ModelingofGasTurbineandIts

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

Ambient
R (speed T1 (>0) temperature
droop) (sec) T2 (>0) (sec) T3 (>0) (sec) load limit, AT KT VMAX VMIN Dturb

0.05 0.4 0.1 3 1 2 0.95 -0.05 0

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 Ke 1
T a.s+1 T e.s+1 s+1
Step 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
T ransfer Fcn4 Clock T o Workspace1

SIM ULAT ION OF AVR

AVR1_dat.m required
 1.0 1.0
In1 Aligv
0.2 In1
Out1
T re Tr1 In2 0.46 Out1
0.46 In2
1 IGV limits Wx
-K- Scope1
Fuel T emp s IGV actuator
Control IGV T emp
Control Tx1
Radiation
Out1 Tx3
0.3/T t T hermo sheild
Out1 couple
Txm1 In1 Out1
In1
1 In1
1/Tt Out1In2
s Out1
Tre Tm In2 Tx Tx2
In3
In1
Out1
Fsrt 0.23 VALVE GAS FUEL In2
Xnr
POSITIONER SYST EM
Fsr
In1 In1
In1 min In1
Wg -K- Out1 Out1 Out1
In2 Out1
In2 In2 In2
In3 FUEL Fb
Fa Fc
Xne LIMITS
Fsrn
Zg Akf
T load
SPEED ROTOR
Wf
GOVERNOR In1
1
1/T 1 Out1 F2
s
ROT OR SPEED In2
n

To Workspace1
FIG NO. BLOCK DIAGRAM OF A GAS TURBINE
Scope

t
Clock To Workspace
 SIMULATION OF GT GOVERNOR SYSTEM
1.009
Different positioner gains
1.008

1.007

1.006

1.005
Speed(p.u)

1.004

1.003

1.002

1.001

0.999
0 10 20 30 40 50 60 70 80 90 100
Time(Sec)
 Combinedcycle
Heatenginesareonlyabletouseaportionof
theenergytheirfuelgenerates(usuallyless
than30%).Theremainingheatfrom
combustionisgenerallywasted.
Combiningtwoormore"cycles"suchasthe
Braytoncycle (GasCycle)andRankinecycle
(SteamCycle)resultsinimprovedoverall
efficiency.
 SimpleGTcycle
FUEL

AIR COMBUSTOR
INLET
EXH AU ST
G AS

DRIVEN
EQUIPMENT

COMPRESSOR TURBINE
Combinedcycleplant
 CombinedCycle(Brayton&RankineCycles)
EXHAUST GAS

LOW PRESSURE STEAM

(For Deaeration)
AIR FUEL
INLET INTERMEDIATE PRESSURE STEAM
(To Intermediate Pressure Steam Turbine)
COMBUSTOR
HIGH PRESSURE STEAM
GENERATOR (To High Pressure Steam Turbine)

HEAT RECOVERY
STEAM
GENERATOR GENERATOR

ELECTRIC COMPRESSOR TURBINE

POWER

ELECTRIC
POWER STEAM
HIGH INTERMEDIATE EXHAUST
PRESSURE PRESSURE
STEAM STEAM

GAS TURBINE STEAM TURBINE CONDENSATE RETURN TO HRSG

 HRSG

Steamisgeneratedbyfiring
hotexhaustgasesfromGas
turbines(GTs)
Remainingsteamrequiredis
generatedbyfiring
Supplementaryfuel.
TypicalIndustrialCogenerationSystem
EXHAUST
EXHAUST SILENCER
BYPASS
SILENCER
DIVERTER
VALVE
AIR INLET
FILTER

GENERATOR HEAT
RECOVERY
STEAM
GENERATOR PROCESS
(HRSG) STEAM
GAS
TURBINE SUPPLE-
MENTARY
BURNER
SteamTurbine
CombinedCyclePowerPlant
 Captive Power Plant - General Overview

AUX
BOILERS
NAPHTHA
GAS OIL 4 x 125 TPH

8X30MW Refinery Fuel Oil

GAS TURBINE 8 X 125 TPH HRSG 4 X 30 MW

NAPHTHA STEAM
GAS OIL TURBINE
TOREFINERY
11KV 33KV

11KV

TOGEB132/220kV 33KV
HPsteam42Kg/cm2
Power Steam To
MPsteam17Kg/cm2 Refinery
INSTALLED CAPACITY 360 MW 1500 TPH
PRESENT GENERATION 269 MW 979 TPH
EXPORT TO GEB CAPABILITY 80 MW ------------
 GAS TURBINES

5 Nos, GE Frame-6 machines supplied by BHEL, Hyderabad

3 Nos, GE Frame-6 machines supplied by NP, Italy.
GT # 1 & 4 are having BLACK START CAPABILITIES.
All gas turbines are capable to run at base load with spread well within the
limit :

MachineDesignoutputDesignoutputSiteoutput
MW(ISO)MW(350C)(MW)

PG 6541 37.52 32.64 28.7

PG 6551 38.48 33.48 28.7
PG 6561 38.82 33.77 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 LP
133 60 TPH to Condenser (Max.)
60 20 TPH to Condenser (Min.)
TPH TPH

180 TPH HP steam (Max)

149 TPH HP steam (Normal)
Pr: 44.8 Kg/CM^2 @ 383 DegC
80 TPH MP steam (Max)
53 TPH MP steam (Normal)
Pr: 18.8 Kg/Cm^2 @ 282 DegC
Normal steam flow
HP section =15.27 MW
MP section = 5.73 MW
LP section = 11.81 MW
 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 4 4 500
HRSGs 8 8 880
Total 12 12 1380

Auxiliary boilers able to ramp up 9 MT /Min/boiler in case of emergency

without much pressure variation at HHP level
Able to meet steam demand when both PRTs trip.
Able to supply HP and MP steam, without pressure drop, if STG trips.
 CPPGenerationandDistributionOverview
X
1321 1322
132kVGEBBUS
1323
132kVRPLBUS

1324 1325 1326 1327

RIL 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

G G G G G G G G G G G G

A3 B10 A4 A7
A4 A7 B4 B8 A5 A6 B7 B11 A12 A3 B5 B4 A12 A3 B11 B3

ESEE94101 ESEE94102 ESRU77201 ESRU77202

MRS#1:BOARD#1 MRS#1:BOARD#2 MRS#2BOARD#1 MRS#2BOARD#2

RIL RPL RPL RPL

BUSA BUSB BUSA BUSB 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

Two major functions

Load management System (LMS)
Electrical Distribution Management System (EDMS)
LMS functions:
Load shedding
Active/Reactive power control
Synchronisation
EDMS main functions:
Data logging & reporting
circuit breaker control
Power System Event Recording & Alarm Annunciation's
CombinedCyclePlant:Schemefor
Modeling
ModelofCombinedCycle
PowerPlant