EON Turbine Control System - Helmut Mauell GmbH
EON Turbine Control System - Helmut Mauell GmbH
EON Turbine Control System - Helmut Mauell GmbH
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VGB KELI 2006<br />
10 May 2006<br />
Heyden Power Station<br />
ME 4012 Digital <strong>Turbine</strong><br />
<strong>Control</strong> <strong>System</strong><br />
Karlheinz Weinfurtner Detlef Baran<br />
Head of Project <strong>Control</strong> <strong>Helmut</strong> <strong>Mauell</strong> <strong>GmbH</strong><br />
Mittelweser Power Station Group
Heyden Power Station: 920 MW Turbo-Generating Set<br />
Unit Details:<br />
Power: 920 MW<br />
OEM: Siemens/ KWU<br />
Live steam: T = 544 °C<br />
P = 210 bar<br />
Intermed. superheater steam:<br />
T = 544 °C<br />
P = 46 bar<br />
Construction: 1987<br />
Operating hours: 110.000 hrs<br />
Start-ups: 1850<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 2
<strong>Turbine</strong> <strong>System</strong> with decentralized Compact Drives<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 3
Compact Drive (Compl. hydraulic unit for <strong>Control</strong> Valve, Shut-off Valve)<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 4
HP <strong>Turbine</strong> with individual Compact Drives for each<br />
<strong>Control</strong> Valve and each Shut-off Valve<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 5
<strong>Control</strong> <strong>System</strong> of the Steam <strong>Turbine</strong> Generator Set<br />
Before retrofitting After retrofitting<br />
10 <strong>System</strong> cabinets, 6 systems<br />
<strong>Turbine</strong> controller:<br />
Iskamatik A and B<br />
Emergency redundancy: hydraulic<br />
Digital valve position controller:<br />
Simadyn D<br />
<strong>Turbine</strong> shut-off valve control:<br />
Iskamatik C<br />
1 <strong>System</strong> cabinet, 1 system: ME 4012<br />
<strong>Turbine</strong> controller: Channel 1<br />
<strong>Turbine</strong> controller: Channel 2<br />
Digital valve position controller:<br />
redundant<br />
<strong>Turbine</strong> shut-off valve control<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 6
<strong>Control</strong> <strong>System</strong> of the Steam <strong>Turbine</strong> Generator Set<br />
Before retrofitting After retrofitting<br />
Signalling and messaging:<br />
Simatic S5, without time stamp<br />
Function group control:<br />
Iskamatik B<br />
<strong>Turbine</strong> protection with 3-channel<br />
signal conditioning and 2-channel<br />
processing: Iskamatik C<br />
<strong>Control</strong> and coordination of 2x 12<br />
Compact Power Trains (CPTs):<br />
Simatic S5 and Teleperm C<br />
Signalling and messaging:<br />
1ms accuracy (GPS-timebase)<br />
Function group control<br />
<strong>Turbine</strong> protection with 3-channel signal<br />
conditioning and 2-channel<br />
processing<br />
<strong>Control</strong> and coordination of<br />
2x 12 Compact Power Trains (CPTs)<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 7
<strong>Control</strong> <strong>System</strong> of the Steam <strong>Turbine</strong> Generator Set<br />
Before retrofitting After retrofitting<br />
Hard-wired connections<br />
between all systems<br />
Mosaic-type operator console<br />
(controller and function groups)<br />
<strong>Control</strong> room display panel with<br />
control modules of secondary<br />
control circuits and test<br />
programs<br />
Interfaces: parallel wires<br />
Bus networking interfaces<br />
throughout the entire installation<br />
Mosaic-type operator console<br />
(controller and functions groups)<br />
<strong>Control</strong> room display panel with<br />
ME-VIEW touch screen<br />
Interface Unit control system<br />
parallel wires<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 8
<strong>Turbine</strong> <strong>Control</strong> <strong>System</strong> Overview, 1oo2<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06<br />
Seite 9
Unit <strong>Control</strong> and <strong>Turbine</strong> <strong>Control</strong> Overview<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 10
ME 4012 <strong>Turbine</strong> <strong>Control</strong> <strong>System</strong><br />
Front side Rear side<br />
Cabinet rear side with patch panel<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 11
KPA-HD / MD<br />
CPT-HP / IP<br />
CPT-LPT<br />
CPT-LPT<br />
Binary<br />
input<br />
Binary<br />
output<br />
Analog<br />
input<br />
Analog<br />
output<br />
CPU<br />
Binary<br />
input<br />
Binary<br />
output<br />
Analog<br />
input<br />
Analog<br />
output<br />
CPU<br />
Binary<br />
input<br />
Binary<br />
output<br />
Analog<br />
input<br />
Analog<br />
output<br />
CPU<br />
Binary<br />
input<br />
Binary<br />
output<br />
Analog<br />
input<br />
Analog<br />
output<br />
CPU<br />
<strong>Turbine</strong> <strong>Control</strong> <strong>System</strong> ME 4012 Hardware Structure<br />
Master<br />
<strong>Turbine</strong> contr. Channel A<br />
<strong>Turbine</strong> contr. Channel B<br />
Slave<br />
CPU<br />
Pulse<br />
input<br />
Binary<br />
output<br />
Analog<br />
output<br />
Analog<br />
input<br />
<strong>Turbine</strong> protection<br />
(2oo3) Option<br />
<strong>Turbine</strong> protection<br />
(2oo3) Option<br />
Analog<br />
input<br />
Analog<br />
output<br />
Binary<br />
output<br />
Pulse<br />
input<br />
CPU<br />
<strong>Turbine</strong> protection<br />
(2oo3) Option<br />
A1<br />
B1<br />
1..<br />
9<br />
1..<br />
8<br />
1.<br />
8<br />
1<br />
.<br />
.8<br />
1<br />
.<br />
.8<br />
1.<br />
.<br />
9<br />
A2<br />
B2<br />
1<br />
2<br />
3<br />
Diagnosis and<br />
documentation<br />
T<br />
Alarm<br />
reports<br />
SSV<br />
Operator control<br />
Kraft we rks-Status<br />
Übersi c ht Bloc k<br />
Kalkförderung<br />
Kohleförderung<br />
Fr 08.J u l 94 Mo nitoranwahl:<br />
Ascheförderung<br />
Ascherezirkulation<br />
Luft/Rauchgas<br />
Ga sfeuerung<br />
Speisewass erre gelung<br />
Überhitzer<br />
Fernwärm eauskopplun g<br />
Eigenb edarf<br />
Archiv<br />
ME-VIEW<br />
2oo3<br />
working current<br />
turbine protection<br />
1 2 3<br />
2oo3<br />
NC current<br />
turbine protection<br />
CV<br />
SUB-NET<br />
Serial<br />
interface<br />
e.g.<br />
Modbus<br />
3964R<br />
Option<br />
External systems<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 12<br />
<strong>Turbine</strong><br />
shaft<br />
G
n Ist<br />
-<br />
+<br />
P<br />
+<br />
+<br />
YA ZUE MIN<br />
04 MAY01 DS001<br />
Drehzahl Regler<br />
SW Ziel<br />
Netz<br />
GRD<br />
-<br />
PI #<br />
SW Hand<br />
NF<br />
+<br />
-<br />
+<br />
SW Sync<br />
+ + +<br />
n SW<br />
MIN<br />
Last<br />
Sprung<br />
Netz<br />
20 %<br />
YR FD<br />
Zentr Anf SW<br />
YR FD<br />
04 MYA01 DU004<br />
Turb Reg Hand/Regeln<br />
MIN<br />
MIN<br />
YR MIN<br />
+ H/R -<br />
YR HR<br />
<strong>Turbine</strong> <strong>Control</strong>ler<br />
04 MYA01 DP001<br />
Grenzdruck Begrenzer<br />
-<br />
65bar<br />
PI #<br />
YR GD<br />
FD SW<br />
ABF SW<br />
MAX<br />
+<br />
10bar<br />
+ -<br />
Hand<br />
NF 100%<br />
04 MYA01 DP002<br />
Vordruck Regler<br />
P Ist<br />
20 0<br />
-<br />
-<br />
+<br />
PI #<br />
YR VD<br />
FD 1 Ist<br />
PI<br />
ABF 1 Ist<br />
PI<br />
P Soll<br />
+<br />
Hand<br />
NF YR LST<br />
04 MYA01 DU001<br />
Leistungs Regler<br />
LST Ist<br />
-<br />
PI #<br />
YR LST<br />
MIN<br />
FD 2 Ist<br />
PI<br />
ABF 2 Ist<br />
PI<br />
LST Soll<br />
GRD<br />
+ H/R -<br />
LST SW<br />
+<br />
Hand<br />
NF YR FD<br />
04 MYA01 DU003<br />
WT Einfluss<br />
-<br />
PI #<br />
YR WT<br />
FD 3 Ist<br />
PI<br />
ABF 3 Ist<br />
PI<br />
WT Betrag<br />
WT Einfluss<br />
X<br />
WT SW<br />
+<br />
Hand<br />
NF 100%<br />
04 MYA01 DU011<br />
Modan Betrieb<br />
ZUE MINDESTDRUCK REGELUNG Ventil Kennlinien KPA Stellungsregelung 4 x Frischdampfventile und 4 x Abfangventile (Mitteldruck)<br />
100%<br />
YR MOD<br />
FD 4 Ist<br />
PI<br />
ABF 4 Ist<br />
PI<br />
YA Modan
Master/Slave Architecture of the <strong>Turbine</strong> <strong>Control</strong>ler<br />
T Housing<br />
T Shaft<br />
(typical)<br />
P<br />
LS<br />
n1 (n2) n2 (n3) HP valve<br />
position<br />
controller<br />
<strong>Turbine</strong> temperature<br />
control<br />
Speed<br />
control<br />
Speed<br />
controller<br />
n 1 n 2 n 3<br />
Prepress. controller Lim.press.contr.<br />
Acceleration<br />
meter dn<br />
dt<br />
T<br />
HP<br />
HP/IP coordinator<br />
(Opening setpoint) min<br />
IP valve<br />
position<br />
controller<br />
P<br />
IS<br />
P min<br />
<strong>Turbine</strong> controller B<br />
<strong>Turbine</strong> controllr A<br />
Power control<br />
Power controller<br />
LPT<br />
Pmin<br />
IS<br />
limit pressure<br />
controller<br />
IP LP LP<br />
Condensator<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 14<br />
G<br />
920MW
Binary-Analog Signal Conditioning for<br />
Status-Oriented Diagnosis<br />
Single-channel feed for sensors, short-circuit proof<br />
Wire-break monitoring<br />
Simulation function on the module<br />
Signal status indication in the front angle<br />
Signal test jack on the module<br />
Overvoltage protection at inputs<br />
Time stamp at signal input at a resolution of 1ms<br />
Measured value acquisition time (A/D conversion): 1ms / signal<br />
HART protocol modulation for configuration at a central point<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 15
Signal Conditioning: <strong>Turbine</strong> Speed<br />
<strong>Turbine</strong><br />
shaft<br />
Channel 1<br />
Channel 2<br />
Channel 3<br />
Reserve sensor<br />
Pulse pre-amplifier <strong>Turbine</strong><br />
overspeed<br />
protection 2oo3<br />
Digital speed measurement:<br />
Accuracy : 0.004 % = +/- 2mHz at 50 Hz line frequency<br />
Signal resolution : 0.5 mHz<br />
Signal scan cycle : 5 msec.<br />
Measuring range : >3 U min -1 up to overspeed<br />
Long-term and temp. stability through digital acquisition and processing<br />
IE2FZ<br />
IE2FZ<br />
IE2FZ<br />
2 v 3<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 16<br />
&<br />
DW Channel 1 Shut-off valve<br />
DW Channel 2 SSV<br />
DW Channel 3<br />
IE2 FZ<br />
<strong>Turbine</strong> speed<br />
measurement<br />
1oo2<br />
I/O bus<br />
Speed and<br />
power controller,<br />
valve position<br />
controller<br />
SUB-NET
<strong>Turbine</strong> Run Monitoring Signals for <strong>Turbine</strong> Protection<br />
LS<br />
Oil pump<br />
Speed<br />
*<br />
Bearing 1<br />
RD 1<br />
WS<br />
P<br />
D abs<br />
Speed :<br />
WS :<br />
RD :<br />
WP:<br />
LS:<br />
D abs:<br />
LS<br />
LS<br />
3x WP<br />
WS<br />
HP IP<br />
LP 1 LP 2 G E<br />
P<br />
P<br />
IS<br />
P<br />
P<br />
LS<br />
RD 2<br />
WS<br />
Seating<br />
Bearing 2 Bearing 3<br />
<strong>Turbine</strong> speed, 3-channel<br />
Shaft vibration, 2x each (x+Y)<br />
Relative expansion<br />
Shaft position<br />
Bearing block vibration<br />
Absolute expansion<br />
Metal temperatures / steam temperatures<br />
Pressure measurement<br />
P<br />
P<br />
P<br />
P<br />
P<br />
P<br />
LS<br />
WS<br />
Bearing 4<br />
Key Phaser<br />
LS<br />
RD 3<br />
WS<br />
Bearing 5<br />
LS<br />
WS<br />
* Integration of a cog wheel (192 teeth),<br />
Alternatively we check wether the existing magnet wheel can be used as transmitter<br />
for the scanning through eddy-current sensors.<br />
P<br />
P<br />
P<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 17<br />
LS
Electronic <strong>Turbine</strong> Protection: 2oo3 Signal Acquisition (Overspeed)<br />
Open-circuit<br />
turbine protect.<br />
Channel 1<br />
+L1 +L2<br />
<strong>Turbine</strong> contr. 1oo2<br />
(Master)<br />
<strong>Turbine</strong><br />
shaft<br />
Open-circuit<br />
turbine protect.<br />
Channel 2<br />
<strong>Turbine</strong> contr. 1oo2<br />
(Slave)<br />
+L3<br />
Open-circuit<br />
turbine protect.<br />
Channel 3<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 18
Overspeed Protection: 2oo3 Signal Processing, SIL 3<br />
Closed-circuit<br />
turbine protect.<br />
Channels 1 - 3<br />
Open-circuit<br />
turbine protect.<br />
Channel 1<br />
Quartz<br />
comparison<br />
AS<br />
RS<br />
Failsafe<br />
open-circuit<br />
protection<br />
DW module 1<br />
Quartz<br />
Quartz<br />
DW DW DW comparison DW DW DW comparison DW DW DW<br />
AS<br />
RS<br />
AS<br />
RS<br />
& &<br />
2oo3<br />
&<br />
&<br />
AS<br />
Open-circuit<br />
turbine protect.<br />
Channel 2<br />
RS<br />
AS<br />
RS<br />
t 0 t 0 2oo3<br />
&<br />
AS<br />
RS<br />
& & &<br />
t 0<br />
AS<br />
RS<br />
AS<br />
RS<br />
AS<br />
RS<br />
& & &<br />
2oo3<br />
&<br />
Failsafe<br />
Failsafe<br />
open-circuit<br />
open-circuit<br />
#<br />
protection<br />
DW module 2<br />
#<br />
protection<br />
DW module 3<br />
#<br />
Open-circuit<br />
turbine protect.<br />
Channel 3<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 19
Protection-Pulse Distribution (2oo3 electric), Protection Tripping<br />
<strong>Turbine</strong> protection<br />
Manual trip<br />
2oo3<br />
LSN24<br />
Test program<br />
Electric<br />
tripping device<br />
Electronic<br />
cutoff<br />
Solenoid valves<br />
(2oo3)<br />
Solenoid valve<br />
activation<br />
(current controller)<br />
Failsafe<br />
open-circuit<br />
protection<br />
DW module 1<br />
Überwachung<br />
#<br />
#<br />
Failsafe<br />
open-circuit<br />
protection<br />
DW module 2<br />
Failsafe<br />
open-circuit<br />
protection<br />
DW module 3<br />
# # #<br />
Überwachung<br />
#<br />
#<br />
EAM 15A EAM 15A EAM 15A<br />
ANS-MV ANS-MV ANS-MV ANS-MV<br />
SSV 1<br />
Channel 1<br />
MV<br />
Power<br />
busbar 24V -<br />
Test Test Test<br />
CPT 1 SSV<br />
SSV 1<br />
Channel 2<br />
MV<br />
Überwachung<br />
RV 12<br />
Channel 1<br />
MV<br />
#<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 20<br />
#<br />
CPT 12 RV<br />
Test<br />
RV 12<br />
Channel 2<br />
MV
<strong>Turbine</strong> Protection (12x shut-off valve SOV, 12x control valve CV)<br />
Test program<br />
SSV and RV<br />
CPT 1 SSV<br />
CPT 1 RV<br />
CPT 12 SSV<br />
CPT 12 RV<br />
Decentralized Hydraulic Tripping<br />
Solenoid valve<br />
activation<br />
(currnt controller)<br />
CPT 1<br />
SSV<br />
ANS-MV ANS-MV ANS-MV ANS-MV<br />
TS 1<br />
SSV 1<br />
Channel 1<br />
MV<br />
Power busbar 24V -<br />
Test Test Test Test<br />
MV<br />
TS 2<br />
SSV 1<br />
Channel 2<br />
CPT 1<br />
RV<br />
G SSV servomotor G<br />
TS 1<br />
RV 1<br />
Channel 1<br />
MV<br />
MV<br />
RV servomotor<br />
TS 2<br />
RV 1<br />
Channel 2<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 21
Structure of a Compact Power Train<br />
(complete hydraulic unit for every control valve (CV) and shut-off valve (SOV))<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 22
Operations Experience<br />
with the Heyden Power Station<br />
Award of contract: January 2004<br />
<strong>Mauell</strong> won the contract although:<br />
not a machine supplier (OEM), no <strong>Mauell</strong> automation equipment<br />
at the Station<br />
Planning and installation: by July 2004<br />
Stage 1: Standby replacement unit for the discontinued Simadyn D<br />
Stage 2: Installation scheduled for forthcoming standard plant revision<br />
(Sept. / Oct. 2005)<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 23
Operations Experience<br />
with the Heyden Power Station<br />
Commissioning: Postponed to January 2006<br />
(exciter damage)<br />
Compact Power Train (CPT), incl. valve position control loops, o. k.<br />
<strong>Control</strong> strategy:<br />
Old → new retrofitting was successful due to close co-operation<br />
between <strong>Mauell</strong> and E.ON<br />
However: automatic load admission up to high-pressure bypass station<br />
was closed = problematic (performance swinging)<br />
After optimising measures carried out together with E.ON = o. k.<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 24
Operations Experience<br />
with the Heyden Power Station<br />
Acceptance: March 2006<br />
Comprehensive function test of the turbine control system:<br />
Automatic turbine acceleration up to rated speed<br />
Automatic synchronization<br />
Automatic load admission, 70 MW/min. approx. until HP turbine bypass<br />
station closed<br />
Pre-pressure control up to 250 MW approx. And transition into natural<br />
sliding pressure operation<br />
Recovery level at house load (40 MW) at 300 and 500 MW<br />
Redundancy test for all operational modes and load levels<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 25
Résumé:<br />
Operations Experience<br />
with the Heyden Power Station<br />
High-quality system technology providing excellent performance<br />
(3 ms / CPU cycle)<br />
Shortcomings in <strong>Mauell</strong> personnel capacity because project was postponed<br />
Support by E.ON specialists required due to their special process<br />
engineering expertise of control valve characteristic and poor<br />
documentation of machine status prior the retrofit<br />
Weinfurtner / Baran 30.03.2006 <strong>Turbine</strong>nleittechnik KW Heyden KELI 06 Seite 26
Dipl.-Ing. Karlheinz Weinfurtner<br />
Head of Project <strong>Control</strong><br />
E.ON Kraftwerke <strong>GmbH</strong><br />
Mittelweser Power Station Group<br />
Tel.: +49 5702 / 29 - 32 49<br />
Fax.: +49 5702 / 29 - 32 75<br />
E-Mail: karlheinz.weinfurtner@eon-energie.com<br />
Dipl.-Ing. Detlef Baran<br />
Head of Sales and Marketing<br />
Power Station and Process <strong>Control</strong><br />
<strong>Helmut</strong> <strong>Mauell</strong> <strong>GmbH</strong><br />
Tel.: +49 2053 / 13 - 478<br />
Fax: +49 2053 / 13 - 403<br />
E-Mail: dba@mauell.com