Professional Documents
Culture Documents
on
Gas Turbine Instrumentation
List of contents
1.GT introduction
2.Why Instrumentation system
3.Speedtronic system
4.Control schemes
5.Protection system
6.Startup & shutdown sequence
7.MARK-IV Hardware configuration
8.Introduction to MARK-V
9.Difference between MARK-IV &MARK-V
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
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
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
These machines provide wide speed range with sufficient power & efficiency
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
The failed section can be serviced and put back into service
The 3 identical sections are named as <R>, <S>, & <T> which are powerful
microcomputers
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
D/A SERVO
<RST>
VALVE
* Digital signals from <RST> computers are converted into analog signals
by A/D converters before going to servo valves
LVDT
Vibration Analog <R>
Pressure I/O
module
Speed Servo
<S>
valve
TCM<R>
T/C’s <T>
TCM<S>
Analog
med I/O
TCM<T>
<C> module
TCM
C1 -C3
All analog & Thermocouple (T/C) signals are connected to <RST> &
<C> computers via analog I/O & thermocouple cards.
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’.
A
AXB C
B
4.Divider
A
C
A/B
B
Maximum C (t)
a(t) CLAMP
The analog output C (t) equals a(t) unless C(t) is limited by either the constants
specified as ‘Minimum’ or ‘Maximum’.
6.Median gate
A Median
B Y
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
Fuel
SRV P2 GCV
Inter
valve
pressure
SRV control
Fuel affecting control
GCV control
Both SRV & GCV are SERVO VALVES which are operated by high pressure
hydraulic oil.
SRV TNH
control
software
If any trip occurs (TNH becomes zero) SRV becomes full tight shut off position
and does not allow any further fuel flow.
SRV control
<RST> Error amplifier
+ +
TNH
- -
P2 Position feedback
Fuel
in SRV P2
Cylinder LVDT
Dump relay
Analog
Servo valve I/O module
SRV Characteristics LVDT Characteristics
P2
inter LVDT
valve output
pressure
TNH TNH
SRV control is designed such that inter valve pressure is linearly related
with TNH signal.
* TNH (HP shaft speed )signal is linearly related with inter valve pressure,P2.
*As TNH and P2 are linearly related, depends upon TNH, <RST> computers
maintains desired P2 by issuing proper command.
* The inter valve pressure signal P2 is compared with TNH signal and the error
signal (if any )is again compared with LVDT position feedback signal to
reposition the valve.
*In this way SRV maintains constant inter valve pressure, P2 depending upon
TNH signal.
During trip condition No
Gas SRV further
fuel fuel
Cylinder
Trip
oil Dump relay
Drain
Servo valve
Hydraulic oil in
* Whenever trip condition exist trip logic actuates the trip oil
*Trip oil intern actuates dump relay, which will drain all the high pressure
hydraulic oil to drain line.
* As there is no hydraulic oil SRV will suddenly come to shut off position.
Principle of GCV control
GCV - Gas Control Valve Fuel
Purpose : To maintain desired gas fuel flow. in
Start up control
Speed control Minimum
Acceleration control value
FSR GCV
Temperature control selector
signal
Shut down control gate
Manual control
There are six independent fuel flow control algorithms , continuously monitor
their own GCV opening ( generally called Fuel Stroke Reference - FSR ).
These six results are fed to a minimum selector gate, which selects lowest
among them.
In this way the lowest value is assigned to FSR (fuel Stroke Reference) signal
which determines Exact fuel flow to the gas turbine.
Brief over view
The fuel flow to the GT is always determined by the lowest value of the following
six FSR signal algorithms.
Startup control is a open loop control which increases FSR signal as the GT
startup sequence progresses to pre assigned plateaus.
First GT should be purged for blowing out present explosive fuel mixture
Once the purging is over startup control initiates firing command, wait for
sometime warm-up the engine and then gradually raise the fuel flow to
accelerate the GT.
100% Gradual raise of fuel
Warm-up takes place to
period
accelerate
to avoid thermal the GT
shock
FSRSU fuel level slightly decreased
Firing
startsFlame
35.6 detected
After warm-up period is over gradual raise of fuel takes place until the control
changeover to speed control loop.
Speed control
Objective
Fuel flow is adjusted by the speed control loop in such a way that the
load demand is maintained
Principle
TNH Speed Minimum
control select
TNR S/W gate
The speed control S/W will change FSR in proportion to the difference between
TNH and TNR
Droop mode
Speed control
Isochronoues mode
Droop mode :
This mode is generally used where the GT is coupled on a large grid system.
Clamper
FSR min FSRN
gate
+ + +
TNR _ _ _
The error signal between TNR and TNH is corrected by droop correction factor
and full speed no load level and then it is limited between 100 % and FSRMIN.
104
103
102 4%
101 Droop
100
% Speed
TNR
0% Load 100%
This means that the speed reference signal (TNR) range of 100% to 104%
corresponds to a load range of 0% to 100%.
So depends upon the load changes (0 - 100% ), speed reference signal (TNR)
will vary and control software takes corrective action.
As TNR is directly related with load it is also called load reference. In general
TNR is called as speed/load reference.
FSR max
FSRN
%
FSNL
0% Load 100%
100% TNR 104%
0% Droop 4%
In droop mode depends upon the load conditions speed reference signal (TNH)
is adjusted automatically.
The controller algorithm position the FSRN signal according to speed reference
change , which is a function of load.
Isochronous mode
This mode is generally used for the purpose of stand alone operation of
turbine - generator unit.
FSNL
TNR Control
software GCV GT
valve Generator
T
N
H Speed
sensor TNH
In this mode the speed set point TNR is always 100%
Here the generator load cannot be set by operator, the load is set by the consumer.
As the load increases TNH signal will come down.the error between TNR&TNH
will increase
As long as the error exist control S/W keep on increasing the output until it
reaches zero.
Temperature control
Objective
*Is to reduce the fuel flow to prevent overheating of the
*To maintain constant firing temperature.
NOTE
Highest temperature point takes place in the combustion chamber (around 1200 )
Isothermal line
Exhaust Constant firing temperature (Tf)
temperature
TTRX Tf = TTRX * (CPD)k
CPD
2.Firing temperature as a function of FSR/LOAD
Isothermal line
As Tf is constant just by measuring
Exhaust CPD or
Constant FSR
firing we can compute
temperature (Tf)
temperature
exhaust temperature TTRX . This signal can be used as the
TTRX Tf = TTRX * (FSR)k
temperature control reference value.
FSR
Temperature control
Temperature control algorithm receives actual exhaust temperature ,TTXM
from thermocouples.
The difference between set point & measured value (TTRX - TTXM) goes
as command signal to limit the exhaust temperature.
1 Reject
2 Receive Sort Reject
all 13 high
high all T/C Average TTXM
T/C &
to less than remaining
values low
13 low constant
T/C
Quantity
13 constant
<RST> computers receives 13 T/C readings and then it sorts out highest value to
lowest value.
Next it rejects all T/C’s less than some constant value.This step is to avoid bad
T/C values
Again it rejects highest & lowest values and then it calculates average of the
remaining T/C’s.The final output is called as actual exhaust temperature TTXM
Acceleration control
To prevent the over speed of the turbine if the load is rejected suddenly.
To limit the rate of change of turbine speed to reduce the thermal shock
constant Mini
+ FSRACC
- select
TNH controller +
gate
+
Z-1 +
FSR
This control compares the present value of the speed signal with the
value at last sample time(0.25 second)
The difference between these two values is the measure of
acceleration. If the acceleration is greater FSRACC is reduced
which will reduce FSR & consequently fuel to the GT.
Manual control (FSRMAN)
In this mode the operator can enter the value for FSR manually.
This mode is not often used , which means that FSRMAN = 100%
will be the default value
Hence FSRMAN acts as the upper limit (100%) for the FSR signal.
Lower
-1
Z
Lowering
Breaker open of FSR
First can out
Intercept Flame out
Start ramp
FSRMIN
% to blow out Fuel shutoff
FSR
time
How final FSR is calculated
<RST>
FSRSU
FSRSD FSRS1
Mini
FSRT
FSRN select
FSRACC gate
FSRMAN
min Median Final
FSRC select FSR to
max gate servo valve
<C>
FSRS1<R> Median
FSRS1<S> select FSRC
FSRS1<T> gate
Each individual computers <R> <S> & <T> generates their own FSR signal
from minimum selector gate.<C> computer provides corrective bias to <RST>
computer.Hence even if <C> fails GT will continue to run.
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.
-5 Full close
Full open condition
*There will be less back pressure and hence more pressure drop across HP
*HP turbine speed will increase
*LP turbine speed will decrease
Full close condition
*Back pressure will be more consequently less pressure drop across HP
*HP turbine speed will decrease
*LP turbine speed will obviously decrease
Hence by varying nozzle angle HP & LP turbine speed can be varied.
Reference set point calculation(TNRH)
Max
Min Median TNRH
TTRX select
-
+ gate
TTXM
Gain
TTRX is calculated from fixed firing temperature and CPD or FSR signal as
in the case of FSRT algorithm.It acts as reference exhaust temperature.
TNRH acts as reference signal for HP turbine. It also acts as reference signal
for maintaining exhaust temperature.
Nozzle angle control contd.
* flame detection
* vibration protection
* combustion monitoring
Protection system schematics
Master Servo GCV
protection
Over speed S/W valve
<R> 2/3
Over temp. Servo
SRV
<S> valve
Vibration 2/3
Under normal operating conditions the speed of the shaft is the under the
control loop.
Overspeed protection
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.
How tripping takes place?
The ultimate aim of trip circuit to shut off the fuel control valve to stop further
fuel flow
Trip command from <RST>computers activates trip oil circuit which finally
closes fuel shutoff valve
Trip oil is controlled by dump solenoid valves which are operated by trip circuits
this dump solenoidvalves are normally enerzised to run
Whenever trip condition exists dump solenoid valve get de energised to trip
This causes all the trip oil get drained. This in term will cause all the high pressure
hydraulic oil in the servo valve will get drained
As there is no hydraulic oil, the servo valve will go to shutoff position.
During running conditions, dump solenoid valves will be energized , trip oil will
alllowes high pressure hydraulic oil to actuate servo valves.
Trip oil schematics Normal condition
Trip condition
In certain failure modes however exhaust temperature and fuel flow can
exceed control limits.
The actual exhaust temperature TTXM is compared with alarm and trip
set points.
Alarm will be generated if TTXM exceeds the temp control reference TTRX
plus the alarm margin(constant 3).
TTXM A
Constant-3 B A>B Alarm
TTRX A A>B
Constant-2 B OR Trip
A A>B gate
Constant-1 B
Isothermal trip
TTXM Trip
Alarm
TTRX.
Ready to start
N Purge completed ?
Y
Firing timer is initiated, Firing FSR is set, Spark plugs are energized
N Flame detected
Y
No flame is detected
Trip A
A
Y
FSR is increased exponentially to accelerate limit
14HA
Ignition
14HM Flame
0 1 Boiler 5 10 15 20
Start Base
purge Loading
command load
Cranking
Shutdown sequence
B
B
Generator breaker
opens
0 1 5 10 15 20
Base Unloading Coasting
load down
What is Hardware ?
Hardware is an electronic circuit arranged in a specific fashion called a module
or a card
This card performs specific functions as directed by the software
The required software (I.e. our requirement) can be stored in any memory unit.
The hardware must be functioning correctly for the software to function properly.
<R>
Critical I/O To
I/O <S> module
signals module field
<T>
Non To
I/O
Critical I/O <C> alarm
module
signals module unit
All the critical inputs which are needed to keep the turbine running are
connected to <RST> computers.
All the non-critical inputs (just for monitoring purpose) are connected to <C>
All this functions are achieved by specific electronic cards (Hardware module)
which are residing in <C> communicator.
M A
1M 1A 1
2M 2A 2
<C> communicator cards
SLOT CARD NA,ME FUNCTION
1A HVDB VIDEO DRIVER DRIVES CRT DISPLAY
1B HCVA ANALOG INPUT OPTIONAL 2 ANALOG OUTPUT
1C HCVA ANALOG INPUT OPTIONAL 2 ANALOG OUTPUT
1D HCVA ANALOG INPUT OPTIONAL 2 ANALOG OUTPUT
1E HCVA ANALOG INPUT OPTIONAL 2 ANALOG OUTPUT
1F HCMA MASTER HIGHWAY OPTIONAL COMMUNICATION
1G HRMB BRAM BRAM - MEMORY STORAGE
1H HUMA UNIVERSAL MEMORY MEMORY STORAGE
1J HUMA UNIVERSAL MEMORY MEMORY STORAGE
1K HUMA UNIVERSAL MEMORY MEMORY STORAGE
1L HXPD EXPANDER MEMORY, INTERRUPT & LOGIC I / O
1M HMPF MICROPROCESSOR PROCESSOR FUNCTIONS & LOGIC OUTPUT
2A HCMA COMMUNICATOR OPTONAL - ADDITIONAL RS 232 LINK
2B NTCF THERMOCOUPLE OPTIONAL 16 T / C INPUTS
2C NTCF THERMOCOUPLE OPTIONAL 16 T / C INPUTS
2D NTCF THERMOCOUPLE OPTIONAL 16 T / C INPUTS
2E HAIC ANALOG INPUT 16 ANALOG INPUTS
2F HAFA AUXILIARY FUNCTION 14 ANALOG INPUTS & 32 LOGIC OUTPUTS
2G HMHA MASTER HIGHWAY COMMUNICATION
2H HIOD DIGITAL I / O 32 DIGITAL INPUT & 32 DIGITAL OUTPUT
2J HCMA COMMUNICATION RS 232 SERIAL DATA LINK TO <R> & <S>
2K HIOD DIGITAL I / O 32 DIGITAL INPUT & 32 DIGITAL OUTPUT
2L HCMA COMMUNICATION RS 232 SERIAL DATA LINK TO <T> & PRINTER
2M HIOD DIGITAL I / O 32 DIGITAL INPUT & 32 DIGITAL OUTPUT
<C> Interface diagram
L-BUS
HMPF
HXPD
Digital
HUMA RDM RELAY output
HIOD
3-6
HRMB
HAIC
HVDV Digital
CRT CIM
input
OPM
<R>
HCMA NTCF TCM
<S>
<T> HAFA
HCMA Analog
PRINT HMHA AIO input
Analog
HCVA output
<RST> computers
<RST> controller contains required software and hardware that will keep the
turbine running and perform a normal shutdown even if <C> fails.
F E D C B A
1
1F 1A
2F 2A 2
<RST> controller cards
Flame HAIC
HAFA
signal RDM Relay
Logic
Vibration NVCB outputs
HXPD
AIO
LVDT HSAA
Analog
output NVCA
Logic
Speed HPRB CIM
input
SPEEDTRONIC MAK - V
It is an advanced version of Mark-IV, introduced by general Electric in 1991.
This system can be used for both single shaft & double shaft machines.
•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
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
<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>
Analog <R>
I/O
Logic
Input/ <QD> <P>
output Analog <S>
I/O
Analog <T>
I/O
DE net
MARK - IV MARK - V
<R>
<R>
<S>
<S> <C>
<C>
<T> <T>
Difference between Mark-IV & Mark-V
MARK - IV MARK - V
<R>, <S> & <T> can talk to <C> <R, <S> < T> & <C> can talk via
independently DE net
MARK - IV MARK - V
All cards are plugged into their Mother board concept is not there.
respective mother boards. All cards are interconnected via
ribbon cables.