Gas Turbine Control System

Speedtronic Mark IV
Kawas Gas Power Project
NTPC Limited

GAS TURBINE CONTROL SYSTEMS

Gas Station

GT Control System

Auriya

MIDAS 8000 (MHI)

Anta

Procontrol-P (ABB)

Jhanor

Procontrol-P (ABB)

Dadri

Teleperm-ME (Siemens)

Faridabad

Teleperm-XP (Siemens)

Kawas

Mark-IV (GE)

Kayamkulam

Mark- V (GE)

CONTROL SYSTEM WORKS ?

CONTROL SYSTEM FUNCTIONS

Monitoring (Supervisory) :
Provides measurement of all the process parameters like
Pressure, position of valves , temp. , flow etc. It also provides
alarms to the operator when required.
Control (CLCS) :
Controls the process parameters to achieve the desired
output while keeping the equipments operating under
designed limitations.
Interlock/ Sequencing/Protection (OLCS) :
Ensures safe and automated start-up logic. All the equipments
do have certain limitations for operating parameters. If it
crosses the limits, the system should trip / stop to prevent
any damages.

CONTROL SYSTEM SIGNALS

Information and commands are transmitted in form of
electrical signals. There are two types of electrical signals
Analog signals
Analog electrical signals have continuous values. They
convey process information within a defined range. Normal
industry standards are 4-20 mA current or voltage signals.
These signals are employed in a CLCS.
They follow arithmetic algebra for calculation of results.
Logic Signals
Logic signal are discrete values normally a 0 or 1. In
electrical terms it can be attributed to presence or absence of
voltage. These signals are employed in an OLCS. Boolean
algebra is applicable for logic signal.

GT Instrumentation

Servo- valves (analog) and solenoids (logic)

Speed Sensors (analog)
LVDTs (analog) and Limit switches (logic)
Spark plug (logic) and flame detectors (logic)
Pressure transmitters (analog) and Pressure Switches
(logic)
Actuators (analog and logic)
Thermocouples (analog) and temperature switches (logic)
Level switches (logic)
Fire sensors (logic) and Leak detectors (logic)
Vibration sensors (logic)

GT CONTROL SYSTEM AT KAWAS

Control system used for Gas Turbines at Kawas is

SPEEDTRONICS MARK IV. This system was developed by
M/s GE, USA in 1982.
The mark IV system is based on TMR control philosophy.
INTEL 8086 & 80286 microprocessor based controllers
( microcomputers ) perform calculations required for the
control , protection & sequencing of the gas turbine.
For governing of the turbine electro-hydraulic technology
is used.

CONTROL PHILOSOPHY

The main concept behind three redundant (TMR)

controllers is for two-third voting concept.
The design of each computer contains circuitry to achieve
fail safe condition.
On loss of power or when Trip condition occurs, it
removes power from the coil.

SPEEDTRONIC HARDWARE
The SPEEDTRONIC panel comprises of following components.
Three redundant controllers < R >, < S >, & < T >.
These controllers are exactly identical in hardware &
software.

One communicator < C >.

Signal processing/conditioning I/O modules
Operator interface/Communication modules
Relays
Power distribution module and power supplies

< R > < S > < T > CONTROLLERS

Perform sequencing of auxiliaries to allow fully

automated startup, shutdown, and cool down.

Control of liquid, gas, or both fuels as per the

requirements of
Start-up and shutdown conditions.
Speed or load control under part-load conditions.
Temperature control under base load conditions.

Inlet guide vanes and water injection control.

Turbine protection against adverse operating situations.

C- COMMUNICATOR

Monitors the healthiness of the voting controllers

< R >, < S > & < T > and initiates an audio visual alarm
when there is disagreement between any control
parameter / logic signal in <R>, <S> & <T>.

Provides User-interface like CRT, Printer & Input

commands.

It contains diagnostic software, interface with logic and

analog input & provides RS 232 link for remote interface.

LOGIC INPUTS
All the critical logic inputs from field are wired to Contact
Input Module (CIM ) 1 or 2, where this signal is paralleled
to the three optical isolators & fed to separate digital input
cards in the < R >, < S > & < T > controllers.
Communicator < C > feed these informations to the CRT.
Logic i/p which are not critical, are fed to communicator
< C > through CIM 3 to 6 after optical isolation.
Optical isolation : A semiconductor device consisting of
an LED & a phototransistor in close proximity. Current
through the LED causes an internal light emission that
forces current to flow in the phototransistor.

LOGIC OUTPUTS
2 out of 3 ( 2/3 ) logic voting for output signal is
performed by Relay Driver Module (RDM).Here fail safe
logic is implemented, means no power will result in safe
condition.
Non voted logic outputs are available through <C>.

ANALOG INPUTS
In Gas turbine control system all the analog inputs like,
LVDT, pressure, vibration etc are fed to analog input ,
output modules, AIO 1,2 & 3.
For temperature measurement TCM modules are used.
There is one module each for <R>, <S> & <T> controllers
and two modules for communicator < C >.

ANALOG OUTPUTS
There are two types of analog outputs

DC milliamp current from controllers,<R>, <S> & <T> to

servo valves for functions such as liquid/gas fuel flow
control and IGV control. If any controller fail remaining
two will be able to drive the servo valve.

4-20 mA and 0-10V DC analog outputs are also available.

BRIEF DESCRIPTION OF HARDWARE

The cards used in Mark-IV Speedtronic control system
are as follows:

HAFA: 16 Analogue and 32 Digital input cards.

HAIC: 16 analogue input and [OPM] interface.
HCMC: RS232 interface
HCVA: Analogue output card (2)
HIOD: 32 Digital I/O Board
HPRB: 4 pulse rate input,
HMPK: Microprocessor Card.
HVDB: Video Driver Board, interface with CRT
HXPD: CPU expander,PROM,16 digital I/O,8 interrupt
NTCF: 14 thermocouple input per card
NVCD: 6 vibration input per card

BRIEF DESCRIPTION OF HARDWARE

HSAA: Servo-amplifier,2 LVDT/servo channel per card.

It is a interface between turbine control system and
hydraulic actuator that positions the valve.

Contact Input Module (CIM): 16 voting input connected

to R/S/T and 32 nonvoting input to C.

Analogue I/O module: It is used for remote analogue

interface and passive filtering

Thermocouple input module (TCM): TCM.R/S/T provides

14 voting input to R/S/T. TCM.C1/C2/C3 gives 14
nonvoting input to C.
First input provides cold junction reference.

FUEL STROKE REFERENCE (FSR)

FSR is a fuel demand signal calculated by the control

system to regulate the amount of fuel injection in the
turbine. Independent FSR values are calculated for the
following controls.
1.
2.
3.
4.

Start up Control (FSRSU)

Acceleration Control (FSRACC)
Speed/Load Control (FSRN)
Temperature Control (FSRT)

All these FSR values are compared and the minimum value is
passed to the fuel control valves.

START - UP + ACCELERATION CONTROL

This is an open loop
controller which
increases the
FSR , as the
turbine start-up
sequence passes
through
pre- assigned states
of Firing, Warm-up
and acceleration.

PART LOAD OPERATION

During part load Gas Turbine is controlled by Speed/Load
control algorithm.
FSRN=(TNR-TNH)*Droop gain+ FSR FSNL

where
TNR- Speed Reference.
Rate of change 0.4 or 0.8 % N/min
TNH- Actual Speed
FSNL FSR-14.5 %
Droop Gain- 10.5 %/%N

BASE LOAD OPERATION

At base load the turbine control shifts to temperature control
algorithm where
FSRT (TTRX-TTXM)

Where
TTRX Exhaust Temperature Control Reference
TTXM Actual Exhaust Temperature

Exhaust Temp. Reference

EXHAUST TEMPERATURE REF. (TTRX) CALCULATION

600

593

590
580

593

593

585.752
578.202

570
560

570.652
563.102
555.552

550
540

548.002
540.452
536.677

530
520
5

10

CPD
Isothermal Limit

Exhaust Temp. Reference

11

FUEL SPLITTER

FSR1 = FX1 * FSR (liquid fuel)

FSR2= [100 FX1] * FSR (Gas Fuel)
FX1= Fraction of Liquid Fuel [Range 0 100%]
FX1=0% Means Total Gas Fuel.
FX1=100% Means Total Liquid Fuel.
Rate of change of FX1 i.e. ramp rate = FXK1 =
1.6%/Sec (1 Minute for fuel changeover)

Auto Fuel Change-over conditions

UNIT RUNNING ON GAS FUEL
Gas pressure low (17.5 Bar Before
Stop Ratio Valve).

Transfer to HSD

VA 13-1,2 inter valve gas pressure

High (>3 Bar, Time delay 40 Sec)

Transfer to HSD, if not

S/D after 45 Sec.

UNIT RUNNING ON HSD

HSD tank level low (2.0 Meters).

Transfer to NGL/ARN

Auto Fuel Change-over conditions

UNIT RUNNING ON NAPHTHA FUEL
Naphtha fuel pressure low - <3.0 Bar
Naphtha tank level very low - <1.1 M
Naphtha fuel flow low 1.8 Kg/Sec
Both high tech pumps not running
Hi-Tech tank level low 10 Min Delay
Purge manifold liquid leak detection
Atomizing air compressor DP low - <1.06 Bar

88-BT ventilation fan trouble.

<C> computer failure

Transfer
To
HSD

Tripping vs Normal Shutdown

Tripping
As soon as a tripping condition is detected, L4 i.e Master
Protective logic signal gets dropped leading to immediate
closing of the fuel valves and hence fast deceleration of the
turbine.
Normal shutdown
In case of a normal shutdown order/condition, TNR (FSR)
value decreases gradually to unload the unit till generator
breaker opens at reverse power.
FSR decreases further as per FSRMIN and fuel is totally cut off
at the blow-out speed of 35%.

INLET GUIDE VANE

The guide vanes are installed at inlet to the compressor.
They are used to direct and control the air flow to the first
stage of the axial flow compressor.
Variable compressor inlet guide vanes provide protection
against compressor pulsation during turbine start - up and
shut down.
It facilitates proper exhaust temperature for combined cycle
operation during partial loading of Gas Turbine.
This variable inlet guide vane actuator is an hydraulically
actuated assembly having a closed feed back control loop , to
control the guide vanes angle.

IGV TEMPERATURE CONTROL

Variable compressor Inlet Guide Vanes modulate to maintain
high exhaust temperature during part load for combined
cycle operation.
Initially during normal start-up the IGV is full closed, i.e.
34 Deg. as proper temp corrected speed is reached IGV will
open to a preset value, i.e.54 DEG, mini & remain at this
position, until exhaust temp. condition asks for more opening
If IGV temperature control is OFF, it starts opening from
54 deg. To 84 deg at approximately 25 MW.
If IGV temperature control is ON, up to 81 % load it
remains 54 deg. , after that it is full open.

SERVO VALVE DRIVER SYSTEM

The gas turbine fuel control system will change fuel flow to
the combustors in response to FSR.
The servo system controls the fuel flow rate by means of
an electro - hydraulic servo valve which ports high
pressure hydraulic oil to either side of piston of an
actuator as per signal. It is used to open & modulate or to
close fuel passage in the fuel circuit.
Thus servo valve is the interface between the electrical
control system & the mechanical system. It converts an
electrical signal to hydraulic output ( movement ).

Thank You