IGV Commissioning For AddFem POCO+ Logic

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 IGV Commissioning For AddFem POCO+ Logic

The primary purpose of the guide vanes is to control the amount of air flow into the Gas Turbine.
This improves GT starting acceleration and improves compressor surge.

For understanding IGV commissioning with new POCO logic it is very important to know the IGV
angles concept and actuator strokes.

M
Z1 A1
Z2 A2
Z3 A3
Z4 A4

Z1 – A1: Verstellweg im Regelbereich [stroke for adjustment range ( SREL –values)]

Z2 – A2: Max. möglicher Verstellweg [max. possible adjustment range]
Z3 – A3: Verstellweg begrenzt vom Endanschlag am Antrieb (Z2 bis A2 + 2 x 2°)
[stroke limited by actuator end stop(Z2 to A2 + 2 x 2°)]
Z4 – A4: Verstellweg begrenzt vom Endanschlag am Verstellring
[stroke limited by end stop of actuation ring]
Pos. – M: Montageposition [assembly position]
Pos. – Z1: “zu” – Regelbereich [ “closed” - adjustment range]
Pos. – A1: “auf” – Regelbereich(100% Massenstrom)
[“open” - adjustment range (100 % mass flow)]
Pos. – Z2: “zu” – max. möglicher Bereich [ “closed” - max. possible adjustment range]
Pos. – A2: “auf” – max. möglicher Bereich
[“open” - max. possible adjustment range]
Pos. – Z3: “zu” – Bereich begrenzt vom Endanschlag am Antrieb
[„close“ – stroke limited by actuator end stop]
Pos. – A3: “auf” – Bereich begrenzt vom Endanschlag am Antrieb
[“open” – stroke limited by actuator end stop]
Pos. – Z4: “zu” – Endanschlag am Ring [“close” - mechanical end stop at actuation ring]
Pos. – A4: “auf” – Endanschlag am Ring [“open” - mechanical end stop at actuation ring]

Three different conventions for describing the vane angle are used.
∂ The “BetaBi angle” or “vane angle”, describes the angle of the vane blade related to
the centerline of the engine. The BetaBi angle can be directly measured only on the
IGV.
∂ The “Aero angle” is the angle of the vane blade relative to the vane blade position at
Base load. When the vanes are fully opened at base load the aero angle is always 0°
∂ The “Alpha angle” or “lever angle” describes the angle of the lever. During
commissioning the protractor measures the “alpha angle” on the VGV.
Positive readings of the protractor indicates vane more “open”, negative readings indicate
more “closed” vane.
The three different angle conventions always have a fixed relation to each other so calculation
of the other angles is easy. The pictures below show as example the relationship between the
different angles for the IGV of SGT5-4000F(9).

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 IGV vane at open position

IGV vane at assembly position

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 Figure 0-1: IGV vanes at closed position

This procedure is divided in to four different phase as mentioned below.

Phase 1: Hydraulic Actuator Mechanical Ends Adjustments.

Phase 2: IGV 0% and 100% Angle Adjustment.

Phase 3: Characterization of Linear to Angular Measurement.

Phase 4: Trim Controller Adjustment

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Phase 1: Hydraulic Actuator Mechanical Ends Adjustments.

In this phase actuator linear sensor calibration has been done. Mechanical person will
decoupled the IGV push rod and adjust the both mechanical end positions of the actuator. To go
to the mechanical end position of the actuator below mentioned settings has to perform.

Open the AddFEM_POCO+ PC and force or verify the following:

Force TRIP_Y to -10%

Force TRIP_Y_ON = 1 (true) – this will send a fixed current (-10% = -3 mA) to the Servo

This smaller value at the TRIP_Y will slower extend the actuator (Closing of IGV).

Force TRIP_Y to +10%

This smaller value at the TRIP_Y will slower retract the actuator (Opening of IGV).

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After the correct stroke for actuator stop is verified at this position. Verify M_RAW_OPEN_POS
is set to 0 & M_RAW_CLSD_POS is set to 100.

Force TRIP_Y to -10%

Force TRIP_Y_ON = 1 (true)

This smaller value at the TRIP_Y will slower extend the actuator (Closing of IGV).

Note the values of the FB_POSITION in Diagram MBX48AS001 XQ11 and XQ12.

Force TRIP_Y to +10%

This smaller value at the TRIP_Y will slower retract the actuator (Opening of IGV).

Note the values of the FB_POSITION in Diagram MBX48AS001 XQ11 and XQ12.

Now the noted values for XQ11 are for M_RAW positions and XQ12 are for R_RAW positions.

Calculate the new RAW values for open and close as per below mentioned formula.

RAW values for IGV open position:

M_RAW_OPEN_POS = 100 – MBX48AS001_XQ11 @ IGV Open Position (TRIP_Y = +10%)

R_RAW_OPEN_POS = 100 – MBX48AS001_XQ12 @ IGV Open Position (TRIP_Y = +10%)

RAW values for IGV close position:

M_RAW_CLSD_POS = 100 – MBX48AS001_XQ11 @ IGV Close Position (TRIP_Y = -10%)

R_RAW_CLSD_POS = 100 – MBX48AS001_XQ12 @ IGV Close Position (TRIP_Y = -10%)

Enter the new calculated RAW values in T3000.

Adjustment of BIAS (Working Point) of the Actuator:

Before adjustment of BIAS force integration upper-lower limit and Dither amplitude to zero.
Stroke the vane to 50% position by simulating the Setpoint to the Poco and examine the value
of the FB_POSITION and the I_OUTP; I_OUTP is the integration portion of the servo’s current
demand and should be 0 +- 0.5%. This is the value of the controller output needed to maintain
position from overcoming the failsafe closed mechanism. The parameter BIAS is used to set the
value. This is typically 4% BIAS, and can be adjusted to get I_OUTP close to 0 when the
demanded position is met.

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Stroke the vane to 0%, 15%, 30%, 45%, 60%, 75%, 90% and 100%, and verify that the position
Feedback measurement is within 0.5% of the demanded position in both the opening and
closing directions to examine any hysteresis.

This completes the Phase 1 of the IGV commissioning.

Phase 2: IGV 0% and 100% Angle Adjustment.

Before beginning it is important to know that mechanical engineer will measure the angle
directly on the vane so this angle is the BetaBi angle and the angle which is mentioned in the
T3000 logic is the Aero angle.

The aero angle needs to be calculated in any case. From the aero angle the SSI display digits
need to be calculated. Tables below show the relationship between the different angle types
and the related digits in various position of the IGV.

Lever Angle Aero Angle SSI Display

ßBi [°]
α [°] Digits

assembly position 23,7 0 -16 1229

Control Range

open - control Range – A1 7,7 -16 0 1593

close - control Range – Z1 53,7 30 -46 546

Maximum possible adjustment range

open - possible adjustment range – A2 1,7 -22 6 1729

close – possible adjustment range – Z2 59,7 36 -52 410

Actuator Range

open - stroke limited by actuator stop – A3 -0,3 -24 8 1775

close - stroke limited by actuator stop – Z3 61,7 38 -54 364

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Lever Angle = BetaBi Angle at particular IGV position - BetaBi Angle @ Assembly Position

For eg. – Lever angle at Mech closed = 61.7 - 23.7 = 38

Aero Angle = BetaBi Angle @ Open Position - BetaBi Angle at particular IGV position

For eg. – Aero angle at Mech closed = 7.7 – 61.7 = -54

Kuebler Digits = 8192/360 * (calculated aero angle - (-70°))

For eg. – Kuebler digits at Mech Closed = 8192/360 * (-54 - (-70°)) = 364.088

Parameterization of SSI Display

The rotary position encoder outputs a digital signal. The interface sending out this signal is
called SSI (Synchronous Serial Interface). The SSI-signal will be transformed to an analogue 4-
20mA signal by the SSI-unit. This SSI-unit is mounted inside the control cabinet. The SSI unit is
powered by 24VDC.

There are two sets of parameters for the SSI module.

Basic setup functions and Operational setup functions.

Default setting: press both keys at the same front for 3 seconds

Mode: Master

Bits: 13 Bit

Format: Gray

Baud: 200

Char: PNP

Bright: 100

Code: No

A-Char: 4-20 mA

Offset: 0

Gain: 10

Basic Setup Functions

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 Setting the operating parameters: press enter key for 3 seconds

M-Factor 1.000

D-Factor: 1.000

P-Factor: 000000

Decimal Point: 000000

Display: Norm

HI Bit: 25

LO Bit: 01

Dir: left or 1

Error: 01

Error Polarity: 0

Round Loop: 008192 bits per 360°, one degree is equal to

22,7555555 digits

Time: 0.01

Reset: Extern

0_Pos: Calculated value (see chapter 7)

Analog Begin: 000000

002060 (IGV)
Analog End:
001537 (VGV's)

Operational setup functions

To enter the Basic setup parameters from the front panel of the SSI press “ENTER” and “set”
push buttons simultaneously for 3 seconds, to enter the operational settings press “ENTER” for
3 seconds.

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After parameterization of SSI display next step is 0% adjustment of IGV angle. For this IGV has
to move until 0% IGV angle is reached (BetaBi 53.7° / Aero -46°). For IGV movement don’t
simulate the setpoint at the POCO because this leads to fast movement of the actuator. So for
the slow actuator movement of the IGV refer software simulations shown in below image.

Mechanical engineer will measure the vane angle with the protractor. For IGV the BetaBi angle
can be measured. Betabi angle for the 0% position will be 53.7° which is -46° aero angle.
Calculate the digits and enter the digit value in “0_Pos” in SSI display unit. Perform encoder
reset.

After encoder reset at 0% position kuebler digits will be displayed on MBA11CG101_1 and
MBA11CG101_2 ASMON block in T3000. ASMON block is followed by the CONV block which
converts Kuebler digits in to corresponding Aero angle.

After encoder reset 546 digits will be displayed on MBA11CG101_1&_2 ASMON block. Next
step is adjusting the G.VLE0.374 (X1 of CONV) such that it will convert to -46° at
MBA11CG101_ZQ01.

After adjustment of 0%, move the IGV to desired angle of 100% position which is 7.7° BetaBi
and 0° Aero angle. After confirmation from mechanical engineer for correct 100% vane angle
the SSI display unit feedback will be approximately 1593 digits. . Next step is adjusting the
G.VLE0.375 (X2 of CONV) such that it will convert to 0° Aero angle at MBA11CG101_ZQ01.

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After adjustment of the Digits to Aero angle CONV block, IGV vanes are adjusted correctly at 0
and 100%.

Next step is to adjust the CONV block for the set-point of the actuator in MBA11DG001. For
this move the IGV at mechanical end open and close position note the angles for both
positions MBA11DG010_XQ12. Enter the corresponding angle for mechanical close position at
G.VLE0.384. Similarly enter the corresponding angle for mechanical open position at
G.VLE0.383.

Actuator Stop
Full Closed Setting

Actuator Stop
Full Open Setting

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This completes the Phase 2 of the IGV commissioning.

Phase 3: Characterization of Linear to Angular Measurement.

The stroke of the actuator is measured by a linear transducer mounted inside the hydraulic
actuator. There is a nonlinear relationship between the actuator stroke and the vane angle. To
ensure an accurate vane position control via the linear transducer, the conversion from stroke to
angle also needs to be accurate. The measured stroke signal is converted to a vane angle with
a linear CONV function in T3000 software (diagrams MBX48AS001). In parallel a POLY function
with 6 points is available to adjust the nonlinearities. Although engineer can increase the points
but don’t forget to increase the N_BP also in POLY function. Before starting the linearization
ensure that the Polygon (MBX48AS001_Linear) is set to 0, both Angular Transmitters are
calibrated and functional, the actuator calibration and mechanical adjustments/calibrations are
completed.

Perform a sweep of the vanes from full closed and full open to collect the characterization. Start
at the closed position and run the vanes to the open position in 20 % steps. At each stop note
the average value of the two rotary encoders (MBA11CG901_ZQ01) and the Linear Position
Feedback in Degrees (MBX48AS001_ZQ01). Calculate and note the Delta between the
Average Angular Position and the Linear Position for each step. Repeat this in the closing
direction and record the values at the same 6 points. For each step determine the average
delta of the opening and closing values at the same setpoint and fill in the values in the Polygon
(MBAX48AS001_LINEAR). Re-stroke Vanes again stopping at same 6 points. At each point the
Linear Position Feedback (MBX48AS001_ZQ01) should be close to the Average of the Angular
Feedbacks (MBA11CG901_ZQ01) for opening and closing the vanes.

Stoke the actuator by corresponding IGV setpoint to avoid fast movement of the actuator. For
example for 20% actuator stroke IGV is 8.6%.

AVG ANG IGV POSN

Setpoint for IGV IGV POSN LINEAR (°) Calculated Delta
(°)

MBA11DG001 ANG POSN - POSN

MBX48AS001 - ZQ01 MBA11CG901 - ZQ01
POCO SETPOINT LINEAR

20

40

60

80

100

Open Direction

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 AVG ANG IGV POSN
Setpoint for IGV IGV POSN LINEAR (°) Calculated Delta
(°)

MBA11DG001 ANG POSN - POSN

MBX48AS001 - ZQ01 MBA11CG901 - ZQ01
POCO SETPOINT LINEAR

100

80

60

40

20

Close Direction

AVG OF CALCULATED DELTA

LINEAR IGV POSN
BETWEEN OPEN AND CLOSE
(%)
DIRECTION

X1 0 Y1

X2 20 Y2

X3 40 Y3

X4 60 Y4

X5 80 Y5

X6 100 Y6

MBX48AS001|LINEAR

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Phase 4: Trim Controller Adjustment

The trim controller adjusts the vanes accurately to the demand position. If the linear transducer
output perfectly relates to the vane angle and there is a perfect mechanical system the trim
controller output would be zero. Because this is never the case there is a trim controller output.
This output can be adjusted by a POLY function to minimize trim controller output. Force the
Output of the Trim Controller (MBA11DG001_ZQ11) and the Output of the Poly to 0 before start
adjusting the Trim Controller Run the vane from closed (actuator extended) to open (actuator
retracted) position by changing the set point. Stop approx. every 20% and note the setpoint in
degrees (MBA11DG010_XQ12) and the Actual Position in Degrees (MBA11CG901_ZQ01).
Repeat this in the closing direction and record the values at the same points. For each step
determine the average delta of the opening and closing values at the same Setpoint. Use the
Setpoint for each Vane as the X coordinate in the Poly and the calculated average Delta for this
point as the Y Coordinate to populate the Poly. After adjusting the Trim Controller, repeat the
same sweeps and verify that the Setpoint in Degrees and the Actual Position are close in both
directions opening and closing. Remove simulations after completing the adjustment.

Important is to adjust the IGV trim controller in IGV working range. So it can be from -8.5% in
case of new compressor design to 113% in case of IGV turn up function.

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 IGV/VGV SETP IGV POSN SP IGV POSN Delta IGV
(%) (°) (°) (°)

MBA11DG010 MBA11DG010 MBA11CG901 SP - Actual

XQ51 XQ12 ZQ01 Position

20

40

60

80

100

80

60

40

20

IGV average delta

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At the end adjust the MINMAX block of the IGV position setpoint. Check the angular feedback of
the IGV at minimum position (0% or -8.5%) and maximum position (100% or 113%) depending
on the DPTI settings. Change the value of G.VLE0.379 to angular feedback for maximum IGV
position or Open limit and change the value of G.VLE0.380 to angular feedback for minimum
IGV position or Close limit. Change the offset limit (LMT_OFFS) to 1.

After completion of all the procedure mechanical engineer will measure all vane angles at 100%
position for documentation.

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