2682606 Steam Turbine Protection System

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Instrumentation & ControlAl Khobar Roadshow, 24 July 2006

Federico CalzolariI&C Product Engineering


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Why a New Controller?

Aging Controls

Maintenance Activity Reliability issues Excellent cost/benefit ratio

Reduction of operatorsintervention Spare parts Turbine Life Extension Possibility to Change Parameters


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Mechanical Governor ReplacementExample: Franco Tosi Turbine


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Mechanical Governor ReplacementExample: Franco Tosi Turbine


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Ansaldo Energia Solution

To supply a steam turbine automation system that

provides a truly integrated solution Minimize the different types of hardware and software Minimize mechanical modification on the existing turbines Deliver information to operators and decision makers in a

single, consistent format


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Steam Turbine Control System

Steam Turbine Control System (STCS)

Microprocessor-based distributed digital control system Designed for controlling and monitoring all types of steamturbines

Modular and flexible system

Todays control with tomorrows requirements Expandable Advanced control capabilities

Independent system jointly developed with ABB EnergyAutomation


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Steam Turbine Control SystemMain Functions

STCS functions

controlling sequence management data acquisition operating station data storage diagnostic interface with

external systems


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Steam Turbine Control SystemTypical System Architecture

C-NET (Redundant Control Network)

FIELD

STEAM TURBINE CONTROL,MONITORING & PROTECTIONSYSTEM (STCS)

Configuration &Maintenance station

REDUNDANT ETHERNET TCP/IP OPC server protocol

Tenore NTOperator Station

CLIENTCLIENT

ANSALDOANSALDO

HARDWIRED

Alarm Printer

Tenore NTOperator Station

TSI Cabinet

PLANTDISTRIBUTED

CONTROLSYSTEM

Cabinet dimensions [mm]:

800 (W) x800 (D) x 2200 (H)

Laser Printer

Ethernet for Printers


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Steam Turbine Protection System (1/2)

The steam turbine tripping system comprises all thelogic necessary to protect the machine.

During a retrofit it is necessary to coordinate themechanical and hydraulic modifications with theelectronic control system requirements.


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Steam Turbine Protection System (2/2)

! Three channel, fail safe principle:Trip, if more than 1-channeldeenergized

! Triple sensors for the mostimportant protection

! Equal trip logic in each channel

! Independent electronicoverspeed trip

! Trip memory and resetting device

! 2oo3 voting of the outputs viael./hydr. Tripping - Unit

! Online testing of all trip channelsvia test program.

- OUTLET PRESS.

- EXTRACTION PRESSURE

- LUBE OIL PRESS.- SHAFT POSITION

- THERM. STRESS

- LEVEL LUBE OIL TANK

- BEARING TEMPs.

- SHAFT - VIBRATIONs

- BOILER PROT.

- GEN. PROT.

PROTECTION CONDITIONS (examples):

ELECTRICAL COMMANDSFROM TTS

Normal Functioning Electrical commands from TTS ON P out = 5-150 bar

Trip Condition OFF P out = 0 bar

PinPressure

from lube oil

pump(5-150 bar)

PoutPressure to

servomotorsSAFETY SYSTEM

2oo3 - Hydraulic Tripping Unit

Electrical commands from TTS


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Additional ControlsFunctional Groups and Turbine Run Up

Auxiliary Automation(Functional Groups)

Lube oil system Turning gear and

lifting oil system Draining system

Gland steam system Control oil system

Turbine Run Up (TRU)

Automatic start-up & shutdown system Increase availability Avoid operator errors and aborted starts


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Additional ControlsThermal Stress Calculation

Rotor Stress Evaluator (RSE)for calculation of

Turbine Thermal Stresses Gradient limits for starting-up

and loading Limit values for alarms

and trips

Advantages Time saving during steam turbine start-up Economic saving during steam turbine start-up Easier operator supervision functions


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Turbine Supervision

Old steam turbines Equipped with no

supervisioninstrumentation

Mechanical devicesdetecting main variables

only Lower reliability

New supervisory equipment Not only Electronics Feasibility study realized

with mechanical experts Design of the modifications On-site manufacturing Huge benefits in design

phase when OEM involved


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Remote Monitoring, Diagnostics

2 diagnostic levels

Basic diagnostic tools Integrated with the operator interface Basic Predictive Maintenance

Advanced diagnostic systems Monitors the dynamic signals In depth analysis Advanced Predictive Maintenance with Technical Support


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Basic Diagnostic Tool - Overview

Allows continuousinformation on themachinery status

Stores and processes fielddata to create reports and

trends

Overview at plant level,plant local areas and

individual machinery


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Basic Diagnostic ToolRe.M.S. (Remote Monitoring System)

Real time graphical operatingparameters and trends ofmachines / plant

Selection of various parameters Transfer of logic diagrams,

control parameters and settingsand system diagnostics

Faster evaluation of possibleanomalies

Improved commissioning1

T E N O RE N T

T e nor e NT ac q uis is c e,e l a b o r a e v i s u a l i z za l ei n f o r m a z i o n i s u g l ia l l a r m i a t t r a v e r s op a g i n e g r a fi c h e et a b u l a t i e d i nd i c aa l l o p e r a t o r e c o m ea c q u i s i r e e d u t i l i z za r et a l i i n f o rm a zi o n i .

Headquarter /Client Hub Site


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Advanced Diagnostic System (1/2)

Why Advanced Diagnostic System? Store and analyse data

Perform quick and effective troubleshooting Improve Availability Clear and quick exchange of information with the Operator Technical support by Ansaldo

TVA System The system for data collection and remote monitoring The solution for advanced predictive maintenance

Rotor Vibrations

GT & ST Run-up, Shut-down, Thermodynamic Parameters Generator Electric Parameters


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it works on 3 levels of competences:

- Expert Centre (Regional) (functional diagnostic, support to Operator)

- Fact Finders and Specialists (structural diagnostic, support to Maintenance)

- Product Engineering (Headquarter) (design analysis, high level specialists)

Technical support to operating units

Advanced Diagnostic System (2/2)


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Power Plant

Expert Centre Expert Centre Solution

?Engineering department

Advanced Diagnostic System:Problem Solution


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Expert Centre

Monitor multiple plantssimultaneously

Staff optimisation

Concentrated OEM expertise

Broad range of data miningand advanced design anddiagnostic tools

Faster problem resolution

POWERPOWER STATIONSTATION

POWERPOWER STATIONSTATIONPOWERPOWER STATIONSTATION


MODEM

MODEM

MODEM

MODEM

MAIN DIAGNOSTIC SITE


MODEM


POWERPOWER STATIONSTATIONPOWERPOWER STATIONSTATION


MODEMMODEM

MODEMMODEM

MODEMMODEM

MODEMMODEM

MAIN DIAGNOSTIC SITE


MODEM


MODEMMODEM


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Power Plant Security (1/3)

Melissa 26 March 1999 >= 100,000 hosts infectedCodeRed 19 July 2001 >= 350,000 hosts infected

Slammer 25 January 2003 >= 75,000 hosts infectedBlaster 11 August 2003 >= 500,000 hosts infectedSasser 30 April 2004 >= 1,000,000 hosts infected

+500 new malicious programs per month worldwide


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Plant security as industrial added value Industrial mission continuity Power plant availability

Industrial plant security Attack/intrusion prevention Consequence minimization Key factor in evaluating

plant operational continuity

Essential for critical infrastructures Power plants Electricity distribution Water Desalination


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Global Security Program Physical security Logical security Operational security

Power Plant Securitywith anintegrated approach


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Success Stories:Steam Turbine Control System Replacement

Gela Refinery Power Plant (ENI Group) Franco Tosi 70 MW steam turbine with double controlled

extraction Complete replacement of Mechanical Hydraulic

Controller by new Digital Electro-Hydraulic ControlSystem Speed and load controller Turbine Tripping System Auxiliary System Automation

Turbine Supervisory Instrumentation Automatic Run-up Sequence


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Summary

Ansaldo Energia own Technology

New unit development applicable to retrofit anyturbine technology

Effective and efficient

State-of-the-art predictive approach to maintenance


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Instrumentation & ControlAl Khobar Roadshow, 24 July 2006Federico Calzolari

I&C Product Engineering

Documents

2682606 Steam Turbine Protection System