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ABB Retrofit Solutions – EGATROL® Performance enhancements for Gas Turbines

A changing market

In a rapidly changing market driven by de-regulation and

globalization, more and more customers are looking into

cost-efficient upgrades increasing the lifecycle of their

capital equipment and meeting more challenging

requirements towards performance, maneuverability and

availability.

ABB´s solution, our customer´s benefit

The Egatrol® concept for retrofitting power plants is a tai

lor-made solution, utilizing electrical and mechanical

components as well as products of the

ABB control system. It ensures a state-of-the-art turbine

control system well integrated into the overall plant.

Situation

Due to the phased out of I&C equipment or the

wear of mechanical parts, older combustion

turbine sets often show a lack of reliability and

availability, whilst the major turbine and

generator components are still offering a

substantial remaining lifetime. Often obsolete

old control and protection system don´t allow to

fulfil the high demands on quality and proper

operation within the power network. Therefore

old combustion turbines run on base load for low

prices, but with over proportional high costs for

operation and maintenance.

Woodward Gas Turbine Control Solutions

Fast, reliable and accurate turbine control solutions with hardware and software

specifically designed for demanding turbomachinery applications for

both aeroderivative gas turbines and heavy duty gas turbines.

Available in simplex, dual and triple modular redundant configurations.

Features and Benefits

• Turbine control solutions designed for safe, accurate and reliable control in harsh environments

• Perfect solution for integrated turbine and compressor control solutions

• High-speed data logging enables optimized diagnosis and fast troubleshooting

• Simplex, dual redundant and triple modular redundant (TMR) configurations with

online (hot swap) repair capability enhance reliability and availability

• Easily integrated with plant control systems (open connectivity)

• Signal isolation provides immunity to EMI/RFI and ground loops

• Flexible and scalable solutions with incremental in-chassis or distributed I/O

• Turbine controls are designed for optimal interfacing with Woodward IIoT prepared drivers,

valves and actuators to get best performance and monitoring capabilities

Product Variants and Specifications

• MicroNet™ Plus Programmable Control

• Flex500 Programmable Control

• RTCNet, LinkNet HT Distributed I/O

• RTN Gateway

• DVP Digital Valve Positioner

• SPC Servo Position Controller

Woodward GSOV50 Features and Benefits

Features and Benefits

• Special seal design in the main piston valve allows long life and prevents leakage.

• Stainless steel construction ensures valve availability despite corrosive service conditions.

• ANSI Class VI shut-off capability in the reserve flow direction with a pressure differential of 500 psi (3449

kPa).

• Designed for several fuel sources: natural gas, propane, ethane, or methane.

• Closes in <0.100 seconds at 900 psig (6200 kPa).

• Rated at <10 psig (69 kPa) pressure drop at flow of 25.000 lb/h (11.340kg/h)

• Safety Integrity Level: Systematic Capability SC 3 (SIL 3 Capable)

• Up to 50% Hydrogen Compatible.

• Formerly known as the GSOV25-HT

Product Variants

• 24 VDC or 125 VDC Input Voltage Options

• Internal or External Pilot Pressure Options

• Proximity Switch with Normally Open or Closed Contacts

Woodward GSOV50 Fuel Isolation Valve

Description

The GSOV50 fuel isolation valve provides shutdown on a gas turbine by rapidly

halting the flow of gaseous fuel. The supply pressure is used to move a spring

loaded piston in the valve. When the valve is energized, gas pressure drives the

spring-loaded piston open, admitting fuel to the turbine. When the current signal to

the electrical solenoid is interrupted, the spring loaded second-stage piston changes

states to vent off primary control pressure. The main spring then forces the primary

piston to the seal, stopping all flow.

Product Variants

• 24 VDC or 125 VDC Input Voltage Options

• Internal or External Pilot Pressure Options

• Proximity Switch with Normally Open or Closed Contacts

Product Specifications

• Gas Supply Pressure: 100-900 psig (690-6200 kPA)

• Fuel Temperature: -4 to +350 degrees Fahrenheit (-20 to +177 degrees Celsius)

• Ambient Temperature: -4 to +250 degrees Fahrenheit (-20 to +121 degrees Celsius)

• Main Seat Forward Leakage: ANSI/FCI 70-2. Class VI

• Main Seat Reverse Leakage: ANSI/FCI 70-2. Class VI, up to 500 psid (3.448kPA) reverse pressure

differential

• Flange: ANSI 600# RF Flange

Woodward GSOV50 Fuel Isolation Valve

Applications

The Woodward GSOV50 fuel isolation valve is designed to provide extremely fast

shutoff of gaseous fuel flow to an industrial gas turbine engine. Gas flow is stopped

when the valve is closed, with zero leakage from inlet to outlet. The HT version can

withstand higher fuel temperatures and higher back pressures than the standard version.

It is suitable for operation with gas temperatures between –4 and +350 °F (–20 and +177 °C).

The valve can achieve ANSI Class VI shut-off capability in the reverse flow direction with

a pressure differential of 500 psi (3448 kPa).

The normally-closed valve may be used for emergency and normal shutdown

operations. The special seal design in the main piston valve allows long life and

prevents leakage. Stainless steel construction ensures valve availability despite

corrosive service conditions.

This product is suitable for use on industrial turbines in the 10 to 50 MW power

output range with single or multiple combustion fuel manifold systems.

ABB DIS850 Features and benefits

Features and benefits

• Digital input for 2-wire field devices (NAMUR proximity switches and contacts according to EN

60947-5-6)

• Can be used in hazardous areas providing IS signals up to Zone 0

• Channel to channel galvanic isolation

• Configurable software signal filter 0…100 ms

• Protected against wrong wiring

• Diagnostics:

– Loop supervision (open circuit and short circuit)

– Hardware error supervision

– Communication supervision

– Internal power supervision

• Sequence of Events (SoE)

• DIS850 supports both Normally Open (NO) and Normally Closed (NC) 24 V loops

• Single loop granularity – each SCM handles a single channel

• Supports hot swap

• Mechanical locking slider which turns off field device power and/or output before removal

• Field disconnect function which can galvanically separate the field loop wiring from the SCM during

commissioning and maintenance

• All SCMs have electronic current limitation

• Mechanical keying to prevent insertion of wrong module type after commissioning

• 24V DC powered through Modulebus

• Configurable through parameters

• LED indicators on the SCM indicate the operational state of the module

ABB DIS850 Compact Product Suite hardware selector

Select I/O is an Ethernet networked, single-channel granular I/O

system for the ABB Ability™ System 800xA automation platform.

Select I/O helps decouple project tasks, minimizes the impact of

late changes, and supports standardization of I/O cabinetry

ensuring automation projects are delivered on time and under

budget. A Signal Conditioning Module (SCM) performs the

necessary signal conditioning and powering of the connected field

device for one I/O channel.

The DIS850 is a Digital Input Signal Conditioning Module for use in

intrinsically safe applications (Zone 0) supporting 2-wire NAMUR

field devices with Sequence of Events (SOE).

Woodward VariStroke Linear Electro-Hydraulic Valve Actuator

VariStroke is Woodward’s line of linear electro-hydraulic valve actuators for operation

of steam or hydro turbine control valves. These linear actuators utilize a low-pressure,

hydraulic oil source (typically turbine lube oil) to provide its output shaft force.

Its superb accuracy and resolution make it ideal for steam valve control and related

turbine speed and load control, where turbine up-time and availability is essential.

Features & Benefits

• Precise and stable control for responsive performance

• Variable/configurable shaft lengths for various application requirements

• Patented dirt tolerant and self-cleaning technology for increased reliability

• High-torque valve and motor design (50 lbs chip shear)

• Fast slew rates/times (up to 10”/sec)

• Side-load tolerant for reducing potential oil leaks

• Integrated driver (4-20 mA) and 11-point linearization table

• Self-tuning adaptive control algorithm

Product Variants

• Cylinder Bore Sizes:

100mm (4 in)

150mm (6 in)

200mm (8 in)

250mm (10 in)

300mm (12 in)

• Configuration

Integrated

Remote

Servo Valve Only

• Cylinder – Max. Stroke

100mm (4 in)

150mm (6 in)

200mm (8 in)

250mm (10 in)

300mm (12 in)

• Action:

Double Acting

Single Acting

No Hydraulic Cylinder

• Rod End

Male Thread

Female Thread

No Hydraulic Cylinder

• Fail-Safe Direction:

Extend

Retract

No Hydraulic Cylinder

• Compliance:

ATEX Zone 1

ATEX Zone 2

Woodward VariStroke-II actuator Side Load Capability

Side Load Capability

A common problem with turbine actuators is oil leaking from their output shaft due to connection to

valve

rack linkages which have an arc-type of motion. This motion results in side loading of the actuator shaft,

and after long periods may result in shaft-seal wear and resultant oil leakage. Designed for a continuous

side load of up to 10% of actuator output, the VariStroke-II actuator incorporates a high-force precision

bearing and triple-seal technology on its output shaft to solve this typical application problem.

Silt Buster A patented self-cleaning feature that flushes silt and debris from the servo valve. At the interval

and amplitude selected by the user, this function  provides a very rapid motion of the servo valve spool,

allowing any silt to be flushed to the drain passage. This motion is followed immediately by a step of

equal amplitude in the opposite direction. The opposing symmetry of the impulse results in no net

change in fluid volume to the hydraulic power cylinder, and thus does not interrupt the control of the

turbine. This unique feature provides a high degree of stability, reliability, and silt resistance.

Woodward Valve Rack Linearization (not currently available)

Silt Buster

A patented self-cleaning feature that flushes silt and debris from the servo valve. At the interval and

amplitude selected by the user, this function  provides a very rapid motion of the servo valve spool,

allowing any silt to be flushed to the drain passage. This motion is followed immediately by a step of

equal amplitude in the opposite direction. The opposing symmetry of the impulse results in no net

change in fluid volume to the hydraulic power cylinder, and thus does not interrupt the control of the

turbine. This unique feature provides a high degree of stability, reliability, and silt resistance.

Valve Rack Linearization (not currently available)

Because steam flow through single and staged inlet steam valves tends to be non-linear throughout their

flow range, turbine controls must be de-tuned to compensate for instability or sluggish control points

throughout this range. As a way of allowing turbine control optimization without detuning, the

VariStroke-II includes an 11-point linearization table to allow turbine OEMs or users to compensate for

poor valvelinea rization by digitally linearizing the control-to-valve flow relationship.

Side Load Capability

A common problem with turbine actuators is oil leaking from their output shaft due to connection to

valve rack linkages which have an arc-type of motion. This motion results in side loading of the actuator

shaft, and after long periods may result in shaft-seal wear and resultant oil leakage. Designed for a

continuous side load of up to 10% of actuator output, the VariStroke-II actuator incorporates a high-force

precision bearing and triple-seal technology on its output shaft to solve this typical application problem.

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