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Gas turbine control system
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OVER VIEW OF GTG PLANT AND OVER VIEW OF GTG PLANT AND CONTROL OF TURBINECONTROL OF TURBINE
MAIN GB
ALTERNATOR
COMPRESSOR
TURBINE & COMBUSTOR
AUX GB STARTING DE
LUBE OIL PUMP
Gas Turbine principleGas Turbine principle
cooler
Heat rejected
Heat added
1
2
3
4
CompressorHeater
Turbine
DescriptionDescription
At point 1 cold gas enter a compressor to raise pressureAt point 1 cold gas enter a compressor to raise pressure At point 2 the gas passes to the heater where At point 2 the gas passes to the heater where
temperature of gas is raisedtemperature of gas is raised At point 3 the hot gas enters the turbine where it At point 3 the hot gas enters the turbine where it
expands to a lower pressure. The shaft work developed expands to a lower pressure. The shaft work developed by turbine flows in two direction.by turbine flows in two direction.
At point 4 the exhaust gas flows to cooler where heat is At point 4 the exhaust gas flows to cooler where heat is rejected and gas is restored in initial positionrejected and gas is restored in initial position
Brayton /Joule cycleBrayton /Joule cycle
Volume
Pressure
1
2 3
4
Two reversible adiabatic or isentropic processes (1-2 and 3-4)
Two constant pressure processes (2-3 and 4-1)
Rankine cycleRankine cycle
Volume
Pressure
1
2 3
4
2-3 (Boiler) 3-4 (Turbine)
1-2 (BFP)
4-1 (Condenser)
Open cycle gas turbineOpen cycle gas turbine
1
2
3
4
CompressorTurbine
Combustion chamber
Fuel
Air from atmosphere Product of combustion to atmosphere
Salient pointsSalient points
The source of energy is normally the combustion of fuel The source of energy is normally the combustion of fuel in airin air
In closed cycle, gas turbine also product of combustion In closed cycle, gas turbine also product of combustion of fuel and air may be passed through the heaterof fuel and air may be passed through the heater
In open cycle cooler is not requiredIn open cycle cooler is not required The heater is replaced by combustion chamber and fuel The heater is replaced by combustion chamber and fuel
is burnt directly in air streamis burnt directly in air stream
Open cycle gas turbine (With heater)Open cycle gas turbine (With heater)
1
2
3
4
CompressorTurbine
Air from atmosphereProduct of combustion to atmosphere
Heat exchanger
Combustion chamber
Fuel
CONTROL SYSTEMCONTROL SYSTEM
A control scheme of a gas turbine attempts to control the A control scheme of a gas turbine attempts to control the followingfollowing
SPEEDSPEED TEMPERATURE (COMBUSTOR OUTLET)TEMPERATURE (COMBUSTOR OUTLET) LOADLOAD START UP CHARACTERISTICSSTART UP CHARACTERISTICS ACCELERATION CONTROLACCELERATION CONTROL
Above characteristics are achieved by modulating fuel Above characteristics are achieved by modulating fuel flow. Control signal ultimately acts on the fuel valveflow. Control signal ultimately acts on the fuel valve
CONTROL SYSTEMCONTROL SYSTEM
SPEEDSPEED: The speed control loop controls the speed of : The speed control loop controls the speed of the turbine by controlling the fuel flow . Speed control the turbine by controlling the fuel flow . Speed control have speed sensing as input to the controller.have speed sensing as input to the controller.
TEMPERATURETEMPERATURE: Materials used in the hot gas path of : Materials used in the hot gas path of gas turbine are stretched much closer to their limits than gas turbine are stretched much closer to their limits than any other machine. The control system takes design any other machine. The control system takes design temperature of hot flue gas path material as set point.temperature of hot flue gas path material as set point.
LOADLOAD: The control loop takes the MW as the set point. : The control loop takes the MW as the set point. The control loop also interferes when rate of loading The control loop also interferes when rate of loading exceeds a certain point as turbine is loaded fast the exceeds a certain point as turbine is loaded fast the damage of the component may occurdamage of the component may occur
CONTROL SYSTEMCONTROL SYSTEM
START UP CHARCTERISTICSTART UP CHARCTERISTIC: The : The control system brings the gas turbine from control system brings the gas turbine from zero speed to operating speed using zero speed to operating speed using preset level of fuel flow through automatic preset level of fuel flow through automatic sequencing of control signals to the sequencing of control signals to the accessories, starting device and fuel accessories, starting device and fuel control systemcontrol system
CONTROL SYSTEMCONTROL SYSTEM
ACCELERATION CONTROLACCELERATION CONTROL: One critical : One critical component of the turbine start sequence is component of the turbine start sequence is the acceleration to synchronous speed. A the acceleration to synchronous speed. A design acceleration rate must be design acceleration rate must be maintained throughout start up to limit maintained throughout start up to limit stress on turbine parts.stress on turbine parts.
MARK VI CONTROL SYSTEMMARK VI CONTROL SYSTEM
The main function of mark VI control The main function of mark VI control system aresystem are
Speed control during start upSpeed control during start up Turbine load control during normal Turbine load control during normal
operation on the gridoperation on the grid Protection against turbine over speed on Protection against turbine over speed on
loss of loadloss of load Automatic generator synchronizationAutomatic generator synchronization
MARK VI CONTROL SYSTEMMARK VI CONTROL SYSTEM
It runs on PC based work station using MS It runs on PC based work station using MS window client server architecture.window client server architecture.
HMI provides operator display and control for HMI provides operator display and control for mark VI turbine controllermark VI turbine controller
HMI contains a number of product featureHMI contains a number of product feature Dynamic graphicsDynamic graphics Alarm displayAlarm display Process variable trendingProcess variable trending Point control display (For maintenance)Point control display (For maintenance) HMI access securityHMI access security
COMMUNICATIONCOMMUNICATION
PLANT DATA HIGHWAY
UNIT DATA HIGHWAY
HMI SERVERNODE
I/O BOARD
UCVx CONTROLLER
DCS ETHERNET GSMDCS ETHERNET MODBUS
MARK VI TMR CONFIGURATIONMARK VI TMR CONFIGURATION
Ethernet < R> CONTL MOD
< S> CONTL MOD
< T> CONTL MOD
X
Y
Z
< P> PROT MOD
TO DCS
Ethernet- IONet
Primary ControllerBackup Protection
To other GE control sys
Software Voting
PS
PS
PS
Primary ControllerPrimary Controller ControlControl ProtectionProtection MonitoringMonitoring
<R>, <S>, <T> are Control processor<R>, <S>, <T> are Control processor
Backup ProtectionBackup Protection Emergency over speedEmergency over speed Synchro check protectionSynchro check protection <X>, <Y>, <Z> are back up processor<X>, <Y>, <Z> are back up processor
MARK VI BOARDSMARK VI BOARDS
I/O Terminal BoardI/O Terminal Board I/O BoardI/O Board Processor CardProcessor Card Communication CardCommunication Card Protective Processor Protective Processor <X>, <Y>, <Z><X>, <Y>, <Z> Rack Power SupplyRack Power Supply Power Distribution BoardPower Distribution Board
MARK VI I/OMARK VI I/O General Purpose I/OGeneral Purpose I/O Contact InputContact Input Relay OutputRelay Output Analog I/OAnalog I/O Thermocouple InputsThermocouple Inputs RTD inputsRTD inputs Turbine specific I/OTurbine specific I/O Vibration InputsVibration Inputs Speed InputsSpeed Inputs Servo channels for control valves (LVDT or LVDR )Servo channels for control valves (LVDT or LVDR ) Flame InputsFlame Inputs Automatic SynchronizingAutomatic Synchronizing
MARK VI COMMUNICATIONMARK VI COMMUNICATION
External CommunicationExternal Communication HMI to Mark VIHMI to Mark VI HMI to DCSHMI to DCS Internal CommunicationInternal Communication VCMI & Control processorsVCMI & Control processors DCMI to I/O boardsDCMI to I/O boards I/O signal flowI/O signal flow Unit data Highway (UDH)Unit data Highway (UDH) Ethernet network between controllers and HMIEthernet network between controllers and HMI Plant data Highway (PDH)Plant data Highway (PDH) Connects HMI server with printers DCS etcConnects HMI server with printers DCS etc
IONETIONET
IONet is Ethernet network used to IONet is Ethernet network used to communicate data between the VCMI communicate data between the VCMI communication board in control module, communication board in control module, the I/O boards and three independent the I/O boards and three independent sections of protection modulesections of protection module
IONet also communicate data between IONet also communicate data between controllers in TMR systemcontrollers in TMR system
CONTROL SYSTEM TOOLBOXCONTROL SYSTEM TOOLBOX
Window based application used to configure & maintain Window based application used to configure & maintain Mark VI control equipmentMark VI control equipment
Primary function includesPrimary function includes Graphical based editor for configuring application codeGraphical based editor for configuring application code Block macros and module library supportBlock macros and module library support Live data block flow diagramsLive data block flow diagrams On line code changeOn line code change On line help filesOn line help files I/O configuration & monitoringI/O configuration & monitoring Signal management and signal trendingSignal management and signal trending Report GenerationReport Generation
PASSWORD ADMINISTRATIONPASSWORD ADMINISTRATION
0-Level: Read only like view, monitor live data 0-Level: Read only like view, monitor live data 1-Level: All function allowed in 0-Level and Change 1-Level: All function allowed in 0-Level and Change
Controller Variables and signals and drive advanced Controller Variables and signals and drive advanced maintenance like change the value of variable, force maintenance like change the value of variable, force signals in a controllersignals in a controller
2-Level: All function allowed in 0 & 1 Level and full 2-Level: All function allowed in 0 & 1 Level and full controller access and drive advanced maintenance like controller access and drive advanced maintenance like make code change, download,put in database and get make code change, download,put in database and get from data basefrom data base
3-Level: Drive Block Area and Menu maintenance like 3-Level: Drive Block Area and Menu maintenance like alter block area and change application menu structurealter block area and change application menu structure
4-Level: Fuull Drive access like change GE 4-Level: Fuull Drive access like change GE parameter,edit hardwareparameter,edit hardware
CIMPLICITYCIMPLICITY
Cimplicity is a graphical interface made up of Cimplicity is a graphical interface made up of one or more screens used to monitor and control one or more screens used to monitor and control the turbine operationthe turbine operation
Cimplicity servers allows operator to directly Cimplicity servers allows operator to directly interface to the mark VI controller (UDH) using interface to the mark VI controller (UDH) using graphical screengraphical screen
The cimplicity server interface to the mark VI is The cimplicity server interface to the mark VI is done by the cimplicity project. This project is done by the cimplicity project. This project is controlled by a project file using cimplicity work controlled by a project file using cimplicity work bench programbench program
TROUBLE SHOOTING TOOLSTROUBLE SHOOTING TOOLS
Finder/Signal BrowserFinder/Signal Browser