TS3000

DOCUMENT DOCUMENT TITLE : Basic Of Design Document DOCUMENT NO

:

MD-502-7000-IN-BOD-1025-1013

REQUISITION NO

:

KAR 760

PURCHASE ORDER NO

:

4500039280

ITEM NO

:

All Items

ITEM DESCRIPTION

:

ITCC APPROVED

WITH COMMENT

REVIEWED

RESUBMIT

This approval or review does not relieve the vendor / subcontractor of his responsibilities to meet all requirements of the purchase order ORIGINAL

CHEKED

APPD(PRJ)

SIGN

FOR RECORD

DATE

SAMSUNG ENGINEERING CO., LTD

D02

04Dec2009

Final(For Record)

HDY

NDD

JIY

D01

23Feb2009

As-Built

PDK

MN

JIY

C01

22Dec2008

Issue for Construction

PDK

MN

JIY

A01

18Sep2008

Issue for Approval

SHE

MN

JIY

REV

DATE

DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

SAUDI ARABIAN MINING COMPANY(MA'ADEN) MA'ADEN AMMONIA PROJECT

Worley Parsons SAMSUNG ENGINEERING CO., LTD. SEOUL KOREA SECL PROJECT NO. : SC2158

Uhde GmbH

INVENSYS PROCESS SYSTEMS (S) PTE LTD

INVENSYS PROCESS SYSTEMS (S) PTE LTD PROJECT NAME

Document

SG60016-TC1-TMC-BODD-30001

Customer

MD-502-7000-IN-BOD-1025-1013

Contract No.

4500039280

Project No.

SG60016

Page

2 of 43

: MA’ADEN AMMONIA PROJECT

CUSTOMER NAME : SAMSUNG ENGINEERING CO. LTD ENDUSER NAME

: SAUDI ARABIAN MINING COMPANY (MA’ADEN)

LOCATION

: KINGDOM OF SAUDI ARABIA

Basis of Design Document 7120-J01-TS01

Steam Turbine Generator

D02

04Dec09

HDY

NDD

JIY

Final(For Record)

D01

23Feb09

PDK

MN

JIY

As-Built

C01

22Dec08

PDK

MN

JIY


A01

18Sep08

SHE

MN

JIY

Issue for approval

Rev

Date

Prep’d

Chk’d

Apr’d

INVENSYS PROCESS SYSTEMS (S) PTE LTD (File Name: SG60016-TC1-TMC-BO SG60016-TC1-TMC-BODD-30001-RD02 DD-30001-RD02.doc) .doc)

INVENSYS PROCESS SYSTEMS (S) PTE LTD PROJECT NAME

Document

SG60016-TC1-TMC-BODD-30001

Customer

MD-502-7000-IN-BOD-1025-1013

Contract No.

4500039280

Project No.

SG60016

Page

2 of 43

: MA’ADEN AMMONIA PROJECT

CUSTOMER NAME : SAMSUNG ENGINEERING CO. LTD ENDUSER NAME

: SAUDI ARABIAN MINING COMPANY (MA’ADEN)

LOCATION

: KINGDOM OF SAUDI ARABIA

Basis of Design Document 7120-J01-TS01

Steam Turbine Generator

D02

04Dec09

HDY

NDD

JIY

Final(For Record)

D01

23Feb09

PDK

MN

JIY

As-Built

C01

22Dec08

PDK

MN

JIY


A01

18Sep08

SHE

MN

JIY

Issue for approval

Rev

Date

Prep’d

Chk’d

Apr’d


Project Name: MA'ADEN AMMONIA PROJECT

Doc. No.

:

SG60016-TC1-TMC-BODD-30001 Rev. : D02 SG60016-TC1-TMC-BODD-30001

Project Location : Ras Az Zawr City ,KSA

Project No.

:

SG60016

Document Description : Basis of Design Document

Contract No.

:

4500039280 4500039280

Area/Unit/System Description – 7120-J01-TS01

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Customer Doc:- MD-502-7000-IN-BOD-1025-10 MD-502-7000-IN-BOD-1025-1013 13

TABLE OF CONTENTS 1

GENERAL...................................................................................................... 5

2

APPLICATION OVERVIEW ............................................................................. 7

3

INTERFACE DESCRIPTION ............................................................................. 9

4

SEQUENCE DESCRIPTION (7120-J01-TS01) (7120-J01-TS01) ................................................... 10

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5

INTRODUCTION...................................................... ............................................... ......... 10 MODE ASSIGNMENTS ........................................... ...................................................... .......................................................... 10 MODE 0 – TURBINE SHUTDOWN......................................... ...................................... 14 MODE 1 – READY-TO-START......... READY-TO-START............................................................... .............................................................................. ........................ 15 MODE 2 – 2 ND IDLE SPEED (1000 RPM) ........................................................... .................................................................... ......... 16 MODE 3 – ACCELERATION........................ ACCELERATION.............................................................................. ................................................................... ............. 18 MODE 4 – RATED SPEED (5194 RPM)........................................................ RPM)........................................................................ ................ 19 MODE 5 – ONLINE OPERATION................................................... OPERATION.................................................................................. ............................... 20 MODE 6 – ISLAND OPERATION ............................................ ...................................... 22 MODE 7 – OVER SPEED TRIP TEST ......................................................... ............................................................................. .................... 23

CONTROL DESCRIPTION DESCRIPTION (7120-J01(7120-J01-TS01)..................................................... TS01)..................................................... 24

5.1 GENERAL................................................................................. GENERAL............................... .................................................. .......................................... 24 5.2 NAMING CONVENTION...................................................... CONVENTION................................................................................................ .......................................... 25 5.3 CONSTANT INITALIZATION........................................ INITALIZATION ........................................ ................................................. 27 5.4 ANALOG INPUT SCALING.......................................................... SCALING............................................................................................. ................................... 27 5.5 TRIPS & ALARMS................................................................ ............................................. 28 5.5.1 TRIPS ............................................................................................... 28 5.5.2 ALARMS ........................................................................................... 28 6

7120-J01/7120-J01 7120-J01/7120-J01-TS01 -TS01 CONTROL MODULE MODULE DESCRIPTION........................... 30

6.1 CONTROL MODULE ASSIGNMENT............................................................................. 30 6.2 7120-J01-TS01 7120-J01-TS01 STEAM TURBINE CONTROL MODULES......................................... MODULES ......................................... 31 6.2.1 SP1 – SPEED INPUT INPUT MEDIAN MEDIAN SELECT SELECT ................................................. 31 6.2.2 SP2 – TARGET TARGET SPEED SPEED SETPOINT ........................................................ 32 6.2.3 SP3 – SPEED SPEED SETPOINT RAMP ........................................................... 33 6.2.4 SP4 – SPEED DROOP......................................................................... DROOP ......................................................................... 34 6.2.5 SP5 – SPEED PID ............................................................................... 35 6.2.6 MW1 – SPEED SETPOINT RAMP ........................................................ 36 6.2.7 MW2 – MW PID................................................................................ PID ................................................................................ 37 TRANSMITTER FAIL-OVER STRATEGY ........................................... ........................ 38 6.3 7

DUAL COIL ACTUATOR CONFIGURATION ................................................... 39 INVENSYS PROCESS SYSTEMS (S) PTE LTD (File Name: SG60016-TC1-TMC-BO SG60016-TC1-TMC-BODD-30001-RD02 DD-30001-RD02.doc) .doc)


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SG60016


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4500039280 4500039280


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Customer Doc:- MD-502-7000-IN-BOD-1025-10 MD-502-7000-IN-BOD-1025-1013 13

APPENDIX A – CONSTANT LIST ......................................................................... 40 APPENDIX B – INTERFACE LIST.......................................................................... 41 APPENDIX C – ANALOG ANALOG INPUT RANGES ............................................................ 42 APPENDIX D – APPLICATION DETAIL ................................................................. 43



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Customer Doc:- MD-502-7000-IN-BOD-1025-1013

1

GENERAL

The Basis of Design Document defines the Triconex Steam Turbine/Generator Control System for the MA'ADEN AMMONIA Plant Project, and provide general control guidelines for Startup, Speed Control, Shutdown, and Anti-Surge Control and other control functions for 7120-J01 – Generator provided to Samsung Engineering Co., Ltd, for Ma’aden by Invensys Process System (s) Pte Ltd, Triconex. (Hereafter referred to as IPS). Once approved, this document forms the basis for designing this system.

Relevant identification data:

Customer:

Samsung Engineering Co., Ltd

End User:

Ma'aden Company.

Project:

Ma'aden Ammonia Project

System Type: TS3000 (TRICON) Location:

Ras Az Zawr City ,KSA

For the development of the detailed design, MHI will provide IPS with the following: I/O Assignment Field Cable Schedule P&ID Control Narrative Turbine Startup Curve Expected Performance Curve

INVENSYS PROCESS SYSTEMS (S) PTE LTD (File Name: SG60016-TC1-TMC-BODD-30001-RD02.doc)


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The Triconex TS3000 (TRICON) Control System is based on the Triconex Tricon Controller - a state-of-the-art fault-tolerant controller based on the Triple Modular Redundant (TMR) architecture. TMR employs three identical isolated system legs of which each leg independently executes the control program in parallel with the other two legs. This tolerates and ensures that a single point of failure will not affect the other “healthy” legs.

The TMR system uses two-out-of-three voting architecture to ensure high integrity and reliability of the I/O signals. On-line replacement and hot sparing of the I/O modules are possible. This will eliminate any undue interrupt to the process or operation should a fault occur in the module.

The entire plant is designed to be fail-to-safe mode. Therefore, the field inputs or outputs are normally in the “Close” or “Energize” state respectively when in normal condition. A logical ‘1’ input signal to the TMR system is treated as a normal state and a ‘0’ logic signal is treated as trip or failure state. Upon total power failure, the output signals should go to ‘0’ state.



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2

APPLICATION OVERVIEW

This application provides Governing and Load Control for the Steam Turbine-Driven Generator Set (7120-J01-TS01).

TS3000 control system will provide the following main functions: •

Auto Startup Sequence

•

Off-Line Speed Control

•

On-Line Speed Droop Control

•

Load (Megawatt) Control

TS3000 will also perform the following: •

Alarming and Tripping



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Figure 2-1

Application Overview (turbine control)



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3

INTERFACE DESCRIPTION

The Triconex TS3000 (TRICON) system provides control for the start-up of the Turbine through, HMI (Local) and DCS (Remote).

The Remote/ Local Selection can be selected from HMI (f7120REMLOC). Remote/Local status indication will be in HMI and DCS. In Local mode, Operator can issue command from HMI, and when in Remote from DCS.

Please refer to Appendix B for Interface List.



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4

SEQUENCE DESCRIPTION (7120-J01-TS01)

4.1 INTRODUCTION This section defines the control implementation in the TS3000 (TRICON) Generator - Steam Turbine (7120-J01-TS01), and discusses the following: •

Sequence Modes

•

Description of the sequential operation 7120-J01-TS01 Steam Turbine

•

Control Description

4.2 MODE ASSIGNMENTS The TS3000 (TRICON) Startup/ Shutdown Sequence is organized into a series of Modes or states defining the progressive stages of the turbine startup and any special considerations involved with the execution of a given Mode. Each defined Mode is assigned a sequential number used within the TS3000 (TRICON) logic. The sequence logic decides which Mode may be entered from the current Mode. This ensures an orderly progression through the Modes and appropriate actions in the event of an operational change.

The sequence mode variable “i7120MODE” defines the various starting, operating, and test Modes that control the program. The sequence of operation for the 7120-J01-TS01 Steam Turbine Control System for Generator will be determined by these modes.

Mode

Description

Mode 0

Turbine Tripped/Shutdown

Mode 1

Ready to Start

Mode 2

2ND Idle Speed (1000 RPM)

Mode 3

Acceleration

Mode 4

Rated Speed (5194 RPM) INVENSYS PROCESS SYSTEMS (S) PTE LTD (File Name: SG60016-TC1-TMC-BODD-30001-RD02.doc)


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Mode 5

Online Operation

Mode 6

Island Operation

Mode 7

Overspeed Test

Refer to Figure 4-2-1

7120-J01-TS01 Steam Turbine Start-up Sequence

The Startup Sequence is organized into a series of modes or states defining the progressive stages of the turbine startup and any special considerations involved with the execution of a given stage. Each defined mode is assigned a sequential number used within the TS3000 logic. The sequence logic in the TS3000 controls which mode may be entered from any given current mode ensures an orderly progression through the modes and appropriate actions in the event of mechanical malfunctions.



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Mode0 Shutdown

AllTripCleared &Start PermissiveClear

AnyTrip

Mode1 ReadytoStart

StartCommand

Mode2 2ndIdleSpeed ( 1000RPM)

AnyTrip

RatedSpeed Command

AnyTrip

Mode3 Acceleration ( 5194RPM)

IdleSpeed Command

Speed=5194 RPM

Mode4 RatedSpeed ( 5194RPM)

UtilityTie Breaker Closed

OverSpeedTestOn OverSpeedTestOff

AnyTrip Mode7 OverSpeed TripTest AnyTrip

AnyTrip

Figure 4-2-1

Mode5 Online Operation

UtilityTie Breaker Opened

Mode6 Island Operation

Generator Breaker Opened

UtilityTie Breaker Closed

Generator Breaker Opened

7120-J01-TS01 Steam Turbine Start-up Sequence



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Figure 4-2-2

7120-J01-TS01 Steam Turbine Start-up Curve



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4.3

MODE 0 – TURBINE SHUTDOWN

Entered

Condition

Remarks

Any Mode

Whenever the turbine is tripped.

If the Trip has not been reset, the TS3000 (TRICON) will remain in Mode 0, Shutdown. It will be prevented from starting until all trips conditions have been cleared and the system has entered Mode 1, Ready-to-Start. Refer to Table 5-5-1 for list of Trip signals

Initial

When TS3000 (TRICON) is powered up.

From

In this Mode: Action The Speed Controller output is clamped to 0%. The minimum and maximum limits on the Governor valve are set to 0 %. The Actual Speed Set point and Target Setpoint are set to 0 RPM. The minimum and maximum limits on the Actual Speed Setpoint are set to 0 RPM. Common Trip Signal will be sent to DCS/HMI/ESD.



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4.4

MODE 1 – READY-TO-START

Entered

Condition

Remarks

From Mode 0 Shutdown

All Trips clear and reset and Governor Start Permissive received from DCS

In this Mode: Action Ready to Start Signal will be sent to DCS/ HMI. The Speed Controller output is clamped to 0%. The minimum and maximum limits on the Governor valve are set to 0 %. The minimum and maximum limits on the Actual Speed setpoint are set to 0.



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4.5

MODE 2 – 2 ND IDLE SPEED (1000 RPM) Entered

Condition

Remarks

A Start Command from HMI (Local) / DCS (Remote) is issued.

The turbine is started manually. Trip and throttle valve will be open gradually by operator. Operator wills warm-up the turbine at approximately, the 1ST Idle Speed (500 RPM) for around 34 minutes as per the startup procedure (it depends on the start-up conditions)

From Mode 1 Ready to Start

After Warm-up at 1ST Idle Speed of 500 RPM is completed, operator may proceed to fully open the T&T Valve. TS3000 (TRICON) will control speed at 2ND Idle Speed of 1000 RPM via V1. The Turbine will be allowed to run at 2ND Idle speed for around 30 minutes as per the startup procedure. NOTE: If the turbine speed increases above 1000 RPM, the Governor Valve, V1 will throttle and take control of the speed. Warm-up Timers are for indication only

Mode 3 Acceleration

“Idle Speed” Command from HMI/DCS is issued and turbine speed is between 2ND Idle speed and Rated speed.

The turbine speed will decreased to 2ND Idle speed.



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In this Mode:

Action The Peak Speed Recorder is reset and begins recording maximum speed. Trip Speed recorder is reset. The Actual Speed Setpoint is clamped between 0 and Rated Speed. The Target Speed setpoint is set to 2ND Idle Speed (1000 RPM). The Actual Speed setpoi nt is ramped towards the target at normal ramp rate (300 RPM/min). Countdown timers are reset. 1ST Idle Speed Countdown timer is started once 450 RPM is reached. The count down stops any time the speed drops below 400 RPM or rises above or equal 550 RPM. 2ND Idle Speed countdown timer is started once 950 RPM is reached. The count down stops any time the speed drops below 900 RPM or rises above or equal 1050 RPM. Both timers are for indication only. Start-up speed tuning parameters for the speed controller are used. The governor valve maximum opening limit default to 80%. Operator can raise/lower this limit from HMI



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4.6

MODE 3 – ACCELERATION

Entered

Condition

Remarks

A “Rated Speed” Command from HMI/DCS is issued and turbine speed is within 50 RPM of 2 ND Idle Speed

Turbine will be brought to Rated speed.

From Mode 2 Idle Speed

In this Mode: Action The Target Speed Setpoint is set to Rated speed (5194 RPM). The Actual Speed Setpoint is ramped to the target at normal ramp rate (300 RPM/MIN). During Critical Speed Band, the Actual Speed Setpoint is ramped towards the target at fast ramp rate (1000 RPM/MIN). The operator can press the speed “Halt” pushbutton from DCS/ HMI provided the Actual Speed Setpoint and Actual Speed are not in the Critical Speed Band. This will cause the turbine sequence to stop. The Target Speed Setpoint will be set to the current Actual Speed Setpoint. The operator can now raise or lower the Target Speed Setpoint from DCS/ HMI. The turbine sequence continues when operator press speed “Continue” pushbutton from DCS/HMI. An indication will be sent to DCS/ HMI when actual speed is in the Critical Band.



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4.7

MODE 4 – RATED SPEED (5194 RPM) Entered

Condition

Remarks

From Mode 3 Acceleration Mode 5 Parallel OR Mode 6 Island Mode 7 Over Speed Trip Test

Actual speed reaches 50 RPM below the Rated Speed (5194 RPM). Generator Breaker has been Opened

An “Over Speed Trip Test” Off command from HMI is issued.

In this Mode: Action The Actual Speed Setpoint is clamped 5094 RPM and 5294 RPM. Target speed setpoint can be raised /lowered from DCS/HMI The Actual Speed Setpoint is ramped to the target at ramp rate (300 RPM/MIN) Over Speed Trip Test can be enabled/disabled from HMI.



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4.8

MODE 5 – ONLINE OPERATION Entered

Condition

Remarks

From Mode 4 Rated Speed Mode 6 Island

Utility Breaker and Generator Breaker have been closed Utility Breaker has been closed

In this Mode: Action Upon first entering this mode, 1- The speed controller setpoint is memorized, for subsequent load rejection recall. 2- Governor valve is stepped by a fixed amount (3~10%) to prevent reverse power on breaker closure and positive generation. The Speed Droop control and MW control are enabled. Target Speed Setpoint can be raised / lowered from DCS/HMI. The Actual Speed Setpoint is clamped between Rated Speed (5194 RPM) and Maximum Speed (5454 RPM based on 5% droop). Speed Droop control is set to control the system initially. MW Control can be activated by 1- Press “SPEED REF RAISE” on DCS/HMI until actual MW is higher than Remote MW or set Remote MW value lower than the actual MW. 2- Continue pressing “SPEED REF RAISE” pushbutton on DCS/HMI until speed reference reaches the maximum speed 3- When MW controller output is less than speed droop controller output, MW control is activated.



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Action The governor valve will open according to the lowest output between the speed droop controller and the MW controller. While in MW control mode, the control system accepts a 4-20mA control signal from the DCS. The MW target is set to this remote setpoint. Actual MW setpoint ramps to the target value at the rate 1.3 MW/Min. MW setpoint is limited to the max MW. If the MW setpoint is lost when running in MW control mode, MW setpoint will be ramped to the maximum MW value, the control will switch to speed droop control. If the MW Transmitter fails while running in MW control mode, MW setpoint will be ramped to the maximum MW value, MW signal will keep the last good value, the control will switch to speed droop control.



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4.9

MODE 6 – ISLAND OPERATION Entered

Condition

Remarks

From Mode 5 Parallel

Utility Breaker has been opened

In this Mode: Action Upon first entering this mode, the Target Speed Setpoint and Actual Speed Setpoint is set the Rated Speed for the duration of 1 scan time. The speed PID output will be set to the governor valve output just before entering Island Mode for the duration of 1 scan time (to quickly transfer the control from MW control to speed droop control). The MW setpoint will be ramped to maximum value. The MW control is disabled and the governor valve will be under speed droop control Target speed Setpoint can be raised / lowered from DCS/HMI



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4.10 MODE 7 – OVER SPEED TRIP TEST

Entered

Condition

Remarks

From Mode 4 Rated Speed

“Over Speed Trip Test” from HMI is switched to EOST or MOST

In this Mode: Action Over Speed Test indication will be sent to DCS/ HMI. The Actual Speed Setpoint high limit is changed to 5750 RPM IF EOST is selected: Turbine trips at EOST trip setpoint of 5661 RPM, when the speed is increased • from HMI/ DCS. The turbine will be tripped by the Protech at 5674 RPM if the EOST fails to trip • the turbine. IF MOST is selected: Governor Overspeed trip setpoint automatically changes to 5713 RPM. • • Turbine trips at Protech trip setpoint of 5674 RPM, when the speed is increased from HMI/ DCS. The turbine will be tripped by EOST at 5713 RPM if the Protech fails to trip the • turbine.



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5

CONTROL DESCRIPTION (7120-J01-TS01)

5.1

General

Depending on operating conditions and load demand the valve position reference can be controlled (limited) by any of the following: •

Speed control (Offline)

•

Speed Droop control (Online/Island)

•

Megawatt control (Online)

This section describes the control system by function.

Refer to the Control Block Diagram in Figure 6-1-1



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5.2

NAMING CONVENTION

The following describes the TS3000 Soft Tag naming convention used for identifying each different type of I/O and location. All I/O are in a general format of “xAAAA”, where: “x” is a small cap prefix, which refers to the I/O’s signal type “AAAAA” refer to the I/O’s Tagname

Naming convention for I/O signal type “x”

Hardwired Signals;

Prefix

Signal

w

Analog Inputs

y

Unscaled Analog Outputs

t

Thermocouple Inputs

d

Digital Inputs

c

Digital Outputs

p

Pulse Inputs

Memory Signals:

Prefix

Signal

f

Digital Memory

m

Digital Memory Alarm

g

Digital Memory Enterable



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Prefix

Signal

i

Analog Memory Integer

r

Analog Memory Real

e

Analog Memory Enterable

k

Constant Memory

All Alarm/Trips are in a general format of “mAAAA_FO”, where: “m” is a small cap prefix, which refers to the I/O’s signal type “AAAA” refer to the I/O’s Tagname “FO” is a capital suffix, which refer to First out flag. Example: mTBA - Common shutdown to DCS mTBA_FO - First out Alarm kNORRR - Actual Speed Setpoint Normal Ramp Rate kFASTRR – Actual Speed Setpoint Fast Ramp Rate



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5.3

CONSTANT INITALIZATION

Constant initialization passes the constant values to the tags which are defined in the logic. These constant values are passed during the first scan of TS3000 (TRICON) operation. Please refer to Appendix A for tags and their values in the Constant List.

5.4

ANALOG INPUT SCALING

All analog inputs are scaled and any square rooting or filtering is performed (as required). It will also perform signal selection (HI, LOW, Mid-selects or any averaging). Alarms that are based on input values or failures are also generated. If fallback or safe values are associated with inputs these values will reside in the appropriate module related to that control function. Analog inputs that have exceeded the allowable range of 3.2 mA and 21.6 mA will have their respective failure flags set false. If an analog input fails, it will remain failed unless it returns to the acceptable range and remains in this range for a period of five minutes. Please refer to Appendix C for Analog Input Ranges.



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5.5 5.5.1

TRIPS & ALARMS TRIPS

The following conditions trip the turbine: Description

When TS3000 (TRICON) is powered down External trip from ESD Fail Safe Trip EOST trip Governor valve 2 coil fail All speed pickups fail trip

From

Trip Setpoints

-

-

ESD TS3000 (TRICON) TS3000 (TRICON) TS3000 (TRICON) TS3000 (TRICON)

False

7120-X-12.41T

False

7120FSTRP

5661 RPM

7120OSTRP

False

7120V1TRP

False

7120SPDFAILTRP

Trip Tagnames

Table 5-5-1-1: Trip Table

A first out block will record the trip that caused the TS3000 (TRICON) Shutdown. An internal trip flag will trigger the first out capture. First out flags will be reset when sequencing enters Mode 1. Data will be generated in the TS3000 (TRICON) and will be captured/ logged in the HMI/ DCS/ SOE.

5.5.2

ALARMS

An alarm is a visual indication of an abnormal event or process condition which requires attention and/or corrective action from the operator. Alarms generated within the TS3000 (TRICON) will be recorded and captured/ logged in the HMI/ DCS/ SOE. Please refer to Appendix B for Interface List.



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The valve position feedback will be continuously monitored and a deviation alarm will be generated if the difference between the valve output and the valve position feed back signal is higher than or equal 20% for 2 seconds.



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6

7120-J01/7120-J01-TS01 CONTROL MODULE DESCRIPTION

6.1 CONTROL MODULE ASSIGNMENT

The control function is organized into Modules, with each Module performing specific tasks.

Operating Mode Speed Raise/ Lower Speed Setpoint

SP2 Target Speed Setpoint

Target Speed

SP3 Speed Setpoint Ramp

Speed A Speed B

Actual Speed Setpoint Speed Controller Output

Drooped Speed Setpoint SP4 Droop

Actual Speed SP1 Speed Input Median Select

Drooped Speed Measurement

SP5 Speed PID

Low Selector Governor Valve SV-2410

Speed C

Actual MW Setpoint

MW Setpoint From DCS

MW1 Megawatt Setpoint Ramp

MW2 Megawatt PID

MW Measurement

Figure 6-1-1 Control Modules The following is a list of control modules used in this application. They are presented here in execution order. Module

Function

SP1

Speed Input Median Select

SP2

Target Speed Setpoint Generator

SP3

Speed Setpoint Ramp.

SP4

Speed Droop

SP5

Speed PID

MW1

MW Setpoint Ramp

MW2

MW PID

Table 6-1-1: Control Modules INVENSYS PROCESS SYSTEMS (S) PTE LTD (File Name: SG60016-TC1-TMC-BODD-30001-RD02.doc)


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6.2 7120-J01-TS01 STEAM TURBINE CONTROL MODULES 6.2.1

SP1 – SPEED INPUT MEDIAN SELECT

This module calculates a combined speed measurement based on the values of the three speed pickup inputs. It will continually output a selected speed value based upon the number of good speed pickups. The function returns an output value of zero when all enabled speed pickups fail or all are disabled. Low speed failure testing can be enabled when certain predetermined condition are met.

Logic •

Pickup failure logic is enabled when the turbine reaches Mode 2 and the speed is above 250 RPM.

•

Once speed pickup failure detection is enabled, a pickup will fail if it drops below 200 RPM.

•

The median value of the three speed pickup is used for Speed Control.

•

If one pickup fails, the higher of the two remaining good speed pickup will be used.

•

If two pickups fail, the remaining speed pickup will be used.

•

The turbine will be tripped when three pickups fail.

•

The turbine will be tripped when actual speed indicates a speed above the over speed trip setpoint.

•

Peak Speed and Trip Speed will be recorded. These variables will be reset upon entering Mode 2 from Mode 1.



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6.2.2

SP2 – TARGET SPEED SETPOINT

Based on the current turbine Mode and various operator inputs, this module produces a target speed setpoint. Since its value changes instantaneously, a ramp function (Module SP3) is used to smooth out the output prior to use by the PID.

Logic •

Based on the current turbine Mode and various Operator inputs, this module determines the target speed setpoint.

•

Reference the Sequencing Logic Description for additional detail.

•

Target Speed Setpoint tracking in Mode 4 only.



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6.2.3

SP3 – SPEED SETPOINT RAMP

Ramp blocks are used to move any of the various actual setpoints to their associated target setpoints at a steady, smooth rate. It is designed for speed setpoint ramping with critical speed band evasion, and speed target setpoint clamping within operating limits. This prevents step changes in the setpoints that could cause instability in the control loop.

Logic •

In Modes 0 or 1, the Target Speed Setpoint and the Actual Speed Setpoint is set to 0 RPM.

•

In all other mode, the Actual Speed Setpoint is ramped towards the Target Speed at the normal ramp rate (300 RPM/MIN).

•

In the critical speed band, the Actual Speed Setpoint is ramped towards the Target Speed at the fast ramp rate (1000 RPM/MIN).

•

During normal operation (Mode 4, Rated speed), the Speed Setpoint Ramp is prevented from driving the speed greater than 5294 RPM.

•

During normal operation (Mode 4, Rated speed), the Speed Setpoint Ramp is prevented from driving the speed less than 5094 RPM.



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6.2.4

SP4 – SPEED DROOP

This function is used to allow multiple controllers, controlling separate turbine generators supplying a plant bus, to properly control speed if islanded, or megawatt load if paralleled with a utility. This is done by introducing a droop into the speed measurement, prior to its use by the speed PID function block. This block calculates the correct amount of droop, adds it to the process measurement, and under certain circumstances, adjusts the speed setpoint. The speed measurement and setpoint outputs of this function block are normally supplied to the speed PID function block.

Logic

This is a standard control algorithm. It will be configured for the following: •

Pass-Through Mode: the module acts as a pass through that is, setpoints and measurements are not modified. This mode effectively removes all droop from the process controller.

•

Speed Droop Mode: the module will run in speed droop mode. The function block will calculate the correct value of droop based on turbine speed and add that value to the turbine speed measurement (input SPEED). The drooped speed measurement is available from output MEAS. It will also set the speed PID setpoint to the value of the drooped process measurement (output MEAS) when transitions occur to make them bumpless. The speed PID output will also be increased by the value of input KICK whenever the controller transitions between the Pass-Through Mode and this mode to cause the machine to pick up load following generator breaker closure.



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6.2.5

SP5 – SPEED PID

This is a standard PID controller. It is always enabled. The direction of controller action is set to reverse action, which means that if the measurement increases, the PID output decreases.

Logic

This is a standard PID control algorithm. It will be configured for the following: •

Reverse Action.

•

Gain on change of error

•

Setpoint tracking is enabled.

•

Output limits are from 0 to 100%.

•

Whenever the Mode is

•

Whenever the Mode is Rated Speed or Overspeed Test, the normal Gain and Reset

<

4, the “start-up” Gain and Reset values are selected

values are selected. •

Whenever the Mode is Online, the online Gain and Reset values are selected.

•

Whenever the Mode is Island, the island Gain and Reset values are selected.

•

During normal operation (Mode 4, Rated speed) the Speed PID Controller’s setpoint is prevented from going above 5454 RPM.

•

During normal operation (Mode 4, Rated speed), the Speed PID Controller’s setpoint is prevented from going below the rated speed (5194 RPM).



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6.2.6

MW1 – SPEED SETPOINT RAMP

Ramp blocks are used to move any of the various actual setpoints to their associated target setpoints at a steady, smooth rate.

Logic •

The Actual MW Setpoint is ramped towards the Target MW at 1.3 MW/min

•

During Mode 5, Online, the MW Setpoint Ramp is prevented from driving the MW greater than the Max MW.



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6.2.7

MW2 – MW PID

This is a standard PID controller. It is always enabled. The direction of controller action is set to reverse action, which means that if the measurement increases, the PID output decreases.

Logic

This is a standard PID control algorithm. It will be configured for the following: •

Reverse Action.

•

Gain on change of error

•

Setpoint tracking is enabled.

•

Output limits are from 0 to 100%.



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6.3 TRANSMITTER FAIL-OVER STRATEGY Transmitter is considered to have failed if its reading falls below 3.2 mA (655 counts) or rises above 21.6 mA (4423 counts) and the transmitter will remain failed unless they return to the acceptable range and remain in this range for a period of five minutes, after which the transmitter will be placed back into service



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7

DUAL COIL ACTUATOR CONFIGURATION

A single high-current analog output supplies the signal for both coils of the dual coil actuator. The current is divided according to the impedance of the two coils. The power produced by the actuator coils is a function of the number of coils and the current through them. If only one coil is used, the current must double to maintain the same power.

Because the controller output is a constant current, failure of one coil diverts all the current through the remaining coil, thus maintaining the correct actuator output. For example: If the controller output is 160 mA and the coil impedance is equal, the controller output is split evenly, supplying 80 mA to each coil. If one coil fails, all of the controller output current (160 mA) goes to the remaining good coil, effectively doubling the force that the failed coil produced before the failure.

The voltage-to-current converter across the controller output responds to changes in the output voltage that would result from the loss of a coil. The Volt/Amp characteristics of the good coils are programmed into the controller. A significant deviation in the volt/amp characteristics causes an alarm to be issued.



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APPENDIX A – CONSTANT LIST Constant List - Sequencing Description

Tagname

Value

Units

k7120IDLSPD

1000

RPM

STG 1ST IDLE SPEED WARM UP TIMER

k7120IDLTMR1

34

MIN

STG 2ND IDLE SPEED WARM UP TIMER

k7120IDLTMR2

30

MIN

STG CRITICAL SPEED BAND - LOWER LIMIT

k7120CRITL

2241

RPM

STG CRITICAL SPEED BAND - UPPER LIMIT

k7120CRITU

4079

RPM

STG RATED SPEED

k7120MINSPD

5194

RPM

STG MAX. GOV. SPEED

k7120MAXSPD

5454

RPM

k7120EOST

5661

RPM

STG GOV. MOST SP

k7120GOVMOST

5713

RPM

STG MAX. GOV. SPEED @ OST STG FAST SPEED RAMP RATE

k7120OSMAXSPD k7120FASTRR

5750 1000

RPM RPM/MIN

k7120NORRR

300

RPM/MIN

Tagname

Value

Units

STG FAIL SAFE SPEED

k7120FSSPD

200

RPM

STG FAIL SAFE SPEED TIMER

k7120FSTMR

300

SEC

STG SPEED PICKUP ENABLE SPEED

k7120SPDENB

250

RPM

STG SPEED PICKUP FAILURE SPEED

k7120SPDFAIL

200

RPM

Tagname

Value

Units

STG STARTUP SPEED CTRL. GAIN

k7120SPDGAINS

2

-

STG STARTUP SPEED CTRL. RESET

k7120SPD_RSTS

10

REPEAT/MIN

STG RUN SPEED CTRL. GAIN

k7120SPDGAINR

1.5

-

STG RUN SPEED CTRL. RESET

k7120SPD_RSTR

5

REPEAT/MIN

Tagname

Value

Units

STG DROOP VALUE

k7120DRP

4

%

STG KICK VALUE

k7120KICK

5

%

k7120DRPDB

6

RPM

k7120MAXMW

30

MW

STG 2ND IDLE SPEED

STG EOST SP

STG NORMAL SPEED RAMP RATE Constant List - Speed Pickup Description

Constant List - Speed Controller Description

Constant List - Speed Droop Description

STG DROOP DEADBAND STG MW SPAN



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APPENDIX B – INTERFACE LIST Interface List - Buttons & Switches S/no Description

HMI

DCS

ESD

1

STG REMOTE/LOCAL SELECT

g7120REMLOC

-

-

2

STG TBN. START

g7120HS2437A

7120-HS-2437

-

3

STG IDLE SPEED SET

g7120HS2435A

7120-HS-2435

-

4

STG RATED SPEED

g7120HS2436A

7120-HS-2436

-

5

STG OVERSPEED TRIP TEST (EOST) FROM HMI

g7120HS2439A

-

-

6

STG OVERSPEED TRIP TEST (MOST) FROM HMI

g7120HS2440A

-

-

7

STG SPEED REF. RAISE/LOWER

g7120HS2431A /

7120-HS-2431 /

g7120HS2432A

7120-HS-2432

8

STG TRIP RESET

-

7120-RST

-

Description STG OVERSPEED TRIP TEST (EOST) FROM HMI STG OVERSPEED TRIP TEST (MOST) FROM HMI STG IDLE SPEED SET STG RATED SPEED

HMI f7120HS2439A f7120HS2440A f7120IDLSPDSET f7120MINSPDSET

DCS 7120-HS2439A 7120-HS2440A 7120-IDLSPDSET 7120-MINSPDSET

ESD -

5

STG DROOP CTRL. SELECT

f7120DRPSELECT

7120-DRPSELECT

-

6

STG MW CTRL. SELECT

f7120MWSELECT

7120-MWSELECT

-

-

Interface List - Lamps & Indications S/no 1 2 3 4

Remarks: Only signals 7120-HS-2431 and 7120-HS-2432 are hardwired signals. The rest are soft-link signals.



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APPENDIX C – ANALOG INPUT RANGES

Analog Input Range

S/no

Description

Tagname

Min Range

Max Range

Eng. Unit

1

STG GEN. MW

7120-MW-2401

0

30

MW

2

STG REMOTE MW

7120-MW-2402

0

30

MW


TS3000

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