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Mauell Field Report Altbach
Mauell Field Report Altbach
Field Report :
Control System ME 4012 for
gas turbine A (93.0 V) at unit 4
Power plant Altbach / Deizisau
1. Tasks of the new Gas Turbine Control System ME 4012 slide 3. Achieved objectives and operational experience: slide
Control System replacement of gas turbine A
• Principle of process Combined Cycle Unit 4 3
• Turbine behavior during start-up and load operation 21
• ME-VIEW scheme of control loops and functional groups 4
• ME4012 System overview Unit 4, Altbach / Deizisau 22
• Air system and combustion process of the gas turbine 5
• Control System characteristics 23
• Air / exhaust gas of the gas turbine 6
• Contract Award 24
• Ignitiongas and naturalgas system 7
• Planning and Manufacturing 24
• Heating oil system of gas turbine
(Draft sketch according to VGB R 170 C) 8 • Mounting 24
• Deionized water injection for NOx-reduction during oil operation 9 • Commissioning 25
• Auxiliary oil / lube oil system of the gas turbine 10 • Acceptance 26
• Turbine Protection System (Turbine surveillance supervision) 11
• Electrical Integration 12 4. Summary after 5 years of plant operation 27
2. Solution: Functions and Control Strategy 5. Reference List Process Control System ME4012:
Gas turbines and Combined Cycle Plants 28
• 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
30 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Power plant Altbach / Deizisau, Unit 4
2 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:
Principle of process Combined Cycle Unit 4
Flue gas
Steam power Injection
Boiler
drum
200MW Water
pipes
Steam turbine
Gas
Sek. - Prim.
Oil
superheater
Oil
Fire Area
Gas Feed water flow
M Burner
Compressor
Cooler
Turbine
Demineralize
50MW Oil
Gas
Combustion
M chamber
3 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:
ME-VIEW scheme of control loops and functional groups
4 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:
air system and combustion process of the gas turbine
5 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:
Air / exhaust gas of the gas turbine
6 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
7 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)
8 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
9 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:
Auxiliary oil / lube oil system of the gas turbine
Turning gear
(Hydro motor)
10 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:
Turbine Protection System (Turbine surveillance supervision)
11 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:
Electrical Integration
12 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Speed-, power-, frequency- and temperature-control
Coordinator
Master
Valve
position > 25MW asynchronous balanced mode
controller
M
F
Compressor M
P Turbine T Deionized
n water- CV
50MW M
13 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy:
Speed-, power-, frequency-, temperature- and fuel-control
100%
Start up
setpoint
60% diagram
15%
0 T
300°C 396°C
C°
Synchronisation
Ramp function
generator Synchronizer
Speed
setpoint Setpoint Speed
generator speed controller
Oil
flow
Turbine EHC-
speed position
Oil-CV
Power position
setpoint Coordinator Setpoint
Setpoint Power i
(bumpless generation
control power controller
switch) amount of fuel
EHC-
position
Electrical Flow Valve position EHC-position
power Shares plate controller
Exhaust controller controller
temperature Gas / Oil and
automatic fuel
switching, Gas-CV-
Temperature Base: position
Setpoint Energy content /
setpoint Temperature
control heat balance Gas
temperature controller flow
Exhaust
temperature
Electrical
power Setpoint Valve
Flow Power
generation position
controller adjuster
deionized water controller
14 David 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)
Master
Diagnostics and
Turbine Governor Channel A
CPU Documentation Operator station
Alarms, SOE,
Analog Protocol
output ME-DRP ME-VIEW
AE4012
Binary
output LAN
SUB-NET
Analog
input
Pulse
input
protection
Analog (2 oo3) SIL 3
output 3
GT
AE4012
Binary 2 oo3
output
E/H-Converter
Servodrive
Servodrive Time critical Realtime funktions
Analog realtime funktions CPU-Functional Area 2
input CPU-Functional Area 1 < 10ms
< 4 ms Funktion group controls
Oil-ESV Öl-CV Speed control setpoint Power control setpoint
CPU Speed controller Power controller
Slave E/H-Converter Acceleration Measurement Frequency influence
Servodrive
Servodrive Fuel valve position controller Flue gas temp. controller
Fuel controller
Life trip system Combustion controller
Channel 3 3
Gas-ESV Gas-CV Deionized water injection
Anti surge control
AE4012
Turbine protection 2 oo 3
15 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Turbine speed measurement for controller and
fail-safe (SIL 3) overspeed protection
Turbine
Pulse pre-amplifier overspeed
protection 2oo3
Channel 1 SIL3
IE2FZ
2 oo 3
Channel 2
&
Turbine IE2FZ
shaft Channel 3
DW channel 1 Emergency
IE2FZ DW channel 2 shut off valve
DW channel 3
Reserve
detector
IE2 FZ
Turbine
speed
measurement
1oo2
SUB-NET
Speed and
Signal resolution : 0,5 mHz power controller
AE4012
Signal scan cycle : 4 ms
-1
Measuring range : >3 - 3600 U min
Long-term- and temperature- stability due to digital acquisition and processing
16 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Gasturbine protection: Overview machine protection
Generator Life trip system 2 oo 3 Failsafe trip system 2 oo 3, SIL 3
protection Electrical and mechanical trip criterions Overspeed protection
+L1 +L2
# #
FST
FST
FST
FST
FST
FST
FST
FST
FST
system
LT
LT
LT
LT
LT
LT
LT
LT
LT
(2 oo 3)
& & & & & &
t0 2 oo 3 t0 2 oo 3
& &
Function group T.-protection latch
Turbine control >3 turns min-1
24V +L1
24V +L2
24V +L3 Turbine protection Failsafe Failsafe Failsafe
trip trip trip
manual trip (2 oo 3) module
module module
LSN24 DW-Modul 1 # DW-Modul 2 # DW-Modul 3 #
emergency stop
(Turbine trip)
Test program
hydraulic trip Fail-Safe 2 v 3 (EAM)
block
Control oil
Hydraulic trip Seat Seat
block 1 oo 2 valve valve
Pi
Turbine hydraulic
system
17 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Gasturbine protection: Overview fuel trip system
Pilot flame
2. Shut-off 1. Shut-off
Propane
Ignitor
valve valve
gas
Pilot light
18 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Operator system ME VIEW and location involvement
Controlroom Unit4 Controlroom HKW 2 Relay room HKW 2
GT-A
ME-DRP
ME-VIEW ME-VIEW ME-VIEW Balance ME-AIS ME-DRP Server /
Client Client Client protocol Client Client
VIEW-LAN
RAID RAID
Gateway 5 5
PC
DRP-
PD-Switch 1 Switch PD-Switch 2
(Rail)
DRP-LAN
19 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Automation Unit AE 4012 and location involvement
PD-Switch 1 PD-Switch 2
SUB-NET Level B
SUB-NET Level A
TC 1 Multi- TC 2 Multi- TP 3 Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi-
TP 1 functions- TP 2 functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions-
processor processor processor processor processor processor processor processor processor processor processor processor processor processor processor processor
Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog-
Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/
Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output
~ ~ ~
~ ~ ~
20 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
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
21 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
ME4012 System overview Unit 4, Altbach / Deizisau
Control Room Unit 4 Control Room Unit 2 Relay Room Unit 2
EMI ME-AIS
250m
30 m
30m
LWL
Splicebox
PI-System
Router
Environment LWK
Office Railswitch
Server 1 Server 2 Gateway
PC
USV USV
Flue gas
emission Fibre optic cable (FOC)
Computer Electronic Room
Hardwired Signals
Unit 2 9,5 m
SUBNET B-Level
SUBNET A-Level
SN
CAN
CAN-Bus only for cabinet internal surveillance
24 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
in the power plant Altbach / Deizisau
25 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
in the power plant Altbach / Deizisau
27 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Reference List Process Control System ME4012:
Gasturbines and Combined Cycle Plants
Manufacturer Steam turbine /
No. Plant Operator Country Function
DT / GT Gas turbine
1 HKW Halle / Trotha D Siemens / Siemens 60 MW / Serial integration of GT-
Siemens V64.3 25 MW and DT-control system in
the Process Control
System ME 4012
2 Stadtwerke Munich D Siemens / Siemens 105 MW / Plant Control System
Heizkraftwerk Süd Siemens V94.1 2x 100 MW ME 4012 for control and
Combined Cycle 1 protection
3 Stadtwerke Munich D ALSTOM Power / 140 MW / Plant Control System
Heizkraftwerk Süd ME 4012 for control and
Combined Cycle 2 protection
General Electric 2x 140 MW Integration of process-bus
Frame 9E into Mark 5-GT-control
system
4 EnBW PP Altbach / D Siemens V93.0 50 MW Plant Control System
Deizisau, GT-A ME 4012 for control and
protection
5 Industry Power Plant D Ruston Tornado 6,3 MW Hard-wired interfacing to
Carl Freudenberg, Unit Control System
Weinheim, GT1 Boiler 4
6 Industry Power Plant D Turbomach 5,5 MW Hard-wired interfacing to
Carl Freudenberg, Caterpillar, Taurus Unit Control System
Weinheim, GT2 Taurus T60 Boiler 5
28 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
Energy
needs Impulses
A01.4012.11E08
29 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008