PT.

CIKARANG LISTRINDO
POWER COMPANY

Inlet Guide Vane System

Gas Turbine Generator
Operation & Maintenance Training
13 – 22 March 2006 and
27 March – 5 April 2006

GTG O&M Training 1 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

System Description
• To prevent possible pulsation in the gas turbine
during acceleration [startup] and deceleration
[shutdown].

• Used during operation under partial load

condition.

• The vanes are automatically positioned within

the operation range.

• Response the control system exhaust

temperature limits for normal loaded operation

• To control system pulsation protection limits

during start-up and shutdown sequences
PP-IGV

GTG O&M Training 2 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

System Description
• The actuator is an hydraulically actuated
assembly having close feedback control loop
to control the IGV angle

• Variable inlet guide vanes are installed in the

aft end of the turbine’s inlet casing.

• The variable vanes are modulated in

conjunction with the control of compressor
bleed air to permit rapid and smooth turbine
starts and shutdowns without compressor
surge and to control air mass flow on certain
load conditions.

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Functional Description
• Guide Vane Actuation

• Variable IGV control

• Pulsation Protection Control

• Exhaust Temperature Control

PP-IGV

GTG O&M Training 5 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Guide Vane Actuation

• The modulated inlet guide vane actuating system
is comprised of the following components:

ƒ Servovalve 90TV-1
ƒ Position sensors (LVDT) 96TV-1 and 96TV-2
ƒ Solenoid valve 20TV-1
ƒ Hydraulic dump valve VH3-1
ƒ Control ring HM3-1
ƒ Hydraulic activating cylinder ACV1

• When the inlet guide vane solenoid 20TV-1 is

energized, lube oil is fed through an orifice to the
dump valve VH3-1.

PP-IGV

GTG O&M Training 6 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Guide Vane Actuation

• Electronic control signals :
ƒ Activate and position the IGV, during normal & trip condition.
ƒ Action servovalve 90TV-1.
ƒ Action hydraulic dump valve VH3-1
ƒ Feedback 96TV-1 &2
ƒ Hydraulic cylinder ACV1

• During normal operation :

ƒ Trip oil [OLT] is pressurized
ƒ Dump valve VH3 is energized
ƒ Allow hydraulic supply to servovalve – 90TV
ƒ Controlled and modulated position of IGV 90TV-1
ƒ Actuator determines the position IGV control ring

PP-IGV

GTG O&M Training 7 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Guide Vane Actuation

• In trip condition :
ƒ Trip oil is dump by action 20TV-1
ƒ VH3-1 move to the dump position by action spring
return
ƒ IGV closes by dumping actuator cylinder

• When turbine rest :

ƒ IGV angle position at closed position
ƒ Limit air flow through the compressor during
acceleration and decelerating sequence
PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Variable Inlet Guide Vane Control

• Provides a method of regulating air flow to the compressor during startup,
operation and shutdown

• Air flow contributes to turbine protection during startup and shutdown

• Improved thermal efficiency during operation

• For normal shutdown, inlet guide vane actuation is the reverse of the startup
sequence;
ƒ The compressor bleed valves will open when the generator breaker is opened.
ƒ The inlet guide vanes will ramp to the full closed position as a function of
temperature corrected speed.

• In the event of a turbine trip,

ƒ The 11th stage bleed valves will open
ƒ The inlet guide vanes will ramp to the closed position as a function of PP-IGV
temperature corrected speed.

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Variable Inlet Guide Vane Control

• During startup:
ƒ Desirable to be able to reduce air flow
ƒ Maintain a lower pressure ratio
ƒ Provides pulsation protection to the unit as its speed builds up

• During operation:
ƒ Air flow permits regulation of performance characteristics to optimize
operation under varying weather and fuel conditions.
ƒ Permit most efficient utilization of exhaust heat for industrial process, or
combine cycle operation
ƒ Control of air flow permit reduction in plant load
ƒ Maintaining a constant firing temperature

• During shutdown:
ƒ Reduce air flow is again desirable, for same reason PP-IGV

GTG O&M Training 10 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Major Components
• Actuator Assembly
• Turn Buckle Assembly
• Two Linear Variable
Differential Transformer [LVDT]
• Inlet Guide Vane Assembly

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Protection Control
• Automatically positioned during a start-up and a shut-down sequence to
avoid gas turbine compressor pulsation.

• The pulsation limit is expressed as a function of IGV angle and corrected

speed, shown by a broken line.

• Corrected speed is a compressor design parameter that is a function of the

actual running speed of the compressor and the inlet air temperature.

• The control system utilizes the measured variables of turbine speed and
ambient temperature to determine the IGV angle and automatically
modulate them to that position.

• The control program is set to avoid IGV operation which would result in
negative pressure at the 5th stage extraction, air used for bearing seals.
PP-IGV

GTG O&M Training 12 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Exhaust Temperature Control

• For applications such as a regenerative cycle in a
generator in the gas turbine exhaust, it is desirable to
maximize the exhaust temperature.

• The control program for such turbines includes an

exhaust temperature control which automatically holds
the IGV at a minimum angle during part-load operations.

• A target is provided to permit the operator to select this

mode of operation.
PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Operation
• During a normal start-up, the inlet guide vanes are held in the full
closed position

• When the proper temperature corrected speed is reached, at which

time, the inlet guide vanes to open.

• The inlet guide vanes remain in the minimum full-open

position with less than :
– 20 % load for a simple cycle and
– 80 % load for a combined cycle

• The compressor bleed valves, which must operate in conjunction

with the guide vanes to maintain compressor surge margin, will
close when the generator breaker is closed.
PP-IGV

GTG O&M Training 14 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Operation
• When the IGV temperature control mode is not activated and the IGV is
in the simple cycle mode, the guide vanes are held at the minimum
full speed angle until the simple cycle IGV exhaust temperature set-
point (700°F) is reached.

• Temperature control setpoint is programmed in the software at

approximately 300°F (167°C) below the base temperature control
setpoint.

• The guide vanes are held at the minimum full speed angle until combined
cycle IGV exhaust temperature control setpoint is programmed at a value
slightly lower than the BASE temperature (fuel) control setpoint, with
the same PCD bias in both.

• The operator can activate or deactivate the IGV temperature control

mode at any time via the monitor main display.
PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Operation
• The control system will automatically reprogram
the IGV to the correct position in a controlled rate.

• Manual control targets are provided in the MK V control

panel :
ƒ To allow the operator to manually position the IGV between
the minimum full speed angle and full open.
ƒ Has authority to command in IGV angle only when LESS
THAN that being called for by the automatic control system.
ƒ In normal operations the manual control is set at full open.

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Actuator Assembly
• Double-acting hydraulic cylinder

• Hydraulic manifold

• Hydraulic filter

• IGV closed position

• Control servovalve

• Drive clevis

• Electrical junction box

• Mounting pedestal PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Hydraulic Cylinder
• Design for high pressures and peak shock pressures that
occur in the gas turbine hydraulic system during transients

• Bolted on top mounting pedestal

• Hydraulic Oil [OH] and hydraulic trip oil [OHT] are piped to the
hydraulic manifold

• OH and OHT are routed to the control servovalve 90TV

• OH and OHT are connected to the IGV dump valve

• Provides absolute filter 10 to 15 mm for hydraulic oil

PP-IGV

GTG O&M Training 18 Rendoc_GTGOM_trn06

Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Servo Valves
• Moog Series 77-100/200/500

• The Moog Electrohydraulic servovales consist of a

polarized electrical torque motor and two stages of
hydraulic power amplification

• Low Leakage servovalve by rugged steel cover box to

protect it from accidental damage

• Servovalve, 90TV have control over the hydraulic cylinder

which actuates IGV

• Control servovalve [90TV] regulates OH flow to the

hydraulic cylinder functions as four-way control devices
PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Turnbuckle Assembly
• Adjustable link which permits IGV
blade position versus hydraulic
cylinder position calibration

• The assembly consists of a bar

with left-hand female thread in one
end right-hand and female thread
in the other end

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

LVDT Assembly
• LVDT, Linear Variable Differential Transformer

• Two LVDTs are used in the hydraulic IGV system for control system
redundancy

• Located in IGV actuator assembly

• Each LVDT is directly coupled to actuator clevis

• The feedback signals of both LVDTs are constantly compared

• If difference between both exceeds an allowable limit, the condition

will be indicate by annunciator drop
PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Combined Cycle Operation

• During Start-up:
– IGVs are in the full-closed poistion
– At 95% speed, trip servovalve operated to energizes the control
servovalve
– IGV opening to minimum closed position
– At 40% load, permit control to modulated

• During Operation:
– At base-load, IGVs will remain full open
– At part-load, fuel flow is reduced cause IGV modulation
– Provides maximum HRSG efficiency and full economy at part-load
– IGV modulation can continue until the IGVs reach minimum closed for
operation at load

PP-IGV

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Maintenance Department@
PT. CIKARANG LISTRINDO
POWER COMPANY

Combined Cycle Operation

• Shutdown gas turbine:
ƒ Fuel flow reduced
ƒ IGV closed until reach minimum closed
position
ƒ At 14HS dropout, 20TV is deenergized
ƒ IGV full-closed position for turbine coast down

PP-IGV

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PT. CIKARANG LISTRINDO
POWER COMPANY

Simple Cycle Operation

• Fuel economy dictates optimizing the heat rate of gas turbine
without heat recovery

• Gas turbine has a lower heat rate at maximum air flow, IGV will not
normally modulated

• During startup, at 95% speed, the trip servovalve will be reset

• IGV will go to minimum closed position, hold at 40% load

• At 40% load, modulation control will drive the IGVs full open and
maintained until turbine shutdown

PP-IGV

GTG O&M Training 24 Rendoc_GTGOM_trn06

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