Gas Turbine

Control & Protection

Systems
by David Lucier
PAL Engineering
Control Systems
 What must be
“controlled”
on GE gas turbines?
9 Turbine Shaft Speed
9 Rate of Change of Speed
(a.k.a. Shaft Acceleration)

9 Exhaust Temperature
9 Rate of Change of Temperature

9 Air Flow through Compressor

9 TNH units: RPM or % speed
Acceleration: RPM/second or
% speed/second

9 TTX units: Degrees Fahrenheit (˚F )

Exhaust Temperature Rate: ˚F per second

9 Airflow: lbs-air per hour

(actual flow not measured)
 What devices
do the controlling?
9 Liquid Fuel Bypass Valve

9 Gas Stop Speed/Ratio Valve

9 Gas Control Valve

9 Variable Inlet Guide Vanes

 Modern GE
Control Systems
Mark IV Control Panel, TMR
(1982 – 1989 Era)

<R>

<S>

<T>
Mark IV Operator Panel
Mark IV Screen
Mark V Control Panel, TMR
(1989 – 2000 Era)
Human Machine Interface
Original <I> versus New <HMI>
Human Machine Interface
(Close-up of HMI Main Screen)
Typical HMI Screens
(Mark V)
Control Principles
 Minimum Value Select:

The control sub-system

“calling for” the least fuel flow
will be in command.
 Simplified
Minimum Value Select

(18) TC’s

TTXM

%TNH

%TNH/sec

FSR
Limits
Min & Max Value Gates

MIN
MAX

MIN (6 inputs)
9 Liquid Fuel Bypass Valve, BPV

9 Gas Stop Speed/Ratio Valve, SRV

9 Gas Control Valve, GCV

9 Variable Inlet Guide Vanes, IGV

Triple Modular Redundant (TMR)
(Speedtronic™ Mark IV thru VI)

TMR

> BPV
<R> > SRV
> GCV
> IGV
<S>

<T>
 Temperature Profile Diagram
(Base Load Operation)
INLET EXHAUST

3000 ˚F
F
20 20 ˚
Tf =
< Temperature >
<
TTX = 1000 ˚F

59˚F < 500

solid line graph > < 45˚F ˚F
 Pressure Profile Diagram
(Base Load Operation)
INLET EXHAUST

150
psia
4 9 psia
> <1
>
e
sur
r es 14.7 psia
14.7psia P
<
dotted line graph >
14.3 psia
Gas Turbine Start-up Curves

TTX %TNH
= 900
˚F >

p
m
Te
h.
Ex

d
ee
Sp
TTX = 550 ˚F

Speed
26%

19.5% Fuel Stroke Ref, FSR

 Fuel Stroke Reference
(FSR constants for Start-up)

% FSR > >

Start-up FSR Algorithms

TIME, Seconds > >

Constants List
 Liquid Fuel
Control Principles
 Fuel Control Principles

Fuel Flow is proportional to:

Bypass Valve Position
&
Fuel Pump Speed

FFN = ƒ (%FSR) x ( %TNH)

 Liquid Fuel Flow

z TNH measured 0 to 100 % speed

z FFN measured in frequency

(measure speed of flow divider)

z FSR measured 0 to 100 percent

of Bypass Valve (full open to closed)

FFN = ƒ (%FSR) x ( %TNH)

 Liquid Fuel Flow Principles

z Fuel Pump is driven by Turbine through

Accessory Gear Box (% TNH)

z By-pass Valve Position is controlled by

Speedtronic™ Panel (% FSR)

z Flow divider speed is proportional to fuel

flow (FFN, gal/min)
Liquid Fuel Control Fundamentals
FFN = ƒ (%FSR) x ( %TNH)

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

--->
--->
<--- --->

< FFN 70.7 cps/gpm

%FSR > < %TNH

Roper Liquid Fuel Pump
& Bypass Valve

< < < <

<<
>>>
>>>

>>>

>>>

<< Fuel Bypass Valve

IMO Liquid Fuel Pump

Scre
wP
ump
Liquid Fuel Bypass Valve

Bypass
Servovalve 65FP > Valve
 Flow Divider
Speed Pickup (77FN-1)

77FN-1 >

Flow Divider
 Flow Divider
Speed Pickups (77FN-2, 3)

> >
3
- 2,
7 FN
7
Liquid Fuel Flow Calibration
(from GE Control Specifications)

Flow Divider Characteristic:

60-tooth wheel
4600 cps = 65 gallons/min

Therefore, 70.7 cps per 1.0 gpm

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

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

1. Assume for “firing” fuel:

%FSR = 14
%TNH = 16
Firing Fuel = .0085 (14) (19)

Firing Fuel Flow Rate = 1.90 gpm

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

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

2. Assume for “full speed/no load” fuel:

%FSR = 14
%TNH = 100
Firing Fuel = .0085 (14) (100)

FSNL Flow Rate = 12.0 gpm

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

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

3. Assume for Base Load Operation:

%FSR = 66.6
%TNH = 100
Firing Fuel = .0085 (66.6) (100)

Base Load Flow Rate = 57.2 gpm

 Gas Fuel
Control Principles
Gas Stop Speed/Ratio & Control Valve
Gas Fuel Control Fundamentals

P1
P2 P3
Gas Fuel Pressure Gages

P1 P2 P3
Gas Stop Speed/Ratio (SRV)
& Gas Control Valve (GCV)

< SRV

GCV >
 P2 Pressure Transmitter
(96FG)

P1

P2, Pressure Transducer > >

Gas Stop Speed/Ratio (SRV)
& Control Valve (GCV)

< SRV

GCV >

< 90SR < 65GC

Servovalves
 Speed/Ratio Valve Calibration
(from GE Control Specifications)

P2 = Speed Ratio (% TNH)

TNH – Preset

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

P2
 Speed/Ratio Valve Calibration

P2 = Speed Ratio (% TNH)

TNH – Preset

96FG transducer calibration

0 to 5.0 DC volts = 0 to 300 psig

P2 = 2.95 (%TNH) – 30 in psig

Speed/Ratio Valve Calibration
(from GE Control Specifications)

P2 = 2.95 (%TNH) – 30 in psig

At 100% shaft speed
P2 = 265psig, constant

P2
Inlet Guide Vane
Control Principles
Variable Inlet Guide Vanes
(VIGV)

Inlet
Guid
e Vane
IGV Actuator & Position Indicator

< IGV Actua tor >

Angle >
IGV
IGV Control Fundamentals

,2 ,
-1 DT
TV V
96 < L
<
Servovalve 90TV >
 IGV Control
(Control air flow into compressor)

T
D
RV
Servovalve 90TV >

< < IGV Modulating > >

20TV >
 Summary of
Control Principles
 Summary of Control Systems
(System calling for “least” fuel controls FSR)

Min Fuel

FSR

MVG
<6
I np
ut S
ign
als
Protection Systems
Four Primary Protections:

9 Overspeed
9 Overtemperature
9 Loss of Flame
9 Vibration
Four Primary Protections (typical settings):

9 Electronic Overspeed: 110 % TNH

9 Mechanical Overspeed: 112% TNH

9 Overtemperature (~ 1000 ˚F)

9 Loss of Flame

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

Triple Modular Redundant (TMR)
(Speedtronic™ Mark IV & V)

TMR

> BPV
<R> > GCV
> SRV
> IGV

<S> Logic “0” or “1”

2/3 Voting

<T>
Many Secondary Protections including:

9 Low Lube Oil Pressure

9 High Lube Oil Header Temperature
9 Low Hydraulic Pressure
9 Generator Lockouts
9 Customer Added Protections
9 Other, as required
 Protection Systems
(High-pressure Hydraulics)

L 4 “trips” >

25 psig 1200 psig

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

< L 4 “trips”

Solenoid Valve
Deenergizes !

1200 psig

< St
op
Clos Valve
es !
!
Redundancy by Association
(Control & Protection Systems)

If operating on Liquid Fuel:

when stop valve closes,

the bypass valves goes to
“full recirculation.”
 Protection Systems
(If a trip occurs, BPV goes
to 100% fuel recirculation)
St o
Cl p V
os alv
es e
>

>> >>

>>>>
<<<<
<<<< [zero flow]
>
n
io
atl
cu
cir
re
el
fu
%
0
10

Flow Divider
Stops
Redundancy by Association
(Control & Protection Systems)

If operating on Gas Fuel:

when stop valve closes,

gas control valve also closes
immediately.
 Protection Systems
(If a trip occurs, both valves close)

Close >>>

Close >>>
 Redundancy by Association
(Control & Protection Systems)

Inlet Guide Vanes:

When a trip occurs, IGV go toward

the “closed” position immediately
to prevent compressor surge.
 Protection Systems
(If a trip occurs, IGV Close)

VDT
R
20TV
de-ene
rgizes

< < < IGV Close

>
 Summary
(Control & Protection Systems)

• Shaft Speed Control

• Shaft Acceleration Control
• Overspeed Protection

• Exhaust Temperature
• Rate of change of Temperature
• Overtemperature Protection

• Vibration
• Loss of Flame
• All Other Protective Devices
 The End

Thank you for

your attention!
Questions ?