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    GER-3107 Controls - General Electric . SPEEDTRONIC Control System

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    GER-3107 Controls - General Electric - SPEEDTRONIC Control System

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    meirangong

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    © All Rights Reserved
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    Ve General Electric SPEEDTRONIC Control Systems Daniel Johnson Manager—Electronic Controls Development William 1. Rowen ‘Manager—Control Systems William C. Coes ‘Manoger—LM2500 anid Conversion Controls Harry 8, Sechrist ‘Manager—Controls Ensinesring Gas Turbine Engineering and Manufacturing Department Gas Turbine Division Schenectady, New York ‘CONTENTS PAGE INTRODUCTION 1 FUNCTIONAL DESCRIPTION 2 SYSTEMS DESIGN 6 COMPONENT DESIGN 13 MAINTENANCE ” INTERFACING LARGER, SYSTEMS "7 SUMMARY 18 CENERAL @® ELECTRIC === GAS TUABINE REFERENCE LIBRARY %\ General Electric's gas turbines are controlled by the SPEEDTRONIC™ electronic control system, which pro vides fully automatic control of the gas turbine and load system, This control system employs the latest electronic technology, including integrated circuits and micropro cessors t0 carry out control, sequencing, and protective funetions. The system includes sensors and servo actuators mounted on the turbine to provide input and output interfacing for the control system, Reliability is achieved through redundancy for key control fun speed and temperature control, High performance, accu: ‘achieved by electronic computation and the use of high resolution hydraulic servos. The protective system is viru ally independent of the control equipment and employs @ high degree of redundaney to seure reliable and safe me chine operation ions, such as “Trademark of the General Electrie Company GERS107B ‘Tho dlacign of the present SPEEDTRONIC MARK II control is based on 10 years of experience with electronic controls for heavy-duty gas turbines. The first electronic control {SPEEDTRONIC MARK 1) was developed in 1967, was commercially introduced in 1969, and was highly suc- ‘cessful, MARK Il SPEEOTRONIC was introduced across the product line in 1973, and employed solid state and ‘integrated eircutts Tor 1oglé and computation functions tor further performance and reliability improvements, Micro: processors were incorporated into the control system in ‘monitoring practical. ‘The sontral cystam asin ig emoloved seross the product line from the LM2500 to the MSGOO1. Standard ‘options are in place so that the control can be used for a variety of applications, such a5 remote, unattended utility Peaking gas turbines, baseloaded industrial generator dives, remote pipeline pumping stations, etc. Today users all over the world have General Electric gas turbines with SPEEDTRONIC control systems in operation ‘and these units have accumulated millions of hours of ope sting experience sinee initial shipments in 1060. The are in service in applications as varied as utility, marine, pipeline, srocess and combined cycles in ambients that vary from plus to minus 50°C. A sioificent number of these Units ace offshore with several hundred located in Russi, the Mid-East, Africa, Australis, South America and Asia This experience has shown the SPEEDTRONIC control to be highly sucoessul FUNCTIONAL DESCRIPTION Control Arrangement ‘The two major arees that comprise the turbine control system are the turbine control panel, which contains the ‘computational electronics. and the machine mounted sensors, devices, and actuators to provide input/output functions The turbine contro! panel also serves as the human/ma ‘chine interface with the turbine. To mest the wide variety fof possible applications several aerangamants far the locs- tion of the turbine pane! ate available, For peaking units, 2 control eab located at the front of the turbine as shown in Fig, 1. is used to house the panel. The cab also contains ‘other equipment such asthe generator panel, motor contrat center, and battery. When several units are located at one site, all the turbine panels msy be packaged in a single con- ‘rol eab for operator convenience. Industria units typically have the turbine panel located in @ control room along with a Figure 1 ‘controls for other equipment. An arrangement used fre ‘quently for pipeline pumpers and platform installations is the Modular Electrical Control Canter (Fig, 2). Tis assor bly ineludes the turbine control, load control, and station contro, all integrated in an enclosed assembly which has walk-in access for maintenance. A key adventege of this arrangement is that much of the interconnecting wiring and testing can be carried out in the factory, thus minimizing the field connection time. Although the control interfaces vy systems, primary emphasis in this paper ison the tur bine control panel The SPRENTRANIC evetem nerfarme the followin functions: 1, Control of turbine output power over the load range 2. Limits maximum output consistent with unit eape bility 3, Sequencing of unit auxiliaries and turbine control Parameters during gas turbine startup. 4, Protective shutdown of the gas turbine in the event of 4 non-recoverable system failure of the controls, tur- bine, or auxiliaries. 5, Monitoring ae annunciation of malfunctions within the gas turbine, the auxiliaries, and the control system, Primary control of the gas turbine is sccomplished by controlling the fusl flow to the combustion system. On some units, fuel control is supplemented by varying cycle airflow by means of changes in compressor speed or the position of variable inlet guide vanes to improve partload perfarmance in applications involving exhaust heat recov- fry. Fuel flow, in turn, is controlled in response to the speed control system, the temperature control system, or the startup control, whichever of the three requires the Feast fuel ‘Speed/Load Control System ‘The gas turbine speed control, oF governor, controls the speed of the turbine output shaft ‘The characteristics of the speed control can be either isochronous (speed precisely held to setpoint regardless of load), or droop (speed decrease with load). In generator drive applications, where the gas turbine operates synchro: nized to a large system, a droop governor charactristic is used, and the speed control inherently performs the load Control tunction a iustrated in Fg, $, While 1m tis oper ating mode, the speed control function is still present and always active, except when the gas turbine is at maximum allowable exhaust temperature, ‘The speed control operates the turbine in response to the setpoint, On isochronous control, turbine speed is ex actly equal to the setpoint, On droop control with the gen- erator synsironized ty Ure syste, he setpoint deters turbine load, In addition, the rate of change of the setpoint determines turbine loading and unloading rates. Preselected load pointe and losd/unlo: command to the setpoint controller comes from either the local switch on the turbine or generator panel, or from a re mote raise/lower switch. Far generator drive aas turbines, the load may also be sot by a load limiter which has as its input a signal proportional to generator load. The load limiter normally has capability for three values of load limit; spinning reserve, an intermediate preselected load, ‘and maximum load, ov mst mietiaical ive applications, gos turbine out Dut is 2 function of the speed of the driven equipment. In this type of application gas turbine speed is not synchro ‘Temperature Control System ‘The temporature control system is designed to limit the firing temperature of a gas turbine to a maximum value, corresponding sither to base or peak operating conditions. ‘A typical temperature control characteristic Ie shown in Fig. 4. The slope of the temperature control lines is selected {0 maintain a constant firing temperature over the fll oper sung range of amovent conarcions, 1m aaaiton, tne exnaust {TVPICAL DROOP SPEED CONTROL CHARACTERISTICS ‘TPICAL TewweaTue CONTROL ‘chaRacTensnics Se 7 Figure 3 92408 ate limited to approximately 1000 F, under all opera ing conditions, 1o protect the exhaust system. The LM2600 temperature control limits the inlet gas temperature to the load turbine to a constant value ‘The temperature control system on all singleshaft units, ‘employ an Integrated Temperature System (ITS) whieh Gas turbines, in applications associated with heat recov ery. may be designed to operate with varying airflow over the load range to maintain maximum exhaust temperature for optimum heatrate at part load. This change in airflow Js accomplished in two ways; by varying compressor inlet ‘guide vane ang, or by varying compressor rotor speed, oF both, This latter method of varying airflow is unique to twoshaft gps turbines having variable area second-stage ozzies, In hese Yon euLIies dhe axl fom compressor is riven by the frst, oF high-pressure stage, of a twostage axial law turbine, The second stage or load turbine is con. rected to the driven equipment. Thees ic ne mechanical connection between the two turbine stages, thus allowing them to run at different speeds. However they are aerody ramicaly coupled by the variable area second stage nozzles ‘whieh vary the division of available energy between the two stages, thus allowing independent control of the compressor speed, and therefore cycle airflow. The resultant part-oad ‘characteristics are shown in Fig, 5. The LMIZEUU, does not have the variable area nozzle and provides variable airflow ‘over the load range by @ wide speed range for the high pressure st (9000 ws 8000 NPA. Startup Control & Sequential System ‘The startup fuel contra is operated in conjunction with ‘the sequential portion of the control system that operates tuxiliory devices durin a unit start, The startup control pro: ‘ides a means of establishing scheduled fuel flow, a5 a func: tion of speed and time, duting the starting sequence when neither the exhaust temperature nor the unit speed are within range of their respective contro: systems, Frior 10, ‘and during the starting sequence, automatic checks are made to ensure that back-up auxiliary systems and the con- mine any abnormalities, the situation is alarmed, and the starting sequence is prevented from proceeding. A typical starting senuence for a single shaft generator drive ais tur bine is shown in Fig, 6. The startup of a tworshaft gos tr bine is similar, except that in addition, the output shaft, oF low-pressure turbine of the gas turbine begins to rotate at about 36-60 percent compressor speed Protective Systems ‘The basic gas turbine protective system is designed to detect sbnormal operating condition: and zafaly hut down ‘the turbine, This is ccomplished through separate, redund: ant shutdown devices. The basic protective functions are: uorenond, cwartemparature, lube oil ressure and tempers tute, lots of flame and vibration. Additional functions such ‘8 combustion system malfunction, compressor stall or fre may also be provided, if required by thespecific application. In most cases a protective system shutdown is preceded emergency shutdown feature is also provided. High reliabil ity is attained by a large degree of redundancy in the pro tective system, At least two means of shutting off fue (Iwo) separate valves) are always provided, and redundant sensors are also provided to key functions, oMMAASTERTICS SINGLE SHAFT GAS TURBINE STARTUP CONTROL CHARACTERISTICS, too 20 vee (MS 5000) Figure 6 Monitoring System ‘The gas turbine control system is provided with a multi point annunciator and supporting circuitry to detect and faiarm abnormal condivians in the curio! systens and ure bine auxiliaries during startup and unit operation. ‘The annunelator ie provided with a “first out Flashing” feature, which causes the first registered fault to flash as {an aid to the operstor in troubleshooting Optional Features ‘The gas turbine control system is designed to allow the incorporation of special festures required by the applics tion, Typical options would include: various fuel com- binations, black start, remote operation, deadload pickup applications. Standard control detigne ate alto avsilahie far water or steam injection fr limiting NO,, emissions. In these cases, @ ‘monitoring and recording system that shows operational compliance with EPA requirements is included as part of ‘the control system, Many other features, such as fast start, fast load, automatic load contol, black start, power aug: mentation and inlet heating are available options for the ‘turbine control system. Operation Completely automatic startup of the gas turbine plant is initiated by simply giving the gas turbine a start signal with the Master Start/Stap Switch (Fig. 7). Status of the gas tur bine, ite auxiliaries, and its controls is provided by status ‘SPEEDTRONIC ‘CONTROL, PANEL Figure 7 Tights on the panel throughout the starting sequence, from a “ready to start” condition through to “complete se- ‘quence,” Manual startup is provided only to the extent that ‘the automatic sequence ean be stopped at preselected wwinis saul a ““cank'" and “fire” (with the operation Selector switch) and typically is used only during system checkout. Selection of fuel, for dual fuel units, is accom Plishad at the panel using the Fuel selector switch Synchronization and loading of generator drive units is accomplished avtomaticslly up to a small load level for Spinning reserve. Initiation of @ second start signal wil cause the gat turbine to load up automatically at a pre- determined rate to the base or peak temperature control point, cepenaing on which was selzcted at te patel, a= visions are also available for manually synchronizing the ‘generator and manually loading it to any desired level. Mon: readily accomplished from the various meters mounted on the turbine control panel. In addition, on units with ITS, a measured operating tomperatures and all Key turbine con: ‘rot parameters can be read out on a current basis by calling for the appropriate listing. Shutdown from any condition of gonerator output is 3 complished by initiating a stop signal using the Master Start/ Stan Switch. Again. unloading and shutdown of the gas tur bine is accomplished completely automatically through the fend of the gas turbine cool-down sequence. The shutdown sequence can be interrupted, and reversed, at any point prior to opening the generator breaker. An emergency trip push button is also provided for use under abnormal con- ditions requiring immediate tripping of the gas turbine Troubleshooting is greatly aided by use of a 40, 60 oF {60 point annunciator, which indicates preselected unit mal functions, plus those which would cause a normal shut- down or turbine trip. The first annunciator drop will be flashing to distinguish it from subsequent drops that will bbe indicated by a steady light. Rectification of the mul function causing the annunciator drops will allow resetting ail lamps, Lamp test provisions are also provided to ensure Identification of dafective indiator lights. On units with ITS, additional information, including historical data of varying age, is frozen in the memory and can be called up in the event difficulty is encountered. Finally, several cate- ‘gories of starts, stops, and operating times are monitored by counters and clock me led maintenance. 1s, a8 an aid in planning sched- In addition to local control atthe turbine panel, options oro availahla far ramote enntral hy means of the Remote Master Control Panel. Control location selection is accom: 5 plistial ot the Gas Turbine Control Panel, thus allowing turbine panel location 10 take priority of control during abnormal conditions SYSTEM DESIGN “The system is comprised at three aisunct areas: rhe eon ‘rol, the protection system and the sequential system as described below. Control Systom “The botie philoconhy in docigning the SPEEDTRONIC control system has been to minimize machine shutdowns resulting from control system failures, Thus, to enhance running reliability, 2 large degree of redundancy has been employed. In general the failure of one of the redundant systems will provide annunciation, with the unit remaining in operation. Further, in areas where full redundancy is hot practical, one functional system serves as a Lachup for thers. For example, the temperature control will control the turbine should the speed control fail, The Basie goal in lie Uesigi uf die angrol hes been to meintsin turbine npr. tion in spite of control failures, recognizing that process interruptions and shutdowns can be costly. “The fundamental concept in the turbine contro is that ‘of a speed governor which commands the fuel control to provide proper fuel flow to the turbine as shown in Fig. 8. ‘The speed control operates through @ minimumvalue gate together with inputs from the temperature limit and the startup schedule such thet the output of the gate, VCE IWoriable controt electronic), 1st all ines the minimum fuel enmmand from any one of these four inputs. Thus if the speed control requires more fuel than the temperature limit, the minimum value gate selects tho temperatureimit value as the VCE command, The VCE output of the gate “tives the fel control, which in turn delivers Tuel to the turbine, The range of the VCE signal is 4 (zero fuel) to 20 (maxim fuel), ‘speed Control Loop When the speed sintral is in command, the control sys tem appears as the loop illustrated in Fig. 9. The output of the speed control is selected by the minimum value gates to produce the VCE signal which, through the fuel contro, provides the required fuel flow to the turbine, The turbine speed is sensed by the speed pickups and compared to the speed command. The speed control adjusts the fuel flow Until the desired (commana) speca is achieved. Orr «wr shaft units the LP set speed loop controls fuel low to con trol low-pressure turbine speed, while the HP speed loop controls the seond stoge nozzle “The speed sensors praduce an AC voltage with frequency reepartianal ta soeed. The sonsor isan electromagnetic de Vice located adjacent to 2 toothed whee! on the turbine shaft and produces a pulse with each.passing tooth, The ‘output of the sensor is converted to an analog signal so that Soltage level is proportional to speed. In adition to provic ing feedback far the speed control loop, this analog voltage drives a speed indicator and is used for input signals to the speed relays, The use ofthis relatively high frequency signs! permits the use of a high gain loop having fast response and high transient accuracy, The speed control can be provided “with cithorieoshronaue or denon characteristics. oF 3 9 fur BAGIC CONTROL CONCEPT PEED AND LOAD CONTRO! SYSTEM (GENERATOR DRIVE 6 Figure 8 Figure 9 ther option, these can be interchanged by input command. Utility units generally are operated in the droop mode (4 percent typical) but may be isochronous for isolated sys- tems, Mechanical drive units typically are operated in the ‘The setpoint for the speed control utilizes an osiliator- driven digital counter, The output of the setpoint provides ' DC analog voltage proportional to the count level in the counter. The raise/lower control enables the oscillator to drive the counter up or down, thus varying the voltage of the setpoint, Ihis concept provides an accurate, stapie vernier control ofthe setpoint, Loading and unloading retes ‘are controlled by the frequency of the oscillator, and sev ral rates are evsileble. Redundant speed pickups are employed and failure of ‘one will aot shut down the turbine but will alarm, The in tegrity of the sensors is checked by continuously measuring the impedances of the sensor with a small DCsignal current. ‘Startup Control During startup, fuel flow to the turbine is determined by f@ startup scneauie, Since bot wie speed cont sid we temperature control during this period will permit higher fuel flows, the minimum value gate selects the startup startup, VGE is held at zoro to prevent fuel flow while the turbine accelerates to firing speed, and purges the gas path. When firing speed is reached, VCE is set at the “fire” level (Fig. 10). When ignition is sensed by the flame detectors, VCE is lowered to the warmup value to minimize thermal shock to hotgas/path parts, At the end of the warmup period (typically 0 to 1 min) VCE is gradually increesea, or STARTUP SCHEDULE ramped, to a value which will accelerate the turbine to full speed, The VCE ramp, however, can De overriagen by an ‘exhaust temperature suppression removal rate limit (typ cally 2.5 to 5 Fisec) and by a rotor acceleration limit (typi tally 02 passant to 2 pereent/seh Temperature Control ‘This control loop limits fuel st startup, or during oor ation when maximum safe operating temperatures. are reached. When the tomperature limit is active, the controt loop is a8 shown in Fig, 11. The turbine exhaust temper- ature is sensed and compared to the setpoint temperature value, and the difference between these values is amplified, and drives the ful control 10 achivwy the sewpoint value ‘The temperature setpoint is generated by biasing the ex- haust temperature with a compressorcischarge pressure to calculate the allowable exhaust fora canstant firing temper. ature as shown in Fig. 11. This setpoint has an upper limit {approximately 1000 F) 0 protect the exhaust system hard ware. The LM2500 temperature control concept differs slightly since temperature is sensed between the gas gener ator and load turbines and a constant temperature limit is imposed. The temperature control system is implemented with snsing laetrania sireuite foe turschatt trina control eve tems, Single-shaft turbine control systems employ a micro- processor-implemented temperature computation system identified asthe Integrated Temperature System (ITS). This ‘computation system carries out the temperature control function in addition to several other functions (combustion monitor, water injection end modulated IGV's) as described tater, ‘TYPICAL TEMPERATURE CONTROL pe) Figure 10 Figure 11 ‘The temperature feedback signal for all turbines is ob- tained by averaging the output signals from multiple ex hnaust thermocouples (13 to 22 depending on the turbine) Cold junction compensation is employed to obtain an accu. rae signal, Nozzle Control “The variable area nozzle on heavy duty tworshaft units is controlled to provide optimum energy division between the hioh-oressure and low-rate chafts. Far ragenerstive nits this control loop maintains constant exhaust temperature, by decreasing compressor speed, as load is decreased as shown in Fig. 12, In the upper half of the load region, the nozzle closes with decreasing load to slow down the com- pressor. AAt about halfload the minimum permissible HP speed is reached, and further decreases in load result in lowering exnaust temperature since air How now remeins Constant. In this region the nozzle must open with decreas: ing load to maintain constant compressor speed. Near rated load the exhaust tempereture is biased downward by com pressor discharge pressure to provide constant firing tem- perature. For simple-cycle units the compressor speed is advantage in maintaining constant exhaust temperature, A block diagram of this control loop for a regenerative unit is itustrated in Fig. 13, Inlet Guice Vanes Ine niet guide vanes tor heat recovery units are mod lated to provide optimum overall cycle efficiency. This control loop adjusts the IGV angle, which varies air flow ture within the IGV control range. The control system is VARIABLE AREA NOZZLE CONTROL LOOP es = Figure 13 similar to that for the nozzle as shown in Fig, 13 except the ‘contro! actuates the IGVs, During startup the IGVs are held fully closed ow sit flow position) to avokd possinie com. pressor pulsation, Water Injection (NO, Control) The controls for the water injection system perform ‘two functions: 1) control of the water according to a pre established schedule, and 2) continuous monitoring of the quantity of water injected to assure compliance with re uirements at all times. A typical water injection schedule is illustrated in Fig. 14. The schedule establishes water flow as a function of fuel flow. US Federal Regulations require time of installation. The control system for the water injec: OPERATING CHARACTERISTICS ‘TWO SHAFT REGENERATIVE TURBINE Figure 12 Figure 14 TYPICAL CONTROL SCHEMATIC WSR TNSECTION Figure 15 tion equipment, illustrated schematically in Fig, 15 includes i low meter to sense weter flow rate and @ micro-compurter fuhich compares the sensed flow with the required flow (05 etermined By the schedule and TUet fom) end yoverate> command signal to the flov-control valve. A postion trans ducer is attachad to the water injection valve to sense valve PoHION. This punlivn signel serves ae a baebun, tn eater rine water flow rete, should the water flove meter fal ‘The micro-computer ato provides the monitoring ture tion, with the required water flow computation based on @ Separate, permanentiy-stored schedule, as the basis for de- termining if the proper amount of water is being injected. For the monitoring function, the actual water-to-fuel ratio is computed, compared to the required ratio, and added to tf tnmeeereyed celeuation for a required aneshour time period. This proces is accomplished on aroll-over type basi inith new date continuously added fone per minute), and ata olrer than one hour removed from the calculation Should the time-averaged ratio (water-to-fue) fall below the required ratio, an alarm occurs with automatic printout Of all pertinent date (60 state points} for the previous hour. fn addition to this printout, periodic logging oxsury at

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