Turbomach Turbotronic 4 Controls System Brochure - Rev J

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Turbotronic 4 Control System

Turbomach SA via Campagna 15 CH-6595 Riazzino – Switzerland

Caterpillar is a trademark of Caterpillar Inc. Solar, and Turbotronic are trademarks of Solar Turbines Incorporated. All other trademarks, service marks, or registered trademarks appearing in this specification are the intellectual property of their respective companies. Specifications are subject to change without notice. Direct customers who receive this Turbomachinery Package Specification along with the purchase of their original equipment may make limited copies of parts of this specification for use in the creation of their own specification documents. However, such customers shall not distribute any part of this Turbomachinery Package Specification outside their own organizations for any other purpose. Any other use without permission is strictly prohibited.

© 2009 Solar Turbines Incorporated. All rights reserved.

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Table of Contents 1 2

OVERVIEW...........................................................................................................................3 CONTROL SYSTEM CONFIGURATIONS ............................................................................4 2.1 2.2 2.3

3

SYSTEM DESCRIPTION ......................................................................................................6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10

4

EXCITATION CONTROL MODES................................................................................................33 SYNCHRONIZATION ...................................................................................................................34 LOAD SHARING...........................................................................................................................34 PROTECTION ..............................................................................................................................35 KILOWATT CONTROL .................................................................................................................36

SUPERVISORY COMMUNICATIONS.................................................................................37 7.1 7.2

8

SEQUENCING..............................................................................................................................30 CONTROL ....................................................................................................................................31 PROTECTION ..............................................................................................................................32 DISPLAY.......................................................................................................................................32

GENERATOR CONTROL ...................................................................................................33 6.1 6.2 6.3 6.4 6.5

7

VIDEO DISPLAY UNIT .................................................................................................................13 TT4000 REMOTE .........................................................................................................................29

TURBINE CONTROL..........................................................................................................30 5.1 5.2 5.3 5.4

6

CONTROL PROCESSOR ..............................................................................................................6 PROCESSOR SOFTWARE............................................................................................................6 UNIT CONTROL NETWORK..........................................................................................................8 INPUT/OUTPUT (I/O) MODULES ..................................................................................................8 BACKUP SHUTDOWN SYSTEM .................................................................................................10 VIBRATION MONITORING SYSTEM...........................................................................................10 FIRE MONITOR............................................................................................................................11 GAS MONITOR ............................................................................................................................11 COMBINATION GENERATOR CONTROL MODULE ..................................................................12 POWER SUPPLIES......................................................................................................................12

TT4000 DISPLAY AND MONITORING SYSTEM ................................................................13 4.1 4.2

5

Advantages of Onskid Controls ......................................................................................................5 Advantages of Offskid Controls ......................................................................................................5 Operator Interface...........................................................................................................................5

DATA INTERFACE.......................................................................................................................37 COMMUNICATION PROTOCOLS ...............................................................................................37

OTHER FEATURES AND OPTIONS ..................................................................................38 8.1 8.2 8.3 8.4

SOFTWARE MODIFICATION ......................................................................................................38 LANGUAGES FOR TT4000 DISPLAY .........................................................................................38 ENGINEERING UNITS.................................................................................................................39 PRINTERS....................................................................................................................................39


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1

Overview The Turbotronic 4 control system provides precise integrated control, protection and monitoring of Turbomach’s turbomachinery packages. It brings Solar and Turbomach’s operating experience to current controls technology, providing rugged and reliable systems with broad functionality. The backbone of each unit control system is a ControlNet network that connects the key components and subsystems listed below, as highlighted in Figure 1: Control Processor. The Allen-Bradley ControlLogix processor is the primary control device in the system. I/O Modules. The Allen-Bradley Flex input/output (I/O) modules provide the interface between the package instrumentation and the processor. Vibration Monitoring. The XM Dynamic Measurement monitors vibration for the turbine and driven equipment. Generator Control. The Allen-Bradley / Basler Electric combination generator control module (CGCM) provides multiple power generation control and protection features, including synchronization and voltage regulation. Backup Protection. A separate backup shutdown system shuts the package down in a safe and orderly manner if primary control is lost. Operator Interface. TT4000 Display and Monitoring System, fully functioned Human Machine Interface (HMI) product, one “on-skid” mounted, one auxiliary desktop PC. Fire Monitoring. A separate certified fire monitoring system provides fire detection and fire extinguishing. Section 3 provides a more detailed description of these components and subsystems.

Figure 1.

Turbotronic 4 Architecture


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2

Control System Configurations The control system components are mounted on panels and cubicles located on an acclimatized room. This control room is mounted on-board of the main skid (on-board control room). This configuration is typically called on-skid Control. For some turbine models there’s the possibility to have a remote control room and in this case the configuration is typically called off-skid Control. On-skid Option Yes Yes Yes Yes Yes Yes

Turbine Model Mercury 50 Mars 100 Taurus 70 HED Centaur 40 Centaur 50 Taurus 60

Off-skid Option No No No Yes Yes Yes

Package without on-skid Control Room (example)

Package with on-skid Control Room (example) Thanks to the modularity of the new control room, it’s now possible to install the turbogenerator also in areas where the space is reduced giving the chance to the customer to place the control room somewhere else.


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2.1

Advantages of Onskid Controls Reduced Cabling. The major advantage of the onskid control system is the large reduction in interconnect cabling. Having the control, the auxiliary, the starting and the supply panels in the same control room placed on skid, connections are minimal. Main power supply and a few signals from/to customer panels are required, while all wires needed, from and to the package, cover a short path. This greatly reduces the bulk and cost of the cables. Factory Wiring. The package, including the control system, is wired and tested at the factory. These connections stay in place and do not have to be rewired in the field. This reduces commissioning time and the opportunity for wiring errors.

PACKAGE SKID ON-BOARD CONTROL ROOM AUXILIARY DESKTOP COMPUTER

ETHERNET

CONTROLNET TT4000 CONTROL PROCESSOR I/O MODULES BACKUP SHUTDOWN SYSTEM FIRE & GAS SYSTEM VIBRATION MONITOR GENERATOR CONTROL MODULE

Figure 2.

2.2

Standard Configurations for Onskid Controls

Advantages of Offskid Controls Reduced Space. The major advantage of the offskid control system is the space reduction required to install the package that now can fit also in small places. All I/O signals are collected in a small auxiliary panel and data are transmitted to the main controller through ControlNet network. Power supply cables and ControlNet cables are the only ones that have to be laid, while all other wires, from and to the package, cover, also with this option, a short path. This greatly reduces the bulk and cost of the cables. Factory Wiring. The package is wired and tested at the factory. These connections stay in place and do not have to be rewired in the field. This reduces commissioning time and the opportunity for wiring errors.

2.3

Operator Interface The operator interface consists of a TT4000 display system with keyboard and track-ball mouse that is typically used during commissioning and servicing. Expanded operator interface is available offskid, typically in a control room area, with a desktop computer configured with the TT4000 system.


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3

System Description 3.1

CONTROL PROCESSOR The ControlLogix control processor (Figure 3) provides primary package and gas turbine control. It governs the gas turbine, the fuel supply, and the functioning sequences of turbogenerator as well as all associated equipments, according to the different systems requirements. The ControlLogix processors, manufactured by Allen-Bradley, are part of a scalable family of "Logix" processors representing the state-of-the-art for industrial process control. The devices offer several important advances: •

They mount in an Allen-Bradley 1756 style rack, which has an integral power supply and can accommodate various communications interface modules, such as ControlNet, Ethernet, Data Highway Plus and Modbus. • The symbolic software architecture is "tag-based," which means program variables are not tied to physical memory addresses in the processor, but are identified by symbols. The symbols reside in the processor. This tag-based architecture is an extremely powerful feature that enables rapid duplication of predefined program subroutines and permits portability within the Logix family of processors.

Figure 3.

ControlLogix Processor Another key benefit of the Logix processors is the ability for field service to make maintenance updates easily, since each subroutine is self-contained and does not affect other sections of the program. The ControlLogix processor, together with RSLogix 5000 programming software, provides a solid and flexible platform for Turbotronic 4 control systems.

3.2

PROCESSOR SOFTWARE The RSLogix 5000 software programming environment offers a Windows-based interface (Figure 4) that supports symbolic programming with structures and arrays. This environment is common to the Rockwell Automation Logix family of processors (ControlLogix, FlexLogix, and MicroLogix) and sets the foundation for future growth toward distributed control systems. The new programming environment enables the development of predefined and qualified sub-system software modules. Each software module is a self-described building block. Each building block supports a corresponding control system feature. The result is flexible and robust software with consistent quality. The RSLogix 5000 structure yields a measurable increase in product quality and shortens commissioning


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cycles. It permits more flexibility in accommodating special balance of plant controls requirements without affecting the predefined software modules used for the control of the turbomachinery.

Figure 4.

RSLogix Software RSLogix 5000 is compliant with the IEC 61131-3 software-programming standard. It offers multiple industry standard programming languages, which can be selected to suit the application:

• • •

Ladder program for relay-type sequential logic Function blocks for logical processes and mathematical functions Structured text allows the creation of user-defined functions for further optimization of the code for turbine control applications. In total, RSLogix 5000 provides the flexibility to build more compact and better-organized code that is efficient to operate and easier to troubleshoot.


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3.3

UNIT CONTROL NETWORK The control processor communicates with the other components of the system using ControlNet 1.5. This high-speed network operates at five megabits per second. It is deterministic and repeatable, meaning that data and instructions adhere to a rigid schedule during each network update. A typical network update time for the control system is five to ten milliseconds. The physical connection is by redundant cables; that is, two duplicate channels connect all devices on the network (Figure 5).

Figure 5.

3.4

Network Adapter

INPUT/OUTPUT (I/O) MODULES To perform many of its functions, the control processor must gather physical data from and send control commands to the package instrumentation. This is accomplished through input/output (I/O) modules. These are supplied as discrete (input, output, or both) or analog (input, output, or both) modules. Discrete inputs are typically used for alarms, shutdowns, and status indications. Analog inputs are used for scalable functions. The I/O modules are mounted to terminal bases (Figure 6). Terminal bases have two primary functions. First, when connected side to side, they serve as a back plane, allowing data to be transferred from the I/O module to a network adapter module and then to the processor via ControlNet. Second, the terminal base acts as the terminal strip for wiring from the field devices. The network adapter serves as a communication hub between each of the attached I/O modules and the processor, providing not only I/O data but also individual module and health status. In addition, the adapter provides the DC power for the I/O modules. Up to eight I/O modules may be connected to one network adapter. Discrete Input Modules. Discrete input modules receive signals from on/off devices, such as level switches, pressure switches, push buttons, relays, and protective equipment normally used during sequencing of the gas turbine. Discrete signals can be used for alarms, shutdowns or simply indicators, but are not necessarily displayed. The discrete input modules have a capacity of up to 16 channels, depending on the configuration.


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Figure 6.

Flex I/O Module and Terminal Base Network Adapter. The adapter module interfaces the FlexIO modules to an I/O scanner port across a communication network. The adapter module contains a built-in power supply that converts 24V dc to 5V dc for the backplane to power the FlexIO modules. One adapter communicates with up to 8 I/O modules Terminal base. Each FlexIO module requires a terminal base unit that snaps onto the DIN rail to the right of the communication adapter. The terminal bases provide terminal connection points for I/O wiring. Discrete Output Modules. Discrete output modules drive output devices such as solenoid valves, relays and motor contactors. The modules are available in both 8 and 16 channel versions. If "dry" contacts are required, then a set of interposing relays are provided. Analog Input Modules. Analog input modules accept analog signals and digitize the data for transfer to the processor. Modules can accept either four or eight single-ended inputs, with different channels being used for different types of inputs. Each channel is individually configured for current or voltage by choosing where the input is connected on the terminal base. Analog Output Modules. Analog output modules send analog signals to position control devices, such as valves, or to provide information for display. The standard analog output module has four channels. Temperature Modules. Temperature modules condition and transfer temperature data from package resistance temperature detectors (RTD) and thermocouples to the processor. 100-ohm platinum RTDs are preferred. The temperature module has eight input channels. Speed Modules. Speed modules perform high-speed frequency algorithms. The frequency inputs can be up to 32,767 Hz. The speed module has two input channels, each of which can accept magnetic pickup signals from 500 mV to 28 VAC peak.


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3.5

BACKUP SHUTDOWN SYSTEM The basic control system is equipped with an independent backup system that initiates emergency shutdown of the turbomachinery and controls the post-lube cycle if the primary processor fails. Critical input signals monitored independently by the backup system include the backup power turbine overspeed monitor, manual emergency stop switches (located at the turbine skid), the processor fail "watchdog," and the fire system relay contacts. When activated by any of the above faults, the relay backup system initiates a safe shutdown of the turbine. The backup control system is a combination of instantaneous and time delay relays. When a failure of the processor occurs, all discrete outputs are automatically switched off. The microprocessor fail relay is de-energized on a fault condition. A fault is initiated by a "watchdog" circuit that monitors the PLC healthy status. The microprocessor fail relay contacts in the relay backup system initiate an emergency shutdown and isolate the generator by commanding the circuit breaker to open. Once a shutdown is initiated by the backup system, operation can only be restored manually by a safety lockout push button on the onskid control room, after all faults have been cleared. This action re-energizes the master control relay and restores associated relays and timers to the normal position.

3.6

VIBRATION MONITORING SYSTEM Turbotronic 4 includes integrated vibration monitoring with the Allen-Bradley 1440 XM Dynamic Measurement Vibration Monitor (Figure 7). The 1440 XM Vibration Monitor permits physical distribution of the vibration monitoring system, as it integrates with the overall control system using Flex I/O ControlNet network adapters. The 1440 XM Vibration Monitor integrates seamlessly into the ControlNet 1.5 system architecture.

Figure 7.

1440 XM Dynamic Measurement Vibration Monitor The 1440 XM Dynamic Measurement Module consists of the following components:

• • • • •

Terminal base Power supply 24-Vdc ControlNet adapter Field monitor modules (proximity probes, accelerometer, velocity, ecc.) Keyphasor (supplied when applicable)

Each 1440 XM field monitor modules can receive 2 vibration channels and a keyphasor input. Typically, four or more 1440 XM field monitor modules are used on a package, depending on the number of vibration channels to be monitored. © 2009 Solar Turbines Incorporated. All rights reserved.

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The vibration data processed by the 1440 XM Dynamic Measurement Module is transmitted to the ControlLogix processor through the ControlNet network for alarming and shutdown. Vibration data values are viewable on the HMI.

3.7

FIRE MONITOR A separate fire control system is provided. The Siemens Cerberus CS1140 monitor provides fire protection and extinguishing agent release using optical flame detectors and smoke detector (on-board control room). This sensor information is then transmitted to the Cerberus control unit to execute the fire suppression logic, to control agent release, signaling, and annunciation outputs, and to communicate with the Turbotronic 4 control processor to initiate turbine shutdown.

Figure 8.

3.8

Fire Monitor

GAS MONITOR The enclosure area is monitored for possible gas leakages by at least two infrared gas sensors. One sensor is located at the outlet air flow of the enclosure. The second is located in the area of the gas supply line. The sensors provide an analogue signal that correspond to the Lower Explosive Level (LEL), and are wired to the main processor input modules. The main processor monitors the LEL and initiates a turbine shutdown when the maximum allowable level is exceeded.

Figure 9.

Gas Sensor


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3.9

COMBINATION GENERATOR CONTROL MODULE In Turbotronic 4 control systems for generator packages, the integrated combination generator control module (CGCM) (Figure 10) provides extensive generator control and protection functions. The functions of line synchronization and automatic voltage regulator are combined into a single device with additional control and protection capabilities. Refer to Section 6 for a more complete description.

Figure 10.

3.10

Combination Generator Control Module

POWER SUPPLIES The Turbotronic 4 control system operates on 24-Vdc power. The package is equipped with a 24-Vdc battery charger and battery system. Depending on the gas turbine package type, a 110-Vdc system may also be required to power the engine actuators, the fuel valve actuators and/or the DC backup lube oil pump. These packages are also equipped with a 110-Vdc battery charger and battery system. The I/O modules, the vibration monitor, the CGCM, the backup shutdown system, the fire system and display systems operate with 24-Vdc power.


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4

TT4000 Display and Monitoring System The TT4000 Display and Monitoring System is a Human Machine Interface (HMI) product developed by Solar Turbines Incorporated and Turbomach SA specifically for turbomachinery control applications. TT4000 displays and stores data and provides a range of control interface capabilities. TT4000 interfaces with, but is separate from, the package control system. This allows TT4000 to perform multiple tasks without interfering with the critical control and protection functions handled by the control processor. TT4000 provides a window into the package control system. It shows engine conditions, stores information, alarms, shutdowns, and events, and can permit varying levels of control. While beneficial to an operator, the TT4000 is not essential for the control of the package, since that responsibility rests with the package control system. TT4000 is a flexible and expandable product. With the following features, TT4000 is consistent with current industry software standards: • •

The system runs under the Windows XP operating system. The system is compliant with Transmission Control Protocol and Internet Protocol (TCP / IP) to permit easy transmission of data between TT4000 and other programs. • Historical data are readily viewable within the program. Also, files in Comma Separated Value (.csv) format can be created for easy export to other programs such as Microsoft Excel. • TT4000 incorporates Visual Basic for Application (VBA) scripting that can be used to assist in the analysis and reduction of data. • The program supports Active-X controls. The TT4000 family of systems includes various configurations to support different operational requirements: •

TT4000 is a fully featured display and monitoring system consisting of a panel-mounted video display unit (VDU) configured with the Windows XP operating system, the TT4000 application software and the specific project software files. The system can store extensive amounts of data in addition to its display, communications and control functions capabilities. It is designed for operation in a nonhazardous area such as a control room. • TT4000 Remote is the version of TT4000 installed on a "remote" PC. It mirrors the functionality of the primary TT4000 system.

4.1

VIDEO DISPLAY UNIT The video display unit (VDU) consists of an industrial computer and Human Machine Interface (HMI) display software. The VDU with TT4000 HMI software performs several key functions to facilitate operation of the turbomachinery equipment through a userfriendly interface. The HMI system monitors the turbine and driven equipment parameters, calculates performance factors, annunciates alarms, reports on the running status of the equipment, stores data and provides a comprehensive set of analysis tools. TT4000 can be integrated as part of a larger network for data sharing and remote display communications. The VDU operates independently of the control system and provides additional operator and maintenance information. Typical screens include:


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4.1.1

Standard Display Screens •

•

•

•

4.1.2

Overview: § Operation Summary § Process Summary § Engine Summary § Enclosure Systems: § Operation sequence § Control System § Engine and Generator Vibration § Lube, Fuel and Starting Systems Details: § Fuel, Engine, Lube and Temperatures Details § Advanced Vibrations Tools: § Maintenance § Alarm, Event and Historical Log § Constants § Strip Chart Optional Display Screens

•

Gas Turbine Performance Map (Figure 34) While any of the screens are being displayed, there is a full-time indication of fault conditions. The top line of the display screen is dedicated to the identification of up to four alarm conditions. If there are more than four, the operator is directed to go to the Alarm Summary screen for a complete sequential listing.

4.1.3

4.1.4

Overview §

Operation Summary provides a view of the overall gas turbine and driven equipment operating parameters (Figure 12).

§

Process Summary provides all the instruments to monitor, synchronize and control the turbomachinery (Figure 13).

§

Engine Summary provides a list of engine parameters and gives the possibility to control the engine (Figure 14).

§

Enclosure allows to monitor the ventilation, fire & gas conditions and other parameters about the enclosure (Figure 15).

Systems §

Operation Sequence screen also displays the starting and stopping sequences. During the package start sequence, the VDU shows the various logics and timed sequences involved from initiation of start- up to running condition. Should the unit fail to start, the operation display screen indicates the particular stage in the start logic sequence in which the start failed. This feature is a valuable troubleshooting resource for operations personnel to quickly identify the source of the starting problem and, thus, reach a faster solution (Figure 16).

§

Control System screen shows turbine and generator main parameters and the operator has the possibility to open the control pages (Figure 17).


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4.1.5

4.1.6

§

Engine and Generator Vibration screens allow the operator to monitor in detailed the vibrations measured (Figure 18 & Figure 19).

§

Lube, Fuel and Start Systems screens show the main parameters of these auxiliary systems in special graphic pages (Figure 20, Figure 21 & Figure 22).

Details §

Fuel, Engine, Lube and Temperatures Details are a group of special screens where all the value, measured and calculated, of these subsystems are shown in details. In this section, temperatures are also shown in graphic way using charts and bargraphs (Figure 23, Figure 24, Figure 25 & Figure 26).

§

Advanced Vibrations is a screen composed by several subpages used for a depth vibrations analysis (Figure 27).

Tools §

Maintenance screen provides instruments for maintenance tests and operations (Figure 28).

§

Alarm, Event and Historical Log display all alarm and shutdown annunciations with a time and date stamp, monitors and records the changes in status of all defined discrete (switch or binary) inputs (events) and allows selection of up to 10 variables for viewing in a digital strip chart format (Historical). Alarms (Figure 29) are time stamped by the HMI in the order in which they are received from the control processor. On the display, alarms are shown in yellow and shutdowns in red. Acknowledged alarms are shown in reverse video. As the malfunctions are acknowledged, they are shown in the corresponding colored text until they are cleared from the system and the RESET switch is pressed. The first four malfunctions detected are displayed at the top of all screens until cleared. The events are displayed as a chronological, time-stamped listing in the order in which they occurred (Figure 30). It is possible to have multiple events with the same time stamp due to the update rate of the display system. Up to 5000 events can be stored in the log. The order of the event listing on the screen can be changed by double clicking on the column headings. This feature provides a historical record of sequence and status events that changed. It can be used to audit package operation or to identify malfunctions that have occurred and areas of the operation that need attention. The objective of historical data monitoring (Figure 31) is to provide information of a type and in a format that allows informed decisions to be made in the areas of operation, maintenance, and optimization of the turbomachinery and associated equipment. The information is collected in databases for online viewing and analysis. Alternatively, Comma Separated Value (.csv) format files can be created for export to other software programs such as Microsoft Excel. Historical data monitoring includes the groups listed below. To view them online, the user selects, from pull-down menus, the desired variable, the pen color, and pen style. Available historical groups include: • Hourly Log. Data are read at one-hour intervals for the past 12 months and stored, one database for each month. This log includes the "Elapsed Time" feature, which records data whether or not the equipment is running. • Minute Log. Data are read at one minute intervals for the past month and stored, one database for each day.


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§

§

4.1.7

• 10-Second Log. Data are read at 10-second intervals for the last 14 days, one file for each day. These files can only be analyzed off-line. • Trigger Log. The Trigger Log function stores data before and after a "trigger event." The trigger event is defined and configured in the control processor. The standard event is a shutdown. Each time the event is triggered, a timer starts. At the end of two minutes, all the analog data for the previous six minutes are written to a file. In this way, data for four minutes before and two minutes after the event are captured. Up to 25 triggered files, each containing six minutes of one-second data points, are stored. This is a powerful diagnostic tool. Constants screen (Figure 32) displays a set of adjustable values in the processor software listed by address number. To change a value, a constant is selected by tag name or address number: double clicking the item brings up the logging menu. Username and password are entered, bringing up the parameter window. The new value can then be entered. The parameter window displays the allowable range and resolution accuracy. Once the new value is entered, it is transmitted to the control processor. TT4000 also creates and stores a log with the modified constant name, new value, username, and time stamp of the most recent change. The Strip Chart function (Figure 33) emulates a 10-pen strip chart recorder. The screen can display real-time data for up to 10 variables selected by the operator. Parameters are selected by assigning each pen a value; the values can be analog or binary data available for monitoring. Each pen can be assigned a different color, line weight, and symbol to easily distinguish different monitored values from one another. The bottom of the strip chart screen displays the corresponding legend for each pen. Each of the plots is scaled for the selected variable and displays the actual numerical value for each variable. The date range and scaling can be changed by double clicking on the desired pen to bring up the configuration pull-down menu. The time axis on the strip chart can be configured for each pen by date, hours, minutes, or seconds. The "zoom" feature allows the user to zero in on the particular area of interest.

Further tools on the screens

Graphic screens offer further information such as: §

The help on line. The main objects shown on the graphic screens there’s the possibility to click on it and understand the main characteristics of the object selected.

§

The advanced tag details. This feature is available for most of the analog indication. Clicking on the value, a pop-up window is opened showing all the object settings like setpoints, bargraph, charts to have the history of the signal in a defined period and the helpon line.

Figure 11.

Advanced Tag Detail


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Figure 12.

Operation Summary

Figure 13.

Process Summary


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Figure 14.

Engine Summary

Figure 15.

Enclosure


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Figure 16.

Operation Sequence

Figure 17.

Control System


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Figure 18.

Engine Vibrations

Figure 19.

Generator Vibrations


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Figure 20.

Lube Oil System

Figure 21.

Fuel Gas System


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Figure 22.

Start System

Figure 23.

Fuel Details


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Figure 24.

Engine Details

Figure 25.

Lube Details


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Figure 26.

Temperature Details

Figure 27.

Advanced Vibrations


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Figure 28.

Maintenance

Figure 29.

Alarm Log


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Figure 30.

Event Log

Figure 31.

Historical Log


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Figure 32.

Constants

Figure 33.

Strip Chart


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Figure 34.

Gas Turbine Performance Map


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4.1.8

Special Functions Special display screens can be provided, but Turbomach must be consulted to determine feasibility. Time required for programming, debugging, and documenting nonstandard interface screens can be significant and should be evaluated carefully to determine project cost and delivery impact.

4.2

TT4000 REMOTE When remote monitoring and control is required from an additional location, an additional TT4000 installation can be provided in a desktop PC. This remote TT4000 can interface with the primary TT4000 system either through an Ethernet or ControlNet network.


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5

Turbine Control The control system provides extensive control and protection functions for the turbine package. Aspects of the turbine control are determined by the specific requirements of a particular project. The following information is applicable for a typical gas fuel package. The four primary functions provided by the control system are: • • • •

5.1

Sequencing Control Protection Display

SEQUENCING The key elements of the sequencing function are: • • • •

5.1.1

Starting Loading Stopping Post Lube Starting The control system is armed by turning on the electrical power and, if necessary, resetting any alarms or shutdown malfunctions. The operating mode is selected, determining whether the system is controlled from local or remote. Start is initiated by the operator and the following actions take place:

• •

Lube oil pump is run through a test cycle. Package enclosure fans are started. At the completion of this pre-crank check, the starter rotates the engine, developing airflow through the compressor to purge gas accumulated in the engine, air inlet, and exhaust duct. The length of the purge cycle is tailored to the exhaust duct volume for the specific project. If the engine does not accelerate to meet a preset speed within a specified time, the start sequence is aborted. Once the engine reached the crank speed and before starting the purge sequence, the pressure test is performed on the gas fuel valves (starting in gas fuel). The valves are opened and closed in sequence with the starting and stopping of timers and the fuel pressure signals are verified. If the test is successful the purge crank can start and during this phase the fuel valves are closed and there is no ignition. After completion of the purge cycle, when the engine has reached the required speed and temperature levels, ignition takes place. A small amount of fuel is introduced into the combustor from the gas torch and ignited by the igniter plug. Fuel from the fuel valve then enters the combustor through the injectors. The fuel valve gradually ramps open. Fuel flow, engine temperature, and turbine speed all increase. If the engine temperature does not reach the light-off temperature set point before a specified time, ignition failure is annunciated and the start sequence is aborted. When the turbine exceeds the starter speed, the clutch allows the starter to freewheel and when the turbine reaches starter dropout speed, the starter is de-energized and the engine continues to accelerate under its own power.


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5.1.2

Generator Loading Loading the generator requires closing the generator circuit breaker. The circuit breaker can be closed to either a dead (de-energized) or hot (energized) bus. When the control system detects a dead bus, the circuit breaker may be closed either manually or automatically by the control system. When the system detects a hot bus, the generator must be synchronized to the bus before the circuit breaker is closed. The control system can automatically synchronize the generator to the bus and close the breaker.

5.1.3

Stopping The turbine may be shutdown either manually or automatically. Manual Stops Activating the Normal Stop command from the HMI results in a cooldown stop. The turbine is unloaded and run at idle speed for a set time to allow the turbine to cool before the fuel valve is closed. Activating the Emergency Stop command (ESD push-buttons from package skid) results in immediate unloading and fuel valve closure without a cooldown period. In both cases, after the package has come to a complete stop and a rundown timer has timed out, the post-lube cycle is started. Automatic Stops The control system automatically shuts the package down in response to specific hazardous or malfunction conditions. These shutdowns are divided into four categories: • • • •

Cooldown Stop Nonlockout (CN) Cooldown Stop Lockout (CL) Fast Stop Nonlockout (FN) Fast Stop Lockout (FL) The Cooldown and Fast Stops correspond to the Manual Normal and Emergency Stops respectively. The Lockout Stops inhibit operation of the control system and the system cannot be restarted until the malfunction is reset. Lockout Stops generally result from more serious malfunctions that require corrective action before the system can be restarted. The Nonlockout Stops typically result from an operation disruption or abnormal condition and can be reset when conditions return to normal.

5.1.4

Post Lube The control system initiates and supervises the post-lube cycle to protect the turbine bearings from thermal damage. The configuration of the pumps and the length of the post-lube cycle depend on the turbine type and package design.

5.2

CONTROL Once the package has completed the start sequence and steady-state operation is reached, the control system keeps the equipment within the specified operating conditions. The minimum power limit is zero load and occurs for generators when the generator circuit breaker is open. The maximum power limit is established by the engine temperature and by the speed. The generator or the main gearbox equipment may also place upper limits on engine power output.

5.2.1

T5 Control Turbine service life is directly related to the temperature at the first-stage turbine nozzle (T3). This high temperature, however, decreases thermocouple reliability. To improve thermocouple reliability, the temperature at the third-stage nozzle (T5) is measured.


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Multiple T5 thermocouples are used, the number being determined by the engine type. Control is based on the average T5 temperature. If one thermocouple reading varies from the average by more than a preset amount, an alarm is annunciated. If two or, in some configurations, three vary by more than that amount, an alarm is annunciated and the package is shut down. 5.2.2

Speed Control Speed pick-up probes continuously monitor the turbine speed and the control system adjusts the speed to meet the operating requirements and to keep the speed within the specified limits. Additional safety is provided by a separate backup overspeed detection system that automatically shuts the engine down if the overspeed limit is reached.

5.3

PROTECTION The control system provides extensive protection of the package by monitoring speed, temperatures, pressures and other variables. Most variables have limits that when exceeded result in a response by the control system. Typically, one level triggers an alarm and a second level triggers an automatic shutdown of the package as described in Section 5.1.3. Alarm summaries and event logs are provided by the display system.

5.4

DISPLAY Section 4 provides a detailed description of the Display and Monitoring System.


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6

Generator Control In addition to monitoring the generator temperature and vibration levels, the Turbotronic 4 control system includes extensive control and protection of the generator and its output, including regulation, synchronizing, and load sharing. The key component for this control is the combination generator control module (CGCM). This device combines the line synchronization module technology developed by Allen-Bradley with the digital automatic voltage regulation technology developed by Basler Electric. The result is an extremely powerful and versatile device that integrates readily into the control system by connecting to the system’s ControlNet network. Figure 35 shows the typical connections required by the CGCM for the management of two circuit breakers. The CGCM provides four modes of regulation based on its voltage and current inputs. It provides the ability to synchronize the generator to one or two reference buses. It permits operation of the generator in either isochronous (isoch) or droop modes. In addition, it permits load sharing between generator sets with similar control systems.

6.1

EXCITATION CONTROL MODES Four modes of regulation are available: • • •

Automatic Voltage Regulation (AVR) – The output voltage of the generator is controlled. Field Current Regulation (FCR) – The field current to the generator is controlled. Power Factor Regulation (PFR) – The power factor of the paralleled machine is used to determine the correct field current. • Reactive Power Regulation (VAR) – The VAR output of the paralleled machine is used to determine the correct field current. GENERATOR CB

GENERATOR

UTILITY CB

BUS PLANT

UTILITY

GENERATOR ARMATURE (Stationary)

RECTIFIER ASSEMBLY

EXCITER ARMATURE

AREP

ROTATING PORTION

GENERATOR FIELD

EXCITER FIELD (Stationary)

GENERATOR POTENTIAL TRANSFORMERS

GENERATOR CURRENT TRANSFORMERS

CROSS CURRENT COMPENSTATION TRANSFORMER

BUS POTENTIAL TRANSFORMERS

EXCITATION POWER EXCITATION OUTPUT To Turbotronic 4 Control Processor

CONTROLNET

LOAD SHARE LINES (To other Combined Generator Control Module or Load Share Module)

COMBINED GENERATOR CONTROL MODULE

Figure 35.

Typical CGCM Connections


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6.2

SYNCHRONIZATION

The CGCM can provide synchronization between two buses by measuring appropriate active bus and synchronization parameters (Figure 36). Voltage matching between buses is also performed through measurement of these parameters. Control and error parameters are provided to the generator governor for bus synchronization and to the CGCM's internal voltage regulator for voltage synchronization. The CGCM synchronizes the generator output voltage, frequency, and phase to a reference power system.

Figure 36.

6.2.1

Process Summary Screen with Synchronization Pop-Up open

Dual Bus Connection It is desirable to have the ability to synchronize a generator to more than one reference bus. Turbomach standard foresees synchronization at 2 different points (generator CB and Utility CB). The CGCM supports this operation by allowing connection to one phase of two different buses. The appropriate bus for synchronization is selected automatically. When used in this manner, the three-phase output of the generator and a single phase from each reference bus should be connected to the CGCM. The CGCM cannot determine the phase rotation of either reference bus since only one phase is connected. Therefore, no phase rotation match can be performed. However, the correct phase rotation, ABC or ACB, can be configured in the device and the CGCM can then verify that the generator output phase rotation matches the configured data. Supplementary Sync check & phase rotation relays are installed in order to allow the closure of Gen CB or Utility CB.

6.3

LOAD SHARING The system provides equal generator real power kW sharing for multiple generators operating in parallel. The controls of the other generators must use the CGCM, the AllenBradley line synchronization module, or other compatible device. The load sharing lines of the CGCM are connected to the equivalent terminals on the parallel generators’ controls. The generators then share load at an equal percentage of each generator’s total capacity.


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6.4

PROTECTION Fourteen fault protection functions are provided as part of the CGCM as backup protection of the main protection relays. Faults are communicated to the control processor via the ControlNet interface. These fault conditions and the industry standard protection codes, where applicable, are:

1. 2. 3. 4. 5. 6. 7.

Field Current Limit Generator Overcurrent (51) Generator Overvoltage (59) Generator Undervoltage (27) Loss of Excitation Current Loss of Operating Power (27) Loss of Sensing (60FL)

8. 9. 10. 11. 12. 13. 14.

Overexcitation Voltage (59F) Overfrequency (81O) Phase Rotation Error (47) Reverse Power (32R) Reverse VAR (40Q) Rotating Diode Monitor Underfrequency (81U)

For Generator protection, digital protections relays are provided as a standard in the Turbine control panel. These are protection relays in a 19” plug-in module design (4U), in which several protective functions are programmable: Model

ANSI code

Description of the function

IDT8N

87T

differential current protection

ING4N

50 / 51 46

over current for short circuit/overload protection unbalanced load protection

UAR4N

27 59 59Uo

under-voltage protection over-voltage protection stator earthing 95% (homopolar voltage)

PQR4N

32 40

reverse power protection loss of excitation


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These protection features only protect the generator. As an option, Turbomach can offer user’s power distribution system protection functions. These additional protection functions will not be part of the CGCM, but part of additional hardware.

6.5

Model

ANSI Code

Description of the function

HAR1N

81

min./max. frequency max. frequency rate of change df/dt max voltage vector shift (∆Θ)

UAR4N

27 59 59Uo

min. voltage max. voltage voltage absence

KILOWATT CONTROL In addition to the control modes listed in Section 6.1, the system can be programmed to provide kilowatt control. This is useful when the generator is operating in parallel with a large power source such as an electric utility. The kilowatt output of the generator can be set at any level within the capability of the unit. In some cases, it may be necessary to prevent power from being imported from or exported to the utility when the preset output of the generator exceeds the utility load requirements. In this case, the system can be programmed to always import or export a preset amount of power.


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7

Supervisory Communications In many cases, the turbomachinery and its controls are part of a larger plant or station that has an overall supervisory control and data acquisition (SCADA) system or distributed control system (DCS). The Turbotronic 4 control system offers several connection options. Connection is directly to the control processor by means of communication modules mounted in the processor rack.

7.1

DATA INTERFACE The ControlLogix processor supports the full Control and Information Protocol (CIP). To read the full tag names, the DCS must be CIP capable. Currently, this means communicating with the unit control processor either using another ControlLogix processor or using a PC with Rockwell RSLinx software. An available alternative to CIP are the protocols described in Section 7.2

7.2 7.2.1

COMMUNICATION PROTOCOLS Modbus (Serial or TCP/IP) The Modbus communication is granted adding a dedicated interface module. The Modbus interface module allows Rockwell Automation ControlLogix processors to interface easily with other Modbus protocol compatible devices. The interface module acts as a Modbus slave device to communicate with a Modbus master device provided by the user. The connection may be with an RS232C, RS422, or RS485 serial link cable, or over Ethernet TCP/IP. Data are transmitted using a subset of the RTU version of the Modbus protocol.

7.2.2

OPC The OPC UA (unified architecture) is granted through a service running on both local and auxiliary HMI The whole set of tags available to be displayed on the HMI screens can be accessed by external OPC UA clients connected to the server via Ethernet. Support for legacy protocols such as OPC DA 2.0 may require the installation of additional software components.


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8

Other Features and Options 8.1

SOFTWARE MODIFICATION There are two sets of project specific software in the Turbotronic 4 control system: the RSLogix 5000 control processor software and the TT4000 HMI software. Both can be modified in the field by qualified service personnel. Note: Software modification should be undertaken only with extreme caution, since changes may cause malfunctions with the potential for equipment damage and personal injury. Equipment under warranty should only be serviced by authorized personnel from Turbomach to prevent voiding of the warranty.

8.1.1

RSLogix 5000 Software Modification of this software requires a licensed copy of the RSLogix 5000 master program installed in a separate computer that is interfaced with the PLC through a suitable connection. The software is installed on a portable laptop computer and the communication can be established either with a special PCMCIA type card and a ControlNet connection cable or with a USB cable or with an Ethernet cable. This means that the connection does not have to be made directly to the control processor; it can be to any network adapter. A different card is available for installation in a desktop PC. Each network adapter on the Turbotronic 4 ControlNet network has an RJ-45 plug for connecting the cable.

8.1.2

TT4000 Software The TT4000 software operates in two different modes: Design Time and Run Time. The Design Time mode is used to create or modify the working files related to a specific project. The Run Time mode uses those files in the normal operation of the equipment. TT4000 is shipped with both modes available to the user. This allows the user to modify the project files if necessary.

8.2

LANGUAGES FOR TT4000 DISPLAY The TT4000 displays can be provided in dual language configurations, allowing the user to switch between English and another language. Available languages include the following, but other language displays can be provided on a special order basis: • • • •

• • • •

Spanish Portuguese French German


Italian Russian Dutch Turkish

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8.3

ENGINEERING UNITS The TT4000 displays can be provided in either English or various Metric units:

English Pressure Temperature Length

2

psig

kPa

bar

kg/cm

°F

°C

°C

°C

inches

mm

mm

mm

3

3

MMSCFD

Msm /d

Flow Act.

ACFM

m /min

m /min

m /min

ft-lbf /lbm

kJ/kg

kJ/kg

kJ/kg

3

Msm /d

3

Flow Std. Head

8.4

Metric

3

Msm /d 3

PRINTERS A printer/logger option is available, which provides a dot matrix printer, for printing the alarm and shutdown log, one event per line. This allows the operator to review recent event history.


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Turbomach Turbotronic 4 Controls System Brochure - Rev J

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