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KELI 2008Field Report :Control System ME 4012 forgas turbine A (93.0 V) at unit 4Power plant Altbach / Deizisau
EnBWElektro-/ LeittechnikDipl. Ing. David [email protected]+49 7153 602 - 55 24 0
06th of Mai 2008
Helmut Mauell GmbHDipl. Ing. Detlef [email protected]+49 2053 - 13 478
30 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Table of contents
1. Tasks of the new Gas Turbine Control System ME 4012 slide
• Principle of process Combined Cycle Unit 4 3
• ME-VIEW scheme of control loops and functional groups 4
• Air system and combustion process of the gas turbine 5
• Air / exhaust gas of the gas turbine 6
• Ignitiongas and naturalgas system 7
• Heating oil system of gas turbine (Draft sketch according to VGB R 170 C) 8
• Deionized water injection for NOx-reduction during oil operation 9
• Auxiliary oil / lube oil system of the gas turbine 10
• Turbine Protection System (Turbine surveillance supervision) 11
• Electrical Integration 12
2. Solution: Functions and Control Strategy
• Speed-, power-, frequency- and temperature-control 13
• Speed-, power-, frequency-, temperature- and fuel-control 14
• Turbine controller (1oo2), Turbine protection (2oo3, SIL3) 15
• Turbine speed measurement for controller and fail-safe (SIL 3) overspeed protection 16
• Gas turbine protection: Overview machine protection 17
• Gas turbine protection: Overview fuel trip system 18
• Operator system ME VIEW and location involvement 19
• Automation Unit AE 4012 and location involvement 20
3. Achieved objectives and operational experience: slide Control System replacement of gas turbine A
• Turbine behavior during start-up and load operation 21
• ME4012 System overview Unit 4, Altbach / Deizisau 22
• Control System characteristics 23
• Contract Award 24
• Planning and Manufacturing 24
• Mounting 24
• Commissioning 25
• Acceptance 26
4. Summary after 5 years of plant operation 27
5. Reference List Process Control System ME4012: Gas turbines and Combined Cycle Plants 28
2 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Power plant Altbach / Deizisau, Unit 4
3 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Principle of process Combined Cycle Unit 4
M
M
Steam power Injection
Steam turbine
200MW Waterpipes
Flue
gas
Feed water flow
Cooler
Demineralize
Sek. - Prim.superheater
Fire Area
Burner
Combustionchamber
OilGas
Compressor
50MW
Turbine
Oil
Gas
Oil
Gas
Boilerdrum
4 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:ME-VIEW scheme of control loops and functional groups
Übersicht des Lieferumfanges
5 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:air system and combustion process of the gas turbine
6 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Air / exhaust gas of the gas turbine
7 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Ignitiongas and naturalgas system
Automatic switch over of operation modes:Diffusion to pre mixed operation
8 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME4012:Heating Oil system of gas turbine (draft sketch according to R170C)
9 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Deionized water injection for NOx reduction during oil operation
10 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Auxiliary oil / lube oil system of the gas turbine
Turning gear(Hydro motor)
11 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Turbine Protection System (Turbine surveillance supervision)
12 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
• Tasks of the new gas turbine control system ME 4012:Electrical Integration
13 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy Speed-, power-, frequency- and temperature-control
Coordinator
Valveposition
controller
Powercontroller
Speedcontroller
Temperaturecontroller
Setpointgeneration
powerSetpoint
generator speedSetpoint
generationtemperature
setpointSpeed Power
setpointTemperatur-
sollwert
Ramp function
generatorSynchronizer Mode of
operationFrequency Exhaust
temperature
Turbinespeed
Electricalpower
M
M
n
P T
M
Flowcontroller
Deionized water
Setpointdeionized water
injection
Deionized water injection(Oil > 25MW)
Exhausttemp.
> 25MW asynchronous balanced mode
F
50MW
Oil-ESV Oil-CV Gas-ESVGas-CV
CompressorTurbine Deionized
water- CV
Mas
ter
Slav
e (fu
ll in
terf
ace
and
proc
essi
ng re
dund
ancy
)
14 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy: Speed-, power-, frequency-, temperature- and fuel-control
Deionized water injection forNOx reduction in oil operation
iCoordinator(bumpless
switch)
Setpointgeneration
amount of fuel
Flowcontroller
Shares plateGas / Oil and
automatic fuelswitching,
Base:Energy content /
heat balance
Fuel
Oilflow
Oil-CVposition
EHC-position
Gasflow
Gas-CV-position
EHC-position
Speedcontroller
Speed setpoint
Powersetpoint
Temperaturesetpoint
Ramp functiongenerator Synchronizer
Turbinespeed
Electricalpower
Exhausttemperature
Powercontroller
Temperaturecontroller
Setpointcontrol power
Setpointgenerator speed
Setpointcontrol
temperature
Operationalmode
Frequency
Setpointgeneration
deionized water
Valveposition
controller
Fuel
Poweradjuster
Deionizedwater flow
Deionized waterCV-position
MMode of operation
15%
60%
100%
Synchronisation300°C 396°C
0 TC°
Start up setpoint diagram
Valve positioncontroller
EHC-positioncontroller
FlowcontrollerExhaust
temperature
Electricalpower Flow
controller
Valve positioncontroller
EHC-positioncontroller
15 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy Turbine controller (1oo2), Turbine protection (2oo3, SIL3)
Turb
ine
Gov
erno
r C
hann
el A
Turb
ine
Cha
nnel
BG
over
nor
Life trip systemChannel 1
Life trip systemChannel 2
E/H-ConverterServodrive
Servodrive
Oil-ESV Öl-CV
Servodrive
Gas-ESV Gas-CV
2 oo3GT
Over speed protection
(2 oo3) SIL 3
1
3
1
3
Realtime funktionsCPU-Functional Area 2
< 10ms
Funktion group controlsPower control setpointPower controllerFrequency influence Flue gas temp. controller Fuel controllerCombustion controllerDeionized water injection Anti surge control Turbine protection 2 oo 3
ME-DRP ME-VIEW
Speed control setpointSpeed controllerAcceleration MeasurementFuel valve position controller
Time critical realtime funktions
CPU-Functional Area 1< 4 ms
CPU
Analogoutput
Analoginput
Pulseinput
Master
Analogoutput
Binaryoutput
Analoginput
CPU
Slave
Diagnostics andDocumentation Operator station
Alarms, SOE,Protocol
LANSUB-NET
Pulseinput
Life trip systemChannel 3
Binaryoutput
E/H-ConverterServodrive
Pulsepre-amplifier
and decoupling
AE4
012
AE4
012
AE4012
16 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control StrategyTurbine speed measurement for controller andfail-safe (SIL 3) overspeed protection
Digital speed measurement :Accuracy : 0,004 % = +/- 2mHz at 50 Hz netw. frequencySignal resolution : 0,5 mHzSignal scan cycle : 4 msMeasuring range : >3 - 3600 U m n Long-term- and temperature- stability due to digital acquisition and processing
i-1
ME4012 Processinterface
Pulse pre-amplifierChannel 1
Channel 2
Channel 3
Turbineshaft
Reservedetector
IE2FZ
IE2FZ
IE2FZ
Turbineoverspeed
protection 2oo3SIL3
2 oo
3
&
DW channel 1DW channel 2
DW channel 3
Emergencyshut off valve
IE2 FZ
Turbinespeed
measurement1oo2
I/O- Bus
Speed andpower controller
AE4012
SUB
-NET
17 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy Gasturbine protection: Overview machine protection
Failsafetrip
module DW-Modul 1
Quarzcomparator DWDW DW DW DW DW DW DW DW
Life trip signal tranfered as Failsafe trip signal
Turbine controller(Slave)
Turbine controller(Master)
+L1 +L2
+L3
Function group Turbine control
1 1 1
Generatorprotection
SUB-NET
Channel 1 Channel 2 Channel 3
# #
Life trip system
Test programoverspeeddetector
24V +L124V +L224V +L3
emergency stop(Turbine trip)
Failsafe trip system 2 oo 3, SIL 3Overspeed protection
Life trip system 2 oo 3Electrical and mechanical trip criterions
Control oil
Failsafefuel
protectionsystem(2 oo 3)
Failsafetrip
module DW-Modul 2
Failsafetrip
module DW-Modul 3
Quarzcomparator
Quarzcomparator
# Criterion permutation
Fuel control valve
T.-protection latch>3 turns min-1
Turbine protectionmanual trip (2 oo 3)
LSN24
&& &2 oo 3
&t 0
LT FST
LT LT FST
#
FST
LT FST
LT LT FST
FST
LT FST
LT LT FST
FST
&& &2 oo 3
&t 0
# #
Pi
Fail-Safe 2 v 3 (EAM)
Turbine hydraulicsystem
Seatvalve
Test programhydraulic trip
block
Seatvalve
Hydraulic tripblock 1 oo 2
18 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy Gasturbine protection: Overview fuel trip system
Seatvalve
Overspeed protection 2 oo 3 (SIL 3)
M
M < 60% iffusiond
operating
Load
> 60% Loadasynchronous balanced operating low NOx
Hydraulictrip block 1 oo 2
Fail-Safeshut off valve
Control oil
Prop
ane
gas
M
Combustion chamber
Life trip system 2 oo 3Turbine controller 1v2
2oo3Fail-Safe fuel trip (SIL3)
Venting system
2. Shut-offvalve
1. Shut-offvalve
Fuel CV ESV 1 ESV 2
Pilot flame
Pilot lightIgnitor
FuelBurner
Turbineshaft
19 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control StrategyOperator system ME VIEW and location involvement
Controlroom Unit4GT-A
Relay room HKW 2
ME-DRPServer /Client
VIEW-Switch 1
PD-Switch 2
Distributed coupling ME4012 Distributed coupling ME4012
DRP-Switch(Rail)
RouterEnBW
Management systemPI-System
DRP-LAN
GatewayPC
VIEW-LAN
PD-Switch 1
VIEW-Switch 2
ME-VIEWClient
ME-AIS ME-DRPClient
RAID5
RAID5
Controlroom HKW 2
ME-VIEWClient
ME-VIEWClient
Balanceprotocol
Documentation VGB standard R 170 C
On-line features: -- Diagnosis -- Configuration -- Simulation
20 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control StrategyAutomation Unit AE 4012 and location involvement
Gas turbine
Fail-Safelogic
TC 1TP 1
TC 2TP 2
TP 3
~
~
Fail-SafeSystem
Turbineprotection
Burnerprotection
Steppingcontrol drives
~
~
Poweradjuster
Turbine controller, Turbine protection Turbine, burner, flue gas flap
Flame /burner
surveillance
~
~
Auxiliarycabinet
Shaftvibration
measurement
Couplingrelays
Steam generatorauxiliary power
Hardware signal exchanges: - Control steam generators - Daily oil tank - Operating load distribution
start-up device / alternator excitation -
SUB-NETCoupler
SUB-NETCoupler
SUB-NET Level B
SUB-NET Level A
Multi-functions-processor
UVIEWAutomation
unitAE 4012
UVIEW SUB-NETCoupler
SUB-NETCoupler
Binary-Input/Output
Analog-Input/
Output
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Multi-functions-processor
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Binary-Input/Output
Analog-Input/Output
Steppingcontrol drives
Steppingcontrol drives
marshalling rack marshalling rackmarshalling rack
PD-Switch 2PD-Switch 1
Automationunit
AE 4012
Automationunit
AE 4012
21 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience Turbine behavior during start-up and load operation, total system integration, efficient control algorithms, high degree of automation
Xw
Turbine controller features:- Cycle time < 4 ms typ.
Speed Measurement (digital):- Accuracy: +/-2,0 mHz abs.- Resolution: 0,5 mHz
22 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience ME4012 System overview Unit 4, Altbach / Deizisau
Control Room Unit 2Control Room Unit 4
LWK
Relay Room Unit 2
Relay-Room Unit 4 (200 MW ST / 50 MW GT)
Power adjusterStepping control drives
Flue gasemissionComputer
30m
250m
SUBNET B-Level
SUBNET A-Level
30 m
SNCAN
250 m
Electronic RoomUnit 2 9,5 m
LWL
250 m
USVUSV
AE4012Turbine protectionTurbine controller
AE4012Turbine burnerExhaust flap
ME4002SFail-Safe logic
Turbine protectionBurner protection
CAN-Bus only for cabinet internal surveillance
Auxiliary CabinetFlame burner surveillance
Burner surveillanceShaft vibration measurement
Coupling relays
AE4012Steam GeneratorAuxiliary power
Hardwired signal exchanges:
- Control steam generators - Daily oil tank- Operating load distribution - Start up device / alternator excitation
GatewayPC
Railswitch
Router
Splicebox
Hardwired Signals
EnvironmentOffice
Client
Client Client Client
EMI
Alarms Balance protocol:- Performance - Work - Operating Hours - Consumption - Cooling water diary
ME-DRPClient
ME-DRPServer
Documentation Diagnosis
Projektdatabase
ME-AIS
PI-System
Server 1 Server 2
Switch
Fibre optic cable (FOC)
FOCFOC
23 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience Control system ME 4012 characteristics for GT-A
• Plant functionality corresponds to the expectations of the plant operator
• Old documentation evaluated with red marks updated or scrapped
• New documentation strictly according VGB Directive: R 170 C
• Improving the control behaviour and the stability of operating transitions
• System-hardware and -software based on standard components of the Process Control System ME 4012, (replacement for Transidyn (controller), Transicont Protection), Simatic P and N)
• Redundant, highly accurate and extremely fast speed detection / control
• High availability with full redundancy of the overall system: - Signal interface, - processing, - communication, - Digital valve positioner (Cycle Time: < 4 ms) - Operator system
• Fully message processing with a time stamp at the signal source: accuracy and resolution: 1ms
• Turbine protection: - Over Speed Trip (SIL3, 2 oo 3)
- Machinery protection (2 oo 3) - Rapid fuel shutdown (SIL3, 2 oo 3)
24 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Contract Award: August 2001
Mauell won the competition although:not machinery supplier, not Station-control system.
Planning and Manufacturing: up July 2002
Control strategy:- Implementation old / new through intensive cooperation Mauell / EnBW.- Mauell adopted the plant functionality to the state of the art.- Existing weaknesses were analyzed and eliminated by new concepts.
Mounting: September / October 2002
During the next major GT revision.
3. Achieved objectives and operational experience in the power plant Altbach / Deizisau
25 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Commissioning: January / February 2003
• Re-commissioning of fuel oil after 13 starts• Re-commissioning of fuel gas after 8 Starts• Optimization of all transitions• Involvement in the site control system: - PI- System (Process Information System) - Unit Control System - operational load dispatcher
3. Achieved objectives and operational experience in the power plant Altbach / Deizisau
26 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Acceptance: March 2003
Extensive functional testing of the turbine control:Automatic start-up of the gas turbine to rated speedAutomatic SynchronizationAutomatic load increase at about 7 MW / min. to base loadSpeed controller load operation:switching speed controller to load controller under loadInterception security from full load to house load (GT or Unit 4)Redundancy test at all operating conditions and loadsFlying fuel change (gas / oil and oil / gas) under loadTesting the primary controlTesting the limit frequency controlHot start testsTrip tests of protection system(Shaft vibration monitoring, over speed, fuel-trip)
3. Achieved objectives and operational experience in the power plant Altbach / Deizisau
27 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Summary: (After 5 years of plant operation)
Excellent system technology with outstanding performanceVery good teamwork of EnBW / Mauell employees in the fieldof special process engineering expertiseHighest level of automation to secure / easy and fast unit start-upModern control concepts for robustic and efficient plant operationFully Integrated Control concepts for all operating modes and transitionsReducing the risk of “combustion chamber drone“High reliability for all applicationsLong-term assets-backed operation (spare parts and service)
4. Summary
28 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Reference List Process Control System ME4012:Gasturbines and Combined Cycle Plants
No. Plant Operator Country ManufacturerDT / GT
Steam turbine /Gas turbine Function
1 HKW Halle / Trotha D Siemens / SiemensSiemens V64.3
60 MW /25 MW
Serial integration of GT-and DT-control system inthe Process ControlSystem ME 4012
2 Stadtwerke MunichHeizkraftwerk SüdCombined Cycle 1
D Siemens / SiemensSiemens V94.1
105 MW /2x 100 MW
Plant Control SystemME 4012 for control andprotection
3 Stadtwerke MunichHeizkraftwerk SüdCombined Cycle 2
D ALSTOM Power /
General ElectricFrame 9E
140 MW /
2x 140 MW
Plant Control SystemME 4012 for control andprotectionIntegration of process-businto Mark 5-GT-controlsystem
4 EnBW PP Altbach /Deizisau, GT-A
D Siemens V93.0 50 MW Plant Control SystemME 4012 for control andprotection
5 Industry Power PlantCarl Freudenberg,Weinheim, GT1
D Ruston Tornado 6,3 MW Hard-wired interfacing toUnit Control SystemBoiler 4
6 Industry Power PlantCarl Freudenberg,Weinheim, GT2
D TurbomachCaterpillar, TaurusTaurus T60
5,5 MW Hard-wired interfacing toUnit Control SystemBoiler 5
29 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
A01.4012.11E08
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