WELCOME TO THE PARTICIPANTS

GAS TURBINE CONTROL SYSTEM

(MARK-VI SPEEDTRONIC CONTROL SYSTEM)

PART-1
BY SRIKANTH KOLUKULA ,BHEL-INDIA
 MARK-VI PANEL

DC DISTRIBUTION
BOARD - DCDB

MOTOR CONTROL CENTRE

HUMAN MACHINE INTERFACE
 Mark IV TMR

HIGH <R> STOP

TEMP

LOW <S> 2/3 VOTE STOP

STOP
PRESS

<T> GO
 Mark V SIFT TMR

PRE-VOTE

HIGH <R> STOP

GO
TEMP

LOW <S> STOP SIFT GO 2/3 VOTE GO

PRESS

<T> GO GO
Speed detection - by magnetic pickups
L14HR Zero-Speed (Approx. 0% TNH)


L14HM Min Speed (Approx.. 16% TNH)



L14HA Accelerating Speed (Approx. 50% TNH)



L14HS Operating speed (Approx..95% TNH)


• Gas turbine is controlled by Speedtronic control
system
• Control loops includes
– Start-up
– Acceleration
– Speed
– Temperature
– Shutdown and
– Manual Control functions
• Major Control loops Secondary control loops
 Start-up Acceleration
 Speed and Manual FSR and
 Temperature Shutdown
• Output of these control loops is fed to a minimum value gate
circuit Display
Fuel

Temperature
Display
FSR
Speed M
Acceleration
I
To Turbine
Rate
Display
N
Start Up
Shut Down

Manual
• Fuel Stroke Reference (FSR)
 Command signal for fuel flow

• Controlling FSR
 Lowest of the six control loops
 Establishes the fuel input to turbine @ rate required by
system which is in control

• Only ONE control loop will be in control at anytime.

 The control loop which controls FSR is displayed in operator
friendly CRT.
 Min Value

Example of Minimum FSR of Six Control Loops on

HMI Screen
Detailed Control
Schematic

We will use this as reference

as we go in detail of the course
 Startup Control

Start up control controls the amount of fuel

to the GT from zero speed to Full Speed No
Load

FSRSU is minimum of the six control loops

 Startup/Shutdown Sequence and Control
• Startup control brings the gas turbine
– Zero speed up to Operating speed.
• Allows proper fuel to establish
– Flame & Accelerate the turbine in such a manner as to
minimize the Low cycle Fatigue of the hot gas path parts
during the sequence
• Software Sequencing involves
– Command signals to Turbine Accessories, Starting device
and Fuel control system
• Safe and successful start-up
– depends on proper functioning of GT equipment.
• Software Sequencing ensures safe operation of
Turbine
 Startup/Shutdown Sequence and Control
• Control logic circuitry is associated not only with
actuating control devices, but enables protective
circuits and obtains permissive conditions before
proceeding.
• Control settings play a vital role in determining the
proper sequencing.
– Actual site specific control settings are generated by
M/s GEICS,USA.
• Speed detection - by magnetic pickups
– L14HR Zero-Speed (Approx. 0% TNH)
– L14HM Min Speed (Approx.. 16% TNH)
– L14HA Accelerating Speed (Approx. 50% TNH)
– L14HS Operating speed (Approx..95% TNH)
 Startup/Shutdown Sequence and Control

• Actual settings of speed relays are listed in Control

specification.

• The control constants are programmed in <RST>

processors EEPROM.

• Always ensure correct site specific, machine specific

control specification.

• Consult your system designer for any queries.

 Start-up Control - FSRSU
• Open loop control
– Uses preset levels of fuel command

• Various Fuel levels

– Zero, Fire, Warm-up, Accelerate and Max.
Typical values for Frame-9E
– Fire 20%
– Warm-up 14%
– Accelerate 30%
– Maximum 100%
Open Loop Control
 Start-up Control - FSRSU
• Startup control FSR (FSRSU) signal operates
through the MIN value gate to ensure other
control functions can limit FSR as required.
FSRSU
FSRACC
FSRN
FSR
FSRT MIN
FSRSYN
FSRMAN
FSR = FSRSU
 Start-up Control - FSRSU
• Speedtronic Control Start-up software
generates Fuel command signal (FSR).
• Speedtronic Control Software also sets the
MAX and MIN limits for FSR for Manual
Control FSR
[ FSRMIN < FSRMAN < FSRMAX ]
• When Turbine Breaks away (starts to rotate)
– L14HR pick-up
– Starting clutch solenoid 20CS de-energizes
– Shuts down the hydraulic ratchet motor (88HR)
•
Acceleration Control
Acceleration control software
- FSRACC
– compares the present value of Speed signal with the value
at the last sample time.
– Difference between these two numbers is a measure of
acceleration.
• When actual acceleration is greater acceleration
reference, FSRACC is reduced, which reduces FSR, thus
reduction in fuel supply to turbine.
• During startup-acceleration reference is a function of
turbine speed.
• Acceleration control takes over after Warm-up state.
 Acceleration Control - FSRACC
• Acceleration reference is a Control constant
programmed in <RST> EEPROMS
Typical

0.35 %/sec

0.10 %/sec
0% 40% 50% 75% 95% 100%

TNH
 Acceleration Control - FSRACC
FSRSU
FSRACC
FSRN
FSR
FSRT MIN
FSRSYN
FSRMAN

FSR = FSRACC
•
Speed Control
Speed Control System software
- FSRN
– controls the speed and load of the gas turbine
generator
– in response to the actual turbine speed signal (TNH)
and the called-for speed reference(TNR)

TNH FSRN

TNR
FSRN = FSKRN1 + FSKRN2(TNR-TNH)
FSKRN1 = FSNL FSR
FSKRN2 = BASE FSR – FSNL FSR
% DROOP
 Speed control schematic

• The Speed Control Loop

ensures the correct speed as
required by the system

• The Load Control Loop

maintains the power out put.
(The load control can be either
Isochronous or Droop, depending
on whether the system is connected
to Grid or Isolated)

 This serves both Speed & Load

functions and so called Speed/Load
Controller

FSRN is the minimum of Six Control Loops

 Speed/Load Control
• Speed/Load Reference:
– Speed control software will change FSR in proportion to
the difference the actual turbine generator speed (TNH)
and the called-for reference (TNR)
• Reference Speed (TNR) range
– 95% (min) to 107% (max) for a generator drive turbine
• Start-up speed reference is 100.3%.
– This is preset when START signal is initiated.
• Turbine follows 100.3% TNH for synchronization
 Speed/Load Control
• Turbine Speed is held constant when Generator Breaker is
closed onto Power grid
• Fuel flow in excess of the necessary to maintain FSNL will
result in increased power produced by the generator.
• Thereby Speed control becomes Load control loop
• Speed Control:
– Isochronous Speed control
– Droop Speed Control
 Isochronous Speed Control
TNH FSRNI

TNR

FSRSU
FSRACC
FSRN (or FSRNI) FSR
FSRT MIN
FSRSYN
FSRMAN FSR = FSRN
•
Droop Speed Control
Droop Control is a proportional control.
– Any change in actual speed (grid frequency) will cause a
proportional change in unit load.
– This proportionality is adjustable to the desired
regulation or ‘Droop’
104 %
FSNL
100 %
Full Speed No Load FSR

Rated FSR
Low Speed Stop
95%
Min TNR FSR
 Speed Control Characteristics

Droop speed control is a proportional

control,
changing FSR in proportion to the
difference between
actual turbine speed and the speed
reference (TNH & TNR)

Isochronous Controller is a closed

loop controller that maintains the
Turbine Speed to the reference speed
by regulating FSR during the isolated
operation.

Droop Control Curve

 Speed/Load Control loop
Raise Rate
Speed Target
Speed Ref. Power
Lower Command
LOG MANUAL
SETPOIINT SETPOINT Primary Os
Speed
Rate Preset
Error

Ememrgency Os
SPEED
CONTROL
Mechanical
Os
Load Raise Rate Speed

Load Ref.
Load Lower Cmd MANUAL
LOG Load Setpoint
SET SET
POIINT POINT
Preset
Load Rate
 Speed Control Schematic
SPEED CONTROL <RST>

FSNL

TNR
SPEED
REF.
+ ERROR + FSRN
+
- SIGNAL
TNH
SPEED
DROOP
<RST>
SPEED CHANGER LOAD SET POINT

MAX. LIMIT
L83SD
RATE
L70R
RAISE
L70L
LOWER
L83PRES MEDIAN TNR
PRESET LOGIC SELECT SPEED
REF.
PRESET

OPERATING
L83TNROP MIN.
MIN. SELECT LOGIC
START-UP
or SHUT DOWN
 Synchronising - FSRSYN
• Automatic synchronization software
– Algorithms programmed into <RST> controller and <P> software.
• Bus and Generator voltage are input signals to Protective
core <P>.
– Isolation transformers are built into <P> core
• <RST> software drives the synch check and system
permissive relays.
– Sequencing and algorithms are programmed into <RST> EEPROM
• <P> hardware and software sends voted command to actual
breaker closure.
 Auto Synchronisation

Speed Raise Speed

Speed
Matching
System Lower Speed
Frequency
Speed
Raise Volts

Generator Volts Voltage

Matching
Lower Volts
System Volts
 Synchronising Scheme
<RST>
AUTO SYNCH
PERMISSIVE
Gen Volts
A
A>B
REF B <XYZ>
L83AS AUTO SYNCH
AND
Auto Synch
Permissive
Line Volts
A
A>B
REF B
Calculated Phase within Limits

Calculated slip within Limits

AND L25
Calculated Acceleration Breaker
Close
Calculated Breaker Lead Time
 Temperature Control - FSRT
• Temp.Control software/algorithms
– limit fuel flow to the turbine to maintain internal
operating temperatures within design parameters of
turbine hot gas path parts.
• Highest temperature is in the flame zone of
combustion chambers.
TTXM FSRT

TTREF
• Firing Temperature
Firing temperature - temperature of gas as it exits
the first stage nozzle.
• Speedtronic limits this firing temperature.
• Firing temperature is calculated by
– thermodynamic relation ships
– GT performance calculations, and
– site conditions
– as a function of Exhaust Temp(Tx) and CPD
fuel
Exhaust temperature (Tx)
Isothermal
air
C T
Compressor Discharge Pressure (CPD)
 FiringcanTemperature
• Firing temperature also be approximated as
– a function of Tx and Fuel flow (FSR) and
– as a function of Tx and Generator MW output
– Line of constant firing temperature are used in control
software to limit the gas turbine operating temp
– whereas the constant exhaust temperature limit protects the
exhaust system during start-up.

Exhaust temperature (Tx)

TA TB TC
Isothermal

TA > TB > TC
Fuel Stroke Reference (FSR)
 Exhaust Temp control software
• Series of application programs written to
– perform critical exhaust temperature control and monitoring.
– Major function is
• Exhaust temperature control.

– Software is Programmed for

 Temperature control command
 Temperature control bias calculations
 Temperature reference selection.
 Temperature Control Schematic <RST>

 If ONE Controller should fail, this TTXDR TTXD2 To Comb.

SORT
program ignore the readings from the TTXDS HIGHEST Monitor
TTXDT TO
failed Controller. TTXM is based on LOWEST

remaining controllers thermocouples.

 Alarm will be generated REJECT
REJECT
HIGH AVERAGE TTXM
LOW
<RST> AND REMAINING
QUANTITY TC’s
Temp Control Ref LOW
of TC’s Used
CORNER
Temperature Control <RST>
-
CPD + - FSRMIN
+
FSRMAX
SLOPE

SLOPE
TTRXB
MIN.
MEDIAN
FSRT
SELECT +
FSR + - TTXM + SELECT
-
- + +

CORNER GAIN
FSR
ISOTHERMAL

 The temp-control-command program in <RST> compares the exhaust temp control setpoint
(calculated in the temp-control-bias program and stored in computer memory) TTRXB to the
TTXM value to determine temp error. The software program converts the temp error to a FSRT
 Temperature Control Bias program
DIGITAL
INPUT COMPUTER
DATA MEMORY

TTKn_K
SELECTED
TTKn_I Isothermal
TEMPERATURE
TEMPERATURE CONTROL COMPUTER
REFERANCE BIAS MEMORY TTKn_C
TABLE PROGRAM

CONSTANT
STORAGE

Temperature Control Bias
 Temp control Bias program calculates the Exhaust
temp control setpoint TTRXB based on CPD data
stored in computer memory and constants from the
selected temp-reference table.
 This Program also calculates another setpoint based
on FSR and constants from another temperature-
reference table.
Final temp control Ref=MIN(FSR bias, CPD bias, Isothermal setpoint (TTKn_I)
CPD
FSR
Exhaust Temp Control Setpoints
 TTKn_C (CPD bias corner) and TTKn_S (CPD bias slope)
are used with the CPD data to determine the CPD
bias exhaust temperature setpoint.
 TTKn_K (FSR bias corner) and TTKn_M (FSR bias slope)
are used with the FSR data to determine the FSR
bias exhaust temperature setpoint.
 Program also selects isothermal setpoint
Primary Exhaust temperature Control Reference
TTRXP = TTKn_I - TTKn_S * (CPR – TTKn_C) + TTRXDSP + CT_BIAS + WQJG

Secondary Exhaust temperature Control Reference (Fuel Stroke Ref Bias)

TTRXS = TTKn_I - TTKn_M * (FSR – TTKn_K) + TTRXDSP + CT_BIAS + WQJG + TNH_BIAS
 Temperature Control Bias Program
• This Program selects the minimum of the three set points, CPD bias, FSR bias, or
isothermal setpoint for the final exhaust temperature control reference.
• During normal operation with Gas or light Distillate fuels, this selection results in a
CPD bias control with an isothermal limit.
– CPD bias setpoint is compared with the FSR bias setpoint by the program and an
alarm occurs when the CPD setpoint exceeds the FSR bias setpoint.
• During normal operation with Heavy fuels, FSR bias setpoint will be selected to
minimize the turbine nozzle plugging on firing temperature.
– FSR bias setpoint is compared with CPD bias setpoint and an alarm occurs when
the FSR bias setpoint exceeds the CPD bias setpoint.
• A ramp function is provided in the program to limit the rate of setpoint change. Both
Max (TTKRXR1) and Min (TTKRXR2) change in ramp rates (slopes) are
programmed.Typical rate change limit is 1.5deg F.
• The output of this ramp function is the Exhaust temp.control setpoint which is
stored in the computer memory.
 Temperature Reference Select Program
• Exhaust temperature control function selects control set points to
allow GT operation at firing temperatures.
• Temperature-control-select program determines the operational level
for control set points based on Digital input information representing
temperature control requirements.
• Three digital input signals are decoded to select one set of constants
which defines the control set points necessary to meet the demand.
Selected
Typical digital signals are Digital Temperature Temperature
BASE SELECT, Input Data Reference Reference
PEAK SELECT and Select Table
HEAVY FUEL SELECT

• When appropriate set of constants

are selected they are stored in the Temperature
Constant
Reference
selected-temperature-reference Storage
Select Program
memory.
 Fuel Control system
– Turbine fuel control system will change fuel flow to the combustors
in response to the fuel stroke reference signal(FSR).
• FSR actually consists of two separate signals added together.
FSR = FSR1 + FSR2
FSR1 = Called-for liquid fuel flow
FSR2 = Called-for gas fuel flow
• Standard fuel systems are designed for operation with Liquid
fuel and/or gas fuel.
Servo Drive System
Electro Hydraulic Servo valve
 Servo drive System
• The heart of Fuel Control System
– 3 coil Electro Hydraulic Servo Valve
• Servo valve is the interface between the electrical and
mechanical systems
• Servo valve controls the direction and rate of motion of a
hydraulic actuator based on the input current to the servo.
• Servo valve contains three electrically isolated coils on the
torque motor.
• Each coil is connected to one of the three controllers <RST>,
thereby redundancy is ensured if one of the controller fails.
• A null-bias spring positions the servo so that actuator goes
to the fail safe position when ALL power and/or control
signal is lost.
 Fuel by
• Fuel gas is controlled Gas System
– Gas Speed ratio/stop valve (SRV)
– Gas Control Valve (GCV)
(Both are servo controlled by signals from Speedtronic control panel and actuated by
spring acting hydraulic cylinders moving against spring-loaded valve plugs)
– GCV controls the desired gas fuel flow in response to the
FSR command signal.
– SRV is designed to maintain a predetermined pressure (P2)
at the inlet of the GCV as a function of turbine speed
P2= % TNH * FPKGNG + FPKGNO
P2 at firing = 35 psig & 325 PSIG at 100%

P1 P2 P3

Fuel Supply
SRV GCV To Turbine
•
Fuel Gas
Gas Fuel System consists of
System
– Fuel handling components
• Gas Strainer - Speed Ratio/Stop Vlv assembly
• Control valve assembly - Dump valves
• Three pressure gauges -
• Gas manifold with ’pigtails’ to respective fuel nozzles
– Electrical control components
• Gas supply press sw 63FG- Fuel gas press xducer(s) 96FG
• Gas fuel vent sol valve 20VG -LVDTs 96GC-1,2 & 96SR-1,2
• Electro hydraulic servo vlv 90SR & 65GC
• Speedtronic control cards TBQB and TCQC
FPRG
Fuel Gas System P&ID
TCQC
POS1
TCQC TCQC

POS2 SPEED RATIO FSR2 GAS GAS CONTROL

VALVE CONTROL CONTROL VALVE POSITION
FPG
VALVE SERVO FEEDBACK

TBQB 96FG-2A
96FG-2B
96FG-2C
20
TRANSDUCERS
VG
VENT
COMBUSTION
CHAMBER
63FG-3 Gas
Stop Control
Ratio Valve
Valve
GAS
P2

LVDT’S LVDT’S
96SR-1.2 TRIP 96GC-1.2 GAS
MANIFOLD
Vh5-1 Dump Relay
90SR SERVO 90GC SERVO

Hydraulic Supply
 Gas Control Valve
• Gas Control Valve
– GCV position is proportional to FSR2
(Actuation of spring-loaded GCV is by a hydraulic cylinder controlled by an
Electro-hydraulic servo valve)
– GCV will open only when permissive L4, L20FGX and
L2TVX (purge complete) are true.
• Stroke of the valve is proportional to FSR
OFFSET
<RST>
GAIN
FSR2 <RST>
L4 TBQC
HI
L3GCV SEL

FSROUT Analog
I/O
 FSR2 goes through Fuel splitter algorithm.
 TCQC converts FSROUT to an analog signal. GCV
GAS
 GCV stem position is sensed by LVDTs and P2
GCV Position Loop
fed back to an op-amp on TCQC card to compare Calibration
with FSROUT input signal at summing junction.

Position
LVDT
LVDT’S
 Op-amp on TCQC converts error signal and sends 96GC -1,-2
Servo
to servo valve to drive GCV accordingly. Valve
FSR
 Speed Ratio/Stop Valve
TNH
 It is dual function valve <RST> <RST>
(It serves as a pressure regulating valve to hold a GAIN

desired fuel gas pressure ahead of GCV) + FPRG D

OFFSET -
 As a Stop Valve L4 FPG A

- integral part of protection system L3GCV HI

SEL
 Speed Ratio/Stop Vlv has Two control loops POS2

 Position loop similar to GCV

 Pressure control loop

• Fuel gas pressure P2 at the inlet of GCV is 96FG-2A
96FG-2B
96FG-2C
controlled by the pressure loop as a function of SRV
turbine speed (in proportion to the turbine speed GAS Analog
96SR-1,2 I/O
TNH) to become Gas fuel press Ref FPRG LVDTs Module TBQB
Op Cyl
• TCQC card converts FPRG to analog signalP2 Posn
(FPG) is compared to the FPRG and the error Dump
Relay
signal is in turn compared with the 96SR LVDT Trip Oil
feedback to reposition the valve as in GCV loop Servo
Valve SRV Pres Calibration
– During a trip or no-run condition, a posive voltage Hydraulic
Oil
bias is placed on servo coils holding them in the P2
“valve closed” position
TNH
P2 = (FPKGNG x TNH) + FPKGNO