Gas Turbine Automation

8/9/2019 Gas Turbine Automation

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Metso DNA

Gas turbine automation

Bandirma, EnerjiSAPicture: © AE&E Power Plant Systems GmbH



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Not every turbine enjoys a diet of dry nat-

ural gas high in methane over its life time.

With the need to diversify the fuel sources

and shave some cost from the gas bill many

users are considering fuel alternatives that

contain the heavier hydrocarbons, more car-

bon dioxide, and more moisture. These gases

in the form of LNG, LPG, refinery gas, andother process gases may be readily available

on site and nearly free. These are the fuels

that require more sophisticated control and

monitoring of your turbine that Metso can

deliver. If your combustion turbine’s diet

consist of liquid fuels containing contami-

nants such as vanadium and sulfur they can

bond to the turbine blades leading to even-

tual failure. By analyzing the vibration signa-

tures throughout the turbine Metso can help

you avoid a catastrophic turbine failure.

The Metso turbine control system can

manage the on-line wash cycles and the

crank wash and rinse cycle to get turbine

power output back to nearly new specifica-

tions and eliminate the mismatch between

compressor isentropic efficiency and the gas

turbine section of the machine.

game quickly with new tools. Control fea-

tures include fuel management, emission

control and turbine monitoring that alerts

you to degradation resulting from hot sec-

tion erosion, temperature imbalances caused

by fuel energy densities that might be out-

side the Wobbe Index of your machine’s

design. You might be sourcing gas withheavy pentane or hexane content that is

actually causing liquid carryover and conse-

quent non-symmetric heating of the hot

sections, particularly near the turbine bot-

tom. Those heavy hydrocarbons can affect

the dew point leading to flame flashbacks

and blowouts as the flame velocity varies

wildly. Metso’s Gas Turbine control package

can identify those profit robbing problems

while you can still do something about it.

ExperienceMetso has delivered turbine controls to

plants around the world for controlling sim-

ple cycle, combined cycle, and combined

heat and power assets. Those Metso systems

included speed, fuel and air controls; emis-

sion controls; startup, shutdown, and cool

down sequencing; temperature symmetry

monitoring, vibration monitoring, overspeed

protection; and engineering tools for

dynamic analysis and system maintenance.

Several have included control of on-line

washing and periodic crank washing.

Comprehensive solution for

gas turbine automation

Benefits of Metso’s

gas turbine

automation

• Open platform,

no black boxes• Control and protection

in one system

• High availability

• Easy and cost-effective

maintenance

Metso answers the needMetso offers the convenience and simplicity

of a stand-alone gas turbine control com-

bined with the thoroughness of a fully inte-

grated system that delivers protection, con-

dition monitoring, and aerothermal analysis,

along with precise control of your turbine.

By integrating gas turbine control, protec-

tion, and scalable information management

into an easily deployed combustion turbine

retrofit package, Metso gets you back in the



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Metso DNA gas turbineautomation

The turbine automation gives you

control of all aspects of turbine

functionality:

All turbine controls easily accessed:

• Speed control

• Load control

• Emission control

• Exhaust temperature control

• Inlet temperature control

• Combustion control

• Fuel control as well as

dual fuel control

• Automatic start-up, shutdown

and cooldown

• Remote control

Integrated system performance:

• Redundancy at all levels

• Overspeed protection

• High exhaust temperature

monitoring

• Machine protection

• Machine condition monitoring

• Performance monitoring

• Simulator for testing and training

• Remote combustion and vibration

monitoring and support



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Automation system I/O The Metso DNA servo control I/O unit deliv-

ers high-speed (5 ms) control. The unit has a

discrete, very fast (2 ms) fail-safe emergency

shutdown function. This control unit is used

together with a valve position measurement

unit that contains an LVDT (Linear Valve

Differential Transmitter) sensor input. A fast

0/4-20 mA input unit is also available.

Actuator controlsServo control action is done by a redun-

dant process controller together with a ser-

vo-control analogue output unit and LVDT

or mA input unit. Valve position feedback is

done with either LVDT or 0/4-20 mA input

units. The LVDT unit is of the type where

only the rod sensor is in the field while all

the electronics are kept within the automa-

tion system. The servo valve and other con-

trols can be done with redundant I/O units

to ensure high availability and easy on-line

hot-swap maintenance.

• Operation

• Maintenance

• Reporting

• Governor control

• Overspeed protection

• Machine protection

• Condition monitoring

Protect your assets Turbine protection is an integral part of

Metso DNA gas turbine automation.

Monitoring and protection is needed to pre-

vent severe mechanical damage, resulting in

production downtime, as well as securing

operational safety. Monitoring functions also

provide predictive condition information

that can be used to maximize production

availability and maintenance efficiency.

Overspeed protection The Metso DNA Overspeed Protection unit is

designed to be easy to use and easy to

Metso DNA for

integrated control and protection



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Machine protectionMachine protection is an important safety

feature in all gas turbines. Gas turbines are

subjected to continuous mechanical and

thermal stress that may result in breakdowns

over time. Metso DNA Machine Protection

monitors a number of critical mechanical

parameters, including:

• Radial shaft vibration

• Bearing housing vibration

• Axial shaft position

• Combustion monitoring

maintain – it fits in different configurations

depending on the need for redundancy, or

whether the 2oo3 (two out of three) voting

is done in the unit or in the hydraulic trip-

block. The unit can read various standard

speed sensors and the design meets the

industry standards for gas turbine overspeed

protection. The unit is designed to meet SIL3

(Safety Integrity Level 3) functional safety

requirements as defined in standard IEC-

61508 ed. 2.0 and to meet the requirements

for overspeed protection as defined in the

API-670 standard.

Dedicated I/O units are provided for measur-

ing static and dynamic positions and abso-

lute vibrations with eddy current probes and

accelerometers. Monitoring parameters are

calculated and monitoring executed accord-

ing to the API-670 standard. Calculated

parameters can also be used for diagnostic

purposes.

Connection to other systemsMetso DNA gas turbine automation can be

connected to other plant systems by stan-

dard communication protocols, such as

Modbus TCP, PROFIBUS DP and OPC.



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Plant managementapplicationsMetso DNA Gas Turbine Performance

Monitoring and Metso DNA Gas Turbine

Wash Manager applications provide the

power plant management and operating

personnel with valuable information about

the performance, condition, fouling and

operating efficiency of the gas turbine. The

purpose of the applications is to calculate,

monitor and report the main performance-

related parameters in reference conditions.

The results of the calculations are present-

ed on displays and web-based reports,

which help visualize the performance of the

gas turbine at a glance.

The calculations are based on the applica-

ble standards and are suitable for all com-

monly used manufacturers’ gas turbines. All

this information is provided both in real time

and over the whole operating history.

Tools for predictivemaintenanceMachine protection monitors the most criti-

cal gas turbine parameters and provides

safety interlocks to avoid catastrophic

machine failures. Mechanical condition mon-

itoring can also be extended to cover a

wider range of diagnostic features for predic-

tive maintenance. Predictive condition moni-

toring provides diagnostic information for

early detection of developing mechanical

faults. This allows you to avoid unexpected

shutdowns and plan maintenance actions

according to need.

Metso DNA Machine Monitoring includes

advanced diagnostic tools for gas turbine

generators, such as shaft orbit monitoring

with amplitude and phase characteristics as

well as spectral vibration analysis. Predictive

condition monitoring can be easily expanded

to cover the balance of the plant machinery

to secure maximum production availability.

Responding tomaintenance needsWith the plant management applications, a

power plant’s maintenance and operating

personnel can detect hidden problems in

the gas turbine operation. These problems

can then be analyzed with Metso DNA’s

advanced tools. This contributes towards

proactive responding to failures before they

cause unpredicted shutdowns. The data

stored in the Metso DNA Historian plays an

important role in monitoring the wear of

components over time. Clear and under-

standable visualization makes the scheduling

of maintenance considerably easier.

In addition to the on-line monitoring of

vibration and combustion, Metso’s experts

can provide remote support. With the stored

history data it is also possible to replay the

disturbance situations and gain knowledge

through the organization. The application is

linked seamlessly to the automation system,

which leverages the benefits of the integrat-

ed system.

Tools for effective

maintenance and management



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Calculated indicators:

Metso DNA

Gas Turbine Monitoring• Compressor inlet temperature

• Exhaust gas temperature

spread (min, ave, max)

• Specific fuel consumption

• Heat rate

• Thermal efficiency

• Electrical efficiency

Metso DNA Gas Turbine

Wash Manager

• Electric power generated

• Heat rate

• Heat consumption

• Electrical efficiency

• Exhaust temperature

• Lost power production due to

compressor/filter fouling

• Economical loss caused by

compressor/filter fouling

• Wash expenses

Turbine simulator

• Runs on Metso DNA platform

• For training and FAT purposes• Operators prepared for

real life situations

• Easy to update and

modify



Metso Automation Inc., www.metso.com/automation E 8 8

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Gas Turbine Automation

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