Power Plant and Process Control Systemspdfs.findtheneedle.co.uk/12491..pdf · - Hot reheater accumulation control - Heat extraction control - Temperature control LP lines - Valve

Power Plant and Process Control Systems

Digital Turbine ControlSystems

System OverviewReference List

GEC-Alsthom Energie GmbH

Digital Turbine Control Systems - System Overview 3

Contents Page

ME 4012 process control systemViews on digital turbine control systems 4

Digital turbine control systems - Perspectives 4

Control system modernization ofexisting turbines - Perspectives 5

Layout diagram 6

Turbine controller 8

Control and instrumentation of the turbineauxiliary plant 8

Turbine monitoring 9

Turbine protection 9

Turbine temperature controller 10

Operator control and process monitoring 10

Turbine control systems - Reference list 11

System Overview

As all fields of engineering, power station technology has pro-gressed enormously during the last years. Especially in the field ofsteam turbines, new knowledge has been gained about materialstrength and long-term behaviour, flow dynamics and design, andhas turned the relatively simple turbine of the past into a hightecunit.

This advance in technical standards in power stations increases therequirements for plant safety, improved availability and maximumturbine life.

With our ME 4012 process control system a digital turbine con-troller is now available that meets these high demands and is capa-ble of recording and independently controlling every single process within the specified limits, thus reliably fulfilling the DVG guidelines.

Higher-level automated function groups ensure optimal interactionof the individual processes so that the entire industrial complex“Power station” with its huge capital expenditure can be operatedsafely and economical for a long time.

Let us take a closer look at a particular part of the power station:the turbine set. For this section alone, the ME 4012 process controlsystem has to meet very specific requirements for safe and reliablecontrol of the five main operating conditions

• starting and synchronization

• loading and power operation with power controller and frequencyinfluence

• controlled deceleration at load shedding and securing the stationservices at load shedding

• load ramp operation

• shut down.

Furthermore, the ME 4012 process control system continuouslymonitors the actual status of the plant so that the necessary conclu-sions for optimal plant operation can be drawn from any changesthat might occur. The aim of this enhanced turbine control systemis to ensure

• operational safety

• availability

• extended life expectancy

• convenient operator guidance and

• easy maintenance.

Throughout its long operational life the turbine set is to run and bemaintained at maximum efficiency.

Digital turbine control systems - Perspectives

With the development of the digital turbine controller, the HelmutMauell company was able to implement the experience and know-how obtained over many years in the

• development

• design

• manufacturing

• installation and

• commissioning

of control and instrumentation systems. The ME 4012 was devel-oped into a process control system that is completely open for allareas of block and turbine control. This also applies to processeswhich impose particularly strict requirements on the controller cycletime, such as turbine speed control.

Main functions of the turbine control system:

• Turbine controller (speed and power control)

• Turbine temperature controller (life expectancy and transient calculation)

• Turbine auxiliary plant (measurement, drives, closed-loop controls, function groups)

• Turbine load current protection (oscillation, expansion, temperatures)

• Automatic test of load current protection

• Turbine no-load current protection (overspeed, generator and tankprotection)

• Automatic test of no-load protection

• Turbine control room (operator control and monitoring, alarm logging)

• Central control system diagnostics, configuration anddocumentation

• Easy interfacing for connection to block control system based onthe SUB-NET process bus

Based on these functions, the utility industry is provided with aprocess control system which, using standard

• system hardware

• firmware

• documentation

• operator interface

economically and conveniently automates, monitors and controlsthe entire power station process which includes the

• steam generator

• turbine set

• auxiliary plant for operation and pollution monitoring.

The resulting advantages for the power supply companies is ourcontribution to new perspectives in digital turbine control.

4 Digital Turbine Control Systems - System Overview

ME 4012 Process Control System Views on Digital Turbine Control Systems


Control System Modernization of Existing Turbines - Perspectives

Digital Turbine Control Concepts

Control System Overall Concept

Conditionsfor future operation

Recommendationsfor future operation

DVG guide lines forplant safety

Life expectancyAvailability / Reliability

Extended safetyOperation monitoring

Primary control(frequency back-up control)

Secondary control(system characteristic control)

Block control reserveOverspeed protection

Fundamental protectionExtended protection

Temperature controller (TLG)Load limit facilityMP inlet control

Protection monitoringTurbine monitoring

Turbine auxiliary plant

Operator control and process monitoringLocal operator control

ME-VIEW

Central configurationand documentation

M

TLG report Logs and reports

Turbinecontroller

Local opera-tor control

Turbine tempe-rature controller

Turbineauxiliary plant

Closed-loopcontrol

Drive control

Signalconditioning

Turbinemonitoring

Turbine monitoringmeasuring system

Turbineprotection

Turbine protectionRS Test

Turbinecontroller

Turbine monitoringmeasuring system

Turbineprotection RS


Turbineprotection AS

Turbinecontroller

Automatedfunction groups

Turbine protectionAS Load current

Turbine protectionAS No-load current

Steam generatorcontrol system

SUB-NET process bus

M

ME 4012 digital turbine control: hardware system overview


Digital Turbine Control Systems - Layout Diagram

Binary/Analog Binary-

SUB-NET

Analog -input

Turbinetemperature

controller

Turbine loadpressurecontroller

Blockpower

coordinator

Turbine controller- Speed controller and speed master controller 2v3- Power controller and power master controller- MP inlet control- Live steam limit pressure control- Hot reheater accumulation control- Heat extraction control- Temperature control LP lines- Valve positioner HP, MP/LP

Turbine temperature controller- Life expectancy calculation- Transient limitation- Logging and reporting- Temperature control backup

Block power coordinator

Turbine auxiliary plaClosed-loop control

- Gland steam pressure- Gland steam tempera- Bearing oil temperatu- Condenser level cont- Condenser min. qty. c- MP bypass control wipressure and injection

Function groups- Function group Coolin- FG Condensed steam- FG Bearing oil, actuatin- FG Evacuation- FG Blocking steam- FG Bleeding- FG Water extraction- FG Turbine control

Steam generator- Coaling, pulverization- Air / flue gas- Coaling (fail-safe)- Feed-water- Superheater- Condensed steam- Long-range energy branch- Station auxiliaries service

Auxiliary plant- Flue gas desulfurization- DeNOx, NH3 tankage- Water treatment- Condensed steam treatment- Coal, lime supply- Ashes, gypsum disposal

#

+ -

K

M

S

F

#

n

P

N

f

FD

HD G~MD/ ND

Block control system

M F

Turbinespeed

controller

Closedcontro

Automatedfunctiongroups

DE

Radioclock

Events

Video printer

ME-VIEWworkstation

Kraftwerks-StatusÜbersicht BlockKalkförderungKohleförderung

Fr 08.Jul 94 Monitoranwahl:

Block console


AscheförderungAscherezirkulationLuft/RauchgasGasfeuerung

SpeisewasserregelungÜberhitzerFernwärmeauskopplungEigenbedarf

ArchivFr 08.Jul 94Monitoranwahl:













Plantinformation

system

Localoperator station

ME-VIEW-PM

ME-AIS

Plantmanagement

Gateway

Shift engineer console





LAN

Printerserver

Alarms

Process dataserver,

redundant


Channel 1

Prozeßbus

Channel 2 Channel 3

SUB-NET

Serial linkThird-party

system


Test

Limit valuesAnalog

input

Limit valuesAnaloginput

Limit valuesAnalog

input

lantl

ure controlerature controlture controlntrol

y. control withion control

oling wateram transportting fluid and rotary mechanism

n

Turbine no-load current protection- Overspeed- Condenser pressure- Bearing oil pressure- Tank protection- Generator protection- Tail blade protection- Shaft position

Protection monitoring No-load current- Electronic protection system- Hydraulic trip

Turbine monitoring- Turbine speed- Shaft oscillation- Bearing housing oscillation- Relative expansion- Shaft position- Absolute expansion- Axial thrust

Turbine load current protection- Sensor 2v3- Processing 2v3- Trip 2v3

Single test Quick-action stop valve

HD MDK X

#

+-

+

+

S

#

L L

Sensor andprocessing

2v3,trip RS

1v2

Single testQuick-action

stop valve

ND G~

ed-looptrol

Drivecontrol

SSV

TR

G

RV

& & &

Turbinen-welle

SS Turbine

LS 01

&

& 1>_

2 v 3 2s 0

SS Turbine

LS 01

&

& 1>_

2 v 3 2s 0

SS Turbine

LS 01

&

& 1>_

2 v 3 2s 0

PD-LAN (redundant)

DEDE#

+ -

K X

#

+-

++

S

#

S

F

L L

#

n

P

N

f

FD

HD GMD/

M

M F

ND ~



Archivl:




ArchivFr 08.Jul 94 Monitoranwahl:

ME-VIEWworkstation

DRP-LANBridge

Diagnosis and documentation room

CDWriter

Measuring anddiagnosis station

Document printer

Configurationand documentation

station

Modem

Telediagnosis

ME-VIEW-PM





CAE-SystemME-DRP


Turbine controller (TR)

As the turbine controller's modular design is based on the ME 4012standard modules, the system for industrial turbines can be of sin-gle-channel structure, whereas a two-channel structure with bump-less transfer can be implemented for the highest power ranges.

The functions of the turbine controller:

• Measuring data preparation

• Speed control

• Pressure control

• Power control

• Valve position control

• Control logics

• Alarm generation

• Operator guidance

Turbine controller special features:

• Controller cycle time of approx. 10ms

• Speed signal resolution: 0.5mHz

• Speed measuring accuracy: 2mHz abs. at 50Hz

Control and instrumentation of the turbine auxiliary plant(THR)

Besides the turbine speed and power control systems, the turbineauxiliary plant too is of great importance for the safe operation andcontrol of the turbine. Some of its main tasks are:

• Gland steam pressure control

• Gland steam temperature control

Using the ME 4012 standard modules, the system can be configured to implement clear and well-structured control solutionsfor the defined tasks.

The system comprises:

• Field units for measuring and instrumentation

• Field installation and cabling

• Measuring data preparation

• Binary signal conditioning

• Drive control

• Closed-loop control and power controller

• Alarm generation

• Automated function groups

• Operator control level

The main functions are:

• Control of the turbine auxiliary control loops

• Control of the servo drives

• Automated function groups for controlled operation

• Operator guidance at manual operating mode

• Operator control and monitoring from a central control room

100 rpm

1 min

600 rpm

1 min

3000

40

3300

(PI-Control response)

Dxd

350-500 ms

(P-Control response)

3150

3240

5 min 1 min

Dxw

99%

max = 5-7%

Turbine behaviour at start-up and load operation and load shedding

Target speed

Steady-state deviationdepending upon load andproportional band(Xp = 4-6%, V = 16-25)

Load shedding

Sycnhronizationphase w.r.t. to power

Load connection,load operation on network

Rotary mechanismoperation

Overspeed protection triggering (emergency tripping)

dndt

dndt

dndt = 300 r.p.s. =Turbine running time constant

tmin

1min

Turbine controller characteristics :- Cycle time : < 15 ms typ.- Speed measurement : + 2 mHz abs. - Resolution : 0,5 mHz

frequency

Turbine behaviour: start-up and load operation


Turbine monitoring

Derived from the investigations into plant safety and availability, theconcept of dynamic simulated tests of all sensors and modules formeasuring data preparation and limit value generation ensuresmaximum availability with only a minimum of expenditure. Also,thanks to the two-channel measuring data preparation and limitvalue generation, any due repairs can be attended to without hav-ing to interrupt turbine operation. Based on elaborate test reports,preventive actions (or measures) can be taken to monitor and slowdown material ageing.

Turbine monitoring comprises:

• Measuring data preparation with interface to the online dynamicsimulated test

• Signal evaluation and limit value generation

• Measuring data indication and alarm generation

Principal measurements:

• Turbine speed (accuracy: ±0.04‰ absolute)

• Shaft oscillation

• Bearing housing oscillation

• Relative and absolute expansion

• Shaft position

• Axial thrust

Turbine protection (TS)

The turbine protection covers all criteria that can cause damage tothe plant. If one of the criteria exceeds a permissible limit, the tur-bine protection interrupts the operation of the plant.

In compliance with the classification of protection criteria (VGBbrochure VGB-R 103-M "Monitoring, safety and protection equip-ment in steam turbine plants"), the turbine protection is structured insuch a way that it fulfills the requirements for reliability and availabil-ity of the overall system.

Turbine protection comprises:

• 3-channel overspeed protection (double redundancy)

• Limit value generation and signal linking

• No-load current tripping signal generation

• Online test facilities for all protection components

Main functions:

• Overspeed protection

• Fundamental protection(bearing oil and condensator pressure, shaft position, tank protection, generator protection, emergency stop)

• Extended protection(shaft oscillation, relative expansion, bearing temperatures, wastesteam temperatures, temperature difference HP, MP

The protection system is completely backed up by a redundant pro-tection system in all areas of signal processing. Wired OR logic isused to link the signals from the turbine monitoring with generalmachine protection. The redundant electromagnetic seat valves inorder to relieve the spring-loaded quick-action stop and servovalves are directly activated via a hard-wired N/C current NANDmodule. Moreover, the automatic test procedure on independentsubprocessors allows the turbine protection facilities - including thequick-action stop valve activation - to be online tested at any time,without significant impairment of the turbine operation.

Channel 1

Channel 2

Channel 3

Reserve

&

2 v

3

Channel 1Channel 2

Turbine shaft

Speed measurement :

Accuracy +/- 2mHz = 0,004 % at 50 Hz

Signal resolution 0,5 mHz

Signal sampling rate 5 msec.

Pulse amplifierTurbine

overspeedprotection

Turbine speedand power controller

Turbinespeed measurement

Turbine speed signal derivation and conditioning


Turbine control mimic diagram

Turbine temperature controller (TLG)

Taking into account various measuring values, the turbine tempera-ture controller computes the permissible transient values of the tur-bine's steam temperatures, performance and valve position. Inaddition, it constantly determines the degree of fatigue of those tur-bine parts which are subjected to heavy strains.

The integration of the TLG hardware in the turbine controller cabi-net and the direct connection to the process ensure that the TLG isoptimally linked to the plant’s control and instrumentationsystem.This allows, for example, to conveniently print out the col-lected data on the allocated TLG report printer or monitor of a localoperator station.

The TLG’s technical features:

• Process computer with 32-bit central unit

• Redundant SUB-NET process interface for all process data andcontrol commands

• Hard disk drive

• TLG report printer

• Monitor interface

• Key board interface

Main tasks of the TLG:

• Life expectancy calculation

• Transient limitation to prolong material life

Operator control and process monitoring

Operator control and process monitoring of the digital turbine con-trol systems (TLT) can be implemented in two ways:

1. Mauell - TLT works as a stand-alone process control systemwhich is linked to a higher-level third-party process control system.

The TLT is linked to a higher-level block control system via a serialinterface.

2. Mauell - TLT is an integrated part of the higher-level ME 4012process control system.

In comparison to the stand-alone system, this solution offers anumber of advantages:

• uniform design

• uniform documentation

• uniform alarm processing

• uniform operator control and process monitoring philosophy

• central configuration and diagnostics

An ME-VIEW-PM system is used for local operator control andprocess monitoring.

Furthermore, the simulation and test equipment can be started bymeans of an operator’s panel provided for each turbine controllerinside the cabinet.


Turbine Control Systems - Reference List(Excerpt)

Cus

tom

erLo

catio

nB

lock

Turb

ine

*O

utpu

tFu

nctio

nTC

SO

EM

(MW

)

ES

KO

M E

ngin

eerin

g G

roup

, Süd

afrik

aM

atim

ba1

- 6M

E6

x 66

5T

S, T

LGM

E 4

012R

L (T

eila

nl.)

AE

ES

KO

M E

ngin

eerin

g G

roup

, Süd

afrik

aLe

thab

o1

- 6M

E6

x 62

0T

S, T

LGM

E 4

012R

L (T

eila

nl.)

AE

EN

SO

Gut

zeit

OY

, Fin

nlan

dIm

atra

1M

E92

TS

, TR

ME

401

2RL

AE

RW

E E

nerg

ie A

G/V

SE

Ens

dorf

C1

ME

315

TR

, TLG

ME

401

2RL

AE

E.O

N /

Gro

ßkr

aftw

erk

Fra

nken

Fra

nken

I2

ME

400

TR

ME

401

2RL

AE

E.O

N /

llse

Bay

ernw

erk

Ene

rgie

anl.

Gm

bHP

lein

ting

QM

E42

5T

HR

ME

401

2RL

E.O

N /

llse

Bay

ernw

erk

Ene

rgie

anl.

Gm

bHP

lein

ting

AA

EG

300

TS

, TH

RM

E 4

002-

Ste

ueru

ng, R

iva-

alt

AE

MD

Pap

ier /

Hai

ndl P

apie

r A

ugsb

urg

IVM

E20

TR

ME

401

2RL

AE

Voe

st A

G, Ö

ster

reic

hLi

nz4

ME

85T

R, T

S, T

LGM

E 4

012S

NA

E

VS

EE

nsdo

rf A

VII

AE

G11

0T

S, T

RM

E 4

012R

LA

E

Hal

le-T

roth

aH

alle

GT

+DT

SIE

INT

ME

401

2RL

Öst

erre

ichi

sche

Dra

ukra

ftwer

ke A

GV

oits

berg

1M

E33

0T

S, T

LGM

E 4

002

+ R

iva

AE

GE

W K

öln

Nie

hlI

ME

323

TR

, TS

ME

401

2SN

AE

PC

K S

chw

edt

Sch

wed

tG

AE

90T

R, T

SM

E 4

012S

NA

E

PC

K S

chw

edt

Sch

wed

tG

AE

90T

R, T

SM

E 4

012S

NA

E

Pei

ßen

berg

er K

raftw

erks

ges.

Pei

ßen

berg

III

ME

40T

R, T

S

ME

401

2SN

AE

IEC

Isra

el E

lect

ric C

orpo

ratio

n Li

mite

dR

uten

berg

5 - 6

ME

2 x

550

TS

, TLG

ME

401

2RL

+ R

iva

AE

MV

A K

iel

Kie

l1

B&

V9

TR

, TH

RM

E 4

00

Rhe

inbr

aun

AG

Wac

htbe

rg2

ME

90T

SM

E 4

012S

N +

HD

-Ste

ll.-R

egle

rA

E

ST

EA

GLü

nen

7A

EG

350

TR

, TS

ME

401

2SN

AE

VK

RK

nepp

erC

AE

G35

0T

R, T

SM

E 4

012S

NA

E

IEC

Isra

el E

lect

ric C

orpo

ratio

n Li

mite

dM

D-B

, Had

era

1, 3

ME

2 x

550

TH

R, T

S, T

GM

E 4

012R

L +

Riv

aA

E

NO

K T

heiß

, Öst

erre

ich

/ EV

NT

heiß

BG

AE

250

TR

, TS

ME

401

2SN

AE

RW

E E

nerg

ie A

GF

rimm

ersd

orf Q

QM

E30

0T

RM

E 4

012S

NA

E

Con

elB

raila

1LM

Z2

x 21

0T

RM

E 4

012S

NA

E

Tha

Too

mT

haila

nd1

- 2G

AE

2 x

160

TR

, TS

ME

401

2SN

AE

Sw

B E

rzeu

gung

, Bre

men

Haf

en6

ME

300

TR

, TS

ME

401

2SN

AE

Ene

rgie

-Ver

sorg

ung

Nie

derö

ster

reic

h A

GD

ürrn

rohr

AM

E32

0T

S, T

LGT

S: M

E 4

012S

N, T

R: R

iva

AE

Bra

unsc

hwei

gisc

he K

ohle

nber

gwer

ke A

GB

usch

haus

2M

E35

0T

LG, T

SM

E 4

012S

N

KE

KK

osov

o1

ME

350

TH

CM

E 4

012S

NA

E

VA

LAF

innl

and

-G

AE

230

TR

, TS

ME

401

2SN

AE

KE

KK

osov

o2

ME

350

TR

ME

401

2SN

Ste

llung

sreg

ler

AE

AW

G W

uppe

rtal

Wup

perta

lT

urb.

A25

TS

ME

401

2SN

ES

KO

M E

ngin

eerin

g G

roup

, Süd

afrik

aM

atla

1 - 6

ME

6 x

600

TR

ME

401

2SN

AE

ICP

ET

S. A

. Buk

ares

tR

umän

ien

TR

ME

400

, ME

401

2SN


Turbine Control Systems - Reference List(Excerpt)

Cus

tom

erLo

catio

nB

lock

Turb

ine

*O

utpu

tFu

nctio

nTC

SO

EM

(MW

)

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 1

Mün

chen

DT

1M

E83

TR

, TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 1

Mün

chen

GT

1S

IE V

9499

TR

, TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 1

Mün

chen

GT

2S

IE V

9499

TR

, TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 2

Mün

chen

DT

Als

tom

150

TR

, TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 2

Mün

chen

GT

1G

E M

ark

V15

0IN

TM

E 4

012S

N

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 2

Mün

chen

GT

2G

E M

ark

V15

0IN

TM

E 4

012S

N

Sta

dtw

erke

Saa

rbrü

cken

, HK

W R

ömer

brüc

keS

aarb

rück

enM

E90

TR

, TS

ME

401

2SN

E.O

N K

raftw

erke

AG

Hey

den

ME

920

TR

ME

401

2SN

HE

W A

GT

iefs

tack

-Ers

atz

TU

7M

E16

0T

R, T

S, T

LGM

E 4

012S

NA

E

MV

A S

tape

lfeld

Sta

pelfe

ldS

iem

ens

14T

RM

E 4

012S

N

RW

E E

nerg

ie A

GH

ucki

ngen

1 - 2

ME

2 x

315

TR

, TLG

ME

401

2RL

AE

EP

ON

, Nie

derla

nde

Ber

gum

1, 3

ME

2x30

0T

LG, T

RLe

itger

ät: M

E 4

012S

N, T

R:R

iva-

alt

AE

VE

AG

, Ber

linJä

nsch

wal

deA

- F

LMZ

6 x

500

TR

, TS

, TLG

ME

401

2RL

AE

ES

KO

M E

ngin

eerin

g G

roup

, Süd

afrik

aG

root

vlei

1 - 6

6 x

200

TS

, TLG

ME

401

2SN

AE

Gas

turb

ines

:

EnB

W K

raftw

erke

Altb

ach

GT

AS

IE V

93T

RM

E 4

012S

N

Fre

uden

berg

Wei

nhei

mG

T 1

6,3

TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 2

Mün

chen

GT

1G

E M

ark

V15

0IN

TM

E 4

012S

N

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 2

Mün

chen

GT

2G

E M

ark

V15

0IN

TM

E 4

012S

N

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 1

Mün

chen

GT

1S

IE V

9499

TR

, TS

ME

401

2SN

Sta

dtw

erke

Mün

chen

, HK

W S

üd -

GU

D 1

Mün

chen

GT

2S

IE V

9499

TR

, TS

ME

401

2SN

* A

bbre

viat

ions

TR

T

urbi

ne s

peed

and

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Power Plant and Process Control Systemspdfs.findtheneedle.co.uk/12491..pdf · - Hot reheater accumulation control - Heat extraction control - Temperature control LP lines - Valve