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Speedtronic® Mark V
Turbine Control System
Gas Turbine
C T G
Control System for Gas Turbine
Gas turbine is controlled Speedtronic control system
Control loops includes
Start-up
Acceleration
Speed
Temperature
Shutdown and
Manual Control functions
Speedtronic Control loops
Major Control loops Secondary control loops
Start-up Acceleration
Speed and Manual FSR and
Temperature Shutdown
Output of these control loops is fed to a minimum value gate
circuit Display
Fuel
Temperature
Display
FSR
Speed M
Acceleration
I
To Turbine
Rate
Display
N
Start Up
Shut Down
Manual
Speedtronic Control loops
Fuel Stroke Reference (FSR)
Command signal for fuel flow
Controlling FSR
Lowest of the six control loops
Establishes the fuel input to turbine @ rate required by system
which is in control
Fire 15.62%
Warm-up 11.62%
Accelerate 19.82%
Maximum 100%
FSRSU
FSRACC
FSR
FSRN
FSRT
MIN
FSRSYN
FSRMAN
FSR = FSRSU
Start-up Control - FSRSU
Speedtronic Control Start-up software generates
Fuel command signal (FSR).
Speedtronic Control Software also sets the MAX
and MIN limits for FSR for Manual Control FSR
[ FSRMIN < FSRMAN < FSRMAX ]
When Turbine Breaks away (starts to rotate)
L14HR pick-up
Starting clutch solenoid 20CS de-energizes
Shuts down the hydraulic ratchet motor (88HR)
Acceleration Control - FSRACC
Acceleration control software
compares the present value of Speed signal with the value at the last
sample time.
Difference between these two numbers is a measure of acceleration.
When actual acceleration is greater acceleration reference,
FSRACC is reduced, which reduces FSR, thus reduction in
fuel supply to turbine.
During startup-acceleration reference is a function of turbine
speed.
Acceleration control takes over after Warm-up state.
Acceleration Control - FSRACC
Acceleration reference is a Control constant
programmed in <RST> EEPROMS
Typical
0.35 %/sec
0.10 %/sec
0% 40% 50% 75% 95% 100%
TNH
Acceleration Control - FSRACC
FSRSU
FSRACC
FSR
FSRN
FSRT MIN
FSRSYN
FSRMAN
FSR = FSRACC
Speed Control - FSRN
Speed Control System software
controls the speed and load of the gas turbine
generator
in response to the actual turbine speed signal (TNH)
and the called-for speed reference(TNR)
TNH FSRN
TNR
Speed/Load Control
Speed/Load Reference:
Speed control software will change FSR in proportion to the
difference the actual turbine generator speed (TNH) and the
called-for reference (TNR)
TNR
FSRSU
FSRACC
FSRN (or FSRNI) FSR
FSRT MIN
FSRSYN
FSRMAN FSR = FSRN
Droop Speed Control
Droop Control is a proportional control.
Any change in actual speed (grid frequency) will cause a
proportional change in unit load.
This proportionality is adjustable to the desired regulation or
‘Droop’
104 % Droo
p1 04% s
etting
Reference TNR
FSNL
100 %
1 00%
S et p
oint
Speed
Rated FSR
Low Speed Stop
95%
Min TNR FSR
Speed/Load Control loop
Raise Rate
Speed Target
Speed Ref. Power
Lower Command
LOG MANUAL
SETPOIINT SETPOINT Primary Os
Speed
Rate Preset
Error
Ememrgency Os
SPEED
CONTROL
Mechanical
Os
Load Raise Rate Speed
Load Ref.
Load Lower Cmd MANUAL
LOG Load Setpoint
SET SET
POIINT POINT
Preset
Load Rate
Speed Control Schematic
SPEED CONTROL <RST>
FSNL
TNR
SPEED
REF.
+ ERROR + FSRN
+
- SIGNAL
TNH
SPEED
DROOP
<RST>
SPEED CHANGER LOAD SET POINT
MAX. LIMIT
L83SD
RATE
L70R
RAISE
L70L
LOWER
L83PRES MEDIAN TNR
PRESET LOGIC SELECT SPEED
REF.
PRESET
OPERATING
L83TNROP MIN.
MIN. SELECT LOGIC
START-UP
or SHUT DOWN
Synchronising - FSRSYN
Automatic synchronization software
Algorithms programmed into <RST> controller and <P> software.
Bus and Generator voltage are input signals to Protective core
<P>.
Isolation transformers are built into <P> core
<RST> software drives the synch check and system permissive
relays.
Sequencing and algorithms are programmed into <RST> EEPROM
<P> hardware and software sends voted command to actual
breaker closure.
Auto Synchronisation
Speed
Matching
System Lower Speed
requency
Speed
Raise Volts
AND L25
Calculated Acceleration Breaker
Close
Calculated Breaker Lead Time
Temperature Control - FSRT
Temp.Control software/algorithms
limit fuel flow to the turbine to maintain internal operating
temperatures within design parameters of turbine hot gas
path parts.
Highest temperature is in the flame zone of
combustion chambers.
TTXM FSRT
TTREF
Firing Temperature
Firing temperature - temperature of gas as it exits the
first stage nozzle.
Speedtronic limits this firing temperature.
Firing temperature is calculated by
thermodynamic relation ships
GT performance calculations, and
site conditions
as a function of Exhaust Temp(Tx) and CPD
fuel
Exhaust temperature (Tx)
Co Isothermal
ns
air tF
C T
ir in
gT
em
p(
Lin
e ari
z ed
)
ISO FIRING TEMP TC
Compressor Discharge Pressure (CPD)
Firing Temperature
Firing temperature can also be approximated as
a function of Tx and Fuel flow (FSR) and
as a function of Tx and Generator MW output
Line of constant firing temperature are used in control
software to limit the gas turbine operating temp
whereas the constant exhaust temperature limit protects the
exhaust system during start-up.
SLOPE TTRXB
MIN.
MEDIAN
FSRT
SELECT +
FSR + - TTXM + SELECT
-
- + +
CORNER GAIN
FSR
ISOTHERMAL
The temp-control-command program in <RST> compares the exhaust temp control setpoint
(calculated in the temp-control-bias program and stored in computer memory) TTRXB to the
TTXM value to determine temp error. The software program converts the temp error to a FSRT
Temperature Control Bias program
DIGITAL TT
COMPUTER
INPUT Kn TT
DATA MEMORY _B Kn
_M
Exhuast Temperature
TTKn_K
SELECTED
TTKn_I Isothermal
TEMPERATURE
TEMPERATURE CONTROL COMPUTER
REFERANCE BIAS MEMORY TTKn_C
TABLE PROGRAM
FS
CP R
D BI
BI AS
AS
CONSTANT
STORAGE
CPD
FSR
Temperature Control Bias Exhaust Temp Control Setpoints
Temp control Bias program calculates the Exhaust TTKn_C (CPD bias corner) and TTKn_S (CPD bias slope)
temp control setpoint TTRXB based on CPD data are used with the CPD data to determine the CPD
stored in computer memory and constants from the bias exhaust temperature setpoint.
selected temp-reference table. TTKn_K (FSR bias corner) and TTKn_M (FSR bias slope)
This Program also calculates another setpoint based are used with the FSR data to determine the FSR
on FSR and constants from another temperature- bias exhaust temperature setpoint.
reference table. Program also selects isothermal setpoint
Final temp control Ref=MIN(FSR bias, CPD bias, Isothermal setpoint (TTKn_I)
Temperature Control Bias Program
This Program selects the minimum of the three set points, CPD bias, FSR bias, or
isothermal setpoint for the final exhaust temperature control reference.
During normal operation with Gas or light Distillate fuels, this selection results in a CPD bias
control with an isothermal limit.
CPD bias setpoint is compared with the FSR bias setpoint by the program and an alarm
occurs when the CPD setpoint exceeds the FSR bias setpoint.
During normal operation with Heavy fuels, FSR bias setpoint will be selected to minimize
the turbine nozzle plugging on firing temperature.
FSR bias setpoint is compared with CPD bias setpoint and an alarm occurs when the
FSR bias setpoint exceeds the CPD bias setpoint.
A ramp function is provided in the program to limit the rate of setpoint change. Both Max
(TTKRXR1) and Min (TTKRXR2) change in ramp rates (slopes) are programmed.Typical
rate change limit is 1.5deg F.
The output of this ramp function is the Exhaust temp.control setpoint which is stored in the
computer memory.
Temperature Reference Select Program
Exhaust temperature control function selects control set points to
allow GT operation at firing temperatures.
Temperature-control-select program determines the operational
level for control set points based on Digital input information
representing temperature control requirements.
Three digital input signals are decoded to select one set of
constants which defines the control set points necessary to meet
the demand.
Selected
Typical digital signals are Digital Temperature Temperature
BASE SELECT, Input Data Reference Reference
PEAK SELECT and Select Table
HEAVY FUEL SELECT
• When appropriate set of constants
are selected they are stored in the Temperature
Constant
Reference
selected-temperature-reference Storage
Select Program
memory.
Fuel Control system
Turbine fuel control system will change fuel flow to the combustors in
response to the fuel stroke reference signal(FSR).
FSR actually consists of two separate signals added together.
FSR = FSR1 + FSR2
FSR1 = Called-for liquid fuel flow
FSR2 = Called-for gas fuel flow
Standard fuel systems are designed for operation with Liquid
fuel and/or gas fuel.
Servo Drive System
Servo drive System
The heart of Fuel Control System
3 coil Electro Hydraulic Servo Valve
Servo valve is the interface between the electrical and
mechanical systems
Servo valve controls the direction and rate of motion of a
hydraulic actuator based on the input current to the servo.
Servo valve contains three electrically isolated coils on the
torque motor.
Each coil is connected to one of the three controllers
<RST>, thereby redundancy is ensured if one of the
controller fails.
A null-bias spring positions the servo so that actuator
goes to the fail safe position when ALL power and/or
control signal is lost.
Liquid Fuel System
Liquid Fuel system consists of
Fuel handling components
– Primary fuel oil filter (low pressure)
– Fuel oil stop valve - Fuel pump
– Fuel bypass valve - Fuel oil pressure relief valve
– Secondary fuel oil filter (High pressure)
– Flow dividers - Combined Selector valve
– False start drain valve- Fuel lines & fuel nozzles
Electrical Control components
– Liquid fuel press sw (upstream) 63FL-2
– Fuel oil stop valve limit sw 33FL
– Fuel pump clutch solenoid 20CF
– Liquid fuel pump bypass valve Servo valve 65FP
– Flow divider magnetic pickups 77FD-1,2,3 and
– Speedtronic Control cards TCQC and TCQA
Liquid Fuel System P&ID
<RST> FQ1
FSR1 <RST>
FQROUT <RST>
TCQA
TNH TCQA
L4 TCQC PR/A
Flow
L20FLX
Divider
Typical
By-pass Valve Asm 77FD-1 Fuel Nozzles
65FP
Combustion
Chamber
63FL-2 Diff Press
Guage
Conn.For Purge
When Required
Fuel
Stop OFV
AD
Valve
VR4
OF
Main Fuel Pump
Atomizing
Air False Start
33FL Accessory 77FD-2 Drain Valve
Gear Chamber OFD
Drive To Drain
77FD-3
OLT-
Control
Oil
Fuel oil Control - Software
Control system checks the permissive L4 and L20FLX to allow FSR1
for closing the Bypass valve (closing bypass valve sends fuel
to the combustors)
These signals control the opening and closing of the fuel oil stop valve.
Fuel pump clutch solenoid (20CF) is energised to drive the pump when
the Stop valve opens.
Fuel splitter algorithm ensures requisite FSR when FSR1 is active
FSR1 is multiplied by TNH - to make it a function of speed (an
important parameter of Turbine)
to ensure better resolution at the lower, more critical speeds where air
flow will be low.
Net result is FQROUT- a digital liquid fuel flow command
At Full speed, TNH does not change
Therefore FQROUT ~~ FSR
Fuel oil Control - Software
Analog signal is converted to digital counts and is used in the
controllers’ software to compare to certain limits as well as for
display in CRT.
The checks performed by software program
L60FFLH - Excessive fuel flow on start-up
L3LFLT - Loss of LVDT position feedback
L3LFBSQ - Bypass valve is not fully open when the stop valve
is closed
L3LFBSC - Servo Current is detected when stop valve is closed
L3LFT - Loss of flow divider feedback
(L60FFLH persists for 2 sec and this fault initiates trip, L3LFT also initiates trip
during start-up)
Fuel Gas System
Fuel gas is controlled by
Gas Speed ratio/stop valve (SRV)
Gas Control Valve (GCV)
(Both are servo controlled by signals from Speedtronic control panel and
actuated by spring acting hydraulic cylinders moving against spring-
loaded valve plugs)
GCV controls the desired gas fuel flow in response to the
FSR command signal.
SRV is designed to maintain a predetermined pressure (P2)
at the inlet of the GCV as a function of turbine speed
P1 P2 P3
Fuel Supply
SRV GCV To Turbine
Fuel Gas System
Gas Fuel System consists of
Fuel handling components
– Gas Strainer - Speed Ratio/Stop Vlv assembly
– Control valve assembly - Dump valves
– Three pressure gauges -
– Gas manifold with ’pigtails’ to respective fuel nozzles
Electrical control components
– Gas supply press sw 63FG - Fuel gas press xducer(s) 96FG
– Gas fuel vent sol valve 20VG -LVDTs 96GC-1,2 & 96SR-1,2
– Electro hydraulic servo vlv 90SR & 65GC
– Speedtronic control cards TBQB and TCQC
Fuel Gas System P&ID
FPRG TCQC TCQC TCQC
POS1
POS2 SPEED RATIO FSR2 GAS GAS CONTROL
VALVE CONTROL CONTROL VALVE POSITION
FPG
VALVE SERVO FEEDBACK
TBQB 96FG-2A
96FG-2B
96FG-2C
20
TRANSDUCERS
VG
VENT
COMBUSTION
CHAMBER
63FG-3 Gas
Stop Control
Ratio Valve
Valve
GAS
P2
LVDT’S LVDT’S
96SR-1.2 TRIP 96GC-1.2 GAS
MANIFOLD
Vh5-1 Dump Relay
90SR SERVO 90GC SERVO
Hydraulic Supply
Gas Control Valve
Gas Control Valve
GCV position is proportional to FSR2
(Actuation of spring-loaded GCV is by a hydraulic cylinder controlled by
an Electro-hydraulic servo valve)
GCV will open only when permissive L4, L20FGX and
L2TVX (purge complete) are true.
– Stroke of the valve is proportional to FSR
OFFSET
<RST>
GAIN
FSR2 <RST>
L4 TBQC
HI
L3GCV SEL
FSROUT Analog
I/O
FSR2 goes through Fuel splitter algorithm.
TCQC converts FSROUT to an analog signal. GCV
GAS
GCV stem position is sensed by LVDTs and P2
GCV Position Loop
fed back to an op-amp on TCQC card to compare Calibration
with FSROUT input signal at summing junction.
Position
LVDT
LVDT’S
Op-amp on TCQC converts error signal and sends 96GC -1,-2
Servo
to servo valve to drive GCV accordingly. Valve
FSR
Speed Ratio/Stop Valve
TNH
It is dual function valve <RST> <RST>
(It serves as a pressure regulating valve to hold a GAIN
GAS
GAS FUEL REFERENCE CONTROL FQROUT
VALVE SERVO GAS CONTROL VALVE
OUTPUT OUTPUT COMMAND
GAS
SPEED REQUIRED PRESSURE
CONTROL
VALVE`
OUTPUT SPEED RATIO VALVE
MIDVALVE GAS FUEL PRESSURE SERVO COMMAND
OUTPUT
UNITS
selected.
FSR1 will remain at its initial value, FSR1
UNITS
required by the SRV would cause slow
FSR2
response in initiating gas flow.
After delay of 30 sec to bleed down the P2 PURGE TIME
SELECT GAS
pressure and fill the gas supply line, the
Transfer from Full Liquid to Mixture.
software program ramps the fuel commands FSR1
FSR2 to increase and FSR1 to decrease at
UNITS
IGV begins to move to full open pos. MIN Full Speed Angle
Servo IGV
Temp. Control Inlet Output Command
Reference
Guide
IGV Reference
Manual
Vane
Compressor
Inlet Temp. Command Ref.
IGV
Part IGV Part Speed Ref.
Speed
Speed Ref.
Wet Low NOx Control
Gas dP
Gas Press Gas Gas Fuel Flow
Flow Basic
Gas Temp Injection Flow
Liq Fuel Flow Required
+
Injection Injection Dead band
Humidity Flow Flow
_ Controller Lower
Injection Flow
Power Augmentation
Flow
Water Flow
Injection
Steam Select Flow
Steam Press Steam
Flow
Steam Temp
Protection Systems
Turbine protection system consists of number of sub-systems
which operate during each normal start-up and shutdown
Few operate strictly during emergency and abnormal operating conditions.
Protection systems are set up to
Detect and alarm the failure.
If the failure is of serious nature, protection system will trip the turbine.
Protection system responds to:
Simple trip signals like
– low lube oil press switch
– high gas compressor discharge pressure etc….
Protection Systems
More Complex parameters like
– Over speed
– Over temperature
– High Vibration,
– Combustion monitor
– Loss of flame etc…..
Relay
20 Liquid
Voting Fuel Stop
Module FL
Valve
Trip Oil System
It is a primary protection interface between the turbine control and
protection system and the components of the turbine which admit
or shut-off, fuel.
System devices are electrically operated by Speedtronic control
system as well as some totally mechanical devices.
Master
Protective Protection
Signals L4 Liquid
Circuits Liquid Fuel
Fuel Stop Valve
20 20
Manual Trip FG
Orifice And FL
(When Provided)
Check Valve
Network 63HL
OLT
Mechanical Over speed system
Consists of
12HP
Over speed bolt assembly in accessory
Manual gear box.
Reset Over speed trip mechanism in the
assessory gear.
Manual
Trip
Position limit switch 12 HA.
Acts as a back-up control
OD Trip setting > Electronic Setting
Overspeed Bolt
Over Temperature Protection
OVER-TEMP. TRIP & ALARM.
Protects GT against TTXM A L30TXA
To Alarm
Message
possible damages TTXOT3
ALARM A>B
B
ALARM And
Speed
against Over firing. Setpoint
Lower
TTRXB
A
1090º F
ISO TRIP TTXOT2
A>B
B
O To
R
40ºF
40ºF A
Master
TTREF TTXOT1 TRIP Set
Prot.
And
Isothermal And Alarm
1030ºF A>B Latch Msg
L86MR1
B
Reset
TRIP
25ºF
25ºF
ALARM
It is a backup protection system,
CONTROL
operates only after the failure of
CPD temperature control system.
Flame Detection & Protection
Speedtronic Mark-V flame detectors perform two functions
One in the Sequencing system
other in Protective system
Flame detected by UV radiation.
Speedtronic control furnish +350VDC to drive the UV detector
tube. In the presence of UV radiation, the gas in the detector tube
ionizes and conducts current.
Speedtronic counts the no.of current pulses/sec through UV
sensor.
Typically 300 pulses/sec when strong UV signal is present.
Flame Detection & Protection
Speedtronic MK-V Flame Detection
28FD TUEBINE
UV SCANNER PROTECTION
<P> LOGIC
28FD
UV SCANNER ANALOG CRT
FLAME
I/O DISPLAY
DETECTION
(Flame LOGIC
28FD Detection
UV SCANNER Channes)
TURBINE
28FD CONTROL
UV SCANNER LOGIC
thermocouples TTKSPL7
A L60SP4
A>B
B
Combustion Monitoring
1 18
High Low
Speedtronic Control Software
Actual Spreads
TTXSP1 = High - LowTTXSP2 = High - 2nd Low
TTXSP3 = High - 3rd Low
Allowable Spread (Spread Limit)
performs
OR
Low Lube Oil Level Trip TURBINE
Low Lube Oil Pressure Trip
Low Servo Pressure Trip
Axial Position Trip
Generator Differential Fault
Manual Trip
Customer Trip