A01 4012 14e10

ME 4012
Keli 2010
Helmut Mauell GmbH Reliability and Safety f the for th Energy E Supply S l Industry I d t
ME 4012 Process Control System for Steam Turbines: Structure, Control Strategies, Protection, Safety, Operation, Application Examples, Similarities to Gas Turbine Control
Detlef Baran KELI 10: Process Control System ME 4012 04. May 2010 1
ME 4012
E.ON Power Plant Heyden Turbine Control System 920 MW Unit data:
P Power: 920 MW Live steam: T = 544C P = 210 bar Intermed. Super Steam: T = 544C P = 46 bar Construction: 1987 Operating hours: 110,000 h Start-ups: 1850
Detlef Baran
KELI 10: Process Control System ME 4012
04. May 2010
ME 4012
Turbine Overview Compact Drive
Detlef Baran
04. May 2010
ME 4012
Hard Ware Structure of the Turbine Control ME 4012
Binary y input i t KPA-HD / MD Binary output Analog input Analog output CPU Binary input Binary output Analog input Analog output CPU Binary input Binary output Analog inp t input Analog output CPU Binary input y Binary output Analog input Analog output CPU
Master
Turbine e contr. Channel A CPU Pulse input Binary output Analog output Analog input Turbine protection (2oo3) Option Turbine protection (2oo3) Option Turbine co ontr. Channel B Analog input Analog output Binary output Pulse input CPU
1 . .8 1 . .8 1. . 9
A1 B1
1 .. 9 1 .. 8 1 . 8 1 2
2oo3 working current turbine protection

1 2 3
CPT-HP / IP
2oo3 NC current turbine protection
Turbine shaft
CPT-LPT T
A2 B2
SSV
CV
Diagnosis and documentation
Slave
Turbine protection (2oo3) Option 3
Operator control Alarm reports ME-VIEW

Kraftwerks-Status Kraftwerks Status Aschefrderung Speisewasserregelung bersicht Block Ascherezirkulation berhitzer Luft/Rauchgas Fernwrmeauskopplung Kalkfrderung Gasfeuerung Eigenbedarf Kohlefrderung Monitoranwahl: Archiv Fr 08.Jul 94
Serial interface
e.g. Modbus 3964R External systems
CPT-LPT
Option
Detlef Baran
04. May 2010
ME 4012
Structure of the Turbine Controller Master/ Slave

T Housing T Shaft
(typical)
Turbine temperature control
Turbine controller B Turbine controllr A Power control
Pmin
Prepress. controller Lim.press.contr. (Opening ( p g setpoint) p ) min Speed control Speed controller
Pmin
Power controller
n1 (n2) n2 (n3)
Acceleration meter dn dt
IS limit pressure controller
HP/IP coordinator
HP valve position controller
IP valve position controller
LPT
P LS
T
IS
n1 n2 n3
Condensator
HP
IP
LP
LP
920MW
Detlef Baran
04. May 2010
ME 4012
Turbine Behavior During Start-up and Load Operation
Xw
Turbine controller features: - Cycle time < 4 ms typ. Speed Measurement (digital): - Accuracy: +/-2,0 mHz abs. - Resolution: R l ti 0 0,5 5 mHz H
F 1.4012.207 D06.97 VP1
Detlef Baran
04. May 2010
ME 4012
Electronic Turbine Protection: 2oo3 Signal Acquisition (Overspeed)
+L1
Turbine shaft
+L2
Turbine contr. 1oo2 (Master)
Turbine contr. 1oo2 (Slave) +L3
Open-circuit turbine protect. Channel 1
Detlef Baran
04. May 2010
ME 4012
Overspeed Protection: 2oo3 Signal Processing, SIL 3
Open-circuit Open circuit turbine protect. Channel 1 Closed-circuit turbine protect. Channels 1 - 3
Open-circuit Open circuit turbine protect. Channel 2
Open-circuit Open circuit turbine protect. Channel 3
Quartz comparison
DW
DW
DW
Quartz comparison
DW
DW
DW
Quartz comparison
DW
DW
DW
RS
RS
RS
RS
RS
AS
AS
AS
AS
AS
RS
RS
AS
AS
AS
RS
&
t 0
& 2oo3 &
&
t 0
&
& 2oo3 &
&
t 0
&
& 2oo3 &
AS
Failsafe open-circuit protection DW module 1
Detlef Baran
RS
&
04. May 2010
ME 4012
Protection-Pulse Distribution (2oo3 Electric), Protection Tripping

Failsafe open-circuit protection DW module d l 1 Failsafe open-circuit protection DW module 2 Failsafe open-circuit protection DW module 3
Turbine protection Manual trip 2oo3 LSN24
Test program Electric tripping device Electronic cutoff Solenoid valves (2oo3)
berwa achung berwa achung
# # # #
berwa achung
# #
EAM 15A
EAM 15A
EAM 15A
Power busbar 24V -
Solenoid valve activation (current controller)
Test
Test
Test
Test
ANS-MV SSV 1 Channel 1 MV
ANS-MV SSV 1 Channel 2 MV
ANS-MV RV 12 Channel 1 MV
ANS-MV RV 12 Channel 2 MV
CPT 1 SSV
CPT 12 RV
Detlef Baran
04. May 2010
ME 4012
Turbine Protection (12 x Shut-off Valve SSV, 12 x Control Valve RV) Decentralized Hydraulic Tripping
Power busbar 24V -
Test program SSV and RV
Solenoid valve activation (currnt controller)
Test
Test
Test
Test
ANS-MV
ANS-MV
ANS-MV
ANS-MV
CPT 1 SSV
CPT 1 SSV CPT 1 RV
TS 1 SSV 1 Channel 1 MV
TS 2 SSV 1 Channel 2
CPT 1 RV
TS 1 RV 1 Channel 1 MV
TS 2 RV 1 Channel 2
MV
MV
CPT 12 SSV CPT 12 RV G SSV servomotor G RV servomotor
Detlef Baran
04. May 2010
10
ME 4012
Design of a Compact Drive

(Complete Hydraulic System every Control Valve, Shut-off Valve)
Detlef Baran
04. May 2010
11
ME 4012
Process Control System Signal Run and Cycle Times
SUB-NET Level B
60-140 ms master cycle
ME-DRP online
ME-VIEW
10 ms
SUB-NET SUB-NET coupler coupler
Time synchronization 1ms accuracy
B1
50 ms master cycle
Radio clock
SUB-NETSUB-NET coupler coupler

RAID 5
PD server
UVIEW UVIEW
SUB-NET Level A1
450 ms 70 ms incl. redundancy adjustment adjust e t

Subprocessor Hot standby
SUB-NET Level A2
Subprocessor Master
Subprocessor Active
Subprocessor Hot standby
Subprocessor Active
Redundancy changeover (bumpless) 2 ms
Subprocessor Slave
I/O bus
I/O bus
Passive expansion module 1
Passive expansion
1 ms module /mod. 15
Detlef Baran
04. May 2010
0,5 s
12
ME 4012
Turbine Control 1150 MW (NPP)
Detlef Baran
04. May 2010
13
ME 4012
Hydraulic Aggregates for the Turbine Hydraulic System
Detlef Baran
04. May 2010
14
ME 4012
Hydraulic Aggregate and Reservoir
Detlef Baran
04. May 2010
15
ME 4012
Turbine Driving Speed Measurement
A A4-m-59684-0001 20
1 ,5 TO 0 LE R AN CE
M8 x 25 EN 24017 8.4 DIN 93 DSF 1210 F SHV Fa. JAQUET A4-m-59651-0004
5 40
Detlef Baran
35
04. May 2010
16
ME 4012
Turbine Speed Measurement Controller 1oo2, Protection 2oo3 / SIL3
Process interface digital speed measurement: Accuracy: 0,004 % = +/- 2 mHz at 50 Hz netw. Frequency Signal resolution: 0,5 mHz Signal scan cycle: 4 ms Measuring range: > 3 - 3600 U/min Long-term and temperature stability due to digital acquisition and processing
Channel 1 IE2FZ Channel 2 IE2FZ Channel 3 IE2FZ DW Channel 3 DW Channel 2 DW Channel 1 IE2 FZ Turbine speed measurement 1oo2 I/O-Bus Speed and power controller AE4012
Pulse pre-amplifier
Turbine overspeed protection 2oo3 SIL3
Reserve detector
Turbine shaft
Servodrive
E / H- Converter Servodrive
Detlef Baran
04. May 2010
17
ME 4012
Generator protection
Steam Turbine Protection Concept Safety and Availability

Failsafe trip system 2 oo 3, SIL 3 Overspeed protection
+L1 # # +L2
Life trip system 2 oo 3 Electrical and mechanical trip criterions
Turbine controller (Master)

Channel 1 Life trip system
1
Turbine controller (Slave)

+L3
Channel 2 SUB-NET
Channel 3
Life trip signal tranfered as Failsafe trip signal # Criterion permutation
Quarz comparator
DW
DW
DW
Quarz comparator
DW
DW
DW
Quarz comparator
DW
DW
DW
Fuel control valve
LT FST
LT FST
LT FST
LT FST
LT FST
LT FST
LT FST
LT FST
& t0
Function group Turbine control 24V +L1 24V +L2 24V +L3 emergency stop (Turbine trip)
T.-protection latch >3 turns min-1
& 2 oo 3 &
& t0
&
& 2 oo 3 &
Turbine protection manual trip (2 oo 3) LSN24
Failsafe trip t p module DW-Modul 1
Failsafe trip p module DW-Modul 2
Failsafe p trip module DW-Modul 3
Test program hydraulic trip block
Fail-Safe 2 v 3 (EAM)
LT FST
Test program overspeed detector
&
Failsafe fuel protection system (2 oo 3)
Control oil Hydraulic trip block 1 oo 2

Seat valve
Pi
Seat valve
Turbine hydraulic system
Detlef Baran
04. May 2010
18
ME 4012
Overspeed Protection Module (SIL 3)
Detlef Baran
04. May 2010
19
ME 4012
Hydraulic Protection Module (SIL3)
Detlef Baran
04. May 2010
20
ME 4012
Turbine Hydraulic System (Servo Drives, Hydraulic Protection Module)
Detlef Baran
04. May 2010
21
ME 4012
Servo Drives for Turbines 1150 MW
Detlef Baran
04. May 2010
22
ME 4012
Servo Drives for Turbines (1150 MW), Efficiency Tests
Detlef Baran
04. May 2010
23
ME 4012
Pipeline Isometric Drawing 1
Detlef Baran
04. May 2010
24
ME 4012
Pipeline Isometric Drawing 2
Detlef Baran
04. May 2010
25
ME 4012
Modification of an Operating Stand 1
Detlef Baran
04. May 2010
26
ME 4012
Modification of an Operating Stand 2
Detlef Baran
04. May 2010
27
ME 4012
Power Plant Altbach/Deizisau, Unit 4
Detlef Baran
04. May 2010
28
ME 4012
Gas Turbine Control System ME 4012: Power Plant Altbach Combined Cycle Unit 4
Steam power Injection
Boiler drum
200MW Steam turbine

Oil Gas Sek. - Prim. superheater Fire Area
Water pipes
Si Siemens GT V93.0 V93 0
Oil Gas
M
Feed water flow Burner
Compressor Turbine
Cooler Demineralize
50MW
Oil Gas
Co bust o Combustion chamber
Detlef Baran
Flue gas
04. May 2010
29
ME 4012
Power, Speed and Temperature Control
Ramp function t generator Speed setpoint
Synchronizer y
Mode of operation
Frequency
Exhaust temperature
Setpoint deionized water injection
Setpoint generator speed
Power setpoint
Setpoint generation power
Temperatursollwert
Setpoint generation temperature
Deionized water injection (Oil > 25MW)
Turbine speed
Speed controller
Electrical power
Power controller
Exhaust temp.
Temperature controller
Flow controller Deionized water
Coordinator Valve position controller
> 25MW asynchronous balanced mode
Oil-ESV
Oil-CV
Gas-CV
Gas-ESV F
M
P n
Compressor
Turbine T
Deionized water- CV
50MW
Detlef Baran
Master
ocessing redunda ancy) Slave (full interface and pro
04. May 2010
30
ME 4012
100% 60%
Power, Speed, Temperature and Fuel Control

Start up setpoint diagram
15% 0
T C
300C Synchronisation
396C
Ramp function generator Speed setpoint
Synchronizer
Setpoint generator speed g p
Speed controller Oil flow Turbine speed EHCposition Fuel Flow controller Oil CV Oil-CV position Valve position controller EHC-position controller
Operational mode Power setpoint
Frequency
Setpoint control power
Power controller
Coordinator (bumpless switch)
Setpoint generation amount of fuel
EHCposition Flow controller Valve position controller Gas-CVposition Gas flow EHC-position controller
Exhaust temperature Temperature setpoint
Electrical power
Setpoint control temperature
Temperature controller
Shares plate Gas / Oil and automatic fuel switching, Base: Energy content / heat balance
Exhaust temperature Deionized water flow Fuel Electrical power Valve position controller Deionized water CV-position
Deionized water injection for NOx reduction in oil operation
Setpoint generation deionized water
Flow controller
Power adjuster dj t
Mode of operation
Detlef Baran
04. May 2010
31
ME 4012
Master CPU Turbine e Governor Channel A
Turbine Controller (1oo2), Turbine Protection (2oo3, SIL3)

Diagnostics and Documentation
Alarms, SOE, Protocol
Operator station
Analog output
ME-DRP
ME-VIEW
AE4012 A
Binary output
Analog input
LAN
SUB-NET
Pulse input Life trip system Channel 1 Life trip system
Channel 2
Pulse input
Pulse pre-amplifier and decoupling
Turbin ne Governor Channel B
1 3
Analog output Binary output
Over speed protection p (2 oo3) SIL 3
AE4012
GT
2 oo3 Servodrive E/H-Converter Servodrive
Analog g input
Oil-ESV l-CV
CPU Slave
Servodrive E/H-Converter Servodrive
Time critical realtime funktions CPU-Functional Area 1 < 4 ms Speed control setpoint Speed controller Acceleration Measurement Fuel valve position controller
Life trip system
Channel 3
3
Gas-ESV Gas-CV
AE4012
Realtime funktions CPU Functional Area 2 CPU-Functional < 10ms Funktion group controls Power control setpoint Power controller Frequency influence Flue gas temp. controller Fuel controller Combustion controller Deionized water injection Anti surge control Turbine protection 2 oo 3
Detlef Baran
04. May 2010
32
ME 4012
Gas Turbine Behavior During Start-up and Load Operation
Xw
Turbine controller features: - Cycle time < 4 ms typ. Speed Measurement (digital): - Accuracy: +/ +/-2 2,0 0 mHz abs abs. - Resolution: 0,5 mHz
Detlef Baran
04. May 2010
33
ME 4012
Turbine Speed Measurement for Control and Fail-Safe Overspeed Protection (SIL 3)
Pulse pre-amplifier
Turbine overspeed protection 2oo3
Channel 1
IE2FZ
2v3 Turbine shaft Channel 2

IE2FZ
&
Channel 3
IE2FZ
DW Channel 1 DW Channel 2 DW Channel 3 IE2 FZ Turbine speed measurement 1oo2
Shut-off valve SSV
R Reserve sensor
Digital speed measurement: Accuracy : 0.004 % = +/- 2mHz at 50 Hz line frequency Signal resolution : 0.5 mHz Signal scan cycle : 4 msec. Measuring range : > 3 up to 3,600 U/min Long-term and temp. stability through digital acquisition and processing
I/O bus
Detlef Baran
SUB-N NET
Speed and power controller, valve position controller
04. May 2010
34
ME 4012
Generator protection
Protection of the Gas Turbine: Overview Machine Protection

Life trip system 2 oo 3 Electrical and mechanical trip criterions Failsafe trip system 2 oo 3, SIL 3 Overspeed protection
+L1 # # +L2
Turbine controller (Master)

Channel 1 Life trip system
1
Turbine controller (Slave)

+L3
Channel 2 SUB-NET
Channel 3
Life trip signal tranfered as Failsafe trip signal # Criterion permutation
Quarz comparator
DW
DW
DW
Quarz comparator
DW
DW
DW
Quarz comparator
DW
DW
DW
Fuel control valve
LT FST
LT FST
LT FST
LT FST
LT FST
LT FST
LT FST
& t0
Function group Turbine control 24V +L1 24V +L2 24V +L3 emergency stop (Turbine trip)
T.-protection latch >3 turns min-1
& 2 oo 3 &
& t0
&
Turbine protection manual trip (2 oo 3) LSN24
Failsafe trip module DW-Modul 1
Failsafe trip odu e module DW-Modul 2
Failsafe trip module DW-Modul 3
Test program hydraulic trip block
Fail-Safe 2 v 3 (EAM)
LT FST LT FST
Test program overspeed detector
& 2 oo 3 &
&
Failsafe fuel protection system (2 oo 3)
Control oil Hydraulic trip block 1 oo 2

Seat S t valve
Pi
Seat S t valve
Turbine hydraulic system
Detlef Baran
04. May 2010
35
ME 4012
Life trip system 2 oo 3 Turbine controller 1v2
Gas Turbine Protection: Overview Fuel Trip System

Overspeed protection 2 oo 3 (SIL 3)
Turbine shaft
Hydraulic trip block 1 oo 2 Fail-Safe shut off valve
Control oil
2oo3 F il S f fuel Fail-Safe f l trip t i (SIL3)
> 60% Load asynchronous M balanced operating low NOx Fuel Burner M < 60% Load diffusion operating M Fuel CV
Seat valve
ESV 1
ESV 2
Pilot flame Ignitor Pilot light

Propane gas 2. Shut-off valve 1. Shut-off valve
Combustion chamber
Detlef Baran KELI 10: Process Control System ME 4012
Venting system
04. May 2010
36
ME 4012
2. Solution: Automation Unit AE 4012 and Location Involvement

PD-Switch 1 PD-Switch 2
SUB-NET Level B
SUB-NET Coupler
SUB-NET Coupler
Automation unit AE 4012
UVIEW
UVIEW
SUB-NET Coupler
SUB-NET Coupler
SUB-NET Level A TC 1 TP 1
Multifunctionsprocessor
TC 2 TP 2
TP 3
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
BinaryInput/ Output
AnalogInput/ Output
marshalling rack
marshalling rack
marshalling rack
Auxiliary cabinet bi t
Flame / burner surveillance Shaft vibration measurement Coupling relays ~
Fail-Safe S t System
Fail-Safe logic
Power adjuster dj t
Stepping control drives
Turbine protection
Stepping control drives
Burner protection ~
Stepping control drives ~
Gas turbine Turbine controller, Turbine protection Turbine, burner, flue gas flap
Steam generator auxiliary power
Hardware signal exchanges: - Control steam generators - Daily oil tank - Operating load distribution - start-up device / alternator excitation
Detlef Baran
04. May 2010
37
ME 4012
Control Room Unit4 GT-A
Operator System ME-VIEW and Location Involvement

Control Room HKW 2 Relay Room HKW 2
ME-VIEW Client
ME-VIEW Client
ME-VIEW Client
Balance protocol
ME-AIS
ME-DRP Client
ME-DRP Server / Client
VIEW-LAN VIEW-Switch 1 VIEW-Switch 2 Documentation VGB standard R 170 C On-line features: -- Diagnosis -- Configuration -- Simulation
EnBW Management system PI-System
Router
Gateway PC PD-Switch 1
RAID 5
RAID 5
DRPSwitch (Rail)
PD-Switch 2
Distributed coupling ME4012
Distributed coupling ME4012
DRP-LAN
Detlef Baran
04. May 2010
38
ME 4012
KELI 2010
Helmut Mauell GmbH Reliability and Safety f the for th Energy E Supply S l Industry I d t
Thank very much for your attention. For more information click here www.mauell.com
Detlef Baran
04. May 2010
39

A01 4012 14e10

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A01 4012 14e10

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ME 4012

KELI 10: Process Control System ME 4012

04. May 2010

Turbine Overview Compact Drive

KELI 10: Process Control System ME 4012

04. May 2010

Hard Ware Structure of the Turbine Control ME 4012

2oo3 working current turbine protection

2oo3 NC current turbine protection

Diagnosis and documentation

Operator control Alarm reports ME-VIEW

e.g. Modbus 3964R External systems

KELI 10: Process Control System ME 4012

04. May 2010

Structure of the Turbine Controller Master/ Slave

Turbine temperature control

Turbine controller B Turbine controllr A Power control

IS limit pressure controller

HP valve position controller

IP valve position controller

KELI 10: Process Control System ME 4012

04. May 2010

Turbine Behavior During Start-up and Load Operation

F 1.4012.207 D06.97 VP1

KELI 10: Process Control System ME 4012

04. May 2010

Electronic Turbine Protection: 2oo3 Signal Acquisition (Overspeed)

Turbine contr. 1oo2 (Master)

Turbine contr. 1oo2 (Slave) +L3

Open-circuit turbine protect. Channel 1

Open-circuit turbine protect. Channel 2

Open-circuit turbine protect. Channel 3

KELI 10: Process Control System ME 4012

04. May 2010

Overspeed Protection: 2oo3 Signal Processing, SIL 3

Open-circuit Open circuit turbine protect. Channel 2

Open-circuit Open circuit turbine protect. Channel 3

& 2oo3 &

& 2oo3 &

& 2oo3 &

Failsafe open-circuit protection DW module 1

Failsafe open-circuit protection DW module 2

Failsafe open-circuit protection DW module 3

KELI 10: Process Control System ME 4012

04. May 2010

Protection-Pulse Distribution (2oo3 Electric), Protection Tripping

Turbine protection Manual trip 2oo3 LSN24

Power busbar 24V -

Solenoid valve activation (current controller)

ANS-MV SSV 1 Channel 1 MV

ANS-MV SSV 1 Channel 2 MV

KELI 10: Process Control System ME 4012

04. May 2010

Power busbar 24V -

Test program SSV and RV

Solenoid valve activation (currnt controller)

CPT 12 SSV CPT 12 RV G SSV servomotor G RV servomotor

KELI 10: Process Control System ME 4012

04. May 2010

Design of a Compact Drive

KELI 10: Process Control System ME 4012

04. May 2010