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Modeling of Gas Turbine and Its Control System: DR M S R Murty
Modeling of Gas Turbine and Its Control System: DR M S R Murty
ControlSystem
DrMSRMurty
GasTurbineScheme
Brayton Cycle
Thecycleismadeupoffourcompletely
irreversible processes:
12Isentropic Compression;
23ConstantPressureheataddition;
34IsentropicExpansion,and
41ConstantPressureheat
T
rejection
TemperatureEntropydiagram
Brayton Cycle
Airisfirstcompressedinanadiabaticprocesswithconstant
entropywithinthecompressor(process12),usuallyanaxial
compressor.Pressureof1320timesthatofatmosphericis
achievedafterthecompressionstage.
Fuel,eitherliquidofgasisthenmixedwiththecompressed
airandburntinthecombustor(process23).Afterwhich,the
hotgassesisallowedtoexpandthroughtheturbine(process
34).Thisgasexpansiondrivesthebladesoftheturbineand
consequentlytheshaftofthegeneratorconnectedtoit.
TransferFunctionBlockDiagram:
Rowens Model
GTControlsmodelled
Therearefourblocksrelatedwithspeed/load
control,temperaturecontrol,fuelcontrol,and
aircontrol.
Speed/loadcontrol:determinesthefuel
demandaccordingtotheloadreferenceandthe
rotorspeeddeviation
Temperaturecontrol: restrictstheexhaust
temperaturenottoinjurethegasturbine.The
measuredexhausttemperatureiscomparedwith
thereferencetemperature.Theoutputisthe
temperaturecontrolsignal.
GTControls
Thefueldemandiscomparedwiththe
temperaturecontrolsignalinthefuelcontrol
block.Thelowervalueisselectedbythelow
valueselector,anditdeterminesthefuelflow
Theaircontrolblockadjuststheairflow
throughcompressorinletguidevanes(IGV)
soastoattainthedesiredexhaust
temperature.Theexhausttemperatureiskept
lowerthanitsratedvalue(say1%).
AirflowControl
Theadjustableairflowisabout30%ofthe
ratedairflow.Theadjustingspeedisslow
comparedwiththefuelflow.
Theairflowisproportionaltotherotorspeed.
GTOperatingparameters
Wf=fuelflow,
W=theairflow,Te=Exhausttemperature,
Tr =referencetemp.Tf =turbineinlettemp
GenerationofValveControlsignal
PowerOutput
Temperaturecontrol
RotorInertia
SimplifiedGTModel
PIDGovernorDetailedModel
Thedroopcircuitincludesan
intentionalfiltertimeconstant,
Td,of0.8s.
GTModelsinPSS/E
GASTGasturbinegovernormodel
Simplemodel
GAST2AGasturbinegovernormodel
SimilartotheRowen model
GASTWDGasturbinegovernormodel
SuitableforWoodwardgovernors
GASTModelinPSS/E
Fuelvalveopening
Flow
ExhaustTemp
R (speed
droop)
0.05
Ambient
temperature
T2 (>0) (sec) T3 (>0) (sec) load limit, AT KT
T1 (>0)
(sec)
0.4
0.1
VMAX
VMIN
0.95
Dturb
-0.05
StepchangeinSpeedReference
Eachdivision10Seconds
Eachdivision10Seconds
TwinShaftGT
PermanentDroopusingCDP
CompressorDischargePressure(CDP)rather
thanvalvepositionorelectricalpower
feedbackisusedforpermanentdroopsetting
onsomeunits
TypicalvaluesofCDPversusoutputpoweris
showninthetable
Thediscontinuitybetween25%
and40%poweriswhenthewater
injectionandinletguide
vanesgointoservice.
OnlineStep
response
OfflineStepresponse
Typicalfrequencyresponsecurves
OUTERLOOPCONTROLS:
Loadcontrol
Someunitsareoperatedwithanouterloop
activepowercontroller.DigitalUnitController
producesapulsetothegovernorraiseor
lowerinputthatisproportionaltothe
distanceawayfromtheMWsetpoint.
Thegovernorisprogrammedtorampthe
referenceatarateof0.3%/swhenreceiving
thesepulses.
OuterLoopControl:pf/VAr Controller
Manygasturbineunitsareequippedwitha
pf/VAr controllerwhichisinservicewhenever
theunitisonline.Thisisanouterloopcontrol,
whichmonitorsgeneratorstatorreactivecurrent
andcontrolstoafixedVAr orpf setpoint.
Thecontrollerisoftenusedinpf mode,
controllingtounitypowerfactor.
Thecontrolstructureisanintegratorwithgain
feedbacktotheAVRsetpoint.
Pf/VARController
Toridethroughsystemtransientdisturbances,
thecontrolshouldbeasslowaspossible,
however,toolongasettingwillresultin
operatorinterventionandovershootinthe
resultingunitoperatingpoint.
Simulink Model
Ka
Step
Ke
T a.s+1
T e.s+1
s+1
T ransfer Fcn
T ransfer Fcn2
T ransfer Fcn1
Scope
Vt
Kf.s
T o Workspace
T fa.s+1
T ransfer Fcn3
Kr
t
T r.s+1
Clock
T ransfer Fcn4
AVR1_dat.m required
T o Workspace1
1.0
1.0
Aligv
In1
0.2
Tr1
T re
-KFuel T emp
Control
1
s
Tm
Fsr
In3
Xne
Fsrn
In1
Fa
GAS FUEL
SYST EM
In1
Out1
In2
-KFb
Tx2
Tx
VALVE
POSITIONER
min
FUEL
LIMITS
Out1
In1
In3
0.23
In2 Out1
Tx3
Out1In2
Out1
In2
Fsrt
Out1
In1
Txm1
In1
1/Tt
Tx1
Radiation
sheild
T hermo
couple
Xnr
Wg
Wx
IGV actuator
Out1
In1
In2
IGV limits
IGV T emp
Control
Tre
Out1
0.46
0.46
0.3/T t
1
s
In1
Out1
In2
Out1
In2
In1
In1
Out1
In2
Out1
In2
Fc
Zg
Akf
ROTOR
SPEED
GOVERNOR
Wf
In1
1
s
ROT OR SPEED
T load
1/T 1
Out1
F2
In2
n
To Workspace1
FIG NO.
t
Clock
To Workspace
Scope1
Speed(p.u)
1.006
1.005
1.004
1.003
1.002
1.001
1
0.999
10
20
30
40
50
60
Time(Sec)
70
80
90
100
Combinedcycle
Heatenginesareonlyabletouseaportionof
theenergytheirfuelgenerates(usuallyless
than30%).Theremainingheatfrom
combustionisgenerallywasted.
Combiningtwoormore"cycles"suchasthe
Braytoncycle (GasCycle)andRankinecycle
(SteamCycle)resultsinimprovedoverall
efficiency.
SimpleGTcycle
FUEL
AIR
INLET
COMBUSTOR
EXH AU ST
G AS
DRIVEN
EQUIPMENT
COMPRESSOR
TURBINE
Combinedcycleplant
CombinedCycle(Brayton&RankineCycles)
EXHAUST GAS
LOW PRESSURE STEAM
(For Deaeration)
AIR
INLET
FUEL
INTERMEDIATE PRESSURE STEAM
(To Intermediate Pressure Steam Turbine)
COMBUSTOR
HIGH PRESSURE STEAM
(To High Pressure Steam Turbine)
GENERATOR
HEAT RECOVERY
STEAM
GENERATOR
GENERATOR
ELECTRIC
POWER
COMPRESSOR
TURBINE
ELECTRIC
POWER
GAS TURBINE
STEAM TURBINE
HIGH
INTERMEDIATE
PRESSURE PRESSURE
STEAM
STEAM
STEAM
EXHAUST
HRSG
Steamisgeneratedbyfiring
hotexhaustgasesfromGas
turbines(GTs)
Remainingsteamrequiredis
generatedbyfiring
Supplementaryfuel.
TypicalIndustrialCogenerationSystem
EXHAUST
BYPASS
SILENCER
EXHAUST
SILENCER
DIVERTER
VALVE
AIR INLET
FILTER
HEAT
RECOVERY
STEAM
GENERATOR
(HRSG)
GENERATOR
GAS
TURBINE
SUPPLEMENTARY
BURNER
PROCESS
STEAM
SteamTurbine
CombinedCyclePowerPlant
AUX
BOILERS
NAPHTHA
GAS OIL
4 x 125 TPH
8X30MW
GAS TURBINE
NAPHTHA
GAS OIL
11KV
8 X 125 TPH
33KV
HRSG
4 X 30 MW
STEAM
TURBINE
TOREFINERY
11KV
TOGEB132/220kV
33KV
HPsteam42Kg/cm2
Power
Steam
MPsteam17Kg/cm2
INSTALLED CAPACITY
PRESENT GENERATION
EXPORT TO GEB CAPABILITY
360 MW
269 MW
80 MW
1500 TPH
979 TPH
------------
To
Refinery
GAS TURBINES
MachineDesignoutputDesignoutputSiteoutput
MW(ISO)MW(350C)(MW)
PG 6541
PG 6551
PG 6561
37.52
38.48
38.82
32.64
33.48
33.77
28.7
28.7
28.7
HRSG
HRSGloadwithGTatbaseloadinunfiredmode:
HHPSteam(TPH)
BHELHRSGs(06nos.)
5355
DBPSHRSG(01No.)
5355
ThermaxHRSG(01No.)
5355
HRSGloadwithGTatbaseloadinfiredmode:
Steam(TPH)Design(TPH)Max(TPH)
BHELHRSGs(06Nos.) 125 125NA
DBPSHRSGs(01No)
125
125NA
ThermaxHRSGs(01No.)
125
125134*
(*Steamflowforonehourin08hrs.shift)
Steam Turbine
All 4 STGs are tested to deliver 30 MW of power.
Steam turbines are provided with HP and MP extractions
Maximum steam flow through one steam turbine shall be as follows
262 TPH HHP steam (Max)
Pr: 109 Kg/CM^2 @ 505 DegC
MP
133
TPH
LP
60
TPH
Auxiliary Boilers
All 4 Auxiliary Boilers are capable to deliver 125 TPH , at 115 KG/CM2(g)
and 510 Deg C.
10 % overload margin i,e 137 TPH at 110 KG/CM2 (g) and 5100 C also tried
for 01hr.
PRDS
Six PRDS are provided to supply HP, MP & LP steam to the process.
PRDS is sized to meet the demand normally met by two steam turbines on the
basis that one trips whilst another is out of service for maintenance.
Design flow rates (TPH) of PRDS are :
Min.NormalMax.
HHPtoHP
21.480186.3
HPtoMP
24.947.4138
MPtoLP
9.134.9120
Startup&letdown
12.525
(HHPtoHP)
STEAM SYSTEM
BoilersNos.Nos.inoperationGeneration(TPH)
AuxiliaryBoilers
HRSGs
Total
4
8
12
4
8
12
500
880
1380
CPPGenerationandDistributionOverview
X
1321
1322
132kVGEBBUS
1323
132kVRPLBUS
1324
1325
RIL
1326
1327
RPL
GTG#8
GTG#3
GTG#2
STG#2
GTG#1
STG#1
STG#3
GTG#4
GTG#5
GTG#6
GTG#7
STG#4
A7
B4
B8
A6
B7
B11
A12
A3
B5
A3
B11
B3
A3
B10
A4
A5
ESEE94101
A7
BUSB
ESRU77202
MRS#2BOARD#1
MRS#2BOARD#2
RPL
RPL
RPL
BUSA
A12
ESRU77201
MRS#1:BOARD#2
RIL
BUSB
B4
ESEE94102
MRS#1:BOARD#1
BUSA
A4
BUSA
BUSB
BUSA
BUSB
1.AROM.733CTA
1.AROM.PX.TR.1B
1.SULPHERA
1.CRUDE2B
1.CRUDE2A
1.COKERA
1.FCCB
1.HYDJN5.75MWM
2.PPSTRMA/BA
2.AROM.PX.TR.2B
2.UTILITY2A
2.UTILITY1A
2.RTFS/S2A
2.TNSHIPA
2.HYDRJNB
2.TNSHIPB
3.PPSTRMCA
3.AROM.PX.TR.3B
3.HYDRGNA
3.CRUD2,4.4MWM
3.COKERB
3.PLATFMR/HNUUA
3.UTILITY1B
3.UTILITY2B
4.AROM.PX.TR.1A
4.PPSTRMA/BB
4.CRUDE14.4MWM
4.SULPHERB
4.RRTFA
4.PRT1FCC
4.CPP772B
4.HYDJN5.75MWM
5.AROM.PX.TR.2A
5.PPSTRMCB
5.HYDJN5.75MWM
5.PLATFMR/HNUUB
5.PLATFMR7.3MW
5.MTFL1C1
5.RRTFB
5.MTFL2C1
6.AROM.TATORYA
6.AROM.TATORYB
6.CRUDE1B
6.RTFS/S2B
6.CPP772A
6.MTFL1C2
6.PRT2FCC
6.MTFL2C2
7.AROM.PX.TR.3A
7.AROM.733CTB
7.PLATFMR7.3MW
7.CPP941B
7.CRUDE14.4MWM
7.FCC10MWM
7.RTFS/S1B
8.CPP941A
8.RTFS/S1A
8.FCCA
9.CRUDE1A
9.PLATFMR7.3MW
10.CRUD2,4.4MWM
PowerPlantControl
Plantparametersaretobemaintainedby
closedloopcontrol
Boiler:Steamparameterslikepressure,
temperature,otherprocessparameterslike
furnacepressure,drumlevel
Turbine Generator:Power(MW),speedor
frequency
NeedforControl
Mismatchingenerationandconsumption
causesdeviationinplantparameter
Mismatchinsteamflow:pressurechange
Mismatchinheatflow:temperaturechange
Mismatchinpower:speedchange
Mismatchingasflow:furnace.pr.change
ControlSystems
GTGControlSystem(GEMarkV)
STGControlSystem(GHHBorsig)
BurnerManagementSystem(ABPLC):48
FoxboroDCS
ControlSystems
DistributedcontrolSystem(Foxboro) 38nodes
EmergencyShutdownSystem(Triconex) 26no.
Fire&GasSystem(Wormald) 35no.
MachineConditionMonitoringSystem(Bentley
Nevada) 23no.
AutomaticTankGaugingSystem(SAAB) 259no.
ElectricalLoadDistributionManagementSystem
CombinedCyclePlant:Schemefor
Modeling
ModelofCombinedCycle
PowerPlant