GEK 106832

March 1998
Replaces CMBMTR00

GE Power Systems
Gas Turbine

Combustion Monitor Function

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchaser’s purposes the matter should be
referred to the GE Company.
 1998 GENERAL ELECTRIC COMPANY
GEK 106832 Combustion Monitos Function

I. INTRODUCTION

Monitoring of the exhaust thermocouples to detect combustion problems is performed by the SPEEDTRON-
IC software coupled with solid state analog devices for interfacing with the primary controls and protective
devices. For operating instructions, calibration, PROM constant listing and operational check procedures for
a specific gas turbine, refer to the Control Specifications. Refer to the software Master Sequence Document
for details of algorithm implementation and identification of selectable display lists and PROM constants.

II. COMBUSTION MONITORING FUNCTION

The primary function of the combustion monitor is to reduce the likelihood of extended damage to the gas
turbine if the combustion system deteriorates. The monitor does this by examining the temperature control
system exhaust temperature thermocouples and compressor discharge temperature thermocouples. From
changes that may occur in the pattern of the thermocouple readings, warning and protective signals are gener-
ated by the combustion monitor and sent to the gas turbine control panel.

This means of detecting abnormalities in the combustion system is effective only to the extent there is incom-
plete mixing as the gases pass through the turbine, and an uneven inlet pattern will cause an uneven exhaust
pattern. The uneven inlet pattern could be caused by a rupture in a transition piece, loss of fuel or flame in
a combustor, or other combustion malfunctions. The usefulness and reliability of the combustion monitor
depends on the condition of the exhaust thermocouples. It is important that each of the thermocouples is in
good working condition.

III. COMBUSTION MONITORING FUNCTION SOFTWARE

The controllers contain a series of programs written to perform the monitoring task (see Combustion Moni-
toring Schematic Figure 1). The main monitor program is written to analyze the thermocouple readings and
make appropriate decisions. Several different algorithms have been developed for doing this depending on
the turbine model series, and the type of thermocouples used. The significant program constants used with
each algorithm are specified in the Control Specification for each gas turbine.

IV. THERMOCOUPLES SCAN AND COLD JUNCTION COMPENSATION

The exhaust thermocouple values, read and sorted in the exhaust temperature feedback algorithm, are used
by the combustion monitor. From each set of readings, the median exhaust temperature, the allowable spread,
and two sets of spread ratios are calculated and compared with specific exhaust temperature limits to deter-
mine whether alarm and trip conditions have been exceeded.

V. ACTUAL SPREADS

Three spreads are calculated from the exhaust thermocouple readings:

SPREAD #1 (TTXSP1)--The difference between the highest and the lowest thermocouple reading;

SPREAD #2 (TTXSP2)--The difference between the highest and the 2nd lowest thermocouple reading;

and,

SPREAD #3 (TTXSP3)--The difference between the highest and the 3rd lowest thermocouple readings.

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Combustion Monitos Function GEK 106832

VI. ALLOWABLE SPREAD

The allowable spread is the sum of two values: a nominal allowable spread and a bias.

The nominal allowable spread is the steady state spread limit. It varies, typically, between 30 and 125 degrees
F as a function of average exhaust temperature and compressor discharge temperature.

The bias is an adder to the nominal allowable spread which accounts for the temporary increase in actual
spreads that occur during transient operational periods. It is a temperature value which varies between 0 and,
typically, 200 degrees F.

During steady state operation, the bias value is 0 degrees F. When a transient operational condition occurs,
such as a rapid change in load, the bias value steps to 200 degrees F. It remains at that value until, typically,
2 minutes after the transient condition ends. Its value then decays exponentially to 0 degrees F on a 2 minute
time constant. Refer to Figure 6.

The transient conditions which cause the bias to step to 200 degrees F are: 1) fuel transfer, 2) turbine startup
and shutdown, 3) load changes produced by a governor RAISE or LOWER signal, and 4) load changes pro-
duced by a rapid change in FSR.

VII. SPREAD TESTS

The combustion monitor algorithm uses the acutal spreads, the allowable spread, and adjacency tests to de-
termine if an actual combustion problem exists. The algorithm logic is summarized by the Venn diagram
shown in Figure 2.

VIII. DISPLAY MESSAGES

The various monitor outputs to the control panel cause alarm message display as well as appropriate control
action. The combustion monitor outputs are given below.

A. Exhaust Thermocouple Trouble Alarm (L30SPTA)

If any thermocouple value causes the largest spread to exceed a constant (usually 5 times the allowable
speed) a thermocouple alarm (L30SPTA) is produced. If this alarm persists for four seconds, the alarm
will latch and the alarm message “EXHAUST THERMOCOUPLE TROUBLE” will be displayed and
remain on until acknowledged and reset.

B. Combustion Trouble Alarm (L30SPA)

A combustion alarm can occur if a thermocouple value causes the largest spread to exceed a constant
(usually the allowable spread). If this alarm persists for three seconds, the alarm will latch and the
“COMBUSTION TROUBLE” message will be displayed and remain on until it acknowledged and re-
set.

C. High Exhaust Temp Spread Trip (L30SPT)

A high exhaust temperature spread trip can occur if a combustion trouble exists and the second largest
spread exceeds 0.8 times the allowable spread and the first and second lowest thermocouples are adja-
cent or if an exhaust thermocouple trouble exists and the second largest spread exceeds 0.8 times the

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GEK 106832 Combustion Monitos Function

allowable spread and the second and third lowest thermocouples are adjacent or if the third spread ex-
ceeds 0.8 times the allowable spread or if a combustion trouble exists and a controller failure occurs.
If any of these conditions exist for 9 seconds, the trip will latch and “HIGH EXHAUST TEMP SPREAD
TRIP” message will be displayed. The turbine will be tripped through the master protective circuit. The
alarm and trip signals will be displayed until they are acknowledged and reset.

D. Monitor Enable (L83SPM)

The protective function of the monitor is enabled by signals from the control panel. The purpose of the
“enable” signal (L83SPM) is to prevent false action during startup and normal shutdown transient condi-
tions. When the monitor is not enabled, no new protective actions are taken. To troubleshoot the monitor
when the gas turbine is not running, the “enable” signal must be simulated, i.e., logic signal L14HS, and
L4 inputs must be “1” ’s.

IX. TROUBLESHOOTING WITH THE COMBUSTION MONITOR FUNCTION

A. General

The two main sources of alarm and trip signals being generated by the combustion monitor are failed
thermocouples and combustion system deterioration. Other causes include poor fuel distribution due to
plugged or worn fuel nozzles, and flameout due to water injection (if used).

The tests for combustion alarm and trip action have been designed to minimize signals due to failed ther-
mocouples but it is impossible to always isolate this cause.

The best protection against shutdowns due to failed thermocouples is good thermocouple maintenance.
Replace failed thermocouples promptly during normal downtime so that the likelihood of operation with
more than one failed thermocouple is low.

The TC TROUBLE ALARM is intended to call attention to failed thermocouples so that they will be
promptly replaced. The TC ALARM will also be activated by the early stages of some combustion prob-
lems.

The COMBUSTION TROUBLE ALARM is intended as an early warning of an actual combustion mal-
function. DO NOT OPERATE THE GAS TURBINE FOR A PROLONGED TIME PERIOD WHEN
THE COMBUSTION ALARM HAS BEEN ACTIVATED. If black smoke is seen in the exhaust, trip
the machine immediately. If there is no black smoke in the exhaust, any period of operation with this
alarm should be used to diagnose the trouble, as failed thermocouples are much easier to detect when
hot than at an ambient temperature. In addition, the fuel oil nozzle pressure can be read during operation
to help diagnose poor fuel distribution. (See Combustion Alarm - Corrective Action.) If the gas turbine
has been tripped by the monitor, it will be necessary to determine the cause.

Figures 3 through 5 are troubleshooting flowcharts to help in that determination.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Condition
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ Figure

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Only the TC Failure Alarm occurs 3

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
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Combustion Monitos Function GEK 106832

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Combustion Alarms occurs

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
(with or without TC failure alarm)
4

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Combustion Alarm and Trip occur

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
(with or without TC failure alarm)
5

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
and gas turbine has tripped

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
If TC Alarm, Trip and Combustion Alarm occur and the gas turbine continues to run, monitor malfunc-
tion has occurred. Attempt to reset monitor.

All possible problems cannot be foreseen and initiative and judgment may be required to troubleshoot.

X. THERMOCOUPLE CHECKING

The monitor display and the printer, if available, can be used to check thermocouple readings at any time.
The combustion monitor will continue to protect the gas turbine while the thermocouple readings are being
displayed and printed.

Thermocouple malfunction may be detected by observing the monitor display. An open thermocouple will
indicate a value of -40°F. A thermocouple may be intermittently open if the display is erratic or cyclic. With
the turbine coasting down and the exhaust metal still hot, but the exhaust air cooler, a thermocouple that reads
significantly higher than the others is probably shorted in its junction box.

XI. THERMOCOUPLE RESISTANCE CHECK

With the turbine not running, disconnect each thermocouple in turn at the termination board and measure
the thermocouple resistance using a good quality ohmmeter. Measure each thermocouple in each polarity
and average the two results to avoid errors from the thermoelectric action. Record all readings, determine
the average, and the deviation of each reading from the average. Any thermocouple with a deviation of more
than 15 ohms from the average reading should be considered defective.

XII. INTERPRETING FAILED THERMOCOUPLE PATTERNS

A. Automatic Trip

If an automatic trip has occurred and a thermocouple has failed, the failed thermocouple may have
caused the trip. If not, assume a possible combustion or associated problem. Proceed in accordance with
Figure 5

CAUTION

Follow the restart instructions carefully. It is impossible to

be sure there is no combustion problem from the tests re-
ferred to above. In case of doubt or if failed thermocouple
patterns are not found, it is recommended that the General
Electric Company Field Service Representative be con-
sulted.

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GEK 106832 Combustion Monitos Function

XIII. COMBUSTION TROUBLE MODES TO BE CONSIDERED

A. Combustor

1. Failed Liner (Cracked or Burned)

2. Failed Transition Piece (Cracked or Burned)

3. Collapsed Liner

4. Hot Crossfire Tubes

B. Fuel System

1. Break in Liquid Fuel Line

2. Break in Gas Fuel Line

3. Plugged Check Valve

4. Check Valve Stuck Open/Closed

5. Liquid Fuel in Gas Manifold

6. Stuck Flow Divider

7. Failed Fuel Pump

C. Fuel Nozzle

1. Plugged Fuel Nozzle (Liquid or Gas)

2. Unscrewed Fuel Nozzle

3. Fuel Nozzle Erosion

4. Red Hot Fuel Nozzle

D. Atomizing Air System

1. Break in Atomizing Air Line

2. Faulty Purge System

3. Atomizing Air Compressor Failure

4. Plugged Atomizing Air Passage at Manifold or Nozzle

E. Pressure Vessel Integrity

1. Cracked Combustor Casing

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Combustion Monitos Function GEK 106832

2. Blown Gasket

3. Damaged Crossfire Tube Piping

4. Cracked or Blown Sight Port

5. Leakage at Flame Detector or Spark Plug

F. First Stage Nozzle

1. Burned Out First Stage Nozzle

2. Plugged First Stage Nozzle

XIV. CORRECTIVE ACTION REQUIREMENTS

A. Combustion Alarm - Corrective Action

In the event of a Combustion Alarm, it is most likely that a condition exists within the turbine that, if
left alone, could lead to serious combustor or turbine damage. Precautionary measures and troubleshoot-
ing procedures should be initiated immediately to locate and correct the problem. Proceed in accordance
with Figure 4 and the following:

WARNING

Keep personnel away from the vicinity of the turbine

and accessory compartments until the problem has
been identified.

1. Look for abnormal smoke from the exhaust. Trip the turbine if abnormal smoke is observed.

CAUTION

During the troubleshooting period, watch the display of

temperature spread closely and trip the turbine in the event
of a continuous or sudden increase.

2. Read and record the exhaust thermocouple temperatures using the display and the printer.

3. Record the “spread” displayed.

4. Proceed with a normal turbine shutdown.

5. If faulty exhaust thermocouples have been discovered, replace the thermocouples.

Proceed with the trouble shooting investigation to locate the problem. Perform the following steps:

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GEK 106832 Combustion Monitos Function

6. Inspect the turbine for signs of leaks or damage.

7. If no evidence is discovered in (6), start the turbine in the crank position (unfired). Inspect the turbine
compartment for leaks or damage.

8. If no evidence is discovered in (7), fire the turbine and hold in a warm-up condition (do not permit
acceleration). Watch for an abnormal smoke condition from the exhaust.

TRIP THE TURBINE IF ABNORMAL SMOKE IS OBSERVED. This fired condition, while the
turbine is at low pressure, will permit personnel to read and record the individual fuel nozzle pres-
sure readings in the accessory compartment on liquid fuel fired gas turbines.

9. If an abnormal condition is observed, trip the turbine and take corrective action.

10. If no abnormal condition can be discovered at this point, the turbine should be shut down and a com-
bustion inspection performed. FURTHER ATTEMPTS AT DIAGNOSIS BY OPERATING THE
MACHINE ARE NOT RECOMMENDED.

11. Preliminary disassembly of the combustor end cover will permit inspection of the combustion liner,
a portion of the transition piece, the fuel nozzles and the crossfire tubes. The extent of the inspection
must be dictated by the nature of the problem.

12. The problem area discovered during the combustion inspection should be corrected and the turbine
should be returned to normal operation.

B. Turbine Trip - Corrective Action (See Figure 5)

In the event of an emergency turbine trip due to the following conditions.

1. Abnormal smoke condition at any time.

2. Combustion Alarm. Thermocouples show combustion alarm pattern, and the thermocouples have
not failed.

3. Thermocouple Alarm, Combustion Alarm and Trip. Trip pattern, and thermocouples have not
failed.

4. Combustion Alarm and Trip. Trip pattern exists and thermocouples have not failed.

Proceed with the following action:

1. It is likely that an abnormal condition exists within the turbine and corrective action should be initi-
ated.

2. Inspect the turbine compartment hardware for signs of leaks or damage.

3. Perform a combustion inspection. Inspect all combustor hardware including the transition piece for
signs of damage. Replace the damaged hardware and return the turbine to normal operation.

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Combustion Monitos Function GEK 106832

C. Automatic Trip - Corrective Action

In the event of an automatic trip due to COMBUSTION ALARM and TRIP (THERMOCOUPLE
TROUBLE ALARM or not) and investigation shows failed thermocouples could have caused the trip,
proceed with the following action.

1. Replace the failed thermocouples.

2. Open the turbine compartment doors and keep all personnel away from line-of-sight of the turbine
compartment.

3. Proceed with a normal start. If an abnormal smoke condition is observed from the exhaust stack,
trip the turbine and proceed with a complete combustion inspection of the liner, transition pieces,
crossfire tubes and fuel nozzles.

4. If no further alarms are noted by FSNL (full speed, no load), proceed with a normal loading proce-
dure and observe the temperature spread reading and exhaust smoke.

5. Any further trips due to the combustion monitor indicates an unsatisfactory condition, and a com-
plete combustion system inspection should be performed.

6. Otherwise resume normal operation.

XV. WATER INJECTION (OPTIONAL)

During water injection, if one or more combustors are extinguished by the water, the combustion alarm func-
tion will shut off the water and the COMBUSTION ALARM will be displayed. The Trip function will trip
the gas turbine if the combustors do not refire within a short time period.

If the combustion alarm function operates, and the water injection is turned off, reset the monitor. If the alarm
does not recur, restart the water injection as desired, using the normal procedures. If the alarm does recur
proceed with troubleshooting procedures in accordance with Figure 4. If a trip occurs during water injection
operation, proceed with troubleshooting procedures in accordance with Figure 5.

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GEK 106832 Combustion Monitos Function

<RST>

Combustion Monitor Algorithm

CTDA( )

TTKSPL1 Median
Max. Select
TTKSPL2 Calculate
Allowable TTXSPL
Min. Apread Median
TTXC Select

TTKSPL5
Max.
TTKSPL7
Calculate
Min. L83SPMB Bias
Values
Constants

A L60SP1
A B
TTXD2 B
A L60SP2
Calculate A B
Actual B
Spreads
A L60SP3
A B
B

A L60SP4
A B
B

Figure 1. Combustion Monitoring Function Algorithm (Schematic)

10
Combustion Monitos Function GE K 106832

S2 Venn Diagram Also Trip If:

5allow S1
> K1
Sallow
Communications
Failure
Trip If S1 & S2
Or S2 & S3
Are Adjacent
Typical K1 = 1.0
K2 = 5.0
Trip if S1 & S2 K3 = 0.8
Are Adjacent
K3
Monitor TC Alarm
Alarm
S1
K1 K2
Sallow

Figure 2. Exhaust Temperature Spread Limits

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GEK 106832 Combustion Monitos Function

TC Failure Alarm (Only)

TC = Thermocouple
Check For
Smoke

Yes Black No
Smoke

Initiate Emergency Trip

– Display and Record
Thermocouple Readings
and Median Exhaust
Temperature
(See Turbine Trip Or – Record Spread 1 and
Shutdown/Corrective Spread 2
Action)
– Record ALW Sprd,
TCD-1 and TCD-2
No Defective Yes
Thermocouples – Record Alarm
Messages

Note: Printout Above

If Printer is Available

* TCD = Compressor Discharge

Temperature

Possible Causes:
– Intermittent Thermocouple
– Transient Gas Turbine Operation
Reset Alarms
– Full System Trouble Clear
Annunciator
– Incipient Combustion Trouble

– Replace Failed Thermocouples

At First Opportunity.

(Operation With Failed

Thermocouples Raises
Risk Of False Trip)

Continue Normal Operation

Figure 3.

12
Combustion Monitos Function GEK 106832

Combustion Alarm
(With or Without TC Failure Alarm)

**WARNING**
Keep Personnel Away From the
Vicinity of the Turbine and TC = Thermocouple
Accessory Compartments Until
the Problem Has Been Identified.

Check For Smoke – Display and Record

Thermocouple Readings
and Median Exhaust
Temperature
– Record Spread 1 and
Spread 2
Yes Black No – Record ALW Sprd,
Smoke? TCD–1 and TCD–2
– Record Alarm
Messages

Note: Printout Above

If Printer is Available

Initiate
Emergency
Trip

See Turbine Trip See Combustion Alarm/

Corrective Action Corrective Action

* TCD = Compressor Discharge

Temperature

Figure 4.

13
GEK 106832 Combustion Monitos Function

Combustion Alarm and Trip

(With or Without TC Failure Alarm)

TC = Thermocouple

Automatic Trip

– Display and Record

Thermocouple Readings
and Median Exhaust
Temperature
– Record Spread 1 and
Spread 2
– Record ALW Sprd,
TCD-1 and TCD-2
– Record Alarm
Messages

Note: Printout Above

If Printer is Available

* TCD = Compressor Discharge

Temperature
Yes No
Any TC Failed

(See Automatic
Trip)

See Automatic See Turbine Trip

Trip/Corrective Corrective
Action Action
Do Not Reset Alarms
Until Ready To Restart
Turbine

Figure 5.

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 Combustion Monitos Function

200 2 Minutes Allowable Spread

Deg F

Temperature
Actual Spread

Time

Steady State Transient Steady State

Operation Period Operation
GEK 106832

Figure 6.

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GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354