Isolated machines in order to keep a plant frequency steady. Load changes do not result in frequency changes, other than the transient speed changes when the load is picked up / dropped off The isochronous controller will adjust the governor output to return the system frequency to the frequency setpoint
50 HZ
Load
Auxiliary Systems
Lubrication oil Control oil Cooling Air Cooling Water Sealing Air Fuel (Gas and Liquid) NOx abatement (Water, Steam or Dry Low NOx technologies) Water Wash Fire and Gas Detection
Turbine Instrumentation
Magnetic Pickups
Typically at least duplicated on even simplex controllers Usually triplicated, sometimes 6 are present, 3 for control and 3 for over-speed protection Magnetic speed-wheel needs to be added to the turbine shaft in the case of mechanical governor retrofits (replacing mechanical linkages) Can be active or passive Also used on liquid fuel flow dividers to measure fuel flow
Switches
Can be used to alarm and trip the turbine in the event of a measured parameter exceeding allowable limits Critical examples are low lube oil pressure, high lube oil temperature, low control oil pressure Critical switches are typically triplicated in critical turbomachinery applications, non-critical usually simplex Modern retrofits often replace old switches with more reliable transmitters, improving reliability and parameter monitoring
Transmitters
Provide accurate feedback on a multitude of turbine parameters (pressure, temperature, level, etc.) Modern transmitters are more reliable than switches, having a lower PFD Multiple transmitters (2oo3) provide ideal replacements for unreliable existing simplex instrumentation
Safety Inputs
Speed pickups Automatically trip the turbine on over-speed conditions May be wired to a dedicated over-speed device, subject to end-user and regulatory requirements and standards Flame Detectors Provide loss of flame indication, prevent explosive atmospheres from forming from excessive unburnt fuel in the turbine Overspeed Mechanical Bolt Typically used as a backup device in the event of a Primary (Electric) over-speed trip failure to operate
Safety Elements
Trip Valve Immediately shuts off the fuel flow in the event of ANY trip situation arising Fuel Control Valve Shuts immediately on any trip condition, typically not gas tight, designed primarily for accurate fuel flow modulation into the turbine Vent Valve Bleeds off trapped gas in between the stop and control valves in a trip or shutdown condition Prevents gas from leaking through control valve into the turbine prior to the next turbine start