FUNDAMENTALS OF GAS TURBINE

CONTROL
 Objectives

• Discuss what parameters determine the output of a gas

turbine

• Define Fuel Stroke Reference and how it is derived in the

Mark V.

• Discuss how each of the six control loops derives its FSR
signal.
 Objectives

• Describe how the Variable Inlet Guide Vanes are

positioned during different operating modes of the gas
turbine and why their position is varied.

• Explain how a servo valve takes an electronic input from

the Mark V and converts it into a hydraulic output to
position device.
 FSR Graph
BREAKER CLOSED SHUTDOWN
BREAKER
FSNL BASE LOAD OPEN

FSRN
100

FSRT

MW
FSRSD

TX

TNH
FSR ACC
FSRSU
 Mass Flow

• Turbines, both gas and steam, are mass flow devices. In

other words, their output is proportional to the amount of
flow through them.

• In the case of gas turbines, the mass flow is comprised of

air and fuel.
 Air and Fuel

• Air flow is a function of the compressor design, ambient

conditions, and speed of the machine. At operating speed
(i.e. 3600 RPM), the amount of flow through the machine
is fixed, for a given set of ambient conditions.

• Therefore, to control output, the control system must

control fuel flow.
 FSR

• Fuel Stroke Reference (FSR) is the signal that the Mark V

control system generates to regulate the amount of fuel
flow.

• FSR is determined by six different control loops. Each

control loop is calculating the amount of flow it thinks is
needed by evaluating its own unique set of parameters.
 Minimum Value Gate

• The Mark V uses a minimum value gate to select the

lowest output of the six control loops for use as the FSR.
Therefore, the signal being used to regulate fuel flow is
always the most conservative.
 Control Loops

• The six control loops calculating required fuel flow are:

– Startup
– Speed
– Temperature
– Acceleration
– Shutdown
– Manual
 Startup Control

• Startup control brings the turbine from zero speed up to

normal operating speed safely by providing proper fuel
flow to establish flame, accelerate the turbine, and to do it
in such a manner as to minimize the low cycle fatigue of
the hot gas path parts during the sequence.
 Startup Control

• The startup control loop operates as an open-loop control

(i.e. it does not use feedback from field devices).

• It has five preset levels of FSR:

Zero Accelerate
Fire Max
Warmup
 Startup Control

• With the turbine at rest, the control system monitors the

status of the fuel valves, accessories, and power supplies.

• When the operating mode is switched from “OFF” to

either “MANUAL” or “AUTO”, and the above checks are
passed, the control system will display “READY TO
START” and “STARTUP STATUS”.
 Startup Control

• When the operate gives the machine a start command, L4

is set to a “1”.

• L4 is the master protective signal, it allows the trip oil

system to pressurize so that fuel flow can be initiated. It is
also an input to many logic functions in the startup routine.

• With L4 set to “1”, and the starting clutch engaged, the

starting device will start turning. As the static starter
accelerates the turbine, the turning gear will disengage.
 Startup Control

• When the turbine reaches approximately 15%, L14HM

becomes a “1”. This is necessary for a fire signal.

• It is possible that while shutdown, a combustible mixture

of fuel and air may have built up in various places of the
hot gas path. To prevent unwanted flashing, the machine is
purged with ~ 4 volumes of air before a fire signal is given.

• Purge timer L2TV starts when L14HM becomes a one.

 Startup Control

• When L2TV times out, the machine coasts down and then
back up to L14HM to ensure the turbine is at exactly the
right speed for firing.

• Once the machine goes above L14HM the second time, the
firing signal is given.

• The firing signal sets FSRSU to the “Fire” level, sends an

ignition signal to the spark plugs, and starts firing timer
L2F.
 Startup Control

• When at least half the flame detectors sense flame

(L28FD), the warmup timer (L2W) starts and FSRSU is
reduced to the “Warmup” level.

• If flame is not detected by the time L2F times out (usually

60 seconds), fuel flow is stopped. The unit can be given
another start signal, but it must go through the purge cycle
again.
 Startup Control

• When the warmup times out, FSRSU is set to its

“Accelerate” level and the machine speeds up.

• The accelerate level is designed to moderate firing

temperature and reduce thermal stresses.

• It is typical for FSRACC to take over from FSRSU during

the acceleration towards FSNL as it becomes the lower
signal.
 Typical 7FA Speed Levels

• L14HR (Zero speed reference): 0.05 (0.13)

• L14HT (C/D slow roll start): 1.5 (1.2)
• L14HM (Minimum speed): 14 (13.5)
• L14HA (Acceleration speed): 50 (46)
• L14HP (Spare signal, used in LCI disconnect): 91 (85)
• L14HS (Synchronous speed): 95 (94)
 Acceleration Control

• Acceleration is a closed control loop. Acceleration control

compares TNH (turbine speed) with the TNH value from
the last sample. The difference in these two samples
reflects the machine’s acceleration.

• The actual acceleration (TNHA) is compared to a reference

value (TNHAR). FSRACC is adjusted to minimize the
difference between the two.
 Acceleration Control

• FSRACC is designed to limit the rate at which the

machine’s speed changes to limit stress on rotor
components.

• During startup, FSRACC will take the turbine from just

past warmup to L14HS (~ 95% speed). L14HA (~ 50%) is
used as evidence of proper machine acceleration.
 Acceleration Control

• Before the turbine reaches full speed, TNHAR varies

between 0.1 and 0.3%/second, depending on TNH.

• When at full speed, TNHAR is 1.0%/second.

 Speed Control

• Speed control is a closed control loop. It compares actual

turbine speed (TNH) with a reference speed (TNR) and
adjusts fuel flow accordingly.

• Turbine speed is detected by 3 magnetic speed pickups

which are mounted in a ring around a 60 tooth wheel
attached to the rotor of the machine.

• The frequency of the AC output signal from the pickups is

equal to the speed of the shaft in RPM.
Speed Control
 Speed Control

• When a “Start” command is given, TNR is set to 100.3%.

• Speed control will take over from FSRACC as the unit

approaches FSNL, and the speed will be locked in at
100.3%.

• This value is chosen so that when the generator is

synchronized, the machine will pick up some load.
 Speed Control

• When the generator is on the grid, the turbine’s speed is

held constant by grid frequency.

• Changes in fuel flow will result in changes in the power

output from the turbine, and therefore, change the output of
the generator.

• The operator can change the generator output by manually

adjusting TNR to change the error between TNR and TNH,
and thereby changing fuel flow.
 Speed Control

• The speed control loop is programmed to operate under

droop control.

• Droop control changes FSR in proportion to the difference

between actual speed and reference speed.

• Typically, a 4% droop is used. In other words, reference

speed will change 4% from no load to full load.
Droop Curve
 Speed Control

• If a turbine were to undergo full load rejection, it would be

possible for FSRN to drive FSR so low that flame out
would occur.

• To prevent this, the Mark V uses FSRMIN, a minimum

level for FSR that is high enough to support continuous
combustion. Speed control cannot drive FSR below
FSRMIN.

• Temperature and startup control are the only loops that can
go below FSRMIN.
 Temperature Control

• Temperature control is a closed loop control which

functions to keep firing temperature below levels which
could damage hot gas path components.

• Since it is not realistic to try to measure firing temperature

directly, temperature control takes inputs from the exhaust
thermocouples and calculates firing temperature based on
this temperature and other parameters.
 Temperature Control

• Normally, the firing temperature calculation uses exhaust

temperature and CPD.

• As a backup, we can also approximate firing temperature

from exhaust temperature and FSR.
Tx vs. CPD
Tx vs. FSR
 Temperature Control

• To control firing temperature, the temperature control

compares actual exhaust temperature (TTXM) with a
reference temperature (TTRXB) and adjust FSR to
minimize the difference.
 Temperature Control

• TTXM is a median of the exhaust temperatures and is

determined as follows:
– The exhaust thermocouple temperatures are compared
to a constant and any that are too low are rejected.
– The highest and lowest signals are then rejected.
– The remaining signals are averaged and the result is
TTXM.
Temperature Control
 Temperature Control

• TTRXB is calculated based on CPD, with another circuit

calculating it based on FSR for backup.

• The values calculated by these two methods are compared,

and the lowest one is used for comparison to TTXM.

• CPD is the desired method, so a bias is added to the FSR

method to ensure it is always higher. Only if CPD
detectors fails high will the FSR method be used.
Temperature Control
 Temperature Control

• The exhaust temperature limit consists of the isothermal

and constant firing temperature portions.

• The constant exhaust temperature, or isothermal, limit is

based on not damaging carbon steel components in the
exhaust system during startup.

• The constant firing temperature portion prevents damage to

the hot gas path components, mainly the 1st stage nozzle
and buckets.
 Temperature Control

• During turbine operation, when exhaust temperature is

below the temperature control curve, FSRN is the
controlling signal.

• FSRT is not in control until TTXM equals TTRXB.

• By definition, operation with FSRT controlling is operation

at Base Load, no matter how many MW’s the generator is
producing.
Temperature Control vs. Speed Control
 Shutdown Control

• A normal shutdown is initiated by giving the “Stop”

command on the <HMI> screen.

• When a stop command is received, FSRSD is ramped from

its normal value of 100% down to the current level of FSR.

• Also, FSRN will lower FSR to reduce load until the

generator breaker (52G) trips on reverse power.
 Shutdown Control

• After 52G opens, FSRSD ramps down to FSRMIN.

• When TNH drops below the predefined level of K60RB

(20 is typical), FSRSD ramps down until one flame
detector senses flame out.

• After one detector sees flame out, FSRSD ramps down

faster until flame out is seen on all flame detectors. At this
point, fuel flow is secured.
 Shutdown Control

• Fired shutdown is an improvement over the previous

method of flame out after 52G opening because it reduces
strain on hot gas path components at the time of fuel
shutoff.
 Manual Control

• Manual control is an open loop control that allows the

operator to set an upper limit to FSR.

• By designating a specific value for FSRMAN, the

minimum value gate will ensure that if the controlling loop
tries to raise FSR above the FSRMAN level, FSRMAN
will take over to keep FSR from increasing.

• Typically, FSRMAN is set at 100%.

 VIGV Control

• Besides fuel, modern gas turbines must also regulate the

position of the Variable Inlet Guide Vanes (VIGV’s).

• Varying inlet guide vane position helps to:

– maintain proper flows and pressures to minimize stress
– maintain a minimum pressure drop across the fuel
nozzles to minimize resonance
– maintain a high exhaust temperature for combined
cycle applications.
 VGV Control

• The VGV control loop adjusts guide vane position based

on corrected turbine speed (TNHCOR) during startup, and
exhaust temperature during operation.

• TNHCOR is turbine speed corrected to a temperature of

80°(F) so that changes in ambient air temperature are
accounted for in VGV positioning.
 VGV Control

• During startup, VGV’s are held fully closed (nominally

27°) from zero speed up to 83.5% TNHCOR.

• At 83.5%, the VGV’s begin to open at approximately

6.7°/percent speed.

• The VGV’s will stop opening at the minimum full speed

angle (nominally 54°) at about 91% speed.
 VGV Control

• When the unit is loaded, VGV’s will open as exhaust

temperature rises. The compressor bleed valves will be
shut when 52G is shut.

• When they reach the full open position depends if they are
operating in single cycle or combined cycle mode.
– In simple cycle, they will be full open at about 700° (F)
– In combined cycle, they will be full open when exhaust
temperature is within 30° (F) of TTRXB.
VGV Schedule
 VGV Control & DLN

• Of course, all this is subject to change depending on the

specific plant application. When operating with DLN
systems, VGV’s are also position to help control firing
temperature and emissions.

• Premix mode is the desired mode of operation due to low

emissions, but it requires higher firing temperatures.

• In this case, VGV’s may be closed to <54° to increase

firing temperature when at lower loads.
 VGV Control & DLN

• Closing the VGV’s this much during operations can result

in compressor surge and icing on compressor blades due to
condensation.

• To prevent this, the inlet bleed heat system will take some
air from the compressor discharge and recirculate it back to
the compressor inlet.

• This warms the air to prevent icing and lowers CPD to

prevent surge.
 VGV Control

• On shutdown, the VGV’s will move to the minimum full

speed angle as exhaust temperatures decrease.

• When 52G opens, the compressor bleed valve will be

opened and the VGV’s will be shut as the turbine slows
down.

• In the advent of a trip, the compressor bleed valves will be

opened, and the VGV’s will go shut.
 Servo Valves

• FSR and IGV position are determined independently by

<RST> each signal is applied to one coil of a three coil
servo.

• The servo valve ports hydraulic oil to position the bypass

valve (liquid fuel), the gas control valve (gas fuel), or the
IGV actuator.
Servo Diagram
Servo Loop