PRESENTATION

ON

GAS TURBINE CONTROL & PROTECTION

Presented
by
Kirit Padalia
Pranav Dave

CPP - INSTRUMENT

April 2, 2016

TOPICS
ACKNOWLEDGEMENT AND REFERENCE
OVERVIEW
PROTECTIONS
CONTROL SCHEMES
MARK V CONTROL SYSTEM
OVERVIEW
STARTUP SEQUENCE

April 2, 2016

REFERENCES
DEP 31-29-70-11-Gen Combustion Gas
Turbines
DEP 31.29-70.31-Gen Combustible Gas
Turbines[amendments] supplement to API619

DEP 31.29 .70.32 Gas Turbine Combustion

Air Intake &
Exhaust system
BHEL GAS TURBINE MANUALS

ACKNOWLEDGEMENT
Sh. DHIREN RINDANI
Sh.
April
2,KRISHNA
2016
SRINI

CONTROL AND INST. FUNCTIONS

SR
No.

FUNCTIONS

LOCAL
DISPLAY

REMOTE
NORMAL
ALARM
TRIP
DISPLAY
S/D

1 FLOW
FUEL
STEAM INJECTION

I,R
I

2 LEVEL
LUBE OIL TANK

L,H

HITECH TANK

L,LL

3 PRESSURE
AIR FILTER DP

AIR COMPRESSOR DISCHARGE

EXHAUST PLENUM

GAS FUEL

I,R

LIQUID FUEL

I,R

LIQUID FUEL TO NOZZLE

ATOMISING AIR

I,R

LUBE OIL

I,R

HYDRAULIC OIL

I,R

TRIP OIL

I,R

SEALING AND VENTING

I,R

COOLING WATER

I,R

LUBE OIL FILTER DP

INJECTION
AprilSTEAM
2, 2016

HH

HH

I,R
HH

LL
LL

H
I,R

HH

CONTROL AND INST. FUNCTIONS

SR
No.
4

LOCAL
DISPLAY

REMOTE
DISPLAY

ALARM

LUBE OIL TANK

I,R

L,H

COOLING WATER

I,R

FUNCTIONS

ATOMISING AIR

H,HH
I
I,R

COMPRESSOR DSCH. AIR

I,R

TURBINE WHEEL SPACE

I,R

TURBINE EXHAUST

I,R

BEARING

I,R

SPEED
FLOW DIVIDER

I,R

TURBINE

I,R

VIBRATION
PROXIMITY PROBES

I,R

SEISMIC SENSOR

I,R

AXIAL DISPLACEMENT

I,R

HH

HH

HH

FLAME
I,R

FIRE & GAS

FIRE DETECTION
GAS DETECTION
MAMNUAL TRIP

HH

COMPRESSOR INLET AIR

TURBINE
8

TRIP

TEMPERATURE

ACOUSTIC ENCLOSURE

NORMAL
S/D

H
X

MISCELLANEOUS

DEVICE
AprilSTARTING
2, 2016

HOW GT WORKS

EXHAUST

C O M B. CH M BR

CO M PRESSO R

TURBINE

3
P2
EXPANSION

4
COMB.

INLET AIR

TEMP.

P1

BRAYTONE CYCLE

2
COMP.
EXHAUST

April 2, 2016

ENTROPY

GAS TURBINE ADVANTAGES

COMPACT
FAST STARTUP & RAPID LOADING
MODERATE FIRST COST
LESS GESTATION PERIOD (TAILOR MADE)
EASY MAINTENANCE
HIGH RELIABILITY
BEST FOR STAND ALONE APPLICATION
LESS ERECTION TIME

April 2, 2016

GAS TURBINE ADVANTAGES

HIGHER THERMAL EFFICIENCY WITH
COMBINED CYCLE OPERATION.
NO COOLING WATER REQUIRED.
FUEL FLEXIBILITY
FEWER AUXILIARIES.
WEIGHT/ POWER RATIO IS LESS

April 2, 2016

GAS TURBINE MAJOR MANUFACTURER

GENERAL ELECTRIC
ABB (ASIA BROWN BOWERI)
SIEMENS
WESTINGHOUSE
ROLLS ROYCE
RUSTONE
April 2, 2016

GAS TURBINE APPLICATIONS

POWER GENERATION
TO DRIVE COMPRESSOR
AVIATION
SHIPPING
RACING MOTOR VEHICLES

April 2, 2016

GAS TURBINE CLASSIFICATION

BASED ON COMBUSTOR
CYLO TYPE COMBUSTION CHAMBER
- ABB, SIEMENS
MULTI CANE COMBUSTOR
- GE, WESTINGHOUSE, RUSTONE
BASED ON No. OF SHAFTS
SINGLE SHAFT (GE, ABB, SIEMENS)
TWIN SHAFT (GE, RUSTONE, WESTINGHOUSE)

April 2, 2016

CYLO TYPE COMBUSTOR

FUEL

TO TURBINE
April
2, 2016

AIR

MULTICANE TYPE COMBUSTOR

COMBUSTOR &
FUEL NOZZLE

TURBINE

April 2, 2016

GAS TURBINE MAIN FEATURES

BUCKET/BLADE AND NOZZLES ARE AIR COOLED .
TURBINE LEGS ARE WATER COOLED.
ENOUGH ROTOR/STATOR CLEARANCE .
BLACK START
IMPULSE TURBINE (STG REACTION TYPE)
GAS TURBINE RANGES (0.1 MW TO 225 MW)

April 2, 2016

GAS TURBINE AUXILIARIES

LUBE OIL SYSTEM
TRIP OIL SYSTEM
ATOMISING AIR SYSTEM
PURGE AIR SYSTEM
STARTING DEVICE
COMPRESSOR PULSATION
INLET AIR SYSTEM
FUEL SYSTEM
April 2, 2016

GAS TURBINE AUXILIARIES

STEAM INJECTION SYSTEM
IGNITION SYSTEM
RATCHETING MECHANISAM
FIRE PROTECTION
COOLING WATER
April 2, 2016

GAS TURBINE PROTECTION

LOSS OF FLAME
VIBRATION
EXHAUST TEMPERATURE
OVER SPEED
EXHAUST PRESSURE
LUBE OIL PRESSURE/ TEMP.
BEARING TEMP
CONTROL/TRIP PRESSURE
FIRE PROTECTION

April 2, 2016

GAS TURBINE PROTECTION

LOW FUEL PRESSURE
INLET AIR FILTER DP
TURBINE COOLING PRESSURE
COMPRESSOR SURGE
STARTING DEVICE TRIP
INLET GUIDE VANE TROUBLE
TRIP FROM DRIVEN EQUIPMENT
EXCESSIVE FUEL

April 2, 2016

EXHAUST TEMPERATURE

ISO TRIP
40 deg F

633 Deg c
618 Deg c
593 Deg c
25 deg F

TRIP

TTREF

ALARM
CONTROL

April 2, 2016

CPD

6.98 BAR

COMBUSTION MONITOR
TOTAL 18 T/C
ACTUAL SPREADS
TTXSP1 = HIGH - LOW
TTXSP2 = HIGH - 2nd LOW
TTXSP3 = HIGH - 3rd LOW
ALLOWABLE SPREAD
TTXSPL = BASED ON CTD & TTXM

April 2, 2016

COMBUSTION MONITOR
ALARM
TTXSP1 => TTXSPL

TRIP
- TTXSP1 > TTXSPL and TTXSP2 > 0.8 * TTXSPL and
LOW T/c IS NEXT TO THE SECOND TO LOW T/c..
- TTXSP2 > 0.8 * TTXSPL and ONE T/c IS FAILED ( TTXSP1

> 5 * TTXSPL) and 2nd LOWEST T/c NEXT TO 3rd

LOWEST T/c.
- TTXSP3 > 0.8 * TTXSPL.

April 2, 2016

OVER SPEED
PRIMARY

110 %

EMERGENCY

112.3 %

MECHANICAL 113 %
TEST

April 2, 2016

113.3 %

GAS TURBINE CONTROL

STARTUP
ACCELERATION
SPEED
EX. TEMP.
SYNC.
MANUAL
April 2, 2016

FSR
MIN. GATE

FINAL FSR

STARTUP FSR (FSRSU)

FIRE

15.6%

WARMUP

11.6%

ACCELERATE19.8%
SPEED

17.6%

>>> OPEN LOOP CONTROL

April 2, 2016

ACCELERATION FSR ( FSRACC)

TNHA

TNRA

April 2, 2016

FSR ACC

ACCELERATION FSR (FSRACC)

0.31

0.31

0.31 % / SEC

TNRA
0.11
0.11
0.10 % / SEC

0.10

0%

40%

50%

TNH
April 2, 2016

75%

95%

100%

SPEED FSR ( FSRN)

ISOCHRONOUS (FSRNI)

TNH

TNR

April 2, 2016

FSRNI / FSRN

SPEED FSR ( FSRN)

DROOP
104 %

100 %

TNH

FSNL
April 2, 2016

LOAD

RATED

TEMPERATURE CONTROL FSR (FSRT)

TTXM

TTREF

April 2, 2016

FSRT

TEMPERATURE CPD BIAS

6.98 Bar

593 Deg C

TTREF

April 2, 2016

16.11 Deg C / Bar

CPD

INLET TEMPERATURE CALCULATION

2.44 *

TET

{0.53(26.7%+
(33.3*CPD))}
{62.8%+(Pexh*4.7%)+
{Pamb*23.5%}}

April 2, 2016

90.35%

TEMPERATURE FSR BIAS

593 Deg C

54.12 %

TTREF

21.5 C / %

FSR

April 2, 2016

OTHER CONTROL LOOPS

SPEED RATIO VALVE
P2

P1

P3

SRV

GCV

FULE GAS SUPPLY TO TURBINE

265.2 psig
P2 = (2.8 psig /% * TNH) - 14.8 psig

P2

13.2 psig

April 2, 2016

10%

TNH

100%

OTHER CONTROL LOOPS

INLET GUIDE VANES
- PREVENT AXIAL COMP. STALLS
- MAXIMIZE HEAT RECOVERY
- STABILIZE FLAME AT LOW LOADS

593 Deg C

6.98 Bar

TTXM
16.11 Deg C / Bar

April 2, 2016

CPD

MARK-V OVERVIEW
DEDICATED TURBINE CONTROLLER
IT IS A TMR PLC (PC BASED UI AND BOI)
AND CAN BE USED AS SIMPLEX.
MINIMUM SCAN TIME 62.5 MS
CONTROL AND PROTECTION MODULES
ARE SEPERATE.

April 2, 2016

MARK V (TMR) PANEL LAYOUT

<S>

<R>

<C>

<T>

<P>

<PD>

<D>

<QD1>

<CD>

April 2, 2016

MARK IV TMR
HIGH
TEMP.

<R>

<S>

<T>

April 2, 2016

STOP

GO

GO

2/3
VOTE

GO

MARK IV TMR
HIGH
TEMP.

LOW
TEMP.

<R>

STOP

<S>

STOP

<T>

GO

April 2, 2016

2/3
VOTE

STOP

MARK V SIFT TMR

HIGH
TEMP.

<R>

GO
GO !
SIFT

LOW
TEMP.

<S>

<T>

April 2, 2016

GO

GO

2/3
VOTE

GAS TURBINE START SEQUENCE

LUBE / CONTROL OIL SYSTEM ON
STARTING CLUTCH ENGAGE
L4 (MASTER PROTECTIVE) RELAY ENERGISED
READY TO START
START COMMAND
STARTING DEVICE ON
SPEED INCREASE TO CRANKING SPEED
AFTER PURGE TIMER SPEED REDUCE TO FIRING
SPEED

April 2, 2016

 IGNITION SYSTEM ON AND FIRING FSR SET

FLAME ESTABLISHED.
WARMUP FSR SET & WARMUP TIMER INITIATED.
ACCELERATION FSR SET.
SELF SUSTAINING SPEED , STARTING DEVICE GETS
DISENGAGED.
IGV STARTS OPENING AT 85 % SPEED
COMP. BLEED VALVES (20CB) CLOSE AT 95% SPEED
M/c REACHES TO FSNL
IGV OPENS TO 57 DGA AT FSNL
M/c READY FOR SYNC.

April 2, 2016

START

GAS TURBINE SET UP AT RPL - JAMNAGAR

TOTAL EIGHT MACHINES
BHEL AND NUOVO PIGNONE SUPPLIED (GE LICENSE)
GE FRAME VI MACHINES
BRIEF SPECS OF GAS TURBINE
> MODEL
: MS6000-PG6541, PG6551 & PG6561
> DOR
: CCW
> SPEED
: 5100 RPM
> CONTROL : MK-V SPEEDTRONIC
> LOAD
: 34 MW AT 30 DEGC,22M ABOVE MSL
> COMPRESSOR STAGES : 17
> TURBINE STAGES : 3

April 2, 2016

ROLL OF DCS WITH GT CONTROL

DCS COMMUNICATE TO MARK-V THROUGH
<I> STATION BY MODBUS PROTOCOL.
DCS ONLY READS ( NOT WRITING ).
DCS USED AS DATA ACQUISITION SYSTEM AND LINK .
BETWEEN GT <I> STATION AND IP 21.
CALCULATION OF HEAT RATE IS DONE IN DCS.
EFFICIENCY CALCULATION CAN BE IMPLEMENTED.

April 2, 2016

GT TRIP REASON
FALSE FIRE TRIP
EXHAUST THERMOCOUPLES IN NP M/c
HIGH TEMP IN TURBINE COMPT.
IGV LVDT INSTALLATION
FUEL PRESSURE CONTROL VALVE OPENING
DURING CHANGEOVER
MOOG VALVE FILTER
COMPRESSOR BLEED VALVE TROUBLE

April 2, 2016

April 2, 2016

GAS TURBINE AIR INTAKE SYSTEM

TO PROVIDE ULTRA CLEAN AIR FOR COMPRESSOR.
PAPER FILTERS SIZE OF 3 Microns ARE USED.
SELF CLEANING SYSTEM FOR FILTERS.
FILTER HEALTHYNESS MONITORED BY INLET PLENUM
PRESSURE.
TOTAL 448 FILTERS USED FOR GEN / COMPRESSOR
AIR FILTERATION.
MACHINE WILL UNLOAD/TRIP WHEN HIGH DP
ACROSS FILTER.

April 2, 2016