Using LabVIEW, PXI, and CompactRIO to Develop a Testbed for the M15 Gas Turbine
System
"To eliminate the drawbacks of this
electropneumatic control system for M15-E
testbeds, we developed a digital control system
based on LabVIEW and NI hardware."
- Srikant Kumar, Aniba Solutions Pvt. Ltd (http://anibasolutions.com/)
The Challenge:
Developing a data acquisition and control system with real-time measurement and logging capabilities for an M15 gas turbine and testbed
subsystem.
The Solution:
Replacing existing instruments with a digital control system based on NI LabVIEW software, and PXI and CompactRIO hardware.
Author(s):
Srikant Kumar - Aniba Solutions Pvt. Ltd (http://anibasolutions.com/)
The 1241-RE class of ships is fitted with M15-E gas turbines (GTs) to propel them through the water. Two cruise GTs and two boost GTs drive a ship. In
the original version of the system, an electropneumatic control system operated and monitored the turbines. To eliminate the drawbacks of this
electropneumatic control system for M15-E testbeds, we developed a digital control system based on LabVIEW (http://www.ni.com/labview/) and NI
hardware. The system logs and stores all data from the time the turbines start running to the time they shut down, which provides a great deal of
information about GT performance over time. This vital information provides useful inputs for periodic maintenance and overhauling the GT.
We developed the testbed facility for an RE class M15-E GT using the LabVIEW Datalogging and Supervisory Control (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/209851) (DSC) Module. We also used a variety of NI hardware products including a PXI-1052 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/14111) chassis, a PXI-8108 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/206087) embedded controller, a
PXI-2567 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/12583)external relay driver, a PXI-6259 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/14129) M
Series DAQ device, a PXI-6229 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/14137) M Series DAQ device, an SCXI-1503 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/204198) resistance temperature detector (RTD) analog input module, an SCXI-1102 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/1654) thermocouple module, an NI PXIe-1078 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/209253)
chassis, an NI PXIe-4353 (http://sine.ni.com/nips/cds/view/p/lang/en/nid/208291) thermocouple module, an NI cRIO-9073 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/205621) real-time controller with a field-programmable gate array (FPGA), an NI 9505 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/202711) DC brushed servo drive module, and an NI MKD-1117 (
http://sine.ni.com/nips/cds/view/p/lang/en/nid/203351) rack-mounted monitor and keyboard.
We designed and simulated the various testbed subsystems, including the fuel system, the lubrication oil system, the cooling water system, and the
HP-AIR system using the LabVIEW DSC Module. We also used the LabVIEW DSC Module to create a human machine interface (HMI) and a supervisory
control and data acquisition (SCADA) system. The features that LabVIEW provides are powerful and customizable enough to meet our exact
specifications.
We also developed a throttle control system using PWM to rotate the throttle at a particular angle. We chose a cRIO-9073, an NI 9505 DC brushed servo
drive module, and a DC servo drive motor to operate this system.
The data acquisition and control system automates as much of the GT test process as possible. The system reports the status and readiness of the
engine, testbed accessories, and support systems. It controls a variety of functions including the GT startup sequence, the various GT operating modes,
the engine, the testbed accessories, and all support systems. It also protects the GT from unsafe operating conditions by monitoring alarms and warnings.
It is responsible for online measurement and monitoring of parameters from the GT as well as parameters from various testbed subsystems. The system
conducts vibration measurement, monitoring, and analysis. Lastly, the system we created reports all test results and provides an easily accessible online
data archive.
The data acquisition and control system has the following major subsystems:
(i) Engine Control System—This system controls the GT startup sequence and controls the GT and RG in various operating modes. It also protects the
GT from unsafe operating conditions.
(ii) Data Acquisition and Monitoring System—This system measures various test parameters from the GT, RG, and the test facility. These parameters
include engine speed, pressure, and temperature. In addition to measuring and displaying these parameters in numeric and graphic format, this system
supports required processing and storage functions.
(iii) Vibration Measurement System—This system measures vibration at various GT and RG locations. It also supports online monitoring and analysis of
vibration signals.
(iv) Operator Warning System—This system monitors and displays all alarm signals. Alarm indication is audiovisual and color coded.
Author Information:
Srikant Kumar
Aniba Solutions Pvt. Ltd (http://anibasolutions.com/)
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Figure 1: Fuel Oil System Simulation
Figure 2: The Second Fuel System
Figure 3: The Fuel System Process Running
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Figure 3: The Fuel System Process Running
Figure 4: The Fuel System Process
Figure 5: The Fuel System Process Running
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Figure 6: The Lube Oil Preservative System Running
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Figure 7: The Lube Oil System Running
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