Mauell Field Report Altbach

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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


Power plant Altbach / Deizisau, Unit 4


• 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


• Tasks of the new gas turbine control system ME 4012:ME-VIEW scheme of control loops and functional groups

Übersicht des Lieferumfanges


• Tasks of the new gas turbine control system ME 4012:air system and combustion process of the gas turbine


• Tasks of the new gas turbine control system ME 4012:Air / exhaust gas of the gas turbine


• 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


• Tasks of the new gas turbine control system ME4012:Heating Oil system of gas turbine (draft sketch according to R170C)


• Tasks of the new gas turbine control system ME 4012:Deionized water injection for NOx reduction during oil operation


• Tasks of the new gas turbine control system ME 4012:Auxiliary oil / lube oil system of the gas turbine

Turning gear(Hydro motor)


• Tasks of the new gas turbine control system ME 4012:Turbine Protection System (Turbine surveillance supervision)


• Tasks of the new gas turbine control system ME 4012:Electrical Integration


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

)


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


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


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


Binaryoutput

E/H-ConverterServodrive

Pulsepre-amplifier

and decoupling

AE4

012

AE4

012

AE4012


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


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


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


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


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
















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



marshalling rack marshalling rackmarshalling rack

PD-Switch 2PD-Switch 1

Automationunit

AE 4012

Automationunit

AE 4012


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 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


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)


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


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



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)



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


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


A01.4012.11E08

Energyneeds Impulses

Mauell Field Report Altbach

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