Please Note:
This is a partial description of the control software.
You can find most of the important functions here.
Please accept, that we cannot provide the whole detailed turbine controls documentation in an
offer.
During start and acceleration, the acceleration fuel reference will limit the
rate of change of speed.
The control signal TNR is the gas turbine speed/load reference in terms of
percent. During startup, this command varies from 0% to 100% speed. After
synchronization to an electrical power grid, TNR becomes a load reference and
typically varies between 100% and 104% to command the power output from 0% to
100% rated load.
DROOP CONTROL
ISOCHRONOUS CONTROL
Constant Settable Droop Control features an inner speed control loop and an
outer megawatt control loop. The inner speed loop is proportional plus
integral control whose mission is to make the turbine speed, TNH, match the
called for reference speed command TNRL. The outer megawatt loop formulates
the droop governor response by creating a speed bias as a function of unit
power output. When the turbine speed is held fixed by an electrical grid,
the turbine fuel consumption and megawatt output is modified (or 'Constantly
Set') such that the TNRL reference speed command is made to equal the turbine
speed,TNH. The scaling of the turbine power output, DWATT, to the speed bias
signal,DWDROOP, defines the droop governor response in terms of megawatt
output changes per percent grid speed changes.
Three watts transducers are used for reliability on the constant settable
droop design. Each transducer must be connected in the correct sense and
independently powered. If the transducers are miswired or unpowered, the
watts feedback signal can act in the sense to over fuel the turbine.
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ACCELERATION CONTROL
This algorithm limits the rate of the HP shaft speed acceleration by limiting
"FSR" at "FSRV1" algorithm. This function acts on the rate of speed increase
to prevent overspeed with load rejection.
Load control: the speed/load setpoint is raised or lowered until the watts
feedback is within the deadband of constants LK90DB1 and LK90DB2.
Temperature control: when the unit reaches temperature control, speed control
continues to count up requiring more FSRN than the temperature limit, FSRT.
This is done to keep the unit steadily on temperature control with minimal
switch back to speed control. Count up is determined by deadband limit,
LK90DB3, where raise is inhibited. As the unit is subject to ambient
temperature change and FSRT drops, a greater deadband limit, LK90DB4, is
exceeded and the setpoint is lowered to keep speed control relatively close.
Load limit LK90MAX is set to prevent exceeding the most critical design limit
on the gas turbine application, i.e. shaft, load coupling, etc.
This optional function provides a rate controlled changer for the preselected
load setting by substituting L90PSEL for the constant LK90PSEL in L90L.
Operators can utilize this, within set limits, without changing constants.
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A thermocouple position is set to 0.0 CNTS when not used. This assures a
number outside the array of possible assignments.
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When the turbine is at operating speed, L14HS, and the gas turbine compressor
discharge pressure, CPD, falls below the constant, CAKCPD, the logic signal,
L3TFLTX, is asserted. This signal latches the compressor discharge pressure
fault alarm, L3TFLT, until a master reset, L86MR1_CMD is asserted. L3TFLT,
is used to initiate backup temperature control in the TTRX algorithm and
alarm the operator. Failure of two CPD transducers on Dry Low NOx units will
cause a turbine trip, L4DLNT2.
n = 0, curve 0
n = 1, curve 1
n = 2, curve 2
n = 3, curve 3
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Bias Options
------------
* The gas turbine exhaust temperature may also be biased by compressor inlet
temperature.
COMBUSTION MONITORING
Combustor
1. Failed Liner (cracked or burned)
2. Failed Transition Piece (cracked or burned)
3. Collapsed Liner
4. Hot Crossfire Tubes
Fuel System
1. Break in Gas fuel line
2. Plugged or Stuck Check Valve
Fuel Nozzle
1. Plugged Fuel Nozzle
2. Unscrewed Fuel Nozzle
3. Fuel Nozzle Erosion
This algorithm uses the max CTDA, and the system exhaust temperature TTXM, to
calculate allowable spread,
TTXSPL is a median selected value between 30 deg F MIN and 125 deg F MAX.
The three highest spreads (TTXSP1, 2, and 3) are calculated and compared to
allowables (constants TTKSP1, 2, 3, & 4). Logic signals L60SP1, 2, or 4,
are satisfied if the highest three spreads are greater than their allowables.
Two adjacency checks are also made to determine if the lowest and second
lowest(L60SP5) are adjacent, and/or if the second lowest and third lowest
(L60SP6)are adjacent. With L2SMP1 and 2, monitor spreads can be observed with
the monitor enabled but before alarms are enabled.
TTXSP1 (s1) = the difference between the highest and the lowest
thermocouple reading. (spread1)
TTXSP2 (s2) = the difference between the highest and the second
lowest thermocouple reading. (spread2)
TTXSP3 (S3) = the difference between the highest and the third
lowest thermocouple reading. (spread3)
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OR,
OR,
There are two dual element thermocouples (TC) in each measurement location to
monitor the wheelspace temperatures. The average temperature measured by the
two TC's is computed and compared to an alarm level for each location. If
this average temperature exceeds the alarm level, a common alarm, L30WSA2, is
generated. For the first hour of operation, WSKALM9 is added to each of the
alarm levels.
The two TC's at each location are also compared against each other. If they
differ by more than WSKALM8, an alarm L30WSA1 is given. All of the average
wheelspace temperature values are compared against each other and the highest
value is selected. This value is then compared to LK69TWW, to allow water
wash.
In the cooldown sequencing, there is a "max" select gate to take the warmest
wheelspace thermocouple and compare it to LK69WSMAX to provide a mandatory
cooldown time to insure adequate cooling of the turbine.
Refer to the appropriate 0416 schematic and the device summary for
thermocouple locations and description. Drain temperatures are normally about
150 deg f.
Rising temperatures may indicate bearing problems or lube system
restrictions.
STARTUP/SHUTDOWN TIMERS
The design criterion for purging the exhaust path before firing, is to
exchange 4 (5 if NFPA requirements are used) times the exhaust heat recovery
volume, to ensure that the machine and exhaust are fully purged of combustion
gases. Purge timer K2TV is set to hold the turbine at the purge speed long
enough to produce these 4 (5 if NFPA requirements are used) volume exchanges.
After K2TVP times out, the Safety Shutoff Valve is opened and timer K2TV
allows the line to pressurize up to the Gas Turbine gas valves. Then firing
is initiated.
The firing timer is the maximum amount of time the control system will
attempt to fire the machine. If flame is not established before the firing
timer times out, fuel is shut off and the spark plugs are de-energized. A
restart can not be attempted until the machine completes another purge cycle.
After flame is established and FSR is cut back to the warm up level, it is
maintained at this level for the duration of the warmup timer to reduce the
thermal stress on the rotor.
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Startup control passes the following levels of FSR to the FSR MIN select
gate.
FSKSU_FI
In order to ignite the combustion system and provide crossfiring around the
turbine's combustors, startup FSR is stepped to the firing value while the
spark plugs are firing.
FSRSU_WU
After flame is detected FSRSU is cut back to the level defined by FSRSU_WU.
This reduced level of FSR is intended to reduce the thermal stress on the
rotor.
During the transition from firing FSR to warmup FSR, a first order filter is
introduced which slows the transition from one FSR level to the next. The
filter uses the time constant FSKSU_TC.
The transition from firing to warmup occurs after one of two conditions is
met:
STARTUP SEQUENCE
The starting means has the ability to apply different levels of torque to the
rotor which are appropriate for the various stages of startup.
The controller has been configured with an automatic refire capability. This
function will repurge and refire the turbine if flame is not established on
the first firing attempt. Timer, K62TT2, sets the number of firing attempts
allowed per operator start selection.
The FSRACC algorithm computes the appropriate fuel stroke reference for
correct control of the turbine shaft acceleration. The algorithm computes an
acceleration reference, TNHAR, and a corresponding fuel stroke to maintain
this acceleration rate. The controller derives actual turbine shaft speed
with respect to time, calculating the shaft acceleration TNHA. TNHAR is
compared with TNHA and FSRACC is adjusted to drive the error between the two
to zero.
However, FSR and FSRACC are limited by startup fuel stroke reference FSRSU on
the high side, and minimum blow out fuel FSRMIN on the low side. Thus beyond
these limits FSRACC will not be in control of the shaft acceleration. (e.g.
the starting means may be controlling the acceleration even though the fuel
to the turbine has been cut back to FSRMIN).
FIRED SHUTDOWN
The FSRSD algorithm controls the gas turbine fuel during a fired shutdown by
initiating FSR ramp down at appropriate events until FSRMIN is intercepted.
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When the generator breaker opens, the shutdown FSR, FSRSD, ramps from
existing FSR to FSRMIN at set rate FSKSD3. FSRSD latches onto FSRMIN and
decreases with corrected speed. When speed drops below a defined threshold,
K60RB, FSRSD ramps to a blowout at one flame detector.
Timers limit the duration of the ramp to blowout. One timer trips after a
fixed time from rampdown. A second timer limits fuel after any functional
flame detector drops out.
MINIMUM FSR
Minimum FSR is the least amount of fuel that will continue to maintain flame
in the combustor. It is required to insure that other forms of FSR control
can not call for a fuel level that will cause the flame to blow out.
If FSKMIND4 is set too low the unit may blow out during load rejection or
synchronizing. If FSKMIND4 is set too high the unit will continue to increase
its speed after 100% speed is reached, as speed control is unable to reduce
FSR below the level defined by FSKMIND4.
During shutdown, FSRMIN settings at open and closed IGV corrected speed allow
correction for airflow as IGV`s close. Two other points are set at lower
speeds to allow for airflow to decrease in a quadratic manner. Values for
shutdown should be set to provide a continuously decreasing combustion
reference temperature, not too close to blowout.
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COOLDOWN SEQUENCE
The lube oil pumps work in conjunction with the hydraulic ratchet mechanism
to rotate the rotor approximately 47 degrees every three (3) minutes. This
provides a uniform cooling of the rotor. In the normal cooldown mode, the
Auxiliary lube oil pumps are operating continuously with the intermittent
operation of the ratchet. When AC power is unavailable, the DC lube oil pumps
are cycled on for 15 seconds at the onset of each 3 minute cooling cycle.
Upon coastdown from a running condition, the cooldown cycle will immediately
take effect, and continue indefinitely until "Cooldown Off" is manually
selected.
Cooldown may also be initiated manually by selecting "Cooldown On" and will
continue indefinitely until "Cooldown Off" is selected.
The FSR algorithm compares all of the previously calculated fuel stroke
references with the exception of FSRMIN and selects the minimum value as the
controlling FSR. The value of FSR is limited to anything greater than or
equal to FSRMIN. FSRMIN in control generates a logic change in the software.
FSR manual control is an open loop fuel control used to suppress the fuel
stroke reference in the FSR minimum select gate algorithm. The FSR setpoint
is preset at 128% out of the way. The FSRMAN below 128% alarms indicating
that the FSRMAN is not at the maximum value. The setpoint may be adjusted
with the following three methods; raise and lower commands, analog setpoint,
or the preset button which sets FSRMAN equal to FSR.
The rate of change of FSR algorithm logic identifies when an excessive FSR
rate of change has been detected. Logic signals change state if the
increasing or decreasing rates have exceeded the alarm settings for three
scans. The change must have exceeded a magnitude for the duration of three
successive scans.
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The FSR Splitter algorithm controls the percentage and the rate of change of
the Gas/Liquid Fuel split. The fuel selection sequence permits and sends the
commands to the fuel splitter to change the fuel split. FSR1 is used to
represent the percentage of liquid fuel and FSR2 is used to represent the
percentage of gas fuel. The L84TL, L84TG, and L84MIXT signals are used in the
fuel sequencing as an indication that the gas turbine is operating on 100%
liquid, 100% gas, liquid/gas mixture respectively. Prefill is initiated at
the beginning of the transfer of fuels.
Transfer should be done above 25% Load (about 10 MW) on this unit. Mixed
fuel operation window is 60%-90% gas and 60% gas at 25% load to 30% Gas at
Base Load. The Mixed window is to prevent combustion chamber pulsation due to
low nozzle pressure ratio. Liquid fuel mixture should be greater than 10% to
prevent excessive liquid fuel recirculation resulting in fuel overheating and
possibly causing fuel pump damage.
Permissives to operate in the mix fuel state are load, (DW_MIN_MIX), minimum
percent gas fuel, (GAS_MIN_MIX), and minimum percent liquid fuel,
(LIQ_MIN_MIX).These are only the minimum requirements and it is up to the
operator to follow the guidelines given in the previous paragraph.
From the time L2TVP is picked up until firing fuel is commanded, the GCV is
checked to verify that it is being closed by saturation current, and held
closed within a small stroke. If there are failures which would cause the
valve to open, it should be detected in this interval before firing. If the
servo valve is failed or not acting in the right sense, the position test
would detect it. During the checking interval, the valve is commanded closed
driving all three coils into saturation. The current saturation test then
gives assurance the servo is working before firing.
The gas control valve FSROUT command to the position regulator is controlled
as a function of the FSR2 signal. Sequencing internal to FSROUT drives FSROUT
negative to close the gas control valve whenever the turbine is tripped or a
gas valve fault occurs.
The FPRG algorithm outputs a negative pressure command, FPKGSD, to hold the
valve closed and saturate the servo before firing. Until the end of any purge
time when L3GRV enables fuel, the SRV is checked for saturation current. At
L3GRV, FPRG outputs the pressure control reference. If there is failure of
the pressure transducer or feedback, the LK3GRVSC excess fuel setting will
trip startup within seconds as the valve goes wide open (the amount of fuel
admitted will be less than that NORMAL to the firing time interval). The
LK3GRVSC setting can be reset to close the actual firing stroke.
The fuel gas supply pressure range specified in this control specification is
selected to assure satisfactory control. If the supply pressure is allowed
to go below the minimum specified, the control valves may operate wide open
and the gas turbine could be subjected to adverse temperature rise when the
pressure is suddenly increased.
The fuel gas supply temperature range specified in this control specification
has been used to calculate fuel flows based on the fuel analysis supplied.
The minimum gas temperature has been reviewed with respect to the hydrocarbon
dewpoint of the gas, to avoid precipitation of hydrocarbons. The fuel gas
supply temperature should be maintained to insure a minimum of 50 deg F
superheat above the hydrocarbon dewpoint. The fuel gas supply must be free of
liquid hydrocarbons and water at all times.
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The pressure ahead of the GCV is controlled by the speed ratio valve (SRV) at
a ratio of TNH plus a preset.
When the fuel gas supply is shut off, the ratio valve acts as a stop valve,
and is given a negative anti-dribble reference to force it closed.
When L4 picks up on gas fuel startup, L20FG picks up trip oil pressure, and
the speed ratio valve is verified closed by L3GRVO. At the end of the purge
time(L2TVX), L3GRV enables FPRG. If the SRV position exceeds LK3GRVSC,
startup is tripped.
Reset LK3GRVSC just above expected firing position with normal supply
pressure.This will also trip if the GCV stroke is abnormal, up until flame is
detected.
When L4 picks up on gas fuel start-up, the GCV position is compared to preset
limit LK3GCVO to verify the GCV is closed.
The actual LVDT position of the IGV's (CSGV) and the IGV servo driver output
(CAGV) are compared to preset limits to annunciate IGV fault conditions.