Turbine Control Software: ITS-Industrial Turbine Services Group
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������� ������� �������� ������ ����� ���� �� � ������� ����������� �� ��� ������� ��������� ��� ��� ���� ���� �� ��� ��������� ��������� ����� ������ ������� ���� �� ������ ������� ��� ����� �������� ������� �������� ������������� �� �� ������ ����� ������� ��� ���������� On Generator drives, drives, speed control can be either droop or isochronous. isochronous. With droop control, the load demand is summed with the speed setpoint. The speed/load setpoint (TNR) is then compared to the speed feedback (TNH) to produce the speed speed control fuel fuel flow demand demand (FSRN). With isochronous isochronous control, used most commonly for island operation, the speed/fuel governor holds a constant speed equivalent to the system frequency over the range of connected load. During start and acceleration, the acceleration fuel reference will limit the rate of change of speed. Overspeed protection protection is provided by by two independent independent electronic electronic circuits. circuits. The software module L12H residing in control processors cuts off fuel when the speed, as measured by the three primary speed pickups, exceeds the overspeed limit.
������� �����/���� ������� ��������� The control signal TNR is the gas turbine speed/load reference in terms of percent. During startup, this command varies from 0% to 100% speed. After synchronization synchronization to an electrical power grid, TNR becomes a load reference and typically varies between 100% and 104% to command the power output from 0% to 100% rated load.
����� ������� Adjust as required. Full speed no load (FSKRN1), initially set as calculated. Droop setting (FSKRN2), assumed = 4 % regulation. This mode of governor control changes FSR in proportion to speed error (droop). With the non-linear droop option [OPT_NLD] selected, TNKRNG is calculated in place of FSKRN.
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����������� ������� When isochronous is selected, L83ISOK picks up, switching the speed/load setpoint from the droop reference (TNR) to the isochronous reference setpoint (TNRI). An optional feature allows allows the isochronous isochronous speed reference reference to be changed by external external raise/lower raise/lower signals. In this case, the rate of change of the setpoint is limited by rate limit TNKRIR1.
�������� �������� ����� �����/���� ������� Constant Settable Droop Speed/Load control represents a method of formulating the gas turbine turbine droop response response as a function function of the unit unit power output. output. This method of speed/load control is applied to units where the fuel stroke reference (FSR) is not predictable as a function of the gas turbine output power due to varying fuel heating values or where fuel is switched between different combustion system injection nozzles. Constant Settable Droop Control features an inner speed control loop and an outer megawatt control loop. The inner speed loop is proportional proportional plus integral control whose mission is to make the turbine speed, TNH, match the called for reference reference speed command TNRL. The outer megawatt megawatt loop formulates formulates the droop governor response by creating a speed bias as a function of unit power output. output. When the turbine speed speed is held held fixed by an electrical electrical grid, grid, the turbine fuel consumption and megawatt output is modified (or 'Constantly Set') such that the TNRL reference speed command is made to equal the turbine speed,TNH. The scaling scaling of the turbine power power output, DWATT, to the speed bias bias signal,DWDROOP, defines the droop governor response in terms of megawatt output changes per percent grid speed changes. Three watts transducers are used for reliability on the constant settable droop design. Each transducer transducer must be connected connected in the correct sense sense and independently powered. If the transducers are miswired miswired or unpowered, unpowered, the watts feedback signal can act in the sense to over fuel the turbine.
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������������ ������� This algorithm limits the rate of the HP shaft speed acceleration by limiting "FSR" at "FSRV1" algorithm. This function acts on the rate of speed increase to prevent overspeed with load rejection.
����������� ���� ������� Load control: the speed/load setpoint is raised or lowered until the watts feedback is within the deadband of constants LK90DB1 and LK90DB2. Temperature control: when the unit reaches temperature control, speed control continues to count up requiring more FSRN than the temperature limit, FSRT. This is done to keep the unit steadily on temperature control with minimal switch back to speed speed control. Count up is is determined determined by deadband limit, LK90DB3, where raise is inhibited. As the unit is subject to ambient temperature change and FSRT drops, a greater deadband limit, LK90DB4, is exceeded and the setpoint is lowered to keep speed control relatively close. Load limit LK90MAX is set to prevent exceeding the most critical design limit on the gas turbine application, i.e. shaft, load coupling, etc.
������ �������� ����������� ���� ������� This optional function provides a rate controlled changer for the preselected load setting by substituting L90PSEL for the constant LK90PSEL in L90L. Operators can utilize this, within set limits, without changing constants.
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������� ����������� �������� & ���������� The Exhaust Temperature Feedback and Protection algorithm averages the exhaust temperature temperature thermocouple thermocouple readings readings to determine the value, TTXM. Any temperature readings which fall below the value of TTXD2_2 by the constant, TTKXCO, are excluded excluded from the the average calculation. calculation. The highest and and lowest of the remaining thermocouple readings are also excluded from the calculation of TTXM. Standard thermocouples are Type K (Chromel-Alumel). (Chromel-Alumel). The constant TTKXCOEF is used to account for errors in the turbine exhaust temperature control readings which are the result of individual thermocouple bias error and positioning error of the exhaust thermocouple array. Type K thermocouples are known to experience an aging phenomenon which tends to raise the the level of thermocouple thermocouple output. output. In addition, addition, thermocouple thermocouple wire is subject to manufacturing variations which can affect the level of the thermocouple output. Due to manufacturing tolerances and operating conditions of the gas turbine, the exhaust thermocouple array position may vary slightly between turbines. This variation can cause an error between the average measured exhaust gas temperature and the true average exhaust gas gas temperature. temperature. For each gas turbine, the proper functioning of MACH7 control using the as shipped value of TTKXCOEF is routinely verified on site by ITS prior to the start of unit operation. operation. For new or upgraded upgraded designs designs where position position error is not not yet defined, ITS will adjust adjust the value of TTKXCOEF to provide unit operation at design conditions. conditions. The value for TTKXCOEF is not not to be adjusted adjusted without the the concurrence and assistance of ITS. The algorithm generates an exhaust over-temperature alarm, L30TXA, an exhaust over-temperature trip, L86TXT, and an exhaust thermocouples open trip, L86TFB. The algorithm also produces lists of the exhaust temperature thermocouple indices sorted by temperature reading. On machines with combustion monitoring,these lists are used to calculate the spread between exhaust temperature thermocouples. thermocouples.
A thermocouple position is set to 0.0 CNTS when number outside the array of possible assignments.
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������� ��������������� ���������� ����� The exhaust overtemperature protection system protects the gas turbine against possible damage caused caused by overfiring. This is a protective protective backup backup system which operates only after failure of the speed and temperature override loops. Under normal operating conditions, the exhaust temperature control system reacts to regulate fuel flow when the firing temperature limit is reached. However,in certain failure modes, the exhaust temperature and fuel flow could exceed the the control control limits. Therefore, the overtemperature overtemperature protection system provides an overtemperature alarm annunciation prior to tripping the gas turbine. This allows the operator to unload unload the the unit unit to avoid a trip situation. If the exhaust temperature temperature should continue continue to to increase, increase, the gas turbine is tripped. The exhaust overtemperature protection curve is shown below.
����������� ������� ���������� When the turbine is at operating speed, L14HS, and the gas turbine compressor discharge pressure, CPD, falls below the constant, CAKCPD, the logic signal, L3TFLTX, is asserted. This signal latches the compressor discharge pressure fault alarm, alarm, L3TFLT, L3TFLT, until a master reset, L86MR1_CMD L86MR1_CMD is asserted. asserted. L3TFLT, is used to initiate backup temperature control in the TTRX algorithm and alarm the operator. Failure of two CPD transducers transducers on Dry Low NOx units will cause a turbine trip, L4DLNT2. Temperature control feedback permissive, L86TFINH, is used to allow exhaust thermocouples open trip, L86TFB, in the TTXM algorithm when operating above acceleration speed, L14HA.
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������� ����������� ������� ��� ���������� The purpose of the exhaust temperature control and protection system is to control the fuel flow to the gas turbine thus maintaining operating temperatures within the design thermal stress limitations of the turbine parts. This system measures and controls turbine exhaust temperature since it is impractical to directly measure combustion chamber temperature. Temperature control is designed to override any other control demand for increased fuel flow. The TTRX algorithm computes the gas turbine exhaust temperature control reference. The exhaust temperature is controlled as a function of compressor discharge pressure, CPD. This allows firing temperature to be limited by a linearized function of exhaust temperature and CPD. A "backup" curve (secondary curve), is also a linearized function of gas turbine output,DWATT which limits firing temperature. The secondary curve is offset above the primary curve by TTKRX2. This ensures that the backup temperature control curve does not interfere with the primary gas turbine exhaust temperature control based on CPD. In the event of a compressor discharge pressure transducer failure as detected by L3TFLT, the constant TTKRX2 is subtracted from the secondary curve. This backup curve now becomes the control curve for gas turbine exhaust temperature. The gas turbine exhaust temperature control reference, TTRX, is computed as the minimum select among TTRXP, TTRXS and TTKn_I and will not exceed the ramp rates TTKRXR1 TTKRXR1 and and TTKRXR2 during transients. transients. The computed computed reference reference is fed into the inlet guide vane algorithm, CSRGV, and used to control the gas turbine IGV's. TTRXB, which is used for fuel control, is then computed as the sum of TTRX and IGV temperature bias, CSRGVTXB.
Primary Exhaust Temperature Control Reference: ----------------------------------------------------------------------------------------TTRXP = TTKn_I - TTKn_S * (CPD - TTKn_C) + TTRXDSP + CT_BIAS + WQJG
Secondary Exhaust Temperature Control Reference: --------------------------------------------------------------------------------------------* Gas Turbine MW Bias TTRXS = TTKn_I - TTKn_LG * (DWATT - TTKn_LO) + TTRXDSP + CT_BIAS + TNH_BIAS + WQJG
Curve selection is defined as follows: n = 0, curve 0 n = 1, curve 1
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Bias Options -----------* The gas turbine exhaust temperature may also be biased by compressor inlet temperature. CT_BIAS = (CTD - TTKTCDO) * TTKTCDG * As mentioned above, TNH_BIAS provides an offset for the secondary exhaust temperature control curve. curve. Once a CPD CPD transducer transducer failure is detected, detected, the backup curve replaces the primary curve by subtracting off the offset, TTKRX2. TNH_BIAS = -1 * TTKRX2 when L3TFLT is TRUE, else TNH_BIAS = 0 * A manual exhaust temperature bias, TTRXDSP, can be used by the operator to manually lower the reference temperature by a desired amount.
����������� ������� ���� ������ ��������� The Temperature Control Fuel Stroke Reference algorithm is a proportional + integral control. control. The exhaust temperature control reference, reference, TTRXB, TTRXB, is compared to the median exhaust temperature, temperature, TTXM. TTXM. The resulting resulting error is multiplied by a proportional proportional gain, FSKTG. The inner loop contains a positive positive feedback, first first order lag with with time constant constant FSKTTC. The resultant resultant output, FSRT, is then passed to the Fuel Stroke Reference algorithm.
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���������� ���������� The primary function of the combustion monitor is to reduce the likelihood of extended damage to the gas turbine if the combustion system deteriorates. This function detects abnormal combustion temperature patterns reflected downstream in exhaust spreads. The function function is enabled when the turbine is enabled with L4 above operating speed, 14HS. Turbulence during startup/shutdown startup/shutdown prevents use of the algorithm to detect abnormal combustion. Combustion abnormalities abnormalities can include ruptured transition pieces, loss of fuel or flame in a combustor,or other combustion malfunctions. In the event of a combustion alarm, it is most likely that a condition exists within the turbine that, if left alone, could lead to serious combustor or turbine damage. The usefulness and reliability of the combustion monitor depends on the condition of the the exhaust thermocouples. thermocouples. It is important important that each of of the thermocouples is in good working condition. The combustion monitor can indicate the following problems: Combustor 1. Failed Liner (cracked or burned) 2. Failed Transition Piece (cracked or burned) 3. Collapsed Liner 4. Hot Crossfire Tubes Fuel System 1. Break in Gas fuel line 2. Plugged or Stuck Check Valve Fuel Nozzle 1. Plugged Fuel Nozzle 2. Unscrewed Fuel Nozzle 3. Fuel Nozzle Erosion Pressure Vessel Integrity 1. Cracked Combustor Casing 2. Damaged Crossfire Tube Piping 3. Leakage at Flame Detector or Spark Plug
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���������� ������� ����������� ������ This algorithm uses the max CTDA, and the system exhaust temperature TTXM, to calculate allowable spread, TTXSPL = (0.145 TTXC-0.08*CTDA + 30) deg F. TTXSPL is a median selected value between 30 deg F MIN and 125 deg F MAX. The three highest spreads (TTXSP1, 2, and 3) are calculated and compared to allowables (constants (constants TTKSP1, TTKSP1, 2, 3, & 4). Logic signals L60SP1, 2, or 4, are satisfied if the highest three spreads are greater than their allowables. Two adjacency checks are also made to determine if the lowest and second lowest(L60SP5) are adjacent, and/or if the second lowest and third lowest (L60SP6)are adjacent. With L2SMP1 and 2, monitor spreads can be observed with the monitor enabled but before alarms are enabled. The allowable spread is increased by an appropriate bias at startup, fuel transfer, load setpoint raise/lower and at high rate of FSR changes, as enabled by L83SPMB. If there is one communication failure, only spread one, TTXSP1 is checked. checked. This is the highest highest minus the the lowest valid thermocouple. thermocouple. In the combustion monitor function: s (allow):
=
the "allowable spread", based on the average exhaust temperature and compressor discharge temperature. the allowable spread must be between the limits TTKSPL7 and TTKSPL6 in degrees F. (usually about 30 deg F and 125 deg F.)
TTXSP1
(s1) =
the difference between the highest and the lowest thermocouple reading. (spread1)
TTXSP2
(s2) =
the difference between the highest and the second lowest thermocouple reading. (spread2)
TTXSP3
(S3) =
the difference between the highest and the third lowest thermocouple reading. (spread3)
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���������� ������� �������� Monitor trip is enabled when the monitor is enabled at operating speed, 14HS master protection is not tripped , L4 NORMAL shutdown is not selected , L94X L30SPTA
=
if any thermocouple signal causes the largest spread to exceed the constant TTKSP2, (usually 5 times the allowable spread) for time K30SPTA, an "Exhaust TC Trouble" alarm will annunciate.
L30SPA
=
if a thermocouple value causes the largest spread to exceed constant TTKSP1, for time K30SPA, a "Combustion Trouble" alarm will annunciate.
L30SPT
=
a high exhaust temperature spread trip can occur if: (1). Spread 1 exceeds allowable, spread 2 exceeds TTKSP3 times the allowable, and they are adjacent. OR, (2). Spread 1 exceeds TTKSP2 times the allowable, (5 times allowable = bad thermocouple) and spread 2 exceeds allowable times TTKSP3,and spread 2 and spread 3 are adjacent. OR, (3). Spread 3 exceeds allowable times TTKSP4 (which implies that spread 1 and 2 also exceed the allowable times TTKSP4) if (1), (2), or (3) exists for time K30SPT, the turbine will trip through the master protective "4" circuit.
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���������� ��������������� ������ There are two dual element thermocouples (TC) in each measurement location to monitor the wheelspace temperatures. The average temperature measured by the two TC's is computed and compared to an alarm level for each location. If this average temperature exceeds the alarm level, a common alarm, L30WSA2, is generated. For the first hour of operation, WSKALM9 is added to each of the alarm levels. The two TC's at at each location location are also compared compared against each other. If they differ by more than WSKALM8, an alarm L30WSA1 is given. All of the average wheelspace temperature values are compared against each other and the highest value is selected. This value is then compared to LK69TWW, to allow water wash.
In the cooldown sequencing, there is a "max" select gate to take the warmest wheelspace thermocouple and compare it to LK69WSMAX to provide a mandatory cooldown time to insure adequate cooling of the turbine.
������� ����� ���������������� ����� Normal bearing lube oil supply temperature is about 130 degrees F. Temperature rise of the bearings usually ranges between 25 to 60 deg F. Rising temperatures may indicate bearing problems or lube system restrictions. Refer to the appropriate 0416 schematic and the device summary for thermocouple locations and description. Drain temperatures are normally about 150 deg f. Rising temperatures may indicate bearing problems or lube system restrictions.
������� ����� ��������������� ����� This function monitors the bearing metal thermocouples for excessive
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�������/�������� ������ PURGE TIMER K2TVP The design criterion for purging the exhaust path before firing, is to exchange 4 (5 if NFPA requirements are used) times the exhaust heat recovery volume, to ensure that the machine and exhaust are fully purged of combustion gases. Purge timer K2TV is set to hold the turbine at the purge speed long enough to produce these 4 (5 if NFPA requirements are used) volume exchanges. After K2TVP times out, the Safety Shutoff Valve is opened and timer K2TV allows the line line to pressurize pressurize up to the the Gas Turbine gas valves. Then firing is initiated.
FIRING TIMER K2F The firing timer is the maximum amount of time the control system will attempt to fire the machine. If flame is not established before the firing timer times out, fuel is shut off and the spark plugs are de-energized. A restart can not be attempted until the machine completes another purge cycle.
WARMUP TIMER K2W K2W After flame is established and FSR is cut back to the warm up level, it is maintained at this level for the duration of the warmup timer to reduce the thermal stress on the rotor.
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������� ���� ������ ��������� The FSRSU algorithm sets a fuel stroke reference schedule capable of accelerating the gas turbine while maintaining a moderate firing temperature rise. It is intended that the acceleration schedule from FSRACC will modulate a lower FSR schedule than permitted by FSR_SU. Startup gate.
control
passes
the
following
levels
of
FSR
to
the
FSR
MIN
select
FSKSU_FI In order to ignite the combustion system and provide crossfiring around the turbine's combustors, combustors, startup FSR is stepped to the firing value while the spark plugs are firing.
FSRSU_WU After flame is detected FSRSU is cut back to the level defined by FSRSU_WU. This reduced level of FSR is intended to reduce the thermal stress on the rotor. During the transition from firing FSR to warmup FSR, a first order filter is introduced which slows the transition from one FSR level to the next. The filter uses the time constant FSKSU_TC.
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������� �������� The starting means has the ability to apply different levels of torque to the rotor which are appropriate for the various stages of startup. The controller has been configured with an automatic refire capability. This function will repurge and refire the turbine if flame is not established on the first firing attempt. Timer, K62TT2, sets the number of firing attempts allowed per operator start selection. Signal Value Units Scale Definition ----------------------------------------------------------------------------------------------------------------------------------------------------K1XY 1.500 sec SEC64 SHUTDOWN CANCEL K62TT 5.0000 sec SEC64 MULTIPLE START K62TT2 2 CNT15 CNT15 MULTIPLE START COUNT SK43_MASK 042D HEX HEX COMMAND STATE MASK CONTROL
������������ ���������, ������ ������� The FSRACC algorithm computes the appropriate fuel stroke reference for correct control of the turbine shaft acceleration. The algorithm computes an acceleration reference, TNHAR, and a corresponding fuel stroke to maintain this acceleration rate. The controller derives actual turbine shaft speed with respect to time, calculating the shaft acceleration TNHA. TNHAR is compared with TNHA and FSRACC is adjusted to drive the error between the two to zero.
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�������� ���� ������ ��������� When the generator breaker opens, the shutdown FSR, FSRSD, ramps from existing FSR to FSRMIN at set rate FSKSD3. FSRSD latches onto FSRMIN and decreases with corrected speed. When speed drops below a defined threshold, K60RB, FSRSD ramps to a blowout at one flame detector. The sequencing logic remembers which flame detectors are functional at breaker open. When any of the functional flame detectors loses flame, FSRSD, then ramps down at fast rate, FSKSD5, until fuel is shutoff with flameout. Timers limit the duration of the ramp to blowout. One timer trips after a fixed time from rampdown. A second timer limits fuel after any functional flame detector drops out.
������� ��� Minimum FSR is the least amount of fuel that will continue to maintain flame in the combustor. It is required to insure that other forms of FSR control can not call for a fuel level that will cause the flame to blow out. Minimum FSR is calculated by performing a linear interpolation as a function of corrected speed TNHCOR. During startup, FSRMIN is generated from a two point point linear interpolator using constants FSKMINU2 FSKMIND4 and corresponding speed constants FSKMINN2
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�������� �������� The lube oil pumps work in conjunction with the hydraulic ratchet mechanism to rotate the rotor approximately 47 degrees every three (3) minutes. This provides a uniform cooling of the rotor. In the normal cooldown mode, the Auxiliary lube oil pumps are operating continuously continuously with the intermittent operation of the ratchet. When AC power is unavailable, the DC lube oil pumps are cycled on for 15 seconds at the onset of each 3 minute cooling cycle. Upon coastdown from a running condition, the cooldown cycle will immediately take effect, and continue indefinitely until "Cooldown Off" is manually selected. Cooldown may also be initiated manually by selecting "Cooldown On" and will continue indefinitely until "Cooldown Off" is selected.
���� ������ ��������� The FSR algorithm compares all of the previously calculated fuel stroke references with the exception of FSRMIN and selects the minimum value as the controlling FSR. The value of FSR is limited to anything greater than or equal to FSRMIN. FSRMIN. FSRMIN in control control generates a logic change change in the software. software.
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���� �������� (���� ����) The FSR Splitter algorithm controls the percentage and the rate of change of the Gas/Liquid Fuel split. The fuel selection sequence permits and sends the commands to the fuel splitter to change the fuel split. FSR1 is used to represent the percentage of liquid fuel and FSR2 is used to represent the percentage of gas fuel. The L84TL, L84TG, and L84MIXT signals are used in the fuel sequencing as an indication that the gas turbine is operating on 100% liquid, 100% gas, liquid/gas mixture respectively. Prefill is initiated at the beginning of the transfer of fuels. Transfer should should be done above 25% Load (about 10 MW) on this this unit. Mixed fuel operation window is 60%-90% gas and 60% gas at 25% load to 30% Gas at Base Load. The Mixed window is to prevent combustion chamber pulsation due to low nozzle pressure pressure ratio. Liquid fuel mixture mixture should be greater than than 10% to prevent excessive liquid fuel recirculation resulting in fuel overheating and possibly causing fuel pump damage.
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��� ���� ������� Gas control valve: From the time L2TVP is picked up until firing fuel is commanded, the GCV is checked to verify that it is being closed by saturation current, and held closed within a small stroke. If there are failures which would cause the valve to open, it should be detected in this interval before firing. If the servo valve is failed or not acting in the right sense, the position test would detect it. During the checking interval, the valve is commanded closed driving all three coils into saturation. The current saturation test then gives assurance the servo is working before firing. The gas control valve FSROUT command to the position regulator is controlled as a function of the FSR2 signal. Sequencing internal to FSROUT drives FSROUT negative to close the gas control valve whenever the turbine is tripped or a
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��� ����� ����� ����������� �������� ��� The pressure ahead of the GCV is controlled by the speed ratio valve (SRV) at a ratio of TNH plus a preset. P2 pressure = FPKGNG * TNH + FPKGNO When the fuel gas supply is shut off, the ratio valve acts as a stop valve, and is given a negative anti-dribble anti-dribble reference to force it closed.
��� ���� ������� ������ When L4 picks up on gas fuel startup, L20FG picks up trip oil pressure, and the speed ratio valve is verified closed by L3GRVO. At the end of the purge
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