From Millivolts To Megawatts - Control of Large Gas Turbines

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68-GT-49

The Society shall not be responsible for. state-


ments or opinions advanced in papers or in dis-
cussion at meetings of the Society .or of its
Divisions or Sections, or printed in its publications.
Discussion is printed only if the paper is published
in an ASME ;ournal or Proceedings.

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$1.50 PER COPY Released for general publication upon presentation

TO ASME MEMBERS
Copyright © 1968 by ASME

From Millivolts to Megawatts - Control of Large


Gas Turbines
J. 0. JOHNSON J. S. WILLIAMSON
Supervisor-Service Engineering, Assistant Project Engineer,
Hamilton Standard Division, Hamilton Standard Division,
United Aircraft Corp., United Aircraft Corp.,
Electronics Department, Electronics Department,
Windsor [ocks, Conn. Windsor Locks, Conn.

K. I. FETTERHOFF
Applications Engineer,
Ha-milton Standard Division,
United Aircraft Corp.,
Electronics Department,
Windsor Locks, Conn.

The adaptation of high power aircraft gas turbines to the ground applications of
pumping gas, generating electricity, or chemical processing has led to the develop-
ment of a- completely electronic fuel control system. The control system is versatile,
presently encompassing single- and multiengine applications in a range from 3000
hp to 240,000 hp. Optimum acceleration and power limiting features are provided
as well as sa.feguard functions for automatic remote engine operation over the total
load range. The service experience accumulated in the past seven years on over 100
controllers is also discussed.

Contributed by the Gas Turbine Division of The American Society of Mechanical Engineers
for presentation at the Gas Turbine Conference & Products Show, Washington, D. C.,
March 17-21, 1968. Manuscript received at ASME Headquarters, January 23, 1968.
Copies will be available until January 1, 1969.

MERICAN SOCIETY OF MECHANICAL ENGINEERS, UNITED ENGINEERING CENTER, 345 EAST 47th STREET, NEW YORK, N.Y. 10017
rom Millivolts to Megawatts - Control of large
Gas Turbines
J, O. JOHNSON K. I. fETTERHOff J. S, WILLIAMSON

STATION CONTROL REQUIREMENTS

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In 1959 the potential application of the The control system for automatically start-
jet engine as a hot gas generator, power- ing, regulating, and shutting down a remote, unat-
turbines for utility and industrial ap- tended gas pumping or electrical generation sta-
plications established requirements for a new line tion is basically divided into two electrical sub-
of electronic engine fuel controls. These control systems. The first is an Engine Control System
systems have been in use for the past seven years designed to meter fuel to the gas generator within
and have demonstrated superior performance and re- safe operating limits. This system works in con-
liability. In recent years the additional require- junction with the Station Sequencer which performs
ments established by the utility companies has led specific timing, speed point measuring, and syn-
to a redesign and refinement of this system to chronizing functions to allow the installation to
meet the versatile needs of many applications in a automatically respond to remote command. The en-
broad power spectrum. The newest of these elec- gine control system will be described in this paper.
tronic control systems is discussed in this paper.
To date, the application of these controls GAS GENERATOR CONTROL SYSTEM REQUIREMENTS
nas been with Pratt & Whitney Gas Turbine Engines
(also referred to as gas generators) in three gen- A primary design consideration for the en-
eral power classifications from 3000 hp to 30,000 gine control system was to make the system com-
np for single-engine applications. Typical in- pletely versatile encompassing a broad engine
stallations are shown in Figs.l and 2. The en- horsepower/speed range and to include multiengine
gines are matched with free turbines manufactured performance for a variety of applications. The de-
by several companies who act as system managers sign specification, therefore, may list a number
for the application of peak power generation, of requirements ranging from (a) simply running
pumping gas, or combinations of power generation the gas generator, to (b) providing power as a
and waste heat recovery. Multiengine applications prime mover for gas pumping, to (c) the complexi-
in pairs are available to produce up to 160-Mw for ties of generating electric power as a single or
a typical eight-engine installation. The control multiengine isolated source.
system is versatile and can be applied in general Aside from the aforementioned design flexi-
to many gas turbine applications. bility, basic requirements of an engine control
system may be grouped and are, in general, desir-
able characteristics of all engine control systems.
These include high reliability, fast response, sta-

Fig.l 140 Megawatt electrical power station Fig.2 First aircraft gas turbine pumping station

1
GENERATOR

Liquid
Mod ELECTRONIC
Gos Valve CONTROLLER
Mod Engine Control
Valve

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Equipment
1 - - - -,...__-_-_-_-_-_-,__- - -Stotio;;- Co~tr~I- -

ENGINE I Equipment
STATION Engine /Station Fig.4 Public Service of New Jersey sequencer
Gos !+-----+-----'----SEQUENCER Permissives
Shutoff L,----~i-- Start up S. Shut-
Volve down Logic
Fuel Status system is required to achieve full capability ~f
Command
Fuel Annunciation Input the prime mover; these include:
Fig.3 System block diagram 9 Precise governing of Nf for stable 5~00
rpm into an isolated load.
10 Droop - Power load sense with correcrJnd-
bility, fail-safe features, black start (battery ing increase in N3 governing error,
power) capability, and completely remote, unmanned 11 Maximum acceleration ability based :n
operation. Specific control requirements for the actual turbine temperature (EGT) as a functic r; Jf
application of gas pumping or power generation may inlet temperature.
be further listed and defined as follows. These 12 Three independent limiting horsepower'
are listed in the order required for their appli- outputs based on inlet temperature schedules.
cation, first as gas pumping, followed by elec- 13 Liquid and gas dual fuel switchover· capa-
trical generation. bility while generating power.
1 Gas generator speed (Ng) governing over 14 Adjustable free turbine (Nf) inlet te::1-
the speed range. perature limiting.
2 A constant maximum horsepower of the gas
generator over the ambient operating range, For multiengine single generator installa-
3 Free turbine speed (Nf) governing over tions where engines are paired to drive free tur-
the speed range. bines coupled to a single output shaft, it is nec-
4 Remote speed setting capability for Ng essary to isolate the Nf function. The Nf speed
and Nf controls. signal is fed to a selected master and this con-
5 Readout of the controlling function (Ng' troller supplies the required signals to its [JS
Nf) for sequencing purposes. generator as well as the other gas generators that
6 Controlled acceleration schedule. are operating. It is then necessary to provide:
7 Automatic resetting of Nf speed reference 15 Light-off sensing to assure both enr~nes
at 75 rpm above Ng speed governing for protection of a turbine pair are supplying power to their
in event of loss of free turbine load. common free turbine.
8 Safety shutdown features: 16 Load sharing between individual gas
(a) Overpressure of the gas generator. generators.
(b) Overtemperature of GG turbine: 750 The aforementioned list of control func'·i·;ns
F below idle, 1200 F above idle rpm. is incorporated into the Model SPC-2A control •hat
(c) Nf overspeed. is designated for the standard electrical
(d) Loss of either speed signal to the ing application. Installations not requirinf: 'tll
control. the functions may be selected at an economic
(e) Loss of exhaust gas temperature vantage by eliminating any option. Before dsccrib-
(EGT) sensor signal. ing the functional operation of the controlle~,
(f) Loss of valve feedback signal. the necessary system hardware will be described.
(g) Flame out (Ng speed below a preset
level). HARDWARE
In addition for the electrical generating
applications, further refinement to the control The block diagram in Fig.3 shows the func-

2
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tional relationship of this equipment with respect
to the engine. It will be seen that the controller Fig.6 Gas modulating valve
is fed signals of gas generator speed, free turbine
speed, inlet temperature signal, exhaust gas tem-
perature signal, and electrical generator output.
The controller provides driving power to a liquid
or gas modulating valve. The station sequencer
provides the commands and monitors the overall en~
gine system. In each of these assemblies, relia-
bility and long life are primary design criteria.

Station Sequencer - Fig.4


The sequencer provides the necessary switch-
ing and monitoring functions to automatically pro-
gram an electrical generating station. The se-
quencer performs the following functions:
1 The pre-start check and activation of en-
gine support equipment.
2 The initiation and monitoring of engine
startup sequence.
3 The monitoring of engine and support sys- Fig.7 Gas shutoff valve
tems performance during acceleration at pre-set
speed points.
4 Regulation of engine speed by pulse sig- the controller with an ac voltage of 2 to 8 v.
nal during automatic synchronizing. The frequency is proportional to the speed of the
5 Emergency shutdown in the event of a respective turbine.
major malfunction.
6 The monitoring of normal engine shutdown Gas Modulating Valve Assembly - Fig.6
and cooldown requirements. The flow of natural gas at 300 psi to the
engine is controlled by a specially designed but-
Inlet Air Temperature Sensor - Fig.5 (Center) terfly valve. The valve serves three functio"ns:
Engine air inlet temperature is sensed by a (1) for engine starting, a minimum flow is main-
dual thermistor unit located in the engine inlet tained by means of an adjustable bypass orifice
duct. An increase in inlet air temperature causes and by a proportional positioning of the butterfly
a decrease in resistance of each element. disk; (2) for governing, the butterfly disk is
modulated through a gear train by a 400-cycle, 2-
Speed Transducers - Fig.5 (Left or Right) phase servomotor; and (3) for low pressure appli-
Engine (Ng) and free turbine (Nf) speed are cations (100 psi) a solenoid bypass is provided to
sensed by electromagnetic transducers mounted in allow the engine to start and apply bootstrap com-
proximity to the face of a special gear driven by pressor operation. A linear potentiometer is
the respective shafts. The transducer provides coupled to the butterfly output shaft to provide

3
,....--

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Fig.8 Electronic controller

Fig.10 Electronic controller details

millisec. For safety reasons, two are used in


series.

SPC-2A Controller
The SPC-2A controller as shown in Fip .8, 9,
and 10 is comprised of five printed circ11i t: func-
tion cards, two drive motor assemblies, a uro-cns
inverter and a power supply card. The chas=io is
a standard rack mount unit with a printed circ1it
board harness interconnecting the subassemtlies.
The function cards are separated by function as
Ng, Nf, EGT, and Servo Card. They are int e;"-
changeable between controls of the same configura-
tion. All customer trims are accessible tts'OcJ['h
the top cover and are marked by function. ~-c

speed set assemblies are gear reduced de mctos·::;


each driving a speed set and read out linear no-
Fig.9 Electronic controller without cover tentiometer. The power supply and inverter are
removable as subassemblies.

valve feedback signal. Also included is a visual SPC-2A FUNCTIONAL DESCRIPTION


indicator of valve position, and a sequencing
switch, actuated when the valve is closed. A simplified functional block diagram the
controller is presented in Fig.11. The ser-,·o O(;C-

Liquid Modulating Valve - (Not Pictured) tion will first be discussed and the three
The liquid valve utilizes an actuator which ing functions will be described separately.
is identical to the one used on the gas modulating
valve. Fuel modulation is accomplished with a Servo System
rotating sleeve type valve modulating across a con- One winding of the two phase servomot
stant differential pressure. the actuator is energized by a 400-cps 115-~
shifted reference source; the other windinf --
Shutoff Valve - Fig,7 controlled by the output from the servo amrlifier.
The shutoff valves are de servo operated Opening and closing of the actuator is achieved,
poppett type valves and function to shut off fuel in a conventional manner, by reversing the sc:e
to the engine while static or when shutdown fea- input to the servo amplifier which is amplifi
tures in the controller or sequencer dictate. Re- and fed to the servomotor. Steady-state c_ :vl
action time to close the valve is less ~han 100 is accomplished around null in which mil'ir:nu•1

4
gL=
POWER SCHEDULE A, I\ C
MV

SPEED N
~---------!AMP>------ SET g

"r.r-

SERVO

~I '------------"'-lliin~
AMPLIFIER

~I Ng

_,.,---1

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EGT .......__ ~~~~SATION VALVE FEEDBACK

I
I
N
f
SPEED
SET
o--1
I Nf Precfae J
I
I
--,----i'AMP and
COMPENSATION
AM >---I I
I I

~
AC POWER ....l'A"-!---1 VDC
SENSE POWER SENSE

Fig.11 SPC2A controller - simplified block diagram

voltage of either phase is delivered to the control shown that turbine temperature is related directly
winding of the servomotor. Valve negative rate to gas generator inlet temperature (air density)
feedback is provided to the input to the servo am- as a function of engine speed. The constant horse-
plifier to assure maximum breakaway torque while power can be related as a function of engine speed
limiting overtravel once the actuator is in motion. and ambient temperature in the safe operating
Additional feedback is provided to the EGT circuit range of the gas generator. The base curve in
to limit valve speed to preset limits, presently Fig.12 shows the relationship of Tt2 versus Ng for
22 deg per sec. a typical gas generator. This function is gener-
ated as a limiting maximum speed (or horsepower)
Selector Circuit parameter within the control, and is standard for
The selector circuit at the input to the a particular model of engine. Maximum station
servo amplifier functions to select one of the trim of the engine is accomplished by adjusting a
three governing functions - Ng, Nf' or EGT. The potentiometer within the control until the trim
selector circuit operates to select the parameter point is achieved. The trim point is defined at
calling for the least fuel flow and provides this 80 F for the individual engine by the engine data
signal to the servo amplifier to correct for any plate. Trimming raises or lowers the total curve
governing error. The selection is accomplished by until the point is reached. During· operation the
gating diodes and adequate function gain is pro- maximum speed that the engine will run is de-
vided to allow clean switchover between functions creased as ambient temperature drops. For example,
without interaction. maximum Ng speed at 0 F is approximately 6 percent
slower than at 80 F •
.Ng Governing In the application of gas turbine engines
Speed governing is accomplished by convert- for industrial usage, life warranties are specified
ing the speed signal to a linear volts per rpm as a power versus time relationship. For example,
voltage ramp and comparing this signal to a refer- the engine warranty is longer if the engine is
ence which is a combination of speed setting paten- used at a lower power level than at higher· power
tiometer signal and inlet temperature schedule levels. Therefore, three independent temperature
signal. The resultant de signal is amplified and schedules are provided so that utilities can
fed to the selector circuit. select: base, peak, and maximum peaking. These
Present applications of the system at base are selectable by relay contact closure and result
power levels call for constant horsepower over the in two additional independent and different sets
ambient range of the gas generator. It can be of curves as shown in Fig.12.

5
1500
TURBIN~ INLET LIMITER-----.
+3% 1400 VARIABLE

+2% 1300
/)
z
I- +I % 1200 /
0
a. 0 1100 / /
1-
V _,,_/v
~ ovY
w
(/)-I 0/o
x
<t.
::!:-2 %
.
!;:: 1000

I- 900
!..
X'
-Q'?'

"'
Z-33
LL
I!)

w BOO
Tr 2 ·120T/
/
~ -4 01o /

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700
::!: TT 2 •-20"F /
:E-5 % 600
LL

&-6%
z
<t.
;J-7 % 5000 6000 7000 8000 9000 10000
::!: Ng SPEED ( R PM)
a.
n: -a o/o 1- TRIM POINT
I
Fig.13 Typical Ng versus EGT acceleration schedule

40 0 40 80 120
INLET TEMPERATURE ( °F)
allow absolute limiting of free turbine temperature
TT2
at any operating speed in the range of from 15oc F
Fig.12 Typical Ng versus TT 2 schedule for single to 800 F. This feature may be used at the systems
engine managers discretion to protect his free turbine.

EGT Shutdown
EGT Limiting and Governing Two independent shutdown limits are provided
The exhaust gas temperature (EGT) signal is to shut down the engine in event of over tempera-
provided by an engine mounted thermocouple array ture. If the temperature exceeds 750 F (adjust-
and is used for limiting during accelerations and able) below idle, the engine will shut down.
if required at power. The temperature limiting Above idle if it exceeds 1205 F (adjustable), it
schedule during maximum accelerations is required will shut down on over temperature. These limits
to prevent engine stall and/or over temperature of are independent of the EGT governing functions.
the turbine, Fig.13 shows the allowable relation-
ship of EGT to turbine speed over the speed range. l:!f Governor
Note that the function is a governing one, and Free turbine governing is accomplished by
that the control will reduce fuel flow so as to comparing a de signal proportional to speed with
not allow turbine temperatures to exceed the indi- the speed set signal and feeding this signal to the
cated temperatures. Acceleration schedules are selector circuit. When the free turbine is syn-
varied as indicated to allow optimum accelerations chronized to the line below peaking power, it is
for the ambient operating temperature. on Nf control and an error must be provided within
The EGT controlling function is generated by Nf control band to increase output power. The
using the low millivolt signal from the thermo- droop circuit provides the additional Nf speed
couple harness. This signal is altered to compen- error. This is accomplished by sensing electrical
sate for line loss and for cold junction compensa- generator output with a current transformer on cne
tion. The signal is then amplified and compared phase of the output power. A voltage proportional
to the schedule. The resultant signal is again to generator output is provided to the control and
amplified and fed through the valve rate limiting added to the Nf speed signal. The droop signal
circuit to the selector circuit. Compensation is can be trimmed and is usually 4 percent above the
provided within the control which allows for the synchronous speed setting.
time constant of the thermocouple. This compensa- For isolated operation a means must be pro-
tion is adjustable so that a variety of thermo- vided to maintain 3600 rpm isochronous governing,
couples may be matched. called Nf precise. This is accomplished by sub-
An additional noteworthy feature provided by stituting a preset voltage level for the N speed
3
this circuit is that EGT can be made to be the set within the control. The governing will then
controlling parameter for free turbine inlet tem- remain at the preset 3600 rpm over the load range
perature. An adjustment is provided that will of the machine.

6
While detail of the electronics was not
stressed, some of the design featurBs are import-
ant from a long life standpoint. Previous genera-
tions of controllers (SPC-1 and SPC-2) utilized 1200
discrete solid-state components on several circuit
boards. The complex analog functions were formed
1000
by ac logic in these circuits. The SPC-2A con-
troller uses integrated circuits as operational
amplifiers, and de signals are used in the majority 800

of the control functions. Gains and compensation


for these high gain operational amplifiers are

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600

computed and held by precision resistors and com-


ponents to maintain controller precision over a 400
temperature range of -40 F to +130 F. All compo-
nents in the control are used in the derated sense
5500 6000 6500 7000 7500 8000 8500
to assure long life. Ng SPEED (RPM)

Fig.14 Typical engine response


SYSTEM OPERATION

In operation, the aforementioned governing in the 7500 rpm region to keep the engine away from
parameters will override one another to provide stall conditions. Effects of ambient temperature
continuous control of the gas turbine. A typical simulation change on acceleration can be seen be-
operating cycle of a single engine installation tween curves A and B. Curve A shows the maximum
would be as follows: The engine is cranked and at governing speed, as 8500 rpm, for the warm day in-
ignition speed, fuel shutoff valves are opened let condition to the control. Curve B, for a
allowing fuel to pass through a bypass and step- cooler day, shows lower acceleration limiting
start position of the modulating valve. The step- throughout the schedule and approximately 8450 rpm
start position is a fixed angle position of the as the limiting speed for the cool day condition,
valve to allow ignition and acceleration to idle, Deceleration, shown on the Curves C, D, E, and F,
and is removed as soon as governing is achieved. was created by rapidly throttling back to the min-
Safety speed checks and fade in of the control imum flow condition and re-accelerating to maximum
functions occurs during this interval. To go speed. This was done in approximately 500 rpm
above idle the Ng speed set is advanced increasing steps as shown by the family of curves. These
the power until Nf reaches 3550 rpm. At this curves are repeatable. Curve G shows the effect
speed the synchronizing equipment pulses the Nf on acceleration of free turbine temperature limit-
speed set up to synchronize on the line at 3600 ing, when EGT limit was adjusted downward to 800
rpm. As additional Nf speed is demanded by ad- F. The dip in this curve is due to the use of
vancing the Nf speed set, the droop circuit pro- longer time constant test thermocouples on the
vides the circuit error to provide increased power. test engine. Thermocouple time constant compensa-
The power will be increased until Ng governiQg (as tion is easily adjusted in the control. For the
n
biased by the ambient temperature signal) takes example shown by Curve G, the long term limiting
over. This will be the maximum power available temperature to the free turbine would remain at
from the machine. Subsequent changes in ambient 800 F and the other gas generator governing param-
1
temperature will change Ng speed in order to main- eters would not be in control. An acceleration
te
tain the maximum power output schedule. The fore- time span is shown across the top of the diagram
.1 going sequence from start initiation to peak power for reference and shows acceleration time of 6 sec
td is accomplished in less than 3 min. from idle to maximum power. Power is not indicated
Typical dynamic operation of a 30,000-hp gas on the diagram, but it is interesting to note that
generator is shown by the response diagram of Fig. over 50 percent of the power capability wou1d be
14. For this engine run, an orifice in the output gained in the last couple seconds of the acceler-
of the gas generator simulated the free turbine, ation.
and the control was operated with Ng in control.
Maximum acceleration from 6000 rpm to 8500 rpm as DUAL FUEL OPERATION
shown was accomplished by deenergizing the idle
clamp which permits full Ng speed error. It will Dual fuel operation of the control system is
be noted that Tt7 acted to limit fuel flow and possible because of twin-engine manifolds allowing
slow the acceleration in the 6500 rpm region and either liquid or gaseous fuel to enter separate

7
engine nozzles. The manifolds are plumbed, respec- the eight-engine Public Service of New Jersey in-
tively, to a liquid control valve and gas modulat- stallation at Sewaren has accumulated a total
ing valve. Both of the control valves are driven single engine time of 11,200 hr.
by similar independent actuators which are powered Of further significance are three engines
by independent servo amplifiers within the con- that supply an average of 33-Mw electrical power
troller. to a Dow Chemical Chlorine Process Plant in Pittc-
Switchover from either liquid to gas, or gas burg, Calif. The units provide the sole indepen-
to liquid may be selected at any speed governing dent and isolated source of power to the plant and
range including maximum power. It is accomplished also provide, with the addition of fuel, waste
by relay switching of the servo amplifier outputs heat recovery to the boilers at the site. The
between the valves. Feedback signals and driving three engines at this site have accumulated 26,200

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signals are compensated so that one valve is driven hr since startup in 1966.
closed and the governing valve is driven open at an
identical rate. As the transfer is being accom- Reliability
plished, the "new fuel" valve is governed by the Reliability of the gas pumping control sys-
engine parameters and will rapidly correct for any tem has been excellent. Actual experience on the
speed error that is due to the change in fuel. gas pumping installations has shown a mean time
The switchover is accomplished in less than 4 sec. between failure rate in excess of 30,000 hr for
Gas generator power change is not audibly detect- operating time. Actually, these controls have
able, although a slight dip in output power can be been energized continuously since installation and
expected, Extensive engine testing of this system this time has not been taken into account for MTPF.
has been accomplished. Calibration checks recently made on controls in
the field for 5 and 6 years show good repeatabil-
EXPERIENCE ity of original control data.
Experience on the electrical peaking con-
Gas Pumping trols has been limited to comparatively low oper-
The first gas pumping installation was in- ating times. However, experience on the high time
stalled at Columbia Gulf Gas Transmission, Clements-units at Dow Chemical indicate very favorable con-
ville, Kentucky, station in late 1960. As of Sep- trol reliability.
tember- 1967, this station had accumulated 50, 000
hr of engine operation. Nine other engines on the
Columbia Gulf and on other gas companies' lines CONCLUSION
have been accumu1ated over 24,000 hr each since
their .installation. A single engine pumping and The control described offers the gas turbine
waste heat recovery system installed at Phillips industry a versatile control system that can be
Petroleum in Dumas, Texas, for gas helium recovery adapted to a broad power range of gas turbines as
0

and dis ti lla te salvage has accumulated 35, 800 hr applied to single or multiengine commercial instal-
since installation in ear1y 1963, Approximate lations. Gas turbine or free turbine governing is
total gas pumping hours as of September 1967 is provided over a broad speed range for each turbine.
summarized, with number of engines indicated. Horsepower limiting by ambient temperature simula-
tion or by actual limitation of turbine tempera-
Total Gas Pumping Operating Time
tures has been developed to provide protection dur-
ing acceleration and provide a constant maximum
SPCl-2 (17) 397,000 hr
horsepower output. Safety and overriding control
SPCl-3 (27) 127,000 hr features assure positive and immediate control of
the large horsepowers available in today's gas tur-
SPCl-5 _u_l 16,ooo hr
bine engines. Such features as dual fuel switch-
Total (46) 540,000 hr over and free turbine temperature lim_i ting are be-
lieved to be the first of this type ever offered
Electrical Power Generation in a control system. Based on seven years of ex-
Total time on 32 single engine electrical perience with this type of system, reliability
peaking units, mpst of which have been installed and functional availability of the installation
in the past two years, is 25,000 hr. In addition, are assured.

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