FFC

GAS TURBINE
OPERATION & CONTROL
1. Introduction
i. Basic Sections
ii. Operating Principle
iii. Gas Turbine Thermal Efficiency
2. INTRODUCTION of GE GAS TURBINES at FFC
3. MAIN COMPONENTS AND THEIR WORKING
i. Start up Equipment
ii. Air Inlet Equipment
iii. Air Compressor
iv. Combustion Section
v. Turbine Section
4. GAS TURBINE AUXILIARY SYSTEMS
i. Fuel Gas System
ii. Lube oil / Hydraulic oil System
iii. Cooling / Sealing Air System
iv. Cooling Water System
PLANT VISIT
5. GAS TURBINE CONTROL SYSTEM
i. Start up Control
ii. Speed Control
iii. Temperature Control
6. GAS TURBINE PROTECTION SYSTEM
i. Over Speed Protection System
ii. Over Temperature Protection System
iii. Vibration Protection System
iv. Fire Protection System
7. PROBLEMS FACED at GAS TURBINES
Three basic sections of gas turbine assembly

1) Air compressor
2) Combustion chamber
3) Turbine Section
Gas turbine cycles

1. Simple cycle
2. Regenerative cycle
 Single rotor of Compressor / Turbine brought to
speed by diesel engine.
Air Compressor draws atmospheric air & increases its
pressure.
High pressure air flows to combustion chamber
where fuel admitted under pressure.
A high voltage spark ignites fuel/air mixture.
High pressure & temperature gases expand thru
Turbine.
Hot gases expanding thru turbine wheel cause rotor
to spin.
Reversible Process
Fluid & Surrounding can always be restored to
their original state. Criteria for Reversibility:
Process must be Frictionless.
Pressure difference between Fluid & its Surrounding must be
infinitely small.
Temperature difference between Fluid & its Surrounding must
be infinitely small.

IR-Reversible Process
Fluid & Surrounding can not be restored to
their original state. No process in practice is truly
Reversible.
Isothermal or Constant Temperature Process
In isothermal Expansion heat to be continuously added to
keep temperature at initial value.
In isothermal Compression heat to be continuously
removed to keep temperature at initial value.

Adiabatic Process
In Adiabatic Process NO heat transfer To or From the fluid.
Adiabatic Process may be Reversible or Ir-reversible.
Entropy
Entropy defined as: dS = dQ/T
Change of Entropy of system is Heat added or
removed from
the system at constant temperature.
For any reversible process S = 0
For any ir-reversible process S > 0
Isentropic Process
The process in which entropy of system
remains constant. i.e. S = 0 or Q = 0
Adiabatic reversible process is called Isentropic
process.
1 2 : Reversible Adiabatic Compression (Ideal)

1 2: Ir-reversible Adiabatic Compression

2 3 : Constant Pressure Heat Supply in Combustion

Chamber

3 4 : Reversible Adiabatic Expansion (Ideal)

3 4: Ir-reversible Adiabatic Expansion ( Actual)

At Compressor, Work Input = Cp (T2 T1 )
In Combustion Chamber, Heat Supplied = Cp ( T3 T2)
At Turbine, Work Output = Cp (T3 T4)

Net Work Output = Cp (T3 T4 ) CP (T2 T1)

Thermal Efficiency = Net Work Output / Heat Supplied

= Cp (T3 T4 ) CP (T2 T1) /

Cp( T3 T2)
Cp = 0.24 Kcal / Kg- oC

Normal Range of Efficiency = 24 32 %

 No. of Gas Turbine Units : 02
Make : General Electric
Turbine application : Generator Drive
Base out put : 18 MW
Shaft speed : 5105 rpm
Air inlet temp. : 43
Exhaust temp. : 482
Atmospheric Pressure : 0.99 bar
 Compressor Section
1) Compressor type : Axial Flow
2) No. of stages : 17
3) Inlet Guide Vanes : Variable
Turbine Section
No. of Turbine Stages : 2
Combustion Section
1) Combustors : 10
2) Arrangement : Concentrically
located around the compressor
 G E TURBINES AT FFC

3) Fuel nozzle : Pressure atomizing

1 per chamber
4) Spark plugs : 02, Electrical type, spring
injected, self
retracting
5) Flame detectors : 02, ultra-violet type

Starting system
Starting device : Diesel Engine
Reduction Gear
Shaft speed ratio: 5089/3000 rpm
 G E TURBINES AT FFC

Generator

i. Type : Air cooled open ventilated

ii. Rating : 31375 kva

iii. Rpm : 3000

iv. Volts : 6300 volts

v. Frequency : 50 Hz.
LAYOUT OF TURBINE & GENERATOR

LOAD GEAR
COUPLING
ACCESSORY AIR INLET TURBINE EXHAUST
COMPARTMENT PLENUM COMPARTMENT PLENUM
 i. STARTING EQUIPMENT
Diesel Engine make : CUMINS USA
Engine Power : 465 HP
Engine rpm : 2100
Cranking or rotation of Gas turbine Shaft is
achieved By Diesel Engine.
Diesel Engine transmits rotating speed to get
break away.
i. Diesel Engine

ii. Hydraulic Torque Converter Assembly

iii. Hydraulic Ratchet System

iv. Starting Jaw Clutch

i. With start signal Starting Diesel Engine starting DC motor
energized.
ii. Engine at idle speed (600 rpm) for two minutes warm up.
iii. At the end of warm-up , Engine governor set at maximum
speed (2100 rpm) until Turbine shaft starts rotation.
iv. Engine speed set between idle & maximum ( 1800 rpm ,
governor speed).
v. Turbine correct firing speed (1000 rpm of Turbine shaft) is
achieved. Engine speed remains at 1800 rpm while Gas
Turbine warm-up period is completed.
vi. At 50% of turbine speed (2800-2900rpm) Gas Turbine
becomes self sustaining & overtakes diesel Engine. Diesel
Engine returns to idle speed & idles for 05 minutes cool down
period & then stops.
Gas turbine: An air breathing machine.
Design consumption of Air at our Gas turbine is 436 Tons/hr
at 15 0C & 1.013 bar.

Performance of Gas turbine is very sensitive to the

quality of Air & is affected through:
i. Fouling of compressor Blades
ii. Erosion of compressor/Turbine Blades

Filtration of Air up to 10 micron size before entering

axial compressor.
 AIR INLET EQUIPMENT (Filter House)

Filter House consists of three stage filter assembly :

Inlet screens & Inertial separators
Screens are installed to avoid entry of birds, leaves, twigs
papers etc. Larger particles are separated from air due to
Inertia & ejected in common chute. A bleed fan maintains
a constant flow (~10%) through the collection chute.
Pre-Filters (Primary Filters)
Pre-filters extend the useful life of high efficiency filters.
These are layer type & directly attached to high efficiency
filters. These are generally replaced when pressure drop
across the filter house reaches 12 cm wc.
High Efficiency filters (secondary filters)
Made with special paper fabric & have efficiency of
99.7% particles removal.
 Implosion Doors

Two implosion doors provided downstream of

secondary filters.
Designed to open at P 15 cm WC. These doors avoid
abnormal blockage in air inlet system.
 17 stage axial compressor with inlet
variable guide vanes.
Compressed air exits through compressor
discharge casing to the combustion
chambers.
Air also extracted from the compressor for
turbine cooling & bearing oil sealing.
Compressor divided into four portions:
Inlet section
Forward section
Aft section
Discharge section
Inlet section

The inlet section directs air flow from Filter House into
compressor blades.

This section contains variable inlet guide vanes assembly,

bearing # 1 assembly & Low pressure air seals.

Variable inlet guide vanes (IGV) permit fast, smooth acceleration

of gas turbine without compressor surge. At start up of IGVs
are set at 430 position & when Turbine accelerates to 95% speed
they turn to 850 position.
When turbine stops vanes rotated to 430 at once.
2) Forward Section
This is at down stream of inlet section & contains the stator
Blading for stages 0 through 3.
3) Aft Section
This is at down stream of inlet section & contains the stator
Blading for stages 4 through 9.
Bleed air from the 4th rotor stage (between 3rd & 4th stator
stage) used for cooling of turbine shell & supports.
4) Discharge Section
This section is down stream of the aft section, contains the
stator blading for the stages 10 through 16 & exit guide vanes
stages 1& 2.
This section provides the mounting surface for combustion
chambers.
Components of Combustion section
Combustion chambers
Fuel Nozzles
Spark plugs
Flame detectors
Transition pieces
v. TURBINE SECTION
Turbine components
First stage nozzles
First stage Buckets & wheel
Second stage nozzles
Second stage Buckets & wheel
 Combustion gases at about 1100 C O expand through two
stages of Turbine.
Expansion takes place in fixed nozzles of both stages.
Nozzles convert heat & pressure energy into high velocity or
kinetic energy and direct this energy to buckets/rotating
blades.
Rotating blades convert kinetic energy into useful shaft horse
power.
Cooling of turbine parts (stationery nozzles, rotary blades,
turbine shaft & supports) with air drawn through compressor
from different stages.
a. Fuel Gas System
Components of Gas Fuel system :
i.Gas strainer
ii.
Gas stop/speed ratio Valve
iii.
Gas control valve
iv.
Low gas pressure alarm
v.Pressure gauges
Fuel gas enters gas turbine through strainer at 18 kg/cm2
pressure.
Low pressure switch (63 FG-3,setting 11.6 kg/cm2) is
installed on gas line before it enters the gas turbine.
Activation of this low pressure switch causes automatic
changeover of fuel to diesel.
 Gas Stop/Speed ratio valve (VSR)
This valve is operated thru hydraulic cylinder & has two
functions;
Stop Function
Tight shut-off of fuel gas achieved by hydraulic oil
drainage thru SOV (20FG).
Speed ratio Function
Regulate inlet pressure to upstream of control valve.
Pressure at downstream of stop/speed ratio valve is maintained at
14.0 kg/cm.2
Electro-hydraulic servo ( 90 SR ) gives position control .
Input to electro-hydraulic servo ( 90 SR ) is the speed
signal & downstream pressure signal ( 96 FG ).
Actual position of valve sensed thru LVDT (liner variable
Differential transformer,96 SR ) and provides feedback
signal to speedtronic.
 Gas Control Valve (VGC)
Gas control valve provides the final precise metering of fuel gas
flow to gas turbine. It regulates gas pressure of 8-10kg/cm2 to
fuel nozzles.
Speedtronic control gives its output signal called VCE to the
electro-hydraulic servo (65 GC). This servo adjusts the hydraulic
pressure to the piston of gas control valve.
Two LVDTs (96 GC-1/2) provided at the stem of gas control
valve give position feedback to the speed tronic control.
VCE signal by the control circuit is compared with the position
feed back signal by LVDTs. If the two signals do not match an
error signal is generated and acts to reposition the valve until
the VCE & feed back signals match.
Fuel Gas Vent valve (20 VG)
Solenoid operated valve (20 VG) vents the gas from the piping in-
between gas stop/speed ratio valve & Gas control valve.
 Closed loop forced oil lubrication system.
Lube oil Tank
Capacity of the system (tank & other components) is
1700 gallons. Lube oil feed piping is contained within the lube oil
tank or drain headers to avoid safety risk in case of leakage.

Lube oil Pumps

The main lube oil pump is positive displacement type

mounted in & driven by accessory gear. 460 GPM
The auxiliary lube oil pump is a submerged centrifugal
pump driven by 380V AC motor. 460 GPM
The emergency lube oil pump is a submerged
centrifugal
pump driven by 110 V DC motor. 250 GPM
 OVER SPEED TRIP BOLT
3.80 kg / cm2

90 kg / cm2

Hydraulic oil Pump

Lube Oil Circuit Securities

i. High lube oil temperature alarm : 75oC

ii. High lube oil temperature Tripping : 80oC
iii. Main lube oil header low pressure alarm : 3.50 kg/cm2
iv. Bearing header low pressure tripping : 0.56 kg/cm2
v. Oil console low level alarm
Cooling of Following Parts by Compressor Forth
Stage Extraction Air
First & second stage turbine wheel forward & aft faces.
First & second stage nozzles
Turbine shell and supports
Combustors casing , liners, transition Pieces.
Sealing of Following Parts by Compressor Tenth Stage
Extraction Air
Main part goes through bleed valves to exhaust plenum
Second part is routed to bearings seals through dirt
separator
PRUPOSE
Heat removal from lube oil & diesel engine systems.
Closed Cooling Water System using de-mineralized water as
make-up & Nalcool-2000 as corrosion inhibitor.

Cooling Water System Components

i. Accessory gear shaft driven pump ( 400 gpm)
ii. Two cooling water tanks
iii. Two cooling water fan skids
iv. Temperature regulating valves
 System Description
Water from Tanks to gear driven pump & diesel engine water
pump
Diesel engine water pump drives water to engine cooling jacket
Accessory gear driven water pump drives water to lube oil
cooler.
Cooling of water in Fan skids (2 units for each turbine)
Fan Skids, finned tube air to water heat exchangers with two
fans under each skid
Cooling water flow regulated thru Temperature regulating
valves sensing lube oil temperature
 GAS TURBINE CONTROL SYSTEM
There are three control loops for turbine operation;

1. START-UP CONTROL
2. SPEED CONTROL
3. TEMPERATURE CONTROL
Each control loop generates an output in terms of Electronic
Control Voltage i.e VCE, which is a command signal to the fuel
valves.
Of the three control loops lowest VCE signal becomes the
controlling VCE which regulate fuel to the gas turbine.
 VCE
TEMPERATURE

VCE LOWEST VCE FUEL

SPEED SYSTEM

VCE
START UP
 Verification of the startup system by speedtronic system
SPEED RELAYS
14 HR ZERO- SPEED SENSOR
14 HM MINIMUM-SPEED SENSOR
14 HA ACCELERATION-SPEED SENSOR
14 HS HIGH-SPEED SENSOR

SPEED SENSORS SPEED PICKUP (RPM) DROPOUT (RPM)

14 HR ZERO 3 2 16 4

14 HM MIN. FIRE ( 18 % ) 875 25 92 25

14 HA ACCELERATE ( 40 % ) 2040 100 1530 400

14 HS OPERATING ( 95 % ) 4845 100 4455 50

THREE LEVELS OF VCE ; FIRE / WARM-UP / ACCELERATE LIMIT

FUEL COMMAND SIGNALS ARE GENERATED BY START-UP

CONTROL SYSTEM.
STARTUP SUPPRESSION

to control mechanical and thermal stresses during startup.

acceleration rate is controlled by speed loop
temperature rise is controlled by temperature control loop
@ 5F/sec
START signal Energizes Master Control & Protection System
Auxiliary equipment starts
Starting clutch is engaged
Diesel engine starts
 START-UP CONTROL
14 HR, ZERO- SPEED SENSOR
indicates that turbine shaft has started rotating
clutch is engaged
cranking sequence starts
During shutdown - ratchet operation starts

14 HM, MINIMUM-SPEED SENSOR

indicates that turbine has reached minimum firing speed
starting clutch is de-energized
purge timer starts
fuel valves open
firing timer starts ( VCE set to firing level )
after flame is established, warm up timer starts ( VCE set to warm up level )
after warm up, acceleration starts ( VCE set to acceleration level )
when turbine accelerates the diesel engine, clutch is disengaged .
 START-UP CONTROL

14 HA, ACCELERATION-SPEED SENSOR

indicates that turbine has reached 40 % speed
indicates that turbine is accelerating

14 HS, HIGH-SPEED SENSOR

indicates that turbine is at operating speed & accelerating sequence is complete
inlet guide vanes ( IGV ) open
compressor bleed valve closes
Auxiliary lube oil pump stops
During shutdown vce becomes zero
fuel valve closes
IGV are closed
compressor bleed valve opens
 CHECK ;
POWER TO PANEL AVAILABLE
SERVO VALVE CHECKS OK
VOLTAGE CHECKS OK
NO TRIP SIGNAL ACTUATED

SELECT OPERATION ;
CRANK / FIRE READY ;
AUTO / REMOTE ALL START CHECKS ARE OK

MASTER PROTECTIVE RELAYS ARE

ENERGIZED ;
START SIGNAL AUXILIARY L.O PUMP STARTS
DIESEL ENGINE STARTS
20FL / 20FG ARE ENERGIZED FOR
FUEL SYSTEM
STARTING CLUTCH IS ENGAGED
TURBINE IS ACCELERATED TO
CRANKING SPEED ;
14HM IS ENERGIZED
NO FLAME DETECTED ; PURGING TIMER 2TV STARTS
BEFORE 2F TIMER TIMES OUT VCE = 0
MASTER PROTECTIVE CIRCUIT
TRIPS THE TURBINE

TURBINE PURGING COMPLETE;

FIRING TIMER 2F INITIATED
FLAME FIRING VCE SET
VCE SET TO WARM UP TIMER 2W SPARK PLUGS ENERGIZED

COMPLETE SEQUENCE ;
WARM UP TIME COMPLETE; SPEED INDICATIONS ;
AUX. LUBE OIL PUMP OFF
VCE SET TO ACCELERATE 14 HA TURBINE ON ACCELERATION
TURBINE WILL TRIP IF INCOMPLETE
LIMIT. 14 HS TURBINE AT 95 % SPEED
TIMER TIMES OUT
 Speed control system controls the speed & load of turbine,
operating in response to the actual turbine speed signal and set
point.
SPEED SIGNAL
1. Speed of turbine is measured by two magnetic sensors installed
at bearing # 1 assembly.
2. Speed is measured in terms of voltage.
i.e 0 ~ 10 volts = 0 ~ 100 % speed.
3. Failure of one sensor does not cause failure of speed signal and
generates alarm only. Speed circuit abnormal
ISOCHRONUS CONTROL
Under Isochronus Speed Control, the turbine operates at its
speed set point (DSP), independent of load.
Even if the load changes, the speed will remain constant.

ACTUAL SPEED VCE

SPEED
CONTROL

DIGITAL SET
POINT

DROOP CONTROL
Under Droop Control, the turbine speed decreases as the load
increases and the speed set point remains unchanged.
DROOP SETTING for TGs = 4% against full load i.e 18 MW
Temperature Control System controls fuel flow, thru VCE, to
the turbine when operating temperature reaches design limits.
The system determines the limiting temperature w.r.t
compressor discharge pressure and defines the control.

VCE
EXHAUST TEMP
TEMPERATURE CONTROL

PCD TEMPERATURE
SET POINT
 THERMOCOUPLE PROCESSING MODULE

Consists of 12 chrome-alumel thermocouples located

around the turbine exhaust plenum.

The module averages the temperature of all 12

thermocouples.

Maximum and minimum values are rejected and average is

sent to Speedtronic card.

In case of grounding of thermocouple, Exhaust

Thermocouple Ground alarm appears.
 LOCATION OF THERMOCOUPLES

TT-XD-12 TT-XD-1
TT-XT-6 TT-XT-1
TT-XD-11 TT-XD-2

10
9 1
TT-XD-10 TT-XD-3

8 2
TT-XT-5 TT-XT-2

TT-XD-9 7 3
TT-XD-4

6 4

TT-XD-8 5
TT-XD-5

TT-XT-4 TT-XT-3
TT-XD-7 TT-XD-6
 559
11 C
C

548
EXHAUST TEMPERATURE

546 11 C
537

28C
535 PEAK MODE
526

11 C
524
515

11 C BASE TRIP
504

BASE ALARM
493

BASE CONTROL
482

6.9 kg/cm2
471

PSIG 80 90 100 110 120 130 140 150

Kg/cm2 5.63 6.33 7.03 7.74 8.44 9.14 9.85 10.55
COMPRESSOR DISCHARGE PRESSURE ( or FSR )
 SET TO LOAD OR SPEED STARTING EXHAUST GASES
INITIATION

SPEEDTRONIC
THERMO
CONTROL TEMP. SIGNAL COUPLE
SEQUENCE
PROTECTION
POWER SPEED SIGNAL
SUPPLY

AIR
VCE FUEL GAS
SPEED TRANSM

C T LOAD
GCV SRV

COMBUST
CHAMBER

LOAD VARIABLE
1. Over speed
2. Over temperature
3. Vibration
4. Flame Detection
5. Fire Protection
 Speed of the shaft is under control of its speed control or
temperature control loop.
Over speed protection actuates after the failure of these systems.

PRIMARY SYSTEM
Set point = 5610 30 rpm ( i.e 10 % )
Speed is sensed thru an electromagnetic sensor located at
bearing # 1 assembly and is independent of speed control loop.
Trips the turbine by dumping the control oil & closing the fuel
valves.
Trip indication of Over Speed Trip is generated.
 SECONDARY SYSTEM
Set point = 5737 50 rpm ( i.e 13 % )
Acts as an independent backup of primary system.
Over speed bolt assembly is mounted in accessory gear shaft,
used to sense the speed of turbine. It is spring loaded,
eccentrically located bolt assembled in cartridge, working
against centrifugal action.
Trips the turbine by dumping the control oil & closing the fuel
valves.
Trip indication of Over Speed Trip is generated.
It can also be actuated manually.
 Acts as backup system of temperature control system.
Protects gas turbine against damage caused by over firing.
It provides alarm and trip w.r.t temperature control limits.
Alarm = 20F + Temperature Control limit
Trip = 40F + Temperature Control limit

Consists of 6 chrome-alumel thermocouples in two groups.

Both the trip channels A & B are independent.
Actuation of either channels leads to turbine tripping.
If difference of averaging module temp. & channel A or B > 38C
then alarm Exhaust Temperature Differential High actuates.
Abnormal temperature spread over combustors trips the turbine.
 Vibration protection system of gas turbine consists of
three independent channels with magnetic pickup sensors.

Location of sensors ;
1. On bearing # 1 housing.
Radially
2. On compressor casing. installed
3. On generator bearing housing ( pedestal brg )
SETTINGS
Normal 0 ~ 0.6 cm/sec
Alarm 1.25 cm/sec
Trip 2.5 cm/sec
 BENTLAY NEVADA VIBRATION
MONITORING SYSTEM

This system is not integrated in trip logic of TG.

All 3 monitoring probes are installed at brg # 1 housing.
SETTINGS;
Alarm 7 mils
Horizontal & Vertical
Danger 10 mils
Alarm 15 mils
Counter
Danger 25 mils
Thrust
Alarm 10 mils
Normal
Danger 25 mils
Fire protection system consists of following components ;
CO2 cylinders
Total cylinders 12 ( sufficient for 40 minutes )
Pilot cylinders 02
CO2 amount 100 lb / 45 kg per cylinder
CO2 Pressure 1000 psi / 70 kg/ cm2 @ 25C

Heat sensitive fire detectors

Accessory compartment 02 ( set pt. 163C )
Turbine compartment 03 ( set pt. 232C )
Reduction gear compart. 01 ( set pt. 316C )
 CO2 DISCHARGE HEADERS

Initial discharge header

Consists of 5 nozzles of large orifice size for initial pressurization
Location of nozzles 01 accessory comprt.
02 turbine comprt.
02 reduction gear comprt.

Extended discharge header

Consists of 3 nozzles of small orifice size to maintain CO2 conc.
Location of nozzles 01 accessory comprt.
01 turbine comprt.
01 reduction gear comprt.
 DESCRIPTION & OPERATION

CO2 is released by actuating sov on pilot cylinders as follows ;

1. SOV on pilot cylinders is actuated by ;
Automatically by electrical signal from fire detectors.
Manually by hand wheel at pilot cylinders.
By manual push button in control compartment.
By actuating the pressure switch on manifold.
2. Pilot cylinder pressure is applied to its discharge valve.
3. CO2 from pilot cylinders then actuates all cylinders.
4. Check valve prevents extended header gas to flow into
initial discharge header.
5. Pressure switch on manifold trips the turbine.
 12
11
10
9
RED. GEAR
8 COMPT.
EXTENDED HEADER

7
6 TURBINE
5 COMPT.
4

PLUG
PRESSURE
SWITCH
INITIAL HEADER
ACCESSORY
COMPT.
SOV 2
3
SOV 1
SIMPLE CYCLE
Exhaust
Combustors
Fuel

Compressed Air

Compressor Turbine Load

Air
Regenerative Cycle
Exhaust

Regenerator
Compressed Air

Combustors

Fuel
Compressor Turbine Load

Air
The person to first outline this was the Frenchman Carnot who, in 1824, described the heat engine w
W Tmax - Tmin
=
carnot = Q Tmax
where:
W = mechanical work
Q = heat supplied
Tmax = maximum temperature
Tmin = minimum temperature
With the Carnot formula, efficiency can be expressed as temperatures. For gas turbines, Tmax is the temperature of the hot gases leaving the combustion chamber gases and Tmin is the ambient temperature