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Energyneeds Impulses
KELI 2008
Field Report :Control System ME 4012 for gas turbine A (93.0 V) at unit 4
Power plant Altbach / Deizisau
EnBWElektro-/ LeittechnikDipl. Ing. David Maier [email protected]
+49 7153 602 - 55 24 0
06th of Mai 2008
Helmut Mauell GmbHDipl. Ing. Detlef [email protected]+49 2053 - 13 478
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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
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Power plant Altbach / Deizisau, Unit 4
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•
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 Water pipes
F l u e g
a s
Feed water flow
Cooler
Demineralize
Sek. - Prim.superheater
Fire Area
Burner
Combustionchamber
Oil
Gas
Compressor
50MW
Turbine
Oil
Gas
O i l
G a s
Boiler drum
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•
Tasks of the new gas turbine control system ME 4012:ME-VIEW scheme of control loops and functional groups
Übersicht des Lieferumfanges
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•
Tasks of the new gas turbine control system ME 4012:air system and combustion process of the gas turbine
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•
Tasks of the new gas turbine control system ME 4012: Air / exhaust gas of the gas turbine
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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
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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)
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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
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10David 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)
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•
Tasks of the new gas turbine control system ME 4012:Turbine Protection System (Turbine surveillance supervision)
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• Tasks of the new gas turbine control system ME 4012:Electrical Integration
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2. Solution: Functions and Control Strategy Speed-, power-, frequency- and temperature-control
Coordinator
Valveposition
controller
Power controller
Speedcontroller
Temperaturecontroller
Setpointgeneration
power Setpoint
generator speed
Setpointgeneration
temperature
setpointSpeed Power
setpointTemperatur-
sollwert
Rampfunction
generator Synchronizer
Mode of operation
Frequency Exhausttemperature
Turbinespeed
Electricalpower
M
M
n
PT
M
Flowcontroller
Deionized water
Setpointdeionized water
injection
Deionizedwater injection
(Oil > 25MW)
Exhausttemp.
> 25MW asynchronous balanced mode
F
50MW
Oil-ESV Oil-CV Gas-ESVGas-CV
Compressor Turbine Deionized
water- CV
M a s t e r
S l a v e ( f u
l l i n t e r f a c e a n d p r o c e s s i n g r e d u n d a n c y )
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2. Solution: Functions and Control Strategy: Speed-, power-, frequency-, temperature- and fuel-control
Deionized water injection for NOx reduction in oil operation
iCoordinator
(bumplessswitch)
Setpoint
generationamount of fuel
Flowcontroller
Shares plateGas / Oil and
automatic fuelswitching,
Base:Energy content /
heat balance
Fuel
Oilflow
Oil-CVposition
EHC-position
Gas
flow
Gas-CV-position
EHC-position
Speedcontroller
Speedsetpoint
Power setpoint
Temperaturesetpoint
Ramp functiongenerator Synchronizer
Turbinespeed
Electricalpower
Exhausttemperature
Power controller
Temperaturecontroller
Setpointcontrol power
Setpoint
generator speed
Setpointcontrol
temperature
Operationalmode
Frequency
Setpoint
generationdeionized water
Valve
positioncontroller
Fuel
Power adjuster
Deionizedwater flow
Deionized water CV-position
MMode of operation
15%
60%
100%
Synchronisation300°C 396°C
0TC°
Start upsetpointdiagram
Valve positioncontroller
EHC-positioncontroller
Flowcontroller Exhaust
temperature
Electricalpower
Flowcontroller
Valve positioncontroller
EHC-positioncontroller
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15David 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)
T u r b i n e G o v e r n o r C h a n n e l A
T u r b i n e
C h a n n e l B
G o v e r n
o r
Life trip systemChannel 1
Life trip systemChannel 2
E/H-Converter
ServodriveServodrive
Oil-ESV Öl-CV
Servodrive
Gas-ESV Gas-CV
2 oo3
GT
Over speedprotection
(2 oo3) SIL 3
1
3
1
3
Realtime funktionsCPU-Functional Area 2
< 10ms
Funktion group controlsPower control setpointPower controller Frequency influenceFlue gas temp. controller
Fuel controller Combustion controller Deionized water injection
Anti surge controlTurbine protection 2 oo 3
ME-DRP ME-VIEW
Speed control setpointSpeed controller
Acceleration MeasurementFuel valve position controller
Time criticalrealtime funktions
CPU-Functional Area 1< 4 ms
CPU
Analogoutput
Analoginput
Pulseinput
Master
Analogoutput
Binaryoutput
Analoginput
CPU
Slave
Diagnostics andDocumentation Operator station
Alarms, SOE,Protocol
LAN
SUB-NET
Pulseinput
Life trip systemChannel 3
Binary
output
E/H-Converter
Servodrive
Pulsepre-amplifier
and decoupling
A E
4 0 1 2
A E 4
0 1 2
AE4012
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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-amplifier
Channel 1
Channel 2
Channel 3
Turbineshaft
Reserve
detector
IE2FZ
IE2FZ
IE2FZ
Turbineoverspeed
protection 2oo3SIL3
2 o o
3
&
DW channel 1
DW channel 2
DW channel 3
Emergencyshut off valve
IE2 FZ
Turbinespeed
measurement1oo2
I/O- Bus
Speed andpower controller
AE4012 S U B - N E T
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2. Solution: Functions and Control Strategy Gasturbine protection: Overview machine protection
Failsafetrip
moduleDW-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 groupTurbine control
1 1 1
Generator protection
SUB-NET
Channel 1 Channel 2 Channel 3
# #
Life trip system
Test programoverspeeddetector
24V +L1
24V +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
moduleDW-Modul 2
Failsafetrip
moduleDW-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
L T F S T
L T L T F S T
#
F S T
L T F S T
L T L T F S T
F S T
L T F S T
L T L T F S T
F S T
&& &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
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2. Solution: Functions and Control Strategy Gasturbine protection: Overview fuel trip system
Seatvalve
Overspeed protection2 oo 3 (SIL 3)
M
M < 60%iffusiondoperating
Load
> 60% Loadasynchronousbalancedoperating low NOx
Hydraulictrip block 1 oo 2
Fail-Safeshut off valve
Control oil
P
r o p a n e
g a s
M
Combustion chamber
Life trip system 2 oo 3Turbine controller 1v2
2oo3
Fail-Safe fuel trip (SIL3)
Venting system
2. Shut-off valve
1. Shut-off valve
Fuel CV ESV 1 ESV 2
Pilot flame
Pilot lightIgnitor
FuelBurner
Turbineshaft
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2. Solution: Functions and Control StrategyOperator system ME VIEW and location involvement
Controlroom Unit4
GT-A
Relay room HKW 2
ME-DRPServer /Client
VIEW-Switch 1
PD-Switch 2
Distributed coupling ME4012 Distributed coupling ME4012
DRP-Switch(Rail)
Router
EnBWManagement system
PI-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
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2. Solution: Functions and Control Strategy Automation Unit AE 4012 and location involvement
Gas turbine
Fail-Safelogic
TC 1TP 1
TC 2TP 2
TP 3
~
~
Fail-SafeSystem
Turbineprotection
Burner protection
Steppingcontrol drives
~
~
Power adjuster
Turbine controller, Turbine protection Turbine, burner, flue gas flap
Flame /burner
surveillance
~
~
Auxiliarycabinet
Shaftvibration
measurement
Couplingrelays
Steam generator
auxiliary 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
UVIEW
Automationunit
AE 4012UVIEW
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
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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
3 Achieved objectives and operational experience
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3. Achieved objectives and operational experience ME 4012 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 adjuster Stepping 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 burner Exhaust 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 Generator Auxiliary 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)
FOC
FOC
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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)
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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
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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
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Acceptance: March 2003
Extensive functional testing of the turbine control:
Automatic start-up of the gas turbine to rated speed Automatic Synchronization Automatic load increase at about 7 MW / min. to base load Speed controller load operation:
switching speed controller to load controller under load Interception security from full load to house load (GT or Unit 4) Redundancy test at all operating conditions and loads
Flying fuel change (gas / oil and oil / gas) under load Testing the primary control Testing the limit frequency control Hot start tests
Trip tests of protection system(Shaft vibration monitoring, over speed, fuel-trip)
3. Achieved objectives and operational experience in the power plant Altbach / Deizisau
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Summary: (After 5 years of plant operation)
Excellent system technology with outstanding performance Very good teamwork of EnBW / Mauell employees in the field
of special process engineering expertise Highest level of automation to secure / easy and fast unit start-up
Modern control concepts for robustic and efficient plant operation Fully Integrated Control concepts for all operating modes and transitions Reducing the risk of “combustion chamber drone“ High reliability for all applications Long-term assets-backed operation (spare parts and service)
4. Summary
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Reference List Process Control System ME4012:
Gasturbines and Combined Cycle Plants
No. Plant Operator CountryManufacturer Steam turbine /
Function
1 HKW Halle / Trotha D Siemens /Siemens 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 /Siemens V94.1
105 MW /2x 100 MW
Plant Control SystemME 4012 for control andprotection
3 Stadtwerke Munich D ALSTOM Power / 140 MW / Plant Control Systeme z ra wer
Combined Cycle 2 General ElectricFrame 9E
2x 140 MW
or con ro an
protectionIntegration of process-businto Mark 5-GT-controls stem
4 EnBW PP Altbach /Deizisau, GT-A
D Siemens V93.0 50 MW Plant Control SystemME 4012 for control andprotection
5 Industry Power D Ruston Tornado 6,3 MW Hard-wired interfacing toPlantCarl Freudenberg,Weinheim, GT1
Unit Control SystemBoiler 4
6 Industry Power D Turbomach 5,5 MW Hard-wired interfacing to
David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 200828
Carl Freudenberg,
Weinheim, GT2
,T60 Boiler 5
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A01.4012.11E08
Energyneeds Impulses