GT Control & Protection Systems

8/13/2019 GT Control & Protection Systems

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Gas TurbineGas Turbine

Control & ProtectionControl & Protection

SystemsSystems

by David Lucier

PAL Engineering


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Control SystemsControl Systems


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What must beWhat must be

controlledcontrolled

onon GEGEgas turbines?gas turbines?


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Turbine Shaft SpeedTurbine Shaft Speed

Rate of Change of SpeedRate of Change of Speed(a.k.a. Shaft Acceleration)

Exhaust TemperatureExhaust Temperature

Rate of Change of TemperatureRate of Change of Temperature

Air Flow through CompressorAir Flow through Compressor


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TNH units: RPM or % speedTNH units: RPM or % speed

Acceleration: RPM/second or

% speed/second

TTX units:TTX units:Degrees Fahrenheit (Degrees Fahrenheit ( F )F )

Exhaust Temperature Rate:F per second

Airflow: lbsAirflow: lbs--air per hourair per hour

(actual flow not measured)


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What devicesWhat devices

do the controlling?do the controlling?


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Liquid Fuel Bypass ValveLiquid Fuel Bypass Valve

Gas Stop Speed/Ratio ValveGas Stop Speed/Ratio Valve

Gas Control ValveGas Control Valve

Variable Inlet Guide VanesVariable Inlet Guide Vanes


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Modern GEModern GE

Control SystemsControl Systems


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Mark IV Control Panel, TMRMark IV Control Panel, TMR(1982(1982 1989 Era)1989 Era)


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Mark IV Operator PanelMark IV Operator Panel


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Mark IV ScreenMark IV Screen

M k V C l P l TMRM k V C t l P l TMR


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Mark V Control Panel, TMRMark V Control Panel, TMR

(1989(19892000 Era)2000 Era)

h fH M hi I f


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Human Machine InterfaceHuman Machine InterfaceOriginal versus New Original versus New

H M hi I fH M hi I f


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Human Machine InterfaceHuman Machine Interface(Close(Close--up of HMI Main Screen)up of HMI Main Screen)

l


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TypicalTypicalHMIHMI ScreensScreens(Mark V)(Mark V)


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Control PrinciplesControl Principles


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Minimum Value Select:Minimum Value Select:

The control subThe control sub--systemsystem

calling forcalling forthethe leastleastfuel flowfuel flow

will be in command.will be in command.


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SimplifiedSimplifiedMinimum Value SelectMinimum Value Select

(18) TC(18) TCss

%TNH%TNH

FSRFSRLimitsLimits

%TNH/sec%TNH/sec

TTXMTTXM


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Min & Max Value GatesMin & Max Value Gates

MIN (6 inputs)MIN (6 inputs)

MINMIN

MAXMAX


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Liquid Fuel Bypass Valve,Liquid Fuel Bypass Valve, BPV

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

Variable Inlet Guide Vanes,Variable Inlet Guide Vanes, IGV

T i l M d l R d d t (T i l M d l R d d t (TMRTMR))


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Triple Modular Redundant (Triple Modular Redundant (TMRTMR))(Speedtronic(SpeedtronicMark IV thru VI)Mark IV thru VI)

> BPV> BPV

> SRV> SRV

> GCV> GCV

> IGV> IGV

TMRTMR

T t P fil DiT t P fil Di


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Temperature Profile DiagramTemperature Profile Diagram(Base Load Operation)(Base Load Operation)

3000 F

INLETINLET EXHAUSTEXHAUST

P P fil DiP P fil Di


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Pressure Profile DiagramPressure Profile Diagram(Base Load Operation)(Base Load Operation)

150psia> dotted line graph >

INLETINLETEXHAUSTEXHAUST


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Gas Turbine StartGas Turbine Start--up Curvesup Curves

%TNH

Fuel Stroke Ref, FSR

TTX=900 F>

26%

19.5%

TTX = 550 FSpee

dEx

h.Tem

p

Speed

Fuel Stroke ReferenceFuel Stroke Reference


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Fuel Stroke ReferenceFuel Stroke Reference(FSR constants for Start(FSR constants for Start--up)up)

%FSR>

>

TIME, Seconds > >

Start-up FSR Algorithms

Constants ListConstants List


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Liquid FuelLiquid Fuel



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Fuel Control PrinciplesFuel Control Principles

Fuel Flow is proportional to:

Bypass Valve Position&

Fuel Pump Speed

FFN =(%FSR) x ( %TNH)


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Liquid Fuel FlowLiquid Fuel Flow

TNHmeasured 0 to 100 % speed

FFNmeasured in frequency

(measure speed of flow divider)

FSRmeasured 0 to 100 percent

of Bypass Valve (full open to closed)

FFN=(%FSR) x ( %TNH)


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Liquid Fuel Flow PrinciplesLiquid Fuel Flow Principles

Fuel Pump is driven by Turbine through

Accessory Gear Box (% TNH)

By-pass Valve Position is controlled bySpeedtronic Panel (% FSR)

Flow divider speed is proportional to fuel

flow (FFN, gal/min)

Liquid Fuel Control FundamentalsLiquid Fuel Control Fundamentals


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Liquid Fuel Control FundamentalsLiquid Fuel Control Fundamentals

FFN=(%FSR)x ( %TNH)

%FSR > < %TNH

< FFN< FFN 70.7 cps/gpm

-- -- -->> -- -- -->> -- -- -->>------

>>>

------>>

Roper Liquid Fuel PumpRoper Liquid Fuel Pump


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p q pp q p

& Bypass Valve& Bypass Valve

>>

>>>

>

>>>

> > >> > >

IMO Li id F l PIMO Li id F l P


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IMO Liquid Fuel PumpIMO Liquid Fuel Pump

ScrewPumpScrewPump

Li id F l B V lLiquid Fuel Bypass Valve


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Liquid Fuel Bypass ValveLiquid Fuel Bypass Valve

Servovalve 65FP >Servovalve 65FP >

BypassBypass

ValveValve

Flow DividerFlow Divider


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Flow DividerSpeed Pickup (Speed Pickup (77FN77FN--11))

77FN77FN--1 >1 >

FlowDividerFlowDivider

Flow DividerFlow Divider


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Speed Pickups (Speed Pickups (77FN77FN--2, 32, 3))

77FN

77FN--2,3>

>2,3>

>

Liquid Fuel Flow CalibrationLiquid Fuel Flow Calibration


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Flow Divider Characteristic:

60-tooth wheel

4600 cps = 65 gallons/min

Therefore, 70.7 cps per 1.0 gpm

Liquid Fuel Flow CalibrationLiquid Fuel Flow Calibration(from GE Control Specifications)(from GE Control Specifications)



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Fuel Flow = .0085 (%FSR) x (%TNH)

1. Assume for firingfuel:

%FSR = 14

%TNH = 16

Firing Fuel = .0085 (14) (19)

Firing Fuel Flow Rate = 1.90 gpm

Liquid Fuel Flow CalibrationLiquid Fuel Flow Calibration(from GE Control Specifications, ISO conditions)(from GE Control Specifications, ISO conditions)



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Fuel Flow = .0085 (%FSR) x (%TNH)

2. Assume for full speed/no loadfuel:

%FSR = 14

%TNH = 100

Firing Fuel = .0085 (14) (100)

FSNL Flow Rate = 12.0 gpm

Liquid Fuel Flow CalibrationLiquid Fuel Flow Calibration(GE Control Specs, ISO conditions)(GE Control Specs, ISO conditions)



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Fuel Flow = .0085 (%FSR) (%TNH)

3. Assume forBase LoadOperation:

%FSR = 66.6%TNH = 100

Firing Fuel = .0085 (66.6) (100)

Base Load Flow Rate = 57.2 gpm

Liquid Fuel Flow CalibrationLiquid Fuel Flow Calibration(GE Control Specs, ISO conditions)(GE Control Specs, ISO conditions)


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Gas FuelGas Fuel


Gas Stop Speed/Ratio & Control ValveGas Stop Speed/Ratio & Control Valve


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Gas Stop Speed/Ratio & Control ValveGas Stop Speed/Ratio & Control Valve

Gas Fuel Control FundamentalsGas Fuel Control Fundamentals


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Gas Fuel Control FundamentalsGas Fuel Control Fundamentals

P2P2P1P1 P3P3

Gas Fuel Pressure GagesGas Fuel Pressure Gages


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Gas Fuel Pressure GagesGas Fuel Pressure Gages

P1P1

P2P2P3P3

Gas Stop Speed/Ratio (Gas Stop Speed/Ratio (SRVSRV))


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& Gas Control Valve (& Gas Control Valve (GCVGCV))

< SRV< SRV

GCV >GCV >

P2 Pressure TransmitterP2 Pressure Transmitter


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((96FG96FG))

P2, Pressure Transducer > >P2, Pressure Transducer > >

P1P1


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Speed/Ratio Valve CalibrationSpeed/Ratio Valve Calibration


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(from GE Control Specifications)(from GE Control Specifications)

P2 = Speed Ratio (% TNH% TNH) Preset

P2 = .49 ((%TNH%TNH) .50 P2 in DC volts

P2P2



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P2 = Speed Ratio (% TNH% TNH) Preset

96FG transducer calibration96FG transducer calibration0 to 5.0 DC volts = 0 to 300 psig0 to 5.0 DC volts = 0 to 300 psig

P2 = 2.95 (%TNH) 30 in psig



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(from GE Control Specifications)(from GE Control Specifications)

P2 = 2.95 (%TNH) 30 in psig

At 100% shaft speedAt 100% shaft speed

P2 = 265psig, constant

P2P2


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Inlet Guide VaneInlet Guide Vane


Variable Inlet Guide VanesVariable Inlet Guide Vanes

((VIGVVIGV))


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((VIGVVIGV))

InletGuideVane

IGV Actuator & Position IndicatorIGV Actuator & Position Indicator


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IGVAngl

e>IGV

Angle>

IGV Control FundamentalsIGV Control Fundamentals


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Servovalve 90TV >


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(Control air flow into compressor)(Control air flow into compressor)

Servovalve 90TV >RV

DTRV

DT

20TV >


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Summary ofSummary of


Summary of Control SystemsSummary of Control Systems(System calling for(System calling for leastleast fuel controls FSR)fuel controls FSR)


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(System calling for(System calling for leastleastfuel controls FSR)fuel controls FSR)

MVGMVG


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Protection SystemsProtection Systems


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Four Primary Protections:

Overspeed

Overtemperature

Loss of Flame

Vibration


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Four Primary Protections (typical settings):

Electronic Overspeed: 110 % TNH

Mechanical Overspeed: 112% TNH

Overtemperature (~ 1000 F)

Loss of Flame

Vibration (1 inch/second, 5 mils peak-peak)

Triple Modular Redundant (Triple Modular Redundant (TMRTMR))(Speedtronic(Speedtronic Mark IV & V)Mark IV & V)


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(Speedtronic(Speedtronic Mark IV & V)Mark IV & V)

> BPV

> GCV

> SRV

> IGV

TMRTMR

Logic 0or 1

2/3 Voting


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Many Secondary Protections including:

Low Lube Oil Pressure

High Lube Oil Header TemperatureLow Hydraulic Pressure

Generator Lockouts

Customer Added Protections

Other, as required

Protection SystemsProtection Systems(High(High--pressure Hydraulics)pressure Hydraulics)


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(High(High pressure Hydraulics)pressure Hydraulics)

1200 psig25 psig

L 4 trips >

Protection SystemsProtection Systems(20 FG energize to run de(20 FG energize to run de energize to trip)energize to trip)


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(20 FG energize to run, de(20 FG energize to run, de--energize to trip)energize to trip)

Solenoid Valve

Deenergizes !


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(Control & Protection Systems)(Control & Protection Systems)

If operating on Liquid Fuel:

when stop valve closes,

the bypass valves goes to

full recirculation.

Protection SystemsProtection Systems(If a trip occurs, BPV goes(If a trip occurs, BPV goes

100% f l i l i )t 100% f l i l ti )


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to 100% fuel recirculation)to 100% fuel recirculation)

< < < >>>

100%

fuelrecirc

ulati

on>

StopValve

Closes

>

> > > >

Flow Divider

Stops

[zero flow]

Redundancy by AssociationRedundancy by Association(Control & Protection Systems)(Control & Protection Systems)


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( y )( y )

If operating on Gas Fuel:

when stop valve closes,

gas control valve also closes

immediately.

Protection SystemsProtection Systems

(If a trip occurs, both valves close)(If a trip occurs, both valves close)


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(If a trip occurs, both valves close)( f p , )

C

lose>>>

C

lose>>>

Redundancy by AssociationRedundancy by Association(Control & Protection Systems)(Control & Protection Systems)


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( y )( y )

Inlet Guide Vanes:

When a trip occurs, IGV go toward

the closed position immediately

to prevent compressor surge.

Protection SystemsProtection Systems(If a trip occurs, IGV Close)(If a trip occurs, IGV Close)


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20TVde-energizes>

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GT Control & Protection Systems