KELI 2008 Field Report : Control System ME 4012 for gas turbine A (93.0 V) at unit 4 Power plant Altbach / Deizisau

Transcription

1 KELI 2008 Field Report : Control System ME 4012 for gas turbine A (93.0 V) at unit 4 Power plant Altbach / Deizisau EnBW Elektro-/ Leittechnik Dipl. Ing. David Maier da.maier@enbw.com th of Mai 2008 Helmut Mauell GmbH Dipl. Ing. Detlef Baran dba@mauell.com Energy needs Impulses

2 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 NO x -reduction during oil operation 9 Auxiliary oil / lube oil system of the gas turbine 10 Turbine Protection System (Turbine surveillance supervision) 11 Electrical Integration 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 Summary after 5 years of plant operation Solution: Functions and Control Strategy Speed-, power-, frequency- and temperature-control Reference List Process Control System ME4012: Gas turbines and Combined Cycle Plants 28 Speed-, power-, frequency-, temperature- and fuel-control 14 Turbine (1oo2), Turbine protection (2oo3, SIL3) 15 Turbine speed measurement for 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

3 Power plant Altbach / Deizisau, Unit 4 2

4 Tasks of the new gas turbine control system ME 4012: Principle of process Combined Cycle Unit 4 Steam power Injection Boiler drum Flue gas 200MW Water pipes Steam turbine Oil Gas Sek. - Prim. superheater Oil Gas Fire Area Feed water flow M Burner Compressor Turbine Cooler Demineralize 50MW Oil Gas M Combustion chamber 3

5 Tasks of the new gas turbine control system ME 4012: ME-VIEW scheme of control loops and functional groups Übersicht des Lieferumfanges 4

6 Tasks of the new gas turbine control system ME 4012: air system and combustion process of the gas turbine 5

7 Tasks of the new gas turbine control system ME 4012: Air / exhaust gas of the gas turbine 6

8 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 7

9 Tasks of the new gas turbine control system ME4012: Heating Oil system of gas turbine (draft sketch according to R170C) 8

10 Tasks of the new gas turbine control system ME 4012: Deionized water injection for NO x reduction during oil operation 9

11 Tasks of the new gas turbine control system ME 4012: Auxiliary oil / lube oil system of the gas turbine Turning gear (Hydro motor) 10

12 Tasks of the new gas turbine control system ME 4012: Turbine Protection System (Turbine surveillance supervision) 11

13 Tasks of the new gas turbine control system ME 4012: Electrical Integration 12

14 2. Solution: Functions and Control Strategy Speed-, power-, frequency- and temperature-control Speed setpoint Turbine speed Ramp function generator Setpoint generator speed Speed Synchronizer Power setpoint Electrical power Mode of operation Coordinator Valve position Setpoint generation power Power Frequency Temperatursollwert Exhaust temp. Exhaust temperature Setpoint generation temperature Temperature > 25MW asynchronous balanced mode Setpoint deionized water injection Deionized water injection (Oil > 25MW) Flow Deionized water Master Slave (full interface and processing redundancy) Oil-ESV Oil-CV Gas-CV Gas-ESV n P Compressor M Turbine T F M Deionized water- CV 50MW M 13

15 2. Solution: Functions and Control Strategy: Speed-, power-, frequency-, temperature- and fuel-control 100% 60% Start up setpoint diagram 15% C 396 C Synchronisation Ramp function generator Synchronizer T C Speed setpoint Setpoint generator speed Turbine speed Speed Oil flow EHCposition Operational mode Frequency Fuel Flow Valve position EHC-position Power setpoint Setpoint control power Power icoordinator (bumpless switch) Setpoint generation amount of fuel Oil-CV position EHCposition Temperature setpoint Exhaust temperature Setpoint control temperature Electrical power Temperature Shares plate Gas / Oil and automatic fuel switching, Base: Energy content / heat balance Gas flow Flow Gas-CVposition Valve position EHC-position Exhaust temperature Deionized water injection for NO x reduction in oil operation Electrical power Fuel Mode of operation Setpoint generation deionized water Deionized water flow Flow Valve position Deionized water CV-position Power adjuster M 14

16 2. Solution: Functions and Control Strategy Turbine (1oo2), Turbine protection (2oo3, SIL3) Master CPU Diagnostics and Documentation Operator station AE4012 Turbine Governor Channel A Analog output Binary output Analog input ME-DRP LAN Alarms, SOE, Protocol ME-VIEW SUB-NET Pulse input Life trip system Channel 1 1 AE4012 Turbine Governor Channel B Life trip system Channel 2 Pulse input Analog output Binary output 1 3 Over speed protection (2 oo3) SIL 3 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 Power Slave E/H-Converter Acceleration Measurement Frequency influence Servodrive Servodrive Fuel valve position Flue gas temp. Fuel Life trip system 3 Combustion Channel 3 Gas-ESV Gas-CV Deionized water injection Anti surge control AE4012 Turbine protection 2 oo oo3 GT Pulse pre-amplifier and decoupling

17 2. Solution: Functions and Control Strategy Turbine speed measurement for and fail-safe (SIL 3) overspeed protection Channel 1 Pulse pre-amplifier Turbine overspeed protection 2oo3 SIL3 Turbine shaft Channel 2 Channel 3 Reserve detector IE2FZ IE2FZ IE2FZ 2 oo 3 & DW channel 1 DW channel 2 DW channel 3 IE2 FZ Emergency shut off valve ME4012 Processinterface Digital speed measurement : Accuracy : 0,004 % = +/- 2mHz at 50 Hz netw. frequency Signal resolution : 0,5 mhz Signal scan cycle : 4 ms -1 Turbine speed measurement 1oo2 I/O- Bus Speed and power AE4012 Measuring range : > U min Long-term- and temperature- stability due to digital acquisition and processing SUB-NET 16

18 2. Solution: Functions and Control Strategy Gasturbine protection: Overview machine protection Generator 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 (Master) Turbine (Slave) Channel 1 1 Channel 2 1 Channel 3 1 Life trip system SUB-NET +L3 Life trip signal tranfered as Failsafe trip signal # Criterion permutation Fuel control valve Function group Turbine control 24V +L1 24V +L2 24V +L3 emergency stop (Turbine trip) Test program overspeed detector T.-protection latch >3 turns min -1 Turbine protection manual trip (2 oo 3) LSN24 Test program hydraulic trip block Quarz comparator t 0 LT FST & Failsafe trip module DW-Modul 1 Quarz Quarz DW DW DW comparator DW DW DW comparator DW DW DW LT FST LT FST & 2 oo 3 & Hydraulic trip block 1 oo 2 Failsafe trip module DW-Modul 2 Failsafe trip # module DW-Modul 3 # Failsafe fuel protection system (2 oo 3) Control oil 17 # & LT FST LT FST LT FST Fail-Safe 2 v 3 (EAM) Seat valve Pi t 0 LT FST & Seat valve LT FST LT FST & 2 oo 3 & & Turbine hydraulic system

19 2. Solution: Functions and Control Strategy Gasturbine protection: Overview fuel trip system Life trip system 2 oo 3 Turbine 1v2 Overspeed protection 2 oo 3 (SIL 3) Turbine shaft Hydraulic trip block 1 oo 2 Fail-Safe shut off valve Control oil 2oo3 Fail-Safe fuel trip (SIL3) M > 60% Load asynchronous balanced operating low NO x Seat valve Fuel Burner M < diffusion 60% Load operating M Fuel CV ESV 1 ESV 2 Pilot flame Pilot light Ignitor 2. Shut-off valve 1. Shut-off valve Propane gas Combustion chamber Venting system 18

20 2. Solution: Functions and Control Strategy Operator system ME VIEW and location involvement Controlroom Unit4 GT-A Controlroom 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 EnBW Management system PI-System Router On-line features: -- Diagnosis -- Configuration -- Simulation Gateway PC RAID 5 RAID 5 PD-Switch 1 DRP- Switch (Rail) PD-Switch 2 Distributed coupling ME4012 Distributed coupling ME4012 DRP-LAN 19

21 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 Coupler SUB-NET Coupler Automation unit AE 4012 UVIEW Automation unit AE 4012 UVIEW SUB-NET Coupler SUB-NET Coupler Automation unit AE 4012 SUB-NET Level A TC 1 TP 1 TC 2 TP 2 TP 3 Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- marshalling rack marshalling rack marshalling rack ~ Auxiliary cabinet Flame / burner surveillance ~ Fail-Safe System Fail-Safe logic ~ Power adjuster Stepping control drives Shaft vibration measurement Coupling relays Turbine protection Burner protection Stepping control drives Stepping control drives ~ ~ ~ Turbine, Turbine protection Gas turbine 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 20

22 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 features: - Cycle time < 4 ms typ. Speed Measurement (digital): - Accuracy: +/-2,0 mhz abs. - Resolution: 0,5 mhz 21

23 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 Client Alarms Client Client Balance protocol: Client - Performance - Work - Operating Hours - Consumption - Cooling water diary ME-DRP Client ME-DRP Server Documentation Diagnosis Projekt database 250m 30m 30 m LWL Environment Office Splicebox LWK Server 1 Server 2 Router Railswitch Gateway PC PI-System Flue gas emission Computer Hardwired Signals Electronic Room Unit 2 9,5 m USV USV Fibre optic cable (FOC) SUBNET B-Level Relay-Room Unit 4 (200 MW ST / 50 MW GT) 250 m FOC Switch FOC 250 m SUBNET A-Level SN CAN CAN-Bus only for cabinet internal surveillance Hardwired signal exchanges: AE4012 AE4012 ME4002S Power adjuster Auxiliary Cabinet AE Control steam generators Turbine protection Turbine burner Fail-Safe logic Stepping control drives Flame burner surveillance Steam Generator - Daily oil tank Turbine Exhaust flap Turbine protection Burner surveillance Auxiliary power - Operating load distribution Burner protection Shaft vibration measurement - Start up device / alternator excitation Coupling relays 22

24 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 (), 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) 23

25 3. Achieved objectives and operational experience in the power plant Altbach / Deizisau 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. 24

26 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 25

27 3. Achieved objectives and operational experience in the power plant Altbach / Deizisau 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 load operation: switching speed to load 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) 26

28 4. Summary 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) 27

29 Reference List Process Control System ME4012: Gasturbines and Combined Cycle Plants No. Plant Operator Country Manufacturer Steam turbine / DT / GT Gas turbine 1 HKW Halle / Trotha D Siemens / Siemens 60 MW / Siemens V MW 2 Stadtwerke Munich Heizkraftwerk Süd Combined Cycle 1 3 Stadtwerke Munich Heizkraftwerk Süd Combined Cycle 2 4 EnBW PP Altbach / Deizisau, GT-A 5 Industry Power Plant Carl Freudenberg, Weinheim, GT1 6 Industry Power Plant Carl Freudenberg, Weinheim, GT2 D Siemens / Siemens Siemens V94.1 D ALSTOM Power / General Electric Frame 9E 105 MW / 2x 100 MW 140 MW / 2x 140 MW Function Serial integration of GTand DT-control system in the Process Control System ME 4012 Plant Control System ME 4012 for control and protection Plant Control System ME 4012 for control and protection Integration of process-bus into Mark 5-GT-control system D Siemens V MW Plant Control System ME 4012 for control and protection D Ruston Tornado 6,3 MW Hard-wired interfacing to Unit Control System Boiler 4 D Turbomach Caterpillar, Taurus Taurus T60 5,5 MW Hard-wired interfacing to Unit Control System Boiler 5 28

30 Energy needs Impulses A E08 29