A01 4012 11e08

KELI 2008
Field Report :
Control System ME 4012 for
gas turbine A (93.0 V) at unit 4
Power plant Altbach / Deizisau
EnBW
Elektro-/ Leittechnik
Dipl. Ing. David Maier
da.maier@enbw.com
+49 7153 602 - 55 24 0
06th of Mai 2008
Helmut Mauell GmbH

Dipl. Ing. Detlef Baran
dba@mauell.com
+49 2053 - 13 478
Energy
needs Impulses
Table of contents
1. Tasks of the new Gas Turbine Control System ME 4012
slide
Principle of process Combined Cycle Unit 4
ME-VIEW scheme of control loops and functional groups
Air system and combustion process of the gas turbine
Air / exhaust gas of the gas turbine
Ignitiongas and naturalgas system
Heating oil system of gas turbine

(Draft sketch according to VGB R 170 C)
3. Achieved objectives and operational experience:

Control System replacement of gas turbine A
slide
Turbine behavior during start-up and load operation
21
ME4012 System overview Unit 4, Altbach / Deizisau
22
Control System characteristics
23
Contract Award
24
Planning and Manufacturing
24
Mounting
24
Deionized water injection for NOx-reduction during oil operation 9
Commissioning
25
Auxiliary oil / lube oil system of the gas turbine
10
Acceptance
26
Turbine Protection System (Turbine surveillance supervision)
11
Electrical Integration
12
4. Summary after 5 years of plant operation
27
5. Reference List Process Control System ME4012:

Gas turbines and Combined Cycle Plants
28
2. Solution: Functions and Control Strategy

Speed-, power-, frequency- and temperature-control
13
Speed-, power-, frequency-, temperature- and fuel-control
14
Turbine controller (1oo2), Turbine protection (2oo3, SIL3)
15
Turbine speed measurement for controller and fail-safe (SIL 3)

overspeed protection
16
Gas turbine protection: Overview machine protection
17
Gas turbine protection: Overview fuel trip system
18
Operator system ME VIEW and location involvement
19
Automation Unit AE 4012 and location involvement
20
30
David Maier / Detlef Baran
KELI 08: Digital Control System ME4012 for gas turbines
06th of Mai 2008
Power plant Altbach / Deizisau, Unit 4
06th of Mai 2008
Tasks of the new gas turbine control system ME 4012:

Principle of process Combined Cycle Unit 4
Steam power
Flue gas
Injection
Boiler
drum
Water
pipes
200MW
Oil
Gas
Steam turbine
Oil
Sek. - Prim.
superheater
Fire Area
Gas
M
Feed water flow

Burner
Compressor
Turbine
Cooler
Demineralize
50MW
Oil
Gas
Combustion
chamber
06th of Mai 2008

ME-VIEW scheme of control loops and functional groups
bersicht des Lieferumfanges
06th of Mai 2008

air system and combustion process of the gas turbine
06th of Mai 2008

Air / exhaust gas of the gas turbine
06th of Mai 2008

Ignitiongas and naturalgas system
Automatic switch over of operation modes:

Diffusion to pre mixed operation
06th of Mai 2008
Tasks of the new gas turbine control system ME4012:

Heating Oil system of gas turbine (draft sketch according to R170C)
06th of Mai 2008

Deionized water injection for NOx reduction during oil operation
06th of Mai 2008

Auxiliary oil / lube oil system of the gas turbine
Turning gear
(Hydro motor)
10
06th of Mai 2008
11

Turbine Protection System (Turbine surveillance supervision)
06th of Mai 2008
12

Electrical Integration
06th of Mai 2008
Ramp
function
generator
Speed
setpoint
Turbine
speed
Synchronizer
Mode of
operation
Power
setpoint
Setpoint
generator speed
Electrical
power
Speed
controller
Frequency
Temperatursollwert
Setpoint
generation
power
Exhaust
temp.
Power
controller
Setpoint
deionized water
injection
Exhaust
temperature
Setpoint
generation
temperature
Deionized
water injection
(Oil > 25MW)
Temperature
controller
Flow
controller
Deionized water
Valve
position
controller
Oil-ESV
Oil-CV
> 25MW asynchronous balanced mode
Gas-CV
Gas-ESV
F
Compressor
13
Turbine T
n
50MW
Master
Coordinator
Slave (full interface and processing redundancy)

Speed-, power-, frequency- and temperature-control
Deionized
water- CV
06th of Mai 2008
2. Solution: Functions and Control Strategy:

Speed-, power-, frequency-, temperature- and fuel-control
Start up
setpoint
diagram
100%
60%
15%
0
300C
Synchronisation
Ramp function
generator
Speed
setpoint
396C
T
C
Synchronizer
Setpoint
generator speed
Speed
controller
Oil
flow
EHCposition
Turbine
speed
Operational
mode
Power
setpoint
Exhaust
temperature
Temperature
setpoint
Power
controller
Setpoint
control power
EHC-position
controller
EHCposition
Shares plate
Gas / Oil and
automatic fuel
switching,
Base:
Energy content /
heat balance
Temperature
controller
Valve position
controller
Oil-CV
position
Setpoint
generation
amount of fuel
Coordinator
(bumpless
switch)
Electrical
power
Setpoint
control
temperature
Flow
controller
Fuel
Frequency
Flow
controller
Valve position
controller
EHC-position
controller
Gas-CVposition
Gas
flow
Exhaust
temperature
Deionized water injection for

NOx reduction in oil operation
Deionized
water flow
Fuel
Electrical
power
Setpoint
generation
deionized water
Flow
controller
Mode of operation
14
Valve
position
controller
Deionized water
CV-position
Power
adjuster
M
06th of Mai 2008

Turbine controller (1oo2), Turbine protection (2oo3, SIL3)
Master
Diagnostics and
Documentation
Turbine Governor Channel A
AE4012
CPU
Analog
output
Operator station
Alarms, SOE,
Protocol
ME-DRP
Binary
output
ME-VIEW
LAN
SUB-NET
Analog
input
Pulse
input
Life trip system
Channel 1
Life trip system
Channel 2
Pulse
pre-amplifier
and decoupling
Turbine Governor Channel B
AE4012
Pulse
input
Analog
output
Over speed
protection
(2 oo3) SIL 3
GT
Binary
output
2 oo3
Servodrive
E/H-Converter
Servodrive
Analog
input
Oil-ESV
l-CV
CPU
Slave
Servodrive
Life trip system
Channel 3
3
Gas-ESV
15
E/H-Converter
Servodrive
Time critical
realtime funktions
CPU-Functional Area 1
< 4 ms
Speed control setpoint
Speed controller
Acceleration Measurement
Fuel valve position controller
Gas-CV
AE4012
Realtime funktions
CPU-Functional Area 2
< 10ms
Funktion group controls
Power control setpoint
Power controller
Frequency influence
Flue gas temp. controller
Fuel controller
Combustion controller
Deionized water injection
Anti surge control
Turbine protection 2 oo 3
06th of Mai 2008

Turbine speed measurement for controller and
fail-safe (SIL 3) overspeed protection
Channel 1
Turbine
overspeed
protection 2oo3
SIL3
2 oo 3
IE2FZ
Channel 2
Turbine
shaft
&
Pulse pre-amplifier
IE2FZ
Channel 3
IE2FZ
Reserve
detector
DW channel 1
Emergency
DW channel 2
shut off valve
DW channel 3
IE2 FZ
Turbine
speed
measurement
1oo2
I/O- Bus
Digital speed measurement :

Accuracy
: 0,004 % = +/- 2mHz at 50 Hz netw. frequency
Speed and
power
controller
Signal resolution : 0,5 mHz
AE4012
Signal scan cycle : 4 ms
-1
Measuring range
: >3 - 3600 U min
Long-term- and temperature- stability due to digital acquisition and processing
16
SUB-NET
ME4012 Processinterface
06th of Mai 2008

Gasturbine protection: Overview machine protection
Generator
protection
Life trip system 2 oo 3

Electrical and mechanical trip criterions
Failsafe trip system 2 oo 3, SIL 3

Overspeed protection
+L1
+L2
Turbine controller
(Slave)
Turbine controller
(Master)
Channel 1
Channel 2
Channel 3
+L3
SUB-NET
Life trip system
Life trip signal tranfered as Failsafe trip signal

# Criterion permutation
&
t0
Function group
Turbine control
24V +L1
24V +L2
24V +L3
emergency stop
(Turbine trip)
T.-protection latch
>3 turns min-1
Turbine protection
manual trip (2 oo 3)
LSN24
&
2 oo 3
&
Failsafe
trip
module
DW-Modul 1
Test program
hydraulic trip
block
DW
DW
Quarz
comparator
DW
&
&
t0
Failsafe
trip
module
DW-Modul 2
DW
&
2 oo 3
&
Failsafe
trip
module
DW-Modul 3
DW
LT
FST
DW
LT
FST
Quarz
comparator
LT
FST
DW
LT
FST
LT
FST
DW
LT
FST
LT
FST
LT
FST
Fuel control valve
Test program
overspeed
detector
DW
LT
FST
Quarz
comparator
&
Failsafe
fuel
protection
system
(2 oo 3)
Fail-Safe 2 v 3 (EAM)
Control oil
Hydraulic trip
block 1 oo 2
Seat
valve
Seat
valve
Pi
17
Turbine hydraulic
system
06th of Mai 2008

Gasturbine protection: Overview fuel trip system
Life trip system 2 oo 3
Turbine controller 1v2
Overspeed protection
2 oo 3 (SIL 3)
Hydraulic
trip block 1 oo 2
Turbine
shaft
Control oil
2oo3
Fail-Safe fuel trip (SIL3)
Fail-Safe
shut off valve
> 60% Load

asynchronous
M balanced
operating low NOx
Fuel
Burner
Seat
valve
M < 60% Load

diffusion
operating
Fuel CV
ESV 1
ESV 2
2. Shut-off
valve
Ignitor
Pilot light
Combustion chamber
18
1. Shut-off
valve
Propane
gas
Pilot flame
Venting system
06th of Mai 2008

Operator system ME VIEW and location involvement
Controlroom Unit4
GT-A
Relay room HKW 2
Controlroom HKW 2
ME-VIEW
Client
ME-VIEW
Client
ME-VIEW
Client
Balance
protocol
ME-AIS
ME-DRP
Client
ME-DRP
Server /
Client
VIEW-LAN
VIEW-Switch 1
EnBW
Management system
PI-System
Documentation
VGB standard R 170 C
VIEW-Switch 2
On-line features:
-- Diagnosis
-- Configuration
-- Simulation
Router
RAID
5
Gateway
PC
PD-Switch 1
Distributed coupling ME4012
RAID
5
DRPSwitch
(Rail)
PD-Switch 2
Distributed coupling ME4012
DRP-LAN
19
06th of Mai 2008

Automation Unit AE 4012 and location involvement
PD-Switch 1
PD-Switch 2
SUB-NET Level B
SUB-NET
Coupler
Automation
unit
AE 4012
SUB-NET
Coupler
Automation
unit
AE 4012
UVIEW
SUB-NET
Coupler
UVIEW
Automation
unit
AE 4012
SUB-NET
Coupler
SUB-NET Level A
TC 1
TP 1
TC 2
TP 2
Multifunctionsprocessor
BinaryInput/
Output
AnalogInput/
Output
BinaryInput/
Output
TP 3
AnalogInput/
Output
BinaryInput/
Output
AnalogInput/
Output
BinaryInput/
Output
AnalogInput/
Output
BinaryInput/
Output
marshalling rack
AnalogInput/
Output
BinaryInput/
Output
AnalogInput/
Output
BinaryInput/
Output
Fail-Safe
System
Power
adjuster
Flame /
burner
surveillance
Fail-Safe
logic
Stepping
control drives
Shaft
vibration
measurement
Turbine
protection
Stepping
control drives
Coupling
relays
Burner
protection
Stepping
control drives
Turbine controller, Turbine protection
BinaryInput/
Output
AnalogInput/
Output
BinaryInput/
Output
AnalogInput/
Output
marshalling rack
Auxiliary
cabinet
AnalogInput/
Output
marshalling rack
Gas turbine
20
Steam generator
Turbine, burner, flue gas flap
auxiliary power
Hardware signal exchanges:

- Control steam generators
- Daily oil tank
- Operating load distribution
- start-up device /
alternator excitation
06th of Mai 2008
3. Achieved objectives and operational experience

Turbine behavior during start-up and load operation,
total system integration, efficient control algorithms,
high degree of automation
Xw
Turbine controller features:

- Cycle time
< 4 ms typ.
Speed Measurement (digital):
- Accuracy:
+/-2,0 mHz abs.
- Resolution:
0,5 mHz
21
06th of Mai 2008

ME 4012 System overview Unit 4, Altbach / Deizisau
Control Room Unit 4
Relay Room Unit 2
Control Room Unit 2
EMI
ME-AIS
Client
Alarms
Client
ME-DRP
Client
Balance protocol: Client

- Performance
- Work
- Operating Hours
- Consumption
- Cooling water diary
Client
ME-DRP
Server
Documentation
Diagnosis
Projekt
database
250m
30 m
30m
LWL
Splicebox
Environment
Office
Flue gas
emission
Computer
Server 1
PI-System
Router
LWK
Server 2
Railswitch
Gateway
PC
USV
USV
Fibre optic cable (FOC)
Electronic Room
Unit 2
9,5 m
Hardwired Signals
SUBNET B-Level
Relay-Room Unit 4
(200 MW ST / 50 MW GT)
FOC
250 m
FOC
Switch
250 m
SUBNET A-Level
SN
CAN
CAN-Bus only for cabinet internal surveillance

Hardwired signal exchanges:
AE4012
Turbine protection
Turbine controller
22
AE4012
Turbine burner
Exhaust flap
ME4002S
Fail-Safe logic
Turbine protection
Burner protection
Power adjuster
Stepping control drives
Auxiliary Cabinet
Flame burner surveillance
Burner surveillance
Shaft vibration measurement
Coupling relays
AE4012
Steam Generator
Auxiliary power
- Control steam generators

- Daily oil tank
- Operating load distribution
- Start up device / alternator excitation
06th of Mai 2008

Control system ME 4012 characteristics for GT-A
Plant functionality corresponds to the expectations of the plant operator
Old documentation evaluated with red marks updated or scrapped
New documentation strictly according VGB Directive: R 170 C
Improving the control behaviour and the stability of operating transitions
System-hardware and -software based on standard components of the
Process Control System ME 4012, (replacement for Transidyn (controller),
Transicont Protection), Simatic P and N)
Redundant, highly accurate and extremely fast speed detection / control
High availability with full redundancy of the overall system:
- Signal interface, - processing, - communication,
- Digital valve positioner (Cycle Time: < 4 ms)
- Operator system
Fully message processing with a time stamp at the signal source:
accuracy and resolution: 1ms
Turbine protection:
- Over Speed Trip (SIL3, 2 oo 3)
- Machinery protection (2 oo 3)
- Rapid fuel shutdown (SIL3, 2 oo 3)
23
06th of Mai 2008

in the power plant Altbach / Deizisau
Contract Award: August 2001

Mauell won the competition although:
not machinery supplier, not Station-control system.
Planning and Manufacturing: up July 2002

Control strategy:
- Implementation old / new through intensive cooperation Mauell / EnBW.
- Mauell adopted the plant functionality to the state of the art.
- Existing weaknesses were analyzed and eliminated by new concepts.
Mounting: September / October 2002

During the next major GT revision.
24
06th of Mai 2008

Commissioning: January / February 2003

Re-commissioning of fuel oil after 13 starts
Re-commissioning of fuel gas after 8 Starts
Optimization of all transitions
Involvement in the site control system:
- PI- System (Process Information System)
- Unit Control System
- operational load dispatcher
25
06th of Mai 2008

Acceptance: March 2003

Extensive functional testing of the turbine control:
y Automatic start-up of the gas turbine to rated speed
y Automatic Synchronization
y Automatic load increase at about 7 MW / min. to base load
y Speed controller load operation:
switching speed controller to load controller under load
y Interception security from full load to house load (GT or Unit 4)
y Redundancy test at all operating conditions and loads
y Flying fuel change (gas / oil and oil / gas) under load
y Testing the primary control
y Testing the limit frequency control
y Hot start tests
y Trip tests of protection system
(Shaft vibration monitoring, over speed, fuel-trip)
26
06th of Mai 2008
4. Summary
Summary: (After 5 years of plant operation)

y Excellent system technology with outstanding performance
y Very good teamwork of EnBW / Mauell employees in the field
of special process engineering expertise
y Highest level of automation to secure / easy and fast unit start-up
y Modern control concepts for robustic and efficient plant operation
y Fully Integrated Control concepts for all operating modes and transitions
y Reducing the risk of combustion chamber drone
y High reliability for all applications
y Long-term assets-backed operation (spare parts and service)
27
06th of Mai 2008
Reference List Process Control System ME4012:

Gasturbines and Combined Cycle Plants
Manufacturer
DT / GT
Siemens /
Siemens V64.3
Steam turbine /
Gas turbine
60 MW /
25 MW
Siemens /
Siemens V94.1
105 MW /
2x 100 MW
ALSTOM Power /
140 MW /
General Electric
Frame 9E
2x 140 MW
No. Plant Operator
Country
HKW Halle / Trotha
Stadtwerke Munich
Heizkraftwerk Sd
Combined Cycle 1
Stadtwerke Munich
H i k ft
Heizkraftwerk
k Sd
Combined Cycle 2
EnBW PP Altbach /
Deizisau, GT-A
Siemens V93.0
50 MW
Industry Power
Plant
Carl Freudenberg,
Weinheim, GT1
Industry Power
Plant
Carl Freudenberg,
Weinheim, GT2
Ruston Tornado
6,3 MW
Turbomach
5,5 MW
Caterpillar Taurus
Caterpillar,
T60
28
Function
Serial integration of GTand DT-control system in
the Process Control
System ME 4012
Plant Control System
ME 4012 for control and
protection
ME 4012 ffor control
t l and
d
protection
Integration of process-bus
into Mark 5-GT-control
system
ME 4012 for control and
protection
Hard-wired interfacing to
Unit Control System
Boiler 4
Hard-wired interfacing to
Unit Control System
Boiler 5
06th of Mai 2008
Energy
needs Impulses
29
A01.4012.11E08
06th of Mai 2008

A01 4012 11e08

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A01 4012 11e08

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KELI 2008

Helmut Mauell GmbH

Principle of process Combined Cycle Unit 4

ME-VIEW scheme of control loops and functional groups

Air system and combustion process of the gas turbine

Air / exhaust gas of the gas turbine

Ignitiongas and naturalgas system

Heating oil system of gas turbine

3. Achieved objectives and operational experience:

Turbine behavior during start-up and load operation

ME4012 System overview Unit 4, Altbach / Deizisau

Control System characteristics

Planning and Manufacturing

Deionized water injection for NOx-reduction during oil operation 9

Auxiliary oil / lube oil system of the gas turbine

Turbine Protection System (Turbine surveillance supervision)

4. Summary after 5 years of plant operation

5. Reference List Process Control System ME4012:

2. Solution: Functions and Control Strategy

Speed-, power-, frequency-, temperature- and fuel-control

Turbine controller (1oo2), Turbine protection (2oo3, SIL3)

Turbine speed measurement for controller and fail-safe (SIL 3)

Gas turbine protection: Overview fuel trip system

Operator system ME VIEW and location involvement

Automation Unit AE 4012 and location involvement

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Power plant Altbach / Deizisau, Unit 4

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

Feed water flow

David Maier / Detlef Baran

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

Automatic switch over of operation modes:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME4012:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

David Maier / Detlef Baran

KELI 08: Digital Control System ME4012 for gas turbines

06th of Mai 2008

Tasks of the new gas turbine control system ME 4012:

David Maier / Detlef Baran