EON Turbine Control System - Helmut Mauell GmbH

VGB KELI 2006 

10 May 2006 

Heyden Power Station 

ME 4012 Digital Turbine 

Control System 

Karlheinz Weinfurtner Detlef Baran 

Head of Project Control Helmut Mauell GmbH 

Mittelweser Power Station Group

Heyden Power Station: 920 MW Turbo-Generating Set 

Unit Details: 

Power: 920 MW 

OEM: Siemens/ KWU 

Live steam: T = 544 °C 

P = 210 bar 

Intermed. superheater steam: 

T = 544 °C 

P = 46 bar 

Construction: 1987 

Operating hours: 110.000 hrs 

Start-ups: 1850 

Weinfurtner / Baran 30.03.2006 Turbinenleittechnik KW Heyden KELI 06 

Seite 2

Turbine System with decentralized Compact Drives 


Seite 3

Compact Drive (Compl. hydraulic unit for Control Valve, Shut-off Valve) 


Seite 4

HP Turbine with individual Compact Drives for each 

Control Valve and each Shut-off Valve 


Seite 5

Control System of the Steam Turbine Generator Set 

Before retrofitting After retrofitting 

10 System cabinets, 6 systems 

Turbine controller: 

Iskamatik A and B 

Emergency redundancy: hydraulic 

Digital valve position controller: 

Simadyn D 

Turbine shut-off valve control: 

Iskamatik C 

1 System cabinet, 1 system: ME 4012 

Turbine controller: Channel 1 

Turbine controller: Channel 2 

Digital valve position controller: 

redundant 

Turbine shut-off valve control 


Seite 6



Signalling and messaging: 

Simatic S5, without time stamp 

Function group control: 

Iskamatik B 

Turbine protection with 3-channel 

signal conditioning and 2-channel 

processing: Iskamatik C 

Control and coordination of 2x 12 

Compact Power Trains (CPTs): 

Simatic S5 and Teleperm C 

Signalling and messaging: 

1ms accuracy (GPS-timebase) 

Function group control 

Turbine protection with 3-channel signal 

conditioning and 2-channel 

processing 

Control and coordination of 

2x 12 Compact Power Trains (CPTs) 


Seite 7



Hard-wired connections 

between all systems 

Mosaic-type operator console 

(controller and function groups) 

Control room display panel with 

control modules of secondary 

control circuits and test 

programs 

Interfaces: parallel wires 

Bus networking interfaces 

throughout the entire installation 

Mosaic-type operator console 

(controller and functions groups) 

Control room display panel with 

ME-VIEW touch screen 

Interface Unit control system 

parallel wires 


Seite 8

Turbine Control System Overview, 1oo2 


Seite 9

Unit Control and Turbine Control Overview 

Weinfurtner / Baran 30.03.2006 Turbinenleittechnik KW Heyden KELI 06 Seite 10

ME 4012 Turbine Control System 

Front side Rear side 

Cabinet rear side with patch panel 


KPA-HD / MD 

CPT-HP / IP 

CPT-LPT 

CPT-LPT 

Binary 

input 

Binary 

output 

Analog 

input 

Analog 

output 

CPU 

Binary 

input 

Binary 

output 

Analog 

input 

Analog 

output 

CPU 

Binary 

input 

Binary 

output 

Analog 

input 

Analog 

output 

CPU 

Binary 

input 

Binary 

output 

Analog 

input 

Analog 

output 

CPU 

Turbine Control System ME 4012 Hardware Structure 

Master 

Turbine contr. Channel A 

Turbine contr. Channel B 

Slave 

CPU 

Pulse 

input 

Binary 

output 

Analog 

output 

Analog 

input 

Turbine protection 

(2oo3) Option 


(2oo3) Option 

Analog 

input 

Analog 

output 

Binary 

output 

Pulse 

input 

CPU 


(2oo3) Option 

A1 

B1 

1.. 

9 

1.. 

8 

1. 

8 

1 

. 

.8 

1 

. 

.8 

1. 

. 

9 

A2 

B2 

1 

2 

3 

Diagnosis and 

documentation 

T 

Alarm 

reports 

SSV 

Operator control 

Kraft we rks-Status 

Übersi c ht Bloc k 

Kalkförderung 

Kohleförderung 

Fr 08.J u l 94 Mo nitoranwahl: 

Ascheförderung 

Ascherezirkulation 

Luft/Rauchgas 

Ga sfeuerung 

Speisewass erre gelung 

Überhitzer 

Fernwärm eauskopplun g 

Eigenb edarf 

Archiv 

ME-VIEW 

2oo3 

working current 

turbine protection 

1 2 3 

2oo3 

NC current 

turbine protection 

CV 

SUB-NET 

Serial 

interface 

e.g. 

Modbus 

3964R 

Option 

External systems 

Weinfurtner / Baran 30.03.2006 Turbinenleittechnik KW Heyden KELI 06 Seite 12 

Turbine 

shaft 

G

n Ist 

- 

+ 

P 

+ 

+ 

YA ZUE MIN 

04 MAY01 DS001 

Drehzahl Regler 

SW Ziel 

Netz 

GRD 

- 

PI # 

SW Hand 

NF 

+ 

- 

+ 

SW Sync 

+ + + 

n SW 

MIN 

Last 

Sprung 

Netz 

20 % 

YR FD 

Zentr Anf SW 

YR FD 

04 MYA01 DU004 

Turb Reg Hand/Regeln 

MIN 

MIN 

YR MIN 

+ H/R - 

YR HR 

Turbine Controller 

04 MYA01 DP001 

Grenzdruck Begrenzer 

- 

65bar 

PI # 

YR GD 

FD SW 

ABF SW 

MAX 

+ 

10bar 

+ - 

Hand 

NF 100% 

04 MYA01 DP002 

Vordruck Regler 

P Ist 

20 0 

- 

- 

+ 

PI # 

YR VD 

FD 1 Ist 

PI 

ABF 1 Ist 

PI 

P Soll 

+ 

Hand 

NF YR LST 

04 MYA01 DU001 

Leistungs Regler 

LST Ist 

- 

PI # 

YR LST 

MIN 

FD 2 Ist 

PI 

ABF 2 Ist 

PI 

LST Soll 

GRD 

+ H/R - 

LST SW 

+ 

Hand 

NF YR FD 

04 MYA01 DU003 

WT Einfluss 

- 

PI # 

YR WT 

FD 3 Ist 

PI 

ABF 3 Ist 

PI 

WT Betrag 

WT Einfluss 

X 

WT SW 

+ 

Hand 

NF 100% 

04 MYA01 DU011 

Modan Betrieb 

ZUE MINDESTDRUCK REGELUNG Ventil Kennlinien KPA Stellungsregelung 4 x Frischdampfventile und 4 x Abfangventile (Mitteldruck) 

100% 

YR MOD 

FD 4 Ist 

PI 

ABF 4 Ist 

PI 

YA Modan

Master/Slave Architecture of the Turbine Controller 

T Housing 

T Shaft 

(typical) 

P 

LS 

n1 (n2) n2 (n3) HP valve 

position 

controller 

Turbine temperature 

control 

Speed 

control 

Speed 

controller 

n 1 n 2 n 3 

Prepress. controller Lim.press.contr. 

Acceleration 

meter dn 

dt 

T 

HP 

HP/IP coordinator 

(Opening setpoint) min 

IP valve 

position 

controller 

P 

IS 

P min 

Turbine controller B 

Turbine controllr A 

Power control 

Power controller 

LPT 

Pmin 

IS 

limit pressure 

controller 

IP LP LP 

Condensator 


G 

920MW

Binary-Analog Signal Conditioning for 

Status-Oriented Diagnosis 

Single-channel feed for sensors, short-circuit proof 

Wire-break monitoring 

Simulation function on the module 

Signal status indication in the front angle 

Signal test jack on the module 

Overvoltage protection at inputs 

Time stamp at signal input at a resolution of 1ms 

Measured value acquisition time (A/D conversion): 1ms / signal 

HART protocol modulation for configuration at a central point 


Signal Conditioning: Turbine Speed 


shaft 

Channel 1 

Channel 2 

Channel 3 

Reserve sensor 

Pulse pre-amplifier Turbine 

overspeed 

protection 2oo3 

Digital speed measurement: 

Accuracy : 0.004 % = +/- 2mHz at 50 Hz line frequency 

Signal resolution : 0.5 mHz 

Signal scan cycle : 5 msec. 

Measuring range : >3 U min -1 up to overspeed 

Long-term and temp. stability through digital acquisition and processing 

IE2FZ 

IE2FZ 

IE2FZ 

2 v 3 


& 

DW Channel 1 Shut-off valve 

DW Channel 2 SSV 

DW Channel 3 

IE2 FZ 

Turbine speed 

measurement 

1oo2 

I/O bus 

Speed and 

power controller, 

valve position 

controller 

SUB-NET

Turbine Run Monitoring Signals for Turbine Protection 

LS 

Oil pump 

Speed 

* 

Bearing 1 

RD 1 

WS 

P 

D abs 

Speed : 

WS : 

RD : 

WP: 

LS: 

D abs: 

LS 

LS 

3x WP 

WS 

HP IP 

LP 1 LP 2 G E 

P 

P 

IS 

P 

P 

LS 

RD 2 

WS 

Seating 

Bearing 2 Bearing 3 

Turbine speed, 3-channel 

Shaft vibration, 2x each (x+Y) 

Relative expansion 

Shaft position 

Bearing block vibration 

Absolute expansion 

Metal temperatures / steam temperatures 

Pressure measurement 

P 

P 

P 

P 

P 

P 

LS 

WS 

Bearing 4 

Key Phaser 

LS 

RD 3 

WS 

Bearing 5 

LS 

WS 

* Integration of a cog wheel (192 teeth), 

Alternatively we check wether the existing magnet wheel can be used as transmitter 

for the scanning through eddy-current sensors. 

P 

P 

P 


LS

Electronic Turbine Protection: 2oo3 Signal Acquisition (Overspeed) 

Open-circuit 

turbine protect. 

Channel 1 

+L1 +L2 

Turbine contr. 1oo2 

(Master) 


shaft 

Open-circuit 


Channel 2 

Turbine contr. 1oo2 

(Slave) 

+L3 

Open-circuit 


Channel 3 


Overspeed Protection: 2oo3 Signal Processing, SIL 3 

Closed-circuit 


Channels 1 - 3 

Open-circuit 


Channel 1 

Quartz 

comparison 

AS 

RS 

Failsafe 

open-circuit 

protection 

DW module 1 

Quartz 

Quartz 

DW DW DW comparison DW DW DW comparison DW DW DW 

AS 

RS 

AS 

RS 

& & 

2oo3 

& 

& 

AS 

Open-circuit 


Channel 2 

RS 

AS 

RS 

t 0 t 0 2oo3 

& 

AS 

RS 

& & & 

t 0 

AS 

RS 

AS 

RS 

AS 

RS 

& & & 

2oo3 

& 

Failsafe 

Failsafe 

open-circuit 

open-circuit 

# 

protection 

DW module 2 

# 

protection 

DW module 3 

# 

Open-circuit 


Channel 3 


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


Manual trip 

2oo3 

LSN24 

Test program 

Electric 

tripping device 

Electronic 

cutoff 

Solenoid valves 

(2oo3) 

Solenoid valve 

activation 

(current controller) 

Failsafe 

open-circuit 

protection 

DW module 1 

Überwachung 

# 

# 

Failsafe 

open-circuit 

protection 

DW module 2 

Failsafe 

open-circuit 

protection 

DW module 3 

# # # 

Überwachung 

# 

# 

EAM 15A EAM 15A EAM 15A 

ANS-MV ANS-MV ANS-MV ANS-MV 

SSV 1 

Channel 1 

MV 

Power 

busbar 24V - 

Test Test Test 

CPT 1 SSV 

SSV 1 

Channel 2 

MV 

Überwachung 

RV 12 

Channel 1 

MV 

# 


# 

CPT 12 RV 

Test 

RV 12 

Channel 2 

MV

Turbine Protection (12x shut-off valve SOV, 12x control valve CV) 

Test program 

SSV and RV 

CPT 1 SSV 

CPT 1 RV 

CPT 12 SSV 

CPT 12 RV 

Decentralized Hydraulic Tripping 

Solenoid valve 

activation 

(currnt controller) 

CPT 1 

SSV 

ANS-MV ANS-MV ANS-MV ANS-MV 

TS 1 

SSV 1 

Channel 1 

MV 

Power busbar 24V - 

Test Test Test Test 

MV 

TS 2 

SSV 1 

Channel 2 

CPT 1 

RV 

G SSV servomotor G 

TS 1 

RV 1 

Channel 1 

MV 

MV 

RV servomotor 

TS 2 

RV 1 

Channel 2 


Structure of a Compact Power Train 

(complete hydraulic unit for every control valve (CV) and shut-off valve (SOV)) 


Operations Experience 

with the Heyden Power Station 

Award of contract: January 2004 

Mauell won the contract although: 

not a machine supplier (OEM), no Mauell automation equipment 

at the Station 

Planning and installation: by July 2004 

Stage 1: Standby replacement unit for the discontinued Simadyn D 

Stage 2: Installation scheduled for forthcoming standard plant revision 

(Sept. / Oct. 2005) 




Commissioning: Postponed to January 2006 

(exciter damage) 

Compact Power Train (CPT), incl. valve position control loops, o. k. 

Control strategy: 

Old → new retrofitting was successful due to close co-operation 

between Mauell and E.ON 

However: automatic load admission up to high-pressure bypass station 

was closed = problematic (performance swinging) 

After optimising measures carried out together with E.ON = o. k. 




Acceptance: March 2006 

Comprehensive function test of the turbine control system: 

Automatic turbine acceleration up to rated speed 

Automatic synchronization 

Automatic load admission, 70 MW/min. approx. until HP turbine bypass 

station closed 

Pre-pressure control up to 250 MW approx. And transition into natural 

sliding pressure operation 

Recovery level at house load (40 MW) at 300 and 500 MW 

Redundancy test for all operational modes and load levels 


Résumé: 



High-quality system technology providing excellent performance 

(3 ms / CPU cycle) 

Shortcomings in Mauell personnel capacity because project was postponed 

Support by E.ON specialists required due to their special process 

engineering expertise of control valve characteristic and poor 

documentation of machine status prior the retrofit 


Dipl.-Ing. Karlheinz Weinfurtner 

Head of Project Control 

E.ON Kraftwerke GmbH 

Mittelweser Power Station Group 

Tel.: +49 5702 / 29 - 32 49 

Fax.: +49 5702 / 29 - 32 75 

E-Mail: karlheinz.weinfurtner@eon-energie.com 

Dipl.-Ing. Detlef Baran 

Head of Sales and Marketing 

Power Station and Process Control 

Helmut Mauell GmbH 

Tel.: +49 2053 / 13 - 478 

Fax: +49 2053 / 13 - 403 

E-Mail: dba@mauell.com

EON Turbine Control System - Helmut Mauell GmbH

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